Komatsu PC100, PC120, PC130 Hydraulic Excavator Repair Service Manual + Operation & Maintenance Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu PC100-2, PC100L-2, PC100-5, PC100-6, PC120-2, PC120-5, PC120-5 Mighty, PC120-6, PC120-6 Excel, PC120LC-6, PC130-6 Hydraulic Excavator, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu PC100-2, PC100L-2, PC100-5, PC100-6, PC120-2, PC120-5, PC120-5 Mighty, PC120-6, PC120-6 Excel, PC120LC-6, PC130-6 Hydraulic Excavator workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PRODUCT DETAILS:
Total Pages: 5,490 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
SEBM0202B03 - Hydraulic Excavator PC100-2, PC100L-2, PC120-2 Shop Manual.pdf
SEBM003307 - Hydraulic Excavator PC100-6, PC120-6 Shop Manual.pdf
SEBM010404 - Hydraulic Excavator PC120-6 Excel Shop Manual.pdf
SEBM010611 - Hydraulic Excavator PC100-6, PC120-6, PC120LC-6, PC130-6 Shop Manual.pdf
SEBM02020508 - Hydraulic Excavator PC100-5, PC120-5, PC120-5 Mighty Shop Manual.pdf
WEAM000402 - Hydraulic Excavator PC110R-1 Operation & Maintenance Manual.pdf
MEAM2P1200 - Hydraulic Excavator PC100-6 Operation & Maintenance Manual.pdf
SEAM002201 - Hydraulic Excavator PC100-6, PC120-6, PC130-6 Mighty Operation & Maintenance Manual.pdf
SEAM002203 - Hydraulic Excavator PC100-6, PC120-6, PC130-6 Mighty Operation & Maintenance Manual.pdf
SEAM002205 - Hydraulic Excavator PC100-6, PC100L-6, PC120-6, PC130-6 Mighty Operation & Maintenance Manual.pdf
SEAM002207 - Hydraulic Excavator PC100-6, PC100L-6, PC120-6, PC130-6 Mighty Operation & Maintenance Manual.pdf
SEAM002213T - Hydraulic Excavator PC100-6, PC100L-6, PC120-6, PC120LG-6, PC130-6 Mighty Operation & Maintenance Manual.pdf
SEAM063601T - Hydraulic Excavator GALEO PC120-6, PC120LC-6 Operation & Maintenance Manual.pdf
MAIN SECTIONS
COVER...1
CONTENTS...2
01 GENERAL...27
GENERAL ASSEMBLY DRAWING...28
SPECIFICATIONS...33
WEIGHT TABLE...41
LIST OF LUBRICANT AND WATER...49
10 STRUCTURE AND FUNCTION...52
RADIATIR AND OIL COOLER...53
PTO(COUPLING)...56
POWER TRAIN ...57
FINAL DRIVE...59
SWING CIRCLE...60
SWING MACHINERY...61
TRACK FARME...62
TRACK SHOE...66
HYDRAULIC PIPING DRAWING ...67
HYDRAULIC CIRCUIT DIAGRAM...69
HYDRAULIC TANK...74
HYDRAULIC PUMP...75
CONTROL VALUE...95
CLSS...108
SWING MOTOR...160
CENTER SWIVEL JOINT...165
TRAVEL MOTOR ...166
VALVE CONTROL...182
WORK EQUIPMENT?SWING PPC VALVED...183
TRAVEL PPC VALVE...187
SERVICE PPC VALVE...191
SAFETY LOCK VALVE ...194
PPC ACCUMULATOR...194
STRAIGHT-TRAVEL SYSTEM...195
SOLENOID VALVE...196
ACCUMULATOR FOR BREAKER...198
ADDITIONAL FILTER FOR BREAKER...199
WORK EQUIPMENT...200
AIR CONDITIONER...201
ACTUAL ELECTRIC WIRING DIAGRAM...202
ELECTRIC CIRCUIT DIAGRAM...206
ENGINE CONTROL SYSTEM...211
ELECTRONIC CONTROL SYSTEM...219
MACHINE MONITOR SYSTEM...256
FRONT WINDOW AUTO PULL-UP SYSTEM...267
20 TESTING AND ADJUSTING...269
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS...270
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS ...272
STANDARD VALUE TABLE FOR ELECTRICAL PARTS ...283
TOOLS FOR TESTING,ADJUSTING,AND TROUBLESHOOTING...292
MEASURING ENGINE SPEED...293
MEASURING EXHAUST COLOR...294
ADJUSTING VALUE CLEARANCE...295
MEASURING BLOW-BY PRESSURE...296
TESTING AND ADJUSTING FUEL INJECTION TIMING ...297
MEASURING ENGINE OIL PRESSURE...298
TESTNG AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR...299
ADJUSTING ENGINE SPEED SENSOR...300
ADJUSTING GOVERNOR MOTOR LEVER STROKE...301
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT,SWING,TRAVEL CIRCUIT...302
TESTING AND ADJUSTING PC VALUE OUTPUT PRESSURE(SERVO PISTION INPUT PRESURE...305
TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE...307
TSETING AND ADJUSTING CONTROL PUMP CIRCUIT OIL PRESSURE...310
TESTING SOLENOID VALVE OUTPUT PRESSURE...312
MEASURING PPC VALVE OUTPUT PRESSURE...313
ADJUSTING WORK EQUIPMENT,SWING PPC VALVE...314
TESTING TRAVEL DEVIATION...315
TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT...316
MEASURING OIL LEAKAGE...317
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT ...319
TESTING GLEARANCE OF SWING CIRCLE BEARING...320
TESTING AND ADJUSTING TRACK SHOE TENSION...321
BLEEDING AIR...322
TROUBLESHOOTING...324
POINTS TO REMEMBER WHEN TROUBLESHOOTING...325
SEQUENCE OF EVENTS IN TROUBLESHOOTING ...326
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE...327
CHECKS BEFORE TROUBLESHOOTING ...335
CONNECTOR TYPES AND MOUNTING LOCATIONS...336
CONNECTOR ARRANGEMENT DIAGRAM...338
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS...341
DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL...352
METHOD OF USING JUDGEMENT TABLE...362
METHOD OF USING TROUBLESHOOTING CHARTS...364
DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE...366
SERVICE CODE TABLE...371
TROUBLESHOOTING OF COMMUNICATIONS SYSTEM(N MODE)...372
N-1 COMMUNICATIONS ABNORMALITY...373
TROUBLESHOOTING OF ENGINE THROTTLE,PUMP CONTROLLER[GOVERNOR CONTROL SYSTEM](E MODE)...375
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF ENGINE THROTTLE,PUMP CONTROLLER(GOVERNOR CONTROL SYSTEM)...376
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE...377
JUDGEMENT TABLE FOR ENGINE THROTTLE,PUMP CONTROLLER(GOVERNOR CONTROL SYSTEM),AND ENGINE RELATED PARTS...381
ELECTRICAL CIRCUIT DIAGRAM OF ENGINE THROTTLE,PUMP CONTROLLER SYSTEM...383
E-1 ABNORMALITY IN ENGINE THROTTLE,PUMP CONTROLLER POWER SOURCE(CONTROLLER LED IS OFF)...385
E-2 [E308] ABNORMALITY IN FUEL CONTROL DIAL INPUT VALUE IS DISPLAYED...386
E-3 [E317] ABNORMALITY (DISCONNECTION) IN GOVERNOR MOTOR DRIVE SYSTEM IS DISPLAYED...387
E-4 [E318] ABNORMALITY (SHORT CIRCUIT) IN GOVERNOR MOTOR DRIVE SYSTEM IS DISPLAYED...388
E-5 [E306] ABNORMALITY IN FEEDBACK POTENTIOMETER SYSTEM IS DISPLAYED...389
E-6 [E315] ABNORMALITY (SHORT CIRCUIT) IN BATTERY RELAY OUTPUT SYSTEM IS DISPLAYED...390
E-7 [E316] ABNORMALITY (STEP-OUT) IN MOTOR IS DISPLAYED...391
E-8 ENGINE DOES NOT START ...392
E-9 ENGINE SPEED IS IRREGULAR ...394
a) LDING SPEED IS IRREGULAR...394
b) THERE IS HUNTING...396
E-10 LACK OF OUTPUT (ENGINE HIGH IDLING SPEED IS TOO LOW)...398
E-11 ENGINE DOES NOT STOP ...400
E-12 DEFECTIVE OPERATION OF BATTERY RELAY SYSTEM (ENGINE DOES NOT STOP)...402
TROUBLESHOOTING OF ENGINE (S MODE)...404
MOTHOD OF USING TROUBLESHOOTING CHART...405
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)...409
S-2 ENGINE DOES NOT START ...411
(1) ENGINE DOES NOT TURN ...411
(2) ENGINE TURNS BUT NO EXHAIST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED)...412
(3) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)...413
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)...414
S-4 ENGINE STOPS DURING OPERATIONS...415
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)...416
S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)...417
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)...418
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)...419
S-9 OIL BECOMES CONTAMINATED QUICKY ...420
S-10 FUEL CONSUMPTION IS EXCESSIVE...421
S-11 OIL IS IN COOLING WATER,OR WATER SPURTS BACK,OR WATER LEVEL GOES DOWN ...422
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)...423
S-13 OIL LEVEL RISES (WATER,FUEL IN OIL)...424
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)...425
S-15 ABNORMAL NOISE IS MADE...426
S-16 VIBRATION IS EXCESSIVE...427
TROUBLESHOOTING OF ENGINE THROTTLE,PUMP CONTROLLER[PUMP CONTROL SYSTEM](C MODE)...428
POINTS TO REMEMBER WHEN TROUBLESHOOTING PUMP CONTROLLER SYSTEM...429
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE...430
JUDGMENT TABLE FOR PUMP CONTROLLER AND HTDRAULIC RELATED PARTS...438
ELECTRICAL CIRCUIT DIAGRAM OF C MODE SYSTEM ...440
C-1 ABNORMALITY IN CONTROLLER POWER SOURCE SYSTEM (CONTROLLER LED IS OFF)...444
C-2 [E232] SHORT CIRCUIT IN PUMP PC-EPC SOLENOID SYSTEM IS DISPLAYED ...445
C-3 [E233] DISCONNECTION IN PC-EPC SOLENOID SYSTEM IS DISPLAYED...447
C-4 [E203] SHORT CIRCUIT IN SWING HOLDING BRAKE SOLENOID SYSTEM IS DISPLAYED...449
C-5 [E213] DISCONNECTION IN SWING HOLDING BRAKE SOLENOID SYSTEM IS DISPLAYED...451
C-6 [E205] SHORT CIRCUIT IN 2-STAGE RELIEF SOLENOID SYSTEM IS DISPLAYED...453
C-7 [E215] DISCONNECTION IN 2-STAGE RELIEF SOLENOID SYSTEM IS DISPLAYED...454
C-8 [E206] SHORT CIRCUIT IN TRAVEL SPEED SOLENOID SYSTEM IS DISPLAYED...455
C-9 [E216] DISCONNECTION IN TRAVEL SPEED SOLENOID SYSTEM IS DISPLAYED...456
C-10 [E207] SHORT CIRCUIT IN ACTIVE MODE SOLENOID SYSTEM IS DISPLAYED...457
C-11 [E208] DISCONNECTION IN ACTIVE MODE SOLENOID SYSTEM IS DISPLAYED ...458
C-12 [E217] MODEL SELECTION INPUT ERROR IS DISPLAYED ...459
C-13 [E222] SHORT CIRCUIT IN IN LS-EPC SOLENOID SYSTEM IS DISPLAYED...461
C-14 [E223] DISCONNECTION IN LS-EPC SOLENOID SYSTEM IS DISPLAYED...462
C-15 [E224] ABNORMALITY IN PUMP PRESSURE SENSOR SYSTEM IS DISPLAYED...463
C-16 [E226] ABNORMALITY IN PRESSSURE SENSOR POWER SOURCE SYSTEM IS DISPLAYED...464
C-17 [E227] ABNORMALITY IN ENGINE SPEED SENSOR SYSTEM IS DISPLAYED...465
C-18 [E302] SHORT CIRCUIT IN SWING STRIKE LIMIT SOLENOID SYSTEM IS DISPLAYED ...466
C-19 [E215] DISCONNECTION IN SWING STROKE LIMIT SYSTEM IS DISPLAYED ...467
TROUBLESHOOTING OF ENGINE THROTTLE,PUMP CONTROLLER [INPUT SIGNAL SYSTEM](F MODE)...468
ELECTRICAL CIRCUIT DIAGRAM OF F MODE SYSTEM ...469
F-1 BIT PATTERN 20-(1) SWING OIL PRESSURE SWITCH DOES NOT LIGHT UP ...473
F-2 BIT PATTERN 20-(2) TRAVEL OIL PRESSURE SWITCH DOES NOT LIGHT UP ...474
F-3 BIT PATTERN 20-(3) BOOM LOWER OIL PRESSURE SWITCH DOES NOT LIGHT UP ...475
F-4 BIT PATTERN 20-(4) BOOM RAISE OIL PRESSURE SWITCH DOES NOT LIGHT UP ...476
F-5 BIT PARRTEN 20-(5) ARM IN OIL PRESSURE SWITCH DOES NOT LIGHT UP ...477
F-6 BIT PARRTEN 20(6) ARM OUT OIL PRESSURE SWITCH DOES NOT LIGHT UP ...478
F-7 BIT PATTERN 21-(1) BUCKET CURL OIL PRESSURE SWITCH DOES NOT LIGHT UP ...479
F-8 BIT PATTERN 21-(2) BUCKET DUMP OIL PRESSURE SWITCH DOES NOT LIGHT UP ...480
F-9 BIT PATTERN 21-(3) SWING LOCK SWITCH DOES NOT LIGHT UP ...481
F-10 BIT PATTERN 22-(5) KEROSENNE MODE CONNECTION DOES NOT LIGHT UP ...482
F-11 BIT PATTERN 22-(6) L.H. KNOB DOES NOT LIGHT UP ...483
TROUBLESHOOTING OF HYDRAULIC,MECHANICAL SYSTEM(H MODE)...484
