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KOMATSU PW60-3 SERVICE REPAIR MANUAL (SN:2001 & UP) – PDF DOWNLOAD
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- KOMATSU PW60-3 SERVICE REPAIR MANUAL
- SERIAL NUMBER:2001 & UP
- PUBLICATION NUMBER:SEBM020B0303
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Description
KOMATSU PW60-3 SERVICE REPAIR MANUAL (SN:2001 & UP)
KOMATSU PW60-3 SERVICE REPAIR MANUAL (SN:2001 & UP) – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU PW60-3 SERVICE REPAIR MANUAL (SN:2001 & UP)
- 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 make judgements. 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 understanding of the structure, but also serves as reference material for troubleshooting. - 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” to ‘Causes” are also included in this section. - DISASSEMBLY AND ASSEMBLY
This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations. - MAINTENANCE STANDARD
This section gives the judgement standards when Inspecting disassembled parts.
TABLE OF CONTENTS:
KOMATSU PW60-3 SERVICE REPAIR MANUAL (SN:2001 & UP)
COVER................................................................................... 1 CONTENTS................................................................................ 2 10 ENGINE............................................................................... 14 11 STRUCTURE AND FUNCTION........................................................... 14 ENGINE CONTROL.................................................................. 15 AUTO-DECELERATION SYSTEM........................................................ 16 12 TESTING AND ADJUSTING............................................................ 19 TESTING AND ADJUSTING DATA...................................................... 20 TESTING AND ADJUSTING TOOL LIST................................................. 20 ADJUSTING VALVE CLEARANCE....................................................... 21 ADJUSTING FUEL INJECTION TIMING................................................. 22 MEASURING COMPRESSION PRESSURE.................................................. 23 MEASURING EXHAUST GAS COLOR..................................................... 24 MEASURING BLOW-BY PRESSURE...................................................... 25 TESTING AND ADJUSTING FAN BELT TENSION.......................................... 25 13 DISASSEMBLY AND ASSEMBLY......................................................... 26 STARTING MOTOR.................................................................. 27 REMOVAL..................................................................... 27 INSTALLATION................................................................ 27 ALTERNATOR...................................................................... 27 REMOVAL..................................................................... 27 INSTALLATION................................................................ 27 ENGINE OIL COOLER............................................................... 27 REMOVAL..................................................................... 27 INSTALLATION................................................................ 27 FAN AND FAN PULLEY.............................................................. 27 REMOVAL..................................................................... 27 INSTALLATION................................................................ 27 FUEL INJECTION PUMP............................................................. 29 REMOVAL..................................................................... 29 INSTALLATION................................................................ 29 WATER PUMP...................................................................... 29 REMOVAL..................................................................... 29 INSTALLATION................................................................ 29 NOZZLE HOLDER................................................................... 31 REMOVAL..................................................................... 31 INSTALLATION................................................................ 31 CYLINDER HEAD................................................................... 33 REMOVAL..................................................................... 33 INSTALLATION................................................................ 35 RADIATOR AND HYDRAULIC OIL COOLER............................................... 37 REMOVAL..................................................................... 37 INSTALLATION................................................................ 37 ENGINE AND HYDRAULIC PUMP....................................................... 39 REMOVAL..................................................................... 39 INSTALLATION................................................................ 43 PTO............................................................................. 47 REMOVAL..................................................................... 47 INSTALLATION................................................................ 47 DISASSEMBLY................................................................. 47 ASSEMBLY.................................................................... 47 20 POWER TRAIN.......................................................................... 49 21 STRUCTURE AND FUNCTION........................................................... 49 POWER TRAIN..................................................................... 50 TRAVEL SYSTEM................................................................... 51 SCHEMATIC OF POWER TRAIN........................................................ 52 HYDRAULIC CIRCUIT DIAGRAM....................................................... 53 TRAVEL MOTOR.................................................................... 54 CENTER SWIVEL JOINT............................................................. 62 TRANSMISSION.................................................................... 63 SOLENOID VALVE FOR FORWARD-REVERSE SELECTION.................................... 65 FORWARD-REVERSE SELECTOR LEVER.................................................. 66 TRAVEL PPC VALVE................................................................ 67 HIGH-LOW SPEED SELECTION CONTROL................................................ 68 SWING SYSTEM.................................................................... 69 SCHEMATIC OF SWING SYSTEM....................................................... 70 HYDRAULIC CIRCUIT DIAGRAM....................................................... 71 SWING MOTOR AND BRAKE VALVE ASSEMBLY............................................ 72 SWING MECHANICAL BRAKE.......................................................... 77 SWING MACHINERY................................................................. 79 SWING CIRCLE.................................................................... 80 22 TESTING AND ADJUSTING............................................................ 81 ADJUSTING TRAVEL SPEED SELECTOR LEVER........................................... 82 23 DISASSEMBLY AND ASSEMBLY......................................................... 83 TRAVEL MOTOR.................................................................... 84 REMOVAL..................................................................... 84 INSTALLATION................................................................ 84 SWIVEL JOINT.................................................................... 86 REMOVAL..................................................................... 86 INSTALLATION................................................................ 88 CENTER SWIVEL JOINT............................................................. 90 DISASSEMBLY................................................................. 90 ASSEMBLY.................................................................... 90 TRANSMISSION.................................................................... 92 REMOVAL..................................................................... 92 INSTALLATION................................................................ 92 DISASSEMBLY................................................................. 94 ASSEMBLY.................................................................... 96 SWING MOTOR.....................................................................100 REMOVAL.....................................................................100 INSTALLATION................................................................100 SWING MACHINERY.................................................................100 REMOVAL.....................................................................100 INSTALLATION................................................................100 DISASSEMBLY.................................................................102 ASSEMBLY....................................................................104 SWING CIRCLE....................................................................110 REMOVAL.....................................................................110 INSTALLATION................................................................110 24 MAINTENANCE STANDARD.............................................................112 TRAVEL BRAKE VALVE..............................................................113 TRAVEL SUCTION VALVE............................................................114 TRANSMISSION....................................................................115 SWING MACHINERY.................................................................117 SWING CIRCLE....................................................................118 SWING MOTOR.....................................................................119 40 STEERING AND BRAKE SYSTEM............................................................120 41 STRUCTURE AND FUNCTION...........................................................120 STEERING SYSTEM.................................................................121 STEERING PUMP...................................................................122 SCHEMATIC OF STEERING SYSTEM....................................................123 HYDRAULIC CIRCUIT DIAGRAM.......................................................124 STEERING VALVE AND MAIN RELIEF VALVE............................................125 STEERING MAIN RELIEF VALVE......................................................126 STEERING VALVE..................................................................127 STEERING CYLINDER...............................................................133 AXLE............................................................................134 DIFFERENTIAL GEAR...............................................................136 FINAL DRIVE.....................................................................137 DRIVE SHAFT.....................................................................138 WHEEL...........................................................................139 BRAKE SYSTEM....................................................................140 SCHEMATIC OF BRAKE SYSTEM.......................................................141 HYDRAULIC CIRCUIT DIAGRAM.......................................................142 BRAKE MASTER CYLINDER...........................................................143 HYDROMASTER.....................................................................145 BRAKE SWIVEL JOINT..............................................................149 BRAKE LOCK VALVE................................................................150 PARKING BRAKE SELECTOR SOLENOID VALVE...........................................155 WHEEL BRAKE.....................................................................157 PARKING BRAKE...................................................................158 PARKING BRAKE CYLINDER..........................................................159 SUSPENSION SYSTEM...............................................................160 SCHEMATIC OF SUSPENSION SYSTEM..................................................161 HYDRAULIC CIRCUIT DIAGRAM.......................................................162 SUSPENSION LOCK VALVE...........................................................163 SUSPENSION LOCK CYLINDER........................................................166 42 TESTING AND ADJUSTING............................................................167 TESTING AND ADJUSTING TOE-IN....................................................168 ADJUSTING MAXIMUM STEERING ANGLE FOR FRONT AXLE.................................169 ADJUSTING PARKING BRAKE.........................................................170 ADJUSTING PARKING BRAKE ROD.....................................................171 BLEEDING AIR FROM BRAKE CIRCUIT.................................................172 43 DISASSEMBLY AND ASSEMBLY.........................................................173 STEERING PUMP...................................................................174 REMOVAL.....................................................................174 INSTALLATION................................................................174 STEERING CYLINDER...............................................................174 REMOVAL.....................................................................174 INSTALLATION................................................................174 FRONT AXLE......................................................................176 REMOVAL.....................................................................176 INSTALLATION................................................................176 REAR AXLE.......................................................................176 REMOVAL.....................................................................176 INSTALLATION................................................................176 FRONT FINAL DRIVE AND HUB.......................................................178 REMOVAL.....................................................................178 INSTALLATION................................................................178 FINAL DRIVE.....................................................................182 REMOVAL.....................................................................182 INSTALLATION................................................................184 DIFFERENTIAL....................................................................186 REMOVAL.....................................................................186 INSTALLATION................................................................186 DISASSEMBLY.................................................................188 ASSEMBLY....................................................................190 WHEEL...........................................................................194 REMOVAL.....................................................................194 INSTALLATION................................................................194 FRONT CALIPER...................................................................194 REMOVAL.....................................................................194 INSTALLATION................................................................194 REAR CALIPER....................................................................196 REMOVAL.....................................................................196 INSTALLATION................................................................196 CALIPER.........................................................................196 DISASSEMBLY.................................................................196 ASSEMBLY....................................................................196 PARKING BRAKE...................................................................198 REMOVAL.....................................................................198 INSTALLATION................................................................198 SUSPENSION LOCK VALVE...........................................................198 REMOVAL.....................................................................198 INSTALLATION................................................................198 SUSPENSION LOCK CYLINDER........................................................200 REMOVAL.....................................................................200 INSTALLATION................................................................200 DISASSEMBLY.................................................................200 ASSEMBLY....................................................................200 44 MAINTENANCE STANDARD.............................................................202 STEERING PUMP...................................................................203 STEERING CYLINDER...............................................................204 DIFFERENTIAL....................................................................205 FINAL DRIVE.....................................................................206 KING PIN AND KNUCKLE AND TIE-ROD................................................207 WHEEL BRAKE.....................................................................208 PARKING BRAKE...................................................................209 SUSPENSION LOCK CYLINDER........................................................210 60 HYDRAULIC SYSTEM.....................................................................211 61 STRUCTURE AND FUNCTION...........................................................211 HYDRAULIC SYSTEM................................................................212 HYDRAULIC PIPING................................................................213 SCHEMATIC OF HYDRAULIC SYSTEM...................................................214 HYDRAULIC CIRCUIT DIAGRAM.......................................................216 HYDRAULIC TANK AND FUEL TANK....................................................217 HYDRAULIC PUMP..................................................................218 PC CONTROL SYSTEM...............................................................227 OLSS SYSTEM(IF EQUIPPED)........................................................231 L.H. 5-SPOOL CONTROL VALVE......................................................242 R.H. 5-SPOOL CONTROL VALVE......................................................244 MAIN RELIEF VALVE...............................................................246 WORK EQUIPMENT CONTROL..........................................................248 BOOM CONTROL....................................................................249 ARM CONTROL.....................................................................251 BUCKET CONTROL..................................................................253 HYDRAULIC CYLINDER..............................................................255 62 TESTING AND ADJUSTING............................................................258 TABLE OF JUDGEMENT STANDARD VALUE...............................................259 TESTING AND ADJUSTING TOOL LIST.................................................266 TESTING AND ADJUSTING MAIN RELIEF VALVE.........................................267 TESTING AND ADJUSTING CHARGING CIRCUIT PRESSURE.................................269 MEASURING DELIVERY OF PISTON PUMP...............................................270 MEASURING OIL LEAKAGE FROM SWING AND TRAVEL MOTORS..............................271 TROUBLESHOOTING.................................................................272 POSITION OF CONNECTOR FOR TROUBLESHOOTING...................................273 CONNECTION TABLE FOR CONNECTOR PINS.........................................276 TROUBLESHOOTING PROCEDURE...................................................280 CHECKS BEFORE TROUBLESHOOTING...............................................281 TROUBLESHOOTING.............................................................282 63 DISASSEMBLY AND ASSEMBLY.........................................................300 CHARGING PUMP...................................................................301 REMOVAL.....................................................................301 INSTALLATION................................................................301 HYDRAULIC PUMP..................................................................303 REMOVAL.....................................................................303 INSTALLATION................................................................303 HYDRAULIC PUMP INPUT SHAFT OIL SEAL.............................................305 REMOVAL.....................................................................305 INSTALLATION................................................................305 L.H. 5-SPOOL CONTROL VALVE......................................................307 REMOVAL.....................................................................307 INSTALLATION................................................................309 R.H. 5-SPOOL CONTROL VALVE......................................................311 REMOVAL.....................................................................311 INSTALLATION................................................................311 CONTROL VALVE...................................................................313 DISASSEMBLY.................................................................313 ASSEMBLY....................................................................313 BOOM CYLINDER...................................................................315 REMOVAL.....................................................................315 INSTALLATION................................................................315 ARM CYLINDER....................................................................315 REMOVAL.....................................................................315 INSTALLATION................................................................315 BUCKET CYLINDER.................................................................317 REMOVAL.....................................................................317 INSTALLATION................................................................317 BLADE CYLINDER..................................................................317 REMOVAL.....................................................................317 INSTALLATION................................................................317 HYDRAULIC CYLINDER..............................................................319 DISASSEMBLY.................................................................319 ASSEMBLY....................................................................321 64 MAINTENANCE STANDARD.............................................................325 L.H. 5-SPOOL CONTROL VALVE......................................................326 R.H. 5-SPOOL CONTROL VALVE......................................................328 HYDRAULIC CYLINDER..............................................................330 CHARGING PUMP...................................................................332 70 WORK EQUIPMENT.......................................................................333 71 STRUCTURE AND FUNCTION...........................................................333 WORK EQUIPMENT..................................................................334 73 DISASSEMBLY AND ASSEMBLY.........................................................336 WORK EQUIPMENT..................................................................337 REMOVAL.....................................................................337 INSTALLATION................................................................337 BOOM............................................................................337 REMOVAL.....................................................................337 INSTALLATION................................................................337 ARM.............................................................................339 REMOVAL.....................................................................339 INSTALLATION................................................................339 BUCKET..........................................................................339 REMOVAL.....................................................................339 INSTALLATION................................................................339 ARM AND BUCKET..................................................................341 REMOVAL.....................................................................341 INSTALLATION................................................................341 BLADE...........................................................................341 REMOVAL.....................................................................341 INSTALLATION................................................................341 74 MAINTENANCE STANDARD.............................................................343 WORK EQUIPMENT..................................................................344 80 ELECTRIC AND ELECTRONIC SYSTEM.......................................................347 81 STRUCTURE AND FUNCTION...........................................................347 ELECTRICAL SYSTEM...............................................................348 ELECTRIC CIRCUIT DIAGRAM........................................................350 82 TESTING AND ADJUSTING............................................................351 ELECTRICAL CIRCUIT DIAGRAM......................................................352 TROUBLESHOOTING.................................................................354 M-1 FUEL GAUGE GIVES NO DISPLAY OR GIVES ABNORMAL DISPLAY...................354 A) DOES NOT DISPLAY.....................................................354 B) GIVES ABNORMAL DISPLAY...............................................354 M-2 WATER TEMPERATURE DISPLAY GIVES NO DISPLAY OR GIVES ABNORMAL DISPLAY....355 A) DOES NOT DISPLAY.....................................................355 B) GIVES ABNORMAL DISPLAY...............................................355
PLEASE NOTE:
⦁ This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
⦁ Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.
