SEBMK203PS02

EiI~~illJ~IL
KOMA1su
PC120-5K
PC130-5K
PC150HD-5K
wwwPC150NHD-5K
.komat supart
sbook
.com
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
~
 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

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00-2 K2
CD
 The affected pages are indicated by the use of the
following marks. It is requested that necessary actions be
Mark Indication Action required
taken to these pages according to the table below.

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
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· 00- 1
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0 00- 2-1 CD 10-12 10-44 10-76 10-105

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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

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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
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00-13 10-29 10-58 10-89 10-117
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· 00-15 CD 10-31 10-60 10-92 10-119

· 00-16
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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

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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)
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10-130 • 20- 9 (g)
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• 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

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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

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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

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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

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• 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

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K2(
00-2-4
~
 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 re-
quire 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 pre-
cautions 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.
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.

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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 op-
erating 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.
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.
1 O. 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
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 compo-
nents 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 car-
rying 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.
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 ma-
chine is being operated.
20. When installing high pressure hoses, make
sure that they are not twisted. Damaged
tubes are dangerous, so be extremely care-
ful 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

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Check that the wire rope, chains and hooks

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fingers or hand. Be careful not to get your
are free from damage. fingers caught in a hole.
Always use lifting equipment which has
ample capacity. 23. When measuring hydraulic pressure, check
Install the lifting equipment at the correct that the measuring tool is correctly assem-
places. Use a hoist or crane and operate bled before taking any measurements.
slowly to prevent the component from hit-
24. Take care when removing or installing the
ting any other part. Do not work with any
tracks of track-type machines.
part still raised by the hoist or crane.
When removing the track, the track sepa-
15. When removing covers which are under in- rates suddenly, so never let anyone stand at
ternal pressure or under pressure from a
either end of the track.
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
 ---------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.

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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
HOW TO READ THE SHOP MANUAL

HOW 'TO READ THE SHOP MANUAL

VOLUMES REVISED EDITION MARK (CD CZ) @ .... )
Shop manuals are issued as a guide to carrying When a manual is revised, an edition mark is
out repairs. They are divided as follows: recorded on the bottom outside corner of the pages.

Chassis volume: Issued for every machine model

Engine volume: Issued for each engine series
Each issued as one
Electrical volume REVISIONS
volume to cover all
Attachments volume : }.
models Revised pages are shown at the LIST OF
These various volumes are designed to avoid du- REVISED PAGES on the between the title page and
plicating the same information. Therefore to deal SAFETY page.
with all repairs for any model, it is necessary that
chassis, engine, electrical and attachment volumes
are ready.
SYMBOLS
DISTRIBUTION AND UPDATING
So that the shop manual can be of ample practical
Any additions, amendments or other changes will use, important places for safety and quality are
be sentto KOMATSU distributers. Get the most up-
marked with the following symbols.
to-date information before you start any work.

FILING METHOD

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Symbol Item Remarks
1. See the page number on the bottom of the page.
File the pages in correct order. Special safety precautions are
2. Following examples show how to read the page necessary when performing the
number. work.
Example 1 (Chassis volume): Safety
Extra special safety precautions
2 1- 3 "A~ are necessary when performing

--+_+-- Unit number (2. Power train)

+ the work because it is under
internal pressure.
~--+- Item number (1. Structure and
Function) Special technical precautions or
~ Consecutive page number for other precautions for
each item.

Example 2 (Engine volume):

* Caution preserving standards are
necessary when performing the
work.

12-410 Weight of parts or systems.

Caution necessary when
........_~......-- __ Unit number (1. Engine) ~ Weight selecting hoisting wire, or when
working posture is important,
'----+---+-_ _ Item number (2. Testing and

Adjusting)
~+--_ _ Group No. (4. Fuel system)
Consecutive page No. (Page 10
of Group 4)
etc.
Places that require special
Tighten-
~ ing torque
attention for the tightening
torque during assembly.

3. Additional pages: Additional pages are indicated Places to be coated with

~ Coat
by a hyphen (-) and number after the page adhesives and lubricants etc.
number. File as in the example.
Places where oil, water or fuel
Example:
fji Oil, water must be added, and the

...
21-4 12-203 capacity.
21-4-1 J- Added pages ---e 112-203-1 Places where oil or water must
21 -4-2 2-203-2 • Drain be drained, and quantity to be
21-5 12-204 drained.

00-6
 HOISTING INSTRUCTIONS

HOISTING INSTRUCTIONS

Slinging near the edge of the hook may cause

A Heavy parts (25 kg or more) must be lifted the rope to slip off the hook during hoisting,
with a hoist etc. In the Disassembly and As- and a serious accident can result. Hooks have
sembly section, every part weighing 25 kg or maximum strength at the middle portion.
more is indicated clearly with the symbol ~

1. If a part cannot be smoothly removed from the

machine by hoisting, the following checks should
be made:
100% 88% 79% 71% 41%
• Check for removal of all bolts fastering the
part to the relative parts. FS0064
• Check for existence of another part causing 3) Do not sling a heavy load with one rope alone,
interference with the part to be removed. but sling with two or more ropes symmetrically
wound on to the load.

2. Wire ropes
A Slinging with one rope may cause turning
of the load during hoisting, untwisting of
1) Use adequate ropes depending on the weight the rope, or slipping of the rope from its
of parts to be hoisted, referring to the table original winding position on the load,
below:

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which can result in a dangerous accident.

Wire ropes 4) Do not sling a heavy load with ropes forming a

(Standard liZ" or liS" twist ropes wide hanging angle from the hook.
without galvanizing) When hoisting a load with two or more ropes,
the force subjected to each rope will increase
Rope diameter (mm) with the hanging angles. The table below
Allowable load (tons)
shows the variation of allowable load (kg) when
10 1.0 hoisting is made with two ropes, each of which
is allowed to sling up to 1 000 kg vertically,'at
11.2 1.4 various hanging angles.
12.5 1.6 When two ropes sling a load vertically, up to
14 2.2 2000 kg of total weight can be suspended. This
weight becomes 1 000 kg when two ropes
16 2.8 make a 1 20° hanging angle. On the other hand,
18 3.6 two ropes are subjected to an excessive force
20 4.4 as large as 4000 kg if they sling a 2000 kg
load at a lifting angle of 150°.
22.4 5.6
30 10.0
40. 18.0
50 28.0
60 40.0

~
'(3
The allowable load value is estimated to be ~1000
one-sixth or one-seventh of the breaking ro
o
~
500
"'0 .........
strength of the rope used. ro
o
....J

2) Sling wire ropes from the middle portion of the

Lifting angle : a
hook. FS0065

00-7
STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE

1. STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS
The following charts give the standard tightening torques of bolts and nuts. Exceptions are given in sections of
"Disassembly and Assembly".

Thread diameter
of bolt
(mm)
Width
across flat
(mm)
Ci) ®
kgm Nm

6 10 1.35±0.15 13.2± 1.4

8 13 3.2±0.3 31.4±2.9
10 17 6.7±0.7 65.7±6.8
12 19 11.5 ± 1.0 112±9.8
14 22 18.0±2.0 177±19

16 24 28.5±3 279±29
18 27 39±4 383±39
20 30 56±6 549±58
22 32 76±8 745±78

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24 36 94.5± 10 927±98

27 41 135 ± 15 1320± 140

30 46 175±20 1720±190
33 50 225±25 2210±240
36 55 280±30 2750±290
39 60 335±35 3280±340

This torque table does not apply to the bolts with which nylon packings or other non-ferrous metal washers are
to be used, or which require tightening to otherwise specified torque.

* Nm (newton meter): 1 Nm ~ 0.1 kgm

2. TIGHTENING TORQUE OF SPLIT FLANGE BOLTS

Use these torques for split flange bolts.

Thread diameter Width Tightening torque

of bolt across flats
(mm) (mm) kgm Nm

10 14 6.7±0.7 65.7±6.8
12 17 11.5 ± 1 112±9.8
16 22 28.5±3 279±29

00-8
 STANDARD TIGHTENING TORQUE

Sealing surface

3. TIGHTENING TORQUE FOR NUTS OF FLARED

Use these torques for nut part of flared.

FS0068

Thread diameter Width across flats Tightening torque

of nut part of nut part
(mm) (mm) kgm Nm

14 19 2.5±0.5 24.5±4.9
18 24 5±2 49± 19.6
22 27 8±2 78.5± 19.6
24 32 14±3 137.3±29.4
30 36 18±3 176.5±29.4
33 41 20±5 196.1±49
36 46 25±5 245.2±49
42 55 30±5 294.2±49

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The recommended coating materials prescribed in Komatsu Shop Manuals are listed below.

Nomenclature Komatsu code Applications

LT-1A Used to apply rubber pads, rubber gaskets, and cork plugs.

Used to apply resin, rubber, metallic and

LT-1 B
Adhesives non-metallic parts when a fast, strong seal is needed.

LT-2* Preventing bolts, nuts and plugs from loosening and leaking oil.

Provides an airtight, electrically insulating seal.

LT-3
Used for aluminum surfaces.

LG-1 Used with gaskets and packings to increase sealing effect.

Heat-resistant gasket for. precombustion chambers

LG-3
and exhaust piping.
Gasket sealant
Used by itself on mounting surfaces on the final drive and trans-
LG-4
mission cases. (Thickness after tightening: 0.07 - 0.08 mm)
Used by itself to seal grease fittings, tapered screw
LG-5 fittings and tapered screw fittings in hydraulic circuits
of less than 50 mm in diameter.
Antifriction com-
pound (Lubricant Applied to bearings and taper shafts to facilitate press-fitting and to
LM-P
including molybde- prevent sticking, burning or rusting.
num disulfide)
Grease Applied to bearings, sliding parts and oil seals for lubrication, rust
G2-LI
(Lithium grease) prevention and facilitation of assembling work.

Vaseline - Used for protecting battery electrode terminals from corrbsion.

*LT -2 is also called LOCTITE in the shop manuals.

00-9
 ELECTRIC WIRE CODE

ELECTRIC ELECTRIC WIRE CODE

In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires.
This wire code table will help you understand WIRING DIAGRAMS.
Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.

CLASSIFICATION BY THICKNESS

Copper wire Current rating

Nominal Cable O.D.
(mm) (A) Applicable circuit
number Number Dia. of strands Cross section
strands (mm) (mm 2 )

0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal etc.

2 26 0.32 2.09 3.1 20 Lighting, signal etc.

5 65 0.32 5.23 4.6 37 Charging and signal

15 84 0.45 13.36 7.0 59 Starting (Glow plug)

40 85 0.80 42.73 11.4 135 Starting

60 127 0.80 63.84 13.6 178 Starting

100 217 0.80 109.1 17.6 230 Starting

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CLASSIFICATION BY COLOR AND CODE

~
Prior- Starting Lighting Instrument Signal Other
Classl- Charging Ground
ity
fication

Code W B B R Y G L
Pri-
1
mary Blue
Color White Black Black Red Yellow Green

Code WR - BW RW YR GW LW
2
Color White & Red - Black & White Red & White Yellow & Red Green & White Blue & White
- Code WB - BY RB YB GR LR
3
Color White & Black - Black & Yellow Red & Black Yellow & Black Green & Red Blue & Red
- Auxi-
liary
Code WL - BR RY YG GY LY
4
Color White & Blue - Black & Red Red & Yellow Yellow & Green Green & Yellow Blue & Yellow
- Code WG - - RG YL (GB) (LB)
5
Color White & Green - - Red & Green Yellow & Blue (Green & Black) (Blue & Black)
- Code - - - RL YW (GL) -
6
Color - - - Red & Blue Yellow & White (Green & Blue) -

00-10
 WEIGHT TABLE
A This weight table is a guide for use when transporting or handling components.

Unit: kg

Machine Model PC120-5K PC130-5K PC150HD-5K PC150NHD-5K

Serial Numbers K20001 and up K20655 and up K20001 and up K20001 and up

P.T.O. 19.5 19.5 19.5 19.5

Radiator and oil cooler assembly 54.5 54.5 54.5 54.5

Revolving frame 1,034 1,034 1,034 1,034

Operator's cab 238 238 238 238

Operator's seat 36.9 36.9 36.9 36.9

Hydraulic tank and fuel tank assembly

174 174 174 174
(excluding fuel and oil)

Counterweight 2,153 2,351 2,153 2,153

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Hydraulic pump assembly 120 120 120 120

L.H. 6-spool control valve 44.5 44.5 44.5 44.5

R.H. 5-spool control valve 40 40 40 40

Swing circle assembly 165 165 165 165

Swing machinery assembly 100 100 100 100

Swing motor 26.6 26.6 26.6 26.6

Center swivel joint 33.5 33.5 33.5 33.5

Track frame assembly

• Track frame 1,300 1,300 2,440 2,440
• Idler 79 x 2 79 x 2 140 x 2 140 x 2
• Idler cushion 75 x 2 75 x 2 135 x 2 135 x 2
• Carrier roller 10.9 x 2 10.9 x 2 21 x 4 21 x 4
• Track roller 22.5 x 14 22.5 x 14 37 x 14 37 x 14
• Travel motor and final drive assembly 165 x 2 165 x 2 459 x 2 459 x 2
• Sprocket 27.3 x 2 27.3 x 2

00-11
(2)
 Unit: kg

Machine Model PC120-5K PC130-5K PC150HD-5K PC150NHD-5K

Serial Numbers K20001 and up K20655 and up K20001 and up K20001 and up

Track shoe assembly

• Triple grouser shoe (500 mm) 1,570 1,570 - -

• Triple grouser shoe (600 mm) 1,780 1,780 2,620 2,620

• Triple grouser shoe (700 mm) 1,980 1,980 2,870 2,870
• Triple grouser shoe (750 mm) 2,080 2,080 - -

• Triple grouser shoe (800 mm) - - 3,120 3,120

• Triple grouser shoe (900 mm) - - 3,380 3,380

Boom assembly 1,179 1,179 1,256 1,256

Arm assembly 444 445 445 445

Link assembly 91 126 126 126

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Bucket assembly 391 408 408 408
LO
0-
Boom cylinder assembly 114 x 2 114 x 2 114 x 2 114 x 2 M
o
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~

Arm cylinder assembly 154.7 154.7 154.7 154.7

Bucket cylinder assembly 90 108 108 108

00-12
~
 Unit: kg

Machine Model PC180LC-5K PC180LLC-5K PC180NLC-5K

Serial Numbers K20001 and up K20001 and up K20001 and up

P.T.O. 24.8 24.8 24.8

Radiator and oil cooler assembly 48.2 48.2 48.2

Revolving frame 1,450 1,450 1,450

Operator's cab 238 238 238

Operator's seat 36.9 36.9 36.9

Fuel tank assembly (excluding fuel) 96 96 96

Hydraulic tank assembly (excluding oil) 113 113 113

Counterweight 2,603 2,603 2,603

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Hydraulic pump assembly

L.H. 6-spool control valve

160

44.5
160

44.5
160

44.5

R.H. 5-spool control valve 40 40 40

Swing circle assembly 223.4 223.4 223.4

Swing machinery assembly 137.4 137.4 137.4

Swing motor 50 50 50

Center swivel joint 35.2 35.2 35.2

Track frame assembly

• Track frame 2,470 3,020 2,408
• Idler 140x 2 140x 2 140 x 2
• Idler cushion 135 x 2 135 x 2 135 x 2
• Carrier roller 21 x 4 21 x 4 21 x 4
• Track roller 37 x 14 37 x 18 37 x 14
• Travel motor and final drive assembly 459x 2 459 x 2 459x 2

00-13
 Unit: kg

Machine Model PC180LC-5K PC180LLC-5K PC180NLC-5K

Serial Numbers K20001 and up K20001 and up K20001 and up

Track shoe assembly

• Triple grouser shoe (600 mm) 2,620 2,850 2,620
• Triple grouser shoe (700 mm) 2,870 3,120 -
• Triple grouser shoe (800 mm) 3,120 3,400 -
• Triple grouser shoe (900 mm) 3,380 3,680 -
• Flat shoe (610 mm) 2,900 - -

Boom assembly 1,078 1,078 1,078

Arm assembly 472 472 472

Link assembly 159 159 159

Bucket assembly 553 553 553

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Boom cylinder assembly

Arm cylinder assembly

135 x 2

190
135 x 2

190
135 x 2

190
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Bucket cylinder assembly 129 129 129

00-14
 LIST OF LUBRICANT AND WATER
PC120,130-5K
AMBIENT TEMPERATURE CAPACITY ( Q )
KIND OF
RESERVOIR 14 32 50 68 86°F
FLUID Specified Refill
-10 0 10 20 30°C

Engine oil pan 13 13

PTO case 1 1
Swing machinery case Engine oil CAl
4 4
Final drive case (each) 4 4
CJ\~10W ><:

Hydraulic system SAE1QW >.:. . :: 150 100

E CAl:'" :;'A' .. .. :.:...::

Carrier roller (1 piece) 0.072

Track roller (1 piece) Gear oil _ _ _SAc 140 0.100-0.115
Idler (1 piece)
0.09
«: .x.:. ::< :::

Fuel tank Diesel fuel 250

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Cooling system Water Add antifreeze 21

* ASTM 0975 No.1

PC150HD, NHD-5K
AMBIENT TEMPERATURE CAPACITY ( Q )
KINU OF
RESERVOIR 14 32 50 68 86°F
FLUID Specified Refill
-10 0 10 20 30°C

<HHHH):»?"SA'E'
................................... ·1' oW?T»>:):Y::><:
Engine oil pan
' .
13 13
. . . '.' ?/({ .SAE'
":-:-:-:-:::-:::-:-:-:::::-:::::::::::::::::::::::::::::::::::~ '1'OW'~3Q }}}~:::n::nn:(( :.:.;.;.;.;.:-:-:-:.:-:.;.;.:-:-..;.;.;.;.; .
......................
h:.:;::::.:j:;::::::::::::::::::::::::::: :::::::::::::::U::::({{}jr $A.~ . .1. .~W ~.4Q.?(: mn::::/::::/~:j:;:::::?::::?:{{{::{:::
PTO case 1.00 1.00
Swing machinery case Engine oil A
4 4
Final drive case (each) 7.6 7.6
• •mJl2•.SAE 10W
Hydrau Iic system 150 100

Carrier roller (1 piece) 0.19-0.21

Track roller (1 piece) Gear oil 'SAE 14~ 0.23-0.25
Idler (1 piece) 0.07-0.08
1:.''-::.;;.:- *<:).
Fuel tank Diesel fuel 250

Cool ing system Water Add antifreeze 21

* ASTM 0975 No.1

00 -15
(2)
PC180LC,LLC,NLC-5K
AMBIENT TEMPERATURE CAPACITY ( Q )
KIND OF
RESERVOIR 14 32 50 68 86°F
FLUID Specified Refill
-10 0 10 20 30°C

Engine oil pan 20 20

j???~~?~IIj~j~Ij~j~~~j~~??~j~j}}~IIl~IIj~j):8AE"","0W'~3Q }~\ <:::::~:::~/:~/:~:~::::::::::: ::::«>::::::::::::::::::>

~~~ ~~ ~ ~ ~ ~i~ ~ ~~~ ~ ~ ~ ~~ ~ j~ ~ ~ ~ ~~~ ~i~~~~~j~ ~~~ j~ j~ ~ j~ j~j~ j~j~j~ j~ j~~ j~ j~~: $A.~.. j.'.$if!·~.49.:::: j: : : : : :~ ~: : : : :
PTO case 1.0 1.0
Swing machinery case Engine oil 4.5 4.5
Final drive case (each) 7.6 7.6

Hydrau Iic system 190 135

Carrier roller (1 piece)

Track roller (1 piece) Gear oil
Idler (1 piece)

Fuel tank Diesel fuel 250

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Cooling system
.com Water Add antifreeze

* ASTM 0975 No.1

27

ASTM: American Society of Testing and

Material
SAE: Society of Automotive Engineers
API: American Petroleum Institute
Specified capacity: Total amount of oil including oil for components and oil in piping.
Refill capacity: Amount of oil needed to refill system during normal inspection and maintenance.

NOTE:
(1) When fuel sulphur content is less than 0.5%, (2) When starting the engine in an atmospheric
change oil in the oil pan every periodic temperature of lower than DoC, be sure to
maintenance hours described in this manual. use engine oil of SAE10W, SAE10W-30 and
Change oil according to the following table SAE15W-40 even though an atmospheric
if fue~ sulphur content is above 0.5%. temperature goes up to 10° C more or less in
the day time.
Change interval of oil in (3) Use API classification CD as engine oil and
Fuel sulphur content engine oil pan if API classification CC, reduce the engine
0.5 to 1.0% 1/2 of regular interval oil change interval to half.

Above 1.0% 1/4 of regular interval

00-16 K~
CD
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 10 STRUCTURE AND FUNCTION

P.T.D....•........................... 10- 2 Center swivel joint 10- 75

Power train 10- 4 Travel motor 10- 77
Final drive 10- 7 Valve control 10- 92
Swing circle 10- 8 PPC valve 10- 94
Swing machinery 10- 10 Accumulator 10- 98
Track frame 10- 12 Safety lock valve 10- 98
Idler 10- 15 Solenoid valve 10- 99
Idler cushion 10- 16 Shuttle valve 10-105

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Track roller 10- 17 Boom holding valve 10-106
Carrier roller 10- 18 Hydraulic cylinder 10-110
Track shoe 10- 19 Work equipment 10-114
Hydraulic piping 10- 23 Electrical wiring diagram 10-116
. Hydraulic circuit diagram 10- 26 Electrical circuit diagram .. " 10-120
Hydraulic tank and fuel tank 10- 29 Engine control system 10-123
Hydraulic pump 10- 32 PEMC system 10-130
L.H. 6-spool control valve 10- 56 EMACC (Electronic Monitor
R.H. 5-spool control valve 10- 62 and Control Console) 10-157
Swing motor 10- 68

10-1
P.T.O.
PC120,130-5K
PC150HD, NHD-5K

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Section A-A

6
Section B-B

FK203P5001

1. Shaft
2. Coupling
3. Breather
4. Case
5. Oil level plug
6. Oil filler plug

10-2
~
 PC180LC,LLC,NLC-5K

====(T
I I

------
--------- -------
6

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Sectoin A-A

FK203P5002

1. Shaft
2. Coupling
3. Breather
4. Case
5. Bearing
6. Oil level plug

10-3
POWER TRAIN
PC120,130-5K

2 3 4 5 6

10 9

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12 202F05008

1. Idler 7. Hydraulic pump

2. Centor swivel joint 8. Engine
3. R.H. 5-spool control valve 9. L.H. 6-spool control valve
4. Travel speed solenoid valve 10. Swing motor
5. Swing brake solenoid valve 11. Swing machinery
6. Travel motor and final drive 12. Swing circle

10-4
~
 PC150HD, NHD-5K

2 3 4 5 6 7

11 10

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13 202F05511

1. Idler 8. Hydraulic. pump

2. Centor swivel joint 9. Engine
3. R.H. 5-spool control valve 10. L.H. 6-spool control valve
4. Travel speed solenoid valve 11. Swing motor
5. Swing brake solenoid valve 12. Swing machinery
6. Final drive 13. Swing circle
7. Travel motor

10-5
PC180LC, LLC, NLC-5K

2 3 4 5 6 7

~-m--i

11 10

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12 11
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\13
FK203P5003

1. Idler 8. Hydraulic pump

2. Centor swivel joint 9. Engine
3. R.H. 5-spool control valve 10. L.H. 6-spool contorl valve
4. Travel speed solenoid valve 11. Swing motor
5. Swing brake solenoid valve 12. Swing machinery
6. Final drive 13. Swing circle
7. Travel motor

10-6
 FINAL DRIVE
PC150HD, NHD-5K
PC180LC, LLC, NLC-5K

1. Oil level plug

2. Drain plug
3. No. 1 sun gear (1 8 teeth)
4. No.2 sun gear (1 2 teeth)
5. No.2 planetary carrier
6. Cover
7. No. 1 planetary carrier
8. Sprocket
9. Floating seal
1O. Travel motor
11.Hub
12. No.1 planet gear (31 teeth)
13. Ring gear (81 teeth)
14. No.2 planet gear (34 teeth)

SPECI FICATIONS
Reduction ratio:
_(811~ 12)x(811~ 18)+1 =

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-41.625

14 13 12 11
205F05009

10-7
SWING CIRCLE
PC120,130-5K
PC150HD, NHD-5K

---------

\ \

I -'~ ~
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1111 __

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b 2 3
Section A - A

202F05009

1. Swing circle outer race SPECIFICATIONS

2. Ball bearing
3. Swing circle inner race (89 teeth) Reduction ratio: 89 = 7.417
12

a. Inner race soft zone "s" Grease volume: 6.5£ (Grease G2-LI)
b. Ou,er race soft zone liS"

10-8
(l)
 PC180LC, LLC, NLC-5K

---------- ~____7L....-----

,/

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-l

J=--+--_ _ U
-~

2 3

~
Section A-A

Section B-B
202F05606

1. Swing circle outer race SPECIFICATIONS

2. Ball bearing
3. Swing circle inner race (94 teeth) ' d· . 94
Re uctlon ratio: 1"4" == 6.714
a. Inner race soft zone "s"
b. Outer race soft zone "s" Grease volume: 9.51 (Grease G2-LI)

10-9
SWING MACHINERY
PC120,130-5K
PC150HD, NHD-5K

\. \\,\\ 1.
Swing pinion (12 teeth)
2.
Cage
3.
Planet carrier
4.
Ring gear (70 teeth)
5.
Bearing holder
6.
Drive gear (16 teeth)
7.
Swing motor
8.
Cover
Driven gear (81 teeth) and
9.
sun gear (14 teeth)
10. Planet gear (28 teeth)
11. Oil level gauge
12. Drain plug

SPECIFICATION

A Reduction ratio: ~~ x (1 + ~~) = 30.375

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11

Section B - B

5 8

4 9 Section C - C

3------+~L..:... . . 10

i 12
Section A - A Section D - D
202F05010

10-10
(l)
 PC180LC,LLC,NLC-5K

1. Swing pinion (14 teeth)

2. Case
3. Planet carrier
4. Ring gear (76 teeth)
5. Bearing holder
6. Drive gear (20 teeth)
7. Cover
8. Swing motor
9. Driven gear (65 teeth) and
sun gear (14 teeth)
10. Planetary gear (31 teeth)
11. Drain plug
12. Level gauge

SPECIFICATION
Reduction ratio:
65 x ( 1 + 76) = 20.893
20 14

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8
omat
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7

9
11
6
Section B-B

Section C-C

Section A-A
202F05607

'0-',
TRACK FRAME
PC120,130-5K

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8 7 6 202F05012

1. Idler 5. Sprocket
2. Track frame 6. Track shoe
3. Carrier roller 7. Idler cushion
4. Travel motor 8. Track roller

10-12
(2)
 PC150HD, NHD-5K
PC180LC, NLC-5K

I
L~~~~~=~~!===U
--=========---

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8 1 6
FK203P5004

1. Idler 5. Sprocket
2. Track frame 6. Track shoe
3. Carrier roller 7. Idler cushion
4. Travel motor 8. Track roller

10-13
PC180LLC-5K

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0-
M
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~

8 7

FK203P5005

1. Idler 5.. Sprocket

2. Track frame 6. Track shoe
3. Carrier roller 7. Idler cushion
4. Travel motor 8. Track roller

10-14
 IDLER
PC120,130-5K
1
1. Idler
2. Floating seal
3. Shaft
4. Support
2

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E- ~ 202F05013

PC150HD, NHD-5K
PC180LC,LLC,NLC-5K

-----d 1. Lubricating plug

2. Support
3 3. Idler
4. Floating seal
5. Shaft
6. Bushing
4

6
202F05013

10-15
~
IDLER CUSHION
PC120,130-5K

1. Yoke
2. Rod
2 3 4 5 6 7 8 9 3. Front support (cylinder)
4. Recoil spring
5. Wear ring
6. Packing
7. Rear support
8. Lubricator
9. Drain plug

SPECIFICATIONS
------------ Grease volume: 320cc (G2-LI)
- - - - ------_
-------------
... _-~-

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202F05014

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PC150HD, NHD-5K
PC180LC,LLC,NLC-5K
• For details, see TRACK FRAME

F203P5006

10-16
~
 TRACK ROLLER
PC120,130-5K

2 3 4 5
1. Floating seal
2. Track roller
3. Shaft
4. Bushing
5. Collar

c=

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--~

F02023302A

PC150HD, NHD-5K
PC180LC, LLC, NLC-5K

2 3 4 5 6

1. Lubricating plug
I! 2. Collar

.-ll
"'-P--~
.
.J
3. Floating seal
4. RoUer
5. Bushing
6. Shaft

~---------:a~~U_~LJI5_" _
f---.--- - - - - - - - - - - - - - - ------~
i
205F2452

10-17
~
CARRIER ROLLER
PC120,130-5K

1. Lubricating plug
2. Carrier roller
3. Bushing
4. Floating seal
5. Collar
6. Shaft

3 4

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5 \~ 6
F02023305A L!)
a..
M
PC150HD, NHD-5K o
C'J
PC180LC, LLC, NLC-5K ~

2 3 4 5 6

1. Shaft
2. Collar
3. Floating seal
4. Roller
5. Ring
6. Cover
7 7. Lubricating plug

205F05014

10-18
~
 TRACK SHOE
PC120,130-5K

2 3 4 5 6

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9 8 1
202F05015

1. Regular bushing SPECIFICATIONS (Standard shoe)

2. Regular pin PC120-5K Shoe width: 500 mm triple-shoe
3. Regular dust seal Link pitch: 175 mm
4. Master shoe Number of shoe: 84
5. Master pin PC130-5K Shoe width: 600 mm triple-shoe
6. Master dust seal Link pitch: 175 mm
7. Shoe Number of shoe: 84
8. Shoe bolt
9. Link

10-19
~
PC150HD, NHD-5K
PC180LC, LLC, NLC-5K

2 3 4 5 6 7 8

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9 10

205F05015

1. link SPECIFICATIONS (standard shoe)

2. Shoe Shoe width: 600 mm triple-shoe
.3·. Regular pin link pitch: 190 mm
4. Regular bushing Number of shoe: 90 (Except PC180llC)
5. Regular dust seal 98 (PC 180llC)
6. Master bushing
7. Master dust seal
8. Master pin
9. Shoe nut
10. Shoe bolt

10-20
 SELECTION OF TRACK SHOE
• Select the most suitable track shoe from the
following table.

Category
Specification
PC120 PC130 PC150HD PC150NHD PC180LC PC180LLC PC180NLC

500mm triple shoe A - - - - - -

600mm triple shoe B A A A A A A

700mm triple shoe C B B B i3 B -
750mm triple shoe C C - - - - -
800mm triple shoe - - C C C C -
900mm triple shoe - - C C C C -
610mm flat shoe - - - - D - -

Category Use Precautions when using

Rocky grond, normal • Travel in Lo speed when traveling on rough ground with
A
river soil obstacles such as large boulders and fallen trees.

• Cannot be used on rough ground where there are large

obstacles such as boulders and fallen trees.

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B Normal soil, soft land • Travel in Hi speed only on flat ground, and when it is
impossible to avoid traveling over obstacles, lower the
travel speed to approx. half of Lo speed.

Extremely soft ground
C (Swampy grond)
• Use only for ground where "A" and "B" si'nk and are
impossible to use.
• Cannot be used on rough ground where there are large
obstacles such as boulders and fallen trees.
• Travel in Hi speed only on flat ground, and when it is
impossible to avoid traveling over obstacles, lower the
travel speed to approx. half of Lo speed.

D Paved surface • The shoes are flat, so they have low gradeability.

* Categories "B" and "c" are wide shoes, so

there are restrictions on their use. Therefore,
before using, check the restrictions and
consider carefully the conditions of use before
recommending a suitable shoe width. If
necessary, give the customer guidance in
their use.
* When selecting the shoe width, select the
narrowest shoe possible within the range that
will give no problem with flotation and ground
pressure.
If a wider shoe than necessary is used, there
will be a large load on the shoe, and this may
lead to bending of the shoe, cracking of the
links, breakage of the pins, loosening of the
shoe bolts, or other problems.

10-21
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 HYDRAULIC TANK AND FUEL TANK
PC120,130-5K
PC150HD, NHD-5K
HYDRAULIC TANK AND FUEL TANK
~.-

1 2 3

vi
Section Section B - B
A-A

4 5 6 7 8
9 10

11

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\\\\tte--12

14 13
202F05018

1. Drain pl'ug (Hydraulic tank) SPECIFICATIONS

2. Cap (Hydraulic tank) Hydraulic tank
3. Pressure valve • Tank capacity: 150 Q
4. Fuel tank • Oil amount: 100 Q
5. Cap (Fuel tank) • Pressure valve
6. Strainer Relief set pressure: 0.39±0.15 kg/cm 2
7. Fuel level sensor Suction set pressure: 0-0.046 kg/cm 2
8. Hydraulic tank • Safety valve set pressure: 1.05±0.20 kg/cm 2
9. Return oil filter (Hydraulic tank)
10. Safety valve Fuel tank
11. Sight gauge (Fuel tank) • Capacity: 250 Q
12. Sight gauge (Hydraulic tank)
13. Suction strainer
14. Drain valve (Fuel tank)

10-29"
(2)
PC180LC, LLC, NLC-5K
FUEL TANK

- -:: - -- - - - - -
'I

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6
202F05613

1. Fuel tank
2. Cap.
3. Strainer
4. Sight gauge
5. Fuel level sensor
6. Drain valve

10-30
 HYDRAULIC TANK

--
- --------
------------ --
----
-

2 3

Section A-A Section B-B

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202F05614

1. Drain plug SPECIFICATIONS

2. Cap • Tank capacity: 190 R
3. Pressure valve • Oil amount: 135 R
4. Safety valve • Pressure valve
5. Return oil filter Relie.f set pressure: 0.39 ±. 0.15 kg/cm 2
6. Hydraulic tank Suction set pressure: 0 .-:. 0.046kg/cm 2
7. Sight gauge • Safety valve set pressure: 1.05 ± 0.20 kg/cm 2
8. Suction strainer

10-31
HYDRAULIC PUMP
PC120,130-5K
PC150HD, NHD-5K
a b c d

e
ViewZ

2 3 4

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8 7 6
202F05019

a. CO cancel pressure PCF IN port 1. lVC valve

b. Jet sensor output pressure Pt IN port 2. Front CO • NC valve
c. to cancel pressure PCR IN port 3. Front servo valve
d. Jet sensor output pressure Pt IN port 4. Rear CO • NC valve
e. Jet sensor output pressure Pd IN port 5. Rear servo valve
. f. Jet sensor output pressure Pd IN port 6. Charging pump and relief valve
7. Rear main pump
8. Front main pump

10-32
CZ)
 1. FRONT MAIN PUMP AND REAR MAIN PUMP (HPV055+055)
a b

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ViewZ

d e f g h j kim

View X ViewY 202F05020

a. Front main pump discharge PA1 port g. Charging pump pressure PSV1 port
b. Rear main pump discharge PA2 port h. Servo valve output pressure PSV1A port
c. Suction Ps port i. Servo valve output pressure PSV1B port
d. Servo valve output pressure PSV1B port j. Charging pump pressure PSV2 port
e. Rear main pump discharge Pa2 port k. Rear main pump discharge Pa2 port
f. Front main pump discharge Pa1 port I. Front main pump discharge Pa1 port
m. Servo valve output pressure PSV2B port

10-33
 2 3 4 5 6' 7 8 9 10 11 12 13 14 15 16

Section B - B
17

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C
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Section A - A Section C - C

202F05021

1. Front drive shaft 7. Front valve plate 13. Rear rocker cam
2. Front cradle 8. End cap 14. Rear pump case
3. Fr.ont pump case 9. Coupling 15. Rear cradle
4. -Front rocker cam 10. Rear valve seat 16. Rear drive shaft
5. Front piston 11. Rear cylinder 17. Servo piston
6. Front cylinder 12. Rear piston

10-34
 PC180LC,LLC,NLC-5K

a b c d

ViewZ

f e

2 3 4 5

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8 7 6

202F05617

a. CO cancel pressure PCF IN port 1. TVC valve

b. Jet sensor output pressure Pt IN port 2. Front CO-NC valve
c. CO cancel pressure PCR IN port 3. Front servo valve
d. Jet sensor output pressure Pt IN port 4. Rear CO-NC valve
e. Jet sensor output pressure Pd IN port 5. Rear servo valve
f. Jet sensor output pressure Pd IN port 6. Charging pump and relief valve
7. Rear main pump
8. Front main pump

10-35
1. FRONT MAIN PUMP AND REAR MAIN PUMP (HPV071 +071)

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ViewZ

b c

d e f g h kim

View X ViewY
202F05618A

a. Suction PS port g. Charging pump pressure PSV1 port

b. Front main pump discharge PA1 port h. Servo valve output pressure PSV1A port
c. Rear main pump discharge PA2 port i. Servo valve output pressure PSV18 port
d. Servo valve output pressure PSV18 port j. Charging pump pressure PSV2 port
e. Rear main pump discharge Pa2 port k. Rear main pump discharge Pa2 port
f. Front main pump discharge Pa1 port I. Front main pump discharge Pa1 port
m. Servo valve output pressure PSV28 port

10-36
 2 4 5 6 7 8 9 10 11 12 13 14 15 16

Section B-B
17
c

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Section C-C
Section A-A

202F05619

1. Front drive shaft 7. Front valve plate 13. Rear rocker cam
2. Front cradle 8. End cap 14. Rear pump case
3. Front pump case 9. Coupling 15. Rear cradle
4. Front rocker cam 10. Rear valve seat 16. Rear drive shaft
5. Front piston 11. Rear cylinder 17. Servo piston
6. Front cylinder 12. Rear piston

10-37
2. SERVO VALVE
* The drawing, shows the servo valve for front main pump.
a b c d

g f e

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Section B - B Section C - C

Section 0 - 0 Section E - E Section F - F Section G - G

202F05022

a. Servo actuator port g. Front main pump output pressure Pa11N port
b. Servo actuator port h. CO, NC valve drain. Pdr IN port
c. Servo actuator port i. CO, NC valve output pressure IN port
d. NC valve output pressure Peen pick-up port j. Charging pump pressure PPo OUT port
e. Servo valve drain Pdr OUT port k. Rear main pump output pressure Pa2.0UT
f. Rear main pump output pressure Pa2 IN port port
I. Front main pump output pressure Pa1 OUT
port

10-38
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Section A - A

202F05023

1. Lock nut 8. Pin 15. Guide spool

2. Cover 9. Control piston 16. Spring
3. Plug 10. Lock nut 17. Plug
4. Spring 11 . Plug 18. Cover
5. Body 12. Lock nut 19. Lock nut
6. Spring 13. Cover
7. Arm 14. Sleeve

FUNCTION
• Discharge volumes 01 and 02 of main pumps
PA1 and PA2 are controlled individually by d
their own servo valve. .....
c:
~
The relationship between pump discharge o
volume 0 and input signal Peen sent to the E
co
servo valve is as shown in the graph on the >-
~
Q)
right. 0 changes in proportion to Peen. .~
0)-

E,
"'C >
c.Q)

~ (.)
a..~

CO,NC valve output pressure Peen (kg/em 2 )

202F05024

10-39
OPERATION
1) Operation for increasing pump discharges (rocker cam angle changes to the large)
15 e h
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M
• Charging pump pressure Psv is sent to port
a.
Signal pressure Pecn from the NC valve is
sent from port b to chamber c.
• As signal pressure Pecn rises, the pressure
in chamber C pushes control piston (9) to the
left in the direction of the arrow. The piston
stops in a position where it is balanced with
the force of springs (4) and (6).
At the same time, arm (7) uses servo piston
(20) as a fulcrum, moves to the left in the
same way as control piston (9), and while
fluctuating, moves guide spool (15) to the left.
10-40
Peen
202F05025
• The movement of guide spool (15) closes port
a and port d, and connects port d with drain
chamber e. As a result, servo piston chamber
f is also connected to chamber e through port
g and port d.
At the same time, port a and port hare
connected, and the flow passes through port
i to servo piston chamber j to push servo
piston (20) to the left in the direction of the
arrow. The rocker cam angle of the main
piston pump becomes larger, and the pump
discharge volume increases.
• Beca use of the movement of servo piston (20),
arm (7) rotates clockwise around pin (8),
moves guide spool (15) to the right, and closes
port a, port d, and port h, so the discharge
volume increases only by an amount corres-
ponding to signal pressure Pecn.
 2) Operation for decreasing pump discharges (rocker cam angle changes to the small)
15 e h
Psv
4
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• When signal pressure Pecn drops, control
piston (9) moves to the right in the direction
of the arrow to a point where the hydraulic
pressure of chamber c is in balance with the
force of springs (4) and (6).
At the same time, arm (7) uses servo piston
(20) as a fulcrum, moves to the right in the
same way as control piston (9), and while
fluctuating, moves guide spool (15) to the
right.
• The movement of guide spool (15) closes port
a and port h, and connects port h with drain
chamber e. As a result, servo piston chamber
j is also connected to chamber e through port
i and port h.
~:~:~:}}~~:::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::tt
a :::::::
I'
Peen
202F05026
At the same time, port a and port dare
connected, and the flow passes through port
9 to servo piston chamber f to push servo
piston (20) to the right in the direction of the
arrow. The rocker cam angle of the main
piston pump becomes smaller, and the pump
discharge volume decreases.
• Because of the movement of servo piston (20),
arm (7) rotates counterclockwise around pin
(8), moves guide spool (15) to the left, and
closes port a, port d, and port h, so the
discharge volume decreases only by an
amount corresponding to signal pressure
Pecn.
10-41
3. TVC VALVE a b c

e d

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E F Section B - B
Section A - A

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Section C - C Section 0 - 0 Section E - E Section F - F

202F05027

a. Charging pump pressure PPo IN port 1. Spring 5. Sleeve

b. Front main pump output pressure Pa1 IN port 2. Spool 6. Piston
c. Rear main pump output pressure Pa2 IN port 3. Piston 7. Body
d. TVC valve drin Pdr OUT port 4. Piston 8. Solenoid
e. TVC valve output pressure Pe OUT portk

10-42
 FUNCTION AND OPERATION

1) When command current from pump controller is small (when pump controller is normal)

TVC valve

Peen
_aliElirBlif8 NC CO
valve valve

Servo valve

Servo piston

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TVC prolix switch

Resjstor
202F05028

FUNCTION
• When the pump controller is normal, the main
pump discharge volume can be controlled as
desired over a wide range according to the
command current from the pump controller
to carry out the power mode function.
• When the pump controller is abnormal,
hydraulic sensing is carried out to control the
main pump discharge volume according to the
load (pump discharge pressure) to carry out
the constant torque control function (prolix
function).
* For details, see PEMC SYSTEM.
OPERATION
• Because of the command current sent from
the controller, solenoid push pin (9) moves,
and piston (2) also moves. It stops at a point
where the sum of the force of spring (1) and
the force of push pin (9) and the force of TVC
output pressure Pe acting on piston (3) is in
balance. When this happens, the command
current is small, so piston (2) balances at the
bottom.
As a result, port a and port b are almost
completely open, and almost all the pressur-
ized oil from the charging pump is output as
TVC output pressure Pe. Because of this, the
pump discharge volume is maximum.

10-43
2) When command current from pump controller is large (when pump controller is normal)

TVC valve

Peen
NC CO
valve valve

Servo valve

Servo piston

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TVC prolix switch

Resistor
202F05029

• Because of the command current sent from

the controller, solenoid push pin (9) moves,
and the piston (2) also moves it stops at the
point where it is balanced with the force of
spring (1). When this happens, the command
current is large, so piston (2) is balanced at
the top: As a result, the flow of oil sent from
the charging pump is throttled at port a and
port b, and the area of the opening at port
b and port c (drain port) becomes larger
because of this, TVC valve output pressure
Pe drops and the pump discharge volume is
reduced.

10-44
 3) Main pump under light load (pump controller abnormal and TVe prolix switch ON)

TVC valve

Peen
NC co
valve valve

Servo valve
4
Servo piston
6
Decrease Increase

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TVC prol ix swi.tch

Resistor
202F05030

• Main pump discharge pressures PA 1 and

PA2 are low, so spool (2) is pushed down
by spring (1). As a result, charging pum.p
discharge pressure Psv and TVC valve output
pressure Pe are equal.
When this happens, TVC valve output pres-
sure Pe is maximum and the main pump
discharge volume is also maximum.

10-45
4) Main pump under heavy load (pump controller abnormal and TVC prolix switch ON)

TVC valve

Servo valve
4
Servo piston
6
Decrease~

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9

.fIJ

TVC prolix switch

Resistor
202F05031

• When main pump discharge pressure PA1

(or PA2) increases, spool (2) is moved 'up by
piston (4) or piston (6). As a result, the flow
at port a and port b is throttled by the notch
in the spool, and the area of .the opening at
port b and port c (drain port) becomes larger.
Because of this, TVC valve output pressure
Pe drops and the main pump discharge
volume is reduced.

10-46
 4. CO. NC VALVE

* The drawing shows the CQ.NC valve for the front main purr

0
a © 0 © 0
- - -- - - - --- --
d g - - - - -- - - - - -- 0 0
0

0
0
0

~
0 0
0
e h
b -------------
0

-- - - --- -- ---- 0 0
0

c
A

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1
8
9

10

11

12
Section A - A 202F05032
a. Charging pump pressure PRO OUT port CO VALVE NC VALVE
b. Main pump output pressure Pa1 (Pa2) OUT 1. Plug 7. Plug
port 2. Piston 8. Sleeve
c. Main pump output pressure Pa2 (Pa1) OUT 3. Spring 9. Piston
port 4. Spool 10. Spool
d. TVC valve output pressure Pe IN port 5. Piston 11. Spring
e. TVC valve drain Pdr port 6. Plug 12. Plug
f. CO cancel pressure Pef (Per) IN port
g. TVC valve output pressure Pe F-R connection * ( ): For rear servo valve
port
h. Jet sensor output pressure Pd IN port
j. Jet sensor output pressure Pt IN port

10-47
FUNCTION AND OPERATION OF CO VALVE

1) When main pump discharge pressure is below relief pressure

CO valve

NC
-valve

Servo valve

Servo piston

-Increase

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••fIJ

fIJ
LJ
C
C'
(
C'
~

202F05033

FUNCTION OPERATION
• If the load increases during operation, and • Spool (4) is pushed down by spring (3).
the main pump discharge pressure increases, As a result, port a and port b are completely
when it becomes nearly the relief pressure, open, and TVC valve output pressure Pee are
the CO valve carries out the cut-off function equal.
to reduce the discharge amount of the pump Because of this, CO valve output pressure Pee
and r~ctuce the relief loss. becomes maximum, and the discharge
• At the same time, the pilot pressure of the volume of the main pump is also maximum.
CO function cancel solenoid valve also has
the function of canceling the cut-off.
• The CO valve is controlled by balancing the
spring with the sum of main pump discharge
pressure PA and CO valve output pressure
Pec..

10-48
 2) When the main pump discharge pressure is higher than the main relief pressure

CO valve

Deacti-
vated

NC
valve Pe

Servo valve

Servo piston

Increase

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202F05034

• When main pump discharge pressure PA

comes close to the relief pressure owing to
an increase in the load, piston (5) is pushed
by main pump discharge pressure PA and at
the same time piston (5) is pushed by CO valve
output pressure Pec. When the force of spring
(3) is overcome by the pressing force of the
pistons, spool (4) moves upward.
As a result, the spool land restricts the oil
flow from port a to port b and at the same
time the opening area of port b and port c
(drain port) are made larger.
Because of this, CO valve output pressure Pec
becomes down, and the discharge volume of
the main pump is also minimum.

10-49
3) When cut-off function is canceled by CO cancel solenoid valve

CO valve

NC
BIIIIIIBJ. val ve Pe TVC
1l• •WSilllBlllm val ve

Servo valve

Servo piston

Decrease - Increase
Discharge

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202F05035

• When the CO cancel solenoid valve is

switched, pilot pressure is taken to port Pc
and piston (2) is pushed down.
As a result, the setting of spring (3) becomes
larger, so even when main pump discharge
pressure PA rises and reaches the relief
pressure, spool (4) is not actuated and CO
valve.o·utput pressure Pec remains at the
maximum.

10-50
 FUNCTION AND OPERATION OF NC VALVE

1) Control valve at neutral

Control val ve Control

valve
NC valve
Pt

.:f.. ". ::-~:~ . '~'" .:~~ .$=.

10

11

Pee CO TVC Psv

• •111111111. val ve valve
:::::::::::::::::::::::::::::::::::::::::::::::::: ::::::::::::..
Servo valve

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Servo piston 12

Decrease-
Discharge

202F05036

FUNCTION OPERATION
• The NC valve controls the main pump • The differential pressure (Pt-Pd) of the jet
discharge volume according to the amount sensor reaches,the maximum and jet sensor
of operation of the control valve spool, and output pressure Pt acting on piston (10)
carries out the function of contro,lIing the oil becomes greater than the sum of the force
flow to reduce the neutral loss and fine control of spring (12) and jet sensor output presure
loss. Pd acting on the lower end of spool (11).
• The NC valve is controlled by balancing the As a result, spool (11) is pushed downward,
sum of jet sensor output pressure Pt and NC causing a restriction of the oil flow between
valve output pressure Peen with the sum of port e and port b and in turn opening port
the force of NC valve spring (12) and jet sensor b and port a (drain port)., '
output pressure Pd. Output pressure Pt of the NC valve is then
• The jet sensor detects the flow of return oil reduced to the minimum and the main pump
passing through the control valve and discharge is also reduced to the minimum
returning to the tank, and takes it as NC valve with the swash plate angle minimized
Pt and Pd. throug'h the operation of the servo valve.

10-51
2) When the control valve is operated

Control valve Control

valve

NC valve

:> ;.: .. -:::r:::'" ~ ~ . . . -._.'fI!J ~ 10

.,

. ' ... ..~.~~

'

Pee Psv
.. .
~
CO TVC
valve valve .fIl

Servo valve

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Servo piston

Discharge
12

202F05037

• With the jet sensor differential pressure (Pt-

Pd) reduced according to the operation of the
control valve, spool (11) is pushed upward,
fully opening porte and port b.
Because of this, the NC valve output pressure
Peen increases. And the main pump dis-
charge is also increased. That is to say, the
pump discharge increases as the stroke of
the lever increases.

10-52
 5. CHARGING PUMP AND RELIEF VALVE

PC120,130-5K
PC150HD, NHD-5K

Suction¢

B
{}
Discharge

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_11-------
-----

Section A - A Section B - B

202F05038

1. Body SPECIFICATIONS
2. Driven gear Type: BAR20
3. Drive gear Theoretical delivery: 20.9 cc/rev.
4. Cover Operating pressure: 30 kg/cm 2
5. Relief valve
6. Filter

10-53
o
PC180LC, LLC, NLC-5K

Q Suction

z+

Discharge
5

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--~

2
III

1---i--3
4
Section B-B

Section A-A

202F05620

1. Body SPECIFICATI'ONS
2. Drive gear Type: BAR25
3. Driven gear Theoretical delivery: 25 cc/rev.
4. Cover Operating pressure: 30 kg/cm 2
5. Relief valve
6. Filter

10-54
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L.H. 6-SPOOL CONTROL VALVE
PC120,130-5K
PC150HD, NHD-5K

a b
c d e

k 5
o P

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202F05039

a. PA3 port (From L.H. PPC valve) k. 85 port (To arm cylinder head side)
b. PAS port (From L.H. PPC valve) I. 83 port (To swing motor MA port)
c. P1 port (From front main pump) m. 82 port (To boom cylinder bottom side)
d. A3 port (To swing motor MB port) n. PB2 port (From R.H. PPC valve)
e. As port (To arm cylinder bottom side) o. PB3 port (From L.H. PPC valve)
f. A6 port (To L.H. trave-I motor A port) p. PS4 port (From swing brake solenoid valve)
g. NCB port (To front main pump NC valve) q. PB5 port (From L.H. PPC valve)
h. NCA port (To front main pump NC valve) r. Ts port (To tank)
I. T port (To tank) s. P2 port (From straight-travel valve)
J. 86 ·port (To L.H. travel motor 8 port)

10-56
o
 2 3 4 5 13

Section E - E

Section A - A 9 10 8 7
Section 14
F - F

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Section G - G

Section B - B

Section H - H

Section C - C
11 12

Section 0 - 0 Section J - J

202F05040

1. Main relief valve 8. Spool return spring

2. Spool (service) 9. Safety-suction valve
3. Spool (boom-Hi) 10. Suction valve
4. Spool (swing) 11 . Check valve
5. Spool (arm-Lo) 12. Check valve spring
6. Spool (L.H. travel) 13. Spool (swing priority)
7. Jet sensor relief valve 14. Jet sensor orifice

10-57
PC180LC, LLC, NLC-5K

a b
c d e f g

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202F05621

a. PA3 port (From L.H. PPC valve) k. B5 port (To arm cylinder head side)
b. PAS port (From L.H. PPC valve) I. B3 port (To swing motor MA port)
c. P, port (From front main pump) m. B2 port (To boom cylinder bottom side)
d. A3 PO(t (To swing motor MB port) n. PB2 port (From R.H. PPC valve)
e. As port (To arm cylinder bottom side) o. PB3 port (From L.H. PPC valve)
f. A6 port (To L.H. travel motor PB port) p. PB4 port (From swing brake solenoid valve)
g. NCB port (To front main pump NC valve) q. PB5 port (From L.H. PPC valve)
h. NCA port (To front main pump NC valve) r. Ts port (To tank)
i. T port (To tank) s. P2 port (From straight-travel valve)"
j. B6 port (To L.H. travel motor PA port)

10-58
 2 3 4 5 6 13
I

Section E-E

Section A-A 9 10 8 7
Section F-F 14

Section G-G

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Section H-H

11 12 Section C-C

Section 0-0 Section J-J

202F05622

1. Main relief valve 8. Spool return spring

2. Spool (service) 9. Safety-suction valve
3. Spool (boom-Hi) 10. Suction valve
4. Spool (swing) 11 . Check valve
5. Spool (arm-Lo) 12. Check valve spring
6. Spool (L.H. travel) 13. Spool (swing priority)
7. Jet sensor relief valve 14. Jet sensor orifice

10-59
SWING PRIORITY VALVE

FUNCTION
• When operating the swing and arm at the
same time, most of the oil flows to the arm,
which has less load. The flow of oil to the
swing circuit is reduced so the arm speed is
faster than the swing speed. This makes
combined operations difficult.
• To prevent this, the swing priority valve is
switched to restrict the flow of pressure oil
to the arm-Lo control valve. This restricts the
arm speed and makes it easier to operate the
arm and swing at the same time.

OPERATION
When swing is at neutral
• When the swing is at neutral, no pilot
pressure oil flows from the solenoid valve.
The swing priority valve is not actuated, so
the pressurized oil from the front main pump
passes through port P, and flows to the arm-

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Lo control valve.

202F05041

When swing is operated

• When the swing is operated, spool (13) of the
swing priority valve is pushed to the left by
the pilot pressure from the solenoid valve.
Because of this, the pressurized oil flowing
from front main pump to the arm Lo control
valve is throttled by the swing priority valve
and the arm speed is controlled, so the
simultaneous operation performance is
improved.

202F05042

10-60
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R.H. 5-SPOOL CONTROL VALVE
PC120,130-5K
PC150HD, NHD-5K

c c

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202F05043

a. Ts port m. B2 port (To L.H. travel control valve)

b. PAS port (From L.H. PPC valve) n. B3 port (To bucket cylinder head side)
c. PA4 port (From R.H. PPC valve) o. B4 port (To boom cylinder head side)
d. PA3 port (From R.H.PPC valve) p. Bs port (To arm cylinder head side)
e. T port (To tank) q. NCB port (To rear main pump NC valve)
f. As port (To arm cylinder bottom side) r. NCA port (To rear main pump NC valve)
g. A4 port (To boom cylinder bottom side) s. PBS port (From L.H. PPC valve)
h. A3 port (To bucket cylinder bottom side) t. PBS port (From R.H. PPC valve)
i. A2 port (From front main pump) u. PB3 port (From R.H. PPC valve)
j. A1 port (To R.H. travel motor B port) v. PB2 port (From straight-travel solenoid valve)
k. P1 port (From rear main pump) w. Pb port
I. B1 port (To R.H. travel motor A port) x. p:z port

10-62
~
 13

Section E - E

Section 14
F - F

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SectionB - B
10

Section H - H

Section C - C
11 12

Section 0 - 0 Section J - J

202F05044

1. Jet sensor relief valve 8. Suction valve

2. Spool (arm-Hi) 9. Safety-suction valve
3. Spool (boom-Lo) 10. Safety valve
4. Spool (bucket) 11. Check valve
5. Spool (R.H. travel). 12. Check valve spring
6. Main relief valve 13. Spool (straight-travel)
7. Spool return spring 14. Jet sensor orifice

10-63
PC180LC, LLC, NLC-5K

c c

t
B

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202F05623

a. Ts port m. 82 port (To L.H. travel control valve)

b. PA5 port (From L.H. PPC valve) n. 83 port (To bucket cylinder head side)
c. PA4 port (From R.H. PPC valve) o. 84 port (To boom cylinder head side)
d. PA3 port (From R.H. PPC valve) p. 85 port (To arm cylinder head side)
e. T port (to tank) q. NC8 port (To rear main pump NC valve)
f. A5 port (To arm cylinder bottom side) r. NCA port (To rear main pump NC valve)
g. A4 port (To boom cylinder bottom side) s. PB5 port (From L.H. PPC valve)
h. A3 port (To bucket cylinder bottom side) t. PB5 port (From R.H. PPC valve)
i. A2 port (From front main pump) u. PB3 port (From R.H. PPC valve)
j. A1 port (To R.H. travel motor P8 port) v. PB2 port (From Straight-travel solenoid valve)
k. P1 port (From rear main pump) w. Pb port
I. 81 port (To R.H. travel motor PA port) x. P2 port

10-64
 2 3 4 5

12

Section E-E

Section F-F 13

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Section G-G

Section B-B

Section H-H

10 11 Section C-C
0>

Section D-D Section J-J

202F05624

1. Jet sensor relief valve 8. Suction valve

2. Spool (arm-Hi) 9. Safety-suction valve
3. Spool (boom-Lo) 10. Safety valve
4. Spool (bucket) 11. Check valve
5. Spool (R.H. travel) 12. Check valve spring
6. Main relief valve 13. Spool (Straight-travel)
7. Spool return spring 14. Jet sensor orifice

10-65
STRAIGHT-TRAVEL VALVE

FUNCTION
• While operating the swing, boom, arm, or
bucket when traveling, the pressure oil
flowing to the R.H. and L.H. travel circuit
branches into the swing, boom, arm, or bucket
circuit.
Since the supply of pressure oil in a branched
travel circuit is less than that in the circuit
before the branch, the motor naturally slows
down, resulting in a turn.
• When the straight-travel valve is switched
over to establish continuity between the R.H.
and L.H. travel circuits, this undesired turning
is prevented by equalizing the supply of
pressure oil to the R.H. and L.H. travel motors
so that they rotate at the same speed.

OPERATION
Bucket
Boom-La
When traveling only Arm-Hi
• Since no pilot pressure oil flows the solenoid

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valve, so the straight-travel valve is not
operated.
• Therefore, the circuit between port PR (R.H.
travel circuit) and port Pl (L.H. travel circuit)
remains closed and both circuits remain
independent.

202F05045

During simultaneous operation

• While operating the work equipment or swing
Bucket
when traveling, spool (13) is pushed to the Boom-La
13 Arm-Hi
right in the direction of the arrow by the pilot
pressure from the straight-travel solenoid
valve.
• Because of this, port PR and port Pl then
become connected to each other and an equal
amount of pressure oil is supplied to the R.H.
and L.H. travel motors, allowing both motors
to rotate at the same speed.
The machine travels thus in a straight line.

202F05046

10-66
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SWING MOTOR
PC120,130-5K
PC150HD, NHD-5K

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d c
e

202F05047

a. T port (To tank) SPECIFICATIONS

b. Sport Type: KMF40AB-2
c. MA port (From L.H. 6-spool control valve) Theoretical delivery: 40.2 cc/rev
d. MB port (From L.H. 6-spool control valve)
Safety valve set pressure: 210+ 5 kg/cm 2
e. B por.t (From swing brake solenoid valve) o
Rated speed: 2,633 rpm
Brake releasing pressure: Max. 14 kg/cm 2

10-68
~
 Section B - B

2 3 4 5 6 7 '8

9 15

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supar
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11
16

17

12

Section A - A 14 13 Section C - C

202F05048

1. Drive shaft 10. Cylinder

2. Cover 11 .'Valve plate
3. Housing 12. Air bleeding plug
4. Disc 13. Center shaft
5. Plate 14. Center spring
6. Brake piston 15. Safety valve
7. Brake spring 16. Check valve
8. End cover 17. 'Check valve spring
9. Piston

10-69
SWING HOLDING BRAKE

OPERATION
1) When swing brake solenoid val,ve is
deactivated
When the swing brake solenoid valve is
deactivated, the pressurized oil from the Swing brake
Charging pump
charging pump is shut off and port B is :solenoid valve
connected to the tank circuit.
Because of this, brake piston (6) is pushed
down in the direction of the arrow by brake
spring (7), so disc (4) and plate (5) are pushed
together and the brake is applied.

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202F05049

2) When swing brake solenoid valve is excited

When the swing brake solenoid valve is
excited, the valve is switched, and the
pressurized oil from the charging pump
enters port B and flows to brake chamber
a. Charging pump Swing brake
solenoid valve
The pressurized oil entering chambe'r a
overcomes the force of brake spring (7), and 7
brake piston (6) is pushed up in the direction
of the arrow. Because of this, disc (4) and 6
plate (5) separate, and the brake is released. B

4
5

202F05050

10-70
www.
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PC180LC, LLC, NLC-5K

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a..
M
o
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b c

d e
202F05625

a. Sport SPECIFICATIONS
b. MB port (From L.H. 6-spool control valve) Type: KMF90AB-Z
c. MA port (From L.H. 6-spool control valve) Theoretical delivery: 87.8 cc/rev
d. B port (From swing brake solenoid valve) Safety valve set pressure: 230 +g kg/cm 2
e. T port (To tank) Rated speed: 1.067 rpm
Brake releasing pressure Max. 14 kg/cm 2

10-72
 Section A-A

15 16 17

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Section C-C
14 13 12
Section B-B
202F05626

1. Brake spring 10. Cylinder

2. Drive shaft 11. Valve plate
3. Cover 12. Air bleeding plug
4. Housing 13. Center shaft
5. Disc 14. Center spring
6. Plate 15. Safety valve
7. Brake piston 16. Check valve
8. End cover 17. Check valve spring
9. Piston

10-73
SWING HOLDING BRAKE

OPERATION
1) When swing brake solenoid valve is
deactivated
When the swing brake solenoid valve is Charging
deactivated, the pressurized oil from the pump

charging pump is shut off and port B is

connected to the tank circuit.
Because of this, brake piston (7) is pushed
down in the direction of the arrow by brake
spring (1 ), so disc (5) and plate (6) are pushed
together and the brake is applied.

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205F05050

u
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2) When swing brake solenoid valve is excited
When the swing brake solenoid valve is
excited, the valve is switched, and the
pressurized oil from the charging pump
enters port B and flows to brake chamber
a. Charging Swing brake
The pressurized oil entering chambe"r a pump solenoid valve
overcomes the force of brake spring (1), and
brake piston (7) is pushed up in the direction
of the arrow. Because of this, disc (5) and
plate (6) separate, and the brake is released.
B

"205F05051

10-74
 CENTER SWIVEL JOINT
PC120,130-5K
PC150HD, NHD-5K
I

I
4 01
I
I
I
I
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I E1
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/

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com
02

82

A2

C2

202F05051A

1. Cover A1. From R.H. 5-spool control D1. From L.H. 6-spool control valve
2. Body valve B1 port 86 port
3., Slipper seal A2. To R.H. travel motor A port D2 From L.H. 6-spool control valve
4. Oil seal 81. From L.H. 6-spool control B port
5. Shaft valve A6 port E1. From travel speed solenoid valve
82 To L.H. travel motor A port E2. To L.H. and R.H. travel motor D port
C1. From R.H. 5-spool A1 port T1 To tank
C2. To R.H. travel motor B port T2 From L.H. and R.H. travel motor C port

10-75
(l)
PC180LC,LLC,NLC-5K z
~

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ViewZ

202F05627

1. Cover 'A1. From R.H. 5-spool control 01. From L.H. 6-spool control valve
2. Body valve 81 port A6 port
~. Slipper seal A2. To R.H. travel motor PA port 02. From L.H. 6-spool control valve
4. Oil seal 81. From L.H. 6-spool control PB port
5. Shaft valve 86 port E1. From travel speed' solenoid valve
82. To L.H. travel motor PA port E2. To L.H. and R.H. travel motor P port
C1. From R.H. 5-spool control T1. To tank
valve A1 port. T2. From L.H. and R.H. travel motorT port
C2. To R.H. travel motor PB port

10-76
 TRAVEL MOTOR
PC120,130-5K

a b c d

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00 0

202F05052

a. A port (From travel conrol valve) SPECIFICATIONS

b. D port (From travel speed solenoid valve) Type: GM17V-D-2 (PC100)
c. B port (From travel control valve) GM17V-B-2 (PC120)
d. C port (To tank) Theoretical delivery: Min. 55.3 cc/rev
Max. 86.3 cc/rev
Rated pressure: 325 kg/cm 2
Rated speed: Min. 1,965 rpm
Max. 1,283 rpm
Brake releasing pressure: 11 kg/cm 2
Hi-Lo switching pressure: 16 kg/cm 2
Final drive reducing ratio: 39.0

10-77
~
 2 7 8 9 10 11

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21

6 5 4 3 29 28 27 26 2524 23 22

202F05053

1. Check valve spring 11 . Brake piston 21. Drain plug

2. Check valve 12. Cylinder 22. Case
3. Safety valve spring 13. Piston 23. Regulator piston
4. Safety valve 14. Rocker cam 24. Spindle
5. Counterbalance valve 15. Crankshaft 25. Floating seal
6. Return spring 16. RV gear 26. Plate
7. End cap 17. RV gear 27. Disk
8. Regulator valve 18. Cover 28. Valve plate
9. Spring 19. Driven gear 29. Spring
10. Brake spring 20. Drive gear 30. Check valve

10-78
 MOTOR

OPERATION
1) At Lo speed (motor rocker cam angle at maximum)

Brake
valve

31

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14 23 a

202F05054

• The solenoid valve is deactivated, so the pilot • As a result, rocker cam (14) is pushed in the
pressure oil from the charging pump does not maximum rocker cam angle direction by the
flow to port D. main pressure oil inside cylinder chamber P,
For this reason, regulator valve (8) is pushed the motor capacity becomes maximum, and
to the left in the diraction of the arrow by the system is set to Lo speed.
spring (9).
Because of this, it pushes check valve (31),
and the main pressure oil from the control
valve to end cover (7) is closed by regulator
valve (8).
• The pressurized oil in chamber a of regulator
piston (23) passes through passage b in
regulator valve (8) and is drained to the motor
case.

10-79
2) At Hi speed (motor rocker cam angle at minimum)

Brake
valve

.., Travel speed

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Travel control . solenoid valve
valve

a
14 23

202F05055

• The solenoid valve is excited, so the pilot • As a result rocker cam (14) moves in th\.:"
pressure oil from the charging pump flows minimum rocker cam angle direction, the
to port 0, and pushes regulator valve (8) is motor capacity becomes minimum,' and the
pushed to the right in the direction of the system is set to Hi speed.
arrow.
• Because of this, the main pressure oil from
the control valve passes through passage c
in regulator valve (8), enters regulator piston
(23) at the bottom, and pushes regulator
piston.(23) to the left in the direction of the
arrow.

10-80
 PARKING BRAKE 10 11 26 27
OPERATION
1) When starting to travel
When the travel lever is operated, the
pressurized oil from the pump actuates
counterbalance valve spool (5), the circuit
to the parking brake is opened, and opened
check valve (30) and the oil flows into
chamber a of brake piston (11), overcomes
the force of spring (10), and pushes piston
(12) to the left in the direction of the arrow.
When this happens, the force pushing, plate
(26) and disc (27) together is lost, so plate
(26) and disc (27) separate and the brake
is released.

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2) When stopping travel

10 11 26 27
When the travel lever is placed in netral,
counterbalance valve spool (5) returns to the
neutral position and the circuit to the parking
brake is closed.
The pressurized oil in chamber a of brake
piston (11) is drained to the case from the
orifice of check valve (31) in the brake piston,
and brake piston (30) is pushed to the right
in the direction of the arrow by spring (10).
As a result, plate (26) and disc' (27) are
pushed together, and the brake is applied.

202F05057,

10-81
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