Komatsu PC1600-1 Hydraulic Excavator Service Repair Shop Manual (10001 and up) - SEBM021TA103

This Complete Workshop Service Repair Manual PDF Download for the PC1600-1 Komatsu Hydraulic Excavator (S/N: 10001 and up) has easy to read text sections with top quality diagrams, pictures and illustrations. The step by step instructions show you how to fault find or complete any repair or overhaul, correctly and efficiently, saving time and avoiding costly mistakes. All specifications and tolerances are listed. Functions of components and systems are also explained.


APPLICABLE MODELS :

Komatsu PC1600-1 - S/N: 10001 and up


TABLE OF CONTENTS :

10 STRUCTURE AND FUNCTION
20 TESTING AND ADJUSTING
30 DISASSEMBLY AND ASSEMBLY
40 MAINTENANCE STANDARD


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : SEBM021TA103
Total Pages : 650


This manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

This manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having PDF files instead of a hard-printed manual is that you can use the Search feature in Acrobat to find just what your looking for and just print out the exact pages you need or all manual.

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CONTENTS

10 STRUCTURE AND FUNCTION
PTO (POWER TAKE-OFF)
PTO LUBRICATION SYSTEM
RADIATOR AND OIL COOLER
AUTO-DECELERATION SYSTEM
POWER TRAIN
TRAVEL AND BRAKE SYSTEM
SWING SYSTEM
TRACK FRAME
IDLER CUSHION
IDLER
TRACK ROLLER
CARRIER ROLLER
TRACK
AIR SYSTEM
AIR GOVERNOR
AIR TANK
AUTO-DRAIN VALVE
SAFETY VALVE
SOLENOID VALVE (FOR LUBRICATION, HORN)
GREASE PUMP
GREASING SYSTEM
HYDRAULIC PIPING DIAGRAM
HYDRAULIC CIRCUIT DIAGRAM
WORK EQUIPMENT CONTROL
AUTOMATIC WORK EQUIPMENT CONTROL SYSTEM
HYDRAULIC TANK
MAIN PUMP
HYDRAULIC OIL FILTER
CHARGING AND PTO LUBRICATING PUMP
2-STAGE AND 3-STAGE MODE SELECTOR OLSS (OPEN CENTER LOAD SENSING SYSTEM)
CONTROL VALVE
PPC VALVE
PPC SHUTTLE VALVE
ACCUMULATOR
PILOT RELIEF VALVE
SAFETY LOCK VALVE
HYDRAULIC CYLINDER
WORK EQUIPMENT
ELECTRICAL CIRCUIT DIAGRAM
ELECTRICAL COMPONENTS OF 3-STAGE MODE SELECTOR OLSS
ELECTRONIC COMPONENTS OF AUTOMATIC WORK EQUIPMENT CONTROL SYSTEM
EVMS (ELECTRONIC VEHICLE MONITORING SYSTEM)

20 TESTING AND ADJUSTING
TABLE OF JUDGEMENT STANDARD VALUE
TABLE OF ELECTRICAL JUDGEMENT STANDARD VALUE
TESTING AND ADJUSTING TOOL LIST
ADJUSTING VALVE CLEARANCE
MEASURING COMPRESSION PRESSURE
ADJUSTING FUEL INJECTION TIMING
ADJUSTING FUEL CONTROL LEVER
ADJUSTING AUTO-DECELERATION SYSTEM
TESTING AND ADJUSTING OF MAIN RELIEF VALVE
TESTING AND ADJUSTING CONTROL CIRCUIT PRESSURE
MEASURING OIL LEAKAGE FROM SWING AND TRAVEL MOTOR
TESTING OIL LEAK FROM SWIVEL JOINT
AIR BLEEDING
CHARGING ACCUMULATOR WITH GAS
TESTING METHOD USING VISUAL AND FUNCTIONAL CHECK
ADJUSTMENT OF WORK EQUIPMENT POTENTIOMETER
ADJUSTMENT OF WORK EQUIPMENT CONTROL BOX (LOADING SHOVEL)
TROUBLESHOOTING
ELECTRICAL CIRCUIT DIAGRAM
CONNECTOR POSITION FOR TROUBLESHOOTING
TYPES AND MOUNTING POSITIONS OF CONNECTORS
CONNECTION TABLE FOR CONNECTOR PINS
TROUBLESHOOTING PROCEDURE
CHECKS BEFORE TROUBLESHOOTING
E, H MODE TROUBLESHOOTING
ABNORMALITY DISPLAYS BY SELF CHECKER
TROUBLESHOOTING (EXCEPT TROUBLESHOOTING FOR MACHINE MONITOR)
E-1 WORK EQUIPMENT, SWING TRAVEL SPEEDS EXTREMELY SLOW, OR LACK OF POWER
(1) CONTROLLER SYSTEM FOR FRONT ENGINE
a) SELF-TESTING DISPLAY SHOWS ABNORMALITY
b) SELF-TESTING DISPLAY SHOWS NORMAL
(2) CONTROLLER SYSTEM FOR REAR ENGINE
a) SELF-TESTING DISPLAY SHOWS ABNORMALITY
b) SELF-TESTING DISPLAY SHOWS NORMAL
E-2 ENGINE STALLS DURING OPERATIONS, OR ENGINE SPEED DROPS
(1) CONTROLLER SYSTEM FOR FRONT ENGINE
a) SELF-TESTING DISPLAY SHOWS ABNORMALITY
b) SELF-TESTING DISPLAY SHOWS NORMAL
(2) CONTROLLER SYSTEM FOR REAR ENGINE
a) SELF-TESTING DISPLAY SHOWS ABNORMALITY
b) SELF-TESTING DISPLAY SHOWS NORMAL
E-3 NO CHANGE IN OUTPUT WHEN MODE SWITCH IS OPERATED
(1) CONTROLLER SYSTEM FOR FRONT ENGINE
a) SELF-TESTING DISPLAY SHOWS ABNORMALITY
b) MODE DOES NOT CHANGE (WHEN SELF-TESTING DISPLAY SHOWS NORMAL)
(2) CONTROLLER SYSTEM FOR REAR ENGINE
a) SELF-TESTING DISPLAY SHOWS ABNORMALITY
b) MODE DOES NOT CHANGE (WHEN SELF-TESTING DISPLAY SHOWS NORMAL)
E-4 AUTO-DECELERATION DOES NOT WORK (IS NOT ACTUATED, OR REMAINS ACTUATED)
a) SELF-TESTING DISPLAY SHOWS ABNORMALITY
b) SELF-TESTING DISPLAY SHOWS NORMAL
E-5 UPPER STRUCTURE DOES NOT SWING
E-6 EXCESSIVE HYDRAULIC DRIFT OF SWING
E-7 DEFECTIVE OPERATION OF BOTTOM CYLINDER
a) BOTTOM CLOSE
b) BOTTOM OPEN
TROUBLESHOOTING FOR H MODE
H-1 EXCESSIVE DEVIATION IN TRAVEL (EXCEEDS STANDARD ONLY WHEN TRAVELING WHILE OPERATING. TRAVEL LEVER FULLY OPERATED.)
H-2 EXCESSIVE DEVIATION IN TRAVEL DURING SIMULTANEOUS OPERATIONS
H-3 EXCESSIVE DEVIATION WHEN STARTING
H-4 CONTROL LEVERS ARE EXTREMELY HEAVY
H-5 WORK EQUIPMENT, TRAVEL, AND SWING START SUDDENLY DURING FINE CONTROL OPERATIONS
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)
a) MACHINE HARDLY MOVES
b) ABNORMALITY IN ONE PART (ABNORMALITY IN SYSTEM ON ONE SIDE)
c) INDIVIDUAL PROBLEMS
d) WHEN ANY OF WORK EQUIPMENT SPEEDS ARE SLOW
e) FOR PROBLEMS OTHER THAN a), b), OR c) (WHEN AUTO-DECELERATION IS NORMAL)
H-7 ENGINE STALLS DURING OPERATIONS OR ENGINE SPEED DROPS
H-8 OUTPUT DOES NOT CHANGE WHEN MODE SWITCH IS USED TO CHANGE MODE
H-9 AUTO-DECELERATION IS NOT ACTUATED OR REMAINS ACTUATED
H-10 ABNORMAL NOISE IS HEARD (FROM AROUND THE PUMP)
H-11 SWING SPEED IS SLOW OR THERE IS EXCESSIVE OVERRUN WHEN STOPPING SWING
H-12 UPPER STRUCTURE DOES NOT SWING
H-13 EXCESSIVE HYDRAULIC DRIFT OF SWING
H-16 EXCESSIVE TIME LAG FOR WORK EQUIPMENT
H-17 DEFECTIVE OPERATION OF BOTTOM CYLINDER
FAILURE MODE AND COMPONENTS
W, L MODE TROUBLESHOOTING
ABNORMALITY JUDGEMENT CONDITIONS FOR SELF-TESTING DISPLAY
TROUBLESHOOTING
W-1 IN ARC DIGGING MODE (HORIZONTAL SELECTOR SWITCH OFF), MACHINE CARRIES OUT HORIZONTAL DIGGING OR BUCKET ANGLE COMPENSATION
W-2 MACHINE DOES NOT CARRY OUT HORIZONTAL DIGGING IN HORIZONTAL DIGGING MODE
a) SELF-CHECKER SHOWS ABNORMAL DISPLAY
b) SELF-CHECKER SHOWS NORMAL DISPLAY
W-3 IN HORIZONTAL DIGGING MODE (BUCKET ANGLE COMPENSATION SWITCH OFF), MACHINE CARRIES OUT BUCKET ANGLE COMPENSATION
W-4 IN HORIZONTAL DIGGING + BUCKET COMPENSATION MODE, MACHINE CARRIES OUT HORIZONTAL DIGGING BUT DOES NOT CARRY OUT BUCKET ANGLE COMPENSATION
a) SELF-CHECKER SHOWS ABNORMAL DISPLAY
b) SELF-CHECKER SHOWS NORMAL DISPLAY
W-5 IN HORIZONTAL DIGGING + BUCKET ANGLE COMPENSATION MODE, MACHINE CARRIES OUT BUCKET ANGLE COMPENSATION BUT DOES NOT CARRY OUT HORIZONTAL DIGGING
a) SELF-CHECKER SHOWS ABNORMAL DISPLAY
b) SELF-CHECKER SHOWS NORMAL DISPLAY
W-6 MACHINE DOES NOT CARRY OUT HORIZONTAL DIGGING OR BUCKET ANGLE COMPENSATION IN HORIZONTAL DIGGING + BUCKET ANGLE COMPENSATION MODE
a) SELF-CHECKER SHOWS ABNORMAL DISPLAY
L-1 MACHINE CANNOT CARRY OUT HORIZONTAL DIGGING OR BUCKET ANGLE COMPENSATION
M MODE TROUBLESHOOTING
M-1 WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL DISPLAY DOES NOT APPEAR
a) NONE OF MONITOR PANEL (GAUGES, MONITORS) WORKS
b) PART OF MONITOR PANEL DOES NOT WORK
M-2 WHEN STARTING SWITCH TURNED ON, MONITOR PANEL DISPLAY DOES NOT GO OUT
M-3 WHEN STARTING SWITCH IS TURNED ON, (DO NOT START ENGINE), CHECK BEFORE STARTING ITEM FLASH OR PREHEATING ITEM LIGHTS UP
a) COOLANT LEVEL FLASHES
b) ENGINE OIL LEVEL FLASHES
c) HYDRAULIC OIL LEVEL FLASHES
d) PREHEATER FLASHES
e) COOLANT LEVEL FLASHES
f) ENGINE OIL LEVEL FLASHES
g) PREHEATER FLASHES
M-4 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, CHECK ITEMS FLASH
a) FRONT ENGINE ALTERNATOR SYSTEM
b) FRONT ENGINE OIL PRESSURE SYSTEM
c) REAR ENGINE ALTERNATOR SYSTEM
d) REAR ENGINE OIL PRESSURE SYSTEM
M-5 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CAUTION ITEMS FLASH
a) FRONT ENGINE SYSTEM
b) REAR ENGINE SYSTEM
M-6 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, CAUTION ITEMS FLASH.(NOTE:NO ABNORMALITLES IN CHECK ITEMS OR ENGINE)
a) ENGINE OIL PRESSURE FLASHES
b) COOLANT LEVEL FLASHES
c) COOLANT TEMPERATURE FLASHES
d) BATTERY CHARGE LEVEL FLASHES
e) HYDRAULIC OIL FILTER FLASHES
f) HYDRAULIC OIL TEMPERATURE FLASHES
g) ENGINE OIL PRESSURE FLASHES
h) COOLANT LEVEL FLASHES
i) BATTERY CHARGE LEVEL FLASHES
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 SOUND
M-8 THERE IS NO ABNORMAL DISPLAY ON MONITOR, BUT BUZZER SOUNDS
M-9 MONITOR PANEL LIGHTING DOES NOT LIGHT UP (LIQUID CRYSTAL DISPLAY IS NORMAL)
M-10 SERVICE METER DOES NOT MOVE AFTER ENGINE IS STARTED. SERVICE METER MOVES AFTER ENGINE IS STOPPED
a) SERVICE METER DOES NOT MOVE AFTER ENGINE IS STARTED
b) SERVICE METER MOVES AFTER ENGINE IS STOPPED
M-11 FRONT COOLANT TEMPERATURE GAUGE SHOWS ABNORMALLY LOW TEMPERATURE
M-12 FRONT COOLANT TEMPERATURE GAUGE GIVES NO DISPLAY
M-13 REAR COOLANT TEMPERATURE GAUGE SHOWS ABNORMALLY LOW TEMPERATURE
M-14 REAR COOLANT TEMPERATURE GAUGE GIVES NO DISPLAY
M-15 FUEL TANK IS NOT FULL BUT DISPLAY SHOWS FULL TANK
M-16 NO DISPLAY IS GIVEN FOR FUEL LEVEL

30 DISASSEMBLY AND ASSEMBLY
STARTING MOTOR
REMOVAL AND INSTALLATION
ALTERNATOR
REMOVAL AND INSTALLATION
ENGINE OIL COOLER
REMOVAL AND INSTALLATION
FUEL INJECTION PUMP
REMOVAL AND INSTALLATION
WATER PUMP
REMOVAL AND INSTALLATION
NOZZLE HOLDER
REMOVAL AND INSTALLATION
TURBOCHARGER
REMOVAL AND INSTALLATION
CYLINDER HEAD
REMOVAL
INSTALLATION
HYDRAULIC OIL COOLER
REMOVAL AND INSTALLATION
RADIATOR
REMOVAL AND INSTALLATION
AFTER COOLER CORE
REMOVAL AND INSTALLATION
ENGINE, PTO, HYDRAULIC PUMP
REMOVAL
INSTALLATION
PTO
REMOVAL
INSTALLATION
DISASSEMBLY AND ASSEMBLY
AUTO-DECELERATOR CYLINDER
REMOVAL AND INSTALLATION
CENTER SWIVEL JOINT
REMOVAL AND INSTALLATION
DISASSEMBLY AND ASSEMBLY
TRAVEL MOTOR
REMOVAL AND INSTALLATION
TRAVEL MOTOR BRAKE VALVE
REMOVAL AND INSTALLATION
TRAVEL MOTOR
DISASSEMBLY
ASSEMBLY
FINAL DRIVE
REMOVAL AND INSTALLATION
DISASSEMBLY
ASSEMBLY
SWING MOTOR
REMOVAL AND INSTALLATION
DISASSEMBLY
ASSEMBLY
REVOLVING FRAME
REMOVAL AND INSTALLATION
SWING CIRCLE
REMOVAL AND INSTALLATION
SWING MACHINERY
REMOVAL AND INSTALLATION
DISASSEMBLY
ASSEMBLY
FRONT IDLER
REMOVAL AND INSTALLATION
IDLER CUSHION CYLINDER
REMOVAL AND INSTALLATION
DISASSEMBLY AND ASSEMBLY
IDLER ADJUSTMENT CYLINDER
DISASSEMBLY AND ASSEMBLY
TRACK ROLLER
REMOVAL AND INSTALLATION
CARRIER ROLLER
REMOVAL AND INSTALLATION
TRACK SHOE
REMOVAL AND INSTALLATION
CHARGING AND PTO LUBRICATION PUMP
REMOVAL AND INSTALLATION
SWING PUMP
REMOVAL AND INSTALLATION
DISASSEMBLY
ASSEMBLY
NO.1,3 PUMP
REMOVAL AND INSTALLATION
NO.2, 4 PUMP
REMOVAL AND INSTALLATION
MAIN PUMP
DISASSEMBLY
ASSEMBLY
CHARGE PUMP RELIEF VALVE
REMOVAL AND INSTALLATION
DISASSEMBLY AND ASSEMBLY
MAIN RELIEF VALVE (FOR SWING)
REMOVAL AND INSTALLATION
DISASSEMBLY AND ASSEMBLY
MAIN RELIEF VALVE (FOR WORK EQUIPMENT, TRAVEL)
REMOVAL AND INSTALLATION
DISASSEMBLY AND ASSEMBLY
SWING CONTROL VALVE
REMOVAL AND INSTALLATION
DISASSEMBLY AND ASSEMBLY
L.H. 4-SPOOL CONTROL VALVE (TOP LEFT)
REMOVAL AND INSTALLATION
R.H. 4-SPOOL CONTROL VALVE (TOP RIGHT)
REMOVAL AND INSTALLATION
L.H. 5-SPOOL CONTROL VALVE (BOTTOM LEFT)
REMOVAL AND INSTALLATION
R.H. 5-SPOOL CONTROL VALVE (BOTTOM RIGHT)
REMOVAL AND INSTALLATION
CONTROL VALVE
DISASSEMBLY AND ASSEMBLY
SERVO VALVE (FOR NO.1, 3 F PUMPS)
REMOVAL AND INSTALLATION
SERVO VALVE (FOR NO.1, 3 R PUMPS)
REMOVAL AND INSTALLATION
SERVO VALVE (FOR NO,2, 4 F PUMPS)
REMOVAL AND INSTALLATION
SERVO VALVE (FOR NO,2, 4 R PUMPS)
REMOVAL AND INSTALLATION
SERVO VALVE (FOR SWING PUMP)
REMOVAL AND INSTALLATION
CO・NC VALVE (FOR NO,2, 4 F PUMPS WITH TVC)
REMOVAL AND INSTALLATION
CO・NC VALVE (FOR NO.2, 4 R PUMPS)
REMOVAL AND INSTALLATION
CO・NC VALVE (FOR SWING PUMP)
REMOVAL AND INSTALLATION
TVC VALVE (FOR NO.2, 4 PUMP)
REMOVAL AND INSTALLATION
TRAVEL PPC VALVE
REMOVAL AND INSTALLATION
DISASSEMBLY AND ASSEMBLY
PPC VALVE
REMOVAL AND INSTALLATION
DISASSEMBLY AND ASSEMBLY
BOOM CYLINDER (LOADING SHOVEL)
REMOVAL
INSTALLATION
ARM CYLINDER (LOADING SHOVEL)
REMOVAL AND INSTALLATION
BUCKET CYLINDER (LOADING SHOVEL)
REMOVAL AND INSTALLATION
BOTTOM CYLINDER (LOADING SHOVEL)
REMOVAL AND INSTALLATION
HYDRAULIC CYLINDER (LOADING SHOVEL)
DISASSEMBLY
ASSEMBLY
BOOM CYLINDER (BACKHOE)
REMOVAL
INSTALLATION
ARM CYLINDER (BACKHOE)
REMOVAL AND INSTALLATION
BUCKET CYLINDER (BACKHOE)
REMOVAL
INSTALLATION
HYDRAULIC CYLINDER (BACKHOE)
DISASSEMBLY
ASSEMBLY
BUCKET (BACKHOE)
REMOVAL AND INSTALLATION
BUCKET (LOADING SHOVEL)
REMOVAL AND INSTALLATION
ARM (BACKHOE)
REMOVAL
INSTALLATION
ARM (LOADING SHOVEL)
REMOVAL AND INSTALLATION
BOOM (BACKHOE)
REMOVAL
INSTALLATION
BOOM (LOADING SHOVEL)
REMOVAL AND INSTALLATION
BUCKET, ARM (BACKHOE)
REMOVAL
INSTALLATION
WORK EQUIPMENT
REMOVAL
INSTALLATION
COUNTERWEIGHT
REMOVAL AND INSTALLATION

40 MAINTENANCE STANDARD
PTO (POWER TAKE-OFF)
TRAVEL MOTOR
TRAVEL SHUTTLE VALVE
STRAIGHT-TRAVEL VALVE
TRAVEL BRAKE VALVE
SWING CONTROL VALVE
JET SENSOR
CONNECTION VALVE
SWING MOTOR
SWING CIRCLE
SWING MACHINERY
FINAL DRIVE
TRACK FRAME
TRACK SHOE
IDLER
TRACK ROLLER
CARRIER ROLLER
CHARGING AND PTO LUBRICATION PUMP
PILOT RELIEF VALVE
V2, V4 CONTROL VALVE
V1 CONTROL VALVE
V3 CONTROL VALVE
PPC VALVE
PPC SHUTTLE VALVE
HYDRAULIC CYLINDER
WORK EQUIPMENT

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