Komatsu PW160-7, PW1607H User Manual
Operation &
Maintenance Manual
PW160-7H
VEAM390100
WHEELED EXCAVATOR
SERIAL NUMBER
PW160-7H - H50051
WARNING
and up
Unsafe use of this machine may cause serious 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.
FOREWORD
PW160-7H VEAM390100 3
FOREWORD FOREWORD
FOREWORD
This manual provides rules and guidelines which will help you use this machine safely and effectively. Keep this
manual handy and have all personnel read it periodically. If this manual has been lost or has become dirty and can
not be read, request a replacement manual from Komatsu or your Komatsu distributor.
If you sell the machine, be sure to give this manual to the new owners.
Continuing improvements in the design of this machine can lead to changes in detail which may not be reflected in
this manual. Consult Komatsu or your Komatsu distributor for the latest available information for your machine or
for questions regarding information in this manual.
WARNING
● This operation & maintenance manual may contain
attachments and optional equipment that are not available in your area. Please consult your local Ko matsu distributor for those items you require.
● This machine complies with EC directive (89/392/EEC).
Machines complying with this directive display the CE
mark
● Improper operation and maintenance of this machine can
be hazardous and could result in serious injury or death.
● Operators and maintenance personnel should read this
manual thoroughly before beginning operation or maintenance.
● Some actions involved in operation and maintenance of
the machine can cause a seriou s ac ciden t, if they are not
done in a manner described in this manual.
● The procedures and precautions given in this manual
apply only to intended uses of the machine. If you use
your machine for any unintended uses that are not specifically prohibited, you must be sure that it is safe for
you and others. In no event should you or others engage
in prohibited uses or actions as described in this manual.
● Komatsu delivers machines that comply with al l applica-
ble regulations and standards of the country to which it
has been shipped. If this machine has been purchased in
another country or purchased from someone in another
country, it may lack certain safety devices and specifications that are necessary for use in your country. If there
is any question abou t whether your prod uct complies
with the applicable standards and regulations of your
country, consult Komatsu or your Komatsu distributor
before operating the machine.
● The description of safety is given, see "SAFETY INFOR-
MATION (5)" and in "SAFETY" from page 19.
4 PW160-7H VEAM390100
FOREWORD SAFETY INFORMATION
SAFETY INFORMAT ION
SAFETY MESSAGES
Most accidents are caused by the failure to follow fundamental
safety rules for the operation and maintenance of machines.
To avoid accidents, read, un derstand and fo llow all pr ecautions
and warnings in this man ual a nd on the m achine be fore pe rforming operation and maintenance.
To identify hazards on the machine pi ctoria l decal s are use d (see
POSITION FOR ATTACHING SAFETY LABELS).
RED WARNING TRIANGLE - This is used on safety
labels where there is a high probability of serious injury or death if
the hazard is not av oided. The se safety message s or labe ls usually describe precautions that must be taken to avoid the hazard.
Failure to avoid this hazard may also result in serious dam age to
the machine.
ORANGE WARNING TRIANGLE - This is used on
safety labels where there is a potentially dangerous situation
which could result in serious injury or death if the hazard is not
avoided. These safety messages or labels usually des cribe precautions 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 result could be damage to the
machine.
NOTICE - This word is used for precautions that must be taken to
avoid actions which could shorten the life of the machine.
Safety precautions are described in SAFETY from page 19.
Komatsu cannot predict every circumstance that might involve a
potential hazard in operation and maintenance. Therefore the
safety message in this manual and on the machine may not
include all possible safety precautions. If any procedures or
actions not s pecifi cally re comm ended o r allow ed in this m anual
are used, you must be sur e that yo u and othe rs ca n do such pr ocedures and actions s afely and w ithout d amagin g the machine. If
you are unsure about the safety of some procedures, contact
Komatsu or your Komatsu distributor.
PW160-7H VEAM390100 5
SAFETY INFORMATION FOREWORD
NOISE
● Sound pressure level at the operator’s station, measured
according to ISO6396 (Dynamic test method, simulated working cycle).
71
● Sound power level emitted. This is the gu aranteed value as
specified in the European directive 2000/14/EC
VIBRATION
● The weighted root mean square acceleration value to whic h
the operator’s arms are subjected does not exceed 2.5 m/s²
● The weighted root mean square acceleration value to whic h
the operator’s body is subjected was measured at 0.5m/s²
These results were obtained by accelerometers during trench digging.
● This machine is equipped with an operators seat which meets
the requirements of ENISO 7096.
101
6 PW160-7H VEAM390100
FOREWORD SAFETY INFORMATION
EMERGENCY STEERING
This machine is equipp ed with an emergency steering system
and complies to ISO 501 0 (BSEN 12643) . In the a dvent o f failure
of the source of power for the steering system (eng ine failure)
whilst travelli ng, the machine can be steer ed allowing the
machine to be safely stopped.
In such a case, the effort required at the steering wheel and the
number of turns to steer the machine will increa se. To confirm
function of emergency 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 t he advent of failure of the sou rce of
power for the b raki ng s ystem ( en gin e failure) whilst tr av el li ng, the
brakes can be actuated from stored energy in the accumulators to
bring the machine safely to a stop.
In such a case, seven brake applications can be made before
exhausting the energy in the accumulators. In the advent of service brake failure, the park brake can be used as an emergency
brake to bring the machine to a stop.
PW160-7H VEAM390100 7
INTRODUCTION FOREWORD
INTRODUCTION
INTENDED USE
This Komatsu HYDRAULIC EXCAVATOR is designed to be used
mainly for the following work:
● Digging
● Smoothing work
● Ditching work
● Loading work
See the section see "WORK POSSIBLE USING HY DRAULIC EXCAVATOR (185)" for further details
FEATURES
● This Komatsu HYDRAULIC EXCAVATOR is equipped with
various controls based on an advanced electronics system.
● The monitor panel greatly facilitates daily maintenance and
self-diagnosis.
● Working mode & travel speed are selectable.
● Digging and lifting force can be incr eased by light -touch con-
trol. (For details, see operation section.)
● Adjustable wrist co ntrol levers make operation s smooth and
easy.
● Fresh filtered air conditioner assures comfortable operation.
● Low noise level and smart urban style design and colouring.
● Superb operation per formance provided by powerful engine
and high-performance hydraulic pump.
● Low fuel consumptio n contro lled by an ele ctronic contr ol sy s-
tem provides an environment-friendly machine.
● Sophisticated driv e train provides fast and smooth tr avelling
on the highway and off road.
8 PW160-7H VEAM390100
FOREWORD INTRODUCTION
BREAKING IN YOUR NEW MACHINE
Your Komatsu machi ne h as been thorou ghly adj uste d and tes ted
before shipment.
However, operating the machine under severe cond itions at the
beginning can adversely affect the performance and shorten the
machine life.
Be sure to break in the machine for the initial 100 hours (as indicated by the hour meter.)
During breaking in:
● Idle the engine for 5 minutes after starting it up.
● Avoid operation with heavy loads or at high speeds.
● Sudden starting or acceleration, unnecessarily abrupt braking
and sharp turning should be avoided except in cases of emergency.
Additionally for the first 20 hours
● Avoid operating engine for prolonged periods at constant
speed (including idle.)
● Avoid high speed travelling for p eriods 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 thi s manual for o perating, mainte nan ce,
and safety procedures are only those that apply when this product
is used for the specified purpose. If the machine is used for a purpose that is not listed in this manual, Komatsu cannot bear any
responsibility for safety. All consideration of safe ty i n such oper ations is the responsibility of the user.
Operations that are prohibited in this manual must never be carried out under any circumstances.
PW160-7H VEAM390100 9
LOCATIONS OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR FOREWORD
LOCATIONS OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR
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
10 PW160-7H VEAM390100
FOREWORD LOCATIONS OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR
MACHINE SERIAL PLATES
STANDARD SERIAL PLA TE
Max. drawbar pull
Identification Number
Weight
Engine power
Product
Model
Manufactured by Komatsu Hanomag GmbH, Hannover, Germany
under License from Komatsu Ltd.
Serial num ber
Manufacturing year
PW160-7H VEAM390100 11
LOCATIONS OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR FOREWORD
12 PW160-7H VEAM390100
CONTENTS
FOREWORD.........................................................................................................3
FOREWORD .................... ................................. ................................ ................................ ...................................... 4
SAFETY INFORMATION ........................................................................................................................................ 5
SAFETY MESSAGES ...................... ....... ...... ................................................................................................ 5
NOISE .................... .......................... .......................... .......................... ......................................................... 6
VIBRATION ................................................................................................................................................... 6
EMERGENCY STEERING ........................................................................................................................... 7
INTRODUCTION ..................................................................................................................................................... 8
INTENDED USE ........................................................................................................................................... 8
FEATURES ................... .......................... .......................... ......................... ................................................... 8
BREAKING IN YOUR NEW MACHINE ........................................................................................................ 9
LOCATIONS OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR ........................................... 10
MACHINE SERIAL NO. PLATE POSITION ................................................................................................ 10
ENGINE SERIAL NO. PLATE POSITION .................................................................................................. 10
TABLE TO ENTER SERIAL NO. 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
POSITION FOR ATTACHING SAFETY LABELS ................................ ...... .............................................. ... 48
LIFTING CAPACITY CHART PW160-7H ............................................................................................................. 56
ONE PIECE BOOM Lift capacity tables ...................................................................................................... 56
TWO PIECE BOOM Lift capacity tables ..................................................................................................... 62
OVERLOAD CAUTION ............................................................................................................................... 68
PW160-7H VEAM390100 13
OPERATION....................................................................................................... 69
GENERAL VIEW ........................................................................................... ...... ................................................. 70
GENERAL VIEW OF MACHINE ............................................. ...... ....... ...... ....... ...... .................................... 70
GENERAL VIEW OF CONTROLS AND GAUGES ..................................................................................... 71
EXPLANATION OF COMPONENTS .................................................................................................................... 72
MACHINE MONITOR ................................................ ....... ...... ...... .............................................................. 72
BASIC CHECK ITEMS ............................ ...... ....... ...... ............................................. ....... ...... ....................... 75
SWITCHES ......................................................................................................................................................... 103
CONTROL LEVERS, PEDALS .......................................................................................................................... 111
FRONT WINDOW ..................................................................................................................................... 117
EMERGENCY EXIT FROM OPERATOR'S CAB ..................................................................................... 121
DOOR LOCK ............................................................................................................................................ 122
CAP, COVER WITH LOCK ....................................................................................................................... 123
FUSE ........................................................................................................................................................ 124
LUGGAGE TRAY ................ ....... ...... ....... ...... ....... ...... ....... ...... ...... ....... ..................................................... 125
ASHTRAY ..................... .......................................................... .................................................................. 125
CUP HOLDER .......................................................................................................................................... 125
HOT AND COOL BOX .............................................................................................................................. 125
CAB RADIO .............................................................................................................................................. 126
POWER PICK-UP PORT .......................................................................................................................... 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
OPERATION OF WORK EQUIPMENT .................................................................................................... 175
WORKING MODE SELECTION ............................................................................................................... 177
PROHIBITIONS FOR OPERATION ............................................. ....... ...... ....... ...... ....... ...... ....... ...... ........ 179
PRECAUTIONS FOR OPERATION ......................................................................................................... 180
RECOMMENDATIONS FOR TRAVELLING ............................................................................................. 182
PRECAUTIONS WHEN TRAVELLING UP OR DOWN HILLS ................................................................. 183
HOW TO ESCAPE FROM MUD ............................................................................................................... 184
WORK POSSIBLE USING HYDRAULIC EXCAVATOR ........................................................................... 185
REPLACEMENT AND INVERSION OF BUCKET .................................................................................... 187
STOPPING ENGINE ................................................................................................................................. 189
CHECK AFTER FINISHING WORK ......................................................................................................... 189
CHECK AFTER STOPPING ENGINE ................................................................................................................ 190
LOCKING ...................... ................................ ................................ ................................. ........................... 190
OVERLOAD WARNING DEVICE ............................................................................................................. 190
HANDLING THE WHEELS ....................................................................................................................... 190
TRANSPORTATION ........................................................................................................................................... 195
LOADING, UNLOADING WORK ............ ...... ....... ...... ............................................. ....... ...... ..................... 195
PRECAUTIONS FOR LOADING .............................................................................................................. 197
PRECAUTIONS FOR TRANSPORTATION ............................................................................................. 200
TRAVELLING POSTURE ......................................................................................................................... 202
COLD WEATHER OPERATION ........................................................................................................................ 204
PRECAUTIONS FOR LOW TEMPERATURE .......................................................................................... 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 MAINTENANCE ............................................................................................................................. 222
OUTLINE OF SERVICE ...................................................................................................................................... 225
OUTLINE OF OIL, FUEL, COOLANT ....................................................................................................... 225
OUTLINE OF ELECTRIC SYSTEM .......................................................................................................... 228
OUTLINE OF HYDRAULIC SYSTEM ....................................................................................................... 229
WEAR PARTS LIST ........................................................................................................................................... 231
USE FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE .......................... 232
PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS ......................................................... 232
PW160-7H VEAM390100 15
USE FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE CONT. .............. 234
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS ..................................................................... 236
INTRODUCTION OF NECESSARY TOOLS ............................................................................................ 236
TIGHTENING TORQUE SPECIFICATIONS ...................................................................................................... 237
TIGHTENING TORQUE LIST ................................................................................................................... 237
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS .......................................................................... 238
SAFETY CRITICAL PARTS .......................... ....... ...... ....... ...... ...... ....... ...... ....... ...... ....... ...... ....... . ............. 239
MAINTENANCE SCHEDULE CHART ............................................................................................................... 240
KEY TO LUBRICATION POINTS ............................................................................................................. 244
SERVICE PROCEDURE .................................................................................................................................... 246
INITIAL 50 HOURS SERVICE .................................................................................................................. 246
CHECK AND TIGHTEN WHEEL NUTS ................................................................................................... 246
INITIAL 250 HOURS SERVICE ................................................................................................................ 246
WHEN REQUIRED ................................................................................................................................... 247
CHECKING 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 HOURS MAINTENANCE ...................................................................................................... 279
EVERY 500 HOURS SERVICE ................................................................................................................ 285
EVERY 1000 HOURS SERVICE .............................................................................................................. 292
EVERY 2000 HOURS SERVICE .............................................................................................................. 299
EVERY 4000 HOURS SERVICE .............................................................................................................. 301
EVERY 5000 HOURS SERVICE .............................................................................................................. 302
SPECIFICATIONS............................................................................................305
SPECIFICATIONS ........................ ................................................................. ..................................................... 306
1 - PIECE BOOM ...................................................................................................................................... 307
2 - PIECE BOOM ...................................................................................................................................... 308
WORKING RANGE: ONE PIECE BOOM ................................................................................................. 309
WORKING RANGE: TWO PIECE BOOM ................................................................................................ 310
OPTIONS, ATTACHMENTS ............................................................................311
GENERAL PRECAUTIONS .......................................... ...... ....... ...... ...... ....... ...... ....... ...... .................................. 312
PRECAUTIONS RELATED TO SAFETY ................................................................................................. 312
PRECAUTIONS WHEN INSTALLING ATTACHMENTS .............................. ..................................................... 313
HANDLING BUCKET WITH HOOK ................................................................................................................... 315
CHECKING FOR DAMAGE TO BUCKET WITH HOOK .......................................................................... 315
PROHIBITED OPERATIONS ................................................................................................................... 315
PRECAUTIONS DURING OPERATIONS ................................................................................................ 315
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
HYDRAULIC PILE DRIVER ...................................................................................................................... 333
HYDRAULIC EXCAVATOR WITH MULTIPURPOSE CRANE ................................................................. 334
INDEX ................................................................................................................................................................. 343
PW160-7H VEAM390100 17
18 PW160-7H VEAM390100
SAFETY
WARNING
Read and follow all safety precautions. Failure to do so may
result in serious injury or death.
This safety secti on also contains precautions fo r optional eq uipment and attachments.
PW160-7H VEAM390100 19
GENERAL PRECAUTIONS SAFETY
WARNING: For reasons of safety, always follow these safety precautions.
GENERAL PRECAUTIONS
SAFETY RULES
● ONLY trained and authorised personnel can operate and
maintain the machine.
● Follow all safety rules, precautions and instructions when
operating or performing maintenance on the machine.
● When working with ano the r o perat or or a p er so n on work si te
traffic duty, be sure all personnel understand all han d signals
that are to be used.
SAFETY FEATURES
● Be sure all guards and covers are in their proper position.
Have guards and covers repaired if damaged.
● Use safety features such as safety lock lever at all times.
● NEVER remove any safety features . ALWAY S keep them in
good operating condition.
● Always wear safety belt when operating machine.
● Improper use of safety features could result in serious bodily
injury or death.
CLOTHING AND PERSONAL PROTECTIVE ITEMS
● Avoid loose clothin g, jew eller y, and loose long h air. They can
catch on controls or in movin g parts and cause serio us 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 gloves if your job
involves scattering metal chips or minute materials, this is so
particularly when driving pins with a hammer and when cleaning the air cleaner element with compressed air.
Check also that there is no one near the machine.
Driving in pins, see"REPLACEMENT AND INVERSION OF
BUCKET (187)"
Cleaning of air cleaner elemen t, see "WHE N REQUIRED
(247)" in service procedure.
UNAUTHORISED MODIFICATION
● Any modification made without authorisation from Komatsu
can create hazards.
● Before making a modi fication, consult your Ko matsu distribu -
tor. Komatsu will not be responsible for an y injury or damage
caused by any unauthorised modific atio n.
20 PW160-7H VEAM390100
SAFETY GENERAL PRECAUTIONS
R
WARNING: Failure to follow these safety precautions may lead to a serious accident.
ALWAYS APPLY (RA ISE) SAFETY LOCK LEVER WHEN
LEAVING OPERATOR’S SEAT
● When standing up from the operator ’s seat, always raise the
safety lock lever to the LOCK position. If you accidentally
touch the travel or swing lever when they are not locked, the
machine may suddenly move and caus e serious injury or
damage.
EMARK
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 , alway s ensure that the left ha nd arm r est is st owed
LOCK
UNLOCK
in the fully up position before operating the safety lock lever.
● When leaving the machine, lower the work e quipment 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 touche d by accident, the wo rk equipment or the machine may move suddenly, and this may lead
to a serious accident. Befo re le aving t he o perat or’s compartment, always raise the safety lock lever to lock the work
equipment controls.
ALWAYS CHOCK THE WHEELS BEFORE GOING UNDER
THE MACHINE
q The chocks are located in the left hand toolbox (A) on the
machine.
A
PW160-7H VEAM390100 21
GENERAL PRECAUTIONS SAFETY
WARNING: For reasons of safety, always follow these safety precautions.
MOUNTING AND DISMOUNTING
● NEVER jump on or off the mac hine. NEVER get on or off a
moving machine.
● When mounting or dismounting, always face the machine and
A
use the handrails (A), machine or chassis steps (B).
● Do not hold any control levers when getting on or off the
machine.
● Ensure safety by al ways ma intaining at leas t thre e-point c on-
tact of hands and feet with the handrails, steps or wheels.
● Always remove an y oil or mu d from the han drails, 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, op en and lock the door
securely in the open posi tion. Othe rwise, the door may move
suddenly, causing you to lose balance and fall.
FIRE PREVENTION FOR FUEL AND OIL
Fuel, oil, and antifreeze can be ignite d by a fla me. Fuel is particularly FLAMMABLE and can be HAZARDOUS.
● Keep flames away from flammable fluids.
● Stop the engine and do not smoke when refuelling.
B
A
B
22 PW160-7H VEAM390100
SAFETY GENERAL PRECAUTIONS
WARNING: Failure to follow these safety precautions may lead to a serious accident.
● Tighten all fuel and oil caps securely.
● Refuelling and o iling should be carried out in well ventilated
areas.
● Keep oil and fuel in a secure place and do not allow unautho-
rised persons to enter.
PRECAUTIONS WHEN HANDLING AT HIGH TEMPERATURES
● Immediately after operations are stopped, the engine coolant,
engine oil, and hydraulic oil are at high temperatures, and are
still under pressure. Attempting to remove the cap, drain the
oil or water, or replace the filters may lead to s erious 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 oil from spurting out:
1. Turn engine off.
2. Allow oil to cool.
3. Slowly loosen cap to relieve pressure before removing.
MACHINES FITTED WITH WHEELS
Never perform any repair work or modifications to wheel rims
while the tyres are fitted, and never apply heat in the vicinity of the
tyres.
PW160-7H VEAM390100 23
GENERAL PRECAUTIONS SAFETY
WARNING: For reasons of safety, always follow these safety precautions.
ASBESTOS DUST HAZARD PREVENTION
Asbestos dust can be HAZARDOUS to your health if it is inhaled.
Your Komatsu machin e and genu ine Kom atsu spare parts do not
contain any asbestos. Use only genuine Komatsu spare parts. If
spare parts containing asbestos ar e used, th e followin g precautions must be observed:
● NEVER use compressed air for cleaning.
● Use water for cleaning to keep down the dust.
● Operate the machine with the wind to your back, wh enever
possible.
● Use an approved respirator if necessary.
CRUSHING OR CUTTING PREVENTION
Do not enter, or put your hand or arm or any other part of your
body between movable parts such as between the work equipment and cylinders, or between the machine and work equipment.
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 phon e numbe rs of pe rsons you s hould
contact in case of an emergency.
PROTECTION AGAINST FALLING OR FLYING OBJECTS
If there is any danger of falli ng or fly ing ob jects hitt ing the opera tor, install protective guards to protect the operator as required for
each particular situation.
● For work with breakers, install a front guard on the wind-
shield. Also, place a laminate coating sheet over the windshield.
● For demolition or shear work, install a front guard on the
windshield and a top guard on the cab. Also, place a laminate
coating sheet over the windshie ld.
24 PW160-7H VEAM390100
SAFETY GENERAL PRECAUTIONS
WARNING: Failure to follow these safety precautions may lead to a serious accident.
● For work in mines, quarries, demolition, tunnels or other
places where there is danger of falling rocks, put FOPS (fall-
ing object protective structure) in place. Also, place a lami-
nate coating sheet over the windshield.
The above comments are made with regards to typical working
conditions. By all means you should put on other guards if
required by conditions at your particular site.
For details of safety gua rds, p lease contact yo ur Kom atsu distri butor.
Also, even for other types of work, if there is any danger of being
hit by falling or flying objects or of objects entering the operator’s
(B)
cab, select and install a guard that matches the working conditions.
(C)
(B): Top guard (C): Front guard
Be sure to close the front window before commencing work.
When carrying ou t the above operations , make sure to keep all
persons other tha n th e o per ato r outside t he ra nge of fall in g o r fly ing objects. Be particularly sure to maintain a proper distance
when carrying out shear operations.
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 a re not authorised by Koma tsu
or your Komatsu distributor. Use of unauthorised attachments
could create a safety problem and adversely affect the proper
operation and useful life of the machine.
● Any injuries, accidents, product failures resulting from the use
of unauthorised attachments wil l not be the re sponsibi lity of
Komatsu.
MACHINES WITH ACCUMULATOR
On machines equipped with an ac cumul ator, for a short time after
the engine is stoppe d, the work equi pment will lower under its
own weight when the work equipment control lever is shifted to
LOWER. After the engine is stopped, raise safety lock lever to the
LOCK position.
AB30052C
When releasing the pressure inside the work equipment circuit on
machines equipped with an ac cumulator, follow the procedure
given in the inspection and maintenance section.
Method of releasing pressure, see "HANDLING ACCUMU-
LATORS (144)"
The accumulator is filled with high-pressure nitrogen gas, and it is
extremely dangerou s if it is handled in the wron g way. Always
observe the following precaution s.
PW160-7H VEAM390100 25
GENERAL PRECAUTIONS SAFETY
WARNING: For reasons of safety, always follow these safety precautions.
● Never make any hole in the accumulator or expose it to flame
or fire.
● Do not weld anything to the accumulator.
● When carrying out dis assembly or maintenan ce of the accu-
mulator, or when disposing of the accumulator, it is necessary
to release the gas from the accum ulator. A special bleed
valve is necessary for this operation, so please contact your
Komatsu distributor.
Gas in accumulator, see "HANDLING ACCUMULATORS
(144)"
EMERGENCY EXIT
● When exit by normal 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 INTERFERENCE
When this machin e is op erati ng cl ose to a sour ce of h igh el ectro magnetic interference, such as a radar station, some abnormal
phenomena may be observed.
● The display on the monitor panel may behave errati ca ll y.
● The warning buzzer may sound.
These effects do not s ignify a m alfuncti on and the machine wi ll
return to normal as soon as the source of interference is removed.
26 PW160-7H VEAM390100
SAFETY PRECAUTION DURING OPERATION
WARNING: Failure to follow these safety precautions may lead to a serious accident.
PRECAUTION DURING OPERATION
BEFORE STARTING ENGINE
SAFETY AT WORKSITE
● Before starting the engin e, thoroughly check th e area for any
unusual conditions that could be dangerous.
● Before starting the engine, examine the terrain and soil condi-
tions of the work site. Determine the best and safest method
of operation.
● Make the slope as horizontal as possible before continuing
operations.
● If you need to operate on a street, p rotect pedestrians and
cars by designating a person for work site traffic duty or by
installing fences around the work site.
● If water lines, gas lines, and high- voltage electric al lines may
be buried under the work site, c ontact eac h uti lit y a nd id enti fy
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 accumulated in the engine compartment.
They coul d cause a fir e.
● Check fuel, lubrication, and hydraulic systems for leaks. Have
any leaks repaired. Wipe up any excess oil, fuel or other flam-
mable fluids.
Check point, see "WALK-AROUND CHECK (145)"
● Be sure a fire extinguisher is present and working.
IN OPERATOR’S CAB
● Do not leave tools or spare parts lying around in the opera-
tor’s compartment. They may damage or break the control
levers or swit ches. Always put them in the t ool box on the
undercarriage.
● Keep the cab f loor, controls, st eps and handrails free of o il,
grease, snow, and excess dirt.
PW160-7H VEAM390100 27
PRECAUTION DURING OPERATION SAFETY
WARNING: For reasons of safety, always follow these safety precautions.
VENTILATION FOR ENCLOSED AREAS
If it is nece ssary to s tart th e eng ine w ithin an enc losed area, pro vide adequate ventil ation. Exhaust fum es from the e ngine can
KILL.
PRECAUTIONS FOR MIRRORS, WINDOWS AND LIGHTS
● Remove all dirt from the surface of the windows and lights to
ensure that you can see well.
● Adjust the rear v iew mirror s so that yo u can see clearly fr om
the operator’s seat, and always keep the su rface of the mirrors clean. If any glass is broken, replace it with a new part.
● Check that the head lamps and working lamps are installed to
match the operating 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 anyone other than the operator to ride in the cab
or on the machine body.
● For machines equipped wit h a reverse alarm buzz er, check
that the warning device operates correctly.
CHECK DIRECTION BEFORE STARTING MACHINE
Before operating the travel pedal, check the direction of the under
carriage.
If the fixed axle is at the front, the forward/neutral/reverse lever
and steering will function in the opposite direction.
A Fixed axle
B Oscillating axle
Travel operations, see "MOVING MACHINE OFF (167)"
B
A
28 PW160-7H VEAM390100
SAFETY PRECAUTION DURING OPERATION
WARNING: Failure to follow these safety precautions may lead to a serious accident.
CHECK THAT NO ONE IS IN THE AREA BEFORE SWINGING
OR TRAVELLING IN REVERSE
● Always position a signalman when operating in dangerous
places or places where the view is not clear.
● Make sure that no one comes inside the swing radius or
direction of travel.
● Before starting to mov e, sound the horn or give a signa l to
warn people not to come close to the machine.
● Make use of all mirrors to ensure that the area around the
machine is clear.
● There are blind spots behind the machine, so if necessary,
swing the upper structure to check that there is no one behind
the machine before travelling in reverse.
PRECAUTIONS 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 pu blic roads, fully rais e dozer blade and
outriggers, lock the outriggers in position with the safety pin,
lock the bucket and arm cylinder with isolation val ves, and
insert swing lock pin.
For details, see "TRAVELLING ON PUBLIC HIGHWAY
(171)"
● When travelling on p ublic roads the safety lo ck lever should
be down (UNLOCKED) and lock lever switc h engaged. This
prevents operation of the control lever s .
● When travelling on rough ground, travel at low speed, and
avoid sudden changes in direction.
● Avoid travelling over obstacles as far as possible. If the
machine has to travel over an obstacle, k eep the wor k equip-
ment as close to the ground as possible and travel at low
speed. Never travel over obstacles which make the machine
tilt strongly (10° or more).
40 - 50cm
INCORRECT
PW160-7H VEAM390100 29
PRECAUTION DURING OPERATION SAFETY
WARNING: For reasons of safety, always follow these safety precautions.
TRAVELLING ON SLOPES
● Travelling on hills, banks or s lo pes tha t ar e s teep co uld result
Downhill
in the machine tipping over or slipping.
● On hills, banks or slopes, carry the bucket closer to the
ground, approximately 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.
Uphill
Method of travelling on slopes, see "RECOMMENDATIONS FOR TRAVELLING (182)"
Do not travel up and down on grass, fallen leaves, and wet steel
plates. These materia ls ma y a llo w th e m ac hin e to sl ip , if it is tr avelling sideways. Keep travel speed very low.
INCORRECT
CORRECT
30 PW160-7H VEAM390100
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