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KOMATSU PW160-7H WHEELED EXCAVATOR Operation & Maintenance Manual (SN:H50051 & up) KOMATSU PW160 7H – PDF DOWNLOAD
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- KOMATSU PW160-7H WHEELED EXCAVATOR Operation & Maintenance Manual
- SERIAL NUMBER:H50051 & up
- PUBLICATION NUMBER:VEAM390100
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Description
KOMATSU PW160-7H WHEELED EXCAVATOR Operation & Maintenance Manual (SN:H50051 & up) KOMATSU PW160 7H
KOMATSU PW160-7H WHEELED EXCAVATOR OPERATION & MAINTENANCE MANUAL (SN:H50051 & UP) KOMATSU PW160 7H – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU PW160-7H WHEELED EXCAVATOR Operation & Maintenance Manual (SN:H50051 & up) KOMATSU PW160 7H
- This manual provides rules and guidelines which will help you use this machine safely and effectively. Keep this manual handy and have all personnel read it periodically. If this manual has been lost or has become dirty and can not be read, request a replacement manual from Komatsu or your Komatsu distributor.
- If you sell the machine, be sure to give this manual to the new owners.
- Continuing improvements in the design of this machine can lead to changes in detail which may not be reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest available information for your machine or for questions regarding information in this manual.
TABLE OF CONTENTS:
KOMATSU PW160-7H WHEELED EXCAVATOR Operation & Maintenance Manual (SN:H50051 & up) KOMATSU PW160 7H
FOREWORD.......................................................................................... 3 FOREWORD...................................................................................... 4 SAFETY INFORMATION............................................................................ 5 SAFETY MESSAGES........................................................................... 5 NOISE..................................................................................... 6 VIBRATION................................................................................. 6 EMERGENCY STEERING........................................................................ 7 INTRODUCTION.................................................................................. 8 INTENDED USE.............................................................................. 8 FEATURES.................................................................................. 8 BREAKING IN YOUR NEW MACHINE.............................................................. 9 LOCATIONS OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR................................ 10 MACHINE SERIAL NO. PLATE POSITION......................................................... 10 ENGINE SERIAL NO. PLATE POSITION.......................................................... 10 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR................................................. 10 MACHINE SERIAL PLATES..................................................................... 11 STANDARD SERIAL PLATE................................................................. 11 SAFETY............................................................................................ 19 GENERAL PRECAUTIONS........................................................................... 20 PRECAUTION DURING OPERATION................................................................... 27 BEFORE STARTING ENGINE.................................................................... 27 OPERATING MACHINE......................................................................... 28 TRANSPORTATION............................................................................ 35 BATTERY................................................................................... 36 TOWING.................................................................................... 37 BUCKET WITH HOOK OR BUCKET LINK WITH LIFTING EYE.......................................... 38 GENERAL PRECAUTIONS................................................................... 38 PRECAUTIONS FOR LIFTING OPERATION..................................................... 40 HANDLING OF FLUIDS........................................................................ 40 PRECAUTIONS FOR MAINTENANCE................................................................... 42 BEFORE CARRYING OUT MAINTENANCE........................................................... 42 DURING MAINTENANCE........................................................................ 45 POSITION FOR ATTACHING SAFETY LABELS.......................................................... 48 POSITION FOR ATTACHING SAFETY LABELS...................................................... 48 LIFTING CAPACITY CHART PW160-7H............................................................... 56 ONE PIECE BOOM Lift capacity tables....................................................... 56 TWO PIECE BOOM Lift capacity tables....................................................... 62 OVERLOAD CAUTION.......................................................................... 68 OPERATION......................................................................................... 69 GENERAL VIEW.................................................................................. 70 GENERAL VIEW OF MACHINE................................................................... 70 GENERAL VIEW OF CONTROLS AND GAUGES....................................................... 71 EXPLANATION OF COMPONENTS..................................................................... 72 MACHINE MONITOR........................................................................... 72 BASIC OPERATION OF MACHINE MONITOR.................................................... 73 BASIC CHECK ITEMS......................................................................... 75 CAUTION ITEMS......................................................................... 77 EMERGENCY STOP ITEMS.................................................................. 81 METER DISPLAY PORTION................................................................. 84 METERS................................................................................ 86 MONITOR SWITCHES...................................................................... 90 SWITCHES......................................................................................103 CONTROL LEVERS, PEDALS........................................................................111 FRONT WINDOW..............................................................................117 EMERGENCY EXIT FROM OPERATOR'S CAB........................................................121 DOOR LOCK.................................................................................122 CAP, COVER WITH LOCK......................................................................123 METHOD OF OPENING AND CLOSING CAP WITH LOCK (For the fuel tank filler port)...........123 METHOD OF OPENING AND CLOSING COVER WITH LOCK (cover with lock).......................123 FUSE......................................................................................124 LUGGAGE TRAY..............................................................................125 ASHTRAY...................................................................................125 CUP HOLDER................................................................................125 HOT AND COOL BOX..........................................................................125 CAB RADIO.................................................................................126 PRECAUTION OF USE.....................................................................126 POWER PICK-UP PORT........................................................................126 HANDLING AIR CONDITIONER..................................................................127 GENERAL LOCATIONS OF CONTROL PANEL....................................................127 METHOD OF OPERATION...................................................................131 PRECAUTIONS WHEN USING AIR CONDITIONER................................................138 CHECK, MAINTAIN MACHINE EQUIPPED WITH AIR CONDITIONER.................................139 OTHER FUNCTIONS.......................................................................139 FUSIBLE LINK..............................................................................140 CONTROLLER................................................................................141 TOOL BOX (CHASSIS)........................................................................141 REFUELLING PUMP...........................................................................141 SAFETY................................................................................141 PROCEDURE.............................................................................141 MAINTENANCE...........................................................................142 WARNING LAMPS.............................................................................143 HANDLING ACCUMULATORS.....................................................................144 OPERATION.....................................................................................145 CHECK BEFORE STARTING ENGINE..............................................................145 WALK-AROUND CHECK.....................................................................145 CHECK BEFORE STARTING.................................................................147 ADJUSTMENT OF OPERATOR’S SEAT (AIR SUSPENSION SEAT)...................................152 SEAT BELT.............................................................................154 ADJUSTMENT OF OPERATOR’S SEAT (MECHANICAL SEAT).......................................154 SEAT BELT.............................................................................155 OPERATIONS AND CHECKS BEFORE STARTING ENGINE..................................................156 STARTING ENGINE...........................................................................158 NORMAL STARTING.......................................................................158 STARTING IN COLD WEATHER..............................................................159 OPERATIONS AND CHECKS AFTER STARTING ENGINE...........................................161 WARMING UP OPERATION..................................................................161 IN COLD AREAS (AUTOMATIC WARMING-UP OPERATION)........................................164 MOVING MACHINE OFF........................................................................167 MOVING MACHINE FORWARD................................................................167 STEERING..................................................................................170 TRAVELLING ON PUBLIC HIGHWAY..............................................................171 STOPPING & PARKING........................................................................172 STOPPING MACHINE (EMERGENCY)..........................................................173 SWINGING (Slewing the upper carriage).....................................................174 OPERATION OF WORK EQUIPMENT...............................................................175 WORKING MODE SELECTION....................................................................177 PROHIBITIONS FOR OPERATION................................................................179 PRECAUTIONS FOR OPERATION.................................................................180 RECOMMENDATIONS FOR TRAVELLING............................................................182 PRECAUTIONS WHEN TRAVELLING UP OR DOWN HILLS..............................................183 HOW TO ESCAPE FROM MUD....................................................................184 WHEN ONE SIDE IS STUCK................................................................184 WHEN BOTH SIDES ARE STUCK.............................................................184 WORK POSSIBLE USING HYDRAULIC EXCAVATOR...................................................185 BACKHOE WORK..........................................................................185 SHOVEL WORK...........................................................................185 DITCHING WORK.........................................................................185 LOADING WORK..........................................................................186 LEVELLING WORK........................................................................186 REPLACEMENT AND INVERSION OF BUCKET.......................................................187 REPLACEMENT...........................................................................187 INVERSION.............................................................................187 STOPPING ENGINE...........................................................................189 CHECK AFTER FINISHING WORK................................................................189 CHECK AFTER STOPPING ENGINE...................................................................190 LOCKING...................................................................................190 OVERLOAD WARNING DEVICE...................................................................190 HANDLING THE WHEELS.......................................................................190 TRANSPORTATION................................................................................195 LOADING, UNLOADING WORK...................................................................195 PRECAUTIONS FOR LOADING...................................................................197 HOW TO LIFT THE MACHINE...............................................................198 PRECAUTIONS FOR TRANSPORTATION............................................................200 TRAVELLING POSTURE........................................................................202 COLD WEATHER OPERATION........................................................................204 PRECAUTIONS FOR LOW TEMPERATURE...........................................................204 FUEL AND LUBRICANTS...................................................................204 BATTERY...............................................................................205 PRECAUTIONS AFTER COMPLETION OF WORK......................................................206 AFTER COLD WEATHER........................................................................206 LONG-TERM STORAGE.............................................................................207 BEFORE STORAGE............................................................................207 DURING STORAGE............................................................................207 AFTER STORAGE.............................................................................208 STARTING MACHINE AFTER LONG-TERM STORAGE..................................................208 TROUBLESHOOTING...............................................................................209 PHENOMENA THAT ARE NOT FAILURES...........................................................209 METHOD OF TOWING MACHINE..................................................................210 PRECAUTIONS ON PARTICULAR JOBSITES........................................................210 DISCHARGED BATTERY........................................................................211 REMOVAL AND INSTALLATION OF BATTERY...................................................211 BATTERY CHARGES.......................................................................212 STARTING ENGINE WITH BOOSTER CABLES...................................................213 OTHER TROUBLE.............................................................................215 ELECTRICAL SYSTEM.....................................................................215 CHASSIS...............................................................................216 ENGINE................................................................................217 ELECTRONIC CONTROL SYSTEM.............................................................219 MAINTENANCE.......................................................................................221 GUIDES TO MAINTENANCE.........................................................................222 OUTLINE OF SERVICE............................................................................225 OUTLINE OF OIL, FUEL, COOLANT.............................................................225 OIL...................................................................................225 FUEL..................................................................................226 COOLANT...............................................................................226 GREASE................................................................................227 CARRYING OUT KOWA (Komatsu Oil Wear Analysis).........................................227 STORING OIL AND FUEL..................................................................228 FILTERS...............................................................................228 OUTLINE OF ELECTRIC SYSTEM................................................................228 OUTLINE OF HYDRAULIC SYSTEM...............................................................229 WEAR PARTS LIST...............................................................................231 USE FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE.............................232 PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS..........................................232 USE FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE CONT........................234 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS................................................236 INTRODUCTION OF NECESSARY TOOLS...........................................................236 TIGHTENING TORQUE SPECIFICATIONS..............................................................237 TIGHTENING TORQUE LIST....................................................................237 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS.................................................238 SAFETY CRITICAL PARTS.....................................................................239 MAINTENANCE SCHEDULE CHART....................................................................240 KEY TO LUBRICATION POINTS.................................................................244 SERVICE PROCEDURE.............................................................................246 INITIAL 50 HOURS SERVICE..................................................................246 CHECK AND TIGHTEN WHEEL NUTS..............................................................246 INITIAL 250 HOURS SERVICE.................................................................246 WHEN REQUIRED.............................................................................247 CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT..........................................247 CLEAN INSIDE OF COOLING SYSTEM........................................................252 CLEAN INSIDE OF COOLING SYSTEM........................................................253 CHECKING COOLANT LEVEL....................................................................255 DRAINING THE SYSTEM...................................................................255 CLEANING THE SYSTEM...................................................................256 FILLING THE SYSTEM....................................................................256 REFILLING AN OVERHEATED SYSTEM........................................................256 CLEANING THE RADIATOR.................................................................257 THERMOSTAT............................................................................257 FAN...................................................................................257 CHECK AND TIGHTEN WHEEL NUTS..............................................................258 CHECK ELECTRICAL INTAKE AIR HEATER........................................................258 CHECK ALTERNATOR..........................................................................258 CHECK START MOTOR.....................................................................259 REPLACE BUCKET SIDE CUTTERS...............................................................259 REPLACE BUCKET TEETH......................................................................260 REPLACE BUCKET TEETH (VERTICAL PIN TYPE)..............................................260 REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)............................................263 ADJUST BUCKET CLEARANCE...................................................................264 CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID................................................265 CHECK AND ADJUST AIR CONDITIONER..........................................................266 CHECK LEVEL OF REFRIGERANT (GAS)......................................................266 DRAIN ENGINE BREATHER OIL CATCHER.....................................................267 CHECK BEFORE STARTING.....................................................................267 CHECK COOLANT LEVEL, ADD WATER............................................................267 CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL............................................268 CHECK FUEL LEVEL, ADD FUEL............................................................269 CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL............................................270 CHECK AIR CLEANER FOR CLOGGING........................................................270 CHECK ELECTRIC WIRING.................................................................271 CHECK FOR WATER AND SEDIMENT IN SEDIMENTOR. DRAIN WATER AND SEDIMENT..................271 CHECK FOR WATER IN PRIMARY FUEL FILTER, DRAIN WATER...................................272 EVERY 50 HOURS............................................................................272 DRAIN WATER AND SEDIMENT FROM FUEL TANK...............................................272 EVERY 100 HOURS SERVICE...................................................................273 LUBRICATING...........................................................................273 CLEANING FRESH AIR FILTER.............................................................277 EVERY 250 HOURS MAINTENANCE...............................................................279 CHECK OIL LEVEL IN MACHINERY CASE, ADD OIL............................................279 CHECK OIL LEVEL IN WHEEL HUBS, ADD OIL (Front Axle)...................................280 CHECK OIL LEVEL IN WHEEL HUBS, ADD OIL (Rear Axle)....................................280 CHECK OIL LEVEL IN AXLES, ADD OIL.....................................................280 CHECK OIL LEVEL IN TRANSMISSION, ADD OIL..............................................281 CHECK LEVEL OF BATTERY ELECTROLYTE....................................................281 BELTS, GENERAL........................................................................282 CHECK FAN BELT TENSION, ADJUST TENSION................................................282 CHECK, ADJUST TENSION OF AIR CONDITIONER COMPRESSOR BELT..............................283 EVERY 500 HOURS SERVICE...................................................................285 REPLACE FUEL FILTER CARTRIDGE.........................................................285 CHECK SWING PINION GREASE LEVEL, ADD GREASE...........................................286 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE.....................287 CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS AND CONDENSER FINS...................288 CLEAN INTERNAL AND EXTERNAL AIR FILTERS OF AIR CONDITIONER SYSTEM.....................289 CLEANING RECIRCULATED AIR FILTER......................................................290 REPLACE HYDRAULIC TANK BREATHER ELEMENT...............................................291 CHECK CONDITION OF MAIN VALVE RUBBER MOUNTS...........................................291 EVERY 1000 HOURS SERVICE..................................................................292 REPLACE HYDRAULIC FILTER ELEMENT......................................................292 CHANGE OIL IN SWING MACHINERY CASE....................................................293 CHECK ALL TIGHTENING PARTS OF TURBOCHARGER............................................293 CHECK PLAY OF TURBOCHARGER ROTOR......................................................294 CHECK & ADJUST VALVE CLEARANCE........................................................294 CHECK FAN BELT TENSIONER BEARING BELT AND FAN HUB.....................................294 CHECK FAN BELT TENSION AND REPLACE FAN BELT...........................................294 CHANGE OIL IN AXLES...................................................................295 CHANGE OIL IN HUBS....................................................................296 CHANGE OIL IN TRANSMISSION ASSEMBLY...................................................297 CHANGE OIL IN DAMPER..................................................................298 EVERY 2000 HOURS SERVICE..................................................................299 CLEAN HYDRAULIC TANK STRAINER.........................................................299 CLEAN, CHECK TURBOCHARGER.............................................................299 CHECK ALTERNATOR, STARTING MOTOR......................................................299 CHANGE ANTIFREEZE.....................................................................299 CLEAN THE STRAINER OF THE BRAKE FILTER................................................300 CHECK AND ADJUST VALVE CLEARANCE......................................................301 EVERY 4000 HOURS SERVICE..................................................................301 CHECK WATER PUMP......................................................................301 EVERY 5000 HOURS SERVICE..................................................................302 CHANGE OIL IN HYDRAULIC TANK AND REPLACE STEER/BRAKE CIRCUIT STRAINER.................302 SPECIFICATIONS....................................................................................305 SPECIFICATIONS................................................................................306 1 - PIECE BOOM............................................................................307 2 - PIECE BOOM............................................................................308 WORKING RANGE: ONE PIECE BOOM.............................................................309 WORKING RANGE: TWO PIECE BOOM.............................................................310 OPTIONS, ATTACHMENTS..............................................................................311 GENERAL PRECAUTIONS...........................................................................312 PRECAUTIONS RELATED TO SAFETY.............................................................312 PRECAUTIONS WHEN INSTALLING ATTACHMENTS.......................................................313 HANDLING BUCKET WITH HOOK.....................................................................315 CHECKING FOR DAMAGE TO BUCKET WITH HOOK...................................................315 PROHIBITED OPERATIONS.....................................................................315 PRECAUTIONS DURING OPERATIONS.............................................................315 MACHINES READY FOR ATTACHMENTS................................................................316 GENERAL LOCATIONS.........................................................................316 HANDLING THE CLAMSHELL BUCKET.............................................................318 How to install clamshell bucket.......................................................318 HOW TO OPERATE........................................................................319 OPERATION.................................................................................320 WHEN USING CRUSHER OR OTHER GENERAL ATTACHMENT........................................321 WHEN USING BREAKER....................................................................322 METHOD FOR RELEASING PRESSURE IN CONTROL CIRCUIT OF MACHINES EQUIPPED WITH ACCUMULATOR....323 LONG-TERM STORAGE.........................................................................323 SPECIFICATIONS........................................................................323 INTRODUCTION OF ATTACHMENTS AND EXTENDING MACHINE SERVICE LIFE................................324 HYDRAULIC BREAKER.........................................................................324 POWER RIPPER..............................................................................327 FORK GRAB.................................................................................328 GRAPPLE BUCKET............................................................................329 SCRAP GRAPPLE.............................................................................330 CRUSHER & SMASHER.........................................................................332 HYDRAULIC PILE DRIVER.....................................................................333 HYDRAULIC EXCAVATOR WITH MULTIPURPOSE CRANE...............................................334 ROTATING ARM..................................................................................336 GENERAL LOCATION AND SPECIFICATIONS.......................................................336 GENERAL VIEW OF CONTROLS..............................................................337 LEFT CONTROL LEVER (with auto-deceleration device)....................................338 RIGHT CONTROL LEVER (with auto-deceleration device)...................................338 ARM ROTATION CONTROL..................................................................339 UPPER BOOM CONTROL PEDAL..............................................................339 PEDAL LOCK FOR BOOM ADJUST............................................................339 EXCAVATOR’S WORK......................................................................340 REPLACEMENT OF BUCKET.................................................................342 HANDLING THE TRAPEZOIDAL BUCKET (If equipped).........................................343 TRAVELLING POSTURE........................................................................345 MAINTENANCE REQUIREMENT...................................................................346 EVERY 100 HOURS SERVICE...............................................................346 EVERY 250 HOURS SERVICE...............................................................347 EVERY 1000 HOURS SERVICE..............................................................348 INDEX.........................................................................................349
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