Komatsu PW140-7 Manual

Operation & Maintenance
Manual
VEAM410104
PW140 -7
PW160 -7
PW180 -7
PW200 -7
PW220 -7
KOMATSU has had this Operation and Maintenance Manual
translated into all languages used in the European Union.
Please contact your KOMATSU distributor if you need a
manual in another language.
NOTE
© 2011 KOMATSU Hanomag GmbH
All Rights Reserved
Printed in Europe 06-2010
Incorrect operation and maintenance of this machine
may be hazardous and cause injuries. The operator and
maintenance personnel must read this manual before
commencing operation or maintenance. Keep this manu-
al within reach at all times and ensure that operating per-
sonnel read it at regular intervals.
DANGER
WHEELED EXCAVATOR
SERIAL NUMBERS
PW140-7 H55051 and up
PW160-7 H55051 and up
PW180-7 H55051 and up
PW200-7 H55051 and up
PW220-7 H65051 and up
ORIGINAL INSTRUCTIONS

1-2 PW180-7E0 – VEAM400101
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Foreword
PW140-7, PW160-7, PW180-7, PW200-7, PW220-7 – VEAM410104 1-1
1. Foreword
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1.1 Foreword Foreword
1-2 PW140-7, PW160-7, PW180-7, PW200-7, PW220-7 – VEAM410104
1.1 Foreword
This manual provides rules and guidelines which will help you
use this machine safely and effectively. The precautions 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 mainte-
nance of machines. Accidents can be prevented by knowing
beforehand conditions that may cause a hazard when perform-
ing operation and maintenance.
WARNING
zOperators and maintenance personnel must always do as
follows before beginning operation or maintenance.
zAlways be sure to read and understand this manual thor-
oughly before performing operation and maintenance.
zRead the safety messages given in this manual and the
safety labels affixed to the machine thoroughly and be sure
that you understand them fully.
zKeep this manual at the storage location for the Operation
and Maintenance Manual given below, and have all person-
nel read it periodically.
zIf this manual has been lost or has become dirty and cannot
be read, request a replacement manual immediately from
KOMATSU or your KOMATSU distributor.
zIf you sell the machine, be sure to give this manual to the
new owners together with the machine.
zKOMATSU 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 distributor before operating
the machine.
Storage location for the Operation and Maintenance Manual:
Pocket (1) at rear of operator's seat
GK032001
1
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Foreword 1.1 Foreword
PW140-7, PW160-7, PW180-7, PW200-7, PW220-7 – VEAM410104 1-3
1.1.1 EU Directives
Machines supplied by us fulfil the Directive for Machinery 89/
392/EEC or 2006/42/EEC (for machines placed on the market
as from 29th December 2009) and all supplements. If the
machine is being used in another country, it is possible that cer-
tain safety regulations and specifications may not be fulfilled for
use in that country. For example, priority vehicle warning lamps
may be used in some countries, but are forbidden in others.
Please contact our dealer before using the machine if you have
any questions regarding the fulfilment of standards and regula-
tions in a specific country.
Notes on subsequent installation of electrical and electronic
equipment and components
Electrical and electronic equipment and/or components which
have been installed subsequently, emit electromagnetic radia-
tion which can influence the function of the electronic compo-
nents and sections of the machine. This can have an influence
on the safety of the machine and endanger persons. For this
reason, please ensure that the following safety instructions are
observed.
If you are installing electrical or electronic equipment and/or
components in the machine and connect them to the vehicle
electrical system, you must check at own responsibility that the
installations do not cause any disturbance to the vehicle’s elec-
tronic system or other components. Above all, you must ensure
that any subsequently installed electrical and electronic compo-
nents comply with the EMV Directive 89/336/EEC or 2004/108/
EC (for machines placed on the market as from 29th December
2009) in its current edition and bear the CE mark.
The following requirements also have to be met for subsequent
installation of mobile communication systems (e.g. radio, tele-
phone):
zOnly equipment approved by national legislation (e.g. BZT
approval for Germany) may be used
zThe unit must be fixed in position
zPortable or mobile units may only be used inside the vehi-
cles if they are connected to a fixed outside antenna
zThe transmitter unit must be spatially separated from the
vehicle’s electronic system
zMake sure when installing the antenna that this is installed
correctly with good earth connection between antenna and
vehicle mass
Also observe KOMATSU and manufacturer’s installation instruc-
tions for wiring, installation and maximum permitted power con-
sumption.
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1.2 Safety information Foreword
1-4 PW140-7, PW160-7, PW180-7, PW200-7, PW220-7 – VEAM410104
1.2 Safety information
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 situations.
1.2.1 Signal words
The following signal words are used to inform you that there is a
potential hazardous situation that may lead to personal injury or
damage.
In this manual and on machine labels, the following signal words
are used to express the potential level of hazard.
DANGER
Indicates an imminently hazardous situation which, if not
avoided, will result in death or serious injury.
WARNING
Indicates a potentially hazardous situation which, if not avoided,
could result in death or serious injury.
CAUTION
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.
Example of safety message using signal word
WARNING
When standing up from the operator's seat, always place the
work equipment 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.
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Foreword 1.2 Safety information
PW140-7, PW160-7, PW180-7, PW200-7, PW220-7 – VEAM410104 1-5
Other signal words
In addition to the above, the following signal words are used to
indicate precautions that should be followed to protect the
machine or to give information that is useful to know.
NOTE
This word is used for precautions that must be taken to avoid
actions which could shorten the life of the machine.
REMARK
This word is used for information that is useful to know.
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1.2 Safety information Foreword
1-6 PW140-7, PW160-7, PW180-7, PW200-7, PW220-7 – VEAM410104
1.2.2 Safety 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.
For details of safety labels, see "Safety labels (2-2)".
Safety labels using pictogram
Safety pictograms use a picture to express a level of hazardous
condition equivalent to the signal word. These safety pictograms
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 condition
at the top or left side, and the method of avoiding the hazardous
condition at the bottom or right side. In addition, the type of haz-
ardous 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 precautions.
If any procedures or actions not specifically recommended or
allowed in this manual are used, it is your responsibility 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.
GK032002
Part No
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Foreword 1.2 Safety information
PW140-7, PW160-7, PW180-7, PW200-7, PW220-7 – VEAM410104 1-7
1.2.3 Emergency steering
This machine is equipped with an emergency steering system
and complies to ISO 5010 (BSEN 12643). In the event 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.
1.2.4 Emergency braking
This machine is equipped with an emergency braking system
and complies to ISO 3450. In the event of failure of the source of
power for the braking system (engine failure) whilst travelling,
the brakes can be actuated from stored energy in the accumula-
tors to bring the machine safely to a stop.
In such a case, five brake applications can be made before
exhausting the energy in the accumulators. In the event of serv-
ice brake failure, the park brake can be used as an emergency
brake to bring the machine to a stop.
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1.3 Introduction Foreword
1-8 PW140-7, PW160-7, PW180-7, PW200-7, PW220-7 – VEAM410104
1.3 Introduction
1.3.1 Use of machine
This KOMATSU machine is designed to be used mainly for the
following work:
zDigging work
zSmoothing
zDitching work
zLoading work
For details of the operating procedure, see "Work possible using
hydraulic excavator (3-152)".
1.3.2 Intended use
If you use the machine for any other purpose than specified
above, we will not accept any responsibility for safety. All consid-
erations concerning safety will then be up to the owner or the
operating and maintenance personnel. In any case, neither you
nor any other person are/is authorised to perform work and func-
tions explicitly prohibited in these operating instructions.
The transport of persons in the work equipment is strictly
forbidden!
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Foreword 1.3 Introduction
PW140-7, PW160-7, PW180-7, PW200-7, PW220-7 – VEAM410104 1-9
1.3.3 Directions of machine
In this manual, the directions of the machine (front, rear, left,
right) are determined according to the view from the operator's
seat in the direction of travel (front) of the machine.
A
B
CD
AFront CLeft
B Rear D Right

1.3 Introduction Foreword
1-10 PW140-7, PW160-7, PW180-7, PW200-7, PW220-7 – VEAM410104
1.3.4 Running 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 run in the machine for the initial 100 hours (as indi-
cated by the hour meter.)
During running in:
zIdle the engine for 5 minutes after starting it up.
zAvoid operation with heavy loads or at high speeds.
zSudden starting or acceleration, unnecessarily abrupt brak-
ing and sharp turning should be avoided except in cases of
emergency.
Additionally for the first 20 hours
zAvoid operating engine for prolonged periods at constant
speed (including idle.)
zAvoid high speed travelling for periods of more than 5 min-
utes.
Pay particular attention to oil pressure and temperature indica-
tors & check coolant and oil levels frequently during breaking in.
The precautions given in this manual for operating, mainte-
nance, 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 car-
ried out under any circumstances.

Foreword 1.4 Necessary information
PW140-7, PW160-7, PW180-7, PW200-7, PW220-7 – VEAM410104 1-11
1.4 Necessary information
When requesting service or ordering replacement parts, please
inform your KOMATSU distributor of the following items.
1.4.1 Product Identification Number (PIN)/Machine serial no. plate and
position
On the front right of the undercarriage.
Version 1
Version 2

1.4 Necessary information Foreword
1-12 PW140-7, PW160-7, PW180-7, PW200-7, PW220-7 – VEAM410104
1.4.2 Engine serial no. plate and position
On the top of the engine.
1.4.3 Position of service meter
The service meter is located on the right side in the cabin.

Foreword 1.4 Necessary information
PW140-7, PW160-7, PW180-7, PW200-7, PW220-7 – VEAM410104 1-13
1.4.4 Table to enter serial no. and distributor
Machine serial No.
Engine serial No.
Product identification number (PIN)
Manufacturer name
Address
KOMATSU Hanomag GmbH
Hanomagstraße 9
D-30449 Hannover
Germany
Distributor name
Address
Service Personnel
Phone/Fax

1.5 Declaration of conformity (for machines placed on the market as from 29th December 2009) Foreword
1-14 PW140-7, PW160-7, PW180-7, PW200-7, PW220-7 – VEAM410104
1.5 Declaration of conformity (for machines placed on
the market as from 29th December 2009)
The manufacturer:
KOMATSU Hanomag GmbH
Hanomag Strasse 9
30449 Hannover
Germany
Declares that this machine:
PW140-7
PW160-7
PW180-7
PW200-7
PW220-7
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

Foreword 1.6 Noise
PW140-7, PW160-7, PW180-7, PW200-7, PW220-7 – VEAM410104 1-15
1.6 Noise
1.6.1 Noise emission levels
Two labels indicating the machine noise level are affixed on the
machine.
zSound 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 A dB, in accordance with
ISO 11201.
zSound 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 direc-
tive 2000/14/EC. This value includes an uncertainty of B dB.
PW140-7 PW160-7 PW180-7 PW200-7
PW220-7
A 2.5 2.5 2.5 2.5
70 72 72 72
PW140-7 PW160-7 PW180-7 PW200-7
PW220-7
B 1.29 1.13 0.96 0.92
102 102 102
103

1.6 Noise Foreword
1-16 PW140-7, PW160-7, PW180-7, PW200-7, PW220-7 – VEAM410104
1.6.2 Vibration levels
When used for its intended purpose, levels of vibration for the
earth-moving machine transmitted from the operator’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 C m/s²
according EN 12096:1997.
The actual acceleration value for the body is less than or equal
to 0.5 m/s². The uncertainty for this value is D m/s² according EN
12096:1997.
These values were determined using a representative machine
and measured during the typical operating condition indicated
below according to the measurement procedures that are
defined in the standards ISO 2631/1 and ISO 5349.
Operating condition:
Excavating: Digging-loading-rotating-unloading-rotating
Guide to reduce vibration levels on machine
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
Tyre pressures
Brake and steering systems
Controls, hydraulic system and linkages
3. Keep the terrain where the machine is working and travelling
in good condition
Remove any large rocks or obstacles
Fill any ditches and holes
Site manager should provide machine operators with
machine and schedule time to maintain terrain condi-
tions
4. Use a seat that meets ISO 7096 and keep the seat main-
tained and adjusted
Adjust the seat and suspension for the weight and size
of the operator
Wear seat belt
Inspect and maintain the seat suspension and adjust-
ment mechanisms
PW140 PW160 PW180 PW200
PW220
C 0.34 0.495 0.91 0.275
D 0.16 0.16 0.22 0.175

Foreword 1.6 Noise
PW140-7, PW160-7, PW180-7, PW200-7, PW220-7 – VEAM410104 1-17
5. Steer, brake, accelerate, shift gears (for wheeled machines),
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
When pushing with bucket or blade, avoid sudden load-
ing; load gradually
Drive around obstacles and rough terrain conditions
Slow down when it is necessary to go over rough terrain
Make the curve radius of travelling path as large as pos-
sible
Travel at low speed when travelling around sharp curves
7. Minimize vibrations for long work cycle or long distance trav-
elling
Reduce speed to prevent bounce
Transport machines long distances between work sites
8. The following guidelines can be effective to minimize risks of
low back pain
Operate the machine only when you are in good health.
Provide breaks to reduce long periods of sitting in the
same posture
Do not jump down from the cab or machine
Do not repeatedly handle and lift loads

1.7 Contents Foreword
1-18 PW140-7, PW160-7, PW180-7, PW200-7, PW220-7 – VEAM410104
1.7 Contents
1. Foreword. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.1 Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.1.1 EU Directives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.2 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.2.1 Signal words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.2.2 Safety labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1.2.3 Emergency steering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7
1.2.4 Emergency braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7
1.3 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
1.3.1 Use of machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
1.3.2 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
1.3.3 Directions of machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-9
1.3.4 Running in your new machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
1.4 Necessary information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
1.4.1 Product Identification Number (PIN)/Machine serial no. plate and position . . . . . . . . . 1-11
1.4.2 Engine serial no. plate and position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
1.4.3 Position of service meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
1.4.4 Table to enter serial no. and distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
1.5 Declaration of conformity (for machines placed on the market as from
29th December 2009) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
1.6 Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
1.6.1 Noise emission levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
1.6.2 Vibration levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
Operating condition: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
Guide to reduce vibration levels on machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
1.7 Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
2. Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.1 Safety labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.1.1 Location of safety labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
2.2 General precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Understanding the machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2.2.1 Precautions before starting operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Ensuring safe operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2.2.2 Preparations for safe operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Precautions regarding safety-related equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
If any problem is found . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Wear well-fitting clothes and protective equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Keep machine clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Precautions inside operator's compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Provide fire extinguisher and first aid kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12