Komatsu Hydraulic Excavator PC160LC-7EO Operation & Maintenance Manual SN K45001 and up – PDF DOWNLOAD

Description

Komatsu Hydraulic Excavator PC160LC-7EO Operation & Maintenance Manual

TABLE OF CONTENTS:

Komatsu Hydraulic Excavator PC160LC-7EO Operation & Maintenance Manual

FOREWORD..............................................................................................................................................................................  3
	FOREWORD..........................................................................................................................................................................  4
	SAFETY INFORMATION................................................................................................................................................................  6
		Vibration levels..............................................................................................................................................................  8
	INTRODUCTION...................................................................................................................................................................... 10
		DIRECTIONS OF MACHINE......................................................................................................................................................... 10
		BREAKING-IN THE NEW MACHINE................................................................................................................................................... 10
	PRODUCT INFORMATION............................................................................................................................................................... 12
		PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE.................................................................................................................. 12
		EPA REGULATIONS, ENGINE NUMBER PLATE.......................................................................................................................................... 12
		SERVICE METER LOCATION........................................................................................................................................................ 13
		YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR................................................................................................................................... 13
		MACHINE SERIAL PLATE.......................................................................................................................................................... 14
		FOREWORD...................................................................................................................................................................... 16
		SAFETY........................................................................................................................................................................ 16
		OPERATION..................................................................................................................................................................... 16
		MAINTENANCE................................................................................................................................................................... 19
		SPECIFICATIONS................................................................................................................................................................ 21
		ATTACHMENTS AND OPTIONS....................................................................................................................................................... 21
		INDEX......................................................................................................................................................................... 22
		COLOPHON...................................................................................................................................................................... 22
SAFETY................................................................................................................................................................................ 23
	SAFETY INFORMATION................................................................................................................................................................ 24
	SAFETY LABELS..................................................................................................................................................................... 26
		LOCATION OF SAFETY LABELS..................................................................................................................................................... 27
		SAFETY LABELS................................................................................................................................................................. 28
	SAFETY INFORMATION................................................................................................................................................................ 34
	SAFETY MACHINE OPERATION.......................................................................................................................................................... 44
		STARTING ENGINE............................................................................................................................................................... 44
		OPERATION..................................................................................................................................................................... 46
		TRANSPORTATION................................................................................................................................................................ 52
		BATTERY....................................................................................................................................................................... 53
		TOWING........................................................................................................................................................................ 55
		LIFTING OBJECTS WITH BUCKET................................................................................................................................................... 56
	SAFETY MAINTENANCE INFORMATION.................................................................................................................................................... 57
OPERATION............................................................................................................................................................................. 65
	MACHINE VIEW ILLUSTRATIONS........................................................................................................................................................ 66
		OVERALL MACHINE VIEW.......................................................................................................................................................... 66
		CONTROLS AND GAUGES........................................................................................................................................................... 67
	DETAILED CONTROLS AND GAUGES...................................................................................................................................................... 69
		MONITORING SYSTEM............................................................................................................................................................. 69
			Basic Operation of Machine Monitor........................................................................................................................................ 70
			Emergency Monitors........................................................................................................................................................ 74
			Caution Monitors.......................................................................................................................................................... 76
			Basic Check Monitors...................................................................................................................................................... 79
			Meter Display Portion..................................................................................................................................................... 81
			Monitor Switches Portion.................................................................................................................................................. 86
		SWITCHES...................................................................................................................................................................... 99
		CONTROL LEVERS AND PEDALS.....................................................................................................................................................103
		SUN ROOF......................................................................................................................................................................106
		WINDSHIELD....................................................................................................................................................................106
		EMERGENCY EXIT FROM OPERATOR'S CAB............................................................................................................................................111
		DOOR LOCK.....................................................................................................................................................................111
		CAP WITH LOCK.................................................................................................................................................................112
		DRINK BOX.....................................................................................................................................................................113
		MAGAZINE BOX..................................................................................................................................................................114
		ASHTRAY.......................................................................................................................................................................114
		AIR CONDITIONER CONTROLS......................................................................................................................................................115
			Air Conditioner Control Panel.............................................................................................................................................115
			Method of Operation.......................................................................................................................................................120
			Use Air Conditioner with Care.............................................................................................................................................127
			Air Conditioner Maintenance...............................................................................................................................................127
			Other Functions...........................................................................................................................................................127
		RADIO.........................................................................................................................................................................129
			Control Panel.............................................................................................................................................................129
			Controls of Radio.........................................................................................................................................................131
			Use Radio with Care.......................................................................................................................................................133
		When the battery is replaced, the settings for the preset buttons are all cleared, so set them again..........................................................................133
	AUXILIARY ELECTRIC POWER..........................................................................................................................................................134
		24V Power Source..............................................................................................................................................................134
		12V Power Source..............................................................................................................................................................134
		FUSE..........................................................................................................................................................................135
		FUSIBLE LINK..................................................................................................................................................................136
		CONTROLLER....................................................................................................................................................................136
		TOOL BOX......................................................................................................................................................................136
		GREASE GUN HOLDER.............................................................................................................................................................136
		REFUELLING PUMP...............................................................................................................................................................137
	MACHINE OPERATIONS AND CONTROLS...................................................................................................................................................138
		BEFORE STARTING ENGINE........................................................................................................................................................138
			Walk-around Checks........................................................................................................................................................138
			Checks Before Starting....................................................................................................................................................140
			Adjustment................................................................................................................................................................147
			Seat Belt.................................................................................................................................................................151
			Operations Before Starting Engine.........................................................................................................................................152
		STARTING ENGINE...............................................................................................................................................................155
		AMBIENT TEMPERATURE RANGE FOR OPERATION.......................................................................................................................................157
		AFTER STARTING ENGINE.........................................................................................................................................................158
			Checking of Engine Startability and Noise.................................................................................................................................158
			Checking of Engine Acceleration and Deceleration..........................................................................................................................158
			Engine Warm Up............................................................................................................................................................159
			Hydraulic Equipment Warm Up...............................................................................................................................................161
			Operation After Completion Of Warm-Up Operation...........................................................................................................................167
		STOPPING THE ENGINE...........................................................................................................................................................169
		MACHINE OPERATION.............................................................................................................................................................170
			Preparations for Moving the Machine.......................................................................................................................................170
			Moving Machine Forward....................................................................................................................................................171
			Moving Machine Backward...................................................................................................................................................172
			Stopping Machine..........................................................................................................................................................173
		STEERING THE MACHINE..........................................................................................................................................................174
			Steering..................................................................................................................................................................174
		SWINGING......................................................................................................................................................................176
		WORK EQUIPMENT CONTROLS AND OPERATIONS........................................................................................................................................177
		WORKING MODE..................................................................................................................................................................178
		PROHIBITED OPERATIONS.........................................................................................................................................................179
		GENERAL OPERATION INFORMATION.................................................................................................................................................181
		TRAVELING ON SLOPES...........................................................................................................................................................182
		ESCAPE FROM MUD...............................................................................................................................................................184
			Track on One Side Stuck...................................................................................................................................................184
			Tracks on Both Sides Stuck................................................................................................................................................184
		RECOMMENDED APPLICATIONS......................................................................................................................................................185
			Backhoe Work..............................................................................................................................................................185
			Shovel Work...............................................................................................................................................................185
			Ditching Work.............................................................................................................................................................185
			Loading Work..............................................................................................................................................................186
		BUCKET REPLACEMENT AND INVERSION..............................................................................................................................................187
			Replacement...............................................................................................................................................................187
			Inversion.................................................................................................................................................................189
		PARKING MACHINE...............................................................................................................................................................190
		MACHINE INSPECTION AFTER DAILY WORK...........................................................................................................................................191
		LOCKING.......................................................................................................................................................................192
	TRANSPORTATION....................................................................................................................................................................193
		TRANSPORTATION PROCEDURE......................................................................................................................................................193
		LOADING AND UNLOADING WITH TRAILER............................................................................................................................................194
			Loading...................................................................................................................................................................195
			Securing Machine..........................................................................................................................................................198
			Unloading.................................................................................................................................................................201
		LIFTING MACHINE...............................................................................................................................................................203
	COLD WEATHER OPERATION............................................................................................................................................................205
		COLD WEATHER OPERATION INFORMATION............................................................................................................................................205
			Fuel and Lubricants.......................................................................................................................................................205
			Cooling System Coolant....................................................................................................................................................205
			Battery...................................................................................................................................................................206
			Monitor...................................................................................................................................................................207
		AFTER DAILY WORK COMPLETION...................................................................................................................................................208
		AFTER COLD WEATHER SEASON.....................................................................................................................................................208
	LONG TERM STORAGE.................................................................................................................................................................209
		BEFORE STORAGE................................................................................................................................................................209
		DURING STORAGE................................................................................................................................................................209
		AFTER STORAGE.................................................................................................................................................................210
		STARTING MACHINE AFTER LONG-TERM STORAGE......................................................................................................................................210
	TROUBLES AND ACTIONS..............................................................................................................................................................211
		RUNNING OUT OF FUEL...........................................................................................................................................................211
		PHENOMENA THAT ARE NOT FAILURES...............................................................................................................................................211
		TOWING THE MACHINE............................................................................................................................................................212
		LIGHTWEIGHT TOWING HOLE.......................................................................................................................................................213
		SEVERE JOB CONDITION..........................................................................................................................................................213
		DISCHARGED BATTERY............................................................................................................................................................214
			Battery Removal and Installation..........................................................................................................................................214
			Battery Charges...........................................................................................................................................................215
			Starting Engine with Booster Cables.......................................................................................................................................216
		OTHER TROUBLE.................................................................................................................................................................218
			Electrical System.........................................................................................................................................................218
			Chassis...................................................................................................................................................................219
			Engine....................................................................................................................................................................220
			Electronic Control System.................................................................................................................................................221
			Point of Contact to Telephone when Error Occurs...........................................................................................................................222
MAINTENANCE...........................................................................................................................................................................223
	MAINTENANCE INFORMATION...........................................................................................................................................................224
	OUTLINE OF SERVICE................................................................................................................................................................226
		HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC........................................................................................................................226
			Oil.......................................................................................................................................................................226
			Fuel......................................................................................................................................................................227
			Antifreeze Coolant and Water for Dilution.................................................................................................................................227
			Grease....................................................................................................................................................................228
			Carrying Out KOWA (Komatsu Oil Wear Analysis).............................................................................................................................228
			Oil and Fuel Storage......................................................................................................................................................229
			Filters...................................................................................................................................................................229
		ELECTRIC SYSTEM MAINTENANCE...................................................................................................................................................229
	WEAR PARTS........................................................................................................................................................................230
		WEAR PARTS LIST...............................................................................................................................................................230
	RECOMMENDED FUEL, COOLANT, AND LUBRICANT..........................................................................................................................................231
		RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL...........................................................................................233
	TIGHTENING TORQUE SPECIFICATIONS..................................................................................................................................................234
		TIGHTENING TORQUE LIST........................................................................................................................................................234
	SAFETY CRITICAL PARTS.............................................................................................................................................................235
		SAFETY CRITICAL PARTS LIST....................................................................................................................................................236
	MAINTENANCE SCHEDULE..............................................................................................................................................................237
		MAINTENANCE SCHEDULE CHART....................................................................................................................................................237
		MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER....................................................................................................................................239
	MAINTENANCE PROCEDURE.............................................................................................................................................................240
		INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)................................................................................................................240
		INITIAL 500 HOURS MAINTENANCE (ONLY AFTER THE FIRST 500 HOURS)................................................................................................................240
		WHEN REQUIRED.................................................................................................................................................................241
			CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT..............................................................................................................................241
			CLEAN INSIDE OF COOLING SYSTEM............................................................................................................................................247
			CHECK AND TIGHTEN TRACK SHOE BOLTS........................................................................................................................................250
			CHECK AND ADJUST TRACK TENSION............................................................................................................................................251
			REPLACE BUCKET TEETH (VERTICAL PIN TYPE)..................................................................................................................................253
			REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)................................................................................................................................256
			ADJUST BUCKET CLEARANCE...................................................................................................................................................258
			CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID................................................................................................................................259
			CHECK AND MAINTENANCE AIR CONDITIONER.....................................................................................................................................260
			WASH WASHABLE FLOOR.......................................................................................................................................................261
			CHECK GAS SPRING..........................................................................................................................................................264
			BLEEDING AIR FROM HYDRAULIC SYSTEM........................................................................................................................................265
			METHOD FOR RELEASING INTERNAL PRESSURE IN HYDRAULIC CIRCUIT...............................................................................................................267
		CHECK BEFORE STARTING.........................................................................................................................................................268
		EVERY 100 HOURS MAINTENANCE...................................................................................................................................................269
			LUBRICATING...............................................................................................................................................................269
		EVERY 250 HOURS MAINTENANCE...................................................................................................................................................270
			CHECK LEVEL OF BATTERY ELECTROLYTE........................................................................................................................................270
			CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST.....................................................................................................................272
			CHECK OIL LEVEL IN SWING MACHINERY CASE, ADD OIL..........................................................................................................................273
		EVERY 500 HOURS MAINTENANCE...................................................................................................................................................274
			LUBRICATING...............................................................................................................................................................274
			LUBRICATE SWING CIRCLE....................................................................................................................................................275
			CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE.........................................................................................................276
			REPLACE FUEL PRE-FILTER CARTRIDGE.........................................................................................................................................278
			CHECK SWING PINION GREASE LEVEL, ADD GREASE...............................................................................................................................280
			CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS, AFTERCOOLER FINS, FUEL COOLER FINS, AND AIR CONDITIONER CONDENSER FINS (only machines equipped with air conditioner)....281
			CLEAN AIR CONDITIONER FRESH/RECIRC FILTERS................................................................................................................................283
			REPLACE BREATHER ELEMENT IN HYDRAULIC TANK................................................................................................................................285
			CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL..............................................................................................................................286
		EVERY 1000 HOURS MAINTENANCE..................................................................................................................................................287
			REPLACE HYDRAULIC OIL FILTER ELEMENT......................................................................................................................................287
			CHANGE OIL IN SWING MACHINERY CASE........................................................................................................................................288
			CHECK OIL LEVEL IN DAMPER CASE, ADD OIL...................................................................................................................................289
			REPLACE FUEL MAIN FILTER CARTRIDGE........................................................................................................................................290
			CHECK ALL TIGHTENING POINTS OF ENGINE EXHAUST PIPE CLAMPS.................................................................................................................292
			CHECK FAN BELT TENSION AND REPLACE FAN BELT...............................................................................................................................292
			CHECK NITROGEN GAS CHARGE PRESSURE IN ACCUMULATOR (for breaker)...........................................................................................................292
		EVERY 2000 HOURS MAINTENANCE..................................................................................................................................................293
			CHANGE OIL IN FINAL DRIVE CASE............................................................................................................................................293
			CLEAN HYDRAULIC TANK STRAINER.............................................................................................................................................294
			CHECKING CHARGE PRESSURE OF NITROGEN GAS IN ACCUMULATOR (FOR CONTROL CIRCUIT).............................................................................................295
			CHECK ALTERNATOR, STARTING MOTOR..........................................................................................................................................299
			CHECK ENGINE VALVE CLEARANCE, ADJUST......................................................................................................................................299
		EVERY 4000 HOURS MAINTENANCE..................................................................................................................................................300
			CHECK WATER PUMP..........................................................................................................................................................300
			REPLACE ACCUMULATOR (FOR CONTROL CIRCUIT).................................................................................................................................301
			CHECK FOR LOOSENESS OF HIGH-PRESSURE PIPING CLAMP, HARDENING OF RUBBER....................................................................................................302
			CHECK FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER..........................................................................................................302
			CHECK OPERATING CONDITION OF COMPRESSOR...................................................................................................................................303
		EVERY 5000 HOURS MAINTENANCE..................................................................................................................................................304
			CHANGE OIL IN HYDRAULIC TANK..............................................................................................................................................304
		EVERY 8000 HOURS MAINTENANCE..................................................................................................................................................305
			REPLACE FUEL SPRAY PREVENTION CAP.........................................................................................................................................305
			REPLACE HIGH-PRESSURE PIPING CLAMP........................................................................................................................................305
SPECIFICATIONS........................................................................................................................................................................307
	SPECIFICATIONS....................................................................................................................................................................308
		EXPLANATION OF LIFTING CAPACITY CHART.........................................................................................................................................310
			MONOBOOM (PC160LC- 7E0KA).................................................................................................................................................310
ATTACHMENTS AND OPTIONS...............................................................................................................................................................313
	ATTACHMENTS AND OPTIONS - GENERAL INFORMATION.....................................................................................................................................314
		SAFETY FIRST..................................................................................................................................................................314
		ATTACHMENT INSTALLATION.......................................................................................................................................................316
	BUCKET WITH HOOK..................................................................................................................................................................317
		HOOK CONDITION................................................................................................................................................................317
		PROHIBITED OPERATIONS.........................................................................................................................................................317
	MACHINE READY FOR ATTACHMENT (DELUXE HCU SYSTEM)..................................................................................................................................318
		LOCATIONS.....................................................................................................................................................................318
		HYDRAULIC CIRCUIT.............................................................................................................................................................321
			Switching Hydraulic Circuit...............................................................................................................................................321
			Adjusting Oil Flow........................................................................................................................................................321
			Switching Between Breaker and General Attachment..........................................................................................................................321
			HYDRAULIC CIRCUIT CONNECTION..............................................................................................................................................322
			PATH OF OIL...............................................................................................................................................................322
		ATTACHMENT REMOVAL AND INSTALLATION...........................................................................................................................................323
			Attachment Removal........................................................................................................................................................323
		ATTACHMENT OPERATIONS.........................................................................................................................................................325
			When Using Breaker........................................................................................................................................................325
			When Using General Attachment Such as Crusher.............................................................................................................................326
		LONG TERM STORAGE.............................................................................................................................................................326
		SPECIFICATIONS................................................................................................................................................................326
	ATTACHMENT GUIDE..................................................................................................................................................................327
		OTHER ATTACHMENTS.............................................................................................................................................................327
		ATTACHMENT COMBINATIONS.......................................................................................................................................................329
		BUCKET TEETH SELECTION........................................................................................................................................................330
			Teeth Selection...........................................................................................................................................................330
			Selection Guide for Horizontal or Vertical Pin Type Tooth.................................................................................................................330
	RECOMMENDED ATTACHMENT OPERATIONS.................................................................................................................................................331
		HYDRAULIC BREAKER.............................................................................................................................................................331
	HANDLING MACHINES EQUIPPED WITH KOMTRAX...........................................................................................................................................335
		BASIC PRECAUTIONS.............................................................................................................................................................335
	HYDRAULIC QUICK COUPLER PIPING....................................................................................................................................................336
		LOCATIONS.....................................................................................................................................................................336
		OPERATION.....................................................................................................................................................................337
INDEX.................................................................................................................................................................................339
	<A>...............................................................................................................................................................................341
	<B>...............................................................................................................................................................................341
	<C>...............................................................................................................................................................................341
	<D>...............................................................................................................................................................................341
	<E>...............................................................................................................................................................................341
	<F>...............................................................................................................................................................................341
	<G>...............................................................................................................................................................................341
	<H>...............................................................................................................................................................................341
	<K>...............................................................................................................................................................................341
	<L>...............................................................................................................................................................................341
	<M>...............................................................................................................................................................................341
	<O>...............................................................................................................................................................................342
	<P>...............................................................................................................................................................................342
	<R>...............................................................................................................................................................................342
	<S>...............................................................................................................................................................................342
	<T>...............................................................................................................................................................................342
	<W>...............................................................................................................................................................................342
	<Y>...............................................................................................................................................................................342
COLOPHON..............................................................................................................................................................................343

KOMATSU HYDRAULIC EXCAVATOR PC160LC-7EO OPERATION & MAINTENANCE MANUAL SN K45001 AND UP – PDF DOWNLOAD:

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Komatsu Hydraulic Excavator PC160LC-7EO Operation & Maintenance Manual

FOREWORD:

This manual provides rules and guidelines which will help you use this machine safely and effectively. The precautions in this manual must be followed at all times when performing operation and maintenance. Most accidents are caused by the failure to follow fundamental safety rules for the operation and maintenance of machines. Accidents can be prevented by knowing beforehand conditions that may cause a hazard when performing operation and maintenance.

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