Operation & Maintenance sean Manual EXCEL HYDRAULIC EXCAVATOR (Ship's Hold Coal Spec.) SERIAL NUMBERS PC120-61626 and up & warning Unsafe use of this machine may cause serious injury or death. Operators and maintenance personnel must read this manual before operating or maintain- ing this machine. This manual should be kept near the machine for reference and periodically reviewed by all personnel who will come into contact with NOTICE Komatsu has Operation & Maintenance Manuals written in ‘some other languages. If a foreign language manual is necessary, contact your local distributor for availabilty1. 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 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. This Operation and Maintenance Manual is for the PC120-6 Excel Ship's Hold Coal specification machine. It gives only description of special parts that are not given in the standard Operation and Maintenance Manual. First, read the Operation and Maintenance Manual for the standard machine and make sure that you fully understand it, then read this Manual. 2 WaRNING ‘© 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. Keep this manual in the luggage box to the rear of the operator's seat, and have all personnel involved in working on the machine read the manual periodically. ‘© 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 manu: ‘© 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 machi © The description of safety is given in SAFETY INFORMATION on page CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some ofits constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm,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. Apancer 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 machi Awarnine This word is used on safety messages and safety labels where there is a potentially dangerous situation which could resutt 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 machin AACAUTION - Thisword 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 machin: 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. f 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.3. INTRODUCTION 3.1 INTENDED USE This Komatsu HYDRAULIC EXCAVATOR is designed to be used mainly for the following work: © Coal loading work 3.2 FEATURES © This Komatsu HYDRAULIC EXCAVATOR is equipped with various controls based on an advanced electronics system. © The monitor panel greatly facilitates daily maintenance and self-diagnosis. © Working mode, active mode and travel speed are selectable, © Active power max. (For details, see the Operation and Maintenance Manual for the standard machine.) © Digging and lifting force can be increased by light-touch control. (For details, see operation section.) ‘© Adjustable wrist control levers make operations smooth and easy. © Air conditioned cab for comfortable operation © Air conditioner with fresh air intake employed (uses new freon) © Large cab employed * Viscous mount employed to reduce lateral swaying of operator's cab ‘© Low noise level and smart urban-style design and coloring. © Superb operating performance provided by powerful engine and high-performance hydraulic pumps. © 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 i © Idle the engine for 5 minutes after starting it up. Avoid operation with heavy loads or at high speeds. © 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.4. HANDLING SHIP'S HOLD COAL SPECIFICATION MACHINE By CAUTION This specification machine has been newly developed as thi Do not use it for any work other than that specified below. ship's hold coal specification machine. 4.1 SPECIFIED WORK FOR SHIP’S HOLD COAL SPECIFICATION MACHINE Work moving coal inside a ship's hold (it has a large bucket, so it cannot be used for soil) 4.2 PROHIBITED WORK By CAUTION 1. Digging work: The large bucket is a light bucket exclusively for the coal specification. It can- not be used for digging soil. 2. It must not be used for any work other than moving coal le a ship's hold. 4.3 EXPLANATION AND HANDLING OF SPECIAL DEVICES FOR SHIP’S HOLD COAL SPECIFICATION 1. Method for lifting machine 2. Fire extinguisher for engine room5. CONTENTS 1. Foreword .. 2. Safety information 2 3. Introduction .... vn 3 4. Handling ship's hold coal specification machine . 4 6. Method of lifting machine 6 7. Method of lifting machine (Track frame) 1 8. xxtinguisher for engine room = 8 9. Specificatio 106. METHOD OF LIFTING MACHINE Ay WARNING © Do not lift the machine with a worker on it. © When lifting the machine, use wire ropes sufficiently strong for the machine weight. © Do not lift the machine in a different position from the Position shown in the following procedure. if it is lifted in a different position, it may be unbalanced. When Wg the machine, stop the machine on flat ground and do as follows. 1 5. 6. Start the engine and set the work equipment to the posture shown in the diagram on the right (boom fully raised, arm, bucket pulled in fully). Set the upper structure facing straight to the front (idler end). Set the safety lock lever to the LOCK position. Stop the engine and confirm that there is nothing around the operator's seat, then get off the machine. Ifthe machine is equipped with cab, close the door and front | glass of the cab securely. Install shackles to the lifting hooks on top of the counterweight and boom. Set the length of the wire rope and the lifting angle to the values shown in the diagram on the right, then raise the machi When the machine is raised, check that there is no change in the posture caused by leakage of oil from the hydraulic circuit at the boom cylinder head end, When the machine leaves the ground, stop and check carefully * that the machine is balanced. When the machine becomes stable, lift it slowly.7. METHOD OF LIFTING MACHINE (Track frame) When lifting the machine, do as follows (when lifting the machine at the track frame} 1. Set the work equipment to the transportation posture and lock the control levers securely with the lock lever. 2. Stop the engine. 3. Fit the lifting tools securely to the brackets on the track fram (@8904* 1240} 160, 354, Note: The dimensions marked with * show one example of a coal hoist. Dimensions marked with @ show the values when the lifting dimension of the tool (sling + hook, shackle) = 4.5 m. © When lifting the machine, balance it, being especially careful of the center of gravity. '® After the machine leaves the ground, stop lifting once. After the machine is stabilized, lift it up slowly. Note: Do not lift the machine with a worker on it. Ber tno | ample strength for the machine weight of 12.5 tons when lifting the machine. Note: Use shackles, hooks, and sling belts with i i rite shoe Main hook (with spring) #5 Track frame bracket Zview8. FIRE EXTINGUISHER FOR ENGINE ROOM Main pump. 1. The fire extinguishers installed to the left and right inside the operator's cab at the rear are the fire ‘extinguishers for dealing with fire inside the engine room. 2. Pull out the safety pin of the fire extinguisher, then grip the lever. The fire extinguishing agent (powder) will be sprayed out from the nozzles at the tip of the pipes at five places. (The spray continues for approx. 18 seconds.) 3. The fire extinguisher on the right side of the machine is used to extinguish fires around the main pump and engine injection pump. 4, The fire extinguisher on the left of the machine is used to extinguish fires around the battery and engine turbocharger.6. inside the pipeline of the fire extinguisher. To make it possible to use the fire extingui 8, FIRE EXTINGUISHER FOR ENGINE ROOM Inspection and maintenance of fire extinguisher {inside engine room) 1) Atleast once every six months, carry out a visual inspection of the fire extinguishers (pressurized type ABC powder, DP-10X x 2) and the piping and hoses. 2) The function and performance of the fire extinguisher will deteriorate after about 5 years. Hf any abnormality is found during visual inspection or 3 years after the date of manufacture, it is necessary to check the function. In such cases, please contact your Komatsu distributor or the fire extinguisher manufacturer. 3) In particular, the extinguishing agent becomes compressed and solidified by humidity and the vibration of the machine. This means that there is danger that it may not function when it is needed, so replace it sooner than normal. 4) Every 6 months, tur the fire extinguisher upside down to prevent the extinguishing agent from solidifying. (Remove the cylinder, put it upside down, shake it lightly, then install it to its original position.) (1) Check that there is no leakage of the extinguishing agent. (2) Check that the safety device has not come off. (3) Check that there is no deformation, damage, corrosion, clogging, or looseness of the container, safety device, lever cap, piping, hose, nozzle, nozzle plug, safety valve, or any other part. Maintenance after using fire extinguisher After the extinguishing agent has been sprayed out from the fire extinguisher, powder will remain ther again, always carry out the following maintenance. 1 2, 3. |. Replace the fire extinguisher with a new fire extinguisher or with a fire extinguisher which has . Remove the tee for connecting tube of PK-7 [Fig. K0830] in the Parts Book. . Remove the spray nozzle at the tip of the above tub 4, After removing the tube, blow with air from the 5. 6. 7. ‘A CAUTION been refilled with fire extinguishing agent. of the tube to remove all the fire extinguishing powder remaining inside the tube. Connect the tee and nozzle agai To prevent the spray hole in the tip of the nozzle becor Install the new fire extinguisher. 1um foil ’ing clogged, cover it with alu 7. Precautions when cleaning inside engine room ‘Ay CAUTION 1. Remove all coal from the surrounding area before opening the hood. 2. When cleaning, remove the undercover and top cover, and remove all coal from inside the engine room and around the pump chamber. 3. When adding hydraulic oil or fuel, be careful not to let the oil or fuel spill from the filler. 4. When cleaning, check the area around the muffler (exhaust manifold, turbocharger, etc.) to check that there is no coal remair9. SPECIFICATION tem | PC120-6 | (ship’s hold coal spec.) weight (without operator) | 12,500 kg Bucket capacity 1am Bucket width 2,200 mm Flywheel horsepower 84 HP/2,200 rpm. ‘Arm length Overall length Overall height Overall width 2495, 7595 6 2790 Kr, ol 1805 2200 2750 11500 3480 2480 10PC120-s EXCEL HYDRAULIC EXCAVATOR (SHIP'S HOLD COAL SPECIFICATION) Form No. SEAMO24700 91998 momaysu Al Rights Reserved Printed in Japan 12-98 (01-1)