Komatsu Excavator PC120-8 service & repair manual

Description Komatsu Excavator PC120-8 service & repair manual

Komatsu Hydraulic Excavator PC120-8 pdf workshop service repair manual

Serial numbers:
80001 and up

Specifications, testing, troubleshooting, maintenance, technical data, electrical diagrams, hydraulic schematics, adjusting, assembly, disassembly, removal, installation instructions and other information

MANUAL CONTENT:
Index and foreword
Foreword and general information
Safety notice
How to read the shop manual
Explanation of terms for maintenance standard
Handling of electric equipment and hydraulic component
Handling of connectors newly used for engines
How to read electric wire code
Precautions when carrying out operation
Method of disassembling and connecting push-pull type coupler
Standard tightening torque table
Conversion table

Specification
Specification and technical data
Specification dimension drawings
Working range diagram
List of weights
List of lubricant and coolant to be filled

Structure, function and maintenance standard
Engine and cooling system
Engine mount
PTO
Cooling system
Power train
Swing circle
Swing machinery
Undercarriage and frame
Track frame
Idler cushion
Idler
Track roller
Carrier roller
Sprocket
Track shoe
Hydraulic system
Hydraulic equipment layout drawing
Valve control
Hydraulic tank and filter
Hydraulic pump
Control valve
CLSS
Functions and operation by valve
PPC valve
Swing motor
Travel motor
Center swivel joint
Solenoid valve
Accumulator
Holding valve
Hydraulic cylinder
Work equipment
Dimensions of components
Cab and its attachments
Air conditioner
Electrical system
Electronic control system
Machine monitor system
KOMTRAX system
Sensor

Standard value table
Standard service value table
Standard value table for engine related parts
Standard value table for chassis related parts

Testing and adjusting
Related information on testing and adjusting
Tools for testing, adjusting, and troubleshooting
Sketches of special tools
Engine and cooling system
Testing engine speed
Testing exhaust temperature
Checking exhaust gas color
Adjusting valve clearance
Testing compression pressure
Testing blow-by pressure
Testing engine oil pressure
Reduced cylinder mode operation
No-injection cranking
Handling fuel system parts
Releasing residual pressure from fuel system
Testing fuel pressure
Testing fuel return rate and fuel leakage
Bleeding air from fuel circuit
Checking fuel circuit for leakage
Testing and adjusting alternator belt tension
Checking and adjusting air conditioner compressor belt tension
Power train
Testing swing circle bearing clearance
Undercarriage and frame
Checking and adjusting track shoe tension
Hydraulic system
Testing and adjusting oil pressure in work equipment, swing, and travel circuits
Testing control circuit basic pressure
Testing and adjusting oil pressure in pump PC control circuit
Testing and adjusting oil pressure in pump LS control circuit
Testing solenoid valve output pressure
Testing PPC valve output pressure
Adjusting play of work equipment and swing PPC valves
Checking parts which cause hydraulic drift of work equipment
Testing and adjusting travel deviation
Releasing residual pressure from hydraulic circuit
Testing oil leakage
Bleeding air from each part
Cab and its attachments
Checking cab tipping stopper
Installation and adjustment of mirrors and camera
Inspection of air conditioner Recirc/Fresh air filter
Electrical system
Special functions of machine monitor
Handling voltage circuit of engine controller
Preparation work for troubleshooting of electrical system
Procedure for testing diodes
Pm-Clinic
Pm Clinic service

Troubleshooting
Related information on troubleshooting
Points to remember when performing troubleshooting
How to proceed in troubleshooting
Checks before troubleshooting
Classification and procedures for troubleshooting
Information described in troubleshooting table
Phenomena looking like troubles and troubleshooting Nos
Connection table of connector by No. of pins
T-box and T-adapter list
Failure code table
Fuse locations
Troubleshooting by failure code
Troubleshooting of electrical system (E-mode)
Troubleshooting of hydraulic and mechanical system (H-mode)
Troubleshooting of engine (S-mode)

Disassembly and assembly
General information on disassembly and assembly
How to read this manual
Coating materials list
Special tool list
Sketch of special tool
Engine and cooling system
Removal and installation of fuel supply pump assembly
Removal and installation of fuel injector assembly
Removal and installation of front oil seal
Removal and installation of rear oil seal
Removal and installation of cylinder head assembly
Removal and installation of radiator assembly
Removal and installation of aftercooler assembly
Removal and installation of work equipment oil cooler assembly
Removal and installation of engine and work equipment pump assembly
Removal and installation of fuel tank assembly
Power train
Removal and installation of travel motor and final drive assembly
Disassembly and assembly of travel motor and final drive assembly
Removal and installation of swing motor and swing machinery assembly
Disassembly and assembly of swing machinery assembly
Removal and installation of swing circle assembly
Undercarriage and frame
Disassembly and assembly of track roller
Disassembly and assembly of idler assembly
Disassembly and assembly of recoil spring
Spreading and installation of track shoe assembly
Removal and installation of sprocket
Removal and installation of revolving frame assembly
Removal and installation of counterweight assembly
Hydraulic system
Removal and installation of center swivel joint assembly
Disassembly and assembly of center swivel joint assembly
Removal and installation of hydraulic tank assembly
Removal and installation of work equipment pump assembly
Removal and installation of control valve assembly
Disassembly and assembly of control valve assembly
Disassembly and assembly of work equipment PPC valve assembly
Disassembly and assembly of travel PPC valve assembly
Disassembly and assembly of hydraulic cylinder assembly
Work equipment
Removal and installation of work equipment assembly
Cab and its attachments
Removal and installation of operator's cab assembly
Removal and installation of operator cab glass (stuck glass)
Removal and installation of front window assembly
Removal and installation of floor frame assembly
Electrical system
Removal and installation of air compressor assembly
Removal and installation of air conditioner condenser
Removal and installation of air conditioner unit assembly
Removal and installation of KOMTRAX communication modem assembly
Removal and installation of monitor assembly
Removal and installation of pump controller assembly
Removal and installation of engine controller assembly

Diagrams and drawings
Hydraulic diagrams and drawings
Symbols used in hydraulic circuit diagrams
Electrical diagrams and drawings
Symbols used in electric circuit diagrams
Connectors table and arrangement drawing

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