Komatsu PVVl70ES-6 Manual

Operation&Maintenance
Manual
EEAMOlO501
WHEELED EXCAVATOR
SERIAL NUMBERS PVVl70ES-6K -K30001 andup
This material is proprietary to Komatsu America International Company and is not to be reproduced, used, or
disclosed except in accordance with written authorization from Komatsu America International Company.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make
changes or add improvements at any time without incurring any obligation to install such changes on products sold
previously.
Due to this continuous program of research and development, periodic revisions may be made to this publication.
It is recommended that customers contact their distributor for information on the latest revision.
September 1999 Copyright 1999 Komatsu
DataKom Publishing Corporation

1. 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 re-
flected 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.
a WARNING
This operation & maintenance manual may contain attachments and optional equipment that are not
available in your area. Please consult your local Komatsu distributor for those items you require.
This machine complies with EC directive (89/392/EEC ).
Machines complying with this directive display the CE mark
Improper operation and maintenance of this machine can be hazardous and could result in serious
injury or death.
Operators and maintenance personnel should read this manual thoroughly before beginning opera-
tion or maintenance.
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 specifically prohibited, you must be sure
that it is safe for you and others. In no event should you or others engage in prohibited uses or
actions as described in this manual.
Komatsu delivers machines that comply with all applicable regulations and standards of the country
to which it has been shipped. If this machine has been purchased in another country or purchased
from someone in another country, it may lack certain safety devices and specifications that are
necessary for use in your country. If there is any question about whether your product complies with
the applicable standards and regulations of your country, consult Komatsu or your Komatsu dis-
tributor before operating the machine.
The description of safety is given in SAFETY INFORMATION on page O-2 and in SAFETY from page
l-l.
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2. SAFETY INFORMATION
2.1 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 performing operation and maintenance.
To identify hazards on the machine pictorial decals are used ( see POSITION FOR ATTACHING SAFETY
LABELS).
a 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 usually describe precautions that must be
taken to avoid the hazard. Failure to avoid this hazard may also
result in serious damage to the machine.
a ORANGE WARNING TRIANGLE - This is used on safety labels where there is a potentially dan-
gerous situation which could result in 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 haz-
ard. Failure to avoid this hazard may also result in serious dam-
age of the machine
a 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-l.
Komatsu cannot predict every circumstance that might involve a potential hazard in operation and mainte-
nance. 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 procedures and actions safely and without damaging the machine.
If you are unsure about the safety of some procedures, contact Komatsu or your Komatsu distributor.
c-2
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2. SAFETY INFORMATION
2.2 NOISE
PW170-6j<
Operator ears noise value
(Sound pressure level)
Ambient noise value
(Sound power level)
\
0 L P A
79
\ 95/27lEC /
1
WA
\
1
Noise level indicated is the guaranteed value measured by the dynamic test method as specified in the directive
86/662lEEC, as amended by 95/27/EC
2.3 VIBRATION
. The weighted root mean square acceleration value to which the operator’s arms are subjected does not
exceed 2.5 m/s*
. The weighted root mean square acceleration value to which the operator’s body is subjected was measured at
0,89 m/s”
These results were obtained by accelerometers during trench digging.
2.4 EMERGENCY STEERING
This machine is equiped with an emergengy steering system and complies to IS0 5010. in the advent of failure
of the source of power for the steering wheel (e.g. engine failure) whilgst travelling, the machine can be steered,
allowing the machine to be safety stopped. In such a case, the elfort , required at the steering wheel an dthe
numbers of turns of the steering wheel to steer the machine will increar.
To confirm the function of the emercency steering system, raise the front wheels off the ground ( using the
work equipment) and with the engine off, turn the steering wheel an d check the movement of the wheels.
o-3
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3. INTRODUCTION
3.1 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 12.14 “WORK POSSIBLE USING HYDRAULIC EXCAVATOR” for futher details
3.2 .
.
.
.
.
.
.
.
.
3.3
FEATURES
This Komatsu HYDRAULIC EXCAVATOR is equipped with various controls based on an advanced elec-
tronics system.
The monitor panel greatly facilitates daily maintenance and self-diagnosis.
Working mode, and travel speed are selectable.
Digging and lifting force can be increased by light-touch control. (For details, see operation section.)
Adjustable wrist control levers make operations smooth and easy.
Fresh filtered air heater assures comfortable operation. (Air conditioner option)
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 system provides an environment-friendly ma-
chine.
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 perform-
ance and shorten the machine life.
Be sure to break in the machine for the initial 100 hours (as indicated by the hour meter.)
During breaking in:
. Idle the engine for 5 minutes after starting it up.
. Avoid operation with heavy loads or at high speeds.
. Sudden starting or acceleration, unnecessarily abrupt braking and sharp turning should be avoided ex-
cept in cases of emergency.
Additionally for the first 20 hours
. Avoid operating engine for prolonged periods at constant speed (including idle.)
. Avoid high speed travelling for periods of more than 5 minutes.
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 purpose that is not listed in
this manual, Komatsu cannot bear any responsibility for safety. All consideration of safety in such operations is the
responsibility of the user.
Operations that are prohibited in this manual must never be carried out under any circumstances.
o-4
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4. LOCATION OF PLATES, TABLE TO ENTER SERIAL
NO. AND DISTRIBUTOR
4.1 MACHINE SERIAL NO. PLATE POSITION
On the front bottom right of the operator’s cab
4.2 ENGINE SERIAL NO. PLATE POSITION
On the gear case front corner.
4.3 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR
Machine serial No.:
Engine serial No.:
Manufactureres name: Komatsu UK Ltd
Address Durham Road
Birtley
Chester-Le-Street
County Durham DH32QX
United Kingdom
Distributor
Address Phone
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4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR
4.4 MACHINE SERIAL PLATE.
o-6
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5. CONTENTS
1. Foreword ............................................................................................................................................... o-1
2. Safety information .................................................................................................................................. o-2
3. Introduction ........................................................................................................................................ o-4
....
4. Location of plates, table to enter serial No. and distributor .................................................................... O-5
SAFETY ........................................................................................................................... l-l
6.
7.
8.
9.
General Precautions .............................................................................................................................. 1-2
Precautions during operation ................................................................................................................. 1-8
7.1 Before starting engine. ................................................................................................................ 1-8
7.2 Operating machine ................................................................................................................... I-10
7.3 Transportation ........................................................................................................................... l-l.5
7.4 Battery ...................................................................................................................................... 1-16
7.5 Towing.. ..................................................................................................................................... 1-17
7.6 Bucket with hook.. ..................................................................................................................... l-18
Precautions for maintenance ............................................................................................................... 1-21
8.1 Before carrying out maintenance .............................................................................................. l-21
8.2 During maintenance.. ................................................................................................................ l-24
Position for attaching safety labels ....................................................................................................... 1-28
9a Lifting capacities ....................................................................................................................... 1-33
OPERATION ..................................................................................................................... 2-1
IO.
11.
General view .......................................................................................................................................... 2-2
10.1 General view of machine ............................................................................................................ 2-2
10.2 General view of controls and gauges ......................................................................................... 2-3
Explanation of components
11.1
11.2
11.3
11.4
11.5
11.6
11.7
11.8
11.9
11.10
11.11
11.12
11.13
11.14
11.15
11.16
11.17
11.18
11.19
11.20
11.21
Machine monitor ............................................................................................................. 2-4
............
Switches ................................................................................................................................... 2-15
Control levers, pedals ............................................................................................................... 2-24
Roof hatch ................................................................................................................................ 2-26
Front window.. ........................................................................................................................... 2-27
Door lock.. ................................................................................................................................. 2-29
Cap, cover with lock .................................................................................................................. 2-30
Fuse ........................................................................................ 2-31
..................................................
Luggage tray ............................................................................................................................. 2-32
Ashtray.. .................................................................................................................................... 2-32
Heater ....................................................................................................................................... 2-32
Air conditioner. .......................................................................................................................... 2-33
Fusible link ................................................................................................................................
Controller .................................................................................................................................. 22:
Toolbox.. .................................................................................................................................... 2-36
Refuelling pump ........................................................................................................................ 2-36
Cab radio .................................................................................................................................. 2-37
Warning lamps .......................................................................................................................... 2-41
c....................................................................................................... 2-42
Warning lamps .......................................................................................................................... 2-44
Handling the accumulators ....................................................................................................... 2-45
O-7
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12. Operation
12.1 Check before starting engine .................................................................................................... 2-47
12.2 Starting engine .......................................................................................................................... 2-57
12.3 Operations and checks after starting engine ............................................................................ 2-60
12.4 Moving machine off.. ................................................................................................................. 2-66
12.5 Steering machine ...................................................................................................................... 2-69
12.6 Stopping machine ..................................................................................................................... 2-70
12.7 Swinging ................................................................................................................................... 2-71
12.8 Operation of work equipment .................................................................................................... 2-72
12.9 Working mode selection ........................................................................................................... 2-73
12.10 Prohibitions for operation .......................................................................................................... 2-75
12.11 Precaution for operation ........................................................................................................... 2-77
12.12 Precaution when travelling up or down hills.. ............................................................................ 2-78
12.13 How to escape from mud .......................................................................................................... 2-80
12.14 Work possible using hydraulic excavator .................................................................................. 2-81
12.15 Replacement and inversion of bucket ....................................................................................... 2-82
12.16 Parking the machine ................................................................................................................. 2-84
12.17 Check after finishing work. ........................................................................................................ 2-85
12.18 Stopping engine ........................................................................................................................ 2-86
12.19 Check after stopping engine ..................................................................................................... 2-87
12.20 Locking ..................................................................................................................................... 2-87
12.21 Handling the wheels ................................................................................................................. 2-88
13. Transportation
13.1 Loading, unloading work ........................................................................................................... 2-93
13.2 Precautions for loading ............................................................................................................. 2-95
13.3 Precautions for transportation.. ................................................................................................. 2-96
13.4 Travelling posture ..................................................................................................................... 2-98
14. Cold weather operation
14.1 Precaution for low temperature.. ............................................................................................. 2-100
14.2 Precautions after completion of work.. .................................................................................... 2-101
14.3 After cold weather ................................................................................................................... 2-l 01
15. Long-term storage
15.1 Before storage ........................................................................................................................ 2-102
15.2 During storage ........................................................................................................................ 2-102
15.3 After storage ........................................................................................................................... 2-103
15.4 Starting machine after long-term storage ............................................................................... 2-103
16. Troubleshooting
16.1 Phenomena that are not failures.. ........................................................................................... 2-l 04
16.2 Method of towing machine ...................................................................................................... 2-104
16.3 Precautions on particular jobsites ........................................................................................... 2-105
16.4 If battery is discharged ............................................................................................................ 2-105
16.5 Other trouble ........................................................................................................................... 2-l 09
o-8
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5. CONTENTS
MAINTENANCE
17.
18.
Guides to maintenance ..
................................__........................... ........................................................... 3-2
19.
20.
21.
22.
23.
24.
Outlines of service ................................................................................................................................. 3-4
18.1 Outline of oil, fuel, coolant .......................................................................................................... 3-5
18.2 Outline of electric system. ........................................................................................................... 3-7
18.3 Outline of hydraulic system ......................................................................................................... 3-8
Wear parts list ........................................................................................................................................ 3-9
Use of fuel, coolant and lubricants according to ambient temperature ................................................ 3-10
Standard tightening torques for bolts and nuts .................................................................................... 3-l 4
21 .l Introduction of necessary tools ................................................................................................. 3-14
21.2 Torque list ................................................................................................................................. 3-15
Periodic replacement of safety critical parts ........................................................................................ 3-16
Maintenance schedule chart ................................................................................................................ 3-18
23.1 Maintenance schedule chart.. ................................................................................................... 3-l 8
23.2 Maintenance interval when using hydraulic breaker ................................................................. 3-20
23.3 Explanation of lubrication decal ............................................................................................... 3-21
Service procedure ................................................................................................................................ 3-24
24.1 When required .......................................................................................................................... 3-24
24.2 Check before starting.. .............................................................................................................. 3-43
24.3 Every 100 hours service ........................................................................................................... 3-49
24.4 Every 250 hours service ........................................................................................................... 3-54
24.5 Every 500 hours service ........................................................................................................... 3-62
24.6 Every 1000 hours service ......................................................................................................... 3-68
24.7 Every 2000 hours service ......................................................................................................... 3-73
24.8 Every 4000 hours ...................................................................................................................... 3-79
SPECIFICATIONS
25. SPECIFICATIONS ................................................................................................................................. 4-2
25.1 Machine specifications.. .............................................................................................................. 4-3
o-9
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