Komatsu PC1600-1 Shop Manual – PDF DOWNLOAD

Komatsu PC1600-1 Shop Manual – PDF DOWNLOAD

DESCRIPTION:

Komatsu PC1600-1 Shop Manual – PDF DOWNLOAD

A SAFETY
GENERAL PRECAUTIONS

Mistakes in operation are extremely dangerous Read the Operation and Maintenance Manual
carefully BEFORE operating the machine
1. Before carrying out any greasing or repairs, read all the precautions given
on the decals which are fixed to the machine
2 When carrying out any operation, always wear safety shoes and helmet. Do not wear
loose work clothes, or clothes with buttons missing
• Always wear safety glasses when hitting parts with a hammer
• Always wear safety glasses when grinding parts with a grinder, etc
3. If welding repairs are needed, always have a trained, experienced welder carry out
the work. When carrying out welding work, always wear welding gloves, apron, glasses,
cap and other clothes suited for welding work
4. When carrying out any operation with two or more workers, always agree on the op­
erating procedure before starting. Always inform your fellow workers before starting any
step of the operation. Before starting work, hang UNDER REPAIR signs on the
controls in the operator’s compartment
5. Keep all tools in good cond 巾on and learn the correct way to use them

6. Decide a place in the repair workshop to keep tools and removed parts. Always keep
the tools and parts in their correct places Always keep the work area clean and make
sure that there is no dirt or oil on the floor. Smoke only in the areas
provided for smoking. Never smoke while working

PREPARATIONS FOR WORK

7. Before adding oil or making any repairs, park the machine on hard, level ground,
and block the wheels or tracks to prevent the machine from moving
8. Before starting work, lower blade, ripper, bucket or any other work equipment to
the ground. If this is not possible, insert the safety pin or use blocks to prevent the
work equipment from falling. In addition, be sure to lock all the control levers
and hang warning signs on them
9. When disassembling or assembling, sup­ port the machine with blocks, jacks
or stands before starting work
10 Remove all mud and oil from the steps or other places used to get on and
off the machine. Always use the handrails, ladders or steps when getting on or
off the machine. Never jump on or off the machine. If it is impossible to use
the handrails, ladders or steps, use a stand to provide safe footing

TABLE OF CONTENTS:

Komatsu PC1600-1 Shop Manual – PDF DOWNLOAD

COVER 1
CONTENTS 2
10 STRUCTURE AND FUNCTION 18
PTO (POWER TAKE-OFF) 19
PTO LUBRICATION SYSTEM 20
RADIATOR AND OIL COOLER 21
AUTO-DECELERATION SYSTEM 22
POWER TRAIN 30
TRAVEL AND BRAKE SYSTEM 31
SWING SYSTEM 45
TRACK FRAME 68
IDLER CUSHION 69
IDLER 72
TRACK ROLLER 73
CARRIER ROLLER 73
TRACK 74
AIR SYSTEM 75
AIR GOVERNOR 76
AIR TANK 76
AUTO-DRAIN VALVE 76
SAFETY VALVE 77
SOLENOID VALVE (FOR LUBRICATION, HORN) 77
GREASE PUMP 78
GREASING SYSTEM 79
HYDRAULIC PIPING DIAGRAM 82
HYDRAULIC CIRCUIT DIAGRAM 83
WORK EQUIPMENT CONTROL 85
AUTOMATIC WORK EQUIPMENT CONTROL SYSTEM 92
HYDRAULIC TANK100
MAIN PUMP101
HYDRAULIC OIL FILTER120
CHARGING AND PTO LUBRICATING PUMP122
2-STAGE AND 3-STAGE MODE SELECTOR OLSS (OPEN CENTER LOAD SENSING SYSTEM)123
CONTROL VALVE140
PPC VALVE149
PPC SHUTTLE VALVE155
ACCUMULATOR156
PILOT RELIEF VALVE157
SAFETY LOCK VALVE159
HYDRAULIC CYLINDER161
WORK EQUIPMENT165
ELECTRICAL CIRCUIT DIAGRAM166
ELECTRICAL COMPONENTS OF 3-STAGE MODE SELECTOR OLSS168
ELECTRONIC COMPONENTS OF AUTOMATIC WORK EQUIPMENT CONTROL SYSTEM173
EVMS (ELECTRONIC VEHICLE MONITORING SYSTEM)177
20 TESTING AND ADJUSTING184
TABLE OF JUDGEMENT STANDARD VALUE185
TABLE OF ELECTRICAL JUDGEMENT STANDARD VALUE196
TESTING AND ADJUSTING TOOL LIST208
ADJUSTING VALVE CLEARANCE209
MEASURING COMPRESSION PRESSURE210
ADJUSTING FUEL INJECTION TIMING211
ADJUSTING FUEL CONTROL LEVER212
ADJUSTING AUTO-DECELERATION SYSTEM214
TESTING AND ADJUSTING OF MAIN RELIEF VALVE215
TESTING AND ADJUSTING CONTROL CIRCUIT PRESSURE218
MEASURING OIL LEAKAGE FROM SWING AND TRAVEL MOTOR222
TESTING OIL LEAK FROM SWIVEL JOINT223
AIR BLEEDING225
CHARGING ACCUMULATOR WITH GAS230
TESTING METHOD USING VISUAL AND FUNCTIONAL CHECK232
ADJUSTMENT OF WORK EQUIPMENT POTENTIOMETER233
ADJUSTMENT OF WORK EQUIPMENT CONTROL BOX (LOADING SHOVEL)234
TROUBLESHOOTING239
ELECTRICAL CIRCUIT DIAGRAM240
CONNECTOR POSITION FOR TROUBLESHOOTING246
TYPES AND MOUNTING POSITIONS OF CONNECTORS248
CONNECTION TABLE FOR CONNECTOR PINS 260
TROUBLESHOOTING PROCEDURE264
CHECKS BEFORE TROUBLESHOOTING265
E, H MODE TROUBLESHOOTING 268
ABNORMALITY DISPLAYS BY SELF CHECKER269
TROUBLESHOOTING (EXCEPT TROUBLESHOOTING FOR MACHINE MONITOR)270
E-1 WORK EQUIPMENT, SWING TRAVEL SPEEDS EXTREMELY SLOW, OR LACK OF POWER274
(1) CONTROLLER SYSTEM FOR FRONT ENGINE274
a) SELF-TESTING DISPLAY SHOWS ABNORMALITY274
b) SELF-TESTING DISPLAY SHOWS NORMAL276
(2) CONTROLLER SYSTEM FOR REAR ENGINE278
a) SELF-TESTING DISPLAY SHOWS ABNORMALITY278
b) SELF-TESTING DISPLAY SHOWS NORMAL280
E-2 ENGINE STALLS DURING OPERATIONS, OR ENGINE SPEED DROPS282
(1) CONTROLLER SYSTEM FOR FRONT ENGINE282
a) SELF-TESTING DISPLAY SHOWS ABNORMALITY282
b) SELF-TESTING DISPLAY SHOWS NORMAL282
(2) CONTROLLER SYSTEM FOR REAR ENGINE283
a) SELF-TESTING DISPLAY SHOWS ABNORMALITY283
b) SELF-TESTING DISPLAY SHOWS NORMAL283
E-3 NO CHANGE IN OUTPUT WHEN MODE SWITCH IS OPERATED284
(1) CONTROLLER SYSTEM FOR FRONT ENGINE284
a) SELF-TESTING DISPLAY SHOWS ABNORMALITY284
b) MODE DOES NOT CHANGE (WHEN SELF-TESTING DISPLAY SHOWS NORMAL)285
(2) CONTROLLER SYSTEM FOR REAR ENGINE288
a) SELF-TESTING DISPLAY SHOWS ABNORMALITY288
b) MODE DOES NOT CHANGE (WHEN SELF-TESTING DISPLAY SHOWS NORMAL)289
E-4 AUTO-DECELERATION DOES NOT WORK (IS NOT ACTUATED, OR REMAINS ACTUATED)292
a) SELF-TESTING DISPLAY SHOWS ABNORMALITY292
b) SELF-TESTING DISPLAY SHOWS NORMAL293
E-5 UPPER STRUCTURE DOES NOT SWING295
E-6 EXCESSIVE HYDRAULIC DRIFT OF SWING298
E-7 DEFECTIVE OPERATION OF BOTTOM CYLINDER299
a) BOTTOM CLOSE299
b) BOTTOM OPEN299
TROUBLESHOOTING FOR H MODE302
H-1 EXCESSIVE DEVIATION IN TRAVEL (EXCEEDS STANDARD ONLY WHEN TRAVELING WHILE OPERATING TRAVEL LEVER FULLY OPERATED)304
H-2 EXCESSIVE DEVIATION IN TRAVEL DURING SIMULTANEOUS OPERATIONS306
H-3 EXCESSIVE DEVIATION WHEN STARTING308
H-4 CONTROL LEVERS ARE EXTREMELY HEAVY310
H-5 WORK EQUIPMENT, TRAVEL, AND SWING START SUDDENLY DURING FINE CONTROL OPERATIONS311
H-6 SPEEDS FOR WORK EQUIPMENT, SWING, AND TRAVEL ARE ALL EXTREMELY SLOW, OR THERE IS NO POWER (THERE IS NO ABNORMALITY IN THE AUTO-DECELERATION SYSTEM)312
a) MACHINE HARDLY MOVES312
b) ABNORMALITY IN ONE PART (ABNORMALITY IN SYSTEM ON ONE SIDE)314
c) INDIVIDUAL PROBLEMS314
d) WHEN ANY OF WORK EQUIPMENT SPEEDS ARE SLOW315
e) FOR PROBLEMS OTHER THAN a), b), OR c) (WHEN AUTO-DECELERATION IS NORMAL)316
H-7 ENGINE STALLS DURING OPERATIONS OR ENGINE SPEED DROPS318
H-8 OUTPUT DOES NOT CHANGE WHEN MODE SWITCH IS USED TO CHANGE MODE319
H-9 AUTO-DECELERATION IS NOT ACTUATED OR REMAINS ACTUATED319
H-10 ABNORMAL NOISE IS HEARD (FROM AROUND THE PUMP)319
H-11 SWING SPEED IS SLOW OR THERE IS EXCESSIVE OVERRUN WHEN STOPPING SWING320
H-12 UPPER STRUCTURE DOES NOT SWING322
H-13 EXCESSIVE HYDRAULIC DRIFT OF SWING324
H-16 EXCESSIVE TIME LAG FOR WORK EQUIPMENT324
H-17 DEFECTIVE OPERATION OF BOTTOM CYLINDER325
FAILURE MODE AND COMPONENTS326
W, L MODE TROUBLESHOOTING327
ABNORMALITY JUDGEMENT CONDITIONS FOR SELF-TESTING DISPLAY328
TROUBLESHOOTING329
W-1 IN ARC DIGGING MODE (HORIZONTAL SELECTOR SWITCH OFF), MACHINE CARRIES OUT HORIZONTAL DIGGING OR BUCKET ANGLE COMPENSATION331
W-2 MACHINE DOES NOT CARRY OUT HORIZONTAL DIGGING IN HORIZONTAL DIGGING MODE332
a) SELF-CHECKER SHOWS ABNORMAL DISPLAY332
b) SELF-CHECKER SHOWS NORMAL DISPLAY339
W-3 IN HORIZONTAL DIGGING MODE (BUCKET ANGLE COMPENSATION SWITCH OFF), MACHINE CARRIES OUT BUCKET ANGLE COMPENSATION341
W-4 IN HORIZONTAL DIGGING + BUCKET COMPENSATION MODE, MACHINE CARRIES OUT HORIZONTAL DIGGING BUT DOES NOT CARRY OUT BUCKET ANGLE COMPENSATION342
a) SELF-CHECKER SHOWS ABNORMAL DISPLAY342
b) SELF-CHECKER SHOWS NORMAL DISPLAY345
W-5 IN HORIZONTAL DIGGING + BUCKET ANGLE COMPENSATION MODE, MACHINE CARRIES OUT BUCKET ANGLE COMPENSATION BUT DOES NOT CARRY OUT HORIZONTAL DIGGING347
a) SELF-CHECKER SHOWS ABNORMAL DISPLAY347
b) SELF-CHECKER SHOWS NORMAL DISPLAY347
W-6 MACHINE DOES NOT CARRY OUT HORIZONTAL DIGGING OR BUCKET ANGLE COMPENSATION IN HORIZONTAL DIGGING + BUCKET ANGLE COMPENSATION MODE349
a) SELF-CHECKER SHOWS ABNORMAL DISPLAY349
L-1 MACHINE CANNOT CARRY OUT HORIZONTAL DIGGING OR BUCKET ANGLE COMPENSATION356
M MODE TROUBLESHOOTING357
M-1 WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL DISPLAY DOES NOT APPEAR358
a) NONE OF MONITOR PANEL (GAUGES, MONITORS) WORKS358
b) PART OF MONITOR PANEL DOES NOT WORK358
M-2 WHEN STARTING SWITCH TURNED ON, MONITOR PANEL DISPLAY DOES NOT GO OUT358
M-3 WHEN STARTING SWITCH IS TURNED ON, (DO NOT START ENGINE), CHECK BEFORE STARTING ITEM FLASH OR PREHEATING ITEM LIGHTS UP359
a) COOLANT LEVEL FLASHES359
b) ENGINE OIL LEVEL FLASHES359
c) HYDRAULIC OIL LEVEL FLASHES360
d) PREHEATER FLASHES360
e) COOLANT LEVEL FLASHES361
f) ENGINE OIL LEVEL FLASHES361
g) PREHEATER FLASHES362
M-4 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, CHECK ITEMS FLASH363
a) FRONT ENGINE ALTERNATOR SYSTEM363
b) FRONT ENGINE OIL PRESSURE SYSTEM363
c) REAR ENGINE ALTERNATOR SYSTEM364
d) REAR ENGINE OIL PRESSURE SYSTEM364
M-5 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CAUTION ITEMS FLASH365
a) FRONT ENGINE SYSTEM365
b) REAR ENGINE SYSTEM366
M-6 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, CAUTION ITEMS FLASH(NOTE:NO ABNORMALITLES IN CHECK ITEMS OR ENGINE)367
a) ENGINE OIL PRESSURE FLASHES367
b) COOLANT LEVEL FLASHES367
c) COOLANT TEMPERATURE FLASHES368
d) BATTERY CHARGE LEVEL FLASHES368
e) HYDRAULIC OIL FILTER FLASHES369
f) HYDRAULIC OIL TEMPERATURE FLASHES369
g) ENGINE OIL PRESSURE FLASHES370
h) COOLANT LEVEL FLASHES370
i) BATTERY CHARGE LEVEL FLASHES370
M-7 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), BUZZER DOES NOT SOUND FOR 1 SEC CAUTION ITEMS ARE FLASHING, BUT BUZZER DOES NOT SOUND371
M-8 THERE IS NO ABNORMAL DISPLAY ON MONITOR, BUT BUZZER SOUNDS371
M-9 MONITOR PANEL LIGHTING DOES NOT LIGHT UP (LIQUID CRYSTAL DISPLAY IS NORMAL)372
M-10 SERVICE METER DOES NOT MOVE AFTER ENGINE IS STARTED SERVICE METER MOVES AFTER ENGINE IS STOPPED373
a) SERVICE METER DOES NOT MOVE AFTER ENGINE IS STARTED373
b) SERVICE METER MOVES AFTER ENGINE IS STOPPED373
M-11 FRONT COOLANT TEMPERATURE GAUGE SHOWS ABNORMALLY LOW TEMPERATURE374
M-12 FRONT COOLANT TEMPERATURE GAUGE GIVES NO DISPLAY374
M-13 REAR COOLANT TEMPERATURE GAUGE SHOWS ABNORMALLY LOW TEMPERATURE375
M-14 REAR COOLANT TEMPERATURE GAUGE GIVES NO DISPLAY375
M-15 FUEL TANK IS NOT FULL BUT DISPLAY SHOWS FULL TANK377
M-16 NO DISPLAY IS GIVEN FOR FUEL LEVEL377
30 DISASSEMBLY AND ASSEMBLY379
STARTING MOTOR382
REMOVAL AND INSTALLATION382
ALTERNATOR382
REMOVAL AND INSTALLATION382
ENGINE OIL COOLER382
REMOVAL AND INSTALLATION382
FUEL INJECTION PUMP384
REMOVAL AND INSTALLATION384
WATER PUMP384
REMOVAL AND INSTALLATION384
NOZZLE HOLDER386
REMOVAL AND INSTALLATION386
TURBOCHARGER386
REMOVAL AND INSTALLATION386
CYLINDER HEAD388
REMOVAL388
INSTALLATION392
HYDRAULIC OIL COOLER396
REMOVAL AND INSTALLATION396
RADIATOR396
REMOVAL AND INSTALLATION396
AFTER COOLER CORE398
REMOVAL AND INSTALLATION398
ENGINE, PTO, HYDRAULIC PUMP400
REMOVAL400
INSTALLATION402
PTO406
REMOVAL406
INSTALLATION408
DISASSEMBLY AND ASSEMBLY412
AUTO-DECELERATOR CYLINDER416
REMOVAL AND INSTALLATION416
CENTER SWIVEL JOINT418
REMOVAL AND INSTALLATION418
DISASSEMBLY AND ASSEMBLY420
TRAVEL MOTOR422
REMOVAL AND INSTALLATION422
TRAVEL MOTOR BRAKE VALVE422
REMOVAL AND INSTALLATION422
TRAVEL MOTOR424
DISASSEMBLY424
ASSEMBLY428
FINAL DRIVE436
REMOVAL AND INSTALLATION436
DISASSEMBLY438
ASSEMBLY442
SWING MOTOR450
REMOVAL AND INSTALLATION450
DISASSEMBLY452
ASSEMBLY456
REVOLVING FRAME462
REMOVAL AND INSTALLATION462
SWING CIRCLE464
REMOVAL AND INSTALLATION464
SWING MACHINERY464
REMOVAL AND INSTALLATION464
DISASSEMBLY466
ASSEMBLY470
FRONT IDLER474
REMOVAL AND INSTALLATION474
IDLER CUSHION CYLINDER474
REMOVAL AND INSTALLATION474
DISASSEMBLY AND ASSEMBLY476
IDLER ADJUSTMENT CYLINDER476
DISASSEMBLY AND ASSEMBLY476
TRACK ROLLER478
REMOVAL AND INSTALLATION478
CARRIER ROLLER478
REMOVAL AND INSTALLATION478
TRACK SHOE480
REMOVAL AND INSTALLATION480
CHARGING AND PTO LUBRICATION PUMP482
REMOVAL AND INSTALLATION482
SWING PUMP484
REMOVAL AND INSTALLATION484
DISASSEMBLY 486
ASSEMBLY490
NO1,3 PUMP500
REMOVAL AND INSTALLATION500
NO2, 4 PUMP502
REMOVAL AND INSTALLATION502
MAIN PUMP504
DISASSEMBLY504
ASSEMBLY508
CHARGE PUMP RELIEF VALVE520
REMOVAL AND INSTALLATION520
DISASSEMBLY AND ASSEMBLY520
MAIN RELIEF VALVE (FOR SWING)522
REMOVAL AND INSTALLATION522
DISASSEMBLY AND ASSEMBLY522
MAIN RELIEF VALVE (FOR WORK EQUIPMENT, TRAVEL)524
REMOVAL AND INSTALLATION524
DISASSEMBLY AND ASSEMBLY524
SWING CONTROL VALVE526
REMOVAL AND INSTALLATION526
DISASSEMBLY AND ASSEMBLY528
LH 4-SPOOL CONTROL VALVE (TOP LEFT)530
REMOVAL AND INSTALLATION530
RH 4-SPOOL CONTROL VALVE (TOP RIGHT)532
REMOVAL AND INSTALLATION532
LH 5-SPOOL CONTROL VALVE (BOTTOM LEFT)534
REMOVAL AND INSTALLATION534
RH 5-SPOOL CONTROL VALVE (BOTTOM RIGHT)536
REMOVAL AND INSTALLATION536
CONTROL VALVE538
DISASSEMBLY AND ASSEMBLY538
SERVO VALVE (FOR NO1, 3 F PUMPS)540
REMOVAL AND INSTALLATION540
SERVO VALVE (FOR NO1, 3 R PUMPS)540
REMOVAL AND INSTALLATION540
SERVO VALVE (FOR NO,2, 4 F PUMPS)542
REMOVAL AND INSTALLATION542
SERVO VALVE (FOR NO,2, 4 R PUMPS)542
REMOVAL AND INSTALLATION542
SERVO VALVE (FOR SWING PUMP)544
REMOVAL AND INSTALLATION544
CO・NC VALVE (FOR NO,2, 4 F PUMPS WITH TVC)544
REMOVAL AND INSTALLATION544
CO・NC VALVE (FOR NO2, 4 R PUMPS)546
REMOVAL AND INSTALLATION546
CO・NC VALVE (FOR SWING PUMP)546
REMOVAL AND INSTALLATION546
TVC VALVE (FOR NO2, 4 PUMP)548
REMOVAL AND INSTALLATION548
TRAVEL PPC VALVE550
REMOVAL AND INSTALLATION550
DISASSEMBLY AND ASSEMBLY550
PPC VALVE552
REMOVAL AND INSTALLATION552
DISASSEMBLY AND ASSEMBLY552
BOOM CYLINDER (LOADING SHOVEL)554
REMOVAL554
INSTALLATION556
ARM CYLINDER (LOADING SHOVEL)558
REMOVAL AND INSTALLATION558
BUCKET CYLINDER (LOADING SHOVEL)560
REMOVAL AND INSTALLATION560
BOTTOM CYLINDER (LOADING SHOVEL)562
REMOVAL AND INSTALLATION562
HYDRAULIC CYLINDER (LOADING SHOVEL)564
DISASSEMBLY564
ASSEMBLY568
BOOM CYLINDER (BACKHOE)572
REMOVAL572
INSTALLATION574
ARM CYLINDER (BACKHOE)576
REMOVAL AND INSTALLATION576
BUCKET CYLINDER (BACKHOE)578
REMOVAL578
INSTALLATION580
HYDRAULIC CYLINDER (BACKHOE)582
DISASSEMBLY582
ASSEMBLY586
BUCKET (BACKHOE)590
REMOVAL AND INSTALLATION590
BUCKET (LOADING SHOVEL)592
REMOVAL AND INSTALLATION592
ARM (BACKHOE)594
REMOVAL594
INSTALLATION596
ARM (LOADING SHOVEL)598
REMOVAL AND INSTALLATION598
BOOM (BACKHOE)600
REMOVAL600
INSTALLATION602
BOOM (LOADING SHOVEL)604
REMOVAL AND INSTALLATION604
BUCKET, ARM (BACKHOE)606
REMOVAL606
INSTALLATION608
WORK EQUIPMENT610
REMOVAL610
INSTALLATION614
COUNTERWEIGHT616
REMOVAL AND INSTALLATION616
40 MAINTENANCE STANDARD618
PTO (POWER TAKE-OFF)619
TRAVEL MOTOR620
TRAVEL SHUTTLE VALVE621
STRAIGHT-TRAVEL VALVE622
TRAVEL BRAKE VALVE623
SWING CONTROL VALVE624
JET SENSOR625
CONNECTION VALVE626
SWING MOTOR627
SWING CIRCLE628
SWING MACHINERY629
FINAL DRIVE630
TRACK FRAME631
TRACK SHOE632
IDLER633
TRACK ROLLER635
CARRIER ROLLER636
CHARGING AND PTO LUBRICATION PUMP637
PILOT RELIEF VALVE638
V2, V4 CONTROL VALVE639
V1 CONTROL VALVE641
V3 CONTROL VALVE643
PPC VALVE645
PPC SHUTTLE VALVE647
HYDRAULIC CYLINDER648
WORK EQUIPMENT649

IMAGES PREVIEW OF THE MANUAL: