Page 1 Operation & VEAM390100 Maintenance Manual PW160-7H WHEELED EXCAVATOR SERIAL NUMBER PW160-7H - H50051 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.
Page 3: Foreword
FOREWORD PW160-7H VEAM390100...
Page 4: Foreword
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.
Page 5: Safety Information
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.
Page 6: Noise
The weighted root mean square acceleration value to which ● the operator’s body is subjected was measured at 0.5m/s² These results were obtained by accelerometers during trench dig- ging. This machine is equipped with an operators seat which meets ● the requirements of ENISO 7096. PW160-7H VEAM390100...
Page 7: Emergency Steering
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. PW160-7H VEAM390100...
Page 8: Introduction
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 (185)" for further details...
Page 9: Breaking In Your New Machine
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.
Page 10: Locations Of Plates, Table To Enter Serial No. And Distributor
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 Hanomag GmbH. Address Hanomagstr. 9 30449 Hannover Germany Distributor Address...
Page 11: Machine Serial Plates
LOCATIONS OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR MACHINE SERIAL PLATES STANDARD SERIAL PLATE Serial number Manufacturing year Model Weight Engine power Product Identification Number Max. drawbar pull Manufactured by Komatsu Hanomag GmbH, Hannover, Germany under License from Komatsu Ltd. PW160-7H VEAM390100...
Page 12 LOCATIONS OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR FOREWORD PW160-7H VEAM390100...
Page 13: Table Of Contents
DURING MAINTENANCE ........................... 45 POSITION FOR ATTACHING SAFETY LABELS ....................48 POSITION FOR ATTACHING SAFETY LABELS ..................48 LIFTING CAPACITY CHART PW160-7H ......................56 ONE PIECE BOOM Lift capacity tables ...................... 56 TWO PIECE BOOM Lift capacity tables ..................... 62 OVERLOAD CAUTION ..........................
Page 14 OPERATION....................... 69 GENERAL VIEW ..............................70 GENERAL VIEW OF MACHINE ......................... 70 GENERAL VIEW OF CONTROLS AND GAUGES ..................71 EXPLANATION OF COMPONENTS ........................72 MACHINE MONITOR ..........................72 BASIC CHECK ITEMS ..........................75 SWITCHES ................................. 103 CONTROL LEVERS, PEDALS .......................... 111 FRONT WINDOW .............................
Page 15 OUTLINE OF OIL, FUEL, COOLANT ....................... 225 OUTLINE OF ELECTRIC SYSTEM ......................228 OUTLINE OF HYDRAULIC SYSTEM ....................... 229 WEAR PARTS LIST ............................231 USE FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE ......232 PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS ............232 PW160-7H VEAM390100...
Page 16 USE FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE CONT....234 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS ..............236 INTRODUCTION OF NECESSARY TOOLS .................... 236 TIGHTENING TORQUE SPECIFICATIONS ...................... 237 TIGHTENING TORQUE LIST ........................237 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS ................238 SAFETY CRITICAL PARTS ........................
Page 17 HYDRAULIC BREAKER ........................... 324 POWER RIPPER ............................327 FORK GRAB ............................. 328 GRAPPLE BUCKET ..........................329 SCRAP GRAPPLE ............................ 330 CRUSHER & SMASHER .......................... 332 HYDRAULIC PILE DRIVER ........................333 HYDRAULIC EXCAVATOR WITH MULTIPURPOSE CRANE ..............334 INDEX ................................. 343 PW160-7H VEAM390100...
Page 18 PW160-7H VEAM390100...
Page 19: Safety
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. PW160-7H VEAM390100...
Page 20: General Precautions
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. PW160-7H VEAM390100...
Page 21 Before leaving the operator’s compart- ment, always raise the safety lock lever to lock the work equipment controls. ALWAYS CHOCK THE WHEELS BEFORE GOING UNDER THE MACHINE The chocks are located in the left hand toolbox (A) on the machine. PW160-7H VEAM390100...
Page 22 FIRE PREVENTION FOR FUEL AND OIL Fuel, oil, and antifreeze can be ignited by a flame. Fuel is particu- larly FLAMMABLE and can be HAZARDOUS. Keep flames away from flammable fluids. ● Stop the engine and do not smoke when refuelling. ● PW160-7H VEAM390100...
Page 23 3. Slowly loosen cap to relieve pressure before removing. MACHINES FITTED WITH WHEELS Never perform any repair work or modifications to wheel rims while the tyres are fitted, and never apply heat in the vicinity of the tyres. PW160-7H VEAM390100...
Page 24 ASBESTOS DUST HAZARD PREVENTION Asbestos dust can be HAZARDOUS to your health if it is inhaled. Your Komatsu machine and genuine Komatsu spare parts do not contain any asbestos. Use only genuine Komatsu spare parts. If spare parts containing asbestos are used, the following precau- tions must be observed: NEVER use compressed air for cleaning.
Page 25 By all means you should put on other guards if required by conditions at your particular site. For details of safety guards, please contact your Komatsu distrib- utor. Also, even for other types of work, if there is any danger of being hit by falling or flying objects or of objects entering the operator’s...
Page 26 When the machine is operated on or beside a road, a rotating ● beacon is required to avoid a traffic accident. Contact your Komatsu distributor to install beacon lamp. ● ELECTROMAGNETIC INTERFERENCE When this machine is operating close to a source of high electro- magnetic interference, such as a radar station, some abnormal phenomena may be observed.
Page 27: Precaution During Operation
They may damage or break the control levers or switches. Always put them in the tool box on the undercarriage. Keep the cab floor, controls, steps and handrails free of oil, ● grease, snow, and excess dirt. PW160-7H VEAM390100...
Page 28: Operating Machine
Before operating the travel pedal, check the direction of the under carriage. If the fixed axle is at the front, the forward/neutral/reverse lever and steering will function in the opposite direction. Fixed axle Oscillating axle Travel operations, see "MOVING MACHINE OFF (167)" PW160-7H VEAM390100...
Page 29 INCORRECT ment as close to the ground as possible and travel at low speed. Never travel over obstacles which make the machine tilt strongly (10° or more). PW160-7H VEAM390100...
Page 30 Method of travelling on slopes, see "RECOMMENDA- TIONS FOR TRAVELLING (182)" Do not travel up and down on grass, fallen leaves, and wet steel plates. These materials may allow the machine to slip, if it is trav- elling sideways. Keep travel speed very low. PW160-7H VEAM390100...
Page 31 Check with the electricity company about the voltage of the ● cables before starting operations. Voltage Min. safety distance 6.6 kV 33.0 kV 66.0 kV 154.0 kV 275.0 kV 10 m PW160-7H VEAM390100...
Page 32 DO NOT HIT THE OPERATOR CAB (for two piece boom only) When the second boom cylinder is retracted, the bucket or ● the attachment can hit the operator cab or chassis. Operate work equipment slowly and carefully to avoid any ● injury and damage. PW160-7H VEAM390100...
Page 33 If the machine has to be used on a slope, pile the soil to make ● a platform that will keep the machine as horizontal as possi- CORRECT ble. (See the lower diagram on the right.) Piled soil on slope, see "RECOMMENDATIONS FOR TRAVELLING (182)" Platform PW160-7H VEAM390100...
Page 34 Before leaving the operator’s compart- ment, always raise the safety lock lever to lock the work equipment controls. Places to lock, see "LOCKING (190)" PW160-7H VEAM390100...
Page 35: Transportation
When shipping the machine on a hauling vehicle, obey all ● state and local laws governing the weight, width, and length of a load. Also obey all applicable traffic regulations. Determine the shipping route while taking into account the ● width, height and weight of the load. PW160-7H VEAM390100...
Page 36: Battery
If any tool touches between the positive (+) terminal and the ● chassis, it will cause sparks. This is dangerous, so be sure to work carefully. ● Connect the batteries in parallel: positive to positive and neg- ative to negative. PW160-7H VEAM390100...
Page 37: Towing
1. Unscrew bolt (A) (Torque=20Nm)2~3 turns, this allows bolt (B) to rotate. (DO NOT REMOVE BOLT ’A’) 2. Turn park brake release bolt (B) 180 degrees so that indicator mark is located at the top position. 3. Re-tighten bolt (A) (Torque 20Nm) PW160-7H VEAM390100...
Page 38: Bucket With Hook Or Bucket Link With Lifting Eye
When carrying out lifting work, a special lifting hook or lifting ● eye is necessary. The lifting hook must be fitted with a safety latch to prevent ● accidental un-hooking of the load. Check safe working load of lifting equipment. ❍ PW160-7H VEAM390100...
Page 39 Always execute operation according to his instructions. Execute operating methods and procedures under his ❍ direction. Select a person responsible for signalling. Operate only ❍ on signals given by such person. HANDLING OF WIRE ROPES ETC. Wear leather gloves when handling wire ropes. ● PW160-7H VEAM390100...
Page 40: Handling Of Fluids
HANDLING OF USED ENGINE OILS Avoid contact with used engine oils. ● Refer to engine oils data sheet for handling and storage pre- ● cautions. PW160-7H VEAM390100...
Page 41 PTO, transmission axles and hubs avoid pro- longed or frequent contact with skin. Refer to manufacturers data sheet for handling and storage ● precautions. HANDLING OF FLUIDS For antifreeze and grease refer to manufacturers data sheet ● for handling and storage precautions. PW160-7H VEAM390100...
Page 42: Precautions For Maintenance
● operator’s cab to alert others that you are working on the machine. Attach additional warning tags around the machine, if necessary. These tags are available from your Komatsu distributor. (Part ● no. 20E-00-K1340) PROPER TOOLS Use only tools suited to the task. Using damaged, low quality, ●...
Page 43 Spilt fuel and oil may cause you to slip, so always wipe it up ● immediately. Always tighten the cap of the fuel and oil fillers securely. ● Never use fuel for washing any parts. ● Always add fuel and oil in a well-ventilated place. ● PW160-7H VEAM390100...
Page 44 Slowly loosen the caps to relieve pressure before removing ● the caps. USE OF LIGHTING When checking fuel, oil, coolant, or battery electrolyte, always ● use lighting with anti-explosion specifications. If such lighting equipment is not used, there is danger of explosion. PW160-7H VEAM390100...
Page 45: During Maintenance
Do not use water or steam to clean the sensors, connectors, or the inside of the operator’s compartment. PRECAUTIONS WITH BATTERY When repairing the electrical system or when carrying out ● electrical welding, remove the negative (-) terminal of the bat- tery to stop the flow of current. PW160-7H VEAM390100...
Page 46 C l e a n i n g i n s i d e or c o o l i n g s y s t e m, s e e " W H E N REQUIRED (247)" Checking cooling water level, hydraulic oil level, see "CHECK COOLANT LEVEL, ADD WATER (267)" Checking lubricating oil level, adding oil, see "MAINTE- NANCE SCHEDULE CHART (240)" Changing oil, replacing filters, see "MAINTENANCE SCHEDULE CHART (240)" PW160-7H VEAM390100...
Page 47 Always put oil drained from your machine in containers. ● Never drain oil directly on the ground. Obey appropriate laws and regulations when disposing of ● harmful materials such as oil, fuel, coolant, solvent, filters, batteries, and others. A0055220A PW160-7H VEAM390100...
Page 48: Position For Attaching Safety Labels
There are other labels in addition to the safety labels listed as fol- lows, so handle them in the same way. Safety labels are available from your Komatsu distributor. POSITION FOR ATTACHING SAFETY LABELS PW160-7H VEAM390100...
Page 49 Follow instructions and warnings in the manuals and labels ● on the machine. Keep this manual in the machine cab, near operator. ● If this manual is lost, please contact Komatsu distributor for ● replacement. Always raise safety lock lever when leaving operators seat. ●...
Page 50 POSITION FOR ATTACHING SAFETY LABELS SAFETY 2. There are 6 amber reflectors located on the revolving frame and arm of the machine (20G-46-K1681) 3. Warning for unsafe machine. Located on the left or right hand levers (20E-00-K1340) Do not start the engine. ●...
Page 51 SAFETY POSITION FOR ATTACHING SAFETY LABELS 6. Warning for hot objects (20E-00-K1190) Warning for high temperature coolant and oil, hot water and oil hazard. To prevent hot water and oil from spurting out: ● Turn engine off. Allow water to cool. ●...
Page 52 POSITION FOR ATTACHING SAFETY LABELS SAFETY 8. Warning for staying clear. This is fitted on both sides of arm (20E-00-K1140) Keeping out of moving area. To prevent SEVERE INJURY or DEATH. Do the following before moving the machine or its attachments: Sound horn to alert people nearby.
Page 53 SAFETY POSITION FOR ATTACHING SAFETY LABELS 10. Stop engine warning (20E-00-K1310) Do not open cover while engine is running. ● 11. Front window lock warning. This is located on the rear win- dow (09803-A0481) Always lock window in raised or lowered position. ●...
Page 54 POSITION FOR ATTACHING SAFETY LABELS SAFETY 13. (20G-00-31030) Radiator fill volume warning. This is located on top of the radiator unit. 14. (20K-00-31360) Read operation manual before operation.This is located inside the cab. 15. Red reflector (20G-47-K1690) 16. (20Y-00-K2220) Emergency exit ●...
Page 55 SAFETY POSITION FOR ATTACHING SAFETY LABELS 18. Operation of attachments is located on the right hand window (20K-00-31140) 19. Lift warning plate. This is located on the right hand window (20E-00-K1450) 20. Do not lift more than the specified load of the machine. 21.
Page 56: Lifting Capacity Chart Pw160-7H
LIFTING CAPACITY CHART PW160-7H SAFETY LIFTING CAPACITY CHART PW160-7H ONE PIECE BOOM Lift capacity tables When removing bucket, linkage or cylinder, lifting capacities can be increased by their respective weights. A - Reach from swing center B - Bucket hook height...
Page 57 SAFETY LIFTING CAPACITY CHART PW160-7H Reach (A) 7.5m 6.0m 4.5m 3.0m 7.5m *2450 *2450 6.0m *2100 *1800 3150 2200 4.5m *1950 1450 3100 2150 5050 3500 3.0m 1900 1250 2050 1350 2950 2050 4700 3200 1.5m 1850 1200 2000 1300...
Page 58 LIFTING CAPACITY CHART PW160-7H SAFETY Reach (A) 7.5m 6.0m 4.5m 3.0m 7.5m *2450 *2450 6.0m *2100 *2100 *3750 2600 4.5m *1950 1750 *4700 2550 *5250 4150 3.0m *1950 1550 *3350 1650 *5100 2450 *6700 3800 1.5m *2050 1500 4000 1600...
Page 59 SAFETY LIFTING CAPACITY CHART PW160-7H Reach (A) 7.5m 6.0m 4.5m 3.0m 7.5m *2450 *2450 6.0m *2100 *2100 *3750 2950 4.5m *1950 *1950 *4700 2900 *5250 4700 3.0m *1950 1800 *3350 1900 *5100 2800 *6700 4350 1.5m *2050 1700 *4150 1850...
Page 60 LIFTING CAPACITY CHART PW160-7H SAFETY Reach (A) 7.5m 6.0m 4.5m 3.0m 7.5m *2450 *2450 6.0m *2100 *2100 *3750 *3750 4.5m *1950 *1950 *4700 3800 *5250 *5250 3.0m *1950 *1950 *3350 2550 *5100 3700 *6700 5800 1.5m *2050 *2050 *4150 2500...
Page 61 SAFETY LIFTING CAPACITY CHART PW160-7H Reach (A) 7.5m 6.0m 4.5m 3.0m 7.5m *2450 *2450 6.0m *2100 *2100 *3750 *3750 4.5m *1950 *1950 *4700 4550 *5250 *5250 3.0m *1950 *1950 *3350 3050 *5100 4400 *6700 *6700 1.5m *2050 *2050 *4150 3000...
Page 62: Two Piece Boom Lift Capacity Tables
LIFTING CAPACITY CHART PW160-7H SAFETY TWO PIECE BOOM Lift capacity tables When removing bucket, linkage or cylinder, lifting capacities can be increased by their respective weights. A - Reach from swing center B - Bucket hook height C - Lifting capacities, including bucket (495 kg),...
Page 63 SAFETY LIFTING CAPACITY CHART PW160-7H Reach (A) 7.5m 6.0m 4.5m 3.0m 7.5m *2300 *2300 *3650 *3650 6.0m *1900 *1900 *3250 2200 *4200 3700 4.5m *1800 1500 *4550 2150 *5100 3600 *5000 *5000 3.0m *1800 1300 *2400 1350 *5300 2050 *6900 3300 1.5m...
Page 64 LIFTING CAPACITY CHART PW160-7H SAFETY Reach (A) 7.5m 6.0m 4.5m 3.0m 7.5m *2300 *2300 *3650 *3650 6.0m *1900 *1900 *3250 2300 *4200 3900 4.5m *1800 1600 *4550 2300 *5100 3750 *5000 *5000 3.0m *1800 1400 *2400 1450 *5300 2200 *6900 3500 1.5m...
Page 65 SAFETY LIFTING CAPACITY CHART PW160-7H Reach (A) 7.5m 6.0m 4.5m 3.0m 7.5m *2300 *2300 *3650 *3650 6.0m *1900 *1900 *3250 2350 *4200 3950 4.5m *1800 1600 *4550 2300 *5100 3800 *5000 *5000 3.0m *1800 1400 *2400 1450 *5300 2200 *6900 3550 1.5m...
Page 66 LIFTING CAPACITY CHART PW160-7H SAFETY Reach (A) 7.5m 6.0m 4.5m 3.0m 7.5m *2300 *2300 *3650 *3650 6.0m *1900 *1900 *3250 2450 *4200 4100 4.5m *1800 1700 *4550 2450 *5100 3950 *5000 *5000 3.0m *1800 1500 *2400 1550 *5300 2350 *6900 3700 1.5m...
Page 67 SAFETY LIFTING CAPACITY CHART PW160-7H Reach (A) 7.5m 6.0m 4.5m 3.0m 7.5m *2300 *2300 *3650 *3650 6.0m *1900 *1900 *3250 2500 *4200 4150 4.5m *1800 1750 *4550 2450 *5100 4000 *5000 *5000 3.0m *1800 1550 *2400 1550 *5300 2350 *6900 3750 1.5m...
Page 68: Overload Caution
LIFTING CAPACITY CHART PW160-7H SAFETY OVERLOAD CAUTION This machine is equipped with an overload caution system which gives a visual warning (on monitor) and an audible warning when lifting a load close to the lift capacity of the machine (active in L mode only).
Page 69: Operation
OPERATION WARNING Please read and make sure that you understand the safety volume before reading this section. PW160-7H VEAM390100...
Page 70: General View
If directions are indicated in this section, they refer to the direc- tions shown by in the arrows in the diagram below. A: FRONT B: REAR C: RIGHT D: LEFT 1. Bucket 5. Boom 2. Bucket cylinder 6. Boom Cylinder 3. Arm 7. Undercarriage 4. Arm cylinder PW160-7H VEAM390100...
Page 71: General View Of Controls And Gauges
34. Full beam indicator 15. Swing override 35. Work lights indicator 16. Travel override 36. Driving light switch 17. Override F/N/R 37. Brake pedal 18. Heated seat 38. Travel pedal 19. Beacon light 39. Undercarriage attachment select 20. Lower wiper PW160-7H VEAM390100...
Page 72: Explanation Of Components
MACHINE MONITOR Maintenance interval warning screen All lights up screen Normal operation screen A: Basic check Items D: Meter Display Portion, Pilot Display Portion B: Caution Items E: Monitor Switches C: Emergency Stop Items PW160-7H VEAM390100...
Page 73 After displaying the maintenance interval warning screen for ● 30 seconds, the screen returns to the normal screen. After displaying the check before starting screen for 2 sec- ● onds, the screen changes to the warning screen or error screen. PW160-7H VEAM390100...
Page 74 (1) or the error screen. After displaying warning screen (1) for 2 seconds, the screen ● automatically changes to warning screen (2), with exception of low brake pressure when warning screen (1) remains per- manently active. PW160-7H VEAM390100...
Page 75: Basic Check Items
This monitor (1) warns the operator that there has been a drop in the radiator water level. If the radiator water level is low, the lamp lights up red, so check the water level in the radiator and the sub- tank, and add water. PW160-7H VEAM390100...
Page 76 This monitor screen goes out after 30 seconds and returns to the normal operation screen. For details of the method of checking the maintenance interval, see "SERVICE MENU SWITCH (95)". If it is desired to change the setting of the maintenance interval, please consult your Komatsu distributor. PW160-7H VEAM390100...
Page 77 (7) Engine oil level low (2) Fuel level monitor (8) Service machine-over due (3) Air cleaner clogging monitor (9) Park brake (4) Engine water temperature monitor (10) Swing lock (5) Hydraulic oil temperature monitor (11) PPC lock (6) Overload Caution Monitor PW160-7H VEAM390100...
Page 78 3. AIR CLEANER CLOGGING MONITOR This monitor (3) warns the operator that the air cleaner is clogged. If it lights up red, stop the engine and inspect and clean the air cleaner. PW160-7H VEAM390100...
Page 79 (an audible warning is also given), if the warning is given lower the load.Refer the lifting capacity chart for safe load. 7. ENGINE OIL LEVEL LOW When monitor (7) lights up, the engine oil level is insufficient. Stop machine immediately and refill to recommended levels PW160-7H VEAM390100...
Page 80 11. PPC LOCK This monitor warns that the machine is travelling at high speed without applying the PPC lock switch. Push the PPC lock switch immediately when the machine is travelling at high speed. PW160-7H VEAM390100...
Page 81 If there is an abnormality, the monitor for the abnormal loca- tion lights up red and the buzzer sounds, so carry out action immediately. (1) Engine water temperature monitor (3) Engine oil pressure monitor (2) Hydraulic oil temperature monitor (4) Low brake pressure PW160-7H VEAM390100...
Page 82 REMARK When the starting switch is ON, this lamp remains illumi- nated, and after the engine starts, it goes out. When the engine starts, the buzzer sounds momentarily, but this is not an abnor- mality. PW160-7H VEAM390100...
Page 83 Fuel level monitor Green – Air cleaner clogging monitor – Engine water temperature monitor Green White Hydraulic oil temperature monitor Green White Engine oil pressure monitor – Overload caution monitor – Low brake pressure Swing lock Control lever lock PW160-7H VEAM390100...
Page 84 (7) Engine water temperature gauge (16) Swing position (8) Fuel Gauge (17) Power max. monitor (9) Hydraulic oil temperature gauge PILOT DISPLAY When the starting switch is ON, the pilot display lights up when the display items are functioning. PW160-7H VEAM390100...
Page 85 The monitor display when the working mode switch is operated is as follows. A mode (for heavy-load operations) E mode (for operations with emphasis on fuel economy) L mode (for fine-control operations and lifting) B mode (for breaker operations) PW160-7H VEAM390100...
Page 86 When the engine is started, if the indicator is at position (C), engine water temperature monitor (1) lights up white. In this case, carry out the warming-up operation. For details, see "WARMING UP OPERATION (161)". PW160-7H VEAM390100...
Page 87 25°C, and hydraulic oil temperature monitor (1) lights up white. In this case, carry out the warming-up operation. For details, see "WARMING UP OPERATION (161)". REMARK If other warnings are displayed, only monitor (1) is displayed and not the range indicator. PW160-7H VEAM390100...
Page 88 This monitor (14) displays the set suspension lock mode. When one of the suspension lock switches is selected the monitor dis- plays one of the following selections. - Auto suspension lock mode - Permanent suspension lock MONITOR SWITCHES PW160-7H VEAM390100...
Page 89 OPERATION EXPLANATION OF COMPONENTS 15. CONTROL LEVER LOCK This lamp will illuminate when the PPC lock is switched on. 16. SWING POSITION This lamp (16) will illuminate when the upper structure is orien- tated to straight ahead. PW160-7H VEAM390100...
Page 90 (5) Menu select key (15) Undo key (6) Service menu (16) Rear left outrigger/blade (7) Engine auto deceleration (17) Front left outrigger/blade (8) Buzzer cancel (18) Front right outrigger (9) Brightness adjust (19) Rear right outrigger (10) Suspension auto lock PW160-7H VEAM390100...
Page 91 If you require a default setting other than ’A mode’ please ● consult your Komatsu distributor or dealership to have the setting amended. REMARK When the mode selector switch is pressed, the mode is dis-...
Page 92 2 seconds before returning to the normal screen display. When loading or unloading from a trailer, always travel at low ● speed. Never operate the travel speed selector switch during the loading or unloading operation. PW160-7H VEAM390100...
Page 93 4. CONTROL LEVER LOCK SWITCH Depressing control lever lock switch will stop lever functionality. Lever lock switch must be engaged when machine travels on highway to prevent accidental use of work equipment.Light on switch will illuminate when active. PW160-7H VEAM390100...
Page 94 5. Press up switch (14) or down switch (13) to adjust to the desired flow. 6. After completing the flow setting, press input confirmation switch (12). The monitor display will return to the normal screen. PW160-7H VEAM390100...
Page 95 Replace engine oil filter Replace fuel filter Replace hydraulic oil filter 1000 Replace hydraulic tank breather Check damper case oil level, add oil 1000 Change swing machinery case oil 1000 Change hydraulic oil 5000 Transmission 1000 Axles 1000 PW160-7H VEAM390100...
Page 96 EXPLANATION OF COMPONENTS OPERATION If it is desired to change the setting for the maintenance interval, please contact your Komatsu distributor. The method of checking the time remaining to maintenance is as follows. 1. Look at the maintenance screen, press up switch (14) or down switch (13) on the monitor switch portion, until required item is highlighted.
Page 97 The lamp on the switch will illuminate when the warning buzzer is sounding. 9. CONTRAST ADJUSTMENT SWITCH When the contrast adjustment switch (9) is depressed this brings up the adjustment menu. For more information see “Adjustment screens” on page 100. PW160-7H VEAM390100...
Page 98 (11) again. Permanent suspension lock should only be used when travelling slowly. Do not use in high speed travel. 12. INPUT CONFIRMATION SWITCH Press this switch (12) to confirm the selected mode when in the maintenance mode, brightness/contrast adjustment mode, or select mode. PW160-7H VEAM390100...
Page 99 Light illuminates when active. 18. FRONT RIGHT OUTRIGGER SWITCH Allows operation of front right outrigger only. Light on switch illuminates when activated. 19. REAR RIGHT OUTRIGGER SWITCH Allows operation of rear right outrigger. Light on switch illuminates when activated. PW160-7H VEAM390100...
Page 100 4. After completing adjustment of the contrast, press input con- firmation switch (12). This will store the new setting and return you to the adjustment menu. REMARK As normal, within any menu, press switch (15) to return to the previous screen at any time. PW160-7H VEAM390100...
Page 101 Year Month Hour Minute 3. After completing adjustment of the clock, press input confir- mation switch (12). This will return you to the above menu and store the new setting. PW160-7H VEAM390100...
Page 102 Day time/Night time. Light blue/Dark blue Dark blue/Light blue 3. After completing adjustment of the background colour, press input confirmation switch (12). This will return you to the above menu and store the new setting. PW160-7H VEAM390100...
Page 103: Switches
34. Full beam indicator 15. Swing override 35. Work lights indicator 16. Travel override 36. Driving light switch 17. Override F/N/R 37. Brake pedal 18. Heated seat 38. Travel pedal 19. Beacon light 39. Undercarriage attachment select 20. Lower wiper PW160-7H VEAM390100...
Page 104 This is used to light cigarettes. To use, push the lighter in. After a few seconds it will spring back.Pull out the lighter (5) and light your cigarette. No other equipment may be connected to the ciga- rette lighter without the prior permission of an authorized Komatsu distributor. PW160-7H VEAM390100...
Page 105 The upper button (26) of the left control lever is used to actuate the power max function. Press the button once (single click) and keep it depressed the power max. function actuates for a max. 8.5 seconds in A and E mode. Left control lever PW160-7H VEAM390100...
Page 106 (1) When abnormal: When the monitor display shows E03 (swing brake system error), the brake is cancelled and it becomes possi- ble to swing the upper structure when this switch is moved up, so normal operations can be carried out. However, the swing brake remains cancelled. PW160-7H VEAM390100...
Page 107 REMARK The caution buzzer sounds when the staring switch is turned from ON to OFF while the driving light switch is in the ON position. The engine compartment light will only illuminate when the side- lights are on. PW160-7H VEAM390100...
Page 108 (1) Turn right: push lever fully forward (2) Turn left: pull lever fully back (direction indicator (a) to the rear of the steering wheel hub will flash) The indicator cancel automatically, but can be cancelled manually by returning return lever to neutral position. PW160-7H VEAM390100...
Page 109 MAIN WINDSCREEN WIPER SWITCH This rotary switch (30d) on column stalk controls main windscreen wiper. INTERMITTENT Rotate switch 30° away. ● From operator for intermittent wipe CONTINUOUS Rotate switch a further 30° away ● From operator for continuous wipe. PW160-7H VEAM390100...
Page 110 SWITCHES OPERATION 12V POWER SUPPLY The 12V socket (21 provided on the cab rear left panel may be used only for electrical accessories drawing 1,5 A. maximum. Any accessories attached to this socket must carry the EC mark. PW160-7H VEAM390100...
Page 111: Control Levers, Pedals
34. Full beam indicator 15. Swing override 35. Work lights indicator 16. Travel override 36. Driving light switch 17. Override F/N/R 37. Brake pedal 18. Heated seat 38. Travel pedal 19. Beacon light 39. Undercarriage attachment select 20. Lower wiper PW160-7H VEAM390100...
Page 112 UNLOCK LOCK LEFT WORK EQUIPMENT CONTROL LEVER (with auto-deceleration device) When the lever in this position, the upper structure and the arm will be retained in the position in which they stop. PW160-7H VEAM390100...
Page 113 If any of the levers are operated, the engine speed will rise to the speed set by the fuel control dial. PW160-7H VEAM390100...
Page 114 The service brakes are operated by depressing pedal (37). The service brakes can be locked in the ’ON’ position for digging and lifting operations, to lock the service brakes in the ’ON’ position fully depress the brake pedal. To unlock the service brakes depress latch (A). Standard PW160-7H VEAM390100...
Page 115 (A). For on highway driving the lock can be disabled. Depress latch Alternative (A) fully. This will prevent the lockfrom operating when the brake pedal (37) is depressed. When the lock as needing again depress latch (B) PW160-7H VEAM390100...
Page 116 CAUTION Do not rest foot on the pedal unless in use. HCU PEDAL (OPTION) Pedal (28) is used to operate the attachment. REMARK Confirm with attachment manufacturer at time of installation, correct pedal and attachment operation before use. PW160-7H VEAM390100...
Page 117: Front Window
It is possible to store (pull up) the front window (top) in the roof of the operator's compartment. When opening 1. Place the work equipment on flat ground and stop the engine. 2. Raise safety lock lever. 9JH02402AA1 3. Check that the wiper blade (A) is stored in the right frame. PW160-7H VEAM390100...
Page 118 5. Hold lower knob (C) with your left hand from inside the opera- tor's cab, and with your right hand, grip top knob (D), pull it up, and firmly push it against lock catch (E) at the rear of the cab to securely lock the window. 9JH02594AA1 9JH02402AA1 PW160-7H VEAM390100...
Page 119 1. Place the work equipment on flat ground and stop the engine. 2. Raise the safety lock lever. LOCK UNLOCK 3. Grip left and right knobs (A), and pull down lock lever (B) to release the lock. PW160-7H VEAM390100...
Page 120 (B). Check it visually. If the arrow on lock case (F) does not line up with the arrow ● on lock lever (B), the lock is not engaged. Repeat the opera- tion in Step 5 to engage the lock. PW160-7H VEAM390100...
Page 121: Emergency Exit From Operator's Cab
3. Do not remove the rear window except when using it as an emergency exit. CEILING WINDOW The operator cab is provided with a fixed clear ceiling window for improved visibility. An optional guard can be provided for working in areas at risk from falling or flying objects. PW160-7H VEAM390100...
Page 122: Door Lock
1. The door will become fixed in place when it is pressed against catch (1). 2. To release the lock, press knob (2) down at the left side of the operator’s seat to release the catch. When fixing the door, fix it firmly to the catch. PW160-7H VEAM390100...
Page 123: Cap, Cover With Lock
1. Insert the key. 2. Turn it counterclockwise and open the cover by pulling the cover grip. To lock the cover 1. Close the cover and insert the key. 2. Turn the key clockwise and take the key out. PW160-7H VEAM390100...
Page 124: Fuse
15 A Clamshell and chassis attachments (16) 10 A Seat compressor and cab interior light (17) 10 A Monitor (regular power) (18) 10 A Starter switch (19) 15 A Hazard warning (20) 20 A Head lights and park lights PW160-7H VEAM390100...
Page 125: Luggage Tray
HOT AND COOL BOX The box is at the rear right of the operator’s seat. It is intercon- nected with the air conditioner. It warms when the heater is being used and cools when the air conditioner is being used. PW160-7H VEAM390100...
Page 126: Cab Radio
Do not use cigarette lighter as the power source for 12V equipment. It will cause damage to the equipment. If the cigarette lighter is removed, it can be used as a power source. The capacity of the cigarette lighter is 85W (24V x 3.5A). PW160-7H VEAM390100...
Page 127: Handling Air Conditioner
This switch (1) is used to stop the fan and air conditioner. When OFF switch (1) is pressed, the set temperature and air ● flow display on display monitor (7) and the lamps above auto switch (5) and air conditioner switch (8) go out, and operation stops. PW160-7H VEAM390100...
Page 128 The temperature is generally set at 25°C. ● The temperature can be set in stages of 0.5°C. ● <Monitor display and the function> Monitor display (°C) Set temperature 18.0 Max. cooling Adjusts temperature inside cab to set 18.5 to 31.5 temperature 32.0 Max. heating PW160-7H VEAM390100...
Page 129 Front and rear vents (including defroster vent) Front and rear vents (including defroster vent) Foot vent Foot, foot vents Cannot be selected for automatic (including defroster vent) operation Front vents Cannot be selected for automatic (including defroster vent) operation PW160-7H VEAM390100...
Page 130 This display monitor displays the status of temperature set- ● ting (a), air flow (b), and vents (c). When OFF switch (1) is pressed, the display of temperature ● setting (a) and air flow (b) goes out, and operation stops. PW160-7H VEAM390100...
Page 131 Select the method of operation as desired. AUTOMATIC OPERATION 1. Turn auto switch (5) ON. The lamp at the top of switch (5) lights up. ❍ The set temperature (a) and air flow (b) are displayed on ❍ the monitor. PW160-7H VEAM390100...
Page 132 STOPPING AUTOMATIC OPERATION Press OFF switch (1). The displays for temperature setting (a) and air flow (b) on the display monitor, and the lamps above auto switch (5) and air conditioner switch (8) go out, and the operation stops. PW160-7H VEAM390100...
Page 133 2. Turn air conditioner switch (8) ON. Check that the lamp at the top of the air conditioner switch lights up. 3. Press the temperature setting switch and adjust the tempera- ture inside the cab. PW160-7H VEAM390100...
Page 134 STOPPING MANUAL OPERATION Press OFF switch (1). The displays for temperature setting (a) and air flow (b) on the display monitor, and the lamps above auto switch (5) and air conditioner switch (8) go out, and the operation stops. PW160-7H VEAM390100...
Page 135 2. Press vent selector switch (4) and set the vent display on the display monitor to the display shown in the diagram on the right. 3. Turn air conditioner switch (8) ON. When this is done, the lamp above the air conditioner switch lights up. PW160-7H VEAM390100...
Page 136 FRESH/RECIRC selector switch (6) to the desired positions. DEFROSTER OPERATION 1. Press fan switch (2) and adjust the air flow. When doing this, check that temperature setting (a) and air flow (b) are dis- played on the display monitor. PW160-7H VEAM390100...
Page 137 3. Press FRESH/RECIRC selector switch (6) and set it to take in fresh air. 4. Press temperature setting switch (3) and set the set tempera- ture display on the display monitor to the maximum heating temperature of 32°C. PW160-7H VEAM390100...
Page 138 Be careful not to make the temperature in the cab too low. When the cooler is on, set the temperature so that it feels slightly cool when entering the cab (5 - 6ºC) lower than the outside tem- PW160-7H VEAM390100...
Page 139 When more than one failure is detected, press the "∧" or "∨" ● portion of temperature setting switch (3) to display the failures in turn. ● After completing the troubleshooting, press OFF switch (1) again to return to the normal display. PW160-7H VEAM390100...
Page 140: Fusible Link
CONTROL LEVERS, PEDALS OPERATION If any abnormality is detected by the self-diagnostic function, ask your Komatsu distributor to carry out inspection and repair. SWITCH SET TEMPERATURE DISPLAY BETWEEN °F AND °C It is possible to switch the set temperature display between °F and °C.
Page 141: Controller
Never splash or spill water, mud or drink over the con- ● troller as this may cause a fault. If a fault occurs in the controller, do not attempt repair, ● but consult your Komatsu distributor. TOOL BOX (CHASSIS) This is used for keeping the tools. REFUELLING PUMP SAFETY Do not bring fire or sparks near fuel - smoking is prohibited.
Page 142 Monthly: Check hose joints, electrical cables and clean the pump body of impurities. Storage: If the pump is not to be used for a period, ensure that fuel is sprayed into the motor housing every two weeks to prevent risk of rusting to the rotor. PW160-7H VEAM390100...
Page 143: Warning Lamps
When the indicator is pulled fully backward, warning light (A) will flash to indicate the driver’s intention to turn to the left. When the indicator is pushed fully forward, warning light (B) will flash to indicate the driver’s intention to turn to the right. PW160-7H VEAM390100...
Page 144: Handling Accumulators
When disposing of accumulators, it is necessary to re- ● lease the gas from the accumulators, so please contact your Komatsu distributor. Brake circuit accumulators (A) X 3 This machine is equipped with accumulators in the brake circuits. The accumulator is a device to store the pressure in the circuit, and when it is installed, the circuit can be operated for a short time even after the engine is stopped.
Page 145: Operation
Check carefully, and if any abnormality is found, always repair it or contact your Komatsu distributor. Before starting the engine, look around the machine and under the machine to check for loose nut or bolts, or leakage of oil, fuel, or coolant, and check the condition of the work equipment and hydraulic system.
Page 146 9. Check lifting eye for damage Check the lifting eye (or hook and safety latch) for damage. If damage is found, contact your Komatsu distributor for repair. 10. Check seat belt and mounting clamps. Check there is no abnormality in the seat belt or mounting clamps.
Page 147 6. If the oil level is correct, tighten the oil filler cap securely and close the engine hood. REMARK Ensure the machine is level when checking oil level and wait 15 minutes after stopping engine before checking the oil level. PW160-7H VEAM390100...
Page 148 (F). Be careful not to get float gauge (G) caught in the tab of fuel filler cap (F), and tighten fuel filler cap (F) securely. For details of the fuel to use, see "USE FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPER- ATURE (232)" Approx 50mm PW160-7H VEAM390100...
Page 149 The oil level will vary depending upon the oil temperature Accordingly, use the following as a guide: Before operation: around midway between H and L ● (Oil temperature 10 to 30°C) Normal operation: around H level ● (Oil temperature 50 to 80°C) PW160-7H VEAM390100...
Page 150 If the fuses frequently blow, if there are traces of short ● circuits in the electrical wiring, locate the cause immedi- ately and carry out repairs, or contact your Komatsu dis- tributor for repairs. Keep the top surface of the battery clean and check the ●...
Page 151 ± Tightening torque of ring nut (2): 40 3 N•m ± {4.1 0.3 kgf•m} 13. Fill filter case (3) with fuel. When the fuel comes out from air bleed plug (5), tighten air bleed plug (5). PW160-7H VEAM390100...
Page 152 The backrest is adjusted using the locking lever (3). Once locking lever (3) is in locked position it should not be possible to move onto another position. (D) Adjustment of arm rest height The inclination of the armrests can be modified by turning the adjustment knob. PW160-7H VEAM390100...
Page 153 The height can be altered by pulling or pressing the actuator lever fully out or in (8) if the adjustment reaches the top or bottom end stop, the height is adjusted automatically in order to guarantee a minimum spring level. PW160-7H VEAM390100...
Page 154 ADJUSTMENT OF OPERATOR’S SEAT (MECHANI- CAL SEAT) (A) Fore-and aft adjustment of seat For details, see "(A) Fore-and-aft adjustment of seat (152)" (B) Forward/aft adjustment of seat For details, see "(B) Forward/aft adjustment of seat and base (152)" PW160-7H VEAM390100...
Page 155 (H) Height adjustment For details, see "(H) Height adjustment (153)" (I) Seat depth adjustment For details, see "(I) Seat depth adjustment (154)" SEAT BELT For details, see "SEAT BELT (154)" PW160-7H VEAM390100...
Page 156: Operations And Checks Before Starting Engine
LOCK UNLOCK 2. Select neutral on the right control lever. Forward Neutral Reverse control lever 3. Insert the key in starting switch (8), turn the key to the ON Heat position, then carry out the following checks. Start PW160-7H VEAM390100...
Page 157 If the monitors or gauges do not light up or the buzzer does not sound, there is probably a broken bulb or disconnection in the monitor wiring, so contact your Komatsu distributor for repairs. After approx. 3 sec., the following gauges will remain on and the other monitors will go out.
Page 158: Starting Engine
2. Turn the key in starting switch to the START position. The engine will start. Heat Heat Start Start 3. When the engine starts, release the key in starting switch. The key will return automatically to the ON position. Heat Heat Start Start PW160-7H VEAM390100...
Page 159 The monitor and gauge also light up when the key is at the Start HEAT position, but this does not indicate any abnormality. If the Start temperature is low, the monitor screen may become dark or it may take time for the display to appear. This is normal. REMARK PW160-7H VEAM390100...
Page 160 Above 0° C Start 0°C to -10°C 20 seconds -10°C to -20°C 30 seconds 4. When the engine starts, release the key in starting switch(6). The key will return automatically to the ON position. Heat Heat Start Start PW160-7H VEAM390100...
Page 161 First, carry out the following operations and checks. 1. Turn fuel control dial (9) to the centre position between LOW IDLING (MIN) and HIGH IDLING (MAX) and run the engine at medium speed for about 5 minutes with no load. MIN. PW160-7H VEAM390100...
Page 162 Left perature rise can be increased quicker. control lever NOTICE When the work equipment is retracted, take care that it does not interfere with the machine body or ground. Left swing Right swing PW160-7H VEAM390100...
Page 163 6. Check that there is no abnormal exhaust gas colour, noise, or vibration. If any abnormality is found, repair it. 7. Press power mode select on the monitor panel until the lamp of the mode to be used lights up. PW160-7H VEAM390100...
Page 164 1. Set fuel control dial (9) at the low idling (MIN) position and run the engine for about 5 minutes without load. MIN. 2. When the automatic warming-up operation is completed, press working mode switch on the monitor panel until the heavy-duty operation mode lamp lights up. PW160-7H VEAM390100...
Page 165 When the hydraulic oil is at a low temperature the machine travel function may have very slow operation. Always carry out the warming up operation before travelling to ensure correct function of the travel system and help extend the life of the machine. PW160-7H VEAM390100...
Page 166 1. Turn fuel control dial to the full speed (MAX) position and hold it for 3 seconds. When fuel control dial is returned to the low idling (MIN) posi- tion, the engine speed will drop. PW160-7H VEAM390100...
Page 167: Moving Machine Off
2. Turn fuel control dial to the min. idling position, engine speed is controlled automatically. 3. Lower the safety lock lever to the UNLOCK position, fold the work equipment, and raise it 40 - 50 cm from the ground. LOCK UNLOCK PW160-7H VEAM390100...
Page 168 Hi mode is for high speed travel, on smooth surfaces with slopes up to 5 degrees. Auto mode: for travelling on roads or job sites with varying terrain. WARNING Do not use auto mode on steep downhill slopes use Lo mode PW160-7H VEAM390100...
Page 169 REMARK When travelling in Auto mode a slight shock may occasionally be heard and/or felt as the automatic transmission clutch oper- ates. This is normal. PW160-7H VEAM390100...
Page 170: Steering
Failure to comply with this notice will result in severe damage to the transmission unit. ● If you are uncertain about how to tow the machine, please contact your local Komatsu distributor for advice. PW160-7H VEAM390100...
Page 171: Travelling On Public Highway
Failure to comply with this notice will result in severe damage to the transmission unit. If you are uncertain about how to tow the machine, ● please contact your local komatsu distributor for advice. PW160-7H VEAM390100...
Page 172: Stopping & Parking
(37) to stop the machine. (The service brakes may be locked by fully de-pressing the service brake pedal until it ‘latches’) 2. Select neutral on right control lever (7) 3. When parking, lower the work equipment until it touches the ground Forward Neutral Reverse Right control lever PW160-7H VEAM390100...
Page 173 Failure to comply with this notice will result in severe damage to the transmission unit. If you are uncertain about how to tow the machine, ● please contact your local Komatsu distributor for advice. PW160-7H VEAM390100...
Page 174: Swinging (Slewing The Upper Carriage)
2. Operate left work equipment control lever to swing the upper structure. Swing Swing Left Right 3. When not operating the swing, turn swing lock switch (12) ON (ACTUATED) Left 4. Before travelling re-apply swing lock brake. control lever PW160-7H VEAM390100...
Page 175: Operation Of Work Equipment
Raise NOTE: This is only possible if the key is returned to the "On" position after the engine is stopped. Right control lever Bucket operation Curl Dump Right control lever PW160-7H VEAM390100...
Page 176 1. When using the dozer blade as stabiliser. Use the dozer blade in the same way as an outrigger. How- ever, use it only on level ground so that uneven loads will not be applied to the blade. PW160-7H VEAM390100...
Page 177: Working Mode Selection
E mode emphasis on efficiency) L mode Lifting operations B mode Breaker operations NOTICE If breaker operations are carried out in the heavy digging mode, the hydraulic equipment may be damaged. Operate the breaker only in B mode. PW160-7H VEAM390100...
Page 178 • This function is not actuated when the working mode is set to L mode or B mode. Left control lever CAUTION Continuous use of this facility will raise the hydraulic oil tem- perature above normal. PW160-7H VEAM390100...
Page 179: Prohibitions For Operation
Prohibited operations using dropping force of bucket INCORRECT Do not use the dropping force of the bucket as a pickaxe, breaker, or pile driver. This will bring excessive force to bear on the rear of PW160-7H VEAM390100...
Page 180: Precautions For Operation
Do not operate machine (working or travelling) on 1 tyre (if twin tyres are fitted) after a puncture as this puts excessive load onto the one remaining tyre. To prevent loss of control refrain from travelling fast over rough ground. PW160-7H VEAM390100...
Page 181 Front axle of machine must be locked as machine will become unstable. REMARK Precautions when using the work equipment. Do not use the park brake to reduce movement of the machine when using work equipment. This will result in premature failure of the park brake. PW160-7H VEAM390100...
Page 182: Recommendations For Travelling
7. Travel over longer distances (e.g. on public roads) at adjusted (medium) speed. 8. Disable the service brake lock (if installed). If the service brake pedal is the alternative type (see “BRAKE PEDAL” on page 114.) disable the lock. PW160-7H VEAM390100...
Page 183: Precautions When Travelling Up Or Down Hills
The upper structure will swing under its own weight. Do not open or close the door on the cab if the machine is on ● a slope. This may cause a sudden change in the door open- ing / closing force. Always keep the door locked. PW160-7H VEAM390100...
Page 184: How To Escape From Mud
If you are uncertain about how to tow the machine, ● please contact your local komatsu distributor for advice. HOW TO ESCAPE FROM MUD Always operate carefully to avoid getting stuck in mud. If the ma- chine does get stuck in mud, use the following procedures to get the machine out.
Page 185: Work Possible Using Hydraulic Excavator
To excavate a wide ditch, first dig out both sides and then finally remove the center portion. PW160-7H VEAM390100...
Page 186 Loading is easier and capacity greater if you begin from the front of the dump truck body than if loading is done from the side. LEVELLING WORK Can be carried out with work equipment or dozer blade (if fitted). PW160-7H VEAM390100...
Page 187: Replacement And Inversion Of Bucket
If the bucket is lowered strongly to the ground, the resistance will be increased and it will be difficult to remove the pins. 2. Remove the stopper bolts and nuts, then remove pins and, and remove the bucket. PW160-7H VEAM390100...
Page 188 PW160-7H VEAM390100...
Page 189: Stopping Engine
4. Check the engine compartment for paper and debris. Clean out any paper and debris to avoid a fire hazard. 5. Remove any mud stuck to the undercarriage. REMARK It is normal for water to drip from aircon drain hoses. PW160-7H VEAM390100...
Page 190: Check After Stopping Engine
Never attempt to repair damaged items. Use the appropriate tools in a good condition to remove the ● various pieces of the rim. Never use metallic hammer, use a mallet with a face made from Rubber, Plastic or Copper. PW160-7H VEAM390100...
Page 191 Rim Base Loose flange Lockring Rim Gutter (groove) Deflation and removal: Before loosening the wheel retaining nuts, completely deflate ● the tyres by removing the valve with the appropriate tool. Always stand to the side during the deflating operation. PW160-7H VEAM390100...
Page 192 Check correct seating of the lock-ring by measuring the dimension of the gap shown in Fig 2. If it is not possible to achieve the stated gap with the lock-ring seated correctly renew the rim assembly. Fig. 2 PW160-7H VEAM390100...
Page 193 ● NO WRONG ASSEMBLY nally opposite wheel nuts and then tighten the tyres to the specified torque in the order shown in Fig. 4. Tightening torque: 80 Kg.m Retighten to the specified torque after 5 hours operation. ● PW160-7H VEAM390100...
Page 194 OPERATION 4. Twin wheel assembly - 2 part rim Some Komatsu machines are fitted with a 2 piece wheel rim of the type shown in Fig. 5. In this case the loose flange and lock- ring are replaced by a single split flange.
Page 195: Transportation
This may cause a sudden change in the operating force. When loading or unloading the machine with the auto- ● matic warming-up operation mode, if the automatic mode is released, the speed may change suddenly. Avoid load- ing or unloading during automatic warming-up operation. PW160-7H VEAM390100...
Page 196 6. Load the machine correctly in the specified position on the trailer. REMARK When the work equipment is installed, load the machine from the front; when the work equipment is not installed, load the machine from the rear. PW160-7H VEAM390100...
Page 197: Precautions For Loading
Be particularly careful to ensure that the machine does not slip sideways. NOTICE When transporting the machine, place rectangular timber under one end of the bucket cylinder to prevent it touching the ground, thereby saving it from possible damage. PW160-7H VEAM390100...
Page 198 3. Raise the safety lock lever to the LOCK position. 4. Stop the engine. Confirm safety around the operator seat. Get off the machine. Be sure to close the cab door, windshield, right and left doors, engine hood, etc. PW160-7H VEAM390100...
Page 199 8. When the machine leaves the ground, stop the machine and make sure sufficiently that the machine is balanced. Then, lift the machine slowly. PW160-7H VEAM390100...
Page 200: Precautions For Transportation
2500 8,365 3,240 8,410 3,200 15,410 3000 15,540 (1) Height for transport = (D) Overall height + (3) height of trailer platform * Weights and dimensions: will vary according to specification. Consult your Komatsu distributor if in doubt. PW160-7H VEAM390100...
Page 201 3208 15,800 3000 5878 3978 8211 3191 15,930 (1) Height for transport = (D) Overall height + (3) height of trailer platform * Weights and dimensions: will vary according to specification. Consult your Komatsu distributor if in doubt. PW160-7H VEAM390100...
Page 202: Travelling Posture
4 m and that the distance between the centre of the steering wheel and the front of the work equipment is less than 3.5 m. REMARK This will necessitate removal of the bucket for machines fitted with 3.0 m arm. PW160-7H VEAM390100...
Page 203 OPERATION TRANSPORTATION Before moving off, lock all machine cover and toolbox doors to prevent accidental opening. PW160-7H VEAM390100...
Page 204: Cold Weather Operation
When replacing coolant containing antifreeze or when handling coolant when repairing the radiator, contact your Komatsu distributor or ask your local antifreeze dealer. Be careful not to let the water flow into drainage ditches or spray on to the ground surface.
Page 205 If the electrolyte level is low, add distilled water in the morning ● before beginning work. To prevent fluid in the battery from freezing in the night, do not add the water after the day's work. PW160-7H VEAM390100...
Page 206: Precautions After Completion Of Work
(winter, one season type) is used instead, or if no antifreeze is used, drain the cooling sys- tem completely, then clean out the inside of the cooling sys- tem thoroughly, and fill with fresh water. PW160-7H VEAM390100...
Page 207: Long-Term Storage
At the same time, also charge the battery. Also carry out cooler operation in the case of machines equipped with an air conditioner. PW160-7H VEAM390100...
Page 208: After Storage
OPERATION AFTER STORAGE NOTICE If the machine is stored without carrying out the monthly rust prevention operation, request your Komatsu distributor for service. Carry out the following procedure when taking the machine out of long-term storage. Wipe off the grease from the hydraulic cylinder rods.
Page 209: Troubleshooting
3. When starting or stopping the swing, noise will be emitted from the brake valve. 4. When going down a steep slope at low speed, a noise will be emitted from the travel motor. PW160-7H VEAM390100...
Page 210: Method Of Towing Machine
2. For heavy-duty operations and deep digging, carry out greas- ing of the work equipment mounting pins every time before operation. 3. After greasing, operate the boom, arm and bucket several times, then grease again. PW160-7H VEAM390100...
Page 211: Discharged Battery
● (normally the (-) terminal). Be careful not to touch the positive (+) terminal and the machine with any tool. Letting a tool touch is dangerous as it causes sparks. When installing, connect the ground side last. ● PW160-7H VEAM390100...
Page 212 Do not use or charge the battery if the battery electrolyte level ● is below the LOWER LEVEL line. This may cause an explo- sion. Always check the battery electrolyte level periodically and add distilled water to bring the electrolyte level to the UPPER LEVEL PW160-7H VEAM390100...
Page 213 Make sure that the cables and clips are firmly connected. ● Check that the safety lock lever is raised in the LOCK ● position and parking brake applied. Check that each lever is in the NEUTRAL position. ● PW160-7H VEAM390100...
Page 214 Battery of the Battery of the (-) terminal of the normal machine. normal machine problem machine 3. Remove one clip of booster cable (A) from the positive (+) ter- Engine block of minal of the normal machine. the problem machine PW160-7H VEAM390100...
Page 215: Other Trouble
4. Remove the other clip of booster cable (A) from the positive (+) terminal of the problem machine. OTHER TROUBLE ELECTRICAL SYSTEM Always contact your Komatsu distributor when dealing with ● these items. In cases of abnormalities or causes which are not listed ●...
Page 216 TROUBLESHOOTING OPERATION CHASSIS Always contact your Komatsu distributor when dealing with ● these items. In cases of abnormalities or causes which are not listed ● below, please contact your Komatsu distributor for repairs. Problem Main causes Remedy Speed of travel, swing, boom, arm,...
Page 217 OPERATION TROUBLESHOOTING ENGINE Always contact your Komatsu distributor when dealing with ● these items. In cases of abnormalities or causes which are not listed ● below, please contact your Komatsu distributor for repairs. Problem Main causes Remedy Engine oil pan oil level is low Add oil to specified level, see ●...
Page 218 Change to specified fuel ● • Overheating Refer to "Radiator water levelmon- ● • Abnormal noise generated (com- itor lights up" as above bustion or mechanical) Damage inside muffler Replace muffler ● • Excessive valve clearance Adjust clearance) ● • PW160-7H VEAM390100...
Page 219 Countermeasure Place the machine in a safe posture, then have it Suspension lock system error inspected immediately by your Komatsu distribu- If the pump override switch is set to the ON posi- tion, operation can be carried out. However, TVC valve system error immediately have the PC-EPC valve system inspected by your Komatsu distributor.
Page 220 TROUBLESHOOTING OPERATION PW160-7H VEAM390100...
Page 221: Maintenance
MAINTENANCE WARNING Please read and make sure that you understand the safety volume before reading this section. PW160-7H VEAM390100...
Page 222: Guides To Maintenance
Check the service meter reading every day to see if the time has come for any necessary maintenance to be carried out. Komatsu genuine replacement parts: Use Komatsu genuine parts specified in the Parts Book as replacement parts. Komatsu genuine oils: Use Komatsu genuine oils and grease.
Page 223 When working in rocky areas, check for damage to the undercar- riage and for looseness, flaws, wear and damage in bolts and nuts. Precautions when washing machine: Never spray steam or water directly on the connectors and ● mechatronics parts. PW160-7H VEAM390100...
Page 224 Avoid mixing oils: Never mix oils of different brands. If you have only oil which is a different brand from the one that is used in the machine, do not add it but replace all the oil. PW160-7H VEAM390100...
Page 225: Outline Of Service
MAINTENANCE OUTLINE OF SERVICE OUTLINE OF SERVICE Use Komatsu genuine parts for replacement. ● When changing or adding oil, do not use a different type of oil. ● Unless otherwise specified, the oil and coolant used at the ● time of shipment from the factory are as shown in the table below.
Page 226 We recommend you to have an analysis made of the oil peri- ● odically to check the condition of the machine. For those who wish to use this service, please contact your Komatsu distrib- utor. FUEL The fuel pump is a precision instrument, and if fuel containing ●...
Page 227 Be particularly careful to wipe off the old grease in places where sand or dirt sticking in the grease would cause wear of the rotating parts. CARRYING OUT KOWA (Komatsu Oil Wear Analy- sis) KOWA is a maintenance service that makes it possible to prevent machine failures and down-time.
Page 228: Outline Of Electric System
Do not carry out sampling on rainy or windy days when ❍ water or dust can get into the oil. For further details of KOWA, please contact your Komatsu distrib- utor. STORING OIL AND FUEL Keep indoors to prevent ingress of water, dirt, or other impuri- ●...
Page 229: Outline Of Hydraulic System
● installed in the machine. Never install any electric components other than these speci- ● fied by Komatsu. Be careful to keep the electric system free of water when ● washing the machine or when it rains. Since the controller for the control system may cause mal- ●...
Page 230 OUTLINE OF SERVICE MAINTENANCE ● The accumulators are charged with high-pressure nitrogen gas. Incorrect handling may be dangerous. For the handling procedure, see "HANDLING ACCUMU- LATORS (144)" PW160-7H VEAM390100...
Page 231: Wear Parts List
The wear parts should be changed correctly in order to use the machine economically. For part change, Komatsu genuine parts of excellent quality should be used. When ordering parts, please check the part number in the parts book.
Page 232: Use Fuel, Coolant And Lubricants According To Ambient Temperature
40° C 20W-40 Rear 2.0 litre REMARK We recommend Komatsu genuine oil which has been specifi- ● cally formulated and approved for use in engine and hydraulic work equipment applications. Only use high quality oils which meet internationally recog- ●...
Page 233 ● grade oil (SAE10W-30, 15W-40), but be sure to add single grade oil that matches the temperature in the table. We recommend Komatsu genuine oil which has been specifi- ● cally formulated and approved for use in engine and hydraulic SPECTRUM XXX work equipment applications.
Page 234: Use Fuel, Coolant And Lubricants According To Ambient Temperature Cont
Essolube D3 *Essolube XD-3 EXXON *Essolube XD-3 Gear oil GP Beacon EP2 (ESSO) Extra Gear oil GX *Esso heavy duty Exxon heavy duty Super duty motor Gulfcrown EP2 Multi-purpose gear GULF Gulfcrown EP lubricant *Super duty plus special PW160-7H VEAM390100...
Page 235 Total Fina Elf TOTAL Total transmission Multis EP2 *Rubia X Glacelf CHP Supra UNION *Guardol MP gear lube LS Unoba EP *Turbostar Multigear VEEDOL *Diesel star Multigear B Multigear C BP Tractran 8 Fuchs Titan Hydra Fuchs 20W-40 PW160-7H VEAM390100...
Page 236: Standard Tightening Torques For Bolts And Nuts
07950-10450 For greasing work Nozzle 07951-41017 Grease cartridge 07950-90403 (Lithium base grease: 400 g) Pinch bar 09055-10390 Socket 20E-98-K1110 33 mm drive socket If any of the above tools are broken, please order them from your Komatsu distributor. PW160-7H VEAM390100...
Page 237: Tightening Torque Specifications
The tightening torque is determined by the width across the flats of the nut and bolt. If it is necessary to replace any nut or bolt, use a Komatsu genu- ine part of the same size as the part that was replaced...
Page 238: Periodic Replacement Of Safety Critical Parts
When replacing the hoses, always replace the O-rings, gaskets, and other such parts at the same time. Ask your Komatsu distributor to replace the safety critical parts. Interval Check items...
Page 239: Safety Critical Parts
Additional attachment line hose (Boom top section) Swing line hose (Swing motor inlet) Main suction hose Heater hose Travel line hose (Control valve - Swivel joint) Travel line hose (Swivel joint - Travel motor) Seat belt Every 3 years PW160-7H VEAM390100...
Page 240: Maintenance Schedule Chart
"CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL" "CHECK AIR CLEANER FOR CLOGGING" "CHECK ELECTRIC WIRING" "CHECK FOR WATER AND SEDIMENT IN SEDIMENTOR. DRAIN WATER AND SEDIMENT" EVERY 50 HOURS SERVICE "DRAIN WATER AND SEDIMENT FROM FUEL TANK" PW160-7H VEAM390100...
Page 241 "Axle pads (If noise heard grease as necessary) (2 points)" ● "Cylinder mount (2 points)" ● "Top link blade pivot pin (2 points)" ● ● "Lower link blade pivot (2 points)" "Dozer blade cylinder rod end (2 points)" ● "Lower link pivot pin (2 points)" ● PW160-7H VEAM390100...
Page 242 "CHECK & ADJUST VALVE CLEARANCE" "CHECK FAN BELT TENSIONER BEARING BELT AND FAN HUB" "CHECK FAN BELT TENSION AND REPLACE FAN BELT" "CHANGE OIL IN AXLES" "CHANGE OIL IN HUBS" "CHANGE OIL IN TRANSMISSION ASSEMBLY" "CHANGE OIL IN DAMPER" PW160-7H VEAM390100...
Page 243 “ C H A N G E O I L I N H Y D R A U L I C TA N K A N D REPLACE STEER/BRAKE CIRCUIT STRAINER” on page 302. The oil change interval is reduced when a breaker is used, see “WHEN USING BREAKER” on page 322. PW160-7H VEAM390100...
Page 244: Key To Lubrication Points
28. Fuel filters change filter 9. Steer links grease 29. Hydraulic oil change filter 10. Axle pads grease 30. Hydraulic filter element change filter check level 11. Axle pivot grease 31. Damper case change oil 12.Rear propshaft grease PW160-7H VEAM390100...
Page 245 MAINTENANCE MAINTENANCE SCHEDULE CHART Interval of service Change filter Lubrication by greasing (G) Amount of oil required at change (litres) Check oil level/change (EO) PW160-7H VEAM390100...
Page 246: Service Procedure
For details, see "CHECK ENGINE VALVE CLEARANCE, ADJUST (246)" For details of the method of replacing or maintaining, see the section on EVERY 500 HOURS and 2000 HOURS SER- VICE. CHANGE OIL IN TRANSMISSION, HUBS + AXLES. ● PW160-7H VEAM390100...
Page 247: When Required
In addition, during the cleaning operation, more dirt stuck to the element will fall inside the inner element. PW160-7H VEAM390100...
Page 248 2. Wipe off or brush off the dirt stuck to cover (6) and the inside of the air cleaner body. Air cleaner body Cover PW160-7H VEAM390100...
Page 249 NOTICE When cleaning the element, do not hit or beat it against ● anything. Do not use an element whose folds or gasket or seal are ● damaged. PW160-7H VEAM390100...
Page 250 Install cover (6) so that the evacuator is facing the ❍ ground. When cover (6) is installed, check that the clearance ❍ between the air cleaner body and cover (6) is not too large. If it is too large, install again. Evacuator valve PW160-7H VEAM390100...
Page 251 The inner element must not be cleaned and used again. When replacing the outer element, replace the inner element at the same time. 5. Set the outer element in position, then lock cover (6) with hooks (2). Evacuator valve PW160-7H VEAM390100...
Page 252: Clean Inside Of Cooling System
The system operates successfully with a water/antifreeze mixture or inhibited/conditioned water as the coolant. Water alone allows rust, scale deposits, and corrosion to occur within the system. Every 2000 hours, the cooling system should be drained, flushed, and refilled as described in this section. PW160-7H VEAM390100...
Page 253 30% by volume is necessary. In areas where the water is hard, add Komatsu genuine corrosion resistor agent KI. One packet of corrosion resistor agent contains 100g. The standard density of the mixture should be 7 g/litres.
Page 254 Antifreeze is flammable, so keep it away from any flame. Use city water for the cooling water. ● If river water, well water or other such water supply must be used, contact your Komatsu distributor. We recommend use of an antifreeze density gauge to control ● the mixing proportions.
Page 255: Checking Coolant Level
4. Remove the coolant drain plug located on the bottom of the radiator (1). 5. Allow the system to completely drain into the container. Do not let drain outlets clog up during draining. 6. Fit the radiator drain Plug (1) 7. Replace undercover. PW160-7H VEAM390100...
Page 256 2. Be sure the drain plug is closed. WARNING Use extreme caution when adding coolant to a hot radiator to avoid being burned. Wear gloves and goggles and keep away from the filler neck. 3. Add coolant to the radiator slowly until full. PW160-7H VEAM390100...
Page 257 This can damage the fan blade(s) and cause fan failure. Check the fan for cracks, loose rivets (for metal fans) and bent or loose blades. Make sure it is securely mounted. Tighten the cap screws if loose. Replace damaged fans. PW160-7H VEAM390100...
Page 258: Check And Tighten Wheel Nuts
Tighten the bolts in the order shown in the diagram. Torque to 80kgm. CHECK ELECTRICAL INTAKE AIR HEATER Before the start of the cold season (once a year), contact your Komatsu distributor to have the electrical intake air heater repaired or checked for dirt or disconnections. CHECK ALTERNATOR GENERAL...
Page 259: Replace Bucket Side Cutters
3. Check nuts and bolts and replace if damaged. 4. Fit new side cutters. 5. Tighten bolts to 110 ± 10 kgm. REMARK When side cutters are not being used shrouds should be fit- ted to prevent wear of the bucket side plate. PW160-7H VEAM390100...
Page 260: Replace Bucket Teeth
If lock pins and rubber pin locks with the following defects are used, the teeth may come off the bucket. Replace them with new ones. The lock pin is too short. ● The lock pin is too short 1/3 of A Align with bottom face PW160-7H VEAM390100...
Page 261 (4), do not try to knock the pin in. There is something preventing tooth (1) from entering adapter (4) fully, so remove the obstruction. When tooth (1) enters adapter (4) fully, knock in lock pin (2). PW160-7H VEAM390100...
Page 262 Replace the rubber pin lock and locking pin at the same time as replacing the teeth. This makes it possible to prevent the teeth from falling out. PW160-7H VEAM390100...
Page 263 Use a round bar with a smaller diameter than that of the pin. 3. Clean the mounting face. Fit a new tooth (2) in the adapter, push in pin (1) partially by hand, then lock it with a hammer to install the tooth to the bucket. PW160-7H VEAM390100...
Page 264: Adjust Bucket Clearance
When play a is smaller than one shim, do not carry out any maintenance. 5. Tighten the four bolts (2). If the bolts (2) are too stiff to tighten, pull out pin stopper bolt (5) for easier tightening. PW160-7H VEAM390100...
Page 265: Check Window Washer Fluid Level, Add Fluid
- 20ºC Winter in extremely cold region Pure washer fluid - 30ºC Pure washer fluid comes in two types: for -10ºC (for general use) and for -30ºC (cold regions). Use pure washer fluid according to operation area and season. PW160-7H VEAM390100...
Page 266: Check And Adjust Air Conditioner
Every 250 hours Blower motor and fan Function (Check for abnormal sound) When required Control mechanism Function (Check for normal function) When required Installation condition looseness of tightening Piping for connection When required connection portions gas leakage, damage PW160-7H VEAM390100...
Page 267: Check Before Starting
(1) to the FULL level. FULL 2. After adding water, tighten the cap securely. 3. If the reserve becomes empty, first inspect for water leaks and then fill the radiator and the reserve tank with water. PW160-7H VEAM390100...
Page 268: Check Oil Level In Engine Oil Pan, Add Oil
6. If the oil level is correct, tighten the oil filler cap securely and close the engine hood. REMARK Ensure that the machine is level when checking oil level. WARNING Allow the engine to cool before checking the oil level to avoid burns by touching hot engine parts. PW160-7H VEAM390100...
Page 269: Check Fuel Level, Add Fuel
ATURE (232)" After adding fuel, tighten the cap securely. REMARK If breather hole (1) on the cap is clogged, the pressure in the tank will drop and fuel will not flow. Clean the holes from time to time. PW160-7H VEAM390100...
Page 270: Check Oil Level In Hydraulic Tank, Add Oil
1. Confirm that the air cleaner clogging monitor does not light up (H). 2. If it lights up, immediately clean or replace the element. For details of the method of cleaning the element, see "CLEAN INSIDE OF COOLING SYSTEM (253)" PW160-7H VEAM390100...
Page 271: Check Electric Wiring
Starting motor ● Alternator ● Please contact your Komatsu distributor for investigation and cor- rection of the cause. CHECK FOR WATER AND SEDIMENT IN SEDIMEN- TOR. DRAIN WATER AND SEDIMENT 1. Open the cover at the rear right of the machine.
Page 272: Every 50 Hours
When doing this, be careful not to get fuel on your- self. 4. When only clean fuel comes out, close drain valve (1). REMARK Never use trichlene for washing the inside of the tank. PW160-7H VEAM390100...
Page 273: Every 100 Hours Service
2. Using a grease pump, pump in grease through the grease fit- tings shown by arrows. 3. After greasing, wipe off any old grease that was pushed out. PW160-7H VEAM390100...
Page 274 7. Boom adjust cylinder rod end (1 points). 8. 1st to 2nd boom pin (3 points). 9. Boom foot pin (2 points). 10. Boom adjust cylinder foot pin (1 point). 11. Boom cylinder foot pin (2 points). 12. Lubricate swing circle (2 points). PW160-7H VEAM390100...
Page 275 17. Outrigger cylinder rod end (2 or 4 points). 18. Outrigger leg pivot (2 or 4 points). 19. Outrigger foot pivot (2 or 4 points). 20. Propshaft (3 points). 21. Not used 22. Axle pivot (2 point) (with outriggers attached) PW160-7H VEAM390100...
Page 276 SERVICE PROCEDURE MAINTENANCE 23. Axle pivot (2 point) (without outriggers) 24. Hub pivot (4 points) 25. Steer links (4 points) PW160-7H VEAM390100...
Page 277 31. Lower link pivot pin (2 points) 32. Top link pivot pin (2 points) 33. Cylinder guard pin (remove and apply coating of grease) CLEANING FRESH AIR FILTER 1. Pull up the lock release lever under the door release lever to release the lock. PW160-7H VEAM390100...
Page 278 4. After cleaning, insert the filter in filter case (3) again, open the cover at the bottom left of the operator's cab by hand, return the filter case to its original position, then close the cover. When doing this, check that the lock is applied. PW160-7H VEAM390100...
Page 279: Every 250 Hours Maintenance
5. If the oil level exceeds the H mark on the dipstick, loosen drain plug (P) to drain the excess oil. 6. After checking oil level or adding oil, insert the dipstick into the hole and install oil filler cap. PW160-7H VEAM390100...
Page 280 CHECK OIL LEVEL IN AXLES, ADD OIL Front Axle Rear Axle 1. Ensure axle is horizontal and remove plug (1). 2. If no oil emerges attach tube and funnel and add oil until oil emerges from the hole after removing tube. PW160-7H VEAM390100...
Page 281 2. Remove cap (1), and check that the electrolyte is at the spec- ified level (10 to 12 mm above the plate). If the electrolyte level is low, add distilled water to the specified level. If the battery electrolyte is spilled, have dilute sulphuric acid added. PW160-7H VEAM390100...
Page 282 Proper tension should be 355 to 455 N.m gauge value. If a Gates type gauge is not available, tension may be checked by belt deflection. Press the belt with your finger at the longest span and measure the deflection. Maximum deflection 9.5 to 12.7 mm. PW160-7H VEAM390100...
Page 283 Press the belt at a point midway between the drive pulley and compressor pulley with a finger force of approx. 58.8 N (6 kgf) Compressor pulley and check that the deflection is 5 - 8 mm. 5 - 8mm AD32942A Drive pulley Adjusting 1. Loosen bolts (1) and (2). PW160-7H VEAM390100...
Page 284 V-groove. 7. If the belt has elongated and there is no more allowance for adjustment, or if the belt is cut or cracked, replace the belt. 8. After replacing the V-belt, operate for one hour, then adjust again. PW160-7H VEAM390100...
Page 285: Every 500 Hours Service
● Prepare a filter wrench and a container to catch the fuel. Use a genuine Komatsu filter cartridge. 1. Set the container to catch the fuel under the filter cartridge. 2. Using a filter wrench, turn filter cartridge (1) counterclockwise to remove it.
Page 286 1. Remove bolts (1) (2 bolts) on the top of the revolving frame and remove cover (A). 2. Check the colour of the grease. If it is milky white, it is neces- sary to change the grease. Please contact your Komatsu dis- tributor. The total amount of grease is 10.5 litres.
Page 287 Check that there is no old packing stuck to the filter holder. If there is any old packing remaining, it will cause oil leakage. 6. When installing, bring the packing surface into contact with the seal surface of the filter holder, then tighten it further 3/4 - 1 turn. PW160-7H VEAM390100...
Page 288 Do not direct the jet directly at the core. If the fins are dam- aged, it will cause leakage of water and overheating. On dusty job sites, inspect fins every day, regardless of the maintenance interval. 1. Open engine hood. PW160-7H VEAM390100...
Page 289 REMARK If the filter is clogged, the air flow is reduced and a muffled sound can be heard from the air conditioner unit. PW160-7H VEAM390100...
Page 290 2. Clean the filter with compressed air. If there is oil on the filter, or if the filter is extremely dirty, wash and dry it thoroughly before using it again. If the clogging of the filter cannot be removed by blowing with air or washing with water, replace with new one. PW160-7H VEAM390100...
Page 291 For component part numbers, see “WEAR PARTS LIST” on page 231. CHECK CONDITION OF MAIN VALVE RUBBER MOUNTS If main valve bracket mounting rubbers (1) appear cracked or worn, replace them. If unsure then contact your komatsu distributor for advice. PW160-7H VEAM390100...
Page 292: Every 1000 Hours Service
9. Install the oil filler cap. 10. To bleed the air, start the engine according to "STARTING ENGINE (158)" and run the engine at low idle for 10 minutes. 11. Stop the engine. PW160-7H VEAM390100...
Page 293 9. Close the drain valve and allow excess oil to drain from the drain tube. Stow the hose and reinstall the undercover. CHECK ALL TIGHTENING PARTS OF TURBO- CHARGER. Contact your Komatsu distributor to have the tightening portions checked. PW160-7H VEAM390100...
Page 294 SERVICE PROCEDURE MAINTENANCE CHECK PLAY OF TURBOCHARGER ROTOR. Ask Komatsu distributor to check the play of the turbocharger rotor. CHECK & ADJUST VALVE CLEARANCE As a special tool is required for removing and adjusting the parts contact your Komatsu distributor for service.
Page 295 4. Replace plug (1). REMARK The oil must be replaced after first hundred hours then main- tenance is thousand hours. Rear Axle 1. Remove plugs (1) and (2) to drain oil. 2. Replace plug (2). PW160-7H VEAM390100...
Page 296 6. If no oil emerges, add oil until there is an excess. Allow Rear excess to drain off and re-install plug (1). REMARK The oil must be replaced after first hundred hours then main- tenance is thousand hours. PW160-7H VEAM390100...
Page 297 1. Remove plugs (1)+(2) and allow oil to drain out. 2. Replace plug (2). 3. Add oil (approx. 4.85 l) until oil emerges from plug (1) hole. 4. Replace plug (1). REMARK The oil must be replaced after first hundred hours then main- tenance is thousand hours. PW160-7H VEAM390100...
Page 298 1. Remove plugs (1),(2),(3) and allow oil to drain out. 2. Replace plug (3). 3. Add oil (approx. 0.75 l) in position (1) until oil emerges from plug (2) hole. 4. Replace plug (1) and (2). The oil must be replaced after thousand hours. PW160-7H VEAM390100...
Page 299: Every 2000 Hours Service
Contact your Komatsu distributor for cleaning or inspection. CHECK ALTERNATOR, STARTING MOTOR The brush may be worn, or the bearing may have run out of grease, so contact your Komatsu distributor for inspection or repair. If the engine is started frequently, carry out inspection every 1000 hours.
Page 300 9. Wipe off excess oil that may have leaked out. 10. Start engine and run until the brake accumulator is charged. Switch off engine. 11. Check level of hydraulic oil. Refill if required. 12. Bleed hydraulic system and replace hydraulic tank oil filler cap. 13. Replace undercover. PW160-7H VEAM390100...
Page 301: Every 4000 Hours Service
CHECK WATER PUMP Since the pulley may have play, oil may leak, water may leak and the drain hole (A) may be clogged, contact your Komatsu distribu- tor for inspection, overhaul or replacement. 9JH02451A...
Page 302: Every 5000 Hours Service
When removing drain plug (P), be careful not to get oil on your- self. NOTE: If the machine is equipped with bio oil the oil change interval is reduced to 2,500 hours. If in doubt about the performance of the brand used consult your Komatsu dealer. PW160-7H VEAM390100...
Page 303 NOTICE Be sure to insert seat before inserting plug. REMARK If the pump is operated without filling the pump case with hydraulic oil, abnormal heat will be generated and this may lead to premature damage of the pump. PW160-7H VEAM390100...
Page 304 NOTICE If, at first, the engine is run at high speed or the cylinder is operated to the end of its stroke, the air inside the cylinder may cause damage to the piston packing or other parts. PW160-7H VEAM390100...
Page 305: Specifications
SPECIFICATIONS PW160-7H VEAM390100...
Page 306: Specifications
35 km/h** cation High speed German specification 20 km/h** Swing speed 11.5 rpm ● ENGINE Model Komatsu SAA4D102E-2 diesel engine ● Flywheel horsepower (NET) 87.5 kW (119 PS /2200 rpm) ● Starting motor 24 V 4.5 kW ● ● Alternator...
Page 307: Piece Boom
SPECIFICATIONS SPECIFICATIONS 1 - PIECE BOOM PW160-7H VEAM390100...
Page 308: Piece Boom
SPECIFICATIONS SPECIFICATIONS 2 - PIECE BOOM PW160-7H VEAM390100...
Page 309: Working Range: One Piece Boom
Max. digging height 8,730 8,930 9,285 Max. dumping height 6,335 6,555 6,911 Max. digging depth 4,925 5,320 5,600 Min. swing radius 3,205 3,160 3,180 E’ Max. digging reach GL 8,620 8,885 9,315 Max. digging reach 8,640 9,070 9,485 PW160-7H VEAM390100...
Page 310: Working Range: Two Piece Boom
2500 3000 Max.digging height 9,745 10,118 10,575 Max.dumping height 7,285 7,655 8,117 Max digging depth 4,960 5,465 5,770 Min. swing radius 2,215 2,385 2,590 E’ Max. digging reach GL 8,310 8,745 9,225 Max. digging reach 8,505 8,930 9,410 PW160-7H VEAM390100...
Page 311: Options, Attachments
OPTIONS, ATTACHMENTS WARNING Please read and make sure that you understand the safety volume before reading this section. PW160-7H VEAM390100...
Page 312: General Precautions
When installing attachments not listed in this Operation and Main- tenance Manual, please contact your Komatsu distributor first. If you do not contact Komatsu, we cannot accept any responsibil- ity for any accident or failure. WARNING...
Page 313: Precautions When Installing Attachments
The following operations are particularly dangerous, so never operate the machine in these ways. Going downhill with the work equipment raised ● Traveling across slopes ● INCORRECT CORRECT PW160-7H VEAM390100...
Page 314 If the correct procedure is not followed, Platform this may lead to serious damage or injury, so please con- sult your Komatsu distributor before carrying out instal- lation. If long work equipment is installed, the working range ●...
Page 315: Handling Bucket With Hook
HANDLING BUCKET WITH HOOK CHECKING FOR DAMAGE TO BUCKET WITH HOOK Check that there is no damage to the hook, stopper, or hook mount. If any abnormality is found, please contract your Komatsu distributor. PROHIBITED OPERATIONS The standard work equipment must not be used for lifting loads. If this machine is to be used for lifting loads, it is necessary to install the special bucket with hook.
Page 316: Machines Ready For Attachments
MACHINES READY FOR ATTACHMENTS GENERAL LOCATIONS Clamshell Operation Selector valves to be in position shown for clamshell operation. Selector valve in normal position to bucket cylinder Selector valve turned to clamshell operation. Both valves must be in same position PW160-7H VEAM390100...
Page 317 This is used to operate the attachment. Pedal for two line attachment (with auto deceleration mechanism) The breaker is operated by right control lever button (2) and (31). The breaker is operated with right pedal (1). Right control lever PW160-7H VEAM390100...
Page 318: Handling The Clamshell Bucket
How to install clamshell bucket 1. Clamshell cylinder head (feed) 2. Clamshell cylinder bottom (return) 3. Rotate left 4. Rotate right Ensure valves (A) are open on both sides. Ensure selector is in correct position. PW160-7H VEAM390100...
Page 319 Do not swing the bucket to crush the rock or to cut ❍ through soil. Do not use the bucket for hammering or pulling out piles, ❍ etc. Before leaving the machine, open the bucket and lower it ❍ to the ground. PW160-7H VEAM390100...
Page 320: Operation
The deterioration of the hydraulic oil when using the breaker ● is much faster than for normal operations, so reduce the maintenance interval for the hydraulic oil and element. For details, see "MAINTENANCE SCHEDULE CHART (240)". PW160-7H VEAM390100...
Page 321 Check that the selector valve is in the position for general ● attachments such as crusher, check that working mode is A mode or E mode. For other precautions when handling the attachment, follow ● the instruction manual from the attachment manufacturer and use the attachment correctly. PW160-7H VEAM390100...
Page 322 For details see “CHANGE OIL IN HYDRAULIC TANK AND REP LACE STE ER/BRA KE CIRCUIT STRA INER” on page 302. Breaker return Breaker valve feed PW160-7H VEAM390100...
Page 323: Method For Releasing Pressure In Control Circuit Of Machines Equipped With Accumulator
SPECIFICATIONS Hydraulic specifications Oil flow - Refer to clamshell and breaker manufacturers rec- ● ommendations for oil flow for specific attachment. Main safety valve set pressure ● When using breaker: 24.5+/- 0.5 MPa (250 +/-5 kg/cm²). PW160-7H VEAM390100...
Page 324: Introduction Of Attachments And Extending Machine Service Life
Select the attachment most suited to the machine body. The machine models to which attachments can be ● mounted vary. For selection of attachment and machine model, consult your Komatsu distributor. HYDRAULIC BREAKER MAIN FIELDS OF APPLICATION Crushed rock ●...
Page 325 Do not operate the cylinder to the end of its stroke. ● AL069800A Always leave approx. 5 cm to spare. Using the mount to gather in pieces of rock AL069810A Operations using the swing force PW160-7H VEAM390100...
Page 326 Holding the chisel horizontal or pointed up when carrying out impacting operations Twisting the chisel when it has penetrated the rock AL069850A Pecking operations Extending the bucket cylinder fully and thrusting to raise the machine off the ground PW160-7H VEAM390100...
Page 327: Power Ripper
Do not operate the cylinder to the end of its stroke. ● Always leave approx. 5 cm to spare. Impact operations using attachment Impact operations using swing force Overloading work equipment during lifting and loading operations PW160-7H VEAM390100...
Page 328: Fork Grab
Do not operate the cylinder to the end of its stroke. ● Always leave approx. 5 cm to spare. AM092240A Operations using the swing force AM092250A Operations using one side of work equipment AM092260A PW160-7H VEAM390100...
Page 329: Grapple Bucket
AM092290A any of the following ways. Do not operate the cylinder to the end of its stroke. ● Always leave approx. 5 cm to spare. Operations using the swing force PW160-7H VEAM390100...
Page 330: Scrap Grapple
To ensure that the machine has a long life, and to ensure that operations are carried out in safety, do not operate the machine in any of the following ways. Do not operate the cylinder to the end of its stroke. ● Always leave approx. 5 cm to spare. AM092340A PW160-7H VEAM390100...
Page 331 OPTIONS, ATTACHMENTS INTRODUCTION OF ATTACHMENTS AND EXTENDING MACHINE SERVICE LIFE Operations using the swing force Operations using one side of work equipment AM092360A Catching and dragging with claw end Gouging. PW160-7H VEAM390100...
Page 332: Crusher & Smasher
Do not operate the cylinder to the end of its stroke. ● Always leave approx. 5 cm to spare. AM092390A Operations using cutting tip on one side only AM092400A Impact operation with no load Twisting operations at end of cylinder stroke PW160-7H VEAM390100...
Page 333: Hydraulic Pile Driver
Do not operate the cylinder to the end of its stroke. ● Always leave approx. 5 cm to spare. Forward or swing motion while grasping a pile Lifting more than two piles at the same time PW160-7H VEAM390100...
Page 334: Hydraulic Excavator With Multipurpose Crane
Do not operate the cylinder to the end of its stroke. ● Always leave approx. 5 cm to spare. Abrupt lever operation Traveling with a suspended load PW160-7H VEAM390100...
Page 335 OPTIONS, ATTACHMENTS INTRODUCTION OF ATTACHMENTS AND EXTENDING MACHINE SERVICE LIFE Operating other work equipment during crane operation Excessive lengthening of wire rope. PW160-7H VEAM390100...
Page 336 (option) 2. Horn 8. Clamshell rotate left 3.Power max button 9. Clamshell rotate right 4. Spare 10. Boom and chassis attachment select 5. Safety lock lever 11. Right control lever 6. Second attachment operation pedal (option) PW160-7H VEAM390100...
Page 337 If any of the levers are oper- ated, the engine speed will rise to the speed set by the fuel control dial. PW160-7H VEAM390100...
Page 338 Shafts with vertical walls can be excavated in all directions and soil can be removed from around sheet piles. SIDE DITCHING The direction of the bucket teeth can be altered to facilitate the excavation of parallel sided ditches. PW160-7H VEAM390100...
Page 339 BOX DIGGING Perfect corners can be dug without having to change position of excavators. SCRAPING With bucket reversed the excavator can scrape faces upward. PW160-7H VEAM390100...
Page 340 Fitting of lager bucket will cause machine to tip over. 3. Couple the arm to hole (1), then connect the link to hole (2) 4. After mounting the stop bolt and nut for each pin, apply grease to each pin.c. PW160-7H VEAM390100...
Page 341 The angles available are 45°, 40° and 38°. 45°, 40°, 38° 45° ditch hole ditch hole 40° ditch hole 38° ditch hole 38°, 40° ditch hole Shape of ditch by 45° bucket Shape of ditch 40° bucket PW160-7H VEAM390100...
Page 342 Operate the boom, the arm and the bucket to make the line A of the side-plate of the bucket vertical. To check this position guide plate B is installed beside the bucket pins. Hold this plate horizontal when digging. PW160-7H VEAM390100...
Page 343: Index
EVERY 250 HOURS MAINTENANCE ....279 EVERY 4000 HOURS SERVICE ......301 EVERY 50 HOURS ..........272 OIL ............... 225 EVERY 500 HOURS SERVICE ......285 OPERATION OF WORK EQUIPMENT ....175 EVERY 5000 HOURS SERVICE ......302 OPTIONS, ATTACHMENTS ....... 311 PW160-7H VEAM390100...
Page 344 TOWING ..............37 TRANSPORTATION ..........195 TRAVELLING ON PUBLIC HIGHWAY ....171 TRAVELLING POSTURE ........202 TROUBLESHOOTING ......... 209 UNAUTHORISED MODIFICATION ....... 20 VIBRATION .............. 6 WARNING LAMPS ..........143 WEAR PARTS LIST ..........231 WORKING MODE MONITOR ........ 85 PW160-7H VEAM390100...

Komatsu PW160-7H Operation & Maintenance Manual

Table of Contents

Foreword

Foreword

Safety Information

Introduction

Locations of Plates, Table to Enter Serial No. and Distributor

General Precautions

Precaution During Operation

Precautions for Maintenance

Position for Attaching Safety Labels

Lifting Capacity Chart Pw160-7H

Operation

General View

Explanation of Components

Switches

Control Levers, Pedals

Operation

Operations and Checks before Starting Engine

Check after Stopping Engine

Transportation

Cold Weather Operation

Long-Term Storage

Troubleshooting

Maintenance

Guides to Maintenance

Outline of Service

Wear Parts List

Use Fuel, Coolant and Lubricants According to Ambient Temperature

Use Fuel, Coolant and Lubricants According to Ambient Temperature Cont

Standard Tightening Torques for Bolts and Nuts

Tightening Torque Specifications

Periodic Replacement of Safety Critical Parts

Maintenance Schedule Chart

Service Procedure

Specifications

Specifications

1 Piece Boom

2 Piece Boom

Options, Attachments

General Precautions

Precautions When Installing Attachments

Handling Bucket with Hook

Machines Ready for Attachments

Introduction of Attachments and Extending Machine Service Life

Index

Quick Links

Chapters

Related Manuals for Komatsu PW160-7H

Summary of Contents for Komatsu PW160-7H