Komatsu PC120-8 HYDRAULIC EXCAVATOR Shop Manual WEN00002-00 PDF

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Komatsu PC120-8 HYDRAULIC EXCAVATOR Shop Manual WEN00002-00 – PDF DOWNLOAD 

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Komatsu PC120-8 HYDRAULIC EXCAVATOR Shop Manual WEN00002-00 – PDF DOWNLOAD 

Language : English
Pages : 968
Downloadable : Yes
File Type : PDF

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DESCRIPTION:

Komatsu PC120-8 HYDRAULIC EXCAVATOR Shop Manual WEN00002-00 – PDF DOWNLOAD 

SERIAL NUMBERS 80001 and up

How to read the shop manual 
1. Composition of shop manual
This shop manual contains the necessary technical information for services performed in a workshop.
For ease of understanding, the manual is divided into the following sections.
00. Index and foreword
This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification
This section explains the specifications of the machine.
10. Structure, function and maintenance standard
This section explains the structure, function, and maintenance standard values of each component.
The structure and function sub-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. The maintenance standard sub-section explains the criteria and remedies for disassembly
and service.
20. Standard value table
This section explains the standard values for new machine and judgement criteria for testing,
adjusting, and troubleshooting. This standard value table is used to check the standard values in
testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting
This section explains measuring instruments and measuring methods for testing and adjusting, and
method of adjusting each part. The standard values and judgement criteria for testing and adjusting
are explained in Testing and adjusting.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is
divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also
explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly
This section explains the special tools and procedures for removing, installing, disassembling, and
assembling each component, as well as precautions for them. In addition, tightening torque and
quantity and weight of coating material, oil, grease, and coolant necessary for the work are also
explained.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
q Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q Engine volume
This section explains the method of reproducing, repairing, and replacing parts.

TABLE OF CONTENTS:

Komatsu PC120-8 HYDRAULIC EXCAVATOR Shop Manual WEN00002-00 – PDF DOWNLOAD 

SERIAL NUMBERS 80001 and up

00 Index and foreword
Index 00-2
Table of contents 00-2
Foreword and general information 00-9
Safety notice 00-9
How to read the shop manual 00-14
Explanation of terms for maintenance standard 00-16
Handling of electric equipment and hydraulic component 00-18
Handling of connectors newly used for engines 00-27
How to read electric wire code 00-30
Precautions when carrying out operation 00-33
Method of disassembling and connecting push-pull type coupler 00-36
Standard tightening torque table 00-39
Conversion table 00-43
01 Specification
Specification and technical data 01-3
Specification dimension drawings 01-3
Working range diagram 01-4
Specifications 01-5
List of weights 01-8
List of lubricant and coolant to be filled 01-10
10 Structure, function and maintenance standard
Engine and cooling system 10-4
Engine mount 10-4
PTO 10-5
Cooling system 10-6
Power train 10-8
Power train 10-8
Swing circle 10-9
Swing machinery 10-10
Undercarriage and frame 10-12
Track frame 10-12
Idler cushion 10-13
Idler 10-14
Track roller 10-15
Carrier roller 10-16
Sprocket 10-17
Track shoe 10-18
Hydraulic system 10-22
Hydraulic equipment layout drawing 10-22
Valve control 10-24
Hydraulic tank and filter 10-26
Hydraulic pump 10-28
Control valve 10-56
CLSS 10-66
Functions and operation by valve 10-70
PPC valve 10-100
Swing motor 10-115
Travel motor 10-123
PC120-8 00-3
00 Index and foreword
Table of contents
Center swivel joint 10-132
Solenoid valve 10-134
Accumulator 10-138
Holding valve 10-140
Hydraulic cylinder 10-146
Work equipment 10-148
Work equipment 10-148
Dimensions of components 10-150
Cab and its attachments 10-154
Air conditioner 10-154
Electrical system 10-156
Electronic control system 10-156
Machine monitor system 10-188
KOMTRAX system 10-201
Sensor 10-203
20 Standard value table
Standard service value table 20-3
Standard value table for engine related parts 20-3
Standard value table for chassis related parts 20-4
30 Testing and adjusting
Related information on testing and adjusting 30-3
Tools for testing, adjusting, and troubleshooting 30-3
Sketches of special tools 30-8
Engine and cooling system 30-9
Testing engine speed 30-9
Testing exhaust temperature 30-10
Checking exhaust gas color 30-11
Adjusting valve clearance 30-12
Testing compression pressure 30-14
Testing blow-by pressure 30-16
Testing engine oil pressure 30-17
Reduced cylinder mode operation 30-18
No-injection cranking 30-18
Handling fuel system parts 30-19
Releasing residual pressure from fuel system 30-19
Testing fuel pressure 30-20
Testing fuel return rate and fuel leakage 30-21
Bleeding air from fuel circuit 30-23
Checking fuel circuit for leakage 30-24
Testing and adjusting alternator belt tension 30-25
Checking and adjusting air conditioner compressor belt tension 30-26
Power train 30-27
Testing swing circle bearing clearance 30-27
Undercarriage and frame 30-28
Checking and adjusting track shoe tension 30-28
Hydraulic system 30-30
Testing and adjusting oil pressure in work equipment, swing, and travel circuits 30-30
Testing control circuit basic pressure 30-33
Testing and adjusting oil pressure in pump PC control circuit 30-34
Testing and adjusting oil pressure in pump LS control circuit 30-37
Testing solenoid valve output pressure 30-40
Testing PPC valve output pressure 30-44
Adjusting play of work equipment and swing PPC valves 30-45
00-4 PC120-8
00 Index and foreword
Table of contents
Checking parts which cause hydraulic drift of work equipment 30-46
Testing and adjusting travel deviation 30-48
Releasing residual pressure from hydraulic circuit 30-50
Testing oil leakage 30-51
Bleeding air from each part 30-54
Cab and its attachments 30-56
Checking cab tipping stopper 30-56
Installation and adjustment of mirrors and camera 30-57
Inspection of air conditioner Recirc/Fresh air filter 30-66
Electrical system 30-68
Special functions of machine monitor 30-68
Handling voltage circuit of engine controller 30-118
Preparation work for troubleshooting of electrical system 30-119
Procedure for testing diodes 30-124
Pm-Clinic 30-125
Pm Clinic service 30-125
40 Troubleshooting
Related information on troubleshooting 40-6
Points to remember when performing troubleshooting 40-6
How to proceed in troubleshooting 40-8
Checks before troubleshooting 40-10
Classification and procedures for troubleshooting 40-11
Information described in troubleshooting table 40-12
Phenomena looking like troubles and troubleshooting Nos 40-14
Connection table of connector by No of pins 40-17
T-box and T-adapter list 40-54
Failure code table 40-58
Fuse locations 40-62
Troubleshooting by failure code 40-65
Failure code [989L00] Engine controller lock caution 1 40-65
Failure code [989M00] Engine controller lock caution 2 40-65
Failure code [989N00] Engine controller lock caution 3 40-66
Failure code [AA10NX] Air cleaner clogging 40-67
Failure code [AB00KE] Charge voltage low 40-68
Failure code [B@BAZG] Eng oil press low 40-70
Failure code [B@BAZK] Eng oil level low 40-71
Failure code [B@BCNS] Eng coolant overheat 40-72
Failure code [B@BCZK] Eng water level low 40-74
Failure code [B@HANS] Hydr oil overheat 40-76
Failure code [CA111] ECM critical internal failure 40-78
Failure code [CA115] Eng Ne and Bkup speed sensor error 40-81
Failure code [CA122] Charge air press sensor high error 40-82
Failure code [CA123] Charge air press sensor low error 40-84
Failure code [CA131] Throttle sensor high error 40-86
Failure code [CA132] Throttle sensor low error 40-88
Failure code [CA144] Coolant temp sensor high error 40-90
Failure code [CA145] Coolant temp sensor low error 40-92
Failure code [CA153] Charge air temp sensor high error 40-94
Failure code [CA154] Charge air temp sensor low error 40-96
Failure code [CA155] Chg air temp high speed derate 40-96
Failure code [CA187] Sensor sup 2 volt low error 40-97
Failure code [CA221] Ambient air press sensor high error 40-98
Failure code [CA222] Ambient air press sensor low error 40-100
Failure code [CA227] Sensor sup 2 volt high error 40-101
Failure code [CA234] Eng overspeed 40-102
PC120-8 00-5
00 Index and foreword
Table of contents
Failure code [CA238] Ne speed sensor sup volt error 40-104
Failure code [CA271] IMV/PCV1 short error 40-106
Failure code [CA272] IMV/PCV1 open error 40-107
Failure code [CA322] Injector #1 (L #1) system open/short error 40-108
Failure code [CA324] Injector #3 (L #3) system open/short error 40-110
Failure code [CA331] Injector #2 (L #2) system open/short error 40-112
Failure code [CA332] Injector #4 (L #4) system open/short error 40-114
Failure code [CA342] Calibration code incompatibility 40-116
Failure code [CA351] Inj drive circuit error 40-117
Failure code [CA352] Sensor sup 1 volt low error 40-120
Failure code [CA386] Sensor sup 1 volt high error 40-122
Failure code [CA435] Abnormality in engine oil pressure switch 40-124
Failure code [CA441] Battery voltage low error 40-125
Failure code [CA442] Battery voltage high error 40-126
Failure code [CA449] Rail press very high error 40-127
Failure code [CA451] Rail press sensor high error 40-128
Failure code [CA452] Rail press sensor low error 40-130
Failure code [CA488] Chg air temp high torque derate 40-131
Failure code [CA553] Rail press high error 40-132
Failure code [CA559] Rail press low error 40-133
Failure code [CA689] Eng Ne speed sensor error 40-136
Failure code [CA731] Eng Bkup speed sensor phase error 40-138
Failure code [CA757] All persistent data lost error 40-139
Failure code [CA778] Eng Bkup speed sensor error 40-140
Failure code [CA1633] KOMNET datalink timeout error 40-142
Failure code [CA2185] Throttle sens sup volt high error 40-144
Failure code [CA2186] Throttle sens sup volt low error 40-146
Failure code [CA2249] Rail press very low error 40-146
Failure code [CA2311] Abnormality in IMV solenoid 40-147
Failure code [D110KB] Battery relay drive short 40-148
Failure code [D19JKZ] Personal code relay abnormality 40-150
Failure code [D862KA] GPS antenna discon 40-152
Failure code [DA22KK] Pump solenoid power low error 40-154
Failure code [DA25KP] 5V sensor 1 power abnormality 40-156
Failure code [DA26KP] 5V sensor 2 power abnormality 40-159
Failure code [DA29KQ] Model selection abnormality 40-160
Failure code [DA2RMC] CAN discon (Pump controller detected) 40-162
Failure code [DAF8KB] Short circuit in camera power supply 40-164
Failure code [DAFGMC] GPS module error 40-166
Failure code [DAFRMC] CAN discon (Monitor detected) 40-168
Failure code [DGH2KB] Hydr oil sensor short 40-170
Failure code [DHPAMA] Pump press sensor abnormality 40-172
Failure code [DHSFMA] Travel left forward PPC press sensor abnormality 40-174
Failure code [DHSGMA] Travel right forward PPC press sensor abnormality 40-176
Failure code [DHSHMA] Travel left reverse PPC press sensor abnormality 40-178
Failure code [DHSJMA] Travel right reverse PPC press sensor abnormality 40-180
Failure code [DHX1MA] Overload sensor abnormality (Analog) 40-182
Failure code [DV20KB] Travel alarm short circuit 40-183
Failure code [DW43KA] Travel speed sol discon 40-184
Failure code [DW43KB] Travel speed sol short 40-185
Failure code [DW45KA] Swing brake sol discon 40-186
Failure code [DW45KB] Swing brake sol short 40-188
Failure code [DW91KA] Travel junction sol discon 40-190
Failure code [DW91KB] Travel junction sol short 40-192
Failure code [DWJ0KA] Merge-divider sol discon 40-194
Failure code [DWJ0KB] Merge-divider sol short 40-196
00-6 PC120-8
00 Index and foreword
Table of contents
Failure code [DWK0KA] 2-stage relief sol discon 40-198
Failure code [DWK0KB] 2-stage relief sol short 40-200
Failure code [DXA8KA] PC-EPC sol discon 40-202
Failure code [DXA8KB] PC-EPC sol short 40-204
Failure code [DXE4KA] Service current EPC discon 40-206
Failure code [DXE4KB] Service current EPC short 40-208
Failure code [DY20KA] Wiper working abnormality 40-210
Failure code [DY20MA] Wiper parking abnormality 40-212
Failure code [DY2CKA] Washer drive discon 40-214
Failure code [DY2CKB] Washer drive short 40-216
Failure code [DY2DKB] Wiper drive (for) short 40-218
Failure code [DY2EKB] Wiper drive (rev) short 40-220
Troubleshooting of electrical system (E-mode) 40-222
Before carrying out troubleshooting of electrical system 40-222
Information in troubleshooting table 40-224
E-1 When starting switch turned ON, machine monitor displays nothing 40-226
E-2 When starting switch turned ON (before starting engine), basic check item lights up 40-228
E-3 Engine does not start (Engine does not turn) 40-231
E-4 Preheater does not operate 40-234
E-5 Automatic warm-up system does not operate (in cold season) 40-236
E-6 All work equipment, swing, and travel mechanism do not move or cannot be locked 40-238
E-7 Precaution lights up while engine is running 40-240
E-8 Emergency stop item lights up while engine is running 40-245
E-9 Engine coolant temperature gauge does not indicate normally 40-246
E-10 Hydraulic oil temperature gauge does not indicate normally 40-247
E-11 Fuel level gauge does not indicate normally 40-249
E-12 Contents of display by machine monitor are different from applicable machine 40-251
E-13 Machine monitor does not display some items 40-251
E-14 Function switch does not work 40-251
E-15 Auto-decelerator does not operate normally 40-252
E-16 Working mode does not change 40-253
E-17 Travel speed does not change 40-254
E-18 Alarm buzzer cannot be stopped 40-255
E-19 Windshield wiper and window washer do not operate 40-256
E-20 Power maximizing function does not operate normally 40-260
E-21 Swing holding brake does not operate normally 40-262
E-22 Travel alarm does not sound or does not stop sounding 40-264
E-23 Air conditioner does not operate normally (including air conditioner abnormality record) 40-265
E-24 While starting switch is in OFF position, service meter is not displayed 40-277
E-25 Machine monitor cannot be set in service mode 40-277
E-26 Monitoring function does not display lever control signal normally 40-278
E-27 KOMTRAX system does not operate normally 40-294
Troubleshooting of hydraulic and mechanical system (H-mode) 40-295
Information contained in troubleshooting table 40-295
System chart for hydraulic and mechanical systems 40-296
H-1 Speed or power of all work equipment, swing, and travel are low 40-298
H-2 Engine speed sharply drops or engine stalls 40-299
H-3 No work equipment, travel and swing move 40-300
H-4 Abnormal noise is heard from around hydraulic pump 40-300
H-5 Fine control mode does not function 40-301
H-6 Speed or power of boom is low 40-302
H-7 Speed or power of arm is low 40-303
H-8 Speed or power of bucket is low 40-304
H-9 Work equipment does not move in its single operation 40-305
H-10 Hydraulic drift of work equipment is large 40-306
H-11 Time lag of work equipment is large 40-307
PC120-8 00-7
00 Index and foreword
Table of contents
H-12 Power maximizing function does not operate normally 40-307
H-13 Work equipment loaded more is slower during compound operation 40-308
H-14 Boom RAISE speed is low in compound operation of swing + boom RAISE 40-308
H-15 Travel speed lowers largely during compound operation of work equipment/swing + travel 40-309
H-16 Machine deviates during travel 40-310
H-17 Travel speed is low 40-311
H-18 Machine cannot be steered easily or steering power is low 40-312
H-19 Travel speed does not change or it is kept low or high 40-313
H-20 Track does not move (Only either side) 40-313
H-21 Machine does not swing 40-314
H-22 Swing acceleration or swing speed is low 40-315
H-23 Excessive overrun when stopping swing 40-316
H-24 When upper structure stops swinging, it makes large shock 40-317
H-25 When upper structure stops swinging, it makes large sound 40-317
H-26 Hydraulic drift of swing is large 40-318
H-27 Flow rate in attachment circuit cannot be adjusted 40-319
Troubleshooting of engine (S-mode) 40-320
Method of using troubleshooting chart 40-320
S-1 Starting performance is poor 40-324
S-2 Engine does not start 40-325
S-3 Engine does not pick up smoothly 40-328
S-4 Engine stops during operations 40-329
S-5 Engine does not rotate smoothly 40-330
S-6 Engine lacks output (or lacks power) 40-331
S-7 Exhaust smoke is black (incomplete combustion) 40-332
S-8 Oil consumption is excessive (or exhaust smoke is blue) 40-333
S-9 Oil becomes contaminated quickly 40-334
S-10 Fuel consumption is excessive 40-335
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) 40-336
S-12 Oil pressure drops 40-337
S-13 Oil level rises (Entry of coolant or fuel) 40-338
S-14 Coolant temperature becomes too high (overheating) 40-339
S-15 Abnormal noise is made 40-340
S-16 Vibration is excessive 40-341
50 Disassembly and assembly
General information on disassembly and assembly 50-4
How to read this manual 50-4
Coating materials list 50-6
Special tool list 50-9
Sketch of special tool 50-13
Engine and cooling system 50-17
Removal and installation of fuel supply pump assembly 50-17
Removal and installation of fuel injector assembly 50-20
Removal and installation of front oil seal 50-23
Removal and installation of rear oil seal 50-25
Removal and installation of cylinder head assembly 50-28
Removal and installation of radiator assembly 50-38
Removal and installation of aftercooler assembly 50-40
Removal and installation of work equipment oil cooler assembly 50-42
Removal and installation of engine and work equipment pump assembly 50-44
Removal and installation of fuel tank assembly 50-52
Power train 50-54
Removal and installation of travel motor and final drive assembly 50-54
Disassembly and assembly of travel motor and final drive assembly 50-56
Removal and installation of swing motor and swing machinery assembly 50-93
00-8 PC120-8
00 Index and foreword
Table of contents
Disassembly and assembly of swing machinery assembly 50-95
Removal and installation of swing circle assembly 50-101
Undercarriage and frame 50-102
Disassembly and assembly of track roller 50-102
Disassembly and assembly of idler assembly 50-105
Disassembly and assembly of recoil spring 50-108
Spreading and installation of track shoe assembly 50-111
Removal and installation of sprocket 50-113
Removal and installation of revolving frame assembly 50-114
Removal and installation of counterweight assembly 50-116
Hydraulic system 50-118
Removal and installation of center swivel joint assembly 50-118
Disassembly and assembly of center swivel joint assembly 50-120
Removal and installation of hydraulic tank assembly 50-121
Removal and installation of work equipment pump assembly 50-124
Removal and installation of control valve assembly 50-128
Disassembly and assembly of control valve assembly 50-133
Disassembly and assembly of work equipment PPC valve assembly 50-144
Disassembly and assembly of travel PPC valve assembly 50-146
Disassembly and assembly of hydraulic cylinder assembly 50-149
Work equipment 50-155
Removal and installation of work equipment assembly 50-155
Cab and its attachments 50-158
Removal and installation of operator’s cab assembly 50-158
Removal and installation of operator cab glass (stuck glass) 50-161
Removal and installation of front window assembly 50-171
Removal and installation of floor frame assembly 50-178
Electrical system 50-182
Removal and installation of air compressor assembly 50-182
Removal and installation of air conditioner condenser 50-183
Removal and installation of air conditioner unit assembly 50-184
Removal and installation of KOMTRAX communication modem assembly 50-187
Removal and installation of monitor assembly 50-188
Removal and installation of pump controller assembly 50-190
Removal and installation of engine controller assembly 50-192
90 Diagrams and drawings
Hydraulic diagrams and drawings 90-3
Symbols used in hydraulic circuit diagrams 90-3
Hydraulic circuit diagram 90-5
Electrical diagrams and drawings 90-9
Symbols used in electric circuit diagrams 90-9
Electrical circuit diagram 90-13
Connectors table and arrangement drawing 90-23
Index 1

S.V 12/12/24