Komatsu Dressta 560C Wheel Loader Service Manual – PDF DOWNLOAD

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Komatsu Dressta 560C Wheel Loader Service Manual – PDF DOWNLOAD

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Komatsu Dressta 560C Wheel Loader Service Manual – PDF DOWNLOAD

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

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TABLE OF CONTENTS:

Komatsu Dressta 560C Wheel Loader Service Manual – 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
		6.SERVICE 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. SPECIFICATIONS.....................................................................100
	4. SERVICE DIAGNOSIS..................................................................101
	5. CHECKING THE CHARGING PUMP FLOW RATE...............................................103
	6. CHECKING TRANSMISSION AND TORQUE CONVERTER PRESSURES...............................104
	7B. TORQUE CONVERTER..................................................................110
		GENERAL...........................................................................111
			1. DESCRIPTION................................................................112
			2. OPERATION..................................................................112
			3. SPECIFICATIONS.............................................................113
			4. SERVICE DIAGNOSIS..........................................................113
		TORQUE CONVERTER..................................................................114
			5. REMOVAL....................................................................114
			6. DISASSEMBLY................................................................118
			7. INSPECTION AND REPAIR......................................................120
			8. REASSEMBLY.................................................................121
			9. INSTALLATION...............................................................125
		CHARGING PUMP.....................................................................128
			10. DESCRIPTION AND OPERATION.................................................128
			11. SPECIAL TORQUES...........................................................129
			12. REMOVAL...................................................................129
			13. DISASSEMBLY...............................................................129
			14. INSPECTION AND REPAIR.....................................................130
			15. REASSEMBLY................................................................130
			16. INSTALLATION..............................................................130
	7C. TRANSMISSION......................................................................132
		GENERAL...........................................................................133
			1. DESCRIPTION................................................................133
			2. OPERATION..................................................................136
			3. SPECIFICATIONS.............................................................140
		TRANSMISSION......................................................................141
			4. REMOVAL....................................................................141
			5. DISASSEMBLY................................................................145
			6. INSPECTION AND REPAIR......................................................151
			7. REASSEMBLY.................................................................151
			8. INSTALLATION...............................................................156
		CLUTCH PACKS......................................................................157
			9. REMOVAL....................................................................157
			10. DISASSEMBLY...............................................................157
			11. INSPECTION AND REPAIR.....................................................164
			12. REASSEMBLY................................................................165
			13. INSTALLATION..............................................................177
		CONTROL VALVE.....................................................................178
			14. REMOVAL...................................................................178
			15. DISASSEMBLY...............................................................178
			16. INSPECTION AND REPAIR.....................................................181
			17. REASSEMBLY................................................................181
			18. INSTALLATION..............................................................182
	7D. DRIVE AXLE AND DIFFERENTIAL.......................................................184
		GENERAL...........................................................................186
			1. DESCRIPTION................................................................186
			2. THEORY OF OPERATION........................................................186
		DRIVE SHAFTS......................................................................187
			3. DESCRIPTION AND OPERATON...................................................187
			4. SPECIFICATIONS.............................................................187
			5. SERVICE DIAGNOSIS..........................................................187
			6. REMOVAL AND DISASSEMBLY....................................................188
			7. INSPECTION AND REPAIR......................................................189
			8. REASSEMBLY AND INSTALLATION................................................189
		TRANSFER DRIVE....................................................................190
			9. DESCRIPTION................................................................190
			10. SPECIFICATIONS............................................................190
			11. SERVICE DIAGNOSIS.........................................................190
			12. REMOVAL...................................................................190
			13. DISASSEMBLY...............................................................191
			14. REASSEMBLY................................................................192
			15. INSTALLATION..............................................................193
		PLANETARY GEAR....................................................................193
			16. DESCRIPTION...............................................................193
			17. THEORY OF OPERATION.......................................................193
			18. SPECIFICATIONS............................................................194
			19. REMOVAL...................................................................194
			20. DISASSEMBLY...............................................................197
			21. REASSEMBLY................................................................197
			22. INSTALLATION..............................................................199
		WHEEL HUB AND SERVICE BRAKES......................................................200
			23. DESCRIPTION...............................................................200
			24. SPECIFICATIONS............................................................201
			25. REMOVAL...................................................................201
			26. SERVICE BRAKE DISASSEMBLY.................................................204
			27. INSPECTION................................................................205
			28. BRAKE REASSEMBLY..........................................................205
			29. WHEEL HUB AND BRAKE UNIT ASSEMBLY.........................................208
			30. PREPARATION FOR THE BRAKE AND WHEEL HUB INSTALLATION......................209
			31. PROCEDURE FOR DETERMINNG WHEEL BEARING SHIM PACK..........................210
			32. INSTALLING WHEEL HUB AND BRAKE UNIT.......................................211
			33. FRICTION DISCS CHECKING...................................................212
		DIFFERENTIAL......................................................................213
			34. DESCRIPTION...............................................................213
			35. THEORY OF OPERATION.......................................................213
			36. SPECIFICATIONS............................................................214
			37. SERVICE DIAGNOSIS.........................................................215
			38. REMOVAL...................................................................216
			39. DISASSEMBLY...............................................................217
			40. INSPECTION AND REPAIR.....................................................220
			41. REASSEMBLY................................................................221
			42. INSTALLATION..............................................................227
		DRIVE AXLE........................................................................227
			43. DESCRIPTION...............................................................227
			44. SPECIFICATIONS............................................................227
			45. SERVICE DIAGNOSIS.........................................................227
			46. REMOVAL AND DISASSEMBLY...................................................229
			47. REASSEMBLY AND INSTALLATION...............................................230
8. ELECTRICAL.............................................................................232
	GENERAL...............................................................................233
		1. DESCRIPTION....................................................................233
	WIRING DIAGRAM........................................................................233
		2. ELECTRICAL LOADER SYSTEM.......................................................233
		3. SERVICE DIAGNOSIS..............................................................248
	ALTERNATOR............................................................................249
		4. SPECIFICATION..................................................................249
		5. INTRODUCTION...................................................................250
		6. OPERATING PRINCIPLES...........................................................250
		7. TROUBLESHOOTING PROCEDURES.....................................................251
		8. INTEGRAL CHARGING SYSTEM REPAIR................................................253
	BATTERY...............................................................................258
		9. SAFETY PRECAUTIONS.............................................................258
		10. ELECTROLYTE STATE OF CHARGE...................................................258
		11. ELECTROLYTE IN TROPICAL AND ARCTIC CLIMATES...................................259
		12. TESTING AND MAINTENANCE OF THE BATTERY........................................260
		13. BATTERY CHARGING GUIDE........................................................261
		14. BATTERY STORAGE...............................................................262
		15. BATTERY PRIMARY RATINGS.......................................................262
		16. COLD ENGINE CRANKING PERFORMANCE..............................................262
		17. DRY CHARGE ACTIVATION.........................................................263
		18. TYPICAL CAUSE OF BATTERY FAILURE..............................................263
		19. VISUAL INSPECTION OF BATTERY..................................................264
	CRANKING MOTOR........................................................................265
		20. SPECIFICATION.................................................................265
		21. INTRODUCTION..................................................................265
		22. OPERATION.....................................................................266
		23. TROUBLESHOOTING THE CRANKING CIRCUIT..........................................266
9. FRAME..................................................................................276
	1. DESCRIPTION AND OPERATION..........................................................277
	2. SPECIFICATIONS.....................................................................278
	3. MAINTENANCE........................................................................278
	4. WELDING............................................................................278
	5. CHECKING HINGE VERTICAL MOVEMENT...................................................279
	6. DISASSEMBLY........................................................................279
	7. INSPECTION AND REPAIR..............................................................284
	8. REASSEMBLY.........................................................................284
10 HYDRAULIC..............................................................................288
	GENERAL...............................................................................289
		1. DESCRIPTION....................................................................290
		2. THEORY OF OPERATION............................................................293
		3. SPECIFICATIONS.................................................................294
		4. SERVICE DIAGNOSIS..............................................................295
	TEST AND ADJUSTMENT...................................................................298
		5. STEERING SYSTEM PERFORMANCE TEST...............................................298
		6. HYDRAULIC SYSTEM PERFORMANCE TEST..............................................299
		7. STEERING SYSTEM PRESSURE TEST..................................................300
		8. HYDRAULIC SYSTEM PRESSURE TEST.................................................301
		9. SUCTION LINE LEAKAGE TEST......................................................301
		10. HYDRAULIC CONTROL LEVER LEAKAGE ADJUSTMENT....................................302
	10A. PUMPS............................................................................305
		STEERING/SWITCH PUMP..............................................................306
			1. DESCRIPTION................................................................306
			2. THEORY OF OPERATION........................................................306
			3. SPECIFICATIONS.............................................................309
			4. PUMP FLOW TEST.............................................................309
			5. DIVERTER VALVE SWITHC POINT TEST AND ADJUSTMENT............................310
			6. REMOVAL....................................................................312
			7. DISASSEMBLY................................................................313
			8. INSPECTION AND REPAIR......................................................315
			9. REASSEMBLY.................................................................315
			10. INSTALLATION..............................................................319
		HYDRAULIC AND BRAKE COOLING PUMP..................................................319
			11. DESCRIPTION...............................................................319
			12. THEORY OF OPERATION.......................................................320
			13. SPECIFICATIONS............................................................320
			14. HYDRAULIC PUMP FLOW TEST..................................................321
			15. REMOVAL...................................................................321
			16. DISASSEMBLY...............................................................322
			17. INSPECTION AND REPAIR.....................................................324
			18. REASSEMBLY................................................................325
			19. INSTALLATION..............................................................326
		GROUND DRIVEN STEERING PUMP (IF EQUIPPED).........................................327
			20. DESCRIPTION AND OPERATION.................................................327
			21. SPECIFICATIONS............................................................328
			22. REMOVAL...................................................................328
			23. DISASSEMBLY...............................................................329
			24. INSPECTION AND REPAIR.....................................................330
			25. REASSEMBLY................................................................330
			26. INSTALLATION..............................................................331
	10B. VALVES...........................................................................333
		STEERING VALVE....................................................................335
			1. DESCRIPTION................................................................335
			2. OPERATION..................................................................336
			3. SPECIFICATIONS.............................................................338
			4. SERVICE DIAGNOSIS..........................................................339
			5. STEERING SYSTEM RELIEF VALVE TEST AND ADJUSTMENT...........................339
			6. STEERING CIRCUIT SHOCK VALVE PRESSURE TEST.................................340
			7. REMOVAL....................................................................341
			8. DISASSEMBLY................................................................342
			9. INSPECTION AND REPAIR......................................................343
			10. REASSEMBLY................................................................344
			11. INSTALLATION..............................................................345
		PILOT CONTROL VALVE...............................................................345
			12. DESCRIPTION...............................................................345
			13. OPERATION.................................................................346
			14. SPECIFICATIONS............................................................351
			15. SERVICE DIAGNOSIS.........................................................352
			16. BUCKET CIRCUIT SHOCK VALVE PRESSURE TEST AND ADJUSTMENT...................353
			17. REMOVAL...................................................................354
			18. DISASSEMBLY...............................................................355
			19. INSPECTION AND REPAIR.....................................................359
			20. REASSEMBLY................................................................359
			21. INSTALLATION..............................................................362
		HYDRAULIC CONTROL VALVE...........................................................363
			22. DESCRIPTION...............................................................363
			23. OPERATION.................................................................364
			24. SPECIFICATIONS............................................................375
			25. SERVICE DIAGNOSIS.........................................................376
			26. MAIN RELIEF VALVE TEST AND ADJUSTMENT.....................................380
			27. LOW PRESSURE RELIEF VALVE TEST AND ADJUSTMENT.............................381
			28. UNLOADING VALVE TEST AND ADJUSTMENT.......................................382
			29. REMOVAL...................................................................383
			30. DISASSEMBLY...............................................................384
			31. INSPECTION AND REPAIR.....................................................390
			32. REASSEMBLY................................................................391
			33. INSTALLATION..............................................................394
		STEERING CYLINDER CHECK VALVES....................................................394
			34. DESCRIPTION...............................................................394
			35. OPERATION.................................................................395
			36. SPECIFICATIONS............................................................395
			37. REMOVAL...................................................................396
			38. DISASSEMBLY...............................................................396
			39. INSPECTION AND REPAIR.....................................................397
			40. REASSEMBLY................................................................397
			41. INSTALLATION..............................................................398
		GROUND DRIVEN STEERING DIVERTER VALVE (IF EQUIPPED)...............................398
			42. DESCRIPTION...............................................................398
			43. OPERATION.................................................................398
			44. SPECIFICATIONS............................................................399
			45. REMOVAL...................................................................399
			46. DISASSEMBLY...............................................................400
			47. INSPECTION AND REPAIR.....................................................401
			48. REASSEMBLY................................................................401
			49. INSTALLATION..............................................................402
		GROUND DRIVEN STEERING CHECK VALVE................................................402
			50. DESCRIPTION AND OPERATION.................................................402
			51. SPECIFICATIONS............................................................403
			52. REMOVAL...................................................................403
			53. DISASSEMBLY...............................................................403
			54. INSPECTION AND REPAIR.....................................................404
			55. REASSEMBLY................................................................404
			56. INSTALLATION..............................................................404
		STEERING RETURN SURGE VALVE.......................................................406
			57. DESCRIPTION AND OPERATION.................................................405
			58. SPECIFICATIONS............................................................405
			59. REMOVAL...................................................................405
			60. DISASSEMBLY...............................................................406
			61. INSPECTION AND REPAIR.....................................................406
			62. REASSEMBLY................................................................406
			63. INSTALLATION..............................................................406
	10C. CYLINDERS........................................................................408
		BUCKET CYLINDER...................................................................409
			1. DESCRIPTION AND OPERATION..................................................409
			2. SPECIFICATIONS.............................................................409
			3. BUCKET CYLINDER LEAKAGE TEST...............................................410
			4. REMOVAL....................................................................410
			5. DISASSEMBLY................................................................412
			6. INSPECTION AND REPAIR......................................................414
			7. REASSEMBLY.................................................................415
			8. INSTALLATION...............................................................418
		BOOM CYLINDERS....................................................................419
			9. DESCRIPTION AND OPERATION..................................................419
			10. SPECIFICATIONS............................................................419
			11. BOOM CYLINDER LEAKAGE TEST................................................420
			12. REMOVAL...................................................................421
			13. DISASSEMBLY...............................................................422
			14. INSPECTION AND REPAIR.....................................................424
			15. REASSEMBLY................................................................425
			16. INSTALLATION..............................................................427
		STEERING CYLINDERS................................................................428
			17. DESCRIPTION AND OPERATION.................................................428
			18. SPECIFICATIONS............................................................428
			19. STEERING CYLINDER LEAKAGE TEST............................................429
			20. REMOVAL...................................................................430
			21. DISASSEMBLY...............................................................430
			22. INSPECTION AND REPAIR.....................................................432
			23. REASSEMBLY................................................................433
			24. INSTALLATION..............................................................435
	10E. RESERVOIRS AND FILTER............................................................437
		1. DESCRIPTION....................................................................438
		2. OPERATION......................................................................438
		3. SPECIFICATION..................................................................438
		4. LOADER RETURN SURGE VALVE TEST.................................................439
		5. REMOVAL........................................................................439
		6. DISASSEMBLY....................................................................440
		7. INSPECTION AND REPAIR..........................................................442
		8. REASSEMBLY.....................................................................443
		9. INSTALLATION...................................................................443
12. POWER.................................................................................445
	1. DESCRIPTION........................................................................446
	2. SPECIFICATIONS.....................................................................446
	3. SERVICE DIAGNOSIS..................................................................447
	4. AIR INTAKE SYSTEM TEST.............................................................448
	5. ENGINE CONTROLS ADJUSTMENT.........................................................450
	6. REMOVAL............................................................................453
	7. ENGINE REPAIR......................................................................462
	8. ENGINE INSTALLATION................................................................462
13. SUPERSTRUCTURE........................................................................467
	GENERAL...............................................................................468
		1. SPECIFICATIONS.................................................................468
	CAB WINDOW GLASS......................................................................468
		2. REPLACEMENT....................................................................468
	R.O.P.S...............................................................................469
		3. REMOVAL........................................................................469
		4. INSTALLATION...................................................................470
14. SUSPENSION............................................................................472
	1. DESCRIPTION........................................................................473
	2. SPECIFICATION......................................................................473
	3. REMOVAL............................................................................473
	4. BOLSTER REPAIR.....................................................................476
	5. INSTALLATION.......................................................................477
15. WHEELS AND TRACKS.....................................................................480
	1. DESCRIPTION........................................................................481
	2. OPERATION..........................................................................481
	3. WHEEL REMOVAL......................................................................481
	4. WHEEL DISASSEMBLY AND ASSEMBLY.....................................................482
	5. WHEEL INSTALLING...................................................................486
17. MOUNTED EQUIPMENT.....................................................................488
	GENERAL...............................................................................489
		1. SAFETY PRECAUTIONS.............................................................489
		2. DESCRIPTION AND OPERATION......................................................489
	LOADER LINKAGE PIVOTS.................................................................490
		3. SPECIFICATIONS.................................................................490
		4. REMOVAL AND DISASSEMBLY........................................................490
		5. REASSEMBLY AND INSTALLATION....................................................492
	BUCKET................................................................................493
		6. SPECIFICATIONS.................................................................493
		7. REMOVAL........................................................................493
		8. INSTALLATION...................................................................494
		9. CUTTING EDGE REPLACEMENT.......................................................494
		10. TOOTH AND ADAPTOR INSTALLATION................................................497

DESCRIPTION:

Komatsu Dressta 560C Wheel Loader Service Manual – PDF DOWNLOAD

• This manual covers the instructions for safe operation, lubrications, adjustments and maintenance for normal daily care. These instructions are divided into six sections to simplify your reference to the information most important to you. Refer to the contents page at the beginning of the section for a complete list of the subjects covered except for Section 1, which should be read entirely.
• This manual has been prepared to help you operate and maintain your machine with utmost efficiency and safety. Read this manual thoroughly and learn your machine before you attempt to operate it.
• It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes or add improvements at any time without incurring any obligation to install such changes on products sold previously.
• Due to this continuous program of research and development, periodic revisions may be made to this publication. It is recommended that customers contact their distributor for information on the latest revision.

S.S 22/12/24