Komatsu Hydraulic Excavator PC75R Repair Service Manual + Operation & Maintenance Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavator PC75R, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu Hydraulic Excavator PC75R-2 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PRODUCT DETAILS:
Total Pages: 1,040 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
WEBM004000 - Hydraulic Excavator PC75R-2 Shop Manual.pdf
WEAM002800A - Hydraulic Excavator PC75R-2 Operation & Maintenance Manual.pdf
WEAM002801 - Hydraulic Excavator PC75R-2 Operation & Maintenance Manual.pdf
WEAM003900 - Hydraulic Excavator PC75R-2 Operation & Maintenance Manual.pdf
MAIN SECTIONS
MAIN MENU...0
COVER...1
CONTENTS...3
LIST OF REVISED PAGES...5
SAFETY...7
FOREWORD...9
HOW TO READ THE SHOP MANUAL...10
HOISTING INSTRUCTIONS...11
STANDARD TIGHTENING TORQUE...12
COATING MATERIALS...14
ELECTRIC WIRE CODE...15
WEIGHT TABLE...16
TABLE OF OIL COOLANT QUANTITIES...17
10. STRUCTURE AND FUNCTION...21
P.T.O...22
POWER TRAIN...23
TRACK FRAME...25
IDLER AND RECOIL SPRING...26
CARRIER ROLLER...27
TRACK ROLLER...27
TRACK SHOE...28
SWING CIRCLE...29
SWING MACHINERY...30
HYDRAULIC CIRCUIT DIAGRAM (STANDARD)...31
HYDRAULIC CIRCUIT DIAGRAM (2-PIECE BOOM)...33
HYDRAULIC PUMP...34
9-SPOOL CONTROL VALVE (STANDARD)...60
10-SPOOL CONTROL VALVE (STANDARD+2-PIECE BOOM)...62
SWING MOTOR...90
CENTER SWIVEL JOINT...94
TRAVEL MOTOR...96
PARKING BRAKE...98
BRAKE VALVE...99
TRAVEL MOTOR...101
REDUCTION GEAR...103
CYLINDERS...104
SERVOCONTROL FEED UNIT...106
ACCUMULATOR...111
PPC VALVE (WORK EQUIPMENT)...112
PPC VALVE (BLADE, BOOM SWING, 2-PIECE BOOM)...116
TRAVEL PPC VALVE...120
BOOM AND ARM SAFETY VALVE...125
BLADE SAFETY VALVE...126
2-PIECE BOOM SAFETY VALVE...127
OVERLOAD SENSOR SWITCH...128
SOLENOID VALVE...129
ELECTRICAL DIAGRAM (1/3)...131
ELECTRICAL DIAGRAM (2/3)...133
ELECTRICAL DIAGRAM (3/3)...135
20. TESTING AND ADJUSTING...139
NORMAL OR STANDARD TECHNICAL DATA...140
SPECIAL TOOLS...157
MEASURING THE ENGINE SPEED...159
ADJUSTING VALVE CLEARANCE...160
MEASURING COMPRESSION PRESSURE...161
TESTING AND ADJUSTING FUEL INJECTION TIMING...162
TESTING AND ADJUSTING FAN BELT TENSION...164
ADJUSTING THE STROKE OF THE ACCELERATOR LEVER...165
ADJUSTING PPC VALVE CLEARANCE...166
ADJUSTING THE SAFETY MICROSWITCH...167
MEASURING THE SWING CIRCLE AXIAL CLEARANCE...168
TESTING AND ADJUSTING TRACK-SHOE TENSION...169
AIR BLEEDING FROM HYDRAULIC CIRCUITS...170
RELEASING RESIDUAL PRESSURE FROM THE CIRCUITS...173
CHECKING AND REGULATING PRESSURE IN THE HYDRAULIC CIRCUITS...174
TESTING AND SETTING OF MAIN VALVES...175
ADJUSTING PC VALVE...177
MEASURING LS DIFFERENTIAL PRESSURE AND ADJUSTING LS VALVE...178
CHECKING AND ADJUSTING PRESSURES IN THE SERVOCONTROL FEED UNIT...180
MEASURING PUMPS DELIVERY AND FLOW CONTROL STARTING POINT PUMP P1...181
MEASURING TRAVEL DEVIATION...183
ADJUSTING THE MAXIMUM SPEED OF THE TRAVEL MOTORS...184
MEASURING INNER OIL LEAKAGE OF TRAVEL MOTOR...185
ADJUSTING BOOM AND ARM SAFETY VALVES...186
ADJUSTING 2nd BOOM SAFETY VALVES...187
MEASURING AND SETTING OF PRESSURE SWITCH SIGNAL OVERLOAD OPERATION...188
MEASUREMENT OF INTERNAL OIL LEAKAGES IN THE SWING MOTOR...189
CHECKING FOR LEAKAGES INSIDE THE SWIVEL JOINT...190
ANALYSIS OF THE CAUSES OF HYDRAULIC DRIFTS...192
30. DISASSEMBLY AND ASSEMBLY...201
HOW TO READ THE MANUAL...203
PRECAUTIONS TO BE TAKEN WHEN WORKING...204
SPECIAL TOOLS...205
STARTER MOTOR...207
REMOVAL AND INSTALLATION...207
ALTERNATOR...208
REMOVAL AND INSTALLATION...208
INJECTION PUMP...209
REMOVAL...209
INSTALLATION...212
NOZZLE HOLDER...213
REMOVAL AND INSTALLATION...213
CYLINDER HEAD...214
REMOVAL...214
INSTALLATION...216
SEAT...217
REMOVAL AND INSTALLATION...217
CABIN...218
REMOVAL AND INSTALLATION...218
ENGINE HOOD...219
REMOVAL AND INSTALLATION...219
FRONT HOOD...220
REMOVAL AND INSTALLATION...220
HEATING FAN...221
REMOVAL AND INSTALLATION...221
RADIATOR...222
REMOVAL...222
INSTALLATION...223
FUEL TANK...224
REMOVAL...224
INSTALLATION...225
HYDRAULIC OIL TANK...226
REMOVAL AND INSTALLATION...226
ENGINE-PUMP GROUP...227
REMOVAL...227
INSTALLATION...230
PUMP GROUP...231
REMOVAL...231
INSTALLATION...232
ENGINE-PUMP COUPLING JOINT...233
REMOVAL AND INSTALLATION...233
MAIN PUMP INPUT SHAFT OIL SEAL...234
REMOVAL AND INSTALLATION...234
GEAR PUMP...235
REMOVAL AND INSTALLATION...235
SWIVEL JOINT...236
REMOVAL AND INSTALLATION...236
SWING MOTOR...237
REMOVAL AND INSTALLATION...237
SWING MACHINERY...238
REMOVAL AND INSTALLATION...238
DISASSEMBLY...239
ASSEMBLY...242
CONTROL VALVE...245
REMOVAL AND INSTALLATION...245
REVOLVING FRAME...246
REMOVAL...246
INSTALLATION...247
COUNTERWEIGHT...248
REMOVAL AND INSTALLATION...248
SWING CIRCLE...249
REMOVAL AND INSTALLATION...249
TRACK SHOES...250
REMOVAL AND INSTALLATION...250
SPROCKET ASSEMBLY...251
REMOVAL AND INSTALLATION...251
TRAVEL GEAR MOTOR...252
REMOVAL AND INSTALLATION...252
DISASSEMBLY...253
ASSEMBLY...268
BALL BEARING PRELOAD...283
ADJUSTING...283
AXIAL CLEARANCE ON TAPERED ROLLER BEARINGS...284
ADJUSTING...284
IDLER AND RECOIL SPRING ASSEMBLY...285
REMOVAL AND INSTALLATION...285
IDLER...286
DISASSEMBLY AND ASSEMBLY...286
RECOIL SPRING GROUP AND CYLINDER...287
DISASSEMBLY AND ASSEMBLY...287
TRACK ROLLER...288
REMOVAL AND INSTALLATION...288
CARRIER ROLLER...289
REMOVAL AND INSTALLATION...289
R.H. PPC VALVE (BOOM-BUCKET)...290
REMOVAL...290
INSTALLATION...291
L.H. PPC VALVE (ARM-SWING)...292
REMOVAL...292
INSTALLATION...293
BLADE PPC VALVE...294
REMOVAL AND INSTALLATION...294
TRAVEL PEDAL CONTROL...295
REMOVAL AND INSTALLATION...295
1st BOOM SWING PEDAL CONTROL...296
REMOVAL AND INSTALLATION...296
BOOM CYLINDER (FOR 1-PIECE BOOM)...297
REMOVAL AND INSTALLATION...297
BOOM CYLINDER (FOR 2-PIECE BOOM)...298
REMOVAL...298
INSTALLATION...299
2nd BOOM CYLINDERS...300
REMOVAL...300
INSTALLATION...301
ARM CYLINDER...302
REMOVAL AND INSTALLATION...302
BUCKET CYLINDER...303
REMOVAL AND INSTALLATION...303
BOOM SWING CYLINDER...304
REMOVAL AND INSTALLATION...304
BLADE CYLINDER...305
REMOVAL AND INSTALLATION...305
WORK EQUIPMENT CYLINDERS...306
DISASSEMBLY...306
ASSEMBLY...307
WORK EQUIPMENT (FOR 1-PIECE BOOM)...311
REMOVAL AND INSTALLATION...311
WORK EQUIPMENT (FOR 2-PIECE BOOM)...312
REMOVAL...312
INSTALLATION...313
BUCKET...314
REMOVAL AND INSTALLATION...314
ARM...315
REMOVAL...315
INSTALLATION...317
2nd BOOM...318
REMOVAL...318
INSTALLATION...319
BOOM (FOR 1-PIECE BOOM)...320
REMOVAL AND INSTALLATION...320
1st BOOM...321
REMOVAL...321
INSTALLATION...322
SWING BRACKET...323
REMOVAL AND INSTALLATION...323
BLADE...324
REMOVAL AND INSTALLATION...324
40. MAINTENANCE STANDARD...327
P.T.O...328
SWING CIRCLE...329
TRACK FRAME...330
IDLER...331
CARRIER ROLLER...332
TRACK ROLLER...333
TRACK SHOE...334
SPROCKET...335
SWING MACHINERY...336
HYDRAULIC PUMP...337
CONTROL VALVE...338
SWING MOTOR...348
SWIVEL JOINT...349
TRAVEL MOTOR...350
SERVOCONTROL FEED UNIT...352
TRAVEL PPC VALVE...353
PPC VALVE...354
BLADE SAFETY VALVE...356
CYLINDERS...358
WORK EQUIPMENT (1-PIECE BOOM)...360
WORK EQUIPMENT (2-PIECE BOOM)...362
MAIN MENU...0
COVER...1
1.1 FOREWORD...3
1.2 INFORMATION ON SAFETY...4
1.3 INTRODUCTION...6
1.3.1 INTENDED USES...6
1.3.2 IMPROPER OR UNAUTHORIZED USE...6
1.3.3 MAIN CHARACTERISTICS...7
1.3.4 RUNNING-IN...7
1.4 PRODUCT IDENTIFICATION...8
1.4.1 MACHINE SERIAL NUMBER...8
1.4.2 MACHINE IDENTIFICATION PLATE...8
1.4.3 ENGINE SERIAL NUMBER AND EMISSION LABEL...9
1.4.4 TRAVEL REDUCTION GEAR SERIAL NUMBER...9
1.4.5 SWING REDUCTION GEAR SERIAL NUMBER...10
1.4.6 CAB SERIAL NUMBER...10
1.4.7 SERIAL NUMBERS AND DEALER?S ADDRESS...11
CONTENTS...12
SAFETY AND ACCIDENT PREVENTION...19
2.1 SAFETY PLATES...20
2.1.1 POSITION OF THE SAFETY PLATES...20
2.1.2 POSITION OF THE PICTOGRAMS...36
2.1.3 PICTOGRAMS AND RELEVANT MEANINGS...37
2.1.4 VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED...39
2.2 GENERAL PRECAUTIONS...40
2.2.1 GENERAL SAFETY RULES...40
2.2.2 SAFETY DEVICES AND GUARDS...40
2.2.3 CLOTHING AND PERSONAL PROTECTION ITEMS...40
2.2.4 UNAUTHORIZED MODIFICATIONS...41
2.2.5 LEAVING THE OPERATOR?S SEAT...41
2.2.6 GETTING ON AND OFF THE MACHINE...42
2.2.7 PREVENTING FIRES DUE TO FUEL AND OIL...42
2.2.8 PREVENTING BURNS...43
2.2.9 PREVENTING DAMAGE DUE TO ASBESTOS POWDER...43
2.2.10 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT...44
2.2.11 FIRE EXTINGUISHERS AND FIRST AID KIT...44
2.2.12 PRECAUTIONS CONCERNING THE CAB STRUCTURE...44
2.2.13 PRECAUTIONS CONCERNING THE EQUIPMENT...44
2.3 PRECAUTIONS TO BE TAKEN BEFORE STARTING THE ENGINE...45
2.3.1 SAFETY ON THE WORK SITE...45
2.3.2 FIRE PREVENTION...45
2.3.3 PRECAUTIONS TO BE TAKEN FOR THE OPERATOR'S CAB...45
2.3.4 ROOM VENTILATION...46
2.3.5 PRECAUTIONS TO BE TAKEN FOR THE LIGHTS...46
2.3.6 CLEANING THE WINDOWS AND THE REAR-VIEW MIRRORS - CHECKING THE WINDSHIELD WIPER BLADES...46
2.4 PRECAUTIONS TO BE TAKEN WHEN WORKING...47
2.4.1 STARTING THE ENGINE...47
2.4.2 CHECK THE DIRECTION BEFORE STARTING THE MACHINE...47
2.4.3 CHECKS FOR TRAVELLING IN REVERSE...47
2.4.4 MOVING THE MACHINE...48
2.4.5 MOVING ON SLOPES...49
2.4.6 WORKING ON SLOPES...50
2.4.7 UNAUTHORIZED OPERATIONS...50
2.4.8 PREVENTING ELECTROCUTION...51
2.4.9 VISIBILITY...52
2.4.10 WORKING ON ICY OR SNOW-COVERED SURFACES...52
2.4.11 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT...52
2.4.12 WORKING ON LOOSE GROUND...52
2.4.13 PARKING THE MACHINE...53
2.5 TRANSPORTING THE MACHINE ON OTHER VEHICLES...54
2.5.1 LOADING AND UNLOADING THE MACHINE...54
2.5.2 SHIPPING...54
2.6 BATTERY...55
2.6.1 SAFETY PRECAUTIONS FOR WORK ON BATTERIES...55
2.6.2 STARTING WITH BOOSTER CABLES...55
2.7 PRECAUTIONS FOR EMERGENCY RECOVERY...56
2.8 PRECAUTIONS TO BE TAKEN DURING MAINTENANCE...57
2.8.1 WARNING PLATES...57
2.8.2 TOOLS...57
2.8.3 PERSONNEL...58
