Description

Komatsu PC120-5K, PC130-5K, PC150HD-5K, PC150NHD-5K, PC180LC-5K Workshop Manual

If you are pulling a hydraulic pump on a Komatsu excavator without the factory specs, you are gambling with a two-thousand-dollar part. The Komatsu PC120-5K, PC130-5K, PC150HD-5K, PC150NHD-5K, PC180LC-5K Workshop Manual is the only document that gives you the exact torque values, clearance specs, and testing procedures Komatsu engineers wrote.

No aftermarket copy will do.

10 Structure and Function – Hydraulic Circuit Maps

Section 10 lays out the entire hydraulic system. You get circuit diagrams that show oil flow through the main pump, control valves, and travel motors. If you need to understand why a boom drifts or track response lags, this is where you start. Page references inside the section guide you to specific components. No guesswork.

20 Testing and Adjusting – Where the Real Work Lives

Testing and Adjusting (section 20) is where you find the pressure settings, flow rates, and timing data. Need the charge pressure? Page 73. Pump torque limit? It is in there. Komatsu wants you to use a pressure gauge and a tachometer, not a calibrated thumb. This section gives you the exact procedures – step-by-step – to measure and set each circuit. If you skip this, you will chase gremlins for days. You will also find the specifications for the pilot pressure, travel speed, and swing brake. Do not assume numbers – look them up. Every time I see a machine that has been ‘adjusted by feel’ it comes back with a burned pump or leaking seals. A torque wrench and a pressure gauge are cheap compared to a new main pump.

Does This Manual Cover Both Engine Types?

Yes. The PC120-5K, PC130-5K, PC150HD-5K, and PC150NHD-5K use the 1004-4T engine. The PC180LC-5K (and the LLC and NLC variants) use the 1006-6T. Both engines are covered in the 1000 Series Engine Shop Manual, but this workshop manual gives you the machine-specific mounting, cooling, and hydraulic drive information. You also get the serial number ranges: K20001 and up for each model. So if you have a PC180LC-5K serial K25000, you are in the right place. If you have a PC120-5K serial K19999, this manual does not apply. The manual cross-references to the engine manual for internal engine work, but includes all the data you need for the hydraulic pumps, swing motor, and final drives that bolt to the engine. The 1004-4T is a four-cylinder, the 1006-6T is a six-cylinder – the mounting points differ, and the manual explains the differences in the bell housing and flex plate. Do not mix them up.

30 Disassembly and Assembly – Getting the Swing Gear Apart

Section 30 is the hands-on part. It walks you through removing the swing gear, final drives, track frame, and boom cylinder. Each step includes required tool lists. You need a puller for the swing pinion, a torque wrench that reads in foot-pounds, and a clean work surface. The manual calls out torque values for every bolt – track shoe bolts get 70-85 ft-lb, for example. Do not use a crow’s foot unless the manual says to. It also includes safety warnings: always block the machine, relieve hydraulic pressure, and use lifting equipment rated for the load. If you are not familiar with how a Manual Transmission works, get the theory from a trusted source before diving into the final drive disassembly.

Why OEM Factory Data Beats Aftermarket Copies

Aftermarket manuals are frequently missing pages, have blurry diagrams, or give generic specs that do not match this exact machine. This is a direct Komatsu publication – revision marks, original page numbers, and the SEBMK203P502 identifier. The 646 pages are scanned from the factory binder. When you need the tolerance for a swing gear backlash, you get the Komatsu number, not a third-party guess. I have seen aftermarket manuals that list the wrong pump displacement. That costs you a core charge. Save yourself the headache. The travel motor output goes through a reduction gearbox, similar to a Manual Transmission in principle.

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Grab the factory manual before you start. Access the Factory Manual and keep a copy on your shop tablet. You will thank yourself when the job goes smooth and the bolts stay tight.

What is the page count?

646 pages.

How do I know if this manual matches my machine’s serial number?

Check the serial number ranges printed on page 00-2: PC120-5K K20001 and up, PC130-5K K20355 and up, PC150HD-5K K20001 and up, PC150NHD-5K K20001 and up, PC180LC-5K K20001 and up, PC180LLC-5K K20001 and up, PC180NLC-5K K20001 and up. If your machine falls within these ranges, this manual covers it. If your serial number is below the start, you need an earlier edition. Always confirm before buying.