Komatsu PC100-6 PC100L-6 PC120-6 PC120LC-6 PC130-6 Shop Manual PDF

Description

Komatsu PC100-6, PC100L-6, PC120-6, PC120LC-6 and PC130-6 Excavator Shop Manual – Document SEBM010611

This Komatsu shop manual covers five hydraulic excavator models in the PC100, PC120 and PC130-6 family and is the workshop reference for anyone servicing, repairing, rebuilding or diagnosing these machines. Everything inside the Komatsu PC100-6 PC100L-6 PC120-6 PC120LC-6 PC130-6 shop manual is written around the S4D102-1 engine family, and the document follows the six-part structure Komatsu used for its workshop documentation: General, Structure and Function, Testing and Adjusting, Disassembly and Assembly, Maintenance Standard, and Others. This is a component-level service document rather than an operator booklet, and it runs past eight hundred pages of specifications, cutaway illustrations, hydraulic and electrical diagrams, and step-by-step teardown and rebuild procedures.

File Details

• Manual type: Shop / Service Repair Manual
• Brand: Komatsu
• Models covered: PC100-6, PC100L-6, PC120-6, PC120LC-6, PC130-6
• Engine family: S4D102-1; PC120-6 Serial No. 70001 and up uses the SAA4D102E-2
• Language: English
• Format: PDF
• Pages: 846
• Document number: SEBM010611

Chapters Covered

• 01 General – general assembly drawing, specifications, weight table, list of lubricant and water
• 10 Structure and Function – radiator, oil cooler, aftercooler, pump drive coupling, hydraulic circuit layout, final drive, swing circle, swing machinery, swing motor, track frame and track shoe standards, hydraulic tank, main pump, LS valve, PC valve, control valve, CLSS outline, unload valve, LS bypass plug, pressure compensation valve, boom holding valve, boom and arm regeneration circuits, travel junction circuit, travel LS bypass circuit, active mode function, swing bleed valve, variable pressure compensation valve, LS select valve, swing motor and swing brake, reverse prevention valve, GM18VL and HMV110-2 travel motors, counterbalance and safety valves, work equipment and travel PPC valves, PPC accumulator, solenoid valves, line filter, engine control system, electronic control system
• 20 Testing and Adjusting – standard value tables for engine, chassis and electrical parts, special tools, measuring engine speed, exhaust gas colour, valve clearance, blow-by pressure, fuel injection timing, engine oil pressure, belt tension, engine speed sensor, governor motor lever stroke, hydraulic pressure in work equipment / swing / travel circuits, PC valve output pressure, LS valve output pressure and LS differential pressure, control pump circuit oil pressure, solenoid valve output pressure, PPC valve output pressure, travel deviation, hydraulic drift, oil leakage, swing circle bearing clearance, track shoe tension, air bleeding, troubleshooting
• 30 Disassembly and Assembly – starting motor, alternator, air conditioner compressor, condenser, aftercooler, engine oil cooler core, fuel injection pump, water pump, nozzle holder, turbocharger, thermostat, governor motor, cylinder head, engine and main pump, hydraulic cooler, radiator, fuel tank, center swivel joint, sprocket, travel motor, final drive, swing machinery, swing motor, revolving frame, swing circle, idler, recoil spring, track roller, carrier roller, track shoe, hydraulic tank, control pump, main pump, control valve, LS select valve, main relief valve, PC/LS-EPC valve, PC valve, LS valve, solenoid valve, work equipment PPC valve, travel PPC valve, boom cylinder, arm cylinder, bucket cylinder, hydraulic cylinder, work equipment, bucket, arm, boom, operator’s cab, counterweight, engine throttle and pump controller, monitor, control stand case
• 40 Maintenance Standard – track shoe wear criteria and repair limits for triple shoe and rubber shoe
• 90 Others – hydraulic circuit diagrams and electrical circuit diagrams for each serial number break

The contents list alone tells you the level at which this Komatsu PC100-6 PC120-6 PC120LC-6 PC130-6 workshop manual operates. The General section gives you the assembly drawings, transport dimensions and weight tables you need before lifting a machine or ordering parts. Structure and Function explains how the CLSS hydraulic system, the HPV95 main pump with its PC and LS valves, the control valve blocks, and the travel and swing motors actually work – the understanding you need before you can diagnose a fault instead of guessing at it. Testing and Adjusting supplies the standard values, service limits and adjustment procedures, including engine speed checks, hydraulic pressure tests, PPC valve output pressures, travel deviation testing and hydraulic drift testing that point to the failing component. Disassembly and Assembly walks through removal, teardown, inspection and rebuild of every major assembly from the starting motor and cylinder head through the main pump, control valve, swing machinery, travel motors and final drives. Maintenance Standard gives the wear limits for undercarriage components. Others carries the hydraulic and electrical circuit diagrams for each serial number range.

What This Shop Manual Enables You to Do

With this Komatsu PC100-6 shop manual in hand you can carry out a full engine service on the S4D102-1 – valve clearance, injection timing, oil pressure, blow-by, governor motor stroke and engine speed sensor adjustment – without guessing at a single value. On the hydraulic side, the manual gives you the test points, set pressures and differential pressure targets to diagnose a slow or weak function on the PC120-6, PC120LC-6 or PC130-6, whether the fault sits in the main pump, the PC or LS valve, the control valve, a PPC valve, the swing motor or the travel motors. If a repair goes deeper, the Disassembly and Assembly chapter covers the complete teardown and rebuild of the swing machinery, swing motor, final drive, travel motor, hydraulic cylinders, control valve and main pump, with tightening torques and clearance-adjustment procedures given alongside. Undercarriage work – idler, recoil spring, track roller, carrier roller, track shoe, sprocket – is covered with its own removal and installation sequences and the wear limits in Maintenance Standard. The 90 Others section adds the hydraulic and electrical circuit diagrams organised by serial number range, so the wiring you are looking at matches the machine in front of you.

Why Correct Procedures and Specifications Matter

These are closed-centre load-sensing machines. Getting the pump, PC valve and LS valve set to the correct pressures is not optional – a machine set up by feel alone will be slow, hot, or will not hold a straight travel line. The Komatsu PC100L-6 PC120-6 PC120LC-6 PC130-6 service manual gives the numbers, the test conditions and the adjustment sequence so the machine ends up behaving the way it was designed to. The same applies to the engine, where valve clearance, injection timing and governor linkage all interact, and to the undercarriage, where wear beyond the stated limit is the difference between a repairable shoe and a replacement. Working from the tested procedure also matters for safety: the manual opens with the Komatsu general precautions covering blocking, hoisting, hydraulic pressure release and battery isolation, and those steps are repeated at the point of use in the disassembly chapters.

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The Komatsu PC100-6 PC100L-6 PC120-6 PC120LC-6 PC130-6 shop manual PDF is delivered immediately after payment, with no shipping and no waiting. It opens on any phone, tablet, laptop or desktop PDF reader, and any page can be printed for use in the workshop – useful when you are standing at the machine with a torque wrench rather than at a screen. Keep it on the service laptop, print the sections you need for the job, and carry the full 846-page reference wherever the machine is working.