Komatsu PC160-6K, PC180LC-6K, PC180NLC-6K Hydraulic Excavator Index:

1. Foreword ……………………………………………………………………………………………………………………………. 0-1
2. Safety information ……………………………………………………………………………………………………………….. 0-2
3. Introduction ………………………………………………………………………………………………………………………… 0-4
4. Location of plates, table to enter serial No. and distributor …………………………………………………….0-5
SAFETY
6. General Precautions ……………………………………………………………………………………………………………. 1-2
7. Precautions during operation ………………………………………………………………………………………………. 1-8
7.1 Before starting engine ………………………………………………………………………………………………….. 1-8
7.2 Operating machine …………………………………………………………………………………………………….. 1-10
7.3 Transportation …………………………………………………………………………………………………………… 1-15
7.4 Battery……………………………………………………………………………………………………………………… 1-16
7.5 Towing ……………………………………………………………………………………………………………………… 1-17
7.6 Bucket with hook ……………………………………………………………………………………………………….. 1-18
8. Precautions for maintenance ……………………………………………………………………………………………… 1-21
8.1 Before carrying out maintenance …………………………………………………………………………………. 1-21
8.2 During maintenance …………………………………………………………………………………………………… 1-24
9. Position for attaching safety labels …………………………………………………………………………………….. 1-28
OPERATION
10. General view
10.1 General view of machine ………………………………………………………………………………………………. 2-2
10.2 General view of controls and gauges ……………………………………………………………………………… 2-3
11. Explanation of components
11.1 Machine monitor………………………………………………………………………………………………………….. 2-4
11.2 Switches …………………………………………………………………………………………………………………… 2-15
11.3 Control levers, pedals …………………………………………………………………………………………………. 2-19
11.4 Roof hatch ………………………………………………………………………………………………………………… 2-24
11.5 Front window …………………………………………………………………………………………………………….. 2-25
11.6 Door lock ………………………………………………………………………………………………………………….. 2-27
11.7 Cap, cover with lock …………………………………………………………………………………………………… 2-28
11.8 Luggage box …………………………………………………………………………………………………………….. 2-29
11.9 Ashtray …………………………………………………………………………………………………………………….. 2-29
11.10 Heater ……………………………………………………………………………………………………………………… 2-29
11.11 Air conditioner …………………………………………………………………………………………………………… 2-30
11.12 Car radio ………………………………………………………………………………………………………………….. 2-33
11.13 Fuse ………………………………………………………………………………………………………………………… 2-34
11.14 Fusible link ……………………………………………………………………………………………………………….. 2-35
11.15 Controllers ………………………………………………………………………………………………………………… 2-35
11.16 Tool box ……………………………………………………………………………………………………………………. 2-35
11.17 Refuelling pump ………………………………………………………………………………………………………… 2-35
11.18 Handling the accumulator …………………………………………………………………………………………… 2-36
0-8
PC160/180-6K-ENG
12. Operation
12.1 Check before starting engine ………………………………………………………………………………………. 2-38
12.2 Starting engine ………………………………………………………………………………………………………….. 2-48
12.3 Operations and checks after starting engine ………………………………………………………………….. 2-51
12.4 Moving machine off ……………………………………………………………………………………………………. 2-57
12.5 Steering machine ………………………………………………………………………………………………………. 2-60
12.6 Stopping machine ……………………………………………………………………………………………………… 2-62
12.7 Swinging ………………………………………………………………………………………………………………….. 2-63
12.8 Operation of work equipment ………………………………………………………………………………………. 2-64
12.9 Working mode/Active mode selection selection ……………………………………………………………… 2-65
12.10 Prohibitions for operation ……………………………………………………………………………………………. 2-69
12.11 Precaution for operation ……………………………………………………………………………………………… 2-71
12.12 Precaution when travelling up or down hills ……………………………………………………………………2-72
12.13 How to escape from mud ……………………………………………………………………………………………. 2-74
12.14 Work possible using hydraulic excavator ………………………………………………………………………. 2-75
12.15 Replacement and inversion of bucket …………………………………………………………………………… 2-76
12.16 Parking the machine ………………………………………………………………………………………………….. 2-78
12.17 Check after finishing work …………………………………………………………………………………………… 2-79
12.18 Stopping engine ………………………………………………………………………………………………………… 2-80
12.19 Check after stopping engine ……………………………………………………………………………………….. 2-81
12.20 Locking …………………………………………………………………………………………………………………….. 2-81
12.21 Overload warning device …………………………………………………………………………………………….. 2-81
13 Transportation
13.1 Loading, unloading work …………………………………………………………………………………………….. 2-82
13.2 Precautions for loading ………………………………………………………………………………………………. 2-84
13.3 Precautions for transportation ……………………………………………………………………………………… 2-85
13.4 Lifting the machine …………………………………………………………………………………………………….. 2-85
14. Cold weather operation
14.1 Precaution for low temperature ……………………………………………………………………………………. 2-87
14.2 Precautions after completion of work ……………………………………………………………………………. 2-88
14.3 After cold weather ……………………………………………………………………………………………………… 2-88
15. Long-term storage
15.1 Before storage …………………………………………………………………………………………………………… 2-89
15.2 During storage …………………………………………………………………………………………………………… 2-90
15.3 After storage …………………………………………………………………………………………………………….. 2-90
15.4 Starting machine after long-term storage ………………………………………………………………………. 2-90
16. Troubleshooting
16.1 Phenomena that are not failures ………………………………………………………………………………….. 2-91
16.2 Method of towing machine ………………………………………………………………………………………….. 2-91
16.3 Using method for light-weight towing hole ………………………………………………………………………2-91
16.4 Precautions on particular jobsites ………………………………………………………………………………… 2-92
16.5 If battery is discharged ……………………………………………………………………………………………….. 2-92
16.6 Other trouble …………………………………………………………………………………………………………….. 2-96

MAINTENANCE
17. Guides to maintenance ………………………………………………………………………………………………………… 3-2
18. Outlines of service …………………………………………………………………………………………………………………. 3-5
18.1 Outline of oil, fuel, coolant …………………………………………………………………………………………….. 3-5
18.2 Outline of electric system ……………………………………………………………………………………………… 3-9
18.3 Outline of hydraulic system …………………………………………………………………………………………. 3-10
19. Wear parts list ……………………………………………………………………………………………………………………. 3-11
20. Use of fuel, coolant and lubricants according to ambient temperature ………………………………… 3-12
20.1 Maintenance and operation for two piece boom ……………………………………………………………..3-15
21. Standard tightening torques for bolts and nuts ……………………………………………………………………3-17
21.1 Introduction of necessary tools ……………………………………………………………………………………. 3-17
21.2 Torque list …………………………………………………………………………………………………………………. 3-18
22. Periodic replacement of safety critical parts ……………………………………………………………………….. 3-19
23. Maintenance schedule chart ………………………………………………………………………………………………. 3-21
23.1 Maintenance schedule chart ……………………………………………………………………………………….. 3-21
23.2 Maintenance interval when using hydraulic breaker …………………………………………………………3-23
24. Service procedure ……………………………………………………………………………………………………………… 3-24
24.0 Initial 250 hours service ……………………………………………………………………………………………… 3-25
24.1 When required …………………………………………………………………………………………………………… 3-26
24.2 Check before starting …………………………………………………………………………………………………. 3-47
24.3 Every 100 hours service ……………………………………………………………………………………………… 3-53
24.4 Every 250 hours service ……………………………………………………………………………………………… 3-56
24.5 Every 500 hours service ……………………………………………………………………………………………… 3-61
24.6 Every 1000 hours service ……………………………………………………………………………………………. 3-68
24.7 Every 2000 hours service ……………………………………………………………………………………………. 3-71
24.8 Every 4000 hours service ……………………………………………………………………………………………. 3-74
24.9 Every 5000 hours service ……………………………………………………………………………………………. 3-75
SPECIFICATIONS
25. SPECIFICATIONS ………………………………………………………………………………………………………………… 4-2
25.1 Machine specifications …………………………………………………………………………………………………. 4-2
25.2 Explanation of lifting capacity chart ………………………………………………………………………………… 4-9
5. CONTENTS
0-10
PC160/180-6K-ENG
OPTIONS AND ATTACHMENTS
26 General Precautions ……………………………………………………………………………………………………………. 5-2
26.1 General precautions related to safety ……………………………………………………………………………… 5-2
26.2 Precautions when installing attachments ………………………………………………………………………… 5-3
27. Handling bucket with hook …………………………………………………………………………………………………… 5-4
27.1 Checking for damage to bucket with hook ………………………………………………………………………..5-4
27.2 Prohibited operations …………………………………………………………………………………………………… 5-4
27.3 Precautions during operation ………………………………………………………………………………………… 5-4
28 Machine ready for attachments…………………………………………………………………………………………….. 5-5
28.1 Explanation of components …………………………………………………………………………………………… 5-5
28.2 Hydraulic circuit …………………………………………………………………………………………………………… 5-7
28.3 Attachment mounting / dismounting procedure …………………………………………………………………5-9
28.4 Operation …………………………………………………………………………………………………………………. 5-11
28.5 Long-term storage ……………………………………………………………………………………………………… 5-12
28.6 Specifications ……………………………………………………………………………………………………………. 5-12
29. Introduction of attachments ……………………………………………………………………………………………….. 5-13
29.1 Specification, use ………………………………………………………………………………………………………. 5-13
29.2 Attachment installing combination table ………………………………………………………………………… 5-14
29.3 Selection of track shoes ……………………………………………………………………………………………… 5-15
29.4 Selection of bucket teeth …………………………………………………………………………………………….. 5-16
29.5 Handling trapezoidal bucket ………………………………………………………………………………………… 5-17
29.6 Handling extension arm ……………………………………………………………………………………………… 5-18
30. Extending machine service life …………………………………………………………………………………………… 5-19
30.1 Hydraulic breaker ………………………………………………………………………………………………………. 5-19
30.2 Power ripper ……………………………………………………………………………………………………………… 5-22
30.3 Fork grab ………………………………………………………………………………………………………………….. 5-23
30.4 Grapple bucket ………………………………………………………………………………………………………….. 5-24
30.5 Scrap grapple ……………………………………………………………………………………………………………. 5-25
30.6 Crusher & cutter ………………………………………………………………………………………………………… 5-26
30.7 Hydraulic pile driver ……………………………………………………………………………………………………. 5-27
30.8 Hydraulic excavator with multi-purpose crane ………………………………………………………………… 5-28