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Komatsu PW150ES-6K Hydraulic Excavator Operation & Maintenance Manual (K35001 and up) PDF
Komatsu PW150ES-6K Hydraulic Excavator Operation & Maintenance Manual (K35001 and up)
FILE DETAILS:
Komatsu PW150ES-6K Hydraulic Excavator Operation & Maintenance Manual (K35001 and up)
File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : UEAM000106
Total Pages : 277
DESCRIPTION:
Komatsu PW150ES-6K Hydraulic Excavator Operation & Maintenance Manual (K35001 and up)
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.
TABLE OF CONTENTS:
Komatsu PW150ES-6K Hydraulic Excavator Operation & Maintenance Manual (K35001 and up)
FOREWORD............................................................................................................ 3 FOREWORD........................................................................................................ 4 SAFETY INFORMATION.............................................................................................. 6 SAFETY MESSAGES............................................................................................. 6 NOISE....................................................................................................... 7 VIBRATION................................................................................................... 7 EMERGENCY STEERING.......................................................................................... 8 INTRODUCTION.................................................................................................... 9 INTENDED USE................................................................................................ 9 FEATURES.................................................................................................... 9 BREAKING IN YOUR NEW MACHINE................................................................................ 9 LOCATIONS OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR.................................................. 11 MACHINE SERIAL NO. PLATE POSITION........................................................................... 11 ENGINE SERIAL NO. PLATE POSITION............................................................................ 11 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR................................................................... 11 MACHINE SERIAL PLATES....................................................................................... 12 STANDARD SERIAL PLATE................................................................................... 12 GERMANY SERIAL PLATE.................................................................................... 12 ITALIAN SERIAL PLATE.................................................................................... 12 STANDARD SERIAL PLATE................................................................................... 13 GERMANY SERIAL PLATE.................................................................................... 13 SAFETY.............................................................................................................. 19 GENERAL PRECAUTIONS............................................................................................. 20 PRECAUTION DURING OPERATION..................................................................................... 26 BEFORE STARTING ENGINE...................................................................................... 26 OPERATING MACHINE........................................................................................... 27 TRANSPORTATION.............................................................................................. 32 BATTERY..................................................................................................... 33 TOWING...................................................................................................... 34 BUCKET WITH HOOK OR BUCKET LINK............................................................................. 35 GENERAL PRECAUTIONS..................................................................................... 35 PRECAUTIONS FOR LIFTING OPERATION....................................................................... 37 PRECAUTIONS FOR MAINTENANCE..................................................................................... 39 BEFORE CARRYING OUT MAINTENANCE............................................................................. 39 DURING MAINTENANCE.......................................................................................... 42 POSITION FOR ATTACHING SAFETY LABELS............................................................................ 45 POSITION FOR ATTACHING SAFETY LABELS........................................................................ 45 OVERLOAD CAUTION................................................................................................ 60 OPERATION........................................................................................................... 61 GENERAL VIEW.................................................................................................... 62 GENERAL VIEW OF MACHINE..................................................................................... 62 GENERAL VIEW OF CONTROLS AND GAUGES......................................................................... 63 EXPLANATION OF COMPONENTS....................................................................................... 65 MACHINE MONITOR............................................................................................. 65 A. BASIC CHECK ITEMS.................................................................................... 65 B. CAUTION ITEMS........................................................................................ 66 C. EMERGENCY STOP ITEMS................................................................................. 66 D. METER DISPLAY PORTION................................................................................ 66 E. SWITCHES............................................................................................. 66 A: BASIC CHECK ITEMS.................................................................................... 67 B: CAUTION ITEMS........................................................................................ 68 C: EMERGENCY STOP ITEMS................................................................................. 69 D: METER DISPLAY PORTION................................................................................ 70 E: SWITCHES............................................................................................. 73 SWITCHES.................................................................................................... 76 CONTROL LEVERS, PEDALS...................................................................................... 86 CLEAR RAIN VISOR........................................................................................ 89 PULL DOWN SUN VISOR..................................................................................... 89 FRONT WINDOW............................................................................................ 90 DOOR LOCK................................................................................................... 93 CAP, COVER WITH LOCK........................................................................................ 94 METHOD OF OPENING AND CLOSING CAP WITH LOCK (For the fuel tank filler port)............................. 94 METHOD OF OPENING AND CLOSING COVER WITH LOCK (cover with Iock)......................................... 94 FUSE........................................................................................................ 95 LUGGAGE TRAY................................................................................................ 96 ASHTRAY..................................................................................................... 96 CUP HOLDER.................................................................................................. 96 HEATER...................................................................................................... 97 VIEW OF CONTROL PANEL................................................................................... 97 AIR CONDITIONER............................................................................................. 99 VIEW OF CONTROL PANEL................................................................................... 99 PRECAUTION WHEN USING AIR CONDITIONER...................................................................101 FUSIBLE LINK................................................................................................102 CONTROLLERS.................................................................................................102 TOOL BOX....................................................................................................102 REFUELLING PUMP.............................................................................................102 CAB RADIO (OPTION)..........................................................................................103 PRECAUTION OF USE.......................................................................................103 WARNING LAMPS...............................................................................................104 HANDLING THE ACCUMULATOR....................................................................................105 OPERATION.......................................................................................................106 CHECK BEFORE STARTING ENGINE................................................................................106 WALK-AROUND CHECK.......................................................................................106 CHECK BEFORE STARTING...................................................................................108 ADJUSTMENT BEFORE OPERATION OPERATOR’S SEAT.............................................................112 OPERATIONS AND CHECKS BEFORE STARTING ENGINE............................................................113 STARTING ENGINE.............................................................................................115 NORMAL STARTING.........................................................................................115 STARTING IN COLD WEATHER................................................................................116 OPERATIONS AND CHECKS AFTER STARTING ENGINE.............................................................117 WHEN NORMAL.............................................................................................117 IN COLD AREAS (AUTOMATIC WARMING-UP OPERATION)..........................................................119 MOVING MACHINE OFF..........................................................................................123 MOVING MACHINE FORWARD..................................................................................123 STEERING....................................................................................................126 STOPPING....................................................................................................127 STOPPING MACHINE (NORMAL)...............................................................................127 SWINGING (Slewing the upper carriage).......................................................................128 OPERATION OF WORK EQUIPMENT.................................................................................129 WORKING MODE SELECTION......................................................................................130 PROHIBITIONS FOR OPERATION..................................................................................132 PRECAUTIONS FOR OPERATION...................................................................................133 PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS.................................................................134 HOW TO ESCAPE FROM MUD......................................................................................135 WHEN ONE SIDE IS STUCK..................................................................................135 WHEN BOTH SIDES ARE STUCK...............................................................................136 WORK POSSIBLE USING HYDRAULIC EXCAVATOR.....................................................................136 BACKHOE WORK............................................................................................136 SHOVEL WORK.............................................................................................136 DITCHING WORK...........................................................................................137 LOADING WORK............................................................................................137 REPLACEMENT AND INVERSION OF BUCKET.........................................................................137 REPLACEMENT.............................................................................................137 INVERSION...............................................................................................138 PARKING MACHINE.............................................................................................140 CHECK AFTER FINISHING WORK..................................................................................141 STOPPING ENGINE.............................................................................................141 CHECK AFTER STOPPING ENGINE.................................................................................142 LOCKING.....................................................................................................142 OVERLOAD WARNING DEVICE.....................................................................................142 HANDLING THE WHEELS.........................................................................................143 TRANSPORTATION..................................................................................................148 LOADING, UNLOADING WORK.....................................................................................148 PRECAUTIONS FOR LOADING.....................................................................................150 HOW TO LIFT THE MACHINE.................................................................................151 PRECAUTIONS FOR TRANSPORTATION..............................................................................152 TRAVELLING POSTURE..........................................................................................153 COLD WEATHER OPERATION..........................................................................................154 PRECAUTIONS FOR LOW TEMPERATURE.............................................................................154 FUEL AND LUBRICANTS.....................................................................................154 COOLANT.................................................................................................154 BATTERY.................................................................................................155 PRECAUTIONS AFTER COMPLETION OF WORK........................................................................155 AFTER COLD WEATHER..........................................................................................156 LONG-TERM STORAGE...............................................................................................157 BEFORE STORAGE..............................................................................................157 DURING STORAGE..............................................................................................157 AFTER STORAGE...............................................................................................158 STARTING MACHINE AFTER LONG-TERM STORAGE....................................................................158 TROUBLESHOOTING.................................................................................................159 PHENOMENA THAT ARE NOT FAILURES.............................................................................159 METHOD OF TOWING MACHINE....................................................................................160 PRECAUTIONS ON PARTICULAR JOBSITES..........................................................................160 IF BATTERY IS DISCHARGED....................................................................................161 STARTING ENGINE WITH BOOSTER CABLE......................................................................161 OTHER TROUBLE...............................................................................................163 ELECTRICAL SYSTEM.......................................................................................163 CHASSIS.................................................................................................164 ENGINE..................................................................................................165 ELECTRONIC CONTROL SYSTEM...............................................................................166 MAINTENANCE.........................................................................................................167 GUIDES TO MAINTENANCE...........................................................................................168 OUTLINES OF SERVICE.............................................................................................171 OUTLINE OF OIL, FUEL, COOLANT...............................................................................171 OIL.....................................................................................................171 FUEL....................................................................................................172 COOLANT.................................................................................................172 GREASE..................................................................................................173 STORING OIL AND FUEL....................................................................................173 FILTERS.................................................................................................173 OUTLINE OF ELECTRIC SYSTEM..................................................................................174 OUTLINE OF HYDRAULIC SYSTEM.................................................................................174 WEAR PARTS LIST.................................................................................................176 USE FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...............................................177 PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS............................................................177 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS..................................................................181 INTRODUCTION OF NECESSARY TOOLS.............................................................................181 TORQUE LIST.................................................................................................181 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...................................................................183 SAFETY CRITICAL PARTS.......................................................................................184 MAINTENANCE SCHEDULE CHART......................................................................................185 MAINTENANCE WHEN USING HYDRAULIC BREAKER....................................................................190 USE OF BIO-DEGRADEABLE OIL..................................................................................190 Filter changes..........................................................................................190 Oil changes.............................................................................................190 SERVICE PROCEDURE...............................................................................................191 INITIAL 250 HOURS SERVICE...................................................................................191 WHEN REQUIRED...............................................................................................192 CHECK, CLEAN AND REPLACE THE AIR CLEANER ELEMENT........................................................192 CLEAN INSIDE OF COOLING SYSTEM..........................................................................193 CHECKING COOLANT LEVEL..................................................................................196 DRAINING THE SYSTEM.....................................................................................196 CLEANING THE SYSTEM.....................................................................................196 FILLING THE SYSTEM......................................................................................197 REFILLING AN OVERHEATED SYSTEM..........................................................................197 CLEANING THE RADIATOR...................................................................................198 CLEANING THE RADIATOR PRE-SCREEN........................................................................198 THERMOSTATS.............................................................................................198 FAN.....................................................................................................199 CHECK AND TIGHTEN WHEEL NUTS............................................................................199 CHECK ELECTRICAL INTAKE AIR HEATER......................................................................199 CHECK ALTERNATOR........................................................................................199 CHECK START MOTOR.......................................................................................200 REPLACE BUCKET SIDE CUTTERS.............................................................................200 REPLACE BUCKET TEETH....................................................................................201 ADJUST BUCKET CLEARANCE.................................................................................202 CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID..............................................................202 CHECK AND ADJUST AIR CONDITIONER........................................................................203 DRAIN ENGINE BREATHER OIL CATCHER.......................................................................204 CHECK BEFORE STARTING.......................................................................................205 CHECK COOLANT LEVEL, ADD WATER..........................................................................205 CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL..............................................................205 CHECK FUEL LEVEL, ADD FUEL..............................................................................206 CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL..............................................................207 CHECK AIR CLEANER FOR CLOGGING..........................................................................207 CHECK ELECTRIC WIRING...................................................................................208 CHECK FOR WATER AND SEDIMENT IN SEDIMENTOR. DRAIN WATER AND SEDIMENT....................................208 EVERY 50 HOURS..............................................................................................209 DRAIN WATER AND SEDIMENT FROM FUEL TANK.................................................................209 EVERY 100 HOURS SERVICE.....................................................................................209 LUBRICATING.............................................................................................209 CHECK OIL LEVEL IN SWING MACHINERY CASE, ADD OIL........................................................212 CLEAN FRESH AIR INTAKE FILTER...........................................................................213 EVERY 250 HOURS SERVICE.....................................................................................214 CHECK OIL LEVEL IN WHEEL HUBS, ADD OIL..................................................................214 CHECK OIL LEVEL IN AXLES, ADD OIL.......................................................................214 CHECK OIL LEVEL IN TRANSMISSION, ADD OIL................................................................215 CHECK LEVEL OF BATTERY ELECTROLYTE......................................................................215 LUBRICATE SWING CIRCLE (2 points).......................................................................216 BELTS, GENERAL..........................................................................................216 CHECK FAN BELT TENSION, ADJUST CHECKING TENSION.........................................................217 REPLACEMENT.............................................................................................217 CHECK ALTERNATOR AND WATER PUMP BELT TENSION, ADJUST CHECKING TENSION...................................217 CHECK AND ADJUST TENSION OF AIR CONDITIONER COMPRESSOR BELT.............................................218 EVERY 500 HOURS SERVICE.....................................................................................219 REPLACE FUEL FILTER CARTRIDGE...........................................................................219 CHECK SWING PINION GREASE LEVEL, ADD GREASE.............................................................221 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE.......................................222 CLEAN AND INSPECT RADIATOR FINS, AFTER COOLER FINS, OIL COOLER FINS AND CONDENSER FINS (ONLY FOR .......223 REPLACE HYDRAULIC TANK BREATHER ELEMENT.................................................................224 REPLACE HYDRAULIC FILTER ELEMENT........................................................................224 EVERY 1000 HOURS SERVICE....................................................................................225 CHANGE OIL IN SWING MACHINERY CASE......................................................................225 CHECK ALL TIGHTENING PARTS OF TURBOCHARGER..............................................................226 CHECK PLAY OF TURBOCHARGER ROTOR........................................................................226 CHECK & ADJUST VALVE CLEARANCE..........................................................................226 CHECK FAN BELT TENSIONER BEARING BELT AND FAN HUB.......................................................228 CHECK FAN BELT TENSION..................................................................................228 EVERY 2000 HOURS SERVICE....................................................................................229 CLEAN HYDRAULIC TANK STRAINER...........................................................................229 CLEAN, CHECK TURBOCHARGER...............................................................................229 CHECK ALTERNATOR, STARTING MOTOR........................................................................229 CHECK VIBRATION DAMPER..................................................................................230 CHANGE OIL IN AXLES.....................................................................................230 CHANGE OIL IN HUBS......................................................................................231 CHANGE OIL IN TRANSMISSION ASSEMBLY.....................................................................231 CHANGE ANTIFREEZE.......................................................................................231 CHECK AND ADJUST VALVE CLEARANCE........................................................................231 EVERY 4000 HOURS SERVICE....................................................................................232 CHECK WATER PUMP........................................................................................232 EVERY 5000 HOURS SERVICE....................................................................................232 CHANGE OIL IN HYDRAULIC TANK............................................................................232 SPECIFICATIONS......................................................................................................237 SPECIFICATIONS..................................................................................................238 1 - PIECE BOOM..............................................................................................239 2 - PIECE BOOM..............................................................................................240 WORKING RANGE: ONE PIECE BOOM...............................................................................241 WORKING RANGE: TWO PIECE BOOM...............................................................................242 OPTIONS, ATTACHMENTS................................................................................................245 GENERAL PRECAUTIONS.............................................................................................246 PRECAUTIONS RELATED TO SAFETY...............................................................................246 PRECAUTIONS WHEN INSTALLING ATTACHMENTS.....................................................................247 HANDLING BUCKET WITH HOOK.......................................................................................248 CHECKING FOR DAMAGE TO BUCKET WITH HOOK.....................................................................248 PROHIBITED OPERATIONS.......................................................................................248 PRECAUTIONS DURING OPERATIONS...............................................................................248 MACHINES READY FOR ATTACHMENTS..................................................................................249 GENERAL LOCATIONS...........................................................................................249 HANDLING THE CLAMSHELL BUCKET...............................................................................251 How to install clamshell bucket.........................................................................251 How to operate..........................................................................................251 OPERATION...................................................................................................252 WHEN USING BREAKER......................................................................................252 HANDLING ACCUMULATOR........................................................................................253 METHOD FOR RELEASING PRESSURE IN CONTROL CIRCUIT OF MACHINES EQUIPPED WITH ACCUMULATOR..................254 LONG-TERM STORAGE...........................................................................................254 SPECIFICATIONS..........................................................................................254 INTRODUCTION OF ATTACHMENTS AND EXTENDING MACHINE SERVICE LIFE..................................................256 HYDRAULIC BREAKER...........................................................................................256 POWER RIPPER................................................................................................259 FORK GRAB...................................................................................................260 GRAPPLE BUCKET..............................................................................................261 SCRAP GRAPPLE...............................................................................................262 CRUSHER & SMASHER...........................................................................................264 HYDRAULIC PILE DRIVER.......................................................................................265 HYDRAULIC EXCAVATOR WITH MULTIPURPOSE CRANE.................................................................266 ROTATING ARM................................................................................................268 GENERAL LOCATION AND SPECIFICATIONS.....................................................................268 GENERAL VIEW OF CONTROLS................................................................................269 LEFT WORK EQUIPMENT CONTROL LEVER (with auto-deceleration device).......................................269 RIGHT WORK EQUIPMENT CONTROL LEVER (with auto-deceleration device)......................................270 ARM ROTATION CONTROL....................................................................................270 UPPER BOOM CONTROL PEDAL................................................................................271 PEDAL LOCK FOR BOOM ADJUST..............................................................................271 EXCAVATOR’S WORK........................................................................................271 REPLACEMENT OF BUCKET...................................................................................272 HANDLING THE TRAPEZOIDAL BUCKET (If equipped)...........................................................273 TRAVELLING POSTURE......................................................................................274 MAINTENANCE REQUIREMENT.................................................................................276 EVERY 100 HOURS SERVICE.................................................................................276 EVERY 250 HOURS SERVICE.................................................................................276 EVERY 1000 HOURS SERVICE................................................................................277
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