Komatsu PC120-5K PC130-5K PC150HD-5K and PC180LC-5K Hydraulic Excavator Service Manual

Description

Komatsu PC120-5K PC130-5K PC150HD-5K and PC180LC-5K Hydraulic Excavator Service Manual

This Komatsu PC120-5K PC130-5K PC150HD-5K and PC180LC-5K Hydraulic Excavator Service Manual is the chassis shop volume used to service the mid-size -5K hydraulic excavator family. The printed cover identifies the machines as Komatsu hydraulic excavators in the PC120-5K, PC130-5K, PC150HD-5K, PC150NHD-5K, PC180LC-5K, PC180LLC-5K and PC180NLC-5K range, with serial-number cut-ins starting at K20001 for most models and K20655 for PC130-5K. The book is written as a workshop aid: structure and function first, then testing and adjusting with troubleshooting charts, then removal and rebuild sequences, then wear limits for inspected parts.

The foreword states that shop manuals are split by volume. This file is the chassis volume issued for these machine models. Engine work is called out separately as an engine-series volume, and electrical or attachment volumes are described as shared books. When a procedure points outside this chassis book, the text says to use the engine shop manual rather than inventing engine overhaul steps here. That split matters on the bench: pumps, valves, travel motors, swing machinery, undercarriage, work equipment and the PEMC / EMACC control package are covered in depth; crankcase, injection pump internals and similar engine rebuild work are not the subject of this volume.

File Details

• Manual type: Service manual / shop manual (chassis volume)
• Brand / product: Komatsu hydraulic excavator
• Models: PC120-5K, PC130-5K, PC150HD-5K, PC150NHD-5K, PC180LC-5K, PC180LLC-5K, PC180NLC-5K
• Language: English
• Page count: 646
• File format: PDF
• Serial coverage printed on the title pages: S/N K20001 and up (PC120-5K, PC150HD-5K, PC150NHD-5K, PC180LC-5K, PC180LLC-5K, PC180NLC-5K); S/N K20655 and up (PC130-5K)
• Revision tracking: list of revised pages with add / replace / discard marks and edition marks ① ②

Machines Covered by This Shop Book

The Komatsu PC120-5K PC130-5K PC150HD-5K and PC180LC-5K Hydraulic Excavator Service Manual groups two undercarriage families. PC120-5K and PC130-5K share the lighter track-frame weights, idlers, rollers and travel-motor packages listed in the opening weight table. PC150HD-5K and PC150NHD-5K use the heavier HD track frame, larger idlers and cushions, four carrier rollers and the heavier travel motor and final-drive assemblies. PC180LC-5K, PC180LLC-5K and PC180NLC-5K sit on the larger upper structure: heavier revolving frame, separate fuel and hydraulic tanks, larger swing circle and swing machinery, 160 kg hydraulic pump assembly, and track-frame weights that change again between LC, LLC and NLC.

Component weights are tabulated so a hoist can be sized before a lift. Examples printed in the weight table include a 1,034 kg revolving frame on PC120 / PC130 / PC150 machines versus 1,450 kg on PC180; counterweights of 2,153 kg (PC120 / PC150), 2,351 kg (PC130) and 2,603 kg (PC180); travel motor and final-drive assemblies at 165 kg each on PC120 / PC130 and 459 kg each on PC150 / PC180; and work-equipment assemblies with boom, arm, link, bucket and cylinder masses listed by model. Heavy parts of 25 kg or more are flagged with the kg symbol in the disassembly section so the correct sling and hook position can be chosen from the hoisting instructions.

IMAGES PREVIEW

Chapters Covered

• 10 Structure and Function — P.T.O.; power train; final drive; swing circle; swing machinery; track frame; idler; idler cushion; track roller; carrier roller; track shoe; hydraulic piping; hydraulic circuit diagram; hydraulic tank and fuel tank; hydraulic pump; L.H. 6-spool control valve; R.H. 5-spool control valve; swing motor; center swivel joint; travel motor; valve control; PPC valve; accumulator; safety lock valve; solenoid valve; shuttle valve; boom holding valve; hydraulic cylinder; work equipment; electrical wiring diagram; electrical circuit diagram; engine control system; PEMC system; EMACC (Electronic Monitor and Control Console)
• 20 Testing and Adjusting — table of judgement standard value; standard value table for electrical system; tools for testing, adjusting and troubleshooting; adjusting travel of governor motor lever; adjusting engine speed sensor; adjusting travel limit switch; inspection of swing circle bearing clearance; testing and adjusting hydraulic pressure in work equipment, swing and travel circuit; charging pump pressure; main pump control pressure; measuring stroke of servo piston; travel deviation; PPC valve output pressure and adjustment; PPC shuttle valve; solenoid valve output port pressure; hydraulic drift of work equipment; bleeding air; releasing remaining pressure in the hydraulic circuit
• 20 Troubleshooting — points to remember; sequence of events; precautions; checks before troubleshooting; electrical circuit diagram; connector positions and connection table; handling connectors; control-mechanism functions; display method for monitor panel, pump controller and engine throttle controller; self-diagnostic function and symptoms; judgement tables and chart method; E-mode engine throttle controller; C-mode pump controller; F-mode pump controller input signals; H-mode hydraulic and mechanical system; P-mode monitor system
• 30 Disassembly and Assembly — method of using the manual; operation precautions; special tool list; weight table; tightening torques and standard values; lubricant and coolant table; hydraulic cooler; radiator and hydraulic cooler; engine and hydraulic pump; PTO; center swivel joint; final drive; travel motor; sprocket; swing motor; swing machinery; revolving frame; swing circle; idler and recoil spring; track roller; carrier roller; track shoe; charging pump; hydraulic pump and piston pump; main pump input shaft oil seal; control valve; main relief valve; TVC valve; CO / NC valve; servo valve; work equipment PPC valve; PPC shuttle valve; boom holding valve; boom, arm and bucket cylinders; hydraulic cylinder rebuild; work equipment (bucket, arm, boom); operator’s cab; counterweight; engine throttle controller; pump controller; monitor panel
• 40 Maintenance Standard — judgement standards for final drive; swing circle; swing machinery; track frame; idler; track roller; carrier roller; track shoe; hydraulic pump; charging pump and relief valve; L.H. 6-spool control valve; R.H. 5-spool control valve; swing motor; center swivel joint; travel motor; PPC valve; boom holding valve; hydraulic cylinder; work equipment

Taken together, those four groups give a technician the map of how each assembly is built, the numbers used to decide if it is still serviceable, the pressure and electrical checks that confirm a complaint, and the order of bolts, slings and oil refill steps used to take it apart and put it back. The Komatsu PC120-5K PC130-5K PC150HD-5K and PC180LC-5K Hydraulic Excavator Service Manual is therefore a working chassis book rather than an operator handbook: it assumes the machine is in the shop and the job is diagnosis or repair.

Hydraulic Circuit, Pump Control and Work Equipment

Section 10 walks the hydraulic path from tank and pump through the left-hand six-spool valve and right-hand five-spool valve to swing, travel and the boom / arm / bucket cylinders. The pump chapter explains how discharge is matched to load. Later testing pages give the shop method for main-circuit relief, charging-pump pressure, TVC valve output, CO and NC valve output, servo-piston stroke and PPC output. Measurement oil temperature is stated as 45–55°C on the pressure sheets. Boom relief in H.O and H mode is listed at 325 ± 15 kgf/cm² in the judgement tables, with a related troubleshooting check around 330 ± 25 kgf/cm² after a main-relief adjustment. Swing-circuit figures in the same family of tables include 240 ± 25 kgf/cm² at high idle for left and right swing relief on the listed models.

Travel pages cover deviation measurement, hydraulic drift on a 12° slope, travel-motor leakage and Hi / Lo speed-solenoid action. Work-equipment pages cover cylinder cycle times, internal leakage limits (standard max. 3.5 cc/min in the printed judgement table), boom holding valve checks and the PPC / shuttle / safety-lock path used for pilot control. Air-bleed sequences are written for the main pump, travel motor, swing motor and cylinders, and a dedicated procedure releases remaining pressure in the PPC hydraulic circuit before hoses come off.

PEMC, Engine Throttle Control and EMACC

The later structure chapters describe the pump and engine mutual control system (PEMC) and the Electronic Monitor and Control Console (EMACC). Working-mode and power-set combinations (H, S and L with related H.O / G.O / F.O / L.O settings) change how the pump controller and engine throttle controller share load. Printed matching figures include 83.8 HP / 2,200 rpm and 64.1 HP / 1,750 rpm on PC120, PC130 and PC150, and 98.6 HP / 2,000 rpm on PC180. Auto-deceleration drops speed about 100 rpm from the dial setting after a short neutral hold, then pulls the governor lever back further if levers stay at neutral. Automatic warming-up targets 1,200 rpm when coolant is below the printed threshold after start; overheat prevention cuts pump load and engine speed if coolant rises too far.

Self-diagnosis is built into the monitor panel, pump controller and engine throttle controller. Section 20 gives LED and code behaviour, connector pin-outs, voltage and resistance windows, and branched charts for complaints such as no start, irregular rotation, low maximum speed, engine that will not stop, hunting, failed auto-deceleration, travel deviation, weak digging force, swing brake that will not release, and flashing CHECK or CAUTION items on the monitor. Several charts end with a pointer to the engine shop manual when the fault leaves the chassis controllers and enters the injection-pump or engine-proper side.

Workshop Data Printed in the Front Matter

Opening pages collect the numbers used every day in the bay. Standard bolt-and-nut torques run from 6 mm (1.35 ± 0.15 kgm / 13.2 ± 1.4 Nm) through 39 mm (335 ± 35 kgm / 3280 ± 340 Nm), with separate tables for split-flange bolts and flared-nut fittings. Coating materials are listed by Komatsu code: LT-1A / LT-1B / LT-2 (also called LOCTITE in the book) / LT-3 adhesives and LG-1 through LG-5 gasket sealants, plus LM-P antifriction compound and G2-LI lithium grease. Wire-code tables decode thickness (nominal 0.85 through 100) and colour stripes used on the wiring diagrams.

Lubricant and water charts split the fleet. PC120 / PC130-5K and PC150HD / NHD-5K list a 13 ℓ engine oil pan (specified and refill), hydraulic system 150 ℓ specified / 100 ℓ refill, fuel tank 250 ℓ and cooling system 21 ℓ. PTO, swing machinery and final-drive fills differ by model (for example final drive 4 ℓ each on PC120 / PC130 and 7.6 ℓ each on PC150). PC180LC / LLC / NLC-5K lists a 20 ℓ oil pan, hydraulic system 190 ℓ specified / 135 ℓ refill, cooling system 27 ℓ and final drive 7.6 ℓ each. Engine oil grades are SAE 30, 10W, 10W-30 and 15W-40 by ambient band; hydraulic oil follows the same viscosity family; roller and idler cavities use SAE 140 gear oil in the printed quantities. Fuel is ASTM D975 No. 2 (No. 1 noted for cold use). Notes shorten the engine-oil interval when fuel sulphur exceeds 0.5% and when API CC oil is used instead of CD.

Safety, Hoisting and Shop Practice

The safety chapter is not filler. It requires the Operation and Maintenance Manual to be read before work, PPE for hammering and grinding, trained welders only, UNDER REPAIR tags on the controls, blocked tracks on level ground, work equipment lowered or pinned, battery negative lead first, pressure released before caps and hoses come off, and no fingers in aligning pin holes. Track removal warns that the chain can separate suddenly. Hoisting instructions give allowable loads for standard wire-rope diameters from 10 mm (1.0 ton) to 60 mm (40.0 ton) and show how hanging angle cuts capacity when two slings open wide.

Disassembly pages repeat those rules with job-specific notes: leave two opposite bolts on spring-loaded covers, coat sliding parts with engine oil or LM-P before press fits, mark hoses, refill to the lubricant table, circulate oil or coolant with the engine and re-check level, and bleed air after pump, motor or cylinder work. Special tools are listed at the start of section 30 rather than left to guesswork.

What This Manual Lets You Do

With the Komatsu PC120-5K PC130-5K PC150HD-5K and PC180LC-5K Hydraulic Excavator Service Manual on the bench you can trace a slow boom, a drifting arm, a noisy swing, a pulling travel or a flashing monitor lamp back to a measured pressure, a controller code or a worn bushing instead of swapping parts. You can set main relief, TVC, charging pump and PPC valves to the printed windows, inspect swing-circle bearing clearance, measure servo-piston stroke, and decide from section 40 whether a final-drive gear, track roller, pump barrel or cylinder tube is still inside limit. You can pull and rebuild the assemblies the contents list names, using the torque and weight figures that belong to this -5K family.

Those procedures only stay safe and repeatable when the numbers and sequences in this shop book are the ones used on the machine. Guessed relief settings, mixed serial-range parts or skipped air-bleed steps are how a repaired excavator comes back with the same complaint. Instant PDF delivery after payment means the file is available on the shop computer, tablet or phone with no wait for a printed shipment, and pages can be printed for the stand beside the machine.