KOMATSU PC400LG5 WITH CUMMINS LTA-IOC ENGINE HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL KOMATSU PC400LG5
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KOMATSU PC400LG5 WITH CUMMINS LTA-IOC ENGINE HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL KOMATSU PC400LG5
- This manual describes procedures for operation, handling, lubrication, maintenance, checking, and adjustment. It will help the operator and maintenance personnel realize peak performance through effective, economical and safe machine operation and maintenance.
- Keep this manual handy and have all personnel read it periodically. If this manual is lost or becomes dirty and can not be read, request a replacement manual from your local distributor. If you sell the machine, be sure to give this manual to the new owner. Continuing improvements in the design of this machine can lead to changes in detail, which may not be reflected in this manual.
- Consult your local distributor or Komatsu Dresser Co. for the latest available information on your machine or for questions regarding information in this manual.
TABLE OF CONTENTS:
KOMATSU PC400LG5 WITH CUMMINS LTA-IOC ENGINE HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL KOMATSU PC400LG5
MAIN MENU........................................................................ 0 1. FORWARD...................................................................... 3 2. SAFETY INFORMATION........................................................... 4 3. INTRODUCTION................................................................. 5 4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR................ 6 5. CONTENTS..................................................................... 7 SAFETY........................................................................... 11 6. GENERAL PRECAUTIONS...................................................... 12 7. PRECAUTIONS DURING OPERATION............................................. 18 7.1 BEFORE STARTING ENGINE.............................................. 18 7.2 OPERATING MACHINE................................................... 20 7.3 TRANSPORTATION...................................................... 26 7.4 BATTERY............................................................. 27 7.5 TOWING.............................................................. 28 7.6 BUCKET WITH HOOK.................................................... 29 8. PRECAUTIONS FOR MAINTENANCE.............................................. 31 8.1 BEFORE CARRYING OUT MAINTENANCE..................................... 31 8.2 DURING MAINTENANCE.................................................. 34 9. POSITION FOR ATTACHING SAFETY LABELS..................................... 38 OPERATION........................................................................ 43 10. GENERAL VIEW............................................................ 44 10.1 GENERAL VIEW OF MACHINE............................................ 44 10.2 GENERAL VIEW OF CONTROLS AND GAUGES................................ 45 11. EXPLANATION OF COMPONENTS............................................... 46 11.1 ELECTRONIC MONITOR AND CONTROL CONSOLE (EMACC)..................... 46 11.2 METER.............................................................. 55 11.3 SWITCHES........................................................... 56 11.4 CONTROL LEVERS, PEDALS............................................. 62 11.5 CEILING WINDOW..................................................... 66 11.6 WINDSHIELD......................................................... 66 11.7 DOOR HOLD OPEN LOCK................................................ 68 11.8 CAP, COVER WITH LOCK............................................... 68 11.9 DEFROSTER CONTROL.................................................. 69 11.10 STORAGE TRAY...................................................... 69 11.11 ASHTRAY........................................................... 69 11.12 FUSE.............................................................. 70 11.13 FUSIBLE LINK...................................................... 70 11.14 HANDLING ACCUMULATOR.............................................. 71 12. OPERATION............................................................... 72 12.1 CHECK BEFORE STARTING.............................................. 72 12.2 STARTING ENGINE.................................................... 86 12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE........................ 89 12.4 MOVING MACHINE OFF................................................. 92 12.5 STEERING THE MACHINE............................................... 93 12.6 STOPPING THE MACHINE............................................... 94 12.7 SWINGING........................................................... 95 12.8 OPERATION OF WORK EQUIPMENT........................................ 96 12.9 WORKING MODE SELECTION............................................. 98 12.10 PROHIBITIONS FOR OPERATION........................................100 12.11 PRECAUTIONS FOR OPERATION.........................................103 12.12 PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS.......................104 12.13 HOW TO ESCAPE FROM MUD............................................105 12.14 WORK POSSIBLE USING HYDRAULIC EXCAVATOR...........................106 12.15 REPLACEMENT AND INVERSION OF BUCKET...............................108 12.16 PARKING MACHINE...................................................109 12.17 CHECK AFTER FINISHING WORK........................................110 12.18 STOPPING ENGINE...................................................110 12.19 CHECK AFTER STOPPING ENGINE.......................................111 12.20 LOCKING AND SECURING MACHINE......................................112 13. TRANSPORTATION..........................................................113 13.1 LOADING AND UNLOADING MACHINE......................................113 13.2 TRANSPORTING MACHINE...............................................114 13.3 PRECAUTIONS FOR TRANSPORTATION.....................................115 13.4 DISASSEMBLING MACHINE FOR TRANSPORT................................115 13.5 PROCEDURE FOR INCREASING OR REDUCING TRACK FRAME GAUGE.............118 14. COLD WEATHER OPERATION..................................................120 14.1 PRECAUTIONS FOR LOW TEMPERATURE....................................120 14.2 PRECAUTIONS AFTER COMPLETION OF WORK...............................121 14.3 AFTER COLD WEATHER.................................................121 15. LONG-TERM STORAGE.......................................................122 15.1 BEFORE STORAGE.....................................................122 15.2 DURING STORAGE.....................................................124 15.3 AFTER STORAGE......................................................125 15.4 STARTING MACHINE AFrER LONG-TERM STORAGE...........................125 16. TROUBLESHOOTING.........................................................126 16.1 MOVING A DISABLED MACHINE..........................................126 16.2 PRECAUTIONS ON PARTICULAR JOBSITES.................................127 16.3 IF BAlTERY IS DISCHARGED...........................................128 16.4 STARTING ENGINE WITH BOOSTER CABLE.................................128 16.5 OTHER TROUBLE......................................................130 16.6 PHENOMENA THAT ARE NOT FAILURES....................................134 MAINTENANCE......................................................................135 17. GUIDES TO MAINTENANCE...................................................136 18. OUTLINES OF SERVICE.....................................................139 18.1 OUTLINE OF OIL, FUEL, COOLANT......................................139 18.2 OUTLINE OF ELECTRICAL SYSTEM.......................................142 18.3 OUTLINE OF HYDRAULIC SYSTEM........................................143 19. WEAR PARTS LIST.........................................................144 20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE....146 20.1 PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS...................146 20.2 ENGINE OIL SPECIFICATIONS..........................................147 20.3 GREASE SPECIFICATIONS..............................................147 20.4 DIESEL FUEL SPECIFICATIONS.........................................148 20.5 COOLANT SPECIFICATIONS.............................................148 21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS..........................153 21.1 STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS.......................153 21.2 TIGHTENING TORQUE OF SPLIT FLANGE BOLTS............................153 21.3 TIGHTENING TORQUE FOR NUTS OF FLARED FllTlNGS......................154 21.4 UNIT CONVERSIONS...................................................155 22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...........................161 23. MAINTENANCE SCHEDULE CHART..............................................162 24. SERVICE PROCEDURE.......................................................165 24.1 SEASONAL PREPARATIONS...............................................165 24.2 AIR CLEANING SYSTEM................................................166 24.3 AIR CONDITIONER....................................................170 24.4 BELTS..............................................................171 24.5 BUCKET.............................................................176 24.6 COOLING SYSTEM.....................................................182 24.7 ELECTRICAL SYSTEM..................................................188 24.8 ENGINE.............................................................191 24.9 ETHER INJECTOR (IF EQUIPPED).......................................196 24.10 FINAL DRIVE.......................................................198 24.11 FUEL SYSTEM.......................................................199 24.12 HYDRAULIC SYSTEM..................................................203 24.13 LUBRICATION FITTINGS..............................................216 24.14 PTO CASE..........................................................218 24.15 SEAT BELT.........................................................218 24.16 SWING MACHINERY...................................................219 24.17 TRACKS............................................................222 24.18 TURBOCHARGER......................................................224 24.19 WALK AROUND INSPECTION............................................226 24.20 WINDOW WASHER.....................................................226 SPECIFICATIONS...................................................................227 25. SPECIFICATIONS..........................................................228 OPTIONS & ATTACHMENTS............................................................231 26. GENERAL PRECAUTIONS.....................................................232 26.1 PRECAUTIONS RELATED TO SAFETY......................................232 26.2 PRECAUTIONS WHEN INSTALLING AlTACHMENTS............................233 27. HANDLING BUCKET WITH HOOK...............................................234 27.1 CHECK FOR DAMAGE TO BUCKET WITH HOOK................................234 27.2 PROHIBITED OPERATIONS..............................................234 27.3 PRECAUTIONS DURING OPERATIONS......................................234 28. OPERATING AIR CONDITIONER...............................................235 28.1 CONTROL PANEL......................................................235 28.2 COOLING............................................................236 28.3 HEATING............................................................237 28.4 DEHUMIDIFY AND HEATING.............................................238 29. RADIO...................................................................239 29.1 OPERATION..........................................................239 29.2 CARE AND MAINTENANCE...............................................239 29.3 TROUBLESHOOTING....................................................239 30. OPTIONAL ELECTRICAL EQUIPMENT...........................................240 30.1 INSTALLATION OF OPTIONAL ELECTRICAL EQUIPMENT......................240 30.2 INSTALLATION OF ADDITIONAL LAMPS...................................241 31. INTRODUCTION OF ATTACHMENTS.............................................242 31.1 BUCKET SELECTION...................................................242 31.2 BUCKET TEETH SELECTION.............................................242 31.3 BUCKET INSTALLATION COMBINATIONS...................................243 31.4 SELECTION OF TRACK SHOES...........................................244 31.5 HANDLING THE CLAMSHELL BUCKET......................................245 32. EXTENDING MACHINE SERVICE LIFE..........................................246 32.1 HYDRAULIC BREAKER..................................................246 32.2 CRUSHER............................................................249 32.3 GRAPPLE............................................................250 32.4 BUCKET WITH THUMB GRAPPLE..........................................251 32.5 ROTATING GRAPPLE...................................................252 32.6 SHEAR..............................................................253 32.7 HYDRAULIC PILE DRIVER..............................................254 32.8 HYDRAULIC EXCAVATOR WITH MULTI-PURPOSE CRANE.......................255
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