Repairing the differential gear on a Komatsu PC200LC-5 excavator involves a series of detailed steps and requires a solid understanding of the machine’s mechanical components. click here for more details on the download manual…..
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Below, I’ll outline the overall procedure, the components involved, and the necessary tools.
### Components of the Differential Gear System
1. **Differential Case**: This houses the differential gears and allows the wheels to rotate at different speeds while maintaining power.
2. **Ring Gear**: This large gear connects to the driveshaft and transfers power to the differential.
3. **Pinion Gear**: This smaller gear engages with the ring gear and is driven by the driveshaft.
4. **Spider Gears**: These are the bevel gears inside the differential case, allowing for the difference in speed between the left and right wheels.
5. **Side Gears**: These connect the spider gears to the axle shafts, transmitting power to the wheels.
6. **Differential Bearings**: These support the differential assembly, allowing smooth rotation.
7. **Oil Seals**: These prevent oil leaks and keep dirt and debris out of the differential housing.
8. **Gaskets**: These provide a seal between the differential case and other components.
### Tools Required
– socket and ratchet set
– Wrench set
– Torque wrench
– Gear puller
– Pry bars
– Clean rags
– Differential oil
– Gasket scraper
– Cleaning solvent
– Safety glasses and gloves
### Differential Gear Repair Procedure
#### 1. **Preparation and Safety**
– **Safety First**: Ensure you wear safety glasses and gloves.
– **Park the Excavator**: On a flat surface, turn off the engine and secure the excavator using wheel chocks or by engaging the parking brake.
– **Disconnect the Battery**: To avoid any electrical issues, disconnect the battery.
#### 2. **Drain the Differential Oil**
– Locate the differential drain plug, usually located at the bottom of the differential housing.
– Place a suitable container under the differential.
– Remove the drain plug and allow the oil to completely drain out.
#### 3. **Remove the Axle Shafts**
– **Remove the Wheel Hubs**: Depending on your model, you may need to remove the wheel hub assemblies to access the axle shafts.
– **Disconnect the Axle Shafts**: Use the appropriate socket to remove the bolts securing the axle shafts to the differential. Carefully slide the shafts out.
#### 4. **Remove the Differential Housing**
– **Unbolt the Differential Cover**: Use a wrench to remove the bolts securing the differential cover. This might require some prying if it’s stuck.
– **Remove the Differential Case**: Gently pull out the differential case from the housing. Be cautious of the spider gears and bearings.
#### 5. **Inspect the Components**
– **Check for Wear and Damage**: Inspect the ring gear, pinion gear, spider gears, side gears, bearings, and seals for wear or damage. Look for scoring, pitting, or any unusual wear patterns.
– **Measure Gear Clearances**: Use a feeler gauge to check the clearances between the gears. Refer to the service manual for the acceptable specifications.
#### 6. **Replace Damaged Components**
– If any components are worn or damaged, replace them with new or refurbished parts.
– Ensure that all components are cleaned before reassembly, using a cleaning solvent and rags.
#### 7. **Reassemble the Differential**
– **Install the Spider Gears and Side Gears**: Place new bearings where necessary and install the spider gears and side gears into the differential case.
– **Install the Differential Case**: Carefully slide the differential case back into the housing, ensuring that the gears mesh correctly.
– **Replace the Differential Cover**: Use a new gasket or sealant, if required,
and bolt the differential cover back in place.
#### 8. **Reinstall the Axle Shafts**
– Slide the axle shafts back into place and secure them with the appropriate bolts.
– Reattach the wheel hubs if they were removed.
#### 9. **Refill Differential Oil**
– Replace the drain plug and refill the differential with the correct type and amount of oil as specified in the service manual.
#### 10. **Final Checks**
– **Inspect for Leaks**: After refilling, check around the differential cover and axle seals for any leaks.
– **Reconnect the Battery**: Once everything is checked, reconnect the battery.
– **Test Run the Excavator**: Start the machine and operate it briefly to ensure everything is functioning correctly.
### Conclusion
Repairing the differential gear on a Komatsu PC200LC-5 requires careful attention to detail and a thorough understanding of the components involved. Always refer to the service manual for specific torque specifications and detailed diagrams. If you’re not experienced with heavy machinery repair, it’s advisable to consult with or hire a professional mechanic to handle the task.
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