Komatsu PC120/PC130/PC150/PC180 Excavators OEM Service & Repair Manual

SEBMK203PS02 EiI~~illJ~IL KOMA1su PC120-5K PC130-5K PC150HD-5K PC150NHD-5K PC180LC-5K PC180LLC-5K PC180NLC-5K MACHINE SERIAL No. MACHINE SERIAL No. MODEL MODEL PC120-5K K20001 and up PC180LC-5K K20001 and up PC130-5K K20655 and up PC180LLC-5K K20001 and up PC150HD-5K K20001 and up PC180NLC-5K K20001 and up PC150NHD-5K K20001 and up • This shop manual may contain attachments and optional equipment that are not available in your area. Please consult your local Komatsu distributor for those items you may require. Materials and specifications are subject to change without notice . • PC120, PC130-5K, PC150HD,NHD-5K mount the 1004-4T engine. PC180LC, LLC, NLC-5K mount the 1006-6T engine. For details of the engine, see the 1000 Series Engine Shop Manual. 00-1 ~ www.komatsupartsbook.com

CONTENTS No. of page 10 STRUCTURE AND FUNCTION Il •• 10-1 20 TESTING AND ADJUSTING 20-1 30 DISASSEMBLY AND ASSEMBLY 30-1 40 MAINTENANCE STANDARD. ..................... .. 40-1 00-2 K2 CD www.komatsupartsbook.com

The affected pages are indicated by the use of the following marks. It is requested that necessary actions be taken to these pages according to the table below. Mark Indication Action required 0 Page to be newly added Add • Page to be replaced Replace ( ) Page to be deleted Discard Pages having no mmarks are those previously revised or made additions LIST OF REVISED PAGES Mark Page Time of Mark Page Time of Mark Page Time of Mark Page Time of Mark Page Time of revision revision revision revision revision · 00- 1 CD 10-10 10-42 10-74 10-103 00- 2 10-11 10-43 10-75 10-104 0 00- 2-1 CD 10-12 10-44 10-76 10-105 0 00- 2-2 CD 10-13 10-45 10-77 10-106 0 00- 2-3 CD 10-14 10-46 10-78 10-107 0 00- 2-4 CD 10-15 10-47 10-79 10-108 00- 3 10-16 10-48 10-80 10-109 00- 4 10-17 10-49 10-81 10-110 00- 5 10-18 10-50 10-82 10-111 00- 6 10-19 10-51 10-83 10-112 00- 7 10-20 10-52 10-84 10-113 00- 8 10-21 10-53 10-85 0 10-113 CD 00- 9 10-23 10-54 10-86 10-114 00-10 10-25 10-56 10-87 10-115 00-12 10-27 10-57 10-88 10-116 00-13 10-29 10-58 10-89 10-117 00-14 10-30 10-59 10-90 10-118 · 00-15 CD 10-31 10-60 10-92 10-119 · 00-16 CD 10-32 10-62 10-93 10-121 10- 1 10-33 10-63 10-94 10-123 10- 2 10-34 10-64 10-95 10-124 10- 3 10-35 10-65 10-96 10-125 10- 4 10-36 10-66 10-97 10-126 10- 5 10-37 10.-68 10-98 10-127 10- 6 10-38 10-69 10-99 10-128 10- 7 10-39 10-70 10-100 10-129 10- 8 10-40 10-72 10-101 10-130 10- 9 10-41 10-73 10-102 10-131 00-2-1 ~ www.komatsupartsbook.com

Mark Page Time of Mark Page Time of Mark Page Time qf Mark Page Time of Mark Page Time of revision revision revision revision revision 10-127 • 20- 6 (g) 20-51 • 20-97 (g) 20-150 10-128 • 20- 7 (g) 20-52 • 20-98 (g) 20-151 10-129 • 20- 8 (g) • 20-53 (g) • 20-99 (g) 20-152 10-130 • 20- 9 (g) • 20-54 (g) 20-101 20-153 • 10-131 (g) • 20-10 (g) 20-55 • 20-102 (g) 20-154 10-132 • 20-11 (g) 20-56 20-103 • 20-155 (g) • 10-133 (g) • 20-12 (g) 20-57 20-104 20-156 • 10-134 (g) 20-13 • 20-58 (g) 20-105 20-158 • 10-135 (g) 20-14 20-59 20-106 20-159 • 10-136 (g) 20-15 • 20-60 (g) 20-107 20-160 • 10-137 (g) 20-16 • 20-61 (g) 20-109 20-161 • 10-138 (g) 20-17 • 20-62 (g) 20-110 20-162 • 10-139 (g) 20-18 • 20-63 (g) • 20-111 (g) 20-163 • 10-140 (g) 20-19 20-64 20-112 20-164 • 10-141 (g) 20-20 20-65 20-113 20-165 10-142 20-21 20-66 20-114 20-166 • 10-143 (g) 20-22 20-67 20-116 20-167 10-144 20-23 20-68 20-117 20-168 10-145 • 20-24 (g) 20-69 20-118 20-169 10-146 20-25 20-70 • 20-120 (g) 20-170 10-147 20-26 20-71 20-121 20-171 10-148 20-27 20-72 20-122 20-172 10-149 20-28 20-73 20-123 20-173 10-150 • 20-29 (g) 20-74 20-124 20-174 • 10-151 (g) • 20-30 (g) 20-75 • 20-126 (g) 20-175 10-152 20-31 20-76 20-127 CD 20-176 10-153 20-32 • 20-77 (g) • 20-128' (g) 20-177 10-154 20-33 20-78 20-129 CD 20-178 10-155 20-34 20-79 • 20-130 (g) 20-179 10-156 20-35 • 20-80 (g) 20-131 20-180 10-157 20-36 20-81 20-132 20-181 10-158 20-37 20-82 20-133 20-182 10-159 20-38 20-83 20-135 20-183 10-160 • 20-39 (g) 20-85 • 20-137 (g) 20-184 10-161 20-40 20-86 20-139 • 20-186 (g) 10-162 • 20-41 (g) 20-87 20-140 20-187 10-163 • 20-42 (g) 20-88 • 20-141 (g) 20-188 • 20-43 (g) 20-89 20-142 20-189 • 20-44 (g) 20-90 20-143 • 20-190 (g) • 20-45 (g) 20-91 20-144 20-191 20- 1 • 20-46 (g) 20-92 20-145 20-192 • 20- 2 (g) • 20-47 (g) 20-93 20-146 20-194 • 20- 3 (g) • 20-48 (g) 20-94 20-147 20-195 • 20- 4 (g) • 20-49 (g) 20-95 CD 20-148 20-196 • 20- 5 (g) 20-50 • 20-96 (g) • 20-149 (g) 20-197 00-2-2 @ K20 www.komatsupartsbook.com

'5 Mark Page Time of Mark Page Time of Mark Page Time of Mark Page Time of Mark Page Time of revision revision revision revision revision 20-198 30- 1 30-46 30-91 30-133-1 CD 20-199 30- 2 30-47 30-92 30-133-2 CD 20-200 30- 3 30-48 30-93 • 30-134 ® 20-201 30- 4 30-49 • 30-94 ® 30-135 • 20-202 ® 30- 5 30-50 30-95 30-136 20-203 • 30- 6 ® 30-51 • 30-96 ® 30-137 • 20-204 ® • 30- 7 ® 30-52 30-97 30-138 20-205 • 30- 8 ® 30-53 30-98 30-139 20-206 • 30- 9 ® 30-54 30-99 30-140 • 20-207 ® • 30-10 ® 30-55 • 30-100 ® 30-141 20-209 • 30-11 ® • 30-56 ® 30-101 30-142 20-210 • 30-12 ® 30-57 30-102 30-143 20-211 30-13 30-58 30-103 • 30-144 ® 20-212 30-14 30-59 30-104 30-145 20-213 30-15 • 30-60 ® 30-105 30-146 20-214 • 30-16 ® 30-61 30-106 30-147 20-215 30-17 30-62 30-107 30-148 20-216 30-18 30-63 30-108 30-149 20-217 30-19 30-64 30-109 20-218 30-20 30-65 30-110 20-219 30-21 • 30-66 ® 30-111 20-220 30-22 30-67 • 30-112 ® 20-221 • 30-23 ® • 30-68 ® 30-113 40- 1 20-222 • 30-24 ® 30-69 30-114 40- 2 20-223 30-25 30-70 30-115 40- 3 20-224 30-26 30-71 30-116 • 40- 4 ® 20-225 • 30-27 ® 30-72 30-117 40- 5 20-226 • 30-28 ® 30-73 • 30-118 ® • 40- 6 ® 20-227 30-29 30-74 30-119 40- 7 20-228 30-30 30-75 • 30-120 ® • 40- 8 ® 20-229 30-31 30-76 30-121 40- 9 20-230 30-32 30-77 30-122 40-10 20-231 30-33 • 30-78 ® 30-123 • 40-11 ® 20-232 30-34 30-79 • 30-124 ® 40-12 20-233 30-35 • 30-80 ® 30-125 40-13 20-234 • 30-36 ® 30-81 30-126 • 40-14 ® 20-235 30-37 30-82 30-127 40-15 20-236 30-38 30-83 30-128 • 40-16 ® 20-237 30-39 • 30-84 ® 30-129 40-17 20-238 30-40 30-85 30-130 • 40-18 ® 20-239 30-41 30-86 30-131 CD 40-19 30-42 30-87 30-131-1 CD 40-20 30-43 • 30-88 ® 30-131-2 CD 40-21 30-44 30-89 30-132 CD • 40-22 ® 30-45 • 30-90 ® 30-133 CD 40-23 00-2-3 (l) www.komatsupartsbook.com

Mark Page Time of Mark Page Time of Mark Page Time of Mark Page Time of Mark Page Time of revision revision revision revision revision • 40-24 @ 40-32 40-40 40-46 40-51-1 CD 40-25 40-33 40-41 40-47 • 40-52 (l) • 40-27 @ • 40-35 (l) • 40-42 (l) 40-48 40-53 40-28 40-36 40-43 • 40-49 (l) 40-54 40-29 40-37 • 40-44 (l) 40-50 40-55 40-31 40-39 40-45 40-51 CD 00-2-4 ~ K2( www.komatsupartsbook.com

A IMPORTANT SAFETY NOTICE Proper service and repair is extremely important for the safe operation of your machine. The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe methods of operation. Some of these operations require the use of tools specially designed by Komatsu for the purpose. To prevent injury to workers, the symbols A and ~+At are used to mark safety precautions in this manual. The cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation. A SAFETY GENERAL PRECAUTIONS Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully BEFORE operating the machine. 1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine. 2. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. • Always wear safety glasses when hitting parts with a hammer. • Always wear safety glasses when grinding parts with a grinder, etc. 3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, glasses, cap and other clothes suited for welding work. 4. When carrying out any operation with two or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator's compartment. 5. Keep all tools in good condition and learn the correct way to use them. 6. Decide a place in 'the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working. PREPARATIONS FOR WORK 7. Before adding oil or making any repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving . 8. Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them. 9. When disassembling or assembling, sup- port the machine with blocks, jacks or stands before starting work. 1O. Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing. 00-3 www.komatsupartsbook.com

PRECAUTIONS DU RING WORK 11 . When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from .spurting out. Before disconnecting or removing components of the oil, water or air circuits, first remove the pressure completely from the circuit. 12. The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned. Wait for the oil and water to cool before carrying out any work on the oil or water circuits. 13. Before starting work, remove the leads from the battery. Always remove the lead from the negative (-) terminal first. 14. When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage. Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane. 15. When removing covers which are under internal pressure or under pressure from a spring, always leave two bolts in position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove. 16. When removing components, be careful not to break or damage the wiring. Damaged wiring may cause electrical fires. 17. When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips on to the floor, wipe it up immediately. Fuel or oil on the .floor can cause you to slip, or can even start fires. 18. As a general rule, do not use gasoline to wash parts. In particular, use only the mini- mum of gasoline when washing electrical parts. 00-4 19. Be sure to assemble all parts again in their original places. Replace any damaged parts with new parts. • When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is being operated. 20. When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely careful when installing tubes for high pressure circuits. Also, check that connecting parts are correctly installed. 21 . When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check, that they are installed correctly. 22. When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. 23. When measuring hydraulic pressure, check that the measuring tool is correctly assem- bled before taking any measurements. 24. Take care when removing or installing the tracks of track-type machines. When removing the track, the track sepa- rates suddenly, so never let anyone stand at either end of the track. www.komatsupartsbook.com

---------FOREWORD--------- This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity. This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into chapters for each main group of components; these chapters are further divided into the following sections. STRUCTURE AND FUNCTION This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. TESTING AND ADJUSTING This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating "Problems" to "Causes" are also included in this section. DISASSEMBLY AND ASSEMBLY This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations. MAINTENANCE STANDARD This section gives the judgement standards when inspecting disassembled parts. NOTICE The specifications contained in this shop manual are subject to change at any time and without any advance notice. Contact your KOMATSU distributor for the latest information. 00-5 www.komatsupartsbook.com

HOW TO READ THE SHOP MANUAL HOW 'TO READ THE SHOP MANUAL VOLUMES Shop manuals are issued as a guide to carrying out repairs. They are divided as follows: Chassis volume: Issued for every machine model Engine volume: Issued for each engine series } Each issued as one Electrical volume . volume to cover all Attachments volume : models These various volumes are designed to avoid du- plicating the same information. Therefore to deal with all repairs for any model, it is necessary that chassis, engine, electrical and attachment volumes are ready. DISTRIBUTION AND UPDATING Any additions, amendments or other changes will be sentto KOMATSU distributers. Get the most up- to-date information before you start any work. FILING METHOD 1. See the page number on the bottom of the page. File the pages in correct order. 2. Following examples show how to read the page number. Example 1 (Chassis volume): 2 1- 3 --+_+-- Unit number (2. Power train) ~--+- Item number (1. Structure and Function) ~ Consecutive page number for each item. Example 2 (Engine volume): 12-410 ........_~......-- __ Unit number (1. Engine) '----+---+-__ Item number (2. Testing and Adjusting) ~+--__ Group No. (4. Fuel system) Consecutive page No. (Page 10 of Group 4) 3. Additional pages: Additional pages are indicated by a hyphen (-) and number after the page number. File as in the example. Example: 21-4 12-203 21-4-1 J- ---e 1 2-203-1 21 -4-2 Added pages 1 2-203-2 21-5 12-204 00-6 REVISED EDITION MARK (CD CZ) @ .... ) When a manual is revised, an edition mark is recorded on the bottom outside corner of the pages. REVISIONS Revised pages are shown at the LIST OF REVISED PAGES on the between the title page and SAFETY page. SYMBOLS So that the shop manual can be of ample practical use, important places for safety and quality are marked with the following symbols. Symbol Item Remarks A Special safety precautions are necessary when performing the work. Safety Extra special safety precautions "A~ are necessary when performing + the work because it is under internal pressure. Special technical precautions or * other precautions for Caution preserving standards are necessary when performing the work. Weight of parts or systems. ~ Caution necessary when Weight selecting hoisting wire, or when working posture is important, etc. ~ Tighten- Places that require special ing torque attention for the tightening torque during assembly. ~ Coat Places to be coated with adhesives and lubricants etc. fji Places where oil, water or fuel Oil, water must be added, and the capacity. • Places where oil or water must ... Drain be drained, and quantity to be drained. www.komatsupartsbook.com

Komatsu PC120/PC130/PC150/PC180 Excavators OEM Service & Repair Manual

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