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KOMATSU PC120-6 EXCEL SERVICE REPAIR MANUAL (SN:57499 & UP) KOMATSU PC120 6 – PDF DOWNLOAD
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- KOMATSU PC120-6 EXCEL SERVICE REPAIR MANUAL
- SERIAL NUMBER:57499 & UP
- PUBLICATION NUMBER:SEBM010404
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Description
KOMATSU PC120-6 EXCEL SERVICE REPAIR MANUAL (SN:57499 & UP) KOMATSU PC120 6
KOMATSU PC120-6 EXCEL SERVICE REPAIR MANUAL (SN:57499 & UP) KOMATSU PC120 6 – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU PC120-6 EXCEL SERVICE REPAIR MANUAL (SN:57499 & UP) KOMATSU PC120 6
- This shop manual has been prepared as an aid to improve the quality of repairs by giving the servicemen an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
- This shop manual mainly contains the necessary technical information for operations performed In a service workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group Of components.
- STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. - TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” to ”Causes‘ are also included in 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 PC120-6 EXCEL SERVICE REPAIR MANUAL (SN:57499 & UP) KOMATSU PC120 6
COVER.......................................................................................................................................... 1 CONTENTS....................................................................................................................................... 2 01 GENERAL..................................................................................................................................... 23 GENERAL ASSEMBLY DRAWING .................................................................................................................. 24 SPECIFICATIONS............................................................................................................................. 25 WEIGHT TABLE............................................................................................................................... 27 LIST OF LUBRICANT AND WATER................................................................................................................ 29 10 STRUCTURE AND FUNCTION...................................................................................................................... 31 RADIATOR AND OIL COOLER.................................................................................................................... 32 ENGINE CONTROL............................................................................................................................. 33 PTO (COUPLING)............................................................................................................................. 34 POWER TRAIN................................................................................................................................ 35 SWING CIRCLE............................................................................................................................... 36 SWING MACHINERY............................................................................................................................ 37 TRACK FRAME ............................................................................................................................... 38 TRACK SHOE................................................................................................................................. 39 HYDRAULIC CIRCUIT DIAGRAM.................................................................................................................. 40 HYDRAULIC TANK............................................................................................................................. 45 HYDRAULIC PUMP............................................................................................................................. 46 CONTROL VALVE.............................................................................................................................. 66 CLSS....................................................................................................................................... 77 SWING MOTOR................................................................................................................................123 CENTER SWIVEL JOINT........................................................................................................................126 TRAVEL MOTOR...............................................................................................................................127 VALVE CONTROL..............................................................................................................................135 WORK EQUIPMENT・SWING PPC VALVE.............................................................................................................137 TRAVEL PPC VALVE...........................................................................................................................141 SERVICE PPC VALVE..........................................................................................................................145 SAFETY LOCK VALVE..........................................................................................................................148 PPC ACCUMULATOR............................................................................................................................148 STRAIGHT-TRAVEL SYSTEM.....................................................................................................................149 SOLENOID VALVE ............................................................................................................................150 ACCUMULATOR FOR BREAKER....................................................................................................................154 ADDITIONAL FILTER FOR BREAKER..............................................................................................................155 WORK EQUIPMENT.............................................................................................................................156 AIR CONDITIONER............................................................................................................................157 ACTUAL ELERICAL WIRING DIAGRAM.............................................................................................................158 ELECTRICAL CIRCUIT DIAGRAM.................................................................................................................162 ELECTRIC CONTROL SYSTEM....................................................................................................................167 MACHINE MONITOR SYSTEM.....................................................................................................................172 SENSORS....................................................................................................................................175 20 TESTING AND ADJUSTING.......................................................................................................................177 STANDARD VALUE TABLE FOR ENGINE RELATED PARTS..............................................................................................178 STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS.............................................................................................179 STANDARD VALUE TABLE FOR ELECTRICAL PARTS..................................................................................................187 TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING..........................................................................................189 MEASURING ENGINE SPEED.....................................................................................................................190 MEASURING EXHAUST COLOR....................................................................................................................191 ADJUSTING VALVE CLEARANCE..................................................................................................................192 MEASURING BLOW-BY PRESSURE.................................................................................................................193 TESTING AND ADJUSTING FUEL INJECTION TIMING................................................................................................194 MEASURING ENGINE OIL PRESSURE..............................................................................................................195 TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR..........................................................................196 ADJUSTING FUEL CONTROL LEVER...............................................................................................................197 ADJUSTING ENGINE SPEED SENSOR..............................................................................................................199 TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT..........................................................200 TESTING AND ADJUSTING PC VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE)...............................................................202 TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE..................................204 TESTING AND ADJUSTING CONTROL PUMP CIRCUIT OIL PRESSURE....................................................................................207 TESTING SOLENOID VALVE OUTPUT PRESSURE.....................................................................................................209 ADJUSTING WORK EQUIPMENT, SWING PPC VALVE..................................................................................................211 TESTING TRAVEL DEVIATION...................................................................................................................212 MEASURING OIL LEAKAGE......................................................................................................................213 RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT..........................................................................................215 TESTING CLEARANCE OF SWING CIRCLE BEARING..................................................................................................216 TESTING AND ADJUSTING TRACK SHOE TENSION...................................................................................................217 MEASURING WEAR OF SPROCKET.................................................................................................................218 BLEEDING AIR...............................................................................................................................219 TROUBLESHOOTING............................................................................................................................221 POINTS TO REMEMBER WHEN TROUBLESHOOTING................................................................................................222 SEQUENCE OF EVENTS IN TROUBLESHOOTING..................................................................................................223 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE.......................................................................................224 CHECKS BEFORE TROUBLESHOOTING..........................................................................................................232 CONNECTOR TYPES AND MOUNTING LOCATIONS.................................................................................................233 CONNECTOR ARRANGEMENT DIAGRAM..........................................................................................................235 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS.............................................................................................237 METHOD OF USING JUDGEMENT TABLE........................................................................................................247 METHOD OF USING TROUBLESHOOTING CHARTS.................................................................................................249 TROUBLESHOOTING OF ENGINE (S MODE).....................................................................................................251 METHOD OF USING TROUBLESHOOTING CHART..............................................................................................252 S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)......................................................................256 S-2 ENGINE DOES NOT START..........................................................................................................258 1) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED)....................................................258 2) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)..................................................259 S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)...........................................................................260 S-4 ENDINE STOPS DURING OPERATIONS.................................................................................................261 S-5 ENGINE DOES NOT ROTATES SMOOTHLY (HUNTING).....................................................................................262 S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)...........................................................................................263 S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION).................................................................................264 S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)........................................................................265 S-9 OIL BECOMES CONTAMINATED QUICKLY...............................................................................................266 S-10 FUEL CONSUMPTION IS EXCESSIVE.................................................................................................267 S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN.......................................................268 S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)....................................................................269 S-13 OIL LEVEL RISES (WATER, FUEL IN OIL)..........................................................................................270 S-14 WATER TEMPERTURE BECOMES TOO HIGH (OVERHEATING)...............................................................................271 S-15 ABNORMAL NOISE IS MADE .......................................................................................................272 S-16 VIBRATION IS EXCESSIVE........................................................................................................273 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)..........................................................................................274 JUDGEMENT TABLE FOR ELECTRICAL, HYDRAULIC, AND MECHANICAL SYSTEMS..................................................................275 E MODE RELATED ELECTRIC CIRCUIT DIAGRAM............................................................................................277 E-1 ABNORMALITY IN PC-EPC SYSTEM...................................................................................................280 a) SPEEDS OF ALL WORK EQUIPMENT, SWING, TRAVEL ARE SLOW OR LACK POWER..........................................................280 b) THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS...................................................................281 E-2 ABNORMALITY IN PPC LOCK SOLENOID SYSTEM........................................................................................283 a) WORK EQUIPMENT, SWING, TRAVEL DO NOT MOVE EVEN WHEN SAFETY LOCK IS PLACED AT FREE...........................................283 b) WORK EQUIPMENT, SWING, TRAVEL MOVE EVEN WHEN SAFETY LOCK IS PLACED AT LOCK..................................................283 E-3 ABNORMALITY IN SWING LOCK SOLENOID SYSTEM......................................................................................286 a) SWING DOES NOT MOVE EVEN WHEN SWING LOCK SWITCH IS PLACED AT FREE...........................................................286 b) SWING MOVES EVEN WHEN SWING LOCK SWITCH IS PLACED AT LOCK...................................................................286 E-4 ABNORMALITY IN TRAVEL SPEED SOLENOID SYSTEM....................................................................................288 a) MACHINE DOES NOT TRAVEL AT HIGH SPEED EVEN WHEN TRAVEL SPEED SELECTOR SWITCH IS AT HI.......................................288 b) MACHINE DOES NOT TRAVEL AT LOW SPEED EVEN WHEN TRAVEL SPEED SELECTOR SWITCH IS AT LO........................................288 E-5 ABNORMALITY IN ENGINE STARTING SYSTEM (ENGINE DOES NOT START)..................................................................290 TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE)...............................................................................293 TABLE OF FAILURE MODES AND CAUSES..................................................................................................294 H-1 SPEEDS OF ALL WORK EQUIPMENT, TRAVEL, SWING ARE SLOW OR LACK POWER.............................................................296 H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS......................................................................296 H-3 NO WORK EQUIPMENT, TRAVEL, SWING MOVE..........................................................................................297 H-4 ABNORMALITY NOISE GENERATED (AROUND PUMP)......................................................................................297 H-5 FINE CONTROL ABLITY IS POOR OR RESPONSE IS POOR................................................................................298 H-6 BOOM IS SLOW OR LACKS POWER....................................................................................................299 H-7 ARM IS SLOW OR LACKS POWER.....................................................................................................299 H-8 BUCKET IS SLOW OR LACKS POWER..................................................................................................301 H-9 WORK EQUIPMENT (BOOM, ARM, BUCKET) DOES NOT MOVE (BUT TRAVEL AND SWING ARE NORMAL).............................................301 H-10 EXCESSIVE HYDRAULIC DRIFT (BOOM, ARM, OR BUCKET)..............................................................................302 H-11 IN COMPOUND OPERATIONS, WORK EQUIPMENT WITH LARGER LOAD IS SLOW ..............................................................302 H-12 IN SWING + BOOM RAISE, BOOM RAISE IS SLOW ....................................................................................303 H-13 IN SWING + TRAVEL, TRAVEL SPEED DROPS EXCESSIVELY.............................................................................303 H-14 IN WORK EQUIPMENT + TRAVEL, TRAVEL SPEED DROPS EXCESSIVELY....................................................................303 H-15 TRAVEL DEVIATION..............................................................................................................304 a) WHEN THERE IS DEVIATION IN NORMAL TRAVEL....................................................................................304 b) DEVIATION IS EXCESSIVE WHEN STARTING........................................................................................304 H-16 TRAVEL SPEED IS SLOW..........................................................................................................305 H-17 STEERING IS DIFFERENT TO TURN OR LACKS POWER..................................................................................306 H-18 TRAVEL SPEED DOES NOT SWITCH..................................................................................................308 H-19 TRAVEL DOES NOT MOVE (ONE SIDE ONLY)..........................................................................................308 H-20 DOES NOT SWING ...............................................................................................................309 a) DOES NOT SWING TO EITHER LEFT OR RIGHT......................................................................................309 b) DOES NOT SWING IN ONE DIRECTION.............................................................................................309 H-21 SWING ACCELERATION IS POOR....................................................................................................310 H-22 EXCESSIVE OVERRUN WHEN STOPPING SWING.........................................................................................312 a) ONE DIRECTION ONLY .........................................................................................................312 b) BOTH DIRECTIONS.............................................................................................................312 H-23 EXCESSIVE SHOCK WHEN STOPPING SWING (ONE DIRECTION ONLY)......................................................................313 H-24 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING..................................................................................313 H-25 EXCESSIVE HYDRULIC DRIFT OF SWING ............................................................................................314 a) WHEN SWING LOCK SWITCH IS OFF...............................................................................................314 b) WHEN SWING LOCK SWITCH IS AT LOCK...........................................................................................314 TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE).....................................................................................315 ELECTRICAL CIRCUIT DIAGRAM FOR M MODE SYSTEM.......................................................................................316 M-1 WHEN THE STARTING SWITCH IS TURNED ON, NO DISPLAY IS GIVEN (3 SECOND SELF CHECK IS ALSO NOT CARRIED OUT).......................317 M-2 WHEN STARTING SWITCH IS TURNED ON, EVEN WHEN SELF CHECK IS COMPLETED (ALL LAMPS LIGHT UP FOR 3 SECOND), LAMPS DO NOT GO OUT....317 M-3 WHEN STARTING SWITCH IS TURNED ON, SOME SELF CHECK LAMPS DO NOT LIGHT UP FOR 3 SECONDS.........................................318 a) NO GAUGE LAMPS LIGHT UP (CAUTION LAMPS LIGHT UP)............................................................................318 b) SWING LOCK OR PREHEATING LAMPS DO NOT LIGHT UP (GAUGE LAMPS ALL LIGHT UP)...................................................318 c) BATTERY CHARGE LAMP DOES NOT LIGHT UP.......................................................................................318 d) ENGINE OIL PRESSURE LAMP DOES NOT LIGHT UP..................................................................................318 M-4 WHEN STARTING SWITCH IS ON (ENGINE STOPPED), BATTERY CHARGE CAUTION LAMP DOES NOT LIGHT UP.....................................319 M-5 WHEN STARTING SWITCH IS ON (ENGINE STOPPED), ENGINE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP................................319 M-6 WHEN STARTING SWITCH IS TURNED TO HEAT, PREHEATING PILOT LAMP DOES NOT LIGHT UP................................................320 M-7 WHEN SWING LOCK IS TURNED ON, SWING LOCK PILOT LAMP DOES NOT LIGHT UP..........................................................320 M-8 WHEN ENGINE IS RUNNING, ENGINE OIL PRESSURE CAUTION LAMP LIGHTS UP (ENGINE OIL PRESSURE IS NORMAL).............................321 M-9 WHEN ENGINE IS RUNNING, BATTERY CHARGE CAUTION LAMP LIGHTS UP..................................................................321 M-10 ABNORMALITY IN ENGINE WATER TEMPERATURE GAUGE.................................................................................322 a) AFTER ENGINE IS STARTED, ONLY LOWEST LEVEL LAMP (WHITE RANGE) LIGHTS UP AND LEVEL DOES NOT RISE.............................322 b) AFTER ENGINE IS STARTED, LEVEL IMMEDIATELY RISES AND ENTERS RED RANGE (THERE IS NO OVERHEATING).............................322 c) GAUGE GOES OUT..............................................................................................................322 M-11 ABNORMALITY IN FUEL GAUGE ....................................................................................................324 a) ALL SEGMENTS OF GAUGE GO OUT ...............................................................................................324 b) FUEL LEVEL HAS GONE DOWN, BUT GAUGE ALWAYS DISPLAYS FULL....................................................................324 c) EVEN WHEN FUEL TANK IS FILED, GAUGE DOES NOT DISPLAY FULL...................................................................324 M-12 DEFETIVE OPERATION OF ALARM BUZZER............................................................................................326 a) BUZZER DOES NOT SOUND.......................................................................................................326 b) BUZZER CONTINUES TO SOUND AND DOES NOT STOP.................................................................................326 M-13 WHEN ENGINE IS RUNNING, SERVICE METER DOES NOT ADVANCE........................................................................327 a) WHEN BATTERY CHARGE CAUTION LAMP DOES NOT LIGHT UP..........................................................................327 b) WHEN BATTERY CHARGE CAUTION LAMP LIGHTS UP..................................................................................327 M-14 NIGHT LIGHTING DOES NOT LIGHT UP..............................................................................................328 a) GAUGE LIGHTING DOES NOT LIGHT UP............................................................................................328 b) SERVICE METER LIGHTING DOES NOT LIGHT UP (SERVICE METER WORKS NORMALLY).....................................................328 M-15 HEATER DOES NOT WORK (MACHINES WITH HEATER)...................................................................................329 a) BOTH LO AND HI DO NOT WORK .................................................................................................329 b) ONLY LO DOES NOT WORK.......................................................................................................329 c) ONLY HI DOES NOT WORK.......................................................................................................329 30 DISASSEMBLY AND ASSEMBLY....................................................................................................................331 METHOD OF USING MANUAL.....................................................................................................................333 PRECAUTIONS WHEN CARRYING OUT OPERATION....................................................................................................334 SPECIAL TOOL LIST..........................................................................................................................336 SKETCHES OF SPECIAL TOOLS..................................................................................................................340 STARTING MOTOR.............................................................................................................................342 REMOVAL AND INSTALLATION...............................................................................................................342 ALTERNATOR.................................................................................................................................343 REMOVAL AND INSTALLATION...............................................................................................................343 AIR CONDITIONER COMPRESSOR.................................................................................................................345 REMOVAL AND INSTALLATION...............................................................................................................345 CONDENSER..................................................................................................................................346 REMOVAL AND INSTALLATION...............................................................................................................346 ENGINE OIL COOLER..........................................................................................................................347 REMOVAL AND INSTALLATION...............................................................................................................347 FUEL INJECTION PUMP........................................................................................................................348 REMOVAL................................................................................................................................348 INSTALLATION...........................................................................................................................350 WATER PUMP.................................................................................................................................352 REMOVAL AND INSTALLATION...............................................................................................................352 NOZZLE HOLDER..............................................................................................................................353 REMOVAL AND INSTALLATION...............................................................................................................353 TURBOCHARGER...............................................................................................................................354 REMOVAL AND INSTALLATION...............................................................................................................354 THERMOSTAT.................................................................................................................................355 REMOVAL AND INSTALLATION...............................................................................................................355 CYLINDER HEAD..............................................................................................................................356 REMOVAL................................................................................................................................356 INSTALLATION...........................................................................................................................361 ENGINE, MAIN PUMP..........................................................................................................................364 REMOVAL................................................................................................................................364 INSTALLATION...........................................................................................................................368 HYDRAULIC COOLER...........................................................................................................................369 REMOVAL AND INSTALLATION...............................................................................................................369 RADIATOR, HYDRAULIC COOLER.................................................................................................................370 REMOVAL................................................................................................................................370 INSTALLATION...........................................................................................................................371 FUEL TANK .................................................................................................................................372 REMOVAL AND INSTALLATION...............................................................................................................372 CENTER SWIVEL JOINT........................................................................................................................373 REMOVAL AND INSTALLATION...............................................................................................................373 DISASSEMBLY AND ASSEMBLY...............................................................................................................374 SPROCKET...................................................................................................................................375 REMOVAL AND INSTALLATION...............................................................................................................375 TRAVEL MOTOR...............................................................................................................................376 REMOVAL AND INSTALLATION...............................................................................................................376 SWING MACHINERY, SWING MOTOR...............................................................................................................377 REMOVAL AND INSTALLATION...............................................................................................................377 SWING MOTOR................................................................................................................................378 REMOVAL AND INSTALLATION...............................................................................................................378 DISASSEMBLY............................................................................................................................379 ASSEMBLY...............................................................................................................................383 SWING MACHINERY............................................................................................................................391 DISASSEMBLY............................................................................................................................391 ASSEMBLY...............................................................................................................................394 REVOLVING FRAME............................................................................................................................398 REMOVAL................................................................................................................................398 INSTALLATION...........................................................................................................................399 SWING CIRCLE...............................................................................................................................400 REMOVAL AND INSTALLATION...............................................................................................................400 IDLER, RECOIL SPRING.......................................................................................................................401 REMOVAL AND INSTALLATION...............................................................................................................401 IDLER......................................................................................................................................402 DISASSEMBLY............................................................................................................................402 ASSEMBLY...............................................................................................................................403 RECOIL SPRING..............................................................................................................................405 DISASSEMBLY............................................................................................................................405 ASSEMBLY...............................................................................................................................406 TRACK ROLLER...............................................................................................................................407 REMOVAL AND INSTALLATION...............................................................................................................407 DISASSEMBLY............................................................................................................................408 ASSEMBLY...............................................................................................................................409 CARRIER ROLLER.............................................................................................................................411 REMOVAL AND INSTALLATION...............................................................................................................411 TRACK SHOE.................................................................................................................................412 REMOVAL AND INSTALLATION...............................................................................................................412 HYDRAULIC TANK.............................................................................................................................413 REMOVAL................................................................................................................................413 INSTALLATION...........................................................................................................................414 CONTROL PUMP...............................................................................................................................415 REMOVAL AND INSTALLATION...............................................................................................................415 MAIN PUMP..................................................................................................................................416 REMOVAL................................................................................................................................416 INSTALLATION...........................................................................................................................417 DISASSEMBLY............................................................................................................................418 ASSEMBLY...............................................................................................................................428 MAIN PUMP INPUT SHAFT OIL SEAL.............................................................................................................440 REMOVAL AND INSTALLATION...............................................................................................................440 CONTROL VALVE..............................................................................................................................441 REMOVAL................................................................................................................................441 INSTALLATION...........................................................................................................................442 DISASSEMBLY............................................................................................................................443 ASSEMBLY...............................................................................................................................448 LS SELECT VALVE............................................................................................................................454 DISASSEMBLY AND ASSEMBLY...............................................................................................................454 PC-EPC VALVE...............................................................................................................................455 REMOVAL AND INSTALLATION...............................................................................................................455 PC VALVE...................................................................................................................................456 REMOVAL AND INSTALLATION...............................................................................................................456 LS VALVE...................................................................................................................................457 REMOVAL AND INSTALLATION...............................................................................................................457 SOLENOID VALVE.............................................................................................................................458 REMOVAL AND INSTALLATION...............................................................................................................458 PPC VALVE..................................................................................................................................460 REMOVAL AND INSTALLATION...............................................................................................................460 WORK EQUIPMENT RIGHT SIDE PPC VALVE........................................................................................................461 REMOVAL AND INSTALLATION...............................................................................................................461 WORK EQUIPMENT, SWING PPC VALVE............................................................................................................462 DISASSEMBLY............................................................................................................................462 ASSEMBLY...............................................................................................................................463 TRAVEL PPC VALVE...........................................................................................................................464 REMOVAL AND INSTALLATION...............................................................................................................464 DISASSEMBLY............................................................................................................................465 ASSEMBLY...............................................................................................................................466 BOOM CYLINDER..............................................................................................................................467 REMOVAL................................................................................................................................467 INSTALLATION...........................................................................................................................468 ARM CYLINDER...............................................................................................................................469 REMOVAL................................................................................................................................469 INSTALLATION...........................................................................................................................470 BUCKET CYLINDER............................................................................................................................471 REMOVAL................................................................................................................................471 INSTALLATION...........................................................................................................................472 HYDRAULIC CYLINDER.........................................................................................................................473 DISASSEMBLY............................................................................................................................473 ASSEMBLY...............................................................................................................................476 WORK EQUIPMENT.............................................................................................................................480 REMOVAL................................................................................................................................480 INSTALLATION...........................................................................................................................481 BUCKET.....................................................................................................................................482 REMOVAL................................................................................................................................482 INSTALLATION...........................................................................................................................483 ARM .......................................................................................................................................484 REMOVAL................................................................................................................................484 INSTALLATION...........................................................................................................................485 BUCKET, ARM................................................................................................................................486 REMOVAL................................................................................................................................486 INSTALLATION...........................................................................................................................487 BOOM.......................................................................................................................................488 REMOVAL................................................................................................................................488 INSTALLATION...........................................................................................................................489 OPERATOR'S CAB.............................................................................................................................490 REMOVAL AND INSTALLATION...............................................................................................................490 COUNTERWEIGHT..............................................................................................................................491 REMOVAL AND INSTALLATION...............................................................................................................491 MONITOR....................................................................................................................................492 REMOVAL AND INSTALLATION...............................................................................................................492 40 MAINTENANCE STANDARD........................................................................................................................493 SWING MACHINERY............................................................................................................................494 SWING CIRCLE...............................................................................................................................496 TRACK FRAME ...............................................................................................................................497 IDLER......................................................................................................................................498 CARRIER ROLLER.............................................................................................................................499 TRACK ROLLER...............................................................................................................................500 SPROCKET...................................................................................................................................501 TRACK SHOE.................................................................................................................................502 HYDRAULIC PUMP.............................................................................................................................509 CONTROL VALVE..............................................................................................................................511 SWING MOTOR................................................................................................................................521 TRAVEL MOTOR...............................................................................................................................522 CENTER SWIVEL JOINT........................................................................................................................523 WORK EQUIPMENT・SWING PPC VALVE.............................................................................................................524 TRAVEL PPC VALVE...........................................................................................................................525 SERVICE PPC VALVE..........................................................................................................................526 HYDRAULIC CYLINDER.........................................................................................................................527 WORK EQUIPMENT.............................................................................................................................529 DIMENSION OF WORK EQUIPMENT ...............................................................................................................531 90 OTHER.......................................................................................................................................535 HYDRAULIC CIRCUIT DIAGRAM PC120-6 EXCEL SERIAL NO.57449-60967..............................................................................536 HYDRAULIC CIRCUIT DIAGRAM PC120-6 EXCEL SERIAL NO.60968 AND UP ............................................................................537 ELECTRICAL CIRCUIT GIAGRAM CHASSIS ELECTRICAL CIRCUIT DIAGRAM (1/2) PC120-6 EXCEL SERIAL NO.57499-60967....................................538 ELECTRICAL CIRCUIT DIAGRAM CHASSIS ELECTRICAL CIRCUIT DIAGRAM (2/2) PC120-6 EXCEL SERIAL NO.57499-60967....................................539 ELECTRICAL CIRCUIT DIAGRAM CHASSIS ELECTRICAL CIRCUIT DIAGRAM (1/2) PC120-6 EXCEL SERIAL NO.60968 AND UP...................................540 ELECTRICAL CIRCUIT DIAGRAM CHASSIS ELECTRICAL CIRCUIT DIAGRAM (2/2) PC120-6 EXCEL SERIAL NO.60968 AND UP ..................................541
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