Komatsu PC300-5 Operation Manual (EN)

FOREWORD

FOREWORD This manual describes procedures for operation, handling, lubrication, maintenance, checking, and adjustment. It will help the operator or anyone realize peak performance through effective, economical and safe machine operation and maintenance. Please read this manual carefully BEFORE operating the machine. Please continue studying this manual until proper operation is completely reinforced into personal habit. This manual describes the basic techniques. Skill is performed as the operator or anyone get the correct knowledge and performance of the machine. Operation, inspection, and maintenance should be carefully carried out, and the safety must be given the first priority.

Safety precautions are indicated with A marks and technical precautions with * marks in this manual. The safety information contained in this manual is intended only to supplement safety codes, insurance requirements, local laws, rules and regulations. Some illustration pictures are different from your machine as technical improvement is continuously reflected on it. Revision to up-to-date manual’s content is performed in later editions. This operation & maintenance manual may contain attachments and optional equipment that are not available in your area. Please consult your local Komatsu distributor for those items you may require.

Materials and specifications are subject to change without notice. -l-

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FOREWORD

BREAKING IN YOUR NEW MACHINE Each machine is carefully adjusted and tested before shipment. However, a new machine requires careful operation during the first 100 hours to break in the various parts. If a machine is subjected to unreasonably hard use at the initial operation stage, the potential of performance will prematurely deteriorate and the ser- vice life will be reduced. A new machine must be operated with care, par- ticularly with regard to the following items. After starting, let the engine idle for 5 minutes to allow proper engine warm-up prior to actual operation. Avoid operation with heavy loads or at high speeds.

Sudden starting or acceleration, unnecessarily abrupt braking and sharp turning should be avoided. During the initial 100 hours, the work equipment fixing pins are to be greased before each operation. Greasing is to be repeated after operation of the boom, arm and bucket is conducted several times. If the machine is delivered without any cooling water in the radiator, flush the cooling system with ample clean water to clean the system, then fill the radiator with cooling water. When replacing oil filter elements (cartridges), check their interiors for dirt and dust. If heavily collected, check for possible cause before starting operation.

Hours of operation are indicated by the service meter. -2-

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CONTENTS

CONTENTS OPERATION GENERAL LOCATIONS AND SPECIFICATIONS ............ INSTRUMENTS AND CONTROLS ........................ METHOD OF USING MODE SELECTOR SWITCHES ....... CHECK BEFORE STARTING .............................. OPERATING YOUR MACHINE ............................ INVERSION AND REPLACEMENT OF BUCKET ............ HANDLING THE TRAPEZOIDAL BUCKET (EXCEPT PC300, 3OOLC-5 MIGHTY) .................... HANDLING THE CLAMSHELL BUCKET (EXCEPT PC300, 3OOLC-5 MIGHTY) .................... SELECTION OF TRACK SHOES (EXCEPT PC300, 3OOLC-5 MIGHTY) .................... SELECTION OF BUCKET TEETH .......................... TRANSPORTATION .....................................

INSTALLATION OF OPTIONAL ELECTRICAL EQUIPMENT . COLD WEATHER OPERATION ........................... .............. .............. . 4 . 6 . 46 . 50 . 56 . 80 .............. .............. . 82 . . . . . . . . . . . . . . . 82 . . . . . . . . . . . . . . ..*....*...... ..**....*..... . 84 . 86 . 88 98 . 100 MAINTENANCE PERIODIC MAINTENANCE ................................................ 109 PRECAUTIONS WHEN DISASSEMBLING MACHINE ..................... 110 BLEEDING AIR FROM CIRCUIT ......................................... 112 PERIODICAL REPLACEMENT OF SAFETY PARTS ....................... 116 MAINTENANCE TABLE ................................................

120 OIL FILLER AND LEVEL GAUGE POSITIONS ............................ 124 EVERY 100 HOURS SERVICE ........................................... 126 EVERY 250 HOURS SERVICE ........................................... 132 EVERY 500 HOURS SERVICE ........................................... 140 EVERY 1000 HOURS SERVICE .......................................... 144 EVERY 2000 HOURS SERVICE .......................................... 148 EVERY 4000 HOURS SERVICE .......................................... 153 WHEN REQUIRED ..................................................... 154 ADJUSTMENT ...........................................................

172 TROUBLE SHOOTING GUIDE ............................................. 174 SERVICE METER ......................................................... 184 MACHINE AND ENGINE SERIAL NUMBERS ............................... 186 FUEL, COOLANT AND LUBRICANTS ...................................... 188 -3-

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GENERAL LOCATIONS AND SPECIFICATIONS

GENERAL LOCATIONS AND SPECIFICATIONS 1. Bucket 2. Bucket cylinder 3. Arm 4. Arm cylinder 5. Boom 6. Boom cylinder 7. Sprocket 8. Track frame 9. Idler IO. Track shoe MACHINE MODEL PC300 PC!JOOLC5 6. PC300-5 PC3OOLC5 PC300HD -5 PC3COLC5K MIGHTY MIGHTY -5 PERFORMANCE WE1 1.32 1.32 1.32 1.32 1.32 Bucket capacity (m3) [CECE] 1.2 1.2 1.2 1.2 1.2 Travel speed (km/h) Hi 5.5 5.5 5.5 5.5 4.4 Lo 3.4 3.4 3.4 3.4 2.5 Swing speed (rpm) IO 10 10 IO IO OPERATING WEIGHT (kg) 29800 31000 30400 31200 36000 ENGINE Model Flywheel horsepower (HP) 207 207 207 207 207 [Rated rpm] [I9501 [I9501 [I9501 [I 9501 [I9501 Komatsu SA6D108 Diesel Engine NOTE: Specifications are subject to change without notice. -4-

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