KOMATSU PC1600-1 SERIES ENGINE SHOP MANUAL SЕВМО21ТА10З – PDF DOWNLOAD
DESCRIPTION:
SERIAL No.
10001 and up
KOMATSU PC1600-1 SERIES ENGINE SHOP MANUAL SЕВМО21ТА10З – PDF DOWNLOAD
GENERAL PRECAUTIONS:
- Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully BEFORE operating the machine Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine 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. 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.
- When carrying out any operation with two or more workers, always agree on the operating 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. Keep all tools in good condition and learn the correct way to use them.
TABLE OF CONTENTS:
KOMATSU PC1600-1 SERIES ENGINE SHOP MANUAL SЕВМО21ТА10З – 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 TANK 100
MAIN PUMP 101
HYDRAULIC OIL FILTER 120
CHARGING AND PTO LUBRICATING PUMP 122
2-STAGE AND 3-STAGE MODE SELECTOR OLSS (OPEN CENTER LOAD SENSING SYSTEM) 123
CONTROL VALVE 140
PPC VALVE 149
PPC SHUTTLE VALVE 155
ACCUMULATOR 156
PILOT RELIEF VALVE 157
SAFETY LOCK VALVE 159
HYDRAULIC CYLINDER 161
WORK EQUIPMENT 165
ELECTRICAL CIRCUIT DIAGRAM 166
ELECTRICAL COMPONENTS OF 3-STAGE MODE SELECTOR OLSS 168
ELECTRONIC COMPONENTS OF AUTOMATIC WORK EQUIPMENT CONTROL SYSTEM 173
EVMS (ELECTRONIC VEHICLE MONITORING SYSTEM) 177
20 TESTING AND ADJUSTING 184
TABLE OF JUDGEMENT STANDARD VALUE 185
TABLE OF ELECTRICAL JUDGEMENT STANDARD VALUE 196
TESTING AND ADJUSTING TOOL LIST 208
ADJUSTING VALVE CLEARANCE 209
MEASURING COMPRESSION PRESSURE 210
ADJUSTING FUEL INJECTION TIMING 211
ADJUSTING FUEL CONTROL LEVER 212
ADJUSTING AUTO-DECELERATION SYSTEM 214
TESTING AND ADJUSTING OF MAIN RELIEF VALVE 215
TESTING AND ADJUSTING CONTROL CIRCUIT PRESSURE 218
MEASURING OIL LEAKAGE FROM SWING AND TRAVEL MOTOR 222
TESTING OIL LEAK FROM SWIVEL JOINT 223
AIR BLEEDING 225
CHARGING ACCUMULATOR WITH GAS 230
TESTING METHOD USING VISUAL AND FUNCTIONAL CHECK 232
ADJUSTMENT OF WORK EQUIPMENT POTENTIOMETER 233
ADJUSTMENT OF WORK EQUIPMENT CONTROL BOX (LOADING SHOVEL) 234
TROUBLESHOOTING 239
ELECTRICAL CIRCUIT DIAGRAM 240
CONNECTOR POSITION FOR TROUBLESHOOTING 246
TYPES AND MOUNTING POSITIONS OF CONNECTORS 248
CONNECTION TABLE FOR CONNECTOR PINS 260
TROUBLESHOOTING PROCEDURE 264
CHECKS BEFORE TROUBLESHOOTING 265
E, H MODE TROUBLESHOOTING 268
ABNORMALITY DISPLAYS BY SELF CHECKER 269
TROUBLESHOOTING (EXCEPT TROUBLESHOOTING FOR MACHINE MONITOR) 270
E-1 WORK EQUIPMENT, SWING TRAVEL SPEEDS EXTREMELY SLOW, OR LACK OF POWER 274
(1) CONTROLLER SYSTEM FOR FRONT ENGINE 274
a) SELF-TESTING DISPLAY SHOWS ABNORMALITY 274
b) SELF-TESTING DISPLAY SHOWS NORMAL 276
(2) CONTROLLER SYSTEM FOR REAR ENGINE 278
a) SELF-TESTING DISPLAY SHOWS ABNORMALITY 278
b) SELF-TESTING DISPLAY SHOWS NORMAL 280
E-2 ENGINE STALLS DURING OPERATIONS, OR ENGINE SPEED DROPS 282
(1) CONTROLLER SYSTEM FOR FRONT ENGINE 282
a) SELF-TESTING DISPLAY SHOWS ABNORMALITY 282
b) SELF-TESTING DISPLAY SHOWS NORMAL 282
(2) CONTROLLER SYSTEM FOR REAR ENGINE 283
a) SELF-TESTING DISPLAY SHOWS ABNORMALITY 283
b) SELF-TESTING DISPLAY SHOWS NORMAL 283
E-3 NO CHANGE IN OUTPUT WHEN MODE SWITCH IS OPERATED 284
(1) CONTROLLER SYSTEM FOR FRONT ENGINE 284
a) SELF-TESTING DISPLAY SHOWS ABNORMALITY 284
b) MODE DOES NOT CHANGE (WHEN SELF-TESTING DISPLAY SHOWS NORMAL) 285
(2) CONTROLLER SYSTEM FOR REAR ENGINE 288
a) SELF-TESTING DISPLAY SHOWS ABNORMALITY 288
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 ABNORMALITY 292
b) SELF-TESTING DISPLAY SHOWS NORMAL 293
E-5 UPPER STRUCTURE DOES NOT SWING 295
E-6 EXCESSIVE HYDRAULIC DRIFT OF SWING 298
E-7 DEFECTIVE OPERATION OF BOTTOM CYLINDER 299
a) BOTTOM CLOSE 299
b) BOTTOM OPEN 299
TROUBLESHOOTING FOR H MODE 302
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 OPERATIONS 306
H-3 EXCESSIVE DEVIATION WHEN STARTING 308
H-4 CONTROL LEVERS ARE EXTREMELY HEAVY 310
H-5 WORK EQUIPMENT, TRAVEL, AND SWING START SUDDENLY DURING FINE CONTROL OPERATIONS 311
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 MOVES 312
b) ABNORMALITY IN ONE PART (ABNORMALITY IN SYSTEM ON ONE SIDE) 314
c) INDIVIDUAL PROBLEMS 314
d) WHEN ANY OF WORK EQUIPMENT SPEEDS ARE SLOW 315
e) FOR PROBLEMS OTHER THAN a), b), OR c) (WHEN AUTO-DECELERATION IS NORMAL) 316
H-7 ENGINE STALLS DURING OPERATIONS OR ENGINE SPEED DROPS 318
H-8 OUTPUT DOES NOT CHANGE WHEN MODE SWITCH IS USED TO CHANGE MODE 319
H-9 AUTO-DECELERATION IS NOT ACTUATED OR REMAINS ACTUATED 319
H-10 ABNORMAL NOISE IS HEARD (FROM AROUND THE PUMP) 319
H-11 SWING SPEED IS SLOW OR THERE IS EXCESSIVE OVERRUN WHEN STOPPING SWING 320
H-12 UPPER STRUCTURE DOES NOT SWING 322
H-13 EXCESSIVE HYDRAULIC DRIFT OF SWING 324
H-16 EXCESSIVE TIME LAG FOR WORK EQUIPMENT 324
H-17 DEFECTIVE OPERATION OF BOTTOM CYLINDER 325
FAILURE MODE AND COMPONENTS 326
W, L MODE TROUBLESHOOTING 327
ABNORMALITY JUDGEMENT CONDITIONS FOR SELF-TESTING DISPLAY 328
TROUBLESHOOTING 329
W-1 IN ARC DIGGING MODE (HORIZONTAL SELECTOR SWITCH OFF), MACHINE CARRIES OUT HORIZONTAL DIGGING OR BUCKET ANGLE COMPENSATION 331
W-2 MACHINE DOES NOT CARRY OUT HORIZONTAL DIGGING IN HORIZONTAL DIGGING MODE 332
a) SELF-CHECKER SHOWS ABNORMAL DISPLAY 332
b) SELF-CHECKER SHOWS NORMAL DISPLAY 339
W-3 IN HORIZONTAL DIGGING MODE (BUCKET ANGLE COMPENSATION SWITCH OFF), MACHINE CARRIES OUT BUCKET ANGLE COMPENSATION 341
W-4 IN HORIZONTAL DIGGING + BUCKET COMPENSATION MODE, MACHINE CARRIES OUT HORIZONTAL DIGGING BUT DOES NOT CARRY OUT BUCKET ANGLE COMPENSATION 342
a) SELF-CHECKER SHOWS ABNORMAL DISPLAY 342
b) SELF-CHECKER SHOWS NORMAL DISPLAY 345
W-5 IN HORIZONTAL DIGGING + BUCKET ANGLE COMPENSATION MODE, MACHINE CARRIES OUT BUCKET ANGLE COMPENSATION BUT DOES NOT CARRY OUT HORIZONTAL DIGGING 347
a) SELF-CHECKER SHOWS ABNORMAL DISPLAY 347
b) SELF-CHECKER SHOWS NORMAL DISPLAY 347
W-6 MACHINE DOES NOT CARRY OUT HORIZONTAL DIGGING OR BUCKET ANGLE COMPENSATION IN HORIZONTAL DIGGING + BUCKET ANGLE COMPENSATION MODE 349
a) SELF-CHECKER SHOWS ABNORMAL DISPLAY 349
L-1 MACHINE CANNOT CARRY OUT HORIZONTAL DIGGING OR BUCKET ANGLE COMPENSATION 356
M MODE TROUBLESHOOTING 357
M-1 WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL DISPLAY DOES NOT APPEAR 358
a) NONE OF MONITOR PANEL (GAUGES, MONITORS) WORKS 358
b) PART OF MONITOR PANEL DOES NOT WORK 358
M-2 WHEN STARTING SWITCH TURNED ON, MONITOR PANEL DISPLAY DOES NOT GO OUT 358
M-3 WHEN STARTING SWITCH IS TURNED ON, (DO NOT START ENGINE), CHECK BEFORE STARTING ITEM FLASH OR PREHEATING ITEM LIGHTS UP 359
a) COOLANT LEVEL FLASHES 359
b) ENGINE OIL LEVEL FLASHES 359
c) HYDRAULIC OIL LEVEL FLASHES 360
d) PREHEATER FLASHES 360
e) COOLANT LEVEL FLASHES 361
f) ENGINE OIL LEVEL FLASHES 361
g) PREHEATER FLASHES 362
M-4 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, CHECK ITEMS FLASH 363
a) FRONT ENGINE ALTERNATOR SYSTEM 363
b) FRONT ENGINE OIL PRESSURE SYSTEM 363
c) REAR ENGINE ALTERNATOR SYSTEM 364
d) REAR ENGINE OIL PRESSURE SYSTEM 364
M-5 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CAUTION ITEMS FLASH 365
a) FRONT ENGINE SYSTEM 365
b) REAR ENGINE SYSTEM 366
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 FLASHES 367
b) COOLANT LEVEL FLASHES 367
c) COOLANT TEMPERATURE FLASHES 368
d) BATTERY CHARGE LEVEL FLASHES 368
e) HYDRAULIC OIL FILTER FLASHES 369
f) HYDRAULIC OIL TEMPERATURE FLASHES 369
g) ENGINE OIL PRESSURE FLASHES 370
h) COOLANT LEVEL FLASHES 370
i) BATTERY CHARGE LEVEL FLASHES 370
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 371
M-8 THERE IS NO ABNORMAL DISPLAY ON MONITOR, BUT BUZZER SOUNDS 371
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 STOPPED 373
a) SERVICE METER DOES NOT MOVE AFTER ENGINE IS STARTED 373
b) SERVICE METER MOVES AFTER ENGINE IS STOPPED 373
M-11 FRONT COOLANT TEMPERATURE GAUGE SHOWS ABNORMALLY LOW TEMPERATURE 374
M-12 FRONT COOLANT TEMPERATURE GAUGE GIVES NO DISPLAY 374
M-13 REAR COOLANT TEMPERATURE GAUGE SHOWS ABNORMALLY LOW TEMPERATURE 375
M-14 REAR COOLANT TEMPERATURE GAUGE GIVES NO DISPLAY 375
M-15 FUEL TANK IS NOT FULL BUT DISPLAY SHOWS FULL TANK 377
M-16 NO DISPLAY IS GIVEN FOR FUEL LEVEL 377
30 DISASSEMBLY AND ASSEMBLY 379
STARTING MOTOR 382
REMOVAL AND INSTALLATION 382
ALTERNATOR 382
REMOVAL AND INSTALLATION 382
ENGINE OIL COOLER 382
REMOVAL AND INSTALLATION 382
FUEL INJECTION PUMP 384
REMOVAL AND INSTALLATION 384
WATER PUMP 384
REMOVAL AND INSTALLATION 384
NOZZLE HOLDER 386
REMOVAL AND INSTALLATION 386
TURBOCHARGER 386
REMOVAL AND INSTALLATION 386
CYLINDER HEAD 388
REMOVAL 388
INSTALLATION 392
HYDRAULIC OIL COOLER 396
REMOVAL AND INSTALLATION 396
RADIATOR 396
REMOVAL AND INSTALLATION 396
AFTER COOLER CORE 398
REMOVAL AND INSTALLATION 398
ENGINE, PTO, HYDRAULIC PUMP 400
REMOVAL 400
INSTALLATION 402
PTO 406
REMOVAL 406
INSTALLATION 408
DISASSEMBLY AND ASSEMBLY 412
AUTO-DECELERATOR CYLINDER 416
REMOVAL AND INSTALLATION 416
CENTER SWIVEL JOINT 418
REMOVAL AND INSTALLATION 418
DISASSEMBLY AND ASSEMBLY 420
TRAVEL MOTOR 422
REMOVAL AND INSTALLATION 422
TRAVEL MOTOR BRAKE VALVE 422
REMOVAL AND INSTALLATION 422
TRAVEL MOTOR 424
DISASSEMBLY 424
ASSEMBLY 428
FINAL DRIVE 436
REMOVAL AND INSTALLATION 436
DISASSEMBLY 438
ASSEMBLY 442
SWING MOTOR 450
REMOVAL AND INSTALLATION 450
DISASSEMBLY 452
ASSEMBLY 456
REVOLVING FRAME 462
REMOVAL AND INSTALLATION 462
SWING CIRCLE 464
REMOVAL AND INSTALLATION 464
SWING MACHINERY 464
REMOVAL AND INSTALLATION 464
DISASSEMBLY 466
ASSEMBLY 470
FRONT IDLER 474
REMOVAL AND INSTALLATION 474
IDLER CUSHION CYLINDER 474
REMOVAL AND INSTALLATION 474
DISASSEMBLY AND ASSEMBLY 476
IDLER ADJUSTMENT CYLINDER 476
DISASSEMBLY AND ASSEMBLY 476
TRACK ROLLER 478
REMOVAL AND INSTALLATION 478
CARRIER ROLLER 478
REMOVAL AND INSTALLATION 478
TRACK SHOE 480
REMOVAL AND INSTALLATION 480
CHARGING AND PTO LUBRICATION PUMP 482
REMOVAL AND INSTALLATION 482
SWING PUMP 484
REMOVAL AND INSTALLATION 484
DISASSEMBLY 486
ASSEMBLY 490
NO 1,3 PUMP 500
REMOVAL AND INSTALLATION 500
NO 2, 4 PUMP 502
REMOVAL AND INSTALLATION 502
MAIN PUMP 504
DISASSEMBLY 504
ASSEMBLY 508
CHARGE PUMP RELIEF VALVE 520
REMOVAL AND INSTALLATION 520
DISASSEMBLY AND ASSEMBLY 520
MAIN RELIEF VALVE (FOR SWING) 522
REMOVAL AND INSTALLATION 522
DISASSEMBLY AND ASSEMBLY 522
MAIN RELIEF VALVE (FOR WORK EQUIPMENT, TRAVEL) 524
REMOVAL AND INSTALLATION 524
DISASSEMBLY AND ASSEMBLY 524
SWING CONTROL VALVE 526
REMOVAL AND INSTALLATION 526
DISASSEMBLY AND ASSEMBLY 528
L H 4-SPOOL CONTROL VALVE (TOP LEFT) 530
REMOVAL AND INSTALLATION 530
R H 4-SPOOL CONTROL VALVE (TOP RIGHT) 532
REMOVAL AND INSTALLATION 532
L H 5-SPOOL CONTROL VALVE (BOTTOM LEFT) 534
REMOVAL AND INSTALLATION 534
R H 5-SPOOL CONTROL VALVE (BOTTOM RIGHT) 536
REMOVAL AND INSTALLATION 536
CONTROL VALVE 538
DISASSEMBLY AND ASSEMBLY 538
SERVO VALVE (FOR NO 1, 3 F PUMPS) 540
REMOVAL AND INSTALLATION 540
SERVO VALVE (FOR NO 1, 3 R PUMPS) 540
REMOVAL AND INSTALLATION 540
SERVO VALVE (FOR NO,2, 4 F PUMPS) 542
REMOVAL AND INSTALLATION 542
SERVO VALVE (FOR NO,2, 4 R PUMPS) 542
REMOVAL AND INSTALLATION 542
SERVO VALVE (FOR SWING PUMP) 544
REMOVAL AND INSTALLATION 544
CO・NC VALVE (FOR NO,2, 4 F PUMPS WITH TVC) 544
REMOVAL AND INSTALLATION 544
CO・NC VALVE (FOR NO 2, 4 R PUMPS) 546
REMOVAL AND INSTALLATION 546
CO・NC VALVE (FOR SWING PUMP) 546
REMOVAL AND INSTALLATION 546
TVC VALVE (FOR NO 2, 4 PUMP) 548
REMOVAL AND INSTALLATION 548
TRAVEL PPC VALVE 550
REMOVAL AND INSTALLATION 550
DISASSEMBLY AND ASSEMBLY 550
PPC VALVE 552
REMOVAL AND INSTALLATION 552
DISASSEMBLY AND ASSEMBLY 552
BOOM CYLINDER (LOADING SHOVEL) 554
REMOVAL 554
INSTALLATION 556
ARM CYLINDER (LOADING SHOVEL) 558
REMOVAL AND INSTALLATION 558
BUCKET CYLINDER (LOADING SHOVEL) 560
REMOVAL AND INSTALLATION 560
BOTTOM CYLINDER (LOADING SHOVEL) 562
REMOVAL AND INSTALLATION 562
HYDRAULIC CYLINDER (LOADING SHOVEL) 564
DISASSEMBLY 564
ASSEMBLY 568
BOOM CYLINDER (BACKHOE) 572
REMOVAL 572
INSTALLATION 574
ARM CYLINDER (BACKHOE) 576
REMOVAL AND INSTALLATION 576
BUCKET CYLINDER (BACKHOE) 578
REMOVAL 578
INSTALLATION 580
HYDRAULIC CYLINDER (BACKHOE) 582
DISASSEMBLY 582
ASSEMBLY 586
BUCKET (BACKHOE) 590
REMOVAL AND INSTALLATION 590
BUCKET (LOADING SHOVEL) 592
REMOVAL AND INSTALLATION 592
ARM (BACKHOE) 594
REMOVAL 594
INSTALLATION 596
ARM (LOADING SHOVEL) 598
REMOVAL AND INSTALLATION 598
BOOM (BACKHOE) 600
REMOVAL 600
INSTALLATION 602
BOOM (LOADING SHOVEL) 604
REMOVAL AND INSTALLATION 604
BUCKET, ARM (BACKHOE) 606
REMOVAL 606
INSTALLATION 608
WORK EQUIPMENT 610
REMOVAL 610
INSTALLATION 614
COUNTERWEIGHT 616
REMOVAL AND INSTALLATION 616
40 MAINTENANCE STANDARD 618
PTO (POWER TAKE-OFF) 619
TRAVEL MOTOR 620
TRAVEL SHUTTLE VALVE 621
STRAIGHT-TRAVEL VALVE 622
TRAVEL BRAKE VALVE 623
SWING CONTROL VALVE 624
JET SENSOR 625
CONNECTION VALVE 626
SWING MOTOR 627
SWING CIRCLE 628
SWING MACHINERY 629
FINAL DRIVE 630
TRACK FRAME 631
TRACK SHOE 632
IDLER 633
TRACK ROLLER 635
CARRIER ROLLER 636
CHARGING AND PTO LUBRICATION PUMP 637
PILOT RELIEF VALVE 638
V2, V4 CONTROL VALVE 639
V1 CONTROL VALVE 641
V3 CONTROL VALVE 643
PPC VALVE 645
PPC SHUTTLE VALVE 647
HYDRAULIC CYLINDER 648
WORK EQUIPMENT 649
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