Komatsu PC160LC-8 Manual

PC160LC-8
PC190LC-
8
PC190NLC-8
SERIALNUMBER
PC160LC-8-K50001andup
PC190LC-8-K50001andup
PC190NLC-8-K50001andup
HYDRAULIC EXCAVATOR
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.
Operation &
Maintenance Manual
UENAM00773
WARNING
ORIGINAL INSTRUCTIONS

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FOREWORD
11
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FOREWORD FOREWORD
1-2
FOREWORD 1
This manual provides rules and guidelines which will help you use this machine safely and effectively. The pre-
cautions in this manual must be followed at all times when performing operation and maintenance. Most accidents
are caused by the failure to follow fundamental safety rules for the operation and maintenance of machines. Acci-
dents can be prevented by knowing beforehand conditions that may cause a hazard when performing operation
and maintenance.
WARNING
Before beginning operation or maintenance, operators and maintenance personnel must always observe
the following points.

Read this manual thoroughly and understand its contents fully.

Read the safety messages and safety labels given in this manual carefully so that they should be under-
stood fully.

Keep this manual at the storage location for the Operation and Maintenance Manual given below so that
all personnel involved in working on the machine can consult it periodically.

In case this manual should be lost or damaged, immediately contact Komatsu or your Komatsu distributor
to obtain a new copy.

When you sell the machine, make sure that this manual should be provided to the new owner together
with the machine.

In this manual, measurements are expressed in international standard units (SI). For the reference pur-
pose, weight units used in the past are also displayed in ( ).
Storage location for the Operation and Maintenance Manual:
magazine box on the left side of the operator's seat.
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FOREWORD SAFETY INFORMATION
1-3
SAFETY INFORMATION 1
To enable you to use this machine safely, safety precautions and labels are given in this manual and affixed to the
machine to give explanations of situations involving potential hazards and of the methods of avoiding such situa-
tions.
Signal words
The following signal words are used to inform you that there is a potential hazardous situation that may lead to per-
sonal injury or damage.
In this manual and on machine labels, the following signal words are used to express the potential level of hazard.
Example of safety message using signal word
WARNING
When standing up from the operator's seat, always place the lock lever in the LOCK position.
If you accidentally touch the control levers when they are not locked, this may cause a serious injury or
death.
Other signal words
In addition to the above, the following signal words are used to indicate precautions that should be followed to pro-
tect the machine or to give information that is useful to know.
Indicates an imminently hazardous situation which, if not avoided, will result in death
or serious injury.
Indicates a potentially hazardous situation which, if not avoided, could result in death
or serious injury.
Indicates a potentially hazardous situation which, if not avoided, may result in minor or
moderate injury. This word is used also to alert against unsafe practices that may
cause property damage.
NOTICE This word is used for precautions that must be taken to avoid actions which could shorten
the life of the machine.
REMARKS This word is used for information that is useful to know.
DANGER
WARNING
CAUTION
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SAFETY INFORMATION FOREWORD
1-4
qSafety labels
Safety labels are affixed to the machine to inform the operator or maintenance worker on the spot when carrying
out operation or maintenance of the machine that may involve hazard.
This machine uses “Safety labels using pictograms“ to indicate safety procedures.
Safety labels using pictogram
Safety pictograms use a picture to express a level of hazard-
ous condition equivalent to the signal word. These safety picto-
grams use pictures in order to let the operator or maintenance
worker understand the level and type of hazardous condition at
all times. Safety pictograms show the type of hazardous condi-
tion at the top or left side, and the method of avoiding the haz-
ardous condition at the bottom or right side. In addition, the
type of hazardous condition is displayed inside a triangle and
the method of avoiding the hazardous condition is shown
inside a circle.
Komatsu cannot predict every circumstance that might involve a potential hazard in operation and maintenance.
Therefore, the safety messages in this manual and on the machine may not include all possible safety precau-
tions.
If any procedures or actions not specifically recommended or allowed in this manual are used, it is your responsi-
bility to take the necessary steps to ensure safety.
In no event should you engage in prohibited uses or actions described in this manual.
The explanations, values, and illustrations in this manual were prepared based on the latest information available
at that time. 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 of
your machine or for questions regarding information in this manual.
The numbers in circles in the illustrations correspond to the numbers in ( ) in the text. (For example: -> (1))
Part No.
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FOREWORD SAFETY INFORMATION
1-5
NOISE (PC160LC) 1
Two labels indicating the machine noise level are affixed on the machine.
qSound pressure level at the operator’s station, measured
according to ISO6396 (Dynamic test method, simulated
working cycle).
The maximum value of the standard deviation of the meas-
ured time-averaged A-weighted emission sound pressure
level at the operator's position is 2.5 dB, in accordance with
ISO 11201.
qSound power level emitted by the machine, measured
according to ISO 6395 (Dynamic test method, simulated
working cycle). This is the guaranteed value as specified in
European directive 2000/14/EC.
This value includes an uncertainty of 0.27 dB.
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SAFETY INFORMATION FOREWORD
1-6
NOISE (PC190LC,190NLC) 1
Two labels indicating the machine noise level are affixed on the machine.
qSound pressure level at the operator’s station, measured
according to ISO6396 (Dynamic test method, simulated
working cycle).
The maximum value of the standard deviation of the meas-
ured time-averaged A-weighted emission sound pressure
level at the operator's position is 2.5 dB, in accordance with
ISO 11201.
qSound power level emitted by the machine, measured
according to ISO 6395 (Dynamic test method, simulated
working cycle). This is the guaranteed value as specified in
European directive 2000/14/EC
This value includes an uncertainty of 0.27 dB.
Vibration levels for PC160 and PC190-8 1
When used for its intended purpose, levels of vibration for the earth-moving machine transmitted from the opera-
tor’s seat are lower than or equal to the tested vibrations for the relative machinery class in compliance with ISO
7096.
The actual acceleration value for the hands and arms is less than or equal to 2.5 m/s², the uncertainty for this
value is 0.48 m/s² according to EN12096:1997.
The actual acceleration value for the body is less than or equal to 0.5 m/s², the uncertainty for this value is 0.23 m/
s² according to EN12096:1997.
These values were determined using a representative machine and measured during the typical operating condi-
tion indicated below according to the measurement procedures that are defined in the standards ISO 2631/1 and
ISO 5349.
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FOREWORD SAFETY INFORMATION
1-7
Operating condition:
Excavating (Digging-loading-rotating-unloading-rotating)
Guide to Reduce Vibration Levels on Machine 1
The following guides can help an operator of this machine to reduce the whole body vibration levels:
1. Use the correct equipment and attachments.
2. Maintain the machine according to this manual
QTension of crawler (for crawler machines)
QBrake and steering systems
QControls, hydraulic system and linkages
3. Keep the terrain where the machine is working and travelling in good condition
QRemove any large rocks or obstacles
QFill any ditches and holes
QSite manager should provide machine operators with machine and schedule time to maintain terrain con-
ditions
4. Use a seat that meets ISO 7096 and keep the seat maintained and adjusted
QAdjust the seat and suspension for the weight and size of the operator
QWear seat belt
QInspect and maintain the seat suspension and adjustment mechanisms
5. Steer, brake, accelerate, and move the attachment levers and pedals slowly so that the machine moves
smoothly
6. Adjust the machine speed and travel path to minimize the vibration level
QWhen pushing with bucket or blade, avoid sudden loading; load gradually
QDrive around obstacles and rough terrain conditions
QSlow down when it is necessary to go over rough terrain
QMake the curve radius of travelling path as large as possible
QTravel at low speed when travelling around sharp curves
7. Minimize vibrations for long work cycle or long distance travelling
QReduce speed to prevent bounce
QTransport machines long distances between worksites
8. The following guidelines can be effective to minimize risks of low back pain
QOperate the machine only when you are in good health.
QProvide breaks to reduce long periods of sitting in the same posture
QDo not jump down from the cab or machine
QDo not repeatedly handle and lift loads
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INTRODUCTION FOREWORD
1-8
INTRODUCTION 1
This Komatsu machine is designed to be used mainly for the following work:
qDigging work
qLevelling work
qDitching work
qLoading work
See the section RECOMMENDED APPLICATIONS (3-168) for further details.
DEMOLITION WORK 1
WARNING
qA demolition machine is a machine based on earth
moving machinery (see EN ISO 6165) and including
equipment and attachment (working tool - e.g. proces-
sor or breaker) specifically designed to demolish, cut,
loosen, separate, pick up, transport component parts
of buildings or civil engineering structures.
qThis machine is not prepared for use in demolition.
qUsing this machine in demolition work gives an
increased risk of serious injury or death.
qAll Komatsu machines that are specifically designed
and can be used for demolition work, will display the
Komatsu demolition decal.
qIf the machinery does not display this decal and it is
necessary to carry out demolition work, contact your
distributor for information on demolition machinery
compliant with the applicable standards.
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FOREWORD INTRODUCTION
1-9
DIRECTIONS OF MACHINE 1
In this manual, the terms front, rear, left, and right refer to the travel direction as seen from the operator's seat
when the operator's seat is facing the front and the sprocket is at the rear of the machine.
OPERATOR PROTECTIVE STRUCTURE
This machine is ROPS compliant to ISO12117-2:2008 when a ROPS plate is installed - see "LOCATION OF
SAFETY LABELS (2-4)" for location of ROPS plate.
VISIBILITY FOR OPERATOR
This machine complies with the visibility standard (ISO 5006).
This machine maintains a close visibility of a height of 1.5 m at a point 1 m away from the outside surface of the
machine and a visibility for a radius of 12 m.
(A) Front (D) Right
(B) Rear (E) Operator's seat
(C) Left (F) Sprocket

INTRODUCTION FOREWORD
1-10
BREAKING-IN THE NEW MACHINE 1
NOTICE
Your Komatsu machine has been thoroughly adjusted and tested before shipment from the factory. How-
ever, operating the machine under full load before breaking the machine in can adversely affect the per-
formance and shorten the machine life.
Be sure to break in the machine for the initial 100 hours (as indicated on the service meter).
Make sure that you fully understand the content of this manual, and pay careful attention to the following points
when breaking in the machine.
qRun the engine at idle for 15 seconds after starting it. Dur-
ing this time, do not operate the control levers or fuel con-
trol dial.
qIdle the engine for 5 minutes after starting it up.
qAvoid operation with heavy loads or at high speeds.
qImmediately after starting the engine, avoid sudden starts,
sudden acceleration, unnecessary sudden stops, and sud-
den changes in direction.

FOREWORD PRODUCT INFORMATION
1-11
PRODUCT INFORMATION 1
When requesting service or ordering replacement parts, please inform your Komatsu distributor of the following
items.
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE 1
On the bottom right of the operator's cab
The design of the nameplate differs according to the territory.
EPA REGULATIONS, ENGINE NUMBER PLATE 1
On the top of the engine cylinder head cover.
EPA: Environmental Protection Agency, U.S.A.

PRODUCT INFORMATION FOREWORD
1-12
SERVICE METER LOCATION 1
On top of the machine monitor

FOREWORD PRODUCT INFORMATION
1-13
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR 1
Machine serial No. 
Engine serial No. 
Product identification number (PIN) 
Manufacturers name:
Address:



KOMATSU UK Ltd.
Durham Road
Birtley
Chester-Le-Street
County Durham DH3 2QX
United Kingdom
Distributor name:
Address:


Service Personnel
Phone/Fax

PRODUCT INFORMATION FOREWORD
1-14
MACHINE SERIAL PLATE 1
SERIAL PLATE (WHERE FITTED) 1
SERIAL PLATE (WHERE FITTED)
205-00-K1291
MODEL
SERIAL No.
MANUFACT. YEAR
MASS
ENGINE POWER
Product Identification Number
kg
kW
MANUFACTURER Manufactured by Komatsu UK Ltd.
for Komatsu Ltd.,Tokyo,Japan
A
B
C
D
E
F
G
A MODEL E ENGINE POWER
B SERIAL F PRODUCT IDENTIFICATION NUMBER
C MANUFACTURING YEAR G MANUFACTURER
DWEIGHT
A
BC
DE
F
G
A MACHINE DESIGNATION/TYPE E ENGINE POWER
B SERIAL F PRODUCT IDENTIFICATION NUMBER
C YEAR OF CONSTRUCTION G MANUFACTURER
DWEIGHT

FOREWORD PRODUCT INFORMATION
1-15
DECLARATION OF CONFORMITY 1
The manufacturer:
KOMATSU UK Ltd
Durham Road
Birtley
Chester-Le-Street
County Durham DH3 2QX
United Kingdom
Declares that this machine:
PC160LC-8
PC190LC-8
PC190NLC-8
Fulfils all the relevant provisions of following EC Directives:
Machinery Directive 2006/42/EC
Electro Magnetic Compatibility Directive 2004/108/EC
Outdoor Noise Directive 2000/14/EC amended by 2005/88/EC

PRODUCT INFORMATION FOREWORD
1-16

CONTENTS
1-17
CONTENTS
FOREWORD
FOREWORD......................................................................................................................................................... 1-2
SAFETY INFORMATION...................................................................................................................................... 1-3
NOISE (PC160LC)...................................................................................................................................... 1-5
NOISE (PC190LC,190NLC)........................................................................................................................ 1-6
Vibration levels for PC160 and PC190-8.................................................................................................... 1-6
Guide to Reduce Vibration Levels on Machine.................................................................................. 1-7
INTRODUCTION................................................................................................................................................... 1-8
DEMOLITION WORK ................................................................................................................................. 1-8
DIRECTIONS OF MACHINE...................................................................................................................... 1-9
OPERATOR PROTECTIVE STRUCTURE................................................................................................. 1-9
VISIBILITY FOR OPERATOR .................................................................................................................... 1-9
BREAKING-IN THE NEW MACHINE ....................................................................................................... 1-10
PRODUCT INFORMATION................................................................................................................................1-11
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE ..................................... 1-11
EPA REGULATIONS, ENGINE NUMBER PLATE................................................................................... 1-11
SERVICE METER LOCATION................................................................................................................. 1-12
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR............................................................................ 1-13
MACHINE SERIAL PLATE....................................................................................................................... 1-14
SERIAL PLATE (WHERE FITTED)................................................................................................. 1-14
DECLARATION OF CONFORMITY......................................................................................................... 1-15
SAFETY
SAFETY................................................................................................................................................................ 2-2
SAFETY LABELS................................................................................................................................................. 2-4
LOCATION OF SAFETY LABELS.............................................................................................................. 2-4
SAFETY LABELS ....................................................................................................................................... 2-5
SAFETY INFORMATION.................................................................................................................................... 2-16
SAFETY RULES.............................................................................................................................. 2-16
IF PROBLEMS ARE FOUND ..........................................................................................................2-16
WORKING WEAR AND PERSONAL PROTECTIVE ITEMS.......................................................... 2-16
FIRE EXTINGUISHER AND FIRST AID KIT................................................................................... 2-16
SAFETY EQUIPMENT .................................................................................................................... 2-17
KEEP MACHINE CLEAN................................................................................................................. 2-17
KEEP OPERATOR'S COMPARTMENT CLEAN............................................................................. 2-17
LEAVING OPERATOR'S SEAT WITH LOCK ................................................................................. 2-17
HANDRAILS AND STEPS............................................................................................................... 2-18

CONTENTS
1-18
MOUNTING AND DISMOUNTING..................................................................................................2-19
LIFTING OF PERSONNEL PROHIBITED.......................................................................................2-19
NO PERSONS ON ATTACHMENTS ..............................................................................................2-19
DO NOT GET CAUGHT IN ARTICULATED PORTION ..................................................................2-19
BURN PREVENTION ......................................................................................................................2-19
ACTION IF FIRE OCCURS .............................................................................................................2-21
WINDSHIELD WASHER FLUID......................................................................................................2-21
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES......................................................2-21
FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION................2-22
ACTIONS IN THE EVENT OF DAMAGE TO SAFETY STRUCTURES..........................................2-23
ATTACHMENT INSTALLATION......................................................................................................2-23
ATTACHMENT COMBINATIONS ...................................................................................................2-23
CAB WINDOW GLASSES...............................................................................................................2-23
UNAUTHORIZED MODIFICATIONS...............................................................................................2-23
SAFETY AT JOBSITE .....................................................................................................................2-24
WORKING ON LOOSE GROUND ..................................................................................................2-24
DISTANCE TO HIGH VOLTAGE CABLES .....................................................................................2-24
ENSURE GOOD VISIBILITY...........................................................................................................2-25
VENTILATION FOR ENCLOSED AREA.........................................................................................2-26
SIGNALMAN'S SIGNAL AND SIGNS..............................................................................................2-26
EMERGENCY EXIT FROM OPERATOR'S CAB ............................................................................2-26
ELECTROMAGNETIC INTERFERENCE........................................................................................2-26
ASBESTOS DUST HAZARD PREVENTION ..................................................................................2-27
SAFETY MACHINE OPERATION......................................................................................................................2-28
STARTING ENGINE.................................................................................................................................2-28
CHECKS BEFORE STARTING ENGINE........................................................................................2-28
SAFETY RULES FOR STARTING ENGINE ...................................................................................2-29
STARTING ENGINE IN COLD WEATHER .....................................................................................2-29
OPERATION.............................................................................................................................................2-30
CHECKS BEFORE OPERATION....................................................................................................2-30
SAFETY RULES FOR CHANGING MACHINE DIRECTIONS........................................................2-30
SAFETY RULES FOR TRAVELLING..............................................................................................2-31
TRAVELLING ON SLOPES.............................................................................................................2-32
OPERATIONS ON SLOPES ...........................................................................................................2-33
PROHIBITED OPERATIONS ..........................................................................................................2-33
OPERATIONS ON SNOW...............................................................................................................2-35
PARKING MACHINE.......................................................................................................................2-35
TRANSPORTATION.................................................................................................................................2-36
LOADING AND UNLOADING..........................................................................................................2-36
SHIPPING THE MACHINE..............................................................................................................2-37
TURN THE BATTERY DISCONNECT SWITCH TO THE OFF POSITION..............................................2-37
BATTERY .................................................................................................................................................2-38
STARTING ENGINE WITH BOOSTER CABLES............................................................................2-39
TOWING ...................................................................................................................................................2-40
SAFETY RULES FOR TOWING .....................................................................................................2-40
LIFTING OBJECTS WITH BUCKET.........................................................................................................2-41
SAFETY RULES FOR LIFTING OBJECTS.....................................................................................2-41