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KOMATSU PC1100-6 PC1100SP-6 PC1100LC-6 SERVICE REPAIR MANUAL (SN:10001 & Up) – PDF Download
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- KOMATSU PC1100-6 PC1100SP-6 PC1100LC-6 SERVICE REPAIR MANUAL (SN:10001 & Up)
- PUBLICATION NUMBER:SEBM014207
- SERIAL NUMBER:PC1100-6 10001 and up
PC1100SP-6 10001 and up
PC1100LC-6 10001 and up
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Description
KOMATSU PC1100-6 PC1100SP-6 PC1100LC-6 SERVICE REPAIR MANUAL (SN:10001 & Up)
KOMATSU PC1100-6 PC1100SP-6 PC1100LC-6 SERVICE REPAIR MANUAL (SN:10001 & UP) – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU PC1100-6 PC1100SP-6 PC1100LC-6 SERVICE REPAIR MANUAL (SN:10001 & Up)
- This shop manual has been prepared as an aid to improve the quality of repairs by giving the servicemen an accurate understanding of the product and by showing him the correct way to perform repairs and make iudgements. Make sure you understand the contents of this manual and use It to full effect at every opportunity.
- This shop manual mainly contains the necessary technical Information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components.
- STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. - TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” to ‘Causes’ are also included in 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 PC1100-6 PC1100SP-6 PC1100LC-6 SERVICE REPAIR MANUAL (SN:10001 & Up)
COVER................................................................................................................................................... 1 CONTENTS................................................................................................................................................ 2 01 GENERAL.............................................................................................................................................. 28 SPECIFICATION DRAWINGS.............................................................................................................................. 29 SPECIFICATIONS...................................................................................................................................... 32 WEIGHT TABLE........................................................................................................................................ 36 FUEL, COOLANT AND LUBRICANTS........................................................................................................................ 40 10 STRUCTURE AND FUNCTION............................................................................................................................... 42 PTO................................................................................................................................................. 43 PTO LUBRICATION SYSTEM.............................................................................................................................. 44 RADIATOR, OIL COOLER, AFTERCOOLER................................................................................................................... 45 POWER TRAIN......................................................................................................................................... 47 SWING MACHINERY..................................................................................................................................... 49 SWING CIRCLE........................................................................................................................................ 50 FINAL DRIVE......................................................................................................................................... 51 TRACK FRAME......................................................................................................................................... 52 TRACE SHOE.......................................................................................................................................... 53 AIR PIPING DIAGRAM.................................................................................................................................. 54 AIR CIRCUIT DIAGRAM................................................................................................................................. 55 AIR GOVERNOR........................................................................................................................................ 56 AIR TANK............................................................................................................................................ 56 SAFETY VALVE........................................................................................................................................ 57 HORN VALVE.......................................................................................................................................... 57 GREASE PUMP......................................................................................................................................... 58 HYDRAULIC PIPING DRAWING............................................................................................................................ 59 HYDRAULIC CIRCUIT DIAGRAM........................................................................................................................... 64 HYDRAULIC TANK...................................................................................................................................... 65 HYDRAULIC PUMP...................................................................................................................................... 66 NO.1 PUMP........................................................................................................................................... 67 NO.2 PUMP........................................................................................................................................... 90 NO.3 PUMP........................................................................................................................................... 95 LINE OIL FILTER.....................................................................................................................................104 PILOT OIL FILTER....................................................................................................................................105 RETURN OIL FILTER...................................................................................................................................106 DRAIN OIL FILTER ...................................................................................................................................107 L.H.5-SPOOL CONTROL VALVE...........................................................................................................................108 R.H.4-SPOOL CONTROL VALVE...........................................................................................................................110 SWING 4-SPOOL CONTROL VALVE.........................................................................................................................112 STRAIGHT-TRAVEL VALVE...............................................................................................................................114 BOOM LOWER REGENERATION VALVE.......................................................................................................................117 SWING MOTOR.........................................................................................................................................120 CENTER SWIVEL JOINT.................................................................................................................................122 TRAVEL MOTOR........................................................................................................................................123 PPC CONTROL RELIEF VALVE............................................................................................................................133 SAFETY LOCK VALVE...................................................................................................................................134 ACCUMULATOR.........................................................................................................................................135 VALVE CONTROL.......................................................................................................................................136 WORK EQUIMENT, SWING PPC VALVE......................................................................................................................137 TRAVLE PPC VALVE....................................................................................................................................141 SOLENOID VALVES.....................................................................................................................................145 WORK EQUIPMENT......................................................................................................................................147 AIR CONDITIONER.....................................................................................................................................148 ACTUAL ELECTRIC WIRING DIAGRAM......................................................................................................................149 ELECTRICAL CIRCUIT DIAGRAM..........................................................................................................................154 ENGINE CONTROL......................................................................................................................................155 MACHINE CONTROL SYSTEM..............................................................................................................................165 MACHINE MONITOR SYSTEM..............................................................................................................................194 20 TESTING AND ADJUSTING................................................................................................................................201 STANDARD VALUE TABLE FOR ENGINE RELATED PARTS.......................................................................................................202 STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS......................................................................................................203 STANDARD VALUE TABLE FOR ELECTRICAL PARTS...........................................................................................................220 TESTING AND ADJUSTING...............................................................................................................................235 TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING...............................................................................................236 MEASURING ENGINE SPEED..........................................................................................................................237 MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE)..................................................................................................238 MEASURING EXHAUST TEMPERATURE...................................................................................................................239 MEASURING EXHAUST COLOR.........................................................................................................................240 ADJUSTING VALVE CLEARANCE.......................................................................................................................241 MEASURING COMPRESSION PRESSURE..................................................................................................................242 MEASURING BLOW-BY PRESSURE......................................................................................................................243 TESTING AND ADJUSTING FUEL INJECTION TIMING.....................................................................................................244 MEASURING ENGINE OIL PRESSURE...................................................................................................................245 TESTING AND ADJUSTING FAN BELT TENSION..........................................................................................................246 TESTING AND ADJUSTING ALTERNATOR BELT TENSION...................................................................................................246 TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR...............................................................................247 ADJUSTING ENGINE SPEED SENSOR...................................................................................................................247 TESTING CLEARANCE OF SWING CIRCLE BEARING.......................................................................................................248 MEASURING WEAR OF SPROCKET......................................................................................................................249 TESTING AND ADJUSTING TRACK SHOE TENSION .......................................................................................................250 TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT...............................................................251 TESTING AND ADJUSTING CONTROL PUMP CIRCUIT OIL PRESSURE.........................................................................................256 TESTING AND ADJUSTING PISTON PUMP CONTROL PRESSURE..............................................................................................257 MEASURING SERVO PISTON STROKE...................................................................................................................265 MEASURING PPC VALVE OUTPUT PRESSURE AND TESTING PPC SHUTTLE VALVE...............................................................................266 TESTING SOLENOID VALVE OUTPUT PRESSURE..........................................................................................................270 ADJUSTING WORK EQUIPMENT, SWING PPC VALVE.......................................................................................................272 TESTING TRAVEL DEVIATION........................................................................................................................273 TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT.....................................................................................274 MEASURING OIL LEAKAGE...........................................................................................................................275 BLEEDING AIR....................................................................................................................................279 RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT...............................................................................................281 TROUBLESHOOTING.....................................................................................................................................282 POINTS TO REMEMBER WHEN TROUBLESHOOTING.........................................................................................................283 SEQUENCE OF EVENTS IN TROUBLESHOOTING...........................................................................................................284 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE................................................................................................285 CHECKS BEFORE TROUBLESHOOTING...................................................................................................................293 CONNECTOR TYPES AND MOUNTING LOCATIONS..........................................................................................................294 COONECTION TABLE FOR CONNECTIOR PIN NUMBERS.....................................................................................................300 EXPLANATION OF CONTROL MECHANISM FOR ELECTRICAL SYSTEM..........................................................................................311 DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL...........................................................................................312 ORDER OF TROUBLESHOOTING WHEN CARRYING OUT TROUBLESHOOTING......................................................................................327 METHOD OF USING JUDGEMENT TABLE.................................................................................................................329 METHOD OF USING TROUBLESHOOTING CHARTS..........................................................................................................331 TROUBLESHOOTING OF COMMUNICATION ABNORMALITY SYSTEM (N MODE)....................................................................................333 ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE..................................................................334 ELECTRICAL CIRCUIT DIAGRAM OF N MODE SYSTEM.................................................................................................336 N-1 [E117, E118 OCCUR AT SAME TIME] MONITOR PANEL COMMUNICATION ABNORMALITY.............................................................337 N-2 [E117, E218 OCCUR AT SAME TIME] ENGINE CONTROLLER COMMUNICATION ABNORMALITY.........................................................339 N-3 [E118, E507 OCCUR AT SAME TIME] PUMP CONTROLLER COMMUNICATION ABNORMALITY...........................................................341 TROUBLESHOOTING OF ENGINE CONTROLLER & APS CONTROLLER SYSTEM (E MODE)...........................................................................343 JUDGEMENT TABLE FOR ENGINE CONTROLLER, APS CONTROLLER, AND ENGINE RELATED PARTS.............................................................344 POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF ENGINE CONTROLLER SYSTEM............................................................347 ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE..................................................................348 ELECTRICAL CIRCUIT DIAGRAM OF E MODE SYSTEM.................................................................................................356 E-1 [E501] ABNORMALITY IN ENGINE CONTROLLER POWER SOURCE SYSTEM IS DISPLAYED............................................................360 E-2 [E502] ABNORMALITY IN ENGINE CONTROLLER IS DISPLAYED................................................................................361 E-3 [E521] DISCONNECTION IN GOVERNOR CONTROL SOLENOID SYSTEM IS DISPLAYED...............................................................362 E-4 [E522] SHORT CIRCUIT IN GOVERNOR CONTROL SOLENOID SYSTEM IS DISPLAYED...............................................................363 E-5 [E531] ABNORMALITY IN GOVERNOR SERVO IS DISPLAYED...................................................................................364 E-6 [E537] ABNORMALITY IN CONTORLLER SOLENOID POWER SUPPLE SYSTEM IS DISPLAYED..........................................................365 E-7 [E508] ABNORMALITY IN RACK SENSOR POWER SOURCE SYSTEM IS DISPLAYED..................................................................366 E-8 [E511] ABNORMALITY IN RACK SENSOR SIGNAL SYSTEM IS DISPLAYED........................................................................367 E-9 [E515] DISCONNECTION IN PRESTROKE CONTROL SOLENOID SYSTEM IS DISPLAYED..............................................................368 E-10 [E516] SHORT CIRCUIT IN PRESTROKE CONCTOR SOLENOID SYSTEM IS DISPLAYED.............................................................369 E-11 [E513] ABNORMALITY IN ENGINE SPEED (1) SYSTEM IS DISPLAYED.........................................................................370 E-12 [E514] ABNORMALITY IN ENGINE SPEED SENSOR (2) SYSTEM IS DISPLAYED..................................................................371 E-13 [E525] DISCONNECTION IN GOVERNOR CUT RELAY SYSTEM IS DISPLAYED.....................................................................372 E-14 [E526] SHORT CIRCUIT IN GOVERNOR CUT RELAY SYSTEM IS DISPLAYED.....................................................................373 E-15 [E505] ABNORMALITY IN FUEL CONTROL DIAL VOLTAGE IS DISPLAYED.......................................................................374 E-16 [E503] MISTAKEN CONNECTION OF CONNECTOR IS DISPLAYED...............................................................................375 E-17 [E504] ENGINE OVERRUN IS DISPLAYED.................................................................................................376 E-18 [E535] ABNORMALITY IN ENGINE CONTORLLER BACKUP POWER SUPPLE SYSTEM IS DISPLAYED....................................................377 E-19 [E536] ABNORMALITY IN CONTROLLER POWER SUPPLE SYSTEM IS DISPLAYED..................................................................378 E-20 ENGINE DOES NOT START..............................................................................................................379 E-21 ENGINE DOES NOT STOP...............................................................................................................382 E-22 DEFECTIVE ACTUATION OF APS.........................................................................................................383 E-23 [E534] ABNORMALITY IN MACHINE SELECTION INPUT TO ENGINE CONTROLLER IS DISPLAYED....................................................390 TROUBLESHOOTING OF ENGINE SYSTEM (S MODE).......................................................................................................391 METHOD OF USING TROUBLESHOOTING CHARTS......................................................................................................392 S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)...............................................................................396 S-2 ENGINE DOES NOT START...................................................................................................................397 S-3 ENGINE DOES NOT PICK UP SMOOTHLY(FOLLOW-UP IS POOR).....................................................................................399 S-4 ENGINE STOPS DURING OPERATIONS..........................................................................................................400 S-5 ENGINE DOES NOT ROTATE SMOOTHLY(HUNTING)................................................................................................401 S-6 ENGINE LACKS OUTPUT(NO POWER)...........................................................................................................402 S-7 EXHAUST SMOKE IS BLACK(INCOMPLETE COMBUSTION)...........................................................................................403 S-8 OIL CONSUMPTION IS EXCESSIVE(OR EXHAUST SMOKE IS BLUE)..................................................................................404 S-9 OIL BECOMES CONTAMINATED QUICKLY........................................................................................................405 S-10 FUEL CONSUMPTION IS EXCESSIVE..........................................................................................................406 S-11 OIL IS IN COOLING WATER,OR WATER SPURTS BACK,OR WATER LEVEL GOES DOWN .................................................................407 S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP(DROP IN OIL PRESSURE)..............................................................................408 S-13 OIL LEVEL RISES........................................................................................................................409 S-14 WATER TEMPERATURE BECOMES TOO HIGH(OVERHEATING)........................................................................................410 S-15 ABNORMAL NOISE IS MADE.................................................................................................................411 S-16 VIBRATION IS EXCESSIVE.................................................................................................................412 TROUBLESHOOTING OF PUMP CONTROLLER SYSTEM(C MODE)...............................................................................................413 JUDGEMENT TABLE FOR PUMP CONTROLLER AND HYDRAULIC(MECHANICAL)RELATED PARTS..................................................................414 POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF PUMP CONTROLLER SYSTEM..............................................................417 ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE..................................................................418 ELECTRICAL CIRCUIT DIAGRAM FOR C MODE SYSTEM................................................................................................424 C-1 ABNORMALITY IN CONTROLLER POWER SOURCE SYSTEM(CONTROLLER LED IS OFF)....................................................................426 C-2 [E232] SHORT CIRCUIT IN TVC SOLENOID SYSTEM IS DISPLAYED................................................................................427 C-3 [E233] DISCONNECTION IN TVC SOLENOID SYSTEM IS DISPLAYED................................................................................429 C-4 [E203] SHORT CIRCUIT IN SWING HOLDING BRAKE SOLENOID RELAY SYSTEM IS DISPLAYED..........................................................431 C-5 [E213] DISCONNECTION IN SWING HOLDING BRAKE SOLENOID RELAY SYSTEM IS DISPLAYED..........................................................433 C-6 [E201] SHORT CIRCUIT IN CO CANCEL SOLENOID SYSTEM IS DISPLAYED..........................................................................435 C-7 [E211] DISCONNECTION IN CO CANCEL SOLENOID SYSTEM IS DISPLAYED..........................................................................436 C-8 [E202] SHORT CIRCUIT IN STRAIGHT-TRAVEL SOLENOID SYSTEM IS DISPLAYED....................................................................437 C-9 [E212] DISCONNECTION IN STRAIGHT-TRAVEL SOLENOID SYSTEM IS DISPLAYED....................................................................438 C-10 [E204] SHORT CIRCUIT IN 2-STAGE RELIEF SOLENOID SYSTEM IS DISPLAYED....................................................................439 C-11 [E214] DISCONNECTION IN 2-STAGE RELIEF SOLENOID SYSTEM IS DISPLAYED....................................................................440 C-12 [E205] SHORT CIRCUIT IN SWING PRIORITY SOLENOID SYSTEM IS DISPLAYED....................................................................441 C-13 [E215] DISCONNECTION IN SWING PRIORITY SOLENOID SYSTEM IS DISPLAYED....................................................................442 C-14 [E206] SHORT CIRCUIT IN TRAVEL SPEED SOLENOID SYSTEM IS DISPLAYED......................................................................443 C-15 [E216] DISCONNECTION IN TRAVELE SPEED SOLENOID SYSTEM IS DISPLAYED.....................................................................444 C-16 [E217] MODEL SELECTION INPUT ERROR IS DISPLAYED........................................................................................445 C-17 [E227] ABNORMALITY IN ENGINE SPEED SENSOR(2)SYSTEM IS DISPLAYED........................................................................447 C-18 [E228] ABNORMALITY IN AUTO-DECELERATION OUTPUT SYSTEM IS DISPLAYED.....................................................................448 C-19 ABNORMALITY IN SWING HOLDING BRAKE SYSTEM(NO SERVICE CODE IS DISPLAYED)................................................................449 C-20 ABNORMALITY IN MACHINE PUSH-UP SOLENOID SYSTEM(NO SERVICE CODE IS DISPLAYED)...........................................................451 C-21 ABNORMALITY IN BOOM SHOCKLESS SOLENOID SYSTEM(NO SERVICE CODE IS DISPLAYED)............................................................453 TROUBLESHOOTING OF PUMP CONTROLLER INPUT SIGNAL SYSTE(F MODE)...................................................................................456 ELECTRICAL CIRCUIT DIAGRAM OF F MODE........................................................................................................457 F-1 [BIT PATTERN 20-(1)] (SWING TO RIGHT OIL PRESSURE SWITCH)DOES NOT LIGHT UP..............................................................459 F-2 [BIT PATTERN 20-(2)] (R.H.TRAVEL OIL PRESSURE SWITCH)DOES NOT LIGHT UP..................................................................460 F-3 [BIT PATTERN 20-(3)] (BOOM LOWER OIL PRESSURE SWITCH)DOES NOT LIGHT UP..................................................................461 F-4 [BIT PATTERN 20-(4)] (BOOM RAISE OIL PRESSURE SWITCH)DOES NOT LIGHT UP..................................................................462 F-5 [BIT PATTERN 20-(5)] (ARM IN OIL PRESSURE SWITCH)DOES NOT LIGHT UP......................................................................463 F-6 [BIT PATTERN 20-(6)] (ARM OUT OIL PRESSURE SWITCH)DOES NOT LIGHT UP.....................................................................464 F-7 [BIT PATTERN 21-(1)] (BUCKET CURL OIL PRESSURE SWITCH)DOES NOT LIGHT UP.................................................................465 F-8 [BIT PATTERN 21-(2)] (BUCKET DUMP OIL PRESSURE SWITCH)DOES NOT LIGHT UP.................................................................466 F-9 [BIT PATTERN 21-(5)] (L.H.TRAVEL OIL PRESSURE SWITCH)DOES NOT LIGHT UP..................................................................467 F-10 [BIT PATTERN 26-(5)] (SWING TO LEFT OIL PRESSURE SWITCH)DOES NOT LIGHT UP..............................................................468 F-11 [BIT PATTERN 21-(3)] (SWING LOCK SWITCH)DOES NOT LIGHT UP..............................................................................469 TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM(H MODE).........................................................................................470 TABLE OF FALIURE MODES AND CAUSES...........................................................................................................471 BEFORE CARRYING OUT TROUBLESHOOTING OF HYDRAULIC SYSTEM(H MODE).............................................................................473 H-1 SPEEDS OF ALL WORK EQUIPMENT,SWING,TRAVEL ARE SLOW OR LACK POWER........................................................................478 H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED,OR ENGINE STALLS................................................................................480 H-3 NO WORK EQUIPMENT,TRAVEL,SEWING MOVE....................................................................................................482 H-4 ABNORMAL NOISE GENERATED(FORM AROUND PUMP)..............................................................................................483 H-5 BOOM IS SLOW OR LACKS POWER.............................................................................................................484 H-6 ARM IS SLOW OR LACKS POWER..............................................................................................................486 H-7 BUCKET IS SLOW OR LACKS POWER...........................................................................................................486 H-8 BOOM DOES NOT MOVE......................................................................................................................487 H-9 ARM DOES NOT MOVE ......................................................................................................................487 H-10 BUCKET DOES NOT MOVE...................................................................................................................487 H-11 EXCESSIVE HYDRAULIC DRIFT..............................................................................................................488 H-12 EXCESSIVE TIME LAG.....................................................................................................................488 H-13 BOOM SHOCKLESS FUNCTION IS NOT ACTUATED OR CANNOT BE CANCELED..........................................................................489 H-14 MACHINE DEVIATES NATURALLY TO ONE SIDE DURING TRAVEL OPERATIONS........................................................................490 H-15 DEVIATION IS EXCESSIVE WHEN STRARTING..................................................................................................492 H-16 TRAVEL DEVIATION IS EXCESSIVE DURING COMPOUND OPERATIONS...............................................................................493 H-17 TRAVEL SPEED IS SLOW OR LACKS POWER....................................................................................................493 H-18 TRAVEL DOES NOT MOVE(ONE SIDE ONLY)....................................................................................................494 H-19 TRAVEL SPEED DOES NOT SWITCH...........................................................................................................495 H-20 DOES NOT SWING ........................................................................................................................496 H-21 SWING SPEED IS SLOW OR SWING ACCELERATION IS POOR......................................................................................497 H-22 IN COMPOUND OPERATIONS WITH BUCKET,SWING SPEED IS SLOW OR SWING ACCELERATION IS POOR...................................................498 H-23 IN COMPOUND OPERATIONS WITH BOON WHEN SWING PRIORITY IS ON,SWING SPEED IS SLOW OR SWING ACCELERATION IS POOR...........................498 H-24 EXCESSIVE OVERRUN WHEN STOPPING SWING..................................................................................................499 H-25 EXCESSIVE SHOCK WHEN STOPPING SWING....................................................................................................500 H-26 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING...........................................................................................501 H-27 EXCESSIVE HYDRAULIC DRIFT OF SWING.....................................................................................................501 TROUBLESHOOTING OF MACHINE MONITOR SYSTEM(M MODE)...............................................................................................502 ACTION TAKEN BY MONITOR PANEL WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE...............................................................503 ELECTRICAL CIRCUIT DIAGRAM FOR M MODE SYSTEM................................................................................................507 M-1 [E101] ABNORMALITY IN ERROR DATA IS DISPLAYED OR [E102]ABNORMALITY IN CLOCK DATA IS DISPLAYEED..........................................509 M-2 [E103] SHOT CIRCUIT IN BUZZER OUTPUT SYSTEM IS DISPLAYED................................................................................510 M-3 [E104] AIR CLEANER CLOGGING DETECTED IS DISPLAYED.......................................................................................511 M-4 [E106] DROP IN ENGINE OIL HI PRESSURE DETECTED IS DISPLAYED.............................................................................511 M-5 [E108] ENGINE WATER TEMPERATURE 105°C DETECTED IS DISPLAYED.............................................................................512 M-6 WHEN STARTING SWITCH IS TURNED ON,NONE OF LAMPS ON MONITOR PANEL LIGHT UP FOR 3 SECONDS.................................................513 M-7 WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL LAMPS ALL STAY LIGHT UP AND DO NOT GO OUT..............................................515 M-8 WHEN STARTING SWITCH IS TURNED ON,ITEMS LIGHTED UP ON MONITOR PANEL ARE DIFFERENT FROM MACHINE..........................................515 M-9 WHEN STARTING SWITCH IS TURNED ON(ENGINE STOPPED),BASIC CHECK ITEMS FLASH...............................................................516 M-10 WHEN STARTING SWITCH IS TURNED ON(ENGINE STOPPED),(PREHEATING MONITOR)DISPLAY IS NOT NORMAL............................................519 M-11 WHEN ENGINE IS STARTED,BASIC CHECK ITEMS FLASH.........................................................................................520 M-12 WHEN STARTING SWITCH IS TURNED ON(ENGINE STOPPED),CAUTION ITEMS,EMERGENCY STOP ITEMS FLASH.............................................522 M-13 WHEN ENGINE IS STARTED,CAUTION ITEMS,EMERGENCY STOP ITEMS FLASH(BUT THERE IS NO ABNORMALITY IN ANY ITEM)...............................524 M-14 WHEN STARTING SWITCH IS TURNED ON(ENGINE STOPPED),BUZZER DOES NOT SOUND FOR 1 SECOND CAUTION ITEM FLASHES BUT BUZZER DOES NOT SOUND....529 M-15 NO ABNORMALITY IS DISPLAYED NO MONITOR BUT BUZZER SOUNDS...............................................................................529 M-16 NIGHT LIGHTING ON MONITOR PANEL DOES NOT LIGHT UP......................................................................................530 M-17 ENGINE WATER TEMPERATURE GAUGE DOES NOT RISE...........................................................................................531 M-18 ENGINE WATER TEMPERATURE GAUGE DOES NOT GIVE ANY DISPLAY(GAUGE DOES NOT EVEN DISPLAY 1ST LEAVE)........................................531 M-19 FUEL LEVEL GAUGE ALWAYS DISPLAYS FULL..................................................................................................532 M-20 FUEL LEVEL GAUGE DOES NOT GIVE ANY DISPLAY(GAUGE DOSENOT EVEN DISPLAY 1ST LEVEN........................................................532 M-21 SWING LOCK SWITCH IS TURNED ON,BUT (SWING LOCK MONITOR) DOES NOT LIGHT UP .............................................................533 M-22 SWING PROLIX SWITCH IS TURNED ON (PROLIX),BUT (SWING LOCK MONITOR) DOES NOT FLASH......................................................534 M-23 SERVICE METER DOES NOT ADVANCE WHILE ENGINE IS RUNNING.................................................................................535 M-24 WHEN STARTING SWITCH IS AT OFF AND TIME SWITCH IS PRESSED,SERVICE METER DOES NOT GIVE DISPLAY..........................................535 M-25 DEFECTIVE FUEL LEVEL SENSOR SYSTEM.....................................................................................................536 M-26 DEFECTIVE ENGINE WATER TEMPERATURE SENSOR SYSTEM AND DEFECTIVE HYDRAULIC OIL TEMPERATURE SENSOR SYSTEM.................................537 M-27 DEFECTIVE ENGINE OIL LEVEL SENSOR SYSTEM AND DEFECTIVE HYDRAULIC OIL LEVEL SENSOR SYSTEM...............................................538 M-28 DEFECTIVE RADIATOR WATER LEVEL SENSOR SYSTEM...........................................................................................539 M-29 DEFECTIVE OPERATION OF WIPER(INCLUDING CASES WHERE[E113]IS DISPLAYED]..................................................................540 M-30 DEFECTIVE OPERATION OF WINDOW WASHER(INCLUDING CASES WHERE SERVICE CODE[E114]IS DISPLAYED).............................................543 30 DISASSEMBLY AND ASSEMBLY.............................................................................................................................546 METHOD OF USING MANUAL..............................................................................................................................548 PRECAUTIONS WHEN CARRYING OUT OPERATION.............................................................................................................550 SPECIAL TOOL LIST...................................................................................................................................552 SKETCHES OF SPECIAL TOOLS...........................................................................................................................559 STARTING MOTOR ASSEMBLY.............................................................................................................................566 REMOVAL AND INSTALLATION........................................................................................................................566 ALTERNATOR ASSEMBLY.................................................................................................................................567 REMOVAL AND INSTALLATION........................................................................................................................567 NOZZLE HOLDER ASSEMBLY..............................................................................................................................568 REMOVAL AND INSTALLATION........................................................................................................................568 ENGINE OIL COOLER ASSEMBLY..........................................................................................................................569 REMOVAL AND INSTALLATION........................................................................................................................569 FUEL INJECTION PUMP ASSEMBLY........................................................................................................................570 REMOVAL.........................................................................................................................................570 INSTALLATION....................................................................................................................................571 WATER PUMP ASSEMBLY.................................................................................................................................572 REMOVAL AND INSTALLATION........................................................................................................................572 TURBOCHARGER ASSEMBLY...............................................................................................................................573 REMOVAL AND INSTALLATION........................................................................................................................573 THERMOSTAT ASSEMBLY.................................................................................................................................574 REMOVAL AND INSTALLATION........................................................................................................................574 AIR COMPRESSOR ASSEMBLY.............................................................................................................................575 REMOVAL AND INSTALLATION........................................................................................................................575 ENGINE FRONT SEAL ..................................................................................................................................576 REMOVAL AND INSTALLATION........................................................................................................................576 ENGINE REAR SEAL ...................................................................................................................................578 REMOVAL AND INSTALLATION........................................................................................................................578 CYLINDER HEAD ASSEMBLY..............................................................................................................................580 REMOVAL.........................................................................................................................................580 INSTALLATION....................................................................................................................................584 AFTERCOOLER ASSEMBLY................................................................................................................................586 REMOVAL AND INSTALLATION........................................................................................................................586 RADIATOR,HYDRAULLIC COOLER ASSEMBLY.................................................................................................................587 REMOVAL.........................................................................................................................................587 INSTALLATION....................................................................................................................................588 HYDRAULIC COOLER ASSEMBLY...........................................................................................................................589 REMOVAL AND INSTALLATION........................................................................................................................589 ENGINE,PTO,HYDRAULIC PUMP ASSEMBLY..................................................................................................................590 REMOVAL.........................................................................................................................................590 INSTALLATION....................................................................................................................................593 PTO ASSEMBLY........................................................................................................................................594 REMOVAL.........................................................................................................................................594 INSTALLATION ...................................................................................................................................595 DISASSEMBLY.....................................................................................................................................596 ASSEMBLY........................................................................................................................................598 FUEL TANK ASSEMBLY..................................................................................................................................600 REMOVAL AND INSTALLATION........................................................................................................................600 FINAL DRIVE ASSEMBLY................................................................................................................................601 REMOVAL AND INSTALLATION........................................................................................................................601 DISASSEMBLY.....................................................................................................................................602 ASSEMBLY........................................................................................................................................606 REVOLVING FRAME ASSEMBLY............................................................................................................................614 REMOVAL AND INSTALLATION........................................................................................................................614 SWING MACHINERY ASSEMBLY............................................................................................................................615 REMOVAL AND INSTALLATION........................................................................................................................615 DISASSEMBLY.....................................................................................................................................616 ASSEMBLY........................................................................................................................................620 SWING CIRCLE ASSEMBLY...............................................................................................................................625 REMOVAL AND INSTALLATION........................................................................................................................625 TRACK SHOE ASSEMBLY.................................................................................................................................626 REMOVAL.........................................................................................................................................626 INSTALLATION....................................................................................................................................627 SPROCKET............................................................................................................................................628 REMOVAL AND INSTALLATION........................................................................................................................628 IDLER ASSEMBLY......................................................................................................................................629 REMOVAL AND INSTALLATION........................................................................................................................629 DISASSEMBLY.....................................................................................................................................630 ASSEMBLY........................................................................................................................................632 IDLER ADJUSTMENT CYLINDER ASSEMBLY..................................................................................................................634 DISASSEMBLY AND ASSEMBLY........................................................................................................................634 RECOIL SPRING ASSEMBLY..............................................................................................................................635 REMOVAL AND INSTALLATION........................................................................................................................635 DISASSEMBLY.....................................................................................................................................637 ASSEMBLY........................................................................................................................................638 CARRIER ROLLER ASSEMBLY.............................................................................................................................639 REMOVAL AND INSTALLATION........................................................................................................................639 DIAASSEMBLY.....................................................................................................................................640 ASSEMBLY........................................................................................................................................641 TRACK ROLLER ASSEMBLY...............................................................................................................................642 REMOVAL AND INSTALLATION........................................................................................................................642 DISASSEMBLY.....................................................................................................................................643 ASSEMBLY........................................................................................................................................644 HYDRAULIC TANK ASSEMBLY.............................................................................................................................646 REMOVAL.........................................................................................................................................646 INSTALLATION....................................................................................................................................647 TVC VALVE ASSEMBLY..................................................................................................................................648 REMOVAL AND INSTALLATION........................................................................................................................648 SERVO VALVE ASSEMBLY................................................................................................................................649 REMOVAL AND INSTALLATION........................................................................................................................649 HYDEAULIC PUMP ASSEMBLY.............................................................................................................................650 REMOVAL AND INSTALLATION........................................................................................................................650 NO.1, 2 PUMP (HPV95+95).............................................................................................................................651 DISASSEMBLY ....................................................................................................................................651 ASSEMBLY........................................................................................................................................661 NO.3 PUMP (HPV160+160)..............................................................................................................................677 DISASSEMBLY.....................................................................................................................................677 ASSEMBLY........................................................................................................................................687 MAIN PUMP INPUT SHAFT OIL SEAL......................................................................................................................702 REMOVAL AND INSTALLATION........................................................................................................................702 MAIN RELIEF VALVE ASSEMBLY..........................................................................................................................703 REMOVAL AND INSTALLATION........................................................................................................................703 DISASSEMBLY AND ASSEMBLY........................................................................................................................704 PILOT RELIEF VALVE ASSEMBLY.........................................................................................................................705 REMOVAL AND INSTALLATION........................................................................................................................705 5-SPOOL CONTROL VALVE ASSEMBLY(NO.1)................................................................................................................706 REMOVAL.........................................................................................................................................706 INSTALLATION....................................................................................................................................707 4-SPOOL CONTROL VALVE ASSEMBLY(NO.2)................................................................................................................708 REMOVAL.........................................................................................................................................708 INSTALLATION....................................................................................................................................709 4-SPOOL CONTROL VALVE ASSEMBLY(NO.3)................................................................................................................710 REMOVAL.........................................................................................................................................710 INSTALLATION ...................................................................................................................................711 CONTROL VALVE ASSEMBLY(NO.1)........................................................................................................................712 DISASSEMBLY.....................................................................................................................................712 ASSEMBLY........................................................................................................................................713 CONTROL VALVE ASSEMBLY(NO.2)........................................................................................................................715 DISASSEMBLY.....................................................................................................................................715 ASSEMBLY........................................................................................................................................716 CONTROL VAVLE ASSEMBLY(NO.3)........................................................................................................................719 DISASSEMBLY.....................................................................................................................................719 ASSEMBLY........................................................................................................................................720 SWING MOTOP ASSEMBLT................................................................................................................................723 REMOVAL AND INSTALLATION........................................................................................................................723 CENTER SWIVEL JOINT ASSEMBLY........................................................................................................................724 REMOVAL AND INSTALLATION........................................................................................................................724 DISASSEMBLY AND ASSEMBLY........................................................................................................................725 TRAVEL MOTOR ASSEMBLY...............................................................................................................................726 REMOVAL AND INSTALLATION........................................................................................................................726 WORK EQUIPMENT PPC VALVE ASSEMBLY...................................................................................................................727 REMOVAL AND INSTALLATION........................................................................................................................727 DISASSEMBLY.....................................................................................................................................728 ASSEMBLY........................................................................................................................................729 TRAVEL PPC VALVE ASSEMBLY...........................................................................................................................730 REMOVAL AND INSTALLATION........................................................................................................................730 DISASSEMBLY.....................................................................................................................................731 ASSEMBLY .......................................................................................................................................732 BUCKET CYLINDER ASSEMBLY............................................................................................................................733 BACKHOE.........................................................................................................................................733 REMOVAL.....................................................................................................................................733 INSTALLATION................................................................................................................................734 LOADING SHOVEL..................................................................................................................................735 REMOVAL.....................................................................................................................................735 INSTALLATION................................................................................................................................736 ARM CYLINDER ASSEMBLY...............................................................................................................................737 BACKHOE.........................................................................................................................................737 REMOVAL.....................................................................................................................................737 INSTALLATION................................................................................................................................738 LOADING.........................................................................................................................................739 REMOVAL.....................................................................................................................................739 INSTALLATION................................................................................................................................740 BOOM CYLINDER ASSEMBLY..............................................................................................................................741 BACKHOE.........................................................................................................................................741 REMOVAL.....................................................................................................................................741 INSTALLATION................................................................................................................................742 LOADING.........................................................................................................................................743 REMOVAL.....................................................................................................................................743 INSTALLATION................................................................................................................................744 BOTTOM DUMP CYLINDER ASSEMBLY.......................................................................................................................745 LOADING SHOVEL..................................................................................................................................745 REMOVAL.....................................................................................................................................745 INSTALLATION................................................................................................................................746 BUCKET ASSEMBLY.....................................................................................................................................747 BACKHOE.........................................................................................................................................747 REMOVAL.....................................................................................................................................747 INSTALLATION................................................................................................................................748 LOADING SHOVEL..................................................................................................................................749 REMOVAL.....................................................................................................................................749 INSTALLATION................................................................................................................................750 ARM ASSEMBLY........................................................................................................................................751 BACKHOE.........................................................................................................................................751 REMOVAL.....................................................................................................................................751 INSTALLATION................................................................................................................................752 LOADING SHOVEL..................................................................................................................................753 REMOVAL ....................................................................................................................................753 INSTALLATION................................................................................................................................754 BOOM ASSEMBLY.......................................................................................................................................755 BACKHOE.........................................................................................................................................755 REMOVAL.....................................................................................................................................755 INSTALLATION................................................................................................................................756 LOADING SHOVEL..................................................................................................................................757 REMOVAL.....................................................................................................................................757 INSTALLATION................................................................................................................................759 BUKET,ARM ASSEMBLY..................................................................................................................................761 REMOVAL.........................................................................................................................................761 INSTALLATION ...................................................................................................................................762 WORK EQUIPMENT ASSEMBLY.............................................................................................................................763 BACKOE..........................................................................................................................................763 REMOVAL.....................................................................................................................................763 INSTALLATION................................................................................................................................764 LOADING SHOVEL..................................................................................................................................765 REMOVAL ....................................................................................................................................765 INSTALLATION................................................................................................................................766 CAB ASSEMBLY........................................................................................................................................767 REMOVAL.........................................................................................................................................767 INSTALLATION....................................................................................................................................768 COUNTERWEIGHT ASSEMBLY..............................................................................................................................769 REMOVAL AND INSTALLATION........................................................................................................................769 RECEIVER TANK ASSEMBLY..............................................................................................................................770 REMOVAL AND INSTALLATION........................................................................................................................770 AIR CONDITIONER CONDENSER ASSEMBLY..................................................................................................................771 REMOVAL AND INSTALLATION........................................................................................................................771 AIR CONDITIONER COMPRESSOR ASSEMBLY.................................................................................................................772 REMOVAL AND INSTALLATION........................................................................................................................772 AIR CONDITIONER UNIT ASSEMBLY.......................................................................................................................773 REMOVAL ........................................................................................................................................773 INSTALLATION ...................................................................................................................................774 SOLENOID VAVLE ASSEMBLY.............................................................................................................................775 REMOVAL AND INSTALLATION........................................................................................................................775 GOVERNOR CONTROLLER ASSEMBLY........................................................................................................................776 REMOVAL AND INSTALLATION........................................................................................................................776 MONITOR PANEL ASSEMBLY..............................................................................................................................777 REMOVAL AND INSTALLATION........................................................................................................................777 PUMP CONTROLLER ASSEMBLY............................................................................................................................778 REMOVAL AND INSTALLATION........................................................................................................................778 BOOM ROCK PREVENTION VALVE ASSEMBLY.................................................................................................................779 REMOVAL AND INSTALLATION........................................................................................................................779 ACCUMULATOR ASSEMBLY................................................................................................................................780 REMOVAL AND INSTALLATION........................................................................................................................780 BOOM LOWER REGENERATION VALVE ASSEMBLY..............................................................................................................781 REMOVAL AND INSTALLATION........................................................................................................................781 40 MAINTENANCE STANDARD.................................................................................................................................782 ENGINE MOUNT........................................................................................................................................783 PTO.................................................................................................................................................784 SWING CIRCLE........................................................................................................................................785 SWING MACHINERY.....................................................................................................................................786 FINAL DRIVE.........................................................................................................................................788 TRACK FRAME.........................................................................................................................................790 IDLER...............................................................................................................................................791 CARRIER ROLLER......................................................................................................................................793 TRACK ROLLER........................................................................................................................................794 TRACK SHOE..........................................................................................................................................795 HYDRAULIC PUMP......................................................................................................................................799 CONTROL,PTO LUBRICATING,AFTERCOOLER FAN DRIVE PUMP..................................................................................................801 L.H.5-SPOOL CONTROL VALVE...........................................................................................................................802 R.H.4-SPOOL CONTROL VALVE...........................................................................................................................804 SWING 4-SPOOL CONTROL VALVE.........................................................................................................................806 STRAIGHT-TRAVEL VALVE...............................................................................................................................809 BOOM LOWER REGENERATION VALVE.......................................................................................................................810 SWING NOTOR.........................................................................................................................................811 TRAVEL MOTOR........................................................................................................................................812 CENTER SWIVEL JOINT.................................................................................................................................814 PPC CONTROL RELIEF VALVE............................................................................................................................815 WORK EQUIPMENT・SWING PPC VALVE......................................................................................................................816 TRAVEL PPC VALVE....................................................................................................................................817 HYDRAULIC CYLINDER .................................................................................................................................818 FOR BACKHOE.....................................................................................................................................818 FOR LOADING SHOVEL..............................................................................................................................820 WORK EQUIPMENT......................................................................................................................................821 FOR BACKHOE.....................................................................................................................................821 FOR LOADING SHOVEL..............................................................................................................................823 DIMENSIONS OF WORK EQUIPMENT........................................................................................................................825 90 OTHERS...............................................................................................................................................829 HYDRAULIC CIRCUIT DIAGRAM...........................................................................................................................830 FOR BACKHOE.....................................................................................................................................830 FOR LOADING SHOVEL..............................................................................................................................831 ELECTRICAL CIRCUIT DIAGRAM..........................................................................................................................832 FOR BACKHOE(1/4)................................................................................................................................832 FOR BACKHOE(2/4)................................................................................................................................833 FOR BACKHOE(3/4)................................................................................................................................834 FOR BACKHOE(4/4)................................................................................................................................835 FOR LOADING SHOVEL(1/4).........................................................................................................................836 FOR LOADING SHOVEL(2/4).........................................................................................................................837 FOR LOADING SHOVEL(3/4).........................................................................................................................838 FOR LOADING SHOVEL(4/4).........................................................................................................................839
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2 reviews for KOMATSU PC1100-6 PC1100SP-6 PC1100LC-6 SERVICE REPAIR MANUAL (SN:10001 & Up) – PDF Download
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Gianni Alvaro –
My engine simply wont start. Any help?
Jeremias Wyatt –