1991 Komatsu PC150-5 Excavator Shop Manual (P/N 07–91(02)00711)

This shop manual covers 1991 and later Komatsu PC150-5 hydraulic excavators, serial numbers 6001 and up, including standard triple-shoe, wide triple-shoe, and swamp-shoe configurations. The cover carries document code SEBM021K0502.

• Engine service: Valve-clearance and compression checks, injection-timing procedures, governor-motor adjustment, and removal and installation of engine components.

• Hydraulic testing: Main-pump and pilot-pressure checks, relief-valve adjustment, cylinder-drift diagnosis, and air-bleeding procedures following component work.

• Pump and valve overhaul: Disassembly and assembly instructions for the main hydraulic pump, control valves, PPC valves, center swivel joint, and boom holding valve.

• Drive and swing repairs: Final-drive, travel-motor, swing-motor, and swing-machinery procedures, including internal assembly checks and associated maintenance standards.

• Undercarriage and work equipment: Track frame, idlers, recoil springs, rollers, track shoes, hydraulic cylinders, and boom, arm, and bucket removal.

• Electrical diagnosis: PEMC and EMACC system descriptions, controller troubleshooting charts, connector layouts, wiring diagrams, and electrical standard-value tables.

Written for service technicians carrying out workshop repairs, this manual assumes suitable lifting equipment, hydraulic test instruments, and the special tools specified for component work.

Engine Service and Scope

Engine procedures cover valve-clearance and compression checks, injection timing, governor-motor adjustment, and removal and installation of the cylinder head and engine assembly. The cover directs readers to the separate 95 Series Engine Shop Manual for detailed S6D95L-1 engine information.

Hydraulic Testing and Component Repair

The structure-and-function section explains OLSS (Open Center Load Sensing System), pump control, PPC valves, and the boom holding and solenoid valves. Hydraulic circuit diagrams, pump-output curves, and flow-control graphs support the pressure-testing and adjustment procedures.

Work-equipment drift checks distinguish cylinder-packing leakage from faults in the control or holding valves, helping narrow the repair before components are removed. Disassembly and assembly instructions cover the variable-displacement hydraulic pump, control valves, center swivel joint, and hydraulic cylinders.

The TVC adjustment procedure warns that forcing a stiff adjustment screw can break its tip. Component work also requires the specified pressure-release precautions, clean working conditions, and test equipment.

Travel, Swing, and Undercarriage Repairs

Final-drive and travel-motor sections include internal disassembly, bearing and seal installation, shim selection, and end-play checks. Swing machinery, track-frame components, and work-equipment joints have separate removal procedures and maintenance-standard tables.

Cross-section views show the final-drive and travel-motor assemblies, while wear limits and clearance tables support inspection of gears, rollers, pins, and bushings. During travel-motor disassembly, the manual specifically cautions against scratching the cylinder block's sliding face with the puller.

PEMC, EMACC, and Electrical Diagnosis

PEMC (Pump and Engine Mutual Control) and EMACC (Electronic Monitor and Control Console) coverage links engine and pump operation with monitor functions. E-, C-, F-, H-, and P-mode troubleshooting charts address controller faults, input signals, hydraulic symptoms, and monitor circuits.

Engine-throttle-controller and pump-controller wiring diagrams and connector pin views support circuit tracing. Wire-code tables identify cable size, current rating, color, and circuit function.

Workshop references also include standard-bolt and split-flange torque tables, tank capacities, and fluid requirements across ambient-temperature ranges. Swing- and travel-motor specifications, cylinder stroke and piston-diameter data, pressure limits, and lifting-angle charts provide further component and handling references.

Selected Adjustment and Electrical Values

A few examples from the testing tables show the adjustment and electrical data included. For the S6D95L-1, valve clearance at normal temperature is 0.35 mm on the intake side and 0.50 mm on the exhaust side.

The engine-speed sensor check specifies 500–1,000 Ω between pins 1 and 2 of connector E7, with the starting switch OFF and the connector disconnected.

PDF Navigation and Included Pages

Search, bookmarks, and wiring labels: PDF text search is unavailable. Embedded bookmarks provide access to the main sections and individual procedures; small wiring labels require zooming, and some labels and lines in the overall electrical diagram remain faint.

One printable English PDF contains 520 pages: 16 preliminary pages, 116 pages of Structure and Function, 212 of Testing and Adjusting, 148 of Disassembly and Assembly, and 28 of Maintenance Standard. The preliminary pages include the cover and three revision-list pages, all included in the total.