PC300LC-6 PC300HD-6
HYDRAULICEXCAVATOR
SERIALNUMBERSPC300LC-6-A83001andup
SERIALNUMBERSPC300HD-6-A83001andup
ThismaterialisproprietarytoKomatsuAmericaInternationalCompanyandisnottobereproduced,used,ordisclosed exceptinaccordancewithwrittenauthorizationfromKomatsuAmericaInternationalCompany.
Itisourpolicytoimproveourproductswheneveritispossibleandpracticaltodoso.Wereservetherighttomake changesoraddimprovementsatanytimewithoutincurringanyobligationtoinstallsuchchangesonproductssold previously.
Duetothiscontinuousprogramofresearchanddevelopment,periodicrevisionsmaybemadetothispublication.Itis recommendedthatcustomerscontacttheirdistributorforinformationonthelatestrevision.
TheaffectedpagesareindicatedbyusingtheMarkIndicationAction followingmarks.Itisrequestedthatnecessaryactions betakentothesepagesaccordingtothetablebelow.•NewpagetobeaddedAdd •PagetobereplacedReplace ()PagetobedeletedDiscard Pageswithoutmarkswerepreviousadditionsorrevised pages.
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VARIOUSPRODUCTPARTS&SERVICEPUBLICATIONSAREAVAILABLETOALLKOMATSUCONSTRUCTION EQUIPMENTOWNERS,INCLUDINGOPERATIONANDMAINTENANCEMANUALS,PARTSBOOKSANDSHOP MANUALS.
SPECIALPUBLICATIONSSUCHASSERVICETOOL,AIRCONDITIONING,ANDTURBOCHARGERSERVICE MANUALSAREALSOAVAILABLEASWELLASSELECTEDOPERATION&SERVICEMANUALSINFOREIGN LANGUAGES.
THEPUBLICATIONSLISTEDBELOWAREAVAILABLEFORTHISPARTICULARMACHINE(S).
PARTSANDSERVICEPUBLICATIONSCANONLYBEACQUIREDBYAUTHORIZEDKOMATSUDISTRIBUTORS, USINGTHEKOMATSUAMERICAINTERNATIONALCOMPANYPARTSINVENTORYPROCESSINGSYSTEM (PIPS).
IFTHEPIPSSYSTEMISNOTAVAILABLEATTHEDISTRIBUTORLOCATION,THENTHEFOLLOWING REQUISITIONFORTECHNICALSERVICEPUBLICATIONSANDSERVICEFORMSCANBEUSED.FORMKDC91D ISSHOWNONTHEREVERSESIDEOFTHISPAGE.
COMPLETEFORM ANDRETURNTO
KomatsuAmericaInternationalCompany
440NorthFairwayDrive
VernonHills,IL60061-8112U.S.A.
Attn:TechnicalPublications
FaxNo.(847)970-4186
TelNo.(847)970-5887
COMPANYNAME
SHIPTO TYPEorPRINT ONLY
ATTN.
STREET
IMPORTANT-TOASSURESHIPMENTOFTHECORRECTPUBLICATION(S),THEMODELNUMBERANDMACHINE SERIALNUMBERMUSTBESHOWN.
SAFETY
SAFETYNOTICE
IMPORTANTSAFETYNOTICE
Properserviceandrepairisextremelyimportantforthesafeoperationofyourmachine.Theserviceandrepair techniquesrecommendedanddescribedinthismanualarebotheffectiveandsafemethodsofoperation. Someoftheseoperationsrequiretheuseoftoolsspeciallydesignedforthepurpose.
Topreventinjurytoworkers,thesymbolsandareusedtomarksafetyprecautionsinthismanual.The cautionsaccompanyingthesesymbolsshouldalwaysbefollowedcarefully.Ifanydangeroussituationarises ormaypossiblyarise,firstconsidersafety,andtakethenecessaryactionstodealwiththesituation.
GENERALPRECAUTIONSPREPARATIONSFORWORK
Mistakesinoperationareextremelydangerous.Readthe7.Beforeaddingoilormakingrepairs,parkthemaOPERATION&MAINTENANCEMANUALcarefullychineonhard,levelground,andblockthewheelsor BEFOREoperatingthemachine.trackstopreventthemachinefrommoving.
1.Beforecarryingoutanygreasingorrepairs,readall8.Beforestartingwork,lowerblade,ripper,bucketor theprecautionsgivenonthedecalswhicharefixedtoanyotherworkequipmenttotheground.Ifthisisnot themachine.possible,insertthesafetypinoruseblockstoprevent
theworkequipmentfromfalling.Inaddition,besure
2.Whencarryingoutanyoperation,alwayswearsafetytolockallthecontrolleversandhangwarningsigns shoesandhelmet.Donotwearlooseworkclothes,onthem. orclotheswithbuttonsmissing.
•Alwayswearsafetyglasseswhenhittingpartsmachinewithblocks,jacksorstandsbeforestarting withahammer.work.
•Alwayswearsafetyglasseswhengrindingparts10.Removeallmudandoilfromthestepsorother withagrinder,etc.placesusedtogetonandoffthemachine.Always
9.Whendisassemblingorassembling,supportthe usethehandrails,laddersorstepswhengettingonor
3.Ifweldingrepairsareneeded,alwayshaveatrained,offthemachine.Neverjumponoroffthemachine. experiencedweldercarryoutthework.Whencarry-Ifitisimpossibletousethehandrails,laddersor ingoutweldingwork,alwayswearweldinggloves,steps,useastandtoprovidesafefooting. apron,glasses,capandotherclothessuitedfor weldingwork.
PRECAUTIONSDURINGWORK
4.Whencarryingoutanyoperationwithtwoormore11.Whenremovingtheoilfillercap,drainplugorhyworkers,alwaysagreeontheoperatingproceduredraulicpressuremeasuringplugs,loosenthem beforestarting.Alwaysinformyourfellowworkersslowlytopreventtheoilfromspurtingout.Before beforestartinganystepoftheoperation.Beforedisconnectingorremovingcomponentsoftheoil, startingwork,hangUNDERREPAIRsignsonthewateroraircircuits,firstremovethepressurecomcontrolsintheoperator'scompartment.pletelyfromthecircuit.
5.Keepalltoolsingoodconditionandlearnthecorrect12.Thewaterandoilinthecircuitsarehotwhenthe waytousethem.engineisstopped,sobecarefulnottogetburned.
Waitfortheoilandwatertocoolbeforecarryingout
6.Decideaplaceintherepairworkshoptokeeptoolsanyworkontheoilorwatercircuits. andremovedparts.Alwayskeepthetoolsandparts intheircorrectplaces.Alwayskeeptheworkarea13.Beforestartingwork,removetheleadsfromthe cleanandmakesurethatthereisnodirtoroilonthebattery.ALWAYSremovetheleadfromthenegative floor.Smokeonlyintheareasprovidedforsmoking.(-)terminalfirst. Neversmokewhileworking.
14.Whenraisingheavycomponents,useahoistor•Wheninstallinghosesandwires,besurethatthey crane.Checkthatthewirerope,chainsandhookswillnotbedamagedbycontactwithotherpartswhen arefreefromdamage.Alwaysuseliftingequipmentthemachineisbeingoperated. whichhasamplecapacity.Installtheliftingequipment atthecorrectplaces.Useahoistorcraneand20.Wheninstallinghighpressurehoses,makesurethat operateslowlytopreventthecomponentfromhittingtheyarenottwisted.Damagedtubesaredangerous, anyotherpart.Donotworkwithanypartstillraisedsobeextremelycarefulwheninstallingtubesforhigh bythehoistorcrane.pressurecircuits.Alsocheckthatconnectingparts
15.Whenremovingcoverswhichareunderpressureor underpressurefromaspring,alwaysleavetwobolts21.Whenassemblingorinstallingparts,alwaysusethe inpositiononoppositesides.Slowlyreleasethespecifiedtighteningtorques.Wheninstallingprotecpressure,thenslowlyloosentheboltstoremove.tivepartssuchasguards,orpartswhichvibrate
16.Whenremovingcomponents,becarefulnottobreakcarefultocheckthattheyareinstalledcorrectly. ordamagethewiring,Damagedwiringmaycause electricalfires.22.Whenaligningtwoholes,neverinsertyourfingersor
17.Whenremovingpiping,stopthefueloroilfromhole. spillingout.Ifanyfueloroildripsontothefloor,wipe itupimmediately.Fueloroilonthefloorcancause23.Whenmeasuringhydraulicpressure,checkthatthe youtoslip,orcanevenstartfires.measuringtooliscorrectlyassembledbeforetaking
18.Asageneralrule,donotusegasolinetowashparts. Inparticular,useonlytheminimumofgasolinewhen24.Takecarewhenremovingorinstallingthetracksof washingelectricalparts.track-typemachines.Whenremovingthetrack,the
19.Besuretoassembleallpartsagainintheiroriginalateitherendofthetrack. places.Replaceanydamagedpartwithnewparts. arecorrectlyinstalled. violentlyorrotateathighspeed,beparticularly hand.Becarefulnottogetyourfingerscaughtina anymeasurements. trackseparatessuddenly,soneverletanyonestand
GENERAL
Thisshopmanualhasbeenpreparedasanaidtoimprovethequalityofrepairsbygivingtheservicemananaccurate understandingoftheproductandbyshowinghimthecorrectwaytoperformrepairsandmakejudgements.Makesure youunderstandthecontentsofthismanualanduseittofulleffectateveryopportunity.
Thisshopmanualmainlycontainsthenecessarytechnicalinformationforoperationsperformedinaserviceworkshop. Foreaseofunderstanding,themanualisdividedintothefollowingsections.Thesesectionsarefurtherdividedintoeach maingroupofcomponents.
GENERAL
Thissectionliststhegeneralmachinedimensions,performancespecifications,componentweights,andfuel, coolantandlubricantspecificationcharts.
STRUCTUREANDFUNCTION
Thissectionexplainsthestructureandfunctionofeachcomponent.Itservesnotonlytogiveanunderstanding ofthestructure,butalsoservesasreferencematerialfortroubleshooting.
TESTING,ADJUSTINGANDTROUBLESHOOTING
Thissectionexplainscheckstobemadebeforeandafterperformingrepairs,aswellasadjustmentstobe madeatcompletionofthechecksandrepairs.Troubleshootingchartscorrelating"Problems"to"Causes"are alsoincludedinthissection.
DISASSEMBLYANDASSEMBLY
Thissectionexplainstheordertobefollowedwhenremoving,installing,disassemblingorassemblingeach component,aswellasprecautionstobetakenfortheseoperations.
MAINTENANCESTANDARD
Thissectiongivesthejudgementstandardswheninspectingdisassembledparts.
NOTICE
Thespecificationscontainedinthisshopmanualaresubjecttochangeatanytimeandwithoutanyadvance notice.Contactyourdistributorforthelatestinformation.
HOWTOREADTHESHOPMANUAL
VOLUMES
Shopmanualsareissuedasaguidetocarryingout repairs.Theyaredividedasfollows:
Chassisvolume:Issuedforeverymachinemodel
Enginevolume:Issuedforeachengineseries
Electricalvolume:Eachissuedasonetocoverall models
Attachmentvolume:Eachissuedasonetocoverall models
Thesevariousvolumesaredesignedtoavoidduplication ofinformation.Thereforetodealwithallrepairsforany model,itisnecessarythatchassis,engine,electricaland attachmentbeavailable.
DISTRIBUTIONANDUPDATING
Anyadditions,amendmentsorotherchangeswillbesent toyourdistributor.Getthemostup-to-dateinformation beforeyoustartanywork.
FILINGMETHOD
1.Seethepagenumberonthebottomofthepage.File thepagesincorrectorder.
2.Followingexamplesshowhowtoreadthepage number:
Example1(Chassisvolume):
10-3
REVISEDEDITIONMARK
Whenamanualisrevised,aneditionmark(....)is recordedonthebottomoutsidecornerofthepages.
REVISIONS
RevisedpagesareshownattheLISTOFREVISED PAGESbetweenthetitlepageandSAFETYpage.
SYMBOLS
Sothattheshopmanualcanbeofamplepracticaluse, importantplacesforsafetyandqualityaremarkedwith thefollowingsymbols.
SymbolItemRemarks
SafetySpecialsafetyprecautionsarenecessarywhenperformingthework.
Caution
Weight
Tightening torque
Coat
Oil,water
Specialtechnicalprecautionsorother precautionsforpreservingstandards arenecessarywhenperformingthe work.
Weightofpartsorsystems.Caution necessarywhenselectinghoisting wireorwhenworkingpostureis important,etc.
Placesthatrequirespecialattention fortighteningtorqueduringassembly.
Placestobecoatedwithadhesives andlubricantsetc.
Placeswhereoil,waterorfuelmust
beadded,andthe Itemcapacity. number(10.Structure andFunction)
Consecutivepagenumber foreachitem
Example2(Enginevolume):
Refertothepertinentenginemanual.
3.Additionalpages:Additionalpagesareindicatedbya hyphen(-)andnumberedafterthepagenumber.File asintheexample.
Example: 10-4
10-4-1Addedpages10-4-2 10-5
Drain
Placeswhereoilorwatermustbe drained,andquantitytobedrained.
HOISTINGINSTRUCTIONS
HOISTING
Heavyparts(25kgormore)mustbeliftedwith ahoistetc.IntheDISASSEMBLYANDASSEMBLYsection,everypartweighing25kgormore isindicatedclearlywiththesymbol
•Ifapartcannotbesmoothlyremovedfromthe machinebyhoisting,thefollowingchecksshouldbe made:
1)Checkforremovalofallboltsfasteningthepart totherelativeparts.
2)Checkforexistenceofanotherpartcausing interfacewiththeparttoberemoved.
WIREROPES
1)Useadequateropesdependingontheweightofparts tobehoisted,referringtothetablebelow:
Wireropes
(Standard"Z"or"S"twistropeswithoutgalvanizing
Ropediameter(mm)Allowableload(tons)
3)Donotslingaheavyloadwithoneropealone,but slingwithtwoormoreropessymmetricallywoundon totheload.
Slingingwithoneropemaycauseturningof theloadduringhoisting,untwistingoftherope, orslippingoftheropefromitsoriginalwindingpositionontheload,whichcanresultinadangerous accident.
4)Donotslingaheavyloadwithropesformingawide hanginganglefromthehook.Whenhoistingaload withtwoormoreropes,theforcesubjectedtoeach ropewillincreasewiththehangingangles.Thetable belowshowsthevariationofallowableload(kg) whenhoistingismadewithtworopes,eachofwhich isallowedtoslingupto1000kgvertically,atvarious hangingangles.Whentworopesslingaloadvertically,upto2000kgoftotalweightcanbe suspended.Thisweightbecomes1000kgwhentwo ropesmakea120hangingangle.Ontheother hand,tworopesaresubjecttoanexcessiveforceas largeas4000kgiftheyslinga2000kgloadata liftingangleof150
Theallowableloadvalueisestimatedtobe1/6or 1/7ofthebreakingstrengthoftheropeused.
2)Slingwireropesfromthemiddleportionofthehook. Slingingneartheedgeofthehookmaycausethe ropetoslipoffthehookduringhoisting,andaserious accidentcanresult.Hookshavemaximumstrength atthemiddleportion.
COATINGMATERIALS
Therecommendedcoatingmaterialsprescribedintheshopmanualsarelistedbelow.
CategoryCodePartNo.QtyContainerMainapplications,features
LT-1A790-129-9030150gTube
•Usedtopreventrubbergaskets,rubbercushionsandcorkplugs fromcomingout
LT-1B790-129-905020g(x2)Usedforplastics(exceptpolyethylene, Polyethylenepolypropylene, container
•Usedinplacesrequiringanimmediatelyeffective,strongadhesive. tetrafluoroethylene,andvinylchloride),rubber,metalandnon-metal.
LT-209940-0003050gPolyethylene•Features:Resistancetoheat,chemicals container•Usedforanti-looseningandsealantpurposesforboltsandplugs.
LT-3HardagtCan•Usedasadhesiveorsealantformetal,glassorplastic.
790-129-9060 Setofadhesive andhardening agent Adh1kg 500kg
AdhesivePolyethylene
LT-4790-129-9040250g•Usedassealantformachined containerholes.
Holtz MH705
790-126-912075gTube•Usedasheatresistingsealantforrepairingengine.
•Quickhardeningtypeadhesive.
ThreePolyethylene bond1735container 790-129-914050g•Curetime:5sec.to3min.
•Usedmainlyforadhesionofmetals,rubbers,plasticsandwoods.
•Quickhardeningtypeadhesive.
Aron-alphaPolyethylene 201container 790-129-91302g•Quickcuretime,max.strengthafter30minutes.
•Usedmainlyforadhesionofmetals,rubbersandplastics.
LoctitePolyethylene•Features:Resistancetoheat,chemicals 648-50container•Usedatjointportionssubjecttohigh 79A-129-911050temperature. cc
LG-1790-129-9010200gTube
Gasket
Molybdenum disulfide lubricant
•Usedasadhesiveorsealantforgasketsandpackingofpowertrain case,etc.
•Features:Resistancetoheat
•Usedassealantforflangesurfacesandboltsathightemperature
LG-3790-129-90701kgCanlocations;usedtopreventseizure.
•Usedassealantforheatresistantgasketforathightemperature locationssuchasenginepre-combustionchamber,exhaustpipe.
•Features:Resistancetowater,oil
•Usedassealantforflangesurface,thread.
LG-4790-129-9020200gTube•Alsopossibletouseassealantforflangeswithlargeclearance.
•Usedassealantformatingsurfacesoffinaldrivecase,transmission case.
LG-5790-129-90801kg•Usedassealantfortaperedplugs,elbows,nipplesof Polyethylenehydraulic container
•Usedassealantforvariousthreads,pipejoints,flanges. piping.
•Features:Siliconbased,resistanttoheat,cold.
LG-609940-00011250gTube•Usedassealantforflangesurface,thread.
•Usedassealantforoilpan,finaldrivecase,etc.
LG-709920-00150150gTube•Usedassealantforflywheelhousing,intakemanifold,oilpan,
•Features:Siliconbased,quickhardeningtype. thermostathousing,etc.
Three bond1211790-129-9090100gTube•Usedasheatresistingsealantforrepairingengine.
LM-G09940-0005160gCan•Usedaslubricantforslidingparts(topreventsqueaking).
•Usedtopreventseizureorscuffingofthethreadwhenpressfitting
LM-P09940-00040200gTubeorshrinkfitting.
•Usedaslubricantforlinkage,bearings,etc.
SYG-350Ll
SYG-400Ll
LithiumgreaseG2-L1SYG-400Ll-AVariousVarious•Generalpurposetype
SYG-160Ll
SYGA-160CNLl