Komatsu PW160-7K Hydraulic Excavator Operation & Maintenance Manual (K40001 and up) - UEAM003203

This manual PDF download describes procedures for operation, handling, lubrication, maintenance, checking, and adjustment for the PW160-7K Komatsu Hydraulic Excavator (S/N: K40001 and up). It will help the operator or anyone realize peak performance through effective, economical and safe machine operation and maintenance.


APPLICABLE MODELS :

Komatsu PW160-7K - S/N: K40001 and up


TABLE OF CONTENTS :

- SAFETY
- OPERATION
- MAINTENANCE
- SPECIFICATIONS
- OPTIONS, ATTACHMENTS


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : UEAM003203
Total Pages : 358


This page sometime can be found use following keyword : service manual, repair manual, workshop manual, technical manual, owner manual, operating manual, maintenance manual, parts manual. Please make sure you read and understand the title of this manual before decided to buy.

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FOREWORD
FOREWORD
SAFETY INFORMATION
SAFETY MESSAGES
Noise emission levels
Vibration levels
Guide to Reduce Vibration Levels on Machine
EMERGENCY STEERING
INTRODUCTION
INTENDED USE
FEATURES
BREAKING IN YOUR NEW MACHINE
LOCATIONS OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR
MACHINE SERIAL NO. PLATE POSITION
ENGINE SERIAL NO. PLATE POSITION
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR
MACHINE SERIAL PLATES
STANDARD SERIAL PLATE
GERMANY SERIAL PLATE
ITALIAN SERIAL PLATE

SAFETY
GENERAL PRECAUTIONS
PRECAUTION DURING OPERATION
BEFORE STARTING ENGINE
OPERATING MACHINE
TRANSPORTATION
BATTERY
TOWING
BUCKET WITH HOOK OR BUCKET LINK WITH LIFTING EYE
GENERAL PRECAUTIONS
PRECAUTIONS FOR LIFTING OPERATION
PRECAUTIONS FOR MAINTENANCE
BEFORE CARRYING OUT MAINTENANCE
DURING MAINTENANCE
POSITION FOR ATTACHING SAFETY LABELS
POSITION FOR ATTACHING SAFETY LABELS
LIFTING CAPACITY CHART PW160-7K
ONE PIECE BOOM Lift capacity tables
TWO PIECE BOOM Lift capacity tables
ROTATING ARM capacity tables
OVERLOAD CAUTION

OPERATION
GENERAL VIEW
GENERAL VIEW OF MACHINE
GENERAL VIEW OF CONTROLS AND GAUGES
EXPLANATION OF COMPONENTS
MACHINE MONITOR
BASIC OPERATION OF MACHINE MONITOR
BASIC CHECK ITEMS
CAUTION ITEMS
EMERGENCY STOP ITEMS
METER DISPLAY PORTION
METERS
MONITOR SWITCHES
SWITCHES
CONTROL LEVERS, PEDALS
FRONT WINDOW
EMERGENCY EXIT FROM OPERATOR'S CAB
DOOR LOCK
CAP, COVER WITH LOCK
METHOD OF OPENING AND CLOSING CAP WITH LOCK (For the fuel tank filler port)
METHOD OF OPENING AND CLOSING COVER WITH LOCK (cover with lock)
FUSE
LUGGAGE TRAY
ASHTRAY
CUP HOLDER
HOT AND COOL BOX
CAB RADIO
PRECAUTION OF USE
POWER PICK-UP PORT
HANDLING AIR CONDITIONER
GENERAL LOCATIONS OF CONTROL PANEL
METHOD OF OPERATION
PRECAUTIONS WHEN USING AIR CONDITIONER
CHECK, MAINTAIN MACHINE EQUIPPED WITH AIR CONDITIONER
OTHER FUNCTIONS
FUSIBLE LINK
CONTROLLER
TOOL BOX (CHASSIS)
REFUELLING PUMP
SAFETY
PROCEDURE
MAINTENANCE
WARNING LAMPS
HANDLING ACCUMULATORS
OPERATION
CHECK BEFORE STARTING ENGINE
WALK-AROUND CHECK
CHECK BEFORE STARTING
ADJUSTMENT OF OPERATOR’S SEAT (AIR SUSPENSION SEAT)
SEAT BELT
ADJUSTMENT OF OPERATOR’S SEAT (MECHANICAL SEAT)
SEAT BELT
OPERATIONS AND CHECKS BEFORE STARTING ENGINE
STARTING ENGINE
NORMAL STARTING
STARTING IN COLD WEATHER
OPERATIONS AND CHECKS AFTER STARTING ENGINE
WARMING UP OPERATION
IN COLD AREAS (AUTOMATIC WARMING-UP OPERATION)
MOVING MACHINE OFF
MOVING MACHINE FORWARD
STEERING
TRAVELLING ON PUBLIC HIGHWAY
STOPPING & PARKING
STOPPING MACHINE (EMERGENCY)
SWINGING (Slewing the upper carriage)
OPERATION OF WORK EQUIPMENT
WORKING MODE SELECTION
PROHIBITIONS FOR OPERATION
PRECAUTIONS FOR OPERATION
PRECAUTIONS WHEN TRAVELLING UP OR DOWN HILLS
HOW TO ESCAPE FROM MUD
WHEN ONE SIDE IS STUCK
WHEN BOTH SIDES ARE STUCK
WORK POSSIBLE USING HYDRAULIC EXCAVATOR
BACKHOE WORK
SHOVEL WORK
DITCHING WORK
LOADING WORK
LEVELLING WORK
REPLACEMENT AND INVERSION OF BUCKET
REPLACEMENT
INVERSION
STOPPING ENGINE
CHECK AFTER FINISHING WORK
CHECK AFTER STOPPING ENGINE
LOCKING
OVERLOAD WARNING DEVICE
HANDLING THE WHEELS
TRANSPORTATION
LOADING, UNLOADING WORK
PRECAUTIONS FOR LOADING
HOW TO LIFT THE MACHINE
PRECAUTIONS FOR TRANSPORTATION
TRAVELLING POSTURE
COLD WEATHER OPERATION
PRECAUTIONS FOR LOW TEMPERATURE
FUEL AND LUBRICANTS
BATTERY
PRECAUTIONS AFTER COMPLETION OF WORK
AFTER COLD WEATHER
LONG-TERM STORAGE
BEFORE STORAGE
DURING STORAGE
AFTER STORAGE
STARTING MACHINE AFTER LONG-TERM STORAGE
TROUBLESHOOTING
PHENOMENA THAT ARE NOT FAILURES
METHOD OF TOWING MACHINE
PRECAUTIONS ON PARTICULAR JOBSITES
DISCHARGED BATTERY
REMOVAL AND INSTALLATION OF BATTERY
BATTERY CHARGES
STARTING ENGINE WITH BOOSTER CABLES
OTHER TROUBLE
ELECTRICAL SYSTEM
CHASSIS
ENGINE
ELECTRONIC CONTROL SYSTEM

MAINTENANCE
GUIDES TO MAINTENANCE
OUTLINE OF SERVICE
OUTLINE OF OIL, FUEL, COOLANT
OIL
FUEL
COOLANT
GREASE
CARRYING OUT KOWA (Komatsu Oil Wear Analysis)
STORING OIL AND FUEL
FILTERS
OUTLINE OF ELECTRIC SYSTEM
OUTLINE OF HYDRAULIC SYSTEM
WEAR PARTS LIST
USE FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE
PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS
USE FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE CONT.
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS
INTRODUCTION OF NECESSARY TOOLS
TIGHTENING TORQUE SPECIFICATIONS
TIGHTENING TORQUE LIST
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS
SAFETY CRITICAL PARTS
MAINTENANCE SCHEDULE CHART
KEY TO LUBRICATION POINTS
SERVICE PROCEDURE
INITIAL 250 HOURS SERVICE
WHEN REQUIRED
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT
CLEAN INSIDE OF COOLING SYSTEM
CLEAN INSIDE OF COOLING SYSTEM
CHECKING COOLANT LEVEL
DRAINING THE SYSTEM
CLEANING THE SYSTEM
FILLING THE SYSTEM
REFILLING AN OVERHEATED SYSTEM
CLEANING THE RADIATOR
THERMOSTAT
FAN
CHECK AND TIGHTEN WHEEL NUTS
CHECK ELECTRICAL INTAKE AIR HEATER
CHECK ALTERNATOR
CHECK START MOTOR
REPLACE BUCKET SIDE CUTTERS
REPLACE BUCKET TEETH
REPLACE BUCKET TEETH (VERTICAL PIN TYPE)
REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)
ADJUST BUCKET CLEARANCE
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID
CHECK AND ADJUST AIR CONDITIONER
CHECK LEVEL OF REFRIGERANT (GAS)
DRAIN ENGINE BREATHER OIL CATCHER
CHECK BEFORE STARTING
CHECK COOLANT LEVEL, ADD WATER
CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL
CHECK FUEL LEVEL, ADD FUEL
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
CHECK FOR WATER IN PRIMARY FUEL FILTER, DRAIN WATER
EVERY 50 HOURS
DRAIN WATER AND SEDIMENT FROM FUEL TANK
EVERY 100 HOURS SERVICE
LUBRICATING
CLEANING FRESH AIR FILTER
EVERY 250 HOURS MAINTENANCE
CHECK OIL LEVEL IN MACHINERY CASE, ADD OIL
CHECK OIL LEVEL IN WHEEL HUBS, ADD OIL (Front Axle)
CHECK OIL LEVEL IN WHEEL HUBS, ADD OIL (Rear Axle)
CHECK OIL LEVEL IN AXLES, ADD OIL
CHECK OIL LEVEL IN TRANSMISSION, ADD OIL
CHECK LEVEL OF BATTERY ELECTROLYTE
BELTS, GENERAL
CHECK FAN BELT TENSION, ADJUST TENSION
CHECK, ADJUST TENSION OF AIR CONDITIONER COMPRESSOR BELT
EVERY 500 HOURS SERVICE
LUBRICATE SWING CIRCLE (2 POINTS)
REPLACE FUEL FILTER CARTRIDGE
CHECK SWING PINION GREASE LEVEL, ADD GREASE
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE
CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS AND CONDENSER FINS
CLEAN INTERNAL AND EXTERNAL AIR FILTERS OF AIR CONDITIONER SYSTEM
CLEANING RECIRCULATED AIR FILTER
REPLACE HYDRAULIC TANK BREATHER ELEMENT
CHECK CONDITION OF MAIN VALVE RUBBER MOUNTS
EVERY 1000 HOURS SERVICE
REPLACE HYDRAULIC FILTER ELEMENT
CHANGE OIL IN SWING MACHINERY CASE.
CHECK ALL TIGHTENING PARTS OF TURBOCHARGER.
CHECK PLAY OF TURBOCHARGER ROTOR.
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
EVERY 2000 HOURS SERVICE
CLEAN HYDRAULIC TANK STRAINER
CLEAN, CHECK TURBOCHARGER
CHECK ALTERNATOR, STARTING MOTOR
CHANGE ANTIFREEZE
CHECK AND ADJUST VALVE CLEARANCE
EVERY 4000 HOURS SERVICE
CHECK WATER PUMP
EVERY 5000 HOURS SERVICE
CHANGE OIL IN HYDRAULIC TANK

SPECIFICATIONS
SPECIFICATIONS
1 - PIECE BOOM
2 - PIECE BOOM
WORKING RANGE: ONE PIECE BOOM
WORKING RANGE: TWO PIECE BOOM
WORKING RANGE: ROTATING ARM

OPTIONS, ATTACHMENTS
GENERAL PRECAUTIONS
PRECAUTIONS RELATED TO SAFETY
PRECAUTIONS WHEN INSTALLING ATTACHMENTS
HANDLING BUCKET WITH HOOK
CHECKING FOR DAMAGE TO BUCKET WITH HOOK
PROHIBITED OPERATIONS
PRECAUTIONS DURING OPERATIONS
MACHINES READY FOR ATTACHMENTS
GENERAL LOCATIONS
HANDLING THE CLAMSHELL BUCKET
How to install clamshell bucket
HOW TO OPERATE
OPERATION
WHEN USING CRUSHER OR OTHER GENERAL ATTACHMENT
WHEN USING BREAKER
METHOD FOR RELEASING PRESSURE IN CONTROL CIRCUIT OF MACHINES EQUIPPED WITH ACCUMULATOR
LONG-TERM STORAGE
SPECIFICATIONS
INTRODUCTION OF ATTACHMENTS AND EXTENDING MACHINE SERVICE LIFE
HYDRAULIC BREAKER
POWER RIPPER
FORK GRAB
GRAPPLE BUCKET
SCRAP GRAPPLE
CRUSHER & SMASHER
HYDRAULIC PILE DRIVER
HYDRAULIC EXCAVATOR WITH MULTIPURPOSE CRANE
GENERAL VIEW OF CONTROLS
LEFT CONTROL LEVER (with auto-deceleration device)
RIGHT CONTROL LEVER (with auto-deceleration device)
UPPER BOOM CONTROL PEDAL
EXCAVATOR’S WORK
REPLACEMENT OF BUCKET
HANDLING THE TRAPEZOIDAL BUCKET (If equipped)
ROTATING ARM
GENERAL LOCATION AND SPECIFICATIONS.
GENERAL VIEW OF CONTROLS
LEFT WORK EQUIPMENT CONTROL LEVER (with auto-deceleration device)
RIGHT WORK EQUIPMENT CONTROL LEVER (with auto-deceleration device)
ARM ROTATION CONTROL
UPPER BOOM CONTROL PEDAL
PEDAL LOCK FOR BOOM ADJUST
TRAVELLING POSTURE
MAINTENANCE
MAINTENANCE REQUIREMENT
EVERY 100 HOURS SERVICE
EVERY 250 HOURS SERVICE
EVERY 500 HOURS SERVICE
EVERY 1000 HOURS SERVICE

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