Description

Komatsu PC100-6, PC120-6 2000 Workshop Manual – The Real Factory Document

If you are working on a Komatsu PC100-6 or PC120-6, you need the factory manual – period. Aftermarket PDFs get the torque wrong, leave out the CLSS diagnostics, and skip the safety lock valve adjustments that keep the boom from dropping on someone. This is the actual 2000 Komatsu publication, SEBM003307, printed in Japan. 1036 pages. Not a reprint. Not a scan of a scan. Original OEM file.

Standard Tightening Torque – Page From the Foreword

You do not guess bolt torque on a 30-ton machine. The Foreword section has a dedicated STANDARD TIGHTENING TORQUE table. That table is the baseline for every bolt on the machine unless a specific procedure calls for a different value. Page numbers? The manual indexes all of this. Grab the torque for the swing motor mounting bolts before you reassemble. One bolt at 80 ft-lb instead of 95 ft-lb and you will be pulling the swing circle again in 50 hours.

Testing Hydraulic Pressure: What Section 20 Covers

Section 20 – TESTING AND ADJUSTING – has the actual flowcharts for diagnosing the hydraulic system. You need to know the LS differential pressure? The manual walks you through testing the TVC valve output pressure and the LD differential pressure. It also includes a TABLE OF JUDGEMENT STANDARD VALUE. That table tells you exactly what pressure range is acceptable at each test port. Do not rely on a forum post. Use the factory standard value table.

7 Major Sections in This 1036-Page Manual

The manual splits into these main sections:
01 GENERAL – specs, weight table, lubricant list
10 STRUCTURE AND FUNCTION – every hydraulic component, and importantly the CLSS (Closed Center Load Sensing System) and the EPC solenoid valve hydraulics
20 TESTING AND ADJUSTING – includes full troubleshooting for engine throttle controller (E mode) and communication abnormality (N mode)
30 DISASSEMBLY AND ASSEMBLY – step‑by‑step with exploded views
40 MAINTENANCE STANDARD – wear limits and clearances
Plus the Foreword with hoisting instructions, push‑pull coupler disassembly, and coating materials. It is all OEM written by people who built the machine.

Read the Safety Section First – This Is Not Joking

The SAFETY section is in every Komatsu shop manual for a reason. It covers how to safely release remaining pressure in the hydraulic circuit, how to bleed air after component replacement, and what to do before working on the accumulator for breaker. You will find that procedure in Section 20 as well. Safety warnings are written into the testing steps. Do not skip them. One bypassed safety lock valve inspection and you have a boom falling on a technician.

Does This Manual Cover the S4D95L-1 Engine?

Yes, the PC100‑6 and PC120‑6 mount the S4D95L‑1. This manual covers that engine’s governor motor adjustment, valve clearance specs, injection timing, blowby pressure measurement. However, for deeper engine overhaul (pistons, rings, liner protrusion) Komatsu directs you to the separate 95 Series Engine Shop Manual. That manual is a companion – we carry it as well: Komatsu PC100-6 PC120-6 PC130-6 2004 Service Manual covers the later revision of the same platform. If you need the full engine tear‑down, also see KOMATSU PC100-6 PC120-6 Shop Manual – wait, that is the same document? No, the linked manual is the same series but different publication. Check the year. For 2004 models, use Komatsu PC100-6, PC100L-6, PC120-6, PC120LC-6, PC130-6 2004 Service Manual. The engine supplement is separate.

Where Does This Manual Fit with Transmission Work?

This machine uses a hydrostatic travel motor – no manual gearbox. If you are coming from working on trucks or cars with a Manual Transmission, the diagnostic approach here is different. The travel motor section (Section 10) shows how to test travel deviation and adjust the travel PPC valve. For automotive reference, check Manual Transmission resources but that is a different world. Stick to the factory hydraulics data for this equipment.

FAQ

Can I use this manual for a PC130-6?

No. The PC130-6 uses a different engine (S4D102L-1) and a longer undercarriage. Use the correct manual for that model.

Where are the wiring diagrams?

Section 10 contains the ELECTRICAL WIRING DIAGRAM and ELECTRICAL CIRCUIT DIAGRAM. The diagrams are factory‑drawn with wire colors (see ELECTRIC WIRE CODE in Foreword) and connector pin numbers. The troubleshooting section in 20 includes connector types, mounting locations, and connection tables. If you need to trace an E‑2 fault code showing fuel control dial input value abnormality, start on the page for ENGINE THROTTLE CONTROLLER SYSTEM CIRCUIT DIAGRAM. That section alone saves hours of meter probing. The manual also covers the N‑mode communication abnormality – N‑1 [E218] – with full flowcharts. Do not guess wire colors; the factory code is the only reliable source.

Related Manuals that you might need alongside this one:

• Komatsu PC100-6 PC120-6 PC130-6 2004 Service Manual
• KOMATSU PC100-6 PC120-6 Shop Manual
• Komatsu PC100-6, PC100L-6, PC120-6, PC120LC-6, PC130-6 2004 Service Manual

Stop fighting with generic PDFs that skip the CLSS adjustment and the EPC solenoid valve output pressure test. Access the Factory Manual – you get the exact same document that Komatsu dealers use. 1036 pages, searchable, printable. No third‑party edits, no missing pages. Direct from the OEM.