Komatsu PC600-8, PC600LC-8 Hydraulic Excavator Operation & Maintenance Manual (K50001 and up)

This manual PDF download describes procedures for operation, handling, lubrication, maintenance, checking, and adjustment for the PC600-8, PC600LC-8 Komatsu Hydraulic Excavator (S/N: K50001 and up). It will help the operator or anyone realize peak performance through effective, economical and safe machine operation and maintenance.


APPLICABLE MODELS :

Komatsu PC600-8 - S/N: K50001 and up
Komatsu PC600LC-8 - S/N: K50001 and up


TABLE OF CONTENTS :

- SAFETY
- OPERATION
- MAINTENANCE
- SPECIFICATIONS
- OPTIONS, ATTACHMENTS


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : UEAM005000
Total Pages : 318


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FOREWORD
SAFETY INFORMATION
Signal words
Example of safety message using signal word
Other signal words
Example of safety label using words
Safety labels using pictogram
NOISE
Vibration levels
Operating condition:
Guide to Reduce Vibration Levels on Machine
INTRODUCTION
DIRECTIONS OF MACHINE
VISIBILITY FROM OPERATOR'S SEAT
PROXIMITY VISIBILITY
12M CIRCUMFERENCE VISIBILITY
BREAKING-IN THE NEW MACHINE
PRODUCT INFORMATION
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION
SERVICE METER LOCATION
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR
MACHINE SERIAL PLATE
FOREWORD
SAFETY
OPERATION
MAINTENANCE
SPECIFICATIONS
ATTACHMENTS AND OPTIONS
INDEX
COLOPHON
SAFETY INFORMATION
SAFETY LABELS
LOCATION OF SAFETY LABELS
SAFETY LABELS
SAFETY INFORMATION
SAFETY RULES
IF PROBLEMS ARE FOUND
WORKING WEAR AND PERSONAL PROTECTIVE ITEMS
FIRE EXTINGUISHER AND FIRST AID KIT
SAFETY EQUIPMENT
KEEP MACHINE CLEAN
KEEP OPERATOR'S COMPARTMENT CLEAN
LEAVING OPERATOR'S SEAT WITH LOCK
HANDRAILS AND STEPS
MOUNTING AND DISMOUNTING
NO PERSONS ON ATTACHMENTS
DO NOT GET CAUGHT IN ARTICULATED PORTION
BURN PREVENTION
FIRE PREVENTION AND EXPLOSION PREVENTION
ACTION IF FIRE OCCURS
WINDSHIELD WASHER FLUID
FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION
ATTACHMENT INSTALLATION
ATTACHMENT COMBINATIONS
CAB WINDOW GLASSES
UNAUTHORIZED MODIFICATIONS
SAFETY AT JOBSITE
WORKING ON LOOSE GROUND
DISTANCE TO HIGH VOLTAGE CABLES
ENSURE GOOD VISIBILITY
VENTILATION FOR ENCLOSED AREA
SIGNALMAN'S SIGNAL AND SIGNS
EMERGENCY EXIT FROM OPERATOR'S CAB
ASBESTOS DUST HAZARD PREVENTION
SAFETY MACHINE OPERATION
STARTING ENGINE
CHECKS BEFORE STARTING ENGINE
SAFETY RULES FOR STARTING ENGINE
STARTING ENGINE IN COLD WEATHER
OPERATION
CHECKS BEFORE OPERATION
SAFETY RULES FOR CHANGING MACHINE DIRECTIONS
SAFETY RULES FOR TRAVELING
TRAVELING ON SLOPES
OPERATIONS ON SLOPES
PROHIBITED OPERATIONS
OPERATIONS ON SNOW
PARKING MACHINE
TRANSPORTATION
LOADING AND UNLOADING
SHIPPING THE MACHINE
BATTERY
BATTERY HAZARD PREVENTION
STARTING ENGINE WITH BOOSTER CABLES
TOWING
SAFETY RULES FOR TOWING
LIFTING OBJECTS WITH BUCKET
SAFETY RULES FOR LIFTING OBJECTS
SAFETY MAINTENANCE INFORMATION
WARNING TAG
KEEP WORK PLACE CLEAN AND TIDY
APPOINT LEADER WHEN WORKING WITH OTHERS
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING
PROPER TOOLS
ACCUMULATOR
PERSONNEL
ATTACHMENTS
WORK UNDER THE MACHINE
NOISE
WHEN USING HAMMER
WELDING WORKS
REMOVING BATTERY TERMINALS
SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION
DO NOT DISASSEMBLE RECOIL SPRINGS
SAFETY RULES FOR HIGH-PRESSURE OIL
PRECAUTION FOR HIGH FUEL PRESSURE
SAFETY HANDLING HIGH-PRESSURE HOSES
PRECAUTION FOR HIGH VOLTAGE
WASTE MATERIALS
AIR CONDITIONER MAINTENANCE
COMPRESSED AIR
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS
MACHINE VIEW ILLUSTRATIONS
OVERALL MACHINE VIEW
CONTROLS AND GAUGES
DETAILED CONTROLS AND GAUGES
MONITORING SYSTEM
Basic Operation of Machine Monitor
If There Is Abnormality When Starting Engine
If Any Abnormality Occurs During Operation
Emergency Monitors
Engine Coolant Temperature Monitor
Hydraulic Oil Temperature Monitor
Engine Oil Pressure Monitor
Caution Monitors
Charge Level Monitor
Fuel Level Monitor
Air Cleaner Clogging Monitor
Engine Coolant Temperature Monitor
Hydraulic Oil Temperature Monitor
Basic Check Monitors
Radiator Coolant Level Monitor
Engine Oil Level Monitor
Maintenance Interval Monitor
Meter Display Portion
Pilot Display
Engine Pre-heating Monitor
Swing Lock Monitor
Wiper Monitor
Auto-deceleration Monitor
Working Mode Monitor
Travel Speed Monitor
One-Touch Power Max. Monitor
Gauges and Meter
Engine Coolant Temperature Gauge
Fuel Gauge
Hydraulic Oil Temperature Gauge
Service Meter
Monitor Switches Portion
Working Mode Selector Switch (Basic Switch)
Auto-deceleration Switch (Selection Switch)
Travel Speed Selector Switch (Selection Switch)
Wiper Switch
Window Washer Switch
Maintenance Switch
User Mode Adjustment Switch
Fan Reverse Rotation
Adjusting Set Value of Economy Mode
Back Switch
Up Switch, Down Switch
Input Confirmation Switch
Liquid Crystal Monitor Adjustment Switch
Adjusting Brightness
Adjusting Contrast
Alarm Buzzer Stop Switch
SWITCHES
Starting Switch
Fuel Control Dial
Cigarette Lighter
Machine Push-up Switch
Lamp Switch
Swing Lock Switch
Boom Shockless Control Switch
Horn Switch
Room Lamp Switch
Emergency Pump Drive Switch
Swing Brake Cancel Switch
Revolving Warning Lamp Switch
Lower Wiper Switch
Step Light Switch
One-Touch Power Max. Switch
Large Capacity Airflow Air Conditioner Blower Switch
CONTROL LEVERS AND PEDALS
Lock Lever
Travel Levers (with Pedals and Auto-deceleration Device)
Work Equipment Control Lever
SUN ROOF
Opening
Closing
WINDSHIELD
Opening
Closing
Removing Lower Windshield
EMERGENCY EXIT FROM OPERATOR'S CAB
DOOR LOCK
CAP WITH LOCK
Opening and Closing Caps with Lock
Opening the Cap
Locking the Cap
Opening and Closing Cover with Lock
Opening the Cover (Locked Cover)
Locking the Cover
HOT AND COOL BOX
MAGAZINE BOX
ASHTRAY
AIR CONDITIONER CONTROLS
Air Conditioner Control Panel
OFF Switch
Fan Switch
Temperature Control Switch
Vent Selector Switch
Auto Switch
FRESH/RECIRC Selector Switch
Display Monitor
Air Conditioner Switch
Sunlight Sensor
Method of Operation
Automatic Operation
Stopping Automatic Operation
Manual Operation
Stopping Manual Operation
Operation with Cold Air to Face and Warm Air to Feet
Defroster Operation
Use Air Conditioner with Care
Ventilation
Temperature Control
Inspection and maintenance of Air Conditioner Equipped Machine
Other Functions
Self-diagnostic Function
Function to Switch Set Temperature Display Between Fahrenheit and Celsius
CAB RADIO
Antenna
Use Radio With Care
AUXILIARY ELECTRIC POWER
24V power source
12V power source
FUSE
Fuse Capacities and Circuit Names
CIRCUIT BREAKER
CONTROLLER
TOOL BOX
GREASE PUMP
Method of Use
Precautions when Using
Supplying Grease
ACCUMULATOR
Releasing Hydraulic Pressure With Accumulator
MACHINE OPERATIONS AND CONTROLS
BEFORE STARTING ENGINE
Walk-around Checks
Checks Before Starting
Check Coolant Level, Add Coolant
Check Oil Level in Engine Oil Pan, Add Oil
Check Fuel Level, Add Fuel
Check for Water and Sediment in Water Separator, Drain Water
Drain Water And Sediment from Fuel Tank
Check Oil Level in Hydraulic Tank, Add Oil
Check Oil Level in Swing Machinery Case, Add Oil
Check Oil Level in P.T.O Case, Add Oil
Check Working Lamp Switch
Check Electric Wiring
Check Function of Horn
Adjustment
Seat Adjustment
Rearview Mirrors
Seat Belt
Fastening and Removing
Fastening Seat Belt
Removing Belt
Operations Before Starting Engine
STARTING ENGINE
AFTER STARTING ENGINE
Warming Up Engine
Warming Up Hydraulic Equipment
Operation After Completion Of Warming-Up Operation
STOPPING THE ENGINE
MACHINE OPERATION
Preparations for Moving the Machine
Moving Machine Forward
Moving Machine Backward
Stopping Machine
STEERING THE MACHINE
Steering
Steering the Machine when Stopped
Changing Direction of the Machine
Counter-rotation Turn (Spin Turn)
SWINGING
WORK EQUIPMENT CONTROLS AND OPERATIONS
WORKING MODE
Working Mode
Setting Economy Mode
PROHIBITED OPERATIONS
Operations Using Swing Force
Operations Using Travel Force
Prohibition of Operations Using Hydraulic Cylinders to Stroke Ends
Operations Using Bucket Dropping Force
Operations Using Machine Dropping Force
Digging Hard Rocky Ground
Sudden Lever Shifting High Speed Travel
GENERAL OPERATION INFORMATION
Traveling
High Speed Travel
Precautions when Carrying Out Operations Continually with the Work Equipment in the Same Posture
Permissible Water Depth
TRAVELING ON SLOPES
Traveling Downhill
Engine Stopped on Slope
Cab Doors on Slope
ESCAPE FROM MUD
Track on One Side Stuck
Tracks on Both Sides Stuck
RECOMMENDED APPLICATIONS
Backhoe Work
Ditching Work
Loading Work
BUCKET REPLACEMENT
Replacement
PARKING MACHINE
MACHINE INSPECTION AFTER DAILY WORK
LOCKING
OVERLOAD WARNING DEVICE (option)
TRANSPORTATION
PRECAUTIONS FOR TRANSPORTATION
LIFTING MACHINE
SHIPPING MACHINE INFORMATION
TRANSPORTATION POSTURE
Three units for transportation
Posture for Each Unit
Upper Structure + Undercarriage
Upper Structure
Undercarriage
Work Equipment
Others
PROCEDURE FOR INCREASING OR REDUCING TRACK FRAME GAUGE
Reducing Track Gauge
Increasing Track Gauge
COLD WEATHER OPERATION
COLD WEATHER OPERATION INFORMATION
Fuel and Lubricants
Cooling System Coolant
Battery
Monitor
AFTER DAILY WORK COMPLETION
AFTER COLD WEATHER SEASON
LONG TERM STORAGE
BEFORE STORAGE
DURING STORAGE
AFTER STORAGE
STARTING MACHINE AFTER LONG-TERM STORAGE
TROUBLES AND ACTIONS
RUNNING OUT OF FUEL
Procedure for Bleeding Air
PHENOMENA THAT ARE NOT FAILURES
TOWING THE MACHINE
SEVERE JOB CONDITION
DISCHARGED BATTERY
Battery Removal and Installation
Battery Charges
Starting Engine with Booster Cables
Connecting and Disconnecting Booster Cables
Booster Cable Connection
Starting the Engine
Booster Cable Disconnection
OTHER TROUBLE
Electrical System
Chassis
Engine
Electronic Control System
Machine Monitoring System
Point of Contact to Telephone when Error Occurs
MAINTENANCE INFORMATION
Service Meter Reading
Komatsu Genuine Replacement Parts
Komatsu Genuine Lubricants
Windshield Washer Fluid
Fresh and Clean Lubricants
Check Drained Oil and Used Filter
Fuel Strainer
Welding Instructions
Do not Drop Things Inside Machine
Dusty Jobsite
Avoid Mixing Lubricants
Locking the Inspection Covers
Hydraulic System - Air Bleeding
Hydraulic Hose Installation
Checks After Inspection and Maintenance Works
OUTLINE OF SERVICE
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC
Oil
Fuel
Cooling System Coolant
Grease
Carrying Out KOWA (Komatsu Oil Wear Analysis)
KOWA Analysis Items
Oil Sampling
Oil and Fuel Storage
Filters
ELECTRIC SYSTEM MAINTENANCE
WEAR PARTS
WEAR PARTS LIST
LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL
TIGHTENING TORQUE SPECIFICATIONS
TIGHTENING TORQUE LIST
SAFETY CRITICAL PARTS
SAFETY CRITICAL PARTS LIST
MAINTENANCE SCHEDULE
MAINTENANCE SCHEDULE CHART
INITIAL 100 HOURS MAINTENANCE (ONLY AFTER THE FIRST 100 HOURS)
INITIAL 500 HOURS MAINTENANCE (ONLY AFTER THE FIRST 500 HOURS)
WHEN REQUIRED
CHECKS BEFORE STARTING
EVERY 10 HOURS MAINTENANCE
EVERY 100 HOURS MAINTENANCE
EVERY 250 HOURS MAINTENANCE
EVERY 500 HOURS MAINTENANCE
EVERY 1000 HOURS MAINTENANCE
EVERY 2000 HOURS MAINTENANCE
EVERY 4000 HOURS MAINTENANCE
EVERY 5000 HOURS MAINTENANCE
EVERY 8000 HOURS MAINTENANCE
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER
REPLACE HYDRAULIC OIL FILTER ELEMENT
CHANGE OIL IN HYDRAULIC TANK
REPLACE ADDITIONAL FILTER ELEMENT FOR BREAKER
MAINTENANCE PROCEDURE
INITIAL 100 HOURS MAINTENANCE (ONLY AFTER THE FIRST 100 HOURS)
INITIAL 500 HOURS MAINTENANCE (ONLY AFTER THE FIRST 500 HOURS)
WHEN REQUIRED
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT
Checking
Cleaning or Replacing Outer Element
Install Air Cleaner Element
CLEAN INSIDE OF COOLING SYSTEM
CHECK AND TIGHTEN TRACK SHOE BOLTS
Tightening
Order for Tightening
CHECK AND ADJUST TRACK TENSION
Checking
Adjustment
Increasing Track Tension
Loosening Track Tension
REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)
ADJUST BUCKET CLEARANCE
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID
Mixture Ratio of Pure Washer Fluid and Water
CHECK AND MAINTENANCE AIR CONDITIONER
Check Level of Refrigerant (gas)
Inspection During Off Season
Inspection and Maintenance Items
CLEAN LINE FILTER, REMOVE DIRT
REPLACE BREAKER CIRCUIT ADDITIONAL OIL FILTER ELEMENT
CLEAN PILOT LINE FILTER, REMOVE DIRT
BLEEDING AIR FROM HYDRAULIC SYSTEM
Operation
CHECK BEFORE STARTING
EVERY 10 HOURS MAINTENANCE
LUBRICATING
EVERY 100 HOURS MAINTENANCE
LUBRICATING SWING CIRCLE
EVERY 250 HOURS MAINTENANCE
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL
CHECK LEVEL OF BATTERY ELECTROLYTE
When Checking Electrolyte Level from Side of Battery
When it is Impossible to Check Electrolyte Level from Side of Battery
When it is Possible to Use Indicator to Check Electrolyte Level
CHECK AND TIGHTEN TRACK FRAME AND AXLE CONNECTING BOLTS
CHECK ALTERNATOR DRIVE BELT TENSION, ADJUST
Checking
Adjustment
CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST
Checking
Adjustment
EVERY 500 HOURS MAINTENANCE
REPLACE FUEL PRE-FILTER CARTRIDGE
CHECK SWING PINION GREASE LEVEL, ADD GREASE
CLEAN,CHECK RADIATOR FINS,OIL COOLER FINS,FUEL COOLER FINS,AFTERCOOLER FINS,CONDENSER FINS (machines equipped with air conditioner),PTO OIL COOLER FINS
CLEAN FRESH/RECIRC AIR FILTERS OF AIR CONDITIONER (ONLY FOR MACHINES EQUIPPED WITH AIR CONDITIONER)
CLEAN RECIRC AIR FILTER
CLEAN FRESH AIR FILTER
CLEAN STRAINER OF P.T.O LUBRICATING OIL FILTER
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE
EVERY 1000 HOURS MAINTENANCE
REPLACE FUEL MAIN FILTER CARTRIDGE
REPLACE HYDRAULIC OIL FILTER ELEMENT
CHANGE OIL IN SWING MACHINERY CASE
CHANGE OIL IN P.T.O CASE
CHECK ALL TIGHTENING POINTS OF ENGINE EXHAUST PIPE CLAMPS
REPLACE CORROSION RESISTOR CARTRIDGE
CHECK WELDED STRUCTURE
REPLACE HYDRAULIC TANK ADDITIONAL BREATHER ELEMENT
CHECK NITROGEN GAS CHARGE PRESSURE IN ACCUMULATOR (for breaker)
REPLACE BREATHER ELEMENT IN HYDRAULIC TANK
EVERY 2000 HOURS MAINTENANCE
CHANGE OIL IN FINAL DRIVE CASE
CLEAN HYDRAULIC TANK STRAINER
CHECKING CHARGE PRESSURE OF NITROGEN GAS IN ACCUMULATOR (FOR CONTROL CIRCUIT)
FUNCTION OF ACCUMULATOR
CHECKING FUNCTION OF ACCUMULATOR
METHOD OF RELEASING PRESSURE IN HYDRAULIC CIRCUIT
CHECK ALTERNATOR, STARTING MOTOR
EVERY 4000 HOURS MAINTENANCE
CHECK WATER PUMP
REPLACE ACCUMULATOR (FOR CONTROL CIRCUIT)
CHECK FOR LOOSENESS OF HIGH-PRESSURE PIPING CLAMP, HARDENING OF RUBBER
CHECK FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER
CHECK OPERATING CONDITION OF COMPRESSOR
EVERY 5000 HOURS MAINTENANCE
CHANGE OIL IN HYDRAULIC TANK
EVERY 8000 HOURS MAINTENANCE
REPLACE HIGH-PRESSURE PIPING CLAMP
REPLACE FUEL SPRAY PREVENTION CAP
SPECIFICATIONS
GENERAL PRECAUTIONS FOR SAFETY
PRECAUTIONS WHEN SELECTING
READ THE INSTRUCTION MANUAL THOROUGHLY
PRECAUTIONS WHEN REMOVING OR INSTALLING
PRECAUTIONS WHEN USING
ATTACHMENT GUIDE
COMBINATIONS OF WORK EQUIPMENT
Working Range Diagram
TRACK SHOES SELECTION
Selection
HANDLING MACHINES EQUIPPED WITH KOMTRAX
BASIC PRECAUTIONS
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