KOMATSU GALEO PC400,400LC-7 PC450,450LC-7 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (TEN00039-03)
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KOMATSU GALEO PC400,400LC-7 PC450,450LC-7 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (TEN00039-03)
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 (TEN00039-03)
COVER................................................................................................................................................................................. 1 FOREWORD.............................................................................................................................................................................. 3 FOREWORD.......................................................................................................................................................................... 4 SAFETY INFORMATION................................................................................................................................................................ 7 INTRODUCTION...................................................................................................................................................................... 9 DIRECTIONS OF MACHINE......................................................................................................................................................... 9 BREAKING-IN THE NEW MACHINE................................................................................................................................................... 9 PRODUCT INFORMATION............................................................................................................................................................... 10 PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE.................................................................................................................. 10 ENGINE SERIAL NUMBER PLATE AND ITS LOCATION................................................................................................................................... 10 SERVICE METER LOCATION........................................................................................................................................................ 11 YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR................................................................................................................................... 11 CONTENTS.............................................................................................................................................................................. 12 SAFETY................................................................................................................................................................................ 17 SAFETY INFORMATION................................................................................................................................................................ 18 SAFETY LABELS..................................................................................................................................................................... 20 LOCATION OF SAFETY LABELS..................................................................................................................................................... 20 SAFETY LABELS................................................................................................................................................................. 21 SAFETY INFORMATION................................................................................................................................................................ 26 SAFETY RULES.................................................................................................................................................................. 26 IF PROBLEMS ARE FOUND......................................................................................................................................................... 26 WORKING WEAR AND PERSONAL PROTECTIVE ITEMS.................................................................................................................................... 26 FIRE EXTINGUISHER AND FIRST AID KIT........................................................................................................................................... 26 SAFETY EQUIPMENT.............................................................................................................................................................. 26 KEEP MACHINE CLEAN............................................................................................................................................................ 27 KEEP OPERATOR'S COMPARTMENT CLEAN............................................................................................................................................. 27 LEAVING OPERATOR'S SEAT WITH LOCK............................................................................................................................................. 27 HANDRAILS AND STEPS........................................................................................................................................................... 28 PRECAUTIONS WHEN WORKING IN HIGH PLACES....................................................................................................................................... 28 MOUNTING AND DISMOUNTING...................................................................................................................................................... 28 NO PERSONS ON ATTACHMENTS..................................................................................................................................................... 28 DO NOT GET CAUGHT IN ARTICULATED PORTION...................................................................................................................................... 29 BURN PREVENTION............................................................................................................................................................... 29 FIRE PREVENTION AND EXPLOSION PREVENTION...................................................................................................................................... 30 ACTION IF FIRE OCCURS......................................................................................................................................................... 31 WINDSHIELD WASHER FLUID....................................................................................................................................................... 31 FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION.............................................................................................................. 31 ATTACHMENT INSTALLATION....................................................................................................................................................... 31 ATTACHMENT COMBINATIONS....................................................................................................................................................... 31 CAB WINDOW GLASSES............................................................................................................................................................ 31 UNAUTHORIZED MODIFICATIONS.................................................................................................................................................... 32 SAFETY AT JOBSITE............................................................................................................................................................. 32 WORKING ON LOOSE GROUND....................................................................................................................................................... 32 DISTANCE TO HIGH VOLTAGE CABLES............................................................................................................................................... 33 ENSURE GOOD VISIBILITY........................................................................................................................................................ 33 VENTILATION FOR ENCLOSED AREA................................................................................................................................................. 34 SIGNALMAN'S SIGNAL AND SIGNS.................................................................................................................................................. 34 EMERGENCY EXIT FROM OPERATOR'S CAB............................................................................................................................................ 34 ASBESTOS DUST HAZARD PREVENTION............................................................................................................................................... 34 SAFETY MACHINE OPERATION.......................................................................................................................................................... 35 STARTING ENGINE............................................................................................................................................................... 35 CHECKS BEFORE STARTING ENGINE............................................................................................................................................. 35 SAFETY RULES FOR STARTING ENGINE.......................................................................................................................................... 36 STARTING ENGINE IN COLD WEATHER........................................................................................................................................... 36 OPERATION..................................................................................................................................................................... 37 CHECKS BEFORE OPERATION................................................................................................................................................... 37 SAFETY RULES FOR CHANGING MACHINE DIRECTIONS.............................................................................................................................. 37 SAFETY RULES FOR TRAVELING................................................................................................................................................ 38 TRAVELING ON SLOPES....................................................................................................................................................... 38 OPERATIONS ON SLOPES...................................................................................................................................................... 39 PROHIBITED OPERATIONS..................................................................................................................................................... 39 OPERATIONS ON SNOW........................................................................................................................................................ 41 PARKING MACHINE........................................................................................................................................................... 42 TRANSPORTATION................................................................................................................................................................ 43 LOADING AND UNLOADING..................................................................................................................................................... 43 SHIPPING THE MACHINE...................................................................................................................................................... 43 BATTERY....................................................................................................................................................................... 44 BATTERY HAZARD PREVENTION................................................................................................................................................. 44 STARTING ENGINE WITH BOOSTER CABLES....................................................................................................................................... 45 TOWING........................................................................................................................................................................ 46 SAFETY RULES FOR TOWING................................................................................................................................................... 46 LIFTING OBJECTS WITH BUCKET................................................................................................................................................... 47 SAFETY RULES FOR LIFTING OBJECTS.......................................................................................................................................... 47 SAFETY MAINTENANCE INFORMATION.................................................................................................................................................... 48 WARNING TAG................................................................................................................................................................... 48 KEEP WORK PLACE CLEAN AND TIDY................................................................................................................................................ 48 APPOINT LEADER WHEN WORKING WITH OTHERS....................................................................................................................................... 48 STOP ENGINE BEFORE CARRYING OUT MAINTENANCE................................................................................................................................... 49 TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING............................................................................................................................ 50 PROPER TOOLS.................................................................................................................................................................. 50 ACCUMULATOR, GAS SPRING....................................................................................................................................................... 51 PERSONNEL..................................................................................................................................................................... 51 ATTACHMENTS................................................................................................................................................................... 51 WORK UNDER THE MACHINE........................................................................................................................................................ 51 NOISE......................................................................................................................................................................... 51 WHEN USING HAMMER............................................................................................................................................................. 52 WELDING WORKS................................................................................................................................................................. 52 REMOVING BATTERY TERMINALS.................................................................................................................................................... 52 SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION.......................................................................................................... 52 DO NOT DISASSEMBLE RECOIL SPRINGS............................................................................................................................................. 52 SAFETY RULES FOR HIGH-PRESSURE OIL............................................................................................................................................ 53 SAFETY HANDLING HIGH-PRESSURE HOSES........................................................................................................................................... 53 WASTE MATERIALS............................................................................................................................................................... 53 AIR CONDITIONER MAINTENANCE................................................................................................................................................... 53 COMPRESSED AIR................................................................................................................................................................ 54 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS................................................................................................................................. 54 OPERATION............................................................................................................................................................................. 55 MACHINE VIEW ILLUSTRATIONS........................................................................................................................................................ 56 OVERALL MACHINE VIEW.......................................................................................................................................................... 56 CONTROLS AND GAUGES........................................................................................................................................................... 57 DETAILED CONTROLS AND GAUGES...................................................................................................................................................... 58 MONITORING SYSTEM............................................................................................................................................................. 58 SWITCHES...................................................................................................................................................................... 71 CONTROL LEVERS AND PEDALS..................................................................................................................................................... 76 SUN ROOF...................................................................................................................................................................... 79 WINDSHIELD.................................................................................................................................................................... 79 EMERGENCY EXIT FROM OPERATOR'S CAB............................................................................................................................................ 84 DOOR LOCK..................................................................................................................................................................... 84 CAP WITH LOCK................................................................................................................................................................. 85 HOT AND COOL BOX.............................................................................................................................................................. 86 MAGAZINE BOX.................................................................................................................................................................. 87 ASHTRAY....................................................................................................................................................................... 87 AIR CONDITIONER CONTROLS...................................................................................................................................................... 88 RADIO.........................................................................................................................................................................102 AUXILIARY ELECTRIC POWER......................................................................................................................................................107 FUSE..........................................................................................................................................................................108 FUSIBLE LINK..................................................................................................................................................................109 CONTROLLER....................................................................................................................................................................109 TOOL BOX......................................................................................................................................................................110 GREASE GUN HOLDER.............................................................................................................................................................110 ACCUMULATOR...................................................................................................................................................................111 MACHINE OPERATIONS AND CONTROLS...................................................................................................................................................112 BEFORE STARTING ENGINE........................................................................................................................................................112 STARTING ENGINE...............................................................................................................................................................126 AFTER STARTING ENGINE.........................................................................................................................................................130 STOPPING THE ENGINE...........................................................................................................................................................137 MACHINE OPERATION.............................................................................................................................................................138 STEERING THE MACHINE..........................................................................................................................................................142 SWINGING......................................................................................................................................................................144 WORK EQUIPMENT CONTROLS AND OPERATIONS........................................................................................................................................145 WORKING MODE..................................................................................................................................................................147 PROHIBITED OPERATIONS.........................................................................................................................................................148 GENERAL OPERATION INFORMATION.................................................................................................................................................150 TRAVELING ON SLOPES...........................................................................................................................................................152 ESCAPE FROM MUD...............................................................................................................................................................154 RECOMMENDED APPLICATIONS......................................................................................................................................................155 BUCKET REPLACEMENT AND INVERSION..............................................................................................................................................157 PARKING MACHINE...............................................................................................................................................................160 CHECK AFTER SHUT OFF ENGINE...................................................................................................................................................161 MACHINE INSPECTION AFTER DAILY WORK...........................................................................................................................................161 LOCKING.......................................................................................................................................................................162 TRANSPORTATION....................................................................................................................................................................163 PRECAUTIONS FOR TRANSPORTATION................................................................................................................................................163 LOADING AND UNLOADING WITH TRAILER............................................................................................................................................164 LIFTING MACHINE...............................................................................................................................................................172 PRECAUTIONS WHEN LOADING......................................................................................................................................................174 TRANSPORTATION POSTURE........................................................................................................................................................175 COLD WEATHER OPERATION............................................................................................................................................................178 COLD WEATHER OPERATION INFORMATION............................................................................................................................................178 AFTER DAILY WORK COMPLETION...................................................................................................................................................180 AFTER COLD WEATHER SEASON.....................................................................................................................................................180 LONG TERM STORAGE.................................................................................................................................................................181 BEFORE STORAGE................................................................................................................................................................181 DURING STORAGE................................................................................................................................................................181 AFTER STORAGE.................................................................................................................................................................181 STARTING MACHINE AFTER LONG-TERM STORAGE......................................................................................................................................182 TROUBLES AND ACTIONS..............................................................................................................................................................183 RUNNING OUT OF FUEL...........................................................................................................................................................183 PHENOMENA THAT ARE NOT FAILURES...............................................................................................................................................184 TOWING THE MACHINE............................................................................................................................................................185 LIGHTWEIGHT TOWING HOLE.......................................................................................................................................................186 SEVERE JOB CONDITION..........................................................................................................................................................186 DISCHARGED BATTERY............................................................................................................................................................187 OTHER TROUBLE.................................................................................................................................................................191 MAINTENANCE...........................................................................................................................................................................197 MAINTENANCE INFORMATION...........................................................................................................................................................198 OUTLINE OF SERVICE................................................................................................................................................................200 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC........................................................................................................................200 ELECTRIC SYSTEM MAINTENANCE...................................................................................................................................................203 WEAR PARTS........................................................................................................................................................................204 WEAR PARTS LIST...............................................................................................................................................................204 LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS.......................................................................................................................................205 TIGHTENING TORQUE SPECIFICATIONS..................................................................................................................................................209 TIGHTENING TORQUE LIST........................................................................................................................................................209 SAFETY CRITICAL PARTS.............................................................................................................................................................210 SAFETY CRITICAL PARTS LIST....................................................................................................................................................210 MAINTENANCE SCHEDULE..............................................................................................................................................................211 MAINTENANCE SCHEDULE CHART....................................................................................................................................................211 MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER....................................................................................................................................213 MAINTENANCE PROCEDURE.............................................................................................................................................................214 INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)................................................................................................................214 INITIAL 1000 HOURS MAINTENANCE (ONLY AFTER THE FIRST 1000 HOURS)..............................................................................................................214 WHEN REQUIRED.................................................................................................................................................................215 CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT..............................................................................................................................215 CLEAN INSIDE OF COOLING SYSTEM............................................................................................................................................220 CHECK AND TIGHTEN TRACK SHOE BOLTS........................................................................................................................................222 CHECK AND ADJUST TRACK TENSION............................................................................................................................................223 CHECK ELECTRICAL INTAKE AIR HEATER........................................................................................................................................224 REPLACE BUCKET TEETH (VERTICAL PIN TYPE)..................................................................................................................................225 REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)................................................................................................................................228 REPLACE BUCKET SIDE CUTTER, SHROUD........................................................................................................................................229 ADJUST BUCKET CLEARANCE...................................................................................................................................................230 CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID................................................................................................................................231 CHECK AND MAINTENANCE AIR CONDITIONER.....................................................................................................................................232 WASH WASHABLE FLOOR.......................................................................................................................................................233 BLEEDING AIR FROM HYDRAULIC SYSTEM........................................................................................................................................236 METHOD FOR RELEASING INTERNAL PRESSURE IN HYDRAULIC CIRCUIT...............................................................................................................238 CHECK NITROGEN GAS CHARGE PRESSURE IN ACCUMULATOR (CONTROL CIRCUIT).......................................................................................................239 CHECK BEFORE STARTING.........................................................................................................................................................240 EVERY 50 HOURS MAINTENANCE....................................................................................................................................................241 LUBRICATING...............................................................................................................................................................241 EVERY 100 HOURS MAINTENANCE...................................................................................................................................................242 LUBRICATING...............................................................................................................................................................242 EVERY 250 HOURS MAINTENANCE...................................................................................................................................................244 CHECK OIL LEVEL IN SWING MACHINERY CASE, ADD OIL..........................................................................................................................244 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL..............................................................................................................................245 CHECK LEVEL OF BATTERY ELECTROLYTE........................................................................................................................................246 LUBRICATE SWING CIRCLE....................................................................................................................................................249 CHECK FAN BELT, ALTERNATOR BELT TENSION, ADJUST...........................................................................................................................249 CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST.....................................................................................................................250 EVERY 500 HOURS MAINTENANCE...................................................................................................................................................251 REPLACE FUEL FILTER CARTRIDGE (MACHINES EQUIPPED WITHOUT ADDITIONAL FUEL FILTER CARTRIDGE)................................................................................251 CHECK, WASH FUEL STRAINER.................................................................................................................................................253 CHECK SWING PINION GREASE LEVEL, ADD GREASE...............................................................................................................................254 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE.........................................................................................................255 CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS, AFTERCOOLER FINS, FUEL COOLER FINS, AND AIR CONDITIONER CONDENSER FINS (ONLY MACHINES EQUIPPED WITH AIR CONDITIONER)....257 CLEAN AIR CONDITIONER FRESH/RECIRC FILTERS................................................................................................................................258 REPLACE BREATHER ELEMENT IN HYDRAULIC TANK................................................................................................................................259 REPLACE ADDITIONAL FUEL FILTER CARTRIDGE (IF EQUIPPED WITH MACHINES)......................................................................................................260 EVERY 1000 HOURS MAINTENANCE..................................................................................................................................................262 REPLACE FUEL FILTER CARTRIDGE (MACHINES EQUIPPED WITH ADDITIONAL FUEL FILTER CARTRIDGE)...................................................................................262 REPLACE HYDRAULIC OIL FILTER ELEMENT......................................................................................................................................264 CHANGE OIL IN SWING MACHINERY CASE........................................................................................................................................265 CHECK OIL LEVEL IN DAMPER CASE, ADD OIL...................................................................................................................................266 CHECK ALL TIGHTENING PARTS OF TURBOCHARGER................................................................................................................................266 CHECK PLAY TURBOCHARGER ROTOR.............................................................................................................................................266 REPLACE CORROSION RESISTOR CARTRIDGE......................................................................................................................................267 REPLACE HYDRAULIC TANK ADDITIONAL BREATHER ELEMENT........................................................................................................................268 CHECK NITROGEN GAS CHARGE PRESSURE IN ACCUMULATOR (FOR BREAKER)...........................................................................................................268 EVERY 2000 HOURS MAINTENANCE..................................................................................................................................................269 CHANGE OIL IN FINAL DRIVE CASE............................................................................................................................................269 CHECK INJECTOR............................................................................................................................................................269 CLEAN HYDRAULIC TANK STRAINER.............................................................................................................................................270 CLEAN ENGINE BREATHER.....................................................................................................................................................270 CLEAN, CHECK TURBOCHARGER.................................................................................................................................................271 CHECK ALTERNATOR, STARTING MOTOR..........................................................................................................................................271 CHECK ENGINE VALVE CLEARANCE, ADJUST......................................................................................................................................271 CHECK VIBRATION DAMPER....................................................................................................................................................271 EVERY 4000 HOURS MAINTENANCE..................................................................................................................................................272 CHECK WATER PUMP..........................................................................................................................................................272 CHECK FOR LOOSENESS OF HIGH-PRESSURE PIPING CLAMP, HARDENING OF RUBBER....................................................................................................272 CHECK FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER..........................................................................................................273 REPLACE INJECTOR NOZZLE ASSEMBLY..........................................................................................................................................273 EVERY 5000 HOURS MAINTENANCE..................................................................................................................................................274 CHANGE OIL IN HYDRAULIC TANK..............................................................................................................................................274 EVERY 8000 HOURS MAINTENANCE..................................................................................................................................................276 REPLACE HIGH-PRESSURE PIPING CLAMP........................................................................................................................................276 REPLACE FUEL SPRAY PREVENTION CAP.........................................................................................................................................276 SPECIFICATIONS........................................................................................................................................................................277 SPECIFICATIONS....................................................................................................................................................................278 ATTACHMENTS, OPTIONS..................................................................................................................................................................281 GENERAL PRECAUTIONS FOR SAFETY....................................................................................................................................................282 PRECAUTIONS WHEN SELECTING....................................................................................................................................................282 READ THE INSTRUCTION MANUAL THOROUGHLY........................................................................................................................................282 PRECAUTIONS WHEN REMOVING OR INSTALLING.......................................................................................................................................282 PRECAUTIONS WHEN USING........................................................................................................................................................282 MACHINE READY FOR ATTACHMENT......................................................................................................................................................283 LOCATIONS.....................................................................................................................................................................283 HYDRAULIC CIRCUIT.............................................................................................................................................................287 ATTACHMENT REMOVAL AND INSTALLATION...........................................................................................................................................291 ATTACHMENT OPERATIONS.........................................................................................................................................................293 LONG TERM STORAGE.............................................................................................................................................................294 SPECIFICATIONS................................................................................................................................................................294 ATTACHMENT GUIDE..................................................................................................................................................................295 ATTACHMENT COMBINATIONS.......................................................................................................................................................295 RECOMMENDED ATTACHMENT OPERATIONS.................................................................................................................................................297 HYDRAULIC BREAKER.............................................................................................................................................................297 MULTI-MONITOR SPECIFICATION...........................................................................................................................................................301 CONTENTS..........................................................................................................................................................................302 OPERATION......................................................................................................................................................................... 0 MACHINE VIEW ILLUSTRATIONS....................................................................................................................................................303 CONTROLS AND GAUGES.......................................................................................................................................................303 DETAILED CONTROLS AND GAUGES..................................................................................................................................................305 MONITORING SYSTEM.........................................................................................................................................................305 MACHINE OPERATIONS AND CONTROLS...............................................................................................................................................330 BEFORE STARTING ENGINE....................................................................................................................................................330 STARTING ENGINE...........................................................................................................................................................333 AFTER STARTING ENGINE.....................................................................................................................................................337 MACHINE OPERATION.........................................................................................................................................................346 SWINGING..................................................................................................................................................................349 WORKING MODE..............................................................................................................................................................350 GENERAL OPERATION INFORMATION.............................................................................................................................................351 CHECK AFTER SHUT OFF ENGINE...............................................................................................................................................352 MACHINE INSPECTION AFTER DAILY WORK.......................................................................................................................................352 COLD WEATHER OPERATION........................................................................................................................................................353 MONITOR...................................................................................................................................................................353 MAINTENANCE....................................................................................................................................................................... 0 MAINTENANCE PROCEDURE.........................................................................................................................................................354 WHEN REQUIRED.............................................................................................................................................................354 ATTACHMENTS AND OPTIONS........................................................................................................................................................... 0 MACHINE READY FOR ATTACHMENT..................................................................................................................................................359 ATTACHMENT OPERATIONS.....................................................................................................................................................359 INDEX.................................................................................................................................................................................361
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