Komatsu PC100-5, PC120-5, PC120-5 Mighty Hydraulic Excavator Shop Manual SEBM02020508

Description

• Model List:
  • PC100-5 Mighty Hydraulic Excavator
  • PC120-5 Mighty Hydraulic Excavator
  • PC120-5 Mighty Hydraulic Excavator

• 1. COVER
• 2. CONTENTS
• 3. STRUCTURE AND FUNCTION
• 3.1. ENGINE RELATED PARTS AND ENGINE MOUNT
• 3.2. RADIATOR AND OIL COOLER
• 3.3. SWING MACHINERY
• 3.4. HYDRAULIC PIPING
• 3.5. HYDRAULIC CIRCUIT DIAGRAM
• 3.6. HYDRAULIC TANK AND FUEL TANK
• 3.7. OLSS (OPEN CENTER LOAD SENSING SYSTEM)
• 3.8. HYDRAULIC PUMP
• 3.9. SPOOL CONTROL VALVE
• 3.10. SPOOL CONTROL VALVE
• 3.11. SWING MOTOR
• 3.12. CENTER SWIVEL JOINT
• 3.13. TRAVEL MOTOR
• 3.14. VALVE CONTROL
• 3.15. PPC VALVE
• 3.16. ACCUMULATOR
• 3.17. SAFETY LOCK VALVE
• 3.18. SOLENOID VALVE
• 3.19. SHUTTLE VALVE
• 3.20. BOOM HOLDING VALVE
• 3.21. HYDRAULIC CYLINDER
• 3.22. ELECTRICAL WIRING DIAGRAM
• 3.23. ELECTRICAL CIRCUIT DIAGRAM
• 3.24. ENGINE CONTROL SYSTEM
• 3.25. PEMC SYSTEM
• 3.26. EMACC (ELECTRONIC MONITOR AND CONTROL CONSOLE)
• 4. TESTING AND ADJUSTING
• 4.1. TABLE OF JUDGEMENT STANDARD VALUE
• 4.2. STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM
• 4.3. TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
• 4.4. ADJUSTING VALVE CLEARANCE
• 4.5. MEASURING COMPRESSION PRESSURE
• 4.6. TESTING AND ADJUSTING FUEL INJECTION TIMING
• 4.7. TESTING AND ADJUSTING TRAVEL OF GOVERNOR MOTOR LEVER
• 4.8. INSPECTION OF SWING CIRCLE BEARING CLEARANCE
• 4.9. ADJUSTING ENGINE SPEED SENSOR
• 4.10. ADJUSTING TRAVEL LIMIT SWITCH
• 4.11. TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT
• 4.12. TESTING AND ADJUSTING CHARGING PUMP PRESSURE
• 4.13. TESTING AND ADJUSTING MAIN PUMP CONTROL PRESSURE
• 4.14. MEASURING STROKE OF SERVO PISTON
• 4.15. TESTING AND ADJUSTING TRAVEL DEVIATION
• 4.16. MEASURING OUTPUT PRESSURE OF PPC VALVE
• 4.17. ADJUSTING PPC VALVE
• 4.18. TESTING PPC SHUTTLE VALVE
• 4.19. MEASURING SOLENOID VALVE OUTLET PORT PRESSURE
• 4.20. TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT
• 4.21. BLEEDING AIR
• 4.22. RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT
• 4.23. TROUBLESHOOTING
• 4.23.1. POINTS TO REMEMBER WHEN TROUBLESHOOTING
• 4.23.2. SEQUENCE OF EVENTS IN TROUBLESHOOTING
• 4.23.3. PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
• 4.23.4. CHECKS BEFORE TROUBLESHOOTING
• 4.23.5. ELECTRICAL CIRCUIT DIAGRAM
• 4.23.6. POSITION OF CONNECTORS FOR TROUBLESHOOTING
• 4.23.7. CONNECTION TABLE FOR CONNECTOR
• 4.23.8. HANDLING CONNECTORS
• 4.23.9. EXPLANATION OF FUNCTIONS OF CONTROL MECHANISM OF ELECTRICAL SYSTEM
• 4.23.10. DISPLAY METHOD FOR MONITOR PANEL, PUMP CONTROLLER AND ENGINE THROTTLE CONTROLLER
• 4.23.11. ACTION OF SELFDIAGNOSTIC FUNCTION AND SYMPTOMS ON MACHINE
• 4.23.12. METHOD OF USING JUDGEMENT TABLE
• 4.23.13. METHOD OF USING TROUBLESHOOTING CHARTS
• 4.23.14. TROUBLESHOOTING OF ENGINE THROTTLE CONTROLLER SYSTEM (E MODE)
• 4.23.15. TROUBLESHOOTING OF PUMP CONTROLLER SYSTEM (C MODE)
• 4.23.16. TROUBLESHOOTING OF PUMP CONTROLLER INPUT SIGNAL SYSTEM (F MODE)
• 4.23.17. TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)
• 4.23.18. TROUBLESHOOTING OF MONITOR SYSTEM (P MODE)
• 5. DISASSEMBLY AND ASSEMBLY
• 5.1. METHOD OF USING MANUAL
• 5.2. PRECAUTIONS WHEN CARRYING OUT OPERATION
• 5.3. SPECIAL TOOL LIST
• 5.4. WEIGHT TABLE
• 5.5. TIGHTENING TORQUES AND STANDARD VALUES TABLE
• 5.6. LUBRICANT AND COOLANT TABLE
• 5.7. ENGINE OIL COOLER
• 5.7.1. REMOVAL
• 5.7.2. INSTALLATION
• 5.8. FUEL INJECTION PUMP
• 5.8.1. REMOVAL
• 5.8.2. INSTALLATION
• 5.9. ENGINE FRONT SEAL
• 5.9.1. REMOVAL
• 5.9.2. INSTALLATION
• 5.10. ENGINE REAR SEAL
• 5.10.1. REMOVAL
• 5.10.2. INSTALLATION
• 5.11. HYDRAULIC COOLER
• 5.11.1. REMOVAL
• 5.11.2. INSTALLATION
• 5.12. RADIATOR, HYDRAULIC COOLER
• 5.12.1. REMOVAL
• 5.12.2. INSTALLATION
• 5.13. ENGINE HYDRAULIC PUMP
• 5.14. CENTER SWIVEL JOINT
• 5.14.1. REMOVAL
• 5.14.2. INSTALLATION
• 5.14.3. DISASSEMBLY
• 5.14.4. ASSEMBLY
• 5.15. FINAL DRIVE (PC1205)
• 5.16. SWING MACHINERY
• 5.17. REVOLVING FRAME
• 5.18. IDLER, RECOIL SPRING
• 5.19. MAIN PUMP INPUT SHAFT
• 5.20. MAIN RELIEF VALVE
• 5.21. WORK EQUIPMENT PPC VALVE
• 5.22. PPC VALVE
• 5.22.1. DISASSEMBLY
• 5.22.2. ASSEMBLY
• 5.23. PPC SHUTTLE VALVE
• 5.23.1. REMOVAL
• 5.23.2. INSTALLATION
• 5.24. BOOM HOLDING VALVE
• 5.25. BUCKET CYLINDER
• 5.25.1. INSTALLATION
• 5.26. HYDRAULIC CYLINDER
• 5.27. ENGINE THROTTLE CONTROLLER
• 5.27.1. REMOVAL
• 5.27.2. INSTALLATION
• 5.28. PUMP CONTROLLER
• 5.28.1. REMOVAL
• 5.28.2. INSTALLATION
• 5.29. MONITOR PANEL
• 5.29.1. REMOVAL
• 5.29.2. INSTALLATION
• 6. MAINTENANCE STANDARD
• 6.1. FINAL DRIVE
• 6.2. SWING CIRCLE
• 6.3. SWING MACHINERY
• 6.4. CHARGING PUMP AND RELIEF VALVE
• 6.5. SPOOL CONTROL VALVE
• 6.6. SPOOL CONTROL VALVE
• 6.7. SWING MOTOR
• 6.8. CENTER SWIVEL JOINT
• 6.9. TRAVEL MOTOR
• 6.10. PPC VALVE
• 6.11. BOOM HOLDING VALVE
• 6.12. HYDRAULIC CYLINDER
• 6.13. WORK EQUIPMENT