Komatsu PC160LC-7KA Manuals

Manuals and User Guides for Komatsu PC160LC-7KA. We have 1 Komatsu PC160LC-7KA manual available for free PDF download: Operation & Maintenance Manual

Komatsu PC160LC-7KA Operation & Maintenance Manual (276 pages)

HYDRAULIC EXCAVATOR

Brand: Komatsu | Category: Excavators | Size: 10.25 MB

Foreword
6
Safety Information
6
Introduction
8
Product Information
9
Machine Serial Number Plate and Its Location
9
Engine Serial Number Plate and Its Location
9
Service Meter Location
10
Machine Serial Plate
11
Table of Contents
12
Safety
19
Safety Information
20
Safety Labels
22
Location of Safety Labels
22
Safety Labels
23
Safety Information
28
Safety Rules
28
If Abnormalities Are Found
28
Working Wear and Personal Protective Items
28
Fire Extinguisher and First Aid Kit
28
Safety Equipment
28
Keep Machine Clean
29
Keep Operator's Compartment Clean
29
Leaving Operator's Seat with Lock
29
Handrails and Steps
30
Mounting and Dismounting
30
No Persons on Attachments
30
Burn Prevention
31
Fire Prevention and Explosion Prevention
31
Action if Fire Occurs
32
Windshield Washer Fluid
32
Falling Objects, Flying Objects and Intruding Objects Prevention
32
Attachment Installation
32
Attachment Combinations
32
Cab Widow Glasses
33
Unauthorized Modifications
33
Safety at Jobsite
33
Working on Loose Ground
33
Distance to High Voltage Cables
34
Ensure Good Visibility
34
Ventilation for Enclosed Area
34
Signalman's Signal and Signs
34
Emergency Exit from Operator's Cab
35
Asbestos Dust Hazard Prevention
35
Safety Machine Operation
36
Starting Engine
36
Checks before Starting Engine
36
Safety Rules for Starting Engine
36
Starting Engine in Cold Weather
36
Operation
37
Checks before Operation
37
Safety Rules for Changing Machine Directions
37
Safety Rules for Traveling
38
Traveling on Slopes
39
Operations on Slopes
40
Prohibited Operations
40
Operations on Snow
41
Parking Machine
41
Transportation
43
Shipping the Machine
43
Battery
44
Battery Hazard Prevention
44
Starting Engine with Booster Cables
45
Towing
46
Safety Rules for Towing
46
Lifting Objects with Bucket
47
Safety Rules for Lifting Objects
47
Safety Maintenance Information
48
Warning Tag
48
Keep Work Place Clean and Tidy
48
Appoint Leader When Working with Others
48
Stop Engine before Carrying out Maintenance
49
Two Workers for Maintenance When Engine Is Running
49
Proper Tools
50
Accumulator
50
Personnel
50
Attachments
50
Work under the Machine
51
Noise
51
When Using Hammer
51
Welding Works
51
Removing Battery Terminals
51
Safety First When Using High-Pressure Grease to Adjust Track Tension
52
Do Not Disassemble Recoil Springs
52
Safety Rules for High-Pressure Oil
52
Safety Handling High-Pressure Hoses
53
Waste Materials
53
Air Conditioner Maintenance
53
Compressed Air
53
Periodic Replacement of Safety Critical Parts
53
Operation
56
Machine View Illustrations
56
Overall Machine View
56
Controls and Gauges
57
Detailed Controls and Gauges
58
Monitoring System
58
Basic Operation of Machine Monitor
59
Basic Check Monitors
61
Caution Monitors
63
Emergency Monitors
65
Meter Display Portion
67
Monitor Switches Portion
71
Switches
81
Control Levers and Pedals
85
Sun Roof
88
Windshield
88
Emergency Exit from Operator's Cab
93
Door Lock
93
Cap with Lock
94
Hot and Cool Box
95
Magazine Box
95
Ashtray
95
Air Conditioner Controls
96
Air Conditioner Control Panel
96
Method of Operation
101
Use Air Conditioner with Care
106
Air Conditioner Maintenance
106
Other Functions
107
Radio
109
Control Panel
109
Controls of Radio
112
Use Radio with Care
113
Auxiliary Electric Power
114
Power Source
114
Fuse
114
Fusiblelink
115
Controllers
116
Tool Box
116
Grease Gun Holder
116
Accumulator
117
Releasing Hydraulic Pressure with Accumulator
117
Machine Operations and Controls
118
Before Starting Engine
118
Walk-Around Checks
118
Checks before Starting
119
Adjustment
125
Seat Belt
127
Operations before Starting Engine
128
Starting Engine
131
Normal Starting
131
Starting Engine in Cold Weather
132
After Starting Engine
135
Breaking-In the New Machine
135
Warming-Up Operation
135
In Cold Weather Areas
138
Stopping the Engine
142
Check after Shut off Engine
142
Machine Operation
143
Preparations for Moving the Machine off
143
Moving Machine Forward
144
Moving Machine Backward
145
Stopping Machine
146
Steering the Machine
147
Steering
147
Swinging
149
Work Equipment Controls and Operations
150
Working Mode
151
Prohibited Operations
152
General Operation Information
154
Traveling on Slopes
155
Escape from Mud
157
Stuck One Side of Track
157
Stuck both Sides of Tracks
157
Recommended Applications
158
Backhoe Work
158
Shovel Work
158
Ditching Work
158
Loading Work
159
Bucket Replacement and Inversion
159
Replacement
159
Inversion
160
Parking Machine
161
Machine Inspection after Daily Work
163
Locking
163
Transportation
164
Transportation Procedure
164
Loading and Unloading with Trailer
164
Loading
165
Securing Machine
167
Unloading
168
Lifting Machine
171
Cold Weather Operation
172
Cold Weather Operation Information
172
Fuel and Lubricants
172
Cooling System Coolant
172
Battery
173
After Daily Work Completion
174
After Cold Weather Season
174
Long Term Storage
175
Before Storage
175
During Storage
175
After Storage
175
Starting Machine after Long-Term Storage
175
Troubles and Actions
176
Running out of Fuel
176
Phenomena that Are Not Failures
176
Towing the Machine
177
Lightweight Towing Hole
177
Severe Job Condition
177
Discharged Battery
178
Battery Removal and Installation
178
Battery Charges
179
Starting Engine with Booster Cables
179
Other Trouble
181
Electrical System
181
Chassis
182
Engine
183
Electronic Control System
185
Point of Contact to Telephone When Error Occurs
186
Maintenance
187
Maintenance Information
188
Lubricants, Coolant and Filters
190
Handling Oil, Fuel, Coolant, and Performing Oil Clinic
190
Oil
190
Fuel
190
Cooling System Coolant
190
Grease
191
Carrying out KOWA (Komatsu Oil Wear Analysis)
191
Oil and Fuel Storage
192
Filters
192
Electric System Maintenance
192
Wear Parts
193
Wear Parts List
193
Lubricants, Fuel and Coolant Specifications
194
Proper Selection
194
Tightening Torque Specifications
198
Tightening Torque List
198
Safety Critical Parts
200
Safety Critical Parts List
201
Maintenance Schedule
202
Maintenance Schedule Chart
202
Maintenance Interval for Hydraulic Breaker
203
Use of Bio-Degradeable Oil
203
Filter Changes
203
Oil Changes
203
Maintenance Procedure
204
Initial 250 Hours Maintenance (Only after the First 250 Hours)
204
Initial 1000 Hours Maintenance (Only after the First 1000 Hours)
204
Replace Fuel Filter Cartridge
204
When Required
205
Check, Clean and Replace Air Cleaner Element
205
Clean Inside of Cooling System
209
Check and Tighten Track Shoe Bolts
211
Check and Adjust Track Tension
211
Check Electrical Intake Air Heater
213
Replace Bucket Teeth (Vertical Pin Type)
213
Replace Bucket Teeth (Horizontal Pin Type)
215
Adjust Bucket Clearance
216
Check Window Washer Fluid Level, Add Fluid
217
Check and Adjust Air Conditioner
218
Check and Adjust Air Conditioner (Only Machines Equipped with Air Conditioner)
218
Wash Washable Floor
219
Washing Washable Floor
219
Bleeding Air from Hydraulic System
222
Method for Releasing Internal Pressure in Hydraulic Circuit
224
Check before Starting
225
Checks before Starting
225
Every 250 Hours Maintenance
226
Check Oil Level in Swing Machinery Case, Add Oil
226
Check Oil Level in Final Drive Case, Add Oil
226
Check Level of Battery Electrolyte
227
Check Air Conditioner Compressor Belt Tension, Adjust
228
Every 500 Hours Maintenance
230
Lubricating
230
Lubricate Swing Circle
231
Lubricate Swing Circle (2 Points)
231
Change Oil in Engine Oil Pan, Replace Engine Oil Filter Cartridge
232
Replace Fuel Filter Cartridge
233
Check Swing Pinion Grease Level, Add Grease
234
Clean and Inspect Radiator Fins, Oil Cooler Fins, Condenser Fins and after Cooler Fins
234
Clean Internal and External Air Filters of Air Conditioner
235
Replace Breather Element in Hydraulic Tank
236
Every 1000 Hours Maintenance
237
Replace Hydraulic Oil Filter Element
237
Change Oil in Swing Machinery Case
238
Check Oil Level in Damper Case, Add Oil
239
Check Fan Belt Tension and Replace Fan Belt
239
Every 2000 Hours Maintenance
240
Change Oil in Final Drive Case
240
Clean Hydraulic Tank Strainer
240
Clean Hydraulic Oil Tank Strainer
240
Check Alternator, Starting Motor
241
Check Engine Valve Clearance, Adjust
241
Every 4000 Hours Maintenance
241
Check Water Pump
241
Every 5000 Hours Maintenance
242
Change Oil in Hydraulic Tank
242
Specifications
243
Attachments and Options
247
Attachments and Options - General Information
248
Safety First
248
Attachment Installation
249
Bucket with Hook
250
Hook Condition
250
Prohibited Operations
250
Machine Ready for Attachment (Deluxe Hcu System)
251
Locations
251
Hydraulic Circuit
254
Switching Hydraulic Circuit
254
Adjusting Oil Flow
254
Switching between Breaker and General Attachment
254
Hydraulic Circuit Connection
255
Oil Flow Path
255
Replace Additional Breaker Filter Element
256
Machine Ready for Attachments
257
(Simple Hcu System)
257
Explanation of Components
257
Stop Valve
257
Selector Valve
258
Attachment Control Pedal
258
Lock Pin
258
Hydraulic Circuit
258
Switching Hydraulic Circuit
259
Adjusting Oil Flow
259
Switching between Breaker and General Attachment
260
Hydraulic Circuit Connection
261
Path of Oil
261
Attachment Removal and Installation
262
Attachment Removal
262
Attachment Installation
263
Attachment Operations
264
When Using Breaker
264
When Using General Attachment such as Crusher
265
Long Term Storage
265
Specifications
265
Attachment Guide
266
Other Attachments
266
Attachment Combinations
268
Track Shoes Selection
269
Bucket Teeth Selection
270
Teeth Selection
270
Selection Guide for Horizontal or Vertical Pin Type Tooth
270
Recommended Attachment Operations
271
Hydraulic Breaker
271

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