Komatsu Pc100-6, Pc120-6, Pc130-6 Mighty Hydraulic Excavator Operation & Maintenance Manual – PDF DOWNLOAD

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Komatsu Pc100-6, Pc120-6, Pc130-6 Mighty Hydraulic Excavator Operation & Maintenance Manual

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Komatsu Pc100-6, Pc120-6, Pc130-6 Mighty Hydraulic Excavator Operation & Maintenance Manual 

Model Specification: KOMATSU PC100-6, PC120-6, PC130-6 MIGHTY HYDRAULIC EXCAVATOR
Language: English
File Format: PDF
Total Pages: 257
Requirements: Adobe PDF Reader
ZOOM IN/OUT: YES
Downloadable: YES

KOMATSU PC100-6, PC120-6, PC130-6 MIGHTY HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL – PDF DOWNLOAD:

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DESCRIPTION:

Komatsu Pc100-6, Pc120-6, Pc130-6 Mighty Hydraulic Excavator Operation & Maintenance Manual 

FOREWORD:

• This manual provides rules and guidelines which will help you use this machine safely and effectively. Keep this manual handy and have all personnel read it periodically. If this manual has been lost or has become dirty and can not be read, request a replacement manual from Komatsu or your Komatsu distributor.
• If you sell the machine, be sure to give this manual to the new owners. Continuing improvements in the design of this machine can lead to changes in detail which may not be reflected in this manual.
• Consult Komatsu or your Komatsu distributor for the latest available information of your machine or for questions regarding information in this manual. This manual may contain attachments and optional equipment that are not available in your area. Consult Komatsu or your Komatsu distributor for those items you may require.

TABLE OF CONTENTS:

Komatsu Pc100-6, Pc120-6, Pc130-6 Mighty Hydraulic Excavator Operation & Maintenance Manual 

MAIN MENU............................................................................................................................  0
COVER................................................................................................................................  1
1. FOREWORD..........................................................................................................................  4
2. SAFETY INFORMATION................................................................................................................  5
3. INTRODUCTION......................................................................................................................  6
4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR.....................................................................  7
5. CONTENTS..........................................................................................................................  8
SAFETY............................................................................................................................... 12
	6. GENERAL PRECAUTIONS........................................................................................................... 13
	7. PRECAUTIONS DURING OPERATION.................................................................................................. 19
		7.1 BEFORE STARTING ENGINE................................................................................................... 19
		7.2 OPERATING MACHINE........................................................................................................ 21
		7.3 TRANSPORTATION........................................................................................................... 26
		7.4 BATTERY.................................................................................................................. 27
		7.5 TOWING................................................................................................................... 28
		7.6 BUCKET WITH HOOK......................................................................................................... 29
	8. PRECAUTIONS FOR MAINTENANCE................................................................................................... 32
		8.1 BEFORE CARRYING OUT MAINTENANCE.......................................................................................... 32
		8.2 DURING MAINTENANCE....................................................................................................... 35
	9. POSITION FOR ATTACHING SAFETY LABELS.......................................................................................... 39
OPERATION............................................................................................................................ 44
	10. GENERAL VIEW................................................................................................................. 45
		10.1 GENERAL VIEW OF MACHINE................................................................................................. 45
		10.2 GENERAL VIEW OF CONTROLS AND GAUGES..................................................................................... 46
	11. EXPLANATION OF COMPONENTS.................................................................................................... 47
		11.1 MACHINE MONITOR......................................................................................................... 47
		11.2 METER................................................................................................................... 58
		11.3 SWITCHES................................................................................................................ 59
		11.4 CONTROL LEVERS, PEDALS.................................................................................................. 64
		11.5 CEILING WINDOW.......................................................................................................... 69
		11.6 FRONT WINDOW............................................................................................................ 70
		11.7 DOOR LOCK............................................................................................................... 72
		11.8 CAP, COVER WITH LOCK.................................................................................................... 73
		11.9 HOT/COOL BOX............................................................................................................ 74
		11.10 LUGGAGE BOX............................................................................................................ 74
		11.11 ASHTRAY................................................................................................................ 74
		11.12 AIR CONDITIONER........................................................................................................ 75
		11.13 CAR RADIO.............................................................................................................. 78
		11.14 FUSE................................................................................................................... 82
		11.15 FUSIBLE LINK........................................................................................................... 83
		11.16 CONTROLLERS............................................................................................................ 83
		11.17 TOOL BOX............................................................................................................... 83
		11.18 GREASE PUMP HOLDER..................................................................................................... 83
	12. OPERATION.................................................................................................................... 84
		12.1 CHECK BEFORE STARTING ENGINE............................................................................................ 84
		12.2 STARTING ENGINE......................................................................................................... 94
		12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE............................................................................. 97
		12.4 MOVING MACHINE OFF......................................................................................................103
		12.5 STEERING MACHINE........................................................................................................106
		12.6 STOPPING MACHINE........................................................................................................108
		12.7 SWINGING................................................................................................................109
		12.8 OPERATION OF WORK EQUIPMENT.............................................................................................110
		12.9 WORKING MODE SELECTION..................................................................................................111
		12.10 PROHIBITIONS FOR OPERATION.............................................................................................113
		12.11 PRECAUTIONS FOR OPERATION..............................................................................................115
		12.12 PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS............................................................................116
		12.13 HOW TO ESCAPE FROM MUD.................................................................................................118
		12.14 WORK POSSIBLE USING HYDRAULIC EXCAVATOR................................................................................119
		12.15 REPLACEMENT AND INVERSION OF BUCKET....................................................................................120
		12.16 PARKING MACHINE........................................................................................................122
		12.17 CHECK AFTER FINISHING WORK.............................................................................................123
		12.18 STOPPING ENGINE........................................................................................................124
		12.19 CHECK AFTER STOPPING ENGINE............................................................................................125
		12.20 LOCKING................................................................................................................125
	13. TRANSPORTATION...............................................................................................................126
		13.1 LOADING, UNLOADING WORK.................................................................................................126
		13.2 PRECAUTIONS FOR LOADING.................................................................................................128
		13.3 PRECAUTIONS FOR TRANSPORTATION..........................................................................................129
	14. COLD WEATHER OPERATION.......................................................................................................131
		14.1 PRECAUTIONS FOR LOW TEMPERATURE.........................................................................................131
		14.2 PRECAUTIONS  AFTER COMPLETION OF WORK...................................................................................133
		14.3 AFTER COLD WEATHER......................................................................................................133
	15. LONG-TERM STORAGE............................................................................................................134
		15.1 BEFORE STORAGE..........................................................................................................134
		15.2 DURING STORAGE..........................................................................................................135
		15.3 AFTER STORAGE...........................................................................................................135
		15.4 STARTING MACHINE AFTER LONG-TERM STORAGE................................................................................135
	16. TROUBLESHOOTING..............................................................................................................136
		16.1 PHENOMENA THAT ARE NOT FAILURES.........................................................................................136
		16.2 METHOD OF TOWING MACHINE................................................................................................136
		16.3 USING METHOD FOR LIGHT-WEIGHT TOWING HOOK...............................................................................136
		16.4 PRECAUTIONS ON PARTICULAR JOBSITES......................................................................................137
		16.5 IF BATTERY IS DISCHARGED................................................................................................137
		16.6 OTHER TROUBLE...........................................................................................................141
MAINTENANCE..........................................................................................................................146
	17. GUIDES TO MAINTENANCE........................................................................................................147
	18. OUTLINES OF SERVICE..........................................................................................................149
		18.1 OUTLINE OF OIL, FUEL, COOLANT...........................................................................................149
		18.2 OUTLINE OF ELECTRIC SYSTEM..............................................................................................152
		18.3 OUTLINE OF HYDRAULIC SYSTEM.............................................................................................153
	19. WEAR PARTS LIST..............................................................................................................154
	20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE.........................................................155
	21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS...............................................................................159
		21.1 INTRODUCTION OF NECESSARY TOOLS.........................................................................................159
		21.2 TORQUE LIST.............................................................................................................160
	22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS................................................................................161
	23. MAINTENANCE SCHEDULE CHART...................................................................................................163
		23.1 MAINTENANCE SCHEDULE CHART..............................................................................................163
		23.2 MAINTENANCE WHEN USING HYDRAULIC BREAKER................................................................................165
	24. SERVICE PROCEDURE............................................................................................................166
		24.1 INITIAL 250 HOURS SERVICE...............................................................................................166
			REPLACE FUEL FILTER CARTRIDGE............................................................................................166
			CHECK ENGINE VALVE CLEARANCE, ADJUST.....................................................................................166
		24.2 WHEN REQUIRED...........................................................................................................167
			CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT.............................................................................167
			CLEAN INSIDE OF COOLING SYSTEM...........................................................................................169
			CHECK AND TIGHTEN TRACK SHOE BOLTS.......................................................................................173
			CHECK AND ADJUST TRACK TENSION...........................................................................................174
			CHECK ELECTRICAL INTAKE AIR HEATER.......................................................................................176
			REPLACE BUCKET TEETH (VERTICAL PIN TYPE).................................................................................177
			REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)...............................................................................180
			ADJUST BUCKET CLEARANCE..................................................................................................181
			CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID...............................................................................182
			CHECK AND ADJUST AIR CONDITIONER.........................................................................................183
			REPLACE ADDITIONAL BREAKER FILTER ELEMENT................................................................................184
		24.3 CHECK BEFORE STARTING...................................................................................................185
			CHECK COOLANT LEVEL, ADD WATER...........................................................................................185
			CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL...............................................................................185
			CHECK FUEL LEVEL, ADD FUEL...............................................................................................186
			CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL...............................................................................187
			CHECK AIR CLEANER FOR CLOGGING...........................................................................................188
			CHECK ELECTRIC WIRINGS...................................................................................................188
			CHECK FOR WATER AND SEDIMENT IN WATER SEPARATOR, DRAIN WATER.............................................................188
		24.4 EVERY 50 HOURS SERVICE..................................................................................................189
			DRAIN WATER AND SEDIMENT FROM FUEL TANK..................................................................................189
		24.5 EVERY 100 HOURS SERVICE.................................................................................................190
			LUBRICATING..............................................................................................................190
				BOOM CYLINDER FOOT PIN (2 POINTS)....................................................................................190
				BOOM FOOT PIN (2 POINTS).............................................................................................190
				BOOM CYLINDER ROD END (2 POINTS).....................................................................................190
				ARM CYLINDER FOOT PIN (1 POINT)......................................................................................191
				BOOM-ARM COUPLING PIN (1 POINT)......................................................................................191
				ARM CYLINDER ROD END (1 POINT).......................................................................................191
				BUCKET CYLINDER FOOT PIN (1 POINT)...................................................................................191
				ARM-LINK COUPLING PIN (1 POINT)......................................................................................191
				ARM-BUCKET COUPLING PIN (1 POINT)....................................................................................191
				LINK COUPLING PIN (1 POINT)..........................................................................................191
				BUCKET CYLINDER ROD END (1 POINT)....................................................................................191
				BUCKET-LINK COUPLING PIN (2 POINTS)..................................................................................191
				CHECK OIL LEVEL IN SWING MACHINERY CASE, ADD OIL.....................................................................192
		24.6 EVERY 250 HOURS SERVICE.................................................................................................193
			CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL.............................................................................193
			CHECK LEVEL OF BATTERY ELECTROLYTE.......................................................................................194
			CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE........................................................195
			REPLACE HYDRAULIC FILTER ELEMENT.........................................................................................196
			CHECK FAN BELT TENSION, ADJUST...........................................................................................198
			CHECK, ADJUST TENSION AIR CONDITIONER COMPRESSOR BELT....................................................................199
		24.7 EVERY 500 HOURS SERVICE.................................................................................................200
			REPLACE FUEL FILTER CARTRIDGE............................................................................................200
			CHECK SWING PINION GREASE LEVEL, ADD GREASE..............................................................................202
			LUBRICATE SWING CIRCLE (2 POINTS)........................................................................................202
			CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS AND CONDENSER FINS (ONLY FOR MACHINES EQUIPPED WITH AIR CONDITIONER)....203
			CLEAN INTERNAL AND EXTERNAL AIR FILTER OF AIR CONDITIONER SYSTEM (ONLY FOR MACHINES EQUIPPED WITH AIR CONDITIONER).......204
		24.8 EVERY 1000 HOURS SERVICE................................................................................................205
			CHANGE OIL IN SWING MACHINERY CASE.......................................................................................205
			CHANGE OIL IN FINAL DRIVE CASE...........................................................................................206
			CHECK ALL TIGHTENING PARTS OF TURBOCHARGER...............................................................................206
			CHECK PLAY OF TURBOCHARGER ROTOR.........................................................................................206
			REPLACE CORROSION RESISTOR CARTRIDGE.....................................................................................207
		24.9 EVERY 2000 HOURS SERVICE................................................................................................208
			CHECK OIL LEVEL IN PTO CASE, ADD OIL.....................................................................................208
			CHANGE OIL IN HYDRAULIC TANK, CLEAN STRAINER.............................................................................209
			CLEAN, CHECK TURBOCHARGER................................................................................................213
			CHECK ALTERNATOR, STARTING MOTOR.........................................................................................213
			CHECK ENGINE VALVE CLEARANCE, ADJUST.....................................................................................213
		24.10 EVERY 4000 HOURS SERVICE...............................................................................................214
			CHECK WATER PUMP.........................................................................................................214
SPECIFICATIONS.......................................................................................................................216
	25. SPECIFICATIONS...............................................................................................................217
OPTIONS, ATTACHMENTS.................................................................................................................224
	26. GENERAL PRECAUTIONS..........................................................................................................225
		26.1 PRECAUTIONS RELATED TO SAFETY...........................................................................................225
		26.2 PRECAUTIONS WHEN INSTALLING ATTACHMENTS.................................................................................226
	27. HANDLING BUCKET WITH HOOK....................................................................................................227
		27.1 CHECKING FOR DAMAGE TO BUCKET WITH HOOK.................................................................................227
		27.2 PROHIBITED OPERATIONS...................................................................................................227
		27.3 PRECAUTIONS DURING OPERATIONS...........................................................................................227
	28. USING SEAT BELT..............................................................................................................228
		28.1 SEAT BELT...............................................................................................................228
	29. HANDLING CAR HEATER..........................................................................................................230
		29.1 EXPLANATION OF COMPONENTS...............................................................................................230
		29.2 PREPARING CAR HEATER....................................................................................................231
	30. MACHINES READY FOR ATTACHMENTS...............................................................................................232
		30.1 GENERAL LOCATIONS.......................................................................................................232
		30.2 HYDRAULIC CIRCUIT.......................................................................................................234
		30.3 OPERATION...............................................................................................................237
		30.4 HANDLING ACCUMULATOR....................................................................................................239
		30.5 LONG-TERM STORAGE.......................................................................................................240
		30.6 SPECIFICATIONS..........................................................................................................240
	31. INTRODUCTION OF OPTIONAL PARTS AND ATTACHMENTS...............................................................................241
		31.1 INTRODUCTION OF OPTIONAL PARTS AND ATTACHMENTS..........................................................................241
		31.2 ATTACHMENT INSTALLATION COMBINATION TABLE...............................................................................242
		31.3 SELECTION OF TRACK SHOES................................................................................................243
		31.4 HANDLING RUBBER PAD SHOE................................................................................................244
	32. EXTENDING MACHINE SERVICE LIFE...............................................................................................246
		32.1 HYDRAULIC BREAKER.......................................................................................................246
		32.2 POWER RIPPER............................................................................................................249
		32.3 FORK GRAB...............................................................................................................250
		32.4 GRAPPLE BUCKET..........................................................................................................251
		32.5 SCRAP GRAPPLE...........................................................................................................252
		32.6 CRUSHER & SMASHER.......................................................................................................253
		32.7 HYDRAULIC PILE DRIVER...................................................................................................254
		32.8 HYDRAULIC EXCAVATOR WITH MULTI-PURPOSE CRANE............................................................................255

PLEASE NOTE:

• This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
• Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.