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KOMATSU PC400LC-8 HYDRAULIC EXCAVATOR Operation & Maintenance Manual (SN:A88001 and UP) – PDF DOWNLOAD
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- KOMATSU PC400LC-8 HYDRAULIC EXCAVATOR Operation & Maintenance Manual
- Serial Number:A88001 and UP
- Publication Number:CEAM009902
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Description
KOMATSU PC400LC-8 HYDRAULIC EXCAVATOR Operation & Maintenance Manual (SN:A88001 and UP)
KOMATSU PC400LC-8 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (SN:A88001 AND UP) – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU PC400LC-8 HYDRAULIC EXCAVATOR Operation & Maintenance Manual (SN:A88001 and UP)
- Before beginning operation or maintenance, operators and maintenance personnel must always observe the following points.
● Read this manual thoroughly and understand its contents fully.
● Read the safety messages and safety labels given in this manual carefully so that they should be understood fully. - Keep this manual at the storage location for the Operation and Maintenance Manual given below so that all personnel involved in working on the machine can consult it periodically.
- In case this manual should be lost or damaged, immediately contact Komatsu or your Komatsu distributor to obtain a new copy.
- When you sell the machine, make sure that this manual should be provided to the new owner together with the machine.
- In this manual, measurements are expressed in international standard units (SI). For reference purposes, weight units used in the past are also displayed in (_).
TABLE OF CONTENTS:
KOMATSU PC400LC-8 HYDRAULIC EXCAVATOR Operation & Maintenance Manual (SN:A88001 and UP)
INTRODUCTION......................................................................................... 3 FOREWORD......................................................................................... 4 SAFETY INFORMATION............................................................................... 5 INTRODUCTION..................................................................................... 7 Directions Of Machine........................................................................ 7 Visibility From Operator's Seat.............................................................. 8 Proximity Visibility..................................................................... 8 12 m Circumference Visibility............................................................ 9 Breaking-in The New Machine.................................................................. 10 Product Information.......................................................................... 11 Product Identification Number (PIN)/machine Serial No. Plate............................. 11 EPA Regulations, Engine Number Plate..................................................... 11 Service Meter Location....................................................................... 12 Your Machine Serial Numbers And Distributor.................................................. 12 TABLE OF CONTENTS................................................................................ 13 SAFETY............................................................................................... 21 SAFETY AND WARNING DECALS........................................................................ 22 Location Of The Safety Decals................................................................ 22 Safety Labels................................................................................ 23 Optional Systems Decal....................................................................... 29 Optional Decal Locations..................................................................... 32 GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE.......................................... 33 Precautions Before Starting Operation........................................................ 33 Ensuring Safe Operation.................................................................. 33 Understanding The Machine................................................................ 33 Preparations For Safe Operation.............................................................. 33 Precautions Regarding Safety-related Equipment........................................... 33 Inspecting Machine....................................................................... 33 SAFETY INFORMATION............................................................................... 33 Safety Rules................................................................................. 33 If Problems Are Found........................................................................ 34 Working Wear And Personal Protective Items................................................... 34 Fire Extinguisher And First Aid Kit.......................................................... 34 Safety Equipment............................................................................. 35 Keep Machine Clean........................................................................... 35 Keep Operator's Compartment Clean............................................................ 35 Precautions When Standing Up From Operator's Seat............................................ 35 Leaving Operator's Seat With Lock............................................................ 36 Emergency Exit From Operator's Cab........................................................... 36 Handrails And Steps.......................................................................... 37 Precautions When Working In High Places...................................................... 37 Mounting And Dismounting..................................................................... 37 No Persons On Attachments.................................................................... 37 Do Not Get Caught In Articulated Portion..................................................... 38 Burn Prevention.............................................................................. 38 Protection Against Falling Or Flying Objects................................................. 38 Fire Prevention And Explosion Prevention..................................................... 39 Action If Fire Occurs........................................................................ 40 Windshield Washer Fluid...................................................................... 40 Falling Objects, Flying Objects And Intruding Objects Prevention............................. 40 Attachment Installation...................................................................... 41 Attachment Combinations...................................................................... 41 Precautions Related To Cab Glass............................................................. 41 Unauthorized Modifications................................................................... 41 Safety At Jobsite............................................................................ 41 Working On Loose Ground...................................................................... 42 Distance To High Voltage Cables.............................................................. 43 Ensure Good Visibility....................................................................... 43 Ventilation For Enclosed Area................................................................ 44 Signalman's Signal And Signs................................................................. 44 Asbestos Dust Hazard Prevention.............................................................. 44 SAFETY MACHINE OPERATION......................................................................... 45 Starting Engine.............................................................................. 45 Checks Before Starting Engine................................................................ 45 Safety Rules For Starting Engine............................................................. 46 Starting Engine In Cold Weather.............................................................. 46 Starting With Booster Cables................................................................. 46 OPERATION........................................................................................ 47 Checks Before Operation...................................................................... 47 Safety Rules For Changing Machine Directions................................................. 47 Safety Rules For Traveling................................................................... 48 Traveling On Slopes.......................................................................... 48 Operations On Slopes......................................................................... 49 Prohibited Operations........................................................................ 50 Operations On Snow........................................................................... 51 Parking Machine.............................................................................. 52 TRANSPORTATION................................................................................... 53 Loading And Unloading........................................................................ 53 Shipping The Machine......................................................................... 54 TOWING........................................................................................... 54 Safety Rules For Towing...................................................................... 54 BATTERY.......................................................................................... 55 Battery Hazard Prevention.................................................................... 55 LIFTING OBJECTS WITH BUCKET...................................................................... 56 Safety Rules For Lifting Objects............................................................. 56 SAFETY MAINTENANCE INFORMATION................................................................... 57 Warning Tag.................................................................................. 57 Keep Work Place Clean And Tidy............................................................... 57 Select Suitable Place For Inspection And Maintenance......................................... 57 Only Authorized Personnel.................................................................... 57 Appoint Leader When Working With Others...................................................... 57 Stop Engine Before Carrying Out Maintenance.................................................. 58 Two Workers For Maintenance When Engine Is Running........................................... 58 Proper Tools................................................................................. 59 Precautions When Working At High Places...................................................... 59 Accumulator, Gas Spring...................................................................... 60 Personnel.................................................................................... 60 Attachments.................................................................................. 60 Work Under The Machine....................................................................... 60 Noise........................................................................................ 60 When Using Hammer............................................................................ 61 Welding Works................................................................................ 61 Removing Battery Terminals................................................................... 61 Safety First When Using High-pressure Grease To Adjust Track Tension......................... 61 Do Not Disassemble Recoil Springs............................................................ 62 Safety Rules For High-pressure Oil........................................................... 62 Precaution For High Fuel Pressure............................................................ 62 Safety Handling High-pressure Hoses.......................................................... 63 Precaution For High Voltage.................................................................. 63 Waste Materials.............................................................................. 63 Air Conditioner Maintenance.................................................................. 64 Compressed Air............................................................................... 64 Periodic Replacement Of Safety Critical Parts................................................ 64 OPERATION............................................................................................ 65 MACHINE VIEW ILLUSTRATIONS....................................................................... 66 Overall Machine View......................................................................... 66 Controls And Gauges.......................................................................... 67 Machine Monitor.............................................................................. 68 DETAILED CONTROLS AND GAUGES..................................................................... 69 Monitoring System............................................................................ 69 Basic Operation Of Machine Monitor........................................................... 70 Emergency Monitors........................................................................... 75 Caution Monitors............................................................................. 77 Basic Check Monitors......................................................................... 79 Meter Display Portion........................................................................ 81 Gauges And Meter............................................................................. 85 Monitor Switches Portion..................................................................... 89 Maintenance Selector Switch..................................................................105 SWITCHES.........................................................................................137 CONTROL LEVERS AND PEDALS........................................................................142 SUN ROOF.........................................................................................145 WINDSHIELD.......................................................................................145 EMERGENCY ESCAPE HAMMER..........................................................................152 DOOR LOCK........................................................................................152 CAP WITH LOCK....................................................................................153 DRINK BOX........................................................................................155 MAGAZINE BOX.....................................................................................155 ASHTRAY..........................................................................................155 AIR CONDITIONER CONTROLS.........................................................................156 Air Conditioner Control Panel................................................................156 Method Of Operation..........................................................................161 Automatic Operation......................................................................161 Stopping Automatic Operation.............................................................162 Manual Operation.........................................................................162 Stopping Manual Operation................................................................164 Operation With Cold Air To Face And Warm Air To Feet.....................................164 Defroster Operation......................................................................166 RADIO............................................................................................169 Control Panel................................................................................169 Controls Of Radio............................................................................171 AUXILIARY ELECTRIC POWER.........................................................................174 24 V Power Source............................................................................174 12 V Power Source............................................................................174 FUSE.............................................................................................175 FUSIBLE LINK.....................................................................................176 CONTROLLER.......................................................................................176 TOOL BOX.........................................................................................177 GREASE PUMP HOLDER...............................................................................177 FIRE EXTINGUISHER................................................................................177 MACHINE OPERATIONS AND CONTROLS..................................................................178 Before Starting Engine.......................................................................178 Walk-around Checks.......................................................................178 Checks Before Starting...................................................................180 Adjustment...................................................................................186 Seat Adjustment..........................................................................186 Adjusting Angle Of Rear View Camera......................................................188 Rear View Mirrors........................................................................190 Seat Belt Inspection.....................................................................193 Seat Belt................................................................................194 Operations Before Starting Engine............................................................195 Starting Engine..............................................................................197 After Starting Engine........................................................................200 Breaking-in the New Machine..................................................................200 Engine Warm Up...............................................................................201 Hydraulic System Warm-up.....................................................................203 Operation After Completion Of Warming-up Operation...........................................209 Stopping The Engine..........................................................................211 MACHINE OPERATION................................................................................212 Preparations For Moving The Machine..........................................................212 Moving Machine Forward.......................................................................213 Moving Machine Backward......................................................................214 Stopping Machine.............................................................................215 Steering The Machine.........................................................................216 Swinging.....................................................................................218 Work Equipment Controls And Operations.......................................................219 Working Mode.................................................................................221 Prohibited Operations........................................................................223 General Operation Information................................................................228 Traveling On Slopes..........................................................................230 Escape From Mud..............................................................................232 Recommended Applications.....................................................................233 BUCKET REPLACEMENT AND INVERSION.................................................................235 Replacement..................................................................................235 Inversion....................................................................................237 PARKING MACHINE..................................................................................239 MACHINE INSPECTION AFTER DAILY WORK..............................................................241 Locking......................................................................................241 TRANSPORTATION...................................................................................242 Transportation Procedure.....................................................................242 Long Distance Transport Mode.................................................................243 Normal Mode Display......................................................................243 Long Distance Transport Mode Display.....................................................243 Loading And Unloading With Trailer...........................................................245 Loading..................................................................................246 Securing Machine.........................................................................249 Unloading................................................................................252 LIFTING MACHINE..................................................................................254 TRANSPORTATION POSTURE...........................................................................256 INCREASING OR REDUCING TRACK FRAME GAUGE.........................................................259 COLD WEATHER OPERATION...........................................................................261 AFTER DAILY WORK COMPLETION......................................................................263 AFTER COLD WEATHER SEASON........................................................................263 LONG TERM STORAGE................................................................................264 Before Storage...............................................................................264 During Storage...............................................................................264 After Storage................................................................................265 Starting Machine After Long-Term Storage.....................................................265 TROUBLES AND ACTIONS.............................................................................266 Running Out Of Fuel..........................................................................266 Phenomena That Are Not Failures..............................................................267 Towing The Machine...........................................................................268 Lightweight Towing Hole......................................................................269 Severe Job Condition.........................................................................269 Discharged Battery...........................................................................270 Starting Engine With Booster Cables..........................................................272 OTHER TROUBLE....................................................................................274 Electrical System............................................................................274 Chassis......................................................................................275 Engine.......................................................................................276 Electronic Control System....................................................................277 MAINTENANCE..........................................................................................279 MAINTENANCE INFORMATION..........................................................................280 OUTLINE OF SERVICE...............................................................................282 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC...........................................282 Oil..........................................................................................282 Fuel.........................................................................................283 Coolant And Water For Dilution...............................................................283 Grease.......................................................................................284 Carrying Out KOWA (Komatsu Oil Wear Analysis)................................................284 KOWA Analysis Items......................................................................284 Oil Sampling.............................................................................285 Storing Oil And Fuel.....................................................................285 Filters..................................................................................285 Electric System Maintenance..............................................................285 WEAR PARTS.......................................................................................286 Wear Parts List..............................................................................286 RECOMMENDED FUEL, COOLANT, AND LUBRICANT.........................................................287 TIGHTENING TORQUE SPECIFICATIONS.................................................................290 Tightening Torque List.......................................................................290 SAFETY CRITICAL PARTS............................................................................291 Safety Critical Parts List...................................................................291 MAINTENANCE SCHEDULE.............................................................................292 Maintenance Schedule Chart...................................................................292 Maintenance Interval For Hydraulic Breaker...................................................294 LUBRICATION CHART................................................................................295 MAINTENANCE PROCEDURE............................................................................295 Initial 1000 Hours Maintenance (Only After The First 1000 Hours).............................295 When Required................................................................................296 Check, Clean And Replace Air Cleaner Element.............................................296 Clean Inside Of Cooling System...........................................................302 Check And Tighten Track Shoe Bolts.......................................................306 Check And Adjust Track Tension...........................................................307 Replace Bucket Teeth (Vertical Pin Type).................................................309 Replace Bucket Teeth (Horizontal Pin Type)...............................................312 Replace Bucket Side Cutter, Shroud.......................................................314 Adjust Bucket Clearance..................................................................315 Check Window Washer Fluid Level, Add Fluid...............................................316 Check And Maintenance Air Conditioner....................................................317 Wash Washable Floor......................................................................318 Check Gas Spring.........................................................................321 Bleeding Air From Hydraulic System.......................................................322 Check Before Starting........................................................................324 Every 50 Hours Maintenance...................................................................325 Lubricating..............................................................................325 Every 250 Hours Maintenance..................................................................326 Lubricate Swing Circle...................................................................326 Check Level Of Battery Electrolyte.......................................................327 Check Fan Belt, Alternator Belt Tension, Adjust..........................................329 Check Air Conditioner Compressor Belt Tension, Adjust....................................330 Every 500 Hours Maintenance..................................................................331 Lubricating..............................................................................331 Replace Fuel Pre-filter Cartridge........................................................333 Check Swing Pinion Grease Level, Add Grease..............................................335 Check Oil Level In Swing Machinery Case, Add Oil.........................................336 Check Oil Level In Final Drive Case, Add Oil.............................................337 Change Oil In Engine Oil Pan, Replace Engine Oil Filter Cartridge........................338 Clean And Inspect Radiator Fins, Oil Cooler Fins, Aftercooler Fins And Condenser Fins....340 Clean Air Conditioner Fresh/recirc Filters...............................................342 Replace Breather Element In Hydraulic Tank...............................................343 Every 1000 Hours Maintenance.................................................................344 Replace Fuel Main Filter Cartridge.......................................................344 Replace Hydraulic Oil Filter Element.....................................................347 Change Oil In Swing Machinery Case.......................................................348 Check Oil Level In Damper Case, Add Oil..................................................349 Check All Tightening Points Of Engine Exhaust Pipe Clamps................................349 Check Nitrogen Gas Charge Pressure In Accumulator (For Breaker)..........................349 Replace Hydraulic Tank Additional Breather Element.......................................350 Replace Corrosion Resistor Cartridge.....................................................351 Every 2000 Hours Maintenance.................................................................352 Change Oil In Final Drive Case...........................................................352 Clean Hydraulic Tank Strainer............................................................353 Checking Charge Pressure Of Nitrogen Gas In Accumulator (For Control Circuit)............354 Checking Function Of Accumulator.........................................................355 Releasing Pressure In Hydraulic Circuit..................................................357 Check Alternator.........................................................................358 Check Engine Valve Clearance, Adjust.....................................................358 Check Vibration Damper...................................................................358 Every 4000 Hours Maintenance.................................................................359 Check Water Pump.........................................................................359 Check Starting Motor.....................................................................359 Replace Accumulator (For Control Circuit)................................................359 Check For Looseness Of High-pressure Piping Clamp, Hardening Of Rubber...................360 Check For Missing Fuel Spray Prevention Cap, Hardening Of Rubber.........................360 Every 5000 Hours Maintenance.................................................................361 Change Oil In Hydraulic Tank.............................................................361 Every 8000 Hours Maintenance.................................................................363 Replace High-pressure Piping Clamp.......................................................363 Replace Fuel Spray Prevention Cap........................................................363 SPECIFICATIONS.......................................................................................365 SPECIFICATIONS...................................................................................366 OPTIONS, ATTACHMENTS.................................................................................369 GENERAL PRECAUTIONS FOR SAFETY...................................................................370 Precautions When Selecting...................................................................370 Read The Instruction Manual Thoroughly.......................................................370 Precautions When Removing Or Installing......................................................370 Precautions When Using.......................................................................370 BUCKET WITH HOOK.................................................................................371 Hook Condition...............................................................................371 Prohibited Operations........................................................................371 MACHINE READY FOR ATTACHMENT.....................................................................372 Locations....................................................................................372 ATTACHMENT REMOVAL AND INSTALLATION..............................................................382 Attachment Removal...........................................................................382 Attachment Installation......................................................................384 ATTACHMENT OPERATIONS............................................................................386 Long Term Storage............................................................................387 Specifications...............................................................................387 HANDLING THE ELECTRIC PRIMING PUMP...............................................................388 Bleeding Air From Fuel Circuit...............................................................388 ATTACHMENT GUIDE.................................................................................391 Attachment Combinations......................................................................391 Track Shoes Selection........................................................................393 Selecting Shoes..........................................................................393 RECOMMENDED ATTACHMENT OPERATIONS................................................................394 Hydraulic Breaker............................................................................394 HANDLING MACHINES EQUIPPED WITH KOMTRAX..........................................................399 COUNTERWEIGHT REMOVER............................................................................400 Removing the Counterweight...................................................................401 Installing the Counterweight.................................................................408
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