Komatsu 560C Wheel Loader Service Manual SM560C99_1E

Description

• Model List:
  • 560C Wheel Loader

• 1. MAIN MENU
• 2. COVER
• 3. CONTENTS
• 4. INTRODUCTION
• 4.1. SAFETY PRECAUTIONS
• 4.1.1. GENERAL
• 4.1.2. OPERATION
• 4.1.3. MAINTENANCE
• 4.2. SHIPPING SPECIFICATIONS
• 4.2.1. DIMENSIONS
• 4.2.2. SYSTEM REFILL CAPACITIES (APROXIMATE)
• 4.3. SERVICE INFORMATION
• 4.3.1. SERVICE PARTS
• 4.3.2. SERIAL NUMBERS
• 4.3.3. INSPECTION AND REPAIR
• 4.4. LOCTITE USAGE
• 4.4.1. SURFACE PREPARATION
• 4.4.2. APPLICATION
• 4.4.3. SETTING TIME (BEFORE PLACING IN OPERATION)
• 4.4.4. REMOVAL
• 4.4.5. APPPLICATION AT LOW TEMPERATURES
• 4.5. STANDARD TORQUES
• 4.5.1. BOLT IDENTIFICATION CHART
• 4.5.2. TORQUE VALUES FOR STANDARD FASTENERS
• 4.5.3. SPLIT FLANGE CONNECTIONS
• 4.5.4. HYDRAULIC TUBES AND FITTINGS
• 4.5.5. HOSE CLAMPS
• 4.6. SERVICE/SPECIAL TOOLS
• 4.6.1. SERVICE/SPECIAL TOOLS
• 5. BRAKES
• 5.1. WHEEL BRAKE
• 5.1.1. DESCRIPTION
• 5.1.2. OPERATIONAL TEST
• 5.1.3. SERVICE DIAGNOSIS
• 5.2. PARKING BRAKE
• 5.2.1. DESCRIPTION
• 5.2.2. SPECIFICATIONS
• 5.2.3. SERVICE DIAGNOSIS
• 5.2.4. ADJUSTING AND OPERATIONAL TEST OF THE BRALE
• 5.2.5. REMOVAL AND DISASSEMBLY
• 5.2.6. INSPECTION AND REPAIR
• 5.2.7. REASSEMBLY AND INSTALLATION
• 5.3. SERVICE BRAKE WARNING LIGHT E AND SWITCHES
• 5.3.1. DESCRIPTION
• 5.4. COOLING BRAKE LOW PRESSURE SWITCH AND BRAKE SYSTEM OIL FILTER WARNING LIGHT SWITCH
• 5.4.1. DESCRIPTION
• 5.5. BRAKE PUMP
• 5.5.1. DESCRIPTION
• 5.5.2. REMOVAL
• 5.5.3. DISASSEMBLY
• 5.5.4. INSPECTION AND REPAIR
• 5.5.5. REASSEMBLY
• 5.5.6. INSTALLATION
• 5.6. BRAKE COOLING PUMP
• 5.7. BRAKE ACCUMULATOR
• 5.7.1. CHECK THE ACCUMULATOR CONDITION
• 5.7.2. CHECKING NITROGEN CHARGE IN ACCUMULATOR
• 5.7.3. CHARGING ACCUMULATOR WITH NITROGEN
• 5.8. CHECK PERFORMANCE OF MAIN BRAKES
• 5.8.1. CHECK THE BRAKES EFFECTIVENESS
• 6. STEERING
• 6.1. GENERAL
• 6.1.1. SPECIFICATIONS
• 6.1.2. SERVICE DIAGNOSIS
• 6.1.3. LINKAGE ADJUSTMENT
• 6.2. STEERING COLUMN
• 6.2.1. DESCRIPTION AND OPERATION
• 6.2.2. SPECIFICATIONS
• 6.2.3. REMOVAL
• 6.2.4. DISASSEMBLY
• 6.2.5. INSPECTION AND REPAIR
• 6.2.6. REASSEMBLY
• 6.2.7. INSTALLATION
• 6.3. STEERING GEAR
• 6.3.1. DESCRIPTION
• 6.3.2. THEORY OF OPERATION
• 6.3.3. SPECIFICATIONS
• 6.3.4. WORM BEARING PRELOAD ADJUSTMENT
• 6.3.5. PITMAN SHAFT PRELOAD ADJUSTMENT
• 6.3.6. REMOVAL
• 6.3.7. DISASSEMBLY
• 6.3.8. INSPECTION AND REPAIR
• 6.3.9. REASSEMBLY
• 6.3.10. INSTALLATION
• 7. COOLING
• 7.1. GENERAL
• 7.1.1. DESCRIPTION
• 7.1.2. OPERATION
• 7.1.3. SPECIFICATIONS
• 7.1.4. SERVICE DIAGNOSIS
• 7.2. STEERING OIL COOLER
• 7.2.1. REMOVAL
• 7.2.2. INSTALLATION
• 7.3. RADIATOR
• 7.3.1. REMOVAL
• 7.3.2. DISASSEMBLY
• 7.3.3. INSPECTION AND REPAIR
• 7.3.4. REASSEMBLY AND INSTALLATION
• 7.4. TRANSMISSION OIL COOLER
• 7.4.1. REMOVAL
• 7.4.2. INSTALLATION
• 8. DRIVE TRAIN
• 8.1. DESCRIPTION
• 8.2. HYDRAULIC OIL FLOW
• 8.3. SPECIFICATIONS
• 8.4. SERVICE DIAGNOSIS
• 8.5. CHECKING THE CHARGING PUMP FLOW RATE
• 8.6. CHECKING TRANSMISSION AND TORQUE CONVERTER PRESSURES
• 8.7. TORQUE CONVERTER
• 8.7.1. GENERAL
• 8.7.2. TORQUE CONVERTER
• 8.7.3. CHARGING PUMP
• 8.8. TRANSMISSION
• 8.8.1. GENERAL
• 8.8.2. TRANSMISSION
• 8.8.3. CLUTCH PACKS
• 8.8.4. CONTROL VALVE
• 8.9. DRIVE AXLE AND DIFFERENTIAL
• 8.9.1. GENERAL
• 8.9.2. DRIVE SHAFTS
• 8.9.3. TRANSFER DRIVE
• 8.9.4. PLANETARY GEAR
• 8.9.5. WHEEL HUB AND SERVICE BRAKES
• 8.9.6. DIFFERENTIAL
• 8.9.7. DRIVE AXLE
• 9. ELECTRICAL
• 9.1. GENERAL
• 9.1.1. DESCRIPTION
• 9.2. WIRING DIAGRAM
• 9.2.1. ELECTRICAL LOADER SYSTEM
• 9.2.2. SERVICE DIAGNOSIS
• 9.3. ALTERNATOR
• 9.3.1. SPECIFICATION
• 9.3.2. INTRODUCTION
• 9.3.3. OPERATING PRINCIPLES
• 9.3.4. TROUBLESHOOTING PROCEDURES
• 9.3.5. INTEGRAL CHARGING SYSTEM REPAIR
• 9.4. BATTERY
• 9.4.1. SAFETY PRECAUTIONS
• 9.4.2. ELECTROLYTE STATE OF CHARGE
• 9.4.3. ELECTROLYTE IN TROPICAL AND ARCTIC CLIMATES
• 9.4.4. TESTING AND MAINTENANCE OF THE BATTERY
• 9.4.5. BATTERY CHARGING GUIDE
• 9.4.6. BATTERY STORAGE
• 9.4.7. BATTERY PRIMARY RATINGS
• 9.4.8. COLD ENGINE CRANKING PERFORMANCE
• 9.4.9. DRY CHARGE ACTIVATION
• 9.4.10. TYPICAL CAUSE OF BATTERY FAILURE
• 9.4.11. VISUAL INSPECTION OF BATTERY
• 9.5. CRANKING MOTOR
• 9.5.1. SPECIFICATION
• 9.5.2. INTRODUCTION
• 9.5.3. OPERATION
• 9.5.4. TROUBLESHOOTING THE CRANKING CIRCUIT
• 10. FRAME
• 10.1. DESCRIPTION AND OPERATION
• 10.2. SPECIFICATIONS
• 10.3. MAINTENANCE
• 10.4. WELDING
• 10.5. CHECKING HINGE VERTICAL MOVEMENT
• 10.6. DISASSEMBLY
• 10.7. INSPECTION AND REPAIR
• 10.8. REASSEMBLY
• 11. HYDRAULIC
• 11.1. GENERAL
• 11.1.1. DESCRIPTION
• 11.1.2. THEORY OF OPERATION
• 11.1.3. SPECIFICATIONS
• 11.1.4. SERVICE DIAGNOSIS
• 11.2. TEST AND ADJUSTMENT
• 11.2.1. STEERING SYSTEM PERFORMANCE TEST
• 11.2.2. HYDRAULIC SYSTEM PERFORMANCE TEST
• 11.2.3. STEERING SYSTEM PRESSURE TEST
• 11.2.4. HYDRAULIC SYSTEM PRESSURE TEST
• 11.2.5. SUCTION LINE LEAKAGE TEST
• 11.2.6. HYDRAULIC CONTROL LEVER LEAKAGE ADJUSTMENT
• 11.3. PUMPS
• 11.3.1. STEERING/SWITCH PUMP
• 11.3.2. HYDRAULIC AND BRAKE COOLING PUMP
• 11.3.3. GROUND DRIVEN STEERING PUMP (IF EQUIPPED)
• 11.4. VALVES
• 11.4.1. STEERING VALVE
• 11.4.2. PILOT CONTROL VALVE
• 11.4.3. HYDRAULIC CONTROL VALVE
• 11.4.4. STEERING CYLINDER CHECK VALVES
• 11.4.5. GROUND DRIVEN STEERING DIVERTER VALVE (IF EQUIPPED)
• 11.4.6. GROUND DRIVEN STEERING CHECK VALVE
• 11.4.7. STEERING RETURN SURGE VALVE
• 11.5. CYLINDERS
• 11.5.1. BUCKET CYLINDER
• 11.5.2. BOOM CYLINDERS
• 11.5.3. STEERING CYLINDERS
• 11.6. RESERVOIRS AND FILTER
• 11.6.1. DESCRIPTION
• 11.6.2. OPERATION
• 11.6.3. SPECIFICATION
• 11.6.4. LOADER RETURN SURGE VALVE TEST
• 11.6.5. REMOVAL
• 11.6.6. DISASSEMBLY
• 11.6.7. INSPECTION AND REPAIR
• 11.6.8. REASSEMBLY
• 11.6.9. INSTALLATION
• 12. POWER
• 12.1. DESCRIPTION
• 12.2. SPECIFICATIONS
• 12.3. SERVICE DIAGNOSIS
• 12.4. AIR INTAKE SYSTEM TEST
• 12.5. ENGINE CONTROLS ADJUSTMENT
• 12.6. REMOVAL
• 12.7. ENGINE REPAIR
• 12.8. ENGINE INSTALLATION
• 13. SUPERSTRUCTURE
• 13.1. GENERAL
• 13.1.1. SPECIFICATIONS
• 13.2. CAB WINDOW GLASS
• 13.2.1. REPLACEMENT
• 13.3.1. REMOVAL
• 13.3.2. INSTALLATION
• 14. SUSPENSION
• 14.1. DESCRIPTION
• 14.2. SPECIFICATION
• 14.3. REMOVAL
• 14.4. BOLSTER REPAIR
• 14.5. INSTALLATION
• 15. WHEELS AND TRACKS
• 15.1. DESCRIPTION
• 15.2. OPERATION
• 15.3. WHEEL REMOVAL
• 15.4. WHEEL DISASSEMBLY AND ASSEMBLY
• 15.5. WHEEL INSTALLING
• 16. MOUNTED EQUIPMENT
• 16.1. GENERAL
• 16.1.1. SAFETY PRECAUTIONS
• 16.1.2. DESCRIPTION AND OPERATION
• 16.2. LOADER LINKAGE PIVOTS
• 16.2.1. SPECIFICATIONS
• 16.2.2. REMOVAL AND DISASSEMBLY
• 16.2.3. REASSEMBLY AND INSTALLATION
• 16.3. BUCKET
• 16.3.1. SPECIFICATIONS
• 16.3.2. REMOVAL
• 16.3.3. INSTALLATION
• 16.3.4. CUTTING EDGE REPLACEMENT
• 16.3.5. TOOTH AND ADAPTOR INSTALLATION