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KOMATSU PC60-7 PC60-7B HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL – PDF DOWNLOAD
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- KOMATSU PC60-7 PC60-7B HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL
- PUBLICATION NUMBER:SEBM010911
- SERIAL NUMBERS: PC60-7 52374 and up
PC60-7B 52374 and up
PC60-7 55720 and up
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Description
KOMATSU PC60-7 PC60-7B HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL
KOMATSU PC60-7 PC60-7B HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL – PDF DOWNLOAD:
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KOMATSU PC60-7 PC60-7B HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL
- This shop manual has been prepared as an aid to improve the quality of repairs by giving the servicemen an accurate understanding of the product and by showing him the correct way to perform repairs and makejudge- ments. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
- This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components.
- STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an under- standing of the structure, but also serves as reference material for troubleshooting. In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards. - TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” with “Causes” are also included in this section. - DISASSEMBLY AND ASSEMBLY
This section explains the procedures for removing, installing. disassembling and assembling each com- ponent, as well as precautions for them. - MAINTENANCE STANDARD
This section gives thejudgment standards for inspection of disassembled parts. The contents of this section may be described in STRUCTURE AND FUNCTION. - OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams. In addition, this section may give the specifications of attachments and options together.
TABLE OF CONTENTS:
KOMATSU PC60-7 PC60-7B HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL
MAIN MENU.................................................................................................................................... 0 COVER........................................................................................................................................ 1 CONTENTS..................................................................................................................................... 2 SAFETY....................................................................................................................................... 7 00 FOREWORD.................................................................................................................................. 9 HOW TO READ THE SHOP MANUAL.............................................................................................................. 9 HOISTING INSTRUCTIONS.................................................................................................................... 10 COATING MATERIALS........................................................................................................................ 13 STANDARD TIGHTENING TORQUE............................................................................................................... 15 ELECTRIC WIRE CODE....................................................................................................................... 18 CONVERSION TABLE......................................................................................................................... 19 UNITS.................................................................................................................................... 25 01 GENERAL................................................................................................................................... 27 DIMENSION................................................................................................................................ 28 SPECIFICATIONS........................................................................................................................... 29 WEIGHT TABLE............................................................................................................................. 33 TABLE OF OIL AND COOLANT CAPACITIES...................................................................................................... 35 10 STRUCTURE AND FUNCTION.................................................................................................................... 37 RADIATOR, OIL COOLER..................................................................................................................... 38 PTO (COUPLING)........................................................................................................................... 41 ENGINE CONTROL........................................................................................................................... 42 POWER TRAIN DIAGRAM...................................................................................................................... 43 SWING CIRCLE............................................................................................................................. 44 SWING MACHINERY.......................................................................................................................... 45 TRACK FRAME.............................................................................................................................. 47 IDLER CUSHION............................................................................................................................ 48 HYDRAULIC PIPING DRAWING................................................................................................................. 49 HYDRAULIC CIRCUIT DIAGRAM................................................................................................................ 50 HYDRAULIC TANK........................................................................................................................... 51 HYDRAULIC PUMP........................................................................................................................... 52 CONTROL VALVE............................................................................................................................ 77 SELF-PRESSURE REDUCING VALVE............................................................................................................. 90 CLSS..................................................................................................................................... 94 SWING MOTOR..............................................................................................................................124 CENTER SWIVEL JOINT......................................................................................................................136 TRAVEL MOTOR.............................................................................................................................140 VALVE CONTROL............................................................................................................................146 WORK EQUIPMENT, SWING PPC VALVE..........................................................................................................147 TRAVEL PPC VALVE.........................................................................................................................151 SERVICE PPC VALVE........................................................................................................................155 SOLENOID VALVE...........................................................................................................................158 HYDRAULIC CYLINDER.......................................................................................................................160 WORK EQUIPMENT........................................................................................................................... 37 WORK EQIPMENT PIN AUTOMATIC GREASING SYSTEM..............................................................................................162 ELECTRICAL ALLOCATION DIAGRAM (1/2)......................................................................................................175 ELECTRICAL ALLOCATION DIAGRAM (2/2)......................................................................................................176 ELECTRICAL CIRCUIT DIAGRAM...............................................................................................................177 ELECTRICAL CONTROL SYSTEM................................................................................................................179 MACHINE MONITOR SYSTEM...................................................................................................................187 20 TESTING AND ADJUSTING.....................................................................................................................192 STANDARD VALVE TABLE FOR ENGINE RELATED PARTS............................................................................................193 STANDARD VALUE TABLE FOR CHASIS RELATED PARTS............................................................................................195 STANDARD VALUE TABLE FOR ELECTRICAL RELATED PARTS........................................................................................204 TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING.........................................................................................205 MEASURING ENGINE SPEED...................................................................................................................206 MEASURING EXHAUST GAS COLOR..............................................................................................................208 ADJUSTING VALVE CLEARANCE................................................................................................................209 MEASURING COMPRESSION PRESSURE...........................................................................................................211 MEASURING BLOWBY PRESSURE................................................................................................................213 TESTING AND ADJUSTING FUEL INJECTION TIMING..............................................................................................215 MEASURING ENGINE OIL PRESSURE............................................................................................................220 TESTING AND ADJUSTING ALTERNATOR BELT TENSION............................................................................................222 ADJUSTING ENGINE STOP SOLENOID LINKAGE...................................................................................................223 ADJUSTING FUEL CONTROL LINKAGE...........................................................................................................225 TESTING AND ADJUSTING OF HYDRUALIC PRESSURE IN WORK EQUIPMENT, SWING AND TRAVEL CIRCUITS.................................................227 ADJUSTING PC VALVE.......................................................................................................................228 MEASURING LS DIFFERENTIAL PRESSURE AND ADJUSTING LS VALVE................................................................................229 TESTING HYDRAULIC PRESSURE IN THE CONTROL CIRCUIT........................................................................................230 TESTING OUTLET PRESSURE OF SOLENOID VALVE................................................................................................231 MEASURING PPC VALVE OUTPUT PRESSURE......................................................................................................232 ADJUSTING WORK EQUIPMENT AND SWING PPC VALVE.............................................................................................232 TESTING TRAVEL DEVATION..................................................................................................................233 MEASURING OIL LEAKAGE....................................................................................................................234 RELEASING REMAINING PRESURE IN HYDRAULIC CIRCUIT ........................................................................................236 CHECKING OF CLEARANCE OF SWING CIRCLE BEARING............................................................................................237 CHECKING AND ADJUSTING OF TRACK SHOE TENSION.............................................................................................238 TESTING WEAR OF SPROKET..................................................................................................................239 BLEEDING AIR.............................................................................................................................240 AUTOMATIC GREASING CONTROLLER............................................................................................................242 TROUBLESHOOTING..........................................................................................................................253 POINTS TO REMEMBER WHEN TROUBLESHOOTING..............................................................................................254 SEQUENCE OF EVENTS IN TROUBLESHOOTING................................................................................................255 POINTS TO REMEMBER WHEN CARRING OUT MAINTENANCE......................................................................................256 CHECKS BEFORE TROUBLESHOOTING........................................................................................................264 CONNECTOR TYPES AND MOUNTING LOCATIONS...............................................................................................265 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS...........................................................................................274 METHOD OF USING JUDGEMENT TABLE......................................................................................................284 METHOD OF USING TROUBLESHOOTING CHARTS...............................................................................................285 FAILURE MODES AND JUDGEMENT TABLE....................................................................................................287 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)........................................................................................289 E-1 WORK EQUIPMENT DOES NOT MOVE EVEN WHEN THE PPC HYDRAULIC PRESSURE LOCK LEVER IS SET TO THE DRIVE SIDE........................290 E-2 WORK EQUIPMENT DOES NOT MOVE EVEN IF THE PPC HYDRAULIC PRESSURE LOCK LEVER IS AT THE LOCK POSITION...........................291 E-3 DOES NOT SWING...............................................................................................................292 E-4 SWING BRAKE DOES NOT WORK....................................................................................................295 E-5 TRAVEL SPEED CANNOT BE SWITCHED..............................................................................................297 A) CANNOT BE SWITCHED TO HI..................................................................................................297 B) CANNOT BE SWITCHED TO LO..................................................................................................297 E-6 POWER MODE CANNOT BE CHANGED.................................................................................................298 A) WORK EQUIPMENT SPEED IS SLOW WHEN ENGINE SPEED IS MIDDLE AND HIGHER.......................................................298 B) EXCESSIVE ENGINE SPEED DROP AT ENGINE SPEED MIDDLE AND LOWER..............................................................298 E-7 ENGINE DOES NOT START........................................................................................................299 A) STARTER DOES NOT WORK.....................................................................................................299 B) ENGINE STOP SOLENOID DOES NOT WORK........................................................................................301 E-8 ENGINE DOES NOT STOP.........................................................................................................302 E-9 WIPER DOES NOT WORK..........................................................................................................303 TROUBLESHOOTING OF ENGINE (S MODE)...................................................................................................304 METHOD OF USING TROUBLESHOOTING CHART............................................................................................305 S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)................................................................309 S-2 ENGINE DOES NOT START....................................................................................................311 (1) ENGINE DOES NOT TURN.................................................................................................311 (2) ENGINE TURNS NO BUT EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED).............................................312 (3) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)...........................................313 S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR).....................................................................314 S-4 ENGINE DOES S-4 ENGINE STOPS DURING OPERATIONS...........................................................................315 S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)................................................................................316 S-6 ENGINE LACKS OUTPUT (OR LACKS POWER).....................................................................................317 S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)...........................................................................318 S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST GAS IS BLUE)....................................................................319 S-9 OIL BECOMES CONTAMINATED QUICKLY.........................................................................................320 S-10 FUEL CONSUMPTION IS EXCESSIVE ..........................................................................................321 S-11 OIL IS IN COOLING WATER, OR WATER, .....................................................................................322 S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)..............................................................323 S-13 OIL LEVEL RISES (WATER, FUEL IN OIL)....................................................................................324 S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)........................................................................325 S-15 ABNORMAL NOISE IS MADE..................................................................................................326 S-16 VIBRATION IS EXCESSIVE..................................................................................................327 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)..........................................................................328 TROUBLESHOOTING FLOW CHARTS FOR EACH FAILURE MODE................................................................................329 ALL WORK EQUIPMENT, TRAVEL, SWING............................................................................................329 H-1 SPEEDS OF ALL WORK EQUIPMENTS, SWING AND TRAVEL ARE SLOW OR LACK OF POWER............................................329 H-2 EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS.....................................................................331 H-3 ALL WORK EQUIPMENTS, TRAVEL AND SWING DO NOT MOVE....................................................................332 H-4 ABNORMAL SOUND IS GENERATED (AROUND THE PUMP)........................................................................332 H-5 FINE CONTROL ABILITY IS POOR, OR RESPONSE IS POOR....................................................................333 WORK EQUIPMENT...............................................................................................................333 H-6 BOOM MOVEMENT IS SLOW OR LACKS OF POWER..............................................................................333 H-7 ARM MOVEMENT IS SLOW OR LACKS OF POWER...............................................................................335 H-8 BUCKET MOVEMENT IS SLOW OR LACKS OF POWER............................................................................337 H-9 WORK EQUIPMENT (BOOM, ARM, BUCKET) DOES NOT MOVE (BUT TRAVEL AND SWING ARE NORMAL)...................................338 H-10 EXCESSIVE HYDRAULIC DRIFT (BOOM, ARM, BUCKET).......................................................................338 H-11 EXCESSIVE TIME LAG (ENGINE AT LOW SPEED)............................................................................339 COMPOUND OPERATIONS..........................................................................................................339 H-12 IN COMPOUND OPERATIONS, WORK EQUIPMENTS, MOVEMENT OF ONE WITH LARGER LOAD IS SLOW...................................339 H-13 IN SING+ BOOM RAISE OPERATION, BOOM RAISE MOVEMENT IS SLOW..........................................................340 H-14 IN TRAVEL + SWING OPERATION, TRAVEL SPEED DROP IS EXCESSIVE.........................................................340 H-15 IN TRAVEL + WORK EQUIPMENT (BOOM RAISE) OPERATION, TRAVEL SPEED DROP IS EXCESSIVE...................................340 TRAVEL SYSTEM................................................................................................................341 H-16 VEHICLE CURCES UNINTENTIONALLY DURING TRAVEL .......................................................................341 H-17 TRAVEL DEVIATION IS LARGER AT STARTING..............................................................................343 H-18 TRAVEL SPEED IS LOW, OR LACKS OF POWER..............................................................................343 H-19 STEERING OPERATION IS DIFFICULT.....................................................................................344 H-20 TRAVEL SPEED CANNOT BE SWITCHED.....................................................................................345 H-21 TRAVEL DOES NOT WORK (ONE SIDE ONLY) ...............................................................................345 SWING SYSTEM.................................................................................................................346 H-22 DOES NOT SWING (BOTH SIDES, ONE SIDE ONLY)..........................................................................346 H-23 SWING ACCELERATION IS POOR..........................................................................................347 H-24 EXCESSIVE OVERRUN WHEN STOPPING SWING (BOTH SIDES, ONE SIDE ONLY)...................................................349 H-25 EXCESSIVE SHOCK WHEN STOPPING SWING (ONE DIRECTION ONLY)............................................................350 H-26 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING (ONE DIRECTION ONLY)...................................................350 H-27 EXCESSIVE HYDRAULIC DRIFT OF SWING (WHEN THE SWING BRAKE IS RELEASED OR ACTIVATED)..................................351 H-28 SWING SPEED IS FASTER THAN THE SPECIFIED SPEED......................................................................352 H-29 BLADE SPEED IS SLOW, OR LACK OF POWER...............................................................................352 H-30 BLADE DOES NOT MOVE.................................................................................................353 H-31 EXCESSIVE HYDRAULIC DRIFT OF THE BLADE..............................................................................353 TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE)...................................................................................354 ELECTRIC CIRCUIT DIAGRAM OF THE MACHINE MONITOR SYSTEM...........................................................................355 M-1 NO INDICATOR LAMP LIGHTS UP WHENTHE STARTING SWITCH IS TURNED ON (3-SECOND SELF-CHECK IS NOT CARRIED OUT EITHER).........357 M-2 ALL THE LAMPS REMAIN LIGHTING-UP AFTER 3-SECOND SELF-CHECK COMPLETED AFTER THE STARTING SWITCH TURNED ON.................357 M-3 SOME LAMPS DO NOT LIGHT UP DURING SELF-CHECK (ALL LAMPS LIGHTS UP FOR 3 SECONDS) UPON STARTING SWITCH ON.................358 A) ALL GAUGE LAMPS DO NOT LIGHT UP (CAUTION LAMP DOES LIGHT UP)..........................................................358 B) SWING LOCK, AUTO-GREASING FAILURE OR PREHEAT DOES NOT LIGHT UP (ALL GAUGE LAMPS LIGHT UP).............................358 C) CHARGE CAUTION LAMP DOES NOT LIGHT UP.................................................................................358 D) ENGINE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP....................................................................358 M-4 WHEN TURNING ON THE POWER................................................................................................359 M-5 WHEN TURNING ON THE POWER (BEFORE ENGINE STARTING), CHARGE CAUTION LAMP DOES NOT LIGHT UP................................359 M-6 AT PREHEATNG, PREHEATING INDICATOR DOES NOT LIGHTS UP....................................................................360 M-7 THOUGH THE SWITCH IS OPERATED, SWING LOCK DOES NOT LIGHT UP .............................................................360 M-8 WHILE ENGINE RUNNING, ENGINE OIL PRESSURE CAUTION LAMP LIGHTS UP (ENGINE OIL PRESSURE IS NORMAL).........................361 M-9 CHARGE CAUTION LAMP LIGHTS UP WHILE ENGINE RUNNING.......................................................................361 M-10 ABNORMALITY IN ENGINE WATER TEMPERATURE GAUGE...........................................................................362 A) INDICATOR REMAINS IN THE LOWER LEVEL (WHITE RANGE) AND DOES NOT RISE AFTER ENGINE STARTED.............................362 B) LEVEL RISES IMMEDIATELY AFTER STARTING THE ENGINE. INDICATOR GOES IN THE RED RANGE THOUGH OVERHEAT DOES NOT OCCUR.....362 C) ENGINE WATER TEMPERATURE GAUGE LAMP GOES OFF..........................................................................362 M-11 ABNORMALITY IN FUEL GAUGE...............................................................................................363 A) ALL SEGMENTS .........................................................................................................363 B) FUEL GAUGE INDICATES FULL THOUGH THE LEVEL IS LOW.....................................................................363 C) FUEL GAUGE DOES NOT INDICATE FULL THOUGH THE TAKIS FULL...............................................................363 M-12 MALFUNCTION OF THE BUZZER...............................................................................................365 A) BUSER DOES NOT SOUND..................................................................................................365 B) BUZZER DOES NOT STOP SOUNDING.........................................................................................365 M-13 SERVICE METER DOES NOT WORK WHILE THE ENGINE IS RUNNING.................................................................366 A) WHEN THE CAHARGE CAUTION LAMP DOES NOT LIGHT UP.......................................................................366 B) WHEN THE CHARGE CAUTION LAMP LIGHTS UP (AUTO-GREASING CONTROLLER IS NORMAL)...........................................366 M-14 AUTO-GREASING ABNORMALITY ALARM LIGHTS UP (AUTO-GREASING CONTROLLER IS NORMAL)..........................................366 M-15 LLUMINATION DOES NOT LIGHT UP...........................................................................................367 A) ILLUMINATION AT GAUGE SECTION DOES NOT LIGHT UP.......................................................................367 B) ILLUMINATION AT THE SERVICE METER SECTON DOES NOT LIGHT UP (SERVICE METER ITSELF DO WORK NORMALLY.....................367 M-16 HEATER DOES NOT WORK....................................................................................................368 A) BOTH HI AND lO DO NOT WORK............................................................................................368 B) LO ONLY DES NOT WORK..................................................................................................368 C) HI ONLY DOES NOT WORK.................................................................................................368 TROUBLESHOOTING OF AUTO-GREASING SYSTEM (D MODE).....................................................................................369 D-1 [ALTERNATE BLINKING OF [E] AND [A]] ABNORMALITY IN PUMP PRESSURIZATION IS DISPLAYED..........................................370 D-2 [ALTERNATE BLINKING OF [E] AND [B]] ABNORMALITY IN DEPRESSURIZATION IS DISPLAYED [ALTERNATE BLINKING OF [E] AND [C] ABNOR....372 D-3 [ALTERNATE BLINKING OF [E] AND [0] ABNORMALITY IN CONTROLLER IS DISPLAYED....................................................372 D-4 ABNORMAL SOUND IS GENERATED FROM THE WORK EQUIPMENT PIN, THOUGH NO ABNORMALITY IS DISPLAYED ON THE MONITOR PANEL AND GREA....373 D-5 ALLIEDS ON THE GREASING CONTROLLER GOES OFF..................................................................................375 D-6 PUMP DOES NOT RUN EVEN THOUGH THE START-UP SWITCH IS PRESSED.................................................................375 30 DISASSEMBLY AND ASSEMBLY..................................................................................................................377 METHOD OF USING MANUAL...................................................................................................................379 PRECAUTIONS WHEN CARRYING OUT OPERATION..................................................................................................380 SPECIAL TOOL LIST........................................................................................................................382 SKETCHES OF SPECIAL TOOLS................................................................................................................386 * STARTING MOTOR.........................................................................................................................394 REMOVAL AND INSTALLATION.............................................................................................................394 * ALTERNATOR.............................................................................................................................395 REMOVAL AND INSTALLATION.............................................................................................................395 * FUEL INJECTION PUMP....................................................................................................................396 REMOVAL..............................................................................................................................396 INSTALLATION.........................................................................................................................398 * WATER PUMP.............................................................................................................................400 REMOVAL AND INSTALLATION.............................................................................................................400 * NOZZLE HOLDER..........................................................................................................................401 REMOVAL AND INSTALLATION.............................................................................................................401 * THERMOSTAT.............................................................................................................................402 REMOVAL AND INSTALLATION.............................................................................................................402 * ENGINE OIL COOLER CORE.................................................................................................................403 REMOVAL..............................................................................................................................403 INSTALLATION.........................................................................................................................404 CYLINDER HEAD............................................................................................................................405 REMOVAL..............................................................................................................................405 INSTALLATION.........................................................................................................................410 ENGINE, MAIN PUMP........................................................................................................................413 REMOVAL..............................................................................................................................413 INSTALLATION.........................................................................................................................419 RADIATOR, HYDRAULIC COOLER...............................................................................................................424 REMOVAL..............................................................................................................................424 INSTALLATION.........................................................................................................................426 FUEL TANK................................................................................................................................429 REMOVAL AND INSTALLATION.............................................................................................................429 CENTER SWIVEL JOINT......................................................................................................................430 REMOVAL..............................................................................................................................430 INSTALLATION.........................................................................................................................431 DISASSEMBLY AND ASSEMBLY.............................................................................................................432 SPROCKET.................................................................................................................................433 REMOVAL AND INSTALLATION.............................................................................................................433 TRAVEL MOTOR.............................................................................................................................434 REMOVAL AND INSTALLATION.............................................................................................................434 DISASSEMBLY, ASSEMBLY OF TRAVEL MOTOR GM09VL2............................................................................................435 SAFETY...............................................................................................................................436 SECTIONAL DRAWING, SINGLE VIEW DRAWING, AND PARTS LIST ..............................................................................437 SECTIONAL DRAWING OF ASSEMBLY....................................................................................................437 SINGLE VIEW DISASSEMBLY DRAWING OF REDUCTION GEAR ASSEMBLY.......................................................................439 SINGLE VIEW DISASSEMBLY DRAWING OF HYDRAULIC MOTOR ASSEMBLY......................................................................440 PARTS LIST.......................................................................................................................441 TOOLS................................................................................................................................442 TIGHENING TORQUE.....................................................................................................................448 WEIGHT TABLE.........................................................................................................................448 DISASSEMBLY..........................................................................................................................449 MAINTENANCE STANDARD TABLE...........................................................................................................469 ASSEMBLY.............................................................................................................................471 DIMENSIONS TABLE OF CLEARENCE ADJUSTMENT PARTS.......................................................................................493 PERFORMANCE CONFIRMATION TEST........................................................................................................494 SWING MOTOR, SWING MACHINERY.............................................................................................................495 REMOVAL AND INSTALLATION.............................................................................................................495 SWING MOTOR..............................................................................................................................496 DISASSEMBLY..........................................................................................................................496 ASSEMBLY.............................................................................................................................500 SWING MACHINERY..........................................................................................................................506 DISASSEMBLY..........................................................................................................................506 ASSEMBLY.............................................................................................................................509 REVOLVING FRAME..........................................................................................................................512 REMOVAL..............................................................................................................................512 INSTALLATION.........................................................................................................................513 SWING CIRCLE.............................................................................................................................516 REMOVAL AND INSTALLATION.............................................................................................................516 IDLER, RECOIL SPRING.....................................................................................................................517 REMOVAL AND INSTALLATION.............................................................................................................517 RECOIL SPRING............................................................................................................................518 DISASSEMBLY..........................................................................................................................518 ASSEMBLY.............................................................................................................................519 IDLER....................................................................................................................................520 DISASSEMLY...........................................................................................................................520 ASSEMBLY.............................................................................................................................521 TRACK ROLLER.............................................................................................................................523 REMOVAL AND INSTALLATION.............................................................................................................523 DISASSEMBLY..........................................................................................................................524 ASSEMBLY.............................................................................................................................526 CARRIER ROLLER...........................................................................................................................528 REMOVAL AND INSTALLATION.............................................................................................................528 TRACK SHOE...............................................................................................................................529 REMOVAL AND INSTALLATION.............................................................................................................529 HYDRAULIC TANK ..........................................................................................................................530 REMOVAL..............................................................................................................................530 INSTALLATION.........................................................................................................................531 MAIN PUMP................................................................................................................................532 REMOVAL..............................................................................................................................532 INSTALLATION.........................................................................................................................533 MAIN PUMP INPUT SHAFT OIL SEAL...........................................................................................................536 REMOVAL AND INSTALLATION.............................................................................................................536 CONTROL VALVE............................................................................................................................537 REMOVAL..............................................................................................................................537 INSTALLATION.........................................................................................................................538 DISASSEMBLY..........................................................................................................................539 ASSEMBLY.............................................................................................................................543 MAIN RELIEF VALVE........................................................................................................................547 DISASSEMBLY AND ASSEMBLY.............................................................................................................547 SOLENOID VALVE...........................................................................................................................548 REMOVAL AND INSTALLATION.............................................................................................................548 WORK EQUIPMENT LEFT SIDE PPC VALVE (FOR ARM, SWING CONTROL) REMOVAL AND INSTALLATION.....................................................549 WORK EQUIPMENT RIGHT SIDE PPC VALVE (FOR BOOM, BUCKET CONTROL) REMOVAL AND INSTALLATION..................................................550 WORK EQUIPMENT PPC VALVE (FOR BOOM, ARM, BUCKET, SWING CONTROL PPC VALUE)................................................................551 DISASSEMBLY..........................................................................................................................551 ASSEMBLY.............................................................................................................................552 TRAVEL PPC VALVE.........................................................................................................................553 REMOVAL AND INSTALLATION.............................................................................................................553 DISASSEMBLY AND ASSEMBLY.............................................................................................................554 BOOM CYCLINDER...........................................................................................................................556 REMOVAL..............................................................................................................................556 INSTALLATION.........................................................................................................................557 ARM CYLINDER.............................................................................................................................558 REMOVAL..............................................................................................................................558 INSTALLATION.........................................................................................................................559 BUCKET CYLINDER..........................................................................................................................560 REMOVAL..............................................................................................................................560 INSTALLATION.........................................................................................................................561 BLADE CYCLINDER..........................................................................................................................562 REMOVAL..............................................................................................................................562 INSTALLATION.........................................................................................................................563 HYDRAULIC CYCLINDER......................................................................................................................564 DISASSEMBLY..........................................................................................................................564 ASSEMBLY.............................................................................................................................567 WORK EQUIPMENT...........................................................................................................................570 REMOVAL..............................................................................................................................570 INSTALLATION.........................................................................................................................571 BUCKET...................................................................................................................................572 REMOVAL..............................................................................................................................572 INSTALLATION.........................................................................................................................573 ARM......................................................................................................................................574 REMOVAL..............................................................................................................................574 INSTALLATION.........................................................................................................................575 BUCKET/ ARM..............................................................................................................................576 REMOVAL..............................................................................................................................576 INSTALLATION.........................................................................................................................577 BOOM.....................................................................................................................................578 REMOVAL..............................................................................................................................578 INSTALLATION.........................................................................................................................579 BLADE....................................................................................................................................580 REMOVAL AND INSTALLATION.............................................................................................................580 OPERATOR'S CAB...........................................................................................................................581 REMOVAL AND INSTALLATION.............................................................................................................581 COUNTERWEIGHT............................................................................................................................582 REMOVAL AND INSTALLATION.............................................................................................................582 MONITOR..................................................................................................................................584 REMOVAL AND INSTALLATION.............................................................................................................584 SWING CONTROLLER.........................................................................................................................584 REMOVAL AND INSTALLATION.............................................................................................................584 AUTO-GREASING CONTROLLER.................................................................................................................585 REMOVAL AND INSTALLATION.............................................................................................................585 AUTO-GREASING PUMP.......................................................................................................................585 REMOVAL AND INSTALLATION.............................................................................................................585 40 MAINTENANCE STANDARD......................................................................................................................586 SWING MACHINERY..........................................................................................................................587 SWING CIRCLE.............................................................................................................................589 TRACK FRAME..............................................................................................................................590 IDLER....................................................................................................................................591 TRACK ROLLER.............................................................................................................................592 CARRIER ROLLER...........................................................................................................................594 TRACK SHOE...............................................................................................................................595 HYDRAULIC PUMP...........................................................................................................................598 CONTROL VALVE............................................................................................................................599 SELF-PRESSURE REDUCING VALVE.............................................................................................................611 SWING MOTOR..............................................................................................................................613 CENTER SWIVEL JOINT......................................................................................................................615 WORK EQUIPMENT, SWING PPC VALVE..........................................................................................................619 TRAVEL PPC VALVE.........................................................................................................................620 SERVICE PPC VALVE........................................................................................................................621 WORK EQUIPMENT...........................................................................................................................622 HYDRAULIC CYCLINDER......................................................................................................................627 50 OTHER SPECIFICATION (PC60-7 (FOR NORWAY)..................................................................................................628 PC60-7 (FOR NORWAY)......................................................................................................................629 CONTENTS.................................................................................................................................630 GENERAL..............................................................................................................................631 DIMENSION........................................................................................................................631 SPECIFICATIONS...................................................................................................................633 WEIGHT TABLE.....................................................................................................................635 TABLE OF OIL AND COOLANT CAPACITY................................................................................................637 STRUCTURE AND FUNCTION...............................................................................................................639 WORK EQUIPMENT PIN AUTOMATIC GREASING SYSTEM (OPT)...............................................................................639 ELECTRICAL ALLOCATION DIAGRAM....................................................................................................652 ELECTRIC CIRCUIT DIAGRAM.........................................................................................................656 MACHINE MONITOR SYSTEM...........................................................................................................658 TESTING AND ADJUSTING................................................................................................................661 CONNECTOR TYPES AND MOUNTING LOCATIONS...........................................................................................661 TROUBLESHOOTING......................................................................................................................666 TROUBLESHOOTING OF MACHINE MONITOR LOCATIONS.....................................................................................666 ELECTRIC CIRCUIT DIAGRAM OF THE MACHINE MONITOR SYSTEM.......................................................................667 M-1 NO INDICATOR LAMP LIGHTS UP WHEN THE STARTING SWITCH IS TURNED ON (3-SECOND SELF-CHECK IS NOT CARRIED OUT EITHER)....668 M-2 ALL THE LAMPS REMAIN LIGHTING-UP AFTER 3-SECOND SELF-CHECK COMPLETED AFTER THE STARTING SWITCH TURNED ON.............668 M-3 SOME LAMPS DO NOT LIGHT UP DURING SELF-CHECK (ALL LAMPS LIGHTS UP FOR 3 SECONDS) UPON STARTING SWITCH ON.............669 A) ALL GAUGE LAMPS DO NOT LIGHT UP (CAUTION LAMP DOES LIGHT UP)......................................................669 B) SWING LOCK, AUTO-GREASING FAILURE OR PREHEAT DOES NOT LIGHT UP (ALL GAUGE LAMPS LIGHHT UP)........................669 C) CHARGE CAUTION LAMP DOES NOT LIGHT UP)............................................................................669 D) ENGINE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP................................................................669 M-4 WHEN TURNING ON THE POWER (BEFORE ENGINE STARTING), ENGINCHARGE CAUTION LAMP DOES NOT LIGHT UP.......................670 M-5 WHEN TURNING ON THE POWER (BEFORE ENGINE STARTING), ENGINE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP...............670 M-6 AT PREHEATING, PREHEATING INDICATOR DOES NOT LIGHT UP................................................................671 M-7 THOUGH THE SWITCH IS OPERATED, SWING LOCK DOES NOT LIGHT UP..........................................................671 M-8 WHILE ENGINE RUNNING, ENGINE OIL PRESSURE CAUTION LAMP LIGHTS UP(ENGINE OIL PRESSURE IS NORMAL)......................672 M-9 CHARGE CAUTION LAMP LIGHTS UP WHILE ENGINE RUNNING...................................................................672 M-10 ABNORMALITY IN ENGINE WATER TEMPERATURE GAUGE.......................................................................673 A) INDICATOR REMAINS IN THE LOWEST LEVEL (WHITE RANGE) AND DOES NOT RISE AFTER ENGINE STARTED........................673 B) LEVEL RISES IMMEDIATELY AFTER STARTING THE ENGINE. INDICATOR GOES IN THE RED RANGE THOUGH OVER HEAT..............673 C) ENGINE WATER TEMPERATURE GAUGE GOES OFF...........................................................................673 M-11 ABNORMALITY IN FUEL GAUGE...........................................................................................674 A) ALL A) ALL SEGMENTS OF THE FUEL GAUGE GO OFF......................................................................674 B) FUEL GAUGE INDICATES FULL THOUGH THE LEVEL IS LOW.................................................................674 C) FUEL GAUGE DOES NOT INDICATE FULL THOUGH THE TANK IS FULL.........................................................674 M-12 MALFUNCTION OF THE BUZZER...........................................................................................676 A) BUZZER DOES NOT SOUND.............................................................................................676 B) BUZZER DOES NOT STOP SOUNDING.....................................................................................676 M-13 SERVICE METER DOES NOT WORK WHILE THE ENGINE IS RUNNING.............................................................677 A) WHEN THE CHARGE CAUTION LAMP DOES NOT LIGHT UP....................................................................677 B) WHEN THE CHARGE CAUTION LAMP LIGHTS UP, REFER TO THE ITEM M-9.....................................................677 M-14 AUTO-GREASING ABNORMALITY ALARM LIGHTS UP (AUTO-GREASING CONTROLLER IS NORMAL.......................................677 M-15 ILLUMINATION DOES NOT LIGHT UP......................................................................................678 A) ILLUMINATION DOES NOT LIGHT UP....................................................................................678 B) ILLUMINATION AT THE SERVICE METER SECTION DOES NOT LIGHT UP (SERVICE METER ITSELF DO WORK NORMALLY)...............678 DISASSEMBLY AND ASSEMBLY.............................................................................................................679 AUTO-GREASING CONTROLLER (OPT)...................................................................................................679 AUTO-GREASING PUMP (OPT).........................................................................................................679 90 OTHERS....................................................................................................................................680 HYDRAULIC PIPING DRAWING.................................................................................................................681 HYDRAULIC CIRCUIT DIAGRAM................................................................................................................682 OVERALL SYSTEM DIAGRAM (1/5).............................................................................................................685 OVERALL SYSTEM DIAGRAM (2/5).............................................................................................................686 OVERALL SYSTEM DIAGRAM (3/5).............................................................................................................687 OVERALL SYSTEM DIAGRAM (4/5).............................................................................................................688 OVERALL SYSTEM DIAGRAM (5/5).............................................................................................................689 ELECTRICAL ALLOCATION DIAGRAM............................................................................................................690 SERIAL NO. : 52374 - 57999...........................................................................................................691 SERIAL NO.: 58001 AND UP.............................................................................................................692 ELECTRIC CIRCUIT DIAGRAM.................................................................................................................693 9PC60-7 SERIAL NO. 55720 AND UP FOR NORWAY)..........................................................................................693 CONNECTOR TYPES AND MOUNTING LOCATIONS...................................................................................................694
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