Komatsu PSC 60-7 HYDRAULIC EXCAVATOR Shop Manual SEBM004101 – PDF DOWNLOAD

Description

Komatsu PSC 60-7 HYDRAULIC EXCAVATOR Shop Manual SEBM004101 – PDF DOWNLOAD

FILE DETAILS:

Komatsu PSC 60-7 HYDRAULIC EXCAVATOR Shop Manual SEBM004101 – PDF DOWNLOAD

Language : English
Pages :502
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu PSC 60-7 HYDRAULIC EXCAVATOR Shop Manual SEBM004101 – PDF DOWNLOAD

SERIAL NUMBER 60-7 – 45001 thru 52373

FOREWORD
GENERAL

• This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgem ents. 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.

TABLE OF CONTENTS:

Komatsu PSC 60-7 HYDRAULIC EXCAVATOR Shop Manual SEBM004101 – PDF DOWNLOAD

SERIAL NUMBER 60-7 – 45001 thru 52373

MAIN MENU 0
COVER 1
CONTENTS 2
SAFETY 6
FOREWORD 8
HOW TO READ THE SHOP MANUAL 9
HOISTING INSTRUCTIONS 10
COATING MATERIALS 11
STANDARD TIGHTENING TORQUE 12
ELECTRIC WIRE CODE 14
COVERSION TABLE 15
01 GENERAL 21
GENERAL ASSEMBLY DRAWING 22
SPECIFICATIONS 23
WEIGHT TABLE 25
LIST OF LUBRICANT AND WATER 27
10 STRUCTURE AND FUNCTION 29
RADIATOR AND OIL COOLER 30
PTO (COUPLING) 31
ENGINE CONTROL 32
POWER TRAIN 33
SWING CIRCLE 34
SWING MACHINERY 35
TRACK FRAME 36
IDLER 37
IDER CUSHION 37
CARRIER ROLLER 38
TRACK ROLLER 38
TRACK SHOE 39
HYDRAULIC PIPING DRAWING 41
HYDRAULIC CIRCUIT DIAGRAM 42
HYDRAULIC TANK 44
HYDRAULIC PUMP 45
BLADE PUMP 71
CONTROL VALVE 72
CLSS 84
BLADE CONTROL VAVE114
SWING MOTOR115
CENTER SWIVEL JOINT119
TRAVEL MOTOR121
VALVE CONTROL127
WORK EQUIPMENT – SWING PPC VALVE128
TRAVEL PPC VALVE132
SERVICE PPC VALVE136
PPC SHUTTLE VALVE142
SOLENOID VALVE143
HYDRAULIC CYLINDER145
WORK EQUIPMENT147
WORK EQUIPMENT PIN AUTO-GREASING SYSTEM148
ELECTRICAL WIRING DIAGRAM161
ELECTRICAL CIRCUIT DIAGRAM163
ELECTRICAL CONTROL SYSTEM165
MACHINE MONITOR SYSTEM173
20 TESTING AND ADJUSTING178
TABLE OF JUDGEMENT STANDARD VALVE179
FOR ENGINE179
FOR CHASSIS181
FOR ELECTRICAL PARTS189
TESTING AND ADJUSTING190
LIST OF EQUlPMENTS FOR INSPECTION ADJUSTMENT AND TROUBLE-SHOOTING 191
MEASURING ENGINE SPEED192
MEASURING EXHAUST GAS COLOR193
ADJUSTING VALVE CLEARANCE194
MEASURING COMPRESSION PRESSURE195
MEASURING BLOWBY PRESSURE196
TESTING AND ADJUSTING FUEL INJECTION TIMING197
MEASURING ENGINE OIL PRESSURE201
TESTING AND ADJUSTING ALTERNATOR FAN BELT TENSION202
ADJUSTING ENGINE OIL SOLENOID203
ADJUSTING FUEL CONTROL LEVER204
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING AND TRAVEL CIRCUITS 205
ADJUSTING PC VALVE206
MEASURING LS DIFFERENTIAL PRESSURE AND ADJUSTING LS VALVE207
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN THE BLADE CIRCUIT209
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN THE CONTROL PUMP CIRCUIT210
TESTING OUTLET PRESSURE OF SOLENOID VALVE212
MEASURING PPC VALVE OUTPUT PRESSURE AND TESTING PPC SHUTTLE VALVE 213
ADJUSTING WORK EQUIPMENT AND SWING PPC VALVE214
TESTING TRAVEL DEVIATION215
MEASURING OIL LEAKAGE216
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT218
CHECKING OF CLEARANCE OF SWING CIRCLE BEARING219
CHECKING AND ADJUSTING TRACK SHOE TENSION220
BLEEDING AIR221
AUTOMATIC GREASING CONTROLLER223
TROUBLESHOOTING234
POINTS TO REMEMBER WHEN TROUBLESHOOTING235
SEQUENCE OF EVENTS IN TROUBLESHOOTING236
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE237
CHECKS BEFORE TROUBLESHOOTING245
CONNECTOR TYPES AND MOUNTING LOCATIONS246
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS249
METHOD OF USING JUDGEMENT TABLE259
METHOD OF USING TROUBLESHOOTING CHARTS260
FAILURE MODES AND JUDGEMENT TABLE262
TROUBLESHOOTING OF ENGINE THROTTLE CONTROLLER SYSTEM (E MODE) AND TROUBLESHOOTING OF ENGINE (S MODE)263
E-1 WORK EQUIPMENT DOES NOT MOVE EVEN WHEN THE PPC HYDRAULIC PRESSURE LOCK LEVER IS SET TO THE DRIVE SIDE264
E-2 WORK EQUIPMENT DOES NOT MOVE EVEN IF THE PPC HYDRAULIC PRESSURE LOCK LEVER IS AT THE LOCK POSITION265
E-3 DOES NOT SWING266
E-4 SWING BRAKE DOES NOT WORK269
E-5 TRAVEL SPEED CANNOT BE SWITCHED271
A) CANNOT BE SWITCHED TO HI271
B) CANNOT BE SWITHED TO LO271
E-6 POWER MODE CANNOT BE CHANGED272
A) WORK EQUIPMENT SPEED IS SLOW WHEN ENGINE SPPED IS MIDDLE AND HIGHER272
B) EXCESSIVE ENGINE SPEED DROP AT ENGINE SPEED MIDDLE AND LOWER272
E-7 ENGINE DOES NOT START273
A) STARTER DOES NOT WORK273
B) ENGINE STOP SOLENOID DOES NOT WORK275
E-8 ENGINE DOES NOT STOP276
E-9 WIPER DOES NOT WORK277
TROUBLESHOOTING OF ENGINE (S MODE)278
METHOD OF USING TROUBLESHOOTING CHART279
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)283
S-2 ENGINE DOES NOT START284
1) ENGINE DOES NOT START284
2) ENGINE RUNS BUT EXHUAST GAS DOES NOT COME OUT (FUEL IS NOT BEING INJECTED)285
3) EXHAUST GAS COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)286
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)287
S-4 ENGINE STOPS DURING OPERATION288
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)289
S-6 ENGINE LACKS OUTPUT (NO POWER)290
S-7 EXHAUST GAS IS BLACK (INCOMPLETE COMBUSTION)291
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST GAS IS BLUE)292
S-9 OIL BECOMES CONTAMINATED QUICKLY293
S-10 FUEL CONSUMPTION IS EXCESSIVE294
S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN295
S-12 OIL PRESSURE WARNING LAMP LIGHTS UP (DROP IN OIL PRESSURE)296
S-13 OIL LEVEL RISES 297
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)298
S-15 ABNORMAL NOISE IS MADE299
S-16 VIBRATION IS EXCESSIVE300
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)301
TROUBLESHOOTING FLOW CHARTS FOR EACH FAILURE MODE301
ALL WORK EQUIPMENT, TRAVEL, SWING302
H-1 SPEEDS OF ALL WORK EQUIPMENTS, SWING AND TRAVEL ARE SLOW OR LACK POWER302
H-2 EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS304
H-3 ALL WORK EQUIPMENT, TRAVEL AND SWING DO NOT MOVE305
H-4 ABNORMAL SOUND IS GENERATED (AROUD THE PUMP)305
H-5 FINE CONTROL ABILITY IS POOR, OR RESPONSE306
WORK EQUIPMENT306
H-6 BOOM MOVEMENT IS SLOW OR LACKS OF POWER306
H-7 ARM MOVEMENT IS SLOW OR LACKS OF POWER308
H-8 BUCKET MOVEMENT IS SLOW OR LACKS OF POWER310
H-9 WORK EQUIPMENT (BOOM, ARM, BUCKET) DOES NOT MOVE (BUT TRAVEL AND SWING ARE NORMAL)311
H-10 EXCESSIVE HYDRAULIC DRIFT (BOOM, ARM, BUCKET)311
H-11 EXCESSIVE TIME LAG (ENGINE AT LOW SPEED)312
COMPOUND OPERATIONS312
H-12 IN COMPOUND OPERATIONS, WORK EQUIPMENTS, MOVEMENT OF ONE WITH LARGER LOAD IS SLOW 312
H-13 iN SWING + BOOM RAISE OPERATION, BOOM RAISE MOVEMENT IS SLOW313
H-14 IN TRAVEL + SWING OPERATION, TRAVEL SPEED DROP IS EXCESSIVE313
H-15 IN TRAVEL + WORK EQUIPMENT (BOOM RAISE) OPERATION, TRAVEL SPEED DROP IS EXCESSIVE313
TRAVEL SYSTEM314
H-16 VEHICLE CURVES UNINTENTIONALLY DURING TRAVEL314
H-17 TRAVEL DEVIATION IS LARGER AT STARTING316
H-18 TRAVEL SPEED IS LOW, OR LACKS OF POWER316
H-19 STEERING OPERATION IS DIFFICULT317
H-20 TRAVEL SPEED CANNOT BE SWITCHED318
H-21 TRAVEL DOES NOT WORK (ONE SIDE ONLY)318
SWING SYSTEM319
H-22 DOES NOT SWING (BOTH SIDES, ONE SIDE ONLY)319
H-23 SWING ACCELERATION IS POOR320
H-24 EXCESSIVE OVERRUN WHEN STOPPING SWING (BOTH SIDES, ONE SIDE ONLY)322
H-25 EXCESSIVE SHOCK WHEN STOPPING SWING (ONE DIRECTION ONLY) 323
H-26 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING (ONE DIRECTION ONLY)323
H-27 EXCESSIVE HYDRAULIC DRIFT OF SWING (WHEN THE SWING BRAKE IS RELEASED OR ACTIVATED)324
H-28 SWING SPEED IS FASTER THAN THE SPECIFIED SPEED325
H-29 BLADE SPEED IS SLOW, OR LACK OF POWER325
H-30 BLADE DOES NOT MOVE326
H-31 EXCESSIVE HYDRAULIC DRIFT OF THE BLADE326
TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE)327
ELECTRIC CIRCUIT DIAGRAM OF MACHINE MONITOR SYSTEM328
M-1 NO INDICATOR LAMP LIGHTS UP WHEN THE STARTING SWITCH IS TURNED ON (3-SECOND SELF-CHECK IS NOT CARRIED OUT EITHER)329
M-2 ALL THE LAMPS REMAIN LIGHTING-UP AFTER 3-SECOND SELF-CHECK COMPLETED AFTER THE STARTING SWITCH IS TURNED ON329
M-3 SOME LAMPS DO NOT LIGHT UP DURING SELF-CHECK (ALL LAMPS LIGHTS UP FOR 3 SECONDS) UPON STARTING SWITCH ON330
A) ALL GAUGE LAMPS DO NOT LIGHT UP (CAUTION LAMP DOES LIGHT UP)330
B) SWING LOCK, AUTO-GREASING FAILURE OR PREHEAT DOES NOT LIGHT UP (ALL GAUGE LAMPS LIGHT UP)330
C) CHARGE CAUTION LAMP DOES NOT LIGHT UP330
D) ENGINE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP330
M-4 WHEN TURNING ON THE POWER (BEFORE ENGINE STARTING), ENGINE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP331
M-5 WHEN TURNING ON THE POWER (BEFORE ENGINE STARTING), ENGINE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP331
M-6 AT PREHEATING, PREHEATING INDICATOR LAMP DOES NOT LIGHT UP332
M-7 THOUGH THE SWITCH IS OPERATED, SWING LOCK DOES NOT LIGHT UP332
M-8 WHILE ENGINE RUNNING, ENGINE OIL PRESSURE CAUTION LAMP LIGHTS UP (ENGINE OIL PRESSURE IS NORMAL)333
M-9 CHARGE CAUTION LAMP LIGHTS UP WHILE ENGINE RUNNING333
M-10 ABNORMALITY IN COOLANT TEMPERATURE GAUGE334
A) INDICATOR REMAINS IN THE LOWEST LEVEL (WHITE RANGE) AND DOES NOT RISE AFTER ENGINE STARTED334
B) LEVEL RISES IMMEDIATELY AFETR STARTING THE ENGINE INDICATOR GOES IN THE RED RANGE LAMP GOES OFF334
C) COOLANT TEMPERATUR GAUGE LAMP GOES OFF334
M-11 ABNORMALITY IN FUEL GAUGE335
A) ALL SEGMENTS OF THE FUEL GAUGE GO OFF335
B) FUEL GAUGE INDICATES FULL THOUGH THE LEVEL IS LOW335
C) FUEL GAUGE DOES NOT INDICATE FULL THOUGH THE TANK IS FULL335
M-12 MALFUNCTION OF BUZZER337
A) BUZZER DOES NOT SOUND337
B) BUZZER DOES NOT STOP SOUNDING337
M-13 SERVICE METER DOES NOT WORK WHILE THE ENGINE IS RUNNING338
A) WHEN THE CHARGE CAUTION LAMP DOES NOT LIGHT UP338
B) WHEN THE CHARGE CAUTION LAMP LIGHTS UP, REFER TO THE ITEM M-9338
M-14 AUTO-GREASING ABNORMALITY ALARM LIGHTS UP (AUTO-GREASING CONTROLLER IS NORMAL)338
M-15 ILLUINATION DOES NOT LIGHT UP339
A) ILLUMINATION AT GAUGE SECTION DOES NOT LIGHT UP339
B) ILLUMINATION AT THE SERVICE METER SECTION DOES NOT LIGHT UP (SERVE METER ITSELF DO WORK NORMALLY) (SERVICE METER ITSELF DO339
M-16 HEATER DOES NOT WORK340
A) BOTH HI AND LO DO NOT WORK340
B) LO ONLY DOES NOT WORK340
C) HI ONLY DOES NOT WORK340
TROUBLESHOOTING OF AUTO-GREASING SYSTEM (D MODE)341
D-1 [ALTERNATE BLINKING OF [E] AND [A]] ABNORMALITY IN PUMP PRESSURIZATION IS DISPLAYED342
D-2 [ALTERNATE BLINKING OF [E] AND [B]] ABNORMALITY IN PUMP DEPRESSURIZATION IS DISPLAYED344
[ALTERNATE BLINKING OF [E] AND [A]] ABNORMALITY IN PUMP PRESSURE DETECTION IS DISPLAYED344
D-3 [ALTERNATE BLINKING OF [E] AND [D]] ABNORMALITY IN CONTROLLER SETTING IS DISPLAYED344
D-4 ABNORMAL SOUND IS GENERATED FROM THE WORK EQUIPMENT PIN, THOUGH NO ABNORMALITY IS DISPLAYED ON THE MONITOR PANEL AND GREA345
D-5 ALL LEDS ON THE GREASING CONTROLLER GOES OFF347
D-6 PUMP DOES NOT RUN EVEN THOUGH THE START-UP SWITCH IS PRESSED347
30 DISASSEMBLY AND ASSEMBLY349
METHOD OF USING MANUAL351
PRECAUTIONS WHEN CARRYING OUT OPERATION353
SPECIAL TOOL LIST355
SPECIAL TOOL 357
STARTING MOTOR360
REMOVAL AND INSTALLATION360
ALTERNATOR361
REMOVAL AND INSTALLATION361
FUEL INJECTION PUMP362
REMOVAL362
INSTALLATION363
WATER PUMP364
REMOVAL AND INSTALLATION364
NOZZLER HOLDER365
REMOVAL AND INSTALLATION365
THERMOSTAT366
REMOVAL AND INSTALLATION366
ENGINE FRONT SEAL367
REMOVAL AND INSTALLATION367
ENGINE REAR SEAL368
REMOVAL AND INSTALLATION368
CYLINDER HEAD369
REMOVAL369
INSTALLATION371
ENGINE – MAIN PUMP373
REMOVAL373
INSTALLATION376
PTO ASSEMBLY377
REMOVAL AND INSTALLATION377
DISASSEMBLY AND ASSEMBLY378
HYDRAULIC OIL COOLER379
REMOVAL AND INSTALLATION379
RADIATOR – HYDRAULIC OIL COOLER380
REMOVAL380
INSTALLATION381
FUEL TANK382
REMOVAL AND INSTALLATION382
CENTER SWIVEL JOINT383
REMOVAL383
INSTALLATION384
DISASSEMBLY AND ASSEMBLY385
SPROCKET386
REMOVAL AND INSTALLATION386
TRAVEL MOTOR387
REMOVAL AND INSTALLATION387
SWING MACHINERY – SWING MOTOR388
REMOVAL AND INSTALLATION388
SWING MACHINERY389
DISASSEMBLY389
ASSEMBLY392
REVOLVING FRAME395
REMOVAL395
INSTALLATION396
SWING CIRCLE397
REMOVAL AND INSTALLATION397
IDER – RECOIL SPRING398
REMOVAL AND INSTALLATION398
RECOIL SPRING399
DISASSEMBLY399
ASSEMBLY400
IDER401
DISASSEMBLY401
ASSEMBLY402
TRACK ROLLER404
REMOVAL AND INSTALLATION404
DISASSEMBLY405
ASSEMBLY406
CARRIER ROLLER407
REMOVAL AND INSTALLATION407
TRACK SHOE408
REMOVAL AND INSTALLATION408
HYDRAULIC TANK409
REMOVAL409
INSTALLATION410
CONTROL PUMP411
REMOVAL AND INSTALLATION411
MAIN PUMP412
REMOVAL412
INSTALLATION413
BLADE PUMP414
REMOVAL AND INSTALLATION414
MAIN PUMP INPUT SHAFT OIL SEAL415
REMOVAL AND INSTALLATION415
CONTROL VALVE416
REMOVAL416
INSTALLATION417
DISASSEMBLY418
ASSEMBLY422
MAIN RELIEF VALVE426
DISASSEMBLY AND ASSEMBLY426
BLADE CONTROL VALVE427
REMOVAL AND INSTALLATION427
DISASSEMBLY AND ASSEMBLY428
BLADE CONTROL VALVE MAIN RELIEF VALVE430
DISASSEMBLY AND ASSEMBLY430
SOLENOID VALVE431
REMOVAL AND INSTALLATION431
WORK EQUIPMENT LEFT SIDE PPC VALVE (FOR ARM, SWING CONTROL)432
REMOVAL AND INSTALLATION432
WORK EQUIPMENT RIGHT SIDE PPC VALVE (FOR BOOM,BUCKET CONTROL)433
REMOVAL AND INSTALLATION433
WORK EQUIPMENT PPC VALVE (FOR BOOM, ARM, BUCKET, SWING CONTROL PPC VALVE)434
DISASSEMBLY434
ASSEMBLY435
TRAVEL PPC VALVE436
REMOVAL INSTALLATION436
DISASSEMBLY AND ASSEMBLY437
BOOM CYLINDER439
REMOVAL439
INSTALLATION440
ARM CYLINDER441
REMOVAL441
INSTALLATION442
BUCKET CYLINDER443
REMOVAL443
INSTALLATION444
BLADE CYLINDER445
REMOVAL445
INSTALLATION446
HYDRAULIC CYLINDER447
DISASSEMBLY447
ASSEMBLY449
WORK EQUIPMENT452
REMOVAL452
INSTALLATION453
BUCKET 454
REMOVAL454
INSTALLATION455
ARM456
REMOVAL456
INSTALLATION457
BUCKET – ARM458
REMOVAL458
INSTALLATION459
BOOM460
REMOVAL460
INSTALLATION461
BLADE462
REMOVAL AND INSTALLATION462
OPERATOR’S CAB463
REMOVAL AND INSTALLATION463
COUNTERWEIGHT464
REMOVAL AND INSTALLATION464
MONITOR465
REMOVAL AND INSTALLATION465
SWING CONTROLLER465
REMOVAL AND INSTALLATION465
AUTO-GREASING CONTROLLER466
REMOVAL AND INSTALLATION466
AUTO-GREASING PUMP466
REMOVAL AND INSTALLATION466
40 MAINTENANCE STANDARD467
SWING MACHINERY468
SWING CIRCLE470
TRACK FRAME471
IDER472
TRACK ROLLER473
CARRIER ROLLER474
SPROCKET475
TRACK SHOE476
HYDRAULIC PUMP479
BLADE PUMP481
CONTROL VALVE482
BLADE CONTROL VALVE489
SWING MOTOR490
CENTER SWIVEL JOINT491
WORK EQUIPMENT – SWING PPC VALVE493
TRAVEL PPC VALVE494
SERVICE PPC VALVE495
WORK EQUIPMENT497
HYDRAULIC CYLINDER501

IMAGES PREVIEW OF THE MANUAL:

S.M 22/12/24