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Komatsu PW160-7K Wheeled Excavator Operation & Maintenance Manual – PDF Download
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- Komatsu PW160-7K Wheeled Excavator Operation & Maintenance Manual
- SERIAL NUMBER:
PW160-7K – K40001 and up - PUBLICATION NUMBER:UEAM003201
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Description
Komatsu PW160-7K Wheeled Excavator Operation & Maintenance Manual
Description:
Komatsu PW160-7K Wheeled Excavator Operation & Maintenance Manual
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 PW160-7K Wheeled Excavator Operation & Maintenance Manual
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 GERMANY SERIAL PLATE.................................................................. 11 ITALIAN 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 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 PW160-7K............................................................... 56 ONE PIECE BOOM Lift capacity tables....................................................... 56 TWO PIECE BOOM Lift capacity tables....................................................... 62 ROTATING ARM capacity tables.............................................................. 68 OVERLOAD CAUTION.......................................................................... 70 OPERATION......................................................................................... 71 GENERAL VIEW.................................................................................. 72 GENERAL VIEW OF MACHINE................................................................... 72 GENERAL VIEW OF CONTROLS AND GAUGES....................................................... 73 EXPLANATION OF COMPONENTS..................................................................... 74 MACHINE MONITOR........................................................................... 74 BASIC OPERATION OF MACHINE MONITOR.................................................... 75 BASIC CHECK ITEMS......................................................................... 77 CAUTION ITEMS......................................................................... 79 EMERGENCY STOP ITEMS.................................................................. 83 METER DISPLAY PORTION................................................................. 86 METERS................................................................................ 88 MONITOR SWITCHES...................................................................... 91 SWITCHES......................................................................................106 CONTROL LEVERS, PEDALS........................................................................114 FRONT WINDOW..............................................................................119 EMERGENCY EXIT FROM OPERATOR'S CAB........................................................123 DOOR LOCK.................................................................................124 CAP, COVER WITH LOCK......................................................................125 METHOD OF OPENING AND CLOSING CAP WITH LOCK (For the fuel tank filler port)...........125 METHOD OF OPENING AND CLOSING COVER WITH LOCK (cover with lock).......................125 FUSE......................................................................................126 LUGGAGE TRAY..............................................................................127 ASHTRAY...................................................................................127 CUP HOLDER................................................................................127 HOT AND COOL BOX..........................................................................127 CAB RADIO.................................................................................128 PRECAUTION OF USE.....................................................................128 POWER PICK-UP PORT........................................................................128 HANDLING AIR CONDITIONER..................................................................129 GENERAL LOCATIONS OF CONTROL PANEL....................................................129 METHOD OF OPERATION...................................................................133 PRECAUTIONS WHEN USING AIR CONDITIONER................................................140 CHECK, MAINTAIN MACHINE EQUIPPED WITH AIR CONDITIONER.................................141 OTHER FUNCTIONS.......................................................................141 FUSIBLE LINK..............................................................................142 CONTROLLER................................................................................142 TOOL BOX (CHASSIS)........................................................................143 REFUELLING PUMP...........................................................................143 SAFETY................................................................................143 PROCEDURE.............................................................................143 MAINTENANCE...........................................................................144 WARNING LAMPS.............................................................................145 HANDLING ACCUMULATORS.....................................................................146 OPERATION.....................................................................................147 CHECK BEFORE STARTING ENGINE..............................................................147 WALK-AROUND CHECK.....................................................................147 CHECK BEFORE STARTING.................................................................149 ADJUSTMENT OF OPERATOR’S SEAT (AIR SUSPENSION SEAT)...................................154 SEAT BELT.............................................................................156 ADJUSTMENT OF OPERATOR’S SEAT (MECHANICAL SEAT).......................................156 SEAT BELT.............................................................................157 OPERATIONS AND CHECKS BEFORE STARTING ENGINE..................................................158 STARTING ENGINE...........................................................................160 NORMAL STARTING.......................................................................160 STARTING IN COLD WEATHER..............................................................161 OPERATIONS AND CHECKS AFTER STARTING ENGINE...........................................163 WARMING UP OPERATION..................................................................163 IN COLD AREAS (AUTOMATIC WARMING-UP OPERATION)........................................166 MOVING MACHINE OFF........................................................................169 MOVING MACHINE FORWARD................................................................169 STEERING..................................................................................172 TRAVELLING ON PUBLIC HIGHWAY..............................................................173 STOPPING & PARKING........................................................................174 STOPPING MACHINE (EMERGENCY)..........................................................175 SWINGING (Slewing the upper carriage).....................................................176 OPERATION OF WORK EQUIPMENT...............................................................177 WORKING MODE SELECTION....................................................................180 PROHIBITIONS FOR OPERATION................................................................181 PRECAUTIONS FOR OPERATION.................................................................182 PRECAUTIONS WHEN TRAVELLING UP OR DOWN HILLS..............................................184 HOW TO ESCAPE FROM MUD....................................................................185 WHEN ONE SIDE IS STUCK................................................................185 WHEN BOTH SIDES ARE STUCK.............................................................185 WORK POSSIBLE USING HYDRAULIC EXCAVATOR...................................................186 BACKHOE WORK..........................................................................186 SHOVEL WORK...........................................................................186 DITCHING WORK.........................................................................186 LOADING WORK..........................................................................187 LEVELLING WORK........................................................................187 REPLACEMENT AND INVERSION OF BUCKET.......................................................187 REPLACEMENT...........................................................................187 INVERSION.............................................................................188 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........................................................................203 PRECAUTIONS FOR LOW TEMPERATURE...........................................................203 FUEL AND LUBRICANTS...................................................................203 BATTERY...............................................................................204 PRECAUTIONS AFTER COMPLETION OF WORK......................................................205 AFTER COLD WEATHER........................................................................205 LONG-TERM STORAGE.............................................................................206 BEFORE STORAGE............................................................................206 DURING STORAGE............................................................................206 AFTER STORAGE.............................................................................207 STARTING MACHINE AFTER LONG-TERM STORAGE..................................................207 TROUBLESHOOTING...............................................................................208 PHENOMENA THAT ARE NOT FAILURES...........................................................208 METHOD OF TOWING MACHINE..................................................................209 PRECAUTIONS ON PARTICULAR JOBSITES........................................................209 DISCHARGED BATTERY........................................................................210 REMOVAL AND INSTALLATION OF BATTERY...................................................210 BATTERY CHARGES.......................................................................211 STARTING ENGINE WITH BOOSTER CABLES...................................................212 OTHER TROUBLE.............................................................................214 ELECTRICAL SYSTEM.....................................................................214 CHASSIS...............................................................................215 ENGINE................................................................................216 ELECTRONIC CONTROL SYSTEM.............................................................218 MAINTENANCE.......................................................................................219 GUIDES TO MAINTENANCE.........................................................................220 OUTLINE OF SERVICE............................................................................223 OUTLINE OF OIL, FUEL, COOLANT.............................................................223 OIL...................................................................................223 FUEL..................................................................................224 COOLANT...............................................................................224 GREASE................................................................................225 CARRYING OUT KOWA (Komatsu Oil Wear Analysis).........................................225 STORING OIL AND FUEL..................................................................226 FILTERS...............................................................................226 OUTLINE OF ELECTRIC SYSTEM................................................................226 OUTLINE OF HYDRAULIC SYSTEM...............................................................227 WEAR PARTS LIST...............................................................................229 USE FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE.............................230 PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS..........................................230 USE FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE CONT........................232 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS................................................234 INTRODUCTION OF NECESSARY TOOLS...........................................................234 TIGHTENING TORQUE SPECIFICATIONS..............................................................235 TIGHTENING TORQUE LIST....................................................................235 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS.................................................236 SAFETY CRITICAL PARTS.....................................................................237 MAINTENANCE SCHEDULE CHART....................................................................238 KEY TO LUBRICATION POINTS.................................................................242 SERVICE PROCEDURE.............................................................................244 INITIAL 250 HOURS SERVICE.................................................................244 WHEN REQUIRED.............................................................................245 CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT..........................................245 CLEAN INSIDE OF COOLING SYSTEM........................................................250 CLEAN INSIDE OF COOLING SYSTEM........................................................251 CHECKING COOLANT LEVEL....................................................................253 DRAINING THE SYSTEM...................................................................253 CLEANING THE SYSTEM...................................................................254 FILLING THE SYSTEM....................................................................254 REFILLING AN OVERHEATED SYSTEM........................................................254 CLEANING THE RADIATOR.................................................................255 THERMOSTAT............................................................................255 FAN...................................................................................255 CHECK AND TIGHTEN WHEEL NUTS..............................................................256 CHECK ELECTRICAL INTAKE AIR HEATER........................................................256 CHECK ALTERNATOR..........................................................................256 CHECK START MOTOR.....................................................................257 REPLACE BUCKET SIDE CUTTERS...............................................................257 REPLACE BUCKET TEETH......................................................................258 REPLACE BUCKET TEETH (VERTICAL PIN TYPE)..............................................258 REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)............................................261 ADJUST BUCKET CLEARANCE...................................................................262 CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID................................................263 CHECK AND ADJUST AIR CONDITIONER..........................................................264 CHECK LEVEL OF REFRIGERANT (GAS)......................................................264 DRAIN ENGINE BREATHER OIL CATCHER.....................................................265 CHECK BEFORE STARTING.....................................................................265 CHECK COOLANT LEVEL, ADD WATER............................................................265 CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL............................................266 CHECK FUEL LEVEL, ADD FUEL............................................................267 CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL............................................268 CHECK AIR CLEANER FOR CLOGGING........................................................268 CHECK ELECTRIC WIRING.................................................................269 CHECK FOR WATER AND SEDIMENT IN SEDIMENTOR. DRAIN WATER AND SEDIMENT..................269 CHECK FOR WATER IN PRIMARY FUEL FILTER, DRAIN WATER...................................270 EVERY 50 HOURS............................................................................270 DRAIN WATER AND SEDIMENT FROM FUEL TANK...............................................270 EVERY 100 HOURS SERVICE...................................................................270 LUBRICATING...........................................................................270 CLEANING FRESH AIR FILTER.............................................................275 EVERY 250 HOURS MAINTENANCE...............................................................276 CHECK OIL LEVEL IN MACHINERY CASE, ADD OIL............................................276 CHECK OIL LEVEL IN WHEEL HUBS, ADD OIL (Front Axle)...................................277 CHECK OIL LEVEL IN WHEEL HUBS, ADD OIL (Rear Axle)....................................277 CHECK OIL LEVEL IN AXLES, ADD OIL.....................................................277 CHECK OIL LEVEL IN TRANSMISSION, ADD OIL..............................................278 CHECK LEVEL OF BATTERY ELECTROLYTE....................................................278 BELTS, GENERAL........................................................................279 CHECK FAN BELT TENSION, ADJUST TENSION................................................279 CHECK, ADJUST TENSION OF AIR CONDITIONER COMPRESSOR BELT..............................280 EVERY 500 HOURS SERVICE...................................................................282 LUBRICATE SWING CIRCLE (2 POINTS).....................................................282 REPLACE FUEL FILTER CARTRIDGE.........................................................283 CHECK SWING PINION GREASE LEVEL, ADD GREASE...........................................284 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE.....................285 CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS AND CONDENSER FINS...................286 CLEAN INTERNAL AND EXTERNAL AIR FILTERS OF AIR CONDITIONER SYSTEM.....................287 CLEANING RECIRCULATED AIR FILTER......................................................288 REPLACE HYDRAULIC TANK BREATHER ELEMENT...............................................289 CHECK CONDITION OF MAIN VALVE RUBBER MOUNTS...........................................289 EVERY 1000 HOURS SERVICE..................................................................290 REPLACE HYDRAULIC FILTER ELEMENT......................................................290 CHANGE OIL IN SWING MACHINERY CASE....................................................291 CHECK ALL TIGHTENING PARTS OF TURBOCHARGER............................................291 CHECK PLAY OF TURBOCHARGER ROTOR......................................................292 CHECK & ADJUST VALVE CLEARANCE........................................................292 CHECK FAN BELT TENSIONER BEARING BELT AND FAN HUB.....................................292 CHECK FAN BELT TENSION AND REPLACE FAN BELT...........................................292 CHANGE OIL IN AXLES...................................................................293 CHANGE OIL IN HUBS....................................................................294 CHANGE OIL IN TRANSMISSION ASSEMBLY...................................................295 EVERY 2000 HOURS SERVICE..................................................................296 CLEAN HYDRAULIC TANK STRAINER.........................................................296 CLEAN, CHECK TURBOCHARGER.............................................................296 CHECK ALTERNATOR, STARTING MOTOR......................................................296 CHANGE ANTIFREEZE.....................................................................296 CHECK AND ADJUST VALVE CLEARANCE......................................................297 EVERY 4000 HOURS SERVICE..................................................................297 CHECK WATER PUMP......................................................................297 EVERY 5000 HOURS SERVICE..................................................................298 CHANGE OIL IN HYDRAULIC TANK..........................................................298 SPECIFICATIONS....................................................................................301 SPECIFICATIONS................................................................................302 1 - PIECE BOOM............................................................................303 2 - PIECE BOOM............................................................................304 WORKING RANGE: ONE PIECE BOOM.............................................................305 WORKING RANGE: TWO PIECE BOOM.............................................................306 WORKING RANGE: ROTATING ARM...............................................................307 OPTIONS, ATTACHMENTS..............................................................................309 GENERAL PRECAUTIONS...........................................................................310 PRECAUTIONS RELATED TO SAFETY.............................................................310 PRECAUTIONS WHEN INSTALLING ATTACHMENTS.......................................................311 HANDLING BUCKET WITH HOOK.....................................................................313 CHECKING FOR DAMAGE TO BUCKET WITH HOOK...................................................313 PROHIBITED OPERATIONS.....................................................................313 PRECAUTIONS DURING OPERATIONS.............................................................313 MACHINES READY FOR ATTACHMENTS................................................................314 GENERAL LOCATIONS.........................................................................314 HANDLING THE CLAMSHELL BUCKET.............................................................316 How to install clamshell bucket.......................................................316 HOW TO OPERATE........................................................................317 OPERATION.................................................................................318 WHEN USING CRUSHER OR OTHER GENERAL ATTACHMENT........................................319 WHEN USING BREAKER....................................................................320 METHOD FOR RELEASING PRESSURE IN CONTROL CIRCUIT OF MACHINES EQUIPPED WITH ACCUMULATOR....321 LONG-TERM STORAGE.........................................................................321 SPECIFICATIONS........................................................................321 INTRODUCTION OF ATTACHMENTS AND EXTENDING MACHINE SERVICE LIFE................................322 HYDRAULIC BREAKER.........................................................................322 POWER RIPPER..............................................................................325 FORK GRAB.................................................................................326 GRAPPLE BUCKET............................................................................327 SCRAP GRAPPLE.............................................................................328 CRUSHER & SMASHER.........................................................................330 HYDRAULIC PILE DRIVER.....................................................................331 HYDRAULIC EXCAVATOR WITH MULTIPURPOSE CRANE...............................................332 GENERAL VIEW OF CONTROLS..............................................................334 LEFT CONTROL LEVER (with auto-deceleration device)....................................335 RIGHT CONTROL LEVER (with auto-deceleration device)...................................335 UPPER BOOM CONTROL PEDAL..............................................................336 ROTATING ARM..................................................................................337 GENERAL LOCATION AND SPECIFICATIONS.......................................................337 GENERAL VIEW OF CONTROLS..................................................................339 LEFT WORK EQUIPMENT CONTROL LEVER (with auto-deceleration device).....................339 RIGHT WORK EQUIPMENT CONTROL LEVER (with auto-deceleration device)....................340 ARM ROTATION CONTROL..................................................................340 UPPER BOOM CONTROL PEDAL..............................................................341 PEDAL LOCK FOR BOOM ADJUST............................................................341 TRAVELLING POSTURE........................................................................341 MAINTENANCE...............................................................................343 MAINTENANCE REQUIREMENT...............................................................343 EVERY 100 HOURS SERVICE...............................................................343 EVERY 250 HOURS SERVICE...............................................................344 EVERY 500 HOURS SERVICE...............................................................345 EVERY 1000 HOURS SERVICE..............................................................345 EXCAVATOR’S WORK......................................................................345 REPLACEMENT OF BUCKET.................................................................347 HANDLING THE TRAPEZOIDAL BUCKET (If equipped).........................................348
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KOMATSU PW160-7K WHEELED EXCAVATOR OPERATION & MAINTENANCE MANUAL – PDF DOWNLOAD:
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