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Komatsu PC300-8, Operation & Maintenance Manual

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Komatsu PC300-8 Operation & Maintenance Manual Download Page 290

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MAINTENANCE

MAINTENANCE PROCEDURE

MAINTENANCE

MAINTENANCE PROCEDURE

12. Drain the coolant from sub-tank (5), clean the inside of the

sub-tank, then add water until the coolant level is between the
FULL and LOW marks.

If the sub-tank is extremely dirty and it is difficult to clean,
replace it with a new part.

13. Stop the engine, wait for approx. 3 minutes, add Supercoolant

up to the bottom of the filler port, then tighten the radiator cap
(2).

4 - 27

Summary of Contents for PC300-8

Page 1: ...eign language manual is necessary contact your local distributor for availability NOTICE Unsafe use of this machine may cause serious injury or death Operators and maintenance personnel must read this...

Page 2: ...1 1...

Page 3: ...ant personnel can read it at any time Storage location for the Operation and Maintenance Manual magazine box on the left side of the operator s seat If this manual is lost or damaged contact your dist...

Page 4: ...ersonal injury or death Follow the instructions in the safety message This signal word indicates an imminently hazardous situation which if not avoided will result in death or serious injury This sign...

Page 5: ...eft Right E F Operator s seat Sprocket In this manual the terms front rear left and right refer to the travel direction as seen from the operator s seat when the operator s seat is facing the front an...

Page 6: ...distributor of the following items PRODUCT IDENTIFICATION NUMBER PIN MACHINE SERIAL NO PLATE On the bottom right of the operator s cab The design of the nameplate differs according to the territory EP...

Page 7: ...ION SERVICE METER LOCATION On top of the machine monitor YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR Machine serial No Engine serial No Product identification number PIN Distributor name Address Servi...

Page 8: ...OR OFF MACHINE 2 15 DO NOT GET CAUGHT IN WORK EQUIPMENT 2 17 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES 2 17 PROTECTION AGAINST FALLING FLYING INTRUDING OBJECTS 2 17 UNAUTHORIZED MODIFICATION 2 18 P...

Page 9: ...NS 3 153 WORKING MODE 3 155 PROHIBITED OPERATIONS 3 157 GENERAL OPERATION INFORMATION 3 162 TRAVELING ON SLOPES 3 164 ESCAPE FROM MUD 3 166 RECOMMENDED APPLICATIONS 3 167 BUCKET REPLACEMENT AND INVERS...

Page 10: ...T 4 15 MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER 4 17 MAINTENANCE PROCEDURE 4 18 INITIAL 1000 HOURS MAINTENANCE ONLY AFTER THE FIRST 1000 HOURS 4 18 WHEN REQUIRED 4 19 CHECK BEFORE STARTING 4 46 EVER...

Page 11: ...TIONS 6 17 LONG TERM STORAGE 6 18 SPECIFICATIONS 6 18 ATTACHMENT GUIDE 6 19 ATTACHMENT COMBINATIONS 6 20 TRACK SHOES SELECTION 6 21 RECOMMENDED ATTACHMENT OPERATIONS 6 22 HYDRAULIC BREAKER 6 22 HANDLI...

Page 12: ...2 1...

Page 13: ...IF ANY PROBLEM IS FOUND 2 13 FIRE PREVENTION 2 14 ACTION IF FIRE OCCURS 2 14 PRECAUTIONS TO PREVENT FIRE 2 14 PRECAUTIONS WHEN GETTING ON OR OFF MACHINE 2 15 USE HANDRAILS AND STEPS WHEN GETTING ON OR...

Page 14: ...RTING ENGINE 2 22 PRECAUTIONS WHEN STARTING ENGINE 2 22 PRECAUTIONS IN COLD AREAS 2 22 STARTING WITH BOOSTER CABLES 2 23 OPERATION 2 23 CHECKS BEFORE OPERATION 2 23 PRECAUTIONS WHEN TRAVELING IN FORWA...

Page 15: ...WORK EQUIPMENT 2 37 PROPER TOOLS 2 37 PRECAUTIONS FOR INSPECTION AND MAINTENANCE 2 38 PRECAUTIONS WHEN WELDING 2 38 HANDLING BATTERY 2 38 PRECAUTIONS WHEN USING HAMMER 2 39 PRECAUTIONS WITH HIGH TEMPE...

Page 16: ...always keep them clean When cleaning them do not use organic solvents or gasoline These may cause the labels to peel off There are also other labels in addition to the warning signs and safety labels...

Page 17: ...SAFETY SAFETY LABELS SAFETY LABELS 1 Caution before operating or maintaining machine 09651 03001 2 Caution before operating 09802 03000 3 Caution for leaving operator s seat 09654 03001 2 6...

Page 18: ...SAFETY SAFETY LABELS SAFETY SAFETY LABELS 4 Caution for going close to electric cables 09801 03001 5 Caution for operating pattern 09822 03000 2 7...

Page 19: ...FETY LABELS 6 Caution when opening or closing front window 09839 03000 7 Caution when stowing front window 09803 03000 8 Caution for high temperature hydraulic oil 09653 03001 9 Caution with high temp...

Page 20: ...tion for handling accumulator and gas spring 09659 53000 11 Caution for adjusting track tension 09657 03003 12 Caution for handling cable 09808 03000 13 Stopping rotation for inspection and maintenanc...

Page 21: ...FETY LABELS SAFETY SAFETY LABELS 15 Caution against falling 09805 23000 16 Caution against falling 09805 13000 17 Prohibited to enter within swing range 09133 23000 18 Beware of work equipment 09134 A...

Page 22: ...AFETY SAFETY LABELS SAFETY SAFETY LABELS 19 Caution when handling battery 14X 98 11370 20 Jump start prohibited 09842 A0481 21 Caution when swinging or traveling in reverse 22B 00 21290 If equipped 2...

Page 23: ...al thoroughly If there are any places in this manual that you do not understand ask the person in charge of safety to give an explanation PREPARATIONS FOR SAFE OPERATION PRECAUTIONS REGARDING SAFETY R...

Page 24: ...obstruct operation and cause the machine to move unexpectedly resulting in serious personal injury or death Do not stick suction pads to the window glass Suction pads act as a lens and may cause fire...

Page 25: ...iesel oil or gasoline There is danger that they may catch fire Do not weld or use a cutting torch to cut any pipes or tubes that contain flammable liquids Determine well ventilated areas for storing o...

Page 26: ...AND STEPS WHEN GETTING ON OR OFF MACHINE To prevent personal injury caused by slipping or falling off the machine always do as follows Use the handrails and steps marked by arrows in the diagram on th...

Page 27: ...f the control levers are touched by mistake the machine may suddenly move and cause serious personal injury or death PRECAUTIONS WHEN LEAVING MACHINE If the proper procedures are not taken when parkin...

Page 28: ...by falling objects or by rolling over its strength will be reduced and it will not be able to fulfill its function properly In such cases always contact your Komatsu distributor for advice on the met...

Page 29: ...erate within not contact When installing and using optional attachments read the instruction manual for the attachment and the general information related to attachments in this manual PRECAUTIONS REL...

Page 30: ...any unauthorized person from entering the operating area In particular if you need to operate on a road protect pedestrian and cars by designating a person for worksite traffic duty or by installing...

Page 31: ...s compartment until it has been confirmed that the electricity has been shut off Also do not let anyone near the machine ENSURE GOOD VISIBILITY This machine is equipped with mirrors and cameras to en...

Page 32: ...masks Do not allow other persons to approach during the operation Always observe the rules and regulations for the work site and environmental standards This machine does not use asbestos but there is...

Page 33: ...ust the mirrors so that the rear of the machine can be seen clearly from the operator s seat When adjusting see Rearview Mirrors PAGE 3 123 If the machine is equipped with cameras adjust the angle so...

Page 34: ...be careful not to let the booster cable clips touch each other or to let the clips touch the machine For details of the starting procedure when using booster cables see Starting Engine with Booster Ca...

Page 35: ...closed Do not allow anyone apart from the operator to ride on the machine If there are any persons in the area around the machine there is danger that they may be hit or caught by the machine and this...

Page 36: ...ground and travel at low speed There is more danger of the machine tipping over to the left or right than tipping over to the front or rear so do not travel over obstacles which make the machine tilt...

Page 37: ...mately 20 to 30 cm 8 to 12 in above the ground and travel at low speed When traveling downhill lower the engine speed keep the travel lever close to the neutral position and travel at low speed Always...

Page 38: ...ontal as possible Do not work on a slope covered with the steel plates Even with slight slopes there is a hazard that the machine may slip PROHIBITED OPERATIONS If the machine rolls over or falls or t...

Page 39: ...mpact The not pass the bucket over the heads of other workers or over the operator s seat of dump trucks or other hauling equipment There is danger that the load may spill or the bucket may hit the du...

Page 40: ...ight slope may cause the machine to slip so be particularly careful when working on slopes With frozen ground surfaces the ground becomes soft when the temperature rises and this may cause the machine...

Page 41: ...sition L then stop the engine Always close the operator s cab door and use the key to lock all the equipment in order to prevent any unauthorized person from moving the machine Always remove the key t...

Page 42: ...moving out of position or coming off Be sure the ramp surface is clean and free of grease oil ice and loose materials Remove dirt from machine tracks On a rainy day in particular be extremely careful...

Page 43: ...g see TOWING THE MACHINE PAGE 3 197 Always confirm that the wire rope or drawbar used for towing has ample strength for the weight of the machine being towed Never use a wire rope which has cut strand...

Page 44: ...m a falling load do not allow any worker inside the area It is dangerous if a raised load hits any person or structure When operating the swing or work equipment always check carefully that the surrou...

Page 45: ...ork place Wipe up all grease oil or other substances that will cause you to slip Always keep the work place clean and tidy to enable you to carry out operations safely If the work place is not kept cl...

Page 46: ...nt control lever back and forth left and right at the full stroke 2 to 3 times to eliminate the remaining internal pressure in the hydraulic circuit and then move lock lever 1 to the LOCK position L C...

Page 47: ...may contact the rotating parts and break or be sent flying Release the residual pressure from the hydraulic system and place Lock lever 1 to its LOCK position For releasing of the residual oil pressur...

Page 48: ...equipment or the machine will suddenly drop This is extremely dangerous Never work under the work equipment or the machine If it is necessary to raise the work equipment or the machine and then go un...

Page 49: ...ble battery filler solution to the UPPER LEVEL mark Do not smoke or bring any flame close to the battery Hydrogen gas is generated when the battery is being charged so remove the battery from the mach...

Page 50: ...ng area If hard metal parts such as pins bucket teeth cutting edges or bearings are hit with a hammer there is a hazard that pieces might be scattered and cause serious personal injury or death Always...

Page 51: ...sight if it contacts your skin or eyes directly If you are hit by a jet of high pressure oil and suffer injury to your skin or eyes wash the place with clean water and consult a doctor immediately fo...

Page 52: ...osed to noise for long periods of time wear ear covers or ear plugs while working If the noise from the machine is too loud it may cause temporary or permanent hearing problems PRECAUTIONS WITH HIGH P...

Page 53: ...gen gas If the accumulator is handled mistakenly it may cause an explosion that could lead to serious personal injury or death For this reason always observe the following precautions Do not disassemb...

Page 54: ...AL PARTS To enable this machine to be used safely for a long period always carry out periodic replacement of safety critical parts that have a particularly close relation to safety such as hoses and t...

Page 55: ......

Page 56: ...3 1...

Page 57: ...RATION MACHINE VIEW ILLUSTRATIONS MACHINE VIEW ILLUSTRATIONS OVERALL MACHINE VIEW 1 2 3 4 5 Bucket Bucket cylinder Arm Arm cylinder Boom 6 7 8 9 10 Boom cylinder Sprocket Track frame Track shoe Idler...

Page 58: ...lighter Right work equipment control lever Starting switch Fuel control dial 13 14 15 16 17 18 19 20 21 22 Lamp switch Swing lock switch Machine push up switch Heated operator seat switch if equipped...

Page 59: ...Working mode monitor Travel speed monitor Fuel gauge ECO gauge Fuel level monitor Working mode selector switch Travel speed selector switch 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 Window washer s...

Page 60: ...s MONITORING SYSTEM AA Screen for standard BB Screen with all lamps lighted up CC Maintenance time warning screen A B C Emergency monitors Caution monitors Basic check monitors D E Meter display porti...

Page 61: ...ng screen DD is displayed for 2 seconds the screen switches to the working mode travel mode display screen HH After the working mode travel mode display screen HH is displayed for 2 seconds the screen...

Page 62: ...e temperature and the battery condition If this happens the display on the machine monitor may momentarily go out but this does not indicate any abnormality Stopping Engine When Situation is Normal Wh...

Page 63: ...CC warning screen FF or error screen EE After displaying the check before starting screen DD for 2 seconds the screen changes to the maintenance interval warning screen CC After displaying the mainten...

Page 64: ...y Occurs During Operation If any abnormality occurs during operation the standard screen BB changes to warning screen FF 1 or the error screen EE After displaying warning screen FF 1 for 2 seconds the...

Page 65: ...itor Color when monitor lights up When normal When abnormal At low temperature 1 Engine coolant temperature monitor Blue Red White 2 Hydraulic oil temperature monitor Blue Red White 3 Fuel level monit...

Page 66: ...lic oil temperature monitor 3 Engine oil pressure monitor Engine Coolant Temperature Monitor Monitor 1 warns operator that the engine coolant temperature has risen If the engine coolant temperature be...

Page 67: ...t low idling until the monitor changes to normal display B Display A at low temperatures Monitor background D is white Display B at correct temperatures Monitor background D is blue Display C when con...

Page 68: ...he abnormal location lights up red 1 2 3 Engine coolant temperature monitor Hydraulic oil temperature monitor Fuel level monitor 4 5 6 Charge level monitor Air cleaner clogging monitor Water separator...

Page 69: ...low When the remaining fuel level reaches approx 60 liters 15 85 US gal the monitor lamp lights up red so add fuel as soon as possible Charge Level Monitor This monitor 4 warns the operator that there...

Page 70: ...mulated inside the water separator For details of the method of draining the water from the water separator see Check for Water and Sediment in Water Separator Drain Water PAGE 3 114 REMARK The water...

Page 71: ...mong the check before starting items that must be checked before starting the engine If there is any abnormality monitor for the location of abnormality will light up 1 2 Radiator coolant level monito...

Page 72: ...lighted after the maintenance time has already passed Lighted yellow The maintenance time is due within 30 hours Lighted red The maintenance time has already passed This monitor lights up when the sta...

Page 73: ...auge Service meter clock ECO gauge Pilot Display The pilot display at the top of the screen consists of the pilot lamps to confirm the actuation of each function When the starting switch is turned ON...

Page 74: ...k monitor is lighted up the brake remains applied Wiper Monitor Monitor 3 indicates operating ststus of the wiper The monitor display when wiper switch is operated as follows When ON lights up Wiper m...

Page 75: ...itch Lo Low speed travel Mi Mid range speed travel Hi High speed travel For details of the positions of the travel speed selector switch see CONTROLS AND GAUGES PAGE 3 3 One Touch Power Max Monitor Th...

Page 76: ...e Stop Guidance If the levers are not operated for more than five minutes and the engine is idling the idling stop message is displayed on the monitor When waiting for work or stopping work for a shor...

Page 77: ...normality display Red range B position Engine speed changes to low idling engine coolant temperature monitor E shows abnormality display alarm buzzer sounds at same time The overheat prevention system...

Page 78: ...ydraulic oil temperature monitor E shows the low temperature display If this happens carry out the warm up operation For details see Hydraulic Equipment Warm Up PAGE 3 137 Display G at low temperature...

Page 79: ...achine is not moving The service meter advances 1 for every hour that the machine is working regardless of the engine speed When the standard screen is being displayed if function switch F4 is pressed...

Page 80: ...range B the load is heavy When the gauge enters the orange range there is no abnormality on the machine but to protect the environment reduce the engine output to a point where there is no adverse ef...

Page 81: ...easier if the mode is selected to match the content of the operation P mode For heavy load operations E mode For operation with emphasis on fuel consumption L mode For fine control operations B mode F...

Page 82: ...hen the monitor starts up if the working mode setting is B mode the confirmation message on the right is displayed and the buzzer sounds When starting up and staying in B mode always press function sw...

Page 83: ...ected working mode is automatically set as the working mode and the screen changes to Steps 3 and Steps 4 REMARK To return to the standard screen without changing the working mode press function switc...

Page 84: ...the same time the message in the illustration on the right is displayed When setting to the breaker mode always press function switch F6 If function switch F5 is pressed the breaker mode is not set an...

Page 85: ...and travel levers are returned to the N position the engine speed will drop after 4 seconds from the operating speed to idling speed This makes it possible to reduce fuel consumption If any lever is o...

Page 86: ...w speed travel Mi lights up Medium speed travel Hi lights up Hi speed travel When the engine is started the speed is automatically set to Lo Each time that the switch is pressed the display changes Lo...

Page 87: ...nges ON INT stop OFF Wiper monitor INT lighted up Wiper operates intermittently Wiper monitor ON lighted up Wiper operates continuously Wiper monitor OFF Wiper stops REMARK Each time wiper switch 4 is...

Page 88: ...wiper will be actuated continuously When switch 5 is released the wiper will continue to operate for 2 cycles then stop If the wiper is moving intermittenly and switch 5 is kept pressed continuously...

Page 89: ...ons are displayed as follows F3 Camera screen selector switch if equipped F4 Service meter time display selector switch F5 Maintenance mode switch F6 User mode switch F1 and F2 are auxiliary switches...

Page 90: ...uidance icon B is pressed it will not function Press switch A immediately below the guidance icon display to operate the function The operation of the function switches if the initial screen is the st...

Page 91: ...F3 is pressed the image display screen is displayed Press switch F1 to display all the screens for images from the No 1 camera Press switch F2 to display all the screens for images from the No 2 camer...

Page 92: ...me time on the monitor On the No 1 camera image display screen if switch F4 is pressed No 1 camera image d and No 2 camera image e are displayed Even if three cameras are installed only the images fro...

Page 93: ...age screen In addition if no operation is carried out for 5 seconds after the screen switches to the air conditioner control screen the screen automatically returns to the camera image screen For deta...

Page 94: ...switch to turn the auto deceleration function ON OFF Even if the auto deceleration switch is pressed the camera image display screen does not switch to another screen It is possible to press the buzze...

Page 95: ...When the error monitor is flashing if no lever is operated for more than 10 seconds the screen automatically returns to the standard screen When the screen returns to the standard screen the error mon...

Page 96: ...creen it is possible to press switch F4 to switch the service meter and clock display at the top of the monitor display When the time is being displayed press switch F4 to switch to the service meter...

Page 97: ...splay are as follows a b Engine oil change 500 Engine oil filter change 500 Fuel main filter change 1000 Fuel pre filter change 500 Hydraulic oil filter change 1000 Hydraulic tank breather change 500...

Page 98: ...esetting the remaining time for the selected item item highlighted in yellow REMARK When resetting the remaining time keep switch F6 pressed for at least 1 5 seconds If switch F6 is not kept pressed f...

Page 99: ...the reset press switch F5 The screen returns to the maintenance list screen On the reset screen if no switch is operated for more than 30 seconds the screen automatically switches to the maintenance...

Page 100: ...ing mode screen for the machine On the User Menu screen it is possible to carry out the following operations with switches F3 to F6 F3 Moves to next item 1 line down When on the last line it moves to...

Page 101: ...30 seconds on the user menu screen the screen automatically returns to the previous screen The following items can be set a Breaker attachment setting machines ready for installation of attachment b...

Page 102: ...tachmentsetting menu to adjust the oil flow in B mode and ATT mode to match the attachment For machines that have no attachment the breaker attachment setting mode is not displayed Changing Breaker Mo...

Page 103: ...owing operations with switches F3 to F6 F3 Moves to next item 1 line down F4 Moves to previous item 1 line up F5 Returns to user menu screen F6 Switches to setting screen for selected item 4 The scree...

Page 104: ...rry out the following operations with switches F3 F6 F3 Moves to next item 1 line down F4 Moves to previous item 1 line up F5 Returns to previous screen F6 Switches to setting screen for selected item...

Page 105: ...the oil flow setting follow the procedure given in Changing breaker flow setting PAGE 3 51 The present oil flow set for B mode is marked with a B in front of the item name as shown in the illustratio...

Page 106: ...6 2 On the Breaker Oil Flow Setting screen select one of the two set values for the oil flow then press switch F6 The default values for the oil flow setting are both set to 230 liter min as shown in...

Page 107: ...up F5 Returns to previous screen F6 Switches to setting screen for selected item 3 On the Breaker Oil Flow Setting screen change the set oil flow After using switches F3 or F4 to change to a suitable...

Page 108: ...OPERATION DETAILED CONTROLS AND GAUGES Changing Attachment Mode Setting 1 On the standard screen press switch F6 2 Select Breaker Attachment Settings on the user menu then press switch F6 3 53...

Page 109: ...h switches F3 to F6 F3 Moves to next item 1 line down F4 Moves to previous item 1 line up F5 Returns to user menu screen F6 Switches to setting screen for selected item 4 The screen switches to the 2...

Page 110: ...rry out the following operations with switches F3 F6 F3 Moves to next item 1 line down F4 Moves to previous item 1 line up F5 Returns to previous screen F6 Switches to setting screen for selected item...

Page 111: ...l flow set for ATT mode is marked with ATT in front of the item name as shown in the illustration on the right If No 2 Way Attachment is selected it becomes impossible to select the attachment mode on...

Page 112: ...itch F6 2 On the 2 Way Attachment Select Oil Flow Setting screen select one of the two set values for the oil flow then press switch F6 The default values for the oil flow setting are both set to 530...

Page 113: ...5 Returns to previous screen F6 Switches to setting screen for selected item 3 On the 2 Way Attachment Oil Flow Setting menu it is possible to change the oil flow setting After using switches F3 or F4...

Page 114: ...s no territory where it is possible to the use the message service In territories where it is not possible to use the message service the message display menu functions as follows 1 On the standard sc...

Page 115: ...ight of the screen 1 On the standard screen press switch F6 2 Select screen adjustment on the user menu then press switch F6 The screen switches to the selection menu screen for screen adjustment On m...

Page 116: ...selection menu for screen adjustment is not displayed If screen adjustment is selected from the user menu the adjustment screen in Step 4 is displayed 4 Use switches F2 to F6 to adjust the brightness...

Page 117: ...t is possible to carry out the following operations with switches F2 to F6 F2 Resets all adjusted values to default value F3 Indicator of selected item moves 1 segment to left F4 Indicator of selected...

Page 118: ...CONTROLS AND GAUGES Clock Adjustment On this clock adjustment menu it is possible to change the setting of the clock displayed on the pilot monitor of the standard display 1 On the standard screen pr...

Page 119: ...CONTROLS AND GAUGES 2 Select Clock Adjustment on the user menu then press switch F6 The screen switches to the time adjustment selection menu screen The following three items can be changed a Clock se...

Page 120: ...me a is not highlighted in yellow press switch F6 to highlight Time a in yellow When this is done hour display b changes to orange Adjust hour display b with the switches as follows If it is not neces...

Page 121: ...Accepts change and goes to setting for 12 24 hour display mode 12h 24h Mode Choose either a 12 hour display am pm or a 24 hour display b 24 hour display c 12 hour display am pm 1 If 12h 24h Mode a is...

Page 122: ...y mode is highlighted in green 2 Change the daylight saving time with the switches as follows F3 Moves 1 item to left F4 Moves 1 item to right F5 Cancels change and returns to user menu F6 Accepts cha...

Page 123: ...d on the monitor display The languages that can be selected are as follows Japanese English Chinese French Spanish Portuguese Italian German Russian Turkish Indonesian Thai 1 On the standard screen pr...

Page 124: ...ge selection screen it is possible to carry out the following operations with switches F3 to F6 F3 Moves to item below F4 Moves to item above F5 Cancels change and returns to user menu screen F6 Accep...

Page 125: ...follows E0 Default E1 Economy Adjustment 1 E2 Economy Adjustment 2 E3 Economy Adjustment 3 The higher the selection is made from E0 to E3 the better the fuel consumption becomes but the production is...

Page 126: ...itch Swing parking brake releasel switch Starting Switch Starting switch 1 is used to start or stop the engine A OFF position The key can be inserted or withdrawn Switches for the electrical system ex...

Page 127: ...Lock Switch WARNING When not using the swing operation e g when traveling put the swing lock switch to the ON position On slopes even when the swing lock switch is at the ON position the weight of the...

Page 128: ...rmal ground soft rock or blasted rock b High pressure setting The thrusting force of the boom becomes more powerful so it is easy to escape from soft ground Heated operator seat switch If equipped Thi...

Page 129: ...ntrol lever is used to actuate the power max functions Press once single click and keep the switch pressed The one touch power max function is actuated for a maximum of 8 5 seconds at P and E mode Cig...

Page 130: ...NORMAL position This switch 13 is used to make it possible to carry out operations temporarilyif any problem should occur in the pump control system when the display shows E02 a EMERGENCY When abnorm...

Page 131: ...k that the condition of the lever is as shown in the diagram When pulling the lock lever up be careful not to touch the work equipment control lever When pushing the lock lever down be careful not to...

Page 132: ...forward when operated in reverse and in reverse when operated forward the left and right directions will also be reversed When operating the travel levers check if the track frame is facing the front...

Page 133: ...ration a Arm OUT b Arm IN Swing operation c Swing to right d Swing to left N Neutral The upper structure and arm are held in position and do not move Right work equipment control lever 4 is used to op...

Page 134: ...nd apply the lock WINDSHIELD WARNING When opening or closing the front window bottom window or door always set the lock lever to the LOCK position If the lock lever is at the FREE position and the con...

Page 135: ...und then stop the engine 2 Set the lock lever 1 securely to the LOCK position L 3 Check that the wiper blade is stowed in the right stay 4 Hold 2 grips A on the left and right top sides of the front w...

Page 136: ...nd push it against lock catch E at the rear of the cab securely to lock the window 6 Check that lever B is securely at the LOCK position The lock is engaged if the arrow on lock case F matches the pos...

Page 137: ...l ground lower the work equipment completely to the ground then stop the engine 2 Set the lock lever 1 securely to the LOCK position L 3 Grip left and right handles A and pull down lever B to release...

Page 138: ...o push it against left and right lock catches G and engage the lock 6 Check that lever B is securely at the LOCK position The lock is engaged if the arrow on lock case F matches the position of the ar...

Page 139: ...icult to remove the window In addition when stowing the sand and dust stuck to the glass will be carried inside the cab To prevent this clean area A before removing 2 After removing the lower windshie...

Page 140: ...o escape To escape from the operator s cab use hammer A to break the glass and escape through the window DOOR LOCK WARNING Before the releasing the door lock always stop the machine on flat ground Nev...

Page 141: ...go to the shoulder A If the key is turned before it is inserted all the way it may break Opening and Closing Caps with Lock Opening the Cap 1 Insert the key into the key slot 2 Turn the key clockwise...

Page 142: ...ening the Cover Locked Cover 1 Insert the key into the key slot 2 Turn the key counterclockwise and open the cover by pulling the cover grip A Open B Lock Locking the Cover 1 Close the cover and inser...

Page 143: ...onditioner MAGAZINE BOX The cup holder is provided separately at the front of the magazine box Located on left side of the operator s seat Keep the Operation and Maintenance Manual in this box so that...

Page 144: ...rature control switch Vent selector switch Auto switch 6 7 8 9 FRESH RECIRC selector switch Display monitor Air conditioner switch Sunlight sensor OFF Switch Switch 1 is used to stop the fan and air c...

Page 145: ...h 3 is used to control temperature inside the cab The temperature can be set between 18 C 64 4 F and 32 C 89 6 F Press the E switch to raise the set temperature press the R switch to lower the set tem...

Page 146: ...witch 4 is pressed the display on monitor display 7 switches and air blows out from the vents displayed During automatic operation the vents are automatically selected A Rear vent 4 places B1 Face ven...

Page 147: ...High but this is not a problem FRESH RECIRC Selector Switch Switch 6 is used to switch the air source between recirculation of the air inside the cab and intake of fresh air from the outside During a...

Page 148: ...nditioner is switched ON and starts to work Press the switch again to stop the air conditioner Air conditioner cannot be operated while the fan is off Sunlight Sensor This sensor 9 automatically adjus...

Page 149: ...also displayed 2 Use temperature set switch 3 to set to the desired temperature The air flow combination of vents and selection of fresh or recirculated air is automatically selected according to the...

Page 150: ...Automatic Operation Press OFF switch 1 Operation stops Manual Operation 1 Press fan switch 2 and adjust the air flow When doing this check that temperature setting a and air flow b are displayed on m...

Page 151: ...emperature inside the cab 4 Press vent selector switch 4 and select the desired vents When this is done the display for vent c of the display monitor changes according to the selection 5 Press RECIRC...

Page 152: ...perate with cold air blowing to the face and warm air blowing to the feet set as follows 1 Press fan switch 2 and adjust the air flow When doing this check that temperature setting a and air flow b ar...

Page 153: ...ILED CONTROLS AND GAUGES OPERATION DETAILED CONTROLS AND GAUGES 3 Turn air conditioner switch 8 ON 4 Adjust fan switch 2 temperature setting switch 3 and RECIRC FRESH selector switch 6 to the desired...

Page 154: ...1 Press fan switch 2 and adjust the air flow When doing this check that temperature setting a and air flow b are displayed on monitor 7 2 Press vent selector switch 4 and set vent display on the disp...

Page 155: ...ture setting switch 3 and set temperature on the display 7 monitor to maximum heating 5 Adjust vents A B1 and B2 so that the air blows onto the window glass Vents C and D are fixed and cannot be adjus...

Page 156: ...g the cab 5 or 6 C 9 or 10 8 F lower than the outside temperature This temperature difference is considered to be the most suitable for your health so always be careful to adjust the temperature prope...

Page 157: ...n The frequency is displayed on display 7 Press the knob again to turn the power off Turn the knob clockwise to increase the volume press counterclockwise to reduce the volume The range for the volume...

Page 158: ...2 seconds it is possible to select one of the already preset stations Wait for 6 sec after pressing the button and then press the button again to select the next preset station If it is impossible to...

Page 159: ...ach for AM and FM can be preset to each Preset button REMARK It is also possible to save to the Preset button by using the auto store button Method of Tuning 1 Press power switch 1 and display the fre...

Page 160: ...mode the display is returned automatically to its original setting after 5 seconds Setting Correct Time 1 Press display selector button 4 to display the time After 5 seconds the display will return t...

Page 161: ...the sound to a level where it is possible to hear outside sounds during operation If water gets into the speaker case or radio it may lead to an unexpected failure so be careful not to get water on th...

Page 162: ...e power supply for 12V equipment It will cause failure of the equipment Pull out the connector plug for taking out electric power from the rear side of the panel Maximum usable electric power is 85 W...

Page 163: ...No Fuse capasity Name of circuit 1 10A Working lamp relay hazard switch 2 30A Electromagnetic valve 3 10A PPC hydraulic lock solenoid 4 10A Window washer cigarette lighter 5 10A Horn 6 10A Auto pre he...

Page 164: ...arge sized fuse wiring installed in the high current flow portion of the circuit to protect electrical components and wiring from burning in the same way as an ordinary fuse CONTROLLER Controller inst...

Page 165: ...do not contact the battery This may cause damage to the battery GREASE PUMP HOLDER This is inside the door at the rear right of the machine When not using the grease gun fit it in this holder FIRE EX...

Page 166: ...d around the engine and radiator Also check for flammable material dry leaves twigs etc around the battery engine muffler turbocharger or other high temperature engine parts If any dirt or flammable m...

Page 167: ...Seat belt and mounting clamps Check for damage or wear to the seat belt and mounting clamps If there is any damage replace with new parts 11 Check bucket with hook if equipped for damage Check for da...

Page 168: ...water level is between the FULL and LOW marks on radiator sub tank 1 shown in the diagram on the right If the water level is low add water through the water filler of sub tank 1 to the FULL level 2 A...

Page 169: ...the water REMARK When only the water separator monitor lights up it lights up in the position shown in the diagram on the right If other monitors also light up the same time the water separator monito...

Page 170: ...n all the water and sediment in the transparent cap 2 and also the fuel accumulated in filter cartridge 1 4 Check that nothing more comes out from drain hose 3 then remove drain valve 4 5 Coat O ring...

Page 171: ...e engine move each control lever for work equipment and travel to the full stroke in all directions to release the internal pressure 4 Check sight gauge G The oil level should be between the H and L m...

Page 172: ...it 4 The oil level should be between the H and L marks on dipstick G If the oil level is below the L mark add oil through oil filler F 5 If the oil is above the H mark on the gauge remove cover 1 dra...

Page 173: ...dust wash the battery cap to clear the breather hole Check that there is no damage to the fuses that fuses of the specified capacity are used that there is no disconnection or trace of short circuitin...

Page 174: ...cking turn the switch back to the OFF position 2 If fuel is found to be low unscrew fuel filler cap F on the fuel tank and add fuel through the filler port until float gauge G comes up to the highest...

Page 175: ...up or there is a disconnection so ask your Komatsu distributor to carry out repairs 1 Turn the starting switch to the ON position 2 Turn the lamp switch ON night mode a and day mode b and check that...

Page 176: ...ortable for operation then release the lever Sit with your back against the seat backrest when adjusting If your back is not against the backrest the backrest may suddenly move forward C Adjusting sea...

Page 177: ...spension if equipped Turn knob 8 to the right to make the suspension harder or to the left to make the suspension softer Adjust the reading of the dial to match the operator s weight and select the op...

Page 178: ...ing on the counterweight as there is always the danger of a serious injury due to falling off from the machine Mirror A Adjust the mirror mount so that it is possible to see people at the rear left of...

Page 179: ...the side view mirror does not move smoothly when adjusting its angle loosen mirror securing bolt 4 and mirror securing stay bolt 5 Tightening torque of bolt 4 4 0 5 4 Nm 0 41 0 55 kgm 3 4 lbft When a...

Page 180: ...mirror C provide clearance V so that the mirror and the mirror stay do not interfere with each other V More than 10 mm If equipped If side view mirror D does not move smoothly when adjusting its angl...

Page 181: ...old using a step ladder and then carry out the work Do not do the work standing on the counterweight as there is always the danger of a serious injury due to falling off from the machine If the image...

Page 182: ...the camera and adjust mounting angle A of the camera so that the center line of mounting bolt 4 is aligned with fourth from bottom scale B REMARK Part of the machine is shown on the monitor screen 5...

Page 183: ...at belt during operations Fit the seat belt so that it is not twisted Fastening and Removing This seat belt has a wind in device so it is not necessary to adjust the length Fastening Seat Belt Hold gr...

Page 184: ...the LOCK position L 2 Check that each control lever and control pedal is at the Neutral position If the control levers and control pedal are not being touched they will be at the Neutral position 3 In...

Page 185: ...butor for repairs 2 After approx 2 seconds the screen will change to the working mode travel speed display monitor Next it will switch to the standard screen Engine coolant temperature gauge 10 Engine...

Page 186: ...te suddenly and cause damage to the engine parts Do not keep the key in starting switch 3 at the START position continuously for more than 20 seconds If the engine does not start wait for at least 2 m...

Page 187: ...engine REMARK If the ambient temperature is low the engine may not start even when the key in the starting switch 3 is kept at the START position for 20 seconds If this happens wait for at least 2 min...

Page 188: ...t least two minutes then start again from Step 1 Turbo protect function The turbo protect function is a function to protect the turbocharger by keeping the engine speed at less than 1000 rpm immediate...

Page 189: ...the hydraulic equipment is not carried out thoroughly and the machine is moved the reaction of the control levers and pedals will be slow and the movement may not be what the operator intended Always...

Page 190: ...This will have an adverse effect on the environment and will also have an adverse effect on the internal structure of the engine If it is necessary to run the engine at idling for more than 20 minute...

Page 191: ...the engine coolant temperature monitor displays the correct temperature the engine warm up operation is completed After checking that the engine coolant temperature monitor displays the correct temper...

Page 192: ...kground C is blue B Display when temperature is low Monitor background C is white The warming up operation for the hydraulic equipment is necessary not only for the circuit between the pump and cylind...

Page 193: ...m up operation of the hydraulic equipment more quickly set the working mode to P mode heavy duty mode For details of the procedure for setting the working mode see Working Mode Selector Switch PAGE 3...

Page 194: ...to push out the arm A Operate the lever to the end of its travel and hold it in position for 30 seconds 10 Repeat the operation in Steps 6 to 9 for 5 minutes 11 Check that hydraulic oil temperature mo...

Page 195: ...mperature monitor 7 Displays correct temperature Fuel gauge 17 Indicator in green range Fuel level monitor 18 Displays appropriate level 14 Check for abnormal exhaust gas color noise or vibration If a...

Page 196: ...tion and run the engine at a mid range speed before operating 17 Before starting operations repeat the following operations slowly 3 to 5 times to circulate warm oil through the control circuits Boom...

Page 197: ...tor is not displaying the correct temperature it is displaying low temperature repeat Steps 6 to 10 until the display is the correct temperature A Display when temperature is correct Monitor backgroun...

Page 198: ...tor background C is blue B Display when temperature is low Monitor background C is white 2 Push working mode selector switch 20 of the machine monitor to select the working mode to be used For details...

Page 199: ...IONS AND CONTROLS OPERATION MACHINE OPERATIONS AND CONTROLS 3 L mode For operations requiring fine control 4 B mode For breaker operations 5 ATT mode For operations with crusher or other double acting...

Page 200: ...stop the engine abruptly except in an emergency If the engine has overheated do not try to stop it abruptly but run it at medium speed to allow it to cool down gradually and then stop it 1 Run the en...

Page 201: ...the horn Do not allow anyone to enter the area around the machine Clear any obstacles from the travel path There is a blind spot at the rear of the machine so be particularly careful when traveling in...

Page 202: ...t the machine either by pushing lever 5 forward slowly or by stepping on the front part of pedal 6 slowly When sprocket is situated at the front of the machine Start the machine either by pulling leve...

Page 203: ...ull the levers 5 backward or slowly depress the rear part of the pedals 6 to move the machine backward When sprocket A is at the front of the machine Slowly push the levers 5 forward or slowly depress...

Page 204: ...ON MACHINE OPERATIONS AND CONTROLS Stopping Machine Avoid stopping suddenly Give yourself ample room when stopping 1 Put the left and right travel levers 1 in the neutral position then stop the machin...

Page 205: ...nt of the machine Use the travel levers to change direction Avoid sudden changes of direction as much as possible Especially when performing counter rotation spin turn stop the machine before turning...

Page 206: ...Forward left turn B Reverse left turn REMARK When turning to the right operate the right travel lever in the same way Counter rotation Turn Spin Turn When using counter rotation spin turn to turn left...

Page 207: ...celeration function the engine speed will suddenly rise operate the levers carefully 1 Before starting the swing operation turn swing lock switch 1 OFF and check that swing lock monitor 2 has gone out...

Page 208: ...hen the levers are released they return to the HOLD position and the work equipment is held in that position Arm control Move the left work equipment control lever to the front or rear to operate the...

Page 209: ...ol circuit on this machine is equipped with an accumulator Even if the engine is stopped if the starting switch key is turned to the ON position within 15 seconds after stopping the engine and the loc...

Page 210: ...t mode to match the type of work Working mode Applicable operations P mode Normal digging or loading operations operations with emphasis on production E mode Normal digging or loading operations opera...

Page 211: ...d and working mode switch 1 is kept pressed the selected mode is accepted and the screen returns to the standard screen If the breaker mode is selected Really Set Breaker Mode is displayed on the scre...

Page 212: ...e to compact soil or break objects This is not only dangerous but will also drastically reduce the life of the machine Operations Using Travel Force Do not dig the bucket into the ground and use the t...

Page 213: ...acts the rock behind the principle of the lever will bring excessive force to bear on the machine or work equipment and there is danger that this may lead to breakage or damage of the machine In such...

Page 214: ...d frame and this will reduce the service life of the machine Digging Hard Rocky Ground Do not attempt to directly excavate hard rocky ground with the work equipment It is better to excavate it after b...

Page 215: ...ls suddenly or take any other action to move the machine quickly 2 Do not operate the levers or pedals suddenly from FORWARD A to REVERSE B or from REVERSE B to FORWARD A 3 Do not operate the levers o...

Page 216: ...ubricatingoil inside the track rollers and final drive will rise to a high temperature and there is danger that this will cause damage to the oil seal or leakage of oil When traveling continuously for...

Page 217: ...g over such obstacles as far as possible If there is no way to avoid traveling over an obstacle reduce the travel speed keep the work equipment close to the ground and try to travel so that the center...

Page 218: ...der water and water will be thrown up by the cooling fan This may cause the fan to break Be extremely careful when driving the machine out of water Do not drive the machine in water deeper than the ce...

Page 219: ...travel downhill in reverse Never turn on slopes or travel across slopes Always go down to a flat place to perform these operations It may be longer but it will ensure safety Always operate or travel i...

Page 220: ...lly applied Engine Stopped on Slope If the engine stops when traveling uphill move the travel levers to the neutral position lower the bucket to the ground stop the machine then start the engine again...

Page 221: ...the bucket in contact with the ground The angle between the boom and arm should be 90 to 110 The same applies when using the bucket installed in the reverse direction When only one side is stuck in m...

Page 222: ...s from a 45 angle away from the machine to a 30 angle towards the machine There may be some differences depending on the excavation depth but try to stay within the above range rather than operating t...

Page 223: ...where the swing angle is narrow work efficiency can be enhanced by locating the dump truck in a place easily visible to the operator Loading is easier and capacity greater if you begin from the front...

Page 224: ...ght Never insert your fingers into the pin holes when aligning the holes Stop the machine on a firm and flat surface and do the work When performing joint work appoint a lead and follow that person s...

Page 225: ...andard groove For link pin portion B install the bucket with O ring 3 fitted in the standard groove 4 Install the stopper bolts and nuts for each pin then grease the pin REMARK Lubricate with grease t...

Page 226: ...to the ground the resistance will be increased and it will be difficult to remove the pins NOTICE After removing the pins make sure that mud or sand does not get on them Dust seals are fitted at both...

Page 227: ...using it next 5 Install the stopper bolts and nuts for each pin then grease the pin REMARK Lubricate with grease thoroughly until the grease comes out from the end face When replacing the bucket repla...

Page 228: ...blocks underneath the track shoes As an additional safety measure thrust the bucket into the ground If the control lever is touched by accident the machine may move suddenly and this may lead to a se...

Page 229: ...BLES AND ACTIONS PAGE 3 195 If the engine oil pressure monitor lights up stop the engine immediately For details of the inspection and action to take see TROUBLES AND ACTIONS PAGE 3 195 6 Stop the eng...

Page 230: ...tank filler port 3 Engine hood 4 Battery box cover 5 Left side door of the machine 6 Right side door of the machine 7 Battery box side cover only machines equipped with fuel supply pump 8 Hydraulic t...

Page 231: ...method of transportation to match the weight and dimensions given in SPECIFICATIONS PAGE 5 2 Note that the weight and dimensions given in SPECIFICATIONS may differ according to the type of shoe or arm...

Page 232: ...y lever except the travel lever The center of gravity of the machine will change suddenly at the joint between the ramps and the trailer and there is danger of the machine losing its balance Travel sl...

Page 233: ...ent them from bending 3 Turn the travel speed selector switch to low speed travel Lo lamp lights up Press travel speed selector switch 5 to switch the travel speed The travel speed Lo Mi Hi is display...

Page 234: ...he direction of travel with the ramps and travel slowly Lower the work equipment as far as possible without causing interference When on the ramps operate only the travel lever Do not operate any othe...

Page 235: ...unstable drive slowly and carefully Never operate the steering 11 At the moment the machine passes the rear wheels it tilts forward be careful not to let the work equipment hit the trailer body Drive...

Page 236: ...the starting switch 4 Close all doors windows and covers Lock the covers caps and doors fitted with locks 5 Place blocks under both ends of the tracks to prevent the machine from moving during transpo...

Page 237: ...use the following procedure After installing the mirrors be sure to adjust them referring to Rearview Mirrors PAGE 3 123 Removal Mirrors A B 1 Loosen mounting bolt 2 then remove mirror 1 from support...

Page 238: ...B 1 Install support 3 and clamp 5 to the handrail then tighten with bolt 4 2 Install mirror 1 to support 3 then tighten lock bolt 2 Mirror C 3 Install bracket 3 to the machine with bolt 4 4 Install mi...

Page 239: ...the ramps to prevent them from bending 3 Remove the chains and wire ropes fastening the machine 4 Start the engine Warm the engine up fully 5 Set the lock lever to FREE position F 6 Turn the travel s...

Page 240: ...110 If the machine is unloaded with the arm pulled in it will cause damage to the machine When moving onto the ramps do not thrust the bucket into the ground This will cause damage to the hydraulic cy...

Page 241: ...hine may lose its balance NOTICE This method of lifting applies to the standard specification machine The method of lifting differs according to the attachments and options installed For details of th...

Page 242: ...2nd track rollers from the rear However for machines equipped with a full roller guard for the track roller pass the wire rope under the track 6 Set the lifting angle A of the wire rope to 30 to 40 t...

Page 243: ...Komatsu distributor to divide the machine up into kits Posture for Each Unit Upper Structure Undercarriage Item Unit PC300 PC300LC PC350 PC350LC A mm ft in 3 145 10 4 3 145 10 4 3 145 10 4 3 145 10 4...

Page 244: ...10 15 5 B mm ft in 1 855 6 1 1 855 6 1 Overall width mm ft in 1 485 4 10 1 485 4 10 Weight kg lb 2 700 5 953 3 230 7 122 Others Counterweight Item Unit PC300 PC300LC PC350 PC350LC A mm ft in 1 120 3 8...

Page 245: ...e amounts of fresh water and see a doctor at once When changing the coolant or when handling coolant containing antifreeze that has been drained when repairing the radiator please contact your Komatsu...

Page 246: ...also drop If the battery charge ratio is low the battery electrolyte may freeze Maintain the battery charge as close as possible to 100 Insulate it against cold temperature to ensure the machine can...

Page 247: ...nd and allow the machine to be moved the next morning Open the drain valve and drain any water collected in the fuel system to prevent it from freezing Fill the fuel tank to capacity This minimizes mo...

Page 248: ...stop valve to the LOCK position on machines ready for attachments Install the blind plugs to the elbows For details of the LOCK and FREE positions of the stop valve see ATTACHMENT REMOVAL AND INSTALLA...

Page 249: ...ipe off the grease from the hydraulic cylinder rods Add oil and grease at all lubrication points When the machine is stored for a long period moisture in the air will mix with the oil Check the oil be...

Page 250: ...ey to the ON position B The electric priming pump is actuated 2 Hold the key at the ON position B for 30 seconds then return it to OFF position A and wait for 10 seconds 3 Repeat Steps 1 and 2 four ti...

Page 251: ...tical position When the bucket control lever is operated to the CURL position and the work equipment is lowered under no load from a high position the bucket speed will drop momentarily when the bucke...

Page 252: ...achine and the machine being towed Operate the machine slowly and be careful not to apply any sudden load to the wire rope NOTICE The maximum towing capacity for this machine is 197 100 N 20 100 kg Al...

Page 253: ...o fit the shackle when towing light objects Permissible towing load Max 108 000 N 11 000 kg SEVERE JOB CONDITION When carrying out digging operations in water if the work equipment mounting pin goes i...

Page 254: ...n removing the battery first disconnect the cable from the ground normally the negative terminal When installing install the positive terminal first If a tool touches the positive terminal and the cha...

Page 255: ...tive terminal of the battery Be sure to attach the clips securely Set the charging current to 1 10 of the value of the rated battery capacity when carrying out rapid charging set it to less than the r...

Page 256: ...ction to the upper structure frame a spark will be caused connect the cable to a spot as far away from the battery as possible Avoid the work equipment however because it is not a good conductor When...

Page 257: ...the machine is working normally or has failed Check also that all the control levers are in the neutral position 1 Make sure the clips are firmly connected to the battery terminals 2 Start engine of...

Page 258: ...starting switch is turned to ON Defective wiring Defective starting motor Insufficient battery charge Check repair Replace Charge Pinion of starting motor keeps going and out Insufficient battery char...

Page 259: ...ng in air Clogged element in hydraulic tank strainer lack of oil Clean see EVERY 2000 HOURS SERVICE Excessive rise in hydraulic oil temperature Loose fan belt Dirty oil cooler Lack of hydraulic oil Ch...

Page 260: ...ck fan belt tension replace Change coolant flush inside of cooling system see WHEN REQUIRED Clean or repair see EVERY 500 HOURS SERVICE Replace thermostat Tighten cap or replace packing Replace sensor...

Page 261: ...ormal noise generated combustion or mechanical Low grade fuel being used Overheating Damage inside muffler Excessive valve clearance Change to specified fuel Refer to Radiator coolant level monitor li...

Page 262: ...E15 Engine sensor coolant temperature fuel pressure oil pressure system error If a display of CA2249 or CA559 appears in the user code screen and yet the machine has not run out of fuel replace both...

Page 263: ...onitor the telephone number for the point of contact is displayed at the bottom of the error screen REMARK If no point of contact telephone number has been registered no telephone number is displayed...

Page 264: ...4 1...

Page 265: ...ways report to the person in charge and carry out suitable action Fuel Strainer If your machine is equipped with a fuel strainer do not remove it while fueling Welding Instructions Cut off power Wait...

Page 266: ...see BLEEDING AIR FROM HYDRAULIC SYSTEM PAGE 4 44 Hydraulic Hose Installation When removing parts at locations where there are O rings or gasket seals clean the mounting surface and replace with new pa...

Page 267: ...e grade and maximum and minimum ambient temperatures recommended in the Operation and Maintenance Manual Even if the oil is not dirty always change the oil at the specified interval Oil corresponds to...

Page 268: ...is used the durability may drop markedly COOLANT AND WATER FOR DILUTION The coolant has the important function of preventing corrosion as well as preventing freezing Even in the areas where freezing i...

Page 269: ...ent machine failures and downtime With KOWA the oil is periodically sampled and analyzed This enables early detection of wear of the machine drive parts and other problems We strongly recommend you to...

Page 270: ...e oil and fuel sulfur content being used Never try to clean the filters cartridge type and use them again Always replace with new filters When replacing oil filters check if any metal particles are at...

Page 271: ...tank breather 20Y 60 21470 Element 1 Every 500 hours Additional breather for hydraulic tank 207 60 51310 Filter 1 Every 500 hours Fuel main filter 6754 79 6130 Cartridge 1 Every 1000 hours Additional...

Page 272: ...F be sure to use the recommended multi grade oil even if the ambient temperature may become higher during the course of the day If the machine is operated at a temperature below 20 C 4 F a separate de...

Page 273: ...4 96 43 8 45 159 84 Refill capacity liter 35 16 5 9 0 1 3 188 32 US gal 9 25 4 36 2 38 0 34 49 67 8 45 NOTICE Always use diesel oil for the fuel To ensure good fuel consumption characteristics and exh...

Page 274: ...ue the use of antifreeze coolant is essential Komatsu machines are supplied with Komatsu Supercoolant AF NAC Komatsu Supercoolant AF NAC has excellent anticorrosion antifreeze and cooling propertiesan...

Page 275: ...5 19 5 8 7 10 8 20 3 25 3 43 4 54 2 72 3 90 4 112 1 141 16 18 20 22 24 24 27 30 32 36 260 360 510 688 883 26 5 37 52 3 70 3 90 191 7 267 6 378 3 508 5 651 235 285 320 400 455 565 610 765 785 980 23 5...

Page 276: ...dition after a certain period of usage This is important to ensure that these parts maintain their full performance at all times Furthermore should anything abnormal be found on any of these parts rep...

Page 277: ...ort 4 11 Work equipment hose bucket cylinder line boom foot 2 12 Work equipment hose bucket cylinder inlet port 2 13 Work equipment hose bucket cylinder inlet port 4 0 m arm 2 14 Work equipment hose a...

Page 278: ...CK WINDOW WASHER FLUID LEVEL ADD FLUID 4 38 CHECK AND MAINTENANCE AIR CONDITIONER 4 39 WASHING WASHABLE FLOOR 4 40 CHECK GAS SPRING 4 43 BLEEDING AIR FROM HYDRAULIC SYSTEM 4 44 CHECKS BEFORE STARTING...

Page 279: ...AL DRIVE CASE 4 71 CLEAN HYDRAULIC TANK STRAINER 4 72 CHECKING CHARGE PRESSURE OF NITROGEN GAS IN ACCUMULATOR FOR CONTROL CIRCUIT 4 73 CHECK ALTERNATOR 4 77 CHECK ENGINE VALVE CLEARANCE ADJUST 4 77 CH...

Page 280: ...ment according to the table on the right Change oil in hydraulic tank Change the oil according to the table on the right Replacing additional filter element for breaker if equipped Use a guideline of...

Page 281: ...y out the following maintenance only after the first 1000 hours of operation on new machines Check engine valve clearance adjust Special tools are needed for inspection and maintenance so contact your...

Page 282: ...ng monitor light up the air cleaner will not be able to display its performance fully and the cleaning efficiency will also go down In addition during the cleaning operation more dirt stuck to the ele...

Page 283: ...4 After removing the outer element 5 cover the inner element 6 with a clean cloth or tape to prevent dirt or dust from entering 5 Wipe off or brush off the dirt stuck to cover 3 and the inside of the...

Page 284: ...is no dirt or oil stuck to the seal portion of the new element or cleaned element Wipe off any dirt or oil 11 Push the outer element in straight with your hand when installing it to the air cleaner b...

Page 285: ...ng 12 Install cover 3 as follows 1 Align cover 3 with the element 2 Hook the tip of hook 2 to the protruding part of the air cleaner body and lock it in position 3 When locking hooks 2 in position app...

Page 286: ...evacuator valve 4 installed to cover 3 NOTICE The inner element must not be cleaned and used again When replacing the outer element replace the inner element at the same time If the inner element is...

Page 287: ...is swollen or the outer element is not pushed in straight and cover 3 is assembled by force to hook 2 there is danger that the hook and air cleaner body may be damaged so be careful when assembling 9...

Page 288: ...e coolant has the important function of preventing corrosion as well as preventing freezing Even in the areas where freezing is not an issue the use of antifreeze coolant is essential Komatsu machines...

Page 289: ...it possible to touch the radiator cap surface by hand then turn radiator cap 2 slowly until it contacts the stopper to release the pressure 3 Following this push radiator cap 2 turn it until it conta...

Page 290: ...ide of the sub tank then add water until the coolant level is between the FULL and LOW marks If the sub tank is extremely dirty and it is difficult to clean replace it with a new part 13 Stop the engi...

Page 291: ...g 1 Tighten first to a tightening torque of 393 39 Nm 40 4 kgm then check that the nut and track shoe are in tight contact with the mating surface of the link 2 After checking tighten a further 120 10...

Page 292: ...the track shoe Deflection a should be 10 30 mm 0 4 1 2 in If the track tension is not at the standard value adjust it in the following manner Adjustment WARNING There is danger of plug 1 flying out u...

Page 293: ...the procedure given below If track tension is not relieved by this procedure contact your Komatsu distributor for repairs 1 Loosen plug 1 gradually to release the grease 2 When loosening plug 1 turn i...

Page 294: ...o one in the surrounding area There is a hazard that fragments will fly during the replacement work so always wear protective equipment like safety glasses and gloves 1 To make it possible to knock ou...

Page 295: ...steel ball is about to come out Steel ball 7 sinks in when it is pushed by hand 5 Clean the surface of adapter 4 and remove the soil with a knife 6 Use your hand or a hammer to push rubber pin lock 3...

Page 296: ...in the pin hole in the tooth 1 and knock it in so that the top surface of lock pin 2 is the same height as the surface of tooth 1 10 After replacing a bucket tooth always check the following 1 After t...

Page 297: ...e is no one in the surrounding area There is a hazard that fragments will fly during the replacement work so always wear protective equipment like safety glasses and gloves 1 To make it possible to kn...

Page 298: ...BUCKET SIDE CUTTER SHROUD WARNING It is dangerous if the work equipment is mistakenly moved when replacing the bucket side cutters and shroud Set the work equipment in a stable condition stop the eng...

Page 299: ...n then remove tooth 2 REMARK If it cannot be removed by this method for safety reasons always contact your Komatsu distributor to have the replacement carried out 2 Clean the mounting face Fit a new s...

Page 300: ...that all the play can be measured at one place the right side in the diagram Use a clearance gauge for easy and accurate measurement 3 Loosen 4 plate mounting bolts 2 and loosen plate 3 The shim is a...

Page 301: ...depending on the freezing temperature 10 C 14 F general use and 30 C 22 F cold area use select according to the area and season Mixture Ratio of Pure Washer Fluid and Water The proportion differs acc...

Page 302: ...o refrigerant REMARK When there are bubbles the refrigerant gas level is low so contact your Komatsu distributors to have refrigerant added If the air conditioner is run with the refrigerant gas level...

Page 303: ...side the operator s cab Never spray water above the pedestal of the operator s seat 2 If any water splashes on the surrounding equipment be sure to wipe it off With the washable floor it is possible t...

Page 304: ...er plate 4 6 Pull the knob of floor mat holder clip 5 and remove clip 5 7 Remove the floor mat 8 Remove the cap from water drain hole 3 9 Flush out the dirt on the floor directly with water through wa...

Page 305: ...de 2 Put blocks under the track and dig the work equipment into the ground Method Using Block WARNING Select a firm flat place Put strong blocks under the undercarriage to stabilize the machine and be...

Page 306: ...it in fire Do not make holes in it or weld it Do not hit it roll it or subject it to any impact When disposing of the gas spring the gas must be released Please contact your Komatsu distributor to ha...

Page 307: ...NGINE PAGE 3 131 Run the engine at low idle for 10 minutes after starting then start operations 3 Bleeding air from cylinders 1 Run the engine at low idle and extend and retract each cylinder 4 to 5 t...

Page 308: ...for 2 minutes Repeat this procedure on both the left and right sides 6 Bleeding air from attachment when installed If a breaker or other attachment has been installed run the engine at low idle and o...

Page 309: ...ant level add coolant Drain water and sediment from fuel tank Check for water and sediment in water separator drain water Check additional water separator drain water and sediment Check oil level in h...

Page 310: ...bjected to jobs in the water be sure to grease the wet pins 1 Set the machine to the greasing posture shown on the right lower the work equipment to the ground then stop the engine 2 Using a grease pu...

Page 311: ...fter the machine was subjected to jobs in the water be sure to grease the wet pins 1 Set the machine to the greasing posture shown on the right lower the work equipment to the ground then stop the eng...

Page 312: ...MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE MAINTENANCE PROCEDURE 7 Boom foot pin 2 places 4 49...

Page 313: ...as and there is danger of explosion do not bring fire or sparks near the battery Battery electrolyte is dangerous If it gets in your eyes or on your skin wash it off with a large amount of water and c...

Page 314: ...ck the electrolyte level from the side of the battery or there is no display of the UPPER LEVEL line on the side of the battery check as follows 1 Remove cap 2 at the top of the battery look through t...

Page 315: ...ting position of bolt 2 as a fulcrum 3 When the position of the compressor is determined tighten bolts 2 and 3 to hold it in position NOTICE Check each pulley for damage wear of the V groove and wear...

Page 316: ...ne consists of more precise parts than the conventional injection pump and nozzle If any part other than a genuine Komatsu filter cartridge is used dust or dirt may get in and cause problems with the...

Page 317: ...is the clean side so do not remove cap B when adding fuel Be careful not to let dirt or dust get into center portion on the clean side 11 When installing tighten until the packing surface contacts th...

Page 318: ...Steps 17 and 18 four times 20 After replacing the filter cartridge start the engine and run it at low idling for 10 minutes Check for leakage of fuel from the filter seal surface and tranparent cap mo...

Page 319: ...move cover 2 3 Insert scale 3 through inspection and maintenance hole A into the grease and check that height S of the grease is at least 54 mm 2 1 in If the grease level is low add grease 4 Check if...

Page 320: ...filler pipe 3 Pull out dipstick G and check that the oil level is between the H and L marks on the dipstick 4 If the oil does not reach the L mark on dipstick G add engine oil through dipstick insert...

Page 321: ...the ground surface 2 Remove plug F using the handle When the oil level reaches a point 10 mm 0 4 in below the bottom of the plug hole the correct amount of oil has been added 3 If the oil level is to...

Page 322: ...er of drain valve P slowly drain the oil then raise the lever to close the valve 3 Open the cover at the rear right then use a filter wrench to turn filter cartridge 2 to the left to remove it 4 Clean...

Page 323: ...hood and add engine oil through oil filler F to between the H and L marks on dipstick G 7 Run the engine at idling for a short time then stop the engine and check again that the oil level is between...

Page 324: ...overheating In a dusty job site check the fins every day regardless of the maintenance interval 1 Open the engine hood 2 Loosen screw 1 and pull up net 2 3 Clean net 2 it is to be installed again as i...

Page 325: ...ENANCE MAINTENANCE PROCEDURE 7 Remove undercover 9 and blow the mud dirt and leaves that have been cleaned off to the outside 8 Push in cleaned net 2 back to the original place and secure it with scre...

Page 326: ...ghly before using it again Replace the filter with a new part every year If the clogging of the filter cannot be removed by blowing with air or washing in water replace the filter immediately The RECI...

Page 327: ...led first cover 2 will not close REPLACE BREATHER ELEMENT IN HYDRAULIC TANK WARNING The parts and oil are at high temperature immediately after the engine is stopped and may cause burns Wait for the t...

Page 328: ...ine 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 1 Remove...

Page 329: ...er cartridge always use a genuine Komatsu part The common rail fuel injection system used on this machine consists of more precise parts than the conventional injection pump and nozzle If any part oth...

Page 330: ...er cartridge 2 bleed the air Bleed the air as follows 9 Add fuel to the fuel tank until full to FULL mark on the fuel gauge 10 Insert the key in the starting switch and turn the key to the ON position...

Page 331: ...doing this the cover may fly out under the force of spring 2 so hold the cover down when removing the bolts 4 After removing spring 2 valve 3 and strainer 4 take out element 5 Inspect the bottom of t...

Page 332: ...city 16 5 liters 4 36 US gal 1 Remove cover A of the inspection hole Only demolition specification machine 2 Set a container under drain valve P under the machine body to catch the oil 3 Loosen drain...

Page 333: ...TICE If excess oil is supplied drain it to the specified amount to avoid overheating 3 Install plug P and cap F 4 Close the door CHECK ALL TIGHTENING POINTS OF ENGINE EXHAUST PIPE CLAMPS Please ask yo...

Page 334: ...release the pressure Refill capacity each 9 0 liters 2 38 US gal Prepare a handle 1 Set the TOP mark at the top with the TOP mark and plug P perpendicular to the ground surface 2 Set a container unde...

Page 335: ...d release the internal pressure 2 Loosen 6 bolts then remove cover 1 When doing this the cover may fly out under the force of spring 2 so push the cover down when removing the bolts 3 Hold the top of...

Page 336: ...or weld it Do not hit it roll it or subject it to any impact When disposing of the accumulator the gas must be released Please contact your Komatsu distributor to have this work carried out NOTICE If...

Page 337: ...ipment in the maximum reach posture arm fully out bucket fully dumped at a height A 1 5 m 4 ft 11 in from the ground Carry out Steps 3 5 within 15 seconds When the engine is stopped the pressure in th...

Page 338: ...equipment goes down under its weight and contacts the ground the accumulator is normal If the work equipment does not go down or stops in midway the charged pressure of the gas in the accumulator for...

Page 339: ...essure in the accumulator gradually goes down For this reason the release can only be carried out immediately after the engine is stopped 4 Stop the engine 5 Turn the starting switch to the ON positio...

Page 340: ...ection carried out every 1000 hours CHECK ENGINE VALVE CLEARANCE ADJUST Special tools are needed for inspection and maintenance so contact your Komatsu distributor CHECK VIBRATION DAMPER Check that th...

Page 341: ...e CHECK WATER PUMP Since the pulley may have play oil may leak water may leak and the drain hole A may be clogged contact your Komatsu distributor for inspection overhaul or replacement CHECK STARTING...

Page 342: ...t the operation In addition loosen the bolts slowly when carrying out the operation Do not disassemble the accumulator Do not bring it near flame or dispose of it in fire Do not make holes in it or we...

Page 343: ...f the rubber If there are any loose bolts or hardened rubber please contact your Komatsu distributor for replacement CHECK FOR MISSING FUEL SPRAY PREVENTION CAP HARDENING OF RUBBER Check that there ar...

Page 344: ...a hydraulic breaker the hydraulic oil will deteriorate much faster than during normal bucket operations For details see MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER PAGE 4 17 when carrying out maintena...

Page 345: ...in plug P A be careful not to get oil on yourself First remove drain plug P at the bottom of the tank then remove drain plug A at the suction tube If they are removed in this order almost the same amo...

Page 346: ...2000 and 4000 hours service should be carried out at the same time REPLACE HIGH PRESSURE PIPING CLAMP Contact your Komatsu distributor to have the engine high pressure clamps replaced REPLACE FUEL SP...

Page 347: ......

Page 348: ...5 1...

Page 349: ...9 3 285 10 9 3 285 10 9 3 285 10 9 C Overall width mm ft in 3 190 10 6 3 290 10 10 3 190 10 6 3 290 10 10 D Track width mm ft in 600 1 12 600 1 12 600 1 12 600 1 12 E Height of cab mm ft in 3 145 10 4...

Page 350: ...4 3 7 380 24 3 7 380 24 3 C Max digging height mm ft in 10 100 33 2 10 100 33 2 10 100 33 2 10 100 33 2 D Max vertical wall digging depth mm ft in 6 400 20 12 6 400 20 12 6 400 20 12 6 400 20 12 E Max...

Page 351: ......

Page 352: ...6 1...

Page 353: ...y out operations with the load kept raised by the crane Always use a stand to prevent the load from falling When removing a heavy part consider the balance after it is removed To prevent the machine f...

Page 354: ...and use the L mode for fine control operations Depending on the posture of the work equipment there is the danger that the wire or load may slip off the hook Always be careful to maintain the correct...

Page 355: ...valve Selector valve Attachment control pedal 4 5 6 Lock pin Breaker circuit additional oil filter Accumulator Stop Valve This valve 1 stops the flow of the hydraulic oil F FREE Hydraulic oil flows L...

Page 356: ...ontrol Pedal WARNING Do not carry out operations with your foot on the pedal If the pedal is depressed by mistake the attachment may suddenly move and cause a serious accident Lock the pedal with the...

Page 357: ...E mode on the monitor and set the lock pin to position c NOTICE When using the breaker if the lock pin is set to position c and the pedal is operated in direction D it will cause damage or defective o...

Page 358: ...or weld it Do not hit it roll it or subject it to any impact When disposing of the accumulator the gas must be released Please contact your Komatsu distributor to have this work carried out This accum...

Page 359: ...24 PSI Crusher or other attachment with two way circuit P mode or E mode Return circuit automatically switched so that it passes through control valve When shipped from factory 24 5 MPa 250 kg cm2 355...

Page 360: ...he stop valve piping Two spots on the left and right Be careful not to lose or damage any part that has been removed 2 Connect attachment piping 2 provided by the attachment maker to the part from whi...

Page 361: ...he oil flow is as shown in the diagram below When the front of the pedal is depressed oil flows to the piping on the left side of the work equipment when the rear of the pedal is depressed oil flows t...

Page 362: ...sses dust mask or other protective equipment NOTICE For details of the replacement interval for the element see MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER PAGE 4 17 Prepare a container to catch the oi...

Page 363: ...accumulated in filter case 2 8 Turn filter case 2 to the left remove it then take out element 3 9 Clean the removed parts then install new element 3 Element 3 must be installed facing in the correct...

Page 364: ...lock lever to the FREE position F 3 After carrying out Step 2 operate each work equipment control lever and attachment control pedal fully to the front rear left and right 2 or 3 times within 15 secon...

Page 365: ...the hoses on the attachment side Install the plugs to the two outlets The plugs are used to prevent the attachment from incorrect operation caused by mixing in of foreign matter After the plugs are c...

Page 366: ...with pin A and then pin B 3 Lower the attachment to the ground and stop the engine 4 Turn the starting switch to the ON position B then set the lock lever to the FREE position F 5 After carrying out...

Page 367: ...nlet port respectively Take care that no dust mud etc adheres to the hose mousepiece portions If O ring is damaged replace it with a new one 9 Connect the hose at the attachment side When doing this c...

Page 368: ...e set to B mode insert the lock pin in front only FREE position b Press the front of the pedal to operate the breaker 1 Set the working mode to B mode When switching the working mode see Working Mode...

Page 369: ...e operation manual provided by the attachment manufacturer to operate the attachment correctly LONG TERM STORAGE If the equipment is not to be used for a long time do as follows Set the stop valve in...

Page 370: ...problems with safety so please contact your Komatsu distributor before installing Installing attachments or options without consulting your Komatsu distributor may not only cause problems with safety...

Page 371: ...gging the boom interferes with the undercarriage Operate the boom carefully Categories of use For general digging Digging or loading sand gravel clay etc For light duty digging Digging or loading dry...

Page 372: ...that will cause no problem within the range for flotation and ground contact pressure of the machine If a larger width of the necessary is used there will be a greater load on the track shoe and this...

Page 373: ...ill vary Hence consult your Komatsu distributor for the selection of optimum attachments HYDRAULIC BREAKER Main Applications Crushed rock Demolition work Road construction This attachment can be used...

Page 374: ...direction of the breaker body will graduallymove out of line with each other always adjust the bucket cylinder to keep them aligned Always keep the chisel pressed against the impact surface properly t...

Page 375: ...RECOMMENDED ATTACHMENT OPERATIONS Operations using the swing force Moving the chisel while carrying out impacting operations Holding the chisel horizontal or pointed up when carrying out impacting ope...

Page 376: ...he machine off the ground Greasing Supply grease in the correct position NOTICE If the breaker is greased in an improper posture it is filled with more grease than necessary As a result soil and sand...

Page 377: ...KOMTRAX equipment or the machine itself Your Komatsu distributor will carry out removal and installation of KOMTRAX Do not allow cables or cords to become caught do not damage or pull cables or cords...

Page 378: ...NK 3 109 G GENERAL OPERATION INFORMATION 3 162 GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE 2 12 DO NOT GET CAUGHT IN WORK EQUIPMENT 2 17 FIRE PREVENTION 2 14 PRECAUTIONS BEFORE STARTING OP...

Page 379: ...WHEN REQUIRED 4 19 MAINTENANCE SCHEDULE 4 15 MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER 4 17 MAINTENANCE SCHEDULE CHART 4 15 MONITORING SYSTEM 3 5 O OUTLINE OF SERVICE 4 4 P PARKING MACHINE 3 173 PREC...

Page 380: ...ES 3 164 TROUBLES AND ACTIONS 3 195 DISCHARGED BATTERY 3 199 LIGHTWEIGHT TOWING HOLE 3 198 OTHER TROUBLE 3 203 PHENOMENA THAT ARE NOT FAILURES 3 196 RUNNING OUT OF FUEL 3 195 SEVERE JOB CONDITION 3 19...

Page 381: ...PC300 8 PC300LC 8 PC350 8 PC350LC 8 HYDRAULIC EXCAVATOR Form No TEN00380 00 2009 KOMATSU All Rights Reserved Printed in Japan 07 09...

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