Pc100 & 120-6 Sebm010611

SEBM010611

MACHINE MODEL

SERIAL NUMBER

PC100-6 PC100L-6 PC120-6 PC120LC-6 PC130-6

45221 and up 15200 and up 57499 and up 65504 and up 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 require. 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 Printed in Japan 04-02(02)

00-1 (11)

CONTENTS No. of page

01

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

10

STRUCTURE AND FUNCTION

20

TESTING AND ADJUSTING

30

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

40

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

90

OTHERS

00-2 3

........................................................... 10-1

................................................................ 20-1

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

PC100,120,130-6

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(11) (6) (11) (11) (6) (6) (11) (11) (11) (11)

PC100,120,130-6

GENERAL

SPECIFICATIONS

Machine model

PC100-6

PC100L-6

Serial Number

45221 and up

15200 and up

Model Type

Performance

Engine

No. of cylinders-bore x stroke Piston displacement Flywheel horsepower Maximum torque High idling speed Low idling speed Min. fuel consumption ratio

mm ¬ {cc}

S4D102-1 4-cycle, water-cooled, in-line, vertical, direct injection, with turbocharger 4–102 × 120 3.92 {3,920}

kW/rpm {HP/rpm} Nm/rpm {kgm/rpm} rpm rpm g/kWh {g/HPh}

60.3/2,100 {82/2,100} 328.5/1,300 {33.5/1,300} 2,300 900 224 {165} 24V, 4.5 kW 24V, 25A 12V, 80Ah × 2 CF19-4

Carrier roller Track roller Track shoe

1 on each side 1 on each side 6 on each side 6 on each side Assembly-type triple Assembly-type triple grouser, 40 on each side grouser, 43 on each side

Control Hydraulic Hydraulic motor valve pump

Radiator type

Hydraulic cylinder

Hydraulic system

Undercarriage

Starting motor Alternator Battery

Type × no. Delivery Set pressure

¬/min MPa {kg/cm2}

HPV95 + BAR020 Variable displacement piston type × 1 + gear type × 1 197 + 32.9 Piston type: 31.9 {325}, gear type: 2.9 {30}

Type × no. Control method

7-spool type × 1 Hydraulic type GM18VL Variable displacement piston type (with brake valve,parking brake) × 2

Travel motor

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

Swing motor

Boom cylinder Type Inside diameter of cylinder Diameter of piston rod Stroke Max. distance between pins Min. distance between pins

Hydraulic tank Hydraulic oil filter Hydraulic oil cooler

PC100,120,130-6

HMV110-2 Variable displacement piston type (with brake valve,parking brake) × 2

mm mm mm mm mm

Arm cylinder

×1

Bucket cylinder

Double-acting piston Double-acting piston Double-acting piston 95 115 90 65 75 60 980 1,005 885 2,470 2,877 2,263 1,490 1,702 1,378 Box-shaped, open Tank return side Air cooled (3A-CS)

01-9 8

GENERAL

SPECIFICATIONS

PC120-6 Machine model

PC120-6

Serial Number m3

0.50

0.50

Operating weight

kg

11,700

11,700

Max. digging depth

mm

5,520

5,520

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

Max. dumping height

mm

6,170

6,170

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

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

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 min. swing radius

mm

6,440

6,440

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

Working ranges Performance Dimensions

70001 and up

Bucket capacity (SAE)

Max. digging force

Ground pressure (standard shoe width: 500 mm)

01-10 (11)

57499 – 70000

PC100,120,130-6

GENERAL

SPECIFICATIONS

Machine model

PC120-6

Serial Number Model Type

Performance

Engine

No. of cylinders-bore x stroke Piston displacement

57499 – 70000

70001 and up

S4D102-1 4-cycle, water-cooled, in-line, vertical, direct injection, with turbocharger

SAA4D102E-2 4-cycle, water-cooled, in-line, vertical, direct injection, with turbocharger and aftercooler

4–102 × 120 3.92 {3,920}

mm ¬ {cc}

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

24V, 4.5 kW 24V, 25A 12V, 64Ah × 2

Hydraulic motor Hydraulic cylinder

Hydraulic system

CF19-4 1 on each side 7 on each side Assembly-type triple grouser, 42 on each side

Carrier roller Track roller Track shoe

Control Hydraulic pump valve

Undercarriage

Radiator type

Type × no. Delivery Set pressure

HPV95 + BAR020 Variable displacement piston type × 1 + gear type × 1 ¬/min MPa {kg/cm2}

Type × no. Control method

197 + 32.9 Piston type: 31.9 {325} Gear type: 2.9 {30}

226 + 45 Piston type (at travel) : 34.8 {355} Piston type (at work equipment) : 31.9 {325} Gear type : 2.9 {30}

7-spool type × 1 Hydraulic type

6-spool type × 1 Hydraulic type

Travel motor

GM18VL Variable displacement piston type (with brake valve,parking brake) × 2

Swing motor

KMF40ABE-3 Fixed displacement piston type (with safety valve,parking brake) × 1 Boom cylinder

Type Inside diameter of cylinder Diameter of piston rod Stroke Max. distance between pins Min. distance between pins

Hydraulic tank Hydraulic oil filter Hydraulic oil cooler

PC100,120,130-6

mm mm mm mm mm

Double-acting piston 105 70 990 2,490 1,500

Arm cylinder

Bucket cylinder

Double-acting piston Double-acting piston 115 95 75 65 1,175 885 2,877 2,263 1,702 1,378 Box-shaped, open Tank return side Air cooled (3A-CS)

01-11 (11)

GENERAL

SPECIFICATIONS

PC120LC-6 Machine model

PC120LC-6

Serial Number m3

0.50

0.50

Operating weight

kg

12,600

12,600

Max. digging depth

mm

5,480

5,480

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

Max. dumping height

mm

6,210

6,210

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

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

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 min. swing radius

mm

6,480

6,480

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

Working ranges Performance

70001 and up

Bucket capacity (SAE)

Max. digging force

Ground pressure (standard shoe width: 500 mm)

Dimensions

65504 – 70000

01-11-1 (11)

PC100,120,130-6

GENERAL

SPECIFICATIONS

Machine model

PC120LC-6

Serial Number Model Type

Performance

Engine

No. of cylinders-bore x stroke Piston displacement

65504 – 70000

70001 and up

S4D102-1 4-cycle, water-cooled, in-line, vertical, direct injection, with turbocharger

SAA4D102E-2 4-cycle, water-cooled, in-line, vertical, direct injection, with turbocharger and aftercooler

4–102 × 120 3.92 {3,920}

mm ¬ {cc}

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

24V, 4.5 kW 24V, 25A 12V, 92Ah × 2

Hydraulic motor Hydraulic cylinder

Hydraulic system

CF19-4 2 on each side 8 on each side Assembly-type triple grouser, 46 on each side

Carrier roller Track roller Track shoe

Control Hydraulic pump valve

Undercarriage

Radiator type

Type × no. Delivery Set pressure

HPV95 + BAR020 Variable displacement piston type × 1 + gear type × 1 ¬/min MPa {kg/cm2}

Type × no. Control method

197 + 32.9 Piston type: 31.9 {325} Gear type: 2.9 {30}

226 + 45 Piston type (at travel) : 34.8 {355} Piston type (at work equipment) : 31.9 {325} Gear type : 2.9 {30}

7-spool type × 1 Hydraulic type

6-spool type × 1 Hydraulic type

Travel motor

GM18VL Variable displacement piston type (with brake valve,parking brake) × 2

Swing motor

KMF40ABE-3 Fixed displacement piston type (with safety valve,parking brake) × 1 Boom cylinder

Type Inside diameter of cylinder Diameter of piston rod Stroke Max. distance between pins Min. distance between pins

Hydraulic tank Hydraulic oil filter Hydraulic oil cooler

PC100,120,130-6

mm mm mm mm mm

Double-acting piston 105 70 990 2,490 1,500

Arm cylinder

Bucket cylinder

Double-acting piston Double-acting piston 115 95 75 65 1,175 885 2,877 2,263 1,702 1,378 Box-shaped, open Tank return side Air cooled (3A-CS)

01-11-2 (11)

GENERAL

WEIGHT TABLE

PC120-6

Unit : kg Machine model Serial Number

PC120-6 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

1,240 79 x 2 72 x 2 11 x 2 21.8 x 14 136.5 x 2 33.7 x 2

1,240 79 x 2 72 x 2 11 x 2 21.8 x 14 136.5 x 2 33.7 x 2

Track frame assembly • Track frame • Idler • Idler cushion • Carrier roller • Track roller • Travel motor • final drive assembly • Sprocket

01-16 (11)

PC100,120,130-6

GENERAL

WEIGHT TABLE

Unit : kg Machine model Serial Numbe

PC120-6 57499 – 70000

70001 and up

• 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

Track shoe assembly

• Swamp shoe (860 mm)

—

—

• Rubber shoe (500 mm)

845 x 2

845 x 2

—

—

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

108.5 x 2

108.5 x 2

144.9

144.9

87.4

87.4

• Large hole triple grouser shoe (500 mm) • Road liner (rubber pad type) (500 mm)

Boom cylinder assembly Arm cylinder assembly Bucket cylinder assembly

PC100,120,130-6

01-17 (11)

GENERAL

WEIGHT TABLE

PC120LC-6

Unit : kg Machine model Serial Number

PC120LC-6 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

1,532 79 x 2 74.2 x 2 11 x 4 21.8 x 16 136.5 x 2 33.7 x 2

1,532 79 x 2 74.2 x 2 11 x 4 21.8 x 16 136.5 x 2 33.7 x 2

Track frame assembly • Track frame • Idler • Idler cushion • Carrier roller • Track roller • Travel motor • final drive assembly • Sprocket

01-17-1 (11)

PC100,120,130-6

GENERAL

WEIGHT TABLE

Unit : kg Machine model Serial Numbe

PC120LC-6 65504 – 70000

70001 and up

• 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

108.5 x 2

108.5 x 2

144.9

144.9

87.4

87.4

Track shoe assembly

Boom cylinder assembly Arm cylinder assembly Bucket cylinder assembly

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. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Radiator cap Radiator Radiator inlet hose Fan guard Radiator outlet hose Fan Drain valve Shroud Oil cooler Reservoir tank

PC100,120,130-6

SPECIFICATIONS Radiator • Core type: CF19-4 • Fine pitch: 3.5/2 mm • Fan guard • Total heat dissipation surface: 34.06 m2 • Pressure valve cracking pressure: 49.03 kPa {0.5 kg/cm2} • Vacuum valve cracking pressure: –4.9 kPa {–0.05 kg/cm2}

Oil cooler • Core type: 3A-CS • Fine pitch: 3.5 mm • Total heat dissipation surface: 12.27 m2 fl The oil cooler is a hinged type, if the 4 mounting bolts are removed, it can opened to make it easier to clean the radiator.

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. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Radiator cap Radiator Radiator inlet hose Fan guard Radiator outlet hose Drain valve Shroud Oil cooler Aftercooler Reservoir tank

A: Oil inlet port B : Oil outlet port

10-3-1 (11)

SPECIFICATIONS Radiator • Core type: CF19-4 • Fine pitch: 3.5/2 mm • Fan guard • Total heat dissipation surface: 34.06 m2 • Pressure valve cracking pressure: 43.03 kPa {0.5 kg/cm2} • Vacuum valve cracking pressure: –4.9 kPa {–0.05 kg/cm2}

Oil cooler • Core type: CF40-1 • Fine pitch: 4.5/2 mm • Total heat dissipation surface: 8.79 m2 After cooler • Core type: F & T • Fine pitch: 3.5/2 mm (Cooling side) 2.75/2 mm (Boost side)

PC100,120,130-6

STRUCTURE AND FUNCTION

PTO

PTO (COUPLING)

1. 2. 3. 4.

Shaft Coupling Breather Cage

10-4

5. Hydraulic pump 6. Oil filler plug 7. Level plug

PC100,120,130-6

STRUCTURE AND FUNCTION

POWER TRAIN

POWER TRAIN PC100, 120, 120LC, 130-6

1. 2. 3. 4. 5. 6. 7.

Idler Center swivel joint Swing motor (KMF40ABE-3) Control valve Swing brake solenoid valve Travel speed solenoid valve Final drive

PC100,120,130-6

8. 9. 10. 11. 12. 13. 14.

Sprocket Travel motor (GM18VL) Control pump (BAR020) Hydraulic pump (HPV95) Engine Swing machinery Swing circle

10-5 (11)

STRUCTURE AND FUNCTION

HYDRAULIC PIPING DRAWING

ª1. PC100-6 PC100L-6 PC120-6 PC120LC-6 PC130-6

Serial No. : 46059 and up Serial No. : 46059 and up Serial No. : 60968 and up Serial No. : 65504 and up Serial No. : 51480 and up

ª2. 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

PC100,120,130-6

ACTUAL ELECTRIC WIRING DIAGRAM

10-127 (11)

STRUCTURE AND FUNCTION

10-128 6

ACTUAL ELECTRIC WIRING DIAGRAM

PC100,120,130-6

STRUCTURE AND FUNCTION

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. ª1 33. ª1 34. 35. 36. 37. 38. 39. 40.

ACTUAL ELECTRIC WIRING DIAGRAM

ª1. PC100-6 PC100L-6 PC120-6 PC130-6

Serial No. : 45221 –␣ 46058 Serial No. : 15200 –␣ 46058 Serial No. : 57499 –␣ 60967 Serial No. : 51020 –␣ 51479

ª2. PC100-6 PC100L-6 PC120-6 PC120LC-6 PC130-6

Serial No. : 46059 and up Serial No. : 46059 and up Serial No. : 60968 and up Serial No. : 65504 and up Serial No. : 51480 and up

Working lamp Fuel level sensor Additional front lamp R.H. auto pull-up lock Room lamp Antenna Starting motor Auto pull-up motor Alternator Pump pressure sensor Coolant level sensor Fusible link (3) Battery relay Battery Air cleaner clogging sensor PPC hydraulic switch (8) L.H. auto pull-up lock Horn Wiper motor Window washer Front lamp Active mode solenoid valve 2-stage relief solenoid valve Swing brake solenoid valve Travel speed solenoid valve Coolant temperature sensor Governor motor Engine speed sensor Heater relay Engine oil pressure sensor Engine oil level sensor Fuse box Relay for light Relay for additional light Alarm buzzer Starting switch Fuel control dial Radio Cigarette lighter Swing lock switch

PC100,120,130-6

41. 42. 43. 44. 45. 46. 47. 48. 49. 50. 51. 52. 53. 54. 55. ª2 56.

ª3, ª4 PC120-6 Serial No. : 70001 and up PC120LC-6 Serial No. : 70001 and up

Wiper switch Light switch Buzzer cancel switch Air conditioner control panel Auto pull-up switch Service meter Speaker Engine throttle controller L.H. knob switch Prolix resistor Wiper, auto pull-up controller Horn switch Monitor panel Swing prolix switch PC prolix switch Swing stroke limit solenoid valve

10-128-1 (11)

STRUCTURE AND FUNCTION

ELECTRICAL CIRCUIT DIAGRAM

ELECTRICAL CIRCUIT DIAGRAM CHASSIS ELECTRICAL CIRCUIT DIAGRAM

(1/2) PC100-6 PC100L-6 PC120-6 PC130-6

Serial No. Serial No. Serial No. Serial No.

: 45221 –␣ 46058 : 15200 –␣ 46058 : 57499 –␣ 60967 : 51020 –␣ 51479

fl For details of this page, see section 90.

10-128-2 6

PC100,120,130-6

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 PC100L-6 PC120-6 PC120LC-6 PC130-6

Serial No. : 46059 and up Serial No. : 46059 and up Serial No. : 60968 – 70000 Serial No. : 65504 – 70000 Serial No. : 51480 and up

fl For details of this page, see section 90.

10-128-4 (11)

PC100,120,130-6

STRUCTURE AND FUNCTION

ENGINE CONTROL SYSTEM

ENGINE CONTROL SYSTEM ª1. PC120-6 Serial No. : 70001 and up PC120LC-6 Serial No. : 70001 and up

1. Starting motor 2. Fuel control dial 3. Engine throttle • Pump controller 4. Battery relay 5. Battery 6. Governor motor 7. Loose spring 8. Fuel injection pump

FUNCTION • •

•

10-130 (11)

The engine can be started and stopped simply by using the starting switch. A dial type engine control is used to control the engine speed. The engine throttle pump controller receives the control signal from the fuel control dial, sends a drive signal to the 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.

PC100,120,130-6

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 discharge 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 Heavy-duty operation (H/O)

PC120, 130 ª 58.8 kW/1,900 rpm 62.5 kW/2,200 rpm 64.7 kW/2,000 rpm {79 HP/1,900 rpm} {84 HP/2,200 rpm} {87 HP/2,000 rpm} PC100

ª 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 General operation (G/O), Finishing operation (F/O)

PC100

PC120, 130

ª 47.8 kW/1,720 rpm 47.8 kW/1,900 rpm 51.5 kW/1,800 rpm {64 HP/1,720 rpm} {64 HP/1,900 rpm} {69 HP/1,800 rpm}

ª PC120 Serial No. : 70001 and up

10-140 (11)

PC100,120,130-6

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 Lifting operation (L/O)

PC120, 130 ª 33.1 kW/14.20 rpm 33.1 kW/1,600 rpm 36.8 kW/1,500 rpm {44 HP/1,420 rpm} {41 HP/1,600 rpm} {49 HP/1,500 rpm} PC100

ª 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 engine is used in a range that provides a much better fuel consumption ratio than for the general operation mode or finishing operation mode. Model Breaker operation (B/O)

PC120, 130 ª 47.8 kW/1,720 rpm 47.8 kW/1,750 rpm 51.5 kW/1,800 rpm {64 HP/1,720 rpm} {64 HP/1,750 rpm} {69 HP/1,800 rpm} PC100

ª PC120 Serial No. : 70001 and up

PC100,120,130-6

10-141 (11)

20 TESTING AND ADJUSTING

Standard valve table for engine related parts ............................................................ 20- 2 Standard table for chassis related parts ..... 20- 3 Standard table for electrical parts ............... 20-14 Tool for testing, adjusting, and troubleshooting .......................................... 20-23 Measuring engine speed ............................. 20-24 Measuring exhaust gas color ...................... 20-25 Adjusting valve clesrance ............................ 20-26 Measuring blow-by pressure ...................... 20-27 Testing and adjusting fuel injection timing .......................................................... 20-28 Measuring engine oil pressure ................... 20-29 Testing and adjusting belt tension for air conditioner compressor ............................ 20-30 Adjusting engine speed sensor ................... 20-31 Adjusting governor motor lever stroke ...... 20-32 Testing and adjusting hydraulic pressure in work equipment, swing, travel circuit ...... 20-33 Testing and adjusting PC valve output pressure (servo piston input pressure) .... 20-36

Testing and adjusting LS valve output pressure (servo piston input pressure) and LS differential pressure .................... 20- 38 Testing and adjusting control pump circuit oil pressure .................................... 20- 41 Testing solenoid valve output pressure ... 20- 43 Measuring PPC valve output pressure ..... 20- 44 Adjusting work equipment, swing PPC valve .................................................. 20- 45 Testing travel deviation .............................. 20- 46 Testing locations causing hydraulic drift of work equipment ........................... 20- 47 Measuring oil leakage ................................ 20- 48 Releasing remaining pressure in hydraulic circuit ........................................ 20- 50 Testing clearance of swing circle bearing ...................................................... 20- 51 Testing and adjusting track shoe tension ...................................................... 20- 52 Bleeding air ................................................. 20- 53 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 machine 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 unauthorized people near the machine.

¤

When checking the water level, always wait for the water to cool down. If the radiator cap is removed 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

STANDARD VALUE TABLE FOR ENGINE RELATED PARTS

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

PC100-6

PC120,130-6

Serial Number

45221 and up

PC120 : 57499 – 70000 PC120LC : 65504 – 70000

Engine Item

S4D102-1

Measurement conditions

Unit

2,100 ± 100

—

2,200 ± 100

—

900 ± 50

—

900 ± 50

—

1,900

—

2,000

—

Bosch index

Max. 5.5

7.5

Max. 5.5

7.5

Max. 1.0

2.0

Max. 1.0

2.0

mm

0.25

—

0.25

—

0.51

—

0.51

—

Max. 490 {50}

980 {100}

Max. 490 {50}

980 {100}

343 – 686 {3.5 – 7.0}

245 {2.5}

343 – 686 {3.5 – 7.0}

245 {2.5}

294 – 686 {3.0 – 7.0}

206 {2.1}

294 – 686 {3.0 – 7.0}

206 {2.1}

At low idling (SAE30 or SAE15W-40)

Min. 98 {1.0}

69 {0.7}

Min. 98 {1.0}

69 {0.7}

At low idling (SAE10W)

Min. 78 {0.8}

69 {0.7}

Min. 78 {0.8}

69 {0.7}

°C

80 – 110

120

80 – 110

120

mm

12 – 15

12 – 15

12 – 15

12 – 15

High idling Engine speed

Standard Standard value for new Service limit value for new Service limit value value machine machine

Low idling

rpm

Rated speed

At sudden acceleration Exhaust gas color At high idling

(Normal temperature) Valve clearance

Intake valve Exhaust valve

Blow-by pressure

(Water temperature: Operating range) At rated output (SAE30 or SAE15W-40)

Pa {mmH2O}

(Water temperature: Operating range) At high idling (SAE30 or SAE15W-40) Oil pressure

(SAE10)

kPa {kg/cm2}

Oil temperature

Whole speed range (inside oil pan)

Belt tension

Deflection when pressed with finger force of approx. 58.8 Nm {6 kg}

20-2 (11)

Crankshaft pulley – air conditioner compressor

PC100,120,130-6

TESTING AND ADJUSTING

fl

STANDARD VALUE TABLE FOR ENGINE RELATED PARTS

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.

Item

Applicable model

PC120

Serial Number

70001 and up

Engine

SAA4D102E-2

Measurement conditions

Unit

2,200 ± 100

—

975 ± 50

—

2,000

—

Bosch index

Max. 5.5

7.5

Max. 1.0

2.0

mm

0.25

—

0.51

—

High idling Engine speed

Low idling

rpm

Rated speed

At sudden acceleration Exhaust gas color At high idling

Standard Standard value for new Service limit value for new Service limit value value machine machine

(Normal temperature) Valve clearance

Intake valve Exhaust valve

Blow-by pressure

(Water temperature: Operating range) At rated output (SAE30 or SAE15W-40)

Pa Max. 490 {mmH2O} {50}

980 {100}

343 – 686 {3.5 – 7.0} 294 – 686 {3.0 – 7.0}

245 {2.5} 206 {2.1}

Min. 98 {1.0} Min. 78 {0.8}

69 {0.7} 69 {0.7}

°C

80 – 110

120

mm

12 – 15

12 – 15

(Water temperature: Operating range) At high idling (SAE30 or SAE15W-40) Oil pressure

(SAE10)

kPa {kg/cm2}

At low idling (SAE30 or SAE15W-40) At low idling (SAE10W)

Oil temperature

Belt tension

PC100,120,130-6

Whole speed range (inside oil pan) Deflection when pressed with finger force of approx. 58.8 Nm {6 kg}

Crankshaft pulley – air conditioner compressor

20-2-1 (11)

STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS

TESTING AND ADJUSTING

Category PC120,130 : Discharge amount of main piston pump (in heavy-duty operation mode)

• Pump speed : At 2,000 rpm, PC-EPC current 400 mA (PC120 Serial No. : 70001 and up : 370 mA)

fl fl

20-12 (11)

Check point

Test pump discharge pressure {kg/cm2}

Average pressure (kg/cm2)

Standard value for discharge amount Q (¬/min)

Judgement standard Q (¬/min)

As desired

P1

P1

See graph

See graph

The error is large near the point where the graph curves, so avoid measuring at this point. 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.

PC100,120,130-6

TESTING AND ADJUSTING

TESTING AND ADJUSTING BELT TENSION 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 follows. 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 (11)

PC100,120,130-6

TESTING AND ADJUSTING

TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVO 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 measure the LS differential pressure. Table 2 Working mode

Fuel control lever

Operation

Differential pressure MPa{kg/cm2}

H/O mode

Full

Levers at neutral

2.7 +1.0 – 0.7 {28 +10 – 7}

H/O mode

Full

Travel speed: Hi Travel circuit under no load (lever fully operated)

2.1 ± 0.1 {21.5 ± 1}

2) Measuring with oil pressure gauge fl The maximum differential pressure is +10 2 2.7 +1.0 – 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 measure 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 install to LS pressure measurement plug (2). iv) Set to the conditions in Table 2 and measure the LS pressure. fl Stand directly in front of the indicator and be sure to read it correctly. (Pump discharge pressure) – (LS pressure) = 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 1 2 3 4 5 6 7 8

Working mode Throttle signal Auto-deceleration Coolant temperature signal — Power max. mode Travel speed Automatic warming up

Pump control

Governor control

G/O mode FULL ON (deceleration mode OFF — ON (power max. possible) Lo —

H/O mode FULL ON (deceleration mode) — — — — 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

Working mode

Active Mode H/O G/O, F/O L/O B/O

PC100,120,130-6

Operation

Max. speed at no load [Values in ( ) are rated speed] (rpm) PC120 : PC120 : 70001 and up PC100 : PC130 : 57499 – 70000 PC120LC : 45221 and up 51020 and up PC120LC : 70001 and up 65504 – 70000

Work equipment Approx.2,300(2,100)

Approx.2,400(2,200)

Approx.2,350(2,150)

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)

Approx.2,300(2,100)

Approx.2,200(2,000)

Approx.2,200(2,000)

Work equipment Approx.1,910(1,720) Approx.1,910( — ) Travel

Approx.2,000(1,800)

Approx.2,000(1,800)

Approx.2,000( — )

Approx.2,000( — )

Work equipment Approx.1,580(1,450)

Approx.1,670(1,500)

Approx.1,670(1,500)

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)

Approx.1,910( — )

Approx.1,850( — )

Approx.2,000( — )

Travel Travel

Travel Travel

20-139 (11)

30 DISASSEMBLY AND ASSEMBLY

METHOD OF USING MANUAL .................... 30- 3 PRECAUTIONS WHEN CARRYING OUT OPERATION ................................................ 30- 4 SPECIAL TOOL LIST ..................................... 30- 6 SKETCHES OF SPECIAL TOOLS .................. 30-10 STARTING MOTOR Removal and Installation ........................... 30-11 ALTERNATOR Removal and Installation ........................... 30-12 AIR CONDITIONER COMPRESSOR Removal and Installation ........................... 30-13 CONDENSER Removal and Installation ........................ 30-13-2 AFTERCOOLER Removal and Installation ........................... 30-14 ENGINE OIL COOLER CORE Removal and Installation ........................... 30-15 FUEL INJECTION PUMP Removal ...................................................... 30-16 Installation .................................................. 30-18 WATER PUMP Removal and Installation ........................... 30-20 NOZZLE HOLDER Removal and Installation ........................... 30-21 TURBOCHARGER Removal and Installation ........................... 30-22 THERMOSTAT Removal and Installation ........................... 30-23 GOVERNOR MOTOR Removal and Installation ........................... 30-24 CYLINDER HEAD Removal ...................................................... 30-25 Installation .................................................. 30-30 ENGINE, MAIN PUMP Removal ...................................................... 30-33 Installation .................................................. 30-37 HYDRAULIC COOLER Removal and Installation ........................... 30-38 RADIATOR, HYDRAULIC COOLER Removal ...................................................... 30-39 Installation .................................................. 30-40 PC100,120,130-6

FUEL TANK Removal and Installation ........................... 30-41 CENTER SWIVEL JOINT Removal and Installation ........................... 30-42 Disassembly and Assembly ...................... 30-43 SPROCKET Removal and Installation ........................... 30-44 TRAVEL MOTOR Removal and Installation ........................... 30-45 Disassembly and Assembly ................... 30-45-1 FINAL DRIVE Disassembly ............................................... 30-46 Assembly .................................................... 30-49 SWING MACHINERY, SWING MOTOR Removal and Installation ........................... 30-54 SWING MOTOR Removal and Installation ........................... 30-55 Disassembly ............................................ 30-55-1 Assembly ................................................. 30-55-5 SWING MACHINERY Disassembly ............................................... 30-56 Assembly .................................................... 30-59 REVOLVING FRAME Removal ...................................................... 30-63 Installation .................................................. 30-65 SWING CIRCLE Removal and Installation ........................... 30-66 IDLER, RECOIL SPRING Removal and Installation ........................... 30-67 RECOIL SPRING Disassembly ............................................... 30-68 Assembly .................................................... 30-69 IDLER Disassembly ............................................... 30-70 Assembly .................................................... 30-71 TRACK ROLLER Removall and Installation .......................... 30-73 Disassembly ............................................... 30-74 Assembly .................................................... 30-75

30-1 (11)

CARRIER ROLLER Removal and Installation ........................... 30-77 Disassembly ............................................... 30-78 Assembly .................................................... 30-80 TRACK SHOE Removal and Installation ........................... 30-82 HYDRAULIC TANK Removal .................................................... 30- 83 Installation ................................................ 30- 84 CONTROL PUMP Removal and Installation ......................... 30- 85 MAIN PUMP Removal .................................................... 30- 86 Installation ................................................ 30- 87 Disassembly .......................................... 30-87- 1 Assembly ............................................... 30-87-11 MAIN PUMP INPUT SHAFT OIL SEAL Removal and Installation ......................... 30- 88 CONTROL VALVE Removal .................................................... 30- 89 Installation ................................................ 30- 90 Disassembly ............................................. 30- 91 Assembly .................................................. 30- 96 LS SELECT VALVE Disassembly and Assembly .................... 30-102 MAIN RELIEF VALVE Disassembly ............................................. 30-103 Assembly .................................................. 30-104 PC.LS-EPC VALVE Removal and Installation ......................... 30-105 PC VALVE Removal and Installation ......................... 30-106 LS VALVE 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 (11)

BUCKET CYLINDER Removal .................................................... 30-119 Installation ................................................ 30-120 HYDRAULIC CYLINDER Disassembly ............................................. 30-121 Assembly .................................................. 30-124 WORK EQUIPMENT Removal .................................................... 30-128 Installation ................................................ 30-129 BUCKET Removal .................................................... 30-130 Installation ................................................ 30-131 ARM Removal .................................................... 30-132 Installation ................................................ 30-133 BUCKET, ARM Removal .................................................... 30-134 Installation ................................................ 30-135 BOOM Removal .................................................... 30-136 Installation ................................................ 30-137 OPERATOR’S CAB Removal .................................................... 30-138 Installation ................................................ 30-140 COUNTERWEIGHT Removal and Installation ......................... 30-141 ENGINE THROTTLE, PUMP CONTROLLER Removal and Installation ......................... 30-142 MONITOR Removal and Installation ......................... 30-143 CONTROL STAND CASE Removal .................................................... 30-144 Installation ................................................ 30-145

PC100,120,130-6

DISASSEMBLY AND ASSEMBLY

STARTING MOTOR

REMOVAL OF STARTING MOTOR ASSEMBLY ¤

Disconnect the cable from the negative (–) terminal 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 removal.

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 (–) terminal of the battery.

1. Open engine hood and remove fan guard (1). 2. Disconnect wires (2). fl Before disconnecting the wiring, fit tags to distinguish the mounting position. 3. Using wrench 1, raise tensioner (3) and remove fan belt (4).

¤

Be extremely careful not to get your fingers caught when removing the fan belt.

PC120-6 Serial No. : 70001 and up

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 removal.

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 alternator pulley is centered with the other pulleys.

30-12 (11)

PC100,120,130-6

DISASSEMBLY AND ASSEMBLY

AIR CONDITIONER COMPRESSOR

REMOVAL OF AIR CONDITIONER COMPRESSOR ASSEMBLY PC100-6 PC120-6 PC120LC-6 PC130-6

¤

Serial No. : 45221 and up Serial No. : 57499 – 70000 Serial No. : 65504 – 70000 Serial No. : 51020 and up

Loosen the flange mounting bolts of the air conditioner hose, and release the refrigerant (R134a) 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 PC120-6 PC120LC-6 PC130-6 •

Serial No. : 45221 and up Serial No. : 57499 – 70000 Serial No. : 65504 – 70000 Serial No. : 51020 and up

Carry out installation in the reverse order to removal.

1 fl When installing the hoses, check that the Orings are not damaged or deteriorated, then connect the hoses. 2 fl Adjust the belt tension. For details, see TESTING 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 conditioner hose, and release the refrigerant (R134a) 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 removal.

1 fl When installing the hoses, check that the Orings are not damaged or deteriorated, then connect the hoses. 2 fl Adjust the belt tension. For details, see TESTING AND ADJUSTING, Testing and adjusting belt tension for air conditioner compressor. •

Fill with refrigerant (R-134a).

30-13-1 (11)

PC100,120,130-6

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 disconnecting 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 removal.

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 assembly (2) to the front side. • Do not disconnect the air conditioner hoses. 3. Open the engine hood and remove the counterweight top cover. 4. Loosen the clamps of hoses (3) and (4).

1

5. Remove 4 mounting bolts (5) and aftercooler assembly (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 removal.

1 3 Hose clamp: 10.8 ± 1 Nm {1.1 ± 0.1 kgm}

30-14 (11)

PC100,120,130-6

DISASSEMBLY AND ASSEMBLY

TURBOCHARGER

REMOVAL OF TURBOCHARGER ASSEMBLY PC100-6 PC120-6 PC120LC-6 PC130-6

Serial No. : 45221 and up Serial No. : 57499 – 70000 Serial No. : 65504 – 70000 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 intermediate 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 PC120-6 PC120LC-6 PC130-6 •

Serial No. : 45221 and up Serial No. : 57499 – 70000 Serial No. : 65504 – 70000 Serial No. : 51020 and up

Carry out installation in the reverse order to removal.

1 3 Turbocharger assembly mounting bolt: 43.1 Nm {4.4 kgm}

30-22 (11)

PC100,120,130-6

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 insulation 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 connecting 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 removal.

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 PC120-6 PC120LC-6 PC130-6

Serial No. : 45221 and up Serial No. : 57499 – 70000 Serial No. : 65504 – 70000 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 disconnecting 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 assembly, be extremely careful not to damage the core. 4 Hydraulic cooler assembly : 30 kg

INSTALLATION OF HYDRAULIC COOLER ASSEMBLY PC100-6 PC120-6 PC120LC-6 PC130-6 •

Serial No. : 45221 and up Serial No. : 57499 – 70000 Serial No. : 65504 – 70000 Serial No. : 51020 and up

Carry out installation in the reverse order to removal.

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 (11)

PC100,120,130-6

DISASSEMBLY AND ASSEMBLY

RADIATOR, HYDRAULIC COOLER

REMOVAL OF RADIATOR, HYDRAULIC COOLER ASSEMBLY PC100-6 PC120-6 PC120LC-6 PC130-6

¤

•

Lower the work equipment completely to the ground and stop the engine. Then loosen the oil filler cap slowly to release the pressure inside 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

•

Serial No. : 45221 and up Serial No. : 57499 – 70000 Serial No. : 65504 – 70000 Serial No. : 51020 and up

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 disconnecting 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 PC120-6 PC120LC-6 PC130-6 •

Serial No. : 45221 and up Serial No. : 57499 – 70000 Serial No. : 65504 – 70000 Serial No. : 51020 and up

Carry out installation in the reverse order to removal.

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

Fill with refrigerant (R-134a).

2 fl Install the radiator and hydraulic cooler assembly so that there is a clearance of 13 mm or more to the left and right, and top and bottom between the fan and shroud. •

Refilling with water fl Add water through the water filler to the specified level. Run the engine to circulate the water through the system. Then check the water 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 (11)

PC100,120,130-6

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 assembly. 1 fl When slinging and removing the radiator and hydraulic oil cooler assembly, take care extremely not to damage the core. 4 Radiator and hydraulic oil cooler assembly: 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 removal.

1 fl Install the radiator and hydraulic oil cooler assembly 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 specified 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 (11)

PC100,120,130-6

DISASSEMBLY AND ASSEMBLY

TRAVEL MOTOR

DISASSEMBLY, ASSEMBLY OF TRAVEL MOTOR GM18VL PC100-6 PC120-6 PC120LC-6 PC130-6

Serial No.: 45221 and up Serial No.: 57499 and up Serial No.: 65504 and up 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 (10)

PC100,120,130-6

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

DANGER

This term means that there is an imminent danger and is used when neglecting the given procedure or instruction can cause death or serious injury.

WARNING

This term means that there is a latent danger and is used when neglecting the given procedure or instruction can cause death or serious injury.

CAUTION

This term means that there is a latent danger and is used when neglecting the given procedure or instruction can cause injury of medium or light degree or damage of equipment or devices.

¤

This symbol is used to draw the reader’s 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 (10)

PC100,120,130-6

DISASSEMBLY AND ASSEMBLY

PC100,120,130-6

TRAVEL MOTOR

30-45-4 (10)

TRAVEL MOTOR

DISASSEMBLY AND ASSEMBLY

PARTS LIST Symbol

1

Part named

Q’ty

Symbol

Part named

Q’ty

REDUCTION GEAR ASSEMBLY

1

HYDRAULIC MOTOR

Hub

1

Rear flange assembly • Rear flange kit

1

Spindle kit • Spindle assembly

1 1

101 123

• • Rear flange • • Spool

1 1

2 3

• • Spindle • • Hold flange

1 1

146 154

• • Hexagon socket head plug • • Hexagon socket head plug

3 7

19

• Reamer bolt

3

179 190

• • Filler • • Orifice

1 1

RV gear assembly • RV gear kit

1 1

199 124

• • Nameplate • Plug

1 2

• • RV gear A • • RV gear B

1 1

125 126

• Spring retainer • Plug

2 2

9 22

• Crankshaft • Tapered roller bearing

3 6

127 128

• Valve • Spring

2 2

23

• Needle roller bearing

6

130 136

• Spring • O-ring

2 2

6

Input gear

1

137 140

• O-ring • O-ring

2 2

7

Spur gear kit • Spur gear

1 3

163 164

• Valve • Stopper

1 1

8

Cover

1

165 166

• Ring • Spring

1 1

14 15

Distance piece Coupling

3 1

168 192

• Ball • Plug

2 2

17

Pin

24

193 194

• O-ring • Ball

2 2

20

Snap ring t = Above 2.20 up to 2.25

3 102

Shaft

1

103 104

Swash plate Cylinder block

1 1

4 5

↓ t = Above 2.75 up to 2.80 21

Ball bearing

2

Piston kit

1

25 27

C-type snap for shaft O-ring

3 2

105

• Piston assembly • Piston

9 1

29 30

O-ring O-ring

1 1

106

• • Shoe

1

Floating seal kit

1

107 108

Retainer plate Thrust ball

1 1

31

• Floating seal

2

109 110

Timing plate Washer

1 2

33 35

Hexagon socket head plug Hexagon socket head bolt

2 10

111 112

Washer Piston

1 1

36

Ball

1

113 114

Spring Spring

8 1

30-45-5 (10)

PC100,120,130-6

DISASSEMBLY AND ASSEMBLY

Symbol

Part named

TRAVEL MOTOR

Q’ty

Symbol

Part named

Q’ty

115

Friction plate

2

209

• O-ring

2

116 117

Mating plate Mating plate

2 1

214 215

• Plug • Plug

1 2

121 132

Plug Oil seal

1 1

216 217

• Ball • Buckup ring

2 4

135 138

O-ring O-ring

1 2

219 220

• Orifice • O-ring

2 1

139 141

O-ring Parallel pin

1 1

222 224

• Hexagon socket head plug • O-ring

6 2

142 143

Parallel pin Hexagon socket head bolt

2 8

145 149

THS snap ring Deep groove ball bearing

1 1

150 151

Deep groove ball bearing Roller

1 3

Piston assembly

1

161 162

• Piston • Shoe

1 1

167

Pivot

2

169 170

Collar Hexagon socket bolt

1 4

171 173

Paraller pin O-ring

2 1

174 191

Spur lock washer Spring

4 1

MSRV2

1

Valve kit • Sleeve kit

2 1

201 202

• • Valve • • Sleeve

1 1

203 204

• Spring retainer • Plug

1 1

205 206

• Shim • Spring

1 1

208 209

• O-ring • O-ring

1 1

210 211

• O-ring • Buckup ring

1 2

Body kit

1

212

• Body piston kit • • Valve body

1 1

213

• • Piston

1

PC100,120,130-6

30-45-6 (10)

TRAVEL MOTOR

DISASSEMBLY AND ASSEMBLY

TOOLS 1. Standard tools No. 1

Name Hexagonal wrench (JIS B 4648)

Model/Dimensions

Q'ty

6 (For M8) 10 (For M12) 14 (For M16)

1 1 1

2

Socket wrench (Ratchet handle) (JIS B 4641)

8-shaped

1

3

Torque wrench (JIS B 4650)

Dial type, 280 Nm {28 kgm} Dial type, 850 Nm {87 kgm}

1 1

4

Torque wrench adapter (12.7-mm square drive)

Nominal size: 17, 19, 27, 32, 36 (Socket) Nominal size: 6, 8, 10 (Rod)

5

Extension bar (JIS B 4637)

150 mm

1

6

Hammer

Nominal size: 12

1

7

Plastic hammer

L = Approx. 300

1

8

Flat-head screwdriver (JIS B 4609)

Approx. 150 mm

1

9

Snap ring priers

For shaft For hole

1 1

10

Hanging tool

Lifting load: Min. 300 kg Eyebolt (For M16) Eyebolt (For PT 1/2) Wire with hook

1 set (2) (2) (1)

11

Press work stand

Pressing capacity: Min. 200 kg

1 set

2

1 each 1 each

1 set

12

Compressed air

For 3 – 5 kgf/cm Nozzle for compressed air

13

Container

Common vat, W450 x D300 x H120

14

Heating tank

Heating temperature: Min. 100ºC Volume: Min. 500 x 500 x 500

15

Leather gloves

16

Sealing tape

17

Depth micrometer

Measurement range: Approx. 30 mm Min. division: 0.01 mm

1

18

Thickness gauge

Measurement range: 0.04 – 0.3 mm

1

30-45-7 (10)

2 1 set 1 set 1

PC100,120,130-6

DISASSEMBLY AND ASSEMBLY

TRAVEL MOTOR

2. Manufactured tools 1) Work table for travel motor • A work table used to carry out disassembly and assembly work of the travel motor easliy and safety.

2) Disassembly/Assembly work stand • Komatsu part No. 790-501-5000 Unit repair stand or 790-501-2001 Engine repair stand 790-901-2110 Bracket 790-901-1350 Plate

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) from cylinder block (104).

fl The figure shows 790-501-5000 repair stand.

5) Holder (II) • A holder used to remove deep groove ball bearing (149) from shaft (102).

3) Clamp • A clamp used to fix spindle (2) and hub (1). • Komatsu part No. 796-720-3700

PC100,120,130-6

30-45-8 (10)

DISASSEMBLY AND ASSEMBLY

TRAVEL MOTOR

6) Holder (III) • A holder used to press fit oil seal (132) to the oil seal hole of spindle (2).

7) Holder (IV) • A holder used to set the RV gear assembly securely. Apply this holder to the outer race of tapered roller bearing (22) of crankshaft (9) of the RV gear assembly and hit it lightly with a hammer to set the RV gear assembly.

9) Eybolt for PT • An eyebolt used together with wires and a crane to take cover (8) out of hub (1). • Thread size: PT 1/2

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

30-45-9 (10)

A

Hub

M16

Spindle

M16

Travel motor

M16

PC100,120,130-6

DISASSEMBLY AND ASSEMBLY

TRAVEL MOTOR

11) Press fitting tool • A tool used to press fit main ball bearing (21) to hub (1).

12) Aluminum rod • A rod used to remove the outer races of tapered roller bearings (22) from spindle (2) and hold flange (3) and install them.

13) Jig to adjust preload on main bearing • A jig used to press fit bearing (21) to hub (1). • A jig used to measure the axial clearance of bearing (21).

PC100,120,130-6

14) Steel rod • A rod used to install ring (165) to flange (101). • ø = 11.8 mm, ¬ = 150 mm

15) Hanging tool (i) • A tool used to install the set of swash plate (103), cylinder block (104), piston (105), and shaft (102) to spindle (2).

30-45-10 (10)

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).

30-45-11 (10)

PC100,120,130-6

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}

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}

192

PC100,120,130-6

30-45-12 (10)

DISASSEMBLY AND ASSEMBLY

TRAVEL MOTOR

DISASSEMBLY 1. Preparation • Before disassembling the travel motor, prepare 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, consider the inspection items, characteristics of the detected trouble, etc. and then work according 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 broken. 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 moisture and dust. Accordingly, if it is obliged to interrupt the work, take rust-preventive measures 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 disassembled, as a rule. Accordingly, prepare the all replacement seals before disassembling.

30-45-13 (10)

PC100,120,130-6

DISASSEMBLY AND ASSEMBLY

DISASSEMBLY OF TRAVEL MOTOR ASSEMBLY (GM18VL) * The symbols of the tools are the reference Nos. in TOOLS. •

TRAVEL MOTOR

5) Remove input gear (6). fl Take care not to lose ball (36) at the end of the gear. 6) Remove the coupling. 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 assembly, 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 plastic hammer.

PC100,120,130-6

30-45-14 (10)

DISASSEMBLY AND ASSEMBLY

4) Remove plug (215) and piston (216). fl If the plug had not been loosened before the valve was removed, grip the valve assembly and remove the plug.

TRAVEL MOTOR

4. Rear flange assembly 1) Remove 8 bolts (143). fl When disassembling the rear flange, 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), retainer (125), and spool (123) from rear flange (101).

30-45-15 (10)

PC100,120,130-6

DISASSEMBLY AND ASSEMBLY

5) Remove both plugs (126), spring (130), and valve (127) from rear flange (101).

TRAVEL MOTOR

2) Remove the O-ring and buffer ring from piston (112).

6) Remove valve (163) in the rear flange, if necessary, according to the following procedure. 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).

5. Parking brake 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}

PC100,120,130-6

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 plate.

30-45-16 (10)

DISASSEMBLY AND ASSEMBLY

TRAVEL MOTOR

3) Remove retainer plate (107), piston (105), thrust ball (108), and washer (111) from cylinder block (104).

7) Remove 2 discs (115), 2 plates (116), and 1 plate (117) from the spindle. 8) Remove swash plate (103).

4) Remove pin (151) from cylinder block (104).

7. Shaft 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 compress the spring with tool 2-4) to remove snap ring (145). 6) Release the spring and remove washer (110), spring (114), and washer (110).

30-45-17 (10)

8. 2nd travel speed selection piston Remove piston (161), shoe (162), and spring (191).

PC100,120,130-6

DISASSEMBLY AND ASSEMBLY

9. Spur gear 1) Remove 3 snap rings (25) from crankshaft (9). 2) Remove 3 spur gears (7) and distance piece (14) under the gear.

TRAVEL MOTOR

3) Turn over the motor assembly. 4) Remove 3 snap rings (20) from hold flange (3). fl Make match marks on the hold flange and snap rings. 5) Remove 3 reamer bolts (19). fl The reamer bolts are secured with adhesive. 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).

PC100,120,130-6

30-45-18 (10)

DISASSEMBLY AND ASSEMBLY

TRAVEL MOTOR

11. Spindle 1) Turn over the motor assembly and remove 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 crankshaft.

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 assembly (4). fl Hit 3 – 4 peripheral parts of the pin lightly.

30-45-19 (10)

PC100,120,130-6

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).

PC100,120,130-6

30-45-20 (10)

TRAVEL MOTOR

DISASSEMBLY AND ASSEMBLY

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).

Part No.

Part name

Trouble

Standard value (Standard dimension)

Allowable value (Criterion)

Clearance 10 – 20 µ

Clearance 25 µ

Spindle kit (2)

Spindle

(3)

Hold flange

(19)

Reamer bolt

• Part surface has visible serious damage. • Part surface is scuffed or worn easily.

RV gear assembly (4) (5) (9) (22) (23)

RV gear (A) RV gear (B) Crankshaft Tapered roller bearing Needle roller bearing

• RV gear tooth surface is worn unevenly. • When crankshaft (9) is revolved, each part does not move 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)

(123)

Rear flange

Spool

30-45-21 (10)

• Moving part against spool (123) has flaw. • Clearance between rear flange and spool is large. • Contact face against valve (127) has flaw. • Depth to contact face against valve (127) is large. • Outside surface has flaw. • Outside surface is worn unevenly.

PC100,120,130-6

DISASSEMBLY AND ASSEMBLY

Part No.

Part name

TRAVEL MOTOR

Trouble

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.

Standard value (Standard dimension)

Allowable value (Criterion)

Piston assembly (105)

Piston

(106)

Shoe

• There is axial clearance between piston (105) and shoe (106). • Shoe is worn abnormally. • 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

116

Mating plate

• Both end faces are worn unevenly. • Specified torque is not produced. • Plate is seized.

149

Deep groove ball bearing

• There is bruise.

150

Deep groove ball bearing

• Surface is worn unevenly.

Valve

• Outside surface has flaw.

Clearance: 0.05 mm

Braking torque: Min. 145.1Nm {Min. 14.8kgm}

Clearance: 0.15 mm

Braking torque: 82.38Nm {8.4kgm} Max. 145.1Nm {Max. 14.8kgm}

• Surface is flaked.

163

PC100,120,130-6

30-45-22 (10)

TRAVEL MOTOR

DISASSEMBLY AND ASSEMBLY

Part No.

Part name

(212)

Body/Piston kit Valve body

(213)

Piston

(202)

Sleeve kit Sleeve

(201)

Valve

30-45-23 (10)

Trouble

Standard value (Standard dimension)

• There are flaws on sliding surface Diametrical clearance against piston (213). • Clearance between valve body and 15 – 20 µ piston (213) is large. • There are flaws on periphery. • Periphery is worn unevenly.

Allowable value (Criterion) Diametrical clearance 25 µ

Diametrical Diametrical • There are flaws on seat surface. • There are flaws on sliding surface clearance 7 – 12 µ clearance 20 µ against valve (201). • Clearance between sleeve and valve (201) is large. • There are flaws on periphery. • Periphery is worn unevenly.

PC100,120,130-6

DISASSEMBLY AND ASSEMBLY

ASSEMBLY •

Carry out assembly in the reverse order to disassembly, as a rule.

1. Preparation Prepare a worktable, tools, and materials for disassembling, similarly to preparation for disassembly. 2. General precautions for work 1) Observe the same general precautions with disassembly. 2) Remove all metal chips and foreign matter from the all parts and check that any part does not have a burr, bruise, etc. before assembling. If there is any burr or bruise, remove it with an oilstone. 3) Replace the O-rings, oil seals, and floating seal with new ones. 4) Replace the reamer bolts with new ones, as a rule. If it is obliged to reuse one, remove all adhesive from it with a brush. If bolt seat has any flaw, remove it with an oilstone and then degrease the reamer bolt. 5) Since the reamer bolt holes of spindle (2) and threaded parts of reamer bolts (19) are to be coated with adhesive when they are assembled, degrease them. 6) When fitting the O-rings, oil seals, and floating seals, take care not to damage them. (Apply 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 malfunction.) 9) Tighten each bolt or plug to the torque shown in the torque table. 10) After finishing the assembly work, plug the all ports to prevent dirt from entering them.

PC100,120,130-6

TRAVEL MOTOR

3. Assembly procedure

¤

If any part is replaced before assembling, the preload on the ball bearing and thickness of the snap ring may need to be adjusted. Accordingly, see if any of the following part has been replaced before assembling. 1) Replacement parts which require adjustment of preload on ball bearing Hub (1), spindle (2), collar (11), hold flange (3), ball bearing (21) 2) Replacement parts which require adjustment of thickness of snap ring

¤

Spindle (2), hold flange (3), crankshaft (9), spacer (12), tapered roller bearing (22), snap ring (20) If any of the above part is replaced before assembling, be sure to use only the adjusted parts. If a part which has not been adjusted is used, the travel motor will malfunction and cause breakage soon. Accordingly, observe this precaution.

30-45-24 (10)

DISASSEMBLY AND ASSEMBLY

ASSEMBLY OF TRAVEL MOTOR ASSEMBLY (GM18VL) • •

Preparation work Clean the all parts and remove burrs, etc. Precautions for assembly 1) Be sure to replace all the O-rings and oil seals with new ones. 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.

TRAVEL MOTOR

3) Using tool 2-16) and 2-17), install floating seal (31) to hub (1). fl Thinly apply grease (G2-LI) to the Oring of the floating seal. fl After installing, check that the distance between the hub end and floating seal surface is less than 1 mm and they are parallel.

1. Ball bearing and floating seal (on hub side) 1) Install hub (1) to tool 2-1) or 2-2).

2) Using tool 2-11), install bearing (21) to hub (1).

30-45-25 (10)

2. Spindle 1) Using tools 2-18) and 2-17), install floating seal (31) to spindle (2). fl Thinly apply grease (G2-LI) to the Oring 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 they are parallel.

PC100,120,130-6

DISASSEMBLY AND ASSEMBLY

2) Using hanging tool 2-8), install spindle (2) to hub (1) and secure spindle (2) and hub (1) with tool 2-3).

TRAVEL MOTOR

3) Hold the crankshaft end with your hands and install RV gear assembly (4), matching it to the outer race installed in advance. fl If the RV gear assembly falls suddenly, the tapered roller bearing will be damaged, 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.

PC100,120,130-6

30-45-26 (10)

DISASSEMBLY AND ASSEMBLY

TRAVEL MOTOR

4. Hold flange 1) Using tool 2-11), install ball bearing (21) to hub (1). 2) Install 3 tapered roller bearings (22) and their outer races.

3) Install the hold flange (3), matching the match marks made when the hold flange was removed. fl When replacing the hold flange, see ASSEMBLY, Adjustment procedure.

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. 6) Set the distance piece and install spur gear (7) to the camshaft. fl When installing the spur gear, set match mark "a" (punch hole) as shown in the 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 (10)

PC100,120,130-6

DISASSEMBLY AND ASSEMBLY

7) Install snap ring (25) to the camshaft.

5. Oil seal and roller bearing 1) Turn over the motor. 2) Using tool 2-6), install oil seal (132) to spindle (2). 2 Oil seal lip: Grease (G2-LI)

3) Install roller bearing (149) to spindle (2).

PC100,120,130-6

TRAVEL MOTOR

6. 2nd travel speed selection piston Install spindle (2), spring (191), piston (161), and shoe (162).

7. Pivot and parallel pin Install 2 parallel pins (171) and 2 pivots (167) 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 ± 0ºC

30-45-28 (10)

DISASSEMBLY AND ASSEMBLY

2) Install washer (110), spring (114), and washer (110) to cylinder block (104), and then compress the spring with tool 2-4) and install snap ring (145).

TRAVEL MOTOR

6) Install swash plate (103) and motor assembly to shaft (102). fl Hold the shaft securely so that it will 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 (10)

PC100,120,130-6

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}

11. Relief valve 1) Install valve (201), spring (206), retainer (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.

4) Set piston (213) to the valve body and install plug (214). 3 Plug: 98.1 ± 19.6 Nm {10 ± 2 kgm} fl Tighten the plug 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 install plug (215). 3 Plug: 29.4 ± 4.9 Nm {3 ± 0.5 kgm}

30-45-31 (10)

PC100,120,130-6

DISASSEMBLY AND ASSEMBLY

12. Cover 1) Set the coupling and install input gear (6). 2) Apply grease (G2-LI) to ball (36) and install it to the end of input gear (6). 3) Add lubricating oil.

5 Engine oil (EO30-CD): 2.5 ¬ 4) Install eyebolts to the drain plug hole and level plug hole and install cover (8).

TRAVEL MOTOR

PROCEDURE FOR ADJUSTING REPLACED PARTS 1. Procedure for adjusting thickness of hold flange (3) after replacing hub (1), spindle kits (2), (3), and (19), and main ball bearing (21) 1) Perform assembly procedures 1 through 4-1). 2) Install pre-load adjusting tool 2-13) for ball bearing (21) to spindle (2). 3) Tighten special nut b of the pre-load adjusting 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 micrometer through the measurement hole of the pre-load adjusting tool. 5) Since dimension B of the pre-load adjusting 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 difference between the threaded part and cover end will be ±1 thread.

PC100,120,130-6

30-45-32 (10)

DISASSEMBLY AND ASSEMBLY

6) Obtain dimension D of hold flange (3).

TRAVEL MOTOR

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 dimension" of the hold flange. • Adjust D to C ± 0.02 mm. i) When actual dimension "D" of hold flange (3) is smaller than specified dimension fl Shave "face E" of the hold flange to the specified dimension with a lathe, etc. ii) When actual dimension "D" of hold flange is in the tolerance of the specified dimension fl Use the hold flange as it is. iii) When actual dimension "D" of hold flange (3) is larger than specified dimension fl Replace the spindle assembly with new one. Some adjustment allowance 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 (10)

3) Fit thinnest snap ring (20) to the snap ring groove of hold flange (3). 4) Hit the periphery of snap ring (20) lightly with tool 2-7) and the hammer. fl Perform this procedure to check that the RV gear assembly is inserted in spindle (2) securely.

PC100,120,130-6

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 currently inserted • Set thickness of snap ring (MIN) MIN = (Thickness of feeler gauge) + (Thickness of snap ring currently 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

30-45-35 (10)

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

PC100,120,130-6

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

1

Installation and piping of GM motor

e ..................... e Install the GM motor to the machine body (sprocket) and pipe it. Do not install the track, however [since the performance test of the GM motor (no-load operation) is executed]. Notes)

2

Running-in of e ..................... e GM motor 1 2

3

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.

Speed of GM motor 10 rpm

Pressure

Revolving direction

Operating time

No load

Right/Left

1 minute or more for each test

20 rpm

Performance confirmation test on GM motor 1

Preparatory operation before testn. .......... Operate until temperature rises to the following points. • Hydraulic oil temperature: 45 - 55°C • Outside temperature of hub of reduction gear assembly: 40 - 80°C

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

PC100,120,130-6

Rejected

➤

➤ Install track.

➤

➤ Acceptable

Disassemble and adjust again.

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 removal.

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 (11)

PC100,120,130-6

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 inside 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 ¬

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 removal.

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 (–) terminal 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 inside 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 ¬

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 turbocharger end, and remove exhaust muffler (3) together 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 (11)

PC100,120,130-6

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 assembly (18) towards counterweight end.

PC120-6 Serial No. : 70001 and up

16. Sling main pump assembly (19), remove mounting 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 removal.

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 removal.

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

ª PC100,120,130-6 1

PC120LC-6

Height

PC100L-6

ª PC100,120,130-6 PC120LC-6 2

Criteria

Remedy

Standard size

Repair limit

25

15

26

16 8

Thickness PC100L-6

ª PC100,120,130-6 PC120LC-6

10 24

3 PC100L-6 Length of base

ª PC100,120,130-6 PC120LC-6

27 19 Rebuild or replace

4 PC100L-6

ª PC100,120,130-6 PC120LC-6

22 18

5 PC100L-6

ª PC100,120,130-6 6

Length of tip

PC120LC-6 PC100L-6

ª PC100,120,130-6 PC120LC-6

21 11 14 18

7 PC100L-6

19

ª PC120-6 Serial No. : 57499 – 70000, PC120LC-6 Serial No. : 65504 – 70000,

40-14 (11)

PC100,120,130-6

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

1 Height of grouser

2 Overall height of shoe 3 Thickness

Criteria Standard size

Repair limit

20

10

29.5

19.5 9.5

4

14

5 Length of grouser top

13

6

15

PC100,120,130-6

Remedy

Repair by build-up welding or replace

40-14-1 (11)

MAINTENANCE STANDARD

TRACK SHOE

RUBBER SHOE

Unit: mm

No.

Check item

Criteria

Remedy

Standard clearance

Repair limit

38

15

2 Wear of roller guard portion

116

94

3 Wear of meshing portion of sprocket

3

–2

4 Wear of contacting portion of roller

28.5

1 Wear of lug height

40-16 (11)

Replace

22.5

PC100,120,130-6

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 PC100L-6 PC120-6

PC100,120,130-6

Serial No. : 46059 and up Serial No. : 46059 and up Serial No. : 60968 – 70000

PC120LC-6 Serial No. : 65504 – 70000 PC130-6 Serial No. : 51480 and up

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 PC100L-6 PC120-6

PC100,120,130-6

Serial No. : 46059 and up Serial No. : 46059 and up Serial No. : 60968 – 70000

PC120LC-6 Serial No. : 65504 – 70000 PC130-6 Serial No. : 51480 and up

90-11 (11)

ELECTRICAL CIRCUIT DIAGRAM (2/2) PC100-6 PC100L-6 PC120-6

PC100,120,130-6

Serial No. : 46059 and up Serial No. : 46059 and up Serial No. : 60968 – 70000

PC120LC-6 Serial No. : 65504 – 70000 PC130-6 Serial No. : 51480 and up

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)