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KOMATSU GALEO PC160LC-7 HYDRAULIC EXCAVATOR Operation & Maintenance Manual (SN:10001 & UP) – PDF DOWNLOAD
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- KOMATSU GALEO PC160LC-7 HYDRAULIC EXCAVATOR Operation & Maintenance Manual
- SERIAL NUMBER:10001 & UP
- PUBLICATION NUMBER:TEN00021-00 (Replaces SEAM047800T)
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Description
KOMATSU GALEO PC160LC-7 HYDRAULIC EXCAVATOR Operation & Maintenance Manual (SN:10001 & UP)
KOMATSU GALEO PC160LC-7 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (SN:10001 & UP) – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU GALEO PC160LC-7 HYDRAULIC EXCAVATOR Operation & Maintenance Manual (SN:10001 & UP)
- Operators and maintenance personnel must always do as follows before beginning operation or maintenance.
- Always be sure to read and understand this manual thoroughly before performing operation and maintenance.
- Read the safety messages given in this manual and the safety labels affixed to the machine thoroughly and be sure that you understand them fully.
- Keep this manual in the storage location for the operation and maintenance manual given below, and have all personnel read it
periodically. - If this manual has been lost or has become dirty and cannot be read, request a replacement manual immediately from Komatsu
or your Komatsu distributor. - If you sell the machine, be sure to give this manual to the new owners together with the machine.
- Komatsu delivers machines that comply with all applicable regulations and standards of the country to which it has been shipped.
If this machine has been purchased in another country or purchased from someone in another country, it may lack certain safety
devices and specifications that are necessary for use in your country. If there is any question about whether your product
complies with the applicable standards and regulations of your country, consult Komatsu or your Komatsu distributor before
operating the machine.
TABLE OF CONTENTS:
KOMATSU GALEO PC160LC-7 HYDRAULIC EXCAVATOR Operation & Maintenance Manual (SN:10001 & UP)
MAIN MENU............................................................................................. 0 COVER................................................................................................. 1 FOREWORD.............................................................................................. 2 FOREWORD.......................................................................................... 3 SAFETY INFORMATION................................................................................ 6 INTRODUCTION...................................................................................... 8 DIRECTIONS OF MACHINE......................................................................... 8 BREAKING-IN THE NEW MACHINE................................................................... 8 PRODUCT INFORMATION............................................................................... 9 PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE.................................. 9 ENGINE SERIAL NUMBER PLATE AND ITS LOCATION................................................... 9 SERVICE METER LOCATION........................................................................ 10 YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR................................................... 10 CONTENTS.............................................................................................. 11 SAFETY................................................................................................ 14 SAFETY INFORMATION................................................................................ 15 SAFETY LABELS..................................................................................... 17 LOCATION OF SAFETY LABELS..................................................................... 17 SAFETY LABELS................................................................................. 18 SAFETY INFORMATION................................................................................ 23 SAFETY RULES.................................................................................. 23 IF ABNORMALITIES ARE FOUND.................................................................... 23 WORKING WEAR AND PERSONAL PROTECTIVE ITEMS.................................................... 23 FIRE EXTINGUISHER AND FIRST AID KIT........................................................... 23 SAFETY EQUIPMENT.............................................................................. 23 KEEP MACHINE CLEAN............................................................................ 24 KEEP OPERATOR'S COMPARTMENT CLEAN............................................................. 24 LEAVING OPERATOR'S SEAT WITH LOCK............................................................. 24 HANDRAILS AND STEPS........................................................................... 25 MOUNTING AND DISMOUNTING...................................................................... 25 NO PERSONS ON ATTACHMENTS..................................................................... 25 BURN PREVENTION............................................................................... 26 FIRE PREVENTION AND EXPLOSION PREVENTION...................................................... 27 ACTION IF FIRE OCCURS......................................................................... 28 WINDSHIELD WASHER FLUID....................................................................... 28 FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION.............................. 28 ATTACHMENT INSTALLATION....................................................................... 28 ATTACHMENT COMBINATIONS....................................................................... 28 CAB WINDOW GLASSES............................................................................ 28 UNAUTHORIZED MODIFICATIONS.................................................................... 29 SAFETY AT JOBSITE............................................................................. 29 WORKING ON LOOSE GROUND....................................................................... 29 DISTANCE TO HIGH VOLTAGE CABLES............................................................... 29 ENSURE GOOD VISIBILITY........................................................................ 30 VENTILATION FOR ENCLOSED AREA................................................................. 30 SIGNALMAN'S SIGNAL AND SIGNS.................................................................. 30 EMERGENCY EXIT FROM OPERATOR'S CAB............................................................ 30 ASBESTOS DUST HAZARD PREVENTION............................................................... 31 SAFETY MACHINE OPERATION.......................................................................... 32 STARTING ENGINE............................................................................... 32 CHECKS BEFORE STARTING ENGINE............................................................. 32 SAFETY RULES FOR STARTING ENGINE.......................................................... 33 STARTING ENGINE IN COLD WEATHER........................................................... 33 OPERATION..................................................................................... 34 CHECKS BEFORE OPERATION................................................................... 34 SAFETY RULES FOR CHANGING MACHINE DIRECTIONS.............................................. 34 SAFETY RULES FOR TRAVELING................................................................ 35 TRAVELING ON SLOPES....................................................................... 36 OPERATIONS ON SLOPES...................................................................... 37 PROHIBITED OPERATIONS..................................................................... 37 OPERATIONS ON SNOW........................................................................ 38 PARKING MACHINE........................................................................... 39 TRANSPORTATION................................................................................ 40 SHIPPING THE MACHINE...................................................................... 40 BATTERY....................................................................................... 41 BATTERY HAZARD PREVENTION................................................................. 41 STARTING ENGINE WITH BOOSTER CABLES....................................................... 42 TOWING........................................................................................ 43 SAFETY RULES FOR TOWING................................................................... 43 LIFTING OBJECTS WITH BUCKET................................................................... 44 SAFETY RULES FOR LIFTING OBJECTS.......................................................... 44 LIFTING WORK USING BUCKET WITH HOOK....................................................... 44 SAFETY MAINTENANCE INFORMATION.................................................................... 45 WARNING TAG................................................................................... 45 KEEP WORK PLACE CLEAN AND TIDY................................................................ 45 APPOINT LEADER WHEN WORKING WITH OTHERS....................................................... 45 STOP ENGINE BEFORE CARRYING OUT MAINTENANCE................................................... 46 TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING............................................ 47 PROPER TOOLS.................................................................................. 47 ACCUMULATOR................................................................................... 48 PERSONNEL..................................................................................... 48 WORK UNDER THE MACHINE........................................................................ 48 NOISE......................................................................................... 48 WHEN USING HAMMER............................................................................. 49 WELDING WORKS................................................................................. 49 REMOVING BATTERY TERMINALS.................................................................... 49 SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION.......................... 49 DO NOT DISASSEMBLE RECOIL SPRINGS............................................................. 49 SAFETY RULES FOR HIGH-PRESSURE OIL............................................................ 50 SAFETY HANDLING HIGH-PRESSURE HOSES........................................................... 50 WASTE MATERIALS............................................................................... 50 AIR CONDITIONER MAINTENANCE................................................................... 50 COMPRESSED AIR................................................................................ 51 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS................................................. 51 OPERATION............................................................................................. 52 MACHINE VIEW ILLUSTRATIONS........................................................................ 53 OVERALL MACHINE VIEW.......................................................................... 53 CONTROLS AND GAUGES........................................................................... 54 DETAILED CONTROLS AND GAUGES...................................................................... 55 MONITORING SYSTEM............................................................................. 55 SWITCHES...................................................................................... 79 CONTROL LEVERS AND PEDALS..................................................................... 84 SUN ROOF...................................................................................... 87 WINDSHIELD.................................................................................... 87 EMERGENCY EXIT FROM OPERATOR'S CAB............................................................ 92 DOOR LOCK..................................................................................... 92 CAP WITH LOCK................................................................................. 93 HOT AND COOL BOX.............................................................................. 94 AIR CONDITIONER CONTROLS...................................................................... 95 RADIO.........................................................................................110 AUXILIARY ELECTRIC POWER......................................................................114 FUSE..........................................................................................115 FUSIBLE LINK..................................................................................116 CONTROLLERS...................................................................................116 TOOL BOX......................................................................................116 GREASE GUN HOLDER.............................................................................116 ACCUMULATOR...................................................................................117 MACHINE OPERATIONS AND CONTROLS...................................................................119 BEFORE STARTING ENGINE........................................................................119 STARTING ENGINE...............................................................................134 AFTER STARTING ENGINE.........................................................................138 STOPPING THE ENGINE...........................................................................147 MACHINE OPERATION.............................................................................148 STEERING THE MACHINE..........................................................................152 SWINGING......................................................................................154 WORK EQUIPMENT CONTROLS AND OPERATIONS........................................................155 WORKING MODE..................................................................................157 PROHIBITED OPERATIONS.........................................................................158 GENERAL OPERATION INFORMATION.................................................................160 TRAVELING ON SLOPES...........................................................................161 ESCAPE FROM MUD...............................................................................163 RECOMMENDED APPLICATIONS......................................................................164 BUCKET REPLACEMENT AND INVERSION..............................................................166 PARKING MACHINE...............................................................................169 CHECK AFTER SHUT OFF ENGINE...................................................................170 MACHINE INSPECTION AFTER DAILY WORK...........................................................170 LOCKING.......................................................................................171 TRANSPORTATION....................................................................................172 TRANSPORTATION PROCEDURE......................................................................172 LOADING AND UNLOADING WITH TRAILER............................................................172 LIFTING MACHINE...............................................................................179 COLD WEATHER OPERATION............................................................................181 COLD WEATHER OPERATION INFORMATION............................................................181 AFTER DAILY WORK COMPLETION...................................................................184 AFTER COLD WEATHER SEASON.....................................................................184 LONG TERM STORAGE.................................................................................185 BEFORE STORAGE................................................................................185 DURING STORAGE................................................................................185 AFTER STORAGE.................................................................................185 STARTING MACHINE AFTER LONG-TERM STORAGE......................................................186 TROUBLES AND ACTIONS..............................................................................187 RUNNING OUT OF FUEL...........................................................................187 PHENOMENA THAT ARE NOT FAILURES...............................................................187 TOWING THE MACHINE............................................................................188 LIGHTWEIGHT TOWING HOLE.......................................................................188 SEVERE JOB CONDITION..........................................................................188 DISCHARGED BATTERY............................................................................189 OTHER TROUBLE.................................................................................193 MAINTENANCE...........................................................................................198 MAINTENANCE INFORMATION...........................................................................199 OUTLINE OF SERVICE................................................................................201 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC........................................201 ELECTRIC SYSTEM MAINTENANCE...................................................................204 WEAR PARTS........................................................................................205 WEAR PARTS LIST...............................................................................205 LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS.......................................................206 PROPER SELECTION..............................................................................206 TIGHTENING TORQUE SPECIFICATIONS..................................................................210 TIGHTENING TORQUE LIST........................................................................210 SAFETY CRITICAL PARTS.............................................................................211 SAFETY CRITICAL PARTS LIST....................................................................211 MAINTENANCE SCHEDULE..............................................................................212 MAINTENANCE SCHEDULE CHART....................................................................212 MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER....................................................213 MAINTENANCE PROCEDURE.............................................................................214 INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)................................214 REPLACE FUEL FILTER CARTRIDGE.............................................................252 INITIAL 1000 HOURS MAINTENANCE (ONLY AFTER THE FIRST 1000 HOURS)..............................214 CHECK ENGINE VALVE CLEARANCE, ADJUST......................................................261 WHEN REQUIRED.................................................................................215 CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT..............................................215 CLEAN INSIDE OF COOLING SYSTEM............................................................220 CHECK AND TIGHTEN TRACK SHOE BOLTS........................................................223 CHECK AND ADJUST TRACK TENSION............................................................224 CHECK ELECTRICAL INTAKE AIR HEATER........................................................225 REPLACE BUCKET TEETH (VERTICAL PIN TYPE)..................................................226 REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)................................................229 ADJUST BUCKET CLEARANCE...................................................................230 CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID................................................231 CHECK AND MAINTENANCE AIR CONDITIONER.....................................................232 WASH WASHABLE FLOOR.......................................................................233 BLEEDING AIR FROM HYDRAULIC SYSTEM........................................................236 METHOD FOR RELEASING INTERNAL PRESSURE IN HYDRAULIC CIRCUIT...............................238 CHECK NITROGEN GAS CHARGE PRESSURE IN ACCUMULATOR (control circuit).......................239 CHECK BEFORE STARTING.........................................................................240 EVERY 250 HOURS MAINTENANCE...................................................................241 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL..............................................242 CHECK LEVEL OF BATTERY ELECTROLYTE........................................................243 CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST.....................................246 CHECK OIL LEVEL IN SWING MACHINERY CASE, ADD OIL..........................................241 EVERY 500 HOURS MAINTENANCE...................................................................247 LUBRICATING...............................................................................247 LUBRICATE SWING CIRCLE....................................................................249 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE.........................250 REPLACE FUEL FILTER CARTRIDGE.............................................................252 CHECK SWING PINION GREASE LEVEL, ADD GREASE...............................................253 CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS, CONDENSER FINS AND AFTER COOLER FINS....254 CLEAN AIR CONDITIONER FRESH/RECIRC FILTERS................................................255 REPLACE BREATHER ELEMENT IN HYDRAULIC TANK................................................256 EVERY 1000 HOURS MAINTENANCE..................................................................257 REPLACE HYDRAULIC OIL FILTER ELEMENT......................................................257 CHANGE OIL IN SWING MACHINERY CASE........................................................258 CHECK OIL LEVEL IN DAMPER CASE, ADD OIL...................................................259 CHECK FAN BELT TENSION AND REPLACE FAN BELT...............................................259 EVERY 2000 HOURS MAINTENANCE..................................................................260 CHANGE OIL IN FINAL DRIVE CASE............................................................260 CLEAN HYDRAULIC TANK STRAINER.............................................................261 CHECK ALTERNATOR, STARTING MOTOR..........................................................261 CHECK ENGINE VALVE CLEARANCE, ADJUST......................................................261 EVERY 4000 HOURS MAINTENANCE..................................................................262 CHECK WATER PUMP..........................................................................262 EVERY 5000 HOURS MAINTENANCE..................................................................263 CHANGE OIL IN HYDRAULIC TANK..............................................................263 SPECIFICATIONS........................................................................................264 SPECIFICATIONS....................................................................................265 ATTACHMENTS, OPTIONS..................................................................................268 GENERAL PRECAUTIONS FOR SAFETY....................................................................269 PRECAUTIONS WHEN SELECTING....................................................................269 READ THE INSTRUCTION MANUAL THOROUGHLY........................................................269 PRECAUTIONS WHEN REMOVING OR INSTALLING.......................................................269 PRECAUTIONS WHEN USING........................................................................269 BUCKET WITH HOOK..................................................................................270 HOOK CONDITION................................................................................270 PROHIBITED OPERATIONS.........................................................................270 MACHINE READY FOR ATTACHMENT......................................................................271 LOCATIONS.....................................................................................271 HYDRAULIC CIRCUIT.............................................................................274 ATTACHMENT REMOVAL AND INSTALLATION...........................................................278 ATTACHMENT OPERATIONS.........................................................................280 LONG TERM STORAGE.............................................................................282 SPECIFICATIONS................................................................................282 ATTACHMENT GUIDE..................................................................................283 OTHER ATTACHMENTS.............................................................................283 ATTACHMENT COMBINATIONS.......................................................................285 TRACK SHOES SELECTION.........................................................................286 BUCKET TEETH SELECTION........................................................................287 RECOMMENDED ATTACHMENT OPERATIONS.................................................................288 HYDRAULIC BREAKER.............................................................................288 INDEX.................................................................................................294
PLEASE NOTE:
⦁ This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
⦁ This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
⦁ Require some other service manual or have any queries: please WRITE to us at [email protected]
