Komatsu PW180-7E0 Hydraulic Excavator Operation & Maintenance Manual (H55051 and up) - VEAM400102

This manual PDF download describes procedures for operation, handling, lubrication, maintenance, checking, and adjustment for the PW180-7E0 Komatsu Hydraulic Excavator (S/N: H55051 and up). It will help the operator or anyone realize peak performance through effective, economical and safe machine operation and maintenance.


APPLICABLE MODELS :

Komatsu PW180-7E0 – S/N: H55051 and up


TABLE OF CONTENTS :

1. Foreword
2. Safety
3. Operation
4. Maintenance
5. Technical Data
6. Attachments, Options
7. Index
8. Notes


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : VEAM400102
Total Pages : 450


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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1. Foreword
1.1 Foreword
1.2 Safety information
1.2.1 Safety messages
1.3 Noise emission levels
1.4 Vibration levels
1.4.1 Guide to reduce vibration levels on machine
1.5 Emergency steering
1.6 Emergency braking
1.7 Introduction
1.7.1 Intended use
1.7.2 Features
1.7.3 Running in your new machine
1.8 Locations of plates, table to enter serial no. and distributor
1.8.1 Machine serial no. plate position
1.8.2 Engine serial no. plate position
1.8.3 Table to enter serial no. and distributor
1.8.4 Machine serial plates
1.9 Contents

2. Safety
2.1 General precautions
Safety rules
Safety features
Clothing and personal protective items
Unauthorised modification
Always apply (raise) safety lock lever when leaving operator’s seat
Always chock the wheels before going under the machine
Mounting and dismounting
Fire prevention for fuel and oil
Precautions when handling at high temperatures
Machines fitted with wheels
Asbestos dust hazard prevention
Crushing or cutting prevention
Fire extinguisher and first aid kit
Protection against falling or flying objects
Precautions for attachments
Precautions for accumulators
Emergency exit
Rotating beacon (option)
Electromagnetic interference
2.2 Precaution during operation
2.2.1 Before starting engine
Safety at worksite
Fire prevention
In operator’s cab
Ventilation for enclosed areas
Precautions for mirrors, windows and lights
2.2.2 Operating machine
When starting the engine
Check direction before starting machine
Check that no one is in the area before swinging or travelling in reverse
Precautions when travelling
Travelling on slopes
Prohibited operations
Do not go close to high-voltage cables
Do not hit work equipment
Ensure good visibility
Operate carefully on snow
Working on loose ground
Do not hit the operator cab (for two piece boom only)
Operations on slopes
Parking the machine
2.2.3 Transportation
Loading and unloading
Shipping
2.2.4 Battery
Battery hazard prevention
Starting with booster cables
2.2.5 Towing
When towing, attach wire to frame
View on transmission
2.2.6 Bucket with hook or bucket link with lifting eye
General precautions
Precautions for lifting operation
2.2.7 Handling of fluids
Handling of used engine oils
Handling of oils
Handling of fluids
2.3 Precautions for maintenance
2.3.1 Before carrying out maintenance
Warning tag
Proper tools
Periodic replacement of safety critical parts
Stop the engine before carrying out inspection and maintenance
Rules to follow when adding fuel or oil
Radiator water level
Use of lighting
2.3.2 During maintenance
Personnel
Attachments
Work under the machine
Keep the machine clean
Precautions with battery
Handling high-pressure hoses
Precautions with high pressure oil
Precautions when carrying out maintenance at high temperature or high pressure
Rotating fan and belt
Waste materials
2.4 Position for attaching safety labels
2.4.1 Position for attaching safety labels
2.5 Lifting capacity chart PW180-7E0
2.5.1 One piece boom - Lift capacity tables for 2.5 metre undercarriage
2.5.2 One piece boom - Lift capacity tables for 2.75 metre undercarriage
2.5.3 Two piece boom - Lift capacity tables for 2.5 metre undercarriage
2.5.4 Two piece boom - Lift capacity tables for 2.75 metre undercarriage
2.6 Overload caution
2.6.1 Monoboom - Overload caution
2.6.2 Two piece boom - Overload caution

3. Operation
3.1 General view
3.1.1 General view of machine
3.1.2 General view of controls and gauges
3.2 Explanation of components
3.2.1 Machine monitor
3.2.2 Basic operation of machine monitor
If there is abnormality when starting engine
If any abnormality occurs during operation
3.3 Basic check items
3.3.1 Caution items
3.3.2 Emergency stop items
3.3.3 Meter display portion
Meters
Monitor switches
Adjustment screens
3.4 Switches
3.5 Control levers, pedals
3.6 Front window
When opening
When closing
Removing front bottom window
3.7 Emergency exit from operator's cab
Ceiling window
Clear rain visor
Pull down sun visor
Door lock
3.8 Cap, cover with lock
3.8.1 Method of opening and closing cap with lock (for the fuel tank filler port)
3.8.2 Method of opening and closing cover with lock (cover with lock)
3.9 Fuse
3.9.1 Fuse box 1
3.9.2 Fuse Box 2
3.10 Luggage tray
3.11 Ashtray
3.12 Cup holder
3.13 Hot and cool box
3.14 Cab radio
3.15 Power pick-up port
3.16 Handling air conditioner
3.16.1 General locations of control panel
3.16.2 Method of operation
Automatic operation
Stopping automatic operation
Manual operation
Stopping manual operation
Operation with cold air to face and warm air to feet
Defroster operation
3.16.3 Precautions when using air conditioner
3.16.4 Check, maintain machine equipped with air conditioner
3.16.5 Other functions
Self-diagnostic function
Switch set temperature display between ˚F and ˚C
3.17 Fusible link
3.18 Controller
3.19 Tool box (chassis)
3.20 Refuelling pump
3.20.1 Safety
3.20.2 Procedure
3.20.3 Maintenance
3.21 Warning lamps
3.22 Handling accumulators
3.22.1 Control circuit accumulator (A)
3.22.2 Clutch control accumulator (B)
3.22.3 Brake circuit accumulators (C) ° 3
3.23 Operation
3.23.1 Check before starting engine
Walk-around check
3.23.2 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 function of horn
Check for water and sediment in water separator, drain water
3.23.3 Adjustment of operator’s seat (air suspension seat)
3.23.4 Rearview mirrors
3.23.5 Seat belt
Fastening and removing seat belt
3.23.6 Adjustment of operator’s seat (mechanical seat)
Seat belt
3.23.7 Operations and checks before starting engine
3.23.8 Starting engine
Starting in cold weather
Operations and checks after starting engine
Warming up operation
In cold areas (automatic warming-up operation)
3.23.9 Moving machine off
Moving machine forward
3.23.10 Steering
3.23.11 Travelling on public highway
3.23.12 Stopping and parking
Stopping machine (emergency)
3.23.13 Swinging (slewing the upper carriage)
3.23.14 Operation of work equipment
Operation of dozer and outriggers
Precautions for using the dozer
3.23.15 Working mode selection
Working mode
One touch power max switch
3.23.16 Prohibitions for operation
3.23.17 Precautions for operation
3.23.18 Recommendations for travelling
3.23.19 Precautions when travelling up or down hills
3.23.20 How to escape from mud
When one side is stuck
When both sides are stuck
3.23.21 Work possible using hydraulic excavator
Backhoe work
Shovel work
Ditching work
Loading work
Levelling work
3.23.22 Replacement and inversion of bucket
Replacement
Inversion
3.23.23 Stopping engine
Check after finishing work
3.23.24 Check after stopping engine
Locking
Handling the wheels
3.24 Transportation
3.24.1 Transportation procedure
3.24.2 Loading, unloading work
3.24.3 Securing machine
3.24.4 Unloading
3.24.5 How to lift the machine
3.24.6 Precautions for transportation
3.24.7 Travelling posture
3.25 Cold weather operation
3.25.1 Precautions for low temperature
Fuel and lubricants
Battery
3.25.2 Precautions after completion of work
3.25.3 After cold weather
3.26 Long-term storage
3.26.1 Before storage
3.26.2 During storage
3.26.3 After storage
3.26.4 Starting machine after long-term storage
3.27 Troubleshooting
3.27.1 Phenomena that are not failures
3.28 Method of towing machine
3.29 Precautions on particular jobsites
3.30 Discharged battery
3.30.1 Removal and installation of battery
3.30.2 Battery charges
3.30.3 Starting engine with booster cables
Connecting and disconnecting booster cables
Booster cable connection
Starting the engine
Booster cable disconnection
3.31 Other trouble
3.31.1 Electrical system
3.31.2 Chassis
3.31.3 Engine
3.31.4 Electronic control system

4. Maintenance
4.1 Guides to maintenance
4.2 Outline of service
4.2.1 Outline of oil, fuel, coolant
Oil
Fuel
Coolant
Grease
Carrying out KOWA (KOMATSU Oil Wear Analysis)
KOWA analysis items
Oil sampling
Storing oil and fuel
Filters
4.2.2 Outline of electric system
4.2.3 Outline of hydraulic system
4.3 Wear parts list
4.4 Use fuel, coolant and lubricants according to ambient temperature
4.4.1 Proper selection of fuel, coolant and lubricants
4.5 Recommended brands, recommended quality for products other than KOMATSU genuine oil
4.6 Standard tightening torques for bolts and nuts
4.6.1 Introduction of necessary tools
4.6.2 Tightening torque specifications
Tightening torque list
4.7 Periodic replacement of safety critical parts
4.7.1 Safety critical parts
4.8 Maintenance schedule chart
4.9 Key to lubrication points
4.10 Maintenance interval for hydraulic breaker
4.11 Maintenance procedure
Check and tighten wheel nuts
Replace fuel pre-filter cartridge
Change oil in transmission, hubs and axles
Replace fuel main filter cartridge
Check, clean and replace air cleaner element
Clean inside of cooling system
Clean inside of cooling system
Checking coolant level
Check the fan
Check and tighten wheel nuts
Check electrical intake air heater
Check alternator
Check start motor
Replace bucket side cutters
Replace bucket teeth
Adjust bucket clearance
Check window washer fluid level, add fluid
Check and adjust air conditioner
Drain engine breather oil catcher
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
Drain water and sediment from fuel tank
Lubricating
Cleaning fresh air filter
Check oil level in swing 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
Replace fuel pre-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
Replace hydraulic filter element
Change oil in swing machinery case
Replace fuel main filter cartridge
Check all tightening points of engine exhaust pipe clamps
Check oil level in damper case, add oil
Check all tightening parts of turbocharger.
Check play of turbocharger rotor.
Check and 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
Clean hydraulic tank strainer
Cleaning the strainer of the brake filter
Checking charge pressure of nitrogen gas in accumulator (for control circuit)
Checking function of accumulator
Method of releasing pressure in hydraulic circuit
Clean, check turbocharger
Check alternator, starting motor
Change antifreeze
Check and adjust valve clearance
Check water pump
Check vibration damper
Replace accumulator (for control circuit)
Check for looseness of high-pressure piping clamp, hardening of rubber
Check for missing fuel spray prevention cap, hardening of rubber
Check operating condition of compressor
Change oil in hydraulic tank and replace steer/brake circuit strainer
Procedure for bleeding air

5. Technical Data
5.1 Specifications
5.1.1 One piece boom
5.1.2 Two piece boom
5.1.3 Working range - One piece boom
5.1.4 Working range - Two piece boom

6. Attachments, Options
6.1 General precautions
6.1.1 Precautions related to safety
6.2 Precautions when installing attachments
6.3 Hydraulic quick coupler piping
6.3.1 Locations
6.3.2 Operation
To release a bucket or attachment
To pick up a new bucket or attachment
6.4 Handling bucket with hook
6.4.1 Checking for damage to bucket with hook
6.4.2 Prohibited operations
6.4.3 Precautions during operations
6.5 Machines ready for attachments
6.5.1 Clamshell operation selector valves
Selector valve in normal position for bucket cylinder operation
6.5.2 Handling the clamshell bucket
How to install clamshell bucket
How to operate
6.5.3 Hydraulic circuit
Switching hydraulic circuit
6.5.4 Operation
When using crusher or other general attachment
When using breaker
6.5.5 Method for releasing pressure in control circuit of machines equipped with accumulator
6.5.6 Long-term storage
6.5.7 Specifications
6.6 Introduction of attachments and extending machine service life
6.6.1 Hydraulic breaker
6.6.2 Power ripper
6.6.3 Fork grab
6.6.4 Grapple bucket
6.6.5 Scrap grapple
6.6.6 Crusher and smasher
6.6.7 Hydraulic pile driver
6.6.8 Hydraulic excavator with multipurpose crane
6.7 Rotating arm
6.7.1 General location and specifications.
6.7.2 Maintenance requirement
Every 100 hours service
Every 250 hours service
Every 500 hours service
Every 1000 hours service
6.7.3 General view of controls
Left control lever (with auto-deceleration device)
Right control lever (with auto-deceleration device)
Upper boom control pedal (two piece boom)
6.7.4 Excavator’s work
6.7.5 Replacement of bucket
Handling the trapezoidal bucket (option)
How to perform excavation

7. Index
7.1 Index

8. Notes

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