Komatsu 560C Service Manual 560C99-1E – PDF DOWNLOAD

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Komatsu Dressta 560C Wheel Loader- PDF DOWNLOAD

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Komatsu Dressta 560C Wheel Loader- PDF DOWNLOAD

Language : English
Pages :500
Downloadable : Yes
File Type : PDF

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Komatsu 560C Service Manual 560C99-1E – PDF DOWNLOAD

INTRODUCTION SECTION 1
SAFETY PRECAUTIONS

GENERAL

• The instructions contained in this service manual are for the information and guidance of the servicemen, who are responsible for overhaul and repair of the machine.
• Throughout this manual the use of the terms „left”, „right”, „front” and „rear” must be understood to avoid confusion when following instructions.
• These terms indicate the side of the vehicle when facing forward in the operator’s seat. Due to a continuous program of research and development, some procedures, specifications and parts may be altered in a constant effort to improve the machines. Some illustrations are of a general application and may not show component parts accurately in all details.

TABLE OF CONTENTS:

Komatsu 560C Service Manual 560C99-1E – PDF DOWNLOAD

MAIN MENU 0
COVER 1
CONTENTS 3
1 INTRODUCTION 5
SAFETY PRECAUTIONS 6
1 GENERAL 6
2 OPERATION 8
3 MAINTENANCE 13
SHIPPING SPECIFICATIONS 20
4 DIMENSIONS 20
5 SYSTEM REFILL CAPACITIES (APROXIMATE) 20
SERVICE INFORMATION 21
6 SERVICE PARTS 21
7 SERIAL NUMBERS 21
8 INSPECTION AND REPAIR 22
LOCTITE USAGE 23
9 SURFACE PREPARATION 23
10 APPLICATION 24
11 SETTING TIME (BEFORE PLACING IN OPERATION) 24
12 REMOVAL 24
13 APPPLICATION AT LOW TEMPERATURES 24
STANDARD TORQUES 25
14 BOLT IDENTIFICATION CHART 25
15 TORQUE VALUES FOR STANDARD FASTENERS 25
16 SPLIT FLANGE CONNECTIONS 27
17 HYDRAULIC TUBES AND FITTINGS 28
18 HOSE CLAMPS 28
SERVICE/SPECIAL TOOLS 30
19 SERVICE/SPECIAL TOOLS 29
4 BRAKES 37
WHEEL BRAKE 39
1 DESCRIPTION 39
2 OPERATIONAL TEST 41
3 SERVICE DIAGNOSIS 41
PARKING BRAKE 42
4 DESCRIPTION 42
5 SPECIFICATIONS 44
6SERVICE DIAGNOSIS 44
7 ADJUSTING AND OPERATIONAL TEST OF THE BRALE 45
8 REMOVAL AND DISASSEMBLY 47
9 INSPECTION AND REPAIR 47
10 REASSEMBLY AND INSTALLATION 48
SERVICE BRAKE WARNING LIGHT “E” AND SWITCHES 48
11 DESCRIPTION 48
COOLING BRAKE LOW PRESSURE SWITCH AND BRAKE SYSTEM OIL FILTER WARNING LIGHT SWITCH 50
12 DESCRIPTION 50
BRAKE PUMP 50
13 DESCRIPTION 50
14 REMOVAL 51
15 DISASSEMBLY 52
16 INSPECTION AND REPAIR 55
17 REASSEMBLY 56
18 INSTALLATION 58
BRAKE COOLING PUMP 58
BRAKE ACCUMULATOR 58
19 CHECK THE ACCUMULATOR CONDITION 58
20 CHECKING NITROGEN CHARGE IN ACCUMULATOR 59
21 CHARGING ACCUMULATOR WITH NITROGEN 60
CHECK PERFORMANCE OF MAIN BRAKES 61
22 CHECK THE BRAKES EFFECTIVENESS 61
5 STEERING 63
GENERAL 64
1 SPECIFICATIONS 64
2 SERVICE DIAGNOSIS 64
3 LINKAGE ADJUSTMENT 64
STEERING COLUMN 67
4 DESCRIPTION AND OPERATION 67
5 SPECIFICATIONS 67
6 REMOVAL 68
7 DISASSEMBLY 68
8 INSPECTION AND REPAIR 69
9 REASSEMBLY 69
10 INSTALLATION 71
STEERING GEAR 71
11 DESCRIPTION 71
12 THEORY OF OPERATION 71
13 SPECIFICATIONS 72
14 WORM BEARING PRELOAD ADJUSTMENT 73
15 PITMAN SHAFT PRELOAD ADJUSTMENT 74
16 REMOVAL 74
17 DISASSEMBLY 75
18 INSPECTION AND REPAIR 76
19 REASSEMBLY 76
20 INSTALLATION 80
6 COOLING 82
GENERAL 83
1 DESCRIPTION 83
2 OPERATION 83
3 SPECIFICATIONS 84
4 SERVICE DIAGNOSIS 85
STEERING OIL COOLER 86
5 REMOVAL 86
6 INSTALLATION 88
RADIATOR 89
7 REMOVAL 89
8 DISASSEMBLY 92
9 INSPECTION AND REPAIR 93
10 REASSEMBLY AND INSTALLATION 93
TRANSMISSION OIL COOLER 94
11 REMOVAL 94
12 INSTALLATION 95
7 DRIVE TRAIN 97
1 DESCRIPTION 98
2 HYDRAULIC OIL FLOW 98
3 SPECIFICATIONS100
4 SERVICE DIAGNOSIS101
5 CHECKING THE CHARGING PUMP FLOW RATE103
6 CHECKING TRANSMISSION AND TORQUE CONVERTER PRESSURES104
7B TORQUE CONVERTER110
GENERAL111
1 DESCRIPTION112
2 OPERATION112
3 SPECIFICATIONS113
4 SERVICE DIAGNOSIS113
TORQUE CONVERTER114
5 REMOVAL114
6 DISASSEMBLY118
7 INSPECTION AND REPAIR120
8 REASSEMBLY121
9 INSTALLATION125
CHARGING PUMP128
10 DESCRIPTION AND OPERATION128
11 SPECIAL TORQUES129
12 REMOVAL129
13 DISASSEMBLY129
14 INSPECTION AND REPAIR130
15 REASSEMBLY130
16 INSTALLATION130
7C TRANSMISSION132
GENERAL133
1 DESCRIPTION133
2 OPERATION136
3 SPECIFICATIONS140
TRANSMISSION141
4 REMOVAL141
5 DISASSEMBLY145
6 INSPECTION AND REPAIR151
7 REASSEMBLY151
8 INSTALLATION156
CLUTCH PACKS157
9 REMOVAL157
10 DISASSEMBLY157
11 INSPECTION AND REPAIR164
12 REASSEMBLY165
13 INSTALLATION177
CONTROL VALVE178
14 REMOVAL178
15 DISASSEMBLY178
16 INSPECTION AND REPAIR181
17 REASSEMBLY181
18 INSTALLATION182
7D DRIVE AXLE AND DIFFERENTIAL184
GENERAL186
1 DESCRIPTION186
2 THEORY OF OPERATION186
DRIVE SHAFTS187
3 DESCRIPTION AND OPERATON187
4 SPECIFICATIONS187
5 SERVICE DIAGNOSIS187
6 REMOVAL AND DISASSEMBLY188
7 INSPECTION AND REPAIR189
8 REASSEMBLY AND INSTALLATION189
TRANSFER DRIVE190
9 DESCRIPTION190
10 SPECIFICATIONS190
11 SERVICE DIAGNOSIS190
12 REMOVAL190
13 DISASSEMBLY191
14 REASSEMBLY192
15 INSTALLATION193
PLANETARY GEAR193
16 DESCRIPTION193
17 THEORY OF OPERATION193
18 SPECIFICATIONS194
19 REMOVAL194
20 DISASSEMBLY197
21 REASSEMBLY197
22 INSTALLATION199
WHEEL HUB AND SERVICE BRAKES200
23 DESCRIPTION200
24 SPECIFICATIONS201
25 REMOVAL201
26 SERVICE BRAKE DISASSEMBLY204
27 INSPECTION205
28 BRAKE REASSEMBLY205
29 WHEEL HUB AND BRAKE UNIT ASSEMBLY208
30 PREPARATION FOR THE BRAKE AND WHEEL HUB INSTALLATION209
31 PROCEDURE FOR DETERMINNG WHEEL BEARING SHIM PACK210
32 INSTALLING WHEEL HUB AND BRAKE UNIT211
33 FRICTION DISCS CHECKING212
DIFFERENTIAL213
34 DESCRIPTION213
35 THEORY OF OPERATION213
36 SPECIFICATIONS214
37 SERVICE DIAGNOSIS215
38 REMOVAL216
39 DISASSEMBLY217
40 INSPECTION AND REPAIR220
41 REASSEMBLY221
42 INSTALLATION227
DRIVE AXLE227
43 DESCRIPTION227
44 SPECIFICATIONS227
45 SERVICE DIAGNOSIS227
46 REMOVAL AND DISASSEMBLY229
47 REASSEMBLY AND INSTALLATION230
8 ELECTRICAL232
GENERAL233
1 DESCRIPTION233
WIRING DIAGRAM233
2 ELECTRICAL LOADER SYSTEM233
3 SERVICE DIAGNOSIS248
ALTERNATOR249
4 SPECIFICATION249
5 INTRODUCTION250
6 OPERATING PRINCIPLES250
7 TROUBLESHOOTING PROCEDURES251
8 INTEGRAL CHARGING SYSTEM REPAIR253
BATTERY258
9 SAFETY PRECAUTIONS258
10 ELECTROLYTE STATE OF CHARGE258
11 ELECTROLYTE IN TROPICAL AND ARCTIC CLIMATES259
12 TESTING AND MAINTENANCE OF THE BATTERY260
13 BATTERY CHARGING GUIDE261
14 BATTERY STORAGE262
15 BATTERY PRIMARY RATINGS262
16 COLD ENGINE CRANKING PERFORMANCE262
17 DRY CHARGE ACTIVATION263
18 TYPICAL CAUSE OF BATTERY FAILURE263
19 VISUAL INSPECTION OF BATTERY264
CRANKING MOTOR265
20 SPECIFICATION265
21 INTRODUCTION265
22 OPERATION266
23 TROUBLESHOOTING THE CRANKING CIRCUIT266
9 FRAME276
1 DESCRIPTION AND OPERATION277
2 SPECIFICATIONS278
3 MAINTENANCE278
4 WELDING278
5 CHECKING HINGE VERTICAL MOVEMENT279
6 DISASSEMBLY279
7 INSPECTION AND REPAIR284
8 REASSEMBLY284
10 HYDRAULIC288
GENERAL289
1 DESCRIPTION290
2 THEORY OF OPERATION293
3 SPECIFICATIONS294
4 SERVICE DIAGNOSIS295
TEST AND ADJUSTMENT298
5 STEERING SYSTEM PERFORMANCE TEST298
6 HYDRAULIC SYSTEM PERFORMANCE TEST299
7 STEERING SYSTEM PRESSURE TEST300
8 HYDRAULIC SYSTEM PRESSURE TEST301
9 SUCTION LINE LEAKAGE TEST301
10 HYDRAULIC CONTROL LEVER LEAKAGE ADJUSTMENT302
10A PUMPS305
STEERING/SWITCH PUMP306
1 DESCRIPTION306
2 THEORY OF OPERATION306
3 SPECIFICATIONS309
4 PUMP FLOW TEST309
5 DIVERTER VALVE SWITHC POINT TEST AND ADJUSTMENT310
6 REMOVAL312
7 DISASSEMBLY313
8 INSPECTION AND REPAIR315
9 REASSEMBLY315
10 INSTALLATION319
HYDRAULIC AND BRAKE COOLING PUMP319
11 DESCRIPTION319
12 THEORY OF OPERATION320
13 SPECIFICATIONS320
14 HYDRAULIC PUMP FLOW TEST321
15 REMOVAL321
16 DISASSEMBLY322
17 INSPECTION AND REPAIR324
18 REASSEMBLY325
19 INSTALLATION326
GROUND DRIVEN STEERING PUMP (IF EQUIPPED)327
20 DESCRIPTION AND OPERATION327
21 SPECIFICATIONS328
22 REMOVAL328
23 DISASSEMBLY329
24 INSPECTION AND REPAIR330
25 REASSEMBLY330
26 INSTALLATION331
10B VALVES333
STEERING VALVE335
1 DESCRIPTION335
2 OPERATION336
3 SPECIFICATIONS338
4 SERVICE DIAGNOSIS339
5 STEERING SYSTEM RELIEF VALVE TEST AND ADJUSTMENT339
6 STEERING CIRCUIT SHOCK VALVE PRESSURE TEST340
7 REMOVAL341
8 DISASSEMBLY342
9 INSPECTION AND REPAIR343
10 REASSEMBLY344
11 INSTALLATION345
PILOT CONTROL VALVE345
12 DESCRIPTION345
13 OPERATION346
14 SPECIFICATIONS351
15 SERVICE DIAGNOSIS352
16 BUCKET CIRCUIT SHOCK VALVE PRESSURE TEST AND ADJUSTMENT353
17 REMOVAL354
18 DISASSEMBLY355
19 INSPECTION AND REPAIR359
20 REASSEMBLY359
21 INSTALLATION362
HYDRAULIC CONTROL VALVE363
22 DESCRIPTION363
23 OPERATION364
24 SPECIFICATIONS375
25 SERVICE DIAGNOSIS376
26 MAIN RELIEF VALVE TEST AND ADJUSTMENT380
27 LOW PRESSURE RELIEF VALVE TEST AND ADJUSTMENT381
28 UNLOADING VALVE TEST AND ADJUSTMENT382
29 REMOVAL383
30 DISASSEMBLY384
31 INSPECTION AND REPAIR390
32 REASSEMBLY391
33 INSTALLATION394
STEERING CYLINDER CHECK VALVES394
34 DESCRIPTION394
35 OPERATION395
36 SPECIFICATIONS395
37 REMOVAL396
38 DISASSEMBLY396
39 INSPECTION AND REPAIR397
40 REASSEMBLY397
41 INSTALLATION398
GROUND DRIVEN STEERING DIVERTER VALVE (IF EQUIPPED)398
42 DESCRIPTION398
43 OPERATION398
44 SPECIFICATIONS399
45 REMOVAL399
46 DISASSEMBLY400
47 INSPECTION AND REPAIR401
48 REASSEMBLY401
49 INSTALLATION402
GROUND DRIVEN STEERING CHECK VALVE402
50 DESCRIPTION AND OPERATION402
51 SPECIFICATIONS403
52 REMOVAL403
53 DISASSEMBLY403
54 INSPECTION AND REPAIR404
55 REASSEMBLY404
56 INSTALLATION404
STEERING RETURN SURGE VALVE406
57 DESCRIPTION AND OPERATION405
58 SPECIFICATIONS405
59 REMOVAL405
60 DISASSEMBLY406
61 INSPECTION AND REPAIR406
62 REASSEMBLY406
63 INSTALLATION406
10C CYLINDERS408
BUCKET CYLINDER409
1 DESCRIPTION AND OPERATION409
2 SPECIFICATIONS409
3 BUCKET CYLINDER LEAKAGE TEST410
4 REMOVAL410
5 DISASSEMBLY412
6 INSPECTION AND REPAIR414
7 REASSEMBLY415
8 INSTALLATION418
BOOM CYLINDERS419
9 DESCRIPTION AND OPERATION419
10 SPECIFICATIONS419
11 BOOM CYLINDER LEAKAGE TEST420
12 REMOVAL421
13 DISASSEMBLY422
14 INSPECTION AND REPAIR424
15 REASSEMBLY425
16 INSTALLATION427
STEERING CYLINDERS428
17 DESCRIPTION AND OPERATION428
18 SPECIFICATIONS428
19 STEERING CYLINDER LEAKAGE TEST429
20 REMOVAL430
21 DISASSEMBLY430
22 INSPECTION AND REPAIR432
23 REASSEMBLY433
24 INSTALLATION435
10E RESERVOIRS AND FILTER437
1 DESCRIPTION438
2 OPERATION438
3 SPECIFICATION438
4 LOADER RETURN SURGE VALVE TEST439
5 REMOVAL439
6 DISASSEMBLY440
7 INSPECTION AND REPAIR442
8 REASSEMBLY443
9 INSTALLATION443
12 POWER445
1 DESCRIPTION446
2 SPECIFICATIONS446
3 SERVICE DIAGNOSIS447
4 AIR INTAKE SYSTEM TEST448
5 ENGINE CONTROLS ADJUSTMENT450
6 REMOVAL453
7 ENGINE REPAIR462
8 ENGINE INSTALLATION462
13 SUPERSTRUCTURE467
GENERAL468
1 SPECIFICATIONS468
CAB WINDOW GLASS468
2 REPLACEMENT468
ROPS469
3 REMOVAL469
4 INSTALLATION470
14 SUSPENSION472
1 DESCRIPTION473
2 SPECIFICATION473
3 REMOVAL473
4 BOLSTER REPAIR476
5 INSTALLATION477
15 WHEELS AND TRACKS480
1 DESCRIPTION481
2 OPERATION481
3 WHEEL REMOVAL481
4 WHEEL DISASSEMBLY AND ASSEMBLY482
5 WHEEL INSTALLING486
17 MOUNTED EQUIPMENT488
GENERAL489
1 SAFETY PRECAUTIONS489
2 DESCRIPTION AND OPERATION489
LOADER LINKAGE PIVOTS490
3 SPECIFICATIONS490
4 REMOVAL AND DISASSEMBLY490
5 REASSEMBLY AND INSTALLATION492
BUCKET493
6 SPECIFICATIONS493
7 REMOVAL493
8 INSTALLATION494
9 CUTTING EDGE REPLACEMENT494
10 TOOTH AND ADAPTOR INSTALLATION497

IMAGES PREVIEW OF THE MANUAL:

S.M 13/12/24