Komatsu Pc400LC-7L Hydraulic Excavator Operation & Maintenance Manual – PDF DOWNLOAD

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Komatsu Pc400LC-7L Hydraulic Excavator Operation & Maintenance Manual

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Komatsu Pc400LC-7L Hydraulic Excavator Operation & Maintenance Manual

Model Specification: KOMATSU PC400LC-7L HYDRAULIC EXCAVATOR
Language: English
File Format: PDF
Total Pages: 320
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KOMATSU PC400LC-7L HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL – PDF DOWNLOAD:

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DESCRIPTION:

Komatsu Pc400LC-7L 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 Komatsu or 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 Komatsu or your local distributor for the latest available information on your machine or for questions regarding information in this manual.

TABLE OF CONTENTS:

Komatsu Pc400LC-7L Hydraulic Excavator Operation & Maintenance Manual

MAIN MENU...............................................................................................................................................................  0
COVER...................................................................................................................................................................  1
INTRODUCTION............................................................................................................................................................  7
	FOREWORD............................................................................................................................................................  8
	SAFETY INFORMATION..................................................................................................................................................  8
		SAFETY LABELS...................................................................................................................................................  9
	INTRODUCTION........................................................................................................................................................ 10
		INTENDED USE.................................................................................................................................................... 10
		DIRECTIONS OF MACHINE........................................................................................................................................... 10
		BREAKING-IN THE NEW MACHINE..................................................................................................................................... 10
	PRODUCT INFORMATION................................................................................................................................................. 11
		MACHINE SERIAL NUMBER PLATE AND ITS LOCATION.................................................................................................................... 11
		ENGINE SERIAL NUMBER PLATE AND ITS LOCATION..................................................................................................................... 11
	SERVICE METER LOCATION.............................................................................................................................................. 12
	YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR......................................................................................................................... 12
TABLE OF CONTENTS....................................................................................................................................................... 13
SAFETY.................................................................................................................................................................. 19
	SAFETY LABELS....................................................................................................................................................... 20
		LOCATION OF SAFETY LABELS....................................................................................................................................... 20
		SAFETY LABELS................................................................................................................................................... 21
	SAFETY INFORMATION.................................................................................................................................................. 28
		SAFETY RULES.................................................................................................................................................... 28
			IF ABNORMALITIES ARE FOUND.................................................................................................................................. 28
			WORKING WEAR AND PERSONAL PROTECTIVE ITEMS.................................................................................................................. 28
			FIRE EXTINGUISHER AND FIRST AID KIT......................................................................................................................... 28
			SAFETY EQUIPMENT............................................................................................................................................ 29
			KEEP MACHINE CLEAN.......................................................................................................................................... 29
			KEEP OPERATOR'S COMPARTMENT CLEAN........................................................................................................................... 29
			LEAVING OPERATOR'S SEAT WITH LOCK........................................................................................................................... 29
			HANDRAILS AND STEPS......................................................................................................................................... 30
			MOUNTING AND DISMOUNTING.................................................................................................................................... 30
			NO PERSONS ON ATTACHMENTS................................................................................................................................... 30
			BURN PREVENTION............................................................................................................................................. 31
			FIRE PREVENTION AND EXPLOSION PREVENTION.................................................................................................................... 31
			ACTION IF FIRE OCCURS....................................................................................................................................... 32
			WINDSHIELD WASHER FLUID..................................................................................................................................... 32
			FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION............................................................................................ 33
			ATTACHMENT INSTALLATION..................................................................................................................................... 33
			ATTACHMENT COMBINATIONS..................................................................................................................................... 33
			CAB WINDOW GLASSES.......................................................................................................................................... 33
			UNAUTHORIZED MODIFICATIONS.................................................................................................................................. 33
			SAFETY AT JOBSITE........................................................................................................................................... 34
			WORKING ON LOOSE GROUND..................................................................................................................................... 34
			DISTANCE TO HIGH VOLTAGE CABLES............................................................................................................................. 35
			ENSURE GOOD VISIBILITY...................................................................................................................................... 35
			VENTILATION FOR ENCLOSED AREA............................................................................................................................... 35
			SIGNALMAN'S SIGNAL AND SIGNS................................................................................................................................ 36
			EMERGENCY EXIT FROM OPERATOR'S CAB.......................................................................................................................... 36
			ASBESTOS DUST HAZARD PREVENTION............................................................................................................................. 36
	SAFETY MACHINE OPERATION............................................................................................................................................ 37
		STARTING ENGINE................................................................................................................................................. 37
			CHECKS BEFORE STARTING ENGINE............................................................................................................................... 37
			SAFETY RULES FOR STARTING ENGINE............................................................................................................................ 37
			STARTING ENGINE IN COLD WEATHER............................................................................................................................. 38
		OPERATION....................................................................................................................................................... 39
			CHECKS BEFORE OPERATION..................................................................................................................................... 39
			SAFETY RULES FOR CHANGING MACHINE DIRECTIONS................................................................................................................ 39
			SAFETY RULES FOR TRAVELING.................................................................................................................................. 40
			TRAVELING ON SLOPES......................................................................................................................................... 41
			OPERATIONS ON SLOPES........................................................................................................................................ 42
			PROHIBITED OPERATIONS....................................................................................................................................... 42
			OPERATIONS ON SNOW.......................................................................................................................................... 44
			PARKING MACHINE............................................................................................................................................. 44
		TRANSPORTATION.................................................................................................................................................. 45
			LOADING AND UNLOADING....................................................................................................................................... 45
			SHIPPING THE MACHINE........................................................................................................................................ 45
		BATTERY......................................................................................................................................................... 46
			BATTERY HAZARD PREVENTION................................................................................................................................... 46
			STARTING ENGINE WITH BOOSTER CABLES......................................................................................................................... 47
		TOWING.......................................................................................................................................................... 48
			SAFETY RULES FOR TOWING..................................................................................................................................... 48
		LIFTING OBJECTS WITH BUCKET..................................................................................................................................... 49
			SAFETY RULES FOR LIFTING OBJECTS............................................................................................................................ 49
	SAFETY MAINTENANCE INFORMATION...................................................................................................................................... 50
		WARNING TAG..................................................................................................................................................... 50
		KEEP WORK PLACE CLEAN AND TIDY.................................................................................................................................. 50
		APPOINT LEADER WHEN WORKING WITH OTHERS......................................................................................................................... 50
		STOP ENGINE BEFORE CARRYING OUT MAINTENANCE..................................................................................................................... 51
		TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING.............................................................................................................. 51
		PROPER TOOLS.................................................................................................................................................... 52
		ACCUMULATOR..................................................................................................................................................... 52
		PERSONNEL....................................................................................................................................................... 52
		ATTACHMENTS..................................................................................................................................................... 53
		WORK UNDER THE MACHINE.......................................................................................................................................... 53
		NOISE........................................................................................................................................................... 53
		WHEN USING HAMMER............................................................................................................................................... 53
		WELDING WORKS................................................................................................................................................... 54
		REMOVING BATTERY TERMINALS...................................................................................................................................... 54
		SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION............................................................................................ 54
		DO NOT DISASSEMBLE RECOIL SPRINGS............................................................................................................................... 54
		SAFETY RULES FOR HIGH-PRESSURE OIL.............................................................................................................................. 55
		SAFETY HANDLING HIGH-PRESSURE HOSES............................................................................................................................. 55
		WASTE MATERIALS................................................................................................................................................. 55
		AIR CONDITIONER MAINTENANCE..................................................................................................................................... 56
		COMPRESSED AIR.................................................................................................................................................. 56
		PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS................................................................................................................... 56
OPERATION............................................................................................................................................................... 57
	MACHINE VIEW ILLUSTRATIONS.......................................................................................................................................... 58
		OVERALL MACHINE VIEW............................................................................................................................................ 58
		CONTROLS AND GAUGES............................................................................................................................................. 59
	DETAILED CONTROLS AND GAUGES........................................................................................................................................ 61
		MONITORING SYSTEM............................................................................................................................................... 61
			BASIC OPERATION OF MACHINE MONITOR.......................................................................................................................... 62
			BASIC CHECK MONITORS........................................................................................................................................ 64
			CAUTION MONITORS............................................................................................................................................ 66
			EMERGENCY MONITORS.......................................................................................................................................... 68
			METER DISPLAY PORTION....................................................................................................................................... 70
			GAUGES AND METER............................................................................................................................................ 73
			MONITOR SWITCHES PORTION.................................................................................................................................... 75
		SWITCHES........................................................................................................................................................ 86
		CONTROL LEVERS AND PEDALS....................................................................................................................................... 91
	SUN ROOF............................................................................................................................................................ 94
	WINDSHIELD.......................................................................................................................................................... 94
	EMERGENCY EXIT FROM OPERATOR'S CAB.................................................................................................................................. 99
	DOOR LOCK........................................................................................................................................................... 99
	CAP WITH LOCK.......................................................................................................................................................100
	HOT AND COOL BOX....................................................................................................................................................101
	MAGAZINE BOX........................................................................................................................................................102
	ASHTRAY.............................................................................................................................................................102
	AIR CONDITIONER CONTROLS............................................................................................................................................103
		AIR CONDITIONER CONTROL PANEL...................................................................................................................................103
		METHOD OF OPERATION.............................................................................................................................................108
		OTHER FUNCTIONS.................................................................................................................................................115
	RADIO...............................................................................................................................................................117
		CONTROL PANEL...................................................................................................................................................117
		CONTROLS OF RADIO...............................................................................................................................................119
			PRESET STATION BUTTONS......................................................................................................................................119
			SETTING CORRECT TIME........................................................................................................................................120
	AUXILIARY ELECTRIC POWER............................................................................................................................................121
		24V POWER SOURCE................................................................................................................................................121
		12V POWER SOURCE................................................................................................................................................121
	FUSE................................................................................................................................................................122
	FUSIBLELINK.........................................................................................................................................................123
	CONTROLLERS.........................................................................................................................................................124
	TOOL BOX............................................................................................................................................................125
	GREASE GUN HOLDER...................................................................................................................................................125
	ACCUMULATOR.........................................................................................................................................................126
		RELEASING HYDRAULIC PRESSURE WITH ACCUMULATOR...................................................................................................................126
	MACHINE OPERATIONS AND CONTROLS.....................................................................................................................................127
		BEFORE STARTING ENGINE..........................................................................................................................................127
			WALK-AROUND CHECKS..........................................................................................................................................127
			CHECKS BEFORE STARTING......................................................................................................................................128
			SEAT ADJUSTMENT.............................................................................................................................................134
			SEAT BELT...................................................................................................................................................137
			OPERATIONS BEFORE STARTING ENGINE...........................................................................................................................138
		STARTING ENGINE.................................................................................................................................................141
			NORMAL STARTING.............................................................................................................................................141
			STARTING ENGINE IN COLD WEATHER.............................................................................................................................143
		AFTER STARTING ENGINE...........................................................................................................................................146
			WARMING-UP OPERATION........................................................................................................................................146
			COLD WEATHER AREAS..........................................................................................................................................150
		STOPPING THE ENGINE.............................................................................................................................................155
		MACHINE OPERATION...............................................................................................................................................156
		STEERING THE MACHINE............................................................................................................................................160
		STRAIGHT TRAVEL SYSTEM (STS) / ATTACHMENT CONTROL PEDAL.........................................................................................................162
			LOCKED PIN POSITIONS........................................................................................................................................162
			STRAIGHT TRAVEL DIRECTION...................................................................................................................................162
		SWINGING........................................................................................................................................................163
		WORK EQUIPMENT CONTROLS AND OPERATIONS..........................................................................................................................164
		WORKING MODE....................................................................................................................................................166
		PROHIBITED OPERATIONS...........................................................................................................................................167
		GENERAL OPERATION INFORMATION...................................................................................................................................169
		TRAVELING ON SLOPES.............................................................................................................................................170
		ESCAPE FROM MUD.................................................................................................................................................172
		RECOMMENDED APPLICATIONS........................................................................................................................................173
		BUCKET REPLACEMENT AND INVERSION................................................................................................................................175
		PARKING MACHINE.................................................................................................................................................178
		CHECK AFTER SHUT OFF ENGINE.....................................................................................................................................179
		MACHINE INSPECTION AFTER DAILY WORK.............................................................................................................................179
		LOCKING.........................................................................................................................................................180
	TRANSPORTATION......................................................................................................................................................181
		PRECAUTIONS FOR TRANSPORTATION..................................................................................................................................181
		LIFTING MACHINE.................................................................................................................................................181
		PRECAUTIONS WHEN LOADING........................................................................................................................................182
		TRANSPORTATION POSTURE..........................................................................................................................................182
		TRACK FRAME GAUGE...............................................................................................................................................186
			REDUCING TRACK GAUGE........................................................................................................................................186
			INCREASING TRACK GUAGE......................................................................................................................................186
	COLD WEATHER OPERATION..............................................................................................................................................187
		COLD WEATHER OPERATION INFORMATION..............................................................................................................................187
		AFTER DAILY WORK COMPLETION.....................................................................................................................................189
		AFTER COLD WEATHER SEASON.......................................................................................................................................189
	LONG TERM STORAGE...................................................................................................................................................190
		BEFORE STORAGE..................................................................................................................................................190
		DURING STORAGE..................................................................................................................................................190
		AFTER STORAGE...................................................................................................................................................191
		STARTING MACHINE AFTER LONG-TERM STORAGE........................................................................................................................191
	TROUBLES AND ACTIONS................................................................................................................................................192
		RUNNING OUT OF FUEL.............................................................................................................................................192
		PHENOMENA THAT ARE NOT FAILURES.................................................................................................................................193
		TOWING THE MACHINE..............................................................................................................................................194
		LIGHTWEIGHT TOWING HOLE.........................................................................................................................................195
		SEVERE JOB CONDITION............................................................................................................................................195
		DISCHARGED BATTERY..............................................................................................................................................196
		OTHER TROUBLE...................................................................................................................................................200
MAINTENANCE.............................................................................................................................................................205
	MAINTENANCE INFORMATION.............................................................................................................................................206
	LUBRICANTS, COOLANT AND FILTERS.....................................................................................................................................208
		HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC..........................................................................................................208
	ELECTRIC SYSTEM MAINTENANCE.........................................................................................................................................211
	WEAR PARTS..........................................................................................................................................................212
		WEAR PARTS LIST.................................................................................................................................................212
	LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS.........................................................................................................................213
	TIGHTENING TORQUE SPECIFICATIONS....................................................................................................................................217
		TIGHTENING TORQUE LIST..........................................................................................................................................217
	SAFETY CRITICAL PARTS...............................................................................................................................................219
		SAFETY CRITICAL PARTS LIST......................................................................................................................................219
	MAINTENANCE SCHEDULE................................................................................................................................................220
		MAINTENANCE SCHEDULE CHART......................................................................................................................................220
		MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER......................................................................................................................222
			REPLACE HYDRAULIC OIL FILTER ELEMENT........................................................................................................................222
			CHANGE OIL IN HYDRAULIC TANK................................................................................................................................222
			REPLACE ADDITIONAL FILTER ELEMENT FOR BREAKER...............................................................................................................222
	MAINTENANCE PROCEDURE...............................................................................................................................................223
		INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)..................................................................................................223
			REPLACE FUEL FILTER CARTRIDGE...............................................................................................................................263
		INITIAL 1000 HOURS MAINTENANCE (ONLY AFTER THE FIRST 1000 HOURS)................................................................................................223
			CHECK ENGINE VALVE CLEARANCE, ADJUST........................................................................................................................282
		WHEN REQUIRED...................................................................................................................................................224
			CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT................................................................................................................224
			CLEAN INSIDE OF COOLING SYSTEM..............................................................................................................................229
			CHECK AND TIGHTEN TRACK SHOE BOLTS..........................................................................................................................232
			CHECK AND ADJUST TRACK TENSION..............................................................................................................................233
			CHECK ELECTRICAL INTAKE AIR HEATER..........................................................................................................................234
			REPLACE BUCKET TEETH (VERTICAL PIN TYPE)....................................................................................................................235
			REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)..................................................................................................................238
			REPLACE BUCKET SIDE CUTTER, SHROUD..........................................................................................................................239
			ADJUST BUCKET CLEARANCE.....................................................................................................................................240
			CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID..................................................................................................................241
			CHECK AND ADJUST AIR CONDITIONER............................................................................................................................242
			WASH WASHABLE FLOOR.........................................................................................................................................243
			BLEEDING AIR FROM HYDRAULIC SYSTEM..........................................................................................................................247
			METHOD FOR RELEASING INTERNAL PRESSURE IN HYDRAULIC CIRCUIT.................................................................................................249
			CHECK NITROGEN GAS CHARGE PRESSURE IN ACCUMULATOR (CONTROL CIRCUIT).........................................................................................250
		CHECK BEFORE STARTING...........................................................................................................................................251
		EVERY 250 HOURS MAINTENANCE.....................................................................................................................................252
			LUBRICATING.................................................................................................................................................252
			CHECK OIL LEVEL IN SWING MACHINERY CASE, ADD OIL............................................................................................................253
			CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL................................................................................................................254
			CHECK LEVEL OF BATTERY ELECTROLYTE..........................................................................................................................255
			LUBRICATE SWING CIRCLE......................................................................................................................................258
			CHECK FAN BELT, ALTERNATOR BELT TENSION, ADJUST.............................................................................................................258
			CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST.......................................................................................................260
		EVERY 500 HOURS MAINTENANCE.....................................................................................................................................261
			LUBRICATING.................................................................................................................................................261
			REPLACE FUEL FILTER CARTRIDGE...............................................................................................................................263
			CHECK, WASH FUEL STRAINER...................................................................................................................................265
			CHECK SWING PINION GREASE LEVEL, ADD GREASE.................................................................................................................266
			CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE...........................................................................................267
			CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS, AFTER COOLER FINS, FUEL COOLER FINS, AND CONDENSER FINS (ONLY MACHINES EQUIPPED WITH AIR CONDI TIONER)....269
			CLEAN AIR CONDITIONER FRESH/RECIRC FILTERS..................................................................................................................270
			REPLACE BREATHER ELEMENT IN HYDRAULIC TANK..................................................................................................................271
			REPLACE ADDITIONAL FUEL FILTER CARTRIDGE....................................................................................................................272
		EVERY 1000 HOURS MAINTENANCE....................................................................................................................................274
			REPLACE HYDRAULIC OIL FILTER ELEMENT........................................................................................................................274
			CHANGE OIL IN SWING MACHINERY CASE..........................................................................................................................276
			CHECK OIL LEVEL IN DAMPER CASE, ADD OIL.....................................................................................................................277
			CHECK ALL TIGHTENING PARTS OF TURBOCHARGER..................................................................................................................277
			CHECK PLAY TURBOCHARGER ROTOR...............................................................................................................................277
			REPLACE CORROSION RESISTOR CARTRIDGE........................................................................................................................278
			REPLACE HYDRAULIC TANK ADDITIONAL BREATHER ELEMENT..........................................................................................................279
			CHECK NITROGEN GAS CHARGE PRESSURE IN ACCUMULATOR (for breaker).............................................................................................279
		EVERY 2000 HOURS MAINTENANCE....................................................................................................................................280
			CHANGE OIL IN FINAL DRIVE CASE..............................................................................................................................280
			CHECK INJECTOR..............................................................................................................................................280
			CLEAN HYDRAULIC TANK STRAINER...............................................................................................................................281
			CLEAN ENGINE BREATHER.......................................................................................................................................281
			CLEAN, CHECK TURBOCHARGER...................................................................................................................................282
			CHECK ALTERNATOR, STARTING MOTOR............................................................................................................................282
			CHECK ENGINE VALVE CLEARANCE, ADJUST........................................................................................................................282
			CHECK VIBRATION DAMPER......................................................................................................................................282
		EVERY 4000 HOURS MAINTENENCE....................................................................................................................................283
			CHECK WATER PUMP............................................................................................................................................283
			CHECK FOR LOOSENESS OF HIGH-PRESSURE CLAMP, HARDENING OF RUBBER.............................................................................................283
			CHECK FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER............................................................................................284
			REPLACE INJECTOR NOZZLE ASSEMBLY............................................................................................................................284
		EVERY 5000 HOURS MAINTENANCE....................................................................................................................................285
			CHANGE OIL IN HYDRAULIC TANK................................................................................................................................285
		EVERY 8000 HOURS MAINTENANCE....................................................................................................................................287
			REPLACE HIGH-PRESSURE PIPING CLAMP..........................................................................................................................287
			REPLACE FUEL SPRAY PREVENTION CAP...........................................................................................................................287
SPECIFICATIONS..........................................................................................................................................................289
	SPECIFICATIONS......................................................................................................................................................290
OPTIONS, ATTACHMENTS....................................................................................................................................................295
	GENERAL PRECAUTIONS FOR SAFETY......................................................................................................................................296
		PRECAUTIONS WHEN SELECTING......................................................................................................................................296
		READ THE INSTRUCTION MANUAL THOROUGHLY..........................................................................................................................296
		PRECAUTIONS WHEN REMOVING OR INSTALLING.........................................................................................................................296
		PRECAUTIONS WHEN USING..........................................................................................................................................297
	MACHINE READY FOR ATTACHMENT........................................................................................................................................298
		LOCATIONS.......................................................................................................................................................298
		HYDRAULIC CIRCUIT...............................................................................................................................................302
		ATTACHMENT REMOVAL AND INSTALLATION.............................................................................................................................306
		ATTACHMENT OPERATIONS...........................................................................................................................................308
		LONG TERM STORAGE...............................................................................................................................................310
		SPECIFICATIONS..................................................................................................................................................310
	ATTACHMENT GUIDE....................................................................................................................................................311
		ATTACHMENT COMBINATIONS.........................................................................................................................................311
	RECOMMENDED ATTACHMENT OPERATIONS...................................................................................................................................313
		HYDRAULIC BREAKER...............................................................................................................................................313

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