Komatsu Hydraulic Excavator PC75R Repair Service Manuals
Catalog:
Model:
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavator PC75R, with all the technical information to maintain, diagnose, repair, and 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.
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
Total Pages: 1,040 pages
File Format: PDF
Language: English
WEAM002800A - Hydraulic Excavator PC75R-2 Operation & Maintenance Manual....2
COVER....2
1.1 FOREWORD....5
1.2 INFORMATION ON SAFETY....6
1.3 INTRODUCTION....8
1.3.1 INTENDED USES....8
1.3.2 IMPROPER OR UNAUTHORIZED USE....8
1.3.3 MAIN CHARACTERISTICS....9
1.3.4 RUNNING-IN....9
1.4 PRODUCT IDENTIFICATION....10
1.4.1 MACHINE SERIAL NUMBER....10
1.4.2 MACHINE IDENTIFICATION PLATE....10
1.4.3 ENGINE SERIAL NUMBER AND EMISSION LABEL....11
1.4.4 TRAVEL REDUCTION GEAR SERIAL NUMBER....11
1.4.5 SWING REDUCTION GEAR SERIAL NUMBER....12
1.4.6 CAB SERIAL NUMBER....12
1.4.7 SERIAL NUMBERS AND DEALER'S ADDRESS....13
CONTENTS....14
SAFETY AND ACCIDENT PREVENTION....21
2.1 SAFETY PLATES....22
2.1.1 POSITION OF THE SAFETY PLATES....22
2.1.2 POSITION OF THE PICTOGRAMS....38
2.1.3 PICTOGRAMS AND RELEVENT MEANINGS....39
2.1.4 VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED....41
2.2 GENERAL PRECAUTIONS....42
2.2.1 GENERAL SAFETY RULES....42
2.2.2 SAFETY DEVICES AND GUARDS....42
2.2.3 CLOTHING AND PERSONAL PROTECTION ITEMS....42
2.2.4 UNAUTHORIZED MODIFICATIONS....43
2.2.5 LEAVING THE OPERATOR'S SEAT....43
2.2.6 GETTING ON AND OFF THE MACHINE....44
2.2.7 PREVENTING FIRES DUE TO FUEL AND OIL....44
2.2.8 PREVENTING BURNS....45
2.2.9 PREVENTING DAMAGE DUE TO ASBESTOS POWDER....45
2.2.10 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT....46
2.2.11 FIRE EXTINGUISHERS AND FIRST AID KIT....46
2.2.12 PRECAUTIONS CONCERNING THE CAB STRUCTURE....46
2.2.13 PRECAUTIONS CONCERNING THE EQUIPMENT....46
2.3 PRECAUTIONS TO BE TAKEN BEFORE STARTING THE ENGINE....47
2.3.1 SAFETY ON THE WORK SITE....47
2.3.2 FIRE PREVENTION....47
2.3.3 PRECAUTIONS TO BE TAKEN FOR THE OPERATOR'S CAB....47
2.3.4 ROOM VENTILATION....48
2.3.5 PRECAUTIONS TO BE TAKEN FOR THE LIGHTS....48
2.3.6 CLEANING THE WINDOWS AND THE REAR-VIEW MIRRORS-CHECKING THE WINDSHIELD WIPER BLADES....48
2.4 PRECAUTIONS TO BE TAKEN WHEN WORKING....49
2.4.1 STARTING THE ENGINE....49
2.4.2 CHECK THE DIRECTION BEFORE STARTING THE MACHINE....49
2.4.3 CHECKS FOR TRAVELLING IN REVERSE....49
2.4.4 MOVING THE MACHINE....50
2.4.5 MOVING THE SLOPES....51
2.4.6 WORKING ON SLOPES....52
2.4.7 UNAUTHORIZED OPERATIONS....52
2.4.8 PREVENTING ELECTROCUTION....53
2.4.9 VISIBILITY....54
2.4.10 WORKING ON ICY OR SNOW-COVERED SURFACES....54
2.4.11 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT....54
2.4.12 WORKING ON LOOSE GROUND....54
2.4.13 PARKING THE MACHINE....55
2.5 TRANSPORTING THE MACHINE ON OTHER VEHICLES....56
2.5.1 LOADING AND UNLOADING THE MACHINE....56
2.5.2 SHIPPING....56
2.6 BATTERY....57
2.6.1 SAFETY PRECAUTIONS FOR WORK ON BATTERIES....57
2.6.2 STARTING WITH BOOSTER CABLES....57
2.7 PRECAUTIONS FOR EMERGENCY RECOVERY....58
2.8 PRECAUTIONS TO BE TAKEN DURING MAINTENANCE....59
2.8.1 WARNING PLATES....59
2.8.2 TOOLS....59
2.8.3 PERSONNEL....60
2.8.4 EQUIPMENT....60
2.8.5 WORKING UNDER THE MACHINE....60
2.8.6 KEEPING THE MACHINE CLEAN....60
2.8.7 USE OF THE ENGINE DURING MAINTENANCE....61
2.8.8 PERIODICAL CHANGE OF THE PARTS THAT ARE CRITICAL FOR SAFETY....61
2.8.9 STOP THE ENGINE BEFORE CARRYING OUT ANY MAINTENANCE OPERATION OR INSPECTION....61
2.8.10 RULES FOR REFUELLING AND ADDING OIL....62
2.8.11 CHECKING THE COOLAND LEVEL IN THE RADIATOR....62
2.8.12 USING LAMPS....62
2.8.13 PRECAUTIONS CONCERNING THE BATTERY AND THE ALTERNATOR....63
2.8.14 PRECAUTIONS CONCERNING THE STARTER....63
2.8.15 PRECAUTIONS CONCERNING HIGH-PRESSURE HOSES....64
2.8.16 PRECAUTIONS TO BE TAKEN WHEN WORKING ON HIGH-PRESSURE SYSTEMS....64
2.8.17 PRECAUTIONS FOR MAINTENANCE WORK INVOLVING HIGH TEMPERATURES AND PRESSURES....64
2.8.18 COOLING FAN AND FAN BELT....65
2.8.19 WASTE MATERIALS....65
DESCRIPTION AND USE OF THE MACHINE....67
3.1 SAFETY LOCKS....68
3.1.1 MACHINE LOCKS....68
3.2 GENERAL VIEWS....69
3.2.1 FRONT GENERAL VIEW (MONOBOOM)....69
3.2.2 FRONT GENERAL VIEW (TWO-PIECE BOOM)....70
3.2.3 CAB INSIDE GENERAL VIEW....71
3.3 INSTRUMENTS AND CONTROLS....73
3.3.1 INSTRUMENTS, WARNING LIGHTS AND PUSH BUTTONS....73
3.3.2 MACHINE CONTROLS....82
3.4 FUSES AND RELAYS....93
3.4.1 CENTRAL UNIT FUSES AND RELAYS....93
3.4.1.1 CENTRAL UNIT FUSES....94
3.4.1.2 CENTRAL UNIT RELAYS....95
3.4.2 ENGINE LINE FUSES AND RELAYS....96
3.4.2.1 ENGINE LINE FUSES....96
3.4.2.2 ENGINE LINE RELAYS....97
3.5 GAURDS AND DRIVER'S SEAT....98
3.5.1 ENGINE HOOD....98
3.5.2 SIDE COVER....98
3.5.3 CAB....99
3.5.4 VENTILATION AND HEATING....103
3.5.5 SEAT....104
3.5.6 SAFETY BELT....105
3.5.7 EMERGENCY EXIT....105
3.5.8 TECHNICAL DOCUMENTATION CASE....106
3.5.9 FIRE EXTINGUISHER....106
3.5.10 FIRST AID KIT....106
3.6 USE OF THE MACHINE....107
3.6.1 CHECKS BEFORE STARTING THE ENGINE....107
3.6.1.1 VISUAL CHECKS....107
3.6.1.2 DAILY CHECKS....107
3.6.1.3 OPERATIONAL CHECKS....108
3.6.2 STARTING THE ENGINE....109
3.6.2.1 STARTING WITH WARM ENGINE OR IN TEMPERATE CLIMATES....109
3.6.2.2 STARTING WITH COLD ENGINE OR IN COLD CLIMATES....110
3.6.3 WARMING THE ENGINE....111
3.6.4 HEATING THE HYDRAULIC OIL....111
3.6.5 HOW TO MOVE THE MACHINE....111
3.6.5.1 STEERING (CHANGING DIRECTION)....113
3.6.5.2 MOVING ON SLOPES....114
3.6.5.3 MAXIMUM IMMERSION DEPTH....115
3.7 PARKING THE MACHINE....116
3.7.1 PARKING ON LEVEL GROUND....116
3.7.2 PARKING ON SLOPES....117
3.8 STOPPING THE ENGINE....118
3.9 TRANSPORTING THE MACHINE ON OTHER VEHICLES....119
3.9.1 LOADING AND UNLOADING THE MACHINE....119
3.9.2 TRANSPORT....120
3.10 PRECAUTIONS TO BE TAKEN IN THE COLD SEASON....121
3.10.1 FUEL AND LUBRICANTS....121
3.10.2 COOLANT....121
3.10.3 BATTERY....122
3.10.4 OTHER PRECAUTIONS....122
3.10.5 PRECAUTIONS TO BE TAKEN AT THE END OF WORK....122
3.11 PRECAUTIONS TO BE TAKEN IN THE WARM SEASON....123
3.12 USING THE WORK EQUIPMENT....124
3.12.1 ORGANIZING THE WORK AREA....124
3.12.2 POSITIONING THE BUCKET ACCORDING T OTHE WORK TO BE CARRIED OUT....124
3.12.3 POSITIONING THE MACHINE FOR DIGGING OPERATIONS....125
3.12.4 DIGGING METHOD....126
3.12.5 CHANGING THE BUCKET....127
3.13 LONG PERIODS OF INACTIVITY....128
3.13.1 BEFORE THE PERIOD OF INACTIVITY....128
3.13.2 DURING THE PERIOD OF INACTIVITY....129
3.13.3 AFTER THE PERIOD OF INACTIVITY....129
3.14 TROUBLESHOOTING....130
3.14.1 HOW TO REMOVE THE MACHINE....130
3.14.2 IF THE FUEL HAS BEEN COMPLETELY DEPLETED....130
3.14.3 IF THE BATTERY IS DEPLETED....131
3.14.3.1 STARTING WITH BOOSTER CABLES....132
3.14.4 OTHER TROUBLES....133
3.14.4.1 ELECTRICAL CIRCUIT....133
3.14.4.2 HYDRAULIC SYSTEM....134
3.14.4.3 ENGINE....135
MAINTENANCE....137
4.1 GUIDE TO MAINTENANCE....138
4.2 MAINTENANCE NOTES....140
4.2.1 NOTES REGARDING THE ENGINE....140
4.2.1.1 ENGINE OIL....140
4.2.1.2 COOLANT....140
4.2.1.3 FUEL....141
4.2.2 NOTES REGARDING THE HYDRAULIC SYSTEM....141
4.2.3 NOTES REGARDING THE ELECTRICAL SYSTEM....142
4.2.4 NOTES REGARDING LUBRICATION....142
4.2.5 PARTS SUBJECT TO WEAR THAT PERIODICALLY NEED CHANGING....143
4.3 FUEL, COOLANT AND LUBRICANTS....144
4.4 NUT AND BOLT TIGHTENING TORQUES....148
4.4.1 STANDARD TIGHTENING TORQUES....148
4.4.2 SPECIFIC TIGHTENING TORQUES....148
4.5 LUBRICATION....149
4.5.1 LUBRICATION DIAGRAM....149
4.6 PERIODICAL CHANGE OF THE COMPONENTS CONNECTED WITH SAFETY....150
4.6.1 CRITICAL PARTS FOR SAFETY....151
4.7 MAINTENANCE PLAN....154
4.7.1 WHEN REQUIRED....157
4.7.1.a CHECKING, CLEANING OR CHANGING THE AIR CLEANER CARTRIDGE....157
4.7.1.b CHECKING AND CLEANING THE CAB AIR FILTER....158
4.7.1.c WASHING THE COOLING CIRCUIT....159
4.7.1.d CLEANING THE WATER SEPARATOR....160
4.7.1.e CHECKING THE STEEL TRACK TENSION....161
4.7.1.f CHECKING THE SHOE FASTENING....163
4.7.1.g CHECKING THE RUBBER TRACKS....164
4.7.1.h CHECKING THE RUBBER TRACK TENSION....166
4.7.1.i CHANGING THE RUBBER TRACK....168
4.7.2 MAINTENANCE INTERVALS IN CASE OF USE OF THE DEMOLITION HAMMER....170
4.7.2.a CHANGING THE HYDRAULIC OIL FILTER....170
4.7.2.b CHANGING THE HYDRAULIC OIL....170
4.7.3 CHECKS BEFORE STARTING....171
4.7.3.a VARIOUS CHECKS....171
4.7.3.b CHECKING THE COOLANT LEVEL....171
4.7.3.c CHECKING THE FUEL LEVEL....172
4.7.3.d CHECKING THE ENGINE OIL LEVEL....172
4.7.3.e CHECKING THE OIL LEVEL IN THE HYDRAULIC CIRCUIT....173
4.7.3.f. DRAINING THE WATER SEPARATOR....174
4.7.4 MAINTENANCE EVERY 10 HOURS OF OPERATION....175
4.7.4.a LUBRICATING THE JOINTS....175
4.7.5 MAINTENANCE AFTER THE FIRST 50 HOURS OF OPERATION....178
4.7.6 MAINTENANCE EVERY 50 HOURS OF OPERATION....178
4.7.6.a CHECKING THE RADIATOR FLUID LEVEL....178
4.7.6.b LUBRICATING THE SWING JOINT....178
4.7.6.c CHECKING THE ELECTRICAL SYSTEM....179
4.7.7 MAINTENANCE EVERY 100 HOURS OF OPERATION....180
4.7.7.a LUBRICATING THE BALL-BEARING RING....180
4.7.8 MAINTENANCE AFTER THE FIRST 250 HOURS OF OPERATION....181
4.7.9 MAINTENANCE EVERY 250 HOURS OF OPERATION....181
4.7.9.a ADJUSTING THE FAN BELT TENSION....181
4.7.9.b CHECKING THE BATTERY ELECTROLYTE LEVEL....182
4.7.9.c CHECKING THE OIL LEVEL IN THE TRAVEL REDUCTION GEARS....183
4.7.9.d CHECKING THE OIL LEVEL IN THE SWING REDUCTION GEAR....183
4.7.10 MAINTENANCE AFTER THE FIRST 500 HOURS OF OPERATION....184
4.7.11 MAINTENANCE EVERY 500 HOURS OF OPERATION....184
4.7.11.a CHANGING THE HYDRAULIC SYSTEM OIL FILTER....184
4.7.11.b CHANGING THE SERVO CONTROL FILTER....185
4.7.11.c CHANGING THE ENGINE OIL....186
4.7.11.d CHANGING THE ENGINE OIL FILTER....187
4.7.11.e CHANGING THE FUEL FILTER....188
4.7.11.f DRAINING THE FUEL TANK....189
4.7.11.g CLEANING THE OUTSIDE OF THE RADIATORS....189
4.7.11.h CHECKING THE BALL-BEARING RING PINION LUBRICANT LEVEL....190
4.7.12 MAINTENANCE EVERY 1000 HOURS OF OPERATION....191
4.7.12.a CHANGING THE OIL IN THE TRAVEL REDUCTION GEARS....191
4.7.12.b CHANGING THE OIL IN THE SWING REDUCTION GEAR....192
4.7.12.c CHECKING AND ADJUSTING THE ENGINE VALVE CLEARANCE....192
4.7.13 MAINTENANCE EVERY 2000 HOURS OF OPERATION....193
4.7.13.a CHANGING THE HYDRAULIC SYSTEM OIL AND CLEANING THE SUCTION FILTER....193
4.7.13.b CHANGING THE COOLANT....196
4.7.13.c CHANGING THE BALL-BEARING RING PINION LUBRICANT....197
4.7.13.d CHECKING THE ALTERNATOR AND THE STARTER....197
TECHNICAL DATA....199
5.1 TECHNICAL DATA....200
5.1.1 STANDARD OVERALL DIMENSIONS....200
5.1.2 TECHNICAL CHARACTERISTICS....201
5.1.3 LIFTING CAPACITIES....202
5.1.3.1 LIFTING CAPACITY TABLE....202
5.1.3.2 LIFTING CAPACITY WITH RAISED BLADE....203
5.1.3.3 LIFTING CAPACITY WITH LOWERED BLADE....204
AUTHORIZED OPTIONAL EQUIPMENT....205
6.1 AUTHORIZED OPTIONAL EQUIPMENT....206
6.1.1 PRECAUTIONS REGARDING SAFETY....206
6.1.2 PRECAUTIONS REGARDING THE INSTALLATION OF EQUIPMENT....207
6.1.3 CHARACTERISTICS OF THE OPTIONAL EQUIPMENT....208
6.2 APPARNGEMENT FOR THE INSTALLATION OF THE DEMOLITION HAMMER....209
6.2.1 DESCRIPTION AND OPERATION....209
6.2.2 USE OF THE DEMOLITION HAMMER AND RULES TO BE OBSERVED....209
6.2.3 INSTALLING AND REMOVING THE DEMOLITION HAMMER....213
6.2.3.1 INSTALLING THE HAMMER....213
6.2.3.2 REMOVING THE HAMMER....214
6.2.4 MAINTENANCE....214
6.3 CLAMSHELL BUCKET....215
6.3.1 DESCRIPTION AND OPERATION....215
6.3.2 INSTALLING THE CLAMSHELL BUCKET....216
6.3.3 MAINTENANCE....218
WEAM002801 - Hydraulic Excavator PC75R-2 Operation & Maintenance Manual....220
COVER....220
1.1 FOREWARD....221
1.2 INFORMATION ON SAFETY....222
1.3 INTRODUCTION....224
1.3.1 INTENDED USES....224
1.3.2 IMPROPER OR UNAUTHORIZED USE....224
1.3.3 MAIN CHARACTERISTICS....225
1.3.4 RUNNING-IN....225
1.4 PRODUCT IDENTIFICATION....226
1.4.1 MACHINE SERIAL NUBER....226
1.4.2 MACHINE IDENTIFICATION PLATE....226
1.4.3 ENGINE SERIAL NUMBER AND EMISSION LABEL....227
1.4.4 TRAVEL REDUCTION GEAR SERIAL NUMBER....227
1.4.5 SWING REDUCTION GEAR SERIAL NUMBER....228
1.4.6 CAB SERIAL NUMBER....228
1.4.7 SERIAL NUMBERS AND DEALER'S ADDRESS....229
CONTENTS....230
SAFETY AND ACCIDENT PREVENTION....237
2.1 SAFETY PLATES....238
2.1.1 POSITION OF THE SAFETY PLATES....238
2.1.2 POSITION OF THE PICTOGRAMS....254
2.1.3 PICTOGRAMS AND RELEVANT MEANINGS....255
2.1.4 VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED....257
2.2 GENERAL PRECAUTIONS....258
2.2.1 GENERAL SAFETY RULES....258
2.2.2 SAFETY DEVICES AND GUARDS....258
2.2.3 CLOTHING AND PERSONAL PROTECTION ITEMS....258
2.2.4 UNAUTHORIZED MODIFICATIONS....259
2.2.5 LEAVING THE OPERATOR'S SEAT....259
2.2.6 GETTING ON AND OFF THE MACHINE....260
2.2.7 PREVENTING FIRES DUE TO FUEL AND OIL....260
2.2.8 PREVENTING BURNS....261
2.2.9 PREVENTING DAMAGE DUE TO ASBESTOS POWDER....261
2.2.10 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT....262
2.2.11 FIRE EXTINGUISHERS AND FIRST AID KIT....262
2.2.12 PRECAUTIONS CONCERNING THE CAB STRUCTURE....262
2.2.13 PRECAUTIONS CONCERNING THE EQUIPMENT....262
2.3 PRECAUTIONS TO BE TAKEN BEFORE STARTING THE ENGINE....263
2.3.1 SAFETY ON THE WORK SITE....263
2.3.2 FIRE PREVENTION....263
2.3.3 PRECAUTIONS TO BE TAKEN FOR THE OPERATOR'S CAB....263
2.3.4 ROOM VENTILATION....264
2.3.5 PRECAUTIONS TO BE TAKEN FOR THE LIGHTS....264
2.3.6 CLEANING THE WINDOWS AND THE REAR-VIEW MIRRORS - CHECKING THE WINDSHIELD WIPER BLADES....264
2.4 PRECAUTIONS TO BE TAKEN WHEN WORKING....265
2.4.1 STARTING THE ENGINE....265
2.4.2 CHECK THE DIRECTION BEFORE STARTING THE MACHINE....265
2.4.3 CHECKS FOR TRAVELLING IN REVERSE....265
2.4.4 MOVING THE MACHINE....266
2.4.5 MOVING ON SLOPES....267
2.4.6 WORKING ON SLOPES....268
2.4.7 UNAUTHORIZED OPERATIONS....268
2.4.8 PREVENTING ELECTROCUTION....269
2.4.9 VISIBILITY....270
2.4.10 WORKING ON ICY OR SNOW-COVERED SURFACES....270
2.4.11 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT....270
2.4.12 WORKING ON LOOSE GROUND....270
2.4.13 PARKING THE MACHINE....271
2.5 TRANSPORTING THE MACHINE ON OTHER VEHICLES....272
2.5.1 LOADING AND UNLOADING THE MACHINE....272
2.5.2 SHIPPING....272
2.6 BATTERY....273
2.6.1 SAFETY PRECAUTIONS FOR WORK ON BATTERIES....273
2.6.2 STARTING WITH BOOSTER CABLES....273
2.7 PRECAUTIONS FOR EMERGENCY RECOVERY....274
2.8 PRECAUTIONS TO BE TAKEN DURING MAINTENANCE....275
2.8.1 WARNING PLATES....275
2.8.2 TOOLS....275
2.8.3 PERSONNEL....276
2.8.4 EQUIPMENT....276
2.8.5 WORKING UNDER THE MACHINE....276
2.8.6 KEEPING THE MACHINE CLEAN....276
2.8.7 USE OF THE ENGINE DURING MAINTENANCE....277
2.8.8 PERIODICAL CHANGE OF THE PARTS THAT ARE CRITICAL FOR SAFETY....277
2.8.9 STOP THE ENGINE BEFORE CARRYING OUT ANY MAINTENANCE OPERATION OR INSPECTION....277
2.8.10 RULES FOR REFUELLING AND ADDING OIL....278
2.8.11 CHECKING THE COOLANT LEVEL IN THE RADIATOR....278
2.8.12 USING LAMPS....278
2.8.13 PRECAUTIONS CONCERNING THE BATTERY AND THE ALTERNATOR....279
2.8.14 PRECAUTIONS CONCERNING THE STARTER....279
2.8.15 PRECAUTIONS CONCERNING HIGH-PRESSURE HOSES....280
2.8.16 PRECAUTIONS TO BE TAKEN WHEN WORKING ON HIGH-PRESSURE SYSTEMS....280
2.8.17 PRECAUTIONS FOR MAINTENANCE WORK INVOLVING HIGH TEMPERATURES AND PRESSURES....280
2.8.18 COOLING FAN AND FAN BELT....281
2.8.19 WASTE MATERIALS....281
2.8.20 PRECAUTIONS FOR THE USE OF THE SYNTHETIC BIODEGRADABLE OIL TYPE HEES....281
THE MACHINE AND ITS OPERATIONS....283
3.1 SAFETY LOCKS....284
3.1.1 MACHINE LOCKS....284
3.2 GENERAL VIEWS....285
3.2.1 FRONT GENERAL VIEW (MONOBOOM)....285
3.2.2 FRONT GENERAL VIEW (TWO-PIECE BOOM)....286
3.2.3 CAB INSIDE GENERAL VIEW....287
3.3 INSTRUMENTS AND CONTROLS....289
3.3.1 INSTRUMENTS....289
3.3.2 WARNING LIGHTS....291
3.3.3 SWITCHES AND PUSH BUTTONS....293
3.3.4 ELECTRICAL ACCESSORIES....300
3.3.5 MACHINE CONTROLS....302
3.4 FUSES AND RELAYS....313
3.4.1 CENTRAL UNIT FUSES AND RELAYS....313
3.4.1.1 CENTAL UNIT FUSES....314
3.4.1.2 CENTRAL UNIT RELAYS....315
3.4.2 ENGINE LINE FUSES AND RELAYS....316
3.4.2.1 ENGINE LINE FUSES....316
3.4.2.2 ENGINE LINE RELAYS....317
3.5 GUARDS AND DRIVER'S SEAT....318
3.5.1 ENGINE HOOD....318
3.5.2 SIDE COVER....318
3.5.3 CAB....319
3.5.4 VENTILATION AND HEATING....323
3.5.5 SEAT....324
3.5.6 SAFETY BELT....325
3.5.7 EMERGENCY EXIT....325
3.5.8 TECHNICAL DOCUMENTATION CASE....326
3.5.9 FIRE EXTINGUISHER....326
3.5.10 FIRST AID KIT....326
3.6 USE OF THE MACHINE....327
3.6.1 CHECKS BEFORE STARTING THE ENGINE....327
3.6.1.1 VISUAL CHECKS....327
3.6.1.2 DAILY CHECKS....327
3.6.1.3 OPERATIONAL CHECKS....328
3.6.2 STARTING THE ENGINE....329
3.6.2.1 STARTING WITH WARM ENGINE OR IN TEMPERATE CLIMATES....329
3.6.2.2 STARTING WITH COLD ENGINE OR IN COLD CLIMATES....330
3.6.3 WARMING THE ENGINE....331
3.6.4 HEATING THE HYDRAULIC OIL....331
3.6.5 HOW TO MOVE THE MACHINE....331
3.6.5.1 STEERING (CHANGING DIRECTION)....333
3.6.5.2 MOVING ON SLOPES....334
3.6.5.3 MAXIMUM IMMERSION DEPTH....335
3.7 PARKING THE MACHINE....336
3.7.1 PARKING ON LEVEL GROUND....336
3.7.2 PARKING ON SLOPES....337
3.8 STOPPING THE ENGINE....338
3.9 TRANSPORTING THE MACHINE ON OTHER VEHICLES....339
3.9.1 LOADING AND UNLOADING THE MACHINE....339
3.9.2 TRANSPORT....340
3.10 PRECAUTIONS TO BE TAKEN IN THE COLD SEASON....341
3.10.1 FUEL AND LUBRICANTS....341
3.10.2 COOLANT....341
3.10.3 BATTERY....342
3.10.4 OTHER PRECAUTIONS....342
3.10.5 PRECAUTIONS TO BE TAKEN AT THE END OF WORK....342
3.11 PRECAUTIONS TO BE TAKEN IN THE WARM SEASON....343
3.12 USING THE WORK EQUIPMENT....344
3.12.1 ORGANIZING THE WORK AREA....344
3.12.2 POSITIONING THE BUCKET ACCORDING TO THE WORK TO BE CARRIED OUT....344
3.12.3 POSITIONING THE MACHINE FOR DIGGING OPERATIONS....345
3.12.4 DIGGING METHOD....346
3.12.5 CHANGING THE BUCKET....347
3.13 LONG PERIODS OF INACTIVITY....348
3.13.1 BEFORE THE PERIOD OF INACTIVITY....348
3.13.2 DURING THE PERIOD OF INACTIVITY....349
3.13.3 AFTER THE PERIOD OF INACTIVITY....349
3.14 TROUBLESHOOTING....350
3.14.1 HOW TO REMOVE THE MACHINE....350
3.14.2 IF THE FUEL HAS BEEN COMPLETELY DEPLETED....350
3.14.3 IF THE BATTERY IS DEPLETED....351
3.14.3.1 STARTING WITH BOOSTER CABLES....352
3.14.4 OTHER TROUBLES....353
3.14.4.1 ELECTRICAL CIRCUIT....353
3.14.4.2 HYDRAULIC SYSTEM....354
3.14.4.3 ENGINE....355
MAINTENANCE....357
4.1 GUIDE TO MAINTENANCE....358
4.2 MAINTENANCE NOTES....360
4.2.1 NOTES REGARDING THE ENGINE....360
4.2.1.1 ENGINE OIL....360
4.2.1.2 COOLANT....360
4.2.1.3 FUEL....361
4.2.2 NOTES REGARDING THE HYDRAULIC SYSTEM....361
4.2.3 NOTES REGARDING THE ELECTRICAL SYSTEM....362
4.2.4 NOTES REGARDING LUBRICATION....362
4.2.5 PARTS SUBJECT TO WEAR THAT PERIODICALLY NEED CHANGING....363
4.3 FUEL, COOLANT AND LUBRICANTS....364
4.3.1 HOMOLOGATED HEES SYNTHETIC BIODEGRADABLE LUBRICANTS....368
4.4 NUT AND BOLT TIGHTENING TORQUES....369
4.4.1 STANDARD TIGHTENING TORQUES....369
4.4.2 SPECIFIC TIGHTENING TORQUES....369
4.5 LUBRICATION....370
4.5.1 LUBRICATION DIAGRAM....370
4.6 PERIODICAL CHANGE OF THE COMPONENTS CONNECTED WITH SAFETY....371
4.6.1 CRITICAL PARTS FOR SAFETY....372
4.7 MAINTENANCE PLAN....375
4.7.1 WHEN REQUIRED....378
4.7.1.a CHECKING, CLEANING OR CHANGING THE AIR CLEANER CARTRIDGE....378
4.7.1 b CHECKING AND CLEANING THE CAB AIR FILTER....379
4.7.1.c WASHING THE COOLING CIRCUIT....380
4.7.1 d CLEANING THE WATER SEPARATOR....381
4.7.1.e CHECKING THE STEEL TRACK TENSION....382
4.7.1.f CHECKING THE SHOE FASTENING....384
4.7.1.g CHECKING THE RUBBER TRACKS....385
4.7.1.h CHECKING THE RUBBER TRACK TENSION....387
4.7.1.j CHANGING THE RUBBER TRACK....389
4.7.2 MAINTENANCE INTERVALS IN CASE OF USE OF THE DEMOLITION HAMMER....391
4.7.2.a CHANGING THE HYDRAULIC OIL FILTER....391
4.7.2.b CHANGING THE HYDRAULIC OIL....391
4.7.3 CHECKS BEFORE STARTING....392
4.7.3.a VARIOUS CHECKS....392
4.7.3.b CHECKING THE COOLANT LEVEL....392
4.7.3.c CHECKING THE FUEL LEVEL....393
4.7.3.d CHECKING THE ENGINE OIL LEVEL....393
4.7.3.e CHECKING THE OIL LEVEL IN THE HYDRAULIC CIRCUIT....394
4.7.3.f DRAINING THE WATER SEPARATOR....395
4.7.4 MAINTENANCE EVERY 10 HOURS OF OPERATION....396
4.7.4.a LUBRICATING THE JOINTS....396
4.7.5 MAINTENANCE AFTER THE FIRST 50 HOURS OF OPERATION (ONLY FOR MACHINES IN WHICH THE SYNTHETIC BIODEGRADABLE OIL TYPE HEES....399
4.7.6 MAINTENANCE EVERY 50 HOURS OF OPERATION....399
4.7.6.a CHECKING THE RADIATOR FLUID LEVEL....399
4.7.6.b LUBRICATING THE SWING JOINT....399
4.7.6.c CHECKING THE ELECTRICAL SYSTEM....400
4.7.7 MAINTENANCE EVERY 100 HOURS OF OPERATION....401
4.7.7.a LUBRICATING THE BALL-BEARING RING....401
4.7.8 MAINTENANCE AFTER THE FIRST 250 HOURS OF OPERATION....402
4.7.9 MAINTENANCE EVERY 250 HOURS OF OPERATION....402
4.7.9.a ADJUSTING THE FAN BELT TENSION....402
4.7.9.b CHECKING THE BATTERY ELECTROLYTE LEVEL....403
4.7.9.c CHECKING THE OIL LEVEL IN THE TRAVEL REDUCTION GEARS....404
4.7.9.d CHECKING THE OIL LEVEL IN THE SWING REDUCTION GEAR....404
4.7.10 MAINTENANCE AFTER THE FIRST 500 HOURS OF OPERATION....405
4.7.11 MAINTENANCE EVERY 500 HOURS OF OPERATION....405
4.7.11.a CHANGING THE HYDRAULIC SYSTEM OIL FILTER....405
4.7.11.b CHANGING THE SERVO CONTROL FILTER....407
4.7.11.c CHANGING THE ENGINE OIL....408
4.7.11.d CHANGING THE ENGINE OIL FILTER....409
4.7.11.e CHANGING THE FUEL FILTER....410
4.7.11.f DRAINING THE FUEL TANK....411
4.7.11.g CLEANING THE OUTSIDE OF THE RADIATORS....411
4.7.11.h CHECKING THE BALL-BEARING RING PINION LUBIRCANT LEVEL....412
4.7.11.j DRAINING THE HYDRAULIC OIL TANK (ONLY FOR MACHINES IN WHICH THE SYNTHETIC BIODEGRADABLE OIL TYPE HEES IS USED)....412
4.7.12 MAINTENANCE EVERY 1000 HOURS OF OPERATION....414
4.7.12.a CHANGING THE OIL IN THE TRAVEL REDUCTION GEARS....414
4.7.12.b CHANGING THE OIL IN THE SWING REDUCTION GEAR....415
4.7.12.c CHECKING AND ADJUSTING THE ENGINE VALVE CLEARANCE....415
4.7.13 MAINTENANCE EVERY 2000 HOURS OF OPERATION....416
4.7.13.a CHANGING THE HYDRAULIC SYSTEM OIL AND CLEANING THE SUCTION FILTER....416
4.7.13.b CHANGING THE COOLANT....419
4.7.13.c CHANGING THE BALL-BEARING RING PINION LUBRICANT....420
4.7.13.d CHECKING THE ALTERNATOR AND THE STARTER....420
TECHNICAL SPECIFICATIONS....421
5.1 TECHNICAL DATA....422
5.1.1 STANDARD OVERALL DIMENSIONS....422
5.1.2 TECHNICAL CHARACTERISTICS....423
5.1.3 LIFTING CHARACTERISTICS....424
5.1.3.1 LIFTING CAPACITY TABLE....424
5.1.3.2 LIFTING CAPACITY WITH RAISED BLADE....425
5.1.3.3 LIFTING CAPACITY WITH LOWERED BLADE....426
AUTHORIZED OPTIONAL EQUIPMENT....427
6.1 AUTHORIZED OPTIONAL EQUIPMENT....428
6.1.1 PRECAUTIONS REGARDING SAFETY....428
6.1.2 PRECAUTIONS REGARDING THE INSTALLATION OF EQUIPMENT....429
6.1.3 CHARACTERISTICS OF THE OPTIONAL EQUIPMENT....430
6.2 ARRANGEMENT FOR THE INSTALLATION OF THE DEMOLITION HAMMER....431
6.2.1 DESCRIPTION AND OPERATION....431
6.2.2 USE OF THE DEMOLITION HAMMER AND RULES TO BE OBSERVED....431
6.2.3 INSTALLING AND REMOVING THE DEMOLITION HAMMER....435
6.2.3.1 INSTALLING THE HAMMER....435
6.2.3.2 REMOVING THE HAMMER....436
6.2.4 MAINTENANCE....436
6.3 CLAMSHELL BUCKET....437
6.3.1 DESRIPTION AND OPERATION....437
6.3.2 INSTALLING THE CLAMSHELL BUCKET....438
6.3.3 MAINTENANCE....440
WEAM003900 - Hydraulic Excavator PC75R-2 Operation & Maintenance Manual....441
COVER....441
1.1 FOREWORD....443
1.2 INFORMATION ON SAFETY....444
1.3 INTRODUCTION....446
1.3.1 INTENDED USES....446
1.3.2 IMPROPER OR UNAUTHORIZED USE....446
1.3.3 MAIN CHARACTERISTICS....447
1.3.4 RUNNING-IN....447
1.4 PRODUCT IDENTIFICATION....448
1.4.1 MACHINE SERIAL NUMBER....448
1.4.2 MACHINE IDENTIFICATION PLATE....448
1.4.3 ENGINE SERIAL NUMBER AND EMISSION LABEL....449
1.4.4 TRAVEL REDUCTION GEAR SERIAL NUMBER....449
1.4.5 SWING REDUCTION GEAR SERIAL NUMBER....450
1.4.6 CAB SERIAL NUMBER....450
1.4.7 SERIAL NUMBERS AND DEALER’S ADDRESS....451
CONTENTS....452
SAFETY AND ACCIDENT PREVENTION....459
2.1 SAFETY PLATES....460
2.1.1 POSITION OF THE SAFETY PLATES....460
2.1.2 POSITION OF THE PICTOGRAMS....476
2.1.3 PICTOGRAMS AND RELEVANT MEANINGS....477
2.1.4 VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED....479
2.2 GENERAL PRECAUTIONS....480
2.2.1 GENERAL SAFETY RULES....480
2.2.2 SAFETY DEVICES AND GUARDS....480
2.2.3 CLOTHING AND PERSONAL PROTECTION ITEMS....480
2.2.4 UNAUTHORIZED MODIFICATIONS....481
2.2.5 LEAVING THE OPERATOR’S SEAT....481
2.2.6 GETTING ON AND OFF THE MACHINE....482
2.2.7 PREVENTING FIRES DUE TO FUEL AND OIL....482
2.2.8 PREVENTING BURNS....483
2.2.9 PREVENTING DAMAGE DUE TO ASBESTOS POWDER....483
2.2.10 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT....484
2.2.11 FIRE EXTINGUISHERS AND FIRST AID KIT....484
2.2.12 PRECAUTIONS CONCERNING THE CAB STRUCTURE....484
2.2.13 PRECAUTIONS CONCERNING THE EQUIPMENT....484
2.3 PRECAUTIONS TO BE TAKEN BEFORE STARTING THE ENGINE....485
2.3.1 SAFETY ON THE WORK SITE....485
2.3.2 FIRE PREVENTION....485
2.3.3 PRECAUTIONS TO BE TAKEN FOR THE OPERATOR'S CAB....485
2.3.4 ROOM VENTILATION....486
2.3.5 PRECAUTIONS TO BE TAKEN FOR THE LIGHTS....486
2.3.6 CLEANING THE WINDOWS AND THE REAR-VIEW MIRRORS - CHECKING THE WINDSHIELD WIPER BLADES....486
2.4 PRECAUTIONS TO BE TAKEN WHEN WORKING....487
2.4.1 STARTING THE ENGINE....487
2.4.2 CHECK THE DIRECTION BEFORE STARTING THE MACHINE....487
2.4.3 CHECKS FOR TRAVELLING IN REVERSE....487
2.4.4 MOVING THE MACHINE....488
2.4.5 MOVING ON SLOPES....489
2.4.6 WORKING ON SLOPES....490
2.4.7 UNAUTHORIZED OPERATIONS....490
2.4.8 PREVENTING ELECTROCUTION....491
2.4.9 VISIBILITY....492
2.4.10 WORKING ON ICY OR SNOW-COVERED SURFACES....492
2.4.11 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT....492
2.4.12 WORKING ON LOOSE GROUND....492
2.4.13 PARKING THE MACHINE....493
2.5 TRANSPORTING THE MACHINE ON OTHER VEHICLES....494
2.5.1 LOADING AND UNLOADING THE MACHINE....494
2.5.2 SHIPPING....494
2.6 BATTERY....495
2.6.1 SAFETY PRECAUTIONS FOR WORK ON BATTERIES....495
2.6.2 STARTING WITH BOOSTER CABLES....495
2.7 PRECAUTIONS FOR EMERGENCY RECOVERY....496
2.8 PRECAUTIONS TO BE TAKEN DURING MAINTENANCE....497
2.8.1 WARNING PLATES....497
2.8.2 TOOLS....497
2.8.3 PERSONNEL....498
2.8.4 EQUIPMENT....498
2.8.5 WORKING UNDER THE MACHINE....498
2.8.6 KEEPING THE MACHINE CLEAN....498
2.8.7 USE OF THE ENGINE DURING MAINTENANCE....499
2.8.8 PERIODICAL CHANGE OF THE PARTS THAT ARE CRITICAL FOR SAFETY....499
2.8.9 STOP THE ENGINE BEFORE CARRYING OUT ANY MAINTENANCE OPERATION OR INSPECTION....499
2.8.10 RULES FOR REFUELLING AND ADDING OIL....500
2.8.11 CHECKING THE COOLANT LEVEL IN THE RADIATOR....500
2.8.12 USING LAMPS....500
2.8.13 PRECAUTIONS CONCERNING THE BATTERY AND THE ALTERNATOR....501
2.8.14 PRECAUTIONS CONCERNING THE STARTER....501
2.8.15 PRECAUTIONS CONCERNING HIGH-PRESSURE HOSES....502
2.8.16 PRECAUTIONS TO BE TAKEN WHEN WORKING ON HIGH-PRESSURE SYSTEMS....502
2.8.17 PRECAUTIONS FOR MAINTENANCE WORK INVOLVING HIGH TEMPERATURES AND PRESSURES....502
2.8.18 COOLING FAN AND FAN BELT....503
2.8.19 WASTE MATERIALS....503
2.8.20 PRECAUTIONS FOR THE USE OF THE synthetic biodegradable oil type HEES....503
THE MACHINE AND ITS OPERATIONS....505
3.1 SAFETY LOCKS....506
3.1.1 MACHINE LOCKS....506
3.2 GENERAL VIEWS....507
3.2.1 FRONT GENERAL VIEW (MONOBOOM)....507
3.2.2 FRONT GENERAL VIEW (TWO-PIECE BOOM)....508
3.2.3 CAB INSIDE GENERAL VIEW....509
3.3 INSTRUMENTS AND CONTROLS....511
3.3.1 INSTRUMENTS....511
3.3.2 WARNING LIGHTS....513
3.3.3 SWITCHES AND PUSH BUTTONS....515
3.3.4 ELECTRICAL ACCESSORIES....523
3.3.5 MACHINE CONTROLS....525
3.4 FUSES AND RELAYS....536
3.4.1 CENTRAL UNIT FUSES AND RELAYS....536
3.4.1.1 CENTRAL UNIT FUSES....537
3.4.1.2 CENTRAL UNIT RELAYS....538
3.4.2 ENGINE LINE FUSES AND RELAYS....539
3.4.2.1 ENGINE LINE FUSES....539
3.4.2.2 ENGINE LINE RELAYS....540
3.4.3 FUSES AND RELAYS OF THE AIR CONDITIONING SYSTEM (if provided)....541
3.5 GUARDS AND DRIVER’S SEAT....543
3.5.1 ENGINE HOOD....543
3.5.2 SIDE COVER....543
3.5.3 CAB....544
3.5.4 VENTILATION AND HEATING....548
3.5.5 AIR CONDITIONER (if provided)....549
3.5.6 SEAT....551
3.5.7 SAFETY BELT....552
3.5.8 EMERGENCY EXIT....552
3.5.9 TECHNICAL DOCUMENTATION CASE....553
3.5.10 FIRE EXTINGUISHER....553
3.5.11 FIRST AID KIT....553
3.6 USE OF THE MACHINE....555
3.6.1 CHECKS BEFORE STARTING THE ENGINE....555
3.6.1.1 VISUAL CHECKS....555
3.6.1.2 DAILY CHECKS....555
3.6.1.3 OPERATIONAL CHECKS....556
3.6.2 STARTING THE ENGINE....557
3.6.2.1 STARTING WITH WARM ENGINE OR IN TEMPERATE CLIMATES....557
3.6.2.2 STARTING WITH COLD ENGINE OR IN COLD CLIMATES....558
3.6.3 WARMING THE ENGINE....559
3.6.4 HEATING THE HYDRAULIC OIL....559
3.6.5 HOW TO MOVE THE MACHINE....559
3.6.5.1 STEERING (CHANGING DIRECTION)....561
3.6.5.2 MOVING ON SLOPES....562
3.6.5.3 MAXIMUM IMMERSION DEPTH....563
3.7 PARKING THE MACHINE....564
3.7.1 PARKING ON LEVEL GROUND....564
3.7.2 PARKING ON SLOPES....565
3.8 STOPPING THE ENGINE....566
3.9 TRANSPORTING THE MACHINE ON OTHER VEHICLES....567
3.9.1 LOADING AND UNLOADING THE MACHINE....567
3.9.2 TRANSPORT....568
3.10 PRECAUTIONS TO BE TAKEN IN THE COLD SEASON....569
3.10.1 FUEL AND LUBRICANTS....569
3.10.2 COOLANT....569
3.10.3 BATTERY....570
3.10.4 OTHER PRECAUTIONS....570
3.10.5 PRECAUTIONS TO BE TAKEN AT THE END OF WORK....570
3.11 PRECAUTIONS TO BE TAKEN IN THE WARM SEASON....571
3.12 USING THE WORK EQUIPMENT....572
3.12.1 ORGANIZING THE WORK AREA....572
3.12.2 POSITIONING THE BUCKET ACCORDING TO THE WORK TO BE CARRIED OUT....572
3.12.3 POSITIONING THE MACHINE FOR DIGGING OPERATIONS....573
3.12.4 DIGGING METHOD....574
3.12.5 CHANGING THE BUCKET....575
3.13 LONG PERIODS OF INACTIVITY....576
3.13.1 BEFORE THE PERIOD OF INACTIVITY....576
3.13.2 DURING THE PERIOD OF INACTIVITY....577
3.13.3 AFTER THE PERIOD OF INACTIVITY....577
3.14 TROUBLESHOOTING....578
3.14.1 HOW TO REMOVE THE MACHINE....578
3.14.2 IF THE FUEL HAS BEEN COMPLETELY DEPLETED....578
3.14.3 IF THE BATTERY IS DEPLETED....579
3.14.3.1 STARTING WITH BOOSTER CABLES....580
3.14.4 OTHER TROUBLES....581
3.14.4.1 ELECTRICAL CIRCUIT....581
3.14.4.2 HYDRAULIC SYSTEM....582
3.14.4.3 ENGINE....583
MAINTENANCE....585
4.1 GUIDE TO MAINTENANCE....586
4.2 MAINTENANCE NOTES....588
4.2.1 NOTES REGARDING THE ENGINE....588
4.2.1.1 ENGINE OIL....588
4.2.1.2 COOLANT....588
4.2.1.3 FUEL....589
4.2.2 NOTES REGARDING THE HYDRAULIC SYSTEM....589
4.2.3 NOTES REGARDING THE ELECTRICAL SYSTEM....590
4.2.4 NOTES REGARDING LUBRICATION....590
4.2.5 PARTS SUBJECT TO WEAR THAT PERIODICALLY NEED CHANGING....591
4.3 FUEL, COOLANT AND LUBRICANTS....592
4.3.1 HOMOLOGATED HEES SYNTHETIC BIODEGRADABLE LUBRICANTS....596
4.4 NUT AND BOLT TIGHTENING TORQUES....597
4.4.1 STANDARD TIGHTENING TORQUES....597
4.4.2 SPECIFIC TIGHTENING TORQUES....597
4.5 LUBRICATION....598
4.5.1 LUBRICATION DIAGRAM....598
4.6 PERIODICAL CHANGE OF THE COMPONENTS CONNECTED WITH SAFETY....599
4.6.1 CRITICAL PARTS FOR SAFETY....600
4.7 MAINTENANCE PLAN....603
4.7.1 WHEN REQUIRED....607
4.7.1.a CHECKING, CLEANING OR CHANGING THE AIR CLEANER CARTRIDGE....607
4.7.1.b CHECKING AND CLEANING THE CAB AIR FILTER....609
4.7.1.c CHECKING AND CLEANING THE AIR RECIRCULATION FILTER (only for machines equipped with air c....610
4.7.1.d CLEANING THE WATER SEPARATOR....611
4.7.1.e CHECKING THE STEEL TRACK TENSION....612
4.7.1.f CHECKING THE SHOE FASTENING....614
4.7.1.g CHECKING THE RUBBER TRACKS....615
4.7.1.h CHECKING THE RUBBER TRACK TENSION....617
4.7.1.j CHANGING THE RUBBER TRACK....619
4.7.2 MAINTENANCE INTERVALS IN CASE OF USE OF THE DEMOLITION HAMMER....621
4.7.2.a CHANGING THE HYDRAULIC OIL FILTER....621
4.7.2.b CHANGING THE HYDRAULIC OIL....621
4.7.3 CHECKS BEFORE STARTING....622
4.7.3.a VARIOUS CHECKS....622
4.7.3.b CHECKING THE COOLANT LEVEL....622
4.7.3.c CHECKING THE FUEL LEVEL....623
4.7.3.d CHECKING THE ENGINE OIL LEVEL....623
4.7.3.e CHECKING THE OIL LEVEL IN THE HYDRAULIC CIRCUIT....624
4.7.3.f DRAINING THE WATER SEPARATOR....625
4.7.4 MAINTENANCE EVERY 10 HOURS OF OPERATION....626
4.7.4.a LUBRICATING THE JOINTS....626
4.7.5 MAINTENANCE AFTER THE FIRST 50 HOURS OF OPERATION (Only for machines in which the synthetic....629
4.7.6 MAINTENANCE EVERY 50 HOURS OF OPERATION....629
4.7.6.a CHECKING THE RADIATOR FLUID LEVEL....629
4.7.6.b LUBRICATING THE SWING JOINT....629
4.7.6.c CHECKING THE ELECTRICAL SYSTEM....630
4.7.7 MAINTENANCE EVERY 100 HOURS OF OPERATION....631
4.7.7.a LUBRICATING THE BALL-BEARING RING....631
4.7.8 MAINTENANCE AFTER THE FIRST 250 HOURS OF OPERATION....632
4.7.9 MAINTENANCE EVERY 250 HOURS OF OPERATION....632
4.7.9.a ADJUSTING THE FAN BELT TENSION....632
4.7.9.b ADJUSTING THE TENSION OF THE A/C COMPRESSOR BELT (only for machines equipped with air con....633
4.7.9.c CHECKING THE BATTERY ELECTROLYTE LEVEL....634
4.7.9.d CHECKING THE OIL LEVEL IN THE TRAVEL REDUCTION GEARS....635
4.7.9.e CHECKING THE OIL LEVEL IN THE SWING REDUCTION GEAR....635
4.7.10 MAINTENANCE AFTER THE FIRST 500 HOURS OF OPERATION (Only for machines in which the synthet....636
4.7.11 MAINTENANCE EVERY 500 HOURS OF OPERATION....636
4.7.11.a CHANGING THE HYDRAULIC SYSTEM OIL FILTER....636
4.7.11.b CHANGING THE SERVO CONTROL FILTER....638
4.7.11.c CHANGING THE ENGINE OIL....639
4.7.11.d CHANGING THE ENGINE OIL FILTER....640
4.7.11.e CHANGING THE FUEL FILTER....641
4.7.11.f DRAINING THE FUEL TANK....642
4.7.11.g CLEANING THE OUTSIDE OF THE RADIATORS....642
4.7.11.h CLEANING THE OUTSIDE OF THE A/C CONDENSER (only for machines equipped with air conditioner)....643
4.7.11.j CHECKING THE BALL-BEARING RING PINION LUBRICANT LEVEL....644
4.7.11.k DRAINING THE HYDRAULIC OIL TANK (Only for machines in which the synthetic biodegradable ....644
4.7.12 MAINTENANCE EVERY 1000 HOURS OF OPERATION....646
4.7.12.a CHECKING AND ADJUSTING THE ENGINE VALVE CLEARANCE....646
4.7.13 MAINTENANCE EVERY 2000 HOURS OF OPERATION....647
4.7.13.a CHANGING THE OIL IN THE TRAVEL REDUCTION GEARS....647
4.7.13.b CHANGING THE OIL IN THE SWING REDUCTION GEAR....648
4.7.13.c CHANGING THE HYDRAULIC SYSTEM OIL AND CLEANING THE SUCTION FILTER....649
4.7.13.d CHANGING THE COOLANT....652
4.7.13.e CHANGING THE BALL-BEARING RING PINION LUBRICANT....653
4.7.13.f CHECKING THE ALTERNATOR AND THE STARTER....653
4.7.13.g CHECKING THE A/C COOLING GAS QUANTITY (only for machines equipped with air conditioner)....654
4.7.14 MAINTENANCE EVERY 4000 HOURS OF OPERATION....655
4.7.14.a CHANGING THE A/C DEHYDRATOR FILTER (only for machines equipped with air conditioner)....655
4.7.14.b CHECKING THE CORRECT OPERATION OF THE A/C COMPRESSOR (only for machines equipped with ai....655
TECHNICAL SPECIFICATIONS....657
5.1 TECHNICAL DATA....658
5.1.1 STANDARD OVERALL DIMENSIONS....658
5.1.2 TECHNICAL CHARACTERISTICS....659
5.1.3 LIFTING CAPACITIES....660
5.1.3.1 LIFTING CAPACITY TABLE....660
5.1.3.2 LIFTING CAPACITY WITH RAISED BLADE....661
5.1.3.3 LIFTING CAPACITY WITH LOWERED BLADE....662
AUTHORIZED OPTIONAL EQUIPMENT....663
6.1 AUTHORIZED OPTIONAL EQUIPMENT....664
6.1.1 PRECAUTIONS REGARDING SAFETY....664
6.1.2 PRECAUTIONS REGARDING THE INSTALLATION OF EQUIPMENT....665
6.1.3 CHARACTERISTICS OF THE OPTIONAL EQUIPMENT....666
6.2 ARRANGEMENT FOR THE INSTALLATION OF THE DEMOLITION HAMMER....667
6.2.1 DESCRIPTION AND OPERATION....667
6.2.2 USE OF THE DEMOLITION HAMMER AND RULES TO BE OBSERVED....667
6.2.3 INSTALLING AND REMOVING THE DEMOLITION HAMMER....671
6.2.3.1 INSTALLING THE HAMMER....671
6.2.3.2 REMOVING THE HAMMER....672
6.2.4 MAINTENANCE....672
6.3 CLAMSHELL BUCKET....673
6.3.1 DESCRIPTION AND OPERATION....673
6.3.2 INSTALLING THE CLAMSHELL BUCKET....674
6.3.3 MAINTENANCE....676
WEBM004000 - Hydraulic Excavator PC75R-2 Shop Manual....677
COVER....677
CONTENTS....679
LIST OF REVISED PAGES....681
SAFETY....683
FOREWORD....685
HOW TO READ THE SHOP MANUAL....686
HOISTING INSTRUCTIONS....687
STANDARD TIGHTENING TORQUE....688
COATING MATERIALS....690
ELECTRIC WIRE CODE....691
WEIGHT TABLE....692
TABLE OF OIL COOLANT QUANTITIES....693
10. STRUCTURE AND FUNCTION....697
P.T.O....698
POWER TRAIN....699
TRACK FRAME....701
IDLER AND RECOIL SPRING....702
CARRIER ROLLER....703
TRACK ROLLER....703
TRACK SHOE....704
SWING CIRCLE....705
SWING MACHINERY....706
HYDRAULIC CIRCUIT DIAGRAM (STANDARD)....707
HYDRAULIC CIRCUIT DIAGRAM (2-PIECE BOOM)....709
HYDRAULIC PUMP....710
9-SPOOL CONTROL VALVE (STANDARD)....736
10-SPOOL CONTROL VALVE (STANDARD+2-PIECE BOOM)....738
SWING MOTOR....766
CENTER SWIVEL JOINT....770
TRAVEL MOTOR....772
PARKING BRAKE....774
BRAKE VALVE....775
TRAVEL MOTOR....777
REDUCTION GEAR....779
CYLINDERS....780
SERVOCONTROL FEED UNIT....782
ACCUMULATOR....787
PPC VALVE (WORK EQUIPMENT)....788
PPC VALVE (BLADE, BOOM SWING, 2-PIECE BOOM)....792
TRAVEL PPC VALVE....796
BOOM AND ARM SAFETY VALVE....801
BLADE SAFETY VALVE....802
2-PIECE BOOM SAFETY VALVE....803
OVERLOAD SENSOR SWITCH....804
SOLENOID VALVE....805
ELECTRICAL DIAGRAM (1/3)....807
ELECTRICAL DIAGRAM (2/3)....809
ELECTRICAL DIAGRAM (3/3)....811
20. TESTING AND ADJUSTING....815
NORMAL OR STANDARD TECHNICAL DATA....816
SPECIAL TOOLS....833
MEASURING THE ENGINE SPEED....835
ADJUSTING VALVE CLEARANCE....836
MEASURING COMPRESSION PRESSURE....837
TESTING AND ADJUSTING FUEL INJECTION TIMING....838
TESTING AND ADJUSTING FAN BELT TENSION....840
ADJUSTING THE STROKE OF THE ACCELERATOR LEVER....841
ADJUSTING PPC VALVE CLEARANCE....842
ADJUSTING THE SAFETY MICROSWITCH....843
MEASURING THE SWING CIRCLE AXIAL CLEARANCE....844
TESTING AND ADJUSTING TRACK-SHOE TENSION....845
AIR BLEEDING FROM HYDRAULIC CIRCUITS....846
RELEASING RESIDUAL PRESSURE FROM THE CIRCUITS....849
CHECKING AND REGULATING PRESSURE IN THE HYDRAULIC CIRCUITS....850
TESTING AND SETTING OF MAIN VALVES....851
ADJUSTING PC VALVE....853
MEASURING LS DIFFERENTIAL PRESSURE AND ADJUSTING LS VALVE....854
CHECKING AND ADJUSTING PRESSURES IN THE SERVOCONTROL FEED UNIT....856
MEASURING PUMPS DELIVERY AND FLOW CONTROL STARTING POINT PUMP P1....857
MEASURING TRAVEL DEVIATION....859
ADJUSTING THE MAXIMUM SPEED OF THE TRAVEL MOTORS....860
MEASURING INNER OIL LEAKAGE OF TRAVEL MOTOR....861
ADJUSTING BOOM AND ARM SAFETY VALVES....862
ADJUSTING 2nd BOOM SAFETY VALVES....863
MEASURING AND SETTING OF PRESSURE SWITCH SIGNAL OVERLOAD OPERATION....864
MEASUREMENT OF INTERNAL OIL LEAKAGES IN THE SWING MOTOR....865
CHECKING FOR LEAKAGES INSIDE THE SWIVEL JOINT....866
ANALYSIS OF THE CAUSES OF HYDRAULIC DRIFTS....868
30. DISASSEMBLY AND ASSEMBLY....877
HOW TO READ THE MANUAL....879
PRECAUTIONS TO BE TAKEN WHEN WORKING....880
SPECIAL TOOLS....881
STARTER MOTOR....883
REMOVAL AND INSTALLATION....883
ALTERNATOR....884
REMOVAL AND INSTALLATION....884
INJECTION PUMP....885
REMOVAL....885
INSTALLATION....888
NOZZLE HOLDER....889
REMOVAL AND INSTALLATION....889
CYLINDER HEAD....890
REMOVAL....890
INSTALLATION....892
SEAT....893
REMOVAL AND INSTALLATION....893
CABIN....894
REMOVAL AND INSTALLATION....894
ENGINE HOOD....895
REMOVAL AND INSTALLATION....895
FRONT HOOD....896
REMOVAL AND INSTALLATION....896
HEATING FAN....897
REMOVAL AND INSTALLATION....897
RADIATOR....898
REMOVAL....898
INSTALLATION....899
FUEL TANK....900
REMOVAL....900
INSTALLATION....901
HYDRAULIC OIL TANK....902
REMOVAL AND INSTALLATION....902
ENGINE-PUMP GROUP....903
REMOVAL....903
INSTALLATION....906
PUMP GROUP....907
REMOVAL....907
INSTALLATION....908
ENGINE-PUMP COUPLING JOINT....909
REMOVAL AND INSTALLATION....909
MAIN PUMP INPUT SHAFT OIL SEAL....910
REMOVAL AND INSTALLATION....910
GEAR PUMP....911
REMOVAL AND INSTALLATION....911
SWIVEL JOINT....912
REMOVAL AND INSTALLATION....912
SWING MOTOR....913
REMOVAL AND INSTALLATION....913
SWING MACHINERY....914
REMOVAL AND INSTALLATION....914
DISASSEMBLY....915
ASSEMBLY....918
CONTROL VALVE....921
REMOVAL AND INSTALLATION....921
REVOLVING FRAME....922
REMOVAL....922
INSTALLATION....923
COUNTERWEIGHT....924
REMOVAL AND INSTALLATION....924
SWING CIRCLE....925
REMOVAL AND INSTALLATION....925
TRACK SHOES....926
REMOVAL AND INSTALLATION....926
SPROCKET ASSEMBLY....927
REMOVAL AND INSTALLATION....927
TRAVEL GEAR MOTOR....928
REMOVAL AND INSTALLATION....928
DISASSEMBLY....929
ASSEMBLY....944
BALL BEARING PRELOAD....959
ADJUSTING....959
AXIAL CLEARANCE ON TAPERED ROLLER BEARINGS....960
ADJUSTING....960
IDLER AND RECOIL SPRING ASSEMBLY....961
REMOVAL AND INSTALLATION....961
IDLER....962
DISASSEMBLY AND ASSEMBLY....962
RECOIL SPRING GROUP AND CYLINDER....963
DISASSEMBLY AND ASSEMBLY....963
TRACK ROLLER....964
REMOVAL AND INSTALLATION....964
CARRIER ROLLER....965
REMOVAL AND INSTALLATION....965
R.H. PPC VALVE (BOOM-BUCKET)....966
REMOVAL....966
INSTALLATION....967
L.H. PPC VALVE (ARM-SWING)....968
REMOVAL....968
INSTALLATION....969
BLADE PPC VALVE....970
REMOVAL AND INSTALLATION....970
TRAVEL PEDAL CONTROL....971
REMOVAL AND INSTALLATION....971
1st BOOM SWING PEDAL CONTROL....972
REMOVAL AND INSTALLATION....972
BOOM CYLINDER (FOR 1-PIECE BOOM)....973
REMOVAL AND INSTALLATION....973
BOOM CYLINDER (FOR 2-PIECE BOOM)....974
REMOVAL....974
INSTALLATION....975
2nd BOOM CYLINDERS....976
REMOVAL....976
INSTALLATION....977
ARM CYLINDER....978
REMOVAL AND INSTALLATION....978
BUCKET CYLINDER....979
REMOVAL AND INSTALLATION....979
BOOM SWING CYLINDER....980
REMOVAL AND INSTALLATION....980
BLADE CYLINDER....981
REMOVAL AND INSTALLATION....981
WORK EQUIPMENT CYLINDERS....982
DISASSEMBLY....982
ASSEMBLY....983
WORK EQUIPMENT (FOR 1-PIECE BOOM)....987
REMOVAL AND INSTALLATION....987
WORK EQUIPMENT (FOR 2-PIECE BOOM)....988
REMOVAL....988
INSTALLATION....989
BUCKET....990
REMOVAL AND INSTALLATION....990
ARM....991
REMOVAL....991
INSTALLATION....993
2nd BOOM....994
REMOVAL....994
INSTALLATION....995
BOOM (FOR 1-PIECE BOOM)....996
REMOVAL AND INSTALLATION....996
1st BOOM....997
REMOVAL....997
INSTALLATION....998
SWING BRACKET....999
REMOVAL AND INSTALLATION....999
BLADE....1000
REMOVAL AND INSTALLATION....1000
40. MAINTENANCE STANDARD....1003
P.T.O....1004
SWING CIRCLE....1005
TRACK FRAME....1006
IDLER....1007
CARRIER ROLLER....1008
TRACK ROLLER....1009
TRACK SHOE....1010
SPROCKET....1011
SWING MACHINERY....1012
HYDRAULIC PUMP....1013
CONTROL VALVE....1014
SWING MOTOR....1024
SWIVEL JOINT....1025
TRAVEL MOTOR....1026
SERVOCONTROL FEED UNIT....1028
TRAVEL PPC VALVE....1029
PPC VALVE....1030
BLADE SAFETY VALVE....1032
CYLINDERS....1034
WORK EQUIPMENT (1-PIECE BOOM)....1036
WORK EQUIPMENT (2-PIECE BOOM)....1038
Komatsu Hydraulic Excavator PC75R Repair Service Manuals
