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KOMATSU PC160LC-7 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (SN:11001 & UP) – PDF DOWNLOAD
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- KOMATSU PC160LC-7 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL
- SERIAL NUMBER:11001 & UP
- PUBLICATION NUMBER:TEN00096-01
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Description
KOMATSU PC160LC-7 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (SN:11001 & UP)
KOMATSU PC160LC-7 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (SN:11001 & UP) – PDF DOWNLOAD:
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KOMATSU PC160LC-7 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (SN:11001 & UP) KOMATSU PC160LC-7
- 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.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.
TABLE OF CONTENTS:
KOMATSU PC160LC-7 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (SN:11001 & UP) KOMATSU PC160LC-7
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 PROBLEMS 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 HIGHT VOLTAGE CABLES............................................................... 30 ENSURE GOOD VISIBILITY......................................................................... 30 VENTILATION FOR ENCLOSED AREA.................................................................. 30 SIGNALMAN'S SIGNAL AND SIGNS................................................................... 31 EMERGENCY EXIT FROM OPERATOR'S CAB............................................................. 31 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 LIFTING WORK USING BUCKET WITH HOOK........................................................ 44 SAFETY RULES FOR LIFTING OBJECTS........................................................... 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 ATTACHMENTS.................................................................................... 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 MAGAZINE BOX................................................................................... 94 ASHTRAY........................................................................................ 94 AIR CONDITIONER CONTROLS....................................................................... 95 RADIO..........................................................................................110 AUXILIARY ELECTRIC POWER.......................................................................115 FUSE...........................................................................................116 FUSIBLE LINK...................................................................................117 CONTROLLERS....................................................................................117 TOOL BOX.......................................................................................117 GREASE GUN HOLDER..............................................................................117 ACCUMULATOR....................................................................................118 MACHINE OPERATIONS AND CONTROLS....................................................................120 BEFORE STARTING ENGINE.........................................................................120 STARTING ENGINE................................................................................135 AFTER STARTING ENGINE..........................................................................139 STOPPING THE ENGINE............................................................................148 MACHINE OPERATION..............................................................................149 STEERING THE MACHINE...........................................................................153 SWINGING.......................................................................................155 WORK EQUIPMENT CONTROLS AND OPERATIONS.........................................................156 WORKING MODE...................................................................................158 PROHIBITED OPERATIONS..........................................................................159 GENERAL OPERATION INFORMATION..................................................................161 TRAVELING ON SLOPES............................................................................162 ESCAPE FROM MUD................................................................................164 RECOMMENDED APPLICATIONS.......................................................................165 BUCKET REPLACEMENT AND INVERSION...............................................................167 PARKING MACHINE................................................................................170 CHECK AFTER SHUT OFF ENGINE....................................................................171 MACHINE INSPECTION AFTER DAILY WORK............................................................171 LOCKING........................................................................................172 TRANSPORTATION.....................................................................................173 TRANSPORTATION PROCEDURE.......................................................................173 LOADING AND UNLOADING WITH TRAILER.............................................................173 LIFTING MACHINE................................................................................180 COLD WEATHER OPERATION.............................................................................182 COLD WEATHER OPERATION INFORMATION.............................................................182 AFTER DAILY WORK COMPLETION....................................................................185 AFTER COLD WEATHER SEASON......................................................................185 LONG TERM STORAGE..................................................................................186 BEFORE STORAGE.................................................................................186 DURING STORAGE.................................................................................186 AFTER STORAGE..................................................................................186 STARTING MACHINE AFTER LONG-TERM STORAGE.......................................................187 TROUBLES AND ACTIONS...............................................................................188 RUNNING OUT OF FUEL............................................................................188 PHENOMENA THAT ARE NOT FAILURES................................................................188 TOWING THE MACHINE.............................................................................189 LIGHTWEIGHT TOWING HOLE........................................................................190 SEVERE JOB CONDITION...........................................................................190 DISCHARGED BATTERY.............................................................................191 OTHER TROUBLE..................................................................................195 MAINTENANCE............................................................................................200 MAINTENANCE INFORMATION............................................................................201 OUTLINE OF SERVICE.................................................................................203 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC.........................................203 ELECTRIC SYSTEM MAINTENANCE....................................................................206 WEAR PARTS.........................................................................................207 WEAR PARTS LIST................................................................................207 LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS........................................................208 TIGHTENING TORQUE SPECIFICATIONS...................................................................212 TIGHTENING TORQUE LIST.........................................................................212 SAFETY CRITICAL PARTS..............................................................................213 SAFETY CRITICAL PARTS LIST.....................................................................213 MAINTENANCE SCHEDULE...............................................................................214 MAINTENANCE SCHEDULE CHART.....................................................................214 MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER.....................................................216 MAINTENANCE PROCEDURE..............................................................................217 INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS).................................217 INITIAL 1000 HOURS MAINTENANCE (ONLY AFTER THE FIRST 1000 HOURS)...............................217 WHEN REQUIRED..................................................................................218 CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT...............................................218 CLEAN INSIDE OF COOLING SYSTEM.............................................................223 CHECK AND TIGHTEN TRACK SHOE BOLTS.........................................................226 CHECK AND ADJUST TRACK TENSION.............................................................227 CHECK ELECTRICAL INTAKE AIR HEATER.........................................................228 REPLACE BUCKET TEETH (VERTICAL PIN TYPE)...................................................229 REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE).................................................232 ADJUST BUCKET CLEARANCE....................................................................233 CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID.................................................234 CHECK AND MAINTENANCE AIR CONDITIONER......................................................235 WASH WASHABLE FLOOR........................................................................236 BLEEDING AIR FROM HYDRAULIC SYSTEM.........................................................239 METHOD FOR RELEASING INTERNAL PRESSURE IN HYDRAULIC CIRCUIT................................241 CHECK NITROGEN GAS CHARGE PRESSURE IN ACCUMULATOR (CONTROL CIRCUIT)........................242 CHECK BEFORE STARTING..........................................................................243 EVERY 100 HOURS MAINTENANCE....................................................................244 LUBRICATING................................................................................244 EVERY 250 HOURS MAINTENANCE....................................................................245 CHECK OIL LEVEL IN SWING MACHINERY CASE, ADD OIL...........................................245 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL...............................................246 CHECK LEVEL OF BATTERY ELECTROLYTE.........................................................247 CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST......................................250 EVERY 500 HOURS MAINTENANCE....................................................................251 LUBRICATING................................................................................251 LUBRICATE SWING CIRCLE.....................................................................252 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE..........................253 REPLACE FUEL FILTER CARTRIDGE..............................................................255 CHECK SWING PINION GREASE LEVEL, ADD GREASE................................................256 CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS, CONDENSER FINS AND AFTER COOLER FINS ....257 CLEAN AIR CONDITIONER FRESH/RECIRC FILTERS.................................................258 REPLACE BREATHER ELEMENT IN HYDRAULIC TANK.................................................260 EVERY 1000 HOURS MAINTENANCE...................................................................261 REPLACE HYDRAULIC OIL FILTER ELEMENT.......................................................261 CHANGE OIL IN SWING MACHINERY CASE.........................................................262 CHECK OIL LEVEL IN DAMPER CASE, ADD OIL....................................................263 CHECK FAN BELT TENSION AND REPLACE FAN BELT................................................263 EVERY 2000 HOURS MAINTENANCE...................................................................264 CHANGE OIL IN FINAL DRIVE CASE.............................................................264 CLEAN HYDRAULIC TANK STRAINER..............................................................265 CHECK ALTERNATOR, STARTING MOTOR...........................................................265 CHECK ENGINE VALVE CLEARANCE, ADJUST.......................................................265 EVERY 4000 HOURS MAINTENANCE...................................................................266 CHECK WATER PUMP...........................................................................266 EVERY 5000 HOURS MAINTENANCE...................................................................267 CHANGE OIL IN HYDRAULIC TANK...............................................................267 SPECIFICATIONS.........................................................................................268 SPECIFICATIONS.....................................................................................269 ATTACHMENTS, OPTIONS...................................................................................271 GENERAL PRECAUTIONS FOR SAFETY.....................................................................272 PRECAUTIONS WHEN SELECTING.....................................................................272 READ THE INSTRUCTION MANUAL THOROUGHLY.........................................................272 PRECAUTIONS WHEN REMOVING OR INSTALLING........................................................272 PRECAUTIONS WHEN USING.........................................................................272 BUCKET WITH HOOK...................................................................................273 HOOK CONDITION.................................................................................273 PROHIBITED OPERATIONS..........................................................................273 MACHINE READY FOR ATTACHMENT.......................................................................274 LOCATIONS......................................................................................274 HYDRAULIC CIRCUIT..............................................................................277 ATTACHMENT REMOVAL AND INSTALLATION............................................................281 ATTACHMENT OPERATIONS..........................................................................283 LONG TERM STORAGE..............................................................................285 SPECIFICATIONS.................................................................................285 ATTACHMENT GUIDE...................................................................................286 OTHER ATTACHMENTS..............................................................................286 ATTACHMENT COMBINATIONS........................................................................288 TRACK SHOES SELECTION..........................................................................289 BUCKET TEETH SELECTION.........................................................................290 RECOMMENDED ATTACHMENT OPERATIONS..................................................................291 HYDRAULIC BREAKER..............................................................................291 INDEX..................................................................................................296
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