Komatsu Pc100-6, Pc120-6, Pc130-6 Mighty Hydraulic Excavator Operation & Maintenance Manual
FILE DETAILS:
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
VIDEO PREVIEW OF THE MANUAL:
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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.
Lucian Harris –