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KOMATUS GALEO PC400-7 PC400LC-7 PC450-7 PC450LC-7 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (SEAM056502T) – PDF DOWNLOAD
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- KOMATUS GALEO PC400-7 PC400LC-7 PC450-7 PC450LC-7 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL
- PUBLICATION NUMBER:SEAM056502T
- SERIAL NUMBERS: PC400-7 50001 and up
PC400LC-7 50001 and up
PC450-7 20001 and up
PC450LC-7 20001 and up
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KOMATUS GALEO PC400-7 PC400LC-7 PC450-7 PC450LC-7 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (SEAM056502T)
KOMATUS GALEO PC400-7 PC400LC-7 PC450-7 PC450LC-7 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (SEAM056502T) – PDF DOWNLOAD:
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DESCRIPTION:
KOMATUS GALEO PC400-7 PC400LC-7 PC450-7 PC450LC-7 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (SEAM056502T)
- This manual provides rules and guidelines which will help you use this machine safely and effectively. The precautions in this manual must be followed at all times when performing operation and maintenance. Most accidents are caused by the failure to follow fundamental safety rules for the operation and maintenance of machines.
- Accidents can be prevented by knowing beforehand conditions that may cause a hazard when performing operation and maintenance If this manual has been lost or has become dirty and cannot be read, request a replacement manual immediately from Komatsu or your Komatsu distributor.
- If you sell the machine, be sure to give this manual to the new owners together with the machine. Komatsu delivers machines that comply with all applicable regulations and standards of the country to which it has been shipped. If this machine has been purchased in another country or purchased from someone in another country, it may lack certain safety devices and specifications that are necessary for use in your country.
- If there is any question about whether your product complies with the applicable standards and regulations of your country, consult Komatsu or your Komatsu distributor before operating the machine.
TABLE OF CONTENTS:
KOMATUS GALEO PC400-7 PC400LC-7 PC450-7 PC450LC-7 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (SEAM056502T)
MAIN MENU.............................................................................................................................................................. 0 COVER.................................................................................................................................................................. 1 FOREWORD............................................................................................................................................................... 2 FOREWORD........................................................................................................................................................... 3 SAFETY INFORMATION................................................................................................................................................. 6 INTRODUCTION....................................................................................................................................................... 8 DIRECTIONS OF MACHINE.......................................................................................................................................... 8 PRODUCT INFORMATION................................................................................................................................................ 9 MACHINE SERIAL NUMBER PLATE AND ITS LOCATION................................................................................................................... 9 ENGINE SERIAL NUMBER PLATE AND ITS LOCATION.................................................................................................................... 9 SERVICE METER LOCATION......................................................................................................................................... 10 YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR.................................................................................................................... 10 CONTENTS............................................................................................................................................................... 11 SAFETY................................................................................................................................................................. 14 SAFETY INFORMATION................................................................................................................................................. 15 SAFETY LABELS...................................................................................................................................................... 17 LOCATION OF SAFETY LABELS...................................................................................................................................... 17 SAFETY LABELS.................................................................................................................................................. 18 SAFETY INFORMATION................................................................................................................................................. 23 SAFETY RULES................................................................................................................................................... 23 IF ABNORMALITIES ARE FOUND..................................................................................................................................... 23 WORKING WEAR AND PERSONAL PROTECTIVE ITEMS..................................................................................................................... 23 FIRE EXTINGUISHER AND FIRST AID KIT............................................................................................................................ 23 SAFETY EQUIPMENT............................................................................................................................................... 23 KEEP MACHINE CLEAN............................................................................................................................................. 24 KEEP OPERATOR'S COMPARTMENT CLEAN.............................................................................................................................. 24 LEAVING OPERATOR'S SEAT WITH LOCK.............................................................................................................................. 24 HANDRAILS AND STEPS............................................................................................................................................ 25 MOUNTING AND DISMOUNTING....................................................................................................................................... 25 NO PERSONS ON ATTACHMENTS...................................................................................................................................... 25 BURN PREVENTION................................................................................................................................................ 26 FIRE PREVENTION AND EXPLOSION PREVENTION....................................................................................................................... 26 ACTION IF FIRE OCCURS.......................................................................................................................................... 27 WINDSHIELD WASHER FLUID........................................................................................................................................ 27 FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION............................................................................................... 27 ATTACHMENT INSTALLATION........................................................................................................................................ 28 ATTACHMENT COMBINATIONS........................................................................................................................................ 28 CAB WINDOW GLASSES............................................................................................................................................. 28 UNAUTHORIZED MODIFICATIONS..................................................................................................................................... 28 SAFETY AT JOBSITE.............................................................................................................................................. 28 WORKING ON LOOSE GROUND........................................................................................................................................ 29 DISTANCE TO HIGH VOLTAGE CABLES................................................................................................................................ 29 ENSURE GOOD VISIBILITY......................................................................................................................................... 29 VENTILATION FOR ENCLOSED AREA.................................................................................................................................. 30 SIGNALMAN'S SIGNAL AND SIGNS................................................................................................................................... 30 EMERGENCY EXIT FROM OPERATOR'S CAB............................................................................................................................. 30 ASBESTOS DUST HAZARD PREVENTION................................................................................................................................ 30 SAFETY MACHINE OPERATION........................................................................................................................................... 31 STARTING ENGINE................................................................................................................................................ 31 CHECKS BEFORE STARTING ENGINE.............................................................................................................................. 31 SAFETY RULES FOR STARTING ENGINE........................................................................................................................... 31 STARTING ENGINE IN COLD WEATHER............................................................................................................................ 32 OPERATION...................................................................................................................................................... 33 CHECKS BEFORE OPERATION.................................................................................................................................... 33 SAFETY RULES FOR CHANGING MACHINE DIRECTIONS............................................................................................................... 33 SAFETY RULES FOR TRAVELING................................................................................................................................. 34 TRAVELING ON SLOPES........................................................................................................................................ 34 OPERATIONS ON SLOPES....................................................................................................................................... 35 PROHIBITED OPERATIONS...................................................................................................................................... 35 OPERATIONS ON SNOW......................................................................................................................................... 37 PARKING MACHINE............................................................................................................................................ 38 TRANSPORTATION................................................................................................................................................. 39 LOADING AND UNLOADING...................................................................................................................................... 39 SHIPPING THE MACHINE....................................................................................................................................... 39 BATTERY........................................................................................................................................................ 40 BATTERY HAZARD PREVENTION.................................................................................................................................. 40 STARTING ENGINE WITH BOOSTER CABLES........................................................................................................................ 41 TOWING......................................................................................................................................................... 42 SAFETY RULES FOR TOWING.................................................................................................................................... 42 LIFTING OBJECTS WITH BUCKET.................................................................................................................................... 43 SAFETY RULES FOR LIFTING OBJECTS........................................................................................................................... 43 SAFETY MAINTENANCE INFORMATION..................................................................................................................................... 44 WARNING TAG.................................................................................................................................................... 44 KEEP WORK PLACE CLEAN AND TIDY................................................................................................................................. 44 APPOINT LEADER WHEN WORKING WITH OTHERS........................................................................................................................ 44 STOP ENGINE BEFORE CARRYING OUT MAINTENANCE.................................................................................................................... 45 TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING............................................................................................................. 45 PROPER TOOLS................................................................................................................................................... 46 ACCUMULATOR.................................................................................................................................................... 46 PERSONNEL...................................................................................................................................................... 46 ATTACHMENTS.................................................................................................................................................... 47 WORK UNDER THE MACHINE......................................................................................................................................... 47 NOISE.......................................................................................................................................................... 47 WHEN USING HAMMER.............................................................................................................................................. 47 WELDING WORKS.................................................................................................................................................. 47 REMOVING BATTERY TERMINALS..................................................................................................................................... 48 SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION........................................................................................... 48 DO NOT DISASSEMBLE RECOIL SPRINGS.............................................................................................................................. 48 SAFETY RULES FOR HIGH-PRESSURE OIL............................................................................................................................. 49 SAFETY HANDLING HIGH-PRESSURE HOSES............................................................................................................................ 49 WASTE MATERIALS................................................................................................................................................ 49 AIR CONDITIONER MAINTENANCE.................................................................................................................................... 49 COMPRESSED AIR................................................................................................................................................. 50 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS.................................................................................................................. 50 OPERATION.............................................................................................................................................................. 52 MACHINE VIEW ILLUSTRATIONS......................................................................................................................................... 53 OVERALL MACHINE VIEW........................................................................................................................................... 53 CONTROLS AND GAUGES............................................................................................................................................ 54 DETAILED CONTROLS AND GAUGES....................................................................................................................................... 56 MONITORING SYSTEM.............................................................................................................................................. 56 SWITCHES....................................................................................................................................................... 81 CONTROL LEVERS AND PEDALS...................................................................................................................................... 86 SUN ROOF....................................................................................................................................................... 89 WINDSHIELD..................................................................................................................................................... 89 EMERGENCY EXIT FROM OPERATOR'S CAB............................................................................................................................. 94 DOOR LOCK...................................................................................................................................................... 94 CAP WITH LOCK.................................................................................................................................................. 95 HOT AND COOL BOX............................................................................................................................................... 96 MAGAZINE BOX................................................................................................................................................... 97 ASHTRAY........................................................................................................................................................ 97 AIR CONDITIONER CONTROLS....................................................................................................................................... 98 RADIO..........................................................................................................................................................112 AUXILIARY ELECTRIC POWER.......................................................................................................................................116 FUSE...........................................................................................................................................................117 FUSIBLELINK....................................................................................................................................................118 CONTROLLERS....................................................................................................................................................118 TOOL BOX.......................................................................................................................................................119 GREASE GUN HOLDER..............................................................................................................................................119 ACCUMULATOR....................................................................................................................................................120 MACHINE OPERATIONS AND CONTROLS....................................................................................................................................121 BEFORE STARTING ENGINE.........................................................................................................................................121 STARTING ENGINE................................................................................................................................................136 AFTER STARTING ENGINE..........................................................................................................................................140 STOPPING THE ENGINE............................................................................................................................................149 MACHINE OPERATION..............................................................................................................................................150 STEERING THE MACHINE...........................................................................................................................................154 SWINGING.......................................................................................................................................................156 WORK EQUIPMENT CONTROLS AND OPERATIONS.........................................................................................................................157 WORKING MODE...................................................................................................................................................159 PROHIBITED OPERATIONS..........................................................................................................................................160 GENERAL OPERATION INFORMATION..................................................................................................................................162 TRAVELING ON SLOPES............................................................................................................................................164 ESCAPE FROM MUD................................................................................................................................................166 RECOMMENDED APPLICATIONS.......................................................................................................................................167 BUCKET REPLACEMENT AND INVERSION...............................................................................................................................169 PARKING MACHINE................................................................................................................................................172 CHECK AFTER SHUT OFF ENGINE....................................................................................................................................173 MACHINE INSPECTION AFTER DAILY WORK............................................................................................................................173 LOCKING........................................................................................................................................................174 TRANSPORTATION.....................................................................................................................................................175 PRECAUTIONS FOR TRANSPORTATION.................................................................................................................................175 LIFTING MACHINE................................................................................................................................................175 PRECAUTIONS WHEN LOADING.......................................................................................................................................176 TRANSPORTATION POSTURE.........................................................................................................................................176 COLD WEATHER OPERATION.............................................................................................................................................180 COLD WEATHER OPERATION INFORMATION.............................................................................................................................180 AFTER DAILY WORK COMPLETION....................................................................................................................................182 AFTER COLD WEATHER SEASON......................................................................................................................................182 LONG TERM STORAGE..................................................................................................................................................183 BEFORE STORAGE.................................................................................................................................................183 DURING STORAGE.................................................................................................................................................183 AFTER STORAGE..................................................................................................................................................183 STARTING MACHINE AFTER LONG-TERM STORAGE.......................................................................................................................184 TROUBLES AND ACTIONS...............................................................................................................................................185 RUNNING OUT OF FUEL............................................................................................................................................185 PHENOMENA THAT ARE NOT FAILURES................................................................................................................................186 TOWING THE MACHINE.............................................................................................................................................187 LIGHTWEIGHT TOWING HOLE........................................................................................................................................187 SEVERE JOB CONDITION...........................................................................................................................................187 DISCHARGED BATTERY.............................................................................................................................................188 OTHER TROUBLE..................................................................................................................................................192 MAINTENANCE............................................................................................................................................................198 MAINTENANCE INFORMATION............................................................................................................................................199 LUBRICANTS, COOLANT AND FILTERS....................................................................................................................................201 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC.........................................................................................................201 ELECTRIC SYSTEM MAINTENANCE....................................................................................................................................204 WEAR PARTS.........................................................................................................................................................205 WEAR PARTS LIST................................................................................................................................................205 LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS........................................................................................................................206 TIGHTENING TORQUE SPECIFICATIONS...................................................................................................................................210 TIGHTENING TORQUE LIST.........................................................................................................................................210 SAFETY CRITICAL PARTS..............................................................................................................................................211 SAFETY CRITICAL PARTS LIST.....................................................................................................................................211 MAINTENANCE SCHEDULE...............................................................................................................................................212 MAINTENANCE SCHEDULE CHART.....................................................................................................................................212 MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER.....................................................................................................................214 MAINTENANCE PROCEDURE..............................................................................................................................................215 INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS).................................................................................................215 REPLACE FUEL FILTER CARTRIDGE..............................................................................................................................255 INITIAL 1000 HOURS MAINTENANCE (ONLY AFTER THE FIRST 1000 HOURS)...............................................................................................215 CHECK ENGINE VALVE CLEARANCE, ADJUST.......................................................................................................................274 WHEN REQUIRED..................................................................................................................................................216 CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT...............................................................................................................216 CLEAN INSIDE OF COOLING SYSTEM.............................................................................................................................221 CHECK AND TIGHTEN TRACK SHOE BOLTS.........................................................................................................................224 CHECK AND ADJUST TRACK TENSION.............................................................................................................................225 CHECK ELECTRICAL INTAKE AIR HEATER.........................................................................................................................227 REPLACE BUCKET TEETH (VERTICAL PIN TYPE)...................................................................................................................228 REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE).................................................................................................................231 REPLACE BUCKET SIDE CUTTER, SHROUD.........................................................................................................................232 ADJUST BUCKET CLEARANCE....................................................................................................................................233 CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID.................................................................................................................234 CHECK AND ADJUST AIR CONDITIONER...........................................................................................................................235 WASH WASHABLE FLOOR........................................................................................................................................236 BLEEDING AIR FROM HYDRAULIC SYSTEM.........................................................................................................................239 METHOD FOR RELEASING INTERNAL PRESSURE IN HYDRAULIC CIRCUIT................................................................................................241 CHECK NITROGEN GAS CHARGE PRESSURE IN ACCUMULATOR (control circuit)........................................................................................242 CHECK BEFORE STARTING..........................................................................................................................................243 EVERY 250 HOURS MAINTENANCE....................................................................................................................................244 LUBRICATING................................................................................................................................................244 CHECK OIL LEVEL IN SWING MACHINERY CASE, ADD OIL...........................................................................................................245 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL...............................................................................................................246 CHECK LEVEL OF BATTERY ELECTROLYTE.........................................................................................................................247 LUBRICATE SWING CIRCLE.....................................................................................................................................250 CHECK FAN BELT, ALTERNATOR BELT TENSION, ADJUST............................................................................................................250 CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST......................................................................................................252 EVERY 500 HOURS MAINTENANCE....................................................................................................................................253 LUBRICATING................................................................................................................................................253 REPLACE FUEL FILTER CARTRIDGE..............................................................................................................................255 CHECK, WASH FUEL STRAINER..................................................................................................................................257 CHECK SWING PINION GREASE LEVEL, ADD GREASE................................................................................................................258 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE..........................................................................................259 CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS, AFTER COOLER FINS, FUEL COOLER FINS, AND CONDENSER FINS (ONLY MACHINES EQUIPPED WITH AIR CONDITIONER)....261 CLEAN AIR CONDITIONER FRESH/RECIRC FILTERS.................................................................................................................262 REPLACE BREATHER ELEMENT IN HYDRAULIC TANK.................................................................................................................263 REPLACE ADDITIONAL FUEL FILTER CARTRIDGE...................................................................................................................264 EVERY 1000 HOURS MAINTENANCE...................................................................................................................................266 REPLACE HYDRAULIC OIL FILTER ELEMENT.......................................................................................................................266 CHANGE OIL IN SWING MACHINERY CASE.........................................................................................................................268 CHECK OIL LEVEL IN DAMPER CASE, ADD OIL....................................................................................................................269 CHECK ALL TIGHTENING PARTS OF TURBOCHARGER.................................................................................................................269 CHECK PLAY TURBOCHARGER ROTOR..............................................................................................................................269 REPLACE CORROSION RESISTOR CARTRIDGE.......................................................................................................................270 REPLACE HYDRAULIC TANK ADDITIONAL BREATHER ELEMENT.........................................................................................................271 CHECK NITROGEN GAS CHARGE PRESSURE IN ACCUMULATOR (for breaker)............................................................................................271 EVERY 2000 HOURS MAINTENANCE...................................................................................................................................272 CHANGE OIL IN FINAL DRIVE CASE.............................................................................................................................272 CHECK INJECTOR.............................................................................................................................................272 CLEAN HYDRAULIC TANK STRAINER..............................................................................................................................273 CLEAN ENGINE BREATHER......................................................................................................................................273 CLEAN, CHECK TURBOCHARGER..................................................................................................................................274 CHECK ALTERNATOR, STARTING MOTOR...........................................................................................................................274 CHECK ENGINE VALVE CLEARANCE, ADJUST.......................................................................................................................274 CHECK VIBRATION DAMPER.....................................................................................................................................274 EVERY 4000 HOURS MAINTENENCE...................................................................................................................................275 CHECK WATER PUMP...........................................................................................................................................275 CHECK FOR LOOSENESS OF HIGH-PRESSURE CLAMP, HARDENING OF RUBBER............................................................................................275 CHECK FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER...........................................................................................276 REPLACE INJECTOR NOZZLE ASSEMBLY...........................................................................................................................276 EVERY 5000 HOURS MAINTENANCE...................................................................................................................................277 CHANGE OIL IN HYDRAULIC TANK...............................................................................................................................277 EVERY 8000 HOURS MAINTENANCE...................................................................................................................................279 REPLACE HIGH-PRESSURE PIPING CLAMP.........................................................................................................................279 REPLACE FUEL SPRAY PREVENTION CAP..........................................................................................................................279 SPECIFICATIONS.........................................................................................................................................................280 SPECIFICATIONS.....................................................................................................................................................281 ATTACHMENTS, OPTIONS...................................................................................................................................................284 GENERAL PRECAUTIONS FOR SAFETY.....................................................................................................................................285 PRECAUTIONS WHEN SELECTING.....................................................................................................................................285 READ THE INSTRUCTION MANUAL THOROUGHLY.........................................................................................................................285 PRECAUTIONS WHEN REMOVING OR INSTALLING........................................................................................................................285 PRECAUTIONS WHEN USING.........................................................................................................................................285 MACHINE READY FOR ATTACHMENT.......................................................................................................................................286 LOCATIONS......................................................................................................................................................286 HYDRAULIC CIRCUIT..............................................................................................................................................290 ATTACHMENT REMOVAL AND INSTALLATION............................................................................................................................294 ATTACHMENT OPERATIONS..........................................................................................................................................296 LONG TERM STORAGE..............................................................................................................................................298 SPECIFICATIONS.................................................................................................................................................298 ATTACHMENT GUIDE...................................................................................................................................................299 ATTACHMENT COMBINATIONS........................................................................................................................................299 RECOMMENDED ATTACHMENT OPERATIONS..................................................................................................................................301 HYDRAULIC BREAKER..............................................................................................................................................301 INDEX..................................................................................................................................................................306
PLEASE NOTE:
⦁ This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
⦁ Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.
