Komatsu PC400LC-5 MIGHTY Manual

PcQoo,4oolt~5
PC400=5MIGHTY
PC4OOlL5MIGHTY
PC400HDm5
HYDRAULIC EXCAVATOR
Pc400,4001c-5 -20603
PC400-5 MIGHTY -20603
SERIAL NUMBERS PC4OOLC-5 MIGHTY -20603 mdup
PC400HD-5 -20603
PC4OOLC-5 -A70501
This material is proprietary to Komatsu Dresser Company and is not to be reproduced, used, or disclosed except
in accordance with written authorization from Komatsu Dresser Company.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make
changes or add improvements at any time without incurring any obligation to install such changes on products sold
previously.
Due to this continuous program of research and development, periodic revisions may be made to this publication.
It is recommended that customers contact their distributor for information on the latest revision.
AUG 1995 Copyright 1995 Komatsu Dresser Company

1. FOREWORD
This manual provides rules and guidelines which will help you use this machine safely and
effectively. Keep this manual handy and have all personnel read it periodically. If this manual has been
lost or has become dirty and can not be read, request a replacement manual from Komatsu or your
Komatsu distributor.
If you sell the machine, be sure to give this manual to the new owners.
Continuing improvements in the design of this machine can lead to changes in detail which may not
be reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest available
information of your machine or for questions regarding information in this manual.
This manual may contain attachments and optional equipment that are not available in your area.
Consult Komatsu or your Komatsu distributor for those items you may require.
A
WARNING
Improper operation and maintenance of this machine can be hazardous and could result in serious
injury or death.
Operators and maintenance personnel should read this manual thoroughly before beginning
operation or maintenance.
Some actions involved in operation and maintenance of the machine can cause a serious accident,
if they are not done in a manner described in this manual.
The procedures and precautions given in this manual apply only to intended uses of the machine.
If you use your machine for any unintended uses that are not specifically prohibited, you must
be sure that it is safe for you and others. In no event should you or others engage in prohibited
uses or actions as described in this manual.
Komatsu delivers machines that comply with all applicable regulations and standards of the
country to which it has been shipped. If this machine has been purchased in another country or
purchased from someone in another country, it may lack certain safety devices and specifications
that are necessary for use in your country. If there is any question about whether your product
complies with the applicable standards and regulations of your country, consult Komatsu or your
Komatsu distributor before operating the machine.
The description of safety is given in SAFETY INFORMATION on page O-2 and in SAFETY from page
l-l.
O-l

2. SAFETY INFORMATION
Most accidents are caused by the failure to follow fundamental safety rules for the operation and
maintenance of machines. To avoid accidents, read, understand and follow all precautions and warnings
in this manual and on the machine before performing operation and maintenance.
To identify safety messages in this manual and on machine labels, the following signal words are
used.
4L DANGER -
4h WARNING -
4L CAUTION -
NOTICE -
This word is used on safety messages and safety labels where there is a high
probability of serious injury or death if the hazard is not avoided. These safety
messages or labels usually describe precautions that must be taken to avoid the
hazard. Failure to avoid this hazard may also result in serious damage to the
machine.
This word is used on safety messages and safety labels where there is a
potentially dangerous situation which could result in serious injury or death if
the hazard is not avoided. These safety messages or labels usually describe
precautions that must be taken to avoid the hazard. Failure to avoid this hazard
may also result in serious damage to the machine.
This word is used on safety messages and safety labels for hazards which could
result in minor or moderate injury if the hazard is not avoided. This word might
also be word for hazards where the only result could be damage to the machine.
This word is used for precautions that must be taken to avoid actions which
could shorten the life of the machine.
Safety precautions are described in SAFETY from page l-l.
Komatsu cannot predict every circumstance that might involve a potential hazard in operation and
maintenance. Therefore the safety messages in this manual and on the machine may not include all
possible safety precautions. If any procedures or actions not specifically recommended or allowed in this
manual are used, you must be sure that you and others can do such procedures and actions safely and
without damaging the machine. If you are unsure about the safety of some procedures, contact Komatsu
distributor.
o-2

3. INTRODUCTION
3.1 INTENDED USE
This Komatsu HYDRAULIC EXCAVATOR is designed to be used mainly for the following work:
l Digging work
l Smoothing work
l Ditching work
l Loading work
See the section “12.14 WORK POSSIBLE USING HYDRAULIC EXCAVATOR” for further details.
3.2 FEATURES
l This Komatsu HYDRAULIC EXCAVATOR is equipped with various controls based on an advanced
electronics system.
o The monitor panel greatly facilitates daily maintenance and self-diagnosis.
o Working mode, travel speed and swing priority are selectable.
o Digging and lifting force can be increased by light-touch control.
(For details, see operation section.)
l Adjustable wrist control levers make operations smooth and easy.
l Air-conditioned operator’s cab assures comfortable operation.
l Low noise level and smart urban-style design and coloring.
l Superb operating performance provided by powerful engine and high-performance hydraulic
pumps.
l Low fuel consumption controlled by an electronic control system provides an environment-friendly
machine.
3.3 BREAKING IN THE MACHINE
Your Komatsu machine has been thoroughly adjusted and tested before shipment.
However, operating the machine under severe conditions at the beginning can adversely affect the
performance and shorten the machine life.
Be sure to break in the machine for the initial 100 hours (as indicated by the service meter.)
During breaking in:
l Idle the engine for 5 minutes after starting it up.
l Avoid operation with heavy loads or at high speeds.
l Avoid sudden starts, sudden acceleration, sudden steering and sudden stops except in cases of
emergency.
The precautions given in this manual for operating, maintenance, and safety procedures are only
those that apply when this product is used for the specified purpose. If the machine is used for a purpose
that is not listed in this manual, Komatsu cannot bear any responsibility for safety. All consideration of
safety in such operations is the responsibility of the user.
Operations that are prohibited in this manual must never be carried out under any circumstances.
o-3

4. LOCATION OF PLATES, TABLE TO ENTER
SERIAL NO. AND DISTRIBUTOR
4.1 MACHINE SERIAL NO. PLATE POSITION
On the front bottom right of the operator’s cab
4.2 ENGINE SERIAL NO. PLATE POSITION
On the upper side of the engine cylinder head cover
4.3 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR
Machine serial No.:
Engine serial No.:
Distributor name:
Address: Phone:
Service personnel for your machine:
I
REMARKS
o-4

5. CONTENTS
1. Foreword ............................................................................................................................................ 0- 1
2. Safety information ............................................................................................................................ o- 2
3. Introduction ........................................................................................................................................ o- 3
4. Location of plates, table to enter serial No. and distributor ...................................................... o- 4
SAFETY
6. General precautions .......................................................................................................................... I- 2
7. Precautions during operation .......................................................................................................... I- 8
7.1 Before starting engine ............................................................................................................. I- 8
7.2 Operating machine .................................................................................................................. l-10
7.3 Transportation .......................................................................................................................... 1-15
7.4 Battery ....................................................................................................................................... I-16
7.5 Towing ...................................................................................................................................... 1-17
7.6 Bucket with hook ..................................................................................................................... I-18
8. Precautions for maintenance ........................................................................................................... 1-21
8.1 Before carrying out maintenance .......................................................................................... 1-21
8.2 During maintenance ................................................................................................................ l-24
9. Position for attaching safety labels ................................................................................................ l-28
OPERATION
10. General view ...................................................................................................................................... 2- 2
10.1 General view of machine.. ....................................................................................................... 2- 2
10.2 General view of controls and gauges ................................................................................... 2- 3
11. Explanation of components ............................................................................................................. 2- 4
11.1 Machine monitor.. .................................................................................................................... 2- 4
11.2 Meter ......................................................................................................................................... 2-14
11.3 Switches .................................................................................................................................... 2-15
11.4 Control levers, pedals .............................................................................................................. 2-18
11.5 Operator’s seat ......................................................................................................................... 2-21
11.6 Dust indicator ........................................................................................................................... 2-21
11.7 Ceiling window ........................................................................................................................ 2-22
11.8 Front window ........................................................................................................................... 2-23
11.9 Door lock ................................................................................................................................... 2-25
11.10 Cap, cover with lock ................................................................................................................ 2-26
11.1 1 Radio ......................................................................................................................................... 2-27
11.12 Fuse ........................................................................................................................................... 2-29
11.13 Monitor panel ........................................................................................................................... 2-29
11.14 Fusible link ................................................................................................................................ 2-30
11.I5 Controllers ................................................................................................................................ 2-30
11.16 Handling accumulator ............................................................................................................. 2-33
o-5

5. CONTENTS
12. Operation ............................................................................................................................................
12.1 Check before starting engine .................................................................................................
12.2 Starting engine .........................................................................................................................
12.3 Operations and checks after starting engine.. ......................................................................
12.4 Moving machine off ................................................................................................................
12.5 Steering machine.. ...................................................................................................................
12.6 Stopping machine.. ..................................................................................................................
12.7 Swinging ...................................................................................................................................
12.8 Operation of work equipment ................................................................................................
12.9 Method of using mode selector switches.. ...........................................................................
12.10 Prohibitions for operation .......................................................................................................
12.11 Precautions for operation .......................................................................................................
12.12 Precautions when traveling up or down hills ......................................................................
12.13 How to escape from mud .......................................................................................................
12.14 Work possible using hydraulic excavator.. ...........................................................................
12.15 Replacement and inversion of bucket.. .................................................................................
12.16 Parking machine ......................................................................................................................
12.17 Check after finishing work ......................................................................................................
12.18 Stopping engine.. .....................................................................................................................
12.19 Check after stopping engine ...................................................................................................
12.20 Locking ......................................................................................................................................
2-35
2-35
2-44
2-47
2-53
2-56
2-58
2-59
2-60
2-61
2-63
2-65
2-66
2-68
2-69
2-70
2-72
2-73
2-74
2-75
2-75
13. Transportation ................................................................................................................................... 2-76
13.1 Loading, unloading work ........................................................................................................ 2-76
13.2 Precautions for loading ........................................................................................................... 2-78
13.3 Precautions for transportation.. .............................................................................................. 2-78
13.4 Method of lifting chassis (machines equipped with lifting hook). .................................... 2-79
13.5 Diving the machine ................................................................................................................. 2-80
13.6 Procedure for increasing or reducing track frame gauge.. ................................................. 2-82
14. Cold weather operation .................................................................................................................... 2-84
14.1 Precautions for low temperature ........................................................................................... 2-84
14.2 Precautions after completion of work ................................................................................... 2-86
14.3 After cold weather ................................................................................................................... 2-86
15. Long-term storage ............................................................................................................................. 2-87
15.1 Before storage .......................................................................................................................... 2-87
15.2 During storage ......................................................................................................................... 2-88
15.3 After storage.. ........................................................................................................................... 2-88
15.4 Starting machine after long-term storage ............................................................................ 2-88
16. Troubleshooting ................................................................................................................................. 2-89
16.1 Phenomena that are not failures ........................................................................................... 2-89
16.2 Method of towing machine .................................................................................................... 2-89
16.3 Using method for light-weight towing hole .......................................................................... 2-89
16.4 Precautions on particular jobsites ......................................................................................... 2-90
16.5 If battery is discharged ........................................................................................................... 2-90
16.6 Other trouble ............................................................................................................................ 2-94
O-6

5. CONTENTS
MAINTENANCE
17. Guides to maintenance ..................................................................................................................... 3- 2
18. Outlines of service ............................................................................................................................ 3- 5
18.1 Outline of oil, fuel, coolant ..................................................................................................... 3- 5
18.2 Outline of electric system ....................................................................................................... 3- 8
18.3 Outline of hydraulic system ................................................................................................... 3- 9
18.4 Precautions when disassembling machine ........................................................................... 3-10
18.5 Bleeding air from circuit ......................................................................................................... 3-11
19. Wear parts list ................................................................................................................................... 3-13
20. Use of fuel, coolant and lubricants according to ambient temperature ................................... 3-15
21. Standard tightening torques for bolts and nuts ........................................................................... 3-19
21.1 introduction of necessary tools.. ............................................................................................ 3-19
21.2 Torque list.. ............................................................................................................................... 3-20
22. Periodic replacement of safety critical parts ................................................................................. 3-21
23. Maintenance schedule chart ............................................................................................................ 3-23
23.1 Maintenance schedule chart.. ................................................................................................. 3-23
23.2 Maintenance interval when using hydraulic breaker.. ......................................................... 3-25
24. Service Procedure ..............................................................................................................................
24.1 Initial 250 hours service ..........................................................................................................
24.2 When required .........................................................................................................................
24.3 Check before starting ..............................................................................................................
24.4 Every 100 hours service.. ........................................................................................................
24.5 Every 250 hours service.. ........................................................................................................
24.6 Every 500 hours service.. ........................................................................................................
24.7 Every 1000 hours service.. ......................................................................................................
24.8 Every 2000 hours service.. ......................................................................................................
24.9 Every 4000 hours service.. ......................................................................................................
3-26
3-26
3-27
3-43
3-48
3-51
3-58
3-62
3-65
3-70
SPECIFICATIONS
25. Specifications ..................................................................................................................................... 4- 2
o-7

5. CONTENTS
OPTIONS, AlTACHMENTS
26.
27.
28.
29.
30.
31.
32.
33.
General precautions ..........................................................................................................................
26.1 Precautions related to safety.. ................................................................................................
26.2 Precautions when installing attachments .............................................................................
Handling bucket with hook .............................................................................................................. 5- 4
27.1 Checking for damage to bucket with hook.. ......................................................................... 5- 4
27.2 Prohibited operations .............................................................................................................. 5- 4
27.3 Precautions during operations ............................................................................................... 5- 4
Using seat belt ...................................................................................................................................
28.1 Seat belt.. ..................................................................................................................................
Handling car cooler ............................................................................................................................
29.1 Control panel ............................................................................................................................
29.2 Checking and maintaining car cooler.. ..................................................................................
Handling air conditioner ....................................................................................................................
30.1 Control panel ............................................................................................................................
30.2 Operation ..................................................................................................................................
30.3 Inspection and maintenance.. .................................................................................................
Operation of attachments ................................................................................................................. 5-12
Introduction of attachments ............................................................................................................
32.1 Specification, use .....................................................................................................................
32.2 Attachment installation combination table.. .........................................................................
32.3 Selection of track shoes.. ........................................................................................................
32.4 Selection of bucket teeth ........................................................................................................
32.5 Handling clamshell bucket.. ....................................................................................................
Extending machine service life ........................................................................................................
33.1 Hydraulic breaker.. ...................................................................................................................
33.2 Power ripper.. ...........................................................................................................................
33.3 Fork grab ...................................................................................................................................
33.4 Grapple bucket .........................................................................................................................
33.5 Scrap grapple ...........................................................................................................................
33.6 Crusher and cutter.. .................................................................................................................
33.7 Hydraulic pile driver ................................................................................................................
33.8 Hydraulic excavator with multi-purpose crane ....................................................................
5- 2
5- 2
5- 3
5- 5
5- 5
5- 7
5- 7
5- 7
5- 8
5- 8
5- 9
5-10
5-14
5-14
5-15
5-16
5-17
5-18
5-19
5-19
5-22
5-23
5-24
5-25
5-26
5-27
5-28
O-8

LOADING SHOVEL
34. General locations ................................................................................................................................ 6- 2
35. instruments and controls .................................................................................................................. 6- 3
35.1 Switches .................................................................................................................................... 6- 3
35.2 Control levers, pedals.. ............................................................................................................ 6- 5
36. Precautions for machine operation.. ................................................................................................ 6- 7
36.1 Precautions during operation ................................................................................................. 6- 7
37. Maintenance.. ...................................................................................................................................... 6-10
37.1 Every 10 hours service.. .......................................................................................................... 6-10
38. Transportations ................................................................................................................................... 6-l 1
39. Specifications ...................................................................................................................................... 6-12
o-9

SAFETY
A WARNING
Read and follow all safety precautions. Failure to do so may
result in serious injury or death.
This safety section also contains precautions for optional equip-
ment and attachments.
l-l

a ~~RN~~G~~cill~o follow these safety precautions may lead 6. GENERAL PRECAUTIONS
l Any modification made without authorization from Komatsu can create hazards.
l Before making a modification, consult your Komatsu distributor. Komatsu will not be responsible
for any injury or damage caused by any unauthorized modification.
ALWAYS u
When standing up from the operator’s seat, always place the safety lock lever securely in the LOCK
position. If you accidentally touch the travel or swing lever when they are not locked, the work
equipment may suddenly move and cause serious injury or damage.
When leaving the machine, lower the work equipment completely to the ground, set the safety
lock lever to the LOCK position, then stop the engine and use the key to lock all the equipment.
Always take the key with you.
Work equipment posture -* See “12.16 PARKING MACHINE.”
Free
AE096630
MOUNTING AND DISMOUNTING I
l NEVER jump on or off the machine. NEVER get on or off a moving machine.
l When mounting or dismounting, always face the machine and use the handrails, machine or track
frame steps, and track shoes.
Do not hold any control levers when getting on or off the machine.
Ensure safety by always maintaining at least three-point contact of hands and feet with the
handrails, steps or track shoes.
Before getting on or off the machine, check the steps, handrail, and track shoe. If necessary, clean
off any oil or dirt and repair any abnormalities.
Do not get on or off the machine while holding tools or other objects. Before getting on the
machine, push the tools or other objects up to a safe place; before getting off the machine, put
the tools or other objects at a safe place, and pick them up after getting off the machine.
If grasping the door handrail when mounting or dismounting or moving on the track, open and
lock the door securely in the open position. Otherwise, the door may move suddenly, causing you
to lose balance and fall.

6. GENERAL PRECAUTIONS a EfVJi/Ee Foiereasons cf safety, always
ty precautrons.
f FIRE PREVENTION FOR -1
Fuel, oil, and antifreeze can be ignited by a flame. Fuel is particularly FLAMMABLE and can be
HAZARDOUS.
Keep a flame away from flammable fluids.
Stop the engine and do not smoke when refueling.
Tighten all fuel and oil caps securely.
Refueling and oiling should be made in well ventilated areas.
Keep oil and fuel in the determined place and do not allow unauthorized persons to enter.
1 PRECAUTIONS WHEN HANDLING AT HIGH TEMPERATURES
Immediately after operations are stopped, the engine coolant, engine oil, and hydraulic oil are at
high temperatures, and are still under pressure. Attempting to remove the cap, drain the oil or
water, or replace the filters may lead to serious burns. Always wait for the temperature to go down,
and follow the specified procedures when carrying out these operations.
To prevent hot water from spurting out:
I) Turn engine off.
2) Allow water to cool.
3) Slowly loosen cap to relieve pressure before removing.
To prevent hot oil from spurting out:
I) Turn engine off.
2) Allow oil to cool.
3) Slowly loosen cap to relieve pressure before removing.
A0055050
l-4

a EPa;;;;G; Pai;ai;o follow these safety precautions may lead 6. GENERAL PRECAUTIONS
ASBESTOS DUST HAZARD PREVENTION
Asbestos dust can be HAZARDOUS to your health if it is inhaled.
If you handle materials containing asbestos fibers, follow these guidelines as given below:
l NEVER use compressed air for cleaning.
l Use water for cleaning to keep down the dust.
l Operate the machine with the wind to your back, whenever possible.
l Use an approved respirator if necessary.
CRUSHING OR CUTTING PREVENTION
l Do not enter, or put your hand or arm or any other part of your body between movable parts such
as between the work equipment and cylinders, or between the machine and work equipment.
If the work equipment is operated, the clearance will change and this may lead to serious damage
or personal injury.
A0066090
l Be sure fire extinguishers have been provided and know how to use them.
l Provide a first aid kit at the storage point.
l Know what to do in the event of a fire.
l Be sure you know the phone numbers of persons you should contact in case of an emergency.
A0055070
1-5

6. GENERAL PRECAUTIONS a )N$GJ;rV3eFo;,reasons of safety, always
ty precautrons.
PROTECTION AGAINST FALLING OR FLYING OBJECTS
If there is any danger of falling or flying objects hitting the operator, install protective guards in place
to protect the operator as required for each particular situation.
l For work with breakers, install a front guard on the windshield. Also, place a laminate coating
sheet over the windshield.
l For demolition or shear work, install a front guard on the windshield and a top guard on the
cab. Also, place a laminate coating sheet over the windshield.
l For work in mines, tunnel or other places where there is danger of falling rocks, put FOPS (falling
object protective structure) in place. Also, place a laminate coating sheet over the windshield.
The above comments are made with regards to typical working conditions. By all means you
should put on other guards if required by conditions at your particular site.
For details of safety guards, please contact your Komatsu distributor.
Also, even for other types of work, if there is any danger of getting hit by falling or flying objects,
or of objects entering the operator’s cab, select and install a guard that matches the working
conditions.
Be sure to close the front window before commencing work.
When carrying out the above operations, make sure to keep all persons other than the operator
outside the range of falling or flying objects. Be particularly sure to maintain a proper distance when
carrying out shear operations.
A0055200 rFOPS
AE081160
FOPS
(falling object protective structure)
l-6

A E;R;;EG; Pai;ai;$ follow these safety precautions may lead 6. GENERAL PRECAUTIONS
PRECAUTIONS FOR AlTACHMENTS
l When installing and using an optional attachment, read the instruction manual for the attachment
and the information related to .attachments in this manual.
l Do not use attachments that are not authorized by Komatsu or your Komatsu distributor. Use of
unauthorized attachments could create a safety problem and adversely affect the proper operation
and useful life of the machine.
l Any injuries, accidents, product failures resulting from the use of unauthorized attachments will
not be the responsibility of Komatsu. 1
On machines equipped with an accumulator, for a short time after the engine is stopped, the work
equipment will lower under its own weight when the work equipment control lever is shifted to
LOWER. After the engine is stopped, set the safety lock lever to the lock position and also lock the
attachment pedal with the lock pin.
When releasing the pressure inside the work equipment circuit on machines equipped with an
accumulator, follow the procedure given in the inspection and maintenance section.
Method of releasing pressure -+ See “11.16 HANDLING ACCUMULATOR”.
The accumulator is filled with high-pressure nitrogen gas, and it is extremely dangerous if it is
handled in the wrong way. Always observe the following precautions.
l Never make any hole in the accumulator or expose it to flame or fire.
l Do not weld any boss to the accumulator.
l When carrying out disassembly or maintenance of the accumulator, or when disposing of the
accumulator, it is necessary to release the gas from the accumulator. A special air bleed valve is
necessary for this operation, so please contact your Komatsu distributor.
Gas in accumulator --) See “11.16 HANDLING ACCUMULATOR”.
l-7

7. PRECAUTIONS DURING
OPERATION A E~v;:/CL&;z;eeasons Of safety, always
y precautions.
7.1 BEFORE STARTING ENGINE
SAFETY AT WORKSITE
Before starting the engine, thoroughly check the area for any
unusual conditions that could be dangerous.
Before starting the engine, examine the terrain and soil condi-
tions of the worksite. Determine the best and safest method of
operation.
Make the slope as horizontal as possible before continuing
operations.
If you need to operate on a street, protect pedestrians and cars
by designating a person for worksite traffic duty or by installing
fences around the worksite.
If water lines, gas lines, and high-voltage electrical lines may be
buried under the worksite, contact each utility and identify their
locations. Be careful not to sever or cut any of these lines.
Check the depth and flow of water before operating in water or
crossing a river. NEVER be in water which is in excess of the
permissible water depth.
Permissible water depth --) See “12.11 PRECAUTIONS FOR
OPERATION”.
FIRE PREVENTION
Thoroughly remove wood chips, leaves, paper and other flammable things accumulated on the
engine compartment. They could cause a fire.
Check fuel, lubrication, and hydraulic systems for leaks. Have any leaks repaired. Wipe up any
excess oil, fuel or other flammable fluids.
Check point + See “12.1.1 WALK-AROUND CHECK”.
Be sure a fire extinguisher is present and working.
IN OPERATOR’S CAB
l Do not leave tools or spare parts lying around in the operator’s compartment. They may damage
or break the control levers or switches. Always put them in the tool box on the right side of the
machine.
l Keep the cab floor, controls, steps and handrails free of oil, grease, snow, and excess dirt.
l Check the seat belt, buckle and hardware for damage or wear. Replace any worn or damaged parts.
Always use seat belts when operating your machine.
l-8