Komatsu Pw150es 6k Operation Maintenance Manual

Full download: http://manualplace.com/download/komatsu-pw150es-6k-operation-maintenance-manual/

UEAM000106
Operation &
Maintenance Manual

PW150ES-6K
HYDRAULIC EXCAVATOR
SERIAL NUMBER
PW150ES-6K - K35001 and up

WARNING
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 personel who will come into
contact with the machine.

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FOREWORD

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 avail-
able information for your machine or for questions regarding infor-
mation in this manual.

WARNING
● This operation & maintenance manual may contain
attachments and optional equipment that are not avail-
able in your area. Please consult your local Komatsu dis-
tributor 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 main-
tenance.

● Some actions involved in operation and maintenance of

the machine can cause a serious accident, if they are not
done in a manner described in this manual.

● The procedures and precautions given in this manual

apply only to intended uses of the machine. If you use
your machine for any unintended uses that are not spe-
cifically 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 all 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 specifica-
tions that are necessary for use in your country. If there
is any question about whether your product complies

4
FOREWORD FOREWORD

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” on page 6. and in "SAFETY" from page 19

5
SAFETY INFORMATION FOREWORD

SAFETY INFORMATION

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, understand and follow all precautions

and warnings in this manual and on the machine before perform-
ing operation and maintenance.

To identify hazards on the machine pictorial decals are used (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 avoided. These safety messages or labels usu-
ally describe precautions that must be taken to avoid the hazard.
Failure to avoid this hazard may also result in serious damage 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 describe pre-
cautions that must be taken to avoid the hazard. Failure to avoid
this hazard may also result in serious damage of the machine

YELLOW SAFETY TRIANGLE - This is used on

safety labels for hazards which could result in minor or moderate
injury if the hazard is not avoided. This word might also be used
for a hazard where the only 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 1-1.

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 specifically recommended or allowed in this manual
are used, you must be sure that you and others can do such pro-
cedures and actions safely and without damaging the machine. If
you are unsure about the safety of some procedures, contact
Komatsu or your Komatsu distributor.

6
FOREWORD SAFETY INFORMATION

NOISE
● Sound pressure level at the operator's station, measured
according to ISO6396 (Dynamic test method, simulated work-
ing cycle)

● Sound power level emitted. This is the guaranteed value as

specified in European directive 2000/14/EC.

This machine complies with the requirements of RAL (German

Institute for quality assurance and marking) pertaining to the
award of the environmental mark (blue angel) for low noise.

VIBRATION
● The weighted root mean square acceleration value to which
the operator’s arms are subjected does not exceed 2.5 m/s²

● The weighted root mean square acceleration value to which

the operator’s body is subjected was measured at 0.64 m/s²

7
SAFETY INFORMATION FOREWORD

These results were obtained by accelerometers during trench dig-

ging.

EMERGENCY STEERING
This machine is equipped with an emergency steering system
and complies to ISO 5010. In the advent of failure of the source of
power for the steering system (engine failure) whilst travelling the
machine can be steered 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 increase. 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.

8
FOREWORD INTRODUCTION

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 “WORK POSSIBLE USING HYDRAULIC

EXCAVATOR” on page 136 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 increased by light-touch con-

trol. (For details, see operation section.)

● Adjustable wrist control levers make operations smooth and

easy.

● Fresh filtered air conditioner assures comfortable operation.

● Low noise level and smart urban style design and colouring.

● Superb operation performance provided by powerful engine

and high-performance hydraulic pump.

● Low fuel consumption controlled by an electronic control sys-

tem provides an environment-friendly machine.

BREAKING IN YOUR NEW MACHINE

Your Komatsu machine has been thoroughly adjusted and tested
before shipment.

However, operating the machine under severe conditions 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 indi-
cated by the hour meter.)

During breaking in:

9
INTRODUCTION FOREWORD

● 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 emer-
gency.

Additionally for the first 20 hours

● Avoid operating engine for prolonged periods at constant

speed (including idle.)

● Avoid high speed travelling for periods of more than 5 min-

utes.

Pay particular attention to oil pressure and temperature indicators

& check coolant and oil levels frequently during breaking in.

The precautions given in this manual for operating, maintenance,

and safety procedures are only those that apply when this product
is used for the specified purpose. If the machine is used for a pur-
pose that is not listed in this manual, Komatsu cannot bear any
responsibility for safety. All consideration of safety in such opera-
tions is the responsibility of the user.

Operations that are prohibited in this manual must never be car-

ried out under any circumstances.

10
FOREWORD LOCATIONS OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR

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 valve cover (A).

TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR

Machine serial No.:

Engine Serial No.:

Product Identification Number :

Manufacturer’s name: Komatsu UK Ltd.

Address

Durham Road
Birtley
Chester-Le-Street
County Durham DH32QX
United Kingdom

Distributor

Address

Phone

11
LOCATIONS OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR FOREWORD

MACHINE SERIAL PLATES

Valid until 31 December 2003

STANDARD SERIAL PLATE

GERMANY SERIAL PLATE

ITALIAN SERIAL PLATE

12
FOREWORD LOCATIONS OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR

Valid as of 1 January 2004

MANUFACTURING YEAR
STANDARD SERIAL PLATE

MODEL
MODEL

SERIAL NUMBER SERIAL No.

MANUFACT. YEAR

MAX. DRAWBAR PULL MAX. DRAWBAR PULL N

MASS kg
MASS
ENGINE POWER kW
ENGINE POWER
Product Identification Number

PRODUCT ID NUMBER MANUFACTURER Manufactured by Komatsu UK Ltd.

for Komatsu Ltd.,Tokyo,Japan
20G-00-K2382

MANUFACTURER
Manufactured by Komatsu UK Ltd.
for Komatsu Ltd., Tokyo, Japan

GERMANY SERIAL PLATE

TYP

FABR. NR.

BAUJAHR

ZUL. ZUGKRAFT N
ZUL.GESAMTGEWICHT kg
LEISTUNG kW
ZUL.ACHSLAST VORN kg
ZUL.ACHSLAST HINTEN kg
Produkt Identifizierung Nummer
HERSTELLER Hergestellt vom Komatsu UK Ltd. Birtley Co Durham,
United Kingdom unter lizenz der Komatsu Ltd.
20G-00-K2392

ITALIAN SERIAL PLATE

MANUFACTURER Manufactured by Komatsu UK Ltd.
for Komatsu Ltd.,Tokyo,Japan.

TIPO
TYPE-MODEL
NUMERO DI OMOLOGAZIONE
HOMOLOGATION NUMBER
MATRICOLA
SERIAL NUMBER
MASSA TOTALE AMMISSIBILE DA A
TOTAL MAX WEIGHT FROM kg TO kg
CARICO AMMISSIBILE ASSE ANT. DA A
WEIGHT FRONT AXLE FROM kg TO kg
CARICO AMMISSIBILE ASSE POST. DA A
WEIGHT REAR AXLE FROM kg TO kg
POTENZA MOTORE ANNO
ENGINE POWER kW YEAR
Numero di Identificazione del Prodotto.
Product Identification Number
Massa rimorchiabile ammissibile:
- Massa rimorchiabile con frenata: non atto
- Massa rimorchiabile con frenatura indipendente: non atto
- Massa rimorchiabile con frenatura ad inerzia: non atto
- Massa rimorchiabile con frenatura assistita: non atto
20E-00-K1932

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LOCATIONS OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR FOREWORD

14
CONTENTS

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

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

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

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GENERAL VIEW .................................................................................................................................................. 62
GENERAL VIEW OF MACHINE ................................................................................................................. 62
GENERAL VIEW OF CONTROLS AND GAUGES ..................................................................................... 63

EXPLANATION OF COMPONENTS .................................................................................................................... 65

MACHINE MONITOR ................................................................................................................................. 65
SWITCHES ................................................................................................................................................. 76
CONTROL LEVERS, PEDALS ................................................................................................................... 86
DOOR LOCK .............................................................................................................................................. 93
CAP, COVER WITH LOCK ......................................................................................................................... 94
FUSE .......................................................................................................................................................... 95
LUGGAGE TRAY ........................................................................................................................................ 96
ASHTRAY ................................................................................................................................................... 96
CUP HOLDER ............................................................................................................................................ 96
HEATER ..................................................................................................................................................... 97
AIR CONDITIONER .................................................................................................................................... 99
FUSIBLE LINK .......................................................................................................................................... 102
CONTROLLERS ....................................................................................................................................... 102
TOOL BOX ................................................................................................................................................ 102
REFUELLING PUMP ................................................................................................................................ 102
CAB RADIO (OPTION) ............................................................................................................................. 103
WARNING LAMPS ................................................................................................................................... 104
HANDLING THE ACCUMULATOR .......................................................................................................... 105

OPERATION ....................................................................................................................................................... 106

CHECK BEFORE STARTING ENGINE .................................................................................................... 106
STARTING ENGINE ................................................................................................................................. 115
MOVING MACHINE OFF .......................................................................................................................... 123
STEERING ................................................................................................................................................ 126
STOPPING ............................................................................................................................................... 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
WORK POSSIBLE USING HYDRAULIC EXCAVATOR ........................................................................... 136
REPLACEMENT AND INVERSION OF BUCKET .................................................................................... 137
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

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TRANSPORTATION ........................................................................................................................................... 148
LOADING, UNLOADING WORK .............................................................................................................. 148
PRECAUTIONS FOR LOADING .............................................................................................................. 150
PRECAUTIONS FOR TRANSPORTATION ............................................................................................. 152
TRAVELLING POSTURE ......................................................................................................................... 153

COLD WEATHER OPERATION ........................................................................................................................ 154

PRECAUTIONS FOR LOW TEMPERATURE .......................................................................................... 154
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
OTHER TROUBLE ................................................................................................................................... 163

MAINTENANCE ............................................................................................... 167

GUIDES TO MAINTENANCE ............................................................................................................................. 168

OUTLINES OF SERVICE ................................................................................................................................... 171

OUTLINE OF OIL, FUEL, COOLANT ....................................................................................................... 171
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

17
SERVICE PROCEDURE .................................................................................................................................... 191
INITIAL 250 HOURS SERVICE ................................................................................................................ 191
WHEN REQUIRED ................................................................................................................................... 192
CHECK BEFORE STARTING .................................................................................................................. 205
EVERY 50 HOURS ................................................................................................................................... 209
EVERY 100 HOURS SERVICE ................................................................................................................ 209
EVERY 250 HOURS SERVICE ................................................................................................................ 214
EVERY 500 HOURS SERVICE ................................................................................................................ 219
EVERY 1000 HOURS SERVICE .............................................................................................................. 225
EVERY 2000 HOURS SERVICE .............................................................................................................. 229
EVERY 4000 HOURS SERVICE .............................................................................................................. 232
EVERY 5000 HOURS SERVICE .............................................................................................................. 232

SPECIFICATIONS............................................................................................ 237
SPECIFICATIONS .............................................................................................................................................. 238

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
OPERATION ............................................................................................................................................. 252
HANDLING ACCUMULATOR ................................................................................................................... 253
LONG-TERM STORAGE .......................................................................................................................... 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

18
 SAFETY

WARNING
Read and follow all safety precautions. Failure to do so may
result in serious injury or death.

This safety section also contains precautions for optional equip-

ment and attachments.

19
Komatsu Pw150es 6k Operation Maintenance Manual
Full download: http://manualplace.com/download/komatsu-pw150es-6k-operation-maintenance-manual/
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 another operator or a person on worksite

traffic duty, be sure all personnel understand all hand 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 properly.

● NEVER remove any safety features. ALWAYS keep them in

good operating condition.

Safety lever, see “PARKING MACHINE” on page 140.

● Improper use of safety features could result in serious bodily

injury or death.

CLOTHING AND PERSONAL PROTECTIVE ITEMS

● Avoid loose clothing, jewellery, and loose long hair. They can
catch on controls or in moving parts and cause serious injury
or death. Also, do not wear oily cloths because they are flam-
mable.

● 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 clean-
ing 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” on page 137.

Cleaning of air cleaner element, see “WHEN REQUIRED”

on page 192. in service procedure.

UNAUTHORISED MODIFICATION

● Any modification made without authorisation from Komatsu

can create hazards.

20
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