Komatsu PC400 - Maintenance

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MAINTENANCE

A

WARNING

Before carrying out maintenance, always attach the WARNING

TAG to the control lever in the operator’s cab.

3-l

Table of Contents

Foreword3
Safety Information4
Introduction5
Location of Plates, Table to Enter Serial No. and Distributor6
Table of Contents7
Safety13
General Precautions16
Precautions During Operation21
- Operating Machine22
- Transportation27
- Battery28
- Bucket with Hook30
Precautions for Maintenance34
- During Maintenance36
Position for Attaching Safety Labels41
Operation45
General View46
- General View of Machine46
Explanation of Components48
- Machine Monitor48
- Meter58
- Switches59
- Operator'sseat65
- Dust Indicator65
- Ceiling Window66
- Front Window67
- Door Lock69
- Cap, Cover with Lock70
- Radio71
- Fuse73
- Monitor Panel73
- Fusible Link74
- Controllers74
- Handling Accumulator77
Operation79
- Check before Starting Engine79
- Starting Engine88
- Moving Machine off97
- Steering Machine100
- Stopping Machine102
- Swinging103
- Operation of Work Equipment104
- Prohibitions for Operation107
- Precautions for Operation109
- Precautions When Traveling up or down Hills110
- How to Escape from Mud112
- Parking Machine116
- Check after Finishing Work117
- Stopping Engine118
- Check after Stopping Engine119
- Locking119
Transportation120
- Loading, Unloading Work120
- Precautions for Loading122
- Precautions for Transportation122
- Diving the Machine124
Cold Weather Operation130
- After Cold Weather132
Long-Term Storage133
- Before Storage133
- During Storage134
- After Storage134
Troubleshooting135
- Phenomena that Are Not Failures135
- Method of Towing Machine135
- Precautions on Particular Jobsites136
- If Battery Is Discharged136
- Other Trouble140
Maintenance145
Guides to Maintenance146
Outlines of Service149
- Outline149
  - Of Oil, Fuel, Coolant149
- Outline152
  - Of Electric System152
- Outline of Hydraulic153
  - System153
  - Air from Circuit155
Wear158
Use of Fuel, Coolant and Lubricants According to Ambient Temperature159
- Introduction of Necessary Tools163
- Torque List164
Periodic Replacement of Safety Critical Parts166
- Service Procedure170
- Initial 250 Hours Service170
- When Required171
- Check before Starting187
- Every 100 Hours Service192
- (Every 100 Hours Service)192
- Boom Foot Pin (2 Points)192
- Every 250 Hours Service195
- Check Oil Level in Final Drive Case, Add Oil195
- Change Oil in Engine Oil Pan, Replace Engine Oil Filter Cartridge197
- Lubricate Swing Circle (3 Points)199
- Drain Water and Sediment from Fuel Filter Cartridge201
- Replace Hydraulic Tank Breather Element201
- Every 500 Hours Service202
- Replace Fuel Filter Cartridge202
- Check Swing Pinion Grease Level, Add Grease204
- Every 1000 Hours Service206
- Every 2000 Hours Service209
- Every 4000 Hours Service214
- Using Seat Belt225
- Seat Belt225
Handling Car Cooler227
- Control Panel227
Handling Air Conditioner228
- Control Panel228
- Operation229
- Inspection and Maintenance230
- Operation of Attachments232
Introduction of Attachments235
- Selection of Track Shoes236
- Selection of Bucket Teeth237
- Handling Clamshell Bucket238
- Hydraulic Breaker239
- Power Ripper242
- Fork Grab243
- Grapple Bucket244
- Scrap Grapple245
- Crusher and Cutter246
- Hydraulic Pile Driver247
Loading Shovel249
Instruments and Controls251
- Switches251
- Control Levers, Pedals253
Precautions for Machine Operation256
Maintenance258
- Every 10 Hours Service258
Transportations259
Specifications260

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