Komatsu PW160-11 Hydraulic Excavator Operation and Maintenance Manual (VENAM69001)

Komatsu PW160-11 Hydraulic Excavator Operation and Maintenance Manual (VENAM69001)

Format: PDF (Printable Document)

File Language: English

File Pages: 510

File Size: 86.23 MB (Speed Download Link)

Brand: Komatsu

Model: PW160-11 Hydraulic Excavator

Book No: VENAM69001

Type of Document: Operation and Maintenance Manual

Categories: Komatsu PDF, PDF

$ 40

Komatsu PW160-11 Hydraulic Excavator Operation and Maintenance Manual (VENAM69001)

On a PW160-11 you’re usually working roadside, in tight urban jobs, or on utility trenches where you’re swinging over traffic and uneven ground all day. This Operation and Maintenance Manual is what I use to set a solid service rhythm so the machine stays predictable and doesn’t surprise you with downtime. When, for example, the swing feels a bit jerky or the hydraulics start to slow under load, I lean on this book to walk through the basic checks in a logical order before we ever call in major repairs.

Applications & Use Cases

Plan daily and weekly checks so the operator can spot leaks, loose hardware, or odd noises before they turn into failures.
Schedule preventive maintenance around your actual workload to keep the excavator available for night work or road closures.
Trace early hydraulic issues by following the recommended inspection steps instead of guessing at components.
Verify adjustments and calibrations after tire, attachment, or implement changes so the machine stays stable and predictable.
Prepare for seasonal changes by adjusting maintenance habits for dust, mud, or cold-weather operation.

FAQ

Q: Can I keep this manual on a tablet in the cab?

A: Yes, it’s practical to use digitally; just make sure pages are easy to zoom and bookmark the maintenance charts you use most.

Q: Is it worth printing parts of it?

A: I’d print the inspection checklists and key service pages and keep them in a binder in the service truck for quick reference.

Safety Note

Always follow the manual’s safety steps before inspecting, lifting, or working under any part of the machine.

📘 Show Index

Komatsu PW160-11 Hydraulic Excavator Index:

FOREWORD
- READ THIS MANUAL
  - EU DIRECTIVES
- KOMATSU MACHINE OPERATOR PRIVACY POLICY
- SAFETY INFORMATION
- SAFETY LABELS
- NOISE
- VIBRATION LEVELS
  - VIBRATION – OPERATING CONDITION
  - GUIDE TO REDUCE VIBRATION LEVELS ON MACHINE
- INTRODUCTION
  - MAIN USE OF MACHINE
  - DEMOLITION WORK
  - DIRECTIONS OF MACHINE
  - VISIBILITY FROM OPERATOR’S SEAT
- ENGINE TECHNOLOGY TO CONFORM EXHAUST GAS EMISSION
- PRODUCT INFORMATION
  - LOCATION OF PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE
  - LOCATION OF ROPS/FOPS SERIAL PLATE
  - LOCATION OF ENGINE NUMBER PLATE
  - TRANSMISSION SERIAL PLATE LOCATION
  - AXLE SERIAL PLATE LOCATION
  - FLUORINATED GREENHOUSE GASES
  - SERVICE METER LOCATION
  - YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR
- SERIAL PLATE
- DECLARATION OF CONFORMITY
- EXPLANATION OF ACRONYMS
- TABLE OF CONTENTS
SAFETY
- SAFETY
- SAFETY LABELS
  - LOCATION OF SAFETY LABELS
  - CONTENTS OF SAFETY LABELS
- GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE
  - PRECAUTIONS BEFORE STARTING OPERATION
  - PREPARATIONS FOR SAFE OPERATION
  - PRECAUTIONS TO PREVENT FIRE
  - PRECAUTIONS WHEN GETTING ON OR OFF MACHINE
  - DO NOT GET CAUGHT IN WORK EQUIPMENT
  - PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES
  - PROTECTION AGAINST FALLING, FLYING OR INTRUDING OBJECTS
  - ACTIONS IN THE EVENT OF DAMAGE TO SAFETY STRUCTURES
  - UNAUTHORIZED MODIFICATION
  - PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS
  - PRECAUTIONS RELATED TO CAB GLASS
  - PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING
- PRECAUTIONS FOR OPERATION
  - PRECAUTIONS FOR JOBSITE
  - START ENGINE
  - PRECAUTIONS FOR OPERATION
  - PRECAUTIONS FOR TRANSPORTATION
  - TOWING AND BEING TOWED
  - LIFTING OBJECTS WITH BUCKET LINK LIFTING DEVICE (OPTIONAL EQUIPMENT)
  - LIFTING OBJECTS WITH BUCKETS
- PRECAUTIONS FOR MAINTENANCE
  - PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE
  - PRECAUTIONS FOR CHECK AND MAINTENANCE
- PRECAUTIONS FOR DEF
  - GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING
  - PRECAUTIONS FOR ADDING
  - SAFETY RULES FOR STORAGE
  - PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE
  - OTHER PRECAUTIONS
  - EXPLANATION OF LIFT CAPACITY CHART (1-PIECE BOOM)
  - EXPLANATION OF LIFT CAPACITY CHART (2-PIECE BOOM)
  - EXPLANATION OF OVERLOAD CAUTION
OPERATION
- GENERAL VIEW
  - MACHINE EQUIPMENT NAME
  - CAB EQUIPMENT NAMES
  - CONTROLS AND GAUGES NAMES
- EXPLANATION OF COMPONENTS
  - EXPLANATION OF MACHINE MONITOR EQUIPMENT
  - SWITCHES
  - CONTROL LEVERS AND PEDALS
  - OTHER EQUIPMENT
- MACHINE OPERATIONS AND CONTROLS
  - CHECKS AND ADJUSTMENT BEFORE STARTING ENGINE
  - METHOD FOR STARTING ENGINE
  - METHOD FOR OPERATIONS AND CHECKS AFTER STARTING ENGINE
  - METHOD FOR STOPPING ENGINE
  - METHOD FOR STARTING MACHINE (TRAVEL FORWARD AND REVERSE) AND STOPPING MACHINE
  - METHOD FOR STEERING MACHINE
  - METHOD FOR TRAVELING ON ROAD
  - METHOD FOR SWINGING MACHINE
  - METHOD FOR OPERATING WORK EQUIPMENT
  - HANDLE WORKING MODE
  - PROHIBITED OPERATIONS
  - PRECAUTIONS FOR OPERATION
  - PRECAUTIONS FOR WORKING ON SLOPE
  - METHOD FOR ESCAPING FROM MUD
  - RECOMMENDED APPLICATIONS
  - EFFECTIVE USE OF HYDRAULIC EXCAVATOR
  - METHOD FOR REPLACING AND INVERTING BUCKET
  - METHOD FOR PARKING MACHINE
  - METHOD FOR CHECKING AFTER FINISHING WORK
  - LOCK
  - HANDLE TIRE
- HANDLE AIR CONDITIONER
  - EXPLANATION OF AIR CONDITIONER EQUIPMENT
  - METHOD FOR OPERATING AIR CONDITIONER
- HANDLE RADIO
  - (Başlıksız)
  - STOW ANTENNA
  - SPACE FOR RADIO CASSETTE
- KomVision
  - PRECAUTIONS WHEN USING KomVision
  - MONITOR DISPLAY
- TRANSPORTATION
  - PRECAUTIONS FOR TRANSPORTING MACHINE
  - LOADING AND UNLOADING WITH TRAILER
  - METHOD FOR LIFTING MACHINE
- COLD WEATHER OPERATION
  - COLD WEATHER OPERATION INFORMATION
  - PRECAUTIONS AFTER DAILY WORK COMPLETION IN COLD WEATHER
  - AFTER COLD WEATHER SEASON
- PRECAUTIONS FOR LONG-TERM STORAGE
  - PREPARATION FOR LONG-TERM STORAGE
  - MAINTENANCE DURING LONG-TERM STORAGE
  - STARTING MACHINE AFTER LONG-TERM STORAGE
- TROUBLES AND ACTIONS
  - ACTIONS WHEN RUNNING OUT OF FUEL
  - PHENOMENA THAT ARE NOT FAILURES
  - PRECAUTIONS FOR TOWING MACHINE
  - PRECAUTIONS FOR SEVERE JOB CONDITION
  - PRECAUTIONS FOR DISCHARGED BATTERY
  - OTHER TROUBLE
- CAMERA SYSTEM CAUTION LAMP
- CAMERA CONTROLLER CAUTION LAMP
- KEY-ON CAMERA POSITION
MAINTENANCE
- PRECAUTIONS FOR MAINTENANCE
  - CHECK SERVICE METER READING
  - KOMATSU GENUINE REPLACEMENT PARTS
  - KOMATSU GENUINE LUBRICANTS
  - ALWAYS USE CLEAN WASHER FLUID
  - FRESH AND CLEAN LUBRICANTS
  - CHECK DRAINED OIL AND USED FILTER
  - PRECAUTIONS FOR REFILLING OIL OR FUEL
  - PRECAUTIONS FOR ADDING DEF
  - WELDING INSTRUCTIONS
  - DO NOT DROP THINGS INSIDE MACHINE
  - PRECAUTIONS FOR SCR ASSEMBLY
  - DUSTY JOBSITES
  - AVOID MIXING OIL
  - LOCK INSPECTION COVERS
  - BLEED AIR FROM HYDRAULIC CIRCUIT
  - PRECAUTIONS WHEN INSTALLING HYDRAULIC HOSES
  - CHECKS AFTER INSPECTION AND MAINTENANCE
  - FUEL AND LUBRICANTS TO MATCH THE AMBIENT TEMPERATURE
  - CLOSE ENGINE HOOD SECURELY
- OUTLINE OF MAINTENANCE
  - HANDLE OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC
  - HANDLE ELECTRICAL COMPONENTS
  - OUTLINE OF HYDRAULIC SYSTEM
- STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS
- MAINTENANCE SCHEDULE
  - MAINTENANCE SCHEDULE TABLE
  - MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER
- MAINTENANCE PROCEDURE
  - INITIAL 50 HOURS MAINTENANCE (ONLY AFTER THE FIRST 50 HOURS)
  - WHEN REQUIRED
  - CHECK AUTOMATIC GREASE SYSTEM
  - CHECKS BEFORE STARTING
  - EVERY 100 HOURS MAINTENANCE
  - EVERY 250 HOURS MAINTENANCE
  - EVERY 500 HOURS MAINTENANCE
  - EVERY 1000 HOURS MAINTENANCE
  - EVERY 2000 HOURS MAINTENANCE
  - EVERY 4000 HOURS MAINTENANCE
  - EVERY 4500 HOURS MAINTENANCE
  - EVERY 5000 HOURS MAINTENANCE
  - EVERY 8000 HOURS MAINTENANCE
  - EVERY 9000 HOURS MAINTENANCE
SPECIFICATIONS
- SPECIFICATIONS
ATTACHMENTS AND OPTIONS
- PRECAUTIONS FOR USING ATTACHMENT AND OPTIONS
  - PRECAUTIONS WHEN SELECTING
  - READ THE OPERATION AND MAINTENANCE MANUAL THOROUGHLY
  - PRECAUTIONS WHEN REMOVING AND INSTALLING
  - PRECAUTIONS WHEN USING
- QUICK COUPLER SYSTEM
  - HANDLING QUICK COUPLER
- AUTOMATIC GREASE SYSTEM
  - CHECK AUTOMATIC GREASE SYSTEM
- 2-PIECE BOOM
  - GENERAL VIEW OF MACHINE FOR 2-PIECE BOOM
  - OPERATION
  - STORAGE POSTURE WHEN LEAVING MACHINE
  - LIFTING
- HANDLE BUCKET WITH HOOK
  - (Başlıksız)
- HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT
  - (Başlıksız)
  - METHOD FOR OPERATING ATTACHMENT
  - METHOD FOR RELEASING PRESSURE IN CONTROL CIRCUIT (MACHINES EQUIPPED WITH ACCUMULATOR)
  - LONG-TERM STORAGE
  - SPECIFICATIONS
- AUXILIARY CIRCUIT CONTROL SYSTEM
  - ACTIVATION OF THE AUXILIARY CIRCUIT
- (Başlıksız)
  - TOOL CONTROL
- BOOM FLOATING
- ECSS (Electronically Controlled Suspension System)
- RECOMMENDED ATTACHMENT OPERATIONS
  - HYDRAULIC BREAKER
  - POWER RIPPER
  - FORK GRAB
  - GRAPPLE BUCKET
  - SCRAP GRAPPLE
  - CRUSHER AND SMASHER
  - HYDRAULIC PILE DRIVER
- TRAILER COUPLING FOR PULLING TRAILERS
  - TRAILER COUPLING AUTOMATIC
  - TRAILER COUPLING BALL
  - METHOD FOR DISASSEMBLY AND ASSEMBLY OF AUTOMATIC TRAILER COUPLING ON BLADE
  - METHOD FOR WORKING WITH BLADE
  - METHOD FOR ASSEMBLY AND DISASSEMBLY OF TRAILER COUPLING ON OUTRIGGER FRAME
  - METHOD FOR COUPLE AND UNCOUPLE OF THE TRAILER
  - MAINTENANCE
REPLACEMENT PARTS
- PERIODIC REPLACEMENT OF DEFINED LIFE PARTS
  - DEFINED LIFE PARTS LIST
- CONSUMABLE PARTS
  - CONSUMABLE PARTS
- RECOMMENDED FUEL, COOLANT, AND LUBRICANT
  - LUBRICATION CHART
  - USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE
  - RECOMMENDED BRANDS AND QUALITIES OTHER THAN KOMATSU GENUINE OILS
INDEX