Komatsu PC100,100L-6 PC120-6 PC130-6 Mighty Hydraulic Excavator Operation & Maintenance Manual SN 41401 15106 50201 and up – PDF DOWNLOAD

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Komatsu PC100,100L-6 PC120-6 PC130-6 Mighty Hydraulic Excavator Operation & Maintenance Manual

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Komatsu PC100,100L-6 PC120-6 PC130-6 Mighty Hydraulic Excavator Operation & Maintenance Manual 

Brands: Komatsu
Equipment Type:  Hydraulic Excavator
Manuals Type: Operation & Maintenance Manual
Machine Model: PC100,100L-6 PC120-6 PC130-6
Serial Number: 41401, 15106, 50201 and up
Book Code: SEAM002205
Language: English
Pages: 271
File Format: Portable Document Format (PDF)

KOMATSU PC100,100L-6 PC120-6 PC130-6 MIGHTY HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL SN 41401 15106 50201 AND UP – PDF DOWNLOAD:

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DESCRIPTION:

Komatsu PC100,100L-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 PC100,100L-6 PC120-6 PC130-6 Mighty Hydraulic Excavator Operation & Maintenance Manual 

MAIN MENU............................................................................................................................  0
COVER................................................................................................................................  1
	1. FOREWARD......................................................................................................................  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 TRANSPORTATION........................................................................................................... 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 MONITOR......................................................................................................... 48
		11.2 SWITCHES................................................................................................................ 59
		11.3 CONTROL LEVERS, PEDALS.................................................................................................. 64
		11.4 CEILING WINDOW.......................................................................................................... 69
		11.5 FRONT WINDOW............................................................................................................ 70
		11.6 DOOR LOCK............................................................................................................... 72
		11.7 CAP, COVER WITH LOCK.................................................................................................... 73
		11.8 HOT/COOL BOX............................................................................................................ 74
		11.9 LUGGAGE BOX............................................................................................................. 74
		11.10 ASHTRAY................................................................................................................ 74
		11.11 AIR CONDITIONER........................................................................................................ 75
		11.12 CAR RADIO.............................................................................................................. 78
		11.13 FUSE................................................................................................................... 83
		11.14 FUSIBLE LINK........................................................................................................... 84
		11.15 CONTROLLERS............................................................................................................ 84
		11.16 TOOL BOX............................................................................................................... 84
		11.17 GREASE PUMP HOLDER..................................................................................................... 84
	12. OPERATION.................................................................................................................... 85
		12.1 CHECK BEFORE STARTING ENGINE............................................................................................ 85
		12.2 STARTING ENGINE......................................................................................................... 98
		12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE.............................................................................101
		12.4 MOVING MACHINE OFF......................................................................................................107
		12.5 STEERING MACHINE........................................................................................................110
		12.6 STOPPING MACHINE........................................................................................................112
		12.7 SWINGING................................................................................................................113
		12.8 OPERATION OF WORK EQUIPMENT.............................................................................................114
		12.9 WORKING MODE SELECTION..................................................................................................115
		12.10 HANDLING ACTIVE MODE...................................................................................................117
		12.11 PROHIBITIONS FOR OPERATION.............................................................................................118
		12.12 PRECAUTIONS FOR OPERATION..............................................................................................120
		12.13 PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS............................................................................121
		12.14 HOW TO ESCAPE FROM MUD.................................................................................................123
		12.15 WORK POSSIBLE USING HYDRAULIC EXCAVATOR................................................................................124
		12.16 REPLACEMENT AND INVERSION OF BUCKET....................................................................................125
		12.17 PARKING MACHINE........................................................................................................127
		12.18 CHECK AFTER FINISHING WORK.............................................................................................128
		12.19 STOPPING ENGINE........................................................................................................129
		12.20 CHECK AFTER STOPPING ENGINE............................................................................................130
		12.21 LOCKING................................................................................................................130
	13. TRANSPORTATION...............................................................................................................131
		13.1 LOADING, UNLOADING WORK.................................................................................................131
		13.2 PRECAUTIONS FOR LOADING.................................................................................................133
		13.3 PRECAUTIONS FOR TRANSPORTATION..........................................................................................134
	14. COLD WEATHER OPERATION.......................................................................................................136
		14.1 PRECAUTIONS FOR LOW TEMPERATURE.........................................................................................136
		14.2 PRECAUTIONS AFTER COMPLETION OF WORK....................................................................................138
		14.3 AFTER COLD WEATHER......................................................................................................138
	15. LONG-TERM STORAGE............................................................................................................139
		15.1 BEFORE STORAGE..........................................................................................................139
		15.2 DURING STORAGE..........................................................................................................140
		15.3 AFTER STORAGE...........................................................................................................140
		15.4 STARTING MACHINE AFTER LONG-TERM STORAGE................................................................................140
	16. TROUBLESHOOTING..............................................................................................................141
		16.1 PHENOMENA THAT ARE NOT FAILURES.........................................................................................141
		16.2 METHOD OF TOWING MACHINE................................................................................................141
		16.3 USING METHOD FOR LIGHT-WEIGHT TOWING HOOK...............................................................................141
		16.4 PRECAUTIONS ON PARTICULAR JOBSITES......................................................................................142
		16.5 IF BATTERY IS DISCHARGED................................................................................................142
		16.6 OTHER TROUBLE...........................................................................................................146
MAINTENANCE..........................................................................................................................151
	17. GUIDES TO MAINTENANCE........................................................................................................152
	18. OUTLINES OF SERVICE..........................................................................................................154
		18.1 OUTLINE OF OIL, FUEL, COOLANT...........................................................................................154
		18.2 OUTLINE OF ELECTRIC SYSTEM..............................................................................................157
		18.3 OUTLINE OF HYDRAULIC SYSTEM.............................................................................................158
	19. WEAR PARTS LIST..............................................................................................................159
	20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE.........................................................160
	21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS...............................................................................164
		21.1 INTRODUCTION OF NECESSARY TOOLS.........................................................................................164
		21.2 TORQUE LIST.............................................................................................................165
	22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS................................................................................166
	23. MAINTENANCE SCHEDULE CHART...................................................................................................168
		23.1 MAINTENANCE SCHEDULE CHART..............................................................................................168
		23.2 MAINTENANCE WHEN USING HYDRAULIC BREAKER................................................................................170
	24. SERVICE PROCEDURE............................................................................................................171
		24.1 INITIAL 250 HOURS SERVICE...............................................................................................171
			REPLACE FUEL FILTER CARTRIDGE............................................................................................168
			CHECK ENGINE VALVE CLEARANCE, ADJUST.....................................................................................168
		24.2 WHEN REQUIRED...........................................................................................................172
			CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT.............................................................................168
			CLEAN INSIDE OF COOLING SYSTEM...........................................................................................168
			CHECK AND TIGHTEN TRACK SHOE BOLTS.......................................................................................168
			CHECK AND ADJUST TRACK TENSION...........................................................................................168
			CHECK ELECTRICAL INTAKE AIR HEATER.......................................................................................168
			REPLACE BUCKET TEETH (VERTICAL PIN TYPE).................................................................................168
			REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)...............................................................................168
			ADJUST BUCKET CLEARANCE..................................................................................................168
			CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID...............................................................................168
			CHECK AND ADJUST AIR CONDITIONER.........................................................................................168
			REPLACE ADDITIONAL BREAKER FILTER ELEMENT................................................................................168
		24.3 CHECK BEFORE STARTING...................................................................................................190
			CHECK COOLANT LEVEL, ADD WATER...........................................................................................168
			CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL...............................................................................168
			CHECK FUEL LEVEL, ADD FUEL...............................................................................................168
			CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL...............................................................................168
			CHECK AIR CLEANER FOR CLOGGING...........................................................................................168
			CHECK ELECTRIC WIRINGS...................................................................................................168
			CHECK FOR WATER AND SEDIMENT IN WATER SEPARATOR, DRAIN WATER.............................................................168
		24.4 EVERY 50 HOURS SERVICE..................................................................................................194
			DRAIN WATER AND SEDIMENT FROM FUEL TANK..................................................................................168
		24.5 EVERY 100 HOURS SERVICE.................................................................................................195
			LUBRICATING..............................................................................................................168
			BOOM CYLINDER FOOT PIN (2 POINTS)........................................................................................168
			BOOM FOOT PIN (2 POINTS).................................................................................................168
			BOOM CYLINDER ROD END (2 POINTS).........................................................................................168
			ARM CYLINDER FOOT PIN (1 POINT)..........................................................................................169
			BOOM-ARM COUPLING PIN (1 POINT)..........................................................................................169
			ARM CYLINDER ROD END (1 POINT)...........................................................................................169
			BUCKET CYLINDER FOOT PIN (1 POINT).......................................................................................169
			ARM-LINK COUPLING PIN (1 POINT)..........................................................................................169
			ARM-BUCKET COUPLING PIN (1 POINT)........................................................................................169
			LINK COUPLING PIN (1 POINT)..............................................................................................169
			BUCKET CYLINDER ROD END (1 POINT)........................................................................................169
			BUCKET-LINK COUPLING PIN (2 POINTS)......................................................................................169
			CHECK OIL LEVEL IN SWING MACHINERY CASE, ADD OIL.........................................................................169
		24.6 EVERY 250 HOURS SERVICE.................................................................................................198
			CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL.............................................................................169
			CHECK LEVEL OF BATTERY ELECTROLYTE.......................................................................................169
			CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE........................................................169
			REPLACE HYDRAULIC FILTER ELEMENT.........................................................................................169
			CHECK FAN BELT TENSION, ADJUST...........................................................................................169
			CHECK, ADJUST TENSION OF AIR CONDITIONER COMPRESSOR BELT.................................................................169
		24.7 EVERY 500 HOURS SERVICE.................................................................................................206
			REPLACE FUEL FILTER CARTRIDGE............................................................................................169
			CHECK SWING PINION GREASE LEVEL, ADD GREASE..............................................................................169
			LUBRICATE SWING CIRCLE (2 POINTS)........................................................................................169
			CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS AND CONDENSER FINS (ONLY FOR MACHINES EQUIPPED WITH AIR CONDITIONER)....169
			CLEAN INTERNAL AND EXTERNAL AIR FILTERS OF AIR CONDITIONER SYSTEM (ONLY FOR MACHINES EQUIPPED WITH AIR CONDITIONER)......169
		24.8 EVERY 1000 HOURS SERVICE................................................................................................211
			CHANGE OIL IN SWING MACHINARY CASE.......................................................................................169
			CHANGE OIL IN FINAL DRIVE CASE...........................................................................................169
			CHECK ALL TIGHTENING PARTS OF TURBOCHARGER...............................................................................169
			CHECK PLAY OF TURBOCHARGER ROTOR.........................................................................................169
			REPLACE CORROSION RESISTOR CARTRIDGE.....................................................................................169
		24.9 EVERY 2000 HOURS SERVICE................................................................................................215
			CHECK OIL LEVEL IN PTO GEAR CASE, ADD OIL................................................................................170
			CHANGE OIL IN HYDRAULIC TANK, CLEAN STRAINER.............................................................................170
			CLEAN, CHECK TURBOCHARGER................................................................................................170
			CHECK ALTERNATOR, STARTING MOTOR.........................................................................................170
			CHECK ENGINE VALVE CLEARANCE, ADJUST.....................................................................................170
		24.10 EVERY 4000 HOURS SERVICE...............................................................................................221
			CHECK WATER PUMP.........................................................................................................170
SPECIFICATIONS.......................................................................................................................223
	25. SPECIFICATIONS...............................................................................................................224
OPTIONS, ATTACHMENTS.................................................................................................................233
	26. GENERAL PRECAUTIONS..........................................................................................................234
		26.1 PRECAUTIONS RELATED TO SAFETY...........................................................................................234
		26.2 PRECAUTIONS WHEN INSTALLING ATTACHMENTS.................................................................................235
	27. HANDLING BUCKET WITH HOOK....................................................................................................236
		27.1 CHECKING FOR DAMAGE TO BUCKET WITH HOOK.................................................................................236
		27.2 PROHIBITED OPERATIONS...................................................................................................236
		27.3 PRECAUTIONS DURING OPERATIONS...........................................................................................236
	28. USING SEAT BELT..............................................................................................................237
		28.1 SEAT BELT...............................................................................................................237
	29. HANDLING CAR HEATER..........................................................................................................239
		29.1 EXPLANATION OF COMPONENTS...............................................................................................239
		29.2 PREPARING CAR HEATER....................................................................................................240
	30. MACHINES READY FOR ATTACHMENTS...............................................................................................241
		30.1 GENERAL LOCATIONS.......................................................................................................241
		30.2 HYDRAULIC CIRCUIT.......................................................................................................243
		30.3 OPERATION...............................................................................................................246
		30.4 HANDLING ACCUMULATOR....................................................................................................248
		30.5 LONG-TERM STORAGE.......................................................................................................249
		30.6 SPECIFICATIONS..........................................................................................................249
	31. INTRODUCTION OF OPTIONAL PARTS AND ATTACHMENTS...............................................................................250
		31.1 INTRODUCTION OF OPTIONAL PARTS AND ATTACHMENTS..........................................................................250
		31.2 ATTACHMENT INSTALLATION COMBINATION TABLE...............................................................................251
		31.3 SELECTION OF TRACK SHOES................................................................................................252
		31.4 HANDLING RUBBER PAD SHOE................................................................................................253
		31.5 HANDLING AUTOMATIC GREASING CONTROLLER..................................................................................255
	32. EXTENDING MACHINE SERVICE LIFE...............................................................................................260
		32.1 HYDRAULIC BREAKER.......................................................................................................260
		32.2 POWER RIPPER............................................................................................................263
		32.3 FORK GRAB...............................................................................................................264
		32.4 GRAPPLE BUCKET..........................................................................................................265
		32.5 SCRAP GRAPPLE...........................................................................................................266
		32.6 CRUSHER & SMASHER.......................................................................................................267
		32.7 HYDRAULIC PILE DRIVER...................................................................................................268
		32.8 HYDRAULIC EXCAVATOR WITH MULTI-PURPOSE CRANE............................................................................269

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