Komatsu PC160LC-7K PC180LC-7K Hydraulic Excavator Official Operation & Maintenance Manual
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This is the COMPLETE Official Manual Operation & Maintenancen for the Komatsu Hydraulic Excavator .
This PDF file is Bookmarked and SEARCHABLE to make what you need easy to find.
rules for the operation and maintenance of machines.
Read, understand and follow all precautions and warnings in this manual and on the machine before performing
operation and maintenance. Failure to do so may result in serious injury or death.
Models And Serials :
PC160LC-7K - K40001 and up
PC180LC-7K - K40001 and up
CONTENTS :
FOREWORD
FOREWORD.....................................................................................1-2
SAFETY INFORMATION..................................................................1-3
NOISE(PC160LC/PC180LC-7K).......................................................1-5
VIBRATION.......................................................................................1-5
INTRODUCTION...............................................................................1-6
DIRECTIONS OF MACHINE ........................................................... 1-6
PRODUCT INFORMATION ............................................................. 1-7
MACHINE SERIAL NUMBER PLATE AND ITS LOCATION ............1-7
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION................1-7
SERVICE METER LOCATION ..........................................................1-8
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR .....................1-8
MACHINE SERIAL PLATE ................................................................1-9
SAFETY
SAFETY INFORMATION.................................................................2-2
SAFETY LABELS........................................................................... 2-4
LOCATION OF SAFETY LABELS ..................................................2-4
SAFETY LABELS .......................................................................... 2-5
SAFETY INFORMATION................................................................2-10
SAFETY MACHINE OPERATION .................................................2-18
STARTING ENGINE ......................................................................2-18
OPERATION...................................................................................2-19
TRANSPORTATION.......................................................................2-25
BATTERY .......................................................................................2-26
TOWING ........................................................................................2-28
LIFTING OBJECTS WITH BUCKET...............................................2-29
SAFETY MAINTENANCE INFORMATION ...................................2-30
OPERATION
MACHINE VIEW ILLUSTRATIONS ...............................................3-2
OVERALL MACHINE VIEW.............................................................3-2
GENERAL VIEW CONTROLS AND GAUGES............................... 3-3
DETAILED CONTROLS AND GAUGES........................................ 3-4
MONITORING SYSTEM................................................................. 3-4
Basic Operation Of Machine Monitor.............................................. 3-5
Basic Check Monitors ......................................................................3-7
Caution Monitors..............................................................................3-9
Emergency Monitors........................................................................3-11
Meter Display Portion .................................................................... 3-13
Monitor Switches Portion.................................................................3-17
STARTING SWITCH ...................................................................... 3-27
CONTROL LEVERS, PEDALS........................................................3-31
SAFETY LOCK LEVER ...................................................................3-31
SUN ROOF.......................................................................................3-34
WINDSHIELD ................................................................................. 3-34
EMERGENCY EXIT FROM OPERATOR'S CAB .............................3-39
DOOR LOCK ....................................................................................3-39
CAP WITH LOCK..............................................................................3-40
HOT AND COOL BOX.......................................................................3-41
MAGAZINE BOX...............................................................................3-41
ASHTRAY .........................................................................................3-41
AIR CONDITIONER CONTROLS......................................................3-42
Air Conditioner Control Panel ...........................................................3-42
Method Of Operation ........................................................................3-47
Use Air Conditioner With Care..........................................................3-52
Air Conditioner Maintenance ............................................................3-52
Other Functions ................................................................................3-53
CAB RADIO...................................................................................... 3-54
ANTENNA......................................................................................... 3-54
AUXILIARY ELECTRIC POWER.......................................................3-54
24 V power source.............................................................................3-54
12 V power source............................................................................ 3-55
FUSE .................................................................................................3-55
FUSE CAPACITIES AND CIRCUIT NAMES..................................... 3-56
FUSIBLELINK....................................................................................3-56
CONTROLLERS............................................................................... 3-57
TOOL BOX.........................................................................................3-57
GREASE GUN HOLDER....................................................................3-57
REFUELLING PUMP..........................................................................3-58
ACCUMULATOR ...............................................................................3-59
Releasing Hydraulic Pressure With Accumulator ............................. 3-59
MACHINE OPERATIONS AND CONTROLS.................................... 3-60
BEFORE STARTING ENGINE ......................................................... 3-60
Walk-Around Checks .........................................................................3-60
Checks Before Starting...................................................................... 3-61
Adjustment.........................................................................................3-67
Seat Belt ............................................................................................3-69
Operations Before Starting Engine.....................................................3-70
STARTING ENGINE......................................................................... .3-73
Normal Starting..................................................................................3-73
Starting Engine In Cold Weather .......................................................3-74
AFTER STARTING ENGINE ............................................................ 3-77
Breaking-In The New Machine ..........................................................3-77
Warming-Up Operation..................................................................... 3-77
In Cold Weather Areas ..................................................................... 3-80
STOPPING THE ENGINE ................................................................ 3-84
CHECK AFTER SHUT OFF ENGINE............................................... 3-84
MACHINE OPERATION .................................................................. 3-85
Preparations For Moving The Machine Off........................................3-85
Moving Machine Forward ................................................................. 3-86
Moving Machine Backward............................................................... 3-87
Stopping Machine ............................................................................ 3-88
STEERING THE MACHINE............................................................. 3-89
Steering .......................................................................................... 3-89
SWINGING .......................................................................................3-91
WORK EQUIPMENT CONTROLS AND OPERATIONS ................ 3-92
WORKING MODE............................................................................3-93
PROHIBITED OPERATIONS ..........................................................3-94
GENERAL OPERATION INFORMATION .......................................3-96
TRAVELING ON SLOPES...............................................................3-97
ESCAPE FROM MUD.....................................................................3-99
Stuck One Side Of Track ................................................................3-99
Stuck Both Sides Of Tracks ............................................................3-99
RECOMMENDED APPLICATIONS................................................3-100
Backhoe Work .............................................................................. 3-100
Shovel Work ................................................................................. 3-100
Ditching Work .................................................................................3-100
Loading Work................................................................................ 3-101
BUCKET REPLACEMENT AND INVERSION ..............................3-102
Replacement..................................................................................3-102
Inversion ........................................................................................3-103
PARKING MACHINE ....................................................................3-105
MACHINE INSPECTION AFTER DAILY WORK ..........................3-106
LOCKING......................................................................................3-106
TRANSPORTATION......................................................................3-107
TRANSPORTATION PROCEDURE .............................................3-107
LOADING AND UNLOADING WITH TRAILER ............................3-107
Loading .........................................................................................3-108
Securing Machine ........................................................................ 3-110
Unloading.......................................................................................3-111
LIFTING MACHINE....................................................................... 3-114
COLD WEATHER OPERATION ...................................................3-115
COLD WEATHER OPERATION INFORMATION......................... 3-115
Fuel And Lubricants ......................................................................3-115
Cooling System Coolant .............................................................. 3-115
Battery ..........................................................................................3-116
AFTER DAILY WORK COMPLETION.......................................... 3-117
AFTER COLD WEATHER SEASON .............................................3-117
LONG TERM STORAGE...............................................................3-118
BEFORE STORAGE......................................................................3-118
DURING STORAGE .....................................................................3-118
AFTER STORAGE...................................................................... 3-118
STARTING MACHINE AFTER LONG-TERM STORAGE ........... 3-118
TROUBLES AND ACTIONS .......................................................3-119
RUNNING OUT OF FUEL ...........................................................3-119
PHENOMENA THAT ARE NOT FAILURES................................ 3-119
TOWING THE MACHINE ........................................................... 3-120
LIGHTWEIGHT TOWING HOLE ............................................... 3-120
SEVERE JOB CONDITION ....................................................... 3-120
DISCHARGED BATTERY........................................................... 3-121
Battery Removal And Installation................................................. 3-121
Battery Charges........................................................................... 3-122
Starting Engine With Booster Cables ........................................ 3-122
OTHER TROUBLE .................................................................... 3-124
Electrical System ........................................................................ 3-124
Chassis........................................................................................ 3-125
Engine......................................................................................... 3-126
Electronic Control System ...........................................................3-128
Point Of Contact To Telephone When Error Occurs ......................3-129
MAINTENANCE
MAINTENANCE INFORMATION .....................................................4-2
LUBRICANTS, COOLANT AND FILTERS ..................................... 4-4
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC 4-4
Oil .....................................................................................................4-4
Fuel...................................................................................................4-4
Cooling System Coolant ...................................................................4-4
Grease..............................................................................................4-5
Carrying out KOWA (Komatsu Oil Wear Analysis) ..........................4-5
Oil And Fuel Storage ....................................................................... 4-6
Filters............................................................................................... 4-6
ELECTRIC SYSTEM MAINTENANCE .............................................4-6
WEAR PARTS.................................................................................. 4-7
WEAR PARTS LIST.......................................................................... 4-7
LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS.............4-8
PROPER SELECTION ......................................................................4-8
TIGHTENING TORQUE SPECIFICATIONS ..................................4-12
TIGHTENING TORQUE LIST...........................................................4-12
SAFETY CRITICAL PARTS ...........................................................4-13
SAFETY CRITICAL PARTS LIST ................................................ 4-14
MAINTENANCE SCHEDULE .......................................................4-15
MAINTENANCE SCHEDULE CHART............................................4-15
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER.......... 4-16
MAINTENANCE PROCEDURE...................................................4-17
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS) ..4-17
INITIAL 1000 HOURS MAINTENANCE (ONLY AFTER THE FIRST 1000 HOURS) ...4-17
WHEN REQUIRED .....................................................................4-18
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT..... 4-18
CLEAN INSIDE OF COOLING SYSTEM ....................................4-22
CHECK AND TIGHTEN TRACK SHOE BOLTS.......................... 4-24
CHECK AND ADJUST TRACK TENSION.................................. 4-24
CHECK ELECTRICAL INTAKE AIR HEATER ........................... 4-26
REPLACE BUCKET TEETH (VERTICAL PIN TYPE) ................ 4-26
REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)............. 4-28
ADJUST BUCKET CLEARANCE ................................................ 4-29
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID ..........4-30
CHECK AND ADJUST AIR CONDITIONER............................... 4-31
WASH WASHABLE FLOOR...................................................... 4-32
BLEEDING AIR FROM HYDRAULIC SYSTEM.......................... 4-35
METHOD FOR RELEASING INTERNAL PRESSURE IN HYDRAULIC CIRCUIT..............4-37
CHECK BEFORE STARTING ...................................................4-38
EVERY 250 HOURS MAINTENANCE.......................................4-39
CHECK OIL LEVEL IN SWING MACHINERY CASE, ADD OIL....4-39
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL ...............4-39
CHECK LEVEL OF BATTERY ELECTROLYTE ........................... 4-40
CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST ..................................... 4-43
EVERY 500 HOURS MAINTENANCE.......................................4-44
LUBRICATING............................................................................4-44
LUBRICATE SWING CIRCLE ....................................................4-45
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE ............... 4-46
REPLACE FUEL FILTER CARTRIDGE ......................................4-47
CHECK SWING PINION GREASE LEVEL, ADD GREASE ........4-48
CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS, CONDENSER FINS AND AFTER COOLER FINS .......................4-48
CLEAN INTERNAL AND EXTERNAL AIR FILTERS OF AIR CONDITIONER................................ 4-49
REPLACE BREATHER ELEMENT IN HYDRAULIC TANK......... 4-50
EVERY 1000 HOURS MAINTENANCE........................................4-51
REPLACE HYDRAULIC OIL FILTER ELEMENT .................... 4-51
CHANGE OIL IN SWING MACHINERY CASE........................... 4-52
CHECK OIL LEVEL IN DAMPER CASE, ADD OIL ................... 4-53
CHECK FAN BELT TENSION AND REPLACE FAN BELT.......... 4-53
EVERY 2000 HOURS MAINTENANCE.......................................4-54
CHANGE OIL IN FINAL DRIVE CASE ........................................4-54
CLEAN HYDRAULIC TANK STRAINER .....................................4-54
CHECK ALTERNATOR, STARTING MOTOR .............................4-55
CHECK ENGINE VALVE CLEARANCE, ADJUST......................4-55
EVERY 4000 HOURS MAINTENENCE.....................................4-56
CHECK WATER PUMP.............................................................4-56
EVERY 5000 HOURS MAINTENANCE.........................................4-57
CHANGE OIL IN HYDRAULIC TANK..........................................4-57
SPECIFICATIONS
SPECIFICATIONS ........................................................................ 5-2
ATTACHMENTS AND OPTIONS
ATTACHMENTS AND OPTIONS - GENERAL INFORAMTION..... 6-2
SAFETY FIRST..................................................................................6-2
ATTACHMENT INSTALLATION......................................................6-3
BUCKET WITH HOOK ...................................................................6-4
HOOK CONDITION .......................................................................6-4
PROHIBITED OPERATIONS ....................................................... 6-4
MACHINES READY FOR ATTACHMENTS ................................. 6-5
EXPLANATION OF COMPONENTS ............................................6-5
(1) STOP VALVE ........................................................................6-5
(2) SELECTOR VALVE ...............................................................6-6
(3) ATTACHMENT CONTROL PEDAL ........................................6-6
(4) LOCK PIN............................................................................. 6-6
HYDRAULIC CIRCUIT...................................................................6-6
SWITCHING HYDRAULIC CIRCUIT.......................................... 6-7
ADJUSTING OIL FLOW ............................................................. 6-7
SWITCHING BETWEEN BREAKER AND GENERAL ATTACHMENT.. 6-8
HYDRAULIC CIRCUIT CONNECTION ........................................... 6-9
PATH OF OIL ................................................................................6-9
ATTACHMENT REMOVAL AND INSTALLATION..........................6-10
Attachment Removal .................................................................... 6-10
OPERATION..................................................................................6-12
....................................................................................................... 6-13
........................................................................................................ 6-13
WHEN USING CRUSHER OR OTHER GENERAL ATTACHMENT.. 6-13
LONG TERM STORAGE.......................................................... 6-13
SPECIFICATIONS ....................................................................6-13
ATTACHMENT GUIDE..............................................................6-14
OTHER ATTACHMENTS ........................................................ 6-14
COMBINATIONS OF WORK EQUIPMENT.............................. 6-16
SELECTION OF TRACK SHOES.............................................. 6-18
ATTACHMENT COMBINATIONS................................................ 6-19
BUCKET TEETH SELECTION .................................................. 6-20
Teeth Selection............................................................................ 6-20
Selection Guide For Horizontal Or Vertical Pin Type Tooth ......... 6-20
RECOMMENDED ATTACHMENT OPERATIONS........................ 6-21
HYDRAULIC BREAKER ...............................................................6-21
