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Komatsu PC75R-2 Install guide

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WEBM004000
40-28
PC15R-8
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CONTENTS
PC75R-2
10 STRUCTURE AND FUNCTION ............................................. 10-1
20 TESTING AND ADJUSTING ................................................ 20-1
30 REMOVAL AND INSTALLATION ........................................... 30-1
40 MAINTENANCE STANDARD ............................................... 40-1
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00-2
PC75R-2
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Pages having no marks are those previously revised
or made additions.
00-2-1
PC75R-2
Mark ndication Action required
CPage to be newly Add
cPage to be replaced Replace
( ) Page to be delete Discard
LIST OF REVISED PAGES
The affected pages are indicated by the use of the
following marks. t is requested that necessary ac-
tions be taken to these pages according to table
below.
Mark Page Time of
revision Mark Page Time of
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revision Mark Page Time of
revision Mark Page Time of
revision
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30-8
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00-2-2
PC75R-2
Mark Page Time of
revision Mark Page Time of
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revision
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GENERAL PRECAUTIONS
Mistakes in operation extremely dangerous.
Read all the Operation and Maintenance Manual care-
fully BEFORE operating the machine.
1. Before carrying out any greasing or repairs, read
all the precautions written on the decals which
are suck on the machine.
2. When carrying out any operation, always wear sa-
fety shoes and helmet. Do not wear loose work
clothes, or clothes with buttons missing.
.Always wear safety glasses when hitting parts
with a hammer.
.Always wear safety glasses when grinding
parts with a grinder, etc.
3. f welding repairs are needed, always have a trai-
ned, experienced welder carry out the work.
When carrying out welding work, always wear
welding gloves, apron, glasses, cap and other clo-
thes suited for welding work.
4. When carrying out any operation with two or more
workers, always agree on the operating procedure
before starting. Always inform your fellow workers
before starting any step of the operation. Before
starting work, hang UNDER REPA R signs on
the controls in the operator's compartment.
5. Keep all tools in good condition and learn the cor-
rect way to use them.
6. Decide a place in the repair workshop to keep
tools and removed parts. Always keep the tools
and parts in their correct places. Always keep
the work area clean and make sure that there is
no dirt or oil on the floor.
Smoke only in the areas provided for smoking.
Never smoke while working.
PREPARATIONS FOR WORK
7. Before adding or making any repairs, park the ma-
chine on hard, level ground, and block the tracks
to prevent the machine from moving.
8. Before starting work, lower blade, bucket or any
other work equipment to the ground. f this is
not possible, use blocks to prevent the work
equipment from falling down. n addition, be sure
to lock all the control levers and hang warning
sign on them.
9. When disassembling or assembling, support the
machine with blocks, jacks or stands before star-
ting work.
10. Remove all mud and oil from the steps or other
places used to get on and off the machine. Always
use the handrails, ladders or steps when getting
on or off the machine.
Never jump on or off the machine.
f it is impossible to use the handrails, ladders or
steps, use a stand to provide safe footing.
PRECAUTIONS DURING WORK
11. When removing the oil filler cap, drain plug or hy-
draulic pressure measuring plugs, loosen them
slowly to prevent the oil from spurting out.
Before disconnecting or removing components of
the hydraulic circuit and engine cooling circuit,
first remove the pressure completely from the cir-
cuit.
12. The water and oil in the circuits are not hot when
the engine in stopped, so be careful not to get
burned.
Wait for the oil water to cool before carrying out
any work on the cooling water circuits.
00-3
PC75R-2
IMPORTANT SAFETY NOTICE
Proper service and repair is extremely important for the safe operation of your machine.
The service and repair techniques recommended by Komatsu and describe in this manual are both ef-
fective and safe methods of operation. Some of these operations require the use of tools specially de-
signed by Komatsu for the purpose.
To prevent injury to workers, the symbols and are used to mark safety precautions in this man-
ual. The cautions accompanying these symbols should always be carefully followed. f any danger arises
or may possibly arise, first consider safety, and take necessary steps to face.
SAFETY
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13. Before starting work, remove the leads from the
battery. Always remove the lead from the negative
( ± ) terminal first.
14. When raising heavy components, use a hoist or
crane. Check that the wire rope, chains and hooks
are free from damage.
Always use lifting equipment which has ample ca-
pacity. nstall the lifting equipment at the correct
places.
Use a hoist or crane and operate slowly to prevent
the component from hitting any other part.
Do not work with any part still raised by the hoist
or crane.
15. When removing covers which are under internal
pressure or under pressure from a spring, always
leave two bolts in position on opposite sides.
Slowly release the pressure, then slowly loosen
the bolts to remove.
16. When removing components, be careful not to
break or damage the wiring.
Damage wiring may cause electrical fires.
17. When removing piping, stop the fuel or oil from
spilling out. f any fuel or oil drips on to the floor,
wipe it up immediately.
Fuel or oil on the floor can cause you to slip, or
can even start fires.
18. As a general rule, do not use gasoline to wash
parts. n particular, use only the minimum of gaso-
line when washing electrical parts.
19. Be sure to assemble all parts again in their origi-
nal places. Replace any damage parts with new
parts.
When installing hoses and wires, be sure that
they will not be damaged by contact with other
parts when the machine is being operated.
20. When installing high pressure hoses, make sure
that they are not twisted. Damaged tubes are dan-
gerous, so be extremely careful when installing
tubes for high pressure circuits. Also, check that
connecting parts are correctly tightened.
21. When assembling or installing parts, always use
specified tightening torques.
When installing the parts which vibrate violently or
rotate at high speed, be particulary careful to
check that they are correctly installed.
22. When aligning two holes, never insert your fingers
or hand.
23. When measuring hydraulic pressure, check that
the measuring tool is correctly assembled before
taking any measurement.
24. Take sure when removing or installing tracks.
When removing the track, the track separates
suddenly, so never let anyone stand at either
end of the track.
00-4
PC75R-2
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00-5
PC75R-2
FOREWORD
This shop manual has been prepared as an aid to improve the quality of repairs by giving the operator an ac-
curate 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 shop manual mainly contains the necessary technical information for operations performed in a service
workshop.
The manual is divided into chapters on each main group of components; these chapters are further divided into
the following sections.
STRUCTURE AND FUNCTION
This section explains the structure and function of each component. t serves not only to give an understan-
ding of the structure, but also serves as reference material for troubleshooting.
TESTING AND ADJUSTING
This sections explains checks to be made before and after performing repairs, as well as adjustments to be
made at completion of the checks and repairs.
Troubleshooting charts correlating «Problems» to «Causes» are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the order to be followed when removing, installing, disassembling or assembling
each component, as well as precautions to be taken for these operations.
MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.
NOTE
The spe ifi ations ontained in this shop manual are subje t to hange at any time and without any
noti e.
Conta t your Komatsu distributor for the latest information.
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VOLUMES
Shop manual are issued as a guide to carry out re-
pairs. These various volumes are designed to avoid
duplicating the same information.
DISTRIBUTION AND UPDATING
Any additions, amendments or other changes will
be sent to Komatsu distributors.
Get the most up-to-date information before you start
any work.
FILING METHOD
1. See the page number on the bottom of the page.
File the pages in correct order.
2. Following examples show you how to read the pa-
ge number.
Example
3. Additional pages: additional pages are indicated
by a hyphen (-) and number after the page num-
ber.
Fle as in the example.
Example:
10-4
10-4-1
10-4-2
10-5
]Added pages
REVISED EDITION MARK
(123....)
When a manual is revised, an edition mark is re-
corded on the bottom outside corner of the pages.
REVISIONS
Revised pages are shown on the L ST OF RE-
V SED PAGES between the title page and SAFETY
page.
SYMBOLS
n order to make the shop manual greatly chelpful,
important points about safety and quality are marked
with the following symbols.
Symbol tem Remarks
Safety
Special safety precautions are ne-
cessary when performing the
work.
Extra special safety precautions
are necessary when performing
the work because it is under inter-
nal pressure.
Caution
Special technical precautions or
other precautions for preserving
standards are necessary when
performing the work.
Weight
Weight of parts or systems.
Caution necessary when selecting
hoisting wire, or when working
posture is important, etc.
Tightening
torque
Parts that require special attention
for the tightening torque during as-
sembly.
Coat Parts to be coated with adhesives
and lubricants etc.
Oil, water Places where oil, water or fuel
must be added, and their quantity.
Drain
Places where oil or water must be
drained, and quantity to be
drained.
HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL
00-6
PC75R-2
tem number (10. Structure
and function)
Consecutive page number for
each item
10 - 3
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