Komatsu 2001 PC160-6K / PC180LC-6K / PC180NLC-6K Excavator Shop Manual (P/N UEBM000601)

Komatsu shop manual P/N UEBM000601 covers the 2001 PC160-6K, PC180LC-6K, and PC180NLC-6K excavators in the K32001-and-up and K34001-and-up serial series. This edition was printed in Belgium in September 2001.

PDF Search, Bookmarks and Diagram Detail

Search and diagram access: Text search has gaps in some tables and circuit-diagram labels. Embedded bookmarks cover chapters and many subsections, but some opening links point to the cover. Small wiring labels require zooming; some remain soft.

Supplied as one printable, English-language, 692-page PDF, including 21 preliminary/reference pages, the two-page hydraulic-tank revision, and blank/memo pages already included in the total.

Hydraulic Controls, Fault Diagnosis and Component Repair

The following selected coverage highlights outline the main workshop content. Other topics include air-conditioner compressor belt adjustment and ESCO Helilok bucket-adapter welding instructions.

• Hydraulic testing: Work-equipment, swing, and travel pressure tests; TVC and LS adjustments; PPC output checks; hydraulic-drift diagnosis and air-bleeding procedures.

• Electrical troubleshooting: Governor and pump-controller diagnostics, monitor service codes, connector-pin tables, sensor tests, and system-specific wiring diagrams.

• Travel and swing drives: Travel-motor removal and installation, final-drive and swing-machinery overhaul, swing-motor assembly, and parking-brake checks.

• Undercarriage service: Track-tension adjustment, swing-circle bearing checks, and removal, disassembly, and assembly procedures for idlers, recoil springs, and rollers.

• Cylinders and work equipment: Boom, arm, and bucket removal; hydraulic-cylinder disassembly and assembly; seal installation and pin-and-bushing inspection standards.

• Engine and cooling assemblies: Engine/pump assembly removal, governor-linkage adjustment, and radiator and hydraulic-oil-cooler removal and installation.

Written for service personnel carrying out workshop repairs, this manual includes hydraulic measurements, electrical diagnosis, and major-assembly work requiring appropriate test and lifting equipment.

CLSS Testing and Controller Fault Isolation

The structure-and-function sections explain how the Closed center Load Sensing System coordinates pump delivery, pressure compensation, and compound movements. Control-valve coverage includes the six-spool arrangement with an additional service valve, along with LS select, shuttle, relief, and pressure-compensation valves.

Hydraulic-drift tests distinguish cylinder-packing leakage from control-valve problems. Combined with the electrical judgment tables, these checks support component-level fault isolation before a repair or replacement is selected.

Circuit references: The Hydraulic Circuit Diagram is accompanied by electrical circuit diagrams for E-mode governor control, C-mode pump control, F-mode input signals, and M-mode machine monitoring. Connector-location views and pin-number tables connect the troubleshooting charts to the machine wiring.

Drive Overhaul and Undercarriage Inspection

Step-by-step procedures extend inside the final drive and swing machinery, covering planetary stages, brake-disc packs, seals, and reassembly checks. Swing-motor instructions include piston/barrel alignment and shim selection.

Workshop tools: The center-swivel section identifies push-puller 790-101-2501. Final-drive procedures reference tools such as AT709C15, while dimensioned tooling drawings support workshop tool preparation.

Maintenance-standard tables provide inspection criteria for gears, bearings, rollers, hydraulic valves, and work-equipment joints. Separate views identify one-piece and two-piece boom arrangements. Center-swivel assembly precautions flag the risk of damaging slipper seals and O-rings during rotor installation.

Engine Controls, Cooling and Lift Planning

Engine scope: This chassis shop manual covers SA4D102E installation, engine-related troubleshooting, and governor controls. It directs detailed engine work to the separate 102 Series Engine Shop Manual, which is not included in this PDF.

Governor-linkage instructions explain how sudden lever movement with the spring assembly disconnected and the starting switch off can generate electricity and cause engine-throttle-controller failure.

Component weight tables and hoisting instructions support planning lifts and handling major assemblies. Standard tightening-torque charts and conversion tables provide supporting workshop references.

Working on heavy machinery carries inherent physical risks. The manual addresses supported work equipment, stored hydraulic pressure, and heavy lifting; undercarriage procedures also warn about grease-pressure ejection from the track-adjustment plug.

Selected Engine, Swing and CLSS Reference Data

The SA4D102E specification table lists maximum torque of 474 Nm at 1,400 rpm. The lubricant and coolant table gives a specified total cooling-system capacity of 20 liters.

The swing-machinery section documents a reduction ratio of 22.667:1 alongside component views of the planetary reduction and holding brake.

In the CLSS operating explanation, the unload valve establishes pump discharge pressure of 3.92 MPa (40 kg/cm²) with the control valve at neutral. This is the neutral unloading condition, distinct from the working-circuit relief-pressure specifications.