Komatsu Pw160 7k Operation Maintenance Manual

Full download: http://manualplace.com/download/komatsu-pw160-7k-operation-maintenance-manual/

Operation & UEAM003201

Maintenance Manual

PW160-7K
WHEELED EXCAVATOR
SERIAL NUMBER
PW160-7K - K40001 and up

WARNING

Unsafe use of this machine may cause serious injury or

death. Operators and maintenance personnel must read
this manual before operating or maintaining this
machine. This manual should be kept inside the cab for
reference and periodically reviewed by all personnel who
will come into contact with the machine.

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FOREWORD

3
FOREWORD FOREWORD

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.

WARNING
● This operation & maintenance manual may contain
attachments and optional equipment that are not avail-
able in your area. Please consult your local Komatsu dis-
tributor for those items you require.

● This machine complies with EC directive (89/392/EEC).

Machines complying with this directive display the CE
mark

● Improper operation and maintenance of this machine can

be hazardous and could result in serious injury or death.

● Operators and maintenance personnel should read this

manual thoroughly before beginning operation or main-
tenance.

● Some actions involved in operation and maintenance of

the machine can cause a serious accident, if they are not
done in a manner described in this manual.

● The procedures and precautions given in this manual

apply only to intended uses of the machine. If you use
your machine for any unintended uses that are not spe-
cifically prohibited, you must be sure that it is safe for
you and others. In no event should you or others engage
in prohibited uses or actions as described in this manual.

● Komatsu delivers machines that comply with all applica-

ble regulations and standards of the country to which it
has been shipped. If this machine has been purchased in
another country or purchased from someone in another
country, it may lack certain safety devices and specifica-
tions that are necessary for use in your country. If there
is any question about whether your product complies
with the applicable standards and regulations of your
country, consult Komatsu or your Komatsu distributor
before operating the machine.

● The description of safety is given, see "SAFETY INFOR-

MATION (5)" and in "SAFETY" from page 19.

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FOREWORD SAFETY INFORMATION

SAFETY INFORMATION

SAFETY MESSAGES
Most accidents are caused by the failure to follow fundamental
safety rules for the operation and maintenance of machines.

To avoid accidents, read, understand and follow all precautions

and warnings in this manual and on the machine before perform-
ing operation and maintenance.

To identify hazards on the machine pictorial decals are used (see

POSITION FOR ATTACHING SAFETY LABELS).

RED WARNING TRIANGLE - This is used on safety

labels where there is a high probability of serious injury or death if
the hazard is not avoided. These safety messages or labels usu-
ally describe precautions that must be taken to avoid the hazard.
Failure to avoid this hazard may also result in serious damage to
the machine.

ORANGE WARNING TRIANGLE - This is used on

safety labels where there is a potentially dangerous situation
which could result in serious injury or death if the hazard is not
avoided. These safety messages or labels usually describe pre-
cautions that must be taken to avoid the hazard. Failure to avoid
this hazard may also result in serious damage of the machine

YELLOW SAFETY TRIANGLE - This is used on

safety labels for hazards which could result in minor or moderate
injury if the hazard is not avoided. This word might also be used
for a hazard where the only result could be damage to the
machine.

NOTICE - This word is used for precautions that must be taken to

avoid actions which could shorten the life of the machine.

Safety precautions are described in SAFETY from page 19.

Komatsu cannot predict every circumstance that might involve a

potential hazard in operation and maintenance. Therefore the
safety message in this manual and on the machine may not
include all possible safety precautions. If any procedures or
actions not specifically recommended or allowed in this manual
are used, you must be sure that you and others can do such pro-
cedures and actions safely and without damaging the machine. If
you are unsure about the safety of some procedures, contact
Komatsu or your Komatsu distributor.

5
SAFETY INFORMATION FOREWORD

NOISE
● Sound pressure level at the operator’s station, measured
according to ISO6396 (Dynamic test method, simulated work-
ing cycle).

● Sound power level emitted. This is the guaranteed value as

specified in the European directive 2000/14/EC
71

101
VIBRATION
● The weighted root mean square acceleration value to which
the operator’s arms are subjected does not exceed 2.5 m/s²

● The weighted root mean square acceleration value to which

the operator’s body is subjected was measured at 0.64 m/s²

These results were obtained by accelerometers during trench dig-

ging.

6
FOREWORD SAFETY INFORMATION

EMERGENCY STEERING
This machine is equipped with an emergency steering system
and complies to ISO 5010 (BSEN 12643). In the advent of failure
of the source of power for the steering system (engine failure)
whilst travelling, the machine can be steered allowing the
machine to be safely stopped.

In such a case, the effort required at the steering wheel and the
number of turns to steer the machine will increase. To confirm
function of emergency steering system, raise the front wheels off
the ground (using the work equipment) and with the engine off,
turn the steering wheel and check movement of the wheels.

EMERGENCY BRAKING

This machine is equipped with an emergency braking system and

complies to ISO 3450. In the advent of failure of the source of
power for the braking system (engine failure) whilst travelling, the
brakes can be actuated from stored energy in the accumulators to
bring the machine safely to a stop.

In such a case, seven brake applications can be made before

exhausting the energy in the accumulators. In the advent of ser-
vice brake failure, the park brake can be used as an emergency
brake to bring the machine to a stop.

7
INTRODUCTION FOREWORD

INTRODUCTION

INTENDED USE
This Komatsu HYDRAULIC EXCAVATOR is designed to be used
mainly for the following work:

● Digging

● Smoothing work

● Ditching work

● Loading work

See the section see "WORK POSSIBLE USING HYDRAU-

LIC EXCAVATOR (186)" for further details

FEATURES
● This Komatsu HYDRAULIC EXCAVATOR is equipped with
various controls based on an advanced electronics system.

● The monitor panel greatly facilitates daily maintenance and

self-diagnosis.

● Working mode & travel speed are selectable.

● Digging and lifting force can be increased by light-touch con-

trol. (For details, see operation section.)

● Adjustable wrist control levers make operations smooth and

easy.

● Fresh filtered air conditioner assures comfortable operation.

● Low noise level and smart urban style design and colouring.

● Superb operation performance provided by powerful engine

and high-performance hydraulic pump.

● Low fuel consumption controlled by an electronic control sys-

tem provides an environment-friendly machine.

● Sophisticated drive train provides fast and smooth travelling

on the highway and off road.

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FOREWORD INTRODUCTION

BREAKING IN YOUR NEW MACHINE

Your Komatsu machine has been thoroughly adjusted and tested
before shipment.

However, operating the machine under severe conditions at the

beginning can adversely affect the performance and shorten the
machine life.

Be sure to break in the machine for the initial 100 hours (as indi-
cated by the hour meter.)

During breaking in:

● Idle the engine for 5 minutes after starting it up.

● Avoid operation with heavy loads or at high speeds.

● Sudden starting or acceleration, unnecessarily abrupt braking

and sharp turning should be avoided except in cases of emer-
gency.

Additionally for the first 20 hours

● Avoid operating engine for prolonged periods at constant

speed (including idle.)

● Avoid high speed travelling for periods of more than 5 min-

utes.

Pay particular attention to oil pressure and temperature indicators

& check coolant and oil levels frequently during breaking in.

The precautions given in this manual for operating, maintenance,

and safety procedures are only those that apply when this product
is used for the specified purpose. If the machine is used for a pur-
pose that is not listed in this manual, Komatsu cannot bear any
responsibility for safety. All consideration of safety in such opera-
tions is the responsibility of the user.

Operations that are prohibited in this manual must never be car-

ried out under any circumstances.

9
LOCATIONS OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR FOREWORD

LOCATIONS OF PLATES, TABLE TO ENTER SERIAL NO.

AND DISTRIBUTOR

MACHINE SERIAL NO. PLATE POSITION

On the front left of the undercarriage

ENGINE SERIAL NO. PLATE POSITION

On the gear case front corner.

TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR

Machine serial No.:

Engine Serial No.:

Product Identification Number.

Manufacturer’s name: Komatsu UK Ltd.

Address

Durham Road
Birtley
Chester-Le-Street
County Durham DH32QX
United Kingdom

Distributor

Address

Phone

10
FOREWORD LOCATIONS OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR

MACHINE SERIAL PLATES

STANDARD SERIAL PLATE Serial number
Model Manufacturing year

MODEL

SERIAL No.

MANUFACT. YEAR

MAX. DRAWBAR PULL N

Max. drawbar pull MASS kg
ENGINE POWER kW
Weight
Product Identification Number
Engine power
MANUFACTURER Manufactured by Komatsu UK Ltd.
Product for Komatsu Ltd.,Tokyo,Japan
20G-00-K2382
Identification Number
Manufactured by Komatsu UK Ltd. Birtley, Co. Durham,
United Kingdom, under License from Komatsu Ltd.

GERMANY SERIAL PLATE

TYP

FABR. NR.

BAUJAHR

ZUL. ZUGKRAFT N
ZUL.GESAMTGEWICHT kg
LEISTUNG kW
ZUL.ACHSLAST VORN kg
ZUL.ACHSLAST HINTEN kg
Produkt Identifizierung Nummer
HERSTELLER Hergestellt vom Komatsu UK Ltd. Birtley Co Durham,
United Kingdom unter lizenz der Komatsu Ltd.
20G-00-K2392

ITALIAN SERIAL PLATE

11
LOCATIONS OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR FOREWORD

12
CONTENTS

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

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

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

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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 CHECK ITEMS ................................................................................................................................ 77

SWITCHES ......................................................................................................................................................... 106

CONTROL LEVERS, PEDALS .......................................................................................................................... 114

FRONT WINDOW ..................................................................................................................................... 119
EMERGENCY EXIT FROM OPERATOR'S CAB ..................................................................................... 123
DOOR LOCK ............................................................................................................................................ 124
CAP, COVER WITH LOCK ....................................................................................................................... 125
FUSE ........................................................................................................................................................ 126
LUGGAGE TRAY ...................................................................................................................................... 127
ASHTRAY ................................................................................................................................................. 127
CUP HOLDER .......................................................................................................................................... 127
HOT AND COOL BOX .............................................................................................................................. 127
CAB RADIO .............................................................................................................................................. 128
POWER PICK-UP PORT .......................................................................................................................... 128
HANDLING AIR CONDITIONER .............................................................................................................. 129
FUSIBLE LINK .......................................................................................................................................... 142
CONTROLLER ......................................................................................................................................... 142
TOOL BOX (CHASSIS) ............................................................................................................................ 143
REFUELLING PUMP ................................................................................................................................ 143
WARNING LAMPS ................................................................................................................................... 145
HANDLING ACCUMULATORS ................................................................................................................ 146

OPERATION ....................................................................................................................................................... 147

CHECK BEFORE STARTING ENGINE .................................................................................................... 147

OPERATIONS AND CHECKS BEFORE STARTING ENGINE ......................................................................... 158

STARTING ENGINE ................................................................................................................................. 160
MOVING MACHINE OFF .......................................................................................................................... 169
STEERING ................................................................................................................................................ 172
TRAVELLING ON PUBLIC HIGHWAY ..................................................................................................... 173
STOPPING & PARKING ........................................................................................................................... 174
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
WORK POSSIBLE USING HYDRAULIC EXCAVATOR ........................................................................... 186

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 REPLACEMENT AND INVERSION OF BUCKET .................................................................................... 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
PRECAUTIONS FOR TRANSPORTATION ............................................................................................. 200
TRAVELLING POSTURE ......................................................................................................................... 202

COLD WEATHER OPERATION ........................................................................................................................ 203

PRECAUTIONS FOR LOW TEMPERATURE .......................................................................................... 203
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
OTHER TROUBLE ................................................................................................................................... 214

MAINTENANCE ............................................................................................... 219

GUIDES TO MAINTENANCE ............................................................................................................................. 220

OUTLINE OF SERVICE ...................................................................................................................................... 223

OUTLINE OF OIL, FUEL, COOLANT ....................................................................................................... 223
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

15
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
CHECKING COOLANT LEVEL ................................................................................................................ 253
CHECK AND TIGHTEN WHEEL NUTS ................................................................................................... 256
CHECK ELECTRICAL INTAKE AIR HEATER .......................................................................................... 256
CHECK ALTERNATOR ............................................................................................................................ 256
REPLACE BUCKET SIDE CUTTERS ...................................................................................................... 257
REPLACE BUCKET TEETH ..................................................................................................................... 258
ADJUST BUCKET CLEARANCE ............................................................................................................. 262
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID ....................................................................... 263
CHECK AND ADJUST AIR CONDITIONER ............................................................................................. 264
CHECK BEFORE STARTING .................................................................................................................. 265
CHECK COOLANT LEVEL, ADD WATER ............................................................................................... 265
EVERY 50 HOURS ................................................................................................................................... 270
EVERY 100 HOURS SERVICE ................................................................................................................ 270
EVERY 250 HOURS MAINTENANCE ...................................................................................................... 276
EVERY 500 HOURS SERVICE ................................................................................................................ 282
EVERY 1000 HOURS SERVICE .............................................................................................................. 290
EVERY 2000 HOURS SERVICE .............................................................................................................. 296
EVERY 4000 HOURS SERVICE .............................................................................................................. 297
EVERY 5000 HOURS SERVICE .............................................................................................................. 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

16
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
OPERATION ............................................................................................................................................. 318
METHOD FOR RELEASING PRESSURE IN CONTROL CIRCUIT OF MACHINES EQUIPPED WITH
ACCUMULATOR ...................................................................................................................................... 321
LONG-TERM STORAGE .......................................................................................................................... 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

ROTATING ARM ................................................................................................................................................ 337

GENERAL LOCATION AND SPECIFICATIONS. ..................................................................................... 337
GENERAL VIEW OF CONTROLS ............................................................................................................ 339
TRAVELLING POSTURE ......................................................................................................................... 341
MAINTENANCE ........................................................................................................................................ 343

17
18
 SAFETY

WARNING
Read and follow all safety precautions. Failure to do so may
result in serious injury or death.

This safety section also contains precautions for optional equip-

ment and attachments.

19
Komatsu Pw160 7k Operation Maintenance Manual
Full download: http://manualplace.com/download/komatsu-pw160-7k-operation-maintenance-manual/
GENERAL PRECAUTIONS SAFETY

WARNING: For reasons of safety, always follow these safety precautions.

GENERAL PRECAUTIONS
SAFETY RULES

● ONLY trained and authorised personnel can operate and

maintain the machine.

● Follow all safety rules, precautions and instructions when

operating or performing maintenance on the machine.

● When working with another operator or a person on work site

traffic duty, be sure all personnel understand all hand signals
that are to be used.

SAFETY FEATURES

● Be sure all guards and covers are in their proper position.

Have guards and covers repaired if damaged.

● Use safety features such as safety lock lever at all times.

● NEVER remove any safety features. ALWAYS keep them in

good operating condition.

● Always wear safety belt when operating machine.

● Improper use of safety features could result in serious bodily

injury or death.

CLOTHING AND PERSONAL PROTECTIVE ITEMS

● Avoid loose clothing, jewellery, and loose long hair. They can
catch on controls or in moving parts and cause serious injury
or death. Also, do not wear oily clothes because they are
flammable.

● Wear a hard hat, safety glasses, safety shoes, mask or

gloves when operating or maintaining the machine. Always
wear safety goggles, hard hat and heavy gloves if your job
involves scattering metal chips or minute materials, this is so
particularly when driving pins with a hammer and when clean-
ing the air cleaner element with compressed air.
Check also that there is no one near the machine.

Driving in pins, see"REPLACEMENT AND INVERSION OF

BUCKET (187)"

Cleaning of air cleaner element, see "WHEN REQUIRED

(245)" in service procedure.

UNAUTHORISED MODIFICATION

● Any modification made without authorisation from Komatsu

can create hazards.

● Before making a modification, consult your Komatsu distribu-

tor. Komatsu will not be responsible for any injury or damage
caused by any unauthorised modification.

20
This is the cut pages sample. Download all 354 page(s) at: ManualPlace.com