KOMATSU PC160LC-8 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (SN:C20001 & UP) KOMATSU PC160LC-8
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KOMATSU PC160LC-8 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (SN:C20001 & UP) KOMATSU PC160LC-8
- 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: magazine box on the left side of the 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 “YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR (PAGE 1-6)”. 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
TABLE OF CONTENTS:
KOMATSU PC160LC-8 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (SN:C20001 & UP) KOMATSU PC160LC-8
FOREWORD 1- 1
BEFORE READING THIS MANUAL 1- 2
SAFETY INFORMATION 1- 3
INTRODUCTION 1- 4
USE OF MACHINE 1- 4
DIRECTIONS OF MACHINE 1- 4
VISIBILITY FROM OPERATOR’S SEAT 1- 4
PRODUCT INFORMATION 1- 5
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE 1- 5
EPA REGULATIONS, ENGINE NUMBER PLATE 1- 5
SERVICE METER LOCATION 1- 6
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR 1- 6
SAFETY 2- 1
SAFETY 2- 2
SAFETY LABELS 2- 5
LOCATION OF SAFETY LABELS 2- 6
SAFETY LABELS 2- 7
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE 2- 14
PRECAUTIONS BEFORE STARTING OPERATION 2- 14
PREPARATIONS FOR SAFE OPERATION 2- 14
FIRE PREVENTION 2- 16
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE 2- 17
DO NOT GET CAUGHT IN WORK EQUIPMENT 2- 19
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES 2- 19
PROTECTION AGAINST FALLING, FLYING, INTRUDING OBJECTS 2- 19
UNAUTHORIZED MODIFICATION 2- 20
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS 2- 20
PRECAUTIONS RELATED TO CAB GLASS 2- 20
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING 2- 20
PRECAUTIONS FOR OPERATION 2- 21
PRECAUTIONS FOR JOBSITE 2- 21
STARTING ENGINE 2- 23
OPERATION 2- 25
TRANSPORTATION 2- 33
TOWING 2- 34
LIFTING OBJECTS WITH BUCKET 2- 34
PRECAUTIONS FOR MAINTENANCE 2- 35
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE 2- 35
PRECAUTIONS FOR INSPECTION AND MAINTENANCE 2- 39
OPERATION 3- 1
MACHINE VIEW ILLUSTRATIONS 3- 2
OVERALL MACHINE VIEW 3- 2
CONTROLS AND GAUGES 3- 3
DETAILED CONTROLS AND GAUGES 3- 5
MONITORING SYSTEM 3- 5
SWITCHES 3- 71
CONTROL LEVERS AND PEDALS 3- 75
SUN ROOF 3- 78
WINDSHIELD 3- 78
EMERGENCY ESCAPE HAMMER 3- 84
DOOR LOCK 3- 84
CAP WITH LOCK 3- 85
DRINK BOX 3- 87
MAGAZINE BOX 3- 87
ASHTRAY 3- 87
AIR CONDITIONER CONTROLS 3- 88
RADIO 3-101
AUXILIARY ELECTRIC POWER 3-106
FUSE 3-107
FUSIBLE LINK 3-108
CONTROLLER 3-108
TOOL BOX 3-108
GREASE GUN HOLDER 3-109
FIRE EXTINGUISHER 3-109
MACHINE OPERATIONS AND CONTROLS 3-110
BEFORE STARTING ENGINE 3-110
STARTING ENGINE 3-129
AFTER STARTING ENGINE 3-132
STOPPING THE ENGINE 3-143
MACHINE OPERATION 3-144
STEERING THE MACHINE 3-148
SWINGING 3-150
WORK EQUIPMENT CONTROLS AND OPERATIONS 3-151
WORKING MODE 3-153
PROHIBITED OPERATIONS 3-155
GENERAL OPERATION INFORMATION 3-158
TRAVELING ON SLOPES 3-160
ESCAPE FROM MUD 3-162
RECOMMENDED APPLICATIONS 3-163
BUCKET REPLACEMENT AND INVERSION 3-165
PARKING MACHINE 3-169
MACHINE INSPECTION AFTER DAILY WORK 3-170
LOCKING 3-171
TRANSPORTATION 3-172
TRANSPORTATION PROCEDURE 3-172
LOADING AND UNLOADING WITH TRAILER 3-173
LIFTING MACHINE 3-183
COLD WEATHER OPERATION 3-185
COLD WEATHER OPERATION INFORMATION 3-185
AFTER DAILY WORK COMPLETION 3-187
AFTER COLD WEATHER SEASON 3-187
LONG TERM STORAGE 3-188
BEFORE STORAGE 3-188
DURING STORAGE 3-188
AFTER STORAGE 3-189
STARTING MACHINE AFTER LONG-TERM STORAGE 3-189
TROUBLES AND ACTIONS 3-190
RUNNING OUT OF FUEL 3-190
PHENOMENA THAT ARE NOT FAILURES 3-190
TOWING THE MACHINE 3-191
LIGHTWEIGHT TOWING HOLE 3-192
SEVERE JOB CONDITION 3-192
DISCHARGED BATTERY 3-193
OTHER TROUBLE 3-197
MAINTENANCE 4- 1
MAINTENANCE INFORMATION 4- 2
OUTLINE OF SERVICE 4- 4
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC 4- 4
ELECTRIC SYSTEM MAINTENANCE 4- 7
WEAR PARTS 4- 8
WEAR PARTS LIST 4- 8
RECOMMENDED FUEL, COOLANT, AND LUBRICANT 4- 9
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER
THAN KOMATSU GENUINE OIL 4- 11
TIGHTENING TORQUE SPECIFICATIONS 4- 12
TIGHTENING TORQUE LIST 4- 12
SAFETY CRITICAL PARTS 4- 13
SAFETY CRITICAL PARTS LIST 4- 14
MAINTENANCE SCHEDULE 4- 15
MAINTENANCE SCHEDULE CHART 4- 15
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER 4- 17
MAINTENANCE PROCEDURE 4- 18
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS) 4- 18
INITIAL 500 HOURS MAINTENANCE (ONLY AFTER THE FIRST 500 HOURS) 4- 18
WHEN REQUIRED 4- 19
CHECK BEFORE STARTING 4- 44
EVERY 100 HOURS MAINTENANCE 4- 45
EVERY 250 HOURS MAINTENANCE 4- 46
EVERY 500 HOURS MAINTENANCE 4- 50
EVERY 1000 HOURS MAINTENANCE 4- 63
EVERY 2000 HOURS MAINTENANCE 4- 69
EVERY 4000 HOURS MAINTENANCE 4- 76
EVERY 5000 HOURS MAINTENANCE 4- 80
EVERY 8000 HOURS MAINTENANCE 4- 81
SPECIFICATIONS 5- 1
SPECIFICATIONS 5- 2
ATTACHMENTS AND OPTIONS 6- 1
GENERAL PRECAUTIONS FOR SAFETY 6- 2
PRECAUTIONS WHEN SELECTING 6- 2
READ THE INSTRUCTION MANUAL THOROUGHLY 6- 2
PRECAUTIONS WHEN REMOVING OR INSTALLING 6- 2
PRECAUTIONS WHEN USING 6- 2
BUCKET WITH HOOK 6- 3
HOOK CONDITION 6- 3
PROHIBITED OPERATIONS 6- 3
MACHINE READY FOR ATTACHMENT 6- 4
LOCATIONS 6- 4
HYDRAULIC CIRCUIT 6- 8
ATTACHMENT REMOVAL AND INSTALLATION 6- 13
1TOWING THE MACHINE 3-191
LIGHTWEIGHT TOWING HOLE 3-192
SEVERE JOB CONDITION 3-192
DISCHARGED BATTERY 3-193
OTHER TROUBLE 3-197
MAINTENANCE 4- 1
MAINTENANCE INFORMATION 4- 2
OUTLINE OF SERVICE 4- 4
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC 4- 4
ELECTRIC SYSTEM MAINTENANCE 4- 7
WEAR PARTS 4- 8
WEAR PARTS LIST 4- 8
RECOMMENDED FUEL, COOLANT, AND LUBRICANT 4- 9
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER
THAN KOMATSU GENUINE OIL 4- 11
TIGHTENING TORQUE SPECIFICATIONS 4- 12
TIGHTENING TORQUE LIST 4- 12
SAFETY CRITICAL PARTS 4- 13
SAFETY CRITICAL PARTS LIST 4- 14
MAINTENANCE SCHEDULE 4- 15
MAINTENANCE SCHEDULE CHART 4- 15
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER 4- 17
MAINTENANCE PROCEDURE 4- 18
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS) 4- 18
INITIAL 500 HOURS MAINTENANCE (ONLY AFTER THE FIRST 500 HOURS) 4- 18
WHEN REQUIRED 4- 19
CHECK BEFORE STARTING 4- 44
EVERY 100 HOURS MAINTENANCE 4- 45
EVERY 250 HOURS MAINTENANCE 4- 46
EVERY 500 HOURS MAINTENANCE 4- 50
EVERY 1000 HOURS MAINTENANCE 4- 63
EVERY 2000 HOURS MAINTENANCE 4- 69
EVERY 4000 HOURS MAINTENANCE 4- 76
EVERY 5000 HOURS MAINTENANCE 4- 80
EVERY 8000 HOURS MAINTENANCE 4- 81
SPECIFICATIONS 5- 1
SPECIFICATIONS 5- 2
ATTACHMENTS AND OPTIONS 6- 1
GENERAL PRECAUTIONS FOR SAFETY 6- 2
PRECAUTIONS WHEN SELECTING 6- 2
READ THE INSTRUCTION MANUAL THOROUGHLY 6- 2
PRECAUTIONS WHEN REMOVING OR INSTALLING 6- 2
PRECAUTIONS WHEN USING 6- 2
BUCKET WITH HOOK 6- 3
HOOK CONDITION 6- 3
PROHIBITED OPERATIONS 6- 3
MACHINE READY FOR ATTACHMENT 6- 4
LOCATIONS 6- 4
HYDRAULIC CIRCUIT 6- 8
ATTACHMENT REMOVAL AND INSTALLATION 6- 13
ATTACHMENT OPERATIONS 6- 17
LONG TERM STORAGE 6- 21
SPECIFICATIONS 6- 21
ATTACHMENT GUIDE 6- 22
ATTACHMENT COMBINATIONS 6- 23
TRACK SHOES SELECTION 6- 24
BUCKET TEETH SELECTION 6- 25
RECOMMENDED ATTACHMENT OPERATIONS 6- 26
HYDRAULIC BREAKER 6- 26
HANDLING MACHINES EQUIPPED WITH KOMTRAX 6- 31
BASIC PRECAUTIONS 6- 31
INDEX 7- 1
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