KOMATSU AVANCE PC300LL-6 LOGGING EXCAVATOR Operation and Maintanence Manual (SN:A84001 and UP) – PDF DOWNLOAD

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KOMATSU AVANCE PC300LL-6 LOGGING EXCAVATOR Operation and Maintanence Manual (SN:A84001 and UP)

KOMATSU AVANCE PC300LL-6 LOGGING EXCAVATOR OPERATION AND MAINTANENCE MANUAL (SN:A84001 AND UP) – PDF DOWNLOAD:

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KOMATSU AVANCE PC300LL-6 LOGGING EXCAVATOR Operation and Maintanence Manual (SN:A84001 and UP)

• 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 Komatsu or 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 Komatsu or your local distributor for the latest available information on your machine or for questions regarding information in this manual.

TABLE OF CONTENTS:

KOMATSU AVANCE PC300LL-6 LOGGING EXCAVATOR Operation and Maintanence Manual (SN:A84001 and UP)

MAIN MENU.......................................................................................................  0
COVER...........................................................................................................  1
INTRODUCTION....................................................................................................  7
	FOREWORD....................................................................................................  8
	SAFETY INFORMATION..........................................................................................  8
	INTRODUCTION................................................................................................  9
		INTENDED USE............................................................................................  9
		FEATURES................................................................................................  9
		BREAKING IN THE MACHINE.................................................................................  9
	LOCATION OF PLATES, TABLE TO ENTER P.I.N. AND DISTRIBUTOR................................................... 10
		P.I.N. PLATE LOCATION................................................................................... 10
		ENGINE SERIAL NO. PLATE LOCATION........................................................................ 10
		TABLE TO ENTER NUMBERS AND DISTRIBUTOR.................................................................. 10
	TABLE OF CONTENTS........................................................................................... 11
SAFETY.......................................................................................................... 19
	WARNING LABELS.............................................................................................. 20
	GENERAL PRECAUTIONS......................................................................................... 27
		SAFETY RULES............................................................................................ 27
		SAFETY FEATURES......................................................................................... 27
		UNAUTHORIZED MODIFICATION............................................................................... 27
		INSIDE OPERATOR’S COMPARTMENT........................................................................... 28
		CLOTHING AND PERSONAL PROTECTIVE ITEMS.................................................................. 28
		ALWAYS APPLY LOCK WHEN LEAVING OPERATOR’S SEAT.......................................................... 28
		MOUNTING AND DISMOUNTING................................................................................ 29
		INJURY FROM WORK EQUIPMENT.............................................................................. 29
		FIRE PREVENTION FOR FUEL AND OIL........................................................................ 29
		PRECAUTIONS AT HIGH TEMPERATURES........................................................................ 30
		ASBESTOS DUST HAZARD PREVENTION......................................................................... 30
		FIRE EXTINGUISHER AND FIRST AID KIT..................................................................... 30
		CAB GLASS............................................................................................... 31
		WINDOW WASHER FLUID..................................................................................... 31
		ESCAPE FROM FIRE........................................................................................ 31
		PROTECTION AGAINST FALLING OR FLYING OBJECTS............................................................ 31
		MACHINES WITH ACCUMULATOR............................................................................... 32
		PRECAUTIONS FOR ATTACHMENTS............................................................................. 32
		INDOOR VENTILATION...................................................................................... 32
		EMERGENCY EXIT FROM OPERATORS CAB....................................................................... 32
	PRECAUTIONS DURING OPERATION................................................................................ 33
		BEFORE STARTING ENGINE.................................................................................. 33
			SAFETY AT WORK SITE................................................................................. 33
			FIRE PREVENTION..................................................................................... 33
			VENTILATION FOR ENCLOSED AREAS...................................................................... 33
			IN OPERATOR’S CAB................................................................................... 33
			PRECAUTIONS FOR MIRROR AND LIGHTS................................................................... 34
			WHEN STARTING ENGINE................................................................................ 34
		OPERATING MACHINE....................................................................................... 35
			WHEN STARTING ENGINE................................................................................ 35
			CHECK DIRECTION BEFORE STARTING MACHINE............................................................. 35
			CHECK THAT NO ONE IS IN AREA BEFORE SWINGING OR TRAVELING IN REVERSE................................ 35
			NEVER LET ANYONE RIDE ON ATTACHMENT................................................................. 35
			PRECAUTIONS WHEN TRAVELING.......................................................................... 36
			OPERATE CAREFULLY ON SNOW........................................................................... 36
			TRAVELING ON SLOPES................................................................................. 37
			PROHIBITED OPERATIONS............................................................................... 37
			PRECAUTIONS FOR OPERATION........................................................................... 38
			DO NOT GO CLOSE TO HIGH VOLTAGE CABLES.............................................................. 38
			WORKING ON LOOSE GROUND............................................................................. 39
			OPERATING ON SLOPES................................................................................. 39
			PARKING THE MACHINE................................................................................. 39
			PRECAUTIONS IN COLD WEATHER......................................................................... 40
		TRANSPORTATION.......................................................................................... 41
			LOADING AND UNLOADING............................................................................... 41
			PRECAUTIONS WHEN LIFTING............................................................................ 41
			SHIPPING............................................................................................ 42
		BATTERY................................................................................................. 43
			BATTERY HAZARD PREVENTION........................................................................... 43
			STARTING WITH BOOSTER CABLES........................................................................ 43
			CHARGING BATTERY.................................................................................... 44
		TOWING.................................................................................................. 45
			PRECAUTIONS WHEN TOWING............................................................................. 45
	PRECAUTIONS FOR MAINTENANCE................................................................................. 46
		BEFORE CARRYING OUT MAINTENANCE......................................................................... 46
			CONTACT WHEN THERE IS FAILURE....................................................................... 46
			WARNING TAG......................................................................................... 46
			CLEAN BEFORE INSPECTION OR MAINTENANCE.............................................................. 46
			NEAT CLEAN WORK PLACE............................................................................... 46
			FOLLOW LEADER IN OPERATIONS WITH OTHER WORKERS...................................................... 46
			RADIATOR COOLANT LEVEL.............................................................................. 47
			PROPER TOOLS........................................................................................ 47
			STOP ENGINE PRIOR TO INSPECTION AND MAINTENANCE..................................................... 47
			SUPPORT FOR WORK EQUIPMENT.......................................................................... 47
			PERIODIC REPLACEMENT OF CRITICAL SAFETY PARTS....................................................... 48
			USE OF LIGHTING..................................................................................... 48
			FIRE PREVENTION..................................................................................... 48
			RULES TO FOLLOW WHEN ADDING FUEL OR OIL............................................................. 48
		DURING MAINTENANCE...................................................................................... 49
			PERSONNEL........................................................................................... 49
			REMOVAL, INSTALLATION AND STORAGE OF ATTACHMENTS.................................................... 49
			WORK UNDER THE MACHINE.............................................................................. 49
			NOISE............................................................................................... 49
			WHEN WORKING ON MACHINE............................................................................. 49
			LOCK INSPECTION COVERS.............................................................................. 49
			TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING.................................................. 50
			DO NOT DROP TOOLS OR PARTS INSIDE MACHINE........................................................... 50
			FLYING PIECES WITH HAMMER WORK...................................................................... 50
			KEEP THE MACHINE CLEAN.............................................................................. 50
			WELDING REPAIRS..................................................................................... 51
			REMOVE BATTERY TERMINALS............................................................................ 51
			ACTION WHEN ABNORMALITY IS FOUND DURING INSPECTION.................................................. 51
			RULES TO FOLLOW WHEN ADDING FUEL.................................................................... 51
			PRECAUTIONS WHEN ADJUSTING TRACK TENSION............................................................ 51
			HANDLING HIGH PRESSURE HOSES........................................................................ 52
			PRECAUTIONS WITH HIGH PRESSURE OIL.................................................................. 52
			PRECAUTIONS AT HIGH TEMPERATURE OR PRESSURE......................................................... 52
			WASTE MATERIALS..................................................................................... 53
			CHECKS AFTER INSPECTION AND MAINTENANCE............................................................. 53
			MAINTENANCE FOR AIR CONDITIONER..................................................................... 53
OPERATION....................................................................................................... 55
	GENERAL..................................................................................................... 56
		VIEW OF MACHINE......................................................................................... 56
		GENERAL VIEW OF OPERATORS COMPARTMENT................................................................... 57
		GENERAL VIEW OF MONITOR PANEL........................................................................... 58
	EXPLANATION OF COMPONENTS................................................................................... 59
		MACHINE MONITOR......................................................................................... 59
			MONITOR LIGHT GROUP................................................................................. 61
			METER DISPLAY PORTION............................................................................... 63
			SWITCHES............................................................................................ 67
		SWITCHES................................................................................................ 70
		CONTROL LEVERS AND PEDALS............................................................................... 75
		OPERATOR’S SEAT AND SEAT BELT........................................................................... 78
			SEAT ADJUSTMENT..................................................................................... 78
			SEAT BELT........................................................................................... 79
		MONITOR PANEL........................................................................................... 80
			ADJUSTMENT ANGLE.................................................................................... 80
		ROOF VENT............................................................................................... 80
			WHEN OPENING........................................................................................ 80
			WHEN CLOSING........................................................................................ 80
		FRONT WINDOW............................................................................................ 81
			WHEN OPENING........................................................................................ 81
			WHEN CLOSING........................................................................................ 82
			FRONT BOTTOM WINDOW................................................................................. 83
		DOOR LOCK............................................................................................... 83
		CAP, COVER WITH LOCK.................................................................................... 84
			METHOD OF OPENING AND CLOSING LOCK CAP.............................................................. 84
			METHOD OF OPENING AND CLOSING COVER LOCK............................................................ 84
		OPERATOR EASE........................................................................................... 85
			HOT AND COOL BOX.................................................................................... 85
			STORAGE BOX......................................................................................... 85
			ASHTRAY............................................................................................. 85
		AIR CONDITIONER......................................................................................... 86
			GENERAL LOCATIONS ON CONTROL PANEL.................................................................. 86
			PRECAUTIONS WHEN USING AIR CONDITIONER.............................................................. 88
			CHECK, MAINTAIN MACHINE WITH AIR CONDITIONER........................................................ 88
		AM/FM RADIO............................................................................................. 89
			EXPLANATION OF COMPONENTS........................................................................... 89
			METHOD OF OPERATION................................................................................. 91
			PRECAUTIONS WHEN USING.............................................................................. 93
			SPECIFICATIONS...................................................................................... 93
		ELECTRIC POWER TAKE OUT ADAPTER......................................................................... 93
		FUSE.................................................................................................... 94
		FUSIBLE LINK............................................................................................ 95
		CONTROLLERS............................................................................................. 95
		TOOL BOX................................................................................................ 95
		GREASE GUN HOLDER....................................................................................... 95
		HANDLING ACCUMULATOR.................................................................................... 96
	OPERATION................................................................................................... 97
		CHECK BEFORE STARTING ENGINE............................................................................ 97
			WALK AROUND CHECK................................................................................... 97
			CHECK BEFORE STARTING............................................................................... 99
			ADJUST OPERATOR’S SEAT..............................................................................102
			ADJUST SEAT BELT....................................................................................102
			ADJUST ARM RESTS....................................................................................102
			ADJUST MONITOR PANEL................................................................................102
			OPERATIONS AND CHECKS BEFORE STARTING ENGINE........................................................103
		STARTING ENGINE.........................................................................................105
			NORMAL STARTING.....................................................................................105
			STARTING IN COLD WEATHER............................................................................106
		OPERATIONS AND CHECKS AFTER STARTING ENGINE.............................................................108
			WHEN NORMAL.........................................................................................108
			AUTOMATIC WARM UP OPERATION.........................................................................111
		MOVING MACHINE..........................................................................................114
			MOVING MACHINE FORWARD..............................................................................114
			MOVING MACHINE REARWARD.............................................................................116
		STEERING MACHINE........................................................................................118
			STEERING (CHANGING DIRECTION).......................................................................118
		STOPPING MACHINE........................................................................................119
		SWINGING................................................................................................120
		OPERATION OF WORK EQUIPMENT.............................................................................121
		ACTIVE MODE.............................................................................................122
		WORKING MODES...........................................................................................123
			WORKING MODE........................................................................................123
			POWER MAX, SWIFT SLOW DOWN..........................................................................123
		PRECAUTIONS FOR OPERATION...............................................................................125
			PRECAUTIONS WHEN TRAVELING..........................................................................125
			PRECAUTIONS AT HI SPEED TRAVEL......................................................................125
			PERMISSIBLE WATER DEPTH.............................................................................125
		PRECAUTIONS WHEN TRAVELING ON HILLS.....................................................................126
			BRAKING WHEN TRAVELING DOWNHILL.....................................................................126
			IF SHOES SLIP.......................................................................................126
			IF ENGINE STOPS.....................................................................................126
			PRECAUTIONS ON SLOPES...............................................................................126
		HOW TO ESCAPE FROM MUD..................................................................................127
			WHEN ONE SIDE IS STUCK..............................................................................127
			WHEN BOTH SIDES ARE STUCK...........................................................................127
		PARKING MACHINE.........................................................................................128
		CHECK AFTER FINISHING WORK..............................................................................130
		STOPPING ENGINE.........................................................................................130
		CHECK AFTER STOPPING ENGINE.............................................................................130
		LOCKING.................................................................................................131
	TRANSPORTATION..............................................................................................132
		TRANSPORTATION PROCEDURE................................................................................132
		LOADING, UNLOADING WORK ON TRAILERS.....................................................................132
			LOADING.............................................................................................133
			SECURING MACHINE....................................................................................134
			UNLOADING...........................................................................................136
		TRACK FRAME GAUGE.......................................................................................139
			REDUCING TRACK GAUGE................................................................................139
			INCREASING TRACK GAUGE..............................................................................139
	COLD WEATHER OPERATION......................................................................................141
		PRECAUTIONS FOR LOW TEMPERATURE.........................................................................141
			FUEL AND LUBRICANTS.................................................................................141
			COOLANT.............................................................................................141
			BATTERY.............................................................................................142
		PRECAUTIONS AFTER COMPLETION OF WORK....................................................................143
		AFTER COLD WEATHER......................................................................................143
	LONG TERM STORAGE...........................................................................................144
		BEFORE STORAGE..........................................................................................144
		DURING STORAGE..........................................................................................144
		AFTER STORAGE...........................................................................................144
		MACHINE START AFTER LONG TERM STORAGE...................................................................145
	TROUBLESHOOTING.............................................................................................146
		PHENOMENA THAT ARE NOT FAILURES.........................................................................146
		METHOD OF TOWING DISABLED MACHINE.......................................................................146
		USING MACHINE FOR LIGHT WEIGHT TOWING...................................................................146
		PRECAUTIONS ON PARTICULAR JOB SITES.....................................................................146
		DISCHARGED BATTERY......................................................................................147
			REMOVING AND INSTALLING BATTERY.....................................................................147
			PRECAUTIONS FOR CHARGING BATTERY....................................................................147
			STARTING ENGINE WITH BOOSTER CABLE..................................................................148
		OTHER TROUBLE...........................................................................................150
			ELECTRICAL SYSTEM...................................................................................150
			CHASSIS.............................................................................................151
			ENGINE..............................................................................................152
			ELECTRONIC CONTROL SYSTEM...........................................................................153
MAINTENANCE.....................................................................................................155
	GUIDES TO MAINTENANCE.......................................................................................156
	OUTLINES OF SERVICE.........................................................................................158
		OUTLINE OF OIL, FUEL, COOLANT...........................................................................158
			OIL.................................................................................................158
			FUEL................................................................................................158
			COOLANT.............................................................................................159
			GREASE..............................................................................................159
			STORING OIL AND FUEL................................................................................159
			FILTERS.............................................................................................159
			RELATING TO ELECTRICAL SYSTEM.......................................................................159
		OUTLINE OF HYDRAULIC SYSTEM.............................................................................160
	WEAR PARTS LIST.............................................................................................161
	USE OF FUEL, COOLANT AND LUBRICANTS.........................................................................162
		PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS........................................................162
			ABBREVIATIONS.......................................................................................162
		ENGINE OIL SPECIFICATIONS...............................................................................163
			NORMAL OPERATION....................................................................................163
			ARCTIC OPERATION....................................................................................163
		DAMPER CASE, SWING MACHINERY CASE, TRACK FRONT IDLERS, TRACK ROLLERS, TOP CARRIER ROLLERS AND HYD.......164
		FINAL DRIVE OIL SPECIFICATIONS..........................................................................164
		FUEL SYSTEM.............................................................................................164
		COOLING SYSTEM..........................................................................................165
			GENERAL.............................................................................................165
			WATER...............................................................................................165
			ANTIFREEZE..........................................................................................165
			INHIBITORS/CONDITIONERS.............................................................................166
	STANDARD TIGHTENING TORQUES.................................................................................170
		INTRODUCTION OF NECESSARY TOOLS.........................................................................170
		BOLT IDENTIFICATION CHART...............................................................................171
	PERIODIC REPLACEMENT OF CRITICAL PARTS......................................................................172
	MAINTENANCE SCHEDULE CHART..................................................................................173
	SERVICE PROCEDURE...........................................................................................175
		INITIAL 250 HOURS SERVICE...............................................................................175
			FUEL FILTER CARTRIDGE...............................................................................175
		WHEN REQUIRED...........................................................................................176
			CHECK, CLEAN OR REPLACE AIR CLEANER ELEMENT.........................................................176
			DRAIN, FLUSH AND REFILL COOLING SYSTEM..............................................................178
			CHECK AND TIGHTEN TRACK SHOE BOLTS..................................................................183
			CHECK AND ADJUST TRACK TENSION......................................................................183
			CHECK ELECTRICAL INTAKE AIR HEATER..................................................................185
			CHECK WINDOW WASHER FLUID, ADD FLUID................................................................185
			CHECK, MAINTAIN AIR CONDITIONER.....................................................................186
			CLEAN IN LINE FILTERS...............................................................................187
		CHECK BEFORE STARTING...................................................................................188
			CHECK COOLANT LEVEL, ADD COOLANT....................................................................188
			CHECK ENGINE OIL LEVEL, ADD OIL.....................................................................188
			CHECK FUEL LEVEL, ADD FUEL..........................................................................189
			CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL..........................................................189
			CHECK AIR CLEANER FOR CLOGGING......................................................................190
			CHECK ELECTRIC WIRING...............................................................................190
			CHECK FUNCTION OF HORN..............................................................................191
			DRAIN WATER FROM THE FUEL WATER SEPARATOR...........................................................191
		EVERY 50 HOURS SERVICE..................................................................................192
			GREASE LUBRICATION..................................................................................192
			DRAIN WATER AND SEDIMENT FROM FUEL TANK.............................................................192
		EVERY 100 HOURS SERVICE.................................................................................193
			PREVIOUS MAINTENANCE................................................................................193
			GREASE LUBRICATION..................................................................................193
			CHECK OIL LEVEL IN SWING MACHINERY CASE, ADD OIL....................................................193
		EVERY 250 HOURS SERVICE.................................................................................194
			PREVIOUS MAINTENANCE................................................................................194
			CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL........................................................194
			CHECK LEVEL OF BATTERY ELECTROLYTE..................................................................194
			LUBRICATE SWING CIRCLE (3 POINTS)...................................................................195
			CHECK BELT TENSION, ADJUST..........................................................................195
			AIR CONDITIONER COMPRESSOR BELT TENSION.............................................................197
		EVERY 500 HOURS SERVICE.................................................................................198
			PREVIOUS MAINTENANCE................................................................................198
			REPLACE FUEL FILTER CARTRIDGE.......................................................................198
			REPLACE IN LINE FUEL STRAINER.......................................................................199
			CHECK SWING PINION GREASE LEVEL, ADD GREASE.........................................................199
			CLEAN AND INSPECT RADIATOR AND OIL COOLER...........................................................200
			CLEAN AIR CONDITIONER FILTERS.......................................................................200
			REPLACE HYDRAULIC TANK BREATHER.....................................................................201
			CHANGE ENGINE OIL, REPLACE FILTER CARTRIDGE.........................................................201
			REPLACE HYDRAULIC FILTER ELEMENT....................................................................203
			CORROSION RESISTOR..................................................................................204
		EVERY 1000 HOURS SERVICE................................................................................205
			PREVIOUS MAINTENANCE................................................................................205
			CHANGE OIL IN SWING MACHINERY CASE..................................................................205
			CHECK OIL LEVEL IN DAMPER CASE, ADD OIL.............................................................205
			CHECK TIGHTENING PARTS OF TURBOCHARGER..............................................................206
			CHECK PLAY OF TURBOCHARGER ROTOR....................................................................206
			CHECK DRIVE BELT, TENSIONER BEARING AND FAN HUB.....................................................206
		EVERY 2000 HOURS SERVICE................................................................................208
			PREVIOUS MAINTENANCE................................................................................208
			CHANGE OIL IN FINAL DRIVE CASE......................................................................208
			CLEAN HYDRAULIC TANK STRAINER.......................................................................208
			CLEAN, CHECK TURBOCHARGER...........................................................................209
			CHECK ALTERNATOR, STARTING MOTOR....................................................................209
			CHECK VIBRATION DAMPER..............................................................................209
			CHECK ENGINE VALVE CLEARANCE, ADJUST................................................................210
		EVERY 4000 HOURS SERVICE................................................................................214
			PREVIOUS MAINTENANCE................................................................................214
			CHECK WATER PUMP....................................................................................214
		EVERY 5000 HOURS SERVICE................................................................................215
			PREVIOUS MAINTENANCE................................................................................215
			CHANGE OIL IN HYDRAULIC TANK........................................................................215
			PROCEDURE FOR BLEEDING AIR..........................................................................216
SPECIFICATIONS..................................................................................................219
	SPECIFICATIONS AND DIMENSIONS...............................................................................220
		SPECIFICATIONS..........................................................................................220
		DIMENSIONS..............................................................................................220
OPTIONS, ATTACHMENTS............................................................................................223
	GENERAL PRECAUTIONS.........................................................................................224
		PRECAUTIONS RELATED TO SAFETY...........................................................................224
	SELECTION OF TRACK SHOES....................................................................................225

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