Komatsu Hydraulic Excavator PC60, PC60L, PC60U, PC60B, PC90 Repair Service Manual + Operation & Maintenance Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavator PC60-5, PC60L-5, PC60U-5, PC60-6, PC60L-6, PC60-7, PC60-7B, PC90-1, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu Hydraulic Excavator PC60-5, PC60L-5, PC60U-5, PC60-6, PC60L-6, PC60-7, PC60-7B, PC90-1 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: 4,376 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
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MAIN SECTIONS
COVER...1
CONTENTS...2
10 STRUCTURE AND FUNCTION...16
ENGINE MOUNT AND ENGINE RELATED PARTS...17
RADIATOR AND OIL COOLER...18
P.T.O...19
POWER TRAIN...20
SWING CIRCLE...22
SWING MACHINERY...23
TRACK FRAME...24
IDLER...27
IDLER CUSHION...27
CARRIER ROLLER...28
TRACK ROLLER...28
TRACK SHOE...29
HYDRAULIC PIPING...31
HYDRAULIC CIRCUIT DIAGRAM...33
HYDRAULIC TANK AND FUEL TANK...37
HYDRAULIC PUMP...38
BLADE PUMP...51
L.H. 6-SPOOL CONTROL VALVE...52
R.H. 5-SPOOL CONTROL VALVE...58
BLADE CONTROL VALVE...65
SWING MOTOR...66
CENTER SWIVEL JOINT...69
TRAVEL MOTOR...71
BOOM SAFETY VALVE...82
VALVE CONTROL...83
PPC VALVE...87
SOLENOID VALVE ASSEMBLY...95
SAFETY LOCK VALVE...98
SHUTTLE VALVE...98
HYDRAULIC CYLINDER...99
WORK EQUIPMENT...101
ELECTRICAL WIRING DIAGRAM...102
ELECTRICAL CIRCUIT DIAGRAM...104
ENGINE CONTROL...106
TOTAL CONTROL SYSTEM...115
EMMAC (ELECTRONIC MONITOR AND CONTROL CONSOLE)...128
20 TESTING AND ADJUSTING...134
TABLE OF JUDGEMENT STANDARD VALUE...135
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING...155
ADJUSTING VALVE CLEARANCE...156
MEASURING COMPRESSION PRESSURE...157
TESTING AND ADJUSTING FUEL INJECTION TIMING...158
ADJUSTING TRAVEL OF GOVERNOR MOTOR LEVER...159
TESTING AND ADJUSTING TRAVEL LEVER, LIMIT SWITCHES...160
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT...161
TESTING AND ADJUSTING CHARGING PUMP PRESSURE...164
MEASURING PPC VALVE OUTPUT PRESSURE...166
ADJUSTING PPC VALVE...167
TESTING PPC SHUTTLE VALVE...169
MEASURING SOLENOID VALVE OUTLET PRESSURE...170
TESTING FOR OIL LEAKAGE FROM CENTER SWIVEL JOINT...172
BLEEDING AIR...173
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT...175
TROUBLESHOOTING...176
POINTS TO REMEMBER WHEN TROUBLESHOOTING...177
SEQUENCE OF EVENTS IN TROUBLESHOOTING...178
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE...179
CHECKS BEFORE TROUBLESHOOTING...186
ELECTRICAL CIRCUIT DIAGRAM...187
POSITION OF CONNECTORS FOR TROUBLESHOOTING...190
CONNECTION TABLE FOR CONNECTOR...192
HANDLING CONNECTORS...200
DISPLAY METHOD FOR MONITOR PANEL AND ENGINE THROTTLE CONTROLLER...201
ACTION OF SELF-DIAGNOSTIC FUNCTION AND SYMPTOMS ON MACHINE...202
METHOD OF USING JUDGEMENT TABLE...203
METHOD OF USING TROUBLESHOOTING CHARTS...205
TROUBLESHOOTING OF ENGINE THROTTLE CONTROLLER SYSTEM (E MODE)...207
ENGINE THROTTLE CONTROLLER OR IN ENGINE RELATED PARTS...208
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING ON ENGINE THROTTLE CONTROLLER SYSTEM...209
E-1 [ABNORMALITY IN POWER SOURCE SYSTEM OR CONTROLLER] IS DISPLAYED (ALL LAMPS OFF)...210
E-2 [SHORT CIRCUIT IN GOVERNOR MOTOR] IS DISPLAY...212
E-3 [ABNORMALITY IN BATTERY RELAY] IS DISPLAYED...213
E-4 [DISCONNECTION IN WIRING HARNESS OF GOVERNOR MOTOR] IS DISPLAYED...214
E-5 [ABNORMALITY IN GOVERNOR POTENTIOMETER] IS DISPLAYED...215
E-6 [ABNORMALITY IN FUEL CONTROL DIAL] IS DISPLAYED...217
E-7 ENGINE DOES NOT START...218
E-8 ENGINE ROTATION IS IRREGULAR...220
E-9 LACK OF OUTPUT POWER (MAX. ENGINE SPEED IS TOO LOW)...224
E-10 ENGINE DOES NOT STOP...226
E-11 AUTOMATIC WARMING-UP OPERATION IS DEFECTIVE...228
TROUBLESHOOTING OF PUMP CONTROLLER SYSTEM (C MODE)...229
CHART FOR DISTINGUISHING IF FAILURE IS IN SYSTEM CONTROLLER OR IN HYDRAULIC RELATED PARTS...230
C-1 AUTO-DECELERATION DOES NOT WORK (ENGINE SPEED DOES NOT RISE EVEN WHEN LEVER IS OPERATED)...231
C-2 AUTO-DECELERATION DOES NOT WORK (ENGINE SPEED DOES NOT DROP EVEN WHEN LEVERS ARE AT NEUTRAL)...233
C-3 DOES NOT SWING (SWING BRAKE SOLENOID IS DOES NOT COME ON)...236
C-4 EXCESSIVE HYDRAULIC DRIFT OF SWING (SWING BRAKE SOLENOID STAYS ON)...237
C-5 EXCESSIVE TRAVEL DEVIATION DURING SIMULTANEOUS OPERATIONS (STRAIGHT-TRAVEL SOLENOID DOES NOT COME NO)...238
C-6 WORK EQUIPMENT SPEED IS SLOW (PARTICULARLY SLOW WHEN ARM IS OPERATED INDEPENDENTLY) (STRAIGHT-TRAVEL SOLENOID STAYS ON)...239
C-7 POWER SET DOES NOT SWITCH TO S MODE (STAYS IN L MODE) (POWER SET SOLENOID STAYS ON)...242
C-8 POWER SET DOES NOT SWITCH TO L MODE (STAYS IN S MODE) (POWER SET SOLENOID DOES NOT COME ON)...244
C-9 TRAVEL SPEED DOES NOT SWITCH TO HI (STAYS IN LO) (TRAVEL SPEED SOLENOID DOES NOT COME ON)...246
C-10 TRAVEL SPEED DOES NOT SWITCH TO LO (STAYS IN HI)(TRAVEL SPEED SOLENOID STAYS ON)...247
C-11 PRESSURE DOES NOT RISE WHEN TRAVELING (REMAINS AT NORMAL HYDRAULIC PRESSURE) (PC90-1)...248
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)...249
H-1 SPEED OF ALL WORK EQUIPMENT, TRAVEL, SWING IS SLOW...250
H-2 ENGINE SPEED DROPS EXCESSIVELY, OR ENGINE STALLS...250
H-3 WORK EQUIPMENT, TRAVEL SWING DO NOT MOVE, OR SPEED IS EXTREMELY SLOW...251
H-4 WORK EQUIPMENT, TRAVEL, SWING LACK POWER...252
H-5 POWER SET DOES NOT SWITCH...252
H-6 ABNORMAL NOISE GENERATED (FROM AROUND PUMP)...253
H-7 AUTO-DECELERATION DOES NOT ACTUATED...253
H-8 BOOM, ARM SPEED IS EXTREMELY SLOW...254
H-9 WORK EQUIPMENT (BOOM, ARM, BUCKET) SPEED IS SLOW...254
H-10 WORK EQUIPMENT (BOOM, ARM, BUCKET) LACKS POWER...255
H-11 EXCESSIVE HYDRAULIC DRIFT...255
H-12 EXCESSIVE TIME LAG...255
H-13 MACHINE DEVIATES NATURALLY WHEN TRAVELING...256
a) DEVIATES IN SAME DIRECTION BOTH IN FORWARD AND REVERSE...256
b) DEVIATES IN DIFFERENT DIRECTION IN FORWARD AND REVERSE...258
H-14 EXCESSIVE DEVIATION DURING COMPOUND OPERATIONS...259
H-15 EXCESSIVE DEVIATION WHEN STARTING...259
H-16 TRAVEL LACKS POWER (OR SPEED IS SLOW)...260
H-17 TRAVEL SPEED DOES NOT SWITCH...260
H-18 MACHINE DOES NOT MOVE (ONE SIDE ONLY)...261
H-19 TRAVEL LEVER IS HEAVY...261
H-20 DOES NOT SWING...262
H-21 SWING SPEED IS SLOW OR ACCELERATION IS POOR...264
H-22 EXCESSIVE OVERRUN WHEN STOPPING SWING...264
H-23 EXCESSIVE SHOCK WHEN STOPPING SWING...265
H-24 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING...265
H-25 EXCESSIVE HYDRAULIC DRIFT OF SWING...266
H-26 WHEN OPERATED SIMULTANEOUSLY WITH ARM, SWING SPEED IS SLOW...266
TROUBLESHOOTING OF MONITOR SYSTEM (P MODE)...267
P-1 MONITOR PANEL LAMPS DO NOT LIGHT UP FOR 3 SECONDS WHEN STARTING SWITCH IS TURNED ON...268
a) NO MONITOR PANEL LAMPS LIGHT UP...268
b) SOME MONITOR PANEL LAMPS DO NOT LIGHT UP...268
P-2 MONITOR PANEL LAMPS ALL LIGHT UP WHEN STARTING SWITCH IS TURNED ON, BUT DO NOT GO OUT...269
P-3 PREHEATING IS NOT BEING USED, BUT (PREHEATING DISPLAY LIGHTS) UP...269
P-4 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), ENGINE OIL PRESSURE CAUTION LAMP LIGHTS UP...270
P-5 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CAUTION ITEMS FLASH...271
P-6 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, CAUTION ITEMS FLASH...272
a) (ENGINE OIL PRESSURE) FLASHES...272
b) (COOLANT TEMPERATURE) FLASHES...272
c) (CHARGE) FLASHES...273
d) (FUEL LEVEL) FLASHES...273
P-7 a) WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), BUZZER DOES NOT SOUND FOR 1 SECOND CAUTION ITEMS IS FLASHING BUT BUZZER DOES NOT SOUND...274
P-7 b) THERE IS NO ABNORMALITY DISPLAY ON THE MONITOR, BUT THE BUZZER SOUNDS...274
P-8 PANEL LIGHTING OF MONITOR PANEL DOES NOT LIGHT UP...275
P-9 COOLANT TEMPERATURE SHOWS ABNORMALLY LOW TEMPERATURE...276
P-10 COOLANT TEMPERATURE GAUGE GIVES NO DISPLAY...276
P-11 FUEL GAUGE ALWAYS DISPLAYS FULL...277
P-12 FUEL GAUGE GIVES NO DISPLAY...277
P-13 a) LAMPS DO NOT LIGHT UP...278
P-13 b) LAMPS LIGHT UP EVEN WHEN LAMP SWITCH IS NOT OPERATED...278
P-14 a) WIPERS DO NOT WORK...280
P-14 b) WIPERS WORK EVEN WHEN WIPER SWITCH IS NOT OPERATED...280
P-15 a) FAN DOES NOT WORK...282
P-15 b) FAN WORKS EVEN WHEN FAN SWITCH IS NOT OPERATED...282
P-16 POWER SET DOES NOT SWITCH...284
P-17 AUTO-DECELERATION DOES NOT SWITCH (DOES NOT ENTER AUTO-DECELERATION; AUTO-DECELERATION IS NOT CANCELED)...285
P-18 TRAVEL SPEED DOES NOT SWITCH BETWEEN HI AND LO...286
P-19 WARNING-UP OPERATION IS NOT CARRIED OUT BELOW 30?, OR WARMING-UP OPERATION IS NOT CANCELED EVEN WHEN TEMPERATURE GOES ABOVE 30?...287
P-20 EVEN WHEN SWING LOCK SWITCH IS TURNED ON (LOCK), SWING LOCK LAMP ON MONITOR PANEL DOES NOT LIGHT UP...288
P-21 COOLANT TEMPERATURE SENSOR SYSTEM DEFECTIVE...289
P-22 FUEL LEVEL SENSOR SYSTEM DEFECTIVE...290
30 DISASSEMBLY AND ASSEMBLY...291
METHOD OF USING MANUAL...293
PRECATIONS WHEN CARRYING OUT OPERATION...294
SPECIAL TOOL LIST...296
WEIGHT TABLE...298
TIGHTENING TORQUES AND STANDARD VALUES TABLE...299
LUBRICANT AND COOLANT TABLE...301
STARTING MOTOR...302
REMOVAL...302
INSTALLATION...302
ALTERNATOR...302
REMOVAL...302
INSTALLATION...302
FUEL INJECTION PUMP...304
REMOVAL...304
INSTALLATION...304
WATER PUMP...306
REMOVAL...306
INSTALLATION...306
NOZZLE HOLDER...306
REMOVAL...306
INSTALLATION...306
THERMOSTAT...308
REMOVAL...308
INSTALLATION...308
ENGINE FRONT SEAL...308
REMOVAL...308
INSTALLATION...308
ENGINE REAR SEAL...310
REMOVAL...310
INSTALLATION...310
GOVERNOR MOTOR...310
REMOVAL...310
INSTALLATION...310
CYLINDER HEAD...312
REMOVAL...312
INSTALLATION...312
RADIATOR, HYDRAULIC COOLER...314
REMOVAL...314
INSTALLATION...314
ENGINE, HYDRAULIC PUMP...316
REMOVAL...316
