PDF Shop Manual Komatsu PC60-7 Hydraulic Excavator - 3 MB
Gain access to factory-level repair and maintenance information for your Komatsu PC60-7 Hydraulic Excavator.
This comprehensive shop manual provides detailed procedures for diagnostics, troubleshooting, disassembly, and assembly.
It is an indispensable tool for professional technicians and equipment owners who need to perform complex repairs.
Following these expert instructions will help maintain your excavator's performance and extend its service life.
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--- Page 1 ---
SEBM004101
Shop
Manual
HYDRAULIC EXCAVATOR
sERIAL~uMBERS PC60-7 - 45001 thru 52373
This material is proprietary to Komatsu America International Company and
is not to be reproduced, used, or
disclosed exceptin accordance with written authorizationfrom Komatsu America International Company.
It is our policyto improve our products whenever it is possible and practicalto do so. We reserve the right to make
changes or add improvementsat any time without incurring any obligationto install such changeson products sold
previously.
Due to this continuous programof research and development, periodic revisions may be made to this publication.
the latest revision.
It is recommended that customers contact their distributor for information on
January 1998 Copyright 1998 Komatsu America International Company
00- 1
0
--- Page 3 ---
FOREWORD COATING MATERIALS
COATING MATERIALS
The recommended coating materials prescribed in Komatsu Shop Manuals are listed below.
Category I Komatsu code Part No. Qâtv Container I M a i n aDDlications,
features
LT-1A 790-129-9030 150 g
Tube I- Used to prevent rubber gaskets, rubber cushions,
and cork duasfrom cominaout
* Used in places requiringanimmediately effec-
Plastic tive, strong adhesive.Used for plastics (except
LT-1 B 790-129-9050 Container polyethylene, polypropylene, tetrafluoroethylene,
and vinyl chloride), rubber, metal, and non-metal.
09940-00030 50 9
Plastic
container -
* Features:Resistance to heat,chemicals
Used for anti-loosening and sealant purposes for
bolts and plugs.
Adhesive
790-129-9060
4dhesive - Used as adhesive or sealant for metal, glass, plastic
:Set of adhesive 1 Kg
1-
LT-3 iardenin!
m d hardenging
)gent:
agent)
500 g Can
E
Plastic Used assealant for machined holes
790-129-9040 250 g container
* Features:Resistance to heat,chemicals
(Loctite 648-50) 79A-129-9110 50 cc - * Used at joint portions subject to high tempera-
ture
* Used as adhesive or sealant for gaskets and
790-1 29-9010 200 g Tube packings of power train case, etc.
* Features:Resistance to heat
Used as sealant for flange surfaces and bolts at
high temperature locations, used to prevent sei-
790-129-9070 Can zure
* Used as sealant for heat resistant gasket for high
temperature locations such as engine precombustion
chamber, exhaust pipe
790-129-9020 200 g Tube
-
*
*
Features:Resistance to water, oil
Used as sealant for flange surface, thread
Also possible to useassealant for flanges with
- large clearance
Used as sealant for mating surfaces of final drive
case, transmission case
Used as sealant for various threads, pipe joints,
Plastic flanges
790-129-9080 1 Kg Used assealant for tapered plugs, elbows, nip-
ples of hydraulic piping
e+
Features: Silicon based, resistance to heat, cold
09940-00011 250 g Used as sealant for flange surface, thread
Used as sealant for oil pan, final drive case, etc.
I LG-7 09920-001 50 150 g
Features: Silicon based, quick hardening type
Used as sealant for flywheel housing, intake mani-
fold, oil pan, thermostat housing, etc.
Rust preven- Used as lubricant forsliding parts (to prevent
09940-00051 Can squeaking)
Molybdenum
bricant
09940-00040 200 g Tube I -- Used to prevent seizure or scuffing of the thread
when press fitting or shrink fitting
Used as lubricant for linkaae.bearinas.etc.
SYG-350LI General purpose type
SYG-400LI
Lithium grease G2-LI SYG-400LI-A Various Various
SYG-16OLI
SYGA-160CNLI
SSG2-400CA * Used for normal temperature, light load bearing
SYG2-350CA at places in contact with water or steam
Calcium grease G2-CA SYG2-400CA-A Various Various
SYG2-160CA
SYGA-16CNCA
disulphide SYG2-400M 400 g 3ellows type
- Used for places with heavy load
10 per cas
arease
00-8
--- Page 4 ---
01 GENERAL
General assembly drawing ................................ 01-2
Specifications ..................................................... 01-3
Weight table......................................................... 01-5
List of lubricant and water................................. 01-7
0
hl
0
01-1
--- Page 5 ---
020107
c N 0 P
0
n
0
0
C
W
r,
2
G)
Y
OY
\
N
0
c
0
D
0
4
0
N
c \ I
--- Page 6 ---
020107
n
N
n
N
â
N
d A
N
I
A 0
\
CD
N
2
n
0
A.
0
0
m
--- Page 7 ---
F
D
I
D
m
I
N
I w
v)
> 0 b
V
0
020107
--- Page 8 ---
TCC VALVE
FUNCTION Standard type
The TCC valve carries out an approximate Standard mode
equal horse-power controlso that the hydrau-
Light-load mode
lic horsepower sucked by the pump does not
exceed the engine horsepower by limiting the CI
+d
C
discharge amount 0 to a specified aboutin re- S
lation with the discharge pressure Pp, even if
the LS valve tries to increase the pump dis-
:
m
P
charge amount Q when the discharge pres- .c
sure Pp becomes high and opening area of v)
5
the control valveis large. Cl
0 Inotherwords,whenaloadbecomeslarge E,
a
during operation and the pump discharge
Pump discharge pressure Pp
pressure Pp rises, the TCC valve reduces the
pump discharge amount 0, and when the 201F07014
pump discharge pressure Pp lowers, it in-
creases the pump discharge amount Q.
Relationshipbetweenthepumpdischarge Blade type
pressure Pp and the pump discharge amount
0 is as shown in the chart. Standard mode
Normally, it is set to the pump suction torque
of the standard mode, but when a signal from Standard mode +
the mode switching solenoid valve is input- Blade pump in operation
I-
ted, the pump suction horsepower lowers by Light-load mode +
o,
0
Blade pump in operation
hl approximately 15% as shown
by
the
light-load
0 mode curve.
Furthermore, for the blade type models, since
the blade pump is mounted separately from
the main pump, when the blade pump is i n
operation, suction torque of the main pump is
reduced by the amount sucked by the blade
Pump discharge pressure Pp
pump so that the sum of the main pumpsuc- 201F07015
tion torque and the blade pump suction
torque becomes the total suction torque
(100%).
10-35
--- Page 9 ---
020107
0
2
5
ul
6
--- Page 10 ---
1 2 3
6 7 8
0
cv
0
201C007045
L.H. and R.H. TRAVEL VALVE BOOM VALVE
1. Suction valve (A) 6.Suction valve (bottom)
2. Suction valve (B) 7. Suction valve (head)
3. Spool 8. Spool
4. Pressure compensation valve R 9. Pressure compensation valve R
5. Pressure compensation valve F IO. Pressure compensation valve F
1 0-55
--- Page 11 ---
2) Introduction of LS pressure
FUNCTION
The LS pressure denotes the actuator load pressure at the outlet port of the controlvalve.
Actually, in the control valves, the pump pressure Pp is reduced to the same pressure of the actuator
circuit pressure A by the pressure reducing valve (3) in the pressure compensation valve before intro-
ducing into theLS circuit PLS.
Furthermore, the orifice C is provided in the middle of the circuit from the pump circuit Pp to the pres-
sure reducing valve(3) for damper function.
In the travelvalves, the actuator circuit pressure A is directly introduced into theLS circuit PLS.
201 F07029
OPERATION
Control valves (boom, arm, bucket, swing) ing valve (3) are same (SA = SLS), and on the
When the spool (1) is operated, the pump SA side, the actuator circuit pressure PA (=A)
pressure Pp starts to flow to the actuator cir- is acting, and on the opposite SLSside, the re-
cuit A from the flow control valve (2)and the duced pump pressure Pp is acting.
spool notch a through the bridge pathb. Therefore, the pressure reducing valve (3) bal-
At the sametime, the pressure reducing valve ances a t the point where the actuator circuit
(3) moves to the right (*) side, so the pump pressure PA and the spring chamber pressure
pressure Pp introduced from the orifice c is PLsl are balanced, and the pump pressure Pp
depressurized by the pressure loss a t the reduced by the notchd is introducedto the LS
notch d and introduced to the LS circuit PLS, circuit PLS as the actuator circuit pressure A.
and then, further introduced to the spring
chamber PLsi.
At this time, the LS circuit PLS is open to the
tank circuit T through the LS bypass plug (4)
(refer to the description of the LS bypass
plug).
Areas of the both ends of the pressure reduc-
10-65
--- Page 12 ---
2. When lowering the boom, if the head pressure B of the cylinder (1) is greater than the bottom pres-
sure A, and the operation is ,in the load process, the check valve (3) closes t o shut off the circuit be-
tween thehead and the bottomsides.
0
(v
0
201F07039
OPERATION
During a loadprocesssuch as loweringthe
boom, etc., the pressure B at the head side of
the boom cylinder (1) becomes higher than
the pressure A at the bottomside.
At this time, the check valve (3) is closed by
the pressure B at the head side and the spring
( 4 , and the passage between the head circuit
and the bottom circuitis shut off.
10-75
--- Page 13 ---
020107
L i
I
W
0
I
J
-1
I
I
--- Page 14 ---
-1
-0-CJwww
0 0 0 0 0
aaaaa
..
020107
--- Page 15 ---
3. During fine control (when the lever is re-
turned)
When the disc (5) starts to be returned, the
spool (1) is pushed up by the force of the cen-
tering spring (3) and the PI port pressure.
By this the fine control hole f opens to the
drain chamber D and the pressure oil a t the PI
port isreleased.
If the pressure at the PI port drops toofar, the
spool (1) is pushed up by the measuring
spring (21, the fine control hole f is shut off
from the drain chamber D, and almost at the
same time, it is connected to the pump pres-
sure chamber Pp to supply pumppressure un-
til the pressure a t the PI port recovers the
pressure corresponding to thelever position.
When the spool of the control valve returns,
oil in the drain chamber D flows in from the
fine control holef' of the valve at the side that
is not working. The oil is then introduced to
the chamber B through the P2 port to fill the
chamber with oil (Fig. 3).
(F i 8. 3)
SBPOl738
4. At full stroke
When the disc (5)pushes down the piston(4)
z
b
0
and theretainer (9) pushes down the spool( I ) ,
the fine control hole f is shut off from the
(v
0 chamber D and
drain connected tothepump
pressure chamber Pp. Therefore, the pilot
pressure oil from the control pump passes the
fine control holef, enters into the chamberA
through the PI port, and pushes the spool of
the controlvalve.
Return oil from the chamberB passes the fine
control hole f' through the P2 port and flows
into the drain chamberD (Fig. 4).
SBPO1739
10-107
0
--- Page 16 ---
3) During fine control
(when control lever is returned)
When lever (5) starts to be returned, spool (1)
is pushed up by the force of centering spring
(3)and thepressure at port PI.
When this happens, fine control holef is con-
nected to drain chamber D and the pressure
oil at port PI is released.
If the pressure at portPI drops too far, spool
(1) is pushed down by metering spring (Z),
and fine control hole f is shut off from drain
chamber PI. At almost the same time, it is
connected to pumppressure chamber Pp, and
the pump pressure is supplied until the pres-
sure at port PI recovers to a pressure that cor-
responds to thelever position.
When the spool of the control valve returns,
oil in drain chamberD flows in from finecon-
trol hole f ' in the valve on the side that is not
working. The oil passes through port P2 and
enters chamber B to fill the chamber with oil.
(Fig. 3)
SAPO 1742
(Fig. 3)
4) At full stroke
When lever (5) pushes down piston (4), and
retainer (7) pushes down spool ( I ) , fine con-
trol hole f is shut off from drain chamber D,
and is connected with pump pressure cham-
ber Pp. Therefore, the pilot pressure from the
control pump passes through fine control
hole f and flows to chamberA from port PI,
and pushes the control valve spool.
The oil returning from chamber B passes
from port Pz through fine control holef ' and
flows to drain chamber D. (Fig. 4)
(Fi a. 4) SAPO1 743
(Fig. 4)
10-114-4
0
--- Page 17 ---
3. COMPONENTS OF THE SYSTEM
I ) Controller
\ i
1 2
\
201F07066
1. Connector I/O signal
2. Controller
3. Fuse CN-P44
SPECIFICATIONS
Type : LC2MP
10-124
--- Page 18 ---
ELECTRICAL WIRING DIAGRAM
7
I
14 13
201F07079
1. Alarm buzzer IO. Radio
2. Swing brake controller 11. Wiper switch
3. Fuel lever limit switch 12. Swing lock switch
4. Horn switch 13. Travel speed switch (forSTD type)
5. Speaker 14. PPC lock limit switch
6. Monitor panel 15. Travel accelerator switch (forblade type)
7. Starter switch 16. Heater
8. Fuse box 17. Glow resistance
9. Swing lock prolix switch
10-134
--- Page 19 ---
4. ONE-TOUCH DECELERATION SWITCH
Engine
Fuel control
lever
I Battery
201F07089
FUCTION OPERATION
Engine
When the vehicle is placed in a waiting status speed (rprn)
for a moment due to waiting for work or wait- I
i n g f o r a d u m p truck, by pushing the one-
touch deceleration switch on the top of the
left lever, engine speed will be lowered imme- Decelerated speed
diately to the deceleration speed to reduce
fuel consumption andnoise. Max. 1
To restart the operation, push the switch
again, and the enginespeed will rise to theset
speed immediately.
201F07090
10-145
--- Page 20 ---
FOR CHASSIS
Machine model PC60-7
Item I Measurement
conditions
Standard
value I value
Permissible
- Hydraulic oil temperature: 45 - 55 "C
1Coolant
relief
pump
temperature:
Min. 1,800 Min. 1,800
rang, operating within(LS relief)
- 1 pump relief: arm relief
Boom control valve
Arm control valve
Bucket control valve
Swing control valve
Travel control valve
202F230:
--
=
Boom control lever Center of the lever knob 100 f 10
100 f 10
Read the max. value t o the end of
stroke
Arm control lever Engine stopped 100 * 10100 f 10
Excluding neutral play
Bucket control lever 100 f 10 100 f 10
Swing control lever 100 f 10
I 100 f 10
Travel control lever 115 f 15 1 115f15
Fuel control lever
I Slow -f Full 140 f 20 1 140i20
Boom, bucket, arm
swing Max. 5
I Max. 5
Play of control lever Travel lever Max. 10 Max. 10
Fuel control lever Max. 30 Max. 30
15.7 f 4.915.7 f 4.9
Hydraulic oil temperature:45 - 55 "C
Fit a push-pull scale to thecenter of th 13.7 i- 4.9 13.7f 4.9
Arm
control
lever
control
lever
knob t o measure
(1.4f 0.5) (1.4f 0.5)
Read the max. value t o the end of
13.7 i- 4.9
(1.4i- 0.5) I 13.7f 4.9
(1.4k 0.5)
Swing control lever
15.7 i 4.9
(1.6k 0.5)(1.6
16.7i 4.9
16.7
I 15.7f 4.9
f 0.5)
k 4.9
Travel control lever
Fuel
lever
control Slow --+ Full
68.6 k 14.7 +
68.6 14.7
(7 f 1.5) (7f 1.5)
20-3
0
--- Page 21 ---
LIST OF EQUlPnIENTS FOR INSPECTION, ADJUSTMENT AND
TROUBLE-SHO( lTlNG
Inspection/adjustment item Symbol Part No. Remarks Part Name
1 799-203-9000 Multi-tachometer Digital display
Engine speed A L : 60 - 2,000 r p m
6210-81-41 11 2Gear box H : 60 - 19,999 r p m
Coolant and oil temperaturc B 799-101-1502 Digital thermometer -50 - 1,200 "C
I I I
Pressure gauge : 2.45(25), 5.88(60),
799-101-5002 Hydraulic tester
I l l I I -
39.2(400), 58.8(600) MPa(kn/cm2)
I I ' 790-261-1203 I Digital
hydraulic
tester I Pressure gauge :
68.6 MPa (700 kQ/cm2)
I 2 I 799-401-2320 I Hydraulicgauge I 0.98 MPa (IOkg/cm2)
Both male and female 14x
-790-261-1311
Hydraulic oil pressure
Both male and female22 x
*790-261-1331 1.5 (female PT1/8)
1 4 1 799-401-2700 1 Differential
pressure gauge1 -
Both male and female 14x
-790-261-1360 Adapter 1.5 (female PT1/8)
5 For 14