KOMATSU PC400LG5 WITH CUMMINS LTA-IOC ENGINE HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL KOMATSU PC400LG5 – PDF DOWNLOAD

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KOMATSU PC400LG5 WITH CUMMINS LTA-IOC ENGINE HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL KOMATSU PC400LG5

KOMATSU PC400LG5 WITH CUMMINS LTA-IOC ENGINE HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL KOMATSU PC400LG5 – PDF DOWNLOAD:

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KOMATSU PC400LG5 WITH CUMMINS LTA-IOC ENGINE HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL KOMATSU PC400LG5

• 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 PC400LG5 WITH CUMMINS LTA-IOC ENGINE HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL KOMATSU PC400LG5

MAIN MENU........................................................................  0
1.  FORWARD......................................................................  3
2.  SAFETY INFORMATION...........................................................  4
3.  INTRODUCTION.................................................................  5
4.  LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR................  6
5.  CONTENTS.....................................................................  7
SAFETY........................................................................... 11
	6.  GENERAL PRECAUTIONS...................................................... 12
	7.  PRECAUTIONS DURING OPERATION............................................. 18
		7.1  BEFORE STARTING ENGINE.............................................. 18
		7.2  OPERATING MACHINE................................................... 20
		7.3  TRANSPORTATION...................................................... 26
		7.4  BATTERY............................................................. 27
		7.5  TOWING.............................................................. 28
		7.6  BUCKET WITH HOOK.................................................... 29
	8.  PRECAUTIONS FOR MAINTENANCE.............................................. 31
		8.1  BEFORE CARRYING OUT MAINTENANCE..................................... 31
		8.2  DURING MAINTENANCE.................................................. 34
	9.  POSITION FOR ATTACHING SAFETY LABELS..................................... 38
OPERATION........................................................................ 43
	10.  GENERAL VIEW............................................................ 44
		10.1  GENERAL VIEW OF MACHINE............................................ 44
		10.2  GENERAL VIEW OF CONTROLS AND GAUGES................................ 45
	11.  EXPLANATION OF COMPONENTS............................................... 46
		11.1  ELECTRONIC MONITOR AND CONTROL CONSOLE (EMACC)..................... 46
		11.2  METER.............................................................. 55
		11.3  SWITCHES........................................................... 56
		11.4  CONTROL LEVERS, PEDALS............................................. 62
		11.5  CEILING WINDOW..................................................... 66
		11.6  WINDSHIELD......................................................... 66
		11.7  DOOR HOLD OPEN LOCK................................................ 68
		11.8  CAP, COVER WITH LOCK............................................... 68
		11.9  DEFROSTER CONTROL.................................................. 69
		11.10  STORAGE TRAY...................................................... 69
		11.11  ASHTRAY........................................................... 69
		11.12  FUSE.............................................................. 70
		11.13  FUSIBLE LINK...................................................... 70
		11.14  HANDLING ACCUMULATOR.............................................. 71
	12.  OPERATION............................................................... 72
		12.1  CHECK BEFORE STARTING.............................................. 72
		12.2  STARTING ENGINE.................................................... 86
		12.3  OPERATIONS AND CHECKS AFTER STARTING ENGINE........................ 89
		12.4  MOVING MACHINE OFF................................................. 92
		12.5  STEERING THE MACHINE............................................... 93
		12.6  STOPPING THE MACHINE............................................... 94
		12.7  SWINGING........................................................... 95
		12.8  OPERATION OF WORK EQUIPMENT........................................ 96
		12.9  WORKING MODE SELECTION............................................. 98
		12.10  PROHIBITIONS FOR OPERATION........................................100
		12.11  PRECAUTIONS FOR OPERATION.........................................103
		12.12  PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS.......................104
		12.13  HOW TO ESCAPE FROM MUD............................................105
		12.14  WORK POSSIBLE USING HYDRAULIC EXCAVATOR...........................106
		12.15  REPLACEMENT AND INVERSION OF BUCKET...............................108
		12.16  PARKING MACHINE...................................................109
		12.17  CHECK AFTER FINISHING WORK........................................110
		12.18  STOPPING ENGINE...................................................110
		12.19  CHECK AFTER STOPPING ENGINE.......................................111
		12.20  LOCKING AND SECURING MACHINE......................................112
	13.  TRANSPORTATION..........................................................113
		13.1  LOADING AND UNLOADING MACHINE......................................113
		13.2  TRANSPORTING MACHINE...............................................114
		13.3  PRECAUTIONS FOR TRANSPORTATION.....................................115
		13.4  DISASSEMBLING MACHINE FOR TRANSPORT................................115
		13.5  PROCEDURE FOR INCREASING OR REDUCING TRACK FRAME GAUGE.............118
	14.  COLD WEATHER OPERATION..................................................120
		14.1  PRECAUTIONS FOR LOW TEMPERATURE....................................120
		14.2  PRECAUTIONS AFTER COMPLETION OF WORK...............................121
		14.3  AFTER COLD WEATHER.................................................121
	15.  LONG-TERM STORAGE.......................................................122
		15.1  BEFORE STORAGE.....................................................122
		15.2  DURING STORAGE.....................................................124
		15.3  AFTER STORAGE......................................................125
		15.4  STARTING MACHINE AFrER LONG-TERM STORAGE...........................125
	16.  TROUBLESHOOTING.........................................................126
		16.1  MOVING A DISABLED MACHINE..........................................126
		16.2  PRECAUTIONS ON PARTICULAR JOBSITES.................................127
		16.3  IF BAlTERY IS DISCHARGED...........................................128
		16.4  STARTING ENGINE WITH BOOSTER CABLE.................................128
		16.5  OTHER TROUBLE......................................................130
		16.6  PHENOMENA THAT ARE NOT FAILURES....................................134
MAINTENANCE......................................................................135
	17.  GUIDES TO MAINTENANCE...................................................136
	18.  OUTLINES OF SERVICE.....................................................139
		18.1  OUTLINE OF OIL, FUEL, COOLANT......................................139
		18.2  OUTLINE OF ELECTRICAL SYSTEM.......................................142
		18.3  OUTLINE OF HYDRAULIC SYSTEM........................................143
	19.  WEAR PARTS LIST.........................................................144
	20.  USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE....146
		20.1  PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS...................146
		20.2  ENGINE OIL SPECIFICATIONS..........................................147
		20.3  GREASE SPECIFICATIONS..............................................147
		20.4  DIESEL FUEL SPECIFICATIONS.........................................148
		20.5  COOLANT SPECIFICATIONS.............................................148
	21.  STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS..........................153
		21.1  STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS.......................153
		21.2  TIGHTENING TORQUE OF SPLIT FLANGE BOLTS............................153
		21.3  TIGHTENING TORQUE FOR NUTS OF FLARED FllTlNGS......................154
		21.4  UNIT CONVERSIONS...................................................155
	22.  PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...........................161
	23.  MAINTENANCE SCHEDULE CHART..............................................162
	24.  SERVICE PROCEDURE.......................................................165
		24.1 SEASONAL PREPARATIONS...............................................165
		24.2  AIR CLEANING SYSTEM................................................166
		24.3  AIR CONDITIONER....................................................170
		24.4  BELTS..............................................................171
		24.5  BUCKET.............................................................176
		24.6  COOLING SYSTEM.....................................................182
		24.7  ELECTRICAL SYSTEM..................................................188
		24.8  ENGINE.............................................................191
		24.9  ETHER INJECTOR (IF EQUIPPED).......................................196
		24.10  FINAL DRIVE.......................................................198
		24.11  FUEL SYSTEM.......................................................199
		24.12  HYDRAULIC SYSTEM..................................................203
		24.13  LUBRICATION FITTINGS..............................................216
		24.14  PTO CASE..........................................................218
		24.15  SEAT BELT.........................................................218
		24.16  SWING MACHINERY...................................................219
		24.17  TRACKS............................................................222
		24.18  TURBOCHARGER......................................................224
		24.19  WALK AROUND INSPECTION............................................226
		24.20  WINDOW WASHER.....................................................226
SPECIFICATIONS...................................................................227
	25.  SPECIFICATIONS..........................................................228
OPTIONS & ATTACHMENTS............................................................231
	26.  GENERAL PRECAUTIONS.....................................................232
		26.1  PRECAUTIONS RELATED TO SAFETY......................................232
		26.2  PRECAUTIONS WHEN INSTALLING AlTACHMENTS............................233
	27.  HANDLING BUCKET WITH HOOK...............................................234
		27.1 CHECK FOR DAMAGE TO BUCKET WITH HOOK................................234
		27.2  PROHIBITED OPERATIONS..............................................234
		27.3  PRECAUTIONS DURING OPERATIONS......................................234
	28.  OPERATING AIR CONDITIONER...............................................235
		28.1  CONTROL PANEL......................................................235
		28.2  COOLING............................................................236
		28.3  HEATING............................................................237
		28.4  DEHUMIDIFY AND HEATING.............................................238
	29.  RADIO...................................................................239
		29.1  OPERATION..........................................................239
		29.2  CARE AND MAINTENANCE...............................................239
		29.3  TROUBLESHOOTING....................................................239
	30.  OPTIONAL ELECTRICAL EQUIPMENT...........................................240
		30.1  INSTALLATION OF OPTIONAL ELECTRICAL EQUIPMENT......................240
		30.2  INSTALLATION OF ADDITIONAL LAMPS...................................241
	31.  INTRODUCTION OF ATTACHMENTS.............................................242
		31.1  BUCKET SELECTION...................................................242
		31.2  BUCKET TEETH SELECTION.............................................242
		31.3  BUCKET INSTALLATION COMBINATIONS...................................243
		31.4  SELECTION OF TRACK SHOES...........................................244
		31.5  HANDLING THE CLAMSHELL BUCKET......................................245
	32.  EXTENDING MACHINE SERVICE LIFE..........................................246
		32.1  HYDRAULIC BREAKER..................................................246
		32.2  CRUSHER............................................................249
		32.3  GRAPPLE............................................................250
		32.4  BUCKET WITH THUMB GRAPPLE..........................................251
		32.5  ROTATING GRAPPLE...................................................252
		32.6  SHEAR..............................................................253
		32.7  HYDRAULIC PILE DRIVER..............................................254
		32.8  HYDRAULIC EXCAVATOR WITH MULTI-PURPOSE CRANE.......................255

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