Komatsu Hydraulic Excavator PW60-3 Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavator PW60-3, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu Hydraulic Excavator PW60-3 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PRODUCT DETAILS:
Total Pages: 488 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
SEAM020B0303 - Hydraulic Excavator PW60-3 Operation & Maintenance Manual.pdf
SEBM020B0303 - Hydraulic Excavator PW60-3 Shop Manual.pdf
MAIN SECTIONS
SEAM020B0303 - Hydraulic Excavator PW60-3 Operation & Maintenance Manual....2
COVER....2
FOREWORD....3
BREAKING IN YOUR NEW MACHINE....4
CONTENTS....5
SAFETY HINTS....6
GENERAL LOCATIONS AND SPECIFICATIONS....14
INSTRUMENTS AND CONTROLS....15
CHECK BEFORE STARTING....40
OPERATING YOUR MACHINE....46
EXCAVATOR'S WORK....61
INVERSION AND REPLACEMENT OF BUCKET....62
HANDLING THE TIRES....63
HANDLING OF BATTERY....65
TRANSPORTATION....68
COLD WEATHER OPERATION....70
PERIODIC MAINTENANCE....75
PRECAUTIONS FOR MAINTENANCE....76
PERIODICAL REPLACEMENT OF SAFETY PARTS....81
MAINTENANCE TABLE....82
OIL FILLER AND LEVEL GAUGE POSITIONS....85
EVERY 50 HOURS SERVICE....86
EVERY 100 HOURS SERVICE....86
EVERY 250 HOURS SERVICE....89
EVERY 500 HOURS SERVICE....95
EVERY 1000 HOURS SERVICE....99
EVERY 2000 HOURS SERVICE....101
EVERY 4000 HOURS SERVICE....106
WHEN REQUIRED....107
ADJUSTMENT....117
HANDLING OUTRIGGER....121
TROUBLE SHOOTING GUIDE....123
STORAGE....126
SERVICE METER....127
MACHINE AND ENGINE SERIAL NUMBERS....128
FUEL,COOLANT AND LUBRICANTS....129
SEBM020B0303 - Hydraulic Excavator PW60-3 Shop Manual....134
COVER....134
CONTENTS....135
10 ENGINE....147
11 STRUCTURE AND FUNCTION....147
ENGINE CONTROL....148
AUTO-DECELERATION SYSTEM....149
12 TESTING AND ADJUSTING....152
TESTING AND ADJUSTING DATA....153
TESTING AND ADJUSTING TOOL LIST....153
ADJUSTING VALVE CLEARANCE....154
ADJUSTING FUEL INJECTION TIMING....155
MEASURING COMPRESSION PRESSURE....156
MEASURING EXHAUST GAS COLOR....157
MEASURING BLOW-BY PRESSURE....158
TESTING AND ADJUSTING FAN BELT TENSION....158
13 DISASSEMBLY AND ASSEMBLY....159
STARTING MOTOR....160
REMOVAL....160
INSTALLATION....160
ALTERNATOR....160
REMOVAL....160
INSTALLATION....160
ENGINE OIL COOLER....160
REMOVAL....160
INSTALLATION....160
FAN AND FAN PULLEY....160
REMOVAL....160
INSTALLATION....160
FUEL INJECTION PUMP....162
REMOVAL....162
INSTALLATION....162
WATER PUMP....162
REMOVAL....162
INSTALLATION....162
NOZZLE HOLDER....164
REMOVAL....164
INSTALLATION....164
CYLINDER HEAD....166
REMOVAL....166
INSTALLATION....168
RADIATOR AND HYDRAULIC OIL COOLER....170
REMOVAL....170
INSTALLATION....170
ENGINE AND HYDRAULIC PUMP....172
REMOVAL....172
INSTALLATION....176
PTO....180
REMOVAL....180
INSTALLATION....180
DISASSEMBLY....180
ASSEMBLY....180
20 POWER TRAIN....182
21 STRUCTURE AND FUNCTION....182
POWER TRAIN....183
TRAVEL SYSTEM....184
SCHEMATIC OF POWER TRAIN....185
HYDRAULIC CIRCUIT DIAGRAM....186
TRAVEL MOTOR....187
CENTER SWIVEL JOINT....195
TRANSMISSION....196
SOLENOID VALVE FOR FORWARD-REVERSE SELECTION....198
FORWARD-REVERSE SELECTOR LEVER....199
TRAVEL PPC VALVE....200
HIGH-LOW SPEED SELECTION CONTROL....201
SWING SYSTEM....202
SCHEMATIC OF SWING SYSTEM....203
HYDRAULIC CIRCUIT DIAGRAM....204
SWING MOTOR AND BRAKE VALVE ASSEMBLY....205
SWING MECHANICAL BRAKE....210
SWING MACHINERY....212
SWING CIRCLE....213
22 TESTING AND ADJUSTING....214
ADJUSTING TRAVEL SPEED SELECTOR LEVER....215
23 DISASSEMBLY AND ASSEMBLY....216
TRAVEL MOTOR....217
REMOVAL....217
INSTALLATION....217
SWIVEL JOINT....219
REMOVAL....219
INSTALLATION....221
CENTER SWIVEL JOINT....223
DISASSEMBLY....223
ASSEMBLY....223
TRANSMISSION....225
REMOVAL....225
INSTALLATION....225
DISASSEMBLY....227
ASSEMBLY....229
SWING MOTOR....233
REMOVAL....233
INSTALLATION....233
SWING MACHINERY....233
REMOVAL....233
INSTALLATION....233
DISASSEMBLY....235
ASSEMBLY....237
SWING CIRCLE....243
REMOVAL....243
INSTALLATION....243
24 MAINTENANCE STANDARD....245
TRAVEL BRAKE VALVE....246
TRAVEL SUCTION VALVE....247
TRANSMISSION....248
SWING MACHINERY....250
SWING CIRCLE....251
SWING MOTOR....252
40 STEERING AND BRAKE SYSTEM....253
41 STRUCTURE AND FUNCTION....253
STEERING SYSTEM....254
STEERING PUMP....255
SCHEMATIC OF STEERING SYSTEM....256
HYDRAULIC CIRCUIT DIAGRAM....257
STEERING VALVE AND MAIN RELIEF VALVE....258
STEERING MAIN RELIEF VALVE....259
STEERING VALVE....260
STEERING CYLINDER....266
AXLE....267
DIFFERENTIAL GEAR....269
FINAL DRIVE....270
DRIVE SHAFT....271
WHEEL....272
BRAKE SYSTEM....273
SCHEMATIC OF BRAKE SYSTEM....274
HYDRAULIC CIRCUIT DIAGRAM....275
BRAKE MASTER CYLINDER....276
HYDROMASTER....278
BRAKE SWIVEL JOINT....282
BRAKE LOCK VALVE....283
PARKING BRAKE SELECTOR SOLENOID VALVE....288
WHEEL BRAKE....290
PARKING BRAKE....291
PARKING BRAKE CYLINDER....292
SUSPENSION SYSTEM....293
SCHEMATIC OF SUSPENSION SYSTEM....294
HYDRAULIC CIRCUIT DIAGRAM....295
SUSPENSION LOCK VALVE....296
SUSPENSION LOCK CYLINDER....299
42 TESTING AND ADJUSTING....300
TESTING AND ADJUSTING TOE-IN....301
ADJUSTING MAXIMUM STEERING ANGLE FOR FRONT AXLE....302
ADJUSTING PARKING BRAKE....303
ADJUSTING PARKING BRAKE ROD....304
BLEEDING AIR FROM BRAKE CIRCUIT....305
43 DISASSEMBLY AND ASSEMBLY....306
STEERING PUMP....307
REMOVAL....307
INSTALLATION....307
STEERING CYLINDER....307
REMOVAL....307
INSTALLATION....307
FRONT AXLE....309
REMOVAL....309
INSTALLATION....309
REAR AXLE....309
REMOVAL....309
INSTALLATION....309
FRONT FINAL DRIVE AND HUB....311
REMOVAL....311
INSTALLATION....311
FINAL DRIVE....315
REMOVAL....315
INSTALLATION....317
DIFFERENTIAL....319
REMOVAL....319
INSTALLATION....319
DISASSEMBLY....321
ASSEMBLY....323
WHEEL....327
REMOVAL....327
INSTALLATION....327
FRONT CALIPER....327
REMOVAL....327
INSTALLATION....327
REAR CALIPER....329
REMOVAL....329
INSTALLATION....329
CALIPER....329
DISASSEMBLY....329
ASSEMBLY....329
PARKING BRAKE....331
REMOVAL....331
INSTALLATION....331
SUSPENSION LOCK VALVE....331
REMOVAL....331
INSTALLATION....331
SUSPENSION LOCK CYLINDER....333
REMOVAL....333
INSTALLATION....333
DISASSEMBLY....333
ASSEMBLY....333
44 MAINTENANCE STANDARD....335
STEERING PUMP....336
STEERING CYLINDER....337
DIFFERENTIAL....338
FINAL DRIVE....339
KING PIN AND KNUCKLE AND TIE-ROD....340
WHEEL BRAKE....341
PARKING BRAKE....342
SUSPENSION LOCK CYLINDER....343
60 HYDRAULIC SYSTEM....344
61 STRUCTURE AND FUNCTION....344
HYDRAULIC SYSTEM....345
HYDRAULIC PIPING....346
SCHEMATIC OF HYDRAULIC SYSTEM....347
HYDRAULIC CIRCUIT DIAGRAM....349
HYDRAULIC TANK AND FUEL TANK....350
HYDRAULIC PUMP....351
PC CONTROL SYSTEM....360
OLSS SYSTEM(IF EQUIPPED)....364
L.H. 5-SPOOL CONTROL VALVE....375
R.H. 5-SPOOL CONTROL VALVE....377
MAIN RELIEF VALVE....379
WORK EQUIPMENT CONTROL....381
BOOM CONTROL....382
ARM CONTROL....384
BUCKET CONTROL....386
HYDRAULIC CYLINDER....388
62 TESTING AND ADJUSTING....391
TABLE OF JUDGEMENT STANDARD VALUE....392
TESTING AND ADJUSTING TOOL LIST....399
TESTING AND ADJUSTING MAIN RELIEF VALVE....400
TESTING AND ADJUSTING CHARGING CIRCUIT PRESSURE....402
MEASURING DELIVERY OF PISTON PUMP....403
MEASURING OIL LEAKAGE FROM SWING AND TRAVEL MOTORS....404
TROUBLESHOOTING....405
POSITION OF CONNECTOR FOR TROUBLESHOOTING....406
CONNECTION TABLE FOR CONNECTOR PINS....409
TROUBLESHOOTING PROCEDURE....413
CHECKS BEFORE TROUBLESHOOTING....414
TROUBLESHOOTING....415
63 DISASSEMBLY AND ASSEMBLY....433
CHARGING PUMP....434
REMOVAL....434
INSTALLATION....434
HYDRAULIC PUMP....436
REMOVAL....436
INSTALLATION....436
HYDRAULIC PUMP INPUT SHAFT OIL SEAL....438
REMOVAL....438
INSTALLATION....438
L.H. 5-SPOOL CONTROL VALVE....440
REMOVAL....440
INSTALLATION....442
R.H. 5-SPOOL CONTROL VALVE....444
REMOVAL....444
INSTALLATION....444
CONTROL VALVE....446
DISASSEMBLY....446
ASSEMBLY....446
BOOM CYLINDER....448
REMOVAL....448
INSTALLATION....448
ARM CYLINDER....448
REMOVAL....448
INSTALLATION....448
BUCKET CYLINDER....450
REMOVAL....450
INSTALLATION....450
BLADE CYLINDER....450
REMOVAL....450
INSTALLATION....450
HYDRAULIC CYLINDER....452
DISASSEMBLY....452
ASSEMBLY....454
64 MAINTENANCE STANDARD....458
L.H. 5-SPOOL CONTROL VALVE....459
R.H. 5-SPOOL CONTROL VALVE....461
HYDRAULIC CYLINDER....463
CHARGING PUMP....465
70 WORK EQUIPMENT....466
71 STRUCTURE AND FUNCTION....466
WORK EQUIPMENT....467
73 DISASSEMBLY AND ASSEMBLY....469
WORK EQUIPMENT....470
REMOVAL....470
INSTALLATION....470
BOOM....470
REMOVAL....470
INSTALLATION....470
ARM....472
REMOVAL....472
INSTALLATION....472
BUCKET....472
REMOVAL....472
INSTALLATION....472
ARM AND BUCKET....474
REMOVAL....474
INSTALLATION....474
BLADE....474
REMOVAL....474
INSTALLATION....474
74 MAINTENANCE STANDARD....476
WORK EQUIPMENT....477
80 ELECTRIC AND ELECTRONIC SYSTEM....480
81 STRUCTURE AND FUNCTION....480
ELECTRICAL SYSTEM....481
ELECTRIC CIRCUIT DIAGRAM....483
82 TESTING AND ADJUSTING....484
ELECTRICAL CIRCUIT DIAGRAM....485
TROUBLESHOOTING....487
M-1 FUEL GAUGE GIVES NO DISPLAY OR GIVES ABNORMAL DISPLAY....487
A) DOES NOT DISPLAY....487
B) GIVES ABNORMAL DISPLAY....487
M-2 WATER TEMPERATURE DISPLAY GIVES NO DISPLAY OR GIVES ABNORMAL DISPLAY....488
A) DOES NOT DISPLAY....488
B) GIVES ABNORMAL DISPLAY....488
