Komatsu PC120-6 Custom Hydraulic Excavator Shop Manual SEBM005503 PDF

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Komatsu PC120-6 Custom Hydraulic Excavator Shop Manual SEBM005503  – PDF DOWNLOAD

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Komatsu PC120-6 Custom Hydraulic Excavator Shop Manual SEBM005503  – PDF DOWNLOAD

Language : English
Pages : 590
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu PC120-6 Custom Hydraulic Excavator Shop Manual SEBM005503  – PDF DOWNLOAD

• MACHINE MODEL                    SERIAL No.
  PC120-6 CUSTOM                    47703 and up

COVER 1
CONTENTS 2
01 GENERAL 26
GENERAL ASSEMBLY DRAWING 27
SPECIFICATIONS 28
WEIGHT TABLE 31
LIST OF LUBRICANT AND WATER 33
10 STRUCTURE AND FUNCTION 34
RADIATOR AND OIL COOLER 35
PTO (COUPLING) 36
POWER TRAIN 37
SWING CIRCLE 38
SWING MACHINERY 39
TRACK FRAME 40
IDLER 41
IDLER CUSHION 41
CARRIER ROLLER 42
TRACK ROLLER 42
TRACK SHOE 43
HYDRAULIC PIPING DRAWING 45
HYDRAULIC CIRCUIT DIAGRAM 46
HYDRAULIC TANK 53
HYDRAULIC PUMP 54
CONTROL VALVE 84
CLSS 96
SWING MOTOR 116
CENTER SWIVEL JOINT 119
TRAVEL MOTOR 120
VALVE CONTROL 126
WORK EQUIPMENT・SWING PPC VALVE 127
TRAVEL PPC VALVE 131
SERVICE PPC VALVE 135
SAFETY LOCK SOLENOID VALVE 138
PPC SHUTTLE・TRAVEL JUNCTION VALVE 139
EPC SOLENOID VALVE 144
BOOM HOLDING VALVE 151
ACCUMULATOR FOR BREAKER 154
ADDITIONAL FILTER FOR BREAKER 155
WORK EQUIPMENT 156
ELECTRICAL WIRING DIAGRAM 157
ELECTRICAL CIRCUIT DIAGRAM 159
ENGINE CONTROL SYSTEM 162
ELECTRIC CONTROL SYSTEM 163
MACHINE MONITOR SYSTEM 170
SENSORS 173
20 TESTING AND ADJUSTING 175
TABLE OF JUDGEMENT STANDARD VALUE 176
STANGARD VALUE TABLE ROR ELECTRICAL PARTS 186
TESTING AND ADJUSTING 189
TOOLS FOR TESTING, ADJUSTING,AND TROUBLESHOOTING 190
MEASURING ENGINE SPEED 191
MEASURING EXHAUST GAS COLOR 192
ADJUSTING VALVE CLEARANCE 193
MEASURING COMPRESSION PRESSURE 194
MEASURING BLOWBY PRESSURE 194
TESTING AND ADJUSTING FUEL INJECTION TIMING 195
MEASURING ENGINE OIL PRESSURE 196
TESTING AND ADJUSTING ALTERNATOR FAN BELT TENSION 197
TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION 197
ADJUSTING FUEL CONTROL LEVER 198
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT,SWING,TRAVEL CIRCUIT 200
TESTING AND ADJUSTING TCC VALVE OUTPUT PRESSURE(SERVO PISTON INPUT PRSSURE) 202
TESTING AND ADJUSTING TVC VALVE OUTPUT PRESSURE(SERVO PISTON INPUT PRESSURE) 204
TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE(SERVO PISTON INPUT PRESSURE) AND LS DIFFERNTIAL PRESSURE 206
TESTING AND ADJUSTING CONTROL PUMP CIRCUIT OIL PRESSURE 212
TESTING SOLENOID VALVE OUTPUT PRESSURE 214
MEASURING PPC VALVE OUTPUT PRESSURE AND TESTING PPC SHUTTLE VALVE 215
ADJUSTING WORK EQUIPMENT AND SWING PPC VALVE 217
TESTING TRAVEL DEVIATION 218
MEASURING OIL LEAKAGE 219
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT 220
TESTING CLEARANCE OF SWING CIRCLE BEARING 221
TESTING AND ADJUSTING TRACK SHOE TENSION 222
BLEEDING AIR 223
TROUBLESHOOTING 225
POINTS TO REMEMBER WHEN TROUBLESHOOTING 226
SEQUENCE OF EVENTS IN TROUBLESHOOTING 227
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE 228
CHECKS BEFORE TROUBLESHOOTING 235
CONNECTOR TYPES AND MOUNTING LOCATIONS 236
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS 238
METHOD OF USING TROUBLESHOOTING CHARTS 248
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE) 250
METHOD OF USING TROUBLESHOOTING CHARTS 251
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME) 255
S-2 ENGINE DOES NOT START 256
(1) ENGINE DOES NOT TURN 256
(2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED) 257
(3) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START(FUEL IS BEING INJECTED) 258
S-3 ENGINE DOES NOT PICK UP SMOOTHLY(FOLLOW-UP IS POOR) 259
S-4 ENGINE STOPS DURING OPERATIONS 260
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING) 261
S-6 ENGINE LACKS OUTPUT (NO POWER) 262
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION) 263
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE) 264
S-9 OIL BECOMES CONTAMINATED QUICKLY) 265
S-10 FUEL CONSUMPTION IS EXCESSIVE 266
S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN 267
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE) 268
S-13 OIL LEVEL RISES (WATER, FUEL IN OIL) 269
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING) 270
S-15 ABNORMAL NOISE IS MADE 271
S-16 VIBRATION IS EXCESSIVE 272
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE) 273
CHART FOR DISTINGUISHING IF FAILURE IS IN ELECTRICAL SYSTEM OR IN HYDRAULIC, MECHANICAL SYSTEM 274
ELECTRICAL CIRCUIT DIAGRAM FOR E MODE 276
E-1 ABNORMALITY IN LS-EPC SOLENOID SYSTEM 278
a) IS NOT ACTUATED (ENGINE SPEED DROPS EXCESSIVELY OR ENGINE STALLS WHEN ENGINE IS MIDRANGE SPEED OR BELOW) 278
b) REMAINS ACTUATED (WORK EPUIPMENT SPEED IS SLOW EVEN WHEN ENGINE IS AT MIDRANGE SPEED OR ABOVE) 279
E-2 ABNORMALITY IN TVC SOLENOID SYSTEM 280
a) IS NOT ACTUATED (ENGINE SPEED DROPS EXCESSIVELY OR ENGINE STALLS WHEN ENGINE SPEED IS MIDRANGE SPEED OR BELOW) 280
b) REMAINS ACTUATED (WORK EQUIPMENT SPEED IS SLOW EVEN WHEN ENGINE IS AT MIDRAGE SPEED OR ABOVE) 281
E-3 ABNORMALITY IN SWING HOLDING BRAKE SOLENOID SYSTEM 282
a) SWING HOLDING BRAKE IS NOT ACTUATED (CANNOT SWING) 282
b) SWING HOLDING BRAKE REMAINS ACTUATED (SWING CANNOT BE LOCKED) 283
E-4 ABNORMALITY IN PPC OIL PRESSURE LOCK SOLENOID SYSTEM 284
a) IS NOT ACTUATED (SAFETY LOCK IS NOT RELEASED) 284
b) REMAINS ACTUATED (SAFETY LOCK IS NOT APPLIED) 285
E-5 ABNORMALITY IN ENGINE STARTING SYSTEM (ENGINE DOES NOT START) 286
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE) 288
TABLE OF FAILURE MODES AND CAUSES 289
H-1 SPEEDS OF ALL WORK EPUIPMENT, SWING, TRAVEL ARE SLOW OR LACK POWER 290
H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS 292
H-3 NO WORK EQUIPMENT, TRAVEL,SWING MOVE 293
H-4 ABNORMAL NOISE GENERATED (FROM AROUND PUMP) 293
H-5 FINE CONTROL ABILITY IS POOR OR RESPONSE IS POOR 293
H-6 BOOM IS SLOW OR LACKS POWER 294
H-7 ARM IS SLOW OR LACKS POWER 296
H-8 BUCKET IS SLOW OR LACKS POWER 298
H-9 WORK EQUIPMENT DOES NOT MOVE (BOOM, ARM, BUCKET),(TRAVEL AND SWING ARE NORMAL) 298
H-10 EXCESSIVE HYDRAULIC DRIFT (BOOM, ARM, BUCKET) 299
H-11 EXCESSIVE TIME LAG (ENGINE AT LOW IDLING) 300
H-12 OTHER EQUIPMENT MOVES WHEN SINGLE CIRCUIT IS RELIEVED 300
H-13 IN COMPOUND OPERATIONS, WORK EQUIPMENT WITH LARGER LOAD IS SLOW 300
H-14 IN SWING + BOOM RAISE, BOOM RAISE IS SLOW 301
H-15 IN SWING + TRAVEL,TRAVEL SPEED DROPS EXCESSIVELY 301
H-16 TRAVEL DEVIATION 302
a) DEVIATION IS EXCESSIVE IN NORMAL TRAVEL 302
b) DEVIATION IS EXCESSIVE WHEN STRATING 302
H-17 TRAVEL SPEED IS SLOW 303
H-18 STEERING DOES NOT TURN OR LACKS POWER 304
H-19 TRAVEL DOES NOT MOVE (ONE SIDE ONLY) 306
H-20 DOES NOT SWING 307
a) DOES NOT SWING IN EITHER DIRECTION 307
b) DOES NOT SWING IN ONE DIRECTION (LEFT OR RIGHT) 307
H-21 SWING ACCELERATION IS POOR 308
H-22 EXCESSIVE OVERRUN WHEN STOPPING SWING 310
a) ONE DIRECTION ONLY 310
b) BOTH DIRECTIONS 310
H-23 EXCESSIVE SHOCK WHEN STOPPING SWING (ONE DIRECTION ONLY) 311
H-24 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING 311
H-25 EXCESSIVE HYDRAULIC DRIFT OF SWING 312
a) WHEN HOLDING BRAKE IS RELEASED 312
b) WHEN HOLDING BRAKE IS APPLIED 312
TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE) 313
ELECTRICAL CIRCUIT DIAGRAM FOR MONITOR SYSTEM 314
M-1 WHEN THE STARTING SWITCH IS TURNED ON, NO DISPLAY IS GIVEN (LAMPS DO NOT LIGHT UP FOR 3 SECONDS) 315
M-2 WHEN STARTING SWITCH IS TURNED ON, LAMPS LIGHT UP FOR 3 SECONDS, BUT THEN DO NOT GO OUT 315
M-3 WHEN STARTING SWITCH IS TURNED ON, SOME LAMPS DO NOT LIGHT UP FOR 3 SECONDS 316
a) NO GAUGE LAMPS LIGHT UP (CAUTION LAMPS LIGHT UP) 316
b) SWING LOCK, PREHEATING LAMPS DO NOT LIGHT UP (ALL GAUGE LAMPS LIGHT UP) 316
c) CHARGE CAUTION LAMP DOES NOT LIGHT UP 316
d) ENGINE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP 316
M-4 WHEN STARTING SWITCH IS ON (ENGINE STOPPED), CHARGE CAUTION LAMP DOES NOT LIGHT UP 317
M-5 WHEN STARTING SWITCH IS ON (ENGINE STOPPED), ENGINE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP 317
M-6 DURING PREHEATING, PREHATING PILOT LAMP DOES NOT LIGHT UP 318
M-7 WHEN SWITCH IS OPERATED, SWING LOCK LAMP DOES NOT LIGHT UP 318
M-8 WHEN ENGINE IS RUNNING, ENGINE OIL PRESSURE CAUTION LAMP LIGHTS UP (ENGINE OIL PRESSURE IS NORMAL) 319
M-9 WHEN ENGINE IS RUNNING, CHARGE CAUTION LAMP LIGHTS UP 319
M-10 ABNORMALITY IN COOLANT TEMPERATURE GAUGE 320
a) AFTER ENGINE IS STARTED, LEVEL STAYS AT BOTTOM (WHITE RANGE) AND DOES NOT MOVE 320
b) AFTER ENGINE IS STARTED, LEVEL IMMEDIATELY RISES ENGINE IS NOT OVERHEATING BUT INDICATOR ENTERS RED RANGE 320
c) COOLANT TEMPERATURE GAUGE GOES OUT 320
M-11 ABNORMALITY IN FUEL GAUGE 321
a) ALL FUEL GAUGE SEGMENTS GO OUT 321
b) EVEN WHEN FUEL LEVEL GOES DOWN, FUEL GAUGE CONTINUES TO SHOW FULL 321
c) EVEN WHEN TANK IS FILLED, FUEL GAUGE DOES NOT SHOW FULL 321
M-12 DEFECTIVE OPERATION OF ALARM BUZZER 323
a) BUZZER DOES NOT SOUND 323
b) BUZZER CONTINUES TO SOUND AND DOES NOT STOP 323
M-13 WHEN ENGINE IS RUNNING, SERVICE METER DOES NOT ADVANCE 324
a) WHEN CHARGE CAUTION LAMP DOES NOT LIGHT UP 324
b) IF CHARGE CAUTION LAMP LIGHTS UP,GO TO M-9 324
M-14 NIGHT LIGHTING DOES NOT LIGHT UP 325
a) GAUGE LIGHTING DOES NOT LIGHT UP 325
b) SERVICE METER LIGHTING DOES NOT LIGHT UP (SERVICE METER IS WORKING NORMALLY) 325
M-15 HEATER DOES NOT WORK 326
a) DOES NOT WORK AT EITHER HI OR LO 326
b) DOES NOT WORK AT LO ONLY 326
c) DOES NOT WORK AT HI ONLY 326
30 DISASSEMBLY AND ASSEMBLY 327
METHOD OF USING MANUAL 329
PRECAUTIONS WHEN CARRYING OUT OPERATION 330
SPECIAL TOOL LIST 332
SPECIAL TOOL 336
STARTING MOTOR 337
REMOVAL AND INSTALLATION 337
ALTERATOR 338
REMOVAL AND INSTALLATION 338
AIR CONDITIONER COMPRESSOR 339
REMOVAL AND INSTALLATION 339
CONDENSER 340
REMOVAL AND INSTALLATION 340
ENGINE OIL COOLER CORE 341
REMOVAL AND INSTALLATION 341
FUEL INJECTION PUMP 342
REMOVAL 342
INSTALLATION 343
WATER PUMP 344
REMOVAL AND INSTALLATION 344
NOZZLE HOLDER 345
REMOVAL AND INSTALLATION 345
TURBOCHARGER 346
REMOVAL AND INSTALLATION 346
THERMOSTAT 347
REMOVAL AND INSTALLATION 347
ENGINE FRONT OIL SEAL 348
REMOVAL AND INSTALLATION 348
ENGINE REAR OIL SEAL 349
REMOVAL AND INSTALLATION 349
CYLINDER HEAD 350
REMOVAL 350
INSTALLATION 352
ENGINE・HYDRAULIC PUMP 354
REMOVAL 354
INSTALLATION 357
HYDRAULIC OIL COOLER 358
REMOVAL AND INSTALLATION 358
REDIATOR・HYDRAULIC OIL COOLER 359
REMOVAL 359
INSTALLATION 360
FUEL TANK 361
REMOVAL AND INSTALLATION 361
CENTER SWIVEL JOINT 362
REMOVAL AND INSTALLATION 362
DISASSEMBLY AND ASSEMBLY 363
SPROCKET 364
REMOVAL AND INSTALLATION 364
TRAVEL MOTOR 365
REMOVAL AND INSTALLATION 365
SWING MACHINERY・SWING MOTOR 366
REMOVAL AND INSTALLATION 366
SWING MACHINERY 367
DISASSEMBLY 367
ASSEMBLY 370
SWING MOTOR 374
REMOVAL AND INSTALLATION 374
DISASSEMBLY 375
ASSEMBLY 378
REVOLVING FRAME 382
REMOVAL 382
INSTALLATION 384
SWING CIRCLE 385
REMOVAL AND INSTALLATION 385
IDLER・RECOIL SPRING 386
REMOVAL AND INSTALLATION 386
RECOIL SPRING 387
DISASSEMBLY 387
ASSEMBLY 388
IDLER 389
DISASSEMBLY 389
ASSEMBLY 390
TRACK ROLLER 392
REMOVAL AND INSTALLATION 392
DISASSEMBLY 393
ASSEMBLY 394
CARRIER ROLLER 396
REMOVAL AND INSTALLATION 396
TRACK SHOE 397
REMOVAL AND INSTALLATION 397
HYDRAULIC TANK 398
REMOVAL 398
INSTALLATION 399
CONTROL PUMP 400
REMOVAL AND INSTALLATION 400
MAIN PUMP 401
REMOVAL 401
INSTALLATION 402
DISASSEMBLY 403
ASSEMBLY 408
MAIN PUMP INPUT SHAFT OIL SEAL 420
REMOVAL AND INSTALLATION 420
CONTROL VALVE 421
REMOVAL 421
INSTALLATION 422
DISASSEMBLY 423
ASSEMBLY 425
LS SELECT VALVE 427
DISASSEMBLY AND ASSEMBLY 427
LS SHUTTLE VALVE 428
DISASSEMBLY AND ASSEMBLY 428
PRESSURE COMPENSATION VALVE 429
DISASSEMBLY 429
ASSEMBLY 430
TCC・LS VALVE 431
REMOVAL AND INSTALLATION 431
LS CONTROL EPC VALVE 432
REMOVAL AND INSTALLATION 432
SOLENOID VALVE 433
REMOVAL AND INSTALLATION 433
WORK EQUIPMENT LEFT SIDE PPC VALVE (FOR ARM, SWING CONTROL) 434
REMOVAL AND INSTALLATION 434
WORK EQUIPMENT RIGHT SIDE PPC VALVE (FOR BOOM, BUCKET CONTROL) 435
REMOVAL AND INSTALLATION 435
WORK EQUIPMENT PPC VALVE (FOR BOOM, ARM, BUCKET, SWING CONTROL PPC VALVE) 436
DISASSEMBLY 436
ASSEMBLY 437
TRAVEL PPC VALVE 438
REMOVAL AND INSTALLATION 438
DISASSEMBLY AND ASSEMBLY 439
BOOM CYLINDER 441
REMOVAL 441
INSTALLATION 442
ARM CYLINDER 443
REMOVAL 443
INSTALLATION 444
BUCKET CYLINDER 445
REMOVAL 445
INSTALLATION 446
HYDRAULIC CYLINDER 447
DISASSEMBLY 447
ASSEMBLY 449
WORK EQUIPMENT 452
REMOVAL 452
INSTALLATION 453
BUCKET 454
REMOVAL 454
INSTALLATION 455
ARM 456
REMOVAL 456
INSTALLATION 457
BUCKET・ARM 458
REMOVAL 458
INSTALLATION 459
BOOM 460
REMOVAL 460
INSTALLATION 461
OPERATOR’S CAB 462
REMOVAL AND INTALLATION 462
COUNTERWEIGHT 463
REMOVAL AND INSTALLATION 463
MONITOR 464
REMOVAL AND INSTALLATION 464
40 MAINTENANCE STANDARD 465
SWING MACHINERY 466
SWING CIRCLE 468
TRACK FRAME 469
IDLER 470
CARRIER ROLLER 471
TRACK ROLLER 472
SPROCKET 473
TRACK SHOE 474
HYDRAULIC PUMP 477
CONTROL VALVE 480
SWING MOTOR 489
CENTER SWIVEL JOINT 490
WORK EQUIPMENT・SWING PPC VALVE 491
TRAVEL PPC VALVE 492
SERVICE PPC VALVE 493
PPC SHUTTLE・TRAVEL JUNCTION VALVE 494
LS CONTROL EPC SOLENOID VALVE 496
BOOM HOLDING VALVE 497
HYDRAULIC CYLINDER 498
WORK EQUIPMENT 499

DESCRIPTION:

Komatsu PC120-6 Custom Hydraulic Excavator Shop Manual SEBM005503  – PDF DOWNLOAD

• MACHINE MODEL                    SERIAL No.
  PC120-6 CUSTOM                    47703 and up

G.B 20/12/24