Komatsu PC60-5 PC60L-5 PC60U-5 Excavator Shop Manual PDF

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Komatsu PC60-5 PC60L-5 PC60U-5 Excavator Shop Manual SEBM02010505 – PDF DOWNLOAD

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Komatsu PC60-5 PC60L-5 PC60U-5 Excavator Shop Manual SEBM02010505 – PDF DOWNLOAD 

Language : English
Pages : 417
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Komatsu PC60-5 PC60L-5 PC60U-5 Excavator Shop Manual SEBM02010505 – PDF DOWNLOAD

MACHINE MODEL    SERIAL No.
РС60-5                          20501 and up
PC60L-5                        7501 and up
PC60U-5                        4501 and up

COVER 1
CONTENTS 2
10 ENGINE 5
11 STRUCTURE AND FUNCTION 5
ENGINE MOUNT 6
RADIATOR 7
PTO 8
FUEL TANK AND PIPING 9
ENGINE CONTROL 10
AUTO-DECELERATION SYSTEM (IF EQUIPPED) 11
12 TESTING AND ADJUSTING 19
TESTING AND ADJUSTING DATA 20
TOOL LIST FOR TESTING AND ADJUSTING 21
ADJUSTING VALVE CLEARANCE 22
MEASURING EXHAUST GAS COLOR 23
MEASURING COMPRESSION PRESSURE 24
MEASURING BLOW-BY PRESSURE 25
ADJUSTING FUEL INJECTION TIMING 26
TESTING AND ADJUSTING FAN BELT TENSION 27
ADJUSTING FUEL CONTROL LEVER 28
ADJUSTING AUTO-DECELERATION SYSTEM (IF EQUIPPED) 29
13 DISASSEMBLY AND ASSEMBLY 30
STARTING MOTOR 31
REMOVAL 31
INSTALLATION 31
ALTERNATOR 31
REMOVAL 31
INSTALLATION 31
AUTO-DECELERATION CYLINDER 32
REMOVAL 32
INSTALLATION 32
FUEL INJECTION PUMP 33
REMOVAL 33
INSTALLATION 33
ENGINE OIL COOLER 34
REMOVAL 34
INSTALLATION 34
FAN AND FAN PULLEY 34
REMOVAL 34
INSTALLATION 34
WATER PUMP 35
REMOVAL 35
INSTALLATION 35
THERMOSTAT 36
REMOVAL 36
INSTALLATION 36
NOZZLE HOLDER 37
REMOVAL 37
INSTALLATION 37
CYLINDER HEAD 38
REMOVAL 38
INSTALLATION 40
HYDRAULIC OIL COOLER 42
REMOVAL 42
INSTALLATION 42
RADIATOR AND HYDRAULIC OIL COOLER 43
REMOVAL 43
INSTALLATION 44
ENGINE 45
REMOVAL 45
INSTALLATION 48
PTO 51
REMOVAL 51
INSTALLATION 51
DISASSEMBLY 52
ASSEMBLY 52
20 POWER TRAIN 53
21 STRUCTURE AND FUNCTION 53
POWER TRAIN 54
TRAVEL SYSTEM 55
TRAVEL CONTROL CIRCUIT SCHEMATICS 56
TRAVEL CONTROL CIRCUIT 57
TRAVEL MOTOR (WITH REDUCTION GEAR AND PARKING BRAKE) 60
CENTER SWIVEL JOINT 67
STRAIGHT TRAVEL SYSTEM 68
TRAVEL CONTROL 70
SWING SYSTEM 71
SWING CONTROL CIRCUIT SCHEMATICS 72
SWING CONTROL CIRCUIT 73
SWING MOTOR AND BRAKE VALVE 74
SWING MECHANICAL BRAKE 80
SWING PRIORITY CIRCUIT 84
SWING MACHINERY 86
SWING CIRCLE 87
SPROCKET 88
23 DISASSEMBLY AND ASSEMBLY 89
CENTER SWIVEL JOINT 90
REMOVAL 90
INSTALLATION 91
DISASSEMBLY 92
ASSEMBLY 92
TRAVEL MOTOR 93
REMOVAL 93
INSTALLATION 93
DISASSEMBLY 94
ASSEMBLY 102
SWING MOTOR 115
REMOVAL 115
INSTALLATION 115
DISASSEMBLY 116
ASSEMBLY 119
SWING CIRCLE 124
REMOVAL 124
INSTALLATION 125
SWING MACHINERY 126
REMOVAL 126
INSTALLATION 126
DISASSEMBLY 127
ASSEMBLY 130
SPROCKET 134
REMOVAL 134
INSTALLATION 134
24 MAINTENANCE STANDARD 135
SWING MACHINERY 136
SWING CIRCLE 137
SWING MOTOR 138
SPROCKET 139
30 UNDERCARRIAGE 140
31 STRUCTURE AND FUNCTION 140
TRACK FRAME 141
IDLER 143
RECOIL SPRING 143
TRACK ROLLER 144
CARRIER ROLLER 144
TRACK SHOE 145
33 DISASSEMBLY AND ASSEMBLY 147
RECOIL SPRING 148
REMOVAL 148
INSTALLATION 148
DISASSEMBLY 149
ASSEMBLY 149
IDLER 150
DISASSEMBLY 150
ASSEMBLY 150
TRACK ROLLER 151
REMOVAL 151
INSTALLATION 151
DISASSEMBLY 152
ASSEMBLY 152
CARRIER ROLLER 153
REMOVAL 153
INSTALLATION 153
DISASSEMBLY 154
ASSEMBLY 154
TRACK SHOE 155
REMOVAL 155
INSTALLATION 156
34 MAINTENANCE STANDARD 157
TRACK FRAME AND RECOIL SPRING 158
IDLER 159
CARRIER ROLLER 160
TRACK ROLLER 161
TRACK SHOE 162
60 HYDRAULIC SYSTEM 164
61 STRUCTURE AND FUNCTION 164
OUTLINE 165
HYDRAULIC PIPING 166
HYDRAULIC SCHEMATICS 168
HYDRAULIC CIRCUIT 170
HYDRAULIC TANK (WITH FUEL TANK) 178
HYDRAULIC PUMP 179
PC CONTROL SYSTEM 188
MODE SELECTION TYPE PC CONTROL SYSTEM (IF EQUIPPED) 190
OLSS SYSTEM (IF EQUIPPED) 195
CONTROL VALVE 213
WORK EQUIPMENT SWIVEL JOINT 218
SAFETY SUCTION VALVE (FOR BOOM SWING) 219
HYDRAULIC CYLINDER 220
WORK EQUIPMENT CONTROL 224
WORK EQUIPMENT 233
62 TESTING AND ADJUSTING 234
TABLE OF JUDGEMENT STANDARD VALUE 235
TROUBLESHOOTING TOOLS 250
MEASURING HYDRAULIC OIL TEMPERATURE 251
TESTING OPERATING FORCE OF CONTROL LEVERS 252
TESTING TRAVEL CONTROL LEVERS 253
TESTING TRAVEL CONTROL VALVE SPOOLS 254
TESTING AND ADJUSTING MAIN RELIEF VALVE 255
TESTING AND ADJUSTING CHARGING PUMP RELIEF VALVE 256
TESTING CONTROL CIRCUIT PRESSURE 257
MEASURING SWING AND BUCKET RELIEF PRESSURE 259
MEASURING DELIVERY OF PISTON PUMP 260
CHECKING PERFORMANCE OF WORK EQUIPMENT 261
AIR BLEEDING 265
CHECKING TRAVEL MOTOR PERFORMANCE 266
CHECKING PERFORMANCE OF SWING MOTORS 268
MEASURING OIL LEAKAGE FROM SWING AND TRAVEL MOTORS 269
CHECKING FOR OIL LEAKAGE FROM SWIVEL JOINT 270
ADJUSTING BOOM SWING KICKOUT (ON PC60U-5) 271
CHECKING VISUALLY OR BY “FEEL” 272
TROUBLESHOOTING 275
ELECTRICAL CIRCUIT 276
POSITION OF CONNECTORS FOR TROUBLESHOOTING 279
CONNECTION TABLE FOR CONNECTOR PINS 286
TROUBLESHOOTING PROCEDURE 290
CHECKS BEFORE TROUBLESHOOTING 291
JUDGEMENT TABLE 292
TROUBLESHOOTING CHART 297
E-1 WORK EQUIPMENT, SWING, TRAVEL SPEEDS EXTREMELY SLOW, OR LACK OF POWER, NO CHANGE IN OUTPUT WHEN MODE SELECTOR SWITCH IS OPERATED 297
E-2 MACHINE DEVIATES EXCESSIVELY (DURING COMPOUND OPERATIONS) 299
E-2 MACHINE DEVIATES EXCESSIVELY (DURING COMPOUND OPERATIONS) (WHEN STARTING) 303
E-3 HYDRAULIC DRIFT OF SWING IS EXCESSIVE, OR UPPER STRUCTURE DOES NOT SWING 307
E-4 AUTO-DECELERATION DOES NOT WORK 311
H-1 MACHINE DEVIATES EXCESSIVELY (DEVIATES MORE THAN STANDARD WHEN ONLY TRAVEL SYSTEM IS USED, TRAVEL LEVER IS PULLED FAULLY) 315
H-1 MACHINE DEVIATES EXCESSIVELY (DEVIATES MORE THAN STANDARD WHEN ONLY TRAVEL SYSTEM IS USED, TRAVEL LEVER AT FULL TRAVEL) 317
H-2 MACHINE DEVIATES EXCESSIVELY DURING COMPOUND OPERATION 319
H-3 MACHINE DEVIATES EXCESSIVELY WHEN STARTING 319
H-4 CONTROL LEVERS ARE EXTREMELY HEAVY 320
H-5 WORK EQUIPMENT, TRAVEL AND SWING START SUDDENLY DURING FINE CONTROL OPERATIONS 321
H-6 SPEEDS FOR WORK EQUIPMENT, SWING, AND TRAVEL ARE ALL EXTREMELY SLOW, OR THERE IS NO POWER 322
H-6 SPEEDS FOR WORK EQUIPMENT, SWING, AND TRAVEL ARE ALL EXTREMELY SLOW, OR THERE IS NO POWER (NO ABNORMALITY IN AUTO-DECELERATION) 324
H-7 SPEEDS FOR BOOM, ARM AND BUCKET ARE SLOW, OR THERE IS NO POWER (NO ABNORMALITY IN AUTO-DECELERATION) 328
H-8 ENGINE STALLS OR ENGINE SPEED DROPS DURING OPERATIONS 329
H-9 NO CHANGE IN OUTPUT WHEN MODE SELECTOR SWITCH OPERATED 330
H-10 AUTO-DECELERATION DOES NOT COME ON, OR DOES NOT GO OFF 331
H-11 ABNORMAL NOISE COMES FROM AROUND PUMP 332
H-12 SWING SPEED IS SLOW, OR OVERRUN WHEN STOPPING SWING IS EXCESSIVE 333
H-13 UPPER STRUCTURE DOES NOT SWING 334
H-14 EXCESSIVE HYDRAULIC DRIFT OF SWING 334
H-15 EXCESSIVE HYDRAULIC DRIFT OF WORK EQUIPMENT 335
H-16 EXCESSIVE TIME LAG FOR WORK EQUIPMENT 336
FAILURE MODE AND COMPONENTS 337
63 DISASSEMBLY AND ASSEMBLY 338
CONTROL PUMP 339
REMOVAL 339
INSTALLATION 339
MAIN PUMP 341
REMOVAL 341
INSTALLATION 342
REMOVAL (WITH OLSS) 343
INSTALLATION (WITH OLSS) 344
DISASSEMBLY 345
ASSEMBLY 349
TVC VALVE AND FRONT CO・NC VALVE (IF EQUIPPED) 360
REMOVAL 360
INSTALLATION 360
REAR CO・NC VALVE (IF EQUIPPED) 361
REMOVAL 361
INSTALLATION 361
SERVO VALVE 362
REMOVAL 362
INSTALLATION 362
MAIN PUMP INPUT SHAFT OIL SEAL 363
REMOVAL 363
INSTALLATION 363
L H 6-SPOOL CONTROL VALVE 364
REMOVAL 364
INSTALLATION 367
R H 5-SPOOL CONTROL VALVE 371
REMOVAL 371
INSTALLATION 373
CONTROL VALVE 375
REMOVAL 375
ASSEMBLY 377
BOOM CYLINDER 379
REMOVAL 379
INSTALLATION 379
ARM CYLINDER 380
REMOVAL 380
INSTALLATION 380
BUCKET CYLINDER 381
REMOVAL 381
INSTALLATION 381
HYDRAULIC CYLINDER 382
DISASSEMBLY 382
ASSEMBLY 384
64 MAINTENANCE STANDARD 387
CHARGING PUMP (BAR 16) 388
L H 6-SPOOL CONTROL VALVE 389
R H 5-SPOOL CONTROL VALVE 391
R H 6-SPOOL CONTROL VALVE 393
HYDRAULIC CYLINDER 395
WORK EQUIPMENT 397
70 WORK EQUIPMENT 401
73 DISASSEMBLY AND ASSEMBLY 401
WORK EQUIPMENT 402
REMOVAL 402
INSTALLATION 402
BUCKET 403
DISASSEMBLY 403
ASSEMBLY 403
ARM 404
REMOVAL 404
INSTALLATION 404
BOOM 405
REMOVAL 405
INSTALLATION 405
ARM,BUCKET 406
REMOVAL 406
INSTALLATION 406
80 ELECTRICAL SYSTEM 407
81 STRUCTURE AND FUNCTION 407
ELECTRICAL SYSTEM 408
ELECTRICAL CIRCUIT DIAGRAM 410
82 TESTING AND ADJUSTING 412
ELECTRICAL CIRCUIT 413
TROUBLESHOOTING CHART 415
M-1 BATTERY CHARGING PILOT LAMP DOES NOT GO OFF 415
M-2 FUEL GAUGE DOES NOT DISPLAY OR DISPLAYS ABNORMALLY 416
M-3 WATER TEMPERATURE GAUGE DOES NOT OPERATE OR DISPLAYS ABNORMALLY 417

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S.V  17/12/24