Description

Komatsu PC100-6, PC120-6 2000 Workshop Manual

You’ve got a PC100-6 or PC120-6 on the rack, and the aftermarket manual you’re using guesses at the torque for the final drive. That’s a leak waiting to happen. I’ve seen it. This is the real thing: Komatsu’s own 2000 Workshop Manual, 1036 pages, direct from the factory. No third-party interpretation.

The factory manual doesn’t waste your time with generic advice. It gives you the exact sequence for disconnecting the push-pull coupler, the coating materials specification, and a conversion table for units. But the part that’ll save your ass is the standard tightening torque table in the FOREWORD. That table is your bible for every fastener on this machine.

Standard Tightening Torque Table

Every bolt on a Komatsu excavator has a specific torque range. The aftermarket books fudge these numbers. Not this manual. Page 2 (in the FOREWORD) lays out the standard tightening torque for metric bolts and nuts. Use that, and you won’t snap a bolt in the swing circle or under-torque the idler cushion. I’ve seen a guy put a final drive back together with a torque wrench set to the wrong spec because he trusted a third-party PDF. Cost him a week of downtime.

Testing and Adjusting: 20 Sections of Hydraulic and Engine Checks

Section 20 is where this manual earns its keep. It covers measuring engine compression pressure, blowby pressure, adjusting valve clearance, fan belt tension, track shoe tension, and a full suite of hydraulic pressure tests. You need to know the LS valve output pressure? It’s in there. The TVC valve servo piston input pressure? Right next to it. Each test includes the required tool list and the judgment standard value table. This is not a generic troubleshooting guide — it’s the exact procedure Komatsu service techs use.

One thing I appreciate: the manual includes a table of judgment standard values and a separate standard value table for electrical parts. That means when you’re probing a connector or measuring resistance, you know whether 0.5 ohms is acceptable or a short. No guesswork.

Komatsu PC100-6, PC120-6 2000 Workshop Manual: Electrical and Hydraulic Systems

Section 10 covers structure and function — hydraulic circuit diagrams, electrical wiring diagrams, the CLSS system, the swing motor, travel motor, PPC valves, solenoid valves, and the boom holding valve. If you’re trying to diagnose a drift in the boom or a slow swing, you need the original wiring diagram. The aftermarket copies often merge multiple revisions and miss pins. This manual has the exact connector locations and pin-out tables. The troubleshooting section even breaks down the N-mode communication abnormality and E-mode engine throttle controller faults with actual flow charts. That’s the difference between a repair that takes hours and one that takes days.

Who Needs This Manual?

If you own a PC100-6 or PC120-6, you need this. Whether you’re a home garage guy doing undercarriage work or a shop foreman trying to get a machine back to a customer, this manual saves you from buying the wrong part or ordering a hydraulic pump you don’t need. A real-world example: a customer came in with a travel deviation issue. We followed the manual’s procedure for testing travel deviation — it identifies whether the problem is in the travel motor, the PPC valve, or the pilot circuit. Without that step, you’d be throwing parts at it.

Beginners: you can use this. The manual has a section called “How to Read the Shop Manual” and explains hoisting instructions, disassembly methods, and coating materials. It doesn’t assume you’re a Komatsu factory tech. But it does assume you have a torque wrench and a multimeter. If you don’t have those, go buy them before you start.

Understand the Hydraulic Circuit Before You Disassemble

Hydraulic circuits on excavators are complex. The manual includes a full hydraulic piping drawing and a hydraulic circuit diagram. Before you crack a fitting on the PTO coupling or the center swivel joint, trace the circuit. Know which line is under residual pressure. The manual tells you how to release remaining pressure in the hydraulic circuit — skip that step, and you’re wearing oil.

Torque matters. Every time. The manual specifies torque not just for general bolts, but for the swing circle bearing, track shoe bolts, and the PPC accumulator. Use the conversion table if you need inch-pounds instead of foot-pounds. It’s all there.

Frequently Asked Questions

Is this manual only for the PC100-6, or does it cover the PC120-6 as well?

It covers both PC100-6 and PC120-6 models, including serial numbers 40001 and up for PC100-6, and 45001 and up for PC120-6.

What kind of torque specifications are included in this manual?

The manual contains a standard tightening torque table in the Foreword that applies to all metric fasteners, plus specific torque values for critical components like the swing circle bearing, track shoe bolts, idler cushion, and the PPC accumulator. Section 20 also lists torque values for hydraulic line fittings and engine mount bolts. These are factory-original specs — not aftermarket approximations. If you’re torquing the final drive mounting bolts, you need the exact number from this manual. The standard table covers bolt grades and sizes from M6 through M30. You also get the conversion table to switch between ft·lb and N·m. I’d ballpark the total torque specifications referenced across the manual at over 500 individual values.

You can find related manuals for other model years: Komatsu PC100-6 PC120-6 PC130-6 2004 Service Manual and KOMATSU PC100-6 PC120-6 Shop Manual SEBM003307. For a broader reference, Komatsu PC100-6, PC100L-6, PC120-6, PC120LC-6, PC130-6 2004 Service Manual covers the extended family. If you’re working on something with a Manual Transmission, this excavator manual won’t help — but the same Komatsu engineering discipline applies. The principles of torque and clearance are universal, and this manual teaches them right.

Access the Factory Manual. Stop fighting vague diagrams and missing torque values. Get the real Komatsu spec — 1036 pages of what your machine needs.