Komatsu Hydraulic Excavator PC1600-1 Operation & Maintenance Manual – PDF DOWNLOAD

Komatsu Hydraulic Excavator PC1600-1 Operation & Maintenance Manual – PDF DOWNLOAD

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Komatsu Hydraulic Excavator PC1600-1 Operation & Maintenance Manual – PDF DOWNLOAD

SERIAL NUMBERS PC 1600-10052 and up

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 available
information of your machine or for questions regarding information in this manual.
This manual may contain attachments and optional equipment that are not available in your area.
Consult Komatsu or your Komatsu distributor for those items you may require.

WARNING
• 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 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. 蜘
• The procedures and precautions given in this manual apply only to intended uses of the machine.
H 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. H 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.
• The description of safety is given in SAFETY INFORMATION on page 0-2 and in SAFETY from page

INTRODUCTION
3.1 INTENDED USE
This Komatsu HYDRAULIC EXCAVATOR is designed to be used mainly for the following work:
• Digging work
• Loading work
See the section “12.14 WORK POSSIBLE USING HYDRAULIC EXCAVATOR” for further details.
3.2 FEATURES .
This Komatsu HYDRAULIC EXCAVATOR is equipped with various controls based on an advanced
electronics system.
o The monitor panel greatly facilitates daily maintenance and self-diagnosis.
o Working mode, travel speed and swing priority are selectable.
Adjustable semi wrist control levers make operations smooth and easy.
Air-conditioned operator’s cab assures comfortable operation.
Improved operator comfort due to noise and vibration, and smart urban-style design and color.
Enhanced safety by addition emergency stop lever, rear-view mirror and grill.
Superb operating performance provided by powerful engine and high-performance hydraulic
pumps.
Low fuel consumption controlled by an electronic control system provides an environment-friendly
machine.
3.3 RUNNING IN THE 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 indicated by the service meter.)
During running in:
• Idle the engine for 5 minutes after starting it up.
• Avoid operation with heavy loads or at high speeds.
• Avoid sudden starts, sudden acceleration, sudden steering and sudden stops except in cases of
emergency.
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 purposes. 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.
TABLE OF CONTENTS:

Komatsu Hydraulic Excavator PC1600-1 Operation & Maintenance Manual – PDF DOWNLOAD

COVER………………………………………………………………… 1
1. FOREWORD…………………………………………………………… 2
2. SAFETY INFORMATION………………………………………………….. 3
3. INTRODUCTION……………………………………………………….. 4
4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR……………. 5
5. CONTENTS…………………………………………………………… 6
SAFETY……………………………………………………………….. 10
6. GENERAL PRECAUTIONS …………………………………………….. 11
7. PRECAUTIONS DURING OPERATION……………………………………… 17
7.1 BEFORE STARTING ENGINE………………………………………. 17
7.2 OPERATING MACHINE…………………………………………… 19
7.3 TRANSPORTATION……………………………………………… 24
7.4 BATTERY……………………………………………………. 25
8. PRECAUTIONS FOR MAINTENANCE………………………………………. 26
8.1 BEFORE CARRYING OUT MAINTENANCE………………………………. 26
8.2 DURING MAINTENANCE………………………………………….. 29
9. POSITION FOR ATTACHING SAFETY LABELS………………………………. 33
OPERATION…………………………………………………………….. 37
10. GENERAL VIEW ………………………………………………….. 38
10.1 GENERAL VIEW OF MACHINE…………………………………….. 38
10.2 GENERAL VIEW OF CONTROLS AND GAUGES………………………….. 39
11. EXPLANATION OF COMPONENTS……………………………………….. 40
11.1 MACHINE MONITOR……………………………………………. 40
11.2 METER AND LAMP…………………………………………….. 47
11.3 SWITCHES …………………………………………………. 48
11.4 CONTROL LEVERS…………………………………………….. 53
11.5 DOOR LOCK…………………………………………………. 56
11.6 DUST INDICATOR…………………………………………….. 56
11.7 POCKET……………………………………………………. 56
11.8 AIR CONDITIONER……………………………………………. 57
11.9 RADIO…………………………………………………….. 63
11.10 FUSE…………………………………………………….. 65
11.11 CONTROLLERS………………………………………………. 66
11.12 TOOL BOX…………………………………………………. 66
11.13 GREASE PUMP………………………………………………. 67
11.14 HANDLING GREASE PUMP………………………………………. 67
11.15 HANDLING ACCUMULATOR………………………………………. 69
12. OPERATION……………………………………………………… 71
12.1 CHECK BEFORE STARTING ENGINE………………………………… 71
12.2 STARTING ENGINE……………………………………………. 80
12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE…………………… 83
12.4 MOVING MACHINE OFF…………………………………………. 85
12.5 STEERING MACHINE…………………………………………… 89
12.6 STOPPING MACHINE…………………………………………… 91
12.7 SWINGING………………………………………………….. 92
12.8 OPERATION OF WORK EQUIPMENT…………………………………. 93
12.9 WORKING MODE SELECTION……………………………………… 94
12.10 PROHIBITIONS FOR OPERATION…………………………………. 95
12.11 PRECAUTIONS FOR OPERATION………………………………….. 98
12.12 PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS………………….. 99
12.13 HOW TO ESCAPE FROM MUD……………………………………..101
12.14 WORK POSSIBLE USING HYDRAULIC EXCAVATOR………………………102
12.15 PARKING MACHINE……………………………………………103
12.16 CHECK AFTER FINISHING WORK………………………………….104
12.17 STOPPING ENGINE……………………………………………105
12.18 CHECK AFTER STOPPING ENGINE…………………………………106
12.19 LOCKING…………………………………………………..106
13. TRANSPORTATION………………………………………………….107
13.1 PRECAUTIONS FOR TRANSPORTATION……………………………….107
13.2 PARTS FOR TRANSPORT…………………………………………108
14. COLD WEATHER OPERATION…………………………………………..114
14.1 PRECAUTIONS FOR LOW TEMPERATURE………………………………114
14.2 PRECAUTIONS AFTER COMPLETION OF WORK………………………….116
14.3 AFTER COLD WEATHER………………………………………….116
15. LONG-TERM STORAGE……………………………………………….117
15.1 BEFORE STORAGE……………………………………………..117
15.2 DURING STORAGE……………………………………………..118
15.3 AFTER STORAGE………………………………………………118
15.4 STARTING MACHINE AFTER LONG-TERM STORAGE………………………118
16. TROUBLESHOOTING…………………………………………………119
16.1 PHENOMENA THAT ARE NOT FAILURES………………………………119
16.2 PRECAUTIONS ON PARTICULAR JOBSITES……………………………119
16.3 IF BATTERY IS DISCHARGED…………………………………….120
16.4 OTHER TROUBLE………………………………………………124
MAINTENANCE……………………………………………………………130
17. GUIDES TO MAINTENANCE……………………………………………131
18. OUTLINES OF SERVICE……………………………………………..135
18.1 OUTLINE OF OIL,FUEL,COOLANT………………………………….135
18.2 OUTLINE OF ELECTRICAL SYSTEM…………………………………138
18.3 OUTLINE OF HYDRAULIC SYSTEM………………………………….139
18.4 RELEASING PRESSURE………………………………………….140
18.5 BLEEDING AIR FROM CIRCUIT……………………………………142
18.6 OIL FILTER AND LEVEL GAUGE POSITIONS………………………….149
19. CONSUMABLE PARTS LIST……………………………………………150
20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE….151
21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS……………………..155
21.1 INTRODUCTION OF NECESSARY TOOLS………………………………155
21.2 TORQUE LIST………………………………………………..156
22. PERIODIC REPLACEMENT OF CRITICAL SAFETY PARTS………………………157
23. MAINTENANCE SCHEDULE CHART……………………………………….163
23.1 MAINTENANCE SCHEDULE CHART…………………………………..163
24. SERVICE PROCEDURE……………………………………………….167
24.1 INITIAL 100 HOURS SERVICE……………………………………167
24.2 INITIAL 250 HOURS SERVICE……………………………………167
24.3 WHEN REQUIRED………………………………………………168
24.4 CHECK BEFORE STARTING……………………………………….187
24.5 EVERY 10 HOURS SERVICE………………………………………192
24.6 EVERY 250 HOURS SERVICE……………………………………..195
24.7 EVERY 500 HOURS SERVICE……………………………………..203
24.8 EVERY 1000 HOURS SERVICE…………………………………….210
24.9 EVERY 2000 HOURS SERVICE…………………………………….212
24.10 EVERY 4000 HOURS SERVICE……………………………………215
SPECIFICATIONS…………………………………………………………216
25. SPECIFICATIONS………………………………………………….217
OPTIONS, ATTACHMENTS……………………………………………………220
26. GENERAL PRECAUTIONS……………………………………………..221
26.1 PRECAUTIONS RELATED TO SAFETY………………………………..221
26.2 PRECAUTIONS WHEN INSTALLING ATTACHMENTS……………………….222
27. INTRODUCTION OF ATTACHMENTS………………………………………223
27.1 SELECTION OF BUCKET TEETH……………………………………223
28. USING SEAT BELT…………………………………………………224
28.1 SEAT BELT………………………………………………….224
BACK HOE SHOVEL………………………………………………………..226
29. GENERAL LOCATIONS……………………………………………….227
30. INSTRUMENTS AND CONTROLS…………………………………………228
30.1 SWITCHES…………………………………………………..228
30.2 CONTROL LEVERS……………………………………………..231
30.3 FUSE BOX…………………………………………………..233
31. OPERATIONS……………………………………………………..234
31.1 OPERATION OF WORK EQUIPMENT………………………………….234
31.2 CHECK BEFORE STARTING ENGINE…………………………………236
31.3 PRECAUTIONS DURING OPERATION…………………………………238
31.4 WORK POSSIBLE USING HYDRAULIC EXCAVATOR……………………….240
31.5 PHENOMENA THAT DO NOT INDICATE FAILURE………………………..240
32. PRECAUTIONS WHEN DISASSEMBLING MACHINE…………………………….241
33. OUTLINES OF SERVICE……………………………………………..242
33.1 OIL FILLER AND LEVEL GAUGE POSITIONS………………………….242
34. SERVICE PROCEDURE……………………………………………….243
34.1 CHECK BEFORE STARTING……………………………………….243
34.2 EVERY 10 HOURS SERVICE………………………………………245
35. TRANSPORTATION………………………………………………….247
35.1 PARTS FOR TRANSPORT…………………………………………247
36. CONSUMABLE PARTS LIST……………………………………………253
37. SPECIFICATIONS………………………………………………….254

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