Komatsu PC160LC-8 Hydraulic Excavator Operation & Maintenance Manual
TABLE OF CONTENTS:
Komatsu PC160LC-8 Hydraulic Excavator Operation & Maintenance Manual
COVER.......................................................................................... 1 FOREWORD....................................................................................... 2 BEFORE READING THIS MANUAL................................................................. 3 SAFETY INFORMATION......................................................................... 4 INTRODUCTION............................................................................... 5 USE OF MACHINE......................................................................... 5 DIRECTIONS OF MACHINE.................................................................. 5 VISIBILITY FROM OPERATOR'S SEAT........................................................ 5 PROTECTIVE STRUCTURE................................................................... 5 PRODUCT INFORMATION........................................................................ 6 PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE........................... 6 EPA REGULATIONS, ENGINE NUMBER PLATE................................................... 6 SERVICE METER LOCATION................................................................. 7 YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR............................................ 7 CONTENTS................................................................................... 8 SAFETY......................................................................................... 12 SAFETY..................................................................................... 13 SAFETY LABELS.............................................................................. 16 LOCATION OF SAFETY LABELS.............................................................. 17 SAFETY LABELS.......................................................................... 18 GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE.................................... 26 PRECAUTIONS BEFORE STARTING OPERATION.................................................. 26 PREPARATIONS FOR SAFE OPERATION........................................................ 26 FIRE PREVENTION........................................................................ 28 PRECAUTIONS WHEN GETTING ON OR OFF MACHINE............................................. 29 DO NOT GET CAUGHT IN WORK EQUIPMENT.................................................... 31 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES........................................... 31 PROTECTION AGAINST FALLING, FLYING, INTRUDING OBJECTS.................................. 32 UNAUTHORIZED MODIFICATION.............................................................. 33 PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS......................................... 33 PRECAUTIONS RELATED TO CAB GLASS....................................................... 33 PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING........................................ 33 PRECAUTIONS FOR OPERATION.................................................................. 34 PRECAUTIONS FOR JOBSITE................................................................ 34 STARTING ENGINE........................................................................ 36 OPERATION.............................................................................. 38 TRANSPORTATION......................................................................... 46 TOWING................................................................................. 47 LIFTING OBJECTS WITH BUCKET............................................................ 47 PRECAUTIONS FOR MAINTENANCE................................................................ 48 PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE................................. 48 OPERATION...................................................................................... 58 MACHINE VIEW ILLUSTRATIONS................................................................. 59 OVERALL MACHINE VIEW................................................................... 59 CONTROLS AND GAUGES.................................................................... 60 DETAILED CONTROLS AND GAUGES............................................................... 62 MONITORING SYSTEM...................................................................... 62 SWITCHES...............................................................................128 CONTROL LEVERS AND PEDALS..............................................................132 SUN ROOF...............................................................................135 WINDSHIELD.............................................................................135 EMERGENCY ESCAPE HAMMER................................................................141 DOOR LOCK..............................................................................141 CAP WITH LOCK..........................................................................142 DRINK BOX..............................................................................144 MAGAZINE BOX...........................................................................144 ASHTRAY................................................................................144 AIR CONDITIONER CONTROLS...............................................................145 RADIO..................................................................................158 AUXILIARY ELECTRIC POWER...............................................................163 FUSE...................................................................................164 FUSIBLE LINK...........................................................................165 CONTROLLER.............................................................................165 TOOL BOX...............................................................................165 GREASE GUN HOLDER......................................................................166 FIRE EXTINGUISHER......................................................................166 MACHINE OPERATIONS AND CONTROLS............................................................167 BEFORE STARTING ENGINE.................................................................167 STARTING ENGINE........................................................................189 AFTER STARTING ENGINE..................................................................192 STOPPING THE ENGINE....................................................................203 MACHINE OPERATION......................................................................204 STEERING THE MACHINE...................................................................208 SWINGING...............................................................................210 WORK EQUIPMENT CONTROLS AND OPERATIONS.................................................211 WORKING MODE...........................................................................213 PROHIBITED OPERATIONS..................................................................215 GENERAL OPERATION INFORMATION..........................................................218 TRAVELING ON SLOPES....................................................................220 ESCAPE FROM MUD........................................................................222 RECOMMENDED APPLICATIONS...............................................................223 BUCKET REPLACEMENT AND INVERSION.......................................................225 PARKING MACHINE........................................................................229 MACHINE INSPECTION AFTER DAILY WORK....................................................230 LOCKING................................................................................231 TRANSPORTATION.............................................................................232 TRANSPORTATION PROCEDURE...............................................................232 LOADING AND UNLOADING WITH TRAILER.....................................................233 LIFTING MACHINE........................................................................243 COLD WEATHER OPERATION.....................................................................245 COLD WEATHER OPERATION INFORMATION.....................................................245 AFTER DAILY WORK COMPLETION............................................................247 AFTER COLD WEATHER SEASON..............................................................247 LONG TERM STORAGE..........................................................................248 BEFORE STORAGE.........................................................................248 DURING STORAGE.........................................................................248 AFTER STORAGE..........................................................................249 STARTING MACHINE AFTER LONG-TERM STORAGE...............................................249 TROUBLES AND ACTIONS.......................................................................250 RUNNING OUT OF FUEL....................................................................250 PHENOMENA THAT ARE NOT FAILURES........................................................250 TOWING THE MACHINE.....................................................................251 LIGHTWEIGHT TOWING HOLE................................................................252 SEVERE JOB CONDITION...................................................................252 DISCHARGED BATTERY.....................................................................253 OTHER TROUBLE..........................................................................257 MAINTENANCE....................................................................................264 MAINTENANCE INFORMATION....................................................................265 OUTLINE OF SERVICE.........................................................................267 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC.................................267 ELECTRIC SYSTEM MAINTENANCE............................................................270 WEAR PARTS.................................................................................271 WEAR PARTS LIST........................................................................271 RECOMMENDED FUEL, COOLANT, AND LUBRICANT...................................................272 RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL....274 TIGHTENING TORQUE SPECIFICATIONS...........................................................275 TIGHTENING TORQUE LIST.................................................................275 SAFETY CRITICAL PARTS......................................................................276 SAFETY CRITICAL PARTS LIST.............................................................277 MAINTENANCE SCHEDULE.......................................................................278 MAINTENANCE SCHEDULE CHART.............................................................278 MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER.............................................280 MAINTENANCE PROCEDURE......................................................................281 INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS).........................281 INITIAL 500 HOURS MAINTENANCE (ONLY AFTER THE FIRST 500 HOURS).........................281 WHEN REQUIRED..........................................................................282 CHECK BEFORE STARTING..................................................................309 EVERY 100 HOURS MAINTENANCE............................................................310 EVERY 250 HOURS MAINTENANCE............................................................311 EVERY 500 HOURS MAINTENANCE............................................................315 EVERY 1000 HOURS MAINTENANCE...........................................................328 EVERY 2000 HOURS MAINTENANCE...........................................................335 EVERY 4000 HOURS MAINTENANCE...........................................................342 EVERY 5000 HOURS MAINTENANCE...........................................................346 EVERY 8000 HOURS MAINTENANCE...........................................................347 SPECIFICATIONS.................................................................................348 SPECIFICATIONS.............................................................................349 ATTACHMENTS AND OPTIONS........................................................................352 GENERAL PRECAUTIONS FOR SAFETY.............................................................353 PRECAUTIONS WHEN SELECTING.............................................................353 READ THE INSTRUCTION MANUAL THOROUGHLY.................................................353 PRECAUTIONS WHEN REMOVING OR INSTALLING................................................353 PRECAUTIONS WHEN USING.................................................................353 BUCKET WITH HOOK...........................................................................354 HOOK CONDITION.........................................................................354 PROHIBITED OPERATIONS..................................................................354 MACHINE READY FOR ATTACHMENT...............................................................355 LOCATIONS..............................................................................355 HYDRAULIC CIRCUIT......................................................................359 ATTACHMENT REMOVAL AND INSTALLATION....................................................364 ATTACHMENT OPERATIONS..................................................................368 LONG TERM STORAGE......................................................................372 SPECIFICATIONS.........................................................................372 ATTACHMENT GUIDE...........................................................................373 ATTACHMENT COMBINATIONS................................................................374 TRACK SHOES SELECTION..................................................................375 BUCKET TEETH SELECTION.................................................................376 RECOMMENDED ATTACHMENT OPERATIONS..........................................................377 HYDRAULIC BREAKER......................................................................377 HANDLING MACHINES EQUIPPED WITH KOMTRAX....................................................382 BASIC PRECAUTIONS......................................................................382 INDEX..........................................................................................384
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DESCRIPTION:
Komatsu PC160LC-8 Hydraulic Excavator Operation & Maintenance Manual
BEFORE READING THIS MANUAL:
This manual gives details of the operation and methods of inspection and maintenance for this machine that must be obeyed in order to use the machine safely. Most accidents are caused by the failure to follow fundamental safety rules for the operation and maintenance of machines. Read, understand and follow all precautions and warnings in this manual and on the machine before performing operation and maintenance. Failure to do so may result in serious injury or death.
- Komatsu cannot predict every circumstance that might involve a potential hazard when the machine is used. Therefore, the safety messages in this manual and on the machine may not include all possible safety precautions. If you carry out any operation, inspection, or maintenance under conditions that are not described in this manual, understand that it is your responsibility to take the necessary precautions to ensure safety. In no event should you or others engage in the prohibited uses or actions described in this manual.
- Improper operation and maintenance of the machine can be hazardous and could result in serious injury or death. If you sell the machine, be sure to give this manual to the new owner together with the machine. Always keep this Operation and Maintenance Manual in the location shown on the right so that all relevant personnel can read it at any time. Storage location for the Operation and Maintenance Manual: Pocket (1) at rear of operator’s seat If this manual is lost or damaged, contact your distributor immediately to arrange for its replacement.
- For details regarding the machine serial No. you will need to provide your Komatsu distributor, see “TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR (PAGE 1-7)”. This manual uses the international units (SI) for units of measurement. For reference, units that have been used in the past are given in ( ). The explanations, values, and illustrations in this manual have been prepared based on the latest information available as of the date of its publication.
- Continuing improvements in the design of this machine may lead to additional changes that are not reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest available information concerning your machine or with questions regarding information contained in this manual.
- The numbers in circles in the illustrations correspond to the numbers in ( ) in the text. (For example:1 → (1)) Komatsu delivers machines that comply with all applicable regulations and standards of the country to which it has been shipped. If this machine has been purchased in another country, it may lack certain safety devices and specifications that are necessary for use in your country. If there is any question about whether your product complies with the applicable standards and regulations of your country, consult Komatsu or your Komatsu distributor before operating the machine.
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