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KOMATSU PC60-5 PC60L-5 PC60U-5 SERVICE REPAIR MANUAL (SEBM02010505) – PDF DOWNLOAD
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- KOMATSU PC60-5 PC60L-5 PC60U-5 SERVICE REPAIR MANUAL
- PUBLICATION NUMBER:SEBM02010505
- SERIAL NUMBER:PC60-5 20501 and up
PC60L-5 7501 and up
PC60U-5 4501 and up
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Description
KOMATSU PC60-5 PC60L-5 PC60U-5 SERVICE REPAIR MANUAL (SEBM02010505)
KOMATSU PC60-5 PC60L-5 PC60U-5 SERVICE REPAIR MANUAL (SEBM02010505) – PDF DOWNLOAD:
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SAMPLE PAGE FROM THE MANUAL:
KOMATSU PC60-5 PC60L-5 PC60U-5 SERVICE REPAIR MANUAL (SEBM02010505)
- 1. Function 1) When stopping the hydraulic motor. this value controls the inertia force of the motor to cow tinue rotation tion to the inertia ul the motor body. Thereby, the motor is smoothly brakcrl until it stops.
- 2) Functions as 0 check valve to pro-tent caviation in the hydraulic motor.
- 3) Brake valves open ports to release parking brake while hydraulic motor is operating or close ports when stopping motor. 2. Operation 1) When starting to travel . The orl from the pump is supplirrd to port PA through the control valve lorcing check valve c. to open. Then, check valve C, allows the oil to flow Irom motor inlet port MA to motor outlet port MB. However. the motor outlet is closed with chock valve Cg, causing the pressure in the oil supply section to go up.
TABLE OF CONTENTS:
KOMATSU PC60-5 PC60L-5 PC60U-5 SERVICE REPAIR MANUAL (SEBM02010505)
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
PLEASE NOTE:
⦁ This is the SAME exact manual used by your dealers to fix your vehicle.
⦁ The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
⦁ Any queries / doubts regarding your purchase, please feel free to contact [email protected]
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