2000 Komatsu PC100-6 & PC120-6 Excavator Shop Manual (P/N SEBM003307)

Komatsu shop manual SEBM003307 (2000 edition) covers 1994–2001 PC100-6 and PC120-6 hydraulic excavators, including standard and auxiliary service-valve configurations.

• Engine service: Valve-clearance and fuel injection timing adjustment, compression and blowby testing, and cylinder-head, injection-pump, and engine/pump assembly removal and installation.

• CLSS hydraulics: Main-pump, LS-valve, and TVC-valve testing; control-valve repair; hydraulic-drift diagnosis; and bleeding procedures for pumps, cylinders, and motors.

• Travel and swing: GM18VL-MSRV travel-motor disassembly, inspection, reassembly, and performance testing, plus swing machinery and model-specific swing-motor service.

• Undercarriage and work equipment: Recoil-spring, idler, and track-roller service; track-shoe replacement; boom, arm, and bucket removal and installation; and hydraulic-cylinder rebuilding.

• Electrical diagnosis: Engine throttle and pump controller fault charts, machine-monitor service modes, wiring diagrams, electrical circuit diagrams, connector locations, and pin tables.

• Auxiliary equipment: Breaker, telescopic-arm, crusher, rotating-crusher, and Log Hunter circuit diagrams, with service-valve layouts and attachment-specific hydraulic components.

Written for service technicians, the procedures call for workshop lifting equipment, hydraulic testers, and the specified service tools.

CLSS Testing and Hydraulic Component Repair

The structure and function section explains the power train, PTO coupling, hydraulic pumps, center swivel joint, and CLSS control circuits. Active and Normal Mode operation is covered alongside standard and auxiliary service-valve arrangements.

Hydraulic-drift checks help distinguish cylinder-packing leakage from control-valve or boom-holding-valve faults before components are removed. The testing section identifies the 799-101-5002 hydraulic tester and provides pressure specifications and adjustment procedures for the main pump and LS/TVC controls.

The HPV95 pump repair section includes contact checks for the cylinder block, valve plate, rocker cam, and cradle. Separate control-valve disassembly procedures apply before and after PC100-6 serial 41401 and PC120-6 serial 50201.

Hydraulic diagram coverage: The full-machine schematics are marked for PC100-6 serial 41230 and up and PC120-6 serial 49821 and up. The separate hydraulic piping drawing listed in the contents is not included in this PDF.

Engine Work and Controller Diagnosis

Engine performance tables include horsepower and torque. Removal and installation procedures also cover the turbocharger, water pump, radiator, and oil coolers. For further engine detail, the manual refers to the separate 95 Series Engine Shop Manual, which is not included.

Controller information distinguishes the earlier separate engine throttle and pump controllers from the combined unit used from PC100-6 serial 41230 and PC120-6 serial 49821. Engine-throttle-controller and machine-monitor circuit diagrams accompany service-code tables and fault charts.

The governor-motor adjustment section explains how sudden lever movement with the spring assembly removed can generate electricity and damage the engine throttle controller, even with the starting switch off.

Motor Rebuilding and Inspection Standards

KMF40AB-2 swing-motor coverage includes disassembly and reassembly; the KMF40AB-3 section provides removal and installation. Travel-motor sectional drawings and parts lists support the GM18VL-MSRV repair procedures.

The travel-motor assembly notes explain how damage to the brake-valve spool or flange bore can cause internal leakage and reduce motor performance.

Maintenance standards provide component-specific wear limits and inspection clearances. General-reference pages contain machine assembly drawings, component weight tables, oil and coolant capacities, standard tightening torques, conversion tables, and push-pull coupler illustrations.

For pressurized hydraulics and heavy components, follow the manual's pressure-release and hoisting precautions.

Selected Valve-Clearance and Swing-Circle Specifications

These are a small selection of the engine-adjustment and lubrication specifications in the manual.

At normal temperature, the S4D95L-1 valve-clearance specifications are 0.35 mm intake and 0.50 mm exhaust for both models.

The swing-circle table specifies 10 liters of G2-LI grease for PC100-6 serials 40001–40623 and PC120-6 serials 45001–47570. This changes to 6.5 liters from serials 40624 and 47571, respectively.

PDF Navigation, Diagram Detail, and Included Pages

Text search and diagram navigation: Most manual text is searchable, but the large hydraulic and electrical schematics on PDF pages 55–64 and 227–236 have no searchable text. Embedded bookmarks cover the main sections and many procedures; the hydraulic-diagram entries land before the drawings. Small circuit labels require zooming.

The download is one printable 1,036-page PDF in English. The total includes the cover, four revision-list pages, 54 blank pages, one revision-request form, and 16 enlarged schematic-detail pages.