Komatsu PC1600-1 Excavator Official Field Assembly Instruction Manual
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This is the COMPLETE Official Field Assembly Instruction Manual for the Komatsu Excavator .
This manual describes how to assemble the units into the complete
machine in the field.
It's contains information and data to this model. has specs, diagrams, and actual real photo illustrations, and schemes.
This PDF file is Bookmarked and SEARCHABLE to make what you need easy to find.
This Field Assembly Instruction manual provides you with everything you need to know in order to assembly your tractor safely and effectively. Step-by-step assembly procedure, parts installation, adjustment and maintenance procedure after completion of assembly.
Diagrams are provided with the listings to aid the service technician in identifying clearly the parts that need to be ordered.
Models And Serials :
PC1600-1 10001 and up
CONTENTS :
A. GENERAL
A-1: POINTS REGARDING LOCAL ASSEMBLY
A-2: PRECAUTIONS WHEN ASSEMBLING,TIGHTENING TORQUE OF BOLTS,SCREWS AND TAPER SEAL HOLES
A-3: SEPARATE UNITS (TRANSPORTATION KITS)
A-4: LIST OF PARTS SENT INDIVIDUALLY
A-5: ASSEMBLY PROCEDURE,ASSEMBLY EQUIPMENT,AND SCHEDULE
A-6: KIT LAYOUT DIAGRAM
A-7: TOOLS AND EQUIPMENT TO BE USED
B. ASSEMBLY OF CHASSIS
B-1: ASSEMBLY OF TRACK FRAME AND AXLE
B-2: TRAVEL MOTOR PIPING
B-3: IDLER CUSHION CYLINDER PIPING
B-4: INSTALLATION OF TRAVEL MOTOR GUARD
B-5: FILLING SWING CIRCLE WITH GREASE
B-6: ASSEMBLY OF REVOLVING FRAME ASSEMBLY AND AXLE ASSEMBLY
B-7: SWIVEL TRAVEL PIPING
B-8: SWING CIRCLE GREASE TUBE PIPING
B-9: INSTALLATION OF LEFT AND RIGHT LADDERS
B-10: INSTALLATION OF LEFT CATWALK
B-11: INSTALLATION OF RIGHT CATWALK
B-12: INSTALLATION OF CATWALK,HANDRAIL BESIDE OPERATOR'S CAB
B-13: INSTALLATION OF OPERATOR'S CAB LADDER
B-14: INSTALLATION OF OPERATOR'S CAB HANDRAIL
B-15: INSTALLATION OF OPERATOR'S CAB LADDER,HANDRAIL
B-16: INSTALLATION OF HANDRAIL AT REAR OF OPERATOR'S CAB
B-17: INSTALLATION OF HANDRAIL FOR STEP AT REAR OF OPERATOR'S CAB
B-18: OPERATOR'S CAB FRONT FRAME,HANDRAIL
B-19: LEFT DECK HANDRAIL
B-20: RIGHT DECK HANDRAIL
B-21: INSTALLATION OF LADDER ON TOP OF HYDRAULIC TANK
B-22: INSTALLATION OF COUNTERWEIGHT
B-23: INSTALLATION OF COUNTERWEIGHT LADDERS
B-24: INSTALLATION OF HANDRAIL ON TOP OF FUEL TANK,COUNTERWEIGHT
B-25: INSTALLATION OF FUEL TANK VIBRATION STOPPER BRACKET
B-26: INSTALLATION OF GREASE REEL,HOSE,BRACKET
B-27: INSTALLATION OF LEFT CAB BASE ASSEMBLY
B-28: INSTALLATION OF OPERATOR'S CAB ASSEMBLY
B-29: INSTALLATION OF WIPER MOTOR COVER INSIDE OPERATOR'S CAB
B-30: INSTALLATION OF OPERATOR'S CAB ASSEMBLY
B-31: CONNECTION OF HYDRAULIC PIPING OF OPERATOR'S CAB ASSEMBLY
B-32: CONNECTION OF WIRING OF LEFT CAB BASE ASSEMBLY
B-33: CONNECTION OF WIRING OF OPERATOR'S CAB ASSEMBLY
B-34: CONNECTION OF WINDOW WASHER HOSE OF OPERATOR'S CAB ASSEMBLY
B-35: CONNECTION OF AIR PIPING OF LEFT CAB BASE ASSEMBLY
B-36: CONNECTION OF GREASE PIPING OF OPERATOR'S CAB ASSEMBLY
B-37: CONNECTION OF AIR CONDITIONER PIPING OF LEFT CAB BASE ASSEMBLY
B-38: CONNECTION OF AIR CONDITIONER PIPING OF OPERATOR'S CAB ASSEMBLY
B-39: INSTALLATION OF COUNTERWEIGHT LAMP (OPTION)
B-40: START ENGINE
B-41: FINAL TIGHTENING OF SWING CIRCLE MOUNTING BOLTS
C. INSTALLATION OF BACKHOE
C-1: INSTALLATION OF BOOM CYLINDER TO CHASSIS
C-2: INSTALLATION OF BOOM CYLINDER PIPING
C-3: BLEEDING AIR FROM BOOM CYLINDER
C-4: BOOM SUB-ASSEMBLY
C-5: INSTALLATION OF BOOM ASSEMBLY
C-6: INSTALLATION OF BOOM CYLINDER TOP PIN
C-7: CONNECTION OF ARM ASSEMBLY TO BOOM
C-8: INSTALLATION OF HOSES BETWEEN BOOM AND CHASSIS
C-9: INSTALLATION OF ARM CYLINDER TOP PIN
C-10: BLEEDING AIR FROM ARM CYLINDER
C-11: INSTALLATION OF HYDRAULIC HOSES BETWEEN BOOM AND ARM
C-12: CONNECTION OF GREASE PIPING BETWEEN BOOM AND CHASSIS
C-13: CONNECTION OF WIRING BETWEEN BOOM AND CHASSIS
C-14: INSTALLATION OF HOSES BETWEEN BOOM AND CHASSIS
C-15: INSTALLATION OF HYDRAULIC HOSE,CLAMPS BETWEEN BOOM AND CHASSIS
C-16: CONNECTION OF BUCKET ASSEMBLY TO ARM
C-17: INSTALLATION OF BUCKET LINK
C-18: BLEEDING AIR FROM BUCKET CYLINDER
D. INSTALLATION OF LOADING SHOVEL
D-1: INSTALLATION OF BOOM CYLINDER TO CHASSIS
D-2: INSTALLATION OF BOOM CYLINDER PIPING
D-3: BLEEDING AIR FROM BOOM CYLINDER
D-4: BOOM SUB-ASSEMBLY
D-5: INSTALLATION OF BOOM ASSEMBLY
D-6: INSTALLATION OF BUCKET CYLINDER FOOT PORTION
D-7: ARM SUB-ASSEMBLY
D-8: INSTALLATION OF ARM ASSEMBLY
D-9: INSTALLATION OF ARM CYLINDER TOP PIN
D-10: BLEEDING AIR FROM ARM CYLINDER
D-11: INSTALLATION OF SIDE LINK
D-12: INSTALLATION OF HOSE BETWEEN BOOM AND CHASSIS
D-13: INSTALLATION OF HYDRAULIC HOSE BETWEEN BOOM AND ARM
D-14: INSTALLATION OF FRONT LINK
D-15: CONNECTION OF BUCKET ASSEMBLY TO ARM
D-16: BLEEDING AIR FROM BUCKET CYLINDER
D-17: CONNECTION OF BOTTOM CYLINDER HOSE
D-18: BLEEDING AIR FROM BOTTOM CYLINDER
D-19: CONNECTION OF GREASE HOSE BETWEEN BOOM AND ARM
D-20: CONNECTION OF GREASE HOSE AT THE ARM CYLINDER TOP
D-21: CONNECTION OF GREASE HOSE AT THE ARM CYLINDER FOOT
D-22: CONNECTION OF GREASE PIPING BETWEEN BOOM AND CHASSIS
D-23: CONNECTION OF WIRING BETWEEN BOOM AND CHASSIS
D-24: INSTALLATION OF ARM POTENTIOMETER
D-25: ADJUSTMENT OF WORK EQUIPMENT POTENTIOMETER
D-26: ADJUSTMENT OF WORK EQUIPMENT CONTROL BOX (LOADING SHOVEL)
E. CHECK OF ALL PARTS DURING AND AFTER ASSEMBLY
E-1: CHECK OF ALL PARTS DURING AND AFTER ASSEMBLY WITH FIELD ASSEMBLY INSPECTION REPORT
E-2: FLUSH THE HYDRAULIC CIRCUIT AS FOLLOWS
