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.

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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

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