Komatsu PC75R-2 Install guide

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.
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30-5
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30-8
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00-2-2
PC75R-2
Mark Page Time of
revision Mark Page Time of revision Mark Page Time of revision Mark Page Time of revision Mark Page Time of revision
30-9
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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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Heavy parts (25 kg (55.116lb.) or more)
must be lifted with a hoist etc. n the Disas-
sembly and Assembly section, every part
weighing 25 kg or more is clearly indicated with
the symbol
1. f a part cannot be smoothly removed from the
machine by hoisting, the following checks should
be made:
.Check for removal of all bolts fastening the part
to the relative parts.
.Check for any part causing interference with
the part to be removed.
2. Wire ropes
1) Use adequate ropes depending on the weight
of parts to be hoisted, referring to the table be-
low:
W RE ROPES
(Standard «S» or «Z» twist ropes
without galvanizing)
Rope diameter (mm) Allowable load (tons)
10
11.2
12.5
14
16
18
20
22.4
30
40
50
60
1.0
1.4
1.6
2.2
2.8
3.6
4.4
5.6
10.0
18.0
28.0
40.0
The allowable load value is estimated to be
one-sixth or one-seventh of the breaking
strength of the rope used.
2) Sling wire ropes from the middle portion of the
hook. Slinging near the edge of the hook may
cause the rope to slip off the hook during hoist-
ing, and a serious accident can result.
Hooks have maximum strength at the middle
portion.
3) Do not sling a heavy load with one rope alone,
but sling with two or more ropes symmetrically
wound on to the load.
Slinging with one rope may cause turning of
the load during hoisting, untwisting of the
rope, or slipping of the rope from its original
winding position on the load, which can
cause dangerous accidents.
4) Do not sling a heavy load with ropes forming a
wide hanging angle from the hook.
When hoisting a load with two or more ropes,
the force subjected to each rope will increase
with the hanging angles.
The table below shows the variation of allowa-
ble load (kg) when hoisting is made with two ro-
pes, each of which is allowed to sling up to
1000 kg vertically, at various handing angles.
When two ropes sling a load vertically, up to
2000 kg of total weight can be suspended.
This weight becomes 1000 kg when two ropes
make a 120ë hanging angle.
On the other hand, two ropes are subjected to
an excessive force as large as 4000 kg if they
sling a 2000 kg load at a lifting angle of 150ë.
HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
00-7
PC75R-2

STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE
00-8
PC75R-2
The following charts give the stardard tightening torques of bolts and nuts. Exceptions are given in sections of «Dis-
assembly and Assembly».
1. STANDARD TIGHTENING TORQUE OF BOLTS AND NUT
Thread
diameter
of bolts
(mm)
Pitch of
bolts
(mm)
Width across flat
(mm)
kgm Nm lb. ft. kgm Nm lb. ft.
6
8
10
12
14
1
1.25
1.5
1.75
2
10
13
17
19
22
5
6
8
10
12
0.96w0.1
2.3w0.2
4.6w0.5
7.8w0.8
12.5w1
9.5w1
23w2
45w4.9
77w8
122w13
7w0.74
17w1.5
6.5w0.6
11w1
17.5w2
1.3w0.15
3.2w0.3
6.5w0.6
11w1
17.5w2
13.5w1.5
32.2w3.5
63w6.5
108w11
172w18
10w1
24w2.6
47w4.8
80w8
127w13
16
18
20
22
24
2
2.5
2.5
2.5
3
24
27
30
32
36
14
14
17
17
19
19.5w2
27w3
38w4
52w6
66w7
191w21
262w28
372w40
511w57
644w70
141w15
194w21
275w30
377w42
475w52
27w3
37w4
53w6
73w8
92w10
268w29
366w36
524w57
719w80
905w98
198w22
270w26
387w42
531w59
668w72
27
30
33
36
39
3
3.5
3.5
4
4
41
46
50
55
60
19
22
24
27
±
96w10
131w14
177w20
230w25
295w33
945w100
1287w140
1740w200
2250w250
2900w330
698w74
950w103
1282w147
1658w184
2137w243
135w15
184w20
250w27
320w35
410w45
1329w140
1810w190
2455w270
3150w350
4050w450
980w103
1336w140
1809w199
2321w258
2985w332
This torque table does not apply to bolts or nuts which have to fasten nylon or other parts non-ferrous metal washer.
.Nm (Newton meter): 1 Nm = 0.102 kgm (0.737 lb.ft.)

STANDARD TIGHTENING TORQUE
00-9
PC75R-2
Superficie di tenuta
Sealing surface
2. TIGHTENING TORQUE FOR NUTS OF FLARED
Use these torques for nut part of flared.
Thread diameter
of nut part
(mm)
Width across flats
of nut part
(mm)
T GHTEN NG TORQUE
kgm Nm lb.ft.
1/2" - 20
9/16" - 18
3/4" - 16
7/8" - 14
1.
1
/16
"
-12
1.
5
/16
"
-12
1.
5
/8
"
-12
22
33
17
17
22
27
32
38
50
27
41
2.6w0.5
4w0.5
6.7w2
8w2
9.7w3
17w3
20w5
8w2
20w5
25.5w4.9
39.2w4.9
65.7w19.6
78.5w19.6
95.15w29.4
166.7w29.4
196.2w49
78.5w19.6
196.2w49
18.8w3.6
28.9w3.6
48.4w14.5
57.9w14.5
70.13w21.7
122.9w21.7
144.6w36
57.9w14.5
144.6w36
Thread diameter
of nut part
(mm)
Width across flats
of nut part
(mm)
T GHTEN NG TORQUE
kgm Nm lb.ft.
9/16" - 18
11/16" - 16
13/16" - 16
1" - 14
1.
3
/16
"
-12
1.
7
/16
"
-12
1.
11
/16
"
-12
2" - 12
17
22
24
30
36
41
50
57
2.3 ± 2.5
3.4 ± 3.9
5.2 ± 5.8
8.2 ± 9.2
12.2 ± 13.3
15.3 ± 17.3
18.4 ± 20.4
20.4 ± 24.4
23 ± 25
33 ± 38
51 ± 57
80 ± 90
120 ± 130
150 ± 170
180 ± 200
200 ± 240
17 ± 18.4
24.3 ± 28
37.6 ± 42
59 ± 66.3
88.4 ± 95.8
110.5 ± 125.3
132.6 ± 147.4
147.4 ± 176.8

00-10
PC75R-2
COATING MATERIALS
The recommended coating materials prescribed in Komatsu Shop Manuals are listed below:
Nomenclature Code Applications
Adhesives
ASL800010 Used to apply rubber pads, rubber gaskets and cork plugs.
ASL800020 Used to apply resin, rubber, metallic and non-metallic parts when a fast, strong
seal is needed.
Loctite 222 Used for low resistance locking of screws, check nuts and adjustment nuts.
Loctite 242
To prevent the loosening of bolts, nuts and plugs and the leakage of oil. Used for
medium resistance locking of screws and nuts of every type, and for locking keys
and bearings.
Loctite 262 Used for high resistant of threaded parts that can be removed with normal tools.
Loctite 270 Used for high resistant locking and for sealing threaded parts, bolts and stud bolts.
Loctite 542 Used for sealing the union threads for hydraulic tubes.
Loctite 573 Used for sealing rather exact plane surfaces when the option of possible future
dismantling is required.
Loctite 601 Used for high resistant locking of mechanical components that can be removed
only after heating
Loctite 675
Used to lock cylindrical couplings and for the permanent locking of threaded parts,
and also to lock shafts to bearings, gears, pulleys, pins, bushings, etc.
Gasket sealant
ASL800060 Used by itself to seal grease fittings, tapered screw fittings and tapered screw fit-
tings in hydraulic circuits of less than 50 mm in diameter.
Loctite 510 Used by itself on mounting flat surface
(Clearance between surfaces within 0.2 mm)
Loctite 518 Used by itself on mounting flat surface
(Clearance between surfaces within 0.5 mm)
Antifriction compound
(Lubricant including
Molybdenum disulfide)
ASL800040 Applied to bearings and taper shaft to facilitate press-fitting and to prevent stic-
king, burning or rusting.
Grease
(Lithium grease) ASL800050 Applied to bearings, sliding parts and oil seals for lubrication, rust prevention and
facilitation of assembling work.
Vaseline ±Used for protecting battery electrode terminals from corrosion.

ELECTRIC WIRE CODE
ELECTRIC WIRE CODE
00-11
PC75R-2
ELECTR C
n the wiring diagrams various colours and symbols are employed to indicate the thickness of wires.
This wire code table will help you understand W R NG D AGRAMS.
Example: R -N 1.5 indicates a cable having a nominal number 1.5 and red coating with black stripe.
CLASSIFICATION BY THICKNESS
Nominal
number
Copper wire Cable O.D.
(mm)
Current rating
(A)
Number
strands
ù of strands
(mm)
Cross section
(mm
2
)
1 14 0.30 0.99 2.80 11
1.5 21 0.30 1.48 3.35 14
2.5 35 0.30 2.47 3.80 20
4 56 0.30 3.95 4.60 28
6 84 0.30 5.93 5.20 37
10 84 0.40 10.55 7.10 53
50 399 0.40 50.11 14 160
CLASSIFICATION BY COLOUR AND CODE
Primary Auxiliary
Code A A-G ± A-N ± A-R ± A-V A/V ± ±
Colour Light blue Light blue - Yellow Light blue - Black Light blue - Red Light blue - Green ±
Code B B-G ± B-N ± B-R B/R ± ± ± ±
Colour White White - Yellow White - Black White - Red ± ±
Code C C-V ± ± ± ± ± ± ± ± ±
Colour Orange Orange - Green ±±±±
Code G G-R ± G-N ± ± ± ± ± ± ±
Colour Yellow Yellow - Red Yellow - Black ± ± ±
Code H H-R ± H-N ± ± ± ± ± ± ±
Colour Gray Gray - Pink Gray - Black ± ± ±
Code L L-R L/R L-B ± ± ± ± ± ± ±
Colour Blue Blue - Red Blue - White ± ± ±
Code M M-N M/N M-V ± ± ± ± ± ± ±
Colour Brown Brown - Black Brown - Green ± ± ±
Code N ±±±±±±±±±±
Colour Black ±±±±±
Code R R-N R/N R-V ± ± ± ± ± ± ±
Colour Red Red - Black Red - Green ± ± ±
Code S S-N ± S-G ± ± ± ± ± ± ±
Colour Pink Pink - Black Pink - Yellow ± ± ±
Code V V-B ± V-N ± ± ± ± ± ± ±
Colour Green Green - White Green - Black ± ± ±
Code Z Z-B ± Z-N ± ± ± ± ± ± ±
Colour Violet Violet - White Violet - Black ± ± ±
COMPOSITION OF THE COLOURS
The coloration of two-colour wires is indicated by the composition of the symbols listed.
Example: R-N = Red-Black with longitudinal colouring.
R/N = Red-Black with transversal colouring.

WEIGHT TABLE
00-12
PC75R-2
This weight table is a guide for use when transporting or handling components.
Unit: kg (lb.)
Machine model PC75R-2
From serial no. 22E5200763-
Engine assembly 380 (837)
Radiator - exchanger 35.5 (78.2)
Hydraulic tank (without hydraulic oil) 60 (132.2)
Fuel tank (without fuel) 40 (88.2)
Revolving frame 765 (1685.3)
Counterweight 1050 (2313.2)
Swing circle 89 (196)
Swing machinery assembly 43 (94.7)
Main pump + gear pump 57 (125.6)
Cabin 250 (550.7)
Seat 32 (70.5)
Seat support 14.5 (32)
Platform 51 (112.4)
Control valve 55 (121.2)
Track frame assembly:
.dler assembly
.Sprocket
.Final drive
.Track roller
.Carrier roller
979 (2156.8)
82 (180.6)
35 (77.1)
90 (198.2)
16 (35.2)
11 (24.2)
Track - shoe assembly (standard) 491 (1081.6)
Engine hood Ð
Front hood Ð
Swivel joint 36 (79.3)
Swing bracket 170 (374.5)
Boom 300 (661)
1
st
boom 245 (540)
2
nd
boom 168 (370)
Arm (L=1700) 125 (275.3)
Arm (L=2100) 167 (368)
Blade 250 (551)
Work equipment (1-piece boom) Ð
Work equipment (2-piece boom) Ð

TABLE OF OIL AND COOLANT QUANTITIES
00-13
PC75R-2
RESERVOIR KIND OF
FLUID
AMBIENT TEMPERATURE CAPACITY
±30 ±20 ±10 0 10 20 30 40 50ëC
±22 ± 4 14 32 50 58 85 104 122ëF 1st filling Change
Engine oil pan O L
.AP CD
9.4 ,
(2.48 US.gall)
9.4 ,
(2.48 US.gall)
Hydraulic circuit O L
.AP CD
138 ,
(36.43 US.gall)
70 ,
(18.48 US.gall)
Final drive
(each)
O L
.AP GL5
1.7 ,
(0.45 US.gall)
1.7 ,
(0.45 US.gall)
Swing
machinery
O L
.AP GL5
1.5 ,
(0.40 US.gall)
1.5 ,
(0.40 US.gall)
Fuel
tank FUEL 100 ,
(26.41 US.gall)
Ð
Engine coolant
system
WATER+
ANT -FREEZE
18 ,
(4.75 US.gall)
Ð
WATER 18 ,
(4.75 US.gall)
Ð
PERMANENT
L QU D
18 ,
(4.75 US.gall)
Ð
]ASTM D975 N. 1
ASTM: America Society of Testing and Materials
SAE: Society of Automotive Engineers
AP : American Petroleum nstitute
M L: USA Military Specification
CCMC: Common Market Constructors Committe
Specified capacity: Total amount of oil including oil for components and oil in piping.
Refill capacity: Amount of oil needed to refill system during normal inspection and maintenance.
SAE 10W
SAE 20W-20
SAE 30
SAE 40
SAE 10W-30
SAE 15W-30
SAE 15W-40
SAE 10W
SAE 80W 90
SAE 30
]
ASTM D975 N. 2

NOTE:
(1) When fuel sulphur content is less than 0.5%,
change oil in the oil pan ebery periodic mainte-
nance hours described in operation and mainte-
nance manual.
Change oil according to the following table if fuel
sulphur content is above 0.5%.
Fuel sulphur ontent Oil hange interval in engine oil
pan
0.5 to 1.0% 1/2 of regular interval
Above 1.0% 1/4 of regular interval
(2) When starting the engine is weathers temperature
below 0ëC, be sure to use engine oil SAE 10W,
SAE 20W-20, even if weather temperature goes
up to 10ëC day time.
(3) Use classification CD as engine oil, if use classifi-
cation CC, reduce the engine oil change interval to
half.
(4) Use original products, which have characteristics
specifically formulated and approved for the en-
gine, the hydraulic circuit of equipment and for re-
ductions.
00-14
PC75R-2

GROUP
10

40-28
PC15R-8