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Komatsu Pw180-7K Wheeled Excavator Operation & Maintenance Manual SN K40001 and up – PDF DOWNLOAD
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Komatsu Pw180-7K Wheeled Excavator Operation & Maintenance Manual
Book Code : UEAM004501
SERIAL NUMBER
PW180-7K – K40001 and up
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Description
Komatsu Pw180-7K Wheeled Excavator Operation & Maintenance Manual
FILE DETAILS:
Komatsu Pw180-7K Wheeled Excavator Operation & Maintenance Manual
Model Specification: KOMATSU PW180-7K WHEELED EXCAVATOR
Language: English
File Format: PDF
Total Pages: 366
Requirements: Adobe PDF Reader
ZOOM IN/OUT: YES
Downloadable: YES
KOMATSU PW180-7K WHEELED EXCAVATOR OPERATION & MAINTENANCE MANUAL SN K40001 AND UP – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu Pw180-7K Wheeled Excavator Operation & Maintenance Manual
FOREWORD:
- 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 Pw180-7K Wheeled Excavator Operation & Maintenance Manual
FOREWORD.......................................................................................... 3 FOREWORD...................................................................................... 4 SAFETY INFORMATION............................................................................ 5 SAFETY MESSAGES........................................................................... 5 Noise emission levels..................................................................... 6 Vibration levels.......................................................................... 6 Guide to Reduce Vibration Levels on Machine........................................... 7 EMERGENCY STEERING........................................................................ 9 EMERGENCY BRAKING......................................................................... 9 INTRODUCTION.................................................................................. 10 INTENDED USE.............................................................................. 10 FEATURES.................................................................................. 10 BREAKING IN YOUR NEW MACHINE.............................................................. 11 LOCATIONS OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR................................ 12 MACHINE SERIAL NO. PLATE POSITION......................................................... 12 ENGINE SERIAL NO. PLATE POSITION.......................................................... 12 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR................................................. 12 MACHINE SERIAL PLATES..................................................................... 13 STANDARD SERIAL PLATE................................................................. 13 GERMANY SERIAL PLATE.................................................................. 13 ITALIAN SERIAL PLATE.................................................................. 13 SAFETY............................................................................................ 21 GENERAL PRECAUTIONS........................................................................... 22 PRECAUTION DURING OPERATION................................................................... 29 BEFORE STARTING ENGINE.................................................................... 29 OPERATING MACHINE......................................................................... 30 TRANSPORTATION............................................................................ 37 BATTERY................................................................................... 38 BATTERY HAZARD PREVENTION............................................................. 38 TOWING.................................................................................... 39 BUCKET WITH HOOK OR BUCKET LINK WITH LIFTING EYE.......................................... 40 GENERAL PRECAUTIONS................................................................... 40 PRECAUTIONS FOR LIFTING OPERATION..................................................... 42 HANDLING OF FLUIDS........................................................................ 44 PRECAUTIONS FOR MAINTENANCE................................................................... 45 BEFORE CARRYING OUT MAINTENANCE........................................................... 45 DURING MAINTENANCE........................................................................ 48 POSITION FOR ATTACHING SAFETY LABELS.......................................................... 51 POSITION FOR ATTACHING SAFETY LABELS...................................................... 51 LIFTING CAPACITY CHART PW180-7K............................................................... 59 ONE PIECE BOOM Lift capacity tables for 2.5 metre undercarriage........................... 59 ONE PIECE BOOM Lift capacity tables for 2.75 metre undercarriage.......................... 65 TWO PIECE BOOM Lift capacity tables for 2.5 metre undercarriage........................... 71 TWO PIECE BOOM Lift capacity tables for 2.75 metre undercarriage.......................... 77 OVERLOAD CAUTION.......................................................................... 83 Monoboom Overload Caution............................................................. 83 2 Piece Boom Overload Caution......................................................... 84 OPERATION......................................................................................... 85 GENERAL VIEW.................................................................................. 86 GENERAL VIEW OF MACHINE................................................................... 86 GENERAL VIEW OF CONTROLS AND GAUGES....................................................... 87 EXPLANATION OF COMPONENTS..................................................................... 88 MACHINE MONITOR........................................................................... 88 BASIC OPERATION OF MACHINE MONITOR.................................................... 89 BASIC CHECK ITEMS......................................................................... 91 CAUTION ITEMS......................................................................... 93 EMERGENCY STOP ITEMS.................................................................. 97 METER DISPLAY PORTION.................................................................100 METERS................................................................................102 MONITOR SWITCHES......................................................................106 SWITCHES......................................................................................119 CONTROL LEVERS, PEDALS........................................................................127 FRONT WINDOW..............................................................................132 EMERGENCY EXIT FROM OPERATOR'S CAB........................................................136 CAP, COVER WITH LOCK......................................................................138 METHOD OF OPENING AND CLOSING CAP WITH LOCK (For the fuel tank filler port)...........138 METHOD OF OPENING AND CLOSING COVER WITH LOCK (cover with lock).......................138 FUSE......................................................................................139 LUGGAGE TRAY..............................................................................140 ASHTRAY...................................................................................140 CUP HOLDER................................................................................140 HOT AND COOL BOX..........................................................................140 CAB RADIO.................................................................................141 PRECAUTION OF USE.....................................................................141 POWER PICK-UP PORT........................................................................141 HANDLING AIR CONDITIONER..................................................................142 GENERAL LOCATIONS OF CONTROL PANEL....................................................142 METHOD OF OPERATION...................................................................146 PRECAUTIONS WHEN USING AIR CONDITIONER................................................152 CHECK, MAINTAIN MACHINE EQUIPPED WITH AIR CONDITIONER.................................152 OTHER FUNCTIONS.......................................................................152 FUSIBLE LINK..............................................................................154 CONTROLLER................................................................................154 TOOL BOX (CHASSIS)........................................................................154 REFUELLING PUMP...........................................................................155 SAFETY................................................................................155 PROCEDURE.............................................................................155 MAINTENANCE...........................................................................156 WARNING LAMPS.............................................................................157 HANDLING ACCUMULATORS.....................................................................158 OPERATION.....................................................................................160 CHECK BEFORE STARTING ENGINE..............................................................160 WALK-AROUND CHECK.....................................................................160 CHECK BEFORE STARTING.................................................................162 ADJUSTMENT OF OPERATOR’S SEAT (AIR SUSPENSION SEAT)...................................167 SEAT BELT.............................................................................169 ADJUSTMENT OF OPERATOR’S SEAT (MECHANICAL SEAT).......................................169 SEAT BELT.............................................................................170 OPERATIONS AND CHECKS BEFORE STARTING ENGINE..................................................171 STARTING ENGINE...........................................................................173 NORMAL STARTING.......................................................................173 STARTING IN COLD WEATHER..............................................................174 OPERATIONS AND CHECKS AFTER STARTING ENGINE...........................................176 WARMING UP OPERATION..................................................................176 IN COLD AREAS (AUTOMATIC WARMING-UP OPERATION)........................................179 MOVING MACHINE OFF........................................................................182 MOVING MACHINE FORWARD................................................................182 STEERING..................................................................................185 TRAVELLING ON PUBLIC HIGHWAY..............................................................186 STOPPING & PARKING........................................................................187 STOPPING MACHINE (EMERGENCY)..........................................................188 SWINGING (Slewing the upper carriage).....................................................189 OPERATION OF WORK EQUIPMENT...............................................................190 WORKING MODE SELECTION....................................................................192 PROHIBITIONS FOR OPERATION................................................................194 PRECAUTIONS FOR OPERATION.................................................................195 RECOMMENDATIONS FOR TRAVELLING............................................................197 PRECAUTIONS WHEN TRAVELLING UP OR DOWN HILLS..............................................198 HOW TO ESCAPE FROM MUD....................................................................199 WHEN ONE SIDE IS STUCK................................................................199 WHEN BOTH SIDES ARE STUCK.............................................................199 WORK POSSIBLE USING HYDRAULIC EXCAVATOR...................................................200 BACKHOE WORK..........................................................................200 SHOVEL WORK...........................................................................200 DITCHING WORK.........................................................................200 LOADING WORK..........................................................................201 LEVELLING WORK........................................................................201 REPLACEMENT AND INVERSION OF BUCKET.......................................................201 REPLACEMENT...........................................................................201 INVERSION.............................................................................202 STOPPING ENGINE...........................................................................203 CHECK AFTER FINISHING WORK................................................................203 CHECK AFTER STOPPING ENGINE...................................................................204 LOCKING...................................................................................204 HANDLING THE WHEELS.......................................................................204 TRANSPORTATION................................................................................209 LOADING, UNLOADING WORK...................................................................209 PRECAUTIONS FOR LOADING...................................................................211 HOW TO LIFT THE MACHINE...............................................................212 PRECAUTIONS FOR TRANSPORTATION............................................................214 TRAVELLING POSTURE........................................................................216 COLD WEATHER OPERATION........................................................................218 PRECAUTIONS FOR LOW TEMPERATURE...........................................................218 FUEL AND LUBRICANTS...................................................................218 BATTERY...............................................................................219 PRECAUTIONS AFTER COMPLETION OF WORK......................................................220 AFTER COLD WEATHER........................................................................220 LONG-TERM STORAGE.............................................................................221 BEFORE STORAGE............................................................................221 DURING STORAGE............................................................................221 AFTER STORAGE.............................................................................222 STARTING MACHINE AFTER LONG-TERM STORAGE..................................................222 TROUBLESHOOTING...............................................................................223 PHENOMENA THAT ARE NOT FAILURES...........................................................223 METHOD OF TOWING MACHINE..................................................................224 PRECAUTIONS ON PARTICULAR JOBSITES........................................................224 DISCHARGED BATTERY........................................................................225 REMOVAL AND INSTALLATION OF BATTERY...................................................225 BATTERY CHARGES.......................................................................226 STARTING ENGINE WITH BOOSTER CABLES...................................................227 OTHER TROUBLE.............................................................................229 ELECTRICAL SYSTEM.....................................................................229 CHASSIS...............................................................................230 ENGINE................................................................................231 ELECTRONIC CONTROL SYSTEM.............................................................233 MAINTENANCE.......................................................................................235 GUIDES TO MAINTENANCE.........................................................................236 OUTLINE OF SERVICE............................................................................239 OUTLINE OF OIL, FUEL, COOLANT.............................................................239 OIL...................................................................................239 FUEL..................................................................................240 COOLANT...............................................................................240 GREASE................................................................................241 CARRYING OUT KOWA (Komatsu Oil Wear Analysis).........................................241 STORING OIL AND FUEL..................................................................242 FILTERS...............................................................................242 OUTLINE OF ELECTRIC SYSTEM................................................................243 OUTLINE OF HYDRAULIC SYSTEM...............................................................244 WEAR PARTS LIST...............................................................................245 USE FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE.............................246 PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS..........................................246 USE FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE CONT........................248 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS................................................250 INTRODUCTION OF NECESSARY TOOLS...........................................................250 TIGHTENING TORQUE SPECIFICATIONS..............................................................251 TIGHTENING TORQUE LIST....................................................................251 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS.................................................252 SAFETY CRITICAL PARTS.....................................................................253 MAINTENANCE SCHEDULE CHART....................................................................254 KEY TO LUBRICATION POINTS.................................................................258 SERVICE PROCEDURE.............................................................................260 INITIAL 250 HOURS SERVICE.................................................................260 WHEN REQUIRED.............................................................................261 CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT..........................................261 CLEAN INSIDE OF COOLING SYSTEM........................................................266 CLEAN INSIDE OF COOLING SYSTEM........................................................267 CHECKING COOLANT LEVEL....................................................................269 DRAINING THE SYSTEM...................................................................269 CLEANING THE SYSTEM...................................................................270 FILLING THE SYSTEM....................................................................270 REFILLING AN OVERHEATED SYSTEM........................................................270 CLEANING THE RADIATOR.................................................................271 THERMOSTAT............................................................................271 FAN...................................................................................272 CHECK AND TIGHTEN WHEEL NUTS..............................................................272 CHECK ELECTRICAL INTAKE AIR HEATER........................................................272 CHECK ALTERNATOR..........................................................................272 CHECK START MOTOR.....................................................................273 REPLACE BUCKET SIDE CUTTERS...............................................................273 REPLACE BUCKET TEETH......................................................................275 REPLACE BUCKET TEETH (VERTICAL PIN TYPE)..............................................275 REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)............................................278 ADJUST BUCKET CLEARANCE...................................................................279 CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID................................................280 CHECK AND ADJUST AIR CONDITIONER..........................................................281 CHECK LEVEL OF REFRIGERANT (GAS)......................................................281 DRAIN ENGINE BREATHER OIL CATCHER.....................................................282 CHECK BEFORE STARTING.....................................................................282 CHECK COOLANT LEVEL, ADD WATER............................................................282 CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL............................................283 CHECK FUEL LEVEL, ADD FUEL............................................................284 CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL............................................285 CHECK AIR CLEANER FOR CLOGGING........................................................285 CHECK ELECTRIC WIRING.................................................................286 CHECK FOR WATER AND SEDIMENT IN SEDIMENTOR. DRAIN WATER AND SEDIMENT..................286 EVERY 50 HOURS............................................................................287 DRAIN WATER AND SEDIMENT FROM FUEL TANK...............................................287 EVERY 100 HOURS SERVICE...................................................................287 LUBRICATING...........................................................................287 CLEANING FRESH AIR FILTER.............................................................292 EVERY 250 HOURS MAINTENANCE...............................................................293 CHECK OIL LEVEL IN MACHINERY CASE, ADD OIL............................................293 CHECK OIL LEVEL IN WHEEL HUBS, ADD OIL (Front Axle)...................................294 CHECK OIL LEVEL IN WHEEL HUBS, ADD OIL (Rear Axle)....................................294 CHECK OIL LEVEL IN AXLES, ADD OIL.....................................................294 CHECK OIL LEVEL IN TRANSMISSION, ADD OIL..............................................295 CHECK LEVEL OF BATTERY ELECTROLYTE....................................................295 BELTS, GENERAL........................................................................296 CHECK FAN BELT TENSION, ADJUST TENSION................................................296 CHECK, ADJUST TENSION OF AIR CONDITIONER COMPRESSOR BELT..............................297 EVERY 500 HOURS SERVICE...................................................................299 LUBRICATE SWING CIRCLE (2 POINTS).....................................................299 REPLACE FUEL FILTER CARTRIDGE.........................................................300 CHECK SWING PINION GREASE LEVEL, ADD GREASE...........................................301 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE.....................302 CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS AND CONDENSER FINS...................303 CLEAN INTERNAL AND EXTERNAL AIR FILTERS OF AIR CONDITIONER SYSTEM.....................304 CLEANING RECIRCULATED AIR FILTER......................................................305 REPLACE HYDRAULIC TANK BREATHER ELEMENT...............................................306 CHECK CONDITION OF MAIN VALVE RUBBER MOUNTS...........................................306 EVERY 1000 HOURS SERVICE..................................................................307 REPLACE HYDRAULIC FILTER ELEMENT......................................................307 CHANGE OIL IN SWING MACHINERY CASE....................................................308 CHECK ALL TIGHTENING PARTS OF TURBOCHARGER............................................309 CHECK PLAY OF TURBOCHARGER ROTOR......................................................309 CHECK & ADJUST VALVE CLEARANCE........................................................309 CHECK FAN BELT TENSIONER BEARING BELT AND FAN HUB.....................................309 CHECK FAN BELT TENSION AND REPLACE FAN BELT...........................................309 CHANGE OIL IN AXLES...................................................................310 CHANGE OIL IN HUBS....................................................................311 CHANGE OIL IN TRANSMISSION ASSEMBLY...................................................312 EVERY 2000 HOURS SERVICE..................................................................313 CLEAN HYDRAULIC TANK STRAINER.........................................................313 CLEANING THE STRAINER OF THE BRAKE FILTER.............................................314 CLEAN, CHECK TURBOCHARGER.............................................................314 CHECK ALTERNATOR, STARTING MOTOR......................................................314 CHANGE ANTIFREEZE.....................................................................314 CHECK AND ADJUST VALVE CLEARANCE......................................................315 EVERY 4000 HOURS SERVICE..................................................................315 CHECK WATER PUMP......................................................................315 EVERY 5000 HOURS SERVICE..................................................................316 CHANGE OIL IN HYDRAULIC TANK AND REPLACE STEER/BRAKE CIRCUIT STRAINER.................316 PROCEDURE FOR BLEEDING AIR............................................................318 SPECIFICATIONS....................................................................................319 SPECIFICATIONS................................................................................320 1 - PIECE BOOM............................................................................322 2 - PIECE BOOM............................................................................324 WORKING RANGE: ONE PIECE BOOM.............................................................326 WORKING RANGE: TWO PIECE BOOM.............................................................327 OPTIONS, ATTACHMENTS..............................................................................329 GENERAL PRECAUTIONS...........................................................................330 PRECAUTIONS RELATED TO SAFETY.............................................................330 PRECAUTIONS WHEN INSTALLING ATTACHMENTS.......................................................331 HANDLING BUCKET WITH HOOK.....................................................................333 CHECKING FOR DAMAGE TO BUCKET WITH HOOK...................................................333 PROHIBITED OPERATIONS.....................................................................333 PRECAUTIONS DURING OPERATIONS.............................................................333 MACHINES READY FOR ATTACHMENTS................................................................334 HANDLING THE CLAMSHELL BUCKET.............................................................336 How to install clamshell bucket.......................................................336 HOW TO OPERATE........................................................................336 HYDRAULIC CIRCUIT.........................................................................338 SWITCHING HYDRAULIC CIRCUIT...........................................................338 OPERATION.................................................................................339 WHEN USING CRUSHER OR OTHER GENERAL ATTACHMENT........................................340 WHEN USING BREAKER....................................................................341 METHOD FOR RELEASING PRESSURE IN CONTROL CIRCUIT OF MACHINES EQUIPPED WITH ACCUMULATOR....342 LONG-TERM STORAGE.........................................................................342 SPECIFICATIONS........................................................................342 INTRODUCTION OF ATTACHMENTS AND EXTENDING MACHINE SERVICE LIFE................................343 HYDRAULIC BREAKER.........................................................................343 POWER RIPPER..............................................................................346 FORK GRAB.................................................................................347 GRAPPLE BUCKET............................................................................348 SCRAP GRAPPLE.............................................................................349 CRUSHER & SMASHER.........................................................................351 HYDRAULIC PILE DRIVER.....................................................................352 HYDRAULIC EXCAVATOR WITH MULTIPURPOSE CRANE...............................................353 GENERAL VIEW OF CONTROLS..............................................................355 LEFT CONTROL LEVER (with auto-deceleration device)....................................356 RIGHT CONTROL LEVER (with auto-deceleration device)...................................356 UPPER BOOM CONTROL PEDAL (2 PIECE BOOM)...............................................357 EXCAVATOR’S WORK......................................................................357 REPLACEMENT OF BUCKET.................................................................359 HANDLING THE TRAPEZOIDAL BUCKET (If equipped).........................................360
PLEASE NOTE:
- This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
- This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
- Require some other service manual or have any queries: please WRITE to us at [email protected]
