Komatsu Hydraulic Excavator PC400LC-8

Warning: This maintenance requires special tools and trained personnel!

This maintenance is only to be performed after the first 1000 hours of operation on new machines.

Has the machine been operated for 1000 hours?

If the machine has not been operated for 1000 hours, stop the procedure.

Check engine valve clearance, is adjustment needed?

If adjustment is needed, contact your Komatsu distributor.

For details of the method of replacing or maintaining, see the section on EVERY 2000 HOURS SERVICE.

Sign off on the initial 1000 hours maintenance

WARNING: After the engine has been operated, all parts are at high temperature, so do not replace the filter immediately. Wait for all parts to cool down before starting the operation.

NOTICE: Genuine Komatsu fuel filter cartridges use a special filter that has highly efficient filtering ability. When replacing the filter cartridge, always use a genuine Komatsu part.

Prepare a container to catch drain fuel.

Turn the valve (1) at the bottom of the fuel tank to the CLOSE position (S).

Set the container to catch the fuel under the filter cartridge (2).

Using a filter wrench, turn filter cartridge (2) counterclockwise to remove it.

Clean the filter holder, coat the packing surface of the new filter cartridge thinly with oil, then install the filter cartridge to the filter holder.

WARNING: The parts and oil are at high temperature immediately after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work.

When removing the oil filler cap, turn it slowly to release the internal pressure, then remove it.

NOTICE: If the machine is equipped with a hydraulic breaker, the hydraulic oil will deteriorate much faster than during normal bucket operations.

Refill capacity: 248 liters (65.52 US gal)

Prepare a handle (for the socket wrench).

Swing the upper structure so that hydraulic tank drain plug (P) and drain plug (A) at the bottom of the pump suction tube are in the middle between the left and right tracks.

Retract the arm and bucket cylinders, then lower the boom and put the teeth in contact with the ground.

Set the lock lever to the LOCK position and stop the engine.

Remove the cap of oil filler port (F) at the top of the hydraulic tank.

Contact your Komatsu distributor for the following tasks

High-pressure piping clamp replaced

Fuel spray prevention cap replaced

Check water pump for play in pulley, oil leaks, or water leaks

If any issues are found with the water pump, contact your Komatsu distributor for inspection, overhaul or replacement.

If the engine is started frequently, have this inspection carried out every 1000 hours. Contact your Komatsu distributor to have the starting motor checked.

Replace accumulator (for control circuit) every 2 years or every 4000 hours, whichever comes sooner.

WARNING: The accumulator is charged with high-pressure nitrogen gas, so mistaken operation may cause an explosion, which will lead to serious injury or damage. When handling the accumulator, always do as follows.

Safety measures when handling the accumulator

Check for looseness of high-pressure piping clamp, hardening of rubber

Check visually and touch with your fingers to check that there are no loose bolts or hardening of rubber parts at clamps (1) to (15). If there is any looseness or hardened rubber, contact your Komatsu distributor for replacement.