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KOMATSU PC300LC-8 PC300HD-8 HYDRAULIC EXCAVATOR Operation & Maintenance Manual (CEAM005902) – PDF DOWNLOAD
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- KOMATSU PC300LC-8 PC300HD-8 HYDRAULIC EXCAVATOR Operation & Maintenance Manual
- PUBLICATION NUMBER:CEAM005902
- SERIAL NUMBERS:
PC300LC-8 A90001 and UP
PC300HD-8 A87001 and UP
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Description
KOMATSU PC300LC-8 PC300HD-8 HYDRAULIC EXCAVATOR Operation & Maintenance Manual (CEAM005902)
KOMATSU PC300LC-8 PC300HD-8 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (CEAM005902) – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU PC300LC-8 PC300HD-8 HYDRAULIC EXCAVATOR Operation & Maintenance Manual (CEAM005902)
Before beginning operation or maintenance, operators and maintenance personnel must always observe the following points.
● Read this manual thoroughly and understand its contents fully.
● Read the safety messages and safety labels given in this manual carefully so that they should be understood fully.
Keep this manual at the storage location for the Operation and Maintenance Manual given below so that all personnel involved in working on the machine can consult it periodically.
In case this manual should be lost or damaged, immediately contact Komatsu or your Komatsu distributor to obtain a new copy.
When you sell the machine, make sure that this manual should be provided to the new owner together with the machine.
In this manual, measurements are expressed in international standard units (SI). For the reference purpose, weight units used in the past are also displayed in (_).
TABLE OF CONTENTS:
KOMATSU PC300LC-8 PC300HD-8 HYDRAULIC EXCAVATOR Operation & Maintenance Manual (CEAM005902)
COVER................................................................................................ 1 INTRODUCTION......................................................................................... 3 FOREWORD......................................................................................... 4 SAFETY INFORMATION............................................................................... 5 INTRODUCTION..................................................................................... 7 Directions Of Machine........................................................................ 7 Breaking-in The New Machine.................................................................. 7 Product Information.......................................................................... 8 Product Identification Number (Pin)/machine Serial No. Plate............................. 8 EPA Regulations, Engine Number Plate..................................................... 8 Service Meter Location....................................................................... 9 Your Machine Serial Numbers And Distributor.................................................. 9 SAFETY............................................................................................... 19 SAFETY AND WARNING DECALS........................................................................ 20 Location Of The Safety Decals................................................................ 20 Safety Labels................................................................................ 21 Optional Systems Decal....................................................................... 28 Optional Decal Locations..................................................................... 30 SAFETY INFORMATION............................................................................... 31 Safety Rules................................................................................. 31 If Problems Are Found........................................................................ 31 Working Wear And Personal Protective Items................................................... 31 Fire Extinguisher And First Aid Kit.......................................................... 31 Safety Equipment............................................................................. 32 Keep Machine Clean........................................................................... 32 Keep Operator's Compartment Clean............................................................ 32 Fire Prevention And Explosion Prevention..................................................... 32 Action If Fire Occurs........................................................................ 33 Handrails And Steps.......................................................................... 34 Precautions When Working In High Places...................................................... 34 Mounting And Dismounting..................................................................... 34 No Persons On Attachments.................................................................... 35 Precautions When Standing Up From Operator's Seat............................................ 35 Leaving Operator's Seat With Lock............................................................ 35 Emergency Exit From Operator's Cab........................................................... 35 Do Not Get Caught In Articulated Portion..................................................... 36 Precautions Related To Protective Structures................................................. 36 Protection Against Falling, Flying, Intruding Objects........................................ 36 Unauthorized Modification.................................................................... 37 Precautions Related To Attachments And Options............................................... 37 Precautions Related To Cab Glass............................................................. 37 Precautions When Running Engine Inside Building.............................................. 38 Safety At Jobsite............................................................................ 38 Working On Loose Ground...................................................................... 38 Distance To High Voltage Cables.............................................................. 39 Ensure Good Visibility....................................................................... 39 Signalman's Signal And Signs................................................................. 40 Asbestos Dust Hazard Prevention.............................................................. 40 Ventilation For Enclosed Area................................................................ 40 SAFETY MACHINE OPERATION......................................................................... 41 Starting Engine.............................................................................. 41 Checks Before Starting Engine................................................................ 41 Safety Rules For Starting Engine............................................................. 42 Starting Engine In Cold Weather.............................................................. 42 Starting With Booster Cables................................................................. 42 OPERATION........................................................................................ 43 Checks Before Operation...................................................................... 43 Safety Rules For Changing Machine Directions................................................. 43 Safety Rules For Traveling................................................................... 44 Traveling On Slopes.......................................................................... 45 Operations On Slopes......................................................................... 46 Prohibited Operations........................................................................ 46 Operations On Snow Or Frozen Surfaces........................................................ 48 Parking Machine.............................................................................. 49 TRANSPORTATION................................................................................... 50 Loading And Unloading........................................................................ 50 Shipping The Machine......................................................................... 51 TOWING........................................................................................... 51 Safety Rules For Towing...................................................................... 51 LIFTING OBJECTS WITH BUCKET...................................................................... 52 Safety Rules For Lifting Objects............................................................. 52 SAFETY MAINTENANCE INFORMATION................................................................... 53 Warning Tag.................................................................................. 53 Keep Work Place Clean And Tidy............................................................... 53 Select Suitable Place For Inspection And Maintenance......................................... 53 Only Authorized Personnel.................................................................... 53 Appoint Leader When Working With Others...................................................... 53 Stop Engine Before Carrying Out Maintenance.................................................. 54 Two Workers For Maintenance When Engine Is Running........................................... 55 Attachments.................................................................................. 55 Precautions When Working At High Places...................................................... 55 Work Under The Machine....................................................................... 56 Proper Tools................................................................................. 56 Battery...................................................................................... 57 Battery Hazard Prevention................................................................ 57 Starting Engine With Booster Cables.......................................................... 58 When Using Hammer............................................................................ 58 Burn Prevention.............................................................................. 59 Hot Coolant.............................................................................. 59 Hot Oil.................................................................................. 59 Safety Rules For High-pressure Oil........................................................... 59 Precaution For High Fuel Pressure............................................................ 60 Safety Handling High-pressure Hoses.......................................................... 60 Precaution For High Voltage.................................................................. 60 Noise........................................................................................ 60 Safety First When Using High-pressure Grease To Adjust Track Tension......................... 61 Do Not Disassemble Recoil Springs............................................................ 61 Accumulator, Gas Spring...................................................................... 62 Compressed Air............................................................................... 62 Air Conditioner Maintenance.................................................................. 62 Personnel.................................................................................... 62 Welding Works................................................................................ 62 Removing Battery Terminals................................................................... 62 Waste Materials.............................................................................. 63 Windshield Washer Fluid...................................................................... 63 Periodic Replacement Of Safety Critical Parts................................................ 63 OPERATION............................................................................................ 65 MACHINE VIEW ILLUSTRATIONS....................................................................... 66 OVERALL MACHINE VIEW............................................................................. 66 Controls And Gauges.......................................................................... 67 Machine Monitor.............................................................................. 68 DETAILED CONTROLS AND GAUGES..................................................................... 69 Monitoring System............................................................................ 69 Basic Operation Of Machine Monitor........................................................... 70 Emergency Monitors........................................................................... 75 Caution Monitors............................................................................. 77 Basic Check Monitors......................................................................... 80 Meter Display Portion........................................................................ 82 Gauges And Meter............................................................................. 86 Monitor Switches Portion..................................................................... 90 Maintenance Selector Switch..................................................................106 SWITCHES.........................................................................................138 CONTROL LEVERS AND PEDALS........................................................................143 SUN ROOF.........................................................................................146 WINDSHIELD.......................................................................................146 EMERGENCY ESCAPE HAMMER..........................................................................152 DOOR LOCK........................................................................................152 CAP WITH LOCK....................................................................................153 DRINK BOX........................................................................................155 MAGAZINE BOX.....................................................................................155 ASHTRAY..........................................................................................155 AIR CONDITIONER CONTROLS.........................................................................156 Air Conditioner Control Panel................................................................156 Method Of Operation..........................................................................161 Automatic Operation......................................................................161 Stopping Automatic Operation.............................................................162 Manual Operation.........................................................................162 Stopping Manual Operation................................................................164 Operation With Cold Air To Face And Warm Air To Feet.....................................164 Defroster Operation......................................................................166 RADIO............................................................................................169 Control Panel................................................................................169 Controls Of Radio............................................................................171 AUXILIARY ELECTRIC POWER.........................................................................174 24V Power Source.............................................................................174 12V Power Source.............................................................................174 FUSE.............................................................................................175 FUSIBLE LINK.....................................................................................176 CONTROLLER.......................................................................................176 TOOL BOX.........................................................................................177 GREASE PUMP HOLDER...............................................................................177 FIRE EXTINGUISHER................................................................................177 MACHINE OPERATIONS AND CONTROLS..................................................................178 Before Starting Engine.......................................................................178 Walk-around Checks.......................................................................178 Checks Before Starting...................................................................180 Adjustment...................................................................................188 Seat Adjustment..........................................................................188 Adjusting Angle Of Rear View Camera......................................................190 Rear View Mirrors........................................................................192 Seat Belt................................................................................195 Operations Before Starting Engine............................................................196 STARTING ENGINE..................................................................................198 Turbo Protect Function.......................................................................200 After Starting Engine........................................................................201 Breaking-in the New Machine..................................................................201 Engine Warm Up...............................................................................202 Hydraulic System Warm-up.....................................................................204 Operation After Completion Of Warming-up Operation...........................................210 Stopping The Engine..........................................................................212 MACHINE OPERATION................................................................................213 Preparations For Moving The Machine..........................................................213 Moving Machine Forward.......................................................................214 Moving Machine Backward......................................................................215 Stopping Machine.............................................................................216 Steering The Machine.........................................................................217 Swinging.....................................................................................219 Work Equipment Controls And Operations.......................................................220 Working Mode.................................................................................222 Prohibited Operations........................................................................224 General Operation Information................................................................229 Traveling On Slopes..........................................................................231 Escape From Mud..............................................................................233 Recommended Applications.....................................................................234 BUCKET REPLACEMENT AND INVERSION.................................................................236 Replacement..................................................................................236 Inversion....................................................................................238 PARKING MACHINE..................................................................................240 MACHINE INSPECTION AFTER DAILY WORK..............................................................242 Locking......................................................................................242 TRANSPORTATION...................................................................................243 Transportation Procedure.....................................................................243 Long Distance Transport Mode.................................................................244 Normal Mode Display......................................................................244 Long Distance Transport Mode Display.....................................................244 Loading And Unloading With Trailer...........................................................246 Loading..................................................................................247 Securing Machine.........................................................................250 Unloading................................................................................253 LIFTING MACHINE..................................................................................255 TRANSPORTATION POSTURE...........................................................................257 COLD WEATHER OPERATION...........................................................................259 AFTER DAILY WORK COMPLETION......................................................................261 AFTER COLD WEATHER SEASON........................................................................261 LONG TERM STORAGE................................................................................262 Before Storage...............................................................................262 During Storage...............................................................................262 After Storage................................................................................263 Starting Machine After Long-term Storage.....................................................263 TROUBLES AND ACTIONS.............................................................................264 Running Out Of Fuel..........................................................................264 Phenomena That Are Not Failures..............................................................265 Towing The Machine...........................................................................266 Lightweight Towing Hole......................................................................267 Severe Job Condition.........................................................................267 Discharged Battery...........................................................................268 Starting Engine With Booster Cables..........................................................270 OTHER TROUBLE....................................................................................272 Electrical System............................................................................272 Chassis......................................................................................273 Engine.......................................................................................274 Electronic Control System....................................................................275 MAINTENANCE..........................................................................................277 MAINTENANCE INFORMATION..........................................................................278 OUTLINE OF SERVICE...............................................................................280 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC...........................................280 Oil..........................................................................................280 Fuel.........................................................................................281 Coolant And Water For Dilution...............................................................281 Grease.......................................................................................282 Carrying Out KOWA (Komatsu Oil Wear Analysis)................................................282 KOWA Analysis Items......................................................................282 Oil Sampling.............................................................................283 Storing Oil And Fuel.....................................................................283 Filters..................................................................................283 Electric System Maintenance..............................................................283 WEAR PARTS.......................................................................................284 Wear Parts List..............................................................................284 RECOMMENDED FUEL, COOLANT, AND LUBRICANT.........................................................285 TIGHTENING TORQUE SPECIFICATIONS.................................................................288 Tightening Torque List.......................................................................288 SAFETY CRITICAL PARTS............................................................................289 Safety Critical Parts List...................................................................289 MAINTENANCE SCHEDULE.............................................................................290 Maintenance Schedule Chart...................................................................290 Maintenance Interval For Hydraulic Breaker...................................................292 MAINTENANCE PROCEDURE............................................................................293 Initial 1000 Hours Maintenance (Only After The First 1000 Hours).............................293 When Required................................................................................294 Check, Clean And Replace Air Cleaner Element.............................................294 Clean Inside Of Cooling System...........................................................300 Check And Tighten Track Shoe Bolts.......................................................304 Check And Adjust Track Tension...........................................................305 Replace Bucket Teeth (Vertical Pin Type).................................................307 Replace Bucket Teeth (Horizontal Pin Type)...............................................310 Replace Bucket Side Cutter, Shroud.......................................................312 Adjust Bucket Clearance..................................................................313 Check Window Washer Fluid Level, Add Fluid...............................................314 Check And Maintenance Air Conditioner....................................................315 Wash Washable Floor......................................................................316 Check Gas Spring.........................................................................319 Bleeding Air From Hydraulic System.......................................................320 Check Before Starting........................................................................322 Every 50 Hours Maintenance...................................................................323 Lubricating..............................................................................323 Every 250 Hours Maintenance..................................................................324 Lubricate Swing Circle...................................................................324 Check Oil Level In Swing Machinery Case, Add Oil.........................................325 Check Oil Level In Final Drive Case, Add Oil.............................................326 Check Level Of Battery Electrolyte.......................................................327 Check Air Conditioner Compressor Belt Tension, Adjust....................................329 Every 500 Hours Maintenance..................................................................330 Lubricating..............................................................................330 Replace Fuel Pre-filter Cartridge........................................................332 Check Swing Pinion Grease Level, Add Grease..............................................335 Change Oil In Engine Oil Pan, Replace Engine Oil Filter Cartridge........................336 Clean And Inspect Radiator Fins, Oil Cooler Fins, Aftercooler Fins And Condenser Fins....338 Clean Air Conditioner Fresh/Recirc Filters...............................................340 Replace Breather Element In Hydraulic Tank...............................................341 Replace Hydraulic Tank Additional Breather Element.......................................342 Every 1000 Hours Maintenance.................................................................343 Replace Fuel Main Filter Cartridge.......................................................343 Replace Hydraulic Oil Filter Element.....................................................345 Change Oil In Swing Machinery Case.......................................................346 Check Oil Level In Damper Case, Add Oil..................................................347 Check All Tightening Points Of Engine Exhaust Pipe Clamps................................347 Check Fan Belt And Alternator Drive Belt Tension, Replace................................347 Check Nitrogen Gas Charge Pressure In Accumulator (For Breaker)..........................347 Replace Corrosion Resistor Cartridge.....................................................348 Every 2000 Hours Maintenance.................................................................349 Change Oil In Final Drive Case...........................................................349 Clean Hydraulic Tank Strainer............................................................350 Checking Charge Pressure Of Nitrogen Gas In Accumulator (For Control Circuit)............351 Checking Function Of Accumulator.........................................................352 Releasing Pressure In Hydraulic Circuit..................................................354 Check Alternator.........................................................................355 Check Engine Valve Clearance, Adjust.....................................................355 Check Vibration Damper...................................................................355 Every 4000 Hours Maintenance.................................................................356 Check Water Pump.........................................................................356 Check Starting Motor.....................................................................356 Replace Accumulator (For Control Circuit)................................................357 Check For Looseness Of High-pressure Piping Clamp, Hardening Of Rubber...................358 Check For Missing Fuel Spray Prevention Cap, Hardening Of Rubber.........................358 Every 5000 Hours Maintenance.................................................................359 Change Oil In Hydraulic Tank.............................................................359 Every 8000 Hours Maintenance.................................................................361 Replace High-pressure Piping Clamp.......................................................361 Replace Fuel Spray Prevention Cap........................................................361 SPECIFICATIONS.......................................................................................363 SPECIFICATIONS...................................................................................364 OPTIONS, ATTACHMENTS.................................................................................367 GENERAL PRECAUTIONS FOR SAFETY...................................................................368 Precautions When Selecting...................................................................368 Read The Instruction Manual Thoroughly.......................................................368 Precautions When Removing Or Installing......................................................368 Precautions When Using.......................................................................368 BUCKET WITH HOOK.................................................................................369 Hook Condition...............................................................................369 Prohibited Operations........................................................................369 MACHINE READY FOR ATTACHMENT.....................................................................370 Locations....................................................................................370 ATTACHMENT REMOVAL AND INSTALLATION..............................................................380 Attachment Removal...........................................................................380 Attachment Installation......................................................................382 ATTACHMENT OPERATIONS............................................................................384 Long Term Storage............................................................................385 Specifications...............................................................................385 ATTACHMENT GUIDE.................................................................................386 Attachment Combinations......................................................................387 Track Shoes Selection........................................................................388 Selecting Shoes..........................................................................388 RECOMMENDED ATTACHMENT OPERATIONS................................................................389 Hydraulic Breaker............................................................................389 HANDLING MACHINES EQUIPPED WITH KOMTRAX..........................................................394
PLEASE NOTE:
⦁ This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
⦁ This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
⦁ Require some other service manual or have any queries: please WRITE to us at [email protected]
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