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Komatsu PW400MH-6 Material Handler Operation & Maintenance Manual SN A84210 and up – PDF DOWNLOAD
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Komatsu PW400MH-6 Material Handler Operation & Maintenance Manual
Book Code : CEAM008300
MACHINE MODEL SERIAL NUMBERS
PW400MH-6 A84210 AND UP
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Description
Komatsu PW400MH-6 Material Handler Operation & Maintenance Manual
FILE DETAILS:
Komatsu PW400MH-6 Material Handler Operation & Maintenance Manual
Model Specification: KOMATSU PW400MH-6 MATERIAL HANDLER
Language: English
File Format: PDF
Total Pages: 250
Requirements: Adobe PDF Reader
ZOOM IN/OUT: YES
Downloadable: YES
KOMATSU PW400MH-6 MATERIAL HANDLER OPERATION & MAINTENANCE MANUAL SN A84210 AND UP – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu PW400MH-6 Material Handler 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 PW400MH-6 Material Handler Operation & Maintenance Manual
MAIN MENU........................................................................... 0 COVER............................................................................... 1 INTRODUCTION........................................................................ 7 FOREWORD........................................................................ 8 SAFETY INFORMATION.............................................................. 8 INTRODUCTION.................................................................... 9 INTENDED USE................................................................ 9 FEATURES.................................................................... 9 BREAKING IN THE MACHINE..................................................... 9 LOCATION OF PLATES, TABLE TO ENTER P.I.N. AND DISTRIBUTOR....................... 10 P.I.N. PLATE LOCATION....................................................... 10 ENGINE SERIAL NO. PLATE LOCATION............................................ 10 TABLE TO ENTER NUMBERS AND DISTRIBUTOR...................................... 10 TABLE OF CONTENTS............................................................... 11 SAFETY.............................................................................. 17 WARNING LABELS.................................................................. 18 GENERAL PRECAUTIONS............................................................. 24 SAFETY RULES................................................................ 24 SAFETY FEATURES............................................................. 24 UNAUTHORIZED MODIFICATION................................................... 24 INSIDE OPERATOR’S COMPARTMENT............................................... 25 CLOTHING AND PERSONAL PROTECTIVE ITEMS...................................... 25 ALWAYS APPLY LOCK WHEN LEAVING OPERATOR’S SEAT.............................. 25 MOUNTING AND DISMOUNTING.................................................... 26 INJURY FROM WORK EQUIPMENT.................................................. 26 FIRE PREVENTION FOR FUEL AND OIL............................................ 26 PRECAUTIONS AT HIGH TEMPERATURES............................................ 27 ASBESTOS DUST HAZARD PREVENTION............................................. 27 FIRE EXTINGUISHER AND FIRST AID KIT......................................... 27 CAB GLASS................................................................... 28 WINDOW WASHER FLUID......................................................... 28 ESCAPE FROM FIRE............................................................ 28 PROTECTION AGAINST FALLING OR FLYING OBJECTS................................ 28 MACHINES WITH ACCUMULATOR................................................... 29 PRECAUTIONS FOR ATTACHMENTS................................................. 29 INDOOR VENTILATION.......................................................... 29 EMERGENCY EXIT FROM OPERATOR’S CAB.......................................... 29 PRECAUTIONS DURING OPERATION.................................................... 30 BEFORE STARTING ENGINE...................................................... 30 SAFETY AT WORK SITE..................................................... 30 FIRE PREVENTION......................................................... 30 VENTILATION FOR ENCLOSED AREAS.......................................... 30 IN OPERATOR’S CAB....................................................... 30 PRECAUTIONS FOR MIRROR AND LIGHTS....................................... 31 WHEN STARTING ENGINE.................................................... 31 OPERATING MACHINE........................................................... 32 WHEN STARTING ENGINE.................................................... 32 CHECK DIRECTION BEFORE STARTING MACHINE................................. 32 CHECK THAT NO ONE IS IN AREA BEFORE SWINGING OR TRAVELING IN REVERSE.... 32 NEVER LET ANYONE RIDE ON ATTACHMENT..................................... 32 PRECAUTIONS WHEN TRAVELING.............................................. 33 OPERATE CAREFULLY ON SNOW............................................... 33 TRAVELING ON SLOPES..................................................... 34 PROHIBITED OPERATIONS................................................... 34 PRECAUTIONS FOR OPERATION............................................... 35 DO NOT GO CLOSE TO HIGH VOLTAGE CABLES.................................. 35 WORKING ON LOOSE GROUND................................................. 36 PARKING THE MACHINE..................................................... 36 PRECAUTIONS IN COLD WEATHER............................................. 36 TRANSPORTATION.............................................................. 37 LOADING AND UNLOADING................................................... 37 PRECAUTIONS WHEN LIFTING................................................ 37 SHIPPING................................................................ 37 BATTERY..................................................................... 38 BATTERY HAZARD PREVENTION............................................... 38 STARTING WITH BOOSTER CABLES............................................ 38 CHARGING BATTERY........................................................ 39 TOWING...................................................................... 40 PRECAUTIONS WHEN TOWING................................................. 40 PRECAUTIONS FOR MAINTENANCE..................................................... 41 BEFORE CARRYING OUT MAINTENANCE............................................. 41 CONTACT WHEN THERE IS FAILURE........................................... 41 WARNING TAG............................................................. 41 CLEAN BEFORE INSPECTION OR MAINTENANCE.................................. 41 NEAT CLEAN WORK PLACE................................................... 41 FOLLOW LEADER IN OPERATIONS WITH OTHER WORKERS.......................... 41 RADIATOR COOLANT LEVEL.................................................. 42 PROPER TOOLS............................................................ 42 STOP ENGINE PRIOR TO INSPECTION AND MAINTENANCE......................... 42 SUPPORT FOR WORK EQUIPMENT.............................................. 42 PERIODIC REPLACEMENT OF CRITICAL SAFETY PARTS........................... 43 USE OF LIGHTING......................................................... 43 FIRE PREVENTION......................................................... 43 RULES TO FOLLOW WHEN ADDING FUEL OR OIL................................. 43 DURING MAINTENANCE.......................................................... 44 PERSONNEL............................................................... 44 REMOVAL, INSTALLATION AND STORAGE OF ATTACHMENTS........................ 44 WORK UNDER THE MACHINE.................................................. 44 NOISE................................................................... 44 WHEN WORKING ON MACHINE................................................. 44 LOCK INSPECTION COVERS.................................................. 44 TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING...................... 45 DO NOT DROP TOOLS OR PARTS INSIDE MACHINE............................... 45 FLYING PIECES WITH HAMMER WORK.......................................... 45 KEEP THE MACHINE CLEAN.................................................. 45 WELDING REPAIRS......................................................... 46 REMOVE BATTERY TERMINALS................................................ 46 ACTION WHEN ABNORMALITY IS FOUND DURING INSPECTION...................... 46 RULES TO FOLLOW WHEN ADDING FUEL........................................ 46 HANDLING HIGH PRESSURE HOSES............................................ 47 PRECAUTIONS WITH HIGH PRESSURE OIL...................................... 47 PRECAUTIONS FOR MAINTENANCE AT HIGH TEMPERATURE OR PRESSURE............. 47 WASTE MATERIALS......................................................... 48 CHECKS AFTER INSPECTION AND MAINTENANCE................................. 48 MAINTENANCE FOR AIR CONDITIONER......................................... 48 MAGNET SAFETY................................................................... 49 READ THE MAGNET INSTRUCTIONS................................................ 49 BEWARE OF HIGH VOLTAGE...................................................... 49 HANDLE MAGNET WITH CARE..................................................... 49 OPERATION........................................................................... 51 GENERAL......................................................................... 52 GENERAL VIEW OF MACHINE..................................................... 52 GENERAL VIEW OF OPERATORS COMPARTMENT....................................... 53 GENERAL VIEW OF MONITOR PANEL............................................... 54 GENERAL VIEW OF OUTRIGGER PANEL............................................. 55 GENERAL VIEW OF MAGNET PANEL................................................ 56 EXPLANATION OF COMPONENTS....................................................... 57 MACHINE MONITOR............................................................. 57 MONITOR LIGHT GROUP..................................................... 59 METER DISPLAY PORTION................................................... 61 SWITCHES................................................................ 64 OUTRIGGER PANEL............................................................. 65 MAGNET GRAPPLE PANEL........................................................ 67 SWITCHES.................................................................... 68 RIGHT CONTROL PANEL..................................................... 68 LEFT CONTROL HANDLE..................................................... 72 RIGHT CONTROL HANDLE.................................................... 72 PILOT PRESSURE SAFETY SHUTOFF SWITCH.................................... 72 STEERING.................................................................... 73 STEERING WHEEL.......................................................... 73 COLUMN TILT LEVER....................................................... 73 CONTROL LEVERS AND PEDALS................................................... 74 SAFETY LOCK - LEFT CONTROL STAND........................................ 74 LEFT CONTROL HANDLE..................................................... 74 RIGHT CONTROL HANDLE.................................................... 75 FOOT PEDALS............................................................. 75 OPERATORS SEAT.............................................................. 76 SEAT BELT............................................................... 77 ROOF VENT................................................................... 78 WHEN OPENING............................................................ 78 WHEN CLOSING............................................................ 78 FRONT WINDOW................................................................ 78 WHEN OPENING............................................................ 78 WHEN CLOSING............................................................ 80 FRONT BOTTOM WINDOW..................................................... 81 DOOR LOCK................................................................... 81 OPERATOR EASE............................................................... 81 HOT AND COOL BOX........................................................ 81 STORAGE BOX............................................................. 81 CAP, COVER WITH LOCK........................................................ 82 METHOD OF OPENING AND CLOSING LOCK CAP.................................. 82 METHOD OF OPENING AND CLOSING COVER LOCK................................ 82 AIR CONDITIONER............................................................. 83 GENERAL LOCATIONS ON CONTROL PANEL...................................... 83 PRECAUTIONS WHEN USING AIR CONDITIONER.................................. 85 CHECK, MAINTAIN MACHINE WITH AIR CONDITIONER............................ 85 AM/FM RADIO................................................................. 86 EXPLANATION OF COMPONENTS............................................... 86 METHOD OF OPERATION..................................................... 88 PRECAUTIONS WHEN USING.................................................. 90 SPECIFICATIONS.......................................................... 90 ELECTRIC POWER TAKE OUT ADAPTER............................................. 90 FUSE........................................................................ 91 FUSIBLE LINK................................................................ 92 CONTROLLERS................................................................. 92 TOOL BOX.................................................................... 92 GREASE GUN HOLDER........................................................... 92 OPERATION....................................................................... 93 CHECK BEFORE STARTING ENGINE................................................ 93 WALK AROUND CHECK....................................................... 93 CHECK BEFORE STARTING................................................... 94 ADJUST OPERATORS SEAT AND BELT.......................................... 98 ADJUSTMENT OF MONITOR PANEL ANGLE....................................... 98 OPERATIONS AND CHECKS BEFORE STARTING ENGINE............................ 99 STARTING ENGINE.............................................................101 NORMAL STARTING.........................................................101 STARTING IN COLD WEATHER................................................102 OPERATIONS AND CHECKS AFTER STARTING ENGINE.................................104 WHEN NORMAL.............................................................104 IN COLD AREAS (AUTOMATIC WARM UP OPERATION).............................107 CANCELING AUTOMATIC WARM UP OPERATION...................................109 MOVING AND STEERING MACHINE.................................................110 MOVING MACHINE..........................................................110 STOPPING MACHINE............................................................112 SWINGING....................................................................113 OPERATION OF WORK EQUIPMENT.................................................114 WORKING MODES...............................................................114 PERMISSIBLE WATER DEPTH.....................................................114 PARKING MACHINE.............................................................115 CHECK AFTER FINISHING WORK..................................................116 STOPPING ENGINE.............................................................116 CHECK AFTER STOPPING ENGINE.................................................116 LOCKING.....................................................................116 TRANSPORTATION..................................................................117 TRANSPORTATION PROCEDURE....................................................117 COLD WEATHER OPERATION..........................................................119 PRECAUTIONS FOR LOW TEMPERATURE.............................................119 FUEL AND LUBRICANTS.....................................................119 COOLANT.................................................................119 BATTERY.................................................................119 PRECAUTIONS AFTER COMPLETION OF WORK........................................120 AFTER COLD WEATHER..........................................................120 LONG TERM STORAGE...............................................................121 BEFORE STORAGE..............................................................121 DURING STORAGE..............................................................121 AFTER STORAGE...............................................................121 MACHINE START AFTER STORAGE.................................................122 METHOD OF TOWING DISABLED MACHINE...........................................122 DISCHARGED BATTERY..........................................................123 REMOVING AND INSTALLING BATTERY.........................................123 PRECAUTIONS FOR CHARGING BATTERY........................................123 STARTING ENGINE WITH BOOSTER CABLE......................................124 OTHER TROUBLE...............................................................126 ELECTRICAL SYSTEM.......................................................126 CHASSIS.................................................................126 ENGINE..................................................................127 ELECTRONIC CONTROL SYSTEM...............................................128 MAINTENANCE.........................................................................129 GUIDES TO MAINTENANCE...........................................................130 OUTLINES OF SERVICE.............................................................132 OUTLINE OF OIL, FUEL, COOLANT...............................................132 OIL.....................................................................132 FUEL....................................................................132 COOLANT.................................................................133 GREASE..................................................................133 STORING OIL AND FUEL....................................................133 FILTERS.................................................................133 RELATING TO ELECTRICAL SYSTEM...........................................133 OUTLINE OF HYDRAULIC SYSTEM.................................................134 WEAR PARTS LIST.................................................................135 USE OF FUEL, COOLANT AND LUBRICANTS.............................................136 PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS............................136 ABBREVIATIONS...........................................................137 ENGINE OIL SPECIFICATIONS...................................................137 NORMAL OPERATION........................................................137 ARCTIC OPERATION........................................................137 DAMPER, SWING MACHINERY AND HYDRAULIC SYSTEM OIL SPECIFICATIONS.............138 FUEL SYSTEM.................................................................138 FRONT AND REAR AXLE HOUSING OIL SPECIFICATIONS..............................138 COOLING SYSTEM..............................................................139 GENERAL.................................................................139 WATER...................................................................139 ANTIFREEZE..............................................................139 INHIBITORS/CONDITIONERS.................................................140 SUPPLEMENTAL COOLANT ADDITIVES..........................................140 STANDARD TIGHTENING TORQUES.....................................................144 INTRODUCTION OF NECESSARY TOOLS.............................................144 BOLT IDENTIFICATION CHART...................................................145 PERIODIC REPLACEMENT OF CRITICAL PARTS..........................................146 MAINTENANCE SCHEDULE CHART......................................................147 SERVICE PROCEDURE...............................................................150 INITIAL 100 HOURS SERVICE...................................................150 CHANGE FRONT AXLE OIL...................................................150 CHANGE REAR AXLE OIL....................................................150 AXLE LUBRICATION........................................................151 INITIAL 250 HOURS SERVICE...................................................152 FUEL FILTER CARTRIDGE...................................................152 ENGINE VALVE CLEARANCE..................................................153 WHEN REQUIRED...............................................................154 CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT............................154 DRAIN, FLUSH AND REFILL COOLING SYSTEM..................................156 CHECK AND TIGHTEN WHEEL HUB NUTS........................................159 CHECK OIL LEVEL IN AXLES, WHEEL HUBS AND REDUCTION BOXES, ADD OIL.......159 REPLACE AXLE BREATHERS..................................................160 CHECK ELECTRICAL INTAKE AIR HEATER......................................160 CHECK WINDOW WASHER FLUID, ADD FLUID....................................160 CHECK, MAINTAIN AIR CONDITIONER.........................................161 CLEAN IN LINE FILTERS...................................................162 CHECK BEFORE STARTING.......................................................163 CHECK COOLANT LEVEL, ADD COOLANT........................................163 CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL..............................163 CHECK FUEL LEVEL, ADD FUEL..............................................164 CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL..............................165 CHECK AIR CLEANER FOR CLOGGING..........................................166 CHECK ELECTRIC WIRING...................................................166 CHECK FUNCTION OF HORN..................................................166 CHECK FOR WATER AND SEDIMENT IN FUEL FILTER.............................167 EVERY 10 HOURS SERVICE - DAILY..............................................168 GREASE LUBRICATION......................................................168 EVERY 50 HOURS SERVICE......................................................170 EVERY 100 HOURS SERVICE.....................................................171 CHECK OIL LEVEL IN SWING MACHINERY CASE, ADD OIL........................171 DRAIN WATER AND SEDIMENT FROM FUEL TANK.................................171 EVERY 250 HOURS SERVICE.....................................................172 CHECK LEVEL OF BATTERY ELECTROLYTE......................................172 CHANGE ENGINE OIL, REPLACE FILTER CARTRIDGE.............................172 LUBRICATE SWING CIRCLE (3 POINTS).......................................174 CHECK FAN BELT TENSION, ADJUST..........................................174 CHECK, ADJUST TENSION OF A/C COMPRESSOR BELT............................175 EVERY 500 HOURS SERVICE.....................................................177 REPLACE FUEL FILTER CARTRIDGE...........................................177 CHECK SWING PINION GREASE LEVEL, ADD GREASE.............................178 CLEAN AND INSPECT RADIATOR, OIL COOLER, AFTER COOLER AND CONDENSER......179 CLEAN FILTERS OF AIR CONDITIONER........................................179 REPLACE HYDRAULIC TANK BREATHER ELEMENT.................................180 REPLACE HYDRAULIC FILTER ELEMENT........................................180 REPLACE STEERING AND GENERATOR PUMP FILTERS.............................181 REPLACE GENERATOR MOTOR CASE DRAIN FILTER...............................181 EVERY 1000 HOURS SERVICE....................................................182 CHANGE OIL IN SWING MACHINERY CASE......................................182 CHECK OIL LEVEL IN DAMPER CASE, ADD OIL.................................182 CHECK OIL LEVEL IN PUMP GEAR CASE.......................................183 CHECK TIGHTENING PARTS OF TURBOCHARGER..................................183 CHECK PLAY OF TURBOCHARGER ROTOR........................................183 REPLACE CORROSION RESISTOR CARTRIDGE....................................183 REPLACE HYDRAULIC TANK BREATHER.........................................184 CHANGE OIL IN FRONT AND REAR AXLES, WHEEL HUBS AND REDUCTION BOXES......185 EVERY 2000 HOURS SERVICE....................................................186 CLEAN HYDRAULIC TANK STRAINER...........................................186 CLEAN ENGINE BREATHER...................................................186 CLEAN, CHECK TURBOCHARGER...............................................187 CHECK ALTERNATOR, STARTING MOTOR........................................187 CHECK ENGINE VALVE CLEARANCE, ADJUST....................................187 CHECK VIBRATION DAMPER..................................................187 CHECK, ADJUST FUEL INJECTION NOZZLES....................................187 EVERY 4000 HOURS SERVICE....................................................188 CHECK WATER PUMP........................................................188 REPLACE FUEL INJECTION NOZZLE TIPS......................................188 EVERY 5000 HOURS SERVICE....................................................189 CHANGE OIL IN HYDRAULIC TANK............................................189 SPECIFICATIONS......................................................................191 SPECIFICATIONS AND DIMENSIONS...................................................192 SPECIFICATIONS..............................................................192 DIMENSIONS..................................................................192 LIFTING CAPACITIES..............................................................194 OUTRIGGERS DOWN.............................................................194 OUTRIGGERS UP...............................................................195 TRANSPORT.......................................................................196 MACHINE SYSTEMS.....................................................................197 HYDRAULIC SCHEMATIC.............................................................198 CAB RISER VALVES................................................................200 UPPER STEERING..................................................................202 UPPER BRAKE.....................................................................204 UPPER TRAVEL....................................................................206 ACCUMULATOR CHARGE AND PRIORITY VALVE...........................................208 PARKING BRAKE AXLE LOCK.........................................................210 UPPER OUTRIGGERS................................................................212 TRAVEL - VALVE TO SWIVEL........................................................214 OUTRIGGER PANEL SCHEMATIC.......................................................216 CARRIER ELECTRICAL..............................................................218 CAB ELECTRICAL..................................................................220 STEERING AND GENERATOR PUMPS....................................................222 GENERATOR AND CONTROLLER PACKAGE................................................224 GENERATOR VALVING AND PIPING....................................................226 MAGNET 230 VOLT ELECTRICAL......................................................228 MAGNET 24 VOLT ELECTRICAL.......................................................230 GENERATOR HYDRAULIC COMPONENTS..................................................232 MAGNET DISCONNECT SWITCH AND CONTROLLER.........................................234 CONTROL HANDLES AND CONNECTIONS.................................................236 GRAPPLE CONTROL GROUP...........................................................238 GRAPPLE CONTROL MAIN VALVE......................................................240 OPEN, CLOSE AND ROTATION FLOW CONTROL VALVE.....................................242 DOI -GRAPPLE- CONTROL VALVE.....................................................244 FRONT AND REAR AXLES............................................................246
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