Komatsu PW160-7H, Operation & Maintenance Manual

Page 1: ... injury or death Operators and maintenance personnel must read this manual before operating or maintaining this machine This manual should be kept inside the cab for reference and periodically reviewed by all personnel who will come into contact with the machine Operation Maintenance Manual VEAM390100 WARNING ...

Page 2: ......

Page 3: ...PW160 7H VEAM390100 3 FOREWORD ...

Page 4: ...can be hazardous and could result in serious injury or death Operators and maintenance personnel should read this manual thoroughly before beginning operation or main tenance Some actions involved in operation and maintenance of the machine can cause a serious accident if they are not done in a manner described in this manual The procedures and precautions given in this manual apply only to intend...

Page 5: ...e hazard is not avoided These safety messages or labels usually describe pre cautions that must be taken to avoid the hazard Failure to avoid this hazard may also result in serious damage of the machine YELLOW SAFETY TRIANGLE This is used on safety labels for hazards which could result in minor or moderate injury if the hazard is not avoided This word might also be used for a hazard where the only...

Page 6: ...d in the European directive 2000 14 EC VIBRATION The weighted root mean square acceleration value to which the operator s arms are subjected does not exceed 2 5 m s The weighted root mean square acceleration value to which the operator s body is subjected was measured at 0 5m s These results were obtained by accelerometers during trench dig ging This machine is equipped with an operators seat whic...

Page 7: ...steering system raise the front wheels off the ground using the work equipment and with the engine off turn the steering wheel and check movement of the wheels EMERGENCY BRAKING This machine is equipped with an emergency braking system and complies to ISO 3450 In the advent of failure of the source of power for the braking system engine failure whilst travelling the brakes can be actuated from sto...

Page 8: ...ily maintenance and self diagnosis Working mode travel speed are selectable Digging and lifting force can be increased by light touch con trol For details see operation section Adjustable wrist control levers make operations smooth and easy Fresh filtered air conditioner assures comfortable operation Low noise level and smart urban style design and colouring Superb operation performance provided b...

Page 9: ...xcept in cases of emer gency Additionally for the first 20 hours Avoid operating engine for prolonged periods at constant speed including idle Avoid high speed travelling for periods of more than 5 min utes Pay particular attention to oil pressure and temperature indicators check coolant and oil levels frequently during breaking in The precautions given in this manual for operating maintenance and...

Page 10: ...R MACHINE SERIAL NO PLATE POSITION On the front right of the undercarriage ENGINE SERIAL NO PLATE POSITION On the gear case front corner TABLE TO ENTER SERIAL NO AND DISTRIBUTOR Machine serial No Engine Serial No Product Identification Number Manufacturer s name Komatsu Hanomag GmbH Address Hanomagstr 9 30449 Hannover Germany Distributor Address Phone ...

Page 11: ...IBUTOR PW160 7H VEAM390100 11 MACHINE SERIAL PLATES STANDARD SERIAL PLATE Model Serial number Manufacturing year Weight Engine power Max drawbar pull Manufactured by Komatsu Hanomag GmbH Hannover Germany under License from Komatsu Ltd Product Identification Number ...

Page 12: ...LOCATIONS OF PLATES TABLE TO ENTER SERIAL NO AND DISTRIBUTOR FOREWORD 12 PW160 7H VEAM390100 ...

Page 13: ...AND DISTRIBUTOR 10 MACHINE SERIAL PLATES 11 SAFETY 19 GENERAL PRECAUTIONS 20 PRECAUTION DURING OPERATION 27 BEFORE STARTING ENGINE 27 OPERATING MACHINE 28 TRANSPORTATION 35 BATTERY 36 TOWING 37 BUCKET WITH HOOK OR BUCKET LINK WITH LIFTING EYE 38 HANDLING OF FLUIDS 40 PRECAUTIONS FOR MAINTENANCE 42 BEFORE CARRYING OUT MAINTENANCE 42 DURING MAINTENANCE 45 POSITION FOR ATTACHING SAFETY LABELS 48 POSI...

Page 14: ... 126 HANDLING AIR CONDITIONER 127 FUSIBLE LINK 140 CONTROLLER 141 TOOL BOX CHASSIS 141 REFUELLING PUMP 141 WARNING LAMPS 143 HANDLING ACCUMULATORS 144 OPERATION 145 CHECK BEFORE STARTING ENGINE 145 OPERATIONS AND CHECKS BEFORE STARTING ENGINE 156 157 STARTING ENGINE 158 MOVING MACHINE OFF 167 STEERING 170 TRAVELLING ON PUBLIC HIGHWAY 171 STOPPING PARKING 172 SWINGING Slewing the upper carriage 174...

Page 15: ...PERATURE 204 PRECAUTIONS AFTER COMPLETION OF WORK 206 AFTER COLD WEATHER 206 LONG TERM STORAGE 207 BEFORE STORAGE 207 DURING STORAGE 207 AFTER STORAGE 208 STARTING MACHINE AFTER LONG TERM STORAGE 208 TROUBLESHOOTING 209 PHENOMENA THAT ARE NOT FAILURES 209 METHOD OF TOWING MACHINE 210 PRECAUTIONS ON PARTICULAR JOBSITES 210 DISCHARGED BATTERY 211 OTHER TROUBLE 215 MAINTENANCE 221 GUIDES TO MAINTENAN...

Page 16: ...NG COOLANT LEVEL 255 CHECK AND TIGHTEN WHEEL NUTS 258 CHECK ELECTRICAL INTAKE AIR HEATER 258 CHECK ALTERNATOR 258 REPLACE BUCKET SIDE CUTTERS 259 REPLACE BUCKET TEETH 260 ADJUST BUCKET CLEARANCE 264 CHECK WINDOW WASHER FLUID LEVEL ADD FLUID 265 CHECK AND ADJUST AIR CONDITIONER 266 CHECK BEFORE STARTING 267 CHECK COOLANT LEVEL ADD WATER 267 EVERY 50 HOURS 272 EVERY 100 HOURS SERVICE 273 EVERY 250 H...

Page 17: ...15 MACHINES READY FOR ATTACHMENTS 316 GENERAL LOCATIONS 316 HANDLING THE CLAMSHELL BUCKET 318 OPERATION 320 METHOD FOR RELEASING PRESSURE IN CONTROL CIRCUIT OF MACHINES EQUIPPED WITH ACCUMULATOR 323 LONG TERM STORAGE 323 INTRODUCTION OF ATTACHMENTS AND EXTENDING MACHINE SERVICE LIFE 324 HYDRAULIC BREAKER 324 POWER RIPPER 327 FORK GRAB 328 GRAPPLE BUCKET 329 SCRAP GRAPPLE 330 CRUSHER SMASHER 332 HY...

Page 18: ...18 PW160 7H VEAM390100 ...

Page 19: ... VEAM390100 19 SAFETY WARNING Read and follow all safety precautions Failure to do so may result in serious injury or death This safety section also contains precautions for optional equip ment and attachments ...

Page 20: ...us bodily injury or death CLOTHING AND PERSONAL PROTECTIVE ITEMS Avoid loose clothing jewellery and loose long hair They can catch on controls or in moving parts and cause serious injury or death Also do not wear oily clothes because they are flammable Wear a hard hat safety glasses safety shoes mask or gloves when operating or maintaining the machine Always wear safety goggles hard hat and heavy ...

Page 21: ...the operator seat to avoid this always ensure that the left hand arm rest is stowed in the fully up position before operating the safety lock lever When leaving the machine lower the work equipment com pletely to the ground set the safety lock lever to the LOCK position then stop the engine and use the key to lock the machine Always take the key with you WARNING If the control lever is touched by ...

Page 22: ... con tact of hands and feet with the handrails steps or wheels Always remove any oil or mud from the handrails steps and track shoes If they are damaged repair them and tighten any loose bolts If grasping the door handrail when mounting or dismounting or moving on the chassis steps open and lock the door securely in the open position Otherwise the door may move suddenly causing you to lose balance...

Page 23: ...tures and are still under pressure Attempting to remove the cap drain the oil or water or replace the filters may lead to serious burns Always wait for the temperature to go down and follow the specified procedures when carrying out these operations To prevent hot water from spurting out 1 Turn engine off 2 Allow water to cool 3 Slowly loosen cap to relieve pressure before removing To prevent hot ...

Page 24: ...between the work equip ment and cylinders or between the machine and work equip ment If the work equipment is operated the clearance will change and this may lead to serious damage or personal injury FIRE EXTINGUISHER AND FIRST AID KIT Know how to use fire extinguisher if installed Provide a first aid kit at the storage point Know what to do in the event of a fire Be sure you know the phone number...

Page 25: ...ons PRECAUTIONS FOR ATTACHMENTS When installing and using an optional attachment read the instruction manual for the attachment and the information related to attachments in this manual Do not use attachments that are not authorised by Komatsu or your Komatsu distributor Use of unauthorised attachments could create a safety problem and adversely affect the proper operation and useful life of the m...

Page 26: ... means is prevented in an emergency you can get out through the emergency exit rear window Pull the ring at the bottom of the window and remove strip This will allow you to push out glass ROTATING BEACON Option When the machine is operated on or beside a road a rotating beacon is required to avoid a traffic accident Contact your Komatsu distributor to install beacon lamp ELECTROMAGNETIC INTERFEREN...

Page 27: ...te contact each utility and identify their locations Be careful not to sever or cut any of these lines Check the depth and flow of water before operating in water or crossing a river NEVER be in water which is in excess of the permissible water depth Permissible water depth see PRECAUTIONS FOR OPERATION 180 FIRE PREVENTION Thoroughly remove wood chips leaves paper and other flammable things accumu...

Page 28: ... conditions Check also that they light up properly OPERATING MACHINE WHEN STARTING THE ENGINE Walk around for machine again just before mounting it to check for people and objects that might be in the way NEVER start the engine if a warning tag has been attached to the wrist control Before starting the engine sound the horn as an alert Start and operate the machine only while seated Do not allow a...

Page 29: ...ECAUTIONS WHEN TRAVELLING Fold in the work equipment as shown in the diagram and keep it at a height of 40 50 cm from the ground level before starting to travel Before travelling on public roads fully raise dozer blade and outriggers lock the outriggers in position with the safety pin lock the bucket and arm cylinder with isolation valves and insert swing lock pin For details see TRAVELLING ON PUB...

Page 30: ... 20 to 30 cm above the ground In case of emergency quickly lower the bucket to the ground to help the machine stop and prevent it from tipping over Do not turn on slopes or travel across slopes Always go down to a flat place to perform these operations Method of travelling on slopes see RECOMMENDA TIONS FOR TRAVELLING 182 Do not travel up and down on grass fallen leaves and wet steel plates These ...

Page 31: ... shock Always maintain the safe distance given below between the machine and the electric cable The following actions are effective in preventing accidents 1 Wear shoes with rubber or leather soles 2 Use a signalman to give warning if the machine approaches too close to the electric cable If the work equipment should touch the electric cable the operator should not leave the operator s compartment...

Page 32: ... and avoid sudden starting stopping or turning When there has been heavy snow the road shoulder and objects placed beside the road are buried in the snow and cannot be seen so always carry out snow clearing operations carefully WORKING ON LOOSE GROUND Avoid operating your machine too close to the edge of cliffs overhangs and deep ditches If these areas collapse your machine could fall or tip over ...

Page 33: ...quipment are operated Always carry out these operations carefully Do not swing the work equipment from the uphill side to the downhill side when the bucket is loaded This operation is dangerous See the upper diagram on the right If the machine has to be used on a slope pile the soil to make a platform that will keep the machine as horizontal as possi ble See the lower diagram on the right Piled so...

Page 34: ...r the safety lock lever to contact the left hand arm rest on the operator seat To avoid this always ensure that the left hand arm rest is stowed in the fully up position before operating the safety lock lever When leaving the machine lower the work equipment com pletely to the ground raise the safety lock lever to the LOCK position then stop the engine and use the key to lock the machine Always ta...

Page 35: ...e level as one another Be sure the ramp surface is clean and free of grease oil ice and loose materials Remove dirt from the machine wheels NEVER correct your steering on the ramps If necessary drive away from the ramps and climb again Swing the upper structure with extreme care on the trailer to avoid a possible accident caused by body instability After loading block the machine wheels and secure...

Page 36: ... the engine and turn the starting switch to the OFF position Avoid short circuiting the battery terminals through accidental contact with metallic objects such as tools across the termi nals When removing or installing check which is the positive terminal and negative terminal Tighten the battery cap securely Tighten the battery terminals securely Loosened terminals can generate sparks and lead to...

Page 37: ...equip ment being towed Set the towing machine and the towing connection of the equipment being towed in a straight line when connecting it Place pieces of wood between the wire ropes and chassis body to protect them from wear of damage When towing the machine without the engine running or in the advent of loss of hydraulic pressure its is necessary to manually release the park brake as follows Vie...

Page 38: ...chine could cause the machine to tip over or cause the load to fall The lift capacity charts are shown in pages 56 to 68 and are affixed inside the operators cabin Be careful to use the correct lift capacity chart for your machine considering the boom type the arm length and the undercarriage attachments installed Lifting operations should always be conducted on firm flat ground Do not attempt lif...

Page 39: ... lifting hook or lifting eye PRECAUTIONS FOR MACHINE INSTALLATION After carrying out a preliminary inspection of ground condi tions select a flat solid location Confirm that the machine can be safely operated without toppling or rolling PROHIBITED OPERATIONS OTHER THAN MAIN APPLICA TIONS When performing lifting operation never raise or lower a per son NO PERSONS SHALL BE PERMITTED TO ENTER THE WOR...

Page 40: ...performance may result in accident or failure Carry out lifting operation within specified load limit of machine and lifting equipment Never carry out operations which may damage the machine such as overload or over impact load Never drag a load laterally or longitudinally nor retract the arm otherwise a dangerous situation may result NEVER TRAVEL WHILE LIFTING A LOAD Never travel while carrying a...

Page 41: ...LING OF OILS For diesel oils hydraulic oils and oils used in the swing machinery PTO transmission axles and hubs avoid pro longed or frequent contact with skin Refer to manufacturers data sheet for handling and storage precautions HANDLING OF FLUIDS For antifreeze and grease refer to manufacturers data sheet for handling and storage precautions ...

Page 42: ...6 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS Replace the following fire related components periodically Fuel system Fuel hose spilling hose and fuel tube cap Hydraulic system Pump outlet hose Replace these components periodically with new ones regardless of whether or not they appear to be defective These components deteriorate over time Replace or repair any such components if any defect is fo...

Page 43: ...l not to touch any lever by mistake Touch the levers only when they have to be operated The worker carrying out the maintenance should be extremely careful not to touch or get caught in the moving parts RULES TO FOLLOW WHEN ADDING FUEL OR OIL Spilt fuel and oil may cause you to slip so always wipe it up immediately Always tighten the cap of the fuel and oil fillers securely Never use fuel for wash...

Page 44: ...dd water to the radiator stop the engine and allow the engine and radiator to cool down before adding the water Slowly loosen the caps to relieve pressure before removing the caps USE OF LIGHTING When checking fuel oil coolant or battery electrolyte always use lighting with anti explosion specifications If such lighting equipment is not used there is danger of explosion ...

Page 45: ...r to their lowest position before performing service or repairs under the machine Always chock the wheels of the machine securely Never work under the machine if the machine is poorly sup ported KEEP THE MACHINE CLEAN Spilt oil or grease or scattered tools or broken pieces are dangerous because they may cause you to slip or trip Always keep your machine clean and tidy If water gets into the electr...

Page 46: ...ses and thick gloves and use a piece of cardboard or a sheet of wood to check for oil leakage If you are hit by a jet of high pressure oil consult a doctor immediately for medical attention PRECAUTIONS WHEN CARRYING OUT MAINTENANCE AT HIGH TEMPERATURE OR HIGH PRESSURE Immediately after stopping operations the engine cooling water and oil at all parts is at high temperature and under high pressure ...

Page 47: ...t in them If your body or tools touch the fan blades or fan belt they may be cut off or sent flying so never touch any rotating parts WASTE MATERIALS Never dump waste oil in a sewer system rivers etc Always put oil drained from your machine in containers Never drain oil directly on the ground Obey appropriate laws and regulations when disposing of harmful materials such as oil fuel coolant solvent...

Page 48: ...ways keep these labels clean If they are lost or damaged attach them again or replace them with a new label There are other labels in addition to the safety labels listed as fol lows so handle them in the same way Safety labels are available from your Komatsu distributor POSITION FOR ATTACHING SAFETY LABELS 1 2 2 2 2 3 2 4 5 6 7 8 8 9 10 12 13 14 15 15 17 18 11 19 2 5 15 15 ...

Page 49: ...the manuals and labels on the machine Keep this manual in the machine cab near operator If this manual is lost please contact Komatsu distributor for replacement Always raise safety lock lever when leaving operators seat Normal steering can only be operated when the engine is run ning Emergency steering is only to be used when stopping the machine safely Serious injury or death can occur if the ma...

Page 50: ...dling accumulator Explosion hazard Keep away from flame Do not weld or drill Read operation manual before operation 5 Warning for staying clear 20K 00 31280 Keeping out of moving area To prevent SEVERE INJURY or DEATH Do the following before moving the machine or its attachments Sound horn to alert people nearby Be sure no one is on or near machine or in the swing area Rotate cab for full view of ...

Page 51: ... the machine 20K 00 31181 Read operation manual before operation With safety lock lever raised the control levers and pedals are disabled With safety lock lever lowered and control lever lock switch on the machine can travel With safety lock lever lowered and control lever lock switch off work equipment and travel can be operated REMARK In certain conditions it may be possible for the safety lock ...

Page 52: ...ne is on or near machine or in the swing area Rotate cab for full view of travel path if it can be done safely Use spotter if view is obstructed Follow above even if machine equipped with travel alarm and mirrors 9 Falling from upper structure warning This is located on the front of the fuel tank on inside of walkway door top of the counterweight 20E 00 K1110 WARNING falling from upper structure K...

Page 53: ...3 10 Stop engine warning 20E 00 K1310 Do not open cover while engine is running 11 Front window lock warning This is located on the rear win dow 09803 A0481 Always lock window in raised or lowered position 12 High pressure oil warning 20E 00 K1270 ...

Page 54: ...p of the radiator unit 14 20K 00 31360 Read operation manual before operation This is located inside the cab 15 Red reflector 20G 47 K1690 16 20Y 00 K2220 Emergency exit Read operation manual before operation 17 Travel Height UK spec only This is fitted to the top right hand corner of the front window 20E 00 K1720 ...

Page 55: ...0 K1450 20 Do not lift more than the specified load of the machine 21 Warning for machine tipping over 20K 00 31770 Do not slew the machine when the work equipment has been removed or the machine has been supplied without work equipment The machine may tip if the machine slewed when no work equipment is fitted WARNING Failure to follow these safety precautions may lead to a seri ous accident ...

Page 56: ...ucket linkage or cylinder lifting capacities can be increased by their respective weights A Reach from swing center B Bucket hook height C Lifting capacities including bucket 495 kg linkage 120 kg and bucket cylinder 109 kg OF Lifting capacity Rating over front OS Lifting capacity Rating over side MAX Rating at maximum reach ...

Page 57: ...5m 1800 1800 6 0m 1600 1600 3150 2200 4 5m 1550 1350 2000 1400 3100 2150 3 0m 1600 1150 2050 1350 3000 2050 4750 3250 9500 6050 1 5m 1700 1100 1950 1300 2850 1900 4450 2950 0 0m 1750 1150 1900 1250 2750 1800 4250 2750 4400 4400 1 5m 1950 1250 2700 1750 4150 2700 7100 5050 3 0m 2400 1600 2700 1800 4200 2750 7550 5150 3 0m 7 5m 1450 1450 2350 2150 6 0m 1300 1300 1450 1350 2900 2200 4 5m 1200 1100 20...

Page 58: ...m 7 5m 1800 1800 6 0m 1600 1600 3200 2600 4 5m 1550 1550 2000 1700 4100 2550 3 0m 1600 1450 3300 1650 4900 2450 6400 3900 10050 7350 1 5m 1700 1400 4000 1600 5300 2300 7350 3600 0 0m 1950 1400 3950 1550 5400 2200 7550 3400 4400 4400 1 5m 2400 1600 5050 2150 6950 3300 7100 6250 3 0m 3150 1950 3850 2200 5550 3350 7550 6400 3 0m 7 5m 1450 1450 2350 2350 6 0m 1300 1300 1450 1450 2900 2650 4 5m 1200 12...

Page 59: ...5m 1800 1800 6 0m 1600 1600 3200 2950 4 5m 1550 1550 2000 1950 4100 2900 3 0m 1600 1600 3300 1900 4900 2800 6400 4450 10050 8550 1 5m 1700 1600 4150 1850 5300 2650 7350 4100 0 0m 1950 1650 4050 1800 5400 2550 7350 3900 4400 4400 1 5m 2400 1850 5050 2500 6950 3850 7100 7100 3 0m 3150 2250 3850 2550 5550 3900 7550 7500 3 0m 7 5m 1450 1450 2350 2350 6 0m 1300 1300 1450 1450 2900 2800 4 5m 1200 1200 2...

Page 60: ... 1800 1800 6 0m 1600 1600 3200 3200 4 5m 1550 1550 2000 2000 4100 3850 3 0m 1600 1600 3300 2550 4900 3700 6400 5900 10050 10050 1 5m 1700 1700 4150 2500 5300 3550 7350 5550 0 0m 1950 1950 4050 2450 5400 3450 7550 5350 4400 4400 1 5m 2400 2400 5050 3400 6950 5250 7100 7100 3 0m 3150 3050 3850 3400 5550 5300 7550 7550 3 0m 7 5m 1450 1450 2350 2350 6 0m 1300 1300 1450 1450 2900 2900 4 5m 1200 1200 27...

Page 61: ...0 4150 7450 6500 1 5m 2750 2750 4850 4100 6650 6450 6900 6900 3 0m 2900 2900 3200 3200 5050 5050 6550 6550 2 5m 7 5m 1800 1800 6 0m 1600 1600 3200 3200 4 5m 1550 1550 2000 2000 4100 4100 3 0m 1600 1600 3300 3050 4900 4400 6400 6400 10050 10050 1 5m 1700 1700 4150 3000 5300 4250 7350 6750 0 0m 1950 1950 4050 2950 5400 4150 7550 6550 4400 4400 1 5m 2400 2400 5050 4100 6950 6450 7100 7100 3 0m 3150 3...

Page 62: ... cylinder lifting capacities can be increased by their respective weights A Reach from swing center B Bucket hook height C Lifting capacities including bucket 495 kg linkage 120 kg and bucket cylinder 109 kg OF Lifting capacity rating over front OS Lifting capacity Rating over side MAX Rating at maximum reach ...

Page 63: ...0 6 0m 1500 1500 3150 2200 3450 3450 4 5m 1400 1300 1750 1350 3850 2150 4000 3600 3500 3500 3 0m 1400 1150 3150 1300 5000 2050 6450 3350 1 5m 1500 1100 3900 1250 5500 1900 7550 3000 0 0m 1650 1100 3850 1200 5700 1800 8000 2850 4050 4050 1 5m 2000 1250 5400 1750 7550 2750 6900 5300 3 0m 4150 1800 6150 2800 3 0m 7 5m 1400 1400 2050 2050 2850 2850 6 0m 1200 1200 2800 2250 2700 2700 4 5m 1100 1100 250...

Page 64: ...50 3350 6 0m 1500 1500 3150 2300 3450 3450 4 5m 1400 1400 1750 1450 3850 2250 4000 3750 3500 3500 3 0m 1400 1200 3150 1400 5000 2150 6450 3500 1 5m 1500 1150 3900 1350 5500 2000 7550 3200 0 0m 1650 1200 3850 1300 5700 1900 8000 3000 4050 4050 1 5m 2000 1350 5400 1850 7550 2900 6900 5500 3 0m 4150 1900 6150 2950 3 0m 7 5m 1400 1400 2050 2050 2850 2850 6 0m 1200 1200 2800 2400 2700 2700 4 5m 1100 11...

Page 65: ...350 6 0m 1500 1500 3150 2350 3450 3450 4 5m 1400 1400 1750 1450 3850 2300 4000 3800 3500 3500 3 0m 1400 1250 3150 1450 5000 2200 6450 3550 1 5m 1500 1200 3900 1400 5500 2050 7550 3250 0 0m 1650 1200 3850 1350 5700 1950 8000 3050 4050 4050 1 5m 2000 1400 5400 1900 7550 2950 6900 5650 3 0m 4150 1950 6150 3000 3 0m 7 5m 1400 1400 2050 2050 2850 2850 6 0m 1200 1200 2800 2400 2700 2700 4 5m 1100 1100 2...

Page 66: ...0 6 0m 1500 1500 3150 2450 3450 3450 4 5m 1400 1400 1750 1550 3850 2400 4000 4000 3500 3500 3 0m 1400 1350 3150 1500 5000 2300 6450 3700 1 5m 1500 1250 3900 1450 5500 2150 7550 3400 0 0m 1650 1300 3850 1400 5700 2050 8000 3200 4050 4050 1 5m 2000 1450 5400 2000 7550 3150 6900 5950 3 0m 4150 2050 6150 3200 3 0m 7 5m 1400 1400 2050 2050 2850 2850 6 0m 1200 1200 2800 2550 2700 2700 4 5m 1100 1100 250...

Page 67: ...00 1500 5800 2150 8050 3350 1 5m 2600 1700 5300 2150 7400 3300 7400 6200 3 0m 5700 3350 2 5m 7 5m 1750 1750 3350 3350 6 0m 1500 1500 3150 2500 3450 3450 4 5m 1400 1400 1750 1550 3850 2450 4000 4000 3500 3500 3 0m 1400 1350 3150 1550 5000 2350 6450 3750 1 5m 1500 1300 3900 1500 5500 2200 7550 3450 0 0m 1650 1350 3850 1450 5700 2100 8000 3250 4050 4050 1 5m 2000 1500 5400 2050 7550 3200 6900 6050 3 ...

Page 68: ...nside the operators cab shows the loads at which the caution warning is given for various work equipment positions Due to the simple nature of the system the overload warning is given at a lower load than actually allowable see full lift capacity charts If lifting to the full capacity of the machine is required it is neces sary to fit a full overload caution system with work equipment position sen...

Page 69: ...PW160 7H VEAM390100 69 OPERATION WARNING Please read and make sure that you understand the safety volume before reading this section ...

Page 70: ...EW OF MACHINE If directions are indicated in this section they refer to the direc tions shown by in the arrows in the diagram below A FRONT B REAR C RIGHT D LEFT B D C A 1 2 4 3 5 6 7 1 Bucket 5 Boom 2 Bucket cylinder 6 Boom Cylinder 3 Arm 7 Undercarriage 4 Arm cylinder ...

Page 71: ...hter 25 Horn 6 F N R switch 26 Power max 7 Right control lever 27 Spare 8 Starter switch 28 Att control pedal option 9 Fuel control dial 29 Hydraulic adjust boom or att control pedal option 10 Park brake 30 Indicator stalk horn windscreen wiper 11 Work light 31 Steering wheel 12 Swing lock 32 Turn indicator warning lights 13 Spare 33 Hazard warning switch 14 Pump override 34 Full beam indicator 15...

Page 72: ... correctly and safely it is important to understand fully the methods of operating the equipment and the meanings of the displays MACHINE MONITOR A Basic check Items D Meter Display Portion Pilot Display Portion B Caution Items E Monitor Switches C Emergency Stop Items All lights up screen Maintenance interval warning screen Normal operation screen A B C D D D B B D B B D B B D B B C E D D D D D D...

Page 73: ...r error screen After displaying the check before starting screen for 2 sec onds the screen changes to the maintenance interval warn ing screen After displaying the maintenance interval warning screen for 30 seconds the screen returns to the normal screen After displaying the check before starting screen for 2 sec onds the screen changes to the warning screen or error screen Check before starting s...

Page 74: ...ation the normal opera tion screen changes to warning screen 1 or the error screen After displaying warning screen 1 for 2 seconds the screen automatically changes to warning screen 2 with exception of low brake pressure when warning screen 1 remains per manently active Normal operation screen Warning screen 1 Warning screen 2 Error screen ...

Page 75: ...is displays the basic items that must be checked before starting the engine If there is any abnormality the monitor for the location of the abnormality will light up 1 RADIATOR WATER LEVEL MONITOR This monitor 1 warns the operator that there has been a drop in the radiator water level If the radiator water level is low the lamp lights up red so check the water level in the radiator and the sub tan...

Page 76: ...level in the engine oil pan and add oil 3 MAINTENANCE INTERVAL MONITOR This monitor 3 lights up to warn the operator that the set time has passed since the maintenance was last carried out This monitor screen goes out after 30 seconds and returns to the normal operation screen For details of the method of checking the maintenance interval see SERVICE MENU SWITCH 95 If it is desired to change the s...

Page 77: ...hould be observed while the engine is run ning If any abnormality occurs the screen displays the item that needs immediate action If there is an abnormality the monitor for the abnormal location lights up red 1 Charge level monitor 7 Engine oil level low 2 Fuel level monitor 8 Service machine over due 3 Air cleaner clogging monitor 9 Park brake 4 Engine water temperature monitor 10 Swing lock 5 Hy...

Page 78: ...N the lamp will remain lit and will go off once the engine is started REMARK When the engine is started or stopped with the starting switch at the ON position the lamp may light up and the buzzer may sound momentarily but this does not indicate any abnormality 2 FUEL LEVEL MONITOR This monitor 2 lights up to warn the operator that the level in the fuel tank is low If the remaining amount of fuel g...

Page 79: ...PERATURE MONITOR If this monitor 5 lights up white in low temperatures carry out the warming up operation For details see WARMING UP OPERATION 161 6 OVERLOAD CAUTION When lifting This monitor warns that the machine is close to tipping due to the load an audible warning is also given if the warning is given lower the load Refer the lifting capacity chart for safe load 7 ENGINE OIL LEVEL LOW When mo...

Page 80: ...ke is applied this lamp will illuminate 10 SWING LOCK This monitor warns that the machine is travelling at high speed without applying the swing lock switch Turn on the swing lock switch immediately when the machine is travelling at high speed 11 PPC LOCK This monitor warns that the machine is travelling at high speed without applying the PPC lock switch Push the PPC lock switch immediately when t...

Page 81: ...plicable location and carry out the necessary action These are items that should be observed while the engine is run ning If there is an abnormality the monitor for the abnormal loca tion lights up red and the buzzer sounds so carry out action immediately 1 Engine water temperature monitor 3 Engine oil pressure monitor 2 Hydraulic oil temperature monitor 4 Low brake pressure 2 1 3 4 ...

Page 82: ...is monitor 2 warns the operator that the hydraulic oil tempera ture has risen If it lights up red during operations run the engine at low idle or stop the engine and wait until the oil temperature goes down and the monitor changes to green 3 ENGINE OIL PRESSURE MONITOR This monitor 3 lights up red if the engine lubrication oil pressure goes below the normal level If it lights up red stop the engin...

Page 83: ...s is as follows Type of monitor Color when monitor lights up When normal When abnormal At low temperature Radiator water level monitor OFF Red Engine oil level monitor OFF Red Maintenance interval monitor OFF Red Charge monitor OFF Red Fuel level monitor Green Red Air cleaner clogging monitor OFF Red Engine water temperature monitor Green Red White Hydraulic oil temperature monitor Green Red White...

Page 84: ... Service Meter and clock 2 Swing Lock Monitor 11 Travel direction monitor 3 Auto deceleration monitor 12 Undercarriage attachment monitor 4 Working mode monitor 13 Park brake 5 Travel mode monitor 14 Suspension lock 6 One touch power up monitor 15 Control lever lock 7 Engine water temperature gauge 16 Swing position 8 Fuel Gauge 17 Power max monitor 9 Hydraulic oil temperature gauge 12 10 15 9 7 4...

Page 85: ...hes when the swing holding brake cancel switch is turned on REMARK The swing motor is equipped with a disc brake that mechani cally stops the rotation When the swing lock monitor lamp is lit up the brake remains applied 3 AUTO DECELERATION MONITOR This monitor 3 shows if the auto deceleration function has been actuated The monitor display when the auto deceleration switch is oper ated is as follow...

Page 86: ...tion stopped METERS 7 ENGINE WATER TEMPERATURE GAUGE This meter 7 indicates the engine cooling water temperature During normal operations the indicator should be in the black range If the indicator enters the red range during operations the overheat prevention system is actuated The overheat prevention system acts as follows Red range position A Engine water temperature monitor 1 turns red Red ran...

Page 87: ...icator should be in the black range If the indicator enters red range A during operations the hydrau lic oil temperature has gone above 102 C Stop the engine or run it at low idle and wait for the hydraulic oil temperature to go down REMARK When the indicator is in the red range A to B the hydraulic oil temperature is as follows Red range position A More than 102 C Red range position B More than 1...

Page 88: ...es is selected the monitor displays one of the following selections 12 UNDERCARRIAGE ATTACHMENT MONITOR When undercarriage attachment is selected from right control lever switch 3 monitor 12 will be displayed This symbol will remain until undercarriage attachment has been deselected 13 PARK BRAKE This lamp 13 will illuminate when the park brake is switched on and when the cautions indicators or er...

Page 89: ... COMPONENTS PW160 7H VEAM390100 89 15 CONTROL LEVER LOCK This lamp will illuminate when the PPC lock is switched on 16 SWING POSITION This lamp 16 will illuminate when the upper structure is orien tated to straight ahead 15 16 ...

Page 90: ...ck 2 Creep speed 12 Accept key 3 High low speed select 13 Scroll down 4 Control lever lock 14 Scroll up 5 Menu select key 15 Undo key 6 Service menu 16 Rear left outrigger blade 7 Engine auto deceleration 17 Front left outrigger blade 8 Buzzer cancel 18 Front right outrigger 9 Brightness adjust 19 Rear right outrigger 10 Suspension auto lock ...

Page 91: ...tomat ically to A mode When the switch is pressed the system will scroll through each mode in turn The display on the monitor display portion changes for each mode If you require a default setting other than A mode please consult your Komatsu distributor or dealership to have the setting amended REMARK When the mode selector switch is pressed the mode is dis played in the centre of the monitor dis...

Page 92: ...vel 0 1 5kph To cancel creep speed press Hi Lo switch REMARK When creep speed is selected the mode is displayed in the centre of the screen for 2 seconds before returning to the normal screen display When loading or unloading from a trailer always travel at low speed Never operate the travel speed selector switch during the loading or unloading operation Display portion ...

Page 93: ... the switch When loading or unloading from a trailer always travel at low speed Never operate the travel speed selector switch during the loading or unloading operation REMARK Each time that the travel speed selector switch is operated the mode is displayed in the centre of the monitor display and the screen returns to the normal screen after 2 seconds 4 CONTROL LEVER LOCK SWITCH Depressing contro...

Page 94: ...y will return to the normal screen REMARK The flow can be adjusted for the attachment installed When the working mode is B mode 1 Press select switch 5 and the normal screen on the monitor display changes to the flow setting screen shown in the dia gram on the right 2 Press up switch 14 or down switch 13 to adjust to the desired flow 3 After completing the flow setting press input confirmation swi...

Page 95: ...nance warn ing screen when the engine is started or when the machine is being operated stop operations immediately When this happens the monitor corresponding to the maintenance warning screen will light up red Press switch 6 to display the maintenance screen and check that there is no abnormality in any other monitor If another monitor is lit up red on the maintenance screen carry out maintenance...

Page 96: ...ut confirmation switch 12 The display screen will switch to the time remain ing to maintenance Press back switch 15 to return to the previous screen 3 Check the time remaining to maintenance a Time remaining to maintenance b Default setting for maintenance interval When only checking the time remaining to maintenance press back switch 15 twice The screen will return to the normal operation monitor...

Page 97: ... and the auto deceleration is actuated the mode is displayed in the centre of the monitor display and the screen returns to the normal screen after 2 seconds 8 BUZZER CANCEL SWITCH REMARK This is used to stop the alarm buzzer when it has sounded to warn of some abnormality that has occurred whilst the machine is operating REMARK The lamp on the switch will illuminate when the warning buzzer is sou...

Page 98: ...stabilize the machine and suspension lock simultaneously as locked front axle may suddenly become free REMARK Permanent and automatic suspension lock cannot be active at the same time Each mode can be turned on and off by their individual switches 11 PERMANENT SUSPENSION LOCK SWITCH Press switch 11 in order to engage permanent front axle lock Front axle will be fixed in place when engaged the perm...

Page 99: ...reens will return you back to the previous screen displayed 16 REAR LEFT OUTRIGGER BLADE SWITCH This switch enables selection of rear left outrigger or rear blade Light illuminates when selected 17 FRONT LEFT OUTRIGGER BLADE SWITCH This switch enables selection of front left outrigger front blade Light illuminates when active 18 FRONT RIGHT OUTRIGGER SWITCH Allows operation of front right outrigge...

Page 100: ...rast screen and press up switch 14 or down switch 13 to select the contrast monitor The selected monitor is inverted to black 3 When the screen changes to the contrast adjustment screen press up switch 14 or down switch 13 to adjust the con trast 4 After completing adjustment of the contrast press input con firmation switch 12 This will store the new setting and return you to the adjustment menu R...

Page 101: ...is will return you to the above menu and store the new setting C Adjusting the clock 1 Use the adjustment screen and press up switch 14 or down switch 13 to select the clock monitor The selected monitor is inverted to black 2 When the screen changes to the clock adjustment screen press up switch 14 or down switch 13 to adjust the year to move to the date press input confirmation switch 12 the orde...

Page 102: ...o black 2 When the screen changes to the background colour adjust ment screen press up switch 14 or down switch 13 to adjust the colour day time and for night time the different combinations of colours are shown below Day time Night time 3 After completing adjustment of the background colour press input confirmation switch 12 This will return you to the above menu and store the new setting Light b...

Page 103: ...F N R switch 26 Power max 7 Right control lever 27 Spare 8 Starter switch 28 Att control pedal option 9 Fuel control dial 29 Hydraulic adjust boom or att control pedal option 10 Park brake 30 Indicator stalk horn windscreen wiper 11 Work light 31 Steering wheel 12 Swing lock 32 Turn indicator warning lights 13 Spare 33 Hazard warning switch 14 Pump override 34 Full beam indicator 15 Swing override...

Page 104: ...ngine in winter set the key to this position When the key is set to the HEAT position the pre heating symbol on the monitor lights up Keep the key at this position until the monitor lamp begins to flash Immediately after the pre heating symbol flashes release the key The key automatically returns to the OFF position Then start the engine by turning the key to the START position FUEL CONTROL DIAL W...

Page 105: ...nd the upper structure will not swing even if the swing lever is activated In this condition monitor indicator lights up OFF position cancelled The swing lock switch should only be activated when the upper structure is motionless and with the swing lock lever in the neutral position HORN BUTTON When the lower button on the left control lever 25 is pressed the horn will sound Note Additional horn s...

Page 106: ...up The pump control override switch is designed to allow operations to be carried out for a short period when there is an abnormality in the pump control system EPC valve system error The abnormality must be repaired immediately SWING LOCK OVERRIDE SWITCH When normal Switch 15 is down 1 When abnormal When the monitor display shows E03 swing brake system error the brake is cancelled and it becomes ...

Page 107: ...function The emergency F N R switch located at the rear of the right pod should be used in conjunction with the Emergency Travel Switch in a situation of emergency PARK BRAKE SWITCH This switch 10 is used to apply and release park brake OFF Park brake released warning light not illuminated ON Park brake applied warning light illuminated Do not apply the park brake while the machine is in motion ex...

Page 108: ...AMSHELL ROTATION CLOCKWISE BREAKER SWITCH Switch 3 operates clockwise rotation of clamshell if fitted CLAMSHELL ROTATION ANTI CLOCKWISE Switch 2 operates anti clockwise rotation of clamshell if fitted or operation of breaker if fitted DIRECTION INDICATOR SWITCH This switch 30 is used to indicate the driver s intention to change direction 1 Turn right push lever fully forward 2 Turn left pull lever...

Page 109: ... and main beams For main beam push steering column stalk fully downwards Note road lights switch 36 must be at position 2 for this function to return to headlights dipped push steering column stalk fully downwards Main beam indicator 34 will illuminate when main beam headlights are illuminated To flash headlights pull steering column stalk fully upwards and release MAIN WINDSCREEN WIPER SWITCH Thi...

Page 110: ... PW160 7H VEAM390100 12V POWER SUPPLY The 12V socket 21 provided on the cab rear left panel may be used only for electrical accessories drawing 1 5 A maximum Any accessories attached to this socket must carry the EC mark 21 ...

Page 111: ...ghter 25 Horn 6 F N R switch 26 Power max 7 Right control lever 27 Spare 8 Starter switch 28 Att control pedal option 9 Fuel control dial 29 Hydraulic adjust boom or att control pedal option 10 Park brake 30 Indicator stalk horn windscreen wiper 11 Work light 31 Steering wheel 12 Swing lock 32 Turn indicator warning lights 13 Spare 33 Hazard warning switch 14 Pump override 34 Full beam indicator 1...

Page 112: ...ing will move creating a potentially dangerous situation When the safety lock lever is lowered take care not to touch the work equipment control lever In certain conditions it may be possible for the safety lock lever to contact the left hand arm rest on the opera tor seat to avoid this always ensure that the left hand arm rest is stowed in the fully up position before operating the safety lock le...

Page 113: ...areful when operating the levers Lever 7 is used to operate the boom and bucket When the lever in the N neutral position the boom and the bucket will be retained in the position in which they stop The engine speed changes as follows because of the auto decel eration mechanism When the travel pedal and work equipment control levers are at neutral even if the fuel control dial is above the mid range...

Page 114: ...t For details see CONTROL LEVER LOCK SWITCH 93 ON position actuated TRAVEL PEDAL The travel pedal is used in conjunction with the Forward Neutral Reverse F N R switch 6 located on the right control lever Select the direction required using F N R switch then depress travel pedal 38 to commence travel BRAKE PEDAL The service brakes are operated by depressing pedal 37 The service brakes can be locked...

Page 115: ...rvice brakes can be locked in the ON position for digging and lifting operations to lock the service brakes in the ON position fully depress the brake pedal To unlock the service brakes depress latch A For on highway driving the lock can be disabled Depress latch A fully This will prevent the lockfrom operating when the brake pedal 37 is depressed When the lock as needing again depress latch B 37 ...

Page 116: ...ite direction HYDRAULIC ADJUST BOOM PEDAL Pedal 29 is used to operate the second boom Neutral position Boom is stopped and held in the same position NOTE On machines equipped with a monoboom this pedal is used to operate the second attachment circuit option CAUTION Do not rest foot on the pedal unless in use HCU PEDAL OPTION Pedal 28 is used to operate the attachment REMARK Confirm with attachment...

Page 117: ...ent completely to the ground stop the engine then carry out the operation When opening the front window hold the grip securely with both hands pull up and do not let go until the auto matic lock catch is locked When closing the front window the window will move quicker under its own weight Hold the grips securely with both hands when closing it It is possible to store pull up the front window top ...

Page 118: ... top bottom left and right of the front window and pull lock lever B to release the lock at the top of the front window The top of the front window will come out 5 Hold lower knob C with your left hand from inside the opera tor s cab and with your right hand grip top knob D pull it up and firmly push it against lock catch E at the rear of the cab to securely lock the window 9JH02594AA1 9JH02402AA1...

Page 119: ...w on lock case F does not line up with the arrow on lock lever B the lock is not properly engaged Repeat the operation in Step 5 to engage the lock When closing WARNING When closing the window lower it slowly and be careful not to get your hand caught 1 Place the work equipment on flat ground and stop the engine 2 Raise the safety lock lever 3 Grip left and right knobs A and pull down lock lever B...

Page 120: ... window reaches the top of the lower window push the top of the window forward to engage the locks against catches G 6 Check that lock lever B is secured at the LOCK position The lock is engaged if the arrow on lock case F lines up with the arrow on lock lever B Check it visually If the arrow on lock case F does not line up with the arrow on lock lever B the lock is not engaged Repeat the opera ti...

Page 121: ...OM OPERATOR S CAB If for some reason the cab door does not open open the rear window and use it as an emergency escape exit Remove the rear window as follows 1 Pull ring 1 and completely remove seal 2 from the rubber core 2 When the corner of the front window glass is pushed strongly it can be removed to the outside 3 Do not remove the rear window except when using it as an emergency exit CEILING ...

Page 122: ...sted to one of three pre set locations by removing the bolts holding the brack ets and re attaching to one of the other prepared locations A second set of retainers is positioned at the bottom of the front window to allow coverage of the clear roof when the front window is in the raised position DOOR LOCK Use the door lock to fix the door in position after opening it 1 The door will become fixed i...

Page 123: ...Turn the key clockwise align the match mark on the cap with the rotor groove then remove the cap To lock the cap 1 Turn the cap into place 2 Turn the key and take the key out Insert the key as far as it will go If the key is turned before it is inserted all the way it may break METHOD OF OPENING AND CLOSING COVER WITH LOCK cover with lock To open the cover locked cover 1 Insert the key 2 Turn it c...

Page 124: ... capacity Name of circuit 1 10 A Controller switched power 2 20 A Solenoid controller 3 10 A PPC lock axle lock park brake and f n r 4 10 A Window washer cigar lighter and quick coupler 5 10 A Horn and power max 6 10 A Wiper controller and lower wiper 7 10 A Beacon 8 10 A Travel sensor and low brake pressure 9 15 A Flasher 10 10 A Refuelling pump 11 20 A A C unit 12 20 A Monitor switched power 13 ...

Page 125: ...artment Always ensure when cigarettes are extin guished they are put in the ashtray and the lid closed CUP HOLDER A cup holder is provided to the left of the operator for holding cups or cans Drinks should not be left in the cup holder whilst operat ing the machine because spillage may occur HOT AND COOL BOX The box is at the rear right of the operator s seat It is intercon nected with the air con...

Page 126: ...e is still audible Ensure no water is splashed over the speaker case or cab radio to prevent malfunction Never use solution such as benzine or thinners to clean the dial or buttons These should be wiped with a dry soft cloth Use a cloth dipped in alcohol for very dirty surfaces At battery replacement all the memory pre set with the pre set buttons will be cleared Perform pre setting again POWER PI...

Page 127: ... 1 is pressed the set temperature and air flow display on display monitor 7 and the lamps above auto switch 5 and air conditioner switch 8 go out and operation stops 1 OFF switch 6 FRESH RECIRC selector switch 2 Fan switch 7 Display monitor 3 Temperature control switch 8 Air conditioner switch 4 Vent selector switch 9 Defroster selector lever 5 Auto switch 9EH02410AA1 Air conditioner control panel...

Page 128: ...re inside the cab The temperature can be set between 18 C and 32 C Press the switch to raise the set temperature press the switch to lower the set temperature The temperature is generally set at 25 C The temperature can be set in stages of 0 5 C Monitor display and the function Monitor display and air flow Liquid crystal display Air flow Air flow low Air flow medium 1 Air flow medium 2 Air flow me...

Page 129: ...laces B Face vent 1 place C Foot vent 1 place D1 Front window vent 1 place D2 Front window vent 1 place Front window vent D2 can be opened or closed by hand A C B D1 D2 Liquid crystal display Vent mode Vent Remarks A B C D Front and rear vents including defroster vent O O O Front and rear vents including defroster vent O O O O Foot vent O Foot foot vents including defroster vent O O O Cannot be se...

Page 130: ...auto switch goes out RECIRC FRESH SELECTOR SWITCH This switch 6 is used to switch the air source between recircula tion of the air inside the cab and intake of air from the outside When switch 6 is pressed the lamp at the top of the selector switch lights up to show that air is being blown out During automatic operation the selection of inside air RECIRC and outside air FRESH is carried out automa...

Page 131: ... air condi tioner switch goes out The air conditioner cannot be operated while the fan is stopped DEFROSTER SELECTOR LEVER This switch 9 is used in cold or rainy weather to remove the mist that forms on the front glass Selector lever forward To defroster open Selector lever back Closed The defroster can be used when the vent selector switch is set to face or face and foot METHOD OF OPERATION The a...

Page 132: ...the air conditioner is operated automati cally to provide the set temperature REMARK When vent display monitor c displays d or e and the engine water temperature is low the air flow is automatically lim ited to prevent cold air from blowing out STOPPING AUTOMATIC OPERATION Press OFF switch 1 The displays for temperature setting a and air flow b on the display monitor and the lamps above auto switc...

Page 133: ...t the air flow When doing this check that temperature setting a and air flow b are dis played on the display monitor 2 Turn air conditioner switch 8 ON Check that the lamp at the top of the air conditioner switch lights up 3 Press the temperature setting switch and adjust the tempera ture inside the cab ...

Page 134: ...ges according to the selection 5 Press RECIRC FRESH selector switch 6 and select recircu lation of the air inside the cab RECIRC or intake of fresh air from outside FRESH STOPPING MANUAL OPERATION Press OFF switch 1 The displays for temperature setting a and air flow b on the display monitor and the lamps above auto switch 5 and air conditioner switch 8 go out and the operation stops ...

Page 135: ... as follows 1 Press fan switch 2 and adjust the air flow When doing this check that temperature setting a and air flow b are dis played on the display monitor 2 Press vent selector switch 4 and set the vent display on the display monitor to the display shown in the diagram on the right 3 Turn air conditioner switch 8 ON When this is done the lamp above the air conditioner switch lights up ...

Page 136: ...an switch 2 temperature setting switch 3 and FRESH RECIRC selector switch 6 to the desired positions DEFROSTER OPERATION 1 Press fan switch 2 and adjust the air flow When doing this check that temperature setting a and air flow b are dis played on the display monitor ...

Page 137: ...t display on the display monitor to the display shown in f or g in the dia gram on the right 3 Press FRESH RECIRC selector switch 6 and set it to take in fresh air 4 Press temperature setting switch 3 and set the set tempera ture display on the display monitor to the maximum heating temperature of 32 C ...

Page 138: ... unexpected failure so be careful not to let water get on these parts In addition never bring any flame near these parts For the auto function of the air conditioner to work prop erly always keep the sunlight sensor clean and do not leave anything around the sunlight sensor that may inter fere with its sensor function Ventilate the cab from time to time when using the cooler If you smoke when the ...

Page 139: ...ch 3 are kept pressed at the same time for at least 3 seconds the trou bleshooting mode is displayed on the liquid crystal display Monitor display and failure mode When more than one failure is detected press the or portion of temperature setting switch 3 to display the failures in turn After completing the troubleshooting press OFF switch 1 again to return to the normal display Display Failure mo...

Page 140: ... fan is running the temperature display will switch between F and C Note that the unit is not displayed FUSIBLE LINK If the starting motor will not rotate when the starting switch is turned ON a possible cause is disconnection of wire type fusible link Open the battery box cover front right hand side of machine to inspect the fusible link and if necessary replace it REMARK A fusible link is a larg...

Page 141: ...not bring fire or sparks near fuel smoking is prohibited In event of ingested fuel do not induce vomiting Drink large quantity of milk or water and seek medical attention Skin protection wear protective gloves when dispensing fuel Plastic gloves conforming to EN388 cat 2 are recommended Attendance transfer of fuel must always take place under the supervision of the operator Location for refuelling...

Page 142: ... full stop the pump Take care not to allow fuel to overflow from the tank 11 Close the cap on the foot valve by screwing fully 12 Replace the hose and the tank cap REMARK The pump is protected by a fuse If pump fails to function check fuse 15A Do not allow the pump to run dry as this will overheat the motor If the barrel is emptied during the refuelling stop the pump immedi ately The maximum permi...

Page 143: ...DICATOR WARNING LAMP When the indicator is pulled fully backward warning light A will flash to indicate the driver s intention to turn to the left When the indicator is pushed fully forward warning light B will flash to indicate the driver s intention to turn to the right A B ...

Page 144: ...tore the pressure in the circuit and when it is installed the circuit can be operated for a short time even after the engine is stopped The accumulators are installed to the position shown in the dia gram on the right Control circuit accumulator B This machine is equipped with an accumulator in the control cir cuit The accumulator is a device to store the pressure in the con trol circuit and when ...

Page 145: ...nd under the machine to check for loose nut or bolts or leakage of oil fuel or coolant and check the condition of the work equipment and hydraulic system Check also for loose wiring play and collection of dust at places which reach high temperatures Always carry out the items in this section before starting the engine each day 1 Check for damage wear play in work equipment cylin ders linkage hoses...

Page 146: ...res 6 Check for damage to handrail and for loose bolts Repair any damaged handrails and tighten any loose bolts 7 Check for damage to gauges monitor loose bolts Check that there is no damage to the gauges and monitor in the operator s cab If any abnormality is found replace the parts Clean off any dirt on the surface 8 Clean rear view mirror check for damage Check that there is no damage to the re...

Page 147: ...ater level is low add water through the water filler of reserve tank to the FULL level 2 After adding water tighten the cap securely 3 If the reserve tank becomes empty first inspect for water leaks and then fill the radiator and the reserve tank with water CHECK OIL LEVEL IN ENGINE OIL PAN ADD OIL 1 Open the engine hood 2 Remove dipstick G and wipe the oil off with a cloth 3 Insert dipstick G ful...

Page 148: ... gauge within filler neck will rise according to fuel level Check that the fuel tank is full by looking into tank and checking float gauge 5 If the tank is not full add fuel through the fuel filler until the float gauge G rises to the maximum position Fuel tank capacity 290 litres Position of tip of float gauge G when tank is full Approx 50 mm from top of surface of fuel tank 6 After adding fuel p...

Page 149: ... the engine run the engine at low speed retract the arm and bucket cylinders then lower the boom set the bucket teeth in contact with the ground and stop the engine 2 Check sight gauge G The oil level is normal if midway between the H and L marks NOTICE Do not add oil if the level is above the H line This will damage the hydraulic equipment and cause oil to spurt out 3 If the level is below the L ...

Page 150: ... it is clogged with dirt or dust wash the battery cap to clean the breather hole Check for damage wrong fuse capacity and any sign of discon nection or short circuit in the electric wiring Check for loose termi nals and tighten any loose parts In particular check the wiring of the battery starting motor and alternator carefully When carrying out walk around checks or checks before starting always ...

Page 151: ...atch the drained FUEL 5 Secure fuel line to prevent leakage 6 Remove air bleed plug 5 at the top of the water separator 7 Loosen drain valve 1 at the bottom of the water separator and drain the water and sediment into the container 8 Loosen ring nut 2 then remove filter case 3 9 Remove element 4 from the separator base 10 Wash element 4 in clean diesel oil 11 Check element 4 and replace it if it i...

Page 152: ...aft adjustment of seat and base Pull lever 2 sideways After the seat is set to the desired position release the lever REMARK This operation will not affect relative position of seat and wrist control levers C Adjustment of reclining seat The backrest is adjusted using the locking lever 3 Once locking lever 3 is in locked position it should not be possible to move onto another position D Adjustment...

Page 153: ... of the automatic and height adjuster 6 with the vehicle at a standstill and the driver sitting on the seat the driver must sit absolutely still during adjustment G Lumbar adjustment The curve of the backrest cushion can be individually adjusted by pressing the upper and lower switches 7 H Height adjustment The height can be altered by pulling or pressing the actuator lever fully out or in 8 if th...

Page 154: ...it the seat belt so that it is not twisted FASTENING AND REMOVING SEAT BELT This seat belt has a retractor so it is not necessary to adjust the length Fastening seat belt Hold grip 2 and pull the belt out from the retractor 1 check that the belt is not twisted then insert tongue 3 into buckle 4 securely Pull the belt lightly to check that it is properly locked Removing belt Press button 5 in buckl...

Page 155: ...Weight adjustment The seat should be adjusted for the drivers weight by turning the weight adjuster lever 6 with the seat empty The set weight can be read from the indicator G Lumbar adjustment By turning the adjustment knob 7 to the left or right both the height and curvature of the backrest cushion can be individually adjusted H Height adjustment For details see H Height adjustment 153 I Seat de...

Page 156: ...that safety lock lever 23 is in the LOCK position REMARK In certain conditions it may be possible for the safety lock lever to contact the left hand arm rest on the operator seat to avoid this always ensure that the left hand arm rest is stowed in the fully up position before operating the safety lock lever 2 Select neutral on the right control lever 3 Insert the key in starting switch 8 turn the ...

Page 157: ...0 If the monitors or gauges do not light up or the buzzer does not sound there is probably a broken bulb or disconnection in the monitor wiring so contact your Komatsu distributor for repairs After approx 3 sec the following gauges will remain on and the other monitors will go out The buzzer will sound intermittently and the monitor will show the low brake pressure symbol if the machine has been i...

Page 158: ...as is toxic when starting the engine in con fined spaces ensure adequate ventilation at all times 1 Set fuel control dial at the low idling MIN position 2 Turn the key in starting switch to the START position The engine will start 3 When the engine starts release the key in starting switch The key will return automatically to the ON position 9 10 12 13 11 8 MIN 9 Heat Off On Start Heat Off On Star...

Page 159: ...r 2 minutes When starting in low temperatures do as follows 1 Set fuel control dial 9 at the low idling MIN position 2 Hold the key in starting switch 8 at the HEAT position and check that preheating monitor lights up After about 30 seconds preheating monitor will flash for about 10 seconds to indicate that preheating is finished REMARK The monitor and gauge also light up when the key is at the HE...

Page 160: ...y in starting switch 6 to the START position to start the engine 4 When the engine starts release the key in starting switch 6 The key will return automatically to the ON position Heat Off On Start Ambient temperature Preheating time Above 0 C 0 C to 10 C 20 seconds 10 C to 20 C 30 seconds Heat Off On Start Heat Off On Start ...

Page 161: ... operation This will help to extend the machine life Do not suddenly accelerate the engine before the warm ing up operation is completed Do not run the engine at low idling or high idling continu ously for more than 20 minutes This will cause leakage of oil from the turbocharger oil supply piping If it is necessary to run the engine at idling apply a load from time to time or run the engine at a m...

Page 162: ...e 4 Carry out bucket and arm operation for 5 minutes at full stroke alternating between bucket operation and arm opera tion at 30 second intervals If the swing lock switch 12 is set to the ON actuated posi tion and swing control lever is operated at full stroke oil tem perature rise can be increased quicker NOTICE When the work equipment is retracted take care that it does not interfere with the m...

Page 163: ...f Engine oil pressure monitor 5 off Charge level monitor 6 off Fuel level monitor 7 green Air cleaner clogging monitor 8 off Engine pre heating lamp 9 green Engine oil level monitor 10 off Hydraulic oil temperature 11 green Hydraulic oil temperature gauge 12 inside black range Replacement monitor of engine oil off 13 6 Check that there is no abnormal exhaust gas colour noise or vibration If any ab...

Page 164: ...at a low temperature do not carry out operations or move the levers suddenly Work equipment control will be slower and less responsive than normal therefore always carry out the warming up operation first to ensure safe operation of the machine and help extend the machine life Do not suddenly accelerate the engine before the warm ing up operation is completed Do not run the engine at low idling or...

Page 165: ...cket and swing for 30 seconds Operate both fully in turn for 5 minutes NOTICE When pulling in the work equipment be careful not to let it hit the chassis or ground 7 Turn fuel control dial to the full speed MAX position and carry out the operation is Step 6 for 3 5 minutes 8 Repeat the following operation 3 5 times and operate slowly Boom operation RAISE LOWER Arm operation IN OUT Bucket operation...

Page 166: ...se working mode switch 1 on the monitor panel to switch to the working mode to be used NOTICE Cancelling automatic warming up operation If it becomes necessary in an emergency to lower the engine speed to low idling cancel the automatic warming up opera tion as follows 1 Turn fuel control dial to the full speed MAX position and hold it for 3 seconds 2 When fuel control dial is returned to the low ...

Page 167: ...de auto decel speed engine speed will rise suddenly Operate the levers carefully Note the direction of undercarriage before moving off Check that low brake pressure warning lamp is off Check service brake just after moving off Always fasten seat belt 1 Set swing lock switch to the ON actuated position and con firm that swing lock monitor lamp lights up 2 Turn fuel control dial to the min idling po...

Page 168: ...ee CREEP SPEED SELECTOR SWITCH 92 Creep mode see CREEP SPEED SELECTOR SWITCH 92 for fine control speed is restricted to 2 5 km h REMARK Creep can be engaged from any other mode by pressing the Creep button Press High Low speed select switch to dis engage Creep Creep mode will only engage fully when the machine comes to a stop Lo mode for travelling on rough surfaces and on steep slopes up or down ...

Page 169: ...e on foot brake to prevent machine rolling REMARK If starting to travel on a steep uphill slope first press the travel pedal fully then release the park brake this will minimise rolling backwards when staring 10 Press the travel pedal 38 smoothly The machine will move off in the selected direction REMARK Engine speed will automatically increase when travel pedal is depressed 11 When changing direc...

Page 170: ... directions and check wheels turn fully Do not press travel pedal until the safety lock lever is fully down UNLOCKED 1 The machine can be steered by turning steering wheel in the desired direction The position of the steering column can be adjusted fore and aft by depressing pedal A moving column to desired position and releasing pedal A WARNING If it becomes necessary to tow the machine the opera...

Page 171: ...oth sides C Arm Cyl inder rear of boom with isolation valves provided 1 Before travelling on a Public Highway with the safety lock lever lowered in the UNLOCK position engage the control lever lock switch to prevent accidental use of the work equip ment the rear brake lights will now become active 2 Before travelling fold the work equipment and raise to 40 50 cm from the ground 3 Before travelling...

Page 172: ... that the left hand arm rest is stowed in the fully up position before operating the safety lock lever When parking the machine select flat hard ground and avoid dangerous places If it is unavoidable to park the machine on a slope insert chocks underneath the wheels As an additional safety measure thrust the bucket into the ground Before travelling re apply the swing brake Do not latch the brake p...

Page 173: ...NCY REMARK In the event of service brake failure 1 Release travel pedal 2 Depress service brake pedal to confirm no braking 3 Brace yourself before engaging emergency brake A seatbelt is fitted for your safety and comfort Please wear this at all times 4 Press park brake switch 10 to on position machine will very quickly come to a halt WARNING If it becomes necessary to tow the machine the operator...

Page 174: ...ma chine is safe 1 Before operating the swing turn swing lock switch 12 OFF CANCELLED NOTICE Check that swing lock monitor goes out at the same time Straight ahead position can be found by using the indicator see SWING POSITION on page 89 2 Operate left work equipment control lever to swing the upper structure 3 When not operating the swing turn swing lock switch 12 ON ACTUATED 4 Before travelling...

Page 175: ...osition and the work equip ment is held in place If the work equipment control lever is returned to the neutral position for 4 seconds even if the fuel control dial is set to FULL the auto deceleration mechanism will act to reduce the engine speed to auto decel speed If the levers are operated within 15 seconds after the engine stops it s possible to lower the work equipment to the ground In addit...

Page 176: ...t will illumi nate next to the switch to confirm selection 3 Right control lever 7 will now operate the dozer outriggers 4 To return right control lever to boom operation activate switch 4 Symbol 12 will now disappear from the monitor panel display WARNING When moving the machine confirm that the chassis attach ment is raised PRECAUTIONS FOR USING THE DOZER 1 When using the dozer blade as stabilis...

Page 177: ...91 to select a working mode that matches the operating condition it is possible to carry out operations efficiently Use the following procedures to make the most effective use of each mode When the starting switch is turned ON the working mode is set to A mode digging Use the working mode switch on the monitor panel to set the most efficient mode to match the type of work NOTICE If breaker operati...

Page 178: ...ary in combination with the working mode 1 Press top right hand switch on the left lever The power is increased for up to 8 5 seconds The increased power is auto matically cancelled after 8 5 seconds After which the button can be re pressed This function is not actuated when the working mode is set to L mode or B mode CAUTION Continuous use of this facility will raise the hydraulic oil tem peratur...

Page 179: ...pment Prohibited operations using travel force Do not leave the bucket dug into the ground and use the travel force to excavate This will bring excessive force to bear on the rear of the machine Precautions when operating hydraulic cylinders to end of stroke If the cylinder is operated to the end of its stroke during opera tions force will be brought to bear on the stopper inside the cylin der and...

Page 180: ...will not only reduce damage to the machine but make for better economy PRECAUTIONS FOR OPERATION PRECAUTIONS WHEN TRAVELLING When travelling over obstacles such as boulders or tree stumps ensure sufficient clearance to avoid undercarriage damage As far as possible remove such obstacles or avoid travelling over them Do not operate machine working or travelling on 1 tyre if twin tyres are fitted aft...

Page 181: ...e the machine in water by more than the permissi ble depth axle centre In addition for parts that have been immersed in water for a long time pump in grease until the old grease comes out from the bearings i e the bucket pins WHEN LIFTING A LOAD Front axle of machine must be locked as machine will become unstable REMARK Precautions when using the work equipment Do not use the park brake to reduce ...

Page 182: ...er brake accelerate shift gears move the attachments and load the attachments smoothly 4 Keep the terrain on work sites where the machine is working and travelling in good condition Remove any large rocks or obstacles Fill any ditches and holes Maintain the terrain conditions 5 Use a seat that meets ISO 7096 and keep the seat main tained and adjusted Adjust the seat and suspension for the weight a...

Page 183: ...rried out pile soil to make platform on the slope so that the machine can be kept horizontal when operating Do not travel on slopes of over 20 as there is danger that the machine may overturn before travelling down steep slopes stop machine engage low gear 1 When travelling down hills of more than 5 first stop and select Low travel mode Release the service brake and pro ceed full hydraulic braking...

Page 184: ...wing procedures to get the machine out WHEN ONE SIDE IS STUCK When only one side is stuck in mud use the bucket to raise the wheels then lay boards or logs and drive the machine out If nec essary put a board under the bucket also NOTICE When using the boom or arm to raise the machine always have the bottom of the bucket in contact with the ground Never push with the teeth The angle between the boo...

Page 185: ...nge for excavating with the arm is from a 45 angle away from the machine to a 30 toward the machine There may be some differences depending on the excavation depth but try to use within the above range rather than going all the way to the extreme end of the cylinder stroke SHOVEL WORK A shovel is suitable for excavating at a position higher than the machine Shovel work is performed by attaching th...

Page 186: ...ngle is small work efficiency can be enhanced by locating the dump truck in a place easily visible to the operator Loading is easier and capacity greater if you begin from the front of the dump truck body than if loading is done from the side LEVELLING WORK Can be carried out with work equipment or dozer blade if fitted ...

Page 187: ... with the ground If the bucket is lowered strongly to the ground the resistance will be increased and it will be difficult to remove the pins 2 Remove the stopper bolts and nuts then remove pins A and B and remove the bucket NOTICE After removing the pins make sure that they do not become contaminated with sand or mud and that the seals of bushing on both sides do not become damaged 3 Align the ar...

Page 188: ...curely 4 Align the arm with holes 1 and the link with holes 2 then install pins A and B WARNING If the control lever is touched by accident the work equipment or the machine may move suddenly and this may lead to a serious accident Before leaving the opera tor s compartment always raise the safety lock lever to LOCK the work equipment controls In certain conditions it may be possible for the safet...

Page 189: ...radually cool down 2 Turn the key in starting switch 8 to the OFF position and stop the engine 3 Remove the key from starting switch 8 CHECK AFTER FINISHING WORK 1 Check the engine water temperature engine oil pressure and fuel level on the monitor 2 Walk around the machine and check the work equipment and undercarriage and check also for leakage of oil or water If any abnormalities are found repa...

Page 190: ...ARNING Incorrect handling of wheels and tyres can result in serious injury or death Particular care is required when working on twin wheel assemblies Before any attempt is made to remove the road wheels the tyres must be fully deflated 1 General information Always replace damaged parts with new parts from your Komatsu distributor Never attempt to repair damaged items Use the appropriate tools in a...

Page 191: ...roceed in accordance with the following procedure paying attention to the information specific to the type of wheel assembly fitted to the machine on which you are working WARNING Failure to observe the following procedure may result in seri ous injury or death 3 Twin wheel assembly 3 part rim Deflation and removal Before loosening the wheel retaining nuts completely deflate the tyres by removing ...

Page 192: ...hly the condition of the wheel and rim for signs of wear or damage Discard any defective or doubtful parts and replace with approved replacement parts Clean the rims with a hard brush paying particular attention to the bottom of the rim gutter groove Fit the tyre to the rim base and fit the tube ensuring that the valve is correctly located in its through hole Place the loose flange against the tyr...

Page 193: ...the lock ring may be ejected from the groove resulting in possible injury Deflate the tyre and repeat the procedure If the lock ring is correctly positioned continue to inflate the tyre to the value given in the previous table Before removing the wheel assembly from the safety cage repeat the visual check When refitting the wheel assemblies tighten at least 2 diago nally opposite wheel nuts and th...

Page 194: ...ove the road wheels following the procedure de tailed previously and perform the following checks Remove all dirt especially in the area of the tyre bead seat and check the condition of the rim If there are any signs of deformation or cracks the wheel must be replaced Check carefully the wheel attachment holes if you notice signs of ovalization or the presence of cracks the wheel must be replaced ...

Page 195: ...from the undercarriage to prevent the machine from slipping to the side on slopes Be sure the ramp surface is clean and free of grease oil ice and loose materials Never change the direction of travel when on the ramps If it is necessary to change direction drive off the ramps and correct the direction then drive on to the ramps again Swing lock switch should always be engaged during transportation...

Page 196: ...the Lo position For details see HIGH LOW SPEED SELECTOR SWITCH 93 3 Turn the auto deceleration switch OFF and return the fuel control dial 9 to reduce the engine speed For details see AUTO DECELERATION SWITCH 97 4 Turn the swing lock switch 12 ON to apply the swing lock 5 Set in the direction of the ramps lower the work equipment as far as possible without letting it hit the trailer then travel sl...

Page 197: ... Raise safety lock lever to LOCK position REMARK In certain conditions it may be possible for the safety lock lever to contact the left hand arm rest on the operator seat to avoid this always ensure that the left hand arm rest is stowed in the fully up position before operating the safety lock lever 4 When transporting the machine hold it down with chains or rope Be particularly careful to ensure ...

Page 198: ...rocedure when lifting a vehicle Otherwise the machine may be unbalanced Lifting a machine must be performed on a flat place with the fol lowing procedure 1 Start the engine and set the machine in the position shown in the figure at the right boom at the top stroke end arm bucket fully retracted Direct the top revolving super structure straight forward REMARK When lifting a machine fitted with 2 pi...

Page 199: ...pe and the lifting angle must be as shown in the figure on the right 7 When lifting make sure that there is no change in the position due to possible leakage in the hydraulic circuit on the boom cylinder head side 8 When the machine leaves the ground stop the machine and make sure sufficiently that the machine is balanced Then lift the machine slowly ...

Page 200: ... and locked before transporting the machine NOTICE Always retract the radio antenna retract or remove the driving mirrors before transportation Obey all state and local laws governing the weight width and length of a load Observe all regulations governing wide loads Monoboom with blade 1 Height for transport D Overall height 3 height of trailer platform Weights and dimensions will vary according t...

Page 201: ...all height 3 height of trailer platform Weights and dimensions will vary according to specification Consult your Komatsu distributor if in doubt Arm Length mm Driving Position Transport Position Weight A B C D 2100 6000 4211 8188 3439 15 765 2500 5862 3978 8225 3208 15 800 3000 5878 3978 8211 3191 15 930 ...

Page 202: ...boom cylinders OR b Extend the first boom cylinders until the boom positioning decals A are aligned correctly 4 Fully retract the second boom cylinders 5 Adjust the arm cylinder such that the front of the arm is verti cle 6 Disable the work equipment levers by switching on the control lever lock switch 7 Close manual lock valves 1 For the bucket cylinder located on the arm 2 For the arm cylinder l...

Page 203: ...OPERATION TRANSPORTATION PW160 7H VEAM390100 203 Before moving off lock all machine cover and toolbox doors to prevent accidental opening ...

Page 204: ...contact your Komatsu distributor or ask your local antifreeze dealer Be careful not to let the water flow into drainage ditches or spray on to the ground surface Antifreeze is flammable so do not bring any flame close Do not smoke when handling antifreeze NOTICE Never use methanol ethanol or propanol based anti freeze Absolutely avoid using any water leak preventing agent weather it is used indepe...

Page 205: ...ry charge ratio is low the battery electro lyte may freeze Maintain the battery charge as close as possible to 100 and insulate it against cold temperature so that the machine can be started easily the next morning REMARK Measure the specific gravity and calculate the rate of charge from the following conversion table Because the battery capacity drops markedly in low tempera tures cover the batte...

Page 206: ...is impossible park the machine on wooden boards The boards help protect the wheels from being frozen in soil and the machine can start next morning Open the drain valve and drain any water collected in the fuel system to prevent it from freezing After operation in water or mud remove water from undercar riage to extend undercarriage service life AFTER COLD WEATHER When season changes and the weath...

Page 207: ...the negative terminals of the battery and cover it or remove it from the machine and store it separately If the ambient temperature is expected to drop below 0ºC add antifreeze to the cooling water Raise safety lock lever to the LOCK position Set the stop valve to the LOCK position on machines which can install attachments Install a plug in the elbow DURING STORAGE WARNING If it is unavoidably nec...

Page 208: ...hine has been stored for a long time the mois ture in the atmosphere will get into the oil Check the oil at all parts before and after starting the engine If there is water in the oil change all the oil STARTING MACHINE AFTER LONG TERM STORAGE When starting the machine after a long term storage first cancel the automatic warming up function as follows 1 Turn the starting switch key to the ON posit...

Page 209: ...e arm is pulled in the speed of movement will drop momentarily when the arm is more or less vertical 2 The arm speed will drop momentarily when the bucket teeth are more or less horizontal 3 When starting or stopping the swing noise will be emitted from the brake valve 4 When going down a steep slope at low speed a noise will be emitted from the travel motor ...

Page 210: ...wire rope as shown in the diagram WHEN USING THE FRONT OF CHASSIS WHEN USING THE REAR OF THE CHASSIS For towing method see TOWING on page 37 PRECAUTIONS ON PARTICULAR JOBSITES 1 When carrying out digging operations in water if the work equipment mounting pin goes into the water carry out greas ing every time the operation is carried out 2 For heavy duty operations and deep digging carry out greas ...

Page 211: ...rst If a tool touches the positive terminal and the chassis there is danger that it will cause a spark be extremely careful If the terminals are loose there is danger that the defec tive contact may generate sparks that will cause an explosion When installing the terminals install them tightly When removing or installing the terminals check which is the positive terminal and which is the negative ...

Page 212: ...e terminal of the battery then connect the negative charger clip of the charger to the negative terminal of the battery Be sure to connect the clips securely Set the charging current to 1 10 of the value of the rated bat tery capacity when doing rapid charging set it to less than the rated battery capacity If the charger current is too high the electrolyte will leak or dry up and this may cause th...

Page 213: ... the upper structure frame but sparks will be generated when this is done so connect to a place as far as possible from the battery However avoid connecting the cable to the work equipment as conduction is poor Use care when removing the cables from a machine that has been started To avoid hydrogen explosion do not allow the cable ends to contact each other or the machine NOTICE The starting syste...

Page 214: ...certain conditions it may be possible for the safety lock lever to contact the left hand arm rest on the opera tor seat to avoid this always ensure that the left hand arm rest is stowed in the fully up position before operating the safety lock lever 1 Make sure the clips are firmly connected to the battery termi nals 2 Start the engine of the normal machine and keep it to running at high idling sp...

Page 215: ...efective alternator Replace Starting motor does not turn when starting switch is turned to ON Defective wiring Defective starting motor Insufficient battery charge Check repair Replace Charge Pinion of starting motor keeps going and out Insufficient battery charge Defective safety relay Charge Replace Starting motor turns engine slug gishly Insufficient battery charge Defective starting motor Char...

Page 216: ...RTING Pump generates abnormal noise sucking in air Clogged element in hydraulic tank strainer lack of oil Clean see EVERY 2000 HOURS SERVICE Excessive rise in hydraulic oil tem perature Loose fan belt Dirty oil cooler Lack of hydraulic oil Check fan belt tension replace Clean see EVERY 500 HOURS SERVICE Add oil to specified level see CHECK BEFORE STARTING Bucket rises slowly does not rise Lack of ...

Page 217: ...CK BEFORE STARTING Check fan belt tension adjust replace Change coolant flush inside of cooling system see WHEN REQUIRED Radiator water level monitor lights up Clogged radiator fins or dam aged fins Defective thermostat Loose radiator filler cap high altitude operations Defective water level sensor Defective monitor Clean or repair see EVERY 500 HOURS SERVICE Replace thermostat Tighten cap or repl...

Page 218: ...le See defective compression above Clean or replace turbocharger Combustion noise occasionally make breathing sound Defective nozzle Replace nozzle Abnormal noise generated com bustion or mechanical Low grade fuel being used Overheating Damage inside muffler Excessive valve clearance Change to specified fuel Refer to Radiator water levelmon itor lights up as above Replace muffler Adjust clearance ...

Page 219: ... brake operate the swing lock manually Depending on the cause of the failure it may be impossible to release the brake In any case have the system inspected immediately by your Komatsu distributor E05 Governor system error Governor will not execute the control function Manually operate the governor lever To fix the governor lever at the full stroke position use the retaining bolt holes on bracket ...

Page 220: ...TROUBLESHOOTING OPERATION 220 PW160 7H VEAM390100 ...

Page 221: ...PW160 7H VEAM390100 221 MAINTENANCE WARNING Please read and make sure that you understand the safety volume before reading this section ...

Page 222: ...ed for ambient temperature Always use clean washer fluid Use automobile window washer fluid and be careful not to let any dirt get into it Always use clean oil and grease Use clean oil and grease Also keep containers of the oil and grease clean Keep foreign materials away from oil and grease Keeping the machine clean Always keep the machine clean This makes is easier to find parts causing problems...

Page 223: ...als or bearings from being between the area to be welded and the position of grounding Do not use the area around the work equipment pins or the hydraulic cylinders as the grounding point Fire prevention Use nonflammable cleaner or light oil for cleaning parts Keep flame or cigarette light away from light oil Clamp faces When O rings or gaskets are removed clean the clamp faces and replace the 0 r...

Page 224: ...r the work to protect components from rusting Lubricate com ponents more frequently than usual Be sure to lubricate work equipment pins daily if they are sub merged in water Dusty worksites When working at dusty worksites do as follows Inspect the air cleaner clogging monitor to see whether the air cleaner is blocked Clean the air cleaner at shorter intervals than specified Clean the radiator core...

Page 225: ...ent any ingress of impurities water metal particles dirt etc The majority of problems with machine are caused by the entry of such impurities Take particular care not to let any impurities get in when storing or adding oil Never mix oils of different grades or brands Always add the specified amount of oil Having too much oil or too little oil are both causes of prob lems If the oil in the work equ...

Page 226: ...sed after adding fuel drain the sediment and water from the fuel tank If the engine runs out of fuel or if the filters have been replaced it is necessary to bleed air from the circuit COOLANT River water contains large amounts of calcium and other impurities so if it is used scale will stick to the engine and radiator and this will cause defective heat exchange and overheating Do not use water tha...

Page 227: ...l Wear Analy sis KOWA is a maintenance service that makes it possible to prevent machine failures and down time With KOWA the oil is periodi cally sampled and analyzed This enables early detection of wear of the machine drive parts and other abnormalities Periodic use of KOWA makes the following possible It enables abnormalities to be detected early leading to reduction of repair costs and machine...

Page 228: ...e sure to use in the order of first in first out use the oldest oil or fuel first FILTERS Filters are extremely important safety parts They prevent impurities in the fuel and air circuits from entering important equipment and causing problems Replace all filters periodically For details see the Operation and Maintenance Manual However when working in severe conditions it is necessary to consider r...

Page 229: ...l remains high In addition high hydraulic pressure is applied to the system Take care when inspecting and maintaining the hydraulic sys tem Stop the machine on level ground lower the bucket to the ground then set so that there is no pressure applied to the cylinder circuit Always stop the engine Immediately after operations the hydraulic oil and lubri cating oil are at high temperature and high pr...

Page 230: ...INE OF SERVICE MAINTENANCE 230 PW160 7H VEAM390100 The accumulators are charged with high pressure nitrogen gas Incorrect handling may be dangerous For the handling procedure see HANDLING ACCUMU LATORS 144 ...

Page 231: ...ring parts please check the part number in the parts book The parts in parentheses are to be replaced at the same time Item Part No Part Name Q ty Replacement frequency Hydraulic oil filter 20Y 60 31171 07000 15195 Element Strainer O ring 1 1 Every 1000 hours service Air cleaner 600 185 2520 600 185 2510 600 184 1280 Single element Safety element O ring 1 1 1 When required Engine oil filter 6736 5...

Page 232: ...in the day time Reservoir Kind of fluid AMBIENT TEMPERATURE Type OF OIL CAPACITY Min Max Specified Refill Engine oil pan Engine oil API CE or CF 4 0 C 20 C 20 C 15 C 30 C 10 C 50 C 50 C SAE 30 CD SAE 10W SAE 10W 30 SAE 15W 40 16 litre 16 litre Swing machinery case Engine oil 20 C 40 C SAE 30 4 5 litre 4 5 litre Hydraulic system Bio oil 20 C 30 C Panolin HLP synth 46 160 litre 120 litre Hydr oil AP...

Page 233: ...according to the following table if fuel sulphur con tent is above 0 5 Specified capacity Total amount of oil including oil for compo nents and oil in piping Refill capacity Amount of oil needed to refill system during nor mal inspection and maintenance Abbreviations ASTM American Society of Testing and Material SAE Society of Automotive Engineers API American Petroleum Institute TYPE CLASS VISCOS...

Page 234: ...ear oil RYKON premium grease 4 ARCO Arcofleet S3 plus Arco HD gear oil Litholine HEP 2 Arco EP moly D 5 BP Vanellus C3 Gear oil EP Hypogear EP Energrease LS EP2 6 CALTEX RPM delo 400 RPM delo 450 Universal thuban Universal thuban EP Marfak all purpose 2 Ultra duty grease 2 7 CASTROL Turbomax RX super CRD EP EPX Hypoy Hypoy B Hypoy C MS3 Spheerol EPL2 8 CHEVRON Delo 400 Universal gear Ultra duty gr...

Page 235: ...irax heavy duty Albania EP grease 17 SUN Sunoco GL5 gear oil Sunoco ultra prestige 2EP Sun prestige 742 18 TEXACO Ursa super plus Ursa premium Multigear Multifak EP2 Starplex 2 Texaco Havoline XLC 19 TOTAL Rubia S Rubia X Total EP Total transmission TM Multis EP2 Total Fina Elf Glacelf CHP Supra 20 UNION Guardol MP gear lube LS Unoba EP 21 VEEDOL Turbostar Diesel star MDC Multigear Multigear B Mul...

Page 236: ...se tools are provided in tool box If any of the above tools are broken please order them from your Komatsu distributor No Name of tool Part No Remarks 1 Wrench 09014 10200 Applicable width across flats 36 mm 41 mm 2 Filter wrench 09019 08035 3 Grease pump 07950 10450 For greasing work 4 Nozzle 07951 41017 5 Grease cartridge 07950 90403 Lithium base grease 400 g 6 Pinch bar 09055 10390 7 Socket 20E...

Page 237: ...diameter a mm Width across flat b mm Tightening torque Target value Service limit N m kgf m N m kgf m 6 10 13 2 1 35 11 8 14 7 1 2 1 5 8 13 31 3 2 27 34 2 8 3 5 10 17 66 6 7 59 74 6 0 7 5 12 19 11 11 5 98 123 10 0 12 5 14 22 177 18 157 196 16 0 20 0 16 24 279 28 5 245 309 25 0 31 5 18 27 382 39 343 425 35 0 43 5 20 30 549 56 490 608 50 0 62 0 22 32 745 76 662 829 67 5 84 5 24 36 927 94 5 824 1030 ...

Page 238: ...ensure that they always maintain their function completely However if these parts show any abnormality before the replace ment interval has passed they should be repaired or replaced immediately If the hose clamps show any deterioration such as deformation or cracking replace the clamps at the same as the hoses When replacing the hoses always replace the O rings gaskets and other such parts at the...

Page 239: ... 5 Pump outlet hose Pump Control valve 2 6 Work equipment hose Boom cylinder inlet 4 7 Work equipment hose Bucket cylinder line Boom foot section 2 8 Work equipment hose Bucket cylinder inlet 2 9 Work equipment hose Arm cylinder line Boom foot section 2 10 Work equipment hose Arm cylinder inlet 2 11 Additional attachment line hose Boom foot section 2 12 Additional attachment line hose Boom top sec...

Page 240: ...2 CHECKING COOLANT LEVEL 255 CHECK AND TIGHTEN WHEEL NUTS 258 CHECK ELECTRICAL INTAKE AIR HEATER 258 CHECK ALTERNATOR 258 CHECK START MOTOR 259 REPLACE BUCKET SIDE CUTTERS 259 REPLACE BUCKET TEETH 260 ADJUST BUCKET CLEARANCE 264 CHECK WINDOW WASHER FLUID LEVEL ADD FLUID 265 CHECK AND ADJUST AIR CONDITIONER 266 DRAIN ENGINE BREATHER OIL CATCHER 267 CHECK BEFORE STARTING CHECK COOLANT LEVEL ADD WATE...

Page 241: ...5 Bucket cylinder rod end 1 point 275 Bucket Link coupling pin 2 points 275 Outrigger cylinder foot pin 2 or 4 points 275 Outrigger cylinder rod end 2 or 4 points 275 Outrigger leg pivot 2 or 4 points 275 Outrigger foot pivot 2 or 4 points 275 Propshaft 3 points 275 Boom adjust cylinder foot pin 1 point 274 Boom adjust cylinder rod end 1 points 274 Axle pivot 2 point with outriggers attached 275 A...

Page 242: ...NG PINION GREASE LEVEL ADD GREASE 286 CHANGE OIL IN ENGINE OIL PAN REPLACE ENGINE OIL FILTER CARTRIDGE 287 CLEAN AND INSPECT RADIATOR FINS OIL COOLER FINS AND CONDENSER FINS 288 CLEAN INTERNAL AND EXTERNAL AIR FILTERS OF AIR CONDITIONER SYSTEM 289 CLEANING RECIRCULATED AIR FILTER 290 REPLACE HYDRAULIC TANK BREATHER ELEMENT 291 CHECK VALVE RUBBER MOUNTS 291 EVERY 1000 HOURS SERVICE REPLACE HYDRAULI...

Page 243: ...AKER on page 322 EVERY 2000 HOURS SERVICE CLEAN HYDRAULIC TANK STRAINER 299 CLEAN CHECK TURBOCHARGER 299 CHECK ALTERNATOR STARTING MOTOR 299 CHANGE ANTIFREEZE 299 CHANGE ANTIFREEZE 299 CLEAN THE STRAINER OF THE BRAKE FILTER 300 CHECK AND ADJUST VALVE CLEARANCE 301 EVERY 4000 HOURS SERVICE CHECK WATER PUMP 301 EVERY 5000 HOURS SERVICE CHANGE OIL IN HYDRAULIC TANK AND REPLACE STEER BRAKE CIRCUIT STR...

Page 244: ...e 3 Swing pinion grease 19 Outrigger cylinder rod end grease 4 Boom arm coupling pin grease 20 Outrigger leg pivot grease 4 Arm cylinder rod end grease 21 Transmission oil check level change oil 4 Bucket cylinder foot pin grease 22 Wheel hubs front check level change oil 4 Arm bucket coupling pin grease 23 Wheel hubs rear check level change oil 4 Arm link coupling pin grease 24 Front axle check le...

Page 245: ...MAINTENANCE MAINTENANCE SCHEDULE CHART PW160 7H VEAM390100 245 Interval of service Change filter Lubrication by greasing G Amount of oil required at change litres Check oil level change EO ...

Page 246: ... INITIAL 250 HOURS SERVICE Carry out the following maintenance only after the first 250 hours REPLACE FUEL FILTER CARTRIDGE For details see REPLACE FUEL FILTER CARTRIDGE 285 CHECK ENGINE VALVE CLEARANCE ADJUST For details see CHECK ENGINE VALVE CLEARANCE ADJUST 246 For details of the method of replacing or maintaining see the section on EVERY 500 HOURS and 2000 HOURS SER VICE CHANGE OIL IN TRANSMI...

Page 247: ...lling out the outer element Checking If air cleaner clogging monitor H on the monitor panel lights up clean the air cleaner element Replacing Replacing element O ring If one year has passed since installing the element or if air cleaner clogging monitor H on the monitor panel flashes immediately after the element is cleaned replace the outer element inner element and O ring Replacing evacuator val...

Page 248: ...e left and right and rotate the element to the left and right to pull it out NOTICE Never remove the inner element It will allow dirt to enter and cause failure of the engine Do not use a screwdriver or other tool 1 After removing the outer element cover the air connector inside the air cleaner body with a clean cloth or tape to pre vent dirt or dust from entering 2 Wipe off or brush off the dirt ...

Page 249: ...year Replace the inner element at the same time Replace both inner and outer elements when the monitor lamp H lights up soon after installing the cleaned outer element even though it has not been cleaned 5 times When replacing the element new stick on seal is packed in the same box as the element Stick the seal in the posi tion 5 Remove the cloth or tape cover installed in Step 3 6 If small holes ...

Page 250: ...n straight 3 Push the outer element in straight with your hand when installing it to the air cleaner body If the element is held and rocked lightly up and down and to the left and right while pushing it in the element can be inserted easily NOTICE When inserting the element if the rubber at the tip is swollen or the outer element is not pushed in straight and cover 6 is assembled by force to hook ...

Page 251: ...an cloth or tape 3 Clean the air cleaner body interior then remove the cover from the air intake port in Step 2 4 Install a new inner element to the connector then tighten the nut NOTICE The inner element must not be cleaned and used again When replacing the outer element replace the inner element at the same time 5 Set the outer element in position then lock cover 6 with hooks 2 6 2 Top GL Evacua...

Page 252: ...ses mounted on the work equipment do not impede the engine hood when it is opened closed GENERAL The cooling system operates under pressure which is controlled by the pressure relief valve in the radiator cap The belt driven water pump circulates the coolant through the engine block cylinder heads radiator and engine oil cooler Cir culation is controlled by the thermostat which by passes coolant f...

Page 253: ...und when cleaning or changing the coolant Use a permanent type of antifreeze If for some reason it is impossible to use permanent type anti freeze use an antifreeze containing ethylene glycol Super Coolant AF ACL has an anti corrosion effect as well as an antifreeze effect The ratio of antifreeze to water depends on the ambient tempera ture but to obtain the corrosion resistance effect a minimum r...

Page 254: ...NG When removing drain plug avoid pouring coolant on your self REMOVAL WARNING Hot scalding coolant can spray out if the radiator cap is removed suddenly Relieve system pressure by slowly turning the cap to the first notch or lifting the safety lever if equipped Remove the cap only after the pressure is relieved Use extreme caution when adding coolant to the radiator to avoid being burned Wear glo...

Page 255: ...efore working on the engine or electrical system dis connect the negative ground battery cable Tag the cable and controls to warn against starting Wear hand and eye protection when draining hot fluids 1 Run the engine until it reaches operating temperature then stop the engine 2 Remove the radiator cap as outlined in this section 3 Remove the undercover Place a container below drain plug 4 Remove ...

Page 256: ...orrosion in the heater 1 Be sure the radiator drain is closed and tightened 2 Fill the cooling system to maximum capacity Fill with anti freeze For coolant specifications see COOLANT 226 See Precautions when filling radiator 224 3 Start engine and run until normal operating temperature is reached Add coolant when needed to keep proper level in reserve tank 4 After all air is removed and level rema...

Page 257: ...t from the radiator core using air or water under pressure Direct the flow through the core opposite to the normal direction of air flow THERMOSTAT REMOVAL 1 Drain the cooling system Refer to DRAINING THE SYSTEM 255 in this section 2 Remove the components and housing to access the thermo stat 3 Remove the thermostat and clean all gasket material from either mating surfaces INSTALLATION 1 Install n...

Page 258: ...y lubricated for life and require attention only at the time of major overhaul The alternator is equipped with an integral transistorized voltage regulator If the alternator fails to operate properly consult your distributor PRECAUTIONS REMARK The unit electrical system is negative ground Be CERTAIN the ground polarity is correct when a Installing a new battery b Connecting a battery charger c Usi...

Page 259: ...work equipment moves by mistake when the teeth are being replaced Set the work equip ment in a stable condition then stop the engine and apply the control lever pad safety lock In certain conditions it may be possible for the safety lock lever to contact the left hand arm rest on the opera tor seat to avoid this always ensure that the left hand arm rest is stowed in the fully up position before op...

Page 260: ...fety glasses gloves and other protective equipment 1 To make it possible to knock out the pin of tooth 1 set the bottom surface of the bucket on a block check that the work equipment is in a stable condition raise the safety lock lever to the LOCK position Set so that the bottom face of the bucket is horizontal 2 Use a hammer and drift to knock out lock pin 2 If the drift is set against rubber pin...

Page 261: ...s the teeth will not enter the adapter properly and there will not be proper contact at the mating portion 7 Fit tooth 1 to adapter 4 and confirm that when the tooth is pressed strongly the rear face of the hole for the pin of the tooth 1 is at the same level as the rear face of the hole for the pin of the adapter If the rear face of the hole for the pin of tooth 1 is protruding to the front from ...

Page 262: ...hit lock pin 2 in the reverse direction from which it was hit in Lightly hit the tip of the point from above and below and hit its sides from right and left Confirm that rubber pin lock 3 and lock pin 2 are set as shown in the figure The life of the teeth can be lengthened and the frequency of their replacement can be reduced by turning them upside down so that they will wear evenly Replace the ru...

Page 263: ...he surrounding area Pieces will often fly during the replacement operation so wear safety glasses gloves and other protective equip ment 1 Set the bottom of the bucket on a block to make it possible to remove pin 1 check that the work equipment is stable then raise the safety lock lever to the LOCK position Set so that the bottom of the bucket is horizontal 2 Place a bar on the pin head and strike...

Page 264: ...K position 2 Shift O ring 1 of the linkage and measure the amount of play a Measurement is easier if you move the bucket to one side or the other so all the play can be measured in one place In the diagram this is on the left hand side Use a gap clearance gauge for easy and accurate measure ment 3 Loosen the four plate fixing bolts 2 and loosen plate 3 Because it uses split shims you can carry out...

Page 265: ...d water Since the ratio should be varied depending on atmospheric tem perature replenish washer fluid at the following mixture ratio tak ing temperature into account Pure washer fluid comes in two types for 10ºC for general use and for 30ºC cold regions Use pure washer fluid according to operation area and season 1 Operation area and season Mixture ratio Freezing temperature Normal Pure washer flu...

Page 266: ...frigerant REMARK When there are bubbles the refrigerant gas level is low so contact your refrigerant dealer to have refrigerant added If the air conditioner is run with the refrigerant gas level low it will cause damage to the compressor Check in off season When not being used for a long period operate the cooler for 3 to 5 minutes once a month to supply lubricant to each component of the compress...

Page 267: ...o not open the radiator cap unless necessary When check ing the coolant always check the radiator reserve tank when the engine is cold 1 Open the rear door on the left side of the machine and check that the cooling water level is between the FULL and LOW marks on radiator reserve tank 1 shown in the diagram on the right If the water level is low add water through the water filler of reserve tank 1...

Page 268: ...tick G fully in the oil gauge pipe then take it out again 4 The oil level should be between the H and L marks on dipstick K If the oil level is below the L mark add engine oil through oil filler F For details of the oil to use Refer to USE FUEL COOL ANT AND LUBRICANTS ACCORDING TO AMBIENT TEM PERATURE 232 5 If the oil is above the H mark drain the excess engine oil from drain plug P and check the ...

Page 269: ...e tank is full 2 If the fuel level is below the E mark on the fuel gauge add fuel through filler port F while watching the float in the filler port Fuel capacity 290 litres For details of the fuel to use see USE FUEL COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPER ATURE 232 After adding fuel tighten the cap securely REMARK If breather hole 1 on the cap is clogged the pressure in the tank will d...

Page 270: ... G The oil level is normal if between the H and L marks REMARK Do not add oil if the level is above the H line This will damage the hydraulic equipment and cause the oil to spurt out 3 If the level is below the L mark remove cap F from the hydraulic tank and add oil For details of the oil to use see USE FUEL COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPER ATURE 232 REMARK The oil level will var...

Page 271: ...spect the water separator and check if the ring inside has risen to the marked line 3 If the ring has risen to the marked line carry out the proce dure from Step 4 4 Set a container under the water separator to catch the drained fuel 5 Secure fuel line to prevent leakage 6 Remove air bleed plug 5 at the top of the water separator 7 Loosen drain valve 1 at the bottom of the water separator and drai...

Page 272: ...L TANK 1 Carry out this procedure before operating the machine 2 Prepare a container to catch the fuel that is drained 3 Open valve 1 at the bottom of the tank and drain the sedi ment and water that has accumulated at the bottom together with fuel When doing this be careful not to get fuel on your self 4 When only clean fuel comes out close drain valve 1 REMARK Never use trichlene for washing the ...

Page 273: ...sing interval is 100 hours however more fre quent greasing will be required depending on conditions environ ment 1 Set the work equipment in the greasing posture below then lower the work equipment to the ground and stop the engine 2 Using a grease pump pump in grease through the grease fit tings shown by arrows 3 After greasing wipe off any old grease that was pushed out ...

Page 274: ...oupling pin 1 point 3 Boom Arm coupling pin 1point 4 Bucket cylinder foot pin 1 point 5 Arm cylinder rod end 1 point 6 Arm cylinder foot pin 1 point 7 Boom adjust cylinder rod end 1 points 8 1st to 2nd boom pin 3 points 9 Boom foot pin 2 points 10 Boom adjust cylinder foot pin 1 point 11 Boom cylinder foot pin 2 points 12 Lubricate swing circle 2 points 1 2 3 4 5 6 7 8 9 10 11 A B B 12 12 A ...

Page 275: ...ylinder rod end 1 point 15 Bucket Link coupling pin 2 points 16 Outrigger cylinder foot pin 2 or 4 points 17 Outrigger cylinder rod end 2 or 4 points 18 Outrigger leg pivot 2 or 4 points 19 Outrigger foot pivot 2 or 4 points 20 Propshaft 3 points 21 Not used 22 Axle pivot 2 point with outriggers attached 14 15 15 13 17 17 16 18 18 19 19 20 20 20 22 22 ...

Page 276: ...SERVICE PROCEDURE MAINTENANCE 276 PW160 7H VEAM390100 23 Axle pivot 2 point without outriggers 24 Hub pivot 4 points 25 Steer links 4 points 23 23 24 24 25 25 26 ...

Page 277: ...vot pin 2 points 29 Lower link blade pivot 2 points 30 Dozer blade cylinder rod end 2 points 31 Lower link pivot pin 2 points 32 Top link pivot pin 2 points 33 Cylinder guard pin remove and apply coating of grease CLEANING FRESH AIR FILTER 1 Pull up the lock release lever under the door release lever to release the lock 32 31 27 28 30 29 27 28 32 31 30 29 33 ...

Page 278: ... extremely dirty wash it in a neutral agent After rinsing it in water dry it thoroughly before using it again If the clogging of the filter cannot be removed by blowing with air or washing in water replace the filter with a new part 4 After cleaning insert the filter in filter case 3 again open the cover at the bottom left of the operator s cab by hand return the filter case to its original positi...

Page 279: ...dipstick G and wipe the oil from the dipstick with a cloth 2 Insert dipstick G fully in the guide 3 When dipstick G is pulled out if the oil level is between the H and L marks of the gauge oil level is correct 4 If the oil does not reach the L mark on dipstick G remove oil filler F and add engine oil 5 If the oil level exceeds the H mark on the dipstick loosen drain plug P to drain the excess oil ...

Page 280: ...NT TEMPER ATURE 232 CHECK OIL LEVEL IN WHEEL HUBS ADD OIL Rear Axle Prepare a hexagonal wrench 1 Rotate hub until the oil level line marked rear is horizontal 2 2 Remove plug 1 3 If no oil emerges add oil until there is an excess Allow excess to drain off and re install plug 1 For details of the oil to use see USE FUEL COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPER ATURE 232 CHECK OIL LEVEL IN...

Page 281: ... AMBIENT TEMPER ATURE 232 CHECK LEVEL OF BATTERY ELECTROLYTE WARNING To avoid gas explosions do not bring fire or sparks near the battery Battery electrolyte is dangerous If it gets in your eyes or on your skin wash it off with large amounts of water and consult a doctor Carry out this check before operating the machine 1 Open the battery box door on the front right hand side of the machine 2 Remo...

Page 282: ...ver on pry bar This will damage the belt side cords which will cause the belts to turn and result in complete destruction of the belts in operation Belts on new machines and replacement belts lose their tension as they seat into the pulley grooves Check the tension of new belts at 20 hour intervals until tension is stabilized and thereafter every 250 hours If the tension falls below the required m...

Page 283: ... should spin freely with no rough spots detected under hand pressure Install the new belt REMARK The belt tensioner is spring loaded and must be pivoted away from the belt Pivoting in the wrong direction can result in damage to the belt tensioner CHECK ADJUST TENSION OF AIR CONDITIONER COMPRESSOR BELT Checking Press the belt at a point midway between the drive pulley and compressor pulley with a f...

Page 284: ...the belt will be 5 8 mm approx 58 8N 6kgf 3 Tighten bolts 1 and 2 to secure bracket 4 4 Loosen bolt 6 to remove from bracket 4 5 Tighten nut 6 Check for damage to the pulleys and wear of the V groove and V belt Be particularly careful to check that the V belt is not in contact with the bottom of the V groove 7 If the belt has elongated and there is no more allowance for adjustment or if the belt i...

Page 285: ... and a container to catch the fuel Use a genuine Komatsu filter cartridge 1 Set the container to catch the fuel under the filter cartridge 2 Using a filter wrench turn filter cartridge 1 counterclockwise to remove it 3 Clean the filter holder fill a new filter cartridge with clean fuel coat the packing surface with engine oil then install it to the filter holder 4 After bringing the packing surfac...

Page 286: ...Use the feed pump to bleed air from the fuel system when the machine has run out of fuel too CHECK SWING PINION GREASE LEVEL ADD GREASE Prepare a scale 1 Remove bolts 1 2 bolts on the top of the revolving frame and remove cover A 2 Check the colour of the grease If it is milky white it is neces sary to change the grease Please contact your Komatsu dis tributor The total amount of grease is 10 5 li...

Page 287: ... the oil then install the plug tightly 3 Remove centre partition then use a filter wrench to turn filter cartridge 1 counter clockwise to remove it 4 Clean the filter holder fill the new filter cartridge with clean engine oil coat the packing surface and thread of the filter cartridge with engine oil or coat it thinly with grease then install the filter cartridge to the filter holder 5 Drain breat...

Page 288: ...he H and L marks on dipstick G For details see CHECK OIL LEVEL IN ENGINE OIL PAN ADD OIL 268 9 Install the undercover CLEAN AND INSPECT RADIATOR FINS OIL COOLER FINS AND CONDENSER FINS WARNING If compressed air high pressure water or steam hit your body directly or they cause dirt or dust to be blown up there is a danger of serious injury Use safety glasses dust mask or other protective equipment ...

Page 289: ...rneath and dispose of the dirt dust dry leaves etc which have fallen on it CLEAN INTERNAL AND EXTERNAL AIR FILTERS OF AIR CONDITIONER SYSTEM WARNING If compressed air high pressure water or steam hit your body directly or they cause dirt or dust to be blown up there is danger of serious injury Use safety glasses dust mask or other protective equipment NOTICE The interval for cleaning the filter is...

Page 290: ...rear left on the inside of the operator s cab then take out the recirculated air filter 2 Clean the filter with compressed air If there is oil on the filter or if the filter is extremely dirty wash and dry it thoroughly before using it again If the clogging of the filter cannot be removed by blowing with air or washing with water replace with new one ...

Page 291: ...ap turn it slowly to release the internal pressure then remove it carefully 1 Remove the cap of oil filter F 2 Replace element 1 inside the cap with a new one For component part numbers see WEAR PARTS LIST on page 231 CHECK CONDITION OF MAIN VALVE RUBBER MOUNTS If main valve bracket mounting rubbers 1 appear cracked or worn replace them If unsure then contact your komatsu distributor for advice F ...

Page 292: ...ne 2 Remove the cap from oil filler F and release the internal pressure 3 Loosen 6 bolts then remove cover 1 When doing this the cover may fly out under the force of spring 2 so hold the cover down when removing the bolts 4 After removing spring 2 valve 3 and strainer 4 take out element 5 Inspect the bottom of the filter case for dirt and remove it if any Be very careful not to let dirt fall into ...

Page 293: ...ody and feed the drain hose from the drain valve into the container 3 Loosen drain valve P and drain the oil Then tighten the drain valve again 4 Remove the cap from oil filler F and add the specified amount of engine oil through oil filler F 5 Pull out dipstick G and wipe the off oil from it with a clean cloth 6 Insert dipstick G into the gauge pipe as far as it will go and then pull out it again...

Page 294: ... tensioned pulley should spin freely with no rough spots defected under hand pressure Check the tensioner bearing Replace bearing if damaged Check fan hub With the drive belt removed rotate fan hub REMARK The fan hub should spin freely without excessive end play Check the fan hub bearing Replace bearing if damaged CHECK FAN BELT TENSION AND REPLACE FAN BELT Special tools are required for inspectio...

Page 295: ...2 to drain oil 2 Replace plug 2 3 Attach tube and funnel to plug 1 hole and add oil until oil emerges when tube is removed 4 Replace plug 1 REMARK The oil must be replaced after first hundred hours then main tenance is thousand hours Rear Axle 1 Remove plugs 1 and 2 to drain oil 2 Replace plug 2 2 1 1 A A 2 ...

Page 296: ... to drain off and re install plug 1 6 If no oil emerges add oil until there is an excess Allow excess to drain off and re install plug 1 REMARK The oil must be replaced after first hundred hours then main tenance is thousand hours 2 Rear Axle 1 Position hub with plug 2 at bottom and remove plug 1 and 2 2 When all oil has drained out re install plug 2 3 Rotate hub until the oil level line marked Re...

Page 297: ...RANSMISSION ASSEMBLY TRANSMISSION 1 Remove plugs 1 2 and allow oil to drain out 2 Replace plug 2 3 Add oil approx 4 85 l until oil emerges from plug 1 hole 4 Replace plug 1 REMARK The oil must be replaced after first hundred hours then main tenance is thousand hours 1 2 ...

Page 298: ...VEAM390100 CHANGE OIL IN DAMPER 1 Remove plugs 1 2 3 and allow oil to drain out 2 Replace plug 3 3 Add oil approx 0 75 l in position 1 until oil emerges from plug 2 hole 4 Replace plug 1 and 2 The oil must be replaced after thousand hours 1 2 3 ...

Page 299: ...ing the bolts 3 Pull up the top of rod 3 and remove spring 2 and strainer 4 4 Remove the dirt stuck to strainer 4 then wash it in clean die sel oil or flushing oil 5 If strainer 4 is damaged replace it with a new one 6 Refit strainer 4 by inserting it into the tank projecting part 5 7 Assemble it so that the protruding part at the bottom of cover 1 holds spring 2 then tighten the cover with the bo...

Page 300: ... oil filler cap turn the cap slowly to release the internal pressure then remove it carefully 3 Remove the undercover located below the radiator 4 Place a container under the brake filter 5 Remove hose 1 and flange 2 6 Remove strainer 3 from housing 4 and clean with diesel fuel 7 Refit strainer 3 into housing 4 Ensure side with o ring faces forward 8 Refit flange 2 and hose 1 9 Wipe off excess oil...

Page 301: ...all your Komatsu distributor for service EVERY 4000 HOURS SERVICE Maintenance for every 100 250 500 1000 and 2000 hours should be carried out at the same time CHECK WATER PUMP Since the pulley may have play oil may leak water may leak and the drain hole A may be clogged contact your Komatsu distribu tor for inspection overhaul or replacement 9JH02451A ...

Page 302: ...itres Prepare a handle for the socket wrench set 1 Retract the arm and bucket cylinders to the stroke end then lower the boom and put the bucket teeth in contact with the ground 2 Lock the safety lock lever and stop the engine 3 After the tank has cooled remove the cap from oil filler F on the hydraulic tank 4 Set an empty oil container under the drain plug under the machine Remove drain plug P an...

Page 303: ...0 Add the specified amount of engine oil through oil filler port F Check that the oil level is midway between H and L on the sight gauge For details of the method of bleeding the air see CHECK OIL LEVEL IN HYDRAULIC TANK ADD OIL 270 Procedure for bleeding air Follow steps 1 2 to bleed the air 1 Bleeding air from pump 1 Loosen air bleeder 1 installed to the drain port and check that oil oozes out C...

Page 304: ...end and retract each cylinder 4 5 times without operating it to the end of its stroke Stop approx 100 mm before the end of the stroke 2 Next alter engine speed to Max and operate each cylinder to the end of its stroke 3 4 times 3 After this operate each cylinder 4 5 times to the end of its stroke to completely bleed the air NOTICE If at first the engine is run at high speed or the cylinder is oper...

Page 305: ...PW160 7H VEAM390100 305 SPECIFICATIONS ...

Page 306: ...CE Bucket capacity standard bucket SAE 0 8 m Travel speed Creep speed 2 5 km h Low speed 10 km h High speed Non German specifi cation 35 km h German specification 20 km h Swing speed 11 5 rpm ENGINE Model Komatsu SAA4D102E 2 diesel engine Flywheel horsepower NET 87 5 kW 119 PS 2200 rpm Starting motor 24 V 4 5 kW Alternator 24 V 45 A Battery 12 V 95 AH x 2 STD 12 V 120AH x 2 OPTION ...

Page 307: ...SPECIFICATIONS SPECIFICATIONS PW160 7H VEAM390100 307 1 PIECE BOOM ...

Page 308: ...SPECIFICATIONS SPECIFICATIONS 308 PW160 7H VEAM390100 2 PIECE BOOM ...

Page 309: ... PIECE BOOM Arm length mm 2100 2500 3000 A Max digging height 8 730 8 930 9 285 B Max dumping height 6 335 6 555 6 911 C Max digging depth 4 925 5 320 5 600 D Min swing radius 3 205 3 160 3 180 E Max digging reach GL 8 620 8 885 9 315 E Max digging reach 8 640 9 070 9 485 ...

Page 310: ...PIECE BOOM Arm length mm 2100 2500 3000 A Max digging height 9 745 10 118 10 575 B Max dumping height 7 285 7 655 8 117 C Max digging depth 4 960 5 465 5 770 D Min swing radius 2 215 2 385 2 590 E Max digging reach GL 8 310 8 745 9 225 E Max digging reach 8 505 8 930 9 410 ...

Page 311: ...PW160 7H VEAM390100 311 OPTIONS ATTACHMENTS WARNING Please read and make sure that you understand the safety volume before reading this section ...

Page 312: ... on a flat firm ground surface When the operation is carried out by two or more work ers determine signals and follow these during the opera tion When carrying heavy objects more than 25 kg use a crane When removing heavy parts always support the part before removing it When lifting such heavy parts with a crane always pay careful attention to the position of the centre of gravity It is dangerous ...

Page 313: ...ays read this sec tion as a refresher every time attachments change WARNING Long work equipment reduces the stability of the chassis so if the swing is operated on a slope or when going down a steep hill the machine may lose its balance and overturn The following operations are particularly dangerous so never operate the machine in these ways Going downhill with the work equipment raised Traveling...

Page 314: ... to the stopping point Furthermore the hydraulic drift also becomes larger when the work equipment is stopped in mid air it will gradually move down under its own weight Always follow the correct procedure when installing the boom and arm If the correct procedure is not followed this may lead to serious damage or injury so please con sult your Komatsu distributor before carrying out instal lation ...

Page 315: ...n carrying out lifting operations reduce the engine speed and use the lifting operation mode Depending on the posture of the work equipment there is danger that the wire or load may slip off the hook Always be careful to maintain the correct hook angle to prevent this from happening Never steer the machine while lifting a load If the bucket with hook is turned and used for operations it will hit t...

Page 316: ...0100 MACHINES READY FOR ATTACHMENTS GENERAL LOCATIONS Clamshell Operation Selector valves to be in position shown for clamshell operation Selector valve in normal position to bucket cylinder Selector valve turned to clamshell operation Both valves must be in same position ...

Page 317: ...t this valve to the LOCK position 2 SELECTOR VALVE 2 This switches the flow of the hydraulic oil Position 1 When clamshell is used Position 2 When normal operation to bucket cylinder 3 CONTROL PEDAL 20 This is used to operate the attachment Pedal for two line attachment with auto deceleration mechanism The breaker is operated by right control lever button 2 and 31 The breaker is operated with righ...

Page 318: ...CUMULA TORS 144 This is installed to release any remaining pressure in the attach ment circuit after the engine is stopped Normally do not touch it HANDLING THE CLAMSHELL BUCKET This bucket is used for digging and loading in side ditches or confined spaces How to install clamshell bucket 1 Clamshell cylinder head feed 2 Clamshell cylinder bottom return 3 Rotate left 4 Rotate right Ensure valves A ...

Page 319: ...velling swing and stopping When mounting a clamshell bucket the bucket cylinder must be positioned at mid stroke to allow access to quick release couplers Connect couplers and retract bucket cylinder REMARK Isolate cylinder using lock valve and secure bucket links Do not swing the bucket to crush the rock or to cut through soil Do not use the bucket for hammering or pulling out piles etc Before le...

Page 320: ...showing the oil flow up or down then press input confirmation switch 12 It is possible to change the oil flow in segments of approx 10 litres min If fine adjustment is not necessary simply press input confir mation switch 12 The default setting is 140 litres min Even if the starting switch is turned OFF the set oil flow when the engine is next started will be the value set by the above procedure P...

Page 321: ...ng the oil flow up or down then press input confirmation switch 12 The default setting is the full flow approx 320 litres min Even if the starting switch is turned OFF the set oil flow when the engine is next started will be the value set by the above procedure Precautions when using Check that the stop valve is at the FREE position Check that the selector valve is in the position for general atta...

Page 322: ...that the stopper valve is in the OPEN position Consult with the attachment maker to decide whether it is necessary to install an accumulator for the attachment circuit For details of other precautions when handling the breaker read and use correctly the instruction manual provided by the breaker manufacturer The deterioration of the hydraulic oil when using the breaker is much faster than normal o...

Page 323: ...t control pedal Note that this does not completely release the pressure so when removing the accumulator in the control circuit loosen the connections slowly and do not stand in the direction where the oil spurs out LONG TERM STORAGE If the machine is not to be used for a long time do as follows Set the stop valve in the LOCK condition Install a blind plug to the valve Set the selector valve to th...

Page 324: ...ine model consult your Komatsu distributor HYDRAULIC BREAKER MAIN FIELDS OF APPLICATION Crushed rock Demolition work Road construction This attachment can be used for a wide range of work including demolition of buildings breaking up of road surfaces tunnel work breaking up slag rock crushing and breaking operations in quar ries Keep the chisel pushed perpendicularly against the impact sur face wh...

Page 325: ... gradually move out of line with each other so always adjust the bucket cylinder to keep them aligned Always keep the chisel pressed against the impact surface prop erly to prevent using the impact force when there is no resistance MISTAKEN METHODS OF USE To ensure that the machine has a long life and to ensure that operations are carried out in safety do not operate the machine in any of the foll...

Page 326: ...ng the chisel while carrying out impacting operations Holding the chisel horizontal or pointed up when carrying out impacting operations Twisting the chisel when it has penetrated the rock Pecking operations Extending the bucket cylinder fully and thrusting to raise the machine off the ground AL069830A AL069850A ...

Page 327: ...emolishing wooden houses and buildings and crushing foundation and roadbeds MISTAKEN METHODS OF USE To ensure that the machine has a long life and to ensure that operations are carried out in safety do not operate the machine in any of the following ways Do not operate the cylinder to the end of its stroke Always leave approx 5 cm to spare Impact operations using attachment Impact operations using...

Page 328: ... wide range of work including collecting or loading demolition waste materials and debris timber grass MISTAKEN METHODS OF USE To ensure that the machine has a long life and to ensure that operations are carried out in safety do not operate the machine in any of the following ways Do not operate the cylinder to the end of its stroke Always leave approx 5 cm to spare Operations using the swing forc...

Page 329: ...restry This bucket is widely used for demolition including breaking up work grading and digging clean up work after natural disasters dumping industrial waste and forestry work etc MISTAKEN METHODS OF USE To ensure that the machine has a long life and to ensure that operations are carried out in safety do not operate the machine in any of the following ways Do not operate the cylinder to the end o...

Page 330: ...al of rock or debris This attachment is mounted to the arm end and used to grasp rock debris etc by opening and closing the claws 3 to 5 corre sponding to the extension and retraction of the hydraulic cylinder MISTAKEN METHODS OF USE To ensure that the machine has a long life and to ensure that operations are carried out in safety do not operate the machine in any of the following ways Do not oper...

Page 331: ...S INTRODUCTION OF ATTACHMENTS AND EXTENDING MACHINE SERVICE LIFE PW160 7H VEAM390100 331 Operations using the swing force Operations using one side of work equipment Catching and dragging with claw end Gouging AM092360A ...

Page 332: ...crete blocks and rock etc The unique blade shape provides heavy crushing power MISTAKEN METHODS OF USE To ensure that the machine has a long life and to ensure that operations are carried out in safety do not operate the machine in any of the following ways Do not operate the cylinder to the end of its stroke Always leave approx 5 cm to spare Operations using cutting tip on one side only Impact op...

Page 333: ...arm and a chuck unit This facilitates operations such as driving and movable by 360 corners vertical driving and removing long piles driving in piles at corners vertical driving etc MISTAKEN METHODS OF USE To ensure that the machine has a long life and to ensure that operations are carried out in safety do not operate the machine in any of the following ways Do not operate the cylinder to the end ...

Page 334: ...ation can be carried out without removing the bucket This machine is used for laying U section gutters and hume pipes for water supply and sewerage as well as river and canal work agricultural civil engineering work and site preparation MISTAKEN METHODS OF USE To ensure that the machine has a long life and to ensure that operations are carried out in safety do not operate the machine in any of the...

Page 335: ...OPTIONS ATTACHMENTS INTRODUCTION OF ATTACHMENTS AND EXTENDING MACHINE SERVICE LIFE PW160 7H VEAM390100 335 Operating other work equipment during crane operation Excessive lengthening of wire rope ...

Page 336: ...OLS 9 10 11 5 1 2 6 3 4 7 8 1 Left control lever 7 Boom pedal for 2 piece boom or second attach ment operation pedal option 2 Horn 8 Clamshell rotate left 3 Power max button 9 Clamshell rotate right 4 Spare 10 Boom and chassis attachment select 5 Safety lock lever 11 Right control lever 6 Second attachment operation pedal option ...

Page 337: ...leration range the engine speed will suddenly increase so be careful when operating the levers This lever is used to operate the boom and bucket When the right control lever in this position the boom and the bucket will be retained in the position in which they stop For levers 3 and 5 the engine speed changes as follows because of the auto deceleration mechanism When the right control levers are a...

Page 338: ... to effectively move the arm through 30 in the direction towards the machine and 45 in the direction away from the machine making for efficient work SHOVEL WORK A shovel is suitable for excavating at a position higher than the machine LOADING WORK About half of the time spent during excavating and loading work is taken up by swinging Maximum work efficiency can be attained by carrying out work is ...

Page 339: ...ch STATIONARY DIGGING The excavation of trenches for main and branch water supply and drainage pipes can be done without changing the machines posi tion LIFTING SPOIL The rotating arm enables working from all directions Even if there is a structure between the excavator and the bucket the work can be done without hitting it BOX DIGGING Perfect corners can be dug without having to change position o...

Page 340: ...for each pin extract pins A and B After removing the pins make sure that they do not become contaminated with sand or mud and that the seals of bushing on both sides do not become damaged CAUTION Bucket size bucket weight Do not fit a bucket larger than those listed overleaf for com bination of undercarriage attachments material to be exca vated Fitting of lager bucket will cause machine to tip ov...

Page 341: ...UCKET If equipped This bucket is used in sloped ditch digging work The three different ditch inclination can be obtained by changing the angle of the attached plate The angles available are 45 40 and 38 Shape of ditch by 45 bucket Shape of ditch 40 bucket 45 ditch hole 45 40 38 ditch hole 40 ditch hole 38 ditch hole 38 40 ditch hole ...

Page 342: ...42 PW160 7H VEAM390100 Shape of ditch 38 bucket How to perform excavation Operate the boom the arm and the bucket to make the line A of the side plate of the bucket vertical To check this position guide plate B is installed beside the bucket pins Hold this plate horizontal when digging ...

Page 343: ...EATING MONITOR 85 ENGINE SERIAL NO PLATE POSITION 10 EVERY 100 HOURS SERVICE 273 EVERY 1000 HOURS SERVICE 292 EVERY 2000 HOURS SERVICE 299 EVERY 250 HOURS MAINTENANCE 279 EVERY 4000 HOURS SERVICE 301 EVERY 50 HOURS 272 EVERY 500 HOURS SERVICE 285 EVERY 5000 HOURS SERVICE 302 EXPLANATION OF COMPONENTS 72 F FEATURES 8 FILTERS 228 FIRE EXTINGUISHER 24 FIRE PREVENTION 22 FIRST AID KIT 24 FOREWORD 3 4 ...

Page 344: ... CRITICAL PARTS 239 SAFETY LOCK LEVER 112 SAFETY MESSAGES 5 SAFETY RULES 20 SEAT BELT 154 SPECIFICATIONS 306 STARTING ENGINE 158 STARTING IN COLD WEATHER 159 STARTING SWITCH 104 STEERING 170 STOPPING PARKING 172 STOPPING MACHINE EMERGENCY 173 STORING OIL AND FUEL 228 SWITCHES 103 T TIGHTENING TORQUE LIST 237 TIGHTENING TORQUE SPECIFICATIONS 237 TOWING 37 TRANSPORTATION 195 TRAVELLING ON PUBLIC HIG...

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Page 346: ...PW160 7H WHEELED EXCAVATOR Form No VEAM390100 2006 Komatsu Hanomag GmbH All Rights Reserved Printed in Germany 03 06 ...