Komatsu PC60-6, PC60L-6, PC90-1 Hydraulic Excavator Service Repair Shop Manual – SEBM02010607

This Complete Service Repair Workshop Manual PDF Download for the PC60-6, PC60L-6, 6 PC90-1 Komatsu Hydraulic Excavator has easy to read text sections with top quality diagrams, pictures and illustrations. The step by step instructions show you how to fault find or complete any repair or overhaul, correctly and efficiently, saving time and avoiding costly mistakes. All specifications and tolerances are listed. Functions of components and systems are also explained.

APPLICABLE MODELS :

Komatsu PC60-6 – S/N: 28001 and up
Komatsu PC60L-6 – S/N: 8001 and up
Komatsu PC90-1 – S/N: 1001 and up

TABLE OF CONTENTS :

10 STRUCTURE AND FUNCTION
20 TESTING AND ADJUSTING
30 DISASSEMBLY AND ASSEMBLY
40 MAINTENANCE STANDARD

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : SEBM02010607
Total Pages : 451

This 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 judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

This manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having PDF files instead of a hard-printed manual is that you can use the Search feature in Acrobat to find just what your looking for and just print out the exact pages you need or all manual.

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COVER
CONTENTS

10 STRUCTURE AND FUNCTION
ENGINE MOUNT AND ENGINE RELATED PARTS
RADIATOR AND OIL COOLER
P.T.O.
POWER TRAIN
SWING CIRCLE
SWING MACHINERY
TRACK FRAME
IDLER
IDLER CUSHION
CARRIER ROLLER
TRACK ROLLER
TRACK SHOE
HYDRAULIC PIPING
HYDRAULIC CIRCUIT DIAGRAM
HYDRAULIC TANK AND FUEL TANK
HYDRAULIC PUMP
BLADE PUMP
L.H. 6-SPOOL CONTROL VALVE
R.H. 5-SPOOL CONTROL VALVE
BLADE CONTROL VALVE
SWING MOTOR
CENTER SWIVEL JOINT
TRAVEL MOTOR
BOOM SAFETY VALVE
VALVE CONTROL
PPC VALVE
SOLENOID VALVE ASSEMBLY
SAFETY LOCK VALVE
SHUTTLE VALVE
HYDRAULIC CYLINDER
WORK EQUIPMENT
ELECTRICAL WIRING DIAGRAM
ELECTRICAL CIRCUIT DIAGRAM
ENGINE CONTROL
TOTAL CONTROL SYSTEM
EMMAC (ELECTRONIC MONITOR AND CONTROL CONSOLE)

20 TESTING AND ADJUSTING
TABLE OF JUDGEMENT STANDARD VALUE
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
ADJUSTING VALVE CLEARANCE
MEASURING COMPRESSION PRESSURE
TESTING AND ADJUSTING FUEL INJECTION TIMING
ADJUSTING TRAVEL OF GOVERNOR MOTOR LEVER
TESTING AND ADJUSTING TRAVEL LEVER, LIMIT SWITCHES
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT
TESTING AND ADJUSTING CHARGING PUMP PRESSURE
MEASURING PPC VALVE OUTPUT PRESSURE
ADJUSTING PPC VALVE
TESTING PPC SHUTTLE VALVE
MEASURING SOLENOID VALVE OUTLET PRESSURE
TESTING FOR OIL LEAKAGE FROM CENTER SWIVEL JOINT
BLEEDING AIR
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT
TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
CHECKS BEFORE TROUBLESHOOTING
ELECTRICAL CIRCUIT DIAGRAM
POSITION OF CONNECTORS FOR TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR
HANDLING CONNECTORS
DISPLAY METHOD FOR MONITOR PANEL AND ENGINE THROTTLE CONTROLLER
ACTION OF SELF-DIAGNOSTIC FUNCTION AND SYMPTOMS ON MACHINE
METHOD OF USING JUDGEMENT TABLE
METHOD OF USING TROUBLESHOOTING CHARTS
TROUBLESHOOTING OF ENGINE THROTTLE CONTROLLER SYSTEM (E MODE)
ENGINE THROTTLE CONTROLLER OR IN ENGINE RELATED PARTS
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING ON ENGINE THROTTLE CONTROLLER SYSTEM
E-1 [ABNORMALITY IN POWER SOURCE SYSTEM OR CONTROLLER] IS DISPLAYED (ALL LAMPS OFF)
E-2 [SHORT CIRCUIT IN GOVERNOR MOTOR] IS DISPLAY
E-3 [ABNORMALITY IN BATTERY RELAY] IS DISPLAYED
E-4 [DISCONNECTION IN WIRING HARNESS OF GOVERNOR MOTOR] IS DISPLAYED
E-5 [ABNORMALITY IN GOVERNOR POTENTIOMETER] IS DISPLAYED
E-6 [ABNORMALITY IN FUEL CONTROL DIAL] IS DISPLAYED
E-7 ENGINE DOES NOT START
E-8 ENGINE ROTATION IS IRREGULAR
E-9 LACK OF OUTPUT POWER (MAX. ENGINE SPEED IS TOO LOW)
E-10 ENGINE DOES NOT STOP
E-11 AUTOMATIC WARMING-UP OPERATION IS DEFECTIVE
TROUBLESHOOTING OF PUMP CONTROLLER SYSTEM (C MODE)
CHART FOR DISTINGUISHING IF FAILURE IS IN SYSTEM CONTROLLER OR IN HYDRAULIC RELATED PARTS
C-1 AUTO-DECELERATION DOES NOT WORK (ENGINE SPEED DOES NOT RISE EVEN WHEN LEVER IS OPERATED)
C-2 AUTO-DECELERATION DOES NOT WORK (ENGINE SPEED DOES NOT DROP EVEN WHEN LEVERS ARE AT NEUTRAL)
C-3 DOES NOT SWING (SWING BRAKE SOLENOID IS DOES NOT COME ON)
C-4 EXCESSIVE HYDRAULIC DRIFT OF SWING (SWING BRAKE SOLENOID STAYS ON)
C-5 EXCESSIVE TRAVEL DEVIATION DURING SIMULTANEOUS OPERATIONS (STRAIGHT-TRAVEL SOLENOID DOES NOT COME NO)
C-6 WORK EQUIPMENT SPEED IS SLOW (PARTICULARLY SLOW WHEN ARM IS OPERATED INDEPENDENTLY) (STRAIGHT-TRAVEL SOLENOID STAYS ON)
C-7 POWER SET DOES NOT SWITCH TO S MODE (STAYS IN L MODE) (POWER SET SOLENOID STAYS ON)
C-8 POWER SET DOES NOT SWITCH TO L MODE (STAYS IN S MODE) (POWER SET SOLENOID DOES NOT COME ON)
C-9 TRAVEL SPEED DOES NOT SWITCH TO HI (STAYS IN LO) (TRAVEL SPEED SOLENOID DOES NOT COME ON)
C-10 TRAVEL SPEED DOES NOT SWITCH TO LO (STAYS IN HI)(TRAVEL SPEED SOLENOID STAYS ON)
C-11 PRESSURE DOES NOT RISE WHEN TRAVELING (REMAINS AT NORMAL HYDRAULIC PRESSURE) (PC90-1)
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)
H-1 SPEED OF ALL WORK EQUIPMENT, TRAVEL, SWING IS SLOW
H-2 ENGINE SPEED DROPS EXCESSIVELY, OR ENGINE STALLS
H-3 WORK EQUIPMENT, TRAVEL SWING DO NOT MOVE, OR SPEED IS EXTREMELY SLOW
H-4 WORK EQUIPMENT, TRAVEL, SWING LACK POWER
H-5 POWER SET DOES NOT SWITCH
H-6 ABNORMAL NOISE GENERATED (FROM AROUND PUMP)
H-7 AUTO-DECELERATION DOES NOT ACTUATED
H-8 BOOM, ARM SPEED IS EXTREMELY SLOW
H-9 WORK EQUIPMENT (BOOM, ARM, BUCKET) SPEED IS SLOW
H-10 WORK EQUIPMENT (BOOM, ARM, BUCKET) LACKS POWER
H-11 EXCESSIVE HYDRAULIC DRIFT
H-12 EXCESSIVE TIME LAG
H-13 MACHINE DEVIATES NATURALLY WHEN TRAVELING
a) DEVIATES IN SAME DIRECTION BOTH IN FORWARD AND REVERSE
b) DEVIATES IN DIFFERENT DIRECTION IN FORWARD AND REVERSE
H-14 EXCESSIVE DEVIATION DURING COMPOUND OPERATIONS
H-15 EXCESSIVE DEVIATION WHEN STARTING
H-16 TRAVEL LACKS POWER (OR SPEED IS SLOW)
H-17 TRAVEL SPEED DOES NOT SWITCH
H-18 MACHINE DOES NOT MOVE (ONE SIDE ONLY)
H-19 TRAVEL LEVER IS HEAVY
H-20 DOES NOT SWING
H-21 SWING SPEED IS SLOW OR ACCELERATION IS POOR
H-22 EXCESSIVE OVERRUN WHEN STOPPING SWING
H-23 EXCESSIVE SHOCK WHEN STOPPING SWING
H-24 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING
H-25 EXCESSIVE HYDRAULIC DRIFT OF SWING
H-26 WHEN OPERATED SIMULTANEOUSLY WITH ARM, SWING SPEED IS SLOW
TROUBLESHOOTING OF MONITOR SYSTEM (P MODE)
P-1 MONITOR PANEL LAMPS DO NOT LIGHT UP FOR 3 SECONDS WHEN STARTING SWITCH IS TURNED ON
a) NO MONITOR PANEL LAMPS LIGHT UP
b) SOME MONITOR PANEL LAMPS DO NOT LIGHT UP
P-2 MONITOR PANEL LAMPS ALL LIGHT UP WHEN STARTING SWITCH IS TURNED ON, BUT DO NOT GO OUT
P-3 PREHEATING IS NOT BEING USED, BUT (PREHEATING DISPLAY LIGHTS) UP
P-4 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), ENGINE OIL PRESSURE CAUTION LAMP LIGHTS UP
P-5 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CAUTION ITEMS FLASH
P-6 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, CAUTION ITEMS FLASH
a) (ENGINE OIL PRESSURE) FLASHES
b) (COOLANT TEMPERATURE) FLASHES
c) (CHARGE) FLASHES
d) (FUEL LEVEL) FLASHES
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
P-7 b) THERE IS NO ABNORMALITY DISPLAY ON THE MONITOR, BUT THE BUZZER SOUNDS
P-8 PANEL LIGHTING OF MONITOR PANEL DOES NOT LIGHT UP
P-9 COOLANT TEMPERATURE SHOWS ABNORMALLY LOW TEMPERATURE
P-10 COOLANT TEMPERATURE GAUGE GIVES NO DISPLAY
P-11 FUEL GAUGE ALWAYS DISPLAYS FULL
P-12 FUEL GAUGE GIVES NO DISPLAY
P-13 a) LAMPS DO NOT LIGHT UP
P-13 b) LAMPS LIGHT UP EVEN WHEN LAMP SWITCH IS NOT OPERATED
P-14 a) WIPERS DO NOT WORK
P-14 b) WIPERS WORK EVEN WHEN WIPER SWITCH IS NOT OPERATED
P-15 a) FAN DOES NOT WORK
P-15 b) FAN WORKS EVEN WHEN FAN SWITCH IS NOT OPERATED
P-16 POWER SET DOES NOT SWITCH
P-17 AUTO-DECELERATION DOES NOT SWITCH (DOES NOT ENTER AUTO-DECELERATION; AUTO-DECELERATION IS NOT CANCELED)
P-18 TRAVEL SPEED DOES NOT SWITCH BETWEEN HI AND LO
P-19 WARNING-UP OPERATION IS NOT CARRIED OUT BELOW 30℃, OR WARMING-UP OPERATION IS NOT CANCELED EVEN WHEN TEMPERATURE GOES ABOVE 30℃
P-20 EVEN WHEN SWING LOCK SWITCH IS TURNED ON (LOCK), SWING LOCK LAMP ON MONITOR PANEL DOES NOT LIGHT UP
P-21 COOLANT TEMPERATURE SENSOR SYSTEM DEFECTIVE
P-22 FUEL LEVEL SENSOR SYSTEM DEFECTIVE

30 DISASSEMBLY AND ASSEMBLY
METHOD OF USING MANUAL
PRECATIONS WHEN CARRYING OUT OPERATION
SPECIAL TOOL LIST
WEIGHT TABLE
TIGHTENING TORQUES AND STANDARD VALUES TABLE
LUBRICANT AND COOLANT TABLE
STARTING MOTOR
REMOVAL
INSTALLATION
ALTERNATOR
REMOVAL
INSTALLATION
FUEL INJECTION PUMP
REMOVAL
INSTALLATION
WATER PUMP
REMOVAL
INSTALLATION
NOZZLE HOLDER
REMOVAL
INSTALLATION
THERMOSTAT
REMOVAL
INSTALLATION
ENGINE FRONT SEAL
REMOVAL
INSTALLATION
ENGINE REAR SEAL
REMOVAL
INSTALLATION
GOVERNOR MOTOR
REMOVAL
INSTALLATION
CYLINDER HEAD
REMOVAL
INSTALLATION
RADIATOR, HYDRAULIC COOLER
REMOVAL
INSTALLATION
ENGINE, HYDRAULIC PUMP
REMOVAL
INSTALLATION
PTO
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
CENTER SWIVEL JOINT
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
TRAVEL MOTOR
REMOVAL
INSTALLATION
SPROCKET
REMOVAL
INSTALLATION
SWING MOTOR
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
SWING MACHINERY
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
REVOLVING FRAME
REMOVAL
INSTALLATION
SWING CIRCLE
REMOVAL
INSTALLATION
IDLER, RECOIL SPRING
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
TRACK ROLLER
REMOVAL
INSTALLATION
CARRIER ROLLER
REMOVAL
INSTALLATION
TRACK SHOE
REMOVAL
INSTALLATION
CHARGING PUMP
REMOVAL
INSTALLATION
HYDRAULIC PUMP
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
MAIN PUMP INPUT SHAFT OIL SEAL
REMOVAL
INSTALLATION
L.H. 6-SPOOL CONTROL VALVE
REMOVAL
INSTALLATION
R.H. 5-SPOOL CONTROL VALVE
REMOVAL
INSTALLATION
CONTROL VALVE
DISASSEMBLY
ASSEMBLY
MAIN RELIEF VALVE
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
SERVO VALVE
REMOVAL
INSTALLATION
WORK EQUIPMENT PPC VALVE
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
PPC VALVE
DISASSEMBLY
ASSEMBLY
PPC SHUTTLE VALVE
REMOVAL
INSTALLATION
BOOM CYLINDER
REMOVAL
INSTALLATION
ARM CYLINDER
REMOVAL
INSTALLATION
BUCKET CYLINDER
REMOVAL
INSTALLATION
HYDRAULIC CYLINDER
DISASSEMBLY
ASSEMBLY
WORK EQUIPMENT
REMOVAL
INSTALLATION
BUCKET
REMOVAL
INSTALLATION
ARM
REMOVAL
INSTALLATION
ARM, BUCKET
REMOVAL
INSTALLATION
BOOM
REMOVAL
INSTALLATION
OPERATOR’S CAB
REMOVAL
INSTALLATION
COUNTERWEIGHT
REMOVAL
INSTALLATION
ENGINE THROTTLE CONTROLLER
REMOVAL
INSTALLATION
SYSTEM CONTROLLER
REMOVAL
INSTALLATION
MONITOR PANEL
REMOVAL
INSTALLATION

40 MAINTENANCE STANDARD
SWING CIRCLE
SWING MACHINERY
TRACK FRAME
SPROCKET
IDLER
TRACK ROLLER
CARRIER ROLLER
TRACK SHOE
HYDRAULIC PUMP
CHARGING PUMP AND RELIEF VALVE
BLADE PUMP
L.H. 6-SPOOL CONTROL VALVE
R.H. 5-SPOOL CONTROL VALVE
BLADE CONTROL VALVE
SWING MOTOR
CENTER SWIVEL JOINT
PPC VALVE
HYDRAULIC CYLINDER
WORK EQUIPMENT

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