Komatsu Pc400LC-6, Pc400HD-6 Hydraulic Excavator Operation & Maintenance Manual SN A80001 and up – PDF DOWNLOAD

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Komatsu Pc400LC-6, Pc400HD-6 Hydraulic Excavator Operation & Maintenance Manual

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Komatsu Pc400LC-6, Pc400HD-6 Hydraulic Excavator Operation & Maintenance Manual

Size : 12.3 MB
Format : PDF
Language : English
Number of Pages : 272 pages

KOMATSU PC400LC-6, PC400HD-6 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL SN A80001 AND UP – PDF DOWNLOAD:

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DESCRIPTION:

Komatsu Pc400LC-6, Pc400HD-6 Hydraulic Excavator Operation & Maintenance Manual

FOREWORD:

• This manual describes procedures for operation, handling, lubrication, maintenance, checking, and adjustment. It will help the operator and maintenance personnel realize peak performance through effective, economical and safe machine operation and maintenance.
• Keep this manual handy and have all personnel read it periodically. If this manual is lost or becomes dirty and can not be read, request a replacement manual from your local distributor. If you sell the machine, be sure to give this manual to the new owner.
• Continuing improvements in the design of this machine can lead to changes in detail, which may not be reflected in this manual. Consult your local distributor or Komatsu Dresser Co. for the latest available information on your machine or for questions regarding information in this manual.

TABLE OF CONTENTS:

Komatsu Pc400LC-6, Pc400HD-6 Hydraulic Excavator Operation & Maintenance Manual

MAIN MENU....................................................................................................................................  0
INTRODUCTION.................................................................................................................................  5
	1. FORWARD...............................................................................................................................  6
	2. SAFETY INFORMATION....................................................................................................................  7
	3. INTRODUCTION..........................................................................................................................  8
		3.1 INTENDED USE.....................................................................................................................  8
		3.2 FEATURES.........................................................................................................................  8
		3.3 BREAKING IN A NEW MACHINE........................................................................................................  8
	4. LOCATION OF PLATES, TABLE TO ENTER....................................................................................................  9
		4.1 MACHINE SERIAL NO. PLATE POSITION................................................................................................  9
		4.2 ENGINE SERIAL NO. PLATE POSITION.................................................................................................  9
		4.3 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR........................................................................................  9
	5. CONTENTS.............................................................................................................................. 10
SAFETY....................................................................................................................................... 16
	6. GENERAL PRECAUTIONS................................................................................................................... 17
	7. PRECAUTIONS DURING OPERATION.......................................................................................................... 24
		7.1 BEFORE STARTING ENGINE........................................................................................................... 24
		7.2 OPERATING MACHINE................................................................................................................ 26
		7.3 TRANSPORTATION................................................................................................................... 32
		7.4 BATTERY.......................................................................................................................... 33
		7.5 TOWING........................................................................................................................... 34
		7.6 BUCKET WITH HOOK................................................................................................................. 35
			7.6.1 GENERAL PRECAUTIONS........................................................................................................ 35
			7.6.2 PRECAUTIONS FOR LIFTING OPERATION.......................................................................................... 36
	8. PRECAUTIONS FOR MAINTENANCE........................................................................................................... 37
		8.1 BEFORE CARRYING OUT MAINTENANCE.................................................................................................. 37
		8.2 DURING MAINTENANCE............................................................................................................... 40
	9. POSITION FOR ATTACHING SAFETY LABELS.................................................................................................. 44
OPERATION.................................................................................................................................... 48
	10. GENERAL VIEW......................................................................................................................... 49
		10.1 GENERAL VIEW OF MACHINE......................................................................................................... 49
		10.2 GENERAL VIEW OF CONTROLS AND GAUGES............................................................................................. 50
	11. EXPLANATION OF COMPONENTS............................................................................................................ 51
		11.1 MACHINE MONITOR................................................................................................................. 51
			11.1.1 A. BASIC CHECK ITEMS...................................................................................................... 51
			11.1.2 B. CAUTION ITEMS.......................................................................................................... 53
			11.1.3 C. EMERGENCY STOP ITEMS................................................................................................... 54
			11.1.4 D. METER DISPLAY PORTION.................................................................................................. 55
			11.1.5 E. SWITCHES............................................................................................................... 58
		11.2 SWITCHES........................................................................................................................ 61
		11.3 CONTROL LEVERS, PEDALS.......................................................................................................... 65
		11.4 CEILING WINDOW.................................................................................................................. 70
		11.5 FRONT WINDOW.................................................................................................................... 71
		11.6 DOOR LOCK....................................................................................................................... 73
		11.7 CAP, COVER WITH LOCK............................................................................................................ 74
			11.7.1 METHOD OF OPENING AND CLOSING CAP WITH LOCK (For the fuel tank filler port)............................................... 74
			11.7.2 METHOD OF OPENING AND CLOSING COVER WITH (For the cover with lock)........................................................ 74
		11.8 HOT/COOL BOX.................................................................................................................... 75
		11.9 LUGGAGE BOX..................................................................................................................... 75
		11.10 ASHTRAY........................................................................................................................ 75
		11.11 HANDLING AIR CONDITIONER....................................................................................................... 76
			11.11.1 GENERAL LOCATIONS ON CONTROL PANEL....................................................................................... 76
			11.11.2 PRECAUTIONS WHEN USING AIR CONDITIONER................................................................................... 78
		11.12 CAR RADIO...................................................................................................................... 79
			11.12.1 EXPLANATION OF COMPONENTS................................................................................................ 79
			11.12.2 LOCATION AND FUNCTION OF CONTROLS........................................................................................ 79
			11.12.3 METHOD OF OPERATION...................................................................................................... 82
			11.12.4 PRECAUTIONS WHEN USING................................................................................................... 83
			11.12.5 SPECIFICATIONS........................................................................................................... 83
		11.13 FUSE........................................................................................................................... 84
		11.14 FUSIBLE LINK................................................................................................................... 85
		11.15 CONTROLLERS.................................................................................................................... 85
		11.16 TOOL BOX....................................................................................................................... 85
		11.17 GREASE GUN HOLDER.............................................................................................................. 85
		11.18 HANDLING ACCUMULATOR........................................................................................................... 86
			11.18.1 METHOD OF RELEASING PRESSURE IN CONTROL.................................................................................. 86
	12. OPERATION............................................................................................................................ 87
		12.1 CHECK BEFORE STARTING........................................................................................................... 87
			12.1.1 WALK AROUND CHECK......................................................................................................... 87
			12.1.2 CHECK BEFORE STARTING..................................................................................................... 89
			12.1.3 ADJUST BEFORE OPERATION................................................................................................... 94
			12.1.4 OPERATIONS AND CHECKS BEFORE STARTING ENGINE.............................................................................. 96
		12.2 STARTING ENGINE................................................................................................................. 98
			12.2.1 NORMAL STARTING........................................................................................................... 98
			12.2.2 STARTING IN COLD WEATHER.................................................................................................. 99
		12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE.....................................................................................101
			12.3.1 WHEN NORMAL...............................................................................................................101
			12.3.2 IN COLD AREAS.............................................................................................................103
		12.4 MOVING MACHINE OFF..............................................................................................................107
			12.4.1 MOVING MACHINE FORWARD....................................................................................................107
			12.4.2 MOVING MACHINE BACKWARD...................................................................................................108
		12.5 STEERING MACHINE................................................................................................................110
			12.5.1 STEERING (CHANGING DIRECTION).............................................................................................110
		12.6 STOPPING MACHINE................................................................................................................112
		12.7 SWINGING........................................................................................................................113
		12.8 OPERATION OF WORK EQUIPMENT.....................................................................................................114
		12.9 WORKING MODE SELECTION..........................................................................................................115
		12.10 PROHIBITIONS FOR OPERATION.....................................................................................................117
		12.11 PRECAUTIONS FOR OPERATION......................................................................................................119
		12.12 PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS....................................................................................120
		12.13 HOW TO ESCAPE FROM MUD.........................................................................................................122
			12.13.1 WHEN ONE SIDE IS STUCK...................................................................................................122
			12.13.2 WHEN BOTH SIDES ARE STUCK................................................................................................122
		12.14 WORK POSSIBLE USING HYDRAULIC EXCAVATOR........................................................................................123
			12.14.1 BACKHOE WORK.............................................................................................................123
			12.14.2 SHOVEL WORK..............................................................................................................123
			12.14.3 DITCHING WORK............................................................................................................123
			12.14.4 LOADING WORK.............................................................................................................123
		12.15 REPLACEMENT AND INVERSION OF BUCKET............................................................................................124
			12.15.1 REPLACEMENT..............................................................................................................124
			12.15.2 INVERSION................................................................................................................125
		12.16 PARKING MACHINE................................................................................................................126
		12.17 CHECK AFTER FINISHING WORK.....................................................................................................127
		12.18 STOPPING ENGINE................................................................................................................128
		12.19 CHECK AFTER STOPPING ENGINE....................................................................................................129
		12.20 LOCKING AND SECURING MACHINE...................................................................................................129
	13. TRANSPORTATION.......................................................................................................................130
		13.1 LOADING AND UNLOADING MACHINE...................................................................................................130
		13.2 PRECAUTIONS FOR LOADING.........................................................................................................132
		13.3 PROCEDURE FOR INCREASING OR REDUCING TRACK FRAME GUAGE (PC400HD-6 AVANCE).......................................................133
		13.4 PRECAUTIONS FOR TRANSPORTATION..................................................................................................134
	14. COLD WEATHER OPERATION...............................................................................................................135
		14.1 PRECAUTIONS FOR LOW TEMPERATURE.................................................................................................135
			14.1.1 FUEL AND LUBRICANTS.......................................................................................................135
			14.1.2 COOLANT...................................................................................................................135
			14.1.3 BATTERY...................................................................................................................136
		14.2 PRECAUTIONS AFTER COMPLETION OF WORK............................................................................................137
		14.3 AFTER COLD WEATHER..............................................................................................................137
	15. LONG-TERM STORAGE....................................................................................................................138
		15.1 BEFORE STORAGE..................................................................................................................138
		15.2 DURING STORAGE..................................................................................................................139
		15.3 AFTER STORAGE...................................................................................................................139
		15.4 STARTING MACHINE AFTER LONG-TERM STORAGE........................................................................................139
	16. TROUBLESHOOTING......................................................................................................................140
		16.1 PHENOMENA THAT ARE NOT FAILURES.................................................................................................140
		16.2 METHOD OF TOWING MACHINE........................................................................................................140
		16.3 METHOD FOR USING LIGHT-WEIGHT TOWING HOLE.......................................................................................140
		16.4 PRECAUTIONS ON PARTICULAR JOB SITES.............................................................................................141
		16.5 IF BATTERY IS DISCHARGED........................................................................................................141
			16.5.1 STARTING ENGINE WITH BOOSTER CABLE........................................................................................142
		16.6 OTHER TROUBLE...................................................................................................................145
			16.6.1 ELECTRICAL SYSTEM.........................................................................................................145
			16.6.2 CHASSIS...................................................................................................................146
			16.6.3 ENGINE....................................................................................................................147
			16.6.4 ELECTRONIC CONTROL SYSTEM.................................................................................................149
MAINTENANCE..................................................................................................................................150
	17. GUIDES TO MAINTENANCE................................................................................................................151
	18. OUTLINES OF SERVICE..................................................................................................................154
		18.1 OUTLINE OF OIL, FUEL, COOLANT...................................................................................................154
			18.1.1 OIL.......................................................................................................................154
			18.1.2 FUEL......................................................................................................................155
			18.1.3 COOLANT...................................................................................................................155
			18.1.4 GREASE....................................................................................................................156
			18.1.5 STORING OIL AND FUEL......................................................................................................156
			18.1.6 FILTERS...................................................................................................................156
		18.2 OUTLINE OF ELECTRIC SYSTEM......................................................................................................157
		18.3 OUTLINE OF HYDRAULIC SYSTEM.....................................................................................................157
		18.4 OUTLINE OF FUEL SYSTEM..........................................................................................................158
	19. WEAR PARTS LIST......................................................................................................................159
	20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE.................................................................161
		20.1 PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS................................................................................161
		20.2 ENGINE OIL SPECIFICATIONS.......................................................................................................162
		20.3 DIESEL FUEL SPECIFICATIONS......................................................................................................163
		20.4 COOLANT SPECIFICATIONS..........................................................................................................164
	21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS.......................................................................................169
		21.1 INTRODUCTION OF NECESSARY TOOLS.................................................................................................169
		21.2 TORQUE LIST.....................................................................................................................170
	22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS........................................................................................171
	23. MAINTENANCE SCHEDULE CHART...........................................................................................................173
		23.1 MAINTENANCE SCHEDULE CHART......................................................................................................173
		23.2 MAINTENANCE INTERVAL WHEN USING HYDRAULIC BREAKER...............................................................................176
	24. SERVICE PROCEDURE....................................................................................................................177
		24.1 WHEN REQUIRED...................................................................................................................177
			24.1.1 CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT..............................................................................177
			24.1.2 CHECK AND TIGHTEN TRACK SHOE BOLTS........................................................................................179
			24.1.3 CHECK AND ADJUST TRACK TENSION............................................................................................180
			24.1.4 CHECK ALTERNATOR..........................................................................................................183
			24.1.5 CHECK STARTER MOTOR.......................................................................................................183
			24.1.6 INSTALLATION OF BUCKET TEETH..............................................................................................184
			24.1.7 ADJUST BUCKET CLEARANCE...................................................................................................189
			24.1.8 CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID................................................................................190
			24.1.9 CHECK AND ADJUST AIR CONDITIONER..........................................................................................191
			24.1.10 REPLACE ATTACHMENT RETURN LINE FILTER (OPTION)...........................................................................192
			24.1.11 CLEAN INLINE FILTER......................................................................................................193
		24.2 CHECK BEFORE STARTING...........................................................................................................194
			24.2.1 CHECK COOLANT LEVEL, ADD COOLANT..........................................................................................194
			24.2.2 CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL................................................................................194
			24.2.3 CHECK FUEL LEVEL, ADD FUEL................................................................................................195
			24.2.4 CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL................................................................................196
			24.2.5 CHECK AIR CLEANER FOR CLOGGING............................................................................................197
			24.2.6 CHECK ELECTRIC WIRING.....................................................................................................197
			24.2.7 DRAIN WATER FROM THE FUEL-WATER SEPARATOR.................................................................................197
		24.3 EVERY 50 HOURS SERVICE..........................................................................................................198
			24.3.1 LUBRICATING...............................................................................................................198
		24.4 EVERY 100 HOURS SERVICE.........................................................................................................200
			24.4.1 LUBRICATING...............................................................................................................200
			24.4.2 CHECK OIL LEVEL IN SWING MACHINERY CASE, ADD OIL..........................................................................201
			24.4.3 DRAIN WATER AND SEDIMENT FROM FUEL TANK...................................................................................201
		24.5 EVERY 250 HOURS SERVICE.........................................................................................................202
			24.5.1 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL..............................................................................202
			24.5.2 CHECK LEVEL OF BATTERY ELECTROLYTE........................................................................................203
			24.5.3 CHECK AIR INTAKE SYSTEM...................................................................................................203
			24.5.4 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE.........................................................204
			24.5.5 REPLACE HYDRAULIC FILTER ELEMENT..........................................................................................205
			24.5.6 LUBRICATE SWING CIRCLE (3 POINTS).........................................................................................206
			24.5.7 BELTS, GENERAL............................................................................................................207
			24.5.8 CHECK ALTERNATOR AND FAN BELT TENSION, ADJUST.............................................................................208
			24.5.9 AIR CONDITIONER COMPRESSOR BELT TENSION...................................................................................210
			24.5.10 COOLANT ADDITIVE CONCENTRATION...........................................................................................211
			24.5.11 REPLACE FUEL FILTER CARTRIDGES...........................................................................................211
			24.5.12 REPLACE CORROSION RESISTOR CARTRIDGE.....................................................................................212
		24.6 EVERY 500 HOURS SERVICE.........................................................................................................214
			24.6.1 CHECK SWING PINION GREASE LEVEL, ADD GREASE...............................................................................214
			24.6.2 CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS, AND CONDENSER FINS (ONLY FOR MACHINES EQUIPPED WITH AIR CONDITIONER)....214
			24.6.3 CLEAN FRESH/RECIRC AIR FILTERS OF AIR CONDITIONER SYSTEM (ONLY FOR MACHINES EQUIPPED WITH AIR CONDITIONER)................215
			24.6.4 REPLACE HYDRAULIC TANK BREATHER ELEMENT...................................................................................215
		24.7 EVERY 1000 HOURS SERVICE........................................................................................................216
			24.7.1 CHANGE OIL IN SWING MACHINERY CASE........................................................................................216
			24.7.2 CHECK OIL LEVEL IN DAMPER CASE, ADD OIL...................................................................................217
		24.8 EVERY 1500 HOURS SERVICE........................................................................................................218
			24.8.1 CHECK ALL TIGHTENING PARTS OF TURBOCHARGER................................................................................218
			24.8.2 CHECK HOSES, REPLACE......................................................................................................218
			24.8.3 STEAM CLEAN ENGINE........................................................................................................218
			24.8.4 CHECK ENGINE VALVE CLEARANCE, ADJUST......................................................................................218
		24.9 EVERY 2000 HOURS SERVICE........................................................................................................219
			24.9.1 CHANGE OIL IN FINAL DRIVE CASE............................................................................................219
			24.9.2 CHANGE OIL IN HYDRAULIC TANK, CLEAN STRAINER..............................................................................220
			24.9.3 CHECK ALTERNATOR, STARTING MOTOR..........................................................................................224
		24.10 EVERY 4000 HOURS SERVICE.......................................................................................................225
			24.10.1 CLEAN INSIDE OF COOLING SYSTEM...........................................................................................225
			24.10.2 CHECK WATER PUMP.........................................................................................................230
		24.11 EVERY 6000 HOURS SERVICE.......................................................................................................231
			24.11.1 CHECK PLAY OF TURBOCHARGER ROTOR.........................................................................................231
			24.11.2 CHECK VIBRATION DAMPER...................................................................................................231
			24.11.3 CHECK FAN HUB............................................................................................................231
			24.11.4 CHECK ENGINE IDLER PULLEY................................................................................................231
			24.11.5 CHECK FAN PULLEY AND TENSION PULLEY......................................................................................231
SPECIFICATIONS...............................................................................................................................232
	25. SPECIFICATIONS.......................................................................................................................233
OPTIONS, ATTACHMENTS.........................................................................................................................238
	26. GENERAL PRECAUTIONS..................................................................................................................239
		26.1 PRECAUTIONS RELATED TO SAFETY...................................................................................................239
		26.2 PRECAUTIONS WHEN INSTALLING ATTACHMENTS.........................................................................................240
	27. HANDLING BUCKET WITH HOOK............................................................................................................241
		27.1 CHECK FOR DAMAGE TO BUCKET WITH HOOK............................................................................................241
		27.2 PROHIBITED OPERATIONS...........................................................................................................241
		27.3 PRECAUTIONS DURING OPERATIONS...................................................................................................241
	28. USING SEAT BELT......................................................................................................................242
		28.1 SEAT BELT.......................................................................................................................242
			28.1.1 FASTEN THE BELT AND REMOVE IT.............................................................................................242
			28.1.2 ADJUST THE BELT LENGTH....................................................................................................243
	29. HANDLING CAB HEATER..................................................................................................................244
		29.1 EXPLANATION OF COMPONENTS.......................................................................................................244
		29.2 PREPARING CAB HEATER............................................................................................................245
	30. HANDLING LARGE CAPACITY CAB HEATER...................................................................................................246
		30.1 EXPLANATION OF COMPONENTS.......................................................................................................246
		30.2 PREPARING CAB HEATER............................................................................................................247
	31. MACHINES READY FOR ATTACHMENT........................................................................................................248
		31.1 EXPLANATION OF COMPONENTS.......................................................................................................248
		31.2 HYDRAULIC CIRCUIT...............................................................................................................250
			31.2.1 CONNECTING HYDRAULIC CIRCUIT..............................................................................................251
		31.3 PROCEDURE FOR REMOVAL AND INSTALLATION OF ATTACHMENT............................................................................252
		31.4 OPERATION.......................................................................................................................254
		31.5 LONG-TERM STORAGE...............................................................................................................255
		31.6 SPECIFICATIONS..................................................................................................................255
	32. INTRODUCTION OF ATTACHMENTS..........................................................................................................256
		32.1 SPECIFICATION, USE..............................................................................................................256
		32.2 SPECIFICATION, USE..............................................................................................................257
		32.3 ATTACHMENT INSTALLATION COMBINATION TABLE.......................................................................................258
		32.4 ATTACHMENT INSTALLATION COMBINATION TABLE.......................................................................................259
		32.5 SELECTION OF TRACK SHOES........................................................................................................260
		32.6 BUCKET SELECTION................................................................................................................261
	33. EXTENDING MACHINE SERVICE LIFE.......................................................................................................262
		33.1 HYDRAULIC BREAKER...............................................................................................................262
		33.2 CRUSHER.........................................................................................................................265
		33.3 GRAPPLE.........................................................................................................................266
		33.4 BUCKET WITH THUMB GRAPPLE.......................................................................................................267
		33.5 ROTATING GRAPPLE................................................................................................................268
		33.6 SHEAR...........................................................................................................................269
		33.7 HYDRAULIC PILE DRIVER...........................................................................................................270
		33.8 HYDRAULIC EXCAVATOR WITH MULTI-PURPOSE CRANE....................................................................................271

PLEASE NOTE:

• This is the SAME exact manual used by your dealers to fix your vehicle.
• The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
• Any queries / doubts regarding your purchase, please feel free to contact [email protected]