KOMATSU GALEO PC400,400LC-7 PC450,450LC-7 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (TEN00038-03)
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KOMATSU GALEO PC400,400LC-7 PC450,450LC-7 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (TEN00038-03)
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.
TABLE OF CONTENTS:
KOMATSU GALEO PC400,400LC-7 PC450,450LC-7 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (TEN00038-03)
COVER.................................................................................................................................................................................... 1 FOREWORD................................................................................................................................................................................. 2 FOREWORD............................................................................................................................................................................. 3 SAFETY INFORMATION................................................................................................................................................................... 6 INTRODUCTION......................................................................................................................................................................... 8 DIRECTIONS OF MACHINE............................................................................................................................................................ 8 BREAKING-IN THE NEW MACHINE...................................................................................................................................................... 8 PRODUCT INFORMATION.................................................................................................................................................................. 9 PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE..................................................................................................................... 9 ENGINE SERIAL NUMBER PLATE AND ITS LOCATION...................................................................................................................................... 9 SERVICE METER LOCATION........................................................................................................................................................... 10 YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR...................................................................................................................................... 10 CONTENTS................................................................................................................................................................................. 11 SAFETY................................................................................................................................................................................... 15 SAFETY INFORMATION................................................................................................................................................................... 16 SAFETY LABELS........................................................................................................................................................................ 18 LOCATION OF SAFETY LABELS........................................................................................................................................................ 18 SAFETY LABELS.................................................................................................................................................................... 19 SAFETY INFORMATION................................................................................................................................................................... 24 SAFETY RULES..................................................................................................................................................................... 24 IF PROBLEMS ARE FOUND............................................................................................................................................................ 24 WORKING WEAR AND PERSONAL PROTECTIVE ITEMS....................................................................................................................................... 24 FIRE EXTINGUISHER AND FIRST AID KIT.............................................................................................................................................. 24 SAFETY EQUIPMENT................................................................................................................................................................. 24 KEEP MACHINE CLEAN............................................................................................................................................................... 25 KEEP OPERATOR'S COMPARTMENT CLEAN................................................................................................................................................ 25 LEAVING OPERATOR'S SEAT WITH LOCK................................................................................................................................................ 25 HANDRAILS AND STEPS.............................................................................................................................................................. 26 PRECAUTIONS WHEN WORKING IN HIGH PLACES.......................................................................................................................................... 26 MOUNTING AND DISMOUNTING......................................................................................................................................................... 26 NO PERSONS ON ATTACHMENTS........................................................................................................................................................ 26 DO NOT GET CAUGHT IN ARTICULATED PORTION......................................................................................................................................... 27 BURN PREVENTION.................................................................................................................................................................. 27 FIRE PREVENTION AND EXPLOSION PREVENTION......................................................................................................................................... 28 ACTION IF FIRE OCCURS............................................................................................................................................................ 29 WINDSHIELD WASHER FLUID.......................................................................................................................................................... 29 FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION................................................................................................................. 29 ATTACHMENT INSTALLATION.......................................................................................................................................................... 29 ATTACHMENT COMBINATIONS.......................................................................................................................................................... 29 CAB WINDOW GLASSES............................................................................................................................................................... 29 UNAUTHORIZED MODIFICATIONS....................................................................................................................................................... 30 SAFETY AT JOBSITE................................................................................................................................................................ 30 WORKING ON LOOSE GROUND.......................................................................................................................................................... 30 DISTANCE TO HIGH VOLTAGE CABLES.................................................................................................................................................. 31 ENSURE GOOD VISIBILITY........................................................................................................................................................... 31 VENTILATION FOR ENCLOSED AREA.................................................................................................................................................... 32 SIGNALMAN'S SIGNAL AND SIGNS..................................................................................................................................................... 32 EMERGENCY EXIT FROM OPERATOR'S CAB............................................................................................................................................... 32 ASBESTOS DUST HAZARD PREVENTION.................................................................................................................................................. 32 SAFETY MACHINE OPERATION............................................................................................................................................................. 33 STARTING ENGINE.................................................................................................................................................................. 33 CHECKS BEFORE STARTING ENGINE................................................................................................................................................ 33 SAFETY RULES FOR STARTING ENGINE............................................................................................................................................. 34 STARTING ENGINE IN COLD WEATHER.............................................................................................................................................. 34 OPERATION........................................................................................................................................................................ 35 CHECKS BEFORE OPERATION...................................................................................................................................................... 35 SAFETY RULES FOR CHANGING MACHINE DIRECTIONS................................................................................................................................. 35 SAFETY RULES FOR TRAVELING................................................................................................................................................... 36 TRAVELING ON SLOPES.......................................................................................................................................................... 36 OPERATIONS ON SLOPES......................................................................................................................................................... 37 PROHIBITED OPERATIONS........................................................................................................................................................ 37 OPERATIONS ON SNOW........................................................................................................................................................... 39 PARKING MACHINE.............................................................................................................................................................. 40 TRANSPORTATION................................................................................................................................................................... 41 LOADING AND UNLOADING........................................................................................................................................................ 41 SHIPPING THE MACHINE......................................................................................................................................................... 41 BATTERY.......................................................................................................................................................................... 42 BATTERY HAZARD PREVENTION.................................................................................................................................................... 42 STARTING ENGINE WITH BOOSTER CABLES.......................................................................................................................................... 43 TOWING........................................................................................................................................................................... 44 SAFETY RULES FOR TOWING...................................................................................................................................................... 44 LIFTING OBJECTS WITH BUCKET...................................................................................................................................................... 45 SAFETY RULES FOR LIFTING OBJECTS............................................................................................................................................. 45 SAFETY MAINTENANCE INFORMATION....................................................................................................................................................... 46 WARNING TAG...................................................................................................................................................................... 46 KEEP WORK PLACE CLEAN AND TIDY................................................................................................................................................... 46 APPOINT LEADER WHEN WORKING WITH OTHERS.......................................................................................................................................... 46 STOP ENGINE BEFORE CARRYING OUT MAINTENANCE...................................................................................................................................... 47 TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING............................................................................................................................... 48 PROPER TOOLS..................................................................................................................................................................... 48 ACCUMULATOR, GAS SPRING.......................................................................................................................................................... 49 PERSONNEL........................................................................................................................................................................ 49 ATTACHMENTS...................................................................................................................................................................... 49 WORK UNDER THE MACHINE........................................................................................................................................................... 49 NOISE............................................................................................................................................................................ 49 WHEN USING HAMMER................................................................................................................................................................ 50 WELDING WORKS.................................................................................................................................................................... 50 REMOVING BATTERY TERMINALS....................................................................................................................................................... 50 SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION............................................................................................................. 50 DO NOT DISASSEMBLE RECOIL SPRINGS................................................................................................................................................ 50 SAFETY RULES FOR HIGH-PRESSURE OIL............................................................................................................................................... 51 SAFETY HANDLING HIGH-PRESSURE HOSES.............................................................................................................................................. 51 WASTE MATERIALS.................................................................................................................................................................. 51 AIR CONDITIONER MAINTENANCE...................................................................................................................................................... 51 COMPRESSED AIR................................................................................................................................................................... 52 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS.................................................................................................................................... 52 OPERATION................................................................................................................................................................................ 53 MACHINE VIEW ILLUSTRATIONS........................................................................................................................................................... 54 OVERALL MACHINE VIEW............................................................................................................................................................. 54 CONTROLS AND GAUGES.............................................................................................................................................................. 55 DETAILED CONTROLS AND GAUGES......................................................................................................................................................... 57 MONITORING SYSTEM................................................................................................................................................................ 57 SWITCHES......................................................................................................................................................................... 82 CONTROL LEVERS AND PEDALS........................................................................................................................................................ 87 SUN ROOF......................................................................................................................................................................... 90 WINDSHIELD....................................................................................................................................................................... 90 EMERGENCY EXIT FROM OPERATOR'S CAB............................................................................................................................................... 95 DOOR LOCK........................................................................................................................................................................ 95 CAP WITH LOCK.................................................................................................................................................................... 96 HOT AND COOL BOX................................................................................................................................................................. 97 MAGAZINE BOX..................................................................................................................................................................... 98 ASHTRAY.......................................................................................................................................................................... 98 AIR CONDITIONER CONTROLS......................................................................................................................................................... 99 RADIO............................................................................................................................................................................113 AUXILIARY ELECTRIC POWER.........................................................................................................................................................118 FUSE.............................................................................................................................................................................119 FUSIBLE LINK.....................................................................................................................................................................120 CONTROLLER.......................................................................................................................................................................120 TOOL BOX.........................................................................................................................................................................121 GREASE GUN HOLDER................................................................................................................................................................121 ACCUMULATOR......................................................................................................................................................................122 MACHINE OPERATIONS AND CONTROLS......................................................................................................................................................123 BEFORE STARTING ENGINE...........................................................................................................................................................123 STARTING ENGINE..................................................................................................................................................................138 AFTER STARTING ENGINE............................................................................................................................................................142 STOPPING THE ENGINE..............................................................................................................................................................151 MACHINE OPERATION................................................................................................................................................................152 STEERING THE MACHINE.............................................................................................................................................................156 SWINGING.........................................................................................................................................................................158 WORK EQUIPMENT CONTROLS AND OPERATIONS...........................................................................................................................................159 WORKING MODE.....................................................................................................................................................................161 PROHIBITED OPERATIONS............................................................................................................................................................162 GENERAL OPERATION INFORMATION....................................................................................................................................................164 TRAVELING ON SLOPES..............................................................................................................................................................166 ESCAPE FROM MUD..................................................................................................................................................................168 RECOMMENDED APPLICATIONS.........................................................................................................................................................169 BUCKET REPLACEMENT AND INVERSION.................................................................................................................................................171 PARKING MACHINE..................................................................................................................................................................174 CHECK AFTER SHUT OFF ENGINE......................................................................................................................................................175 MACHINE INSPECTION AFTER DAILY WORK..............................................................................................................................................175 LOCKING..........................................................................................................................................................................176 TRANSPORTATION.......................................................................................................................................................................177 PRECAUTIONS FOR TRANSPORTATION...................................................................................................................................................177 LOADING AND UNLOADING WITH TRAILER...............................................................................................................................................178 LIFTING MACHINE..................................................................................................................................................................186 TRANSPORTATION POSTURE...........................................................................................................................................................188 COLD WEATHER OPERATION...............................................................................................................................................................191 COLD WEATHER OPERATION INFORMATION...............................................................................................................................................191 AFTER DAILY WORK COMPLETION......................................................................................................................................................194 AFTER COLD WEATHER SEASON........................................................................................................................................................194 LONG TERM STORAGE....................................................................................................................................................................195 BEFORE STORAGE...................................................................................................................................................................195 DURING STORAGE...................................................................................................................................................................195 AFTER STORAGE....................................................................................................................................................................195 STARTING MACHINE AFTER LONG-TERM STORAGE.........................................................................................................................................196 TROUBLES AND ACTIONS.................................................................................................................................................................197 RUNNING OUT OF FUEL..............................................................................................................................................................197 PHENOMENA THAT ARE NOT FAILURES..................................................................................................................................................198 TOWING THE MACHINE...............................................................................................................................................................199 LIGHTWEIGHT TOWING HOLE..........................................................................................................................................................200 SEVERE JOB CONDITION.............................................................................................................................................................200 DISCHARGED BATTERY...............................................................................................................................................................201 OTHER TROUBLE....................................................................................................................................................................205 MAINTENANCE..............................................................................................................................................................................211 MAINTENANCE INFORMATION..............................................................................................................................................................212 OUTLINE OF SERVICE...................................................................................................................................................................214 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC...........................................................................................................................214 ELECTRIC SYSTEM MAINTENANCE......................................................................................................................................................217 WEAR PARTS...........................................................................................................................................................................218 WEAR PARTS LIST..................................................................................................................................................................218 LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS..........................................................................................................................................219 TIGHTENING TORQUE SPECIFICATIONS.....................................................................................................................................................223 TIGHTENING TORQUE LIST...........................................................................................................................................................223 SAFETY CRITICAL PARTS................................................................................................................................................................224 SAFETY CRITICAL PARTS LIST.......................................................................................................................................................224 MAINTENANCE SCHEDULE.................................................................................................................................................................225 MAINTENANCE SCHEDULE CHART.......................................................................................................................................................225 MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER.......................................................................................................................................227 MAINTENANCE PROCEDURE................................................................................................................................................................228 INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)...................................................................................................................228 INITIAL 1000 HOURS MAINTENANCE (ONLY AFTER THE FIRST 1000 HOURS).................................................................................................................228 WHEN REQUIRED....................................................................................................................................................................229 CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT.................................................................................................................................229 CLEAN INSIDE OF COOLING SYSTEM...............................................................................................................................................234 CHECK AND TIGHTEN TRACK SHOE BOLTS...........................................................................................................................................236 CHECK AND ADJUST TRACK TENSION...............................................................................................................................................237 CHECK ELECTRICAL INTAKE AIR HEATER...........................................................................................................................................238 REPLACE BUCKET TEETH (VERTICAL PIN TYPE).....................................................................................................................................239 REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)...................................................................................................................................242 REPLACE BUCKET SIDE CUTTER, SHROUD...........................................................................................................................................243 ADJUST BUCKET CLEARANCE......................................................................................................................................................244 CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID...................................................................................................................................245 CHECK AND MAINTENANCE AIR CONDITIONER........................................................................................................................................246 WASH WASHABLE FLOOR..........................................................................................................................................................247 BLEEDING AIR FROM HYDRAULIC SYSTEM...........................................................................................................................................250 METHOD FOR RELEASING INTERNAL PRESSURE IN HYDRAULIC CIRCUIT..................................................................................................................252 CHECK NITROGEN GAS CHARGE PRESSURE IN ACCUMULATOR (CONTROL CIRCUIT)..........................................................................................................253 CHECK BEFORE STARTING............................................................................................................................................................254 EVERY 50 HOURS MAINTENANCE.......................................................................................................................................................255 LUBRICATING..................................................................................................................................................................255 EVERY 250 HOURS MAINTENANCE......................................................................................................................................................256 CHECK OIL LEVEL IN SWING MACHINERY CASE, ADD OIL.............................................................................................................................256 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL.................................................................................................................................257 CHECK LEVEL OF BATTERY ELECTROLYTE...........................................................................................................................................258 LUBRICATE SWING CIRCLE (2 POINTS)............................................................................................................................................261 CHECK FAN BELT, ALTERNATOR BELT TENSION, ADJUST..............................................................................................................................261 CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST........................................................................................................................262 EVERY 500 HOURS MAINTENANCE......................................................................................................................................................263 LUBRICATING..................................................................................................................................................................263 REPLACE FUEL FILTER CARTRIDGE (MACHINES EQUIPPED WITHOUT ADDITIONAL FUEL FILTER CARTRIDGE)...................................................................................265 CHECK, WASH FUEL STRAINER....................................................................................................................................................267 CHECK SWING PINION GREASE LEVEL, ADD GREASE..................................................................................................................................268 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE............................................................................................................269 CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS, AFTER COOLER FINS, FUEL COOLER FINS, AND AIR CONDITIONER CONDENSER FINS (ONLY MACHINES EQUIPPED WITH AIR CONDITIONER)....271 CLEAN AIR CONDITIONER FRESH/RECIRC FILTERS...................................................................................................................................272 REPLACE BREATHER ELEMENT IN HYDRAULIC TANK...................................................................................................................................273 REPLACE ADDITIONAL FUEL FILTER CARTRIDGE (IF EQUIPPED WITH MACHINES).........................................................................................................274 EVERY 1000 HOURS MAINTENANCE.....................................................................................................................................................276 REPLACE FUEL FILTER CARTRIDGE (MACHINES EQUIPPED WITH ADDITIONAL FUEL FILTER CARTRIDGE)......................................................................................276 REPLACE HYDRAULIC OIL FILTER ELEMENT.........................................................................................................................................278 CHANGE OIL IN SWING MACHINERY CASE...........................................................................................................................................279 CHECK OIL LEVEL IN DAMPER CASE, ADD OIL......................................................................................................................................280 CHECK ALL TIGHTENING PARTS OF TURBOCHARGER...................................................................................................................................280 CHECK PLAY TURBOCHARGER ROTOR................................................................................................................................................280 REPLACE CORROSION RESISTOR CARTRIDGE.........................................................................................................................................281 REPLACE HYDRAULIC TANK ADDITIONAL BREATHER ELEMENT...........................................................................................................................282 CHECK NITROGEN GAS CHARGE PRESSURE IN ACCUMULATOR (FOR BREAKER)..............................................................................................................282 EVERY 2000 HOURS MAINTENANCE.....................................................................................................................................................283 CHANGE OIL IN FINAL DRIVE CASE...............................................................................................................................................283 CHECK INJECTOR...............................................................................................................................................................283 CLEAN HYDRAULIC TANK STRAINER................................................................................................................................................284 CLEAN ENGINE BREATHER........................................................................................................................................................284 CLEAN, CHECK TURBOCHARGER....................................................................................................................................................285 CHECK ALTERNATOR, STARTING MOTOR.............................................................................................................................................285 CHECK ENGINE VALVE CLEARANCE, ADJUST.........................................................................................................................................285 CHECK VIBRATION DAMPER.......................................................................................................................................................285 EVERY 4000 HOURS MAINTENANCE.....................................................................................................................................................286 CHECK WATER PUMP.............................................................................................................................................................286 CHECK FOR LOOSENESS OF HIGH-PRESSURE PIPING CLAMP, HARDENING OF RUBBER.......................................................................................................286 CHECK FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER.............................................................................................................287 REPLACE INJECTOR NOZZLE ASSEMBLY.............................................................................................................................................287 EVERY 5000 HOURS MAINTENANCE.....................................................................................................................................................288 CHANGE OIL IN HYDRAULIC TANK.................................................................................................................................................288 EVERY 8000 HOURS MAINTENANCE.....................................................................................................................................................290 REPLACE HIGH-PRESSURE PIPING CLAMP...........................................................................................................................................290 REPLACE FUEL SPRAY PREVENTION CAP............................................................................................................................................290 SPECIFICATIONS...........................................................................................................................................................................291 SPECIFICATIONS.......................................................................................................................................................................292 ATTACHMENTS, OPTIONS.....................................................................................................................................................................295 GENERAL PRECAUTIONS FOR SAFETY.......................................................................................................................................................296 PRECAUTIONS WHEN SELECTING.......................................................................................................................................................296 READ THE INSTRUCTION MANUAL THOROUGHLY...........................................................................................................................................296 PRECAUTIONS WHEN REMOVING OR INSTALLING..........................................................................................................................................296 PRECAUTIONS WHEN USING...........................................................................................................................................................296 MACHINE READY FOR ATTACHMENT.........................................................................................................................................................297 LOCATIONS........................................................................................................................................................................297 HYDRAULIC CIRCUIT................................................................................................................................................................301 ATTACHMENT REMOVAL AND INSTALLATION..............................................................................................................................................305 ATTACHMENT OPERATIONS............................................................................................................................................................307 LONG TERM STORAGE................................................................................................................................................................309 SPECIFICATIONS...................................................................................................................................................................309 ATTACHMENT GUIDE.....................................................................................................................................................................310 ATTACHMENT COMBINATIONS..........................................................................................................................................................310 RECOMMENDED ATTACHMENT OPERATIONS....................................................................................................................................................312 HYDRAULIC BREAKER................................................................................................................................................................312 LOADING SHOVEL...........................................................................................................................................................................316 EXPLANATION OF COMPONENTS............................................................................................................................................................317 SWITCHES.........................................................................................................................................................................317 OPERATIONS...........................................................................................................................................................................320 OPERATION OF WORK EQUIPMENT......................................................................................................................................................320 PRECAUTIONS DURING OPERATION.....................................................................................................................................................322 EXCAVATOR WORK...................................................................................................................................................................326 PRECAUTIONS WHEN DISASSEMBLING MACHINE...............................................................................................................................................327 RELEASING PRESSURE...............................................................................................................................................................327 TRANSPORTATION.......................................................................................................................................................................328 MACHINE CONFIGURATION FOR TRANSPORT..............................................................................................................................................328 MAINTENANCE..........................................................................................................................................................................332 CHECK BEFORE STARTING............................................................................................................................................................332 EVERY 10 HOURS MAINTENANCE.......................................................................................................................................................333 SPECIFICATION........................................................................................................................................................................334 COMBINATION OF WORK EQUIPMENT........................................................................................................................................................336 COMBINATION OF WORK EQUIPMENT....................................................................................................................................................336 INDEX....................................................................................................................................................................................338
PLEASE NOTE:
⦁ This is the SAME exact manual used by your dealers to fix your vehicle.
⦁ The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
⦁ Any queries / doubts regarding your purchase, please feel free to contact [email protected]
Kendrick Emmett –