Komatsu PC2000-8 - Page 415

Komatsu PC2000-8

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MAINTENANCE MAINTENANCE PROCEDURE

4-97

Table of Contents

Foreword4
Before Reading this Manual4
Safety Information5
- Noise Emission Levels6
- Vibration Levels6
  - Guide to Reduce Vibration Levels on Machine7
Introduction8
- Use of Machine8
- Visibility from Operator's Seat9
  - Proximity Visibility9
  - Circumference Visibility10
Product Information11
- Product Identification Number (Pin)/Machine Serial No. Plate11
- Epa Regulations, Engine Number Plate12
- Service Meter Location13
- MACHINE SERIAL NUMBER PLATE (According Directive 2006/42/EC)14
- Declaration According Directive 2006/42/EC Annex I Point 1.7.4.2 (C)15
- Table of Contents16
Safety Labels26
- Location of Safety Labels27
- Safety Labels28
General Precautions Common to Operation and Maintenance33
- Precautions before Starting Operation33
- Preparations for Safe Operation33
- Ensuring Safe Operation33
- Understanding the Machine33
- Precautions Regarding Safety-Related Equipment33
- Inspecting Machine33
- Wear Well-Fitting Clothes and Protective Equipment33
- Keep Machine Clean34
- Precautions Inside Operator's Compartment34
- Provide Fire Extinguisher and First Aid Kit34
- If any Problem Is Found34
- Fire Prevention35
- Action if Fire Occurs35
- Precautions to Prevent Fire35
- Precautions When Getting on or off Machine36
- Use Handrails and Steps When Getting on or off Machine36
- No Jumping on or off Machine37
- Lifting of Personnel Prohibited37
- No People on Attachments37
- Precautions When Standing up from Operator's Seat37
- Do Not Get Caught in Work Equipment38
- Precautions Related to Protective Structures38
- Precautions When Leaving Machine38
- Emergency Exit from Operator's Cab38
- Protection against Falling, Flying, Intruding Objects39
- Unauthorized Modification39
- Precautions Related to Attachments and Options39
- Precautions Related to Cab Glass40
- Precautions When Running Engine Inside Building40
Precautions for Operation41
- Precautions for Jobsite41
- Investigate and Confirm Jobsite Conditions41
- Working on Loose Ground41
- Do Not Go Close to High-Voltage Cables41
- Ensure Good Visibility42
- Checking Signs and Signalman's Signals42
- Starting Engine43
- Beware of Asbestos Dust43
- Use Warning Tags43
- Inspection and Maintenance before Starting Engine44
- Precautions When Starting Engine44
- Precautions in Cold Areas44
- Starting with Booster Cables45
- Starting with Jump Start Cables45
- Operation46
- Checks before Operation46
- Precautions When Traveling in Forward or Reverse and Swinging46
- Precautions When Traveling47
- Traveling on Slopes48
- Operating on Slopes49
- Prohibited Operations49
- Traveling on Snow-Covered or Frozen Surfaces51
- Parking Machine51
- Transportation52
- Loading and Unloading52
- Towing53
- Lifting Objects with Bucket53
- Precautions When Towing53
- Precautions for Lifting Operations53
Precautions for Maintenance55
- Precautions before Starting Inspection and Maintenance55
- Display Warning Tag During Inspection and Maintenance55
- Keep Workplace Clean and Tidy56
- Select Suitable Place for Inspection and Maintenance56
- Stability56
- Guards56
- Only Authorized Personnel56
- Appoint Leader When Working with Others56
- Stop Engine before Carrying out Inspection and Maintenance57
- Two Workers for Maintenance When Engine Is Running58
- Installing, Removing, or Storing Attachments58
- Precautions When Working at High Places58
- Precautions When Working under Machine or Work Equipment59
- Proper Tools59
- Precautions for Inspection and Maintenance60
- Precautions When Welding60
- Handling Battery60
- Precautions When Using Hammer61
- Precautions with High-Temperature Coolant62
- Precautions with High-Temperature Oil62
- Precautions with High-Pressure Oil62
- Precautions with High-Pressure Fuel62
- Handling High-Pressure Hoses and Piping63
- Noise63
- Precautions with High-Pressure Grease When Adjusting Track Tension64
- Handling Accumulator and Gas Spring64
- Handling Opg Top Guard64
- Precautions with Compressed Air65
- Chemical Hazard65
- Maintenance of Air Conditioner65
- Disposing of Waste Materials65
- Mercury Containing Component(S)65
- Method of Selecting Window Washer Fluid65
- Periodic Replacement of Safety Critical Parts65
- End of Service Life66
Operation67
Machine View Illustrations68
- Overall Machine View68
- Controls and Gauges69
Detailed Controls and Gauges73
- Monitoring System73
  - Basic Operation of Machine Monitor74
  - Basic Check Monitors77
  - Caution Monitors80
  - Emergency Monitors84
  - Meter Display Portion87
  - Monitor Switches Portion97
  - Handling Function Switches105
- Switches (Inside Operator's Cab)141
- Switches (Inside Cab Base Room)150
- Switches (Outside of Machine)153
- Lamp (Inside Operator's Cab)163
- Lamp (Outside of Machine)166
- Control Levers and Pedals168
- Door Lock170
- Emergency Exit from Operator's Cab170
- Emergency Escape Hammer171
- Handling Emergency Ladder172
  - Escape Procedure172
  - Precaution When Storing Rope Ladder174
- Fire Extinguisher175
- Cap with Lock175
- Ashtray177
- Cup Holder177
- Magazine Box177
- Hook178
- Utility Box178
- Air Conditioner Controls179
  - Air Conditioner Control Panel179
  - Method of Operation185
  - Use Air Conditioner with Care191
  - Inspection and Maintenance of Air Conditioner Equipped Machine191
  - Other Functions191
- Radio193
  - Control Panel193
  - Controls of Radio195
  - Use Radio with Care198
Contents199
- Auxiliary Electric Power199
  - Power Source199
  - Additional Power Source199
- Fuse200
- Circuit Breaker202
- Fuse (if Equipped)205
- Controller206
- Tool, Can Storage Place207
- Handling Grease Pump and Grease Gun207
- Accumulator214
  - Method of Releasing Pressure in Accumulator for Hydraulic Control Circuit215
- Handling Hydraulic Ladder216
  - Procedure for Operating Hydraulic Ladder216
  - Action When Machine Does Not Move Because of Failure in Proximity Switch218
- HANDLING MACHINES EQUIPPED with KOMTRAX Plus222
  - KOMTRAX Plus INSTALLED, COMMUNICATIONS TERMINAL NOT INSTALLED222
  - KOMTRAX Plus and COMMUNICATIONS TERMINAL INSTALLED222
Machine Operations and Controls224
- Before Starting Engine224
- Starting Engine255
- After Starting Engine258
- Stopping the Engine268
- Machine Operation276
- Steering the Machine280
  - Steering280
- Swinging282
- Work Equipment Controls and Operations283
- Working Mode285
- Prohibited Operations286
- General Operation Information290
- Traveling on Slopes291
- Escape from Mud293
  - Track on One Side Stuck293
  - Tracks on both Sides Stuck293
- Recommended Applications294
  - Backhoe Work294
  - Loading Work294
- Bucket Replacement295
  - Replacement295
- Parking Machine297
- Check before Shut off Engine298
- Machine Inspection after Daily Work298
- Locking299
Transportation300
- Transportation Procedure300
- Precautions for Transportation300
- Method of Lifting Units for Transportation300
- Transportation Posture300
Cold Weather Operation301
- Cold Weather Operation Information301
- After Daily Work Completion303
- After Cold Weather Season303
Long Term Storage304
- Before Storage304
- During Storage304
- After Storage305
- Starting Machine after Long-Term Storage305
Troubles and Actions306
- Running out of Fuel306
- Phenomena that Are Not Failures306
- Towing the Machine307
- Severe Job Condition307
- Discharged Battery308
- Other Trouble312
Maintenance319
Maintenance Information320
Outline of Service323
- Handling Oil, Fuel, Coolant, and Performing Oil Clinic323
- Electric System Maintenance327
Wear Parts328
- Wear Parts List328
Recommended Fuel, Coolant, and Lubricant329
- Recommended Brands, Recommended Quality for Products Other than Komatsu Genuine Oil331
Tightening Torque Specifications332
- Tightening Torque List332
Safety Critical Parts333
- Safety Critical Parts List334
Maintenance Schedule335
- Maintenance Schedule Chart335
Maintenance Procedure337
- Initial 100 Hours Maintenance (Only after the First 100 Hours)337
- Initial 500 Hours Maintenance (Only after the First 500 Hours)337
- Initial 4000 Hours Maintenance (Only after the First 4000 Hours)337
- Change Oil in Swing Machinery Case337
- Change Oil in Pto Case337
- Change Oil in Final Drive Case337
- Check Welded Structure337
- When Required338
- Check before Starting382
- Checks before Starting382
- Every 250 Hours Maintenance383
- Every 500 Hours Maintenance390
- Every 1000 Hours Maintenance403
- Every 2000 Hours Maintenance422
- Every 4000 Hours Maintenance424
- Every 5000 Hours Maintenance428
  - Change Oil in Hydraulic Tank, Clean Strainer428
- Every 8000 Hours Maintenance432
Specifications433
Attachments and Options437
General Precautions for Safety438
- Precautions When Selecting438
- Read the Instruction Manual Thoroughly438
- Precautions When Removing or Installing438
- Precautions When Using439
Attachment Guide440
- Combinations of Work Equipment440
- Front Guard441
Handling Fuel Quick Charge442
- General Locations442
- Procedure for Operating Fuel Charge443
- Replace Fuel Tank Breather Element446
- Action When Machine Does Not Move Because of Failure in Proximity Switch447
Handling Service Center451
- General Locations451
- Procedure for Operating Service Arm452
Contents455
- Method of Draining, Adding Lubricant and Coolant from Service Panel455
- Greasing Ladder Service Arm466
- Replace Fuel Tank Breather Element467
- Action When Machine Does Not Move Because of Failure in Proximity Switch468
Handling Jump Start Receptacle472
- General Locations472
- Connected Procedure of External Power Source472
Orbcom Controller (Communications Terminal)474
Loading Shovel475
Machine View Illustrations476
- Overall Machine View476
Explanation of Components477
- Switches477
Operations479
- Operation of Work Equipment479
- Precautions During Operation481
- Excavator Work485
Precautions When Disassembling Machine486
- Releasing Pressure486
  - Releasing Pressure from Work Equipment Circuit, Swing Circuit, Travel Circuit486
  - Releasing Pressure in Accumulator Circuit486
Transportation487
- Machine Configuration for Transport487
Maintenance488
- Every 10 Hours Maintenance488
Specification493
Wear Parts495
- Wear Parts List495
Combination of Work Equipment496

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