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SEBM014207

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PC1100-6
PC1100SP-6
PC1100LC-6
MACHINE MODEL SERIAL NUMBER

PC1100-6 10001 and up


PC1100SP-6 10001 and up
PC1100LC-6 10001 and up

• This shop manual may contain attachments and optional equipment that are not available
in your area. Please consult your local Komatsu distributor for those items you may
require. Materials and specifications are subject to change without notice.

• PC1100-6 mount the SAA6D170-2 engine.


For details of the engine, see the 6D170-2 Series Engine Shop Manual.

© 2002 1
All Rights Reserved
00-1
Printed in Japan 02-02(01) 7
CONTENTS

No. of page

01 GENERAL ........................................................................ 01-1

10 STRUCTURE AND FUNCTION ...................................... 10-1

20 TESTING AND ADJUSTING .......................................... 20-1

30 DISASSEMBLY AND ASSEMBLY ................................. 30-1

40 MAINTENANCE STANDARD ......................................... 40-1

90 OTHERS........................................................................... 90-1

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PC1100-6 00-2-3
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30-138 4 30-162 2 40-38
30-138-1 4 30-163 2 40-39
30-138-2 4 30-164 2 40-40 4
30-139 4 30-165 2 40-41 1
30-140 4 40-41-1 4
30-140-1 4 40-42 4
30-140-2 4 40- 1 4 40-43 1
30-140-3 4 40- 2 40-43-1 4
30-140-4 4 40- 3 40-43-2 4
30-141 4 40- 4 40-44
30-142 4 40- 6 40-45
30-142-1 4 40- 7 40-46
30-142-2 4 40- 8 40-47
30-143 4 40- 9
30-144 4 40-10
30-144-1 4 40-12 90- 1 4
30-144-2 4 40-13 90- 3
30-145 4 40-14 90- 3-2 4
30-146 4 40-15 90- 5
30-146-1 4 40-16 90- 7
30-146-2 4 40-17 90- 9
30-146-3 4 40-18 90-11
30-146-4 4 40-19 90-13 4
30-147 2 40-20 90-15 4
30-148 2 40-21 90-17 4
30-149 4 40-22 1 90-19 4
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PC1100-6 00-2-5
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TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE RELATED PARTS

STANDARD VALUE TABLE FOR ENGINE RELATED PARTS

Machine model PC1100-6

Engine SAA6D170-2

Item Measurement condition Unit Standard value Permissible value

High idling 2,000 ± 50 2,000 ± 50

Engine speed Low idling rpm 730 ± 25 730 ± 25

Rated speed 1,800 —

kPa
Intake air pressure At rated output Min. 120 {900} Min. 96 {720}
{mmHg}

All speed range


Exhaust gas pressure (intake air temp.: 20°C) °C Max. 620 Max. 670

At sudden acceleration Max. 4.5 Max. 5.5


Bosch
Exhaust gas color
index
At high idling Max. 1.0 Max. 2.0

(normal temperature)
Intake valve 0.4 —
Valve clearance mm
Exhaust valve 1.0 —

Oil temperature:
40 – 60°C
Compression pressure MPa
(Engine speed: {kg/cm2} Min. 2.9 {30} Min. 2.1 {21}
210 – 250 rpm)
(SAE30 oil)

(Coolant temperature:
within operating range)
Blow-by pressure (SAE30 oil) kPa Max. 3.9 {400} Max. 7.9 {800}
{mmH2O}
At rated output

(Coolant temperature:
Min. 80°C)
Oil pressure At high idling (SAE30) MPa 0.39 – 0.54 {4.0 – 5.5} Min. 0.21 {2.1}
At low idling (SAE30) {kg/cm2} Min. 0.12 {1.2} 0.07 {0.7}
At high idling (SAE10W) 0.34 – 0.49 {3.0 – 5.0} Min. 0.18 {1.8}
At low idling (SAE10W) Min. 0.1 {1.0} Min. 0.07 {0.7}

All speed range


Oil temperature (inside oil pan) °C 80 – 110 Max. 120

Serial No. 10001 – 20300: Serial No. 10001 – 20300:


16 ± 0.5 16 ± 0.5
deg. Serial No. 20301 and up: Serial No. 20301 and up:
Fuel injection timing B. T. D. C. (°) 18 ± 0.5 18 ± 0.5
For 55°C specification: For 55°C specification:
22 ± 0.5 22 ± 0.5

Deflection when pressed


Alternator belt tension with finger force of 10 – 15 —
approx. 58.8 N {6 kg}
mm
Deflection when pressed
Air conditioner com-
with finger force of 10 ± 15 —
pressor belt tension
approx. 58.8 N {6 kg}

20-2 PC1100-6
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TESTING AND ADJUSTING TESTING AND ADJUSTING FUEL INJECTION TIMING

TESTING AND ADJUSTING


FUEL INJECTION TIMING
1. Remove No. 1 cylinder nozzle holder assembly
(1).
fl For details, see DISASSEMBLY AND ASSEM-
BLY, REMOVAL OF NOZZLE HOLDER AS-
SEMBLY.
2. Remove the coupling cover of the fuel injection
pump.
3. Crank the engine to rotate the crankshaft in the
normal direction and align “1.6TOP” line (3) with
pointer (2) to set the No. 1 cylinder to compres-
sion top dead center.
fl Carry out cranking with the barring device
on the flywheel housing.
fl At compression top dead center, line “a” on
the coupling is near line “b” on the fuel
injection pump.
If the lines are not near each other, the cyl-
inder is not at compression top dead center,
so rotate one more turn and align the lines
again.
4. Set so that the tip of gauge assembly H con-
tacts the head of the piston.
5. At near the top dead center, rotate the crank-
shaft in the normal direction and in the reverse
direction to set the top dead center accurately
with the scale of the dial gauge.
fl Set the scale on the dial gauge to 0 when
the piston is at top dead center.
6. Rotate the crankshaft in the reverse direction
from the top dead center position until the scale
on the dial gauge is approx. 10 mm.
7. Rotate the crankshaft again in the normal direc-
tion until the scale on the dial gauge shows
stroke “c” to align the fuel injection timing.
fl Stroke c: Serial No. 10001 – 20300:
0.24 mm (BTDC 16 ± 0.5°)
4.19 +– 0.27
Serial No. 20301 and up:
0.28 mm (BTDC 18 ± 0.5°)
5.29 +– 0.30
For 55°C specification:
7.86 ± 0.35 mm (BTDC 22 ± 0.5°)
fl Always rotate the crankshaft in the normal
direction to align the position. If stroke “c”
is passed, carry out the operation again from
Step 6.
8. When doing this, check that line “a” on the
coupling is aligned with line “b” on the fuel
injection pump body.
fl If the lines are not aligned, loosen 2 mount-
ing bolts (4) in the oblong holes in the cou-
pling, rotate the coupling to align the lines,
then tighten the mounting bolts.
3 Nut: 147 – 166 Nm {15 – 17 kgm}

20-110 PC1100-6
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7
TESTING AND ADJUSTING MEASURING ENGINE OIL PRESSURE

fl After completion of adjustment, rotate the crank-


shaft in the normal direction and check again
that when it passes the compression top dead
center, the error on the dial gauge display is
+ 0.31
000
– 0.30 mm.
If the error is not within the specified range,
carry out the adjustment again from Step 5.

MEASURING ENGINE OIL


PRESSURE
fl Measure the engine oil pressure under the fol-
lowing conditions.
• Coolant temperature: Within operating range

1. Remove engine oil high-pressure switch (1) (PT1/


8).

2. Install the nipple q of oil pressure gauge J1


and connect to oil pressure gauge J2 (0.98 MPa
{10 kg/cm2}).

3. Start the engine, and measure the oil pressure


with the engine at low idling and at high idling.

PC1100-6 20-111
1
7
TESTING AND ADJUSTING TESTING AND ADJUSTING TRACK SHOE TENSION

TESTING AND ADJUSTING


TRACK SHOE TENSION
TESTING
1. Travel the machine forward by the length of
track on ground, keeping the engine at low idling,
and stop the machine slowly.

2. Place straight bar [1] on the track shoe between


the 2nd and the 3rd carrier roller.
fl L beam is recommended for bar [1], because
of its deflection-free nature.

3. Measure max. clearance a between bar [1] and


the track shoe.
• Max. standard clearance a: 10 – 30 mm

ADJUSTING
fl If the track shoe tension is not proper, adjust it
in the following manner.

1 . When the tension is too strong


Discharge grease by loosening valve (1).
¤ Do not loosen valve (1) by more than one
turn, because grease will spurt due to its
internal high pressure.

2 . When the tension is too weak


Add grease through grease fitting (2).
fl If the normal track shoe tension is not re-
stored even after greasing, move the ma-
chine slowly back and forth.

20-116 PC1100-6
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DISASSEMBLY AND ASSEMBLY BUCKET CYLINDER

BACKHOE

REMOVAL OF BUCKET
CYLINDER ASSEMBLY
 Set mounting pin (1) and link (2) at the bucket
cylinder rod end to a position where there is no
interference, then set the back face of the bucket
on a block.
 Stop the engine, then operate the bucket con-
trol lever to release the remaining pressure in
the hydraulic circuit.

1. Remove stopper, then remove rod pin (1) from


link (2). 1
fl After removing the pin, start the engine, and
retract the piston rod, then tie the piston rod
with wire to prevent it from coming out.
fl Extend the arm and set block 1 between
the cylinder and the arm.
fl The bucket and link are still installed, so be
careful when extending the arm.
fl There are shims installed, so check the
number and thickness, and keep in a safe
place.

2. Disconnect 2 left and right cylinder bottom


grease hoses (3).

3. Disconnect right cylinder bottom hose (4) and


head hose (5).

4. Disconnect left cylinder bottom hose (6) and


head hose (7).
fl If there is remaining pressure in the hydrau-
lic circuit, the oil may spurt out, so check
while disconnecting.
fl Fit blind plugs in the hoses after disconnect-
ing them.

5. Sling right bucket cylinder assembly (8) and re-


move lock plate (9), then remove pin (10). 2
fl Pull out pin (10) to a position where the
right cylinder comes off.
fl There are shims installed, so check the
number and thickness, and keep in a safe
place.

6. Lift off right bucket cylinder assembly (8).

7. Remove the cylinder assembly on the left side


in the same way.

4 Bucket cylinder assembly: 700 kg

PC1100-6 30-135
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