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SEBM010611

MACHINE MODEL SERIAL NUMBER

PC100-6 45221 and up


PC100L-6 15200 and up
PC120-6 57499 and up
PC120LC-6 65504 and up
PC130-6 51020 and up
This shop manual may contain attachments and optional equipment that are not available
in your area. Please consult your local Komatsu distributor for those items you may re-
quire.
Materials and specifications are subject to change without notice.

PC100,120,130 mount the S4D102-1 engine.


For details of the engine, see the 102 Series Engine Shop Manual.

2004 1
All Rights Reserved 00-1
Printed in Japan 04-02(02) (11)
CONTENTS

No. of page

01 GENERAL ............................................................................................................ 01-1

10 STRUCTURE AND FUNCTION ........................................................... 10-1

20 TESTING AND ADJUSTING ................................................................ 20-1

30 DISASSEMBLY AND ASSEMBLY ..................................................... 30-1

40 MAINTENANCE STANDARD ............................................................... 40-1

90 OTHERS ............................................................................................................... 90-1

00-2 PC100,120,130-6
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LIST OF REVISED PAGES


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b 00-1 (11) 01-14 (8) 10-24 (6) 10-64 10-99


00-2 (3) 01-15 (8) 10-25 10-65 10-100 (8)
b 00-2-1 (11) b 01-16 (11) 10-26 (6) 10-66 10-101
b 00-2-2 (11) b 01-17 (11) 10-27 (6) 10-67 10-102
b 00-2-3 (11) c 01-17-1 (11) 10-28 (6) 10-68 10-103
b 00-2-4 (11) c 01-17-2 (11) 10-29 (6) 10-69 10-104
00-3 01-18 (8) 10-30 (6) 10-70 (3) 10-105
00-4 01-19 (8) 10-31 (6) 10-71 10-106
00-5 01-20 (8) 10-32 (6) 10-72 10-107
00-6 01-21 (8) 10-33 10-73 10-107-1 (3)
00-7 01-22 (8) 10-34 (6) 10-74 10-107-2 (3)
00-8 10-35 10-75 10-107-3 (3)
00-9 10-1 (5) 10-36 (6) 10-76 10-107-4 (3)
00-10 10-2 (3) 10-37 (6) 10-77 10-107-5 (3)
00-11 b 10-3 (11) 10-38 (6) 10-78 (6) 10-107-6 (3)
00-12 c 10-3-1 (11) 10-39 (6) 10-79 10-107-7 (3)
00-13 b 10-4 10-39-1 (8) 10-79-1 (8) 10-107-8 (3)
00-14 b 10-5 (11) 10-39-2 (6) 10-79-2 (6) 10-108 (8)
00-15 10-5-1 (5) 10-40 10-80 (8) 10-109 (8)
00-16 10-5-2 (3) 10-41 (8) 10-81 (8) 10-110
00-17 10-6 10-42 10-82 (8) 10-111
00-18 10-7 10-43 10-83 10-112
00-19 10-8 10-44 (8) 10-84 10-113
00-20 10-8-1 (3) 10-45 10-85 10-114
00-21 10-8-2 (8) 10-46 10-86 (6) 10-115
00-22 10-9 (8) 10-47 10-87 (8) 10-116
10-10 (8) 10-48 (3) 10-88 (6) 10-117 (6)
01-1 (8) 10-12 (6) 10-49 10-90 (6) 10-117-1 (6)
01-2 b 10-12-1 (11) 10-50 10-91 (8) 10-117-2 (6)
01-3 (3) 10-13 (8) 10-51 10-92 (6) 10-118
01-4 (3) 10-13-1 (8) 10-52 (8) 10-93-1 (6) 10-119
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01-6 (8) 10-15 10-54 10-93-3 (6) 10-121 (8)
01-8 (8) 10-16 10-55 10-93-5 (6) 10-122
01-9 (8) 10-17 10-56 10-93-6 (8) 10-123
b 01-10 (11) 10-18 10-57 10-93-7 (6) 10-124
b 01-11 (11) 10-19 (5) 10-58 10-94 10-125
c 01-11-1 (11) 10-20 (6) 10-60 (8) 10-95 10-126 (6)
c 01-11-2 (11) 10-21 10-61 10-96 b 10-127 (11)
01-12 (8) 10-22 10-62 10-97 10-128 (6)
01-13 (8) 10-23 (6) 10-63 10-98 b 10-128-1 (11)

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10-128-2 (6) 10-169 (5) 20-44 (1) b 20-139 (11) 20-318 (1)
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b 10-128-4 (11) 10-170-1 (5) 20-46 (1) 20-141 (8) 20-320 (1)
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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)
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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)

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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)

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30-110 (7) 40-9-10 (3)


30-111 (7) 40-10 (8)
30-112 (2) 40-11 (7)
30-113 (2) 40-12 (1)
30-114 (2) 40-13 (8)
30-115 (2) 40-13-1 (3)
30-116 (2) 40-13-2 (3)
30-117 (2) 40-13-3 (3)
30-118 (2) 40-13-4 (3)
30-119 (2) b 40-14 (11)
30-120 (2) c 40-14-1 (11)
30-121 (2) 40-15 (8)
30-122 (2) b 40-16 (11)
30-123 (2) 40-17 (6)
30-124 (2) 40-18 (1)
30-125 (2) 40-19 (6)
30-126 (2) 40-19-1 (8)
30-127 (2) 40-20 (1)
30-128 (2) 40-21 (8)
30-129 (2) 40-22 (1)
30-130 (2) 40-23 (1)
30-131 (2) 40-24 (8)
30-132 (2) 40-25 (1)
30-133 (2) 40-26 (1)
30-134 (2) 40-27 (1)
30-135 (2) 40-28 (1)
30-136 (5) 40-29 (1)
30-137 (5) 40-30 (3)
30-138 (2) 40-30-1 (3)
30-139 (2) 40-31 (1)
30-140 (2) 40-32 (1)
30-141 (2) 40-33 (1)
30-142 (2) 40-34 (1)
30-143 (2) 40-35 (1)
30-144 (5) 40-36 (1)
30-145 (5) 40-37 (1)
40-38 (1)
40-1 (3) 40-39 (1)
40-2 (1) 40-40 (1)
40-3 (1) 40-41 (1)
40-4 (1) 40-42 (1)
40-6 (3) 40-43 (1)
40-7 (3)
40-8 (3) b 90-1 (11)
40-9 (3) 90-3 (6)
40-9-1 (8) b 90-5 (11)
40-9-2 (8) c 90-5-2 (11)
40-9-3 (3) 90-7 (6)
40-9-4 (3) 90-9 (6)
40-9-5 (8) b 90-11 (11)
40-9-6 (3) b 90-13 (11)
40-9-7 (8) c 90-15 (11)
40-9-8 (3) c 90-17 (11)
40-9-9 (8)

00-2-4 PC100,120,130-6
(11)
GENERAL SPECIFICATIONS

Machine model PC100-6 PC100L-6

Serial Number 45221 and up 15200 and up

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

Flywheel horsepower kW/rpm {HP/rpm} 60.3/2,100 {82/2,100}


Engine

Maximum torque Nm/rpm {kgm/rpm} 328.5/1,300 {33.5/1,300}


High idling speed rpm 2,300
Low idling speed rpm 900
Min. fuel consumption ratio g/kWh {g/HPh} 224 {165}

Starting motor 24V, 4.5 kW


Alternator 24V, 25A
Battery 12V, 80Ah 2

Radiator type CF19-4

Carrier roller 1 on each side 1 on each side


carriage

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

Type no. HPV95 + BAR020


Control Hydraulic

Variable displacement piston type 1 + gear type 1


pump

Delivery /min 197 + 32.9


Set pressure MPa {kg/cm2} Piston type: 31.9 {325}, gear type: 2.9 {30}

Type no. 7-spool type 1


Hydraulic motor valve

Control method Hydraulic type

GM18VL HMV110-2
Variable displacement Variable displacement
Travel motor piston type piston type
(with brake (with brake
Hydraulic system

valve,parking brake) 2 valve,parking brake) 2


KMF40ABE-3
Swing motor Fixed displacement piston type
(with safety valve,parking brake) 1

Boom cylinder Arm cylinder Bucket cylinder


Hydraulic cylinder

Type Double-acting piston Double-acting piston Double-acting piston


Inside diameter of cylinder mm 95 115 90
Diameter of piston rod mm 65 75 60
Stroke mm 980 1,005 885
Max. distance between pins mm 2,470 2,877 2,263
Min. distance between pins mm 1,490 1,702 1,378

Hydraulic tank Box-shaped, open


Hydraulic oil filter Tank return side
Hydraulic oil cooler Air cooled (3A-CS)

PC100,120,130-6 01-9
8
GENERAL SPECIFICATIONS

PC120-6

Machine model PC120-6

Serial Number 57499 70000 70001 and up

Bucket capacity (SAE) m3 0.50 0.50

Operating weight kg 11,700 11,700

Max. digging depth mm 5,520 5,520


Working ranges

Max. vertical wall depth mm 4,940 4,940


Max. digging reach mm 8,290 8,290
Max. reach at ground level mm 8,170 8,170
Max. digging height mm 8,610 8,610
Performance

Max. dumping height mm 6,170 6,170

Max. digging force kN {kg} 76.5 {7,800} 76.5 {7,800}


Swing speed rpm 12 12
Swing max. slope angle deg. 20 20
Travel speed km/h Lo:2.7 Mi:3.6 Hi:5.5 Lo:2.7 Mi:3.6 Hi:5.5
Gradeability deg. 35 35
Ground pressure
(standard shoe width: 500 mm) kPa {kg/cm2} 38.25 {0.39} 38.25 {0.39}

Overall length (for transport) mm 7,595 7,595


Overall width mm 2,490 2,490
Overall width of track mm 2,460 2,460
Overall height (for transport) mm 2,715 2,715
Overall height to top of cab mm 2,715 2,715
Dimensions

Ground clearance of counterweight mm 855 855


Min. ground clearance mm 400 400
Tail swing radius mm 2,130 2,130
Min. swing radius of work equipment mm 2,330 2,330
Height of work equipment at
mm 6,440 6,440
min. swing radius
Length of track on ground mm 2,750 2,750
Track gauge mm 1,960 1,960
Height of machine cab mm 1,805 1,805

01-10 PC100,120,130-6
(11)
GENERAL SPECIFICATIONS

Machine model PC120-6

Serial Number 57499 70000 70001 and up

Model S4D102-1 SAA4D102E-2


Type 4-cycle, water-cooled, 4-cycle, water-cooled, in-line,
in-line, vertical, direct vertical, direct injection, with
injection, with turbocharger turbocharger and aftercooler
No. of cylinders-bore x stroke mm 4102 120
Piston displacement {cc} 3.92 {3,920}
Performance

Flywheel horsepower kW/rpm {HP/rpm} 64/2,200 {87/2,200} 66/2,200 {89/2,200}


Engine

Maximum torque Nm/rpm {kgm/rpm} 328.5/1,300 {33.5/1,300} 371.4/1,300 {37.9/1,300}


High idling speed rpm 2,400
Low idling speed rpm 900
Min. fuel consumption ratio g/kWh {g/HPh} 224 {165}

Starting motor 24V, 4.5 kW


Alternator 24V, 25A
Battery 12V, 64Ah 2

Radiator type CF19-4

Carrier roller 1 on each side


carriage
Under-

Track roller 7 on each side


Track shoe Assembly-type triple grouser, 42 on each side
Hydraulic pump

Type no. HPV95 + BAR020


Variable displacement piston type 1 + gear type 1
Delivery /min
197 + 32.9 226 + 45
Set pressure MPa {kg/cm2}
Piston type: 31.9 {325} Piston type (at travel) : 34.8 {355}
Gear type: 2.9 {30} Piston type (at work equipment)
: 31.9 {325}
Gear type : 2.9 {30}
Control

Type no. 7-spool type 1 6-spool type 1


valve

Control method Hydraulic type Hydraulic type


Hydraulic motor
Hydraulic system

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

Boom cylinder Arm cylinder Bucket cylinder


Hydraulic cylinder

Type Double-acting piston Double-acting piston Double-acting piston


Inside diameter of cylinder mm 105 115 95
Diameter of piston rod mm 70 75 65
Stroke mm 990 1,175 885
Max. distance between pins mm 2,490 2,877 2,263
Min. distance between pins mm 1,500 1,702 1,378

Hydraulic tank Box-shaped, open


Hydraulic oil filter Tank return side
Hydraulic oil cooler Air cooled (3A-CS)

PC100,120,130-6 01-11
(11)
GENERAL SPECIFICATIONS

PC120LC-6

Machine model PC120LC-6

Serial Number 65504 70000 70001 and up

Bucket capacity (SAE) m3 0.50 0.50

Operating weight kg 12,600 12,600

Max. digging depth mm 5,480 5,480


Working ranges

Max. vertical wall depth mm 4,900 4,900


Max. digging reach mm 8,290 8,290
Max. reach at ground level mm 8,170 8,170
Max. digging height mm 8,650 8,650
Performance

Max. dumping height mm 6,210 6,210

Max. digging force kN {kg} 76.5 {7,800} 76.5 {7,800}


Swing speed rpm 12 12
Swing max. slope angle deg. 20 20
Travel speed km/h Lo:2.7 Mi:3.3 Hi:5.0 Lo:2.7 Mi:3.3 Hi:5.0
Gradeability deg. 35 35
Ground pressure
(standard shoe width: 500 mm) kPa {kg/cm2} 30.40 {0.31} 30.40 {0.31}

Overall length (for transport) mm 7,595 7,595


Overall width mm 2,590 2,590
Overall width of track mm 2,590 2,590
Overall height (for transport) mm 2,755 2,755
Overall height to top of cab mm 2,755 2,755
Dimensions

Ground clearance of counterweight mm 895 895


Min. ground clearance mm 400 400
Tail swing radius mm 2,130 2,130
Min. swing radius of work equipment mm 2,330 2,330
Height of work equipment at
mm 6,480 6,480
min. swing radius
Length of track on ground mm 3,100 3,100
Track gauge mm 1,990 1,990
Height of machine cab mm 1,845 1,845

01-11-1 PC100,120,130-6
(11)
GENERAL SPECIFICATIONS

Machine model PC120LC-6

Serial Number 65504 70000 70001 and up

Model S4D102-1 SAA4D102E-2


Type 4-cycle, water-cooled, 4-cycle, water-cooled, in-line,
in-line, vertical, direct vertical, direct injection, with
injection, with turbocharger turbocharger and aftercooler
No. of cylinders-bore x stroke mm 4102 120
Piston displacement {cc} 3.92 {3,920}
Performance

Flywheel horsepower kW/rpm {HP/rpm} 64/2,200 {87/2,200} 66/2,200 {89/2,200}


Engine

Maximum torque Nm/rpm {kgm/rpm} 328.5/1,300 {33.5/1,300} 371.4/1,300 {37.9/1,300}


High idling speed rpm 2,400
Low idling speed rpm 900
Min. fuel consumption ratio g/kWh {g/HPh} 224 {165}

Starting motor 24V, 4.5 kW


Alternator 24V, 25A
Battery 12V, 92Ah 2

Radiator type CF19-4

Carrier roller 2 on each side


carriage
Under-

Track roller 8 on each side


Track shoe Assembly-type triple grouser, 46 on each side
Control Hydraulic pump

Type no. HPV95 + BAR020


Variable displacement piston type 1 + gear type 1
Delivery /min
197 + 32.9 226 + 45
Set pressure MPa {kg/cm2}
Piston type: 31.9 {325} Piston type (at travel) : 34.8 {355}
Gear type: 2.9 {30} Piston type (at work equipment)
: 31.9 {325}
Gear type : 2.9 {30}

Type no. 7-spool type 1 6-spool type 1


valve

Control method Hydraulic type Hydraulic type


Hydraulic motor
Hydraulic system

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

Boom cylinder Arm cylinder Bucket cylinder


Hydraulic cylinder

Type Double-acting piston Double-acting piston Double-acting piston


Inside diameter of cylinder mm 105 115 95
Diameter of piston rod mm 70 75 65
Stroke mm 990 1,175 885
Max. distance between pins mm 2,490 2,877 2,263
Min. distance between pins mm 1,500 1,702 1,378

Hydraulic tank Box-shaped, open


Hydraulic oil filter Tank return side
Hydraulic oil cooler Air cooled (3A-CS)

PC100,120,130-6 01-11-2
(11)
GENERAL WEIGHT TABLE

PC120-6 Unit : kg

Machine model PC120-6

Serial Number 57499 70000 70001 and up

Engine assembly (excl. water, oil) 385 410

Coupling assembly (PTO) 3.3 3.3

Radiator oil cooler assembly 62.5 72.0

Revolving frame assembly 1,000 1,000

Operator's cab 287 287

Operator's seat 29.3 29.3

Fuel tank (excl. fuel) 96.8 96.8

Hydraulic tank (excl. hydraulic oil) 102.4 102.4

Counterweight 2,305 2,255

Hydraulic pump assembly 86 86

Control valve 96 96

Swing circle assembly 153 153

Swing machinery assembly 72.2 72.2

Swing motor 25.5 25.5

Center swivel joint 29.2 29.2

Track frame assembly


Track frame 1,240 1,240
Idler 79 x 2 79 x 2
Idler cushion 72 x 2 72 x 2
Carrier roller 11 x 2 11 x 2
Track roller 21.8 x 14 21.8 x 14
Travel motor final drive assembly 136.5 x 2 136.5 x 2
Sprocket 33.7 x 2 33.7 x 2

01-16 PC100,120,130-6
(11)
GENERAL WEIGHT TABLE

Unit : kg

Machine model PC120-6

Serial Numbe 57499 70000 70001 and up

Track shoe assembly


Standard triple grouser shoe (500 mm) 740 x 2 710 x 2
Standard triple grouser shoe (800 mm)
Wide triple grouser shoe (600 mm) 830 x 2 795 x 2
Wide triple grouser shoe (700 mm) 925 x 2 885 x 2
Wide triple grouser shoe (750 mm) 970 x 2 925 x 2
Wide triple grouser shoe (900 mm)
Flat shoe (480 mm) 760 x 2 755 x 2
Swamp shoe (750 mm) 875 x 2 870 x 2
Swamp shoe (860 mm)
Rubber shoe (500 mm) 845 x 2 845 x 2
Large hole triple grouser shoe (500 mm)
Road liner (rubber pad type) (500 mm) 766 x 2 765 x 2

Boom assembly 1,247 1,247

Arm assembly 447.5 447.5

Link assembly 92.7 92.7

Bucket assembly 399 399

Boom cylinder assembly 108.5 x 2 108.5 x 2

Arm cylinder assembly 144.9 144.9

Bucket cylinder assembly 87.4 87.4

PC100,120,130-6 01-17
(11)
GENERAL WEIGHT TABLE

PC120LC-6 Unit : kg

Machine model PC120LC-6

Serial Number 65504 70000 70001 and up

Engine assembly (excl. water, oil) 385 385

Coupling assembly (PTO) 3.3 3.3

Radiator oil cooler assembly 62.5 62.5

Revolving frame assembly 1,000 1,000

Operator's cab 287 287

Operator's seat 29.3 29.3

Fuel tank (excl. fuel) 96.8 96.8

Hydraulic tank (excl. hydraulic oil) 102.4 102.4

Counterweight 2,455 2,455

Hydraulic pump assembly 86 86

Control valve 96 96

Swing circle assembly 153 153

Swing machinery assembly 72.2 72.2

Swing motor 25.5 25.5

Center swivel joint 29.2 29.2

Track frame assembly


Track frame 1,532 1,532
Idler 79 x 2 79 x 2
Idler cushion 74.2 x 2 74.2 x 2
Carrier roller 11 x 4 11 x 4
Track roller 21.8 x 16 21.8 x 16
Travel motor final drive assembly 136.5 x 2 136.5 x 2
Sprocket 33.7 x 2 33.7 x 2

01-17-1 PC100,120,130-6
(11)
GENERAL WEIGHT TABLE

Unit : kg

Machine model PC120LC-6

Serial Numbe 65504 70000 70001 and up

Track shoe assembly


Standard triple grouser shoe (500 mm)
Standard triple grouser shoe (800 mm)
Wide triple grouser shoe (600 mm) 907 x 2 907 x 2
Wide triple grouser shoe (700 mm)
Wide triple grouser shoe (750 mm)
Wide triple grouser shoe (900 mm)
Flat shoe (480 mm)
Swamp shoe (750 mm)
Swamp shoe (860 mm)
Rubber shoe (500 mm)
Large hole triple grouser shoe (500 mm)
Road liner (rubber pad type) (500 mm)

Boom assembly 1,247 1,247

Arm assembly 447.5 447.5

Link assembly 92.7 92.7

Bucket assembly 399 399

Boom cylinder assembly 108.5 x 2 108.5 x 2

Arm cylinder assembly 144.9 144.9

Bucket cylinder assembly 87.4 87.4

PC100,120,130-6 01-17-2
(11)
STRUCTURE AND FUNCTION RADIATOR AND OIL COOLER

PC120-6 Serial No. : 57499 70000


PC120LC-6 Serial No. : 65504 70000
PC130-6

1. Radiator cap SPECIFICATIONS Oil cooler


2. Radiator Core type: 3A-CS
3. Radiator inlet hose Radiator Fine pitch: 3.5 mm
4. Fan guard Core type: CF19-4 Total heat dissipation surface:
5. Radiator outlet hose Fine pitch: 3.5/2 mm 12.27 m2
6. Fan Fan guard
7. Drain valve Total heat dissipation fl The oil cooler is a hinged type, if
8. Shroud surface: 34.06 m2 the 4 mounting bolts are removed, it
9. Oil cooler Pressure valve crack- can opened to make it easier to
10. Reservoir tank ing pressure: clean the radiator.
49.03 kPa {0.5 kg/cm2}
Vacuum valve crack-
ing pressure:
4.9 kPa {0.05 kg/cm2}

PC100,120,130-6 10-3
(11)
STRUCTURE AND FUNCTION RADIATOR AND OIL COOLER

PC120-6 Serial No. : 70001 and up


PC120LC-6 Serial No. : 70001 and up

1. Radiator cap SPECIFICATIONS Oil cooler


2. Radiator Core type: CF40-1
3. Radiator inlet hose Radiator Fine pitch: 4.5/2 mm
4. Fan guard Core type: CF19-4 Total heat dissipation surface:
5. Radiator outlet hose Fine pitch: 3.5/2 mm 8.79 m2
6. Drain valve Fan guard
7. Shroud Total heat dissipation After cooler
8. Oil cooler surface: 34.06 m2 Core type: F & T
9. Aftercooler Pressure valve crack- Fine pitch: 3.5/2 mm (Cooling side)
10. Reservoir tank ing pressure: 2.75/2 mm (Boost side)
43.03 kPa {0.5 kg/cm2}
A: Oil inlet port Vacuum valve crack-
B : Oil outlet port ing pressure:
4.9 kPa {0.05 kg/cm2}

10-3-1 PC100,120,130-6
(11)
STRUCTURE AND FUNCTION PTO

PTO (COUPLING)

1. Shaft 5. Hydraulic pump


2. Coupling 6. Oil filler plug
3. Breather 7. Level plug
4. Cage

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

1. Working lamp 41. Wiper switch


2. Fuel level sensor 42. Light switch
3. Additional front lamp 43. Buzzer cancel switch
4. R.H. auto pull-up lock 44. Air conditioner control panel
5. Room lamp 45. Auto pull-up switch
6. Antenna 46. Service meter
7. Starting motor 47. Speaker
8. Auto pull-up motor 48. Engine throttle controller
9. Alternator 49. L.H. knob switch
10. Pump pressure sensor 50. Prolix resistor
11. Coolant level sensor 51. Wiper, auto pull-up controller
12. Fusible link (3) 52. Horn switch
13. Battery relay 53. Monitor panel
14. Battery 54. Swing prolix switch
15. Air cleaner clogging sensor 55. PC prolix switch
16. PPC hydraulic switch (8) 2 56. Swing stroke limit solenoid valve
17. L.H. auto pull-up lock
18. Horn
19. Wiper motor
20. Window washer
21. Front lamp
22. Active mode solenoid valve
23. 2-stage relief solenoid valve
24. Swing brake solenoid valve
25. Travel speed solenoid valve
26. Coolant temperature sensor
27. Governor motor
28. Engine speed sensor
29. Heater relay
30. Engine oil pressure sensor
31. Engine oil level sensor
32. Fuse box
1 33. Relay for light
1 34. Relay for additional light
35. Alarm buzzer
36. Starting switch
37. Fuel control dial
38. Radio
39. Cigarette lighter
40. Swing lock switch

PC100,120,130-6 10-128-1
(11)
STRUCTURE AND FUNCTION ELECTRICAL CIRCUIT DIAGRAM

ELECTRICAL CIRCUIT DIAGRAM


CHASSIS ELECTRICAL CIRCUIT DIAGRAM
(1/2)
PC100-6 Serial No. : 45221 46058
PC100L-6 Serial No. : 15200 46058
PC120-6 Serial No. : 57499 60967
PC130-6 Serial No. : 51020 51479

fl For details of this page, see section 90.

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

ENGINE CONTROL SYSTEM

1.
PC120-6 Serial No. : 70001 and up
PC120LC-6 Serial No. : 70001 and up

1. Starting motor FUNCTION


2. Fuel control dial
3. Engine throttle Pump The engine can be started and stopped simply
controller by using the starting switch.
4. Battery relay A dial type engine control is used to control
5. Battery the engine speed. The engine throttle pump
6. Governor motor controller receives the control signal from the
7. Loose spring fuel control dial, sends a drive signal to the
8. Fuel injection pump governor motor, and controls the angle of
the governor lever in the fuel injection pump.
At the same time, the engine throttle pump
controller also receives signals from other
controllers to control the engine speed.

10-130 PC100,120,130-6
(11)
STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM

1) Control method in each mode


Heavy-duty operation (H/O) mode
Matching point in heavy-duty operation mode: Rated output point
When the load on the pump rises and the pressure rises, the engine speed goes down.
When this happens, the pump discharge amount is reduced, and the engine speed is controlled so
that it becomes the rated speed.
If the reverse happens and the pressure goes down, the system is controlled so that the pump dis-
charge amount is increased until the engine speed reaches the rated speed.
By repeating this control, the engine can always be used at near the rated output point.

Model PC100 PC120, 130



Heavy-duty 58.8 kW/1,900 rpm 62.5 kW/2,200 rpm 64.7 kW/2,000 rpm
operation {79 HP/1,900 rpm} {84 HP/2,200 rpm} {87 HP/2,000 rpm}
(H/O)
PC120 Serial No. : 70001 and up

General operation (G/O), finishing operation (F/O) mode


Matching point in general operation and finishing operation modes: 75% partial output point.
When the load on the pump rises and the pressure rises, the engine speed goes down.
When this happens, mutual control of the engine and pump is used to control the system so that the
pump absorption torque follows the equal horsepower curve of the engine, and the engine speed is
lowered while keeping the torque constant.
In this way, the engine is used in a range which provides good fuel efficiency.

Model PC100 PC120, 130


General
operation
(G/O), 47.8 kW/1,720 rpm 47.8 kW/1,900 rpm 51.5 kW/1,800 rpm
Finishing {64 HP/1,720 rpm} {64 HP/1,900 rpm} {69 HP/1,800 rpm}
operation
(F/O)

PC120 Serial No. : 70001 and up

10-140 PC100,120,130-6
(11)
STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM

Lifting operation (L/O) mode


Matching point in lifting operation mode: 50% partial output point
When the lifting operation mode is selected, the engine speed is automatically lowered to the partial
position.
In this condition, control is carried out in the same way as for the general operation and finishing
operation modes to match the load on the pump.
In this way, the fuel consumption is reduced and the fine control ability is improved.

Model PC100 PC120, 130



Lifting 33.1 kW/14.20 rpm 33.1 kW/1,600 rpm 36.8 kW/1,500 rpm
operation {44 HP/1,420 rpm} {41 HP/1,600 rpm} {49 HP/1,500 rpm}
(L/O)
PC120 Serial No. : 70001 and up

Breaker operation (B/O) mode


Matching point in breaker operation mode: 75% partial output point
The pump absorption torque in the breaker operation mode is the same as for the general operation
and finishing operation modes, and is controlled to become an even lower speed.
As a result, the pump absorption torque needed to ensure the breaker drive is ensured, and the en-
gine is used in a range that provides a much better fuel consumption ratio than for the general
operation mode or finishing operation mode.

Model PC100 PC120, 130



Breaker 47.8 kW/1,720 rpm 47.8 kW/1,750 rpm 51.5 kW/1,800 rpm
operation {64 HP/1,720 rpm} {64 HP/1,750 rpm} {69 HP/1,800 rpm}
(B/O)
PC120 Serial No. : 70001 and up

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

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.

Applicable model PC100-6 PC120,130-6

PC120 : 57499 70000


Serial Number 45221 and up
PC120LC : 65504 70000
Engine S4D102-1
Standard Standard
Item Measurement conditions Unit value for new Service limit value for new Service limit
machine value machine value

High idling 2,100 100 2,200 100


Engine speed Low idling rpm 900 50 900 50
Rated speed 1,900 2,000

At sudden acceleration Bosch Max. 5.5 7.5 Max. 5.5 7.5


Exhaust gas color index
At high idling Max. 1.0 2.0 Max. 1.0 2.0

(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}

Whole speed range


Oil temperature (inside oil pan) C 80 110 120 80 110 120

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.

Applicable model PC120

Serial Number 70001 and up

Engine SAA4D102E-2
Standard Standard
Item Measurement conditions Unit value for new Service limit value for new Service limit
machine value machine value

High idling 2,200 100


Engine speed Low idling rpm 975 50
Rated speed 2,000

At sudden acceleration Bosch Max. 5.5 7.5


Exhaust gas color index
At high idling Max. 1.0 2.0

(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}

Whole speed range


Oil temperature (inside oil pan) C 80 110 120

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)

Test pump dis- Standard value for Judgement


Check point charge pressure Average pressure discharge amount standard
{kg/cm2} (kg/cm2) Q (/min) Q (/min)

As desired P1 P1 See graph See graph

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

TESTING AND ADJUSTING


BELT TENSION FOR AIR
CONDITIONER COMPRESSOR
fl If the deflection of the belt when it is pressed at a
point midway between the crankshaft pulley and
the compressor pulley is not within the standard
value, or when carrying out maintenance after
replacing the belt, adjust the belt tension as fol-
lows.

1. Remove cover (1).

2. Remove covers (5) and (6).


fl PC120-6 Serial No. : 70001 and up

3. Loosen mounting bolt (3) and adjustment bolt (4)


of compressor assembly (2).

4. Move the position of compressor assembly (2)


and adjust the belt tension.

5. When the position of compressor assembly (4) is


fixed, tighten adjustment bolt (4) and mounting
bolt (3) to secure in position.

6. After adjusting the belt tension, repeat the above


procedure to check that the belt tension is within
the standard value.

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. Measuring LS differential pressure


1) Measuring with a differential pressure gauge
i) Remove oil pressure measurement plugs
(1) and (2) (Thread dia.=10mm, Pitch
=1.25mm), and install differential pressure
gauge C4.
ii) Set to the conditions in Table 2 and mea-
sure the LS differential pressure.
Table 2
Fuel Differential
Working control pressure
mode Operation
lever MPa{kg/cm2}

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)

2) Measuring with oil pressure gauge


fl The maximum differential pressure is
2.7 +1.0 +10 2
0.7 MPa {28 7 kg/cm }, so measure with
the same gauge.
i) Install oil pressure gauge C1 (58.8 MPa
{600 kg/cm2}) to plug (1) for measuring the
pump discharge pressure.
fl Use a gauge with a scale in units of
1.0 MPa {10 kg/cm2}.
(If no 58.8 MPa {600 kg/cm2} pressure
gauge is available, a 39.2 MPa {400 kg/
cm2} pressure gauge can be used.)
ii) Set to the conditions in Table 2 and mea-
sure the pump discharge pressure.
fl Stand directly in front of the indicator
and be sure to read it correctly.
iii) Remove oil pressure gauge C1, then in-
stall to LS pressure measurement plug (2).
iv) Set to the conditions in Table 2 and mea-
sure the LS pressure.
fl Stand directly in front of the indicator
and be sure to read it correctly.
(Pump discharge pressure) (LS pres-
sure) = Differential pressure

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)

1. Procedure for checking monitor panel output signal


fl For details of operating the monitoring mode, see MONITOR PANEL DISPLAY AND SPECIAL
FUNCTIONS.
1. Connection condition of components
1) Set to the monitoring mode and display monitoring code 08.
2) The time display (bits) will light up to display the components that are connected.
fl Engine throttle pump controller (pump control system) (1) and engine throttle pump
controller (governor control system) (2) will light up.

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

METHOD OF USING MANUAL .................... 30- 3 FUEL TANK


PRECAUTIONS WHEN CARRYING OUT Removal and Installation ........................... 30-41
OPERATION ................................................ 30- 4 CENTER SWIVEL JOINT
SPECIAL TOOL LIST ..................................... 30- 6 Removal and Installation ........................... 30-42
SKETCHES OF SPECIAL TOOLS .................. 30-10 Disassembly and Assembly ...................... 30-43
STARTING MOTOR SPROCKET
Removal and Installation ........................... 30-11 Removal and Installation ........................... 30-44
ALTERNATOR TRAVEL MOTOR
Removal and Installation ........................... 30-12 Removal and Installation ........................... 30-45
AIR CONDITIONER COMPRESSOR Disassembly and Assembly ................... 30-45-1
Removal and Installation ........................... 30-13 FINAL DRIVE
CONDENSER Disassembly ............................................... 30-46
Removal and Installation ........................ 30-13-2 Assembly .................................................... 30-49
AFTERCOOLER SWING MACHINERY, SWING MOTOR
Removal and Installation ........................... 30-14 Removal and Installation ........................... 30-54
ENGINE OIL COOLER CORE SWING MOTOR
Removal and Installation ........................... 30-15 Removal and Installation ........................... 30-55
FUEL INJECTION PUMP Disassembly ............................................ 30-55-1
Removal ...................................................... 30-16 Assembly ................................................. 30-55-5
Installation .................................................. 30-18 SWING MACHINERY
WATER PUMP Disassembly ............................................... 30-56
Removal and Installation ........................... 30-20 Assembly .................................................... 30-59
NOZZLE HOLDER REVOLVING FRAME
Removal and Installation ........................... 30-21 Removal ...................................................... 30-63
TURBOCHARGER Installation .................................................. 30-65
Removal and Installation ........................... 30-22 SWING CIRCLE
THERMOSTAT Removal and Installation ........................... 30-66
Removal and Installation ........................... 30-23 IDLER, RECOIL SPRING
GOVERNOR MOTOR Removal and Installation ........................... 30-67
Removal and Installation ........................... 30-24 RECOIL SPRING
CYLINDER HEAD Disassembly ............................................... 30-68
Removal ...................................................... 30-25 Assembly .................................................... 30-69
Installation .................................................. 30-30 IDLER
ENGINE, MAIN PUMP Disassembly ............................................... 30-70
Removal ...................................................... 30-33 Assembly .................................................... 30-71
Installation .................................................. 30-37 TRACK ROLLER
HYDRAULIC COOLER Removall and Installation .......................... 30-73
Removal and Installation ........................... 30-38 Disassembly ............................................... 30-74
RADIATOR, HYDRAULIC COOLER Assembly .................................................... 30-75
Removal ...................................................... 30-39
Installation .................................................. 30-40

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.

1. Open engine hood and remove side cover (1) and


exhaust manifold cover (2).

2. Disconnect wires (3).

3. Remove 3 bolts (4). 1

4. Remove starting motor assembly (5).


PC120-6 Serial No. : 70001 and up

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.

1. Open engine hood and remove fan guard (1).

2. Disconnect wires (2).


fl Before disconnecting the wiring, fit tags to distin-
guish the mounting position.

3. Using wrench 1, raise tensioner (3) and remove


fan belt (4).
Be extremely careful not to get your fingers PC120-6 Serial No. : 70001 and up
caught when removing the fan belt.

4. Remove alternator mounting bolts (5) and (6),


then remove alternator assembly (7) 1

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}

fl Use a straight edge and check that the alter-


nator pulley is centered with the other pul-
leys.

30-12 PC100,120,130-6
(11)
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER COMPRESSOR

REMOVAL 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

Loosen the flange mounting bolts of the air con-


ditioner hose, and release the refrigerant (R-
134a) slowly.

1. Open engine hood and remove counterweight top


cover.

2. Disconnect connector (1).

3. Disconnect hoses (2) and (3). 1

4. Loosen mount bolt and adjustment bolt (4), and


remove belt (5).

5. Remove mount bolt and adjustment bolt (4), then


remove air conditioner compressor (6). 2

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

Carry out installation in the reverse order to re-


moval.

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.

Fill with refrigerant (R-134a).

PC100,120,130-6 30-13
(11)
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER COMPRESSOR

REMOVAL OF AIR CONDITIONER


COMPRESSOR ASSEMBLY
PC120-6 Serial No. : 70001 and up
PC120LC-6 Serial No. : 70001 and up

Loosen the flange mounting bolts of the air con-


ditioner hose, and release the refrigerant (R-
134a) slowly.

1. Open the engine hood and remove counterweight


top cover (7).

2. Disconnect hose (8) from the aftercooler and place


it on the center of the engine.

3. Remove fan guard (9) and cover (10).

4. Disconnect connector (1).

5. Disconnect hoses (2) and (3). 1

6. Loosen the mounting bolt and adjustment bolt


(4) and remove belt (5).

7. Remove the mounting bolt and adjustment bolt


(4), and then remove air conditioner compressor
assembly (6). 2

INSTALLATION OF AIR
CONDITIONER COMPRESSOR
ASSEMBLY
PC120-6 Serial No. : 70001 and up
PC120LC-6 Serial No. : 70001 and up

Carry out installation in the reverse order to re-


moval.

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.

Fill with refrigerant (R-134a).

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.

2. Open engine side cover and disconnect hoses (1)


and (2). 1
fl Loosen the sleeve nuts slightly and release
the refrigerant (R134a) completely before dis-
connecting the hoses.
fl Fit blind plugs into the hoses to prevent the
entry of moisture, dust or dirt.

3. Remove condenser assembly (3).


PC120-6 Serial No. : 70001 and up

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.

Fill with refrigerant (R-134a).

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

1. Open the engine side cover (on the left side).

2. Remove 4 bolts (1) and move condenser assem-


bly (2) to the front side.
Do not disconnect the air conditioner hoses.

3. Open the engine hood and remove the counter-


weight top cover.

4. Loosen the clamps of hoses (3) and (4). 1

5. Remove 4 mounting bolts (5) and aftercooler as-


sembly (6).

INSTALLATION OF
AFTERCOOLER ASSEMBLY
PC120-6 Serial No. : 70001 and up
PC120LC-6 Serial No. : 70001 and up

Carry out installation in the reverse order to re-


moval.

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

1. Open engine hood and remove insulator (1).

2. Disconnect intake hose (2).

3. Loosen clamp of air supply connector intermedi-


ate hose (3), then move hose towards pipe.

4. Remove clamp (4) connecting turbocharger and


exhaust muffler.

5. Disconnect turbocharger lubrication inlet hose (5)


and drain tube (6).

6. Remove divider plate between muffler and main


pump assembly, then remove 4 mounting bolts
(8) of bracket of muffler assembly (7), and move
towards pump.

7. Remove 4 turbocharger mounting nuts (9), then


remove turbocharger assembly (10). 1

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

Carry out installation in the reverse order to re-


moval.

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

1. Open the engine hood and remove heat insula-


tion cover (1) and muffler connector cover (2).

2. Disconnect air intake hose (3). 1

3. Disconnect air intake connector intermediate hose


(4) from the turbocharger. 2

4. Remove connecting clamp (5) which is connect-


ing the turbocharger and muffler connector.

5. Disconnect turbocharger lubrication inlet hose (6),


drain tube (7), and boost hose (8).

6. Remove the partition between the muffler and


main pump assembly and 4 muffler assembly
mounting bolts (9) and move the muffler toward
the pump.

7. Remove turbocharger assembly (10). 3

INSTALLATION OF
TURBOCHARGER ASSEMBLY
PC120-6 Serial No. : 70001 and up
PC120LC-6 Serial No. : 70001 and up

Carry out installation in the reverse order to re-


moval.

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

1. Remove engine hood, then remove counterweight


top cover and control valve top cover.

2. Open engine side cover, then disconnect hoses


(1) and (2). 1
fl Loosen the sleeve nuts slightly and release
the refrigerant (gas) completely before discon-
necting the hoses.
fl Fit blind plugs into the hoses to prevent the
entry of moisture, dust or dirt.

3. Remove condenser (3).

4. Disconnect cooler hoses (4).

5. Sling hydraulic cooler assembly (5), then remove


6 mounting bolts, and lift off slowly.
fl When removing the hydraulic cooler assem-
bly, be extremely careful not to damage the
core.
4 Hydraulic cooler assembly : 30 kg

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

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.

Fill with refrigerant (R-134a).

Refilling with oil (hydraulic tank)


fl Add oil through the oil filler to the specified
level. Run the engine to circulate the oil
through the system. Then check the oil level
again.

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

Lower the work equipment completely to the


ground and stop the engine. Then loosen the
oil filler cap slowly to release the pressure in-
side the hydraulic tank.

Remove the hydraulic tank strainer, and using tool


B, stop the oil.
When not using tool B, remove the drain plug,
and drain the oil from the hydraulic tank and
inside the system.
6 Hydraulic tank : Approx. 100
Drain coolant

1. Remove engine hood, then remove counterweight


top cover and control valve top cover.

2. Disconnect hoses (1) and (2). 1


fl Loosen the sleeve nut slightly and release the
refrigerant (gas) completely before discon-
necting the hoses.
fl Fit blind plugs into the hoses to prevent the
entry of moisture, dust or dirt.

3. Remove condenser (3).

4. Remove bracket (4).

5. Remove left and right stays (5).

6. Disconnect hydraulic cooler hoses (6).

7. Disconnect aeration hose (7).

8. Disconnect radiator inlet hose (8).

9. Remove fan guard (9).

PC100,120,130-6 30-39
(11)
DISASSEMBLY AND ASSEMBLY RADIATOR, HYDRAULIC COOLER

10. Disconnect radiator outlet hose (10).

11. Sling radiator and hydraulic cooler assembly (11),


then remove 4 bottom mounting bolts, and lift
off slowly. 2
fl When removing the radiator and hydraulic
cooler assembly, be extremely careful not to
damage the core.
4 Radiator, hydraulic cooler assembly :
75 kg.

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

Carry out installation in the reverse order to re-


moval.

1
fl Check that the O-ring is not damaged or dete-
riorated, then connect the hoses.

Fill with refrigerant (R-134a).

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.

Refilling with water


fl Add water through the water filler to the speci-
fied level. Run the engine to circulate the wa-
ter through the system. Then check the wa-
ter level again.

Refilling with oil (hydraulic tank)


fl Add oil through the oil filler to the specified
level. Run the engine to circulate the oil
through the system. Then check the oil level
again.

30-40 PC100,120,130-6
(11)
DISASSEMBLY AND ASSEMBLY RADIATOR, HYDRAULIC COOLER

REMOVAL OF RADIATOR AND


HYDRAULIC OIL COOLER
ASSEMBLY
PC120-6 Serial No. : 70001 and up
PC120LC-6 Serial No. : 70001 and up

Lower the work equipment to the ground and


stop the engine. Then, loosen the hydraulic oil
filler cap slowly to release the internal pressure
of the hydraulic tank.

Remove the hydraulic tank strainer and stop the


oil with tool B.

When not using tool B, remove the drain plug to


drain the oil from the hydraulic tank and piping.
6 Hydraulic tank: Approx. 100

Drain the coolant.

1. Remove the engine hood, counterweight top


cover, and control valve top cover.

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.

3. Remove right and left stays (5).

4. Disconnect hydraulic oil cooler hose (6).

5. Disconnect aeration hose (7).

6. Disconnect radiator inlet hose (8).

7. Remove fan guard (9).

PC100,120,130-6 30-40-1
(11)
DISASSEMBLY AND ASSEMBLY RADIATOR, HYDRAULIC COOLER

8. Disconnect radiator outlet hose (10).

9. Sling radiator and hydraulic oil cooler assembly


(11) temporarily. Remove the 4 lower mounting
bolts and radiator and hydraulic oil cooler assem-
bly. 1
fl When slinging and removing the radiator and
hydraulic oil cooler assembly, take care ex-
tremely not to damage the core.
4 Radiator and hydraulic oil cooler assem-
bly: 75 kg

INSTALLATION OF RADIATOR
AND HYDRAULIC OIL COOLER
ASSEMBLY
PC120-6 Serial No. : 70001 and up
PC120LC-6 Serial No. : 70001 and up

Carry out installation in the reverse order to re-


moval.

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.

Refilling with water


fl Add water through the water filler to the speci-
fied level. Run the engine to circulate the
water through the system. Then, check the
water level again.

Refilling with oil


fl Add oil through the oil filler to the specified
level. Run the engine to circulate the oil
through the system. Then, check the oil level
again.

30-40-2 PC100,120,130-6
(11)
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR

DISASSEMBLY, ASSEMBLY OF TRAVEL MOTOR


GM18VL
PC100-6 Serial No.: 45221 and up
PC120-6 Serial No.: 57499 and up
PC120LC-6 Serial No.: 65504 and up
PC130-6 Serial No.: 51020 and up

CONTENTS

Safety ................................................................................................................................................... 30-45- 2


Sectional drawing, single view drawing, and parts list ................................................................... 30-45- 3
Parts list ................................................................................................................................................. 30-45- 5
Tools ...................................................................................................................................................... 30-45- 7
Tightening torque ................................................................................................................................. 30-45-12
Disassembly .......................................................................................................................................... 30-45-13
Disassembly of travel motor assembly (GM18VL) ............................................................................ 30-45-14
Maintenance standards table .............................................................................................................. 30-45-21
Assembly .............................................................................................................................................. 30-45-24
Assembly of travel motor assembly (GM18VL) ................................................................................. 30-45-25
Clearance adjusting parts list .............................................................................................................. 30-45-35
Performance confirmation test ........................................................................................................... 30-45-36

30-45-1 PC100,120,130-6
(10)
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR

SAFETY

TYPES AND MEANING OF WARNING TERMS

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.

WARNING TERM MEANING

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.

This symbol is used to draw the readers attention or emphasize some


information.

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

SECTIONAL DRAWING, SINGLE VIEW DRAWING, AND PARTS LIST

SECTIONAL DRAWING OF ASSEMBLY

30-45-3 PC100,120,130-6
(10)
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR

PC100,120,130-6 30-45-4
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DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR

PARTS LIST

Symbol Part named Qty Symbol Part named Qty

REDUCTION GEAR ASSEMBLY 1 HYDRAULIC MOTOR

1 Hub 1 Rear flange assembly


Rear flange kit 1
Spindle kit 1 101 Rear flange 1
Spindle assembly 1 123 Spool 1
2 Spindle 1 146 Hexagon socket head plug 3
3 Hold flange 1 154 Hexagon socket head plug 7
19 Reamer bolt 3 179 Filler 1
190 Orifice 1
RV gear assembly 1 199 Nameplate 1
RV gear kit 1 124 Plug 2
4 RV gear A 1 125 Spring retainer 2
5 RV gear B 1 126 Plug 2
9 Crankshaft 3 127 Valve 2
22 Tapered roller bearing 6 128 Spring 2
23 Needle roller bearing 6 130 Spring 2
136 O-ring 2
6 Input gear 1 137 O-ring 2
140 O-ring 2
Spur gear kit 1 163 Valve 1
7 Spur gear 3 164 Stopper 1
165 Ring 1
8 Cover 1 166 Spring 1
14 Distance piece 3 168 Ball 2
15 Coupling 1 192 Plug 2
17 Pin 24 193 O-ring 2
194 Ball 2
20 Snap ring 3
t = Above 2.20 up to 2.25 102 Shaft 1
<At interval of 0.05> 103 Swash plate 1
t = Above 2.75 up to 2.80 104 Cylinder block 1

21 Ball bearing 2 Piston kit 1


25 C-type snap for shaft 3 Piston assembly 9
27 O-ring 2 105 Piston 1
29 O-ring 1 106 Shoe 1
30 O-ring 1
107 Retainer plate 1
Floating seal kit 1 108 Thrust ball 1
31 Floating seal 2 109 Timing plate 1
110 Washer 2
33 Hexagon socket head plug 2 111 Washer 1
35 Hexagon socket head bolt 10 112 Piston 1
36 Ball 1 113 Spring 8
114 Spring 1

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DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR

Symbol Part named Qty Symbol Part named Qty

115 Friction plate 2 209 O-ring 2


116 Mating plate 2 214 Plug 1
117 Mating plate 1 215 Plug 2
121 Plug 1 216 Ball 2
132 Oil seal 1 217 Buckup ring 4
135 O-ring 1 219 Orifice 2
138 O-ring 2 220 O-ring 1
139 O-ring 1 222 Hexagon socket head plug 6
141 Parallel pin 1 224 O-ring 2
142 Parallel pin 2
143 Hexagon socket head bolt 8
145 THS snap ring 1
149 Deep groove ball bearing 1
150 Deep groove ball bearing 1
151 Roller 3

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

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DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR

TOOLS
1. Standard tools

No. Name Model/Dimensions Q'ty

1 Hexagonal wrench 6 (For M8) 1


10 (For M12) 1
(JIS B 4648) 14 (For M16) 1
2 Socket wrench 8-shaped 1
(Ratchet handle)
(JIS B 4641)
3 Torque wrench Dial type, 280 Nm {28 kgm} 1
(JIS B 4650) Dial type, 850 Nm {87 kgm} 1
4 Torque wrench adapter Nominal size: 17, 19, 27, 32, 36 (Socket) 1 each
(12.7-mm square drive) Nominal size: 6, 8, 10 (Rod) 1 each
5 Extension bar 150 mm 1
(JIS B 4637)
6 Hammer Nominal size: 12 1
7 Plastic hammer L = Approx. 300 1
8 Flat-head screwdriver Approx. 150 mm 1
(JIS B 4609)
9 Snap ring priers For shaft 1
For hole 1
10 Hanging tool Lifting load: Min. 300 kg 1 set
Eyebolt (For M16) (2)
Eyebolt (For PT 1/2) (2)
Wire with hook (1)
11 Press work stand Pressing capacity: Min. 200 kg 1 set
2
12 Compressed air For 3 5 kgf/cm 1 set
Nozzle for compressed air
13 Container Common vat, W450 x D300 x H120 2
14 Heating tank Heating temperature: Min. 100C 1 set
Volume: Min. 500 x 500 x 500
15 Leather gloves 1 set
16 Sealing tape 1
17 Depth micrometer Measurement range: Approx. 30 mm 1
Min. division: 0.01 mm
18 Thickness gauge Measurement range: 0.04 0.3 mm 1

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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

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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.

10) Pointed punch


A punch used to remove ring (165) in
the pilot valve.

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

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11) Press fitting tool


A tool used to press fit main ball bear-
ing (21) to hub (1).

14) Steel rod


A rod used to install ring (165) to
flange (101).
12) Aluminum rod = 11.8 mm, = 150 mm
A rod used to remove the outer races
of tapered roller bearings (22) from
spindle (2) and hold flange (3) and in-
stall them.

15) Hanging tool (i)


A tool used to install the set of swash
plate (103), cylinder block (104), pis-
ton (105), and shaft (102) to spindle
13) Jig to adjust preload on main bearing (2).
A jig used to press fit bearing (21) to
hub (1).
A jig used to measure the axial clear-
ance of bearing (21).

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DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR

16) Jig to fit floating seal (I)


A jig used to fit floating seal (31) to
hub (1).

17) Jig to fit floating seal (II)


A jig used to fit floating seal (31) to
hub (1) and spindle (2).

18) Jig to fit floating seal (III)


A jig used to fit floating seal (31) to
spindle (2).

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DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR

TIGHTENING TORQUE

Part No. Part name Thread size Q'ty Tightening torque

35 Hexagon socket head bolt M12 (P1.75) 10 102 15.7 Nm {10.4 1.6 kgm}

19 Reamer bolt M24 (P2.0) 3 686 49 Nm {70 5 kgm}

33 Hexagon socket head plug PT 1/2 2 98.1 19.6 Nm {10 2 kgm}

121 Plug M20 (P1.5) 1 78.5 9.8 Nm {8 1 kgm}

124 Plug M30 (P1.5) 2 353 39.2 Nm {36 4 kgm}

126 Plug M24 (P1.5) 2 127.5 14.7 Nm {13 1.5 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}

202 Sleeve PF 5/8 2 127.5 19.6 Nm {13 2 kgm}

204 Plug M18 (P1.5) 2 78.5 19.6 Nm {8 2 kgm}

214 Plug PF 1/2 1 98.1 19.6 Nm {10 2 kgm}

215 Plug PF 1/4 2 29.4 4.9 Nm {3 0.5 kgm}

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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.

2. General precautions for work


fl Since the disassembled internal parts are
coated with hydraulic oil, the are slippery.
Take care not to let them slip down to hurt
you or themselves.
fl Combustible liquid such as kerosene is used
to clean the parts. Handle it very carefully
since it can cause a fire and a burn on you.
1) Before disassembling the travel motor, con-
sider the inspection items, characteristics of
the detected trouble, etc. and then work ac-
cording to the given disassembly procedure.
2) Since the parts are made very precisely,
handle them carefully. Take care not to hit
them against each other or drop them.
3) If a firmly fitted part is removed by hitting or
prying it, it may have burrs or may be bro-
ken. As a result, it cannot be installed any
more and the performance may be lowered
by it. Work on such a part patiently.
4) If the travel motor is left disassembled partly
or perfectly, its parts may be rusted by mois-
ture and dust. Accordingly, if it is obliged to
interrupt the work, take rust-preventive mea-
sures and protect the parts from dust.
5) When disassembling, make match marks on
the mating faces of the parts.
6) Arrange the removed parts well so that they
will not be damaged or lost.
7) Replace each seal once the travel motor is dis-
assembled, as a rule. Accordingly, prepare
the all replacement seals before disassem-
bling.

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DISASSEMBLY OF TRAVEL MOTOR 5) Remove input gear (6).


ASSEMBLY (GM18VL) fl Take care not to lose ball (36) at the
end of the gear.
* The symbols of the tools are the reference 6) Remove the coupling.
Nos. in TOOLS. 7) Drain the oil from the reduction gear unit
and receive it with an oil pan.
Preparation work
Clean the travel motor assembly thoroughly
with a steam cleaner, etc.
fl When cleaning, plug the hydraulic ports
securely so that water will not enter them.

1. Travel motor assembly


Set the travel motor assembly to tool 2-1) or
2-2).

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.

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DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR

4) Remove plug (215) and piston (216). 4. Rear flange assembly


fl If the plug had not been loosened be- 1) Remove 8 bolts (143).
fore the valve was removed, grip the fl When disassembling the rear flange,
valve assembly and remove the plug. loosen the plug in advance.
2) Remove rear flange assembly (101) from
the spindle.
fl The shaft may be removed, too, at this
time. Take care.

5) Remove plug (215) and ball (216).

3) Remove timing plate (109), brake spring


(113), parallel pin (141), and ball bearing
(150) from the rear flange and hydraulic
motor.

6) Remove sleeve (202) from the valve body.


7) Remove plug (204), shim (205), retainer
(203), spring (206), and valve (201).

4) Remove both plugs (124), spring (126), re-


tainer (125), and spool (123) from rear
flange (101).

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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).

6) Remove valve (163) in the rear flange, if


necessary, according to the following pro-
cedure.
i) Put tool 2-10) in the cut of ring (165)
and hit it with a hammer to remove
ring (165).
ii) Direct the ring side down and remove
stopper (164), spring (166), and valve
(163).

6. Disassembly of motor section


1) Place an oil pan under the motor and set
the motor on its side to drain the oil from
the motor.
2) Move cylinder block (104) to the right and
left several times, and then remove it and
the piston together.
fl Before removing the cylinder block,
separate the shoe from the swash
5. Parking brake plate.
1) Supply air through the brake release port
of the spindle to remove piston (112).
fl If air is supplied quickly, the piston
jumps out. Take care.
fl Air pressure:
0.3 0.5 MPa {3 5 kg/cm2}

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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).

4) Remove pin (151) from cylinder block 7. Shaft


(104). 1) Remove shaft (102).
2) Remove 2 pivots (167) and 2 parallel pins
(171) from the spindle.

5) Set the cylinder block to a press and com-


press the spring with tool 2-4) to remove
snap ring (145). 8. 2nd travel speed selection piston
6) Release the spring and remove washer Remove piston (161), shoe (162), and spring
(110), spring (114), and washer (110). (191).

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DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR

9. Spur gear 3) Turn over the motor assembly.


1) Remove 3 snap rings (25) from crankshaft 4) Remove 3 snap rings (20) from hold flange
(9). (3).
2) Remove 3 spur gears (7) and distance fl Make match marks on the hold flange
piece (14) under the gear. and snap rings.
5) Remove 3 reamer bolts (19).
fl The reamer bolts are secured with ad-
hesive. When they are loosened, if the
adhesive is left on them, they may
cause seizure. Accordingly, loosen the
reamer bolts as slowly as possible. If
they become heavy halfway, do not
loosen them forcibly, but tighten them
again and then loosen them slowly
again.

6) Remove hold flange (3) from spindle (2).


fl Make match marks on the hold flange
and spindle.

10. Hold flange


1) Turn over the motor assembly.
2) Secure hub (1) and spindle (2) with tool
2-3).

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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).

2) Using tool 2-10), remove bearing (21) on


the opposite side from hub (1).

4) Remove floating seal (31) from spindle (2).


5) Using tool 2-12), remove the outer races
of tapered roller bearings (22) of the crank-
shaft.

13. Roller bearing and oil seal


fl Remove the roller bearing and oil seal only
when they need to be replaced. Once they
are removed, do not reuse them.
1) Drive out roller bearing (149) from the oil
seal side.
2) Drive out oil seal (132) from the opposite
side of the roller bearing fitting section.

12. RV gear assembly


fl If the bearing comes off, the RV gear and
pin fall. Accordingly, place a container to
receive them and spread a rubber mat,
etc. in it.
1) Hit pin (17) with tool 2-10) and pull down
ball bearing (21) to remove RV gear as-
sembly (4).
fl Hit 3 4 peripheral parts of the pin
lightly.

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DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR

14. Inner race of roller bearing


fl Remove the inner race only when it needs
to be replaced. Once it is removed, do
not reuse it.
fl When removing the roller bearing, be
sure to remove the inner race, too.
1) Support the flange of the inner race of
bearing (149) with tool 2-5) and push the
shaft with a press to remove the inner
race.
2) Remove collar (169).

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DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR

MAINTENANCE STANDARD TABLE

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).

Standard value Allowable value


Part No. Part name Trouble
(Standard dimension) (Criterion)

Spindle kit

(2) Spindle Part surface has visible serious


damage.
(3) Hold flange Part surface is scuffed or worn
easily.
(19) Reamer bolt

RV gear assembly

(4) RV gear (A) RV gear tooth surface is worn


(5) RV gear (B) unevenly.
(9) Crankshaft When crankshaft (9) is revolved,
(22) Tapered roller bearing each part does not move
(23) Needle roller bearing smoothly.

20 Snap ring Periphery or end faces are worn


abnormally.

21 Ball bearing There is bruise.


Surface is flaked.
Surface is worn unevenly.

Rear flange kit

(101) Rear flange Moving part against spool (123)


has flaw.
Clearance between rear flange Clearance Clearance
and spool is large. 10 20 25
Contact face against valve (127)
has flaw.
Depth to contact face against
valve (127) is large.
(123) Spool Outside surface has flaw.
Outside surface is worn unevenly.

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DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR

Standard value Allowable value


Part No. Part name Trouble
(Standard dimension) (Criterion)

102 Shaft Contact face against oil seal (132)


is worn.
Spline is worn.

104 Cylinder block Spline is worn.


Inside of bore is worn remarkably.
Sliding surface against timing
plate (109) is scratched and worn
unevenly.

Piston assembly

(105) Piston There is axial clearance between


piston (105) and shoe (106). Clearance: Clearance:
(106) Shoe
Shoe is worn abnormally. 0.05 mm 0.15 mm
Shoe is worn unevenly.

107 Retainer plate Periphery and end faces are worn


unevenly.

108 Thrust ball Spherical sliding parts against


retainer plate (107) is worn
unevenly.

109 Timing plate Sliding surface is seized and worn


unevenly.

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}

149 Deep groove ball There is bruise.


bearing
Surface is flaked.
150 Deep groove ball
bearing Surface is worn unevenly.

163 Valve Outside surface has flaw.

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DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR

Standard value Allowable value


Part No. Part name Trouble
(Standard dimension) (Criterion)

Body/Piston kit There are flaws on sliding surface Diametrical Diametrical


(212) Valve body against piston (213). clearance clearance
Clearance between valve body and 15 20 25
piston (213) is large.
(213) Piston There are flaws on periphery.
Periphery is worn unevenly.

Sleeve kit There are flaws on seat surface. Diametrical Diametrical


(202) Sleeve There are flaws on sliding surface clearance 7 12 clearance 20
against valve (201).
Clearance between sleeve and
valve (201) is large.
(201) Valve There are flaws on periphery.
Periphery is worn unevenly.

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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.

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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.

1. Ball bearing and floating seal (on hub side)


1) Install hub (1) to tool 2-1) or 2-2).

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).

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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.

4) Install 24 pins (17) between the pin


grooves of hub (1) and the tooth spaces
of the gear.

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.

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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.

5) Install 3 snap rings (20) to hold flange (3).


fl For how to select the thickness of the
snap ring after replacing the hold
flange, see ASSEMBLY, Adjustment
procedure.
3) Install the hold flange (3), matching the 6) Set the distance piece and install spur gear
match marks made when the hold flange (7) to the camshaft.
was removed. fl When installing the spur gear, set match
fl When replacing the hold flange, see mark "a" (punch hole) as shown in the
ASSEMBLY, Adjustment procedure. figure.

4) Tighten 3 reamer bolts (19) evenly little


by little.
fl If only 1 reamer bolt is tightened first,
the hold flange will slant and the
reamer bolts will be seized. Take care.
fl Degrease the reamer bolts thoroughly
before installing them.
2 Reamer part of reamer bolt:
Anti-friction compound (LM-P)
2 Threaded part of reamer bolt:
Adhesive (LT-2)
3 Reamer bolt:
686.5 49 m {70 5 kgm}

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).

5. Oil seal and roller bearing


1) Turn over the motor.
7. Pivot and parallel pin
2) Using tool 2-6), install oil seal (132) to
Install 2 parallel pins (171) and 2 pivots (167)
spindle (2).
to spindle (2).
2 Oil seal lip: Grease (G2-LI)

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.

3) Install 3 pins (151) to cylinder block (104).

4) Set washers (111) on pins (151) installed


in 3), and then install thrust ball (108).
5) Set piston (105) to retainer plate (107) and
install them to cylinder block (104).

9. Brake disc, plate, and piston


1) Install plate (117), and then install 2 discs
(115) and 2 plates (116) alternately.
2) Install piston (112) on which the O-ring
and buffer ring are set.

30-45-29 PC100,120,130-6
(10)
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR

3) Install spool (123), retainer (125), and


spring (126) to rear flange (101), and then
tighten plugs (124) on the right and left
sides.
3 Plug: 353 39.2 Nm {36 4 kgm}
fl Tighten the plugs to the specified
torque after installing the rear flange.

10. Rear flange assembly


1) Install valve (163) in the rear flange, spring
(166), and stopper (164) in order, and then
push in ring (165) to secure them.

4) Install ball bearing (150) to rear flange


(101).
2 Ball bearing: Engine oil (EO10-CD)
5) Set parallel pin (141) and install timing
plate (109).
fl Apply sufficient grease to the timing
plate so that it will not fall from the
rear flange.
6) Install 10 brake springs (113).
2) Install valve (127) and spring (130) to rear
flange (101) and tighten plugs (126) on the
right and left sides.
3 Plug: 127 14.7 Nm {13 1.5 kgm}
fl Tighten the plugs to the specified
torque after installing the rear flange.

PC100,120,130-6 30-45-30
(10)
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR

7) Matching the bolt holes, install rear flange


assembly (101) to spindle (2).
3 Mounting bolt:
57.8 9.8 Nm {5.9 1 kgm}

4) Set piston (213) to the valve body and in-


stall plug (214).
3 Plug: 98.1 19.6 Nm {10 2 kgm}
fl Tighten the plug to the specified
11. Relief valve torque after installing the valve body
1) Install valve (201), spring (206), retainer to the rear flange.
(203), and shim (205) to sleeve (202) and
tighten plug (204).
3 Plug: 78.5 19.6 Nm {8 2 kgm}
2) Install sleeve (202) to the valve body.
3 Sleeve: 127 19.6 Nm {13 2 kgm}
fl Tighten the sleeve to the specified
torque after installing the valve body
to the rear flange.

5) Install 2 balls (194) to the rear flange.


6) Install valve body (212) to the rear flange.
3 Mounting bolt:
29.4 4.9 Nm {3 0.5 kgm}
fl At this time, tighten the sleeves, plugs,
etc. which have not been tightened to
the specified torque.

3) Set ball (216) to the valve body and in-


stall plug (215).
3 Plug: 29.4 4.9 Nm {3 0.5 kgm}

30-45-31 PC100,120,130-6
(10)
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR

12. Cover PROCEDURE FOR ADJUSTING REPLACED


1) Set the coupling and install input gear (6). PARTS
2) Apply grease (G2-LI) to ball (36) and in- 1. Procedure for adjusting thickness of hold
stall it to the end of input gear (6). flange (3) after replacing hub (1), spindle kits
3) Add lubricating oil. (2), (3), and (19), and main ball bearing (21)
5 Engine oil (EO30-CD): 2.5
1) Perform assembly procedures 1 through
4) Install eyebolts to the drain plug hole and 4-1).
level plug hole and install cover (8). 2) Install pre-load adjusting tool 2-13) for ball
bearing (21) to spindle (2).
3) Tighten special nut b of the pre-load ad-
justing tool to the specified torque.
3 Special nut:
88.3 19.8 Nm {9 2 kgm}

5) Tighten 10 mounting bolts (35).


3 Mounting bolt:
102 15.7 Nm {10.4 1.6 kgm}

4) Measure depth A with a depth microme-


ter through the measurement hole of the
pre-load adjusting tool.
5) Since dimension B of the pre-load adjust-
ing tool is known, obtain clearance C by
the following formula.
fl C = A B
A: Measured value
B : Dimension of tool body
C : Clearance
6) Wind sealing tape onto drain plug (33) and
level plug (33) and install them.
fl Tighten each plug so that the level dif-
ference between the threaded part
and cover end will be 1 thread.

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)

1) Perform assembly procedures 1 through


4-4).
2) Install the 3 outer races to tapered roller
bearings (22) of crankshaft (9) of the RV
gear assembly and hit them lightly with
toll 2-7) and a hammer.

7) Adjust the thickness of the hold flange


from the measurement results in 2) - 6),
according to the following procedure.
Dimension C is the "specified dimen-
sion" of the hold flange.
Adjust D to C 0.02 mm.
i) When actual dimension "D" of hold
flange (3) is smaller than specified di-
mension
fl Shave "face E" of the hold flange
to the specified dimension with a 3) Fit thinnest snap ring (20) to the snap ring
lathe, etc. groove of hold flange (3).
ii) When actual dimension "D" of hold 4) Hit the periphery of snap ring (20) lightly
flange is in the tolerance of the speci- with tool 2-7) and the hammer.
fied dimension fl Perform this procedure to check that
fl Use the hold flange as it is. the RV gear assembly is inserted in
iii) When actual dimension "D" of hold spindle (2) securely.
flange (3) is larger than specified di-
mension
fl Replace the spindle assembly with
new one. Some adjustment al-
lowance is always given to the
hold flange (3) of the new spindle
assembly.
8) Remove the pre-load adjusting tool from
the spindle.

30-45-33 PC100,120,130-6
(10)
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR

5) Measure the clearance between snap ring


(20) and the outer race of tapered roller
bearing (22) with a feeler gauge.

6) Selection of thickness of snap ring


Set thickness of snap ring (MAX)
MAX = Thickness of feeler gauge +
Thickness of snap ring cur-
rently inserted
Set thickness of snap ring (MIN)
MIN = (Thickness of feeler gauge) +
(Thickness of snap ring cur-
rently inserted) 0.05
7) After deciding the snap ring thickness,
select proper one from the snap rings of
12 kinds and set it to the hold flange.
fl See clearance adjusting parts list

PC100,120,130-6 30-45-34
(10)
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR

CLEARANCE ADJUSTING PARTS LIST

Part name Dimension

Snap ring [20]


Class symbol Dimension t

A Above 2.20, below 2.25

B Above 2.25, below 2.30

C Above 2.30, below 2.35

D Above 2.35, below 2.40

E Above 2.40, below 2.45

F Above 2.45, below 2.50

G Above 2.50, below 2.55

H Above 2.55, below 2.60

I Above 2.60, below 2.65

J Above 2.65, below 2.70

K Above 2.70, below 2.75

L Above 2.75, below 2.80

30-45-35 PC100,120,130-6
(10)
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR

PERFORMANCE CONFIRMATION TEST

After maintaining the GM motor, test its performance according to the following procedure.

1. Necessary measuring instruments

1 Pressure gauge (For 3.43 MPa {35 kg/cm2}) 2 pcs.

2 Measuring cylinder (For 5 liters) 1 pc.

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].

Notes) 1. Pipe the GM motor so that a pressure gauge (main circuit)


can be installed and the draining rate of the hydraulic motor
can be measured.
2. Do not install the GM motor by hitting it with a hammer, etc.
but install it carefully by utilizing the bolt holes.

2 Running-in of e ..................... e Speed of GM motor Pressure Revolving direction Operating time


GM motor 1 10 rpm 1 minute or
No load Right/Left more for each
2 20 rpm test

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

Install track. Disassemble and adjust again.

PC100,120,130-6 30-45-36
(10)
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK

10. Disconnect hydraulic tank inlet hose (16).

11. Disconnect wiring connectors (17), remove


bracket (18) tightened together with tube, then
remove control pump inlet tube (19).

12. Remove main pump suction tube (20).

PC120-6 Serial No. : 70001 and up


13. Remove mounting bolts, and lift off hydraulic tank
assembly (21). 1
4 Hydraulic tank assembly : 120 kg

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}

Refilling with oil (hydraulic tank)


fl Add oil through the oil filler to the specified
level. Run the engine to circulate the oil
through the system. Then check the oil level
again.

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

REMOVAL OF CONTROL PUMP


ASSEMBLY
Lower the work equipment completely to the
ground and stop the engine. Then loosen the
oil filler cap slowly to release the pressure in-
side the hydraulic tank.

Remove the hydraulic tank strainer, and using tool


B, stop the oil.
When not using tool B, remove the drain plug,
and drain the oil from the hydraulic tank and in-
side the system.
6 Hydraulic tank : Approx. 100

1. Disconnect wiring connectors (1), remove bracket


(2) tightened together with tube, then remove
control pump inlet tube (3).

2. Disconnect control pump outlet hose (4).

3. Remove branch hose (5).

4. Remove control pump assembly (6), then remove


coupling (7). 1

PC120-6 Serial No. : 70001 and up

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}

Refilling with oil (hydraulic tank)


fl Add oil through the oil filler to the specified
level. Run the engine to circulate the oil
through the system. Then check the oil level
again.

PC100,120,130-6 30-85
(11)
DISASSEMBLY AND ASSEMBLY MAIN PUMP

REMOVAL OF MAIN PUMP


ASSEMBLY
Disconnect the cable from the negative () ter-
minal of the battery.
Lower the work equipment completely to the
ground and stop the engine. Then loosen the
oil filler cap slowly to release the pressure in-
side the hydraulic tank.
Remove the hydraulic tank strainer, and using tool
B, stop the oil.
When not using tool B, remove the drain plug,
and drain the oil from the hydraulic tank and in-
side the system.
6 Hydraulic tank : Approx. 100

1. Drain oil from PTO gear case.

6 PTO gear case : Approx. 0.75

2. Open engine hood, and remove main pump top


cover, then remove exhaust muffler cover (1) and
insulator (2).

3. Disconnect connecting pipe portion at turbo-


charger end, and remove exhaust muffler (3) to-
gether with bracket.

4. Disconnect wiring connectors (4), remove bracket


(5) tightened together with tube, then remove
control pump suction tube (6).

5. Disconnect main pump suction tube (7).

6. Remove branch hose (8).

7. Disconnect control pump outlet hose (9).

8. Disconnect main pump outlet hose (10).

9. Disconnect main pump drain hose (11).

10. Disconnect LS pressure input hose (12).

11. Disconnect hose (13).

12. Disconnect EPC valve basic pressure hose.


PC120-6 Serial No. : 70001 and up

30-86 PC100,120,130-6
(11)
DISASSEMBLY AND ASSEMBLY MAIN PUMP

13. Disconnect ground connection (15).

14. Remove exhaust drain pipe (16).

15. Remove bracket (17), then remove 2 mounting


bolts, and move governor motor bracket assem-
bly (18) towards counterweight end.

PC120-6 Serial No. : 70001 and up


16. Sling main pump assembly (19), remove mount-
ing bolts, then use forcing screws 1 to remove.
1
2 Main pump assembly : 90 kg

INSTALLATION OF MAIN PUMP


ASSEMBLY
Carry out installation in the reverse order to re-
moval.

1
2 Mating surface of pump case :
Gasket sealant (LG-6)

Refilling with oil (PTO gear case)


fl Add engine oil through the oil filler to the
specified level.

Refilling with oil (hydraulic tank)


fl Add oil through the oil filler to the specified
level. Run the engine to circulate the oil
through the system. Then check the oil level
again.

Bleeding air
fl Bleed the air from main pump. For details, see
TESTING AND ADJUSTING, Bleeding air.

PC100,120,130-6 30-87
(11)
DISASSEMBLY AND ASSEMBLY PC, LS-EPC VALVE

REMOVAL OF PC, LS-EPC


VALVE ASSEMBLY
1. Remove bottom cover of main pump assembly.

2. Disconnect wiring connector (1).

3. Disconnect hoses (2) and (3).

4, Remove PC-EPC valve assembly (4) and LS-EPC


valve assembly (3). 1

PC120-6 Serial No. : 70001 and up

INSTALLATION OF PC, LS-EPC


VALVE ASSEMBLY
Carry out installation in the reverse order to re-
moval.

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
(11)
MAINTENANCE STANDARD TRACK SHOE

TRIPLE SHOE

Unit: mm

No. Check item Criteria Remedy

Standard size Repair limit

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
(11)
MAINTENANCE STANDARD TRACK SHOE

TRIPLE SHOE
PC120-6 Serial No. : 70001 and up`
PC120LC-6 Serial No. : 70001 and up

Unit: mm

No. Check item Criteria Remedy

Standard size Repair limit


1 Height of grouser
20 10

2 Overall height of shoe 29.5 19.5

Repair by
3 Thickness 9.5 build-up
welding or
replace
4 14

5 Length of grouser top 13

6 15

PC100,120,130-6 40-14-1
(11)
MAINTENANCE STANDARD TRACK SHOE

RUBBER SHOE

Unit: mm

No. Check item Criteria Remedy

Standard clearance Repair limit


1 Wear of lug height
38 15

2 Wear of roller guard portion 116 94


Replace

3 Wear of meshing portion of 3 2


sprocket

4 Wear of contacting portion 28.5 22.5


of roller

40-16 PC100,120,130-6
(11)
90 OTHER

Hydraulic circuit diagram


PC100-6 Serial No. : 45221 46058
PC100L-6 Serial No. : 15200 46058
PC120-6 Serial No. : 57499 60967
PC130-6 Serial No. : 51020 51479 ................ 90- 3
Hydraulic circuit diagram
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 ................. 90- 5
Hydraulic circuit diagram
PC120-6 Serial No. : 70001 and up ..................... 90-5-2
Electrical circuit diagram (1/2)
PC100-6 Serial No. : 45221 46058
PC100L-6 Serial No. : 15200 46058
PC120-6 Serial No. : 57499 60967
PC130-6 Serial No. : 51020 51479 ................ 90- 7
Electrical circuit diagram (2/2)
PC100-6 Serial No. : 45221 46058
PC100L-6 Serial No. : 15200 46058
PC120-6 Serial No. : 57499 60967
PC130-6 Serial No. : 51020 51479 .................. 90-9
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 ................. 90-11
Electrical circuit diagram (2/2)
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 ................. 90-13
Electrical circuit diagram (1/2)
PC120-6 Serial No. : 70001 and up ...................... 90-15
Electrical circuit diagram (2/2)
PC120-6 Serial No. : 70001 and up ...................... 90-17

PC100,120,130-6 90-1
(11)
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
(11)
HYDRAULIC CIRCUIT DIAGRAM
PC120-6 Serial No. : 70001 and up

PC100,120,130-6 90-5-2
(11)
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
(11)
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
(11)
ELECTRICAL CIRCUIT DIAGRAM (1/2)
PC120-6 Serial No. : 70001 and up

PC100,120,130-6 90-15
(11)
ELECTRICAL CIRCUIT DIAGRAM (2/2)
PC120-6 Serial No. : 70001 and up

PC100,120,130-6 90-17
(11)