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KOMATSU PC100-6 PC120-6 PC120LC-6 PC130-6 SERVICE REPAIR MANUAL – PDF DOWNLOAD
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- KOMATSU PC100-6 PC120-6 PC120LC-6 PC130-6 SERVICE REPAIR MANUAL
- PUBLICATION NUMBER:SEBM010611
- SERIAL NUMBER: 45221 and up
15200 and up
57499 and up
65504 and up
51020 and up
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Description
KOMATSU PC100-6 PC120-6 PC120LC-6 PC130-6 SERVICE REPAIR MANUAL
KOMATSU PC100-6 PC120-6 PC120LC-6 PC130-6 SERVICE REPAIR MANUAL – PDF DOWNLOAD:
SCREENSHOT OF THE MANUAL:
DESCRIPTION:
KOMATSU PC100-6 PC120-6 PC120LC-6 PC130-6 SERVICE REPAIR MANUAL
- 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 ls 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 this section. - 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 PC100-6 PC120-6 PC120LC-6 PC130-6 SERVICE REPAIR MANUAL
COVER...................................................................................................................................................................................................... 1 CONTENTS................................................................................................................................................................................................... 2 01 GENERAL................................................................................................................................................................................................. 27 GENERAL ASSEMBLY DRAWING............................................................................................................................................................................... 28 SPECIFICATIONS......................................................................................................................................................................................... 33 WEIGHT TABLE........................................................................................................................................................................................... 41 LIST OF LUBRICANT AND WATER............................................................................................................................................................................ 49 10 STRUCTURE AND FUNCTION.................................................................................................................................................................................. 52 RADIATIR AND OIL COOLER................................................................................................................................................................................ 53 PTO(COUPLING).......................................................................................................................................................................................... 56 POWER TRAIN ........................................................................................................................................................................................... 57 FINAL DRIVE............................................................................................................................................................................................ 59 SWING CIRCLE........................................................................................................................................................................................... 60 SWING MACHINERY........................................................................................................................................................................................ 61 TRACK FARME............................................................................................................................................................................................ 62 TRACK SHOE............................................................................................................................................................................................. 66 HYDRAULIC PIPING DRAWING .............................................................................................................................................................................. 67 HYDRAULIC CIRCUIT DIAGRAM.............................................................................................................................................................................. 69 HYDRAULIC TANK......................................................................................................................................................................................... 74 HYDRAULIC PUMP......................................................................................................................................................................................... 75 CONTROL VALUE.......................................................................................................................................................................................... 95 CLSS...................................................................................................................................................................................................108 SWING MOTOR............................................................................................................................................................................................160 CENTER SWIVEL JOINT....................................................................................................................................................................................165 TRAVEL MOTOR ..........................................................................................................................................................................................166 VALVE CONTROL..........................................................................................................................................................................................182 WORK EQUIPMENT・SWING PPC VALVED........................................................................................................................................................................183 TRAVEL PPC VALVE.......................................................................................................................................................................................187 SERVICE PPC VALVE......................................................................................................................................................................................191 SAFETY LOCK VALVE .....................................................................................................................................................................................194 PPC ACCUMULATOR........................................................................................................................................................................................194 STRAIGHT-TRAVEL SYSTEM.................................................................................................................................................................................195 SOLENOID VALVE.........................................................................................................................................................................................196 ACCUMULATOR FOR BREAKER................................................................................................................................................................................198 ADDITIONAL FILTER FOR BREAKER..........................................................................................................................................................................199 WORK EQUIPMENT.........................................................................................................................................................................................200 AIR CONDITIONER........................................................................................................................................................................................201 ACTUAL ELECTRIC WIRING DIAGRAM.........................................................................................................................................................................202 ELECTRIC CIRCUIT DIAGRAM...............................................................................................................................................................................206 ENGINE CONTROL SYSTEM..................................................................................................................................................................................211 ELECTRONIC CONTROL SYSTEM..............................................................................................................................................................................219 MACHINE MONITOR SYSTEM.................................................................................................................................................................................256 FRONT WINDOW AUTO PULL-UP SYSTEM.......................................................................................................................................................................267 20 TESTING AND ADJUSTING...................................................................................................................................................................................269 STANDARD VALUE TABLE FOR ENGINE RELATED PARTS..........................................................................................................................................................270 STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS ........................................................................................................................................................272 STANDARD VALUE TABLE FOR ELECTRICAL PARTS .............................................................................................................................................................283 TOOLS FOR TESTING,ADJUSTING,AND TROUBLESHOOTING........................................................................................................................................................292 MEASURING ENGINE SPEED.................................................................................................................................................................................293 MEASURING EXHAUST COLOR................................................................................................................................................................................294 ADJUSTING VALUE CLEARANCE..............................................................................................................................................................................295 MEASURING BLOW-BY PRESSURE.............................................................................................................................................................................296 TESTING AND ADJUSTING FUEL INJECTION TIMING ...........................................................................................................................................................297 MEASURING ENGINE OIL PRESSURE..........................................................................................................................................................................298 TESTNG AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR.......................................................................................................................................299 ADJUSTING ENGINE SPEED SENSOR..........................................................................................................................................................................300 ADJUSTING GOVERNOR MOTOR LEVER STROKE..................................................................................................................................................................301 TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT,SWING,TRAVEL CIRCUIT........................................................................................................................302 TESTING AND ADJUSTING PC VALUE OUTPUT PRESSURE(SERVO PISTION INPUT PRESURE.............................................................................................................................305 TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE..............................................................................................307 TSETING AND ADJUSTING CONTROL PUMP CIRCUIT OIL PRESSURE................................................................................................................................................310 TESTING SOLENOID VALVE OUTPUT PRESSURE.................................................................................................................................................................312 MEASURING PPC VALVE OUTPUT PRESSURE....................................................................................................................................................................313 ADJUSTING WORK EQUIPMENT,SWING PPC VALVE...............................................................................................................................................................314 TESTING TRAVEL DEVIATION...............................................................................................................................................................................315 TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT............................................................................................................................................316 MEASURING OIL LEAKAGE..................................................................................................................................................................................317 RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT .....................................................................................................................................................319 TESTING GLEARANCE OF SWING CIRCLE BEARING..............................................................................................................................................................320 TESTING AND ADJUSTING TRACK SHOE TENSION...............................................................................................................................................................321 BLEEDING AIR...........................................................................................................................................................................................322 TROUBLESHOOTING........................................................................................................................................................................................324 POINTS TO REMEMBER WHEN TROUBLESHOOTING............................................................................................................................................................325 SEQUENCE OF EVENTS IN TROUBLESHOOTING .............................................................................................................................................................326 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE...................................................................................................................................................327 CHECKS BEFORE TROUBLESHOOTING .....................................................................................................................................................................335 CONNECTOR TYPES AND MOUNTING LOCATIONS.............................................................................................................................................................336 CONNECTOR ARRANGEMENT DIAGRAM......................................................................................................................................................................338 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS.........................................................................................................................................................341 DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL..............................................................................................................................................352 METHOD OF USING JUDGEMENT TABLE....................................................................................................................................................................362 METHOD OF USING TROUBLESHOOTING CHARTS.............................................................................................................................................................364 DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE...........................................................................................................................................366 SERVICE CODE TABLE.................................................................................................................................................................................371 TROUBLESHOOTING OF COMMUNICATIONS SYSTEM(N MODE)...................................................................................................................................................372 N-1 COMMUNICATIONS ABNORMALITY.................................................................................................................................................................373 TROUBLESHOOTING OF ENGINE THROTTLE,PUMP CONTROLLER[GOVERNOR CONTROL SYSTEM](E MODE)................................................................................................................375 POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF ENGINE THROTTLE,PUMP CONTROLLER(GOVERNOR CONTROL SYSTEM)...............................................................................376 ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE.....................................................................................................................377 JUDGEMENT TABLE FOR ENGINE THROTTLE,PUMP CONTROLLER(GOVERNOR CONTROL SYSTEM),AND ENGINE RELATED PARTS..........................................................................................381 ELECTRICAL CIRCUIT DIAGRAM OF ENGINE THROTTLE,PUMP CONTROLLER SYSTEM...........................................................................................................................383 E-1 ABNORMALITY IN ENGINE THROTTLE,PUMP CONTROLLER POWER SOURCE(CONTROLLER LED IS OFF).........................................................................................................385 E-2 [E308] ABNORMALITY IN FUEL CONTROL DIAL INPUT VALUE IS DISPLAYED...........................................................................................................................386 E-3 [E317] ABNORMALITY (DISCONNECTION) IN GOVERNOR MOTOR DRIVE SYSTEM IS DISPLAYED.............................................................................................................387 E-4 [E318] ABNORMALITY (SHORT CIRCUIT) IN GOVERNOR MOTOR DRIVE SYSTEM IS DISPLAYED.............................................................................................................388 E-5 [E306] ABNORMALITY IN FEEDBACK POTENTIOMETER SYSTEM IS DISPLAYED...........................................................................................................................389 E-6 [E315] ABNORMALITY (SHORT CIRCUIT) IN BATTERY RELAY OUTPUT SYSTEM IS DISPLAYED.............................................................................................................390 E-7 [E316] ABNORMALITY (STEP-OUT) IN MOTOR IS DISPLAYED........................................................................................................................................391 E-8 ENGINE DOES NOT START .....................................................................................................................................................................392 E-9 ENGINE SPEED IS IRREGULAR .................................................................................................................................................................394 a) LDING SPEED IS IRREGULAR................................................................................................................................................................394 b) THERE IS HUNTING........................................................................................................................................................................396 E-10 LACK OF OUTPUT (ENGINE HIGH IDLING SPEED IS TOO LOW)......................................................................................................................................398 E-11 ENGINE DOES NOT STOP .....................................................................................................................................................................400 E-12 DEFECTIVE OPERATION OF BATTERY RELAY SYSTEM (ENGINE DOES NOT STOP)........................................................................................................................402 TROUBLESHOOTING OF ENGINE (S MODE).................................................................................................................................................................404 MOTHOD OF USING TROUBLESHOOTING CHART..........................................................................................................................................................405 S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)..................................................................................................................................409 S-2 ENGINE DOES NOT START .....................................................................................................................................................................411 (1) ENGINE DOES NOT TURN ..................................................................................................................................................................411 (2) ENGINE TURNS BUT NO EXHAIST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED)...............................................................................................................412 (3) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED).............................................................................................................413 S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR).......................................................................................................................................414 S-4 ENGINE STOPS DURING OPERATIONS.............................................................................................................................................................415 S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)..................................................................................................................................................416 S-6 ENGINE LACKS OUTPUT (OR LACKS POWER).......................................................................................................................................................417 S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION).............................................................................................................................................418 S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)....................................................................................................................................419 S-9 OIL BECOMES CONTAMINATED QUICKY ...........................................................................................................................................................420 S-10 FUEL CONSUMPTION IS EXCESSIVE.............................................................................................................................................................421 S-11 OIL IS IN COOLING WATER,OR WATER SPURTS BACK,OR WATER LEVEL GOES DOWN ....................................................................................................................422 S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)................................................................................................................................423 S-13 OIL LEVEL RISES (WATER,FUEL IN OIL).......................................................................................................................................................424 S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)..........................................................................................................................................425 S-15 ABNORMAL NOISE IS MADE....................................................................................................................................................................426 S-16 VIBRATION IS EXCESSIVE....................................................................................................................................................................427 TROUBLESHOOTING OF ENGINE THROTTLE,PUMP CONTROLLER[PUMP CONTROL SYSTEM](C MODE)....................................................................................................................428 POINTS TO REMEMBER WHEN TROUBLESHOOTING PUMP CONTROLLER SYSTEM.................................................................................................................................429 ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE.....................................................................................................................430 JUDGMENT TABLE FOR PUMP CONTROLLER AND HTDRAULIC RELATED PARTS.................................................................................................................................438 ELECTRICAL CIRCUIT DIAGRAM OF C MODE SYSTEM ...................................................................................................................................................440 C-1 ABNORMALITY IN CONTROLLER POWER SOURCE SYSTEM (CONTROLLER LED IS OFF)......................................................................................................................444 C-2 [E232] SHORT CIRCUIT IN PUMP PC-EPC SOLENOID SYSTEM IS DISPLAYED ..........................................................................................................................445 C-3 [E233] DISCONNECTION IN PC-EPC SOLENOID SYSTEM IS DISPLAYED................................................................................................................................447 C-4 [E203] SHORT CIRCUIT IN SWING HOLDING BRAKE SOLENOID SYSTEM IS DISPLAYED...................................................................................................................449 C-5 [E213] DISCONNECTION IN SWING HOLDING BRAKE SOLENOID SYSTEM IS DISPLAYED...................................................................................................................451 C-6 [E205] SHORT CIRCUIT IN 2-STAGE RELIEF SOLENOID SYSTEM IS DISPLAYED........................................................................................................................453 C-7 [E215] DISCONNECTION IN 2-STAGE RELIEF SOLENOID SYSTEM IS DISPLAYED........................................................................................................................454 C-8 [E206] SHORT CIRCUIT IN TRAVEL SPEED SOLENOID SYSTEM IS DISPLAYED..........................................................................................................................455 C-9 [E216] DISCONNECTION IN TRAVEL SPEED SOLENOID SYSTEM IS DISPLAYED..........................................................................................................................456 C-10 [E207] SHORT CIRCUIT IN ACTIVE MODE SOLENOID SYSTEM IS DISPLAYED..........................................................................................................................457 C-11 [E208] DISCONNECTION IN ACTIVE MODE SOLENOID SYSTEM IS DISPLAYED .........................................................................................................................458 C-12 [E217] MODEL SELECTION INPUT ERROR IS DISPLAYED ..........................................................................................................................................459 C-13 [E222] SHORT CIRCUIT IN IN LS-EPC SOLENOID SYSTEM IS DISPLAYED............................................................................................................................461 C-14 [E223] DISCONNECTION IN LS-EPC SOLENOID SYSTEM IS DISPLAYED...............................................................................................................................462 C-15 [E224] ABNORMALITY IN PUMP PRESSURE SENSOR SYSTEM IS DISPLAYED............................................................................................................................463 C-16 [E226] ABNORMALITY IN PRESSSURE SENSOR POWER SOURCE SYSTEM IS DISPLAYED...................................................................................................................464 C-17 [E227] ABNORMALITY IN ENGINE SPEED SENSOR SYSTEM IS DISPLAYED.............................................................................................................................465 C-18 [E302] SHORT CIRCUIT IN SWING STRIKE LIMIT SOLENOID SYSTEM IS DISPLAYED ..................................................................................................................466 C-19 [E215] DISCONNECTION IN SWING STROKE LIMIT SYSTEM IS DISPLAYED ...........................................................................................................................467 TROUBLESHOOTING OF ENGINE THROTTLE,PUMP CONTROLLER [INPUT SIGNAL SYSTEM](F MODE)...................................................................................................................468 ELECTRICAL CIRCUIT DIAGRAM OF F MODE SYSTEM ...................................................................................................................................................469 F-1 BIT PATTERN 20-(1) SWING OIL PRESSURE SWITCH DOES NOT LIGHT UP ............................................................................................................................473 F-2 BIT PATTERN 20-(2) TRAVEL OIL PRESSURE SWITCH DOES NOT LIGHT UP ...........................................................................................................................474 F-3 BIT PATTERN 20-(3) BOOM LOWER OIL PRESSURE SWITCH DOES NOT LIGHT UP .......................................................................................................................475 F-4 BIT PATTERN 20-(4) BOOM RAISE OIL PRESSURE SWITCH DOES NOT LIGHT UP .......................................................................................................................476 F-5 BIT PARRTEN 20-(5) ARM IN OIL PRESSURE SWITCH DOES NOT LIGHT UP ...........................................................................................................................477 F-6 BIT PARRTEN 20(6) ARM OUT OIL PRESSURE SWITCH DOES NOT LIGHT UP ...........................................................................................................................478 F-7 BIT PATTERN 21-(1) BUCKET CURL OIL PRESSURE SWITCH DOES NOT LIGHT UP ......................................................................................................................479 F-8 BIT PATTERN 21-(2) BUCKET DUMP OIL PRESSURE SWITCH DOES NOT LIGHT UP ......................................................................................................................480 F-9 BIT PATTERN 21-(3) SWING LOCK SWITCH DOES NOT LIGHT UP ....................................................................................................................................481 F-10 BIT PATTERN 22-(5) KEROSENNE MODE CONNECTION DOES NOT LIGHT UP ...........................................................................................................................482 F-11 BIT PATTERN 22-(6) L.H. KNOB DOES NOT LIGHT UP ...........................................................................................................................................483 TROUBLESHOOTING OF HYDRAULIC,MECHANICAL SYSTEM(H MODE).............................................................................................................................................484 TABLE OF FAILURE MODES AND CAUSES FOR HYDRAULIC AND MECHANICAL SYSTEM .........................................................................................................................485 H-1 SPEEDS OF ALL WORK EQUIPMENT,SWING,TRAVEL ARE SLOW OR LACK POWER ..........................................................................................................................487 H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED,OR ENGINE STALLS...................................................................................................................................489 H-3 NO WORK EQUIPMENT,TRAVEL,SWING MOVE .......................................................................................................................................................490 H-4 ABNORMAL NOISE GENERATED(AROUND PUMP)......................................................................................................................................................490 H-5 AUTO-DECELERATION DOES NOT WORK (WHEN PPC SHUTTLE VALVE IS CAUSE)..........................................................................................................................491 H-6 FINE CONTROL ABILITY IS POOR OR RESPONSE IS POOR ..........................................................................................................................................491 H-7 BOOM IS SLOW OR LACKS POWER ...............................................................................................................................................................492 H-8 ARM IS SLOW OR LACKS POWER ................................................................................................................................................................494 H-9 BUCKET IS SLOW OR LACKS POWER .............................................................................................................................................................496 H-10 WORK EQUIPMENT(BOOM,ARM ,BUCKET) DOES NOT MOVE (BUT TRAVEL AND SWING ARE NORMAL)..........................................................................................................497 H-11 EXCESSIVE HYDRAULIC DRIFT (BOOM,ARM,BUCKET)...............................................................................................................................................497 H-12 EXCESSIVE TIME LAG(ENGINE AT LOW IDLING)..................................................................................................................................................498 H-13 LACK OF POWER WHEN PRESSURE RISES ........................................................................................................................................................498 H-14 OTHER EQUIPMENT MOVES WHEN SINGLE CIRCUIT IS RELIEVED.....................................................................................................................................498 H-15 WORK EQUIPMENT SPEED IS SLOW WHEN ACTIVE MODE IS ON,OR IS FAST WHEN ACTIVE MODE IS OFF....................................................................................................499 a)BOOM LOWER,ARM IN SPEEDS ARE TOO SLOW OR TOO FAST........................................................................................................................................499 b)BOOM RAISE,ARM OUT,BUCKET CURL,DUMP SPEEDS ARE TOO SLOW OR TOO FAST .....................................................................................................................499 H-16 IN F/O MODE, ARM IN SPEED IS FASTER THAN SPECIFIED SPEED .................................................................................................................................500 H-17 IN COMPOUND OPERATIONS,WORK EQUIPMENT WITH LARGER LOAD IS LOW.............................................................................................................................500 H-18 IN SWING+BOOM RAISE,BOOM RAISE IS SLOW ...................................................................................................................................................501 H-19 IN SWING+TRAVEL,TRAVEL SPEED DROPS EXCESSIVELY............................................................................................................................................501 H-20 IN WORK EQUIPMENT+TRAVEL,TRAVEL SPEEED DROPS EXCESSIVELY..................................................................................................................................501 H-21 TRAVEL DEVIATION..........................................................................................................................................................................502 a)WHEN THERE IS DEVIATION NORMAL TRAVEL....................................................................................................................................................502 b)EXCESSIVE TRAVEL DEVIATION WHEN STARTING.................................................................................................................................................502 H-22 TRAVEL SPEED IS SLOW .....................................................................................................................................................................503 H-23 STEERING IS DIFFICULT TO TURN OR LACKS POWER .............................................................................................................................................505 H-24 TRAVEL SPEED DOES NOT SWITCH OR IS FASTER THAN SPECIFIED SPEED............................................................................................................................507 H-25 TRAVEL DOES NOT MOVE (ONE SIDE ONLY)......................................................................................................................................................507 H-26 DOES NOT SWING ...........................................................................................................................................................................508 a)DOES NOT SWING TO EITHER LEFT OR RIGHT...................................................................................................................................................508 b)DOES NOT SWING IN ONE DIRECTION .........................................................................................................................................................508 H-27 SWING ACCELERATION IS POOR ...............................................................................................................................................................509 H-28 EXCESSIVE OVERRUN WHEN STOPPING SWING ....................................................................................................................................................511 a)ONE DIRECTION ONLY.......................................................................................................................................................................511 b)BOTH DIRECTIONS..........................................................................................................................................................................511 H-29 EXCESSIVE SHOCK WHEN STOPPING SWING (ONE DIRECTION ONLY)..................................................................................................................................512 H-30 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING..............................................................................................................................................512 H-31 EXCESSIVE HYDRAULIC DRIFT OF SWING........................................................................................................................................................513 a)WHEN HOLDING BRAKE IS RELEASED ..........................................................................................................................................................513 b)WHEN HOLDING BRAKE IS APPLIED ...........................................................................................................................................................513 H-32 SWING SPEED IS FASTER THAN SPECIFIED SWING SPEED .........................................................................................................................................514 TROUBLESHOOTING OF MACHINE MONITOR PANEL SYSTEM(M MODE)............................................................................................................................................515 ACTION TAKEN BY MONITOR PANEL WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE .................................................................................................................517 ELECTRICAL CIRCUIT DIAGRAM FOR M MODE SYSTEM ..................................................................................................................................................521 M-1 [E101] ABNORMALITY IN TROUBLE DATA MEMORY IS DISPLAYED [E102] ERROR IN TIME DATA IS DISPLAYED .............................................................................................523 M-2 [E103] SHORT CIRCUIT IN BUZZER OUTPUT OR CONTACT OF 24V WIRING HARNESS WITH BUZZER DRIVE HARNESS IS DISPLAYED..............................................................................524 M-3 [E104] AIR CLEANER CLOGGING DETECTED IS DISPLAYED..........................................................................................................................................525 M-4 [E106] DROP IN ENGINE OIL PRESSURE DETECTED IS DISPLAYED ..................................................................................................................................525 M-5 [E108] ENGINE WATER TEMPERATURE 105゜C DETECTED IS DISPLAYED ...............................................................................................................................526 M-6 WHEN STARTING SWITCH IS TURNED ON,NONE OF LAMPS ON MONITOR PANEL LIGHT UP FOR 3 SECONDS....................................................................................................527 a)NONE OF LAMPS ON MONITOR PANEL LIGHT UP .................................................................................................................................................527 b)SOME OF LAMPS ON MONITOR PANEL DO NOT LIGHT UP ..........................................................................................................................................527 M-7 WHEN STARTING SWITCH IS TURNED ON,MONITOR PANEL LAMPS ALL STAY LIGHTED UP AND DO NOT GO OUT ...............................................................................................529 M-8 WHEN STARTING SWITCH IS TURNED ON,ITEMS LIGHTED UP ON MONITOR PANEL ARE DIFFERENT FROM ACTUAL MACHINE (MODEL)..............................................................................529 M-9 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED),BASIC CHECK ITEMS FLASH.................................................................................................................530 a)(COOLANT LEVEL) FLASHES..................................................................................................................................................................530 b)(ENGINE OIL LEVEL)FLASHES................................................................................................................................................................531 M-10 PREHEATING IS NOT BEING USED BUT(PREHEATING MONITOR) LIGHTS UP ...........................................................................................................................532 M-11 WHEN STARRTING SWITCH IS TURNED ON AND ENGINE IS STARTED,BASIC CHECK ITEMS FLASH..........................................................................................................533 a)ALTERNATOR SYSTEM .......................................................................................................................................................................533 b)ENGINE OIL PRESSURE SYSTEM ..............................................................................................................................................................534 M-12 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED),CAUTION ITEMS,EMERGENCY STOP ITEMS FLASH (BUT WHEN BATTERY,ENGINE OIL PRESSURE DO NOT LIGHT UP ).......................................535 a)ALTERNATOR SYSTEM........................................................................................................................................................................535 b)ENGINE OIL PRESSURE SENSOR SYSTEM .......................................................................................................................................................536 M-13 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED,CAUTION ITEMS,EMERGENCY STOP ITEMS FLASH (BUT WHEN THERE IS NO ABNORMALITY IN ENGINE OR ITEMSTO CHECK BEFORE TROUBLESHOOTING).....537 a)(ENGINE OIL PRESSURE) FLASHES............................................................................................................................................................537 b)(COOLANT LEVEL) FLASHES..................................................................................................................................................................537 c)CHARGE LEVEL) FLASHES....................................................................................................................................................................537 d)(COOLANT TEMPERATURE) FLASHES............................................................................................................................................................538 e)(FUEL LEVEL) FLASHES.....................................................................................................................................................................538 f)(AIR CLEANER CLOGGING) FLASHES...........................................................................................................................................................539 M-14 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED),BUZZER DOES NOT SOUND FOR 1 SECOND CAUTION ITEMS ARE FLASHING BUT BUZZER DOES NOT SOUND................................................540 M-15 NO ABNORMALITY IS DISPLAYED ON MONITOR BUT BUZZER SOUNDS..................................................................................................................................540 M-16 LIQUID CRYSTAL NIGHT LIGHTING ON MONITOR PANEL DOES NOT LIGHT UP (LIQUID CRYSTAL DISPLAY IS NORMAL).......................................................................................541 M-17 COOLANT TEMPERATURE GAUGE DOES NOT RISE ..................................................................................................................................................542 M-18 COOLANT TEMPERATURE GAUGE DOES NOT GIVE ANY DISPLAY (NONE OF GAUGE LAMPS LIGHT UP DURING OPERATION).......................................................................................542 M-19 FUEL LEVEL GAUGE ALWAYS DISPLAYS FULL.....................................................................................................................................................543 M-20 FUEL LEVEL GAUGE DOES NOT GIVE DISPLAY....................................................................................................................................................543 M-21 SWING LOCK SWITCH IS TURNED ON (LOCK) BUT (SWING LOCK MONITOR) DOES NOT LIGHT UP .........................................................................................................544 M-22 SWING PROLIX SWITCH IS ON (PROLIX),BUT (SWING LOCK MONITOR) DOES NOT NOT FLASH ...........................................................................................................544 M-23 SERVICE METER DOES NOT ADVANCE WHEN ENGINE IS RUNNING ....................................................................................................................................545 M-24 WHEN STARTING SWITCH IS OFF AND TIME SWITCH IS PRESSED,TIME,SERVICE METER ARE NOT DISPLAYED...............................................................................................545 M-25 DEFECTIVE FUEL LEVEL SENSOR SYSTEM .......................................................................................................................................................546 M-26 DEFECTIVE COOLANT TEMPERATURE SENSOR SYSTEM ..............................................................................................................................................547 M-27 DEFECTIVE ENGINE OIL LEVEL SENSOR SYSTEM .................................................................................................................................................548 M-28 DEFECTIVE COOLANT LEVEL SENSOR SYSTEM.....................................................................................................................................................549 M-29 WIPER DOES NOT WORK OR SWITCH IS NOT BEING USED BUT WIPER IS ACTUATED.....................................................................................................................550 a)WIPER DOES NOT WORK......................................................................................................................................................................550 b)WIPER SWITCH IS NOT BEING USED BUT WIPER IS ACTUATED.....................................................................................................................................553 M-30 WASHER MOTOR DOE SNOT WORK,OR SWITCH IS NOT BEING USED BUT WASHER MOTOR IS ACTUATED ......................................................................................................556 a)WASHER MOTOR DOE SNOT WORK...............................................................................................................................................................556 b)SWITCH IS NOT BEING USED BUT WASHER MOTOR IS ACTUATED....................................................................................................................................557 30 DISASSEMBLY AND ASSEMBLY................................................................................................................................................................................558 METHOD OF USING MANUAL.................................................................................................................................................................................560 SPECIAL TOOL LIST......................................................................................................................................................................................563 PRECAUTIONS WHEN CARRYING OUT OPERATION................................................................................................................................................................561 SKETCHES OF SPECIAL TOOLS..............................................................................................................................................................................568 STARTING MOTOR ........................................................................................................................................................................................570 REMOVAL AND INSTALLATION...........................................................................................................................................................................570 ALTERNATOR ............................................................................................................................................................................................571 REMOVAL AND INSTALLATION...........................................................................................................................................................................571 AIR CONDITIONER COMPRESSOR.............................................................................................................................................................................572 REMOVAL AND INSTALLATION...........................................................................................................................................................................572 CONDENSER..............................................................................................................................................................................................574 REMOVAL AND INSTALLATION...........................................................................................................................................................................574 AFTERCOOLER ...........................................................................................................................................................................................575 REMOVAL AND INSTALLATION...........................................................................................................................................................................575 ENGINE OIL COOLER CORE.................................................................................................................................................................................576 REMOVAL AND INSTALLATION...........................................................................................................................................................................576 FUEL INJECTION PUMP....................................................................................................................................................................................577 REMOVAL ...........................................................................................................................................................................................577 INSTALLATION.......................................................................................................................................................................................579 WATER PUMP.............................................................................................................................................................................................581 REMOVAL AND INSTALLATION...........................................................................................................................................................................581 NOZZLE HOLDER .........................................................................................................................................................................................582 REMOVAL AND INSTALLATION...........................................................................................................................................................................582 TURBOCHARGER...........................................................................................................................................................................................583 REMOVAL AND INSTALLATION...........................................................................................................................................................................583 THERMOSTAT.............................................................................................................................................................................................585 REMOVAL AND INSTALLATION...........................................................................................................................................................................585 GOVERNOR MOTOR.........................................................................................................................................................................................586 REMOVAL AND INSTALLATION...........................................................................................................................................................................586 CYLINDER HEAD..........................................................................................................................................................................................587 REMOVAL ...........................................................................................................................................................................................587 INSTALLATION.......................................................................................................................................................................................592 ENGINE,MAIN PUMP ......................................................................................................................................................................................595 REMOVAL............................................................................................................................................................................................595 INSTALLATION.......................................................................................................................................................................................599 HYDRAULIC COOLER.......................................................................................................................................................................................600 REMOVAL AND INSTALLATION...........................................................................................................................................................................600 RADIATOR,HYDRAULIC COOLER..............................................................................................................................................................................601 REMOVAL............................................................................................................................................................................................601 INSTALLATION.......................................................................................................................................................................................602 RADIATOR AND HYDRAULIC OIL COOLER......................................................................................................................................................................603 REMOVAL ...........................................................................................................................................................................................603 INSTALLATION.......................................................................................................................................................................................604 FUEL TANK .............................................................................................................................................................................................605 REMOVAL AND INSTALLATION...........................................................................................................................................................................605 CENTER SWIVEL JOIN ....................................................................................................................................................................................606 REMOVAL AND INSTALLATION...........................................................................................................................................................................606 DISASSEMBLY AND ASSEMBLY ..........................................................................................................................................................................607 SPROCKET ..............................................................................................................................................................................................608 REMOVAL AND INSTALLATION...........................................................................................................................................................................608 TRAVEL MOTOR ..........................................................................................................................................................................................609 REMOVAL AND INSTALLATION...........................................................................................................................................................................609 DISASSEMBLY AND ASSEMBLY...........................................................................................................................................................................610 FINAL DRIVE ...........................................................................................................................................................................................646 DISASSEMBLY........................................................................................................................................................................................646 ASSEMBLY ..........................................................................................................................................................................................649 SWING MACHINERY,SWING MOTOR............................................................................................................................................................................654 REMOVAL AND INSTALLATION...........................................................................................................................................................................654 SWING MOTOR............................................................................................................................................................................................655 REMOVAL AND INSTALLATION...........................................................................................................................................................................655 DISASSEMBLY .......................................................................................................................................................................................656 ASSEMBLY ..........................................................................................................................................................................................660 SWING MACHINERY........................................................................................................................................................................................668 DISASSEMBLY........................................................................................................................................................................................668 ASSEMBLY...........................................................................................................................................................................................671 REVOLVING FARME........................................................................................................................................................................................675 REMOVAL ...........................................................................................................................................................................................675 INSTALLATION.......................................................................................................................................................................................677 SWING CIRCLE...........................................................................................................................................................................................678 REMOVAL AND INSTALLATION...........................................................................................................................................................................678 IDLER,RECOIL SPRING....................................................................................................................................................................................679 REMOVAL AND INSTALLATION...........................................................................................................................................................................679 RECOIL SPRING .........................................................................................................................................................................................680 DISASSEMBLY........................................................................................................................................................................................680 ASSEMBLY...........................................................................................................................................................................................681 IDLER..................................................................................................................................................................................................682 DISASSEMBLY........................................................................................................................................................................................682 ASSEMBLY...........................................................................................................................................................................................683 TRACK ROLLER ..........................................................................................................................................................................................685 REMOVAL AND INSTALLATION...........................................................................................................................................................................685 DISASSEMBLY........................................................................................................................................................................................686 ASSEMBLY...........................................................................................................................................................................................687 CARRIER ROLLER.........................................................................................................................................................................................689 REMOVAL AND INSTALLATION...........................................................................................................................................................................689 DISASSEMBLY........................................................................................................................................................................................690 ASSEMBLY ..........................................................................................................................................................................................692 TRACK SHOE.............................................................................................................................................................................................694 REMOVAL AND INSTALLATION...........................................................................................................................................................................694 HYDRAULIC TANK ........................................................................................................................................................................................695 REMOVAL............................................................................................................................................................................................695 INSTALLATION.......................................................................................................................................................................................696 CONTROL PUMP ..........................................................................................................................................................................................697 REMOVAL AND INSTALLATION...........................................................................................................................................................................697 MAIN PUMP..............................................................................................................................................................................................698 REMOVAL............................................................................................................................................................................................698 INSTALLATION.......................................................................................................................................................................................699 DISASSEMBLY .......................................................................................................................................................................................700 ASSEMBLY ..........................................................................................................................................................................................710 MAIN PUMP INPUT SHAFT OIL SEAL ........................................................................................................................................................................722 REMOVAL AND INSTALLATION...........................................................................................................................................................................722 CONTROL VALUE..........................................................................................................................................................................................723 REMOVAL ...........................................................................................................................................................................................723 INSTALLATION.......................................................................................................................................................................................724 DISASSEMBLY........................................................................................................................................................................................725 ASSEMBLY...........................................................................................................................................................................................730 LS SELECT .............................................................................................................................................................................................736 DISASSEMBLY AND ASSEMBLY...........................................................................................................................................................................736 MAIN RELIEF VALVE .....................................................................................................................................................................................737 DISASSEMBLY........................................................................................................................................................................................737 ASSEMBLY...........................................................................................................................................................................................738 PC,LS-EPC VALVE........................................................................................................................................................................................739 REMOVAL AND INSTALLATION...........................................................................................................................................................................739 PC VALVE...............................................................................................................................................................................................740 REMOVAL AND INSTALLATION...........................................................................................................................................................................740 LS VALVE ..............................................................................................................................................................................................741 REMOVAL AND INSTALLATION...........................................................................................................................................................................741 SOLENOID VALVE ........................................................................................................................................................................................742 REMOVAL AND INSTALLATION...........................................................................................................................................................................742 WORK EQUIPMENT PPC VALVE...............................................................................................................................................................................743 REMOVAL AND INSTALLATION...........................................................................................................................................................................743 DISASSEMBLY .......................................................................................................................................................................................744 ASSEMBLY...........................................................................................................................................................................................745 TRAVEL PPC VALVE.......................................................................................................................................................................................746 REMOVAL AND INSTALLATION...........................................................................................................................................................................746 DISASSEMBLY .......................................................................................................................................................................................747 ASSEMBLY ..........................................................................................................................................................................................748 BOOM CYLINDER .........................................................................................................................................................................................749 REMOVAL............................................................................................................................................................................................749 INSTALLATION.......................................................................................................................................................................................750 ARM CYLINDER ..........................................................................................................................................................................................751 REMOVAL ...........................................................................................................................................................................................751 INSTALLATION.......................................................................................................................................................................................752 BUCKET CYLINDER .......................................................................................................................................................................................753 REMOVAL ...........................................................................................................................................................................................753 INSTALLATION.......................................................................................................................................................................................754 HYDRAULIC CYLINDER.....................................................................................................................................................................................755 DISASSEMBLY........................................................................................................................................................................................755 ASSEMBLY...........................................................................................................................................................................................758 WORK EQUIPMENT.........................................................................................................................................................................................762 REMOVAL............................................................................................................................................................................................762 INSTALLATION.......................................................................................................................................................................................763 BUCKET.................................................................................................................................................................................................764 REMOVAL............................................................................................................................................................................................764 INSTALLATION.......................................................................................................................................................................................765 ARM....................................................................................................................................................................................................766 REMOVAL............................................................................................................................................................................................766 INSTALLATION.......................................................................................................................................................................................767 BUCKET,ARM.............................................................................................................................................................................................768 REMOVAL............................................................................................................................................................................................768 INSTALLATION.......................................................................................................................................................................................769 BOOM ..................................................................................................................................................................................................770 REMOVAL ...........................................................................................................................................................................................770 INSTALLATION.......................................................................................................................................................................................771 OPERATOR'S CAB ........................................................................................................................................................................................772 REMOVAL............................................................................................................................................................................................772 INSTALLATION.......................................................................................................................................................................................774 COUNTERWEIGHT..........................................................................................................................................................................................775 REMOVAL AND INSTALLATION...........................................................................................................................................................................775 ENGINE THROTTLE,PUMP CONTROLLER .......................................................................................................................................................................776 REMOVAL AND INSTALLATION...........................................................................................................................................................................776 MONITOR................................................................................................................................................................................................777 REMOVAL AND INSTALLATION...........................................................................................................................................................................777 CONTROL STAND .........................................................................................................................................................................................778 REMOVAL ...........................................................................................................................................................................................778 INSTALLATION.......................................................................................................................................................................................779 40 MAINTENANCE STANDARD....................................................................................................................................................................................780 SWING MACHINERY .......................................................................................................................................................................................781 SWING CIRCLE ..........................................................................................................................................................................................783 FINAL DRIVE ...........................................................................................................................................................................................784 TRACK FARME............................................................................................................................................................................................786 IDLER..................................................................................................................................................................................................789 CARRIER ROLLER.........................................................................................................................................................................................792 TRACK ROLLER...........................................................................................................................................................................................794 SPROCKET...............................................................................................................................................................................................796 TRACK SHOE ............................................................................................................................................................................................798 HYDRAULIC PUMP ........................................................................................................................................................................................810 CONTROL VALVE .........................................................................................................................................................................................812 CENTER SWIVEL JOINT....................................................................................................................................................................................824 WORK EQUIPMENT・SWING PPC VALVE ........................................................................................................................................................................825 TRAVEL PPC VALVE.......................................................................................................................................................................................826 SPERVICE PPC VALVE ....................................................................................................................................................................................827 EPC SOLENOID VALVE ....................................................................................................................................................................................828 HYDRAULIC CYLINDER.....................................................................................................................................................................................829 WORK EQUIPMENT.........................................................................................................................................................................................831 DIMENSION OF WORK EQUIPMENT............................................................................................................................................................................833 90 OTHER...................................................................................................................................................................................................837 HYDRAULIC CIRCUIT DIAGRAM PC100-6 SERIAL NO.:45221-46058 PC100L-6 SERIAL NO.:15200-46058 PC120-6 SERIAL NO.:57499-60967 PC130-6 SERIAL NO.:51020-51479.................................................838 HYDRAULIC CIRCUIT DIAGRAM PC100-6 SERIAL NO.:46059 AND UP PC100L-6 SERIAL NO.:46059 AND UP PC120-6 SERIAL NO.:60968-70000 PC120LC-6 SERIAL NO.:65504-70000 PC130-6 SERIAL NO.:51480 AND UP ...........839 HYDRAULIC CIRCUIT DIAGRAM PC 120-6 SERIAL NO.:70001 AND UP.............................................................................................................................................840 ELECTRICAL CIRCUIT DIAGRAM(1/2) PC100-6 SERIAL NO.:45221-46058 PC100L-6 SERIAL NO.:15200-46058 PC120-6 SERIAL NO.:57499-60967 PC130-6 SERIAL NO.:51020-51479...........................................841 ELECTRICAL CIRCUIT DIAGRAM(2/2) PC100-6 SERIAL NO.:45221-46058 PC100L-6 SERIAL NO.:15200-46058 PC120-6 SERIAL NO.:57499-60967 PC130-6 SERIAL NO.:51020-51479...........................................842 ELECTRICAL CIRCUIT DIAGRAM(1/2) PC100-6 SERIAL NO.:46059 AND UP PC100L-6 SERIAL NO.:46059 AND UP PC120-6 SERIAL NO.:60968-70000 PC120LC-6 SERIAL NO.:65504-70000 PC130-6 SERIAL NO.:51480 AND UP ....843 ELECTRICAL CIRCUIT DIAGRAM(2/2) PC100-6 SERIAL NO.:46059 AND UP PC100L-6 SERIAL NO.:46059 AND UP PC120-6 SERIAL NO.:60968-70000 PC120LC-6 SERIAL NO.:65504-70000 PC130-6 SERIAL NO.:51480 AND UP ....844 ELECTRICAL CIRCUIT DIAGRAM(1/2) PC120-6 SERIAL NO.:70001 AND UP .......................................................................................................................................845 ELECTRICAL CIRCUIT DIAGRAM(2/2) PC120-6 SERIAL NO.:70001 AND UP .......................................................................................................................................845
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