Komatsu Hydraulic Excavator Excel PC120-6 Shop Manual SEBM010404 – PDF DOWNLOAD
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Komatsu Hydraulic Excavator Excel PC120-6 Shop Manual SEBM010404 – PDF DOWNLOAD
Description
Komatsu Hydraulic Excavator Excel PC120-6 Shop Manual SEBM010404 – PDF DOWNLOAD
FILE DETAILS:
Komatsu Hydraulic Excavator Excel PC120-6 Shop Manual SEBM010404 – PDF DOWNLOAD
Language : English
Pages :541
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Komatsu Hydraulic Excavator Excel PC120-6 Shop Manual SEBM010404 – PDF DOWNLOAD
FOREWORD
GENERAL
- This shop manual has been prepared as an aid to improve the quality of repairs by
giving the serviceman an accurate understanding of the product and by showing him the correct way
to perform repairs and make judgements. Make sure you understand the contents of this manual and
use it to full effect at every opportunity. - This shop manual mainly contains the necessary technical information for operations performed
in a service workshop. For ease of understanding, the manual is divided into the following
chapters; these chapters are further divided into the each main group of components.
This section explains the structure and function of each component. It serves not only to
give an understanding of the structure, but also serves as reference material for
troubleshooting.
This section explains checks to be made before and after performing repairs, as well
as adjustments to be made at completion of the checks and repairs.
Troubleshooting charts correlating “Problems” to “Causes” are also included in this section.
This section explains the order to be followed when removing, installing, disassembling
or assembling each component, as well as precautions to be taken for these operations.
This section gives the judgement standards when inspecting disassembled parts.
Komatsu Hydraulic Excavator Excel PC120-6 Shop Manual SEBM010404 – PDF DOWNLOAD
COVER 1
CONTENTS 2
01 GENERAL 23
GENERAL ASSEMBLY DRAWING 24
SPECIFICATIONS 25
WEIGHT TABLE 27
LIST OF LUBRICANT AND WATER 29
10 STRUCTURE AND FUNCTION 31
RADIATOR AND OIL COOLER 32
ENGINE CONTROL 33
PTO (COUPLING) 34
POWER TRAIN 35
SWING CIRCLE 36
SWING MACHINERY 37
TRACK FRAME 38
TRACK SHOE 39
HYDRAULIC CIRCUIT DIAGRAM 40
HYDRAULIC TANK 45
HYDRAULIC PUMP 46
CONTROL VALVE 66
CLSS 77
SWING MOTOR123
CENTER SWIVEL JOINT126
TRAVEL MOTOR127
VALVE CONTROL135
WORK EQUIPMENT・SWING PPC VALVE137
TRAVEL PPC VALVE141
SERVICE PPC VALVE145
SAFETY LOCK VALVE148
PPC ACCUMULATOR148
STRAIGHT-TRAVEL SYSTEM149
SOLENOID VALVE 150
ACCUMULATOR FOR BREAKER154
ADDITIONAL FILTER FOR BREAKER155
WORK EQUIPMENT156
AIR CONDITIONER157
ACTUAL ELERICAL WIRING DIAGRAM158
ELECTRICAL CIRCUIT DIAGRAM162
ELECTRIC CONTROL SYSTEM167
MACHINE MONITOR SYSTEM172
SENSORS175
20 TESTING AND ADJUSTING177
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS178
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS179
STANDARD VALUE TABLE FOR ELECTRICAL PARTS187
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING189
MEASURING ENGINE SPEED190
MEASURING EXHAUST COLOR191
ADJUSTING VALVE CLEARANCE192
MEASURING BLOW-BY PRESSURE193
TESTING AND ADJUSTING FUEL INJECTION TIMING194
MEASURING ENGINE OIL PRESSURE195
TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR196
ADJUSTING FUEL CONTROL LEVER197
ADJUSTING ENGINE SPEED SENSOR199
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT200
TESTING AND ADJUSTING PC VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE)202
TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE204
TESTING AND ADJUSTING CONTROL PUMP CIRCUIT OIL PRESSURE207
TESTING SOLENOID VALVE OUTPUT PRESSURE209
ADJUSTING WORK EQUIPMENT, SWING PPC VALVE211
TESTING TRAVEL DEVIATION212
MEASURING OIL LEAKAGE213
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT215
TESTING CLEARANCE OF SWING CIRCLE BEARING216
TESTING AND ADJUSTING TRACK SHOE TENSION217
MEASURING WEAR OF SPROCKET218
BLEEDING AIR219
TROUBLESHOOTING221
POINTS TO REMEMBER WHEN TROUBLESHOOTING222
SEQUENCE OF EVENTS IN TROUBLESHOOTING223
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE224
CHECKS BEFORE TROUBLESHOOTING232
CONNECTOR TYPES AND MOUNTING LOCATIONS233
CONNECTOR ARRANGEMENT DIAGRAM235
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS237
METHOD OF USING JUDGEMENT TABLE247
METHOD OF USING TROUBLESHOOTING CHARTS249
TROUBLESHOOTING OF ENGINE (S MODE)251
METHOD OF USING TROUBLESHOOTING CHART252
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)256
S-2 ENGINE DOES NOT START258
1) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED)258
2) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)259
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)260
S-4 ENDINE STOPS DURING OPERATIONS261
S-5 ENGINE DOES NOT ROTATES SMOOTHLY (HUNTING)262
S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)263
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)264
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)265
S-9 OIL BECOMES CONTAMINATED QUICKLY266
S-10 FUEL CONSUMPTION IS EXCESSIVE267
S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN268
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)269
S-13 OIL LEVEL RISES (WATER, FUEL IN OIL)270
S-14 WATER TEMPERTURE BECOMES TOO HIGH (OVERHEATING)271
S-15 ABNORMAL NOISE IS MADE 272
S-16 VIBRATION IS EXCESSIVE273
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)274
JUDGEMENT TABLE FOR ELECTRICAL, HYDRAULIC, AND MECHANICAL SYSTEMS275
E MODE RELATED ELECTRIC CIRCUIT DIAGRAM277
E-1 ABNORMALITY IN PC-EPC SYSTEM280
a) SPEEDS OF ALL WORK EQUIPMENT, SWING, TRAVEL ARE SLOW OR LACK POWER280
b) THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS281
E-2 ABNORMALITY IN PPC LOCK SOLENOID SYSTEM283
a) WORK EQUIPMENT, SWING, TRAVEL DO NOT MOVE EVEN WHEN SAFETY LOCK IS PLACED AT FREE283
b) WORK EQUIPMENT, SWING, TRAVEL MOVE EVEN WHEN SAFETY LOCK IS PLACED AT LOCK283
E-3 ABNORMALITY IN SWING LOCK SOLENOID SYSTEM286
a) SWING DOES NOT MOVE EVEN WHEN SWING LOCK SWITCH IS PLACED AT FREE286
b) SWING MOVES EVEN WHEN SWING LOCK SWITCH IS PLACED AT LOCK286
E-4 ABNORMALITY IN TRAVEL SPEED SOLENOID SYSTEM288
a) MACHINE DOES NOT TRAVEL AT HIGH SPEED EVEN WHEN TRAVEL SPEED SELECTOR SWITCH IS AT HI288
b) MACHINE DOES NOT TRAVEL AT LOW SPEED EVEN WHEN TRAVEL SPEED SELECTOR SWITCH IS AT LO288
E-5 ABNORMALITY IN ENGINE STARTING SYSTEM (ENGINE DOES NOT START)290
TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE)293
TABLE OF FAILURE MODES AND CAUSES294
H-1 SPEEDS OF ALL WORK EQUIPMENT, TRAVEL, SWING ARE SLOW OR LACK POWER296
H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS296
H-3 NO WORK EQUIPMENT, TRAVEL, SWING MOVE297
H-4 ABNORMALITY NOISE GENERATED (AROUND PUMP)297
H-5 FINE CONTROL ABLITY IS POOR OR RESPONSE IS POOR298
H-6 BOOM IS SLOW OR LACKS POWER299
H-7 ARM IS SLOW OR LACKS POWER299
H-8 BUCKET IS SLOW OR LACKS POWER301
H-9 WORK EQUIPMENT (BOOM, ARM, BUCKET) DOES NOT MOVE (BUT TRAVEL AND SWING ARE NORMAL)301
H-10 EXCESSIVE HYDRAULIC DRIFT (BOOM, ARM, OR BUCKET)302
H-11 IN COMPOUND OPERATIONS, WORK EQUIPMENT WITH LARGER LOAD IS SLOW 302
H-12 IN SWING + BOOM RAISE, BOOM RAISE IS SLOW 303
H-13 IN SWING + TRAVEL, TRAVEL SPEED DROPS EXCESSIVELY303
H-14 IN WORK EQUIPMENT + TRAVEL, TRAVEL SPEED DROPS EXCESSIVELY303
H-15 TRAVEL DEVIATION304
a) WHEN THERE IS DEVIATION IN NORMAL TRAVEL304
b) DEVIATION IS EXCESSIVE WHEN STARTING304
H-16 TRAVEL SPEED IS SLOW305
H-17 STEERING IS DIFFERENT TO TURN OR LACKS POWER306
H-18 TRAVEL SPEED DOES NOT SWITCH308
H-19 TRAVEL DOES NOT MOVE (ONE SIDE ONLY)308
H-20 DOES NOT SWING 309
a) DOES NOT SWING TO EITHER LEFT OR RIGHT309
b) DOES NOT SWING IN ONE DIRECTION309
H-21 SWING ACCELERATION IS POOR310
H-22 EXCESSIVE OVERRUN WHEN STOPPING SWING312
a) ONE DIRECTION ONLY 312
b) BOTH DIRECTIONS312
H-23 EXCESSIVE SHOCK WHEN STOPPING SWING (ONE DIRECTION ONLY)313
H-24 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING313
H-25 EXCESSIVE HYDRULIC DRIFT OF SWING 314
a) WHEN SWING LOCK SWITCH IS OFF314
b) WHEN SWING LOCK SWITCH IS AT LOCK314
TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE)315
ELECTRICAL CIRCUIT DIAGRAM FOR M MODE SYSTEM316
M-1 WHEN THE STARTING SWITCH IS TURNED ON, NO DISPLAY IS GIVEN (3 SECOND SELF CHECK IS ALSO NOT CARRIED OUT)317
M-2 WHEN STARTING SWITCH IS TURNED ON, EVEN WHEN SELF CHECK IS COMPLETED (ALL LAMPS LIGHT UP FOR 3 SECOND), LAMPS DO NOT GO OUT317
M-3 WHEN STARTING SWITCH IS TURNED ON, SOME SELF CHECK LAMPS DO NOT LIGHT UP FOR 3 SECONDS318
a) NO GAUGE LAMPS LIGHT UP (CAUTION LAMPS LIGHT UP)318
b) SWING LOCK OR PREHEATING LAMPS DO NOT LIGHT UP (GAUGE LAMPS ALL LIGHT UP)318
c) BATTERY CHARGE LAMP DOES NOT LIGHT UP318
d) ENGINE OIL PRESSURE LAMP DOES NOT LIGHT UP318
M-4 WHEN STARTING SWITCH IS ON (ENGINE STOPPED), BATTERY CHARGE CAUTION LAMP DOES NOT LIGHT UP319
M-5 WHEN STARTING SWITCH IS ON (ENGINE STOPPED), ENGINE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP319
M-6 WHEN STARTING SWITCH IS TURNED TO HEAT, PREHEATING PILOT LAMP DOES NOT LIGHT UP320
M-7 WHEN SWING LOCK IS TURNED ON, SWING LOCK PILOT LAMP DOES NOT LIGHT UP320
M-8 WHEN ENGINE IS RUNNING, ENGINE OIL PRESSURE CAUTION LAMP LIGHTS UP (ENGINE OIL PRESSURE IS NORMAL)321
M-9 WHEN ENGINE IS RUNNING, BATTERY CHARGE CAUTION LAMP LIGHTS UP321
M-10 ABNORMALITY IN ENGINE WATER TEMPERATURE GAUGE322
a) AFTER ENGINE IS STARTED, ONLY LOWEST LEVEL LAMP (WHITE RANGE) LIGHTS UP AND LEVEL DOES NOT RISE322
b) AFTER ENGINE IS STARTED, LEVEL IMMEDIATELY RISES AND ENTERS RED RANGE (THERE IS NO OVERHEATING)322
c) GAUGE GOES OUT322
M-11 ABNORMALITY IN FUEL GAUGE 324
a) ALL SEGMENTS OF GAUGE GO OUT 324
b) FUEL LEVEL HAS GONE DOWN, BUT GAUGE ALWAYS DISPLAYS FULL324
c) EVEN WHEN FUEL TANK IS FILED, GAUGE DOES NOT DISPLAY FULL324
M-12 DEFETIVE OPERATION OF ALARM BUZZER326
a) BUZZER DOES NOT SOUND326
b) BUZZER CONTINUES TO SOUND AND DOES NOT STOP326
M-13 WHEN ENGINE IS RUNNING, SERVICE METER DOES NOT ADVANCE327
a) WHEN BATTERY CHARGE CAUTION LAMP DOES NOT LIGHT UP327
b) WHEN BATTERY CHARGE CAUTION LAMP LIGHTS UP327
M-14 NIGHT LIGHTING DOES NOT LIGHT UP328
a) GAUGE LIGHTING DOES NOT LIGHT UP328
b) SERVICE METER LIGHTING DOES NOT LIGHT UP (SERVICE METER WORKS NORMALLY)328
M-15 HEATER DOES NOT WORK (MACHINES WITH HEATER)329
a) BOTH LO AND HI DO NOT WORK 329
b) ONLY LO DOES NOT WORK329
c) ONLY HI DOES NOT WORK329
30 DISASSEMBLY AND ASSEMBLY331
METHOD OF USING MANUAL333
PRECAUTIONS WHEN CARRYING OUT OPERATION334
SPECIAL TOOL LIST336
SKETCHES OF SPECIAL TOOLS340
STARTING MOTOR342
REMOVAL AND INSTALLATION342
ALTERNATOR343
REMOVAL AND INSTALLATION343
AIR CONDITIONER COMPRESSOR345
REMOVAL AND INSTALLATION345
CONDENSER346
REMOVAL AND INSTALLATION346
ENGINE OIL COOLER347
REMOVAL AND INSTALLATION347
FUEL INJECTION PUMP348
REMOVAL348
INSTALLATION350
WATER PUMP352
REMOVAL AND INSTALLATION352
NOZZLE HOLDER353
REMOVAL AND INSTALLATION353
TURBOCHARGER354
REMOVAL AND INSTALLATION354
THERMOSTAT355
REMOVAL AND INSTALLATION355
CYLINDER HEAD356
REMOVAL356
INSTALLATION361
ENGINE, MAIN PUMP364
REMOVAL364
INSTALLATION368
HYDRAULIC COOLER369
REMOVAL AND INSTALLATION369
RADIATOR, HYDRAULIC COOLER370
REMOVAL370
INSTALLATION371
FUEL TANK 372
REMOVAL AND INSTALLATION372
CENTER SWIVEL JOINT373
REMOVAL AND INSTALLATION373
DISASSEMBLY AND ASSEMBLY374
SPROCKET375
REMOVAL AND INSTALLATION375
TRAVEL MOTOR376
REMOVAL AND INSTALLATION376
SWING MACHINERY, SWING MOTOR377
REMOVAL AND INSTALLATION377
SWING MOTOR378
REMOVAL AND INSTALLATION378
DISASSEMBLY379
ASSEMBLY383
SWING MACHINERY391
DISASSEMBLY391
ASSEMBLY394
REVOLVING FRAME398
REMOVAL398
INSTALLATION399
SWING CIRCLE400
REMOVAL AND INSTALLATION400
IDLER, RECOIL SPRING401
REMOVAL AND INSTALLATION401
IDLER402
DISASSEMBLY402
ASSEMBLY403
RECOIL SPRING405
DISASSEMBLY405
ASSEMBLY406
TRACK ROLLER407
REMOVAL AND INSTALLATION407
DISASSEMBLY408
ASSEMBLY409
CARRIER ROLLER411
REMOVAL AND INSTALLATION411
TRACK SHOE412
REMOVAL AND INSTALLATION412
HYDRAULIC TANK413
REMOVAL413
INSTALLATION414
CONTROL PUMP415
REMOVAL AND INSTALLATION415
MAIN PUMP416
REMOVAL416
INSTALLATION417
DISASSEMBLY418
ASSEMBLY428
MAIN PUMP INPUT SHAFT OIL SEAL440
REMOVAL AND INSTALLATION440
CONTROL VALVE441
REMOVAL441
INSTALLATION442
DISASSEMBLY443
ASSEMBLY448
LS SELECT VALVE454
DISASSEMBLY AND ASSEMBLY454
PC-EPC VALVE455
REMOVAL AND INSTALLATION455
PC VALVE456
REMOVAL AND INSTALLATION456
LS VALVE457
REMOVAL AND INSTALLATION457
SOLENOID VALVE458
REMOVAL AND INSTALLATION458
PPC VALVE460
REMOVAL AND INSTALLATION460
WORK EQUIPMENT RIGHT SIDE PPC VALVE461
REMOVAL AND INSTALLATION461
WORK EQUIPMENT, SWING PPC VALVE462
DISASSEMBLY462
ASSEMBLY463
TRAVEL PPC VALVE464
REMOVAL AND INSTALLATION464
DISASSEMBLY465
ASSEMBLY466
BOOM CYLINDER467
REMOVAL467
INSTALLATION468
ARM CYLINDER469
REMOVAL469
INSTALLATION470
BUCKET CYLINDER471
REMOVAL471
INSTALLATION472
HYDRAULIC CYLINDER473
DISASSEMBLY473
ASSEMBLY476
WORK EQUIPMENT480
REMOVAL480
INSTALLATION481
BUCKET482
REMOVAL482
INSTALLATION483
ARM 484
REMOVAL484
INSTALLATION485
BUCKET, ARM486
REMOVAL486
INSTALLATION487
BOOM488
REMOVAL488
INSTALLATION489
OPERATOR’S CAB490
REMOVAL AND INSTALLATION490
COUNTERWEIGHT491
REMOVAL AND INSTALLATION491
MONITOR492
REMOVAL AND INSTALLATION492
40 MAINTENANCE STANDARD493
SWING MACHINERY494
SWING CIRCLE496
TRACK FRAME 497
IDLER498
CARRIER ROLLER499
TRACK ROLLER500
SPROCKET501
TRACK SHOE502
HYDRAULIC PUMP509
CONTROL VALVE511
SWING MOTOR521
TRAVEL MOTOR522
CENTER SWIVEL JOINT523
WORK EQUIPMENT・SWING PPC VALVE524
TRAVEL PPC VALVE525
SERVICE PPC VALVE526
HYDRAULIC CYLINDER527
WORK EQUIPMENT529
DIMENSION OF WORK EQUIPMENT 531
90 OTHER535
HYDRAULIC CIRCUIT DIAGRAM PC120-6 EXCEL SERIAL NO57449-60967536
HYDRAULIC CIRCUIT DIAGRAM PC120-6 EXCEL SERIAL NO60968 AND UP 537
ELECTRICAL CIRCUIT GIAGRAM CHASSIS ELECTRICAL CIRCUIT DIAGRAM (1/2) PC120-6 EXCEL SERIAL NO57499-60967538
ELECTRICAL CIRCUIT DIAGRAM CHASSIS ELECTRICAL CIRCUIT DIAGRAM (2/2) PC120-6 EXCEL SERIAL NO57499-60967539
ELECTRICAL CIRCUIT DIAGRAM CHASSIS ELECTRICAL CIRCUIT DIAGRAM (1/2) PC120-6 EXCEL SERIAL NO60968 AND UP540
ELECTRICAL CIRCUIT DIAGRAM CHASSIS ELECTRICAL CIRCUIT DIAGRAM (2/2) PC120-6 EXCEL SERIAL NO60968 AND UP 541
IMAGES PREVIEW OF THE MANUAL:
S.M 14/12/24
