2004 Komatsu PC100-6, PC100L-6, PC120-6, PC120LC-6, PC130-6 Excavator Shop Manual (P/N SEBM010611)

Komatsu shop manual SEBM010611 covers the 2004 PC100-6, PC100L-6, PC120-6, PC120LC-6, and PC130-6 excavators. The publication carries the print code 04-02(02).

• Engine checks and removal: Valve-clearance adjustment, fuel injection timing, blow-by measurement, and engine, cylinder-head, and injection-pump removal and installation.

• Hydraulic pump and CLSS: Main-pump and control-valve disassembly and assembly, LS and PC valve testing, pressure adjustment, and pump, cylinder, and swing-motor air bleeding.

• Travel drives: GM18VL travel-motor overhaul and performance confirmation, plus separate PC100L-6 final-drive disassembly and assembly procedures.

• Swing and swivel assemblies: KMF40ABE-3 swing-motor repair, swing-machinery overhaul, and center swivel joint disassembly and assembly.

• Electrical diagnosis: Machine-monitor service codes, engine-throttle and pump-controller troubleshooting, wiring diagrams, and connector pin-number tables.

• Undercarriage and work equipment: Track-tension checks, idler and roller repair, and removal and installation of hydraulic cylinders, boom, arm, and bucket.

• Workshop reference data: Assembly weights, tightening torques, coating materials, lubricant capacities, maintenance standards, and pressure, temperature, and torque conversion tables.

Written to support service-workshop repairs, this manual suits technicians familiar with hydraulic pressure testing, electrical measurements, and lifting heavy machine assemblies.

System Structure and Hydraulic Documentation

The drivetrain drawings show how engine output reaches the hydraulic pump, travel drives, and swing machinery. PTO coupling details and track-frame drawings explain the relationship between these assemblies.

The CLSS section explains LS and PC valve operation, pressure compensation, and how pump discharge responds to actuator loads. Testing sections address main relief pressure, control-pump pressure, PPC valve output, hydraulic drift, and component leakage.

Configuration differences: Serial-specific sections distinguish control-valve arrangements and add-on service valves. The PC120-6 and PC120LC-6 revisions also document the aftercooled engine configuration and revised cooling layout. Hydraulic circuit diagrams and actual electric wiring diagrams support identification of the applicable arrangement.

Machine Monitor and Electrical Diagnostics

The diagnostic judgment tables connect displayed service codes and machine symptoms to electrical, hydraulic, or mechanical troubleshooting charts. This helps narrow a slow-function complaint to the relevant control circuit or hydraulic test before an assembly is removed.

Monitor-panel sections explain stored fault information, machine-data displays, input bit patterns, and governor-motor adjustment mode. The connector arrangement diagram, pin-number connection tables, and system-specific electrical circuit diagrams support checks at the engine-throttle controller, pump-control solenoids, and monitor circuits.

Engine Service and Repair Scope

The engine sections cover checks made with the engine installed and removal of major components. Fuel injection timing, valve clearance, engine oil pressure, and blow-by measurements are described alongside cylinder-head and injection-pump removal and installation.

For detailed internal engine repair, this publication refers the reader to the separate 102 Series Engine Shop Manual, which is not included in this PDF.

Travel-Motor Overhaul and Component Inspection

The GM18VL section includes a sectional assembly drawing, parts lists, clearance-adjusting parts, and a performance confirmation test. Tool information identifies the 796-720-3700 clamp and 790-501-5000 unit repair stand.

Its disassembly notes flag adhesive-secured hold-flange reamer bolts as a seizure risk. Assembly notes identify replacement parts that require bearing-preload or snap-ring-thickness adjustment; unadjusted parts can cause early travel-motor failure.

Maintenance-standard tables provide inspection criteria for the pump, control valve, swing and travel motors, undercarriage, and work-equipment joints. Weight tables identify major assemblies, including track frames, counterweights, and boom and arm cylinders, for lifting preparation.

Follow the manual's precautions for stored hydraulic pressure, supported work equipment, and heavy lifting during service.

A Preview of Torque and Electrical Test Data

These examples are a small selection of the manual's tightening and electrical-check data.

The general metric bolt table lists 279 ± 30 Nm for its 16 mm thread entry; the illustrated bolt-head categories apply, and component-specific instructions take precedence. The electrical table specifies 4–6 kΩ between terminals 1 and 3 of the E06 fuel-control dial connector, with the starting switch off and the connector disconnected.

PDF Search, Bookmarks, and Circuit-Sheet Detail

Finding text and reading diagrams: Text search is available across many sections, but some specification tables and diagram pages lack searchable text. Embedded bookmarks cover the main chapters and individual procedures. Large circuit sheets require zooming to read small wire codes and pin numbers.

Supplied as one printable, English-language, 865-page PDF. The total already includes three blank pages and a one-page revision-request form.