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Komatsu PC100-5 PC120-5 PC120-5 MIGHTY Excavator Shop Manual 28001, 30001, 36601 and up – DOWNLOAD
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Komatsu PC100-5 PC120-5 PC120-5 MIGHTY Excavator Shop Manual
Book Code: SEBM02020508
MACHINE MODEL SERIAL No.
- PC100-5 28001 and up
- PC120-5 30001 and up
- PC120-5 MIGHTY 36601 and up
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Description
Komatsu PC100-5 PC120-5 PC120-5 MIGHTY Excavator Shop Manual
FILE DETAILS:
Komatsu PC100-5 PC120-5 PC120-5 MIGHTY Excavator Shop Manual
Brands: Komatsu
Equipment Type: Hydraulic Excavator
Manuals Type: Shop Manual
Machine Model: PC100-5, PC120-5, PC120-5 MIGHTY
Serial Number: 28001 and up, 30001 and up, 36601 and up
Book Code: SEBM02020508
Language: English
Pages: 644
File Format: Portable Document Format (PDF)
KOMATSU PC100-5 PC120-5 PC120-5 MIGHTY EXCAVATOR SHOP MANUAL 28001, 30001, 36601 AND UP – DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu PC100-5 PC120-5 PC120-5 MIGHTY Excavator Shop Manual
FOREWORD:
GENERAL:
- This shop manual has been prepared as an aid to improve the quality of repairs by giving the servicemen 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.
STRUCTURE AND FUNCTION:
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.
TESTING AND ADJUSTING:
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 thissection.
DISASSEMBLY AND ASSEMBLY:
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.
MAINTENANCE STANDARD :
This section gives the judgement standards when inspecting disassembled parts.
TABLE OF CONTENTS:
Komatsu PC100-5 PC120-5 PC120-5 MIGHTY Excavator Shop Manual
COVER............................................................................................................................................................ 1 CONTENTS......................................................................................................................................................... 2 10 STRUCTURE AND FUNCTION........................................................................................................................................ 25 ENGINE RELATED PARTS AND ENGINE MOUNT........................................................................................................................ 26 RADIATOR AND OIL COOLER...................................................................................................................................... 27 P.T.O........................................................................................................................................................ 29 FUEL SYSTEM.................................................................................................................................................. 30 POWER TRAIN.................................................................................................................................................. 31 FINAL DRIVE.................................................................................................................................................. 33 SWING CIRCLE................................................................................................................................................. 34 SWING MACHINERY.............................................................................................................................................. 35 TRACK FRAME.................................................................................................................................................. 36 IDLER........................................................................................................................................................ 38 IDLER CUSHION................................................................................................................................................ 38 CARRIER ROLLER............................................................................................................................................... 39 TRACK ROLLER................................................................................................................................................. 39 TRACK SHOE................................................................................................................................................... 40 HYDRAULIC PIPING............................................................................................................................................. 43 HYDRAULIC CIRCUIT DIAGRAM.................................................................................................................................... 45 HYDRAULIC TANK AND FUEL TANK................................................................................................................................. 52 OLSS (OPEN CENTER LOAD SENSING SYSTEM)....................................................................................................................... 54 HYDRAULIC PUMP............................................................................................................................................... 56 L.H. 6-SPOOL CONTROL VALVE................................................................................................................................... 75 R.H. 5-SPOOL CONTROL VALVE................................................................................................................................... 80 SWING MOTOR.................................................................................................................................................. 85 CENTER SWIVEL JOINT.......................................................................................................................................... 88 TRAVEL MOTOR................................................................................................................................................. 89 VALVE CONTROL................................................................................................................................................103 PPC VALVE....................................................................................................................................................105 ACCUMULATOR..................................................................................................................................................113 SAFETY LOCK VALVE............................................................................................................................................114 SOLENOID VALVE...............................................................................................................................................115 SHUTTLE VALVE................................................................................................................................................120 BOOM HOLDING VALVE...........................................................................................................................................125 HYDRAULIC CYLINDER...........................................................................................................................................129 ELECTRICAL WIRING DIAGRAM....................................................................................................................................131 ELECTRICAL CIRCUIT DIAGRAM...................................................................................................................................135 ENGINE CONTROL SYSTEM........................................................................................................................................141 PEMC SYSTEM..................................................................................................................................................152 EMACC (ELECTRONIC MONITOR AND CONTROL CONSOLE)...............................................................................................................183 20 TESTING AND ADJUSTING.........................................................................................................................................191 TABLE OF JUDGEMENT STANDARD VALUE............................................................................................................................192 STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM...................................................................................................................207 TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING............................................................................................................229 ADJUSTING VALVE CLEARANCE....................................................................................................................................230 MEASURING COMPRESSION PRESSURE...............................................................................................................................231 TESTING AND ADJUSTING FUEL INJECTION TIMING..................................................................................................................232 TESTING AND ADJUSTING TRAVEL OF GOVERNOR MOTOR LEVER.........................................................................................................233 INSPECTION OF SWING CIRCLE BEARING CLEARANCE.................................................................................................................234 ADJUSTING ENGINE SPEED SENSOR................................................................................................................................235 ADJUSTING TRAVEL LIMIT SWITCH................................................................................................................................235 TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT............................................................................236 TESTING AND ADJUSTING CHARGING PUMP PRESSURE.................................................................................................................238 TESTING AND ADJUSTING MAIN PUMP CONTROL PRESSURE.............................................................................................................240 MEASURING STROKE OF SERVO PISTON.............................................................................................................................247 TESTING AND ADJUSTING TRAVEL DEVIATION.......................................................................................................................248 MEASURING OUTPUT PRESSURE OF PPC VALVE.......................................................................................................................250 ADJUSTING PPC VALVE..........................................................................................................................................252 TESTING PPC SHUTTLE VALVE....................................................................................................................................254 MEASURING SOLENOID VALVE OUTLET PORT PRESSURE................................................................................................................255 TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT..................................................................................................257 BLEEDING AIR.................................................................................................................................................259 RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT............................................................................................................261 TROUBLESHOOTING..............................................................................................................................................262 POINTS TO REMEMBER WHEN TROUBLESHOOTING..................................................................................................................263 SEQUENCE OF EVENTS IN TROUBLESHOOTING....................................................................................................................264 PRECAUTIONS WHEN CARRYING OUT MAINTENANCE................................................................................................................265 CHECKS BEFORE TROUBLESHOOTING............................................................................................................................272 ELECTRICAL CIRCUIT DIAGRAM...............................................................................................................................273 POSITION OF CONNECTORS FOR TROUBLESHOOTING...............................................................................................................280 CONNECTION TABLE FOR CONNECTOR...........................................................................................................................291 HANDLING CONNECTORS......................................................................................................................................299 EXPLANATION OF FUNCTIONS OF CONTROL MECHANISM OF ELECTRICAL SYSTEM.......................................................................................300 DISPLAY METHOD FOR MONITOR PANEL, PUMP CONTROLLER AND ENGINE THROTTLE CONTROLLER.........................................................................303 ACTION OF SELF-DIAGNOSTIC FUNCTION AND SYMPTOMS ON MACHINE...............................................................................................307 METHOD OF USING JUDGEMENT TABLE..........................................................................................................................312 METHOD OF USING TROUBLESHOOTING CHARTS..................................................................................................................314 TROUBLESHOOTING OF ENGINE THROTTLE CONTROLLER SYSTEM (E MODE)............................................................................................316 ENGINE THROTTLE CONTROLLER OR IN ENGINE RELATED PARTS................................................................................................317 POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING ON ENGINE THROTTLE CONTROLLER SYSTEM............................................................318 E-1 [ABNORMALITY IN POWER SOURCE SYSTEM OR CONTROLLER] IS DISPLAYED (ALL LAMPS OFF)..................................................................319 E-2 [SHORT CIRCUIT GOVERNOR MOTOR] IS DISPLAYED......................................................................................................323 E-3 [ABNORMALITY IN BATTERY RELAY] IS DISPLAYED......................................................................................................324 E-4 [DISCONNECTION IN WIRING HARNESS OF GOVERNOR MOTOR] IS DISPLAYED.................................................................................326 E-5 [ABNORMALITY IN GOVERNOR POTENTIOMETER] IS DISPLAYED.............................................................................................327 E-6 [ABNORMALITY IN FUEL CONTROL DIAL] IS DISPLAYED..................................................................................................329 E-7 [ABNORMALITY IN NO.2 THROTTLE SIGNAL] IS DISPLAYED...............................................................................................330 E-8 ENGINE DOES NOT START............................................................................................................................332 E-9 ENGINE ROTATION IS IRREGULAR.....................................................................................................................336 a) IDLING ROTATION IS IRREGULAR..................................................................................................................336 b) THERE IS HUNTING..............................................................................................................................338 E-10 LACK OF OUTPUT POWER (MAX,ENGINE SPEED IS TOO LOW)..............................................................................................340 E-11 ENGINE DOES NOT STOP............................................................................................................................342 E-12 AUTOMATIC WARMING-UP OPERATION IS DEFECTIVE.....................................................................................................346 TROUBLESHOOTING OF PUMP CONTROLLER SYSTEM (C MODE).......................................................................................................347 CHART FOR DISTINGUISHING IF FAILURE IS IN PUMP CONTROLLER OR IN HYDRAULIC RELATED PARTS..............................................................348 C-1 [OFF] SELF-DIAGNOSTIC DISPLAY OF CONTROLLER DOES NOT LIGHT UP....................................................................................350 C-2 [01] [SHORT CIRCUIT IN STRAIGHT-TRAVEL SOLENOID SYSTEM] IS DISPLAYED.............................................................................352 C-3 [02] [SHORT CIRCUIT IN BOOM HALF FLOW SOLENOID SYSTEM] IS DISPLAYED..............................................................................353 C-4 [03] [SHORT CIRCUIT IN ARM HALF FLOW SOLENOID SYSTEM] IS DISPLAYED...............................................................................354 C-5 [04] [SHORT CIRCUIT IN SWING BRAKE SOLENOID SYSTEM] IS DISPLAYED.................................................................................355 C-6 [05] [SHORT CIRCUIT IN TRAVEL SPEED SOLENOID SYSTEM] IS DISPLAYED................................................................................356 C-7 [07] [SHORT CIRCUIT IN CO CANCEL SOLENOID SYSTEM] IS DISPLAYED...................................................................................357 C-8 [08] [SHORT CIRCUIT IN TVC SOLENOID SYSTEM (1)] IS DISPLAYED.....................................................................................358 C-9 [09] [SHORT CIRCUIT IN TVC SOLENOID SYSTEM (2)] IS DISPLAYED.....................................................................................359 C-10 [11] [DISCONNECTION IN STRAIGHT-TRAVEL SOLENOID SYSTEM] IS DISPLAYED............................................................................360 C-11 [12] [DISCONNECTION IN BOOM HALF FLOW SOLENOID SYSTEM] IS DISPLAYED.............................................................................361 C-12 [13] [DISCONNECTION IN ARM HALF FLOW SOLENOID SYSTEM] IS DISPLAYED..............................................................................362 C-13 [14] [DISCONNECTION IN SWING BRAKE SOLENOID SYSTEM] IS DISPLAYED................................................................................363 C-14 [15] [DISCONNECTION IN TRAVEL SPEED SOLENOID SYSTEM] IS DISPLAYED...............................................................................364 C-15 [17] [DISCONNECTION IN CO CANCEL SOLENOID SYSTEM] IS DISPLAYED..................................................................................365 C-16 [18] [DISCONNECTION IN TVC SOLENOID SYSTEM] IS DISPLAYED........................................................................................366 C-17 [21] [ABNORMALITY IN NO.2 THROTTLE SIGNAL SYSTEM] IS DISPLAYED..................................................................................367 C-18 [22] [ABNORMALITY IN THROTTLE SIGNAL SYSTEM] IS DISPLAYED.......................................................................................368 C-19 [23] [ABNORMALITY IN PUMP PRESSURE SENSOR SIGNAL SYSTEM] IS DISPLAYED...........................................................................369 C-20 [25] [ABNORMALITY IN PUMP PRESSURE SENSOR POWER SOURCE SYSTEM] IS DISPLAYED.....................................................................371 C-21 [26] [ABNORMALITY IN ENGINE SPEED SENSOR SYSTEM] IS DISPLAYED...................................................................................372 C-22 [28] [ABNORMALITY IN AUTO-DECELERATION SIGNAL OUTPUT SYSTEM] IS DISPLAYED.......................................................................373 C-23 [29] [ABNORMALITY IN OVERHEAT SIGNAL SYSTEM] IS DISPLAYED.......................................................................................374 C-24 [88] [CONTROLLER ABNORMALITY SYSTEM] IS DISPLAYED...............................................................................................375 TROUBLESHOOTING OF PUMP CONTROLLER INPUT SIGNAL SYSTEM (F MODE)..........................................................................................376 F-1 PUMP CONTROLLER MONITOR DOES NOT DISPLAY [P1] [WORK EQUIPMENT OIL PRESSURE SWITCH]...............................................................377 F-2 PUMP CONTROLLER MONITOR DOES NOT DISPLAY [P2] [SWING OIL PRESSURE SWITCH]........................................................................378 F-3 PUMP CONTROLLER MONITOR DOES NOT DISPLAY [P6] [TRAVEL LIMIT SWITCH]..............................................................................379 F-4 PUMP CONTROLLER MONITOR DOES NOT DISPLAY [b5] [SWING LOCK SWITCH]................................................................................380 F-5 PUMP CONTROLLER MONITOR DOES NOT DISPLAY [HI OR LO] [TRAVEL SPEED SWITCH]........................................................................381 F-6 PUMP CONTROLLER MONITOR DOES NOT DISPLAY [Ad] [AUTO-DECELERATION SWITCH].........................................................................382 F-7 PUMP CONTROLLER MONITOR DOES NOT DISPLAY [88] [DECIMAL POINT OF ENGINE SPEED SENSOR].............................................................383 F-8 PUMP CONTROLLER WORKING MODE DISPLAY DOES NOT SWITCH [1234]......................................................................................384 F-9 PUMP CONTROLLER POWER SET DISPLAY DOES NOT SWITCH [H5L]..........................................................................................385 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)..............................................................................................386 H-1 SPEEDS OF WORK EQUIPMENT, TRAVEL SWING ARE ALL SLOW..............................................................................................387 H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS........................................................................................389 H-3 WORK EQUIPMENT, TRAVEL, SWING DO NOT MOVE, OR SPEED IS EXTREMELY SLOW............................................................................391 H-4 ALL WORK EQUIPMENT, TRAVEL, SWING LACK POWER.....................................................................................................393 H-5 POWER SET SELECTION SYSTEM DOES NOT SWITCH.......................................................................................................393 H-6 ABNORMAL NOISE GENERATED (FROM AROUND PUMP)......................................................................................................394 H-7 AUTO-DECELERATION DOES NOT ACTUATED..............................................................................................................394 H-8 BOOM, ARM SPEED IS EXTREMELY SLOW................................................................................................................395 H-9 WORK EQUIPMENT (BOOM, ARM, BUCKET) SPEED IS SLOW.................................................................................................396 H-10 WORK EQUIPMENT (BOOM, ARM, BUCKET) LACKS POWER..................................................................................................400 H-11 EXCESSIVE HYDRAULIC DRIFT.......................................................................................................................400 H-12 EXCESSIVE TIME LAG..............................................................................................................................402 H-13 DOES NOT ENTER FINISHING OPERATION (F.O) MODE...................................................................................................402 H-14 WHEN MACHINE IS TRAVELING, IT DEVIATES NATURALLY TO ONE SIDE....................................................................................403 a) DEVIATES IN SAME DIRECTION BOTH IN FORWARD AND REVERSE........................................................................................403 b) DEVIATES IN DIFFERENT DIRECTION IN FORWARD AND REVERSE........................................................................................405 H-15 EXCESSIVE DEVIATION DURING COMPOUND OPERATIONS..................................................................................................406 H-16 EXCESSIVE DEVIATION WHEN STARTING...............................................................................................................407 H-17 TRAVEL LACKS POWER (OR SPEED IS SLOW)...........................................................................................................409 H-18 TRAVEL SPEED DOES NOT SWITCH....................................................................................................................409 H-19 MACHINE DOES NOT MOVE (ONE SIDE ONLY)...........................................................................................................410 H-20 TRAVEL LEVER IS HEAVY...........................................................................................................................410 H-21 DOES NOT SWING..................................................................................................................................411 H-22 SWING SPEED IS SLOW OR ACCELERATION IS POOR.....................................................................................................413 H-23 EXCESSIVE OVERRUN WHEN STOPPING SWING...........................................................................................................414 H-24 EXCESSIVE SHOCK WHEN STOPPING SWING.............................................................................................................414 H-25 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING....................................................................................................415 H-26 EXCESSIVE HYDRAULIC DRIFT OF SWING..............................................................................................................415 H-27 WHEN OPERATED SIMULTANEOUSLY WITH ARM, SWING SPEED IS SLOW......................................................................................415 TABLE OF FAILURE MODES AND CAUSES....................................................................................................................416 TROUBLESHOOTING OF MONITOR SYSTEM (P MODE)...............................................................................................................418 P-1 MONITOR PANEL LAMPS DO NOT LIGHT UP FOR 3 SECONDS WHEN STARTING SWITCH IS TURNED ON..............................................................419 a) NO MONITOR PANEL LAMPS LIGHT UP...............................................................................................................419 b) SOME MONITOR PANEL LAMPS DO NOT LIGHT UP......................................................................................................419 P-2 MONITOR PANEL LAMPS ALL LIGHT UP WHEN STARTING SWITCH IS TURNED ON, BUT DO NOT GO OUT............................................................420 P-3 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CHECK ITEMS FLASH (LEVELS FOR CHECK ITEMS ARE AS SPECIFIED)..................................421 a) COOLANT LEVEL FLASHES.........................................................................................................................421 b) ENGINE OIL LEVEL FLASHES......................................................................................................................422 P-4 PREHEATING IS NOT BEING USED, BUT PREHEATING DISPLAY LIGHTS UP...................................................................................423 P-5 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, CHECK ITEMS FLASH.......................................................................424 a) ALTERNATOR SYSTEM.............................................................................................................................424 b) ENGINE OIL PRESSURE SYSTEM....................................................................................................................424 P-6 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CAUTION ITEMS FLASH..........................................................................425 P-7 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, CAUTION ITEMS FLASH.....................................................................426 a) ENGINE OIL PRESSURE FLASHES...................................................................................................................426 b) COOLANT LEVEL FLASHES.........................................................................................................................426 c) COOLANT TEMPERATURE FLASHES...................................................................................................................427 d) CHARGE FLASHES................................................................................................................................427 e) FUEL LEVEL FLASHES............................................................................................................................428 P-8..................................................................................................................................................429 a) WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), BUZZER DOES NOT SOUND FOR 1 SECOND.CAUTION ITEM IS FLASHING BUT BUZZER DOES NOT SOUND.....429 b) THERE IS NO ABNORMALITY DISPLAY ON THE MONITOR, BUT THE BUZZER SOUNDS.........................................................................429 P-9 PANEL LIGHTING OF MONITOR PANEL DOES NOT LIGHT UP (LIQUID CRYSTAL DISPLAY IS NORMAL).............................................................430 P-10 COOLANT TEMPERATURE SHOWS ABNORMALLY LOW TEMPERATURE............................................................................................431 P-11 COOLANT TEMPERATURE GAUGE GIVES NO DISPLAY (DURING OPERATION,NO LEVEL OF GAUGE IS DISPLAYED)....................................................431 P-12 FUEL GAUGE ALWAYS DISPLAYS FULL.................................................................................................................432 P-13 FUEL GAUGE GIVES NO DISPLAY.....................................................................................................................432 P-14.................................................................................................................................................433 a) LAMPS DO NOT LIGHT UP ........................................................................................................................433 b) LAMPS LIGHT UP EVEN WHEN LAMP SWITCH IS NOT OPERATED..........................................................................................433 P-15.................................................................................................................................................435 a) WIPERS DO NOT WORK............................................................................................................................435 b) WIPERS WORK EVEN WHEN WIPER SWITCH IS NOT OPERATED............................................................................................435 P-16.................................................................................................................................................437 a) FAN DOES NOT WORK.............................................................................................................................437 b) FAN WORKS EVEN WHEN FAN SWITCH IS NOT OPERATED................................................................................................437 P-17 WORKING MODE DOES NOT SWITCH....................................................................................................................439 P-18 POWER SET DOES NOT SWITCH.......................................................................................................................440 P-19 AUTO-DECELERATION DOES NOT SWITCH (DOES NOT ENTER AUTO-DECELERATION; AUTO-DECELERATION IS NOT CANCELED).........................................441 P-20 TRAVEL SPEED DOES NOT SWITCH BETWEEN HI AND LO..................................................................................................442 P-21 WARMING-UP OPERATION IS NOT CARRIED OUT BELOW 30℃, OR WARMING-UP OPERATION IS NOT CANCELED EVEN WHEN TEMPERATURE GOES ABOVE 30℃.................443 P-22 EVEN WHEN SWING LOCK SWITCH IS TURNED ON (LOCK), SWING LOCK LAMP ON MONITOR PANEL DOES NOT LIGHT UP.............................................444 P-23 FUEL LEVEL SENSOR SYSTEM DEFECTIVE..............................................................................................................445 P-24 COOLANT TEMPERATURE SENSOR SYSTEM DEFECTIVE.....................................................................................................446 P-25 ENGINE OIL LEVEL SENSOR SYSTEM DEFECTIVE........................................................................................................447 P-26 COOLANT LEVEL SENSOR SYSTEM DEFECTIVE...........................................................................................................448 30 DISASSEMBLY AND ASSEMBLY......................................................................................................................................449 METHOD OF USING MANUAL.......................................................................................................................................451 PRECAUTIONS WHEN CARRYING OUT OPERATION......................................................................................................................452 SPECIAL TOOL LIST............................................................................................................................................454 WEIGHT TABLE.................................................................................................................................................456 TIGHTENING TORQUES AND STANDARD VALUES TABLE.................................................................................................................457 LUBRICANT AND COOLANT TABLE..................................................................................................................................459 STARTING MOTOR...............................................................................................................................................460 REMOVAL..................................................................................................................................................460 INSTALLATION.............................................................................................................................................460 ALTERNATOR...................................................................................................................................................460 REMOVAL..................................................................................................................................................460 INSTALLATION.............................................................................................................................................460 ENGINE OIL COOLER............................................................................................................................................462 REMOVAL..................................................................................................................................................462 INSTALLATION.............................................................................................................................................462 FUEL INJECTION PUMP..........................................................................................................................................462 REMOVAL..................................................................................................................................................462 INSTALLATION.............................................................................................................................................462 WATER PUMP...................................................................................................................................................464 REMOVAL..................................................................................................................................................464 INSTALLATION.............................................................................................................................................464 NOZZLE HOLDER................................................................................................................................................464 REMOVAL..................................................................................................................................................464 INSTALLATION.............................................................................................................................................464 TURBOCHARGER.................................................................................................................................................466 REMOVAL..................................................................................................................................................466 INSTALLATION.............................................................................................................................................466 THERMOSTAT...................................................................................................................................................466 REMOVAL..................................................................................................................................................466 INSTALLATION.............................................................................................................................................466 ENGINE FRONT SEAL............................................................................................................................................468 REMOVAL..................................................................................................................................................468 INSTALLATION.............................................................................................................................................468 ENGINE REAR SEAL.............................................................................................................................................468 REMOVAL..................................................................................................................................................468 INSTALLATION.............................................................................................................................................468 GOVERNOR MOTOR...............................................................................................................................................470 REMOVAL..................................................................................................................................................470 INSTALLATION.............................................................................................................................................470 CYLINDER HEAD................................................................................................................................................472 REMOVAL..................................................................................................................................................472 INSTALLATION.............................................................................................................................................472 HYDRAULIC COOLER ............................................................................................................................................474 REMOVAL..................................................................................................................................................474 INSTALLATION.............................................................................................................................................474 RADIATOR, HYDRAULIC COOLER...................................................................................................................................474 REMOVAL..................................................................................................................................................474 INSTALLATION.............................................................................................................................................474 ENGINE HYDRAULIC PUMP........................................................................................................................................476 REMOVAL..................................................................................................................................................476 INSTALLATION.............................................................................................................................................476 PTO..........................................................................................................................................................478 REMOVAL..................................................................................................................................................478 INSTALLATION.............................................................................................................................................478 DISASSEMBLY..............................................................................................................................................478 ASSEMBLY.................................................................................................................................................478 CENTER SWIVEL JOINT..........................................................................................................................................480 REMOVAL..................................................................................................................................................480 INSTALLATION.............................................................................................................................................480 DISASSEMBLY..............................................................................................................................................480 ASSEMBLY.................................................................................................................................................480 FINAL DRIVE (PC120-5)........................................................................................................................................482 REMOVAL..................................................................................................................................................482 INSTALLATION.............................................................................................................................................482 DISASSEMBLY..............................................................................................................................................484 ASSEMBLY.................................................................................................................................................486 TRAVEL MOTOR.................................................................................................................................................492 DISASSEMBLY..............................................................................................................................................492 ASSEMBLY.................................................................................................................................................500 SPROCKET.....................................................................................................................................................522 REMOVAL..................................................................................................................................................522 INSTALLATION.............................................................................................................................................522 SWING MACHINERY..............................................................................................................................................524 DISASSEMBLY..............................................................................................................................................524 ASSEMBLY.................................................................................................................................................526 SWING MOTOR..................................................................................................................................................530 DISASSEMBLY..............................................................................................................................................530 ASSEMBLY.................................................................................................................................................534 REVOLVING FRAME..............................................................................................................................................540 REMOVAL..................................................................................................................................................540 INSTALLATION.............................................................................................................................................540 SWING CIRCLE.................................................................................................................................................540 REMOVAL..................................................................................................................................................540 INSTALLATION.............................................................................................................................................540 IDLER, RECOIL SPRING.........................................................................................................................................542 REMOVAL..................................................................................................................................................542 INSTALLATION.............................................................................................................................................542 RECOIL SPRING................................................................................................................................................544 DISASSEMBLY..............................................................................................................................................544 ASSEMBLY.................................................................................................................................................544 TRACK ROLLER.................................................................................................................................................546 REMOVAL..................................................................................................................................................546 INSTALLATION.............................................................................................................................................546 CARRIER ROLLER...............................................................................................................................................546 REMOVAL..................................................................................................................................................546 INSTALLATION.............................................................................................................................................546 TRACK SHOE...................................................................................................................................................548 REMOVAL..................................................................................................................................................548 INSTALLATION.............................................................................................................................................548 CHARGING PUMP................................................................................................................................................548 REMOVAL..................................................................................................................................................548 INSTALLATION.............................................................................................................................................548 HYDRAULIC PUMP...............................................................................................................................................550 REMOVAL..................................................................................................................................................550 INSTALLATION.............................................................................................................................................550 MAIN PUMP INPUT SHAFT........................................................................................................................................550 REMOVAL..................................................................................................................................................550 INSTALLATION.............................................................................................................................................550 PISTON PUMP..................................................................................................................................................552 DISASSEMBLY..............................................................................................................................................552 ASSEMBLY.................................................................................................................................................556 CONTROL VALVE................................................................................................................................................566 REMOVAL..................................................................................................................................................566 INSTALLATION.............................................................................................................................................566 DISASSEMBLY..............................................................................................................................................568 ASSEMBLY.................................................................................................................................................568 MAIN RELIEF VALVE............................................................................................................................................570 REMOVAL..................................................................................................................................................570 INSTALLATION.............................................................................................................................................570 DISASSEMBLY..............................................................................................................................................570 ASSEMBLY.................................................................................................................................................570 TVC VALVE....................................................................................................................................................572 REMOVAL..................................................................................................................................................572 INSTALLATION.............................................................................................................................................572 CO.NC VALVE..................................................................................................................................................572 REMOVAL..................................................................................................................................................572 INSTALLATION.............................................................................................................................................572 SERVO VALVE..................................................................................................................................................574 REMOVAL..................................................................................................................................................574 INSTALLATION.............................................................................................................................................574 WORK EQUIPMENT PPC VALVE.....................................................................................................................................574 REMOVAL..................................................................................................................................................574 INSTALLATION.............................................................................................................................................574 PPC VALVE....................................................................................................................................................576 DISASSEMBLY..............................................................................................................................................576 ASSEMBLY.................................................................................................................................................576 PPC SHUTTLE VALVE............................................................................................................................................580 REMOVAL..................................................................................................................................................580 INSTALLATION.............................................................................................................................................580 BOOM HOLDING VALVE...........................................................................................................................................582 REMOVAL..................................................................................................................................................582 INSTALLATION.............................................................................................................................................582 DISASSEMBLY..............................................................................................................................................582 ASSEMBLY.................................................................................................................................................582 BOOM CYLINDER................................................................................................................................................584 REMOVAL..................................................................................................................................................584 INSTALLATION.............................................................................................................................................584 ARM CYLINDER.................................................................................................................................................586 REMOVAL..................................................................................................................................................586 INSTALLTAION.............................................................................................................................................586 BUCKET CYLINDER..............................................................................................................................................586 REMOVAL..................................................................................................................................................586 INSTALLATION.............................................................................................................................................586 HYDRAULIC CYLINDER...........................................................................................................................................590 DISASSEMBLY..............................................................................................................................................590 ASSEMBLY.................................................................................................................................................592 WORK EQUIPMENT...............................................................................................................................................594 REMOVAL..................................................................................................................................................594 INSTALLATION.............................................................................................................................................594 BUCKET.......................................................................................................................................................596 REMOVAL..................................................................................................................................................596 INSTALLATION.............................................................................................................................................596 ARM..........................................................................................................................................................596 REMOVAL..................................................................................................................................................596 INSTALLATION.............................................................................................................................................596 ARM, BUCKET..................................................................................................................................................598 REMOVAL..................................................................................................................................................598 INSTALLATION.............................................................................................................................................598 BOOM.........................................................................................................................................................600 REMOVAL..................................................................................................................................................600 INSTALLATION.............................................................................................................................................600 OPERATOR'S CAB...............................................................................................................................................602 REMOVAL..................................................................................................................................................602 INSTALLATION.............................................................................................................................................602 COUNTERWEIGHT................................................................................................................................................602 REMOVAL..................................................................................................................................................602 INSTALLATION.............................................................................................................................................602 ENGINE THROTTLE CONTROLLER...................................................................................................................................604 REMOVAL..................................................................................................................................................604 INSTALLATION.............................................................................................................................................604 PUMP CONTROLLER..............................................................................................................................................604 REMOVAL..................................................................................................................................................604 INSTALLATION.............................................................................................................................................604 MONITOR PANEL................................................................................................................................................606 REMOVAL..................................................................................................................................................606 INSTALLATION.............................................................................................................................................606 40 MAINTENANCE STANDARD..........................................................................................................................................608 FINAL DRIVE..................................................................................................................................................609 SWING CIRCLE.................................................................................................................................................611 SWING MACHINERY..............................................................................................................................................612 TRACK FRAME..................................................................................................................................................613 IDLER........................................................................................................................................................614 TRACK ROLLER.................................................................................................................................................615 CARRIER ROLLER...............................................................................................................................................616 TRACK SHOE...................................................................................................................................................617 HYDRAULIC PUMP...............................................................................................................................................620 CHARGING PUMP AND RELIEF VALVE...............................................................................................................................621 L.H. 6-SPOOL CONTROL VALVE...................................................................................................................................622 R.H. 5-SPOOL CONTROL VALVE...................................................................................................................................628 SWING MOTOR..................................................................................................................................................634 CENTER SWIVEL JOINT..........................................................................................................................................635 TRAVEL MOTOR.................................................................................................................................................636 PPC VALVE....................................................................................................................................................637 BOOM HOLDING VALVE...........................................................................................................................................639 HYDRAULIC CYLINDER...........................................................................................................................................641 WORK EQUIPMENT...............................................................................................................................................643
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- This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
- This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
- Require some other service manual or have any queries: please WRITE to us at [email protected]
1 review for Komatsu PC100-5 PC120-5 PC120-5 MIGHTY Excavator Shop Manual 28001, 30001, 36601 and up – DOWNLOAD
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Wade Owen –
friendly service, quick processing, perfect