Description

Komatsu PC1100-6, PC1100SP-6, PC1100LC-6 2002 Workshop Manual

You are tracking a hydraulic leak that shows up only under load. The aftermarket diagram you pulled off some forum has the pump ports swapped. Now you are replacing a $4,000 pump because someone’s guess cost you billable time. That is why I reach for the factory binder first. This is the Komatsu PC1100-6, PC1100SP-6, PC1100LC-6 2002 Workshop Manual — 885 pages of the same documentation the dealer techs use. No repackaged third-party PDF. OEM print, OEM specs, OEM wiring colors.

Engine and Fuel System Data

PC1100-6 mounts the SAA6D170-2 engine. The manual starts with a full specification section — bore, stroke, compression ratio, and the exact fuel, coolant, and lubricant recommendations from the factory. Section 01 gives you the weight table, so you know what you are lifting before you chain it. Fuel injection timing adjustment procedure is in Section 20 with the step-by-step and the required tool list. Need the charge pressure for the fuel system? That data is on page 73 of the standard value table. Do not guess injection pump timing. This manual walks you through the lock-wire method and the timing marks.

Valve Clearance and Related Adjustments

Valve clearance is a feeler-gauge procedure, but the spec varies between intake and exhaust, and between cold and hot engine. The factory table on page 20-13 lists each. You also get the belt tension procedure for the fan, alternator, and A/C compressor. Every adjustment step includes the torque sequence. The manual tells you which belts to tension first and why. I have seen guys snap a compressor bracket by over-tensioning the wrong belt. The OEM procedure prevents that.

Testing and Adjusting: What Section 20 Actually Covers

This is the section that separates a pro from a parts-changer. You get standard value tables for engine-related parts, chassis parts, and electrical parts. Then the testing procedures: measuring engine speed, boost pressure (air supply pressure), exhaust temperature, compression pressure, blow-by pressure. There is a dedicated procedure for testing and adjusting fuel injection timing. Hydraulic pressure tests for work equipment, swing, and travel circuits. Control pump circuit oil pressure. Piston pump control adjustments. The troubleshooting chapter is split by control system — N mode for communication abnormalities (E117, E118, E218, E507), E mode for engine controller and APS controller. Each fault has its own electrical circuit diagram and a judgment table. You isolate the fault, you do not shotgun parts.

Structure and Function: Hydraulics and Wiring

Section 10 breaks down every major assembly: PTO, radiator/oil cooler/aftercooler, power train, swing machinery, final drive, track frame, track shoe, air system (piping, circuit, governor, tank, safety valve, horn valve). Hydraulic section covers the tank, all three pumps (No.1, No.2, No.3), filters, the L.H. 5-spool control valve, R.H. 4-spool control valve, swing 4-spool, straight-travel valve, boom lower regeneration valve, swing motor, center swivel joint, travel motor, PPC relief, safety lock valve, accumulator, solenoid valves. There is an actual electric wiring diagram and an electric circuit diagram. Engine control, machine control system, machine monitor system all get their own subsections. If you are chasing an electrical gremlin, you need the factory wire colors, not a scan of a scan. The manual gives you connector types, pin numbers, and mounting locations. That is the difference between a two-hour diag and a two-day guess.

Why OEM Documentation Matters

Aftermarket manuals get the torque specs wrong. I have a drawer full of parts that failed because some paperback book told someone to use 200 ft-lb on a bolt that should be 180 with thread locker. This manual is printed by Komatsu in 2002. It includes the list of revised pages — you can see exactly which pages were amended, with marks and revision dates. That is traceability. You do not get that from a pirated PDF. Every specification drawing, every hydraulic piping drawing, every actual wiring diagram is from the factory. If your machine has serial number 10001 and up, this is the book for it. Check the KOMATSU PC1100-6 Field Assembly Instruction for the pre-delivery steps. The Komatsu PC1100-6 PC1100SP-6 PC1100LC-6 2002 Workshop Manual on this site is the same file as the dealer network uses. Also see the Komatsu PC1100-6 PC1100SP-6 PC1100LC-6 Shop Manual for the companion maintenance standard volume.

7 Systems, One Book

The manual is split into five sections: GENERAL (01), STRUCTURE AND FUNCTION (10), TESTING AND ADJUSTING (20), DISASSEMBLY AND ASSEMBLY (30), MAINTENANCE STANDARD (40), and OTHERS (90). That covers the engine, powertrain, hydraulics, electrical, air conditioning, track undercarriage, and control systems. If you work on heavy excavators, you know that a single job — say, replacing a swing motor — can require wiring schematics, hydraulic circuit diagrams, torque tables, and assembly steps. This manual has them all in one 885-page file. No flipping between three different books. Contrast that with a generic Manual Transmission guide that has nothing to do with this machine. For a true comparison of shop manual quality, read this Manual Transmission article on Wikipedia — but for Komatsu, use the factory book.

FAQ

Does this manual cover the PC1100LC-6 with long track?

Yes. The manual includes all three variants: PC1100-6, PC1100SP-6, and PC1100LC-6. Serial numbers 10001 and up for each. The track frame, track shoe, and final drive sections apply to the LC model.

Are torque specs given in ft-lb or Nm?

Both. The specification drawings and standard value tables list torque in both imperial (ft-lb) and metric (Nm). You will also find tightening sequences for head bolts, main bearings, and track shoe bolts.

What is the page count of the troubleshooting section?

Hundreds of pages. The troubleshooting chapter alone runs from about page 20-50 through 20-200. It covers communication faults (N mode) and engine controller faults (E mode) with specific judgment tables and circuit diagrams.

Can I use this for a PC1100-6 that has been modified with an aftermarket hydraulic pump?

You can still use the manual for the base machine structure, wiring, and engine. But the factory pump control settings and test procedures assume the Komatsu pump. If you swapped pumps, cross-reference the standard value table for pressures and adjust accordingly. The manual gives you the baseline to understand what changed.

You are already paying for a machine that costs six figures. Buying a $40 factory manual is not a cost. It is insurance against a $4,000 mistake. Access the Factory Manual now and get the full 885 pages in a digital format you can search, zoom, and print on demand. No reprints, no third-party edits — just the original Komatsu workshop manual file.