Komatsu PC600-6 - User Manual

This document is an operation and maintenance manual for the Komatsu PC600-6 and PC600LC-6 Hydraulic Excavators. It provides essential information for safe and effective use, covering operational procedures, technical specifications, and maintenance guidelines.

The manual emphasizes safety throughout, with a dedicated "Safety Information" section (pages 2-2 to 2-18) detailing rules, personal protective equipment, fire prevention, and jobsite safety. It highlights the importance of reading and understanding the manual and all safety labels before operation or maintenance. Key safety warnings include:

• Always read and understand the manual and safety labels.
• Keep the manual in the designated storage location (manual luggage box behind the operator's seat).
• Report any abnormalities (noise, vibration, smell, incorrect gauges, smoke, oil leakage) immediately and do not operate the machine until corrected.
• Wear appropriate personal protective items (hard hat, safety shoes, glasses, mask, gloves, ear plugs, safety belt).
• Keep the machine and operator's compartment clean to prevent slipping or fire hazards.
• Always lower the work equipment completely to the ground and set the safety lock lever to the LOCK position before leaving the operator's seat.
• Use handrails and steps for mounting/dismounting, maintaining three-point contact.
• Never allow anyone to ride on work equipment or attachments.
• Exercise caution around hot coolant and oil to prevent burns.
• Prevent fires and explosions by avoiding flames near fuel/oil, stopping the engine before refueling, and cleaning flammable materials.
• Be aware of falling or flying objects on jobsites and install necessary guards.
• Maintain safe distances from high-voltage cables.
• Ensure good visibility, especially in dark or poor weather conditions.
• Prevent asbestos dust hazards by spraying water, operating upwind, and using approved respirators.
• Periodically replace safety-critical parts like seatbelts and hoses.

Function Description:

The Komatsu PC600-6 and PC600LC-6 are hydraulic excavators designed for various heavy-duty tasks. Their primary functions include:

• Digging work: Excavating soil, rock, and other materials.
• Leveling work: Smoothing and grading surfaces.
• Ditching work: Creating and maintaining trenches.
• Loading work: Transferring excavated materials onto dump trucks or other hauling equipment.
• Demolition work: Breaking down structures.

The machine's operation is controlled via left and right work equipment control levers, travel levers/pedals, and various switches on the monitor panel. The left lever controls arm and swing movements, while the right lever controls boom and bucket movements.

Important Technical Specifications (PC600-6 / PC600LC-6):

• Operating weight (with operator): 56,680 kg (124,980 lb) / 57,680 kg (127,185 lb)
• Bucket capacity: 2.7 m³ (3.5 cu.yd)
• Engine model: Komatsu SA6D140E diesel engine
• Flywheel horsepower: 287 kW (385 HP) / 1,800 rpm (for PC600-6) and 390 HP / 1,800 rpm (for PC600LC-6)
• Overall length: 12,810 mm (42')
• Overall height: 4,300 mm (14' 1'')
• Overall width: 3,900 mm (12' 10'')
• Track shoe width: 600 mm (2')
• Height of cab: 3,310 mm (10' 10'')
• Radius of upper structure: 3,675 mm (12' 1'')
• Length of track: 5,340 mm (17' 6'') / 5,690 mm (10' 8'')
• Tumbler center distance: 4,250 mm (13' 11'') / 4,600 mm (15' 1'')
• Min. ground clearance: 780 mm (2' 7'')
• Travel speed (Low/High): 3.0/4.9 km/h (1.9/3.1 MPH)
• Swing speed: 8.3 rpm
• Fuel tank capacity: 880 liters (232.5 US gal)
• Engine oil pan refill capacity: 37 liters (9.8 US gal)
• Swing machinery case refill capacity: 13 liters (3.4 US gal)
• P.T.O case refill capacity: 6 liters (1.6 US gal)
• Hydraulic tank refill capacity: 360 liters (95.1 US gal)

Usage Features:

• Starting Switch: Used to start or stop the engine, with OFF, ON, START, and HEAT positions. The HEAT position is for cold weather preheating.
• Fuel Control Dial: Adjusts engine speed and output (Low idling to Full speed).
• Cigarette Lighter: Provides a power source (85W, 24V x 3.5A).
• Swing Lock Switch: Locks the upper structure to prevent swinging.
• Windshield Wiper Switch: Operates the front glass wiper continuously or intermittently, and sprays washer fluid.
• Lamp Switch: Turns on various lamps (front, working, additional, rear, monitor lighting).
• Alarm Buzzer Stop Switch: Silences the alarm buzzer.
• Cab Heater Switch: Activates the cab heater (if equipped).
• Machine Push-up Switch: Increases boom thrust force for easier escape from mud or difficult digging.
• Horn Switch: Sounds the horn.
• Knob Switch (One-touch power max. function): Temporarily increases digging power in DH or H mode for up to 8.5 seconds.
• Room Lamp Switch: Lights the room lamp.
• Pump Drive Emergency Switch: Allows temporary operation in case of pump control system failure (display E02).
• Swing Holding Brake Release Switch: Allows temporary swing operation in case of swing brake system failure (display E03).
• Working Mode Selection Switch: Selects between DH (Powerful), H (Heavy-duty), and G (Normal) modes to match operating conditions.
• Auto-deceleration Switch: Automatically lowers engine speed to idling when control levers are neutral, reducing fuel consumption.
• Travel Speed Switch: Selects between Low (Lo) and High (Hi) travel speeds.
• Monitor Display: Includes basic check items (radiator coolant, engine oil, hydraulic oil, engine oil deterioration), caution items (charge level, fuel level, air cleaner clogging), and emergency stop items (engine coolant temperature, engine oil pressure, hydraulic oil temperature).
• Seat Adjustment: Allows adjustment of fore-and-aft position, reclining angle, seat tilt, armrest angle, and suspension (if equipped).
• Rearview Mirrors: Adjustable for optimal visibility around the machine.
• Windshield: Can be opened and stored in the roof of the operator's compartment.
• Door Lock: Secures the cab door in position.
• Cap with Lock: Used to open and close locks on caps and covers (fuel tank, engine hood, battery box, side doors, tool box, hydraulic tank, spare pail cover).
• Hot and Cool Box: Interconnected with the air conditioner for warming or cooling items.
• Luggage Box: Storage for the Operation and Maintenance Manual.
• Radio: Features power/volume control, tone control, FM/AM selection, display selection, tuning buttons, preset station buttons, and stereo indicator.
• Circuit Breaker: Protects electrical components from overcurrent.
• Grease Pump: Stored in a box on the chassis for greasing.

Maintenance Features:

• Service Meter Reading: Daily check to determine maintenance intervals.
• Komatsu Genuine Parts and Lubricants: Emphasizes using genuine parts and specified oils/greases for optimal performance and durability.
• Drained Oil and Used Filter Check: Inspect for metal particles or dirt to detect potential issues.
• Fuel Strainer: Do not remove while fueling.
• Welding Instructions: Turn off engine ignition, do not exceed 200V, connect grounding cable within 1m of weld area, avoid seals/bearings, and do not use work equipment pins/hydraulic cylinders as grounding points.
• Prevent Dropping Objects: Exercise caution when opening inspection windows or filler ports.
• Dusty Jobsite Precautions: Frequent checks of air cleaner, radiator core, and fuel filter.
• Avoid Mixing Lubricants: Drain old oil completely before adding a different brand or grade.
• Locking Inspection Covers: Secure covers during maintenance.
• Hydraulic System Air Bleeding: Procedure for bleeding air after repairs or component replacement.
• Checks After Maintenance: Verify all inspection and maintenance items are performed correctly, check for leaks, and ensure proper function.
• Cooling System Coolant: Use permanent antifreeze (ethylene glycol with corrosion inhibitor) suitable for ambient temperatures.
• Battery Maintenance: Wear safety glasses and rubber gloves, avoid flames, disconnect ground (-) terminal first, connect positive (+) terminal first.
• Track Shoe Bolts: Check and tighten periodically.
• Track Tension Adjustment: Procedure for increasing or loosening track tension.
• Bucket Teeth Replacement: Guidelines for safe replacement of horizontal pin type bucket teeth.
• Bucket Clearance Adjustment: Procedure for adjusting free play in the bucket coupling section.
• Fan Belt and Auto Tensioner: Auto-tensioner eliminates manual adjustment until replacement.
• Window Washer Fluid: Check level and add appropriate mixture for ambient temperature.
• Air Conditioner Maintenance: Check refrigerant level, inspect during off-season, and follow inspection/maintenance items.
• Line Filter Cleaning: Procedure for cleaning the line filter and removing dirt.
• Breaker Circuit Additional Oil Filter Element: Replacement procedure (if equipped).
• Hydraulic Tank Oil Change and Strainer Cleaning: Procedure for draining oil and cleaning the strainer.
• P.T.O Case Oil Change: Procedure for draining and refilling oil.
• Turbocharger Checks: Inspect tightening parts and rotor play.
• Corrosion Resistor Cartridge Replacement: Procedure for replacing the cartridge.
• Welded Structure Check: Visual and color check for cracks on revolving frame, center frame, boom, and arm.
• Water Pump Check: Inspect for oil/water leakage or clogging.
• Vibration Damper Check: Inspect for leakage, dents, or runout.
• Fan Pulley and Tension Pulley Check: Inspect for play and grease leakage.
• Air Compressor Adjustment: Special tool required.
• High-Pressure Clamp and Fuel Spray Prevention Cap Checks: Inspect for looseness, hardening of rubber, or missing parts.
• Injector Nozzle Assembly Replacement: Contact Komatsu distributor.