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: 263
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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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..........................................................................................................................  5
2. SAFETY INFORMATION................................................................................................................  6
3. INTRODUCTION......................................................................................................................  7
4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR.....................................................................  8
5. CONTENTS..........................................................................................................................  9
SAFETY............................................................................................................................... 13
	6. GENERAL PRECAUTIONS........................................................................................................... 14
	7. PRECAUTIONS DURING OPERATION.................................................................................................. 20
		7.1 BEFORE STARTING ENGINE .................................................................................................. 20
		7.2 OPERATING MACHINE........................................................................................................ 22
		7.3 TRANSPORATION............................................................................................................ 27
		7.4 BATTERY.................................................................................................................. 28
		7.5 TOWING................................................................................................................... 29
		7.6 BUCKET WITH HOOK......................................................................................................... 30
	8. PRECAUTIONS FOR MAINTENANCE................................................................................................... 33
		8.1 BEFORE CARRYING OUT MAINTENANCE.......................................................................................... 33
		8.2 DURING MAINTENANCE....................................................................................................... 36
	9. POSITION FOR ATTACHING SAFETY LABELS.......................................................................................... 40
OPERATION............................................................................................................................ 45
	10. GENERAL VIEW................................................................................................................. 46
		10.1 GENERAL VIEW OF MACHINE................................................................................................. 46
		10.2 GENERAL VIEW OF CONTROLS AND GAUGES..................................................................................... 47
	11. EXPLANATION OF COMPONENTS.................................................................................................... 48
		11.1 MACHINE MAONITOR........................................................................................................ 48
		11.2 METER................................................................................................................... 59
		11.3 SWITCHES................................................................................................................ 60
		11.4 CONTROL LEVERS, PEDALS.................................................................................................. 65
		11.5 CEILING WINDOW.......................................................................................................... 70
		11.6 FRONT WINDOW............................................................................................................ 71
		11.7 DOOR LOCK............................................................................................................... 73
		11.8 CAP, COVER WITH LOCK.................................................................................................... 74
		11.9 HOT/COOL BOX............................................................................................................ 75
		11.10 LUGGAGE BOX............................................................................................................ 75
		11.11 ASHTRAY................................................................................................................ 75
		11.12 AIR CONDITIONER........................................................................................................ 76
		11.13 CAR RADIO.............................................................................................................. 79
		11.14 FUSE................................................................................................................... 83
		11.15 FUSIBLE LINK........................................................................................................... 84
		11.16 CONTROLLERS............................................................................................................ 84
		11.17 TOOL BOX............................................................................................................... 84
		11.18 GREASE PUMP HOLDER..................................................................................................... 84
	12. OPERATION.................................................................................................................... 85
		12.1 CHECK BEFORE STARTING ENGINE............................................................................................ 85
		12.2 STARTING ENGINE......................................................................................................... 95
		12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE............................................................................. 98
		12.4 MOVING MACHINE OFF......................................................................................................104
		12.5 STEERING MACHINE........................................................................................................107
		12.6 STOPPING MACHINE........................................................................................................109
		12.7 SWINGING................................................................................................................110
		12.8 OPERATION OF WORK EQUIPMENT.............................................................................................111
		12.9 WORKING MODE SELECTION..................................................................................................112
		12.10 PROHIBITIONS FOR OPERATION.............................................................................................114
		12.11 PRECAUTIONS FOR OPERATION..............................................................................................116
		12.12 PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS............................................................................117
		12.13 HOW TO ESCAPE FROM MUD.................................................................................................119
		12.14 WORK POSSIBLE USING HYDRAULIC EXCAVATOR................................................................................120
		12.15 REPLACEMENT AND INVERSION OF BUCKET....................................................................................121
		12.16 PARKING MACHINE........................................................................................................123
		12.17 CHECK AFTER FINISHING WORK.............................................................................................124
		12.18 STOPPING ENGINE........................................................................................................125
		12.19 CHECK AFTER STOPPING ENGINE............................................................................................126
		12.20 LOCKING................................................................................................................126
	13. TRANSPORTATION...............................................................................................................127
		13.1 LOADING, UNLOADING WORK.................................................................................................127
		13.2 PRECAUTIONS FOR LOADING.................................................................................................129
		13.3 PRECAUTIONS FOR TRANSPORTATION..........................................................................................130
	14. COLD WEATHER OPERATION.......................................................................................................132
		14.1 PRECAUTIONS FOR LOW TEMPERATURE.........................................................................................132
		14.2 PRECAUTIONS AFTER COMPLETION OF WORK....................................................................................134
		14.3 AFTER COLD WEATHER......................................................................................................134
	15. LONG-TERM STORAGE............................................................................................................135
		15.1 BEFORE STORAGE..........................................................................................................135
		15.2 DURING STORAGE..........................................................................................................136
		15.3 AFTER STORAGE...........................................................................................................136
		15.4 STARTING MACHINE AFTER LONG-TERM STORAGE................................................................................136
	16. TROUBLESHOOTING..............................................................................................................137
		16.1 PHENOMENA THAT ARE NOT FAILURES.........................................................................................137
		16.2 METHOD OF TOWING MACHINE................................................................................................137
		16.3 USING METHOD FOR LIGHT-WEIGHT TOWING HOOK...............................................................................137
		16.4 PRECAUTIONS OF PARTICULAR JOBSITES......................................................................................138
		16.5 IF BATTERY IS DISCHARGED................................................................................................138
		16.6 OTHER TROUBLE...........................................................................................................142
MAINTENANCE..........................................................................................................................147
	17. GUIDES TO MAINTENANCE........................................................................................................148
	18. OUTLINES OF SERVICE..........................................................................................................150
		18.1 OUTLINE OF OIL, FUEL, COOLANT...........................................................................................150
		18.2 OUTLINE OF ELECTRIC SYSTEM..............................................................................................153
		18.3 OUTLINE OF HYDRAULIC SYSTEM.............................................................................................154
	19. WEAR PARTS LIST..............................................................................................................155
	20. USE OF FUEL ,COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE.........................................................156
	21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS...............................................................................160
		21.1 INTRODUCTION OF NECESSARY TOOLS.........................................................................................160
		21.2 TORQUE LIST.............................................................................................................161
	22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS................................................................................162
	23. MAINTENANCE SCHEDULE CHART...................................................................................................164
		23.1 MAINTENANCE SCHEDULE CHART..............................................................................................164
		23.2 MAINTENANCE WHEN USING HYDRAULIC BREAKER................................................................................166
	24. SERVICE PROCEDURE............................................................................................................167
		24.1 INITIAL 250 HOURS SERVICE...............................................................................................167
			REPLACE FUEL CARTRIDGE...................................................................................................201
			CHECK ENGINE VALVE CLEARANCE, ADJUST.....................................................................................214
		24.2 WHEN REQUIRED...........................................................................................................168
			CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT.............................................................................168
			CLEAN INSIDE OF COOLING SYSTEM...........................................................................................170
			CHECK AND TIGHTEN TRACK SHOE BOLTS.......................................................................................174
			CHECK AND ADJUST TRACK TENSION...........................................................................................175
			CHECK ELECTRICAL INTAKE AIR HEATER.......................................................................................177
			REPLACE BUCKET TEETH (VERTICAL PIN TYPE).................................................................................178
			REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)...............................................................................181
			ADJUST BUCKET CLEARANCE..................................................................................................182
			CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID...............................................................................183
			CHECK AND ADJUST AIR CONDITIONER.........................................................................................184
			REPLACE ADDITIONAL BREAKER FILTER ELEMENT................................................................................185
		24.3 CHECK BEFORE STARTING ..................................................................................................186
			CHECK COOLANT LEVEL, ADD WATER...........................................................................................186
			CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL...............................................................................186
			CHECK FUEL LEVEL, ADD FUEL...............................................................................................187
			CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL...............................................................................188
			CHECK AIR CLEANER FOR CLOGGING ..........................................................................................189
			CHECK ELECTRIC WIRINGS...................................................................................................189
			CHECK FOR WATER AND SEDIMENT IN WATER SEPARATOR, DRAIN WATER.............................................................189
		24.4 EVERY 50 HOURS SERVICE..................................................................................................190
			DRAIN WATER AND SEDIMENT FROM FUEL TANK..................................................................................190
		24.5 EVERY 100 HOURS SERVICE.................................................................................................191
			LUBRICATING..............................................................................................................191
				BOOM CYLINDER FOOT PIN (2 POINTS)....................................................................................191
				BOOM FOOT PIN (2 POINTS).............................................................................................191
				BOOM CYLINDER ROD END (2 POINTS).....................................................................................191
				ARM CYLINDER PIN (1 POINT)...........................................................................................191
				BOOM-ARM COUPLING PIN (1 POINT)......................................................................................192
				ARM CYLINDER ROD END (1 POINT).......................................................................................192
				BUCKET CYLINDER FOOT PIN (1 POINT)...................................................................................192
				ARM-LINK COUPLING PIN (1 POINT)......................................................................................192
				ARM-BUCKET COUPLING PIN (1 POINT)....................................................................................192
				LINK COUPLING PIN (1 POINT)..........................................................................................192
				BUCKET CYLINDER ROD END (1 POINT)....................................................................................192
				BUCKET-LINK COUPLING PIN (2 POINTS)..................................................................................192
			CHECK OIL LEVEL IN SWING MACHINERY CASE, ADD OIL.........................................................................193
		24.6 EVERY 250 HOURS SERVICE.................................................................................................194
			CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL.............................................................................194
			CHECK LEVEL OF BATTERY ELECTROLYTE.......................................................................................195
			CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE........................................................196
			REPLACE HYDRAULIC FILTER ELEMENT.........................................................................................197
			CHECK FAN BELT TENSION, ADJUST...........................................................................................199
			CHECK, ADJUST TENSION OF AIR CONDITIONER COMPRESSOR BELT.................................................................200
		24.7 EVERY 500 HOURS SERVICE.................................................................................................201
			REPLACE FUEL FILTER CARTRIDGE ...........................................................................................201
			CHECK SWING PINION GREASE LEVEL, ADD GREASE..............................................................................203
			LUBRICATE SWING CIRCLE (2 POINTS)........................................................................................203
			CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS AND CONDENSER FINS (ONLY FOR MACHINES EQUIPPED WITH AIR CONDITIONER)....204
			CLEAN INTERNAL AND EXTERNAL AIR FILTERS OF AIR CONDITIONER SYSTEM (ONLY FOR MACHINES EQUIPPED WITH AIR CONDITIONER)......205
		24.8 EVERY 1000 HOURS SERVICE................................................................................................206
			CHANGE OIL IN SWING MACHINERY CASE.......................................................................................206
			CHANGE OIL IN FINAL DRIVE CASE...........................................................................................207
			CHECK ALL TIGHTENING PARTS OF TURBOCHARGER...............................................................................207
			CHECK PLAY OF TURBOCHARGER ROTOR.........................................................................................207
			REPLACE CORROSION RESISTOR CARTRIDGE.....................................................................................208
		24.9 EVERY 2000 HOURS SERVICE................................................................................................209
			CHECK OIL LEVEL IN PTO GEAR CASE, ADD OIL................................................................................209
			CHANGE OIL IN HYDRAULIC TANK, CLEAN STRAINER.............................................................................210
			CLEAN, CHECK TURBOCHARGER................................................................................................214
			CHECK ALTERNATOR, STARTING MOTOR.........................................................................................214
			CHECK ENGINE VALVE CLEARANCE, ADJUST.....................................................................................214
		24.10 EVERY 4000 HOURS SERVICE...............................................................................................215
			CHECK WATER PUMP.........................................................................................................215
SPECIFICATIONS.......................................................................................................................217
	25. SPECIFICATIONS...............................................................................................................218
OPTIONS, ATTACHMENTS.................................................................................................................225
	26. GENERAL PRECAUTIONS..........................................................................................................226
		26.1 PRECAUTIONS RELATED TO SAFETY...........................................................................................226
		26.2 PRECAUTIONS WHEN INSTALLING ATTACHMENTS.................................................................................227
	27. HANDLING BUCKET WITH HOOD....................................................................................................228
		27.1 CHECKING FOR DAMAGE TO BUCKET WITH HOOD.................................................................................228
		27.2 PROHIBITED OPERATIONS...................................................................................................228
		27.3 PRECAUTIONS DURING OPERATIONS...........................................................................................228
	28. USING SEAT BELT..............................................................................................................229
		28.1 SEAT BELT...............................................................................................................229
	29. HANDLING CAR HEATER..........................................................................................................231
		29.1 EXPLANATION OF COMPONENTS...............................................................................................231
		29.2 PREPARING CAR HEATER....................................................................................................232
	30. MACHINE READY FOR ATTACHMENTS................................................................................................233
		30.1 GENERAL LOCATIONS.......................................................................................................233
		30.2 HYDRAULIC CIRCUIT.......................................................................................................235
		30.3 OPERATION...............................................................................................................238
		30.4 HANDLING ACCUMULATOR....................................................................................................240
		30.5 LONG-TERM STORAGE.......................................................................................................241
		30.6 SPECIFICATIONS..........................................................................................................241
	31. INTRODUCTION OF OPTIONAL PARTS AND ATTACHMENTS...............................................................................242
		31.1 INTRODUCTION OF OPTIONAL PARTS AND ATTACHMENTS..........................................................................242
		31.2 ATTACHMENT INSTALLATION COMBINATION TABLE...............................................................................243
		31.3 SELECTION OF TRACK SHOES................................................................................................244
		31.4 HANDLING RUBBER PAD SHOE................................................................................................245
		31.5 HANDLING AUTOMATIC GREASING CONTROLLER..................................................................................247
	32. EXTENDING MACHINE SERVICE LIFE...............................................................................................252
		32.1 HYDRAULIC BREAKER.......................................................................................................252
		32.2 POWER RIPPER............................................................................................................255
		32.3 FORK GRAB...............................................................................................................256
		32.4 GRAPPLE BUCKET..........................................................................................................257
		32.5 SCRAP GRAPPLE...........................................................................................................258
		32.6 CRUSHER & SHASHER.......................................................................................................259
		32.7 HYDRAULIC PILE DRIVER...................................................................................................260
		32.8 HYDRAULIC EXCAVATOR WITH MULTIPURPOSE CRANE.............................................................................261

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