Professional Documents
Culture Documents
2004 1
All Rights Reserved 00-1
Printed in Japan 04-02(02) (11)
CONTENTS
No. of page
00-2 PC100,120,130-6
3
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following marks. It is requested that necessary ac-
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PC100,120,130-6 00-2-1
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number number number number number
10-128-2 (6) 10-169 (5) 20-44 (1) b 20-139 (11) 20-318 (1)
10-128-3 (6) 10-170 (5) 20-45 (1) 20-140 (5) 20-319 (1)
b 10-128-4 (11) 10-170-1 (5) 20-46 (1) 20-141 (8) 20-320 (1)
10-128-5 (6) 10-170-2 (5) 20-47 (1) 20-142 (1) 20-321 (1)
10-129 10-171 20-48 (1) 20-143 (6) 20-322 (1)
b 10-130 (11) 10-172 20-49 (1) 20-201 (1) 20-323 (1)
10-131 10-173 20-50 (4) 20-202 (1) 20-324 (1)
10-132 10-174 20-51 (1) 20-203 (1) 20-351 (6)
10-133 10-175 20-52 (9) 20-251 (1) 20-352 (1)
10-134 (6) 20-53 (1) 20-252 (1) 20-354 (1)
10-135 (5) 20-1 (1) 20-54 (4) 20-254 (1) 20-355 (1)
10-136 (8) b 20-2 (11) 20-101 (3) 20-255 (1) 20-356 (1)
10-137 (6) c 20-2-1 (11) 20-102 (1) 20-256 (1) 20-357 (1)
10-137-1 (6) 20-3 (6) 20-103 (1) 20-257 (1) 20-358 (1)
10-137-3 (6) 20-4 (1) 20-104 (1) 20-258 (1) 20-359 (1)
10-137-4 (6) 20-5 (5) 20-105 (1) 20-259 (1) 20-360 (6)
10-137-5 (8) 20-6 (1) 20-106 (1) 20-260 (1) 20-361 (6)
10-137-6 (6) 20-7 (1) 20-107 (1) 20-261 (1) 20-362 (1)
10-138 (1) 20-8 (1) 20-108 (1) 20-262 (8) 20-363 (6)
10-139 20-9 (1) 20-109 (1) 20-263 (1) 20-364 (6)
b 10-140 (11) 20-10 (1) 20-110 (1) 20-264 (1) 20-365 (1)
b 10-141 (11) 20-11 (1) 20-111 (1) 20-265 (1) 20-365-1 (8)
10-142 (5) b 20-12 (11) 20-112 (1) 20-266 (1) 20-365-2 (6)
10-143 (8) 20-13 (1) 20-112-2 (7) 20-267 (1) 20-366 (1)
10-144 20-14 (1) 20-112-3 (8) 20-268 (1) 20-368 (1)
10-145 (1) 20-15 (6) 20-112-4 (6) 20-270 (1) 20-369 (1)
10-146 (1) 20-16 (6) 20-112-5 (6) 20-271 (1) 20-370 (1)
10-147 20-17 (1) 20-112-6 (8) 20-272 (1) 20-371 (1)
10-148 20-18 (6) 20-113 (1) 20-273 (1) 20-372 (1)
10-149 20-19 (6) 20-114 (1) 20-274 (1) 20-373 (1)
10-150 (1) 20-20 (1) 20-115 (1) 20-275 (1) 20-374 (1)
10-151 20-21 (1) 20-116 (1) 20-276 (1) 20-375 (1)
10-152 20-22 (6) 20-117 (1) 20-277 (1) 20-376 (1)
10-153 20-23 (1) 20-118 (1) 20-278 (1) 20-377 (1)
10-154 20-24 (1) 20-119 (1) 20-279 (1) 20-378 (1)
10-155 (1) 20-25 (4) 20-120 (1) 20-280 (1) 20-379 (1)
10-156 20-26 (1) 20-121 (1) 20-281 (1) 20-380 (1)
10-157 20-27 (1) 20-122 (1) 20-301 (1) 20-381 (1)
10-158 (6) 20-28 (1) 20-123 (5) 20-302 (1) 20-382 (1)
10-159 20-29 (1) 20-124 (1) 20-303 (1) 20-383 (1)
10-159-1 (8) b 20-30 (11) 20-125 (5) 20-304 (1) 20-384 (1)
10-159-2 (6) 20-31 (1) 20-126 (5) 20-305 (1) 20-385 (1)
10-160 20-32 (1) 20-127 (1) 20-306 (1) 20-386 (1)
10-161 20-33 (1) 20-128 (1) 20-307 (1) 20-387 (1)
10-162 (6) 20-34 (1) 20-129 (1) 20-308 (1) 20-388 (1)
10-163 (5) 20-35 (1) 20-130 (6) 20-309 (1) 20-389 (6)
10-163-1 (8) 20-36 (1) 20-131 (1) 20-310 (1) 20-390 (6)
10-163-2 (6) 20-37 (1) 20-132 (1) 20-311 (1) 20-401 (1)
10-164 (8) 20-38 (5) 20-133 (1) 20-312 (1) 20-402 (6)
10-164-1 (6) b 20-39 (11) 20-134 (1) 20-313 (1) 20-403 (1)
10-165 (5) 20-40 (1) 20-135 (1) 20-314 (1) 20-403-1 (8)
10-166 (5) 20-41 (1) 20-136 (1) 20-315 (1) 20-403-2 (6)
10-167 (5) 20-42 (1) 20-137 (1) 20-316 (1) 20-404 (1)
10-168 (5) 20-43 (7) 20-138 (1) 20-317 (1) 20-405 (1)
00-2-2 PC100,120,130-6
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Revision Revision Revision Revision Revision
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number number number number number
20-406 (1) 20-516 (1) 30-21 (2) 30-45-27 (10) 30-78 (2)
20-407 (1) 20-517 (1) b 30-22 (11) 30-45-28 (10) 30-79 (2)
20-408 (1) 20-518 (1) c 30-22-1 (11) 30-45-29 (10) 30-80 (2)
20-409 (1) 20-519 (1) 30-23 (2) 30-45-30 (10) 30-81 (2)
20-410 (1) 20-520 (1) 30-24 (2) 30-45-31 (10) 30-82 (2)
20-411 (1) 20-521 (1) 30-25 (2) 30-45-32 (10) 30-83 (2)
20-412 (1) 20-522 (1) 30-26 (2) 30-45-33 (10) b 30-84 (11)
20-413 (1) 20-523 (1) 30-27 (2) 30-45-34 (10) b 30-85 (11)
20-414 (1) 20-524 (1) 30-28 (2) 30-45-35 (10) b 30-86 (11)
20-451 (1) 20-525 (1) 30-29 (2) 30-45-36 (10) b 30-87 (11)
20-452 (1) 20-526 (1) 30-30 (2) 30-46 (2) 30-87-1 (5)
20-453 (6) 20-527 (1) 30-31 (2) 30-47 (2) 30-87-2 (5)
20-454 (1) 20-528 (1) 30-32 (2) 30-48 (2) 30-87-3 (5)
20-455 (1) 20-529 (1) 30-33 (2) 30-49 (2) 30-87-4 (5)
20-456 (1) 20-530 (1) 30-34 (2) 30-50 (2) 30-87-5 (5)
20-457 (1) 20-531 (1) 30-35 (2) 30-51 (2) 30-87-6 (5)
20-458 (1) 20-532 (1) 30-36 (2) 30-52 (2) 30-87-7 (5)
20-460 (1) 20-533 (1) 30-37 (2) 30-53 (2) 30-87-8 (5)
20-461 (1) 20-534 (1) b 30-38 (11) 30-54 (2) 30-87-9 (5)
20-462 (1) 20-535 (1) b 30-39 (11) 30-55 (2) 30-87-10 (5)
20-463 (1) 20-536 (1) b 30-40 (11) 30-55-1 (6) 30-87-11 (5)
20-464 (1) 20-538 (1) c 30-40-1 (11) 30-55-2 (6) 30-87-12 (5)
20-465 (1) 20-539 (1) c 30-40-2 (10) 30-55-3 (6) 30-87-13 (5)
20-466 (1) 20-540 (1) 30-41 (2) 30-55-4 (6) 30-87-14 (5)
20-467 (1) 20-541 (1) 30-42 (2) 30-55-5 (6) 30-87-15 (5)
20-468 (1) 20-542 (1) 30-43 (2) 30-55-6 (6) 30-87-16 (5)
20-469 (6) 20-543 (1) 30-44 (2) 30-55-7 (6) 30-87-17 (5)
20-470 (6) 20-544 (1) 30-45 (2) 30-55-8 (6) 30-87-18 (5)
20-472 (1) 20-545 (1) 30-45-1 (10) 30-55-9 (6) 30-87-19 (5)
20-473 (1) 30-45-2 (10) 30-55-10 (6) 30-87-20 (5)
20-474 (1) b 30-1 (11) 30-45-3 (10) 30-55-11 (6) 30-87-21 (5)
20-475 (1) b 30-2 (11) 30-45-4 (10) 30-55-12 (6) 30-87-22 (5)
20-476 (1) 30-3 (2) 30-45-5 (10) 30-56 (2) 30-88 (2)
20-477 (1) 30-4 (2) 30-45-6 (10) 30-57 (2) 30-89 (2)
20-478 (1) 30-5 (2) 30-45-7 (10) 30-58 (2) 30-90 (2)
20-479 (1) 30-6 (2) 30-45-8 (10) 30-59 (2) 30-91 (2)
20-480 (1) 30-7 (2) 30-45-9 (10) 30-60 (2) 30-92 (2)
20-481 (1) 30-8 (2) 30-45-10 (10) 30-61 (2) 30-93 (2)
20-482 (1) 30-9 (6) 30-45-11 (10) 30-62 (2) 30-94 (2)
20-483 (1) 30-9-1 (6) 30-45-12 (10) 30-63 (2) 30-95 (2)
20-501 (1) 30-10 (6) 30-45-13 (10) 30-64 (2) 30-96 (2)
20-502 (1) 30-10-1 (6) 30-45-14 (10) 30-65 (2) 30-97 (2)
20-504 (1) b 30-11 (11) 30-45-15 (10) 30-66 (2) 30-98 (2)
20-505 (1) b 30-12 (11) 30-45-16 (10) 30-67 (2) 30-99 (2)
20-506 (1) b 30-13 (11) 30-45-17 (10) 30-68 (8) 30-100 (2)
20-507 (1) c 30-13-1 (11) 30-45-18 (10) 30-69 (2) 30-101 (2)
20-508 (1) c 30-13-2 (11) 30-45-19 (10) 30-70 (2) 30-102 (2)
20-509 (1) b 30-14 (11) 30-45-20 (10) 30-71 (2) 30-103 (2)
20-510 (1) 30-15 (2) 30-45-21 (10) 30-72 (2) 30-104 (2)
20-511 (1) 30-16 (2) 30-45-22 (10) 30-73 (2) b 30-105 (11)
20-512 (1) 30-17 (2) 30-45-23 (10) 30-74 (2) 30-106 (2)
20-513 (1) 30-18 (2) 30-45-24 (10) 30-75 (2) 30-107 (2)
20-514 (1) 30-19 (2) 30-45-25 (10) 30-76 (2) 30-108 (6)
20-515 (1) 30-20 (2) 30-45-26 (10) 30-77 (2) 30-109 (2)
PC100,120,130-6 00-2-3
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number number number number number
00-2-4 PC100,120,130-6
(11)
GENERAL SPECIFICATIONS
Model S4D102-1
Type 4-cycle, water-cooled, in-line, vertical,
direct injection, with turbocharger
No. of cylinders-bore x stroke mm 4102 120
Piston displacement {cc} 3.92 {3,920}
Performance
6 on each side
Under-
6 on each side
Track roller Assembly-type triple Assembly-type triple
Track shoe grouser, 40 on each side grouser, 43 on each side
GM18VL HMV110-2
Variable displacement Variable displacement
Travel motor piston type piston type
(with brake (with brake
Hydraulic system
PC100,120,130-6 01-9
8
GENERAL SPECIFICATIONS
PC120-6
01-10 PC100,120,130-6
(11)
GENERAL SPECIFICATIONS
GM18VL
Travel motor Variable displacement piston type
(with brake valve,parking brake) 2
KMF40ABE-3
Swing motor Fixed displacement piston type
(with safety valve,parking brake) 1
PC100,120,130-6 01-11
(11)
GENERAL SPECIFICATIONS
PC120LC-6
01-11-1 PC100,120,130-6
(11)
GENERAL SPECIFICATIONS
GM18VL
Travel motor Variable displacement piston type
(with brake valve,parking brake) 2
KMF40ABE-3
Swing motor Fixed displacement piston type
(with safety valve,parking brake) 1
PC100,120,130-6 01-11-2
(11)
GENERAL WEIGHT TABLE
PC120-6 Unit : kg
Control valve 96 96
01-16 PC100,120,130-6
(11)
GENERAL WEIGHT TABLE
Unit : kg
PC100,120,130-6 01-17
(11)
GENERAL WEIGHT TABLE
PC120LC-6 Unit : kg
Control valve 96 96
01-17-1 PC100,120,130-6
(11)
GENERAL WEIGHT TABLE
Unit : kg
PC100,120,130-6 01-17-2
(11)
STRUCTURE AND FUNCTION RADIATOR AND OIL COOLER
PC100,120,130-6 10-3
(11)
STRUCTURE AND FUNCTION RADIATOR AND OIL COOLER
10-3-1 PC100,120,130-6
(11)
STRUCTURE AND FUNCTION PTO
PTO (COUPLING)
10-4 PC100,120,130-6
STRUCTURE AND FUNCTION POWER TRAIN
POWER TRAIN
PC100, 120, 120LC, 130-6
1. Idler 8. Sprocket
2. Center swivel joint 9. Travel motor (GM18VL)
3. Swing motor (KMF40ABE-3) 10. Control pump (BAR020)
4. Control valve 11. Hydraulic pump (HPV95)
5. Swing brake solenoid valve 12. Engine
6. Travel speed solenoid valve 13. Swing machinery
7. Final drive 14. Swing circle
PC100,120,130-6 10-5
(11)
STRUCTURE AND FUNCTION HYDRAULIC PIPING DRAWING
1.
PC100-6 Serial No. : 46059 and up
PC100L-6 Serial No. : 46059 and up
PC120-6 Serial No. : 60968 and up
PC120LC-6 Serial No. : 65504 and up
PC130-6 Serial No. : 51480 and up
2.
PC120-6 Serial No. : 70001 and up
PC120LC-6 Serial No. : 70001 and up
PC100,120,130-6 10-12-1
(11)
STRUCTURE AND FUNCTION ACTUAL ELECTRIC WIRING DIAGRAM
PC100,120,130-6 10-127
(11)
STRUCTURE AND FUNCTION ACTUAL ELECTRIC WIRING DIAGRAM
10-128 PC100,120,130-6
6
STRUCTURE AND FUNCTION ACTUAL ELECTRIC WIRING DIAGRAM
1. 3, 4
PC100-6 Serial No. : 45221 46058 PC120-6 Serial No. : 70001 and up
PC100L-6 Serial No. : 15200 46058 PC120LC-6 Serial No. : 70001 and up
PC120-6 Serial No. : 57499 60967
PC130-6 Serial No. : 51020 51479
2.
PC100-6 Serial No. : 46059 and up
PC100L-6 Serial No. : 46059 and up
PC120-6 Serial No. : 60968 and up
PC120LC-6 Serial No. : 65504 and up
PC130-6 Serial No. : 51480 and up
PC100,120,130-6 10-128-1
(11)
STRUCTURE AND FUNCTION ELECTRICAL CIRCUIT DIAGRAM
10-128-2 PC100,120,130-6
6
STRUCTURE AND FUNCTION ELECTRICAL CIRCUIT DIAGRAM
(2/2)
fl For details of this page, see section 90.
PC100,120,130-6 10-128-3
6
STRUCTURE AND FUNCTION ELECTRICAL CIRCUIT DIAGRAM
(1/2)
PC100-6 Serial No. : 46059 and up
PC100L-6 Serial No. : 46059 and up
PC120-6 Serial No. : 60968 70000
PC120LC-6 Serial No. : 65504 70000
PC130-6 Serial No. : 51480 and up
fl For details of this page, see section 90.
10-128-4 PC100,120,130-6
(11)
STRUCTURE AND FUNCTION ENGINE CONTROL SYSTEM
1.
PC120-6 Serial No. : 70001 and up
PC120LC-6 Serial No. : 70001 and up
10-130 PC100,120,130-6
(11)
STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM
10-140 PC100,120,130-6
(11)
STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM
PC100,120,130-6 10-141
(11)
20 TESTING AND ADJUSTING
Standard valve table for engine related Testing and adjusting LS valve output
parts ............................................................ 20- 2 pressure (servo piston input pressure)
Standard table for chassis related parts ..... 20- 3 and LS differential pressure .................... 20- 38
Standard table for electrical parts ............... 20-14 Testing and adjusting control pump
Tool for testing, adjusting, and circuit oil pressure .................................... 20- 41
troubleshooting .......................................... 20-23 Testing solenoid valve output pressure ... 20- 43
Measuring engine speed ............................. 20-24 Measuring PPC valve output pressure ..... 20- 44
Measuring exhaust gas color ...................... 20-25 Adjusting work equipment, swing
Adjusting valve clesrance ............................ 20-26 PPC valve .................................................. 20- 45
Measuring blow-by pressure ...................... 20-27 Testing travel deviation .............................. 20- 46
Testing and adjusting fuel injection Testing locations causing hydraulic
timing .......................................................... 20-28 drift of work equipment ........................... 20- 47
Measuring engine oil pressure ................... 20-29 Measuring oil leakage ................................ 20- 48
Testing and adjusting belt tension for air Releasing remaining pressure in
conditioner compressor ............................ 20-30 hydraulic circuit ........................................ 20- 50
Adjusting engine speed sensor ................... 20-31 Testing clearance of swing circle
Adjusting governor motor lever stroke ...... 20-32 bearing ...................................................... 20- 51
Testing and adjusting hydraulic pressure in Testing and adjusting track shoe
work equipment, swing, travel circuit ...... 20-33 tension ...................................................... 20- 52
Testing and adjusting PC valve output Bleeding air ................................................. 20- 53
pressure (servo piston input pressure) .... 20-36 Troubleshooting ......................................... 20-101
fl Note the following when making judgements using the standard value tables for testing, adjusting,
or troubleshooting.
1. The standard value for a new machine given in the table is the value used when shipping the ma-
chine from the factory and is given for reference. It is used as a guideline for judging the progress of
wear after the machine has been operated, and as a reference value when carrying out repairs.
2. The service limit value given in the tables is the estimated value for the shipped machine based on
the results of various tests. It is used for reference together with the state of repair and the history of
operation to judge if there is a failure.
3. These standard values are not the standards used in dealing with claims.
When carrying out testing, adjusting, or troubleshooting, park the machine on level ground, inset
the safety pins, and use blocks to prevent the machine from moving.
When carrying out work together with other workers, always use signals and do not let unautho-
rized people near the machine.
When checking the water level, always wait for the water to cool down. If the radiator cap is re-
moved when the water is still hot, the water will spurt out and cause burns.
Be careful not to get caught in the fan, fan belt or other rotating parts.
PC100,120,130-6 20-1
1
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE RELATED PARTS
(Normal temperature)
Valve clearance Intake valve mm 0.25 0.25
Exhaust valve 0.51 0.51
(Water temperature:
Blow-by pressure Operating range) Pa Max. 490 980 Max. 490 980
{mmH2O} {50} {100} {50} {100}
At rated output
(SAE30 or SAE15W-40)
(Water temperature:
Operating range)
At high idling 343 686 245 343 686 245
(SAE30 or SAE15W-40) {3.5 7.0} {2.5} {3.5 7.0} {2.5}
(SAE10) kPa 294 686 206 294 686 206
Oil pressure {3.0 7.0} {2.1} {3.0 7.0} {2.1}
{kg/cm2}
At low idling Min. 98 69 Min. 98 69
(SAE30 or SAE15W-40) {1.0} {0.7} {1.0} {0.7}
At low idling (SAE10W) Min. 78 69 Min. 78 69
{0.8} {0.7} {0.8} {0.7}
Deflection Crankshaft
when pulley air
pressed with conditioner
Belt tension finger force of compressor mm 12 15 12 15 12 15 12 15
approx. 58.8
Nm {6 kg}
20-2 PC100,120,130-6
(11)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE RELATED PARTS
fl The standard value for new machine and Service limit value in the table below are all values when measured
in the heavy-duty operation (H/O) mode.
Engine SAA4D102E-2
Standard Standard
Item Measurement conditions Unit value for new Service limit value for new Service limit
machine value machine value
(Normal temperature)
Valve clearance Intake valve mm 0.25
Exhaust valve 0.51
(Water temperature:
Blow-by pressure Operating range) Pa Max. 490 980
{mmH2O} {50} {100}
At rated output
(SAE30 or SAE15W-40)
(Water temperature:
Operating range)
At high idling 343 686 245
(SAE30 or SAE15W-40) {3.5 7.0} {2.5}
(SAE10) 294 686 206
Oil pressure kPa {3.0 7.0} {2.1}
{kg/cm2}
At low idling Min. 98 69
(SAE30 or SAE15W-40) {1.0} {0.7}
At low idling (SAE10W) Min. 78 69
{0.8} {0.7}
Deflection Crankshaft
when pulley air
pressed with conditioner
Belt tension finger force of mm 12 15 12 15
compressor
approx. 58.8
Nm {6 kg}
PC100,120,130-6 20-2-1
(11)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
Cat-
egory PC120,130 : Discharge amount of main piston pump (in heavy-duty operation mode)
Pump speed : At 2,000 rpm, PC-EPC current 400 mA (PC120 Serial No. : 70001 and up : 370 mA)
fl The error is large near the point where the graph curves, so avoid measuring at this point.
fl When measuring with the pump mounted on the machine, if it is impossible to set the engine speed
to the specified speed with the fuel control dial, take the pump discharge amount and the engine
speed (same as pump speed) at the point of measurement, and use them as a base for calculating
the pump discharge amount at the specified speed.
20-12 PC100,120,130-6
(11)
TESTING AND ADJUSTING BELT TENSION
TESTING AND ADJUSTING FOR AIR CONDITIONER COMPRESSOR
20-30 PC100,120,130-6
(11)
TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVO
TESTING AND ADJUSTING PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE
2.7 +1.0
0.7
H/O mode Full Levers at neutral {28 +10
7}
Travel speed: Hi
Travel circuit under no 2.1 0.1
H/O mode Full {21.5 1}
load (lever fully operated)
PC100,120,130-6 20-39
(11)
TROUBLESHOOTING DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE
If there is no abnormality display in the communications system transmitted in S-NET, it can be taken
that the output signal from the monitor panel has been transmitted. However, even if there is no
abnormality display, if the operation is defective, use the following procedure when checking directly.
If any abnormality occurs in the S-NET system, the system is automatically switched to the following
default mode, so be careful when carrying out troubleshooting.
Default Mode when communications cannot be carried out for the monitor and engine throttle
pump controller
Set mode Pump control Governor control
1 Working mode G/O mode H/O mode
2 Throttle signal FULL FULL
3 Auto-deceleration ON (deceleration mode ON (deceleration mode)
4 Coolant temperature signal OFF
5
6 Power max. mode ON (power max. possible)
7 Travel speed Lo
8 Automatic warming up ON (automatic warming-up mode)
2. Checking working mode signal {check No. 2 throttle signal (monitoring code 16) at the same
time}
1) Set to the monitoring mode and display monitoring code 10.
2) Switch the working mode as shown in Table 1 and check that the engine speed changes.
Table 1
Max. speed at no load [Values in ( ) are rated speed] (rpm)
PC120 : PC120 :
Operation PC100 : 57499 70000 PC130 : 70001 and up
Working mode
45221 and up PC120LC : 51020 and up PC120LC :
65504 70000 70001 and up
Work equipment Approx.2,300(2,100) Approx.2,400(2,200) Approx.2,350(2,150)
Active Mode
Travel Approx.2,300(2,100) Approx.2,400(2,200) Approx.2,350(2,150)
Work equipment Approx.2,100(1,900) Approx.2,200(2,000) Approx.2,200(2,000)
H/O
Travel Approx.2,300(2,100) Approx.2,200(2,000) Approx.2,200(2,000)
Work equipment Approx.1,910(1,720) Approx.2,000(1,800) Approx.2,000(1,800)
G/O, F/O
Travel Approx.1,910( ) Approx.2,000( ) Approx.2,000( )
Work equipment Approx.1,580(1,450) Approx.1,670(1,500) Approx.1,670(1,500)
L/O
Travel Approx.1,580( ) Approx.1,670( ) Approx.1,670( )
Work equipment Approx.1,910(1,720) Approx.1,850(1,650) Approx.2,000(1,800)
B/O
Travel Approx.1,910( ) Approx.1,850( ) Approx.2,000( )
PC100,120,130-6 20-139
(11)
30 DISASSEMBLY AND ASSEMBLY
PC100,120,130-6 30-1
(11)
CARRIER ROLLER BUCKET CYLINDER
Removal and Installation ........................... 30-77 Removal .................................................... 30-119
Disassembly ............................................... 30-78 Installation ................................................ 30-120
Assembly .................................................... 30-80 HYDRAULIC CYLINDER
TRACK SHOE Disassembly ............................................. 30-121
Removal and Installation ........................... 30-82 Assembly .................................................. 30-124
HYDRAULIC TANK WORK EQUIPMENT
Removal .................................................... 30- 83 Removal .................................................... 30-128
Installation ................................................ 30- 84 Installation ................................................ 30-129
CONTROL PUMP BUCKET
Removal and Installation ......................... 30- 85 Removal .................................................... 30-130
MAIN PUMP Installation ................................................ 30-131
Removal .................................................... 30- 86 ARM
Installation ................................................ 30- 87 Removal .................................................... 30-132
Disassembly .......................................... 30-87- 1 Installation ................................................ 30-133
Assembly ............................................... 30-87-11 BUCKET, ARM
MAIN PUMP INPUT SHAFT OIL SEAL Removal .................................................... 30-134
Removal and Installation ......................... 30- 88 Installation ................................................ 30-135
CONTROL VALVE BOOM
Removal .................................................... 30- 89 Removal .................................................... 30-136
Installation ................................................ 30- 90 Installation ................................................ 30-137
Disassembly ............................................. 30- 91 OPERATORS CAB
Assembly .................................................. 30- 96 Removal .................................................... 30-138
LS SELECT VALVE Installation ................................................ 30-140
Disassembly and Assembly .................... 30-102 COUNTERWEIGHT
MAIN RELIEF VALVE Removal and Installation ......................... 30-141
Disassembly ............................................. 30-103 ENGINE THROTTLE, PUMP CONTROLLER
Assembly .................................................. 30-104 Removal and Installation ......................... 30-142
PC.LS-EPC VALVE MONITOR
Removal and Installation ......................... 30-105 Removal and Installation ......................... 30-143
PC VALVE CONTROL STAND CASE
Removal and Installation ......................... 30-106 Removal .................................................... 30-144
LS VALVE Installation ................................................ 30-145
Removal and Installation ......................... 30-107
SOLENOID VALVE
Removal and Installation ......................... 30-108
WORK EQUIPMENT PPC VALVE
Removal and Installation ......................... 30-109
Disassembly ............................................. 30-110
Assembly .................................................. 30-111
TRAVEL PPC VALVE
Removal and Installation ......................... 30-112
Disassembly ............................................. 30-113
Assembly .................................................. 30-114
BOOM CYLINDER
Removal .................................................... 30-115
Installation ................................................ 30-116
ARM CYLINDER
Removal .................................................... 30-117
Installation ................................................ 30-118
30-2 PC100,120,130-6
(11)
DISASSEMBLY AND ASSEMBLY STARTING MOTOR
REMOVAL OF STARTING
MOTOR ASSEMBLY
Disconnect the cable from the negative () ter-
minal of the battery.
INSTALLATION OF STARTING
MOTOR ASSEMBLY
Carry out installation in the reverse order to re-
moval.
1
3 Starting motor assembly mounting bolt:
43.1 Nm {4.4 kgm}
PC100,120,130-6 30-11
(11)
DISASSEMBLY AND ASSEMBLY ALTERNATOR
REMOVAL OF ALTERNATOR
ASSEMBLY
Disconnect the cable from the negative () ter-
minal of the battery.
INSTALLATION OF
ALTERNATOR ASSEMBLY
Carry out installation in the reverse order to re-
moval.
1
3 Alternator assembly mounting bolt: :
(5): 80.4 Nm {8.2 kgm}
(6): 43.1 Nm {4.4 kgm}
30-12 PC100,120,130-6
(11)
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER COMPRESSOR
INSTALLATION OF AIR
CONDITIONER COMPRESSOR
ASSEMBLY
PC100-6 Serial No. : 45221 and up
PC120-6 Serial No. : 57499 70000
PC120LC-6 Serial No. : 65504 70000
PC130-6 Serial No. : 51020 and up
1
fl When installing the hoses, check that the O-
rings are not damaged or deteriorated, then
connect the hoses.
2
fl Adjust the belt tension. For details, see TEST-
ING AND ADJUSTING, Testing and adjusting
belt tension for air conditioner compressor.
PC100,120,130-6 30-13
(11)
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER COMPRESSOR
INSTALLATION OF AIR
CONDITIONER COMPRESSOR
ASSEMBLY
PC120-6 Serial No. : 70001 and up
PC120LC-6 Serial No. : 70001 and up
1
fl When installing the hoses, check that the O-
rings are not damaged or deteriorated, then
connect the hoses.
2
fl Adjust the belt tension. For details, see TEST-
ING AND ADJUSTING, Testing and adjusting
belt tension for air conditioner compressor.
30-13-1 PC100,120,130-6
(11)
DISASSEMBLY AND ASSEMBLY CONDENSER
REMOVAL OF CONDENSER
ASSEMBLY
1. Open engine hood and remove counterweight top
cover.
INSTALLATION OF CONDENSER
ASSEMBLY
Carry out installation in the reverse order to re-
moval.
1
fl Check that the O-rings are not damaged or
deteriorated, then connect the hoses.
PC100,120,130-6 30-13-2
(11)
DISASSEMBLY AND ASSEMBLY AFTERCOOLER
REMOVAL OF AFTERCOOLER
ASSEMBLY
PC120-6 Serial No. : 70001 and up
PC120LC-6 Serial No. : 70001 and up
INSTALLATION OF
AFTERCOOLER ASSEMBLY
PC120-6 Serial No. : 70001 and up
PC120LC-6 Serial No. : 70001 and up
1
3 Hose clamp: 10.8 1 Nm {1.1 0.1 kgm}
30-14 PC100,120,130-6
(11)
DISASSEMBLY AND ASSEMBLY TURBOCHARGER
REMOVAL OF TURBOCHARGER
ASSEMBLY
PC100-6 Serial No. : 45221 and up
PC120-6 Serial No. : 57499 70000
PC120LC-6 Serial No. : 65504 70000
PC130-6 Serial No. : 51020 and up
INSTALLATION OF
TURBOCHARGER ASSEMBLY
PC100-6 Serial No. : 45221 and up
PC120-6 Serial No. : 57499 70000
PC120LC-6 Serial No. : 65504 70000
PC130-6 Serial No. : 51020 and up
1
3 Turbocharger assembly mounting bolt:
43.1 Nm {4.4 kgm}
30-22 PC100,120,130-6
(11)
DISASSEMBLY AND ASSEMBLY TURBOCHARGER
REMOVAL OF TURBOCHARGER
ASSEMBLY
PC120-6 Serial No. : 70001 and up
PC120LC-6 Serial No. : 70001 and up
INSTALLATION OF
TURBOCHARGER ASSEMBLY
PC120-6 Serial No. : 70001 and up
PC120LC-6 Serial No. : 70001 and up
1
3 Hose clamp: 8.8 0.5 Nm {0.9 0.05 kgm}
2
3 Hose clamp: 10.8 1 Nm {1.1 0.1 kgm}
3
3 Turbocharger mounting nut:
29.4 44.2 Nm {3 4.5 kgm}
PC100,120,130-6 30-22-1
(11)
DISASSEMBLY AND ASSEMBLY HYDRAULIC COOLER
REMOVAL OF HYDRAULIC
COOLER ASSEMBLY
PC100-6 Serial No. : 45221 and up
PC120-6 Serial No. : 57499 70000
PC120LC-6 Serial No. : 65504 70000
PC130-6 Serial No. : 51020 and up
INSTALLATION OF HYDRAULIC
COOLER ASSEMBLY
PC100-6 Serial No. : 45221 and up
PC120-6 Serial No. : 57499 70000
PC120LC-6 Serial No. : 65504 70000
PC130-6 Serial No. : 51020 and up
1
fl Check that the O-rings are not damaged or
deteriorated, then connect the hoses.
30-38 PC100,120,130-6
(11)
DISASSEMBLY AND ASSEMBLY RADIATOR, HYDRAULIC COOLER
REMOVAL OF RADIATOR,
HYDRAULIC COOLER ASSEMBLY
PC100-6 Serial No. : 45221 and up
PC120-6 Serial No. : 57499 70000
PC120LC-6 Serial No. : 65504 70000
PC130-6 Serial No. : 51020 and up
PC100,120,130-6 30-39
(11)
DISASSEMBLY AND ASSEMBLY RADIATOR, HYDRAULIC COOLER
INSTALLATION OF RADIATOR,
HYDRAULIC COOLER
ASSEMBLY
PC100-6 Serial No. : 45221 and up
PC120-6 Serial No. : 57499 70000
PC120LC-6 Serial No. : 65504 70000
PC130-6 Serial No. : 51020 and up
1
fl Check that the O-ring is not damaged or dete-
riorated, then connect the hoses.
2
fl Install the radiator and hydraulic cooler as-
sembly so that there is a clearance of 13 mm
or more to the left and right, and top and bot-
tom between the fan and shroud.
30-40 PC100,120,130-6
(11)
DISASSEMBLY AND ASSEMBLY RADIATOR, HYDRAULIC COOLER
2. Open the engine side cover (on the left side) and
remove air conditioner condenser (1), aftercooler
assembly (2), and their brackets together.
For removal and installation of these parts,
see the sections of them.
PC100,120,130-6 30-40-1
(11)
DISASSEMBLY AND ASSEMBLY RADIATOR, HYDRAULIC COOLER
INSTALLATION OF RADIATOR
AND HYDRAULIC OIL COOLER
ASSEMBLY
PC120-6 Serial No. : 70001 and up
PC120LC-6 Serial No. : 70001 and up
1
fl Install the radiator and hydraulic oil cooler as-
sembly so that the clearance between the fan
and shroud will be 13 mm or larger at the
right, left, top, and bottom.
30-40-2 PC100,120,130-6
(11)
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR
CONTENTS
30-45-1 PC100,120,130-6
(10)
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR
SAFETY
The four warning terms shown in the following table are used in the maintenance manual according
to the degree of expected danger (or the scale of an expected accident).
Understand the meaning of these warning terms and observe the instructions given together with
these terms.
This term means that there is an imminent danger and is used when
DANGER neglecting the given procedure or instruction can cause death or seri-
ous injury.
This term means that there is a latent danger and is used when ne-
WARNING glecting the given procedure or instruction can cause death or serious
injury.
This term means that there is a latent danger and is used when ne-
CAUTION glecting the given procedure or instruction can cause injury of me-
dium or light degree or damage of equipment or devices.
The terms of Danger and Warning do not appear in this maintenance manual, however.
PC100,120,130-6 30-45-2
(10)
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR
30-45-3 PC100,120,130-6
(10)
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR
PC100,120,130-6 30-45-4
(10)
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR
PARTS LIST
30-45-5 PC100,120,130-6
(10)
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR
Piston assembly 1
161 Piston 1
162 Shoe 1
167 Pivot 2
169 Collar 1
170 Hexagon socket bolt 4
171 Paraller pin 2
173 O-ring 1
174 Spur lock washer 4
191 Spring 1
MSRV2 1
Valve kit 2
Sleeve kit 1
201 Valve 1
202 Sleeve 1
203 Spring retainer 1
204 Plug 1
205 Shim 1
206 Spring 1
208 O-ring 1
209 O-ring 1
210 O-ring 1
211 Buckup ring 2
Body kit 1
Body piston kit 1
212 Valve body 1
213 Piston 1
PC100,120,130-6 30-45-6
(10)
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR
TOOLS
1. Standard tools
30-45-7 PC100,120,130-6
(10)
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR
2. Manufactured tools
1) Work table for travel motor
A work table used to carry out disas-
sembly and assembly work of the
travel motor easliy and safety.
4) Holder (I)
A holder used to insert spring (114),
washer (110), and snap ring (145) in
cylinder block (104).
A holder used to remove spring (114)
2) Disassembly/Assembly work stand from cylinder block (104).
Komatsu part No.
790-501-5000 Unit repair stand or
790-501-2001 Engine repair stand
790-901-2110 Bracket
790-901-1350 Plate
fl The figure shows 790-501-5000 repair
stand.
5) Holder (II)
A holder used to remove deep groove
ball bearing (149) from shaft (102).
3) Clamp
A clamp used to fix spindle (2) and hub
(1).
Komatsu part No.
796-720-3700
PC100,120,130-6 30-45-8
(10)
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR
6) Holder (III)
A holder used to press fit oil seal (132)
to the oil seal hole of spindle (2).
9) Eybolt for PT
An eyebolt used together with wires
and a crane to take cover (8) out of
7) Holder (IV) hub (1).
A holder used to set the RV gear as- Thread size: PT 1/2
sembly securely. Apply this holder to
the outer race of tapered roller bear-
ing (22) of crankshaft (9) of the RV gear
assembly and hit it lightly with a ham-
mer to set the RV gear assembly.
8) Long eyebolt
An eyebolt used to sling the travel
motor, spindle (2), and hub (1).
Use A
Hub M16
Spindle M16
Travel motor M16
30-45-9 PC100,120,130-6
(10)
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR
PC100,120,130-6 30-45-10
(10)
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR
30-45-11 PC100,120,130-6
(10)
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR
TIGHTENING TORQUE
35 Hexagon socket head bolt M12 (P1.75) 10 102 15.7 Nm {10.4 1.6 kgm}
143 Hexagon socket head bolt M10 (P1.5) 8 57.8 9.8 Nm {5.9 1 kgm}
146, 218 Hexagon socket head plug PT 1/8 8 12.3 2.4 Nm {1.25 0.25 kgm}
192 Hexagon socket head screw plug PF 1/4 2 29.4 4.9 Nm {3 0.5 kgm}
154, 222 Hexagon socket head plug NPTF 1/16 8 5.9 2.4 Nm {0.6 0.25 kgm}
170 Hexagon socket head bolt M8 (P1.25) 4 29.4 4.9 Nm {3 0.5 kgm}
PC100,120,130-6 30-45-12
(10)
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR
DISASSEMBLY
1. Preparation
Before disassembling the travel motor, pre-
pare the following items.
1) Preparation of work table
Prepare a work table for disassembling
the travel motor.
The work table must be so strong that the
internal parts of the travel motor can be
disassembled and assembled on it and its
top must be so wide that those parts can
be arranged on it and will not move or
fall during the work.
Spread a rubber or vinyl sheet over the
work table.
2) Preparation of tools and materials
Prepare the tools and materials shown in the
tool section.
30-45-13 PC100,120,130-6
(10)
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR
3. Relief valve
1) Turn over the motor.
2) Remove the 4 mounting bolts and relief
valve body (212).
fl When disassembling the valve assem-
bly, loosen the plugs, sleeves, etc.
which have high tightening torque in
advance.
3) Remove 2 balls (194).
2. Cover
1) Set the travel motor with cover (8) side
up.
2) Remove drain plug (33) and level plug (33)
(PT 1/2).
3) Remove the 10 mounting bolts.
4) Install eyebolts (2-9) to the drain plug hole
and level plug hole to remove cover (8).
fl If the cover is not removed, sling it
while hitting its rim evenly with a plas-
tic hammer.
PC100,120,130-6 30-45-14
(10)
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR
30-45-15 PC100,120,130-6
(10)
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR
5) Remove both plugs (126), spring (130), 2) Remove the O-ring and buffer ring from
and valve (127) from rear flange (101). piston (112).
PC100,120,130-6 30-45-16
(10)
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR
3) Remove retainer plate (107), piston (105), 7) Remove 2 discs (115), 2 plates (116), and
thrust ball (108), and washer (111) from 1 plate (117) from the spindle.
cylinder block (104). 8) Remove swash plate (103).
30-45-17 PC100,120,130-6
(10)
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR
PC100,120,130-6 30-45-18
(10)
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR
11. Spindle
1) Turn over the motor assembly and re-
move the tool.
2) Using hanging tool 2-8), remove spindle
(2).
fl Sling the spindle slowly so that it will
not damage the bearing in the hub.
3) Remove floating seal (31) from hub (1).
30-45-19 PC100,120,130-6
(10)
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR
PC100,120,130-6 30-45-20
(10)
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR
Disassemble and inspect the GM motor according to the following standard. Handle its parts carefully.
In particular, take care not to damage the moving parts and sliding parts.
1) Seals
Replace the all seals (O-rings, oil seals, and floating seals) once they are removed, even if they are
free from damage.
2) Maintenance standard for worn parts
i) Replace all the parts which have visible extreme damages.
ii) Replace the parts which have the following trouble (phenomenon).
Spindle kit
RV gear assembly
30-45-21 PC100,120,130-6
(10)
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR
Piston assembly
115 Friction plate Both end faces are worn un- Braking torque: Braking torque:
evenly. Min. 145.1Nm 82.38Nm {8.4kgm}
116 Mating plate
Specified torque is not produced. {Min. 14.8kgm} Max. 145.1Nm
Plate is seized. {Max. 14.8kgm}
PC100,120,130-6 30-45-22
(10)
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR
30-45-23 PC100,120,130-6
(10)
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR
ASSEMBLY
3. Assembly procedure
Carry out assembly in the reverse order to disas- If any part is replaced before assem-
sembly, as a rule. bling, the preload on the ball bearing
and thickness of the snap ring may
1. Preparation
need to be adjusted. Accordingly, see
Prepare a worktable, tools, and materials for dis-
if any of the following part has been
assembling, similarly to preparation for disassem-
replaced before assembling.
bly.
1) Replacement parts which require ad-
2. General precautions for work
justment of preload on ball bearing
1) Observe the same general precautions with
Hub (1), spindle (2), collar (11), hold
disassembly.
flange (3), ball bearing (21)
2) Remove all metal chips and foreign matter
2) Replacement parts which require ad-
from the all parts and check that any part does
justment of thickness of snap ring
not have a burr, bruise, etc. before assem-
bling. If there is any burr or bruise, remove it Spindle (2), hold flange (3), crankshaft
with an oilstone. (9), spacer (12), tapered roller bearing
3) Replace the O-rings, oil seals, and floating seal (22), snap ring (20)
with new ones. If any of the above part is replaced be-
4) Replace the reamer bolts with new ones, as a fore assembling, be sure to use only
rule. If it is obliged to reuse one, remove all the adjusted parts. If a part which has
adhesive from it with a brush. If bolt seat has not been adjusted is used, the travel
any flaw, remove it with an oilstone and then motor will malfunction and cause
degrease the reamer bolt. breakage soon. Accordingly, observe
5) Since the reamer bolt holes of spindle (2) and this precaution.
threaded parts of reamer bolts (19) are to be
coated with adhesive when they are as-
sembled, degrease them.
6) When fitting the O-rings, oil seals, and float-
ing seals, take care not to damage them. (Ap-
ply a little amount of grease to their surface
so that they will fit smoothly.)
7) When installing the hydraulic motor parts and
moving or sliding parts of the valves, be sure
to apply clean hydraulic oil (NAS Standard
Grade 9 or higher) to them.
8) When assembling, do not put on cloth gloves.
(If they are used, a fiber can cause malfunc-
tion.)
9) Tighten each bolt or plug to the torque shown
in the torque table.
10) After finishing the assembly work, plug the
all ports to prevent dirt from entering them.
PC100,120,130-6 30-45-24
(10)
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR
ASSEMBLY OF TRAVEL MOTOR 3) Using tool 2-16) and 2-17), install floating
ASSEMBLY (GM18VL) seal (31) to hub (1).
fl Thinly apply grease (G2-LI) to the O-
Preparation work ring of the floating seal.
Clean the all parts and remove burrs, etc. fl After installing, check that the distance
Precautions for assembly between the hub end and floating seal
1) Be sure to replace all the O-rings and oil surface is less than 1 mm and they are
seals with new ones. parallel.
2) Tighten all the mounting bolts and plugs
to the specified torque with torque
wrenches.
3) Coat the sliding surfaces and rotary parts
with clean engine oil before installing.
2. Spindle
1) Using tools 2-18) and 2-17), install float-
ing seal (31) to spindle (2).
fl Thinly apply grease (G2-LI) to the O-
ring of the floating seal.
fl After installing, check that the distance
between the spindle end and floating
seal surface is less than 1 mm and
2) Using tool 2-11), install bearing (21) to hub they are parallel.
(1).
30-45-25 PC100,120,130-6
(10)
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR
2) Using hanging tool 2-8), install spindle (2) 3) Hold the crankshaft end with your hands
to hub (1) and secure spindle (2) and hub and install RV gear assembly (4), match-
(1) with tool 2-3). ing it to the outer race installed in advance.
fl If the RV gear assembly falls suddenly,
the tapered roller bearing will be dam-
aged, and that can cause malfunction
of the motor.
3. RV gear assembly
1) Turn over the motor.
2) Install the outer races of tapered roller
bearings (22) to the 3 holes of the spindle.
PC100,120,130-6 30-45-26
(10)
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR
4. Hold flange
1) Using tool 2-11), install ball bearing (21)
to hub (1).
2) Install 3 tapered roller bearings (22) and
their outer races.
30-45-27 PC100,120,130-6
(10)
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR
7) Install snap ring (25) to the camshaft. 6. 2nd travel speed selection piston
Install spindle (2), spring (191), piston (161),
and shoe (162).
3) Install roller bearing (149) to spindle (2). 8. Motor and shaft assembly
1) Install collar (169) to shaft (102), and then
install the inner race of bearing (149) by
shrink fit.
fl Shrink fit temperature: 100 0C
PC100,120,130-6 30-45-28
(10)
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR
2) Install washer (110), spring (114), and 6) Install swash plate (103) and motor as-
washer (110) to cylinder block (104), and sembly to shaft (102).
then compress the spring with tool 2-4) fl Hold the shaft securely so that it will
and install snap ring (145). not slant.
7) Using hanging tool 2-15), sling shaft (102)
and install it to spindle (2). At this time,
match the pivot hole of swash plate (103)
to the pivot.
fl Take care not to damage the roller
bearing and oil seal.
fl After installing the motor assembly,
turn the cylinder block with the hand
to check that it has no play.
fl After installing the motor, never pull
out the cylinder block.
30-45-29 PC100,120,130-6
(10)
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR
PC100,120,130-6 30-45-30
(10)
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR
30-45-31 PC100,120,130-6
(10)
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR
PC100,120,130-6 30-45-32
(10)
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR
6) Obtain dimension D of hold flange (3). 2. Procedure for adjusting thickness of snap ring
(20) after replacing spindle kits (2), (3), and
(19) and RV gear assemblies (4), (5), (9), (22),
and (23)
30-45-33 PC100,120,130-6
(10)
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR
PC100,120,130-6 30-45-34
(10)
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR
30-45-35 PC100,120,130-6
(10)
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR
After maintaining the GM motor, test its performance according to the following procedure.
3 Stopwatch 1 pc.
2. Test procedure
e ..................... e Install the GM motor to the machine body (sprocket) and pipe it.
1 Installation and
piping of GM Do not install the track, however [since the performance test of the GM
motor motor (no-load operation) is executed].
3 Performance
confirmation test
on GM motor
1 Preparatory operation before testn. .......... Operate until temperature rises to the following points.
Hydraulic oil temperature: 45 - 55C
Outside temperature of hub of reduction gear assembly:
40 - 80C
2 Confirmation test ......................................... Measure the following items to check the performance.
Criteria Drive pressure of GM motor
Max. 1.57 MPa {16 kg/cm2} at 10 rpm
Draining rate of hydraulic motor
Max. 1.2 liters/min. at 10 rpm
Acceptable Rejected
PC100,120,130-6 30-45-36
(10)
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK
INSTALLATION OF HYDRAULIC
TANK ASSEMBLY
Carry out installation in the reverse order to re-
moval.
1
2 Thread of hydraulic tank mounting bolt :
Thread tightener (LT-2)
3 Hydraulic tank mounting bolt :
277.0 31.9 Nm {28.25 3.25 kgm}
Bleeding air
fl Bleed the air. For details, see TESTING AND
ADJUSTING, Bleeding air.
30-84 PC100,120,130-6
(11)
DISASSEMBLY AND ASSEMBLY CONTROL PUMP
INSTALLATION OF CONTROL
PUMP ASSEMBLY
Carry out installation in the reverse order to re-
moval.
1
3 Control pump mounting bolt :
66.2 7.4 Nm {6.75 0.75 kgm}
PC100,120,130-6 30-85
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DISASSEMBLY AND ASSEMBLY MAIN PUMP
30-86 PC100,120,130-6
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DISASSEMBLY AND ASSEMBLY MAIN PUMP
1
2 Mating surface of pump case :
Gasket sealant (LG-6)
Bleeding air
fl Bleed the air from main pump. For details, see
TESTING AND ADJUSTING, Bleeding air.
PC100,120,130-6 30-87
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DISASSEMBLY AND ASSEMBLY PC, LS-EPC VALVE
1
3 PC, LS-EPC valve mounting bolt:
11.3 1.5 Nm {1.15 0.15 kgm}
3 Hose nut:
66.2 7.4 Nm {6.75 0.75 kgm}
PC100,120,130-6 30-105
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MAINTENANCE STANDARD TRACK SHOE
TRIPLE SHOE
Unit: mm
PC100,120,130-6 25 15
1 Height PC120LC-6
PC100L-6 26 16
PC100,120,130-6 8
PC120LC-6
2 Thickness
PC100L-6 10
PC100,120,130-6 24
PC120LC-6
3
PC100L-6 27
Length of
base
PC100,120,130-6
19
PC120LC-6
4 Rebuild or
replace
PC100L-6 22
PC100,120,130-6 18
PC120LC-6
5
PC100L-6 21
PC100,120,130-6
11
Length of PC120LC-6
6
tip
PC100L-6 14
PC100,120,130-6 18
PC120LC-6
7
PC100L-6 19
PC120-6 Serial No. : 57499 70000, PC120LC-6 Serial No. : 65504 70000,
40-14 PC100,120,130-6
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MAINTENANCE STANDARD TRACK SHOE
TRIPLE SHOE
PC120-6 Serial No. : 70001 and up`
PC120LC-6 Serial No. : 70001 and up
Unit: mm
Repair by
3 Thickness 9.5 build-up
welding or
replace
4 14
6 15
PC100,120,130-6 40-14-1
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MAINTENANCE STANDARD TRACK SHOE
RUBBER SHOE
Unit: mm
40-16 PC100,120,130-6
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90 OTHER
PC100,120,130-6 90-1
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HYDRAULIC CIRCUIT DIAGRAM
PC100-6 Serial No. : 46059 and up PC120LC-6 Serial No. : 65504 70000
PC100L-6 Serial No. : 46059 and up PC130-6 Serial No. : 51480 and up
PC120-6 Serial No. : 60968 70000
PC100,120,130-6 90-5
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HYDRAULIC CIRCUIT DIAGRAM
PC120-6 Serial No. : 70001 and up
PC100,120,130-6 90-5-2
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ELECTRICAL CIRCUIT DIAGRAM (1/2)
PC100-6 Serial No. : 46059 and up PC120LC-6 Serial No. : 65504 70000
PC100L-6 Serial No. : 46059 and up PC130-6 Serial No. : 51480 and up
PC120-6 Serial No. : 60968 70000
PC100,120,130-6 90-11
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ELECTRICAL CIRCUIT DIAGRAM (2/2)
PC100-6 Serial No. : 46059 and up PC120LC-6 Serial No. : 65504 70000
PC100L-6 Serial No. : 46059 and up PC130-6 Serial No. : 51480 and up
PC120-6 Serial No. : 60968 70000
PC100,120,130-6 90-13
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ELECTRICAL CIRCUIT DIAGRAM (1/2)
PC120-6 Serial No. : 70001 and up
PC100,120,130-6 90-15
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ELECTRICAL CIRCUIT DIAGRAM (2/2)
PC120-6 Serial No. : 70001 and up
PC100,120,130-6 90-17
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