Komatsu PC100-3 PC100L-3 PC120-3 PC150HD-3 PC150NHD-3 Excavator Shop Manual SEBM02020309 PDF

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Komatsu PC100-3 PC100L-3 PC120-3 PC150HD-3 PC150NHD-3 Excavator Shop Manual SEBM02020309 – PDF DOWNLOAD

FILE DETAILS:

Komatsu PC100-3 PC100L-3 PC120-3 PC150HD-3 PC150NHD-3 Excavator Shop Manual SEBM02020309 – PDF DOWNLOAD 

Language : English
Pages : 629
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu PC100-3 PC100L-3 PC120-3 PC150HD-3 PC150NHD-3 Excavator Shop Manual SEBM02020309 – PDF DOWNLOAD 

GENERAL PRECAUTIONS :

Mistakes in operation are extremely dangerous. Read the OPERATION & MAINTENANCE MANUAL carefully BEFORE operating the machine.

PREPARATIONS FOR WORK:

TABLE OF CONTENTS:

Komatsu PC100-3 PC100L-3 PC120-3 PC150HD-3 PC150NHD-3 Excavator Shop Manual SEBM02020309 – PDF DOWNLOAD 

COVER 1
CONTENTS 2
01 GENERAL 15
GENERAL VIEW 16
GENERAL ASSEMBLY DRAWING 17
SPECIFICATIONS 21
ENGINE ASSEMBLY DRAWING 25
LIST OF WEIGHT 26
LIST OF LUBRICANT AND WATER 28
10 ENGINE 29
11 STRUCTURE AND FUNCTION 29
ENGINE MOUNT 30
PTO 31
RADIATOR 32
FUEL TANK AND PIPING 34
ENGINE CONTROL 35
AUTO-DECELERATION SYSTEM (IF EQUIPPED) 37
12 TESTING AND ADJUSTING 50
TESTING AND ADJUSTING DATA 51
TESTING AND ADJUSTING TOOL LIST 52
TESTING AND ADJUSTING DECELERATOR SPEED 53
ADJUSTING VALVE CLEARANCE 54
MEASURING COMPRESSION PRESSURE 55
TESTING AND ADJUSTING FUEL INJECTION TIMING 56
TESTING AND ADJUSTING FAN BELT TENSION 58
MEASURING BLOW-BY PRESSURE 59
MEASURING EXHAUST GAS COLOR 60
13 DISASSEMBLY AND ASSEMBLY 61
STARTING MOTOR 62
DISMOUNTING 62
MOUNTING 62
ALTERNATOR 63
DISMOUNTING 63
MOUNTING 63
FUEL INJECTION PUMP 64
DISMOUNTING 64
MOUNTING 65
ENGINE OIL COOLER 66
DISMOUNTING 66
MOUNTING 66
WATER PUMP 67
DISMOUNTING 67
MOUNTING 69
NOZZLE HOLDER 71
DISMOUNTING 71
MOUNTING 71
CYLINDER HEAD 72
DISMOUNTING 72
MOUNTING 75
HYDRAULIC OIL COOLER 79
DISMOUNTING 79
MOUNTING 80
RADIATOR, HYDRAULIC OIL COOLER 81
DISMOUNTING 81
MOUNTING 84
ENGINE 87
DISMOUNTING 87
MOUNTING 92
PTO 97
DISMOUNTING 97
MOUNTING 97
DISASSEMBLY 98
ASSEMBLY 98
DECELERATION CYLINDER 99
DISMOUNTING 99
MOUNTING 99
20 POWER TRAIN 100
21 STRUCTURE AND FUNCTION 100
POWER TRAIN 101
1 OUTLINE 101
2 POWER TRAIN HYDRAULIC PIPING 102
TRAVEL SYSTEM 105
1 OUTLINE 105
(1) STRAIGHT TRAVEL SYSTEM 107
(2) STRAIGHT TRAVEL VALVE 109
2 TRAVEL CONTROL (WRIST CONTROL TYPE) 110
2 TRAVEL CONTROL (LONG LEVER CONTROL TYPE) 111
3 CENTER SWIVEL JOINT 112
4 TRAVEL MOTOR 113
PC100-3, PC120-3, PC120-3K 113
PC100L-3 119
SWING SYSTEM 132
1 OUTLINE 132
(1) SCHEMATIC OF SWING SYSTEM 133
2 SWING MOTOR AND BRAKE VALVE 136
(1) SWING MOTOR 137
(2) SWING BRAKE VALVE 139
(3) SWING MECHANICAL BRAKE 142
3 SWING CIRCLE 144
4 SWING MACHINERY 145
23 DISASSEMBLY AND ASSEMBLY 147
CENTER SWIVEL JOINT 148
DISMOUNTING 148
MOUNTING 148
DISASSEMBLY 149
ASSEMBLY 149
TRAVEL MOTOR 150
DISMOUNTING 150
MOUNTING 150
DISASSEMBLY (PC100,120) 151
ASSEMBLY (PC100,120) 157
DISASSEMBLY (PC100L) 168
ASSEMBLY (PC100L) 176
SWING MOTOR 185
DISMOUNTING 185
MOUNTING 185
DISASSEMBLY 186
ASSEMBLY 189
SWING CIRCLE 194
DISMOUNTING 194
MOUNTING 196
SWING MACHINERY 198
DISMOUNTING 198
MOUNTING 200
DISASSEMBLY 202
ASSEMBLY 205
SPROCKET 209
DISMOUNTING 209
MOUNTING 209
24 MAINTENANCE STANDARD 210
SWING MACHINERY 211
SWING CIRCLE 213
SPROCKET 214
SWING MOTOR 215
TRAVEL MOTOR 216
FINAL DRIVE 217
30 UNDERCARRIAGE 218
31 STRUCTURE AND FUNCTION 218
TRACK FRAME 219
RECOIL SPRING 222
IDLER 224
TRACK ROLLER 225
CARRIER ROLLER 228
TRACK SHOE 231
33 DISASSEMBLY AND ASSEMBLY 233
IDLER, RECOIL SPRING 234
DISMOUNTING 234
MOUNTING 234
RECOIL SPRING 235
DISASSEMBLY 235
ASSEMBLY 235
TRACK ROLLER 236
DISMOUNTING 236
MOUNTING 236
CARRIER ROLLER 237
DISMOUNTING 237
MOUNTING 237
TRACK SHOE 238
DISMOUNTING 238
MOUNTING 239
34 MAINTENANCE STANDARD 240
TRACK FRAME 241
IDLER 245
TRACK ROLLER 249
CARRIER ROLLER 254
TRACK SHOE 259
60 HYDRAULIC SYSTEM 265
61 STRUCTURE AND FUNCTION 265
OUTLINE 266
1 WORK EQUIPMENT PIPING 266
2 HYDRAULIC CIRCUIT DIAGRAM (WRIST CONTROL TYPE) 268
3 SCHEMATIC OF HYDRAULIC SYSTEM (WRIST CONTROL TYPE) 270
4 HYDRAULIC CIRCUIT DIAGRAM (WRIST CONTROL TYPE) 271
5 SCHEMATIC OF HYDRAULIC SYSTEM (WRIST CONTROL TYPE) 272
6 HYDRAULIC CIRCUIT DIAGRAM (WRIST CONTROL TYPE) 273
7 SCHEMATIC OF HYDRAULIC SYSTEM (LONG LEVER CONTROL TYPE) 274
8 HYDRAULIC CIRCUIT DIAGRAM (LONG LEVER CONTROL TYPE) 275
9 SCHEMATIC OF HYDRAULIC SYSTEM (LONG LEVER CONTROL TYPE) 276
10 HYDRAULIC CIRCUIT DIAGRAM (LONG LEVER CONTROL TYPE) 277
11 SCHEMATIC OF HYDRAULIC SYSTEM 278
・ PC150HD,NHD-3K 278
12 HYDRAULIC CIRCUIT DIAGRAM 279
・ PC150HD,NHD-3K 279
HYDRAULIC TANK (WITH FUEL TANK) 280
HYDRAULIC PUMP 282
1 MAIN PUMP (HPV 055+055) 283
2 SERVO VALVE , TVC VALVE, CO VALVE AND NC VALVE 287
(1) SERVO VALVE 289
(2) TVC VALVE 293
(3) CO AND NC VALVE ASSEMBLY 294
(4) CHARGING PUMP (BAR20) 295
(5) RELIEF VALVE 296
OLSS SYSTEM (OPEN CENTER LOAD SENSING SYSTEM) 297
1 OUTLINE 297
2 BASIC CIRCUIT OF OLSS 299
3 SCHEMATIC OF OLSS 300
4 FUNCTION OF OLSS 301
a CONSTANT TORQUE CONTROL 302
b CUT-OFF CONTROL 304
c FLOW CONTROL 306
CONTROL VALVE 308
1 L H 6-SPOOL CONTROL VALVE (WRIST CONTROL TYPE) 308
2 R H 5-SPOOL CONTROL VALVE (WRIST CONTROL TYPE) 312
3 L H 6-SPOOL CONTROL VALVE (LONG LEVER CONTROL TYPE) 314
4 R H 5-SPOOL CONTROL VALVE (LONG LEVER CONTROL TYPE) 318
5 RELIEF VALVE 320
6 SAFETY-SUCTION VALVE 321
7 SAFETY VALVE 322
8 SUCTION VALVE 323
HYDRAULIC CYLINDER 324
1 BOOM CYLINDER 324
2 ARM CYLINDER 324
3 BUCKET CYLINDER 325
4 CUSHION CYLINDER (ARM CYLINDER HEAD,BOTTOM SIDE) 326
WORK EQUIPMENT HYDRAULIC CONTROL (WRIST CONTROL TYPE) 327
1 OUTLINE 327
2 BOOM CONTROL 328
3 ARM CONTROL 330
4 BUCKET CONTROL 332
5 PPC VALVE (PROPORTIONAL PRESSURE CONTROL VALVE) 334
6 SHUTTLE VALVE 338
7 ACCUMULATOR 339
WORK EQUIPMENT HYDRAULIC CONTROL (LONG LEVER CONTROL TYPE) 340
1 OUTLINE 340
2 BOOM CONTROL 341
3 ARM CONTROL 343
4 BUCKET CONTROL 345
62 TESTING AND ADJUSTING 347
TABLE OF JUDGEMENT STANDARD VALUE 348
TROUBLESHOOTING TOOLS 361
TESTING AND ADJUSTING 362
TROUBLESHOOTING 390
ELECTRICAL CIRCUIT 391
CONNECTION TABLE FOR CONNECTOR PINS 393
TROUBLESHOOTING PROCEDURE 396
CHECKS BEFORE TROUBLESHOOTING 397
JUDGEMENT TABLE 398
TROUBLESHOOTING CHART 403
E-1 MACHINE DEVIATES EXCESSIVELY (WHEN TRAVELING NORMALLY) WORK EQUIPMENT, SWING, TRAVEL SPEEDS EXTREMELY SLOW, OR LACK OF POWER NO CHANGE IN OUTPUT WHEN MODE SWITCH IS OPERATED 403
E-2 MACHINE DEVIATES EXCESSIVELY (DURING COMPOUND OPERATIONS) MACHINE DEVIATES EXCESSIVELY (WHEN STARTING) 406
E-3 HYDRAULIC DRIFT OF SWING IS EXCESSIVE, OR UPPER STRUCTURE DOES NOT SWING 412
E-4 AUTO-DECELERATION DOES NOT WORK 416
H-1 MACHINE DEVIATES EXCESSIVELY (DEVIATES MORE THAN STANDARD WHEN ONLY TRAVEL SYSTEM IS USED, TRAVEL LEVER AT FULL TRAVEL) 430
H-2 MACHINE DEVIATES EXCESSIVELY DURING COMPOUND OPERATIONS 430
H-3 MACHINE DEVIATES EXCESSIVELY WHEN STARTING 432
H-4 CONTROL LEVERS ARE EXTREMELY HEAVY 434
H-5 WORK EQUIPMENT, TRAVEL AND SWING START SUDDENLY DURING FINE CONTROL OPERATIONS 438
H-6 SPEEDS FOR WORK EQUIPMENT, SWING AND TRAVEL ARE ALL EXTREMELY SLOW,OR THERE IS NO POWER (NO ABNORMALITY IN AUTO-DECELERATION (IF EQUIPPED))) 439
H-7 SPEEDS FOR BOOM, ARM AND BUCKET ARE SLOW, OR THERE IS NO POWER (NO ABNORMALITY IN AUTO-DECELERATION (IF EQUIPPED)) 445
H-8 ENGINE STALLS OR ENGINE SPEED DROPS DURING OPERATIONS 446
H-9 NO CHANGE IN OUTPUT WHEN MODE SELECTOR SWITCH IS OPERATED 446
H-10 AUTO-DECELERATOR DOES NOT COME ON, OR DOES NOT GO OFF 447
H-11 ABNORMAL NOISE COMES FROM AROUND PUMP 447
H-12 SWING SPEED IS SLOW, OR OVERRUN WHEN STOPPING SWING IS EXCESSIVE 449
H-13 UPPER STRUCTURE DOES NOT SWING 451
H-14 EXCESSIVE HYDRAULIC DRIFT OF SWING 453
H-15 EXCESSIVE HYDRAULIC DRIFT FOR WORK EQUIPMENT 454
H-17 EXCESSIVE TIME LAG FOR WORK EQUIPMENT 455
FAILURE MODE AND COMPONENTS 456
63 DISASSEMBLY AND ASSEMBLY 457
CHARGING PUMP 458
REMOVAL 458
INSTALLATION 460
MAIN PUMP 462
DISMOUNTING 462
MOUNTING 464
MAIN PUMP INPUT SHAFT OIL SEAL 467
REMOVAL 467
INSTALLATION 468
SERVO VALVE 469
DISMOUNTING 469
MOUNTING 469
TVC VALVE 470
DISMOUNTING 470
MOUNTING 470
CO,NC VALVE 471
DISMOUNTING 471
MOUNTING 471
MAIN PUMP 472
DISASSEMBLY 472
ASSEMBLY 476
L H 6-SPOOL CONTROL VALVE 490
DISMOUNTING 490
MOUNTING 494
R H 5-SPOOL CONTROL VALVE 498
DISMOUNTING 498
MOUNTING 503
DISASSEMBLY 509
ASSEMBLY 511
SOLENOID VALVE 513
DISMOUNTING 513
MOUNTING 513
BOOM CYLINDER 514
DISMOUNTING 514
MOUNTING 514
ARM CYLINDER 515
DISMOUNTING 515
MOUNTING 515
BUCKET CYLINDER 516
DISMOUNTING 516
MOUNTING 516
HYDRAULIC CYLINDER 517
DISASSEMBLY 517
ASSEMBLY 519
PISTON RING AND WEAR RING OF HYDRAULIC CYLINDER 522
DISMOUNTING 522
MOUNTING 522
PPC VALVE 523
DISMOUNTING 523
MOUNTING 523
DISASSEMBLY 524
ASSEMBLY 524
64 MAINTENANCE STANDARD 525
CHARGING PUMP (BAR20) 526
L H 6 SPOOL CONTROL VALVE 527
R H 5 SPOOL CONTROL VALVE 533
L H 6 SPOOL CONTROL VALVE (OPTION) 537
R H 5 SPOOL CONTROL VALVE (OPTION) 541
HYDRAULIC CYLINDER 545
70 WORK EQUIPMENT 547
73 DISASSEMBLY AND ASSEMBLY 547
WORK EQUIPMENT (PC100,120-3) 548
DISMOUNTING 548
MOUNTING 549
OPERATOR’S CAB 550
DISMOUNTING 550
MOUNTING 550
74 MAINTENANCE STANDARD 551
WORK EQUIPMENT 552
80 ELECTRICAL SYSTEM 554
81 STRUCTURE AND FUNCTION 554
ELECTRICAL SYSTEM 555
ELECTRICAL WIRING 556
ELECTRICAL CIRCUIT DIAGRAM 558
ELECTRIC VEHICLE MONITOR SYSTEM (EVMS) 563
82 TESTING AND ADJUSTING 573
ELECTRICAL CIRCUIT DIAGRAM 575
PRECAUTION WHEN TROUBLESHOOTING 578
TROUBLESHOOTING CHART 582
・PC100-3 SERIAL NO 18001-21844,・PC100L-3 SERIAL NO 12001-12324,・PC120-3 SERIAL NO 18001-23282 582
M-1 WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL DISPLAY DOES NOT APPEAR 582
a) NO DISPLAY AT ALL APPEARS ON MONITOR PANEL (GAUGE ASSEMBLY AND MONITOR PANEL ASSEMBLY) 582
b) DISPLAY OF MONITOR ASSEMBLY OR GAUGE ASSEMBLY DOES NOT APPEAR ON MONITOR PANEL 582
c) DISPLAY DOES NOT APPEAR ON PART OF MONITOR PANEL ASSEMBLY 583
M-2 WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL DISPLAY DOES NOT GO OUT 583
M-3 WHEN STARTING SWITCH IS TURNED ON (DO NOT START ENGINE), CHECK BEFORE STARTING ITEM FLASH OR PREHEARTING ITEM LIGHT UP 585
a) COOLANT LEVEL FLASHES 585
b) ENGINE OIL LEVEL FLASHES 585
c) HYDRAULIC OIL LEVEL FLASHES 586
d) HEATER SIGNAL FLASHES 586
M-4 WHEN STARTING SWITCH IS TURNED ON, (ENGINE STARTED), CHECKS BEFORE STARTING ITEMS FLASH 590
a) ALTERNATOR SYSTEM 590
b) ENGINE OIL PRESSURE CIRCUIT 590
M-5 WHEN STARTING SWITCH IS TURNED ON, (DO NOT START ENGINE), CAUTION ITEMS FLASH 592
M-6 WHEN STARTING SWITCH IS TURNED ON, (ENGINE STARTED), CAUTION ITEMS FLASH 594
a) ENGINE OIL PRESSURE FLASHES 594
b) COOLANT LEVEL FLASHES 594
c) COOLANT TEMPERATURE GAUGE FLASHES 595
d) GAUGE LEVEL FLASHES 595
M-7 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED) FOR 2 SECONDS, OR WHEN CAUTION ITEMS ARE FLASHING, WARNING BUZZER DOES NOT SOUND 598
M-8 NO DISPLAY ON MONITOR BUT WARNING BUZZER SOUNDS 600
M-9 MONITOR PANEL LAMPS DO NOT LIGHT UP 602
a) NO LAMPS ON PANEL LIGHT UP 602
b) SOME LAMPS ON PANEL DO NOT LIGHT UP 602
M-10 WHEN ENGINE IS STARTED, SERVICE METER DOES NOT MOVE WHEN ENGINE IS STOPPED, SERVICE METER MOVES 604
a) SERVICE METER DOES NOT MOVE 604
b) SERVICE METER MOVES 605
M-11 ENGINE COOLANT TEMPERATURE IS HIGH, BUT LOWEST LEVEL DISPLAYED 607
M-12 ENGINE COOLANT TEMPERATURE GAUGE GIVES NO DISPLAY 607
M-13 FUEL TANK IS NOT FULL BUT DISPLAY SHOWS FULL TANK 608
M-14 NO DISPLAY IS GIVEN FOR FUEL LEVEL 608
・PC100-3 SERIAL NO 21845 AND UP,・PC100L-3 SERIAL NO 12325 AND UP,・PC120-3 SERIAL NO 23283 AND UP 609
M-1 WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL DISPLAY DOES NOT APPEAR 609
a) NO DISPLAY APPEARS ON MONITOR PANEL (GAUGES AND MONITOR ITEMS) 609
b) DISPLAY DOES NOT APPEAR ON PART OF MONITOR PANEL ASSEMBLY 609
M-2 WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL DISPLAY DOES NOT GO OUT 609
M-3 WHEN STARTING SWITCH IS TURNED ON (DO NOT START ENGINE), CHECK BEFORE STARTING ITEMS FLASH OR PREHEATING ITEMS LIGHTS UP 610
a) COOLANT LEVEL FLASHES 610
b) ENGINE OIL LEVEL FLASHES 610
c) HYDRAULIC OIL LEVEL FLASHES 611
d) HEATER SIGNAL FLASHES 611
M-4 WHEN STARTING SWITCH IS TURNED ON, (ENGINE STARTED), CHECKS BEFORE STARTING ITEMS FLASH 613
a) ALTERNATOR SYSTEM 613
b) EMGINE OIL PRESSURE CIRCUIT 613
M-5 WHEN STARTING SWITCH IS TURNED ON, (DO NOT START ENGINE), CAUTION ITEMS FLASH 615
M-6 WHEN STARTING SWITCH IS ON (ENGINE STARTED), CAUTION ITEMS FLASH 616
a) ENGINE OIL PRESSURE FLASHES 616
b) COOLANT LEVEL FLASHES 616
c) COOLANT TEMPERATURE GAUGE FLASHES 617
d) CHARGE LEVEL FLASHES 617
M-7 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED) FOR 1 SECONDS, OR WHEN CAUTION ITEMS ARE FLASHING, WARNING BUZZER DOES NOT SOUND 619
M-8 NO ABNORMAL DISPLAY ON MONITOR BUT WARNING BUZZER SOUNDS 619
M-9 MONITOR PANEL LAMPS DO NOT LIGHT UP (INDICATION ON MONITOR PANEL IS CORRECT) 621
M-10 WHEN ENGINE IS STARTED, SERVICE METER DOES NOT MOVE WHEN ENGINE IS STOPPED, SERVICE METER MOVES 622
a) SERVICE METER DOES NOT MOVE,WHEN ENGINE IS STARTED 622
b) SERVICE METER DOES NOT STOP MOVING,WHEN ENGINE IS STOPPED 622
M-11 ENGINE COOLANT TEMPERATURE IS HIGH, BUT LOWEST LEVEL DISPLAYED 624
M-12 ENGINE COOLANT TEMPERATURE GAUGE GIVES NO DISPLAY 624
M-13 FUEL TANK IS NOT FULL BUT DISPLAY SHOWS FULL TANK 626
M-14 NO DISPLAY IS GIVEN FOR FUEL LEVEL 626
90 OTHERS 628
91 STRUCTURE AND FUNCTION 628
HEATER 629

IMAGES PREVIEW OF THE MANUAL:

S.V 27/12/24