Komatsu P100-3, P100L-3, P120-3, P150HD-3, P150NHD-3 Shop Manual SEBM02020309

Description

• Model List:
  • P100-3
  • P100L-3
  • P120-3
  • P150HD-3
  • P150NHD-3

• 1. COVER
• 2. CONTENTS
• 3. GENERAL
• 3.1. GENERAL VIEW
• 3.2. GENERAL ASSEMBLY DRAWING
• 3.3. SPECIFICATIONS
• 3.4. ENGINE ASSEMBLY DRAWING
• 3.5. LIST OF WEIGHT
• 3.6. LIST OF LUBRICANT AND WATER
• 4. ENGINE
• 4.1. STRUCTURE AND FUNCTION
• 4.1.1. ENGINE MOUNT
• 4.1.3. RADIATOR
• 4.1.4. FUEL TANK AND PIPING
• 4.1.5. ENGINE CONTROL
• 4.1.6. AUTODECELERATION SYSTEM (IF EQUIPPED)
• 4.2. TESTING AND ADJUSTING
• 4.2.1. TESTING AND ADJUSTING DATA
• 4.2.2. TESTING AND ADJUSTING TOOL LIST
• 4.2.3. TESTING AND ADJUSTING DECELERATOR SPEED
• 4.2.4. ADJUSTING VALVE CLEARANCE
• 4.2.5. MEASURING COMPRESSION PRESSURE
• 4.2.6. TESTING AND ADJUSTING FUEL INJECTION TIMING
• 4.2.7. TESTING AND ADJUSTING FAN BELT TENSION
• 4.2.8. MEASURING BLOWBY PRESSURE
• 4.2.9. MEASURING EXHAUST GAS COLOR
• 4.3. DISASSEMBLY AND ASSEMBLY
• 4.3.1. FUEL INJECTION PUMP
• 4.3.1.1. DISMOUNTING
• 4.3.1.2. MOUNTING
• 4.3.2. ENGINE OIL COOLER
• 4.3.3. HYDRAULIC OIL COOLER
• 4.3.3.1. DISMOUNTING
• 4.3.3.2. MOUNTING
• 4.3.4. RADIATOR, HYDRAULIC OIL COOLER
• 4.3.5. DECELERATION CYLINDER
• 4.3.5.1. DISMOUNTING
• 4.3.5.2. MOUNTING
• 5. POWER TRAIN
• 5.1. STRUCTURE AND FUNCTION
• 5.1.1. POWER TRAIN
• 5.1.1.1. OUTLINE
• 5.1.1.2. POWER TRAIN HYDRAULIC PIPING
• 5.1.2. TRAVEL SYSTEM
• 5.1.2.1. OUTLINE
• 5.1.2.2. TRAVEL CONTROL (WRIST CONTROL TYPE)
• 5.1.2.3. TRAVEL CONTROL (LONG LEVER CONTROL TYPE)
• 5.1.2.4. CENTER SWIVEL JOINT
• 5.1.2.5. TRAVEL MOTOR
• 5.1.3. SWING SYSTEM
• 5.1.3.1. OUTLINE
• 5.1.3.2. SWING MOTOR AND BRAKE VALVE
• 5.1.3.3. SWING CIRCLE
• 5.1.3.4. SWING MACHINERY
• 5.2. DISASSEMBLY AND ASSEMBLY
• 5.2.1. CENTER SWIVEL JOINT
• 5.2.1.1. DISASSEMBLY (PC100,120)
• 5.2.1.2. ASSEMBLY (PC100,120)
• 5.2.1.3. DISASSEMBLY (PC100L)
• 5.2.1.4. ASSEMBLY (PC100L)
• 5.2.2. SWING MACHINERY
• 5.3. MAINTENANCE STANDARD
• 5.3.1. SWING MACHINERY
• 6. UNDERCARRIAGE
• 6.1. STRUCTURE AND FUNCTION
• 6.2. DISASSEMBLY AND ASSEMBLY
• 6.2.1. IDLER, RECOIL SPRING
• 6.3. MAINTENANCE STANDARD
• 7. HYDRAULIC SYSTEM
• 7.1. STRUCTURE AND FUNCTION
• 7.1.1. OUTLINE
• 7.1.1.1. WORK EQUIPMENT PIPING
• 7.1.1.2. HYDRAULIC CIRCUIT DIAGRAM (WRIST CONTROL TYPE)
• 7.1.1.3. SCHEMATIC OF HYDRAULIC SYSTEM (WRIST CONTROL TYPE)
• 7.1.1.4. HYDRAULIC CIRCUIT DIAGRAM (WRIST CONTROL TYPE)
• 7.1.1.5. SCHEMATIC OF HYDRAULIC SYSTEM (WRIST CONTROL TYPE)
• 7.1.1.6. HYDRAULIC CIRCUIT DIAGRAM (WRIST CONTROL TYPE)
• 7.1.1.7. SCHEMATIC OF HYDRAULIC SYSTEM (LONG LEVER CONTROL TYPE)
• 7.1.1.8. HYDRAULIC CIRCUIT DIAGRAM (LONG LEVER CONTROL TYPE)
• 7.1.1.9. SCHEMATIC OF HYDRAULIC SYSTEM (LONG LEVER CONTROL TYPE)
• 7.1.1.10. HYDRAULIC CIRCUIT DIAGRAM (LONG LEVER CONTROL TYPE)
• 7.1.1.11. SCHEMATIC OF HYDRAULIC SYSTEM
• 7.1.1.12. HYDRAULIC CIRCUIT DIAGRAM
• 7.1.2. HYDRAULIC TANK (WITH FUEL TANK)
• 7.1.3. HYDRAULIC PUMP
• 7.1.3.1. MAIN PUMP (HPV 055055)
• 7.1.3.2. SERVO VALVE , TVC VALVE, CO VALVE AND NC VALVE
• 7.1.4. OLSS SYSTEM (OPEN CENTER LOAD SENSING SYSTEM)
• 7.1.4.1. OUTLINE
• 7.1.4.2. BASIC CIRCUIT OF OLSS
• 7.1.4.3. SCHEMATIC OF OLSS
• 7.1.4.4. FUNCTION OF OLSS
• 7.1.5. CONTROL VALVE
• 7.1.5.1. SPOOL CONTROL VALVE (WRIST CONTROL TYPE)
• 7.1.5.2. SPOOL CONTROL VALVE (WRIST CONTROL TYPE)
• 7.1.5.3. SPOOL CONTROL VALVE (LONG LEVER CONTROL TYPE)
• 7.1.5.4. SPOOL CONTROL VALVE (LONG LEVER CONTROL TYPE)
• 7.1.5.5. RELIEF VALVE
• 7.1.5.6. SAFETYSUCTION VALVE
• 7.1.5.7. SAFETY VALVE
• 7.1.5.8. SUCTION VALVE
• 7.1.6. HYDRAULIC CYLINDER
• 7.1.6.1. BOOM CYLINDER
• 7.1.6.2. ARM CYLINDER
• 7.1.6.3. BUCKET CYLINDER
• 7.1.6.4. CUSHION CYLINDER (ARM CYLINDER HEAD,BOTTOM SIDE)
• 7.1.7. WORK EQUIPMENT HYDRAULIC CONTROL (WRIST CONTROL TYPE)
• 7.1.7.1. OUTLINE
• 7.1.7.2. BOOM CONTROL
• 7.1.7.3. ARM CONTROL
• 7.1.7.4. BUCKET CONTROL
• 7.1.7.5. PPC VALVE (PROPORTIONAL PRESSURE CONTROL VALVE)
• 7.1.7.6. SHUTTLE VALVE
• 7.1.7.7. ACCUMULATOR
• 7.1.8. WORK EQUIPMENT HYDRAULIC CONTROL (LONG LEVER CONTROL TYPE)
• 7.1.8.1. OUTLINE
• 7.1.8.2. BOOM CONTROL
• 7.1.8.3. ARM CONTROL
• 7.1.8.4. BUCKET CONTROL
• 7.2. TESTING AND ADJUSTING
• 7.2.1. TABLE OF JUDGEMENT STANDARD VALUE
• 7.2.2. TROUBLESHOOTING TOOLS
• 7.2.3. TESTING AND ADJUSTING
• 7.2.4. TROUBLESHOOTING
• 7.2.4.1. ELECTRICAL CIRCUIT
• 7.2.4.2. CONNECTION TABLE FOR CONNECTOR PINS
• 7.2.4.3. TROUBLESHOOTING PROCEDURE
• 7.2.4.4. CHECKS BEFORE TROUBLESHOOTING
• 7.2.4.5. JUDGEMENT TABLE
• 7.2.4.6. TROUBLESHOOTING CHART
• 7.2.4.7. FAILURE MODE AND COMPONENTS
• 7.3. DISASSEMBLY AND ASSEMBLY
• 7.3.1. MAIN PUMP INPUT SHAFT OIL SEAL
• 7.3.2. SPOOL CONTROL VALVE
• 7.3.2.1. DISMOUNTING
• 7.3.2.2. MOUNTING
• 7.3.3. SPOOL CONTROL VALVE
• 7.3.4. BUCKET CYLINDER
• 7.3.4.1. DISMOUNTING
• 7.3.4.2. MOUNTING
• 7.3.5. HYDRAULIC CYLINDER
• 7.3.5.1. DISASSEMBLY
• 7.3.5.2. ASSEMBLY
• 7.3.6. PISTON RING AND WEAR RING OF HYDRAULIC CYLINDER
• 7.4. MAINTENANCE STANDARD
• 7.4.1. CHARGING PUMP (BAR20)
• 7.4.2. SPOOL CONTROL VALVE
• 7.4.3. SPOOL CONTROL VALVE
• 7.4.4. SPOOL CONTROL VALVE (OPTION)
• 7.4.5. SPOOL CONTROL VALVE (OPTION)
• 7.4.6. HYDRAULIC CYLINDER
• 8. WORK EQUIPMENT
• 8.1. DISASSEMBLY AND ASSEMBLY
• 8.1.1. WORK EQUIPMENT (PC100,1203)
• 8.2. MAINTENANCE STANDARD
• 8.2.1. WORK EQUIPMENT
• 9. ELECTRICAL SYSTEM
• 9.1. STRUCTURE AND FUNCTION
• 9.1.1. ELECTRICAL SYSTEM
• 9.1.2. ELECTRICAL WIRING
• 9.1.3. ELECTRICAL CIRCUIT DIAGRAM
• 9.1.4. ELECTRIC VEHICLE MONITOR SYSTEM (EVMS)
• 9.2. TESTING AND ADJUSTING
• 9.2.1. ELECTRICAL CIRCUIT DIAGRAM
• 9.2.2. PRECAUTION WHEN TROUBLESHOOTING
• 9.2.3. TROUBLESHOOTING CHART
• 9.2.3.1. PC1003 SERIAL NO.1800121844,PC100L3 SERIAL NO.1200112324,PC1203 SERIAL NO.1800123282
• 9.2.3.2. PC1003 SERIAL NO. 21845 AND UP,PC100L3 SERIAL NO. 12325 AND UP,PC1203 SERIAL NO. 23283 AND UP
• 10. OTHERS
• 10.1. STRUCTURE AND FUNCTION
• 10.1.1. HEATER