Operation & Maintenance
Manual
SEAM002205
PC1 00,10014
PC1 204
PC1 304 MIGHTY
HYDRAULIC EXCAVATOR
PClOO-6 - 41401
PClOOL6 - 15106
SERIAL NUMBERS
Pc120-6 n 50201 andw
PC13016 - 50201
This material is proprietary to Komatsu America International Company and is not to be reproduced, used, or
disclosed except in accordance with written authorization from Komatsu America International Company.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make
changes or add improvements at any time without incurring any obligation to install such changes on products sold
previously.
Due to this continuous program of research and development, periodic revisions may be made to this publication.
It is recommended that customers contact their distributor for information on the latest revision.
October 1996 Copyright 1996 Komatsu America International Company
A WARNING
Unsafe use of this machine may cause serious injury or death.
Operators and maintenance personnel must read this manual
before operating or maintaining this machine. This manual
should be kept near the machine for reference and periodically
reviewed by all personnel who come in contact with it.
CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects and
other reproductive harm.
I
CALIFORNIA
Proposition 65 Warning
Battery posts, terminals and related accessories contain
lead and lead compounds, chemicals known to the state
of California to cause cancer, birth defects and
reproductive harm. Wash hands after handling.
KOMA”U Printed in USA
DAlhKOM
EMISSION CONTROL WARRANTY
EMISSION CONTROL WARRANTY STATEMENT (APPLIES TO CANADA ONLY)
1. Products Warranted
Komatsu America International Company. Komatsu Mining Systems Inc. and Komatsu Utility Corporation (collecttvely “Komatsu”) produce and/or
market products under brand names of Komatsu. Dresser. Dressta. Haulpak and Galion. This emissions warranty applies to new engines bearing the
Komatsu name installed in these products and used in Canada in machines designed for industrial off-highway use. This warranty applies only to
these engines produced on or after January I. 2000. This warranty will be administered by Komatsu distribution in Canada.
2. Coverage
Komatsu warrants to the ultimate purchaser and each subsequent purchaser that the engine is designed, built and equipped so as to conform. at the
time of sale by Komatsu. with all U.S. Federal emission regulations applicable at the time of manufacture and that it is free from defects in
workmanship or material which would cause it not to meet these regulations within five years or 3.000 hours of operation, whichever occurs tirst. as
measured from the date ofdelIvery of the engine to the ultimate purchaser.
3. Limitations
Failures, other than those resulting from defects in materials or workmanship, are not covered by this warranty. Komatsu is not responsible for
failures or damage resulting from what Komatsu determines to be abuse or neglect, includin,,(7 but not limited to: operation without adequate coolant
or lubricants; over fueling; over speed& lack of maintenance of lubricating, cooling or intake systems; improper storage, starting. warn-up. run-in
or shutdown practices; unauthorized modifications of the engine. Komatsu is also not responsible for failures caused by incorrect fuel or by water,
dirt or other contaminants in the fuel. Komatsu is not responsible for non-engine repairs. “downtnne” expense. related damage, tines. all business
costs or other losses resulting from a warrantable failure.
KOMATSU IS NOT RESPONSIBLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES.
This warranty, together with the express commercial warranties, are the sole warranties of Komatsu. THERE ARE NO OTHER
WARRANTIES, EXPRESS OR IMPLIED, OR OF MERCHANTABILITY OR FITNESS FOR A PARTICUALR PURPOSE.
GARANTIE SUR LE CONTR~LE DES EMISSIONS
~NONCG DE GARANTIE SUR LE CONTR~LE DES OMISSIONS (APPLICABLE AU CANADA SEULEMENT):
Produits garantis:
Komatsu America International Company, Komatsu Mining Systems Inc. et Komatsu Utility Corporation (collectivement Komatsu) produisent et/au font la
mise en marche de prod&s portant les noms de marque Komatsu, Dresser. Dressta. Haulpak et Galion. Cette garantie sur les emissions s’applique a tous les
nouveaux moteurs pottant le nom Komatsu, install& dans ces prodmts et utilises au Canada dans des machines concues pour utihsation industrielle non-
rout&e. Cette garantie s’applique seulement sur les moteurs produits a partir du ler Janvier 2000. Cette garantie sera administree par la distribution de
Komatsu au Canada.
Couverture:
Komatsu garantit a I’acheteur ultime et chaque acheteur subsequent que le moteur est concu, construit et Cquipt en toute confonnite. au moment de la vente
par Komatsu. avec tomes les Reglementations fed&ales americaines sur les emissions applicables au moment de la fabrication et qu’il est exempt de defauts
de construction ou de materiaux qui auraient pour effet de contrevenir a ces reglementations en dedans de 5 ans ou 3000 heures d’operation, mesure a partir
de la date de livraison du moteur au client ultime.
Limitations:
Les bris, autres que ceux resultant de defauts de materiaux ou de construction, ne sont pas couverts par cette Garantie. Komatsu n’est pas responsable pour
bris ou dommages resultant de ce que Komatsu determine comme etant de I’abus ou negligence, incluant mais ne se limitant pas a: I’operation sans
lubrifiants ou agent refroidissants adequats; la suralimentation d’essence; la survitesse; le manque d’entretien des systemes de lubritication, de
refroidissement ou d’entree; de pratiques non-propices d’entreposage, demise en marche, de rtchauffement. de conditionnement ou d’arret: les
modifications non-autorisees du moteur. De plus, Komatsu n’est pas responsable de bris causes par de I’essence inadequate ou de I’eau, des saletes ou autres
contaminants dans I’essence. Komatsu n’est pas responsable des reparations non-reliees au moteur, des dtpenses encoumes suite aux temps d’arrets, des
dommages relatifs, amendes. et de tout autre codt d’affaires ou autres pertes resultant d’un bris couvert par la garantie.
KOMATSU N’EST PAS RESPONSABLE DES INCIDENTS OU DOMMAGES CONSkQUENTS.
Cette garantie, ainsi que les garanties expresses commerciales, sont les seules garanties de Komatsu. IL N’Y A AUCUNE AUTRE
GARANTIE, EXPRESSE OU SOUS-ENTENDUE, MARCHANDABLE OU PROPICE A UNE UTILISATION PARTICULIkRE.
CEHQ000700 - Komatsu America International Company 12199
INFORMATION IMPORTANTE SUR LE MOTEUR
CE MOTEUR EST CONFORME AUX NORMES AMERICAINES DB’EPA (ANNCE DU
MODCLE) ET DE LA CALIFORNIE POUR LES MOTEURS LARGES NON-ROUTIERS A IGNI-
TION PAR COMPRESSION. CE MOTEUR EST CERTIFIE POUR OPERATION A ESSENCE
DIhEL.
CHARGE DE SORTIE ADV.
PORTBE DE VALVE I\ FROID
(mm)
RkGLAGE DE UALLUMAGE -
INJECTION INITIALE
AVERTISSEMENT
DES BLESSURES PEUVENT RisULTER ET LA GARANTIE
S’ANNULER SI LES RPM DU TAUX D’ESSENCE OU CALTITUDE
EXCkDENT LES VALEURS MAXIMALES PUBLIEES POUR CE
MODELE ET SON APPLIWTION.
r
IMPORTANT ZGINE INFORMATION
.
THIS ENGINE CONFORMSTO YYYY MODEL YEAR U.S. EPA REGULATION AND THE CALIFORNIA
REGULATIONS LARGE NON ROAD COMPRESSION IGNITION ENGINES. THIS ENGINE IS CERTI-
FIED TO OPERATE ON DIESEL FUEL.
WARNING
INJURY MAY RESULT AND WARRANTY IS VOIDED IF FUEL R4TE RPM OR ALTITUDES EXCEED
PUBLISHED MAXIMUM VALUES FOR THIS MODEL AND APPLICATION.
ENGINE MODEL
I
ISERIAL NO. T
I I I
ENGINE FAMILY IDISPLACEMENT I LITERS
EXHAUST EMISSION
CONTROL SYSTEM
ADV. LOAD OUTPUT
FIRING ORDER l-5-3-6-2-4
I.
Kw ( HP)
RPM -------
E(,,sH /IN. 1 mm3/STROKE
IDLE SPEED RPM FAMILY EMISSION LIMIT
INITIAL INJECTION DEG. BTDC DATE OF MANUFACTURE -
TIMING
,’
MADE IN JAPAN
KOMATSU LTD. /
KOMATSU LT$E
FABRIQUI? AU JAPON
/
DBPLACEMENT
BQUENCE DE MISE A FEU
IMITE D’I?MISSION DE
LA FAMILLE
ENGINE DATAPLATE - ENGLISH / FRENCH
1mFOREWORD
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.
a
WARNING
1
Improper operation and maintenance of this machine can be hazardous and could result in serious
injury or death.
Operators and maintenance personnel should read this manual thoroughly before beginning
operation or maintenance.
Some actions involved in operation and maintenance of the machine can cause a serious accident,
if they are not done in a manner described in this manual.
The procedures and precautions given in this manual apply only to intended uses of the machine.
If you use your machine for any unintended uses that are not specifically prohibited, you must
be sure that it is safe for you and others. In no event should you or others engage in prohibited
uses or actions as described in this manual.
Komatsu delivers machines that comply with all applicable regulations and standards of the
country to which it has been shipped. If this machine has been purchased in another country or
purchased from someone in another country, it may lack certain safety devices and specifications
that are necessary for use in your country. If there is any question about whether your product
complies with the applicable standards and regulations of your country, consult Komatsu or your
Komatsu distributor before operating the machine.
The description of safety is given in SAFETY INFORMATION on page O-2 and in SAFETY from page
1-I.
CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its
constituents are known to the State
of California to cause cancer, birth
defects, and other reproductive
harm.
O-1
2. SAFETY INFORMATION
Most accidents are caused by the failure to follow fundamental safety rules for the operation and
maintenance of machines. To avoid accidents, read, understand and follow all precautions and warnings
in this manual and on the machine before performing operation and maintenance.
To identify safety messages in this manual and on machine labels, the following signal words are
used.
4L
DANGER - This word is used on safety messages and safety labels where there is a high
probability of serious injury or death if the hazard is not avoided. These safety
messages or labels usually describe precautions that must be taken to avoid the
hazard. Failure to avoid this hazard may also result in serious damage to the
machine.
a
WARNING - This word is used on safety messages and safety labels where there is a
potentially dangerous situation which could result in serious injury or death if
the hazard is not avoided. These safety messages or labels usually describe
precautions that must be taken to avoid the hazard. Failure to avoid this hazard
may also result in serious damage to the machine.
CAUTION - This word is used on safety messages and safety labels for hazards which could
result in minor or moderate injury if the hazard is not avoided. This word might
also be word for hazards where the only result could be damage to the machine.
NOTICE - This word is used for precautions that must be taken to avoid actions which
could shorten the life of the machine.
Safety precautions are described in SAFETY from page l-l.
Komatsu cannot predict every circumstance that might involve a potential hazard in operation and
maintenance. Therefore the safety messages in this manual and on the machine may not include all
possible safety precautions. If any procedures or actions not specifically recommended or allowed in this
manual are used, you must be sure that you and others can do such procedures and actions safely and
without damaging the machine. If you are unsure about the safety of some procedures, contact Komatsu
distributor.
o-2
3. INTRODUCTION
3.1 INTENDED USE
This Komatsu HYDRAULIC EXCAVATOR is designed to be used mainly for the following work:
l Digging work
l Smoothing work
l Ditching work
l Loading work
See the section “12.15 WORK POSSIBLE USING HYDRAULIC EXCAVATOR” for further details.
3.2 FEATURES
o This Komatsu HYDRAULIC EXCAVATOR is equipped with various controls based on an advanced
electronics system.
o The monitor panel greatly facilitates daily maintenance and self-diagnosis.
o Working mode, active mode and travel speed are selectable.
o Digging and lifting force can be increased by light-touch control.
(For details, see operation section.)
l Adjustable wrist control levers make operations smooth and easy.
l Air-conditioned operator’s cab assures comfortable operation.
l Low noise level and smart urban-style design and coloring.
l Superb operating performance provided by powerful engine and high-performance hydraulic
pumps.
l Low fuel consumption controlled by an electronic control system provides an environment-friendly
machine.
3.3 BREAKING IN THE MACHINE
Your Komatsu machine has been thoroughly adjusted and tested before shipment.
However, operating the machine under severe conditions at the beginning can adversely affect the
performance and shorten the machine life.
Be sure to break in the machine for the initial 100 hours (as indicated by the service meter.)
During breaking in:
l Idle the engine for 5 minutes after starting it up.
l Avoid operation with heavy loads or at high speeds.
l Avoid sudden starts, sudden acceleration, sudden steering and sudden stops except in cases of
emergency.
The precautions given in this manual for operating, maintenance, and safety procedures are only
those that apply when this product is used for the specified purpose. If the machine is used for a purpose
that is not listed in this manual, Komatsu cannot bear any responsibility for safety. All consideration of
safety in such operations is the responsibility of the user.
Operations that are prohibited in this manual must never be carried out under any circumstances.
o-3
4. LOCATION OF PLATES, TABLE TO ENTER
SERIAL NO. AND DISTRIBUTOR
4.1 MACHINE SERIAL NO. PLATE POSITION
On the front bottom right of the operator’s cab
4.2 ENGINE SERIAL NO. PLATE POSITION
On the upper side of the engine cylinder head cover
AM101060
4.3 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR
Machine serial No.:
Engine serial No.:
Distributor name:
Address:
Service personnel for your machine:
Phone:
REMARKS
o-4
5. CONTENTS
1.
2.
3.
4.
Foreword ............................................................................................................................................ 0- 1
Safety information
............................................................................................................................ o- 2
Introduction
o- 3
.............................
...........................................................................................................
Location of plates, table to enter serial No. and distributor ...................................................... 0- 4
SAFETY
6.
7.
General precautions .. . .. . .. .. . . . . .._................................................................ . . .. . . . . . . .. . . .. . .. .. . . . .. . . . .. . .. .. . . . .. I- 2
Precautions during operation
.......................................................................................................... I- 8
7.1 Before starting engine
............................................................................................................. I- 8
7.2 Operating machine .................................................................................................................. I-IO
7.3 Transportation
.......................................................................................................................... I-15
7.4 Battery. ......................................................................................................................................
1-16
7.5 Towing
...................................................................................................................................... 1-17
7.6 Bucket with hook ..................................................................................................................... 1-18
8. Precautions for maintenance
...........................................................................................................
8.1 Before carrying out maintenance ..........................................................................................
8.2 During maintenance
................................................................................................................
1-21
1-21
q-24
9. Position for attaching safety labels
.. . . .. . . .. . .. . . . . . .. . . .. . . . . ... . . . .. . . . . . . .. .. . .. . . . .. . . .. . .. . . . . . . .. . .. . . .. .. . . . . .. . . . . .. . . .. . . l-28
OPERATION
10. General view
2- 2 .................................................... ..................................................................................
10.1 General view of machine..
...................................................................................................... 2- 2
10.2 General view of controls and gauges
................................................................................... 2- 3
11. Explanation of components . .. . . .. .. . . .. .. . . .. . . . . . .. . . .. . .. . .. . . . . . .. .. . .. . . .. . . . . . . . . . .. .._........................................... 2- 4
11.1
11.2
11.3
11.4
11.5
11.6
11.7
11.8
11.9
11.10
11.11
11.12
11.13
11.14
11.15
11.16
11.17
Machine monitor ......................................................................................................................
Switches..
..................................................................................................................................
Control levers, pedals..
............................................................................................................
Ceiling window
........................................................................................................................
Front window ...........................................................................................................................
Door lock..
.................................................................................................................................
Cap, cover with lock
................................................................................................................
Hot / Cool box.
.........................................................................................................................
Luggage box.. ...........................................................................................................................
Ashtray ......................................................................................................................................
Air conditioner
.........................................................................................................................
Car radio
...................................................................................................................................
Fuse ...........................................................................................................................................
Fusible link..
...............................................................................................................................
Controllers
................................................................................................................................
Tool box..
..................................................................................................................................
Grease pump holder
...............................................................................................................
2- 4
2-15
2-20
2-25
2-26
2-28
2-29
2-30
2-30
2-30
2-31
2-34
2-39
2-40
2-40
2-40
2-40
o-5
5. CONTENTS
12. Operation
............................................................................................................................................ 2-41
12.1 Check before starting engine ................................................................................................. 2-41
12.2 Starting engine.. .......................................................................................................................
2-54
12.3 Operations and checks after starting engine ........................................................................ 2-57
12.4 Moving machine off ................................................................................................................ 2-63
12.5 Steering machine
..................................................................................................................... 2-66
12.6 Stopping machine ....................................................................................................................
2-68
12.7 Swinging
................................................................................................................................... 2-69
12.8 Operation of work equipment ................................................................................................
2-70
12.9 Working mode selection ......................................................................................................... 2-71
12.10 Handling active mode .............................................................................................................
2-73
12.1 1 Prohibitions for operation.. .....................................................................................................
2-74
12.12 Precautions for operation
....................................................................................................... 2-76
12.13 Precautions when traveling up or down hills ...................................................................... 2-77
12.14 How to escape from mud
....................................................................................................... 2-79
12.15 Work possible using hydraulic excavator
............................................................................. 2-80
12.16 Replacement and inversion of bucket ...................................................................................
2-81
12.17 Parking machine ......................................................................................................................
2-83
12.18 Check after finishing work ...................................................................................................... 2-84
12.19 Stopping engine.. .....................................................................................................................
2-85
12.20 Check after stopping engine
................................................................................................... 2-86
12.21 Locking
...................................................................................................................................... 2-86
13. Transportation
................................................................................................................................... 2-87
13.1 Loading, unloading work
........................................................................................................
2-87
13.2 Precautions for loading ...........................................................................................................
2-89
13.3 Precautions for transportation
................................................................................................
2-90
14. Cold weather operation ....................................................................................................................
2-92
14.1 Precautions for low temperature ........................................................................................... 2-92
14.2 Precautions after completion of work ................................................................................... 2-94
14.3 After cold weather ...................................................................................................................
2-94
15. Long-term storage
............................................................................................................................. 2-95
15.1 Before storage
.......................................................................................................................... 2-95
15.2 During storage
......................................................................................................................... 2-96
15.3 After storage .............................................................................................................................
2-96
15.4 Starting machine after long-term storage
............................................................................
2-96
16. Troubleshooting .................................................................................................................................
2-97
16.1 Phenomena that are not failures ........................................................................................... 2-97
16.2 Method of towing machine .................................................................................................... 2-97
16.3 Using method for light-weight towing hook
........................................................................
2-97
16.4 Precautions on particular jobsites ......................................................................................... 2-98
16.5 If battery is discharged
........................................................................................................... 2-98
16.6 Other trouble ............................................................................................................................
2-102
O-6
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KOMATSU PC100 100L-6 PC120-6 PC130-6 Maintenance Manual
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Description
This operation and maintenance manual is essential for the effective, safe, and economical operation and maintenance of the KOMATSU PC100-6, 100L-6, PC120-6, and PC130-6 MIGHTY HYDRAULIC EXCAVATOR. It provides detailed procedures for operation, handling, lubrication, maintenance, checking, and adjustment, ensuring peak performance.
Both professional mechanics and DIY enthusiasts will find this manual invaluable. It contains crucial information on safety, operation, maintenance, specifications, as well as options and attachments.
It is important to pay attention to the specific serial numbers contained in this manual:
- PC100-6: 41401
- PC100L-6: 15106
- PC120-6: 50201 and up
- PC130-6: 50201
This manual comes in a PDF format with 271 pages and a size of 15Mb. The language used in the manual is English, making it accessible to a wide range of users.
If you have any questions or are in search of a specific manual for Komatsu machines, feel free to reach out. We have a comprehensive collection of manuals and are here to assist you.
Ensure this manual is readily available and periodically reviewed by all personnel for optimal machine performance. Have a great day!
