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CONTENTS

No. of page

10 STRUCTURE AND FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

20 TESTING AND ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1

30 DISASSEMBLY AND ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-1

40 MAINTENANCE STANDARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1

PW75R-2 00-1
00-2 PW75R-2
The affected pages are indicated by the use of the
following marks. It is requested that necessary ac- Mark Indication Action required
tions be taken to these pages according to table

C Page to be newly Add

c Page to be replaced Replace

( ) Page to be delete Discard

Pages having no marks are those previously revised


or made additions.

LIST OF REVISED PAGES

Time of Time of Time of Time of Time of


Mark Page Mark Page Mark Page Mark Page Mark Page
revision revision revision revision revision

00-1 10-25 10-66 10-107 20-1


00-2 10-26 10-67 10-108 20-2
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10-21 10-62 10-103 10-144 20-38
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10-24 10-65 10-106 10-147 20-41

PW75R-2 00-2-1
Time of Time of Time of Time of Time of
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30-20 30-77 30-134 40-20
30-21 30-78 30-135 40-21

00-2-2 PW75R-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 FKI and describe in this manual are both effective
and safe methods of operation. Some of these operations require the use of tools specially designed by
FKI for the purpose.
To prevent injury to workers, the symbols and are used to mark safety precautions in this ma-
nual. The cautions accompanying these symbols should always be carefully followed. If any danger ari-
ses or may possibly arise, first consider safety, and take necessary steps to face.

SAFETY
GENERAL PRECAUTIONS PREPARATIONS FOR WORK
Mistakes in operation extremely dangerous. 7. Before adding or making any repairs, park the ma-
Read all the Operation and Maintenance Manual care- chine on hard, level ground, and block the wheels
fully BEFORE operating the machine. to prevent the machine from moving.
1. Before carrying out any greasing or repairs, read 8. Before starting work, lower outrigger, bucket or
all the precautions written on the decals which any other work equipment to the ground. If this
are suck on the machine. is not possible, use blocks to prevent the work
2. When carrying out any operation, always wear sa- equipment from falling down. In addition, be sure
fety shoes and helmet. Do not wear loose work to lock all the control levers and hang warning
clothes, or clothes with buttons missing. sign on them.
. Always wear safety glasses when hitting parts 9. When disassembling or assembling, support the
with a hammer. machine with blocks, jacks or stands before star-
. Always wear safety glasses when grinding ting work.
parts with a grinder, etc.
10. Remove all mud and oil from the steps or other
3. If welding repairs are needed, always have a trai- places used to get on and off the machine. Always
ned, experienced welder carry out the work. use the handrails, ladders or steps when getting
When carrying out welding work, always wear on or off the machine.
welding gloves, apron, glasses, cap and other clo- Never jump on or off the machine.
thes suited for welding work. If it is impossible to use the handrails, ladders or
steps, use a stand to provide safe footing.
4. When carrying out any operation with two or more
workers, always agree on the operating procedure
before starting. Always inform your fellow workers PRECAUTIONS DURING WORK
before starting any step of the operation. Before 11. When removing the oil filler cap, drain plug or hy-
starting work, hang UNDER REPAIR signs on draulic pressure measuring plugs, loosen them
the controls in the operator's compartment. slowly to prevent the oil from spurting out.
5. Keep all tools in good condition and learn the cor- Before disconnecting or removing components of
rect way to use them. the hydraulic circuit and engine cooling circuit,
first remove the pressure completely from the cir-
6. Decide a place in the repair workshop to keep cuit.
tools and removed parts. Always keep the tools
and parts in their correct places. Always keep 12. The water and oil in the circuits are not hot when
the work area clean and make sure that there is the engine in stopped, so be careful not to get
no dirt or oil on the floor. burned.
Smoke only in the areas provided for smoking. Wait for the oil water to cool before carrying out
Never smoke while working. any work on the cooling water circuits.

PW75R-2 00-3
13. Before starting work, remove the leads from the 19. Be sure to assemble all parts again in their origi-
battery. Always remove the lead from the negative nal places. Replace any damage parts with new
( ± ) terminal first. parts.
14. When raising heavy components, use a hoist or . When installing hoses and wires, be sure that
crane. Check that the wire rope, chains and hooks they will not be damaged by contact with other
parts when the machine is being operated.
are free from damage.
Always use lifting equipment which has ample ca- 20. When installing high pressure hoses, make sure
pacity. Install the lifting equipment at the correct that they are not twisted. Damaged tubes are dan-
places. gerous, so be extremely careful when installing
Use a hoist or crane and operate slowly to prevent tubes for high pressure circuits. Also, check that
the component from hitting any other part. connecting parts are correctly tightened.
Do not work with any part still raised by the hoist
or crane. 21. When assembling or installing parts, always use
specified tightening torques.
15. When removing covers which are under internal When installing the parts which vibrate violently or
pressure or under pressure from a spring, always rotate at high speed, be particulary careful to
leave two bolts in position on opposite sides. check that they are correctly installed.
Slowly release the pressure, then slowly loosen
the bolts to remove. 22. When aligning two holes, never insert your fingers
or hand.
16. When removing components, be careful not to
break or damage the wiring. 23. When measuring hydraulic pressure, check that
Damage wiring may cause electrical fires. the measuring tool is correctly assembled before
taking any measurement.
17. When removing piping, stop the fuel or oil from
spilling out. If any fuel or oil drips on to the floor, 24. Take sure when removing or installing tracks of in
wipe it up immediately. particular rubber tracks. When removing the
Fuel or oil on the floor can cause you to slip, or track, the track separates suddenly, so never let
can even start fires. anyone stand at either end of the wheel.

18. As a general rule, do not use gasoline to wash


parts. In particular, use only the minimum of gaso-
line when washing electrical parts.

00-4 PW75R-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. It 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 specifications contained in this shop manual are subject to change at any time and without any
notice.
Contact your FKI distributor for the latest information.

PW75R-2 00-5
HOW TO READ THE SHOP MANUAL

HOW TO READ THE SHOP MANUAL

VOLUMES SYMBOLS
Shop manual are issued as a guide to carry out re- In order to make the shop manual greatly chelpful,
pairs. These various volumes are designed to avoid important points about safety and quality are marked
duplicating the same information. with the following symbols.

Symbol Item Remarks


DISTRIBUTION AND UPDATING
Any additions, amendments or other changes will Special safety precautions are ne-
be sent to FKI distributors. cessary when performing the
Get the most up-to-date information before you start work.
any work. Safety
Extra special safety precautions
are necessary when performing
the work because it is under inter-
FILING METHOD
nal pressure.
1. See the page number on the bottom of the page.
File the pages in correct order. Special technical precautions or
other precautions for preserving
2. Following examples show you how to read the pa- Caution standards are necessary when
ge number. performing the work.

Example Weight of parts or systems.


10 - 3 Caution necessary when selecting
Weight hoisting wire, or when working po-
sture is important, etc.
Numero dell'articolo (10. Struttura e
funzionamento) Parts that require special attention
Tightening for the tightening torque during as-
torque
Numero di pagina progressivo per sembly.
ogni articolo
Parts to be coated with adhesives
Coat and lubricants etc.
3. Additional pages: additional pages are indicated
by a hyphen (-) and number after the page num- Places where oil, water or fuel
Oil, water must be added, and their quantity.
ber.
Fle as in the example.
Places where oil or water must be
Example:
Drain drained, and quantity to be drai-
10-4
ned.
10-4-1
10-4-2
] Added pages
10-5

REVISED EDITION MARK


(1 2 3 ....)
When a manual is revised, an edition mark is recor-
ded on the bottom outside corner of the pages.

REVISIONS
Revised pages are shown on the LIST OF REVI-
SED PAGES between the title page and SAFETY pa-
ge.

00-6 PW75R-2
HOISTING INSTRUCTIONS

HOISTING INSTRUCTIONS

ing, and a serious accident can result.


Heavy parts (25 kg or more) must be lifted Hooks have maximum strength at the middle
with a hoist etc. In the Disassembly and As- portion.
sembly section, every part weighing 25 kg or
more is clearly indicated with the symbol

1. If 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. 3) Do not sling a heavy load with one rope alone,
but sling with two or more ropes symmetrically
wound on to the load.
2. Wire ropes Slinging with one rope may cause turning of
1) Use adequate ropes depending on the weight the load during hoisting, untwisting of the ro-
of parts to be hoisted, referring to the table be- pe, or slipping of the rope from its original
low: winding position on the load, which can cau-
se dangerous accidents.

WIRE ROPES
(Standard «S» or «Z» twist ropes
without galvanizing)
4) Do not sling a heavy load with ropes forming a
Rope diameter (mm) Allowable load (tons) wide hanging angle from the hook.
When hoisting a load with two or more ropes,
10 1.0 the force subjected to each rope will increase
with the hanging angles.
11.2 1.4 The table below shows the variation of allowa-
ble load (kg) when hoisting is made with two ro-
12.5 1.6 pes, each of which is allowed to sling up to
1000 kg vertically, at various handing angles.
14 2.2 When two ropes sling a load vertically, up to
16 2.8 2000 kg of total weight can be suspended.
This weight becomes 1000 kg when two ropes
18 3.6 make a 120ë hanging angle.
On the other hand, two ropes are subjected to
20 4.4 an excessive force as large as 4000 kg if they
sling a 2000 kg load at a lifting angle of 150ë.
22.4 5.6
30 10.0
40 18.0
50 28.0
60 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-

PW75R-2 00-7
STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE

The following charts give the standard tightening torques of bolts and nuts. Exceptions are given in sections of «Di-
sassembly and Assembly».

1. STANDARD TIGHTENING TORQUE OF BOLTS AND NUT

Width across flat


Thread diameter Pitch of (mm)
of bolts bolts
(mm) (mm)
kgm Nm kgm Nm

6 1 10 5 0,96w0,1 9,5w1 1,3w0,15 13,5w1,5

8 1,25 13 6 2,3w0,2 23w2 3,2w0,3 32,2w3,5

10 1,5 17 8 4,6w0,5 45w4,9 6,5w0,6 63w6,5

12 1,75 19 10 7,8w0,8 77w8 11w1 108w11

14 2 22 12 12,5w1 122w13 17,5w2 172w18

16 2 24 14 19,5w2 191w21 27w3 268w29

18 2,5 27 14 27w3 262w28 37w4 366w36

20 2,5 30 17 38w4 372w40 53w6 524w57

22 2,5 32 17 52w6 511w57 73w8 719w80

24 3 36 19 66w7 644w70 92w10 905w98

27 3 41 19 96w10 945w100 135w15 1329w140

30 3,5 46 22 131w14 1287w140 184w20 1810w190

33 3,5 50 24 177w20 1740w200 250w27 2455w270

36 4 55 27 230w25 2250w250 320w35 3150w350

39 4 60 Ð 295w33 2900w330 410w45 4050w450

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

00-8 PW75R-2
STANDARD TIGHTENING TORQUE

2. TIGHTENING TORQUE FOR NUTS OF FLARED


Use these torques for nut part of flared.

Thread diameter Width across flats TIGHTENING TORQUE


of nut part of nut part
(mm) (mm) kgm Nm

1/2" - 20 17 2.6w0.5 25.5w4.9


9/16" - 18 17 4w0.5 39.2w4.9
3/4" - 16 22 6.7w2 65.7w19.6
7/8" - 14 27 8w2 78.5w19.6
1.1/16" - 12 32 9.7w3 95.15w29.4
1.5/16" - 12 38 17w3 166.7w29.4
1.5/8" - 12 50 20w5 196.2w49
22 27 8w2 78.5w19.6
33 41 20w5 196.2w49

Sealing
Superficie surface
di tenuta

Thread diameter Width across flats TIGHTENING TORQUE


of nut part of nut part
(mm) (mm) kgm Nm
9/16" - 18 17 2.3 ± 2.5 23 ± 25
11/16" - 16 22 3.4 ± 3.9 33 ± 38
13/16" - 16 24 5.2 ± 5.8 51 ± 57
1" - 14 30 8.2 ± 9.2 80 ± 90
1.3/16" - 12 36 12.2 ± 13.3 120 ± 130
1.7/16" - 12 41 15.3 ± 17.3 150 ± 170
1.11/16" - 12 50 18.4 ± 20.4 180 ± 200
2" - 12 57 20.4 ± 24.4 200 ± 240

PW75R-2 00-9
COATING MATERIALS
The recommended coating materials prescribed in FKI Shop Manuals are listed below:

Nomenclature Code Applications


ASL800010 Used to apply rubber pads, rubber gaskets and cork plugs.
Used to apply resin, rubber, metallic and non-metallic parts when a fast, strong
ASL800020 seal is needed.

Loctite 222 Used for low resistance locking of screws, check nuts and adjustment nuts.
To prevent the loosening of bolts, nuts and plugs and the leakage of oil. Used for
Loctite 242 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.
Adhesives
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.
Used for sealing rather exact plane surfaces when the option of possible future
Loctite 573 dismantling is required.

Used for high resistant locking of mechanical components that can be removed
Loctite 601 only after heating

Used to lock cylindrical couplings and for the permanent locking of threaded parts,
Loctite 675 and also to lock shafts to bearings, gears, pulleys, pins, bushings, etc.

Used by itself to seal grease fittings, tapered screw fittings and tapered screw fit-
ASL800060 tings in hydraulic circuits of less than 50 mm in diameter.

Used by itself on mounting flat surface


Gasket sealant Loctite 510 (Clearance between surfaces within 0.2 mm)

Used by itself on mounting flat surface


Loctite 518 (Clearance between surfaces within 0.5 mm)

Antifriction compound
Applied to bearings and taper shaft to facilitate press-fitting and to prevent stic-
(Lubricant including ASL800040 king, burning or rusting.
Molybdenum disulfide)
Grease Applied to bearings, sliding parts and oil seals for lubrication, rust prevention and
(Lithium grease) ASL800050 facilitation of assembling work.

Vaseline ± Used for protecting battery electrode terminals from corrosion.

00-10 PW75R-2
ELECTRIC WIRE CODE

ELECTRIC WIRE CODE ELECTRIC


In the wiring diagrams various colours and symbols are employed to indicate the thickness of wires.
This wire code table will help you understand WIRING DIAGRAMS.
Example: R -N 1.5 indicates a cable having a nominal number 1.5 and red coating with black stripe.
CLASSIFICATION BY THICKNESS
Copper wire
Nominal Cable O.D. Current rating
number Number ù of strands Cross section (mm) (A)
strands (mm) (mm2)
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 A±B ±
Colour Light blue Light blue - Yellow Light blue - Black Light blue - Red Light blue - Green Light blue - White
Code B B-G ± B-N ± B-R B/R ± ± ± ±
Colour White White - Yellow White - Black White - Red ± ±
Code C C-V ± C-N C/N C±B C/B C±L ± ± ±
Colour Orange Orange - Green Orange - Black Orange - White Orange - Blue ±
Code G G-R G/R G-N G/N G±V ± G±L ± ± ±
Colour Yellow Yellow - Red Yellow - Black Yellow - Green Yellow - Blue ±
Code H H-R ± H-N ± H±G ± H±L ± ± ±
Colour Gray Gray - Pink Gray - Black Gray - Yellow Gray - Blue ±
Code L L-R L/R L-B ± ± L/G ± ± ± ±
Colour Blue Blue - Red Blue - White Blue - Yellow ± ±
Code M M-N M/N M±V ± M±B ± ± ± ± ±
Colour Brown Brown - Black Brown - Green Brown - White ± ±
Code N ± ± ± ± ± ± ± ± ± ±
Colour Black ± ± ± ± ±
Code R R-N R/N R-V ± R±G ± ± ± ± ±
Colour Red Red - Black Red - Green Red - Yellow ± ±
Code S S-N ± S±G ± ± ± ± ± ± ±
Colour Pink Pink - Black Pink - Yellow ± ± ±
Code V V-B V/B V-N ± ± ± ± ± ± ±
Colour Green Green - White Green - Black ± ± ±
Code Z Z-B 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: G-V = Yellow-Green with longitudinal colouring.
G/V = Yellow-Green with transversal colouring.

PW75R-2 00-11
WEIGHT TABLE
This weight table is a guide for use when transporting or handling components.
Unit: kg

Machine model PW75R-2


From serial no. 22E0200001-
Engine assembly 380
Radiator - exchanger 35,5
Hydraulic tank (without hydraulic oil) 60
Fuel tank (without fuel) 40
Counterweight 1050
Swing circle 89
Revolving frame 765
Swing machinery assembly 43
Main hydraulic pump ± Gear pump 57
Cabin 250
Seat 32
Seat support 14,5
Platform 51
Control valve 60
Track frame assembly 640
Front axle 357
Rear axle (2WS) 301
Rear axle (4WS) 378
Wheel 74
Swivel joint 54
Axle locking cylinder 22
Swing bracket 170
Engine hood ±
Front hood ±
Boom 300
1st boom 245
nd
2 boom 162
Arm (L=1700) 125
Arm (L=2100) 167
Outrigger 76
Bracket 28
Blade - outrigger support 105
Blade 191

00-12 PW75R-2
TABLE OF OIL AND COOLANT QUANTITIES
AMBIENT TEMPERATURE CAPACITY ( < )
KIND OF
RESERVOIR ±20 ±10 0 10 20 30ëC
FLUID Specified Refill

FKI 907 10W

FKI 907 20W-20


OIL
Crankcase sump 9.4 9.4
. API CD FKI 907 SAE 30

FKI 907 SAE 40

OIL FKI 907 10W


Hydraulic system 158 70
. API CD
Front axle: 4.8 4.8
. differential

. final drive (each) 0.7 0.7


OIL
FKI 918
Rear axle . UTTO FLUID
. differential 4.8 4.8

. final drive (each) 0.7 0.7

OIL
Transmission . API GL5 FKI 918 SAE 80W/90 1.5 1.5
. MIL-L-2105 D
OIL
Swing . API CD-SG FKI 907 SAE 30 1.5 1.5
machinery . MIL-L-2104 E
. CCMC D4-G4

]
Fuel tank GASOIL 100 ÐÐ
ASTM D975 N. 2

WATER+
18 ÐÐ
ANTI-FREEZE

Cooling system WATER 18 ÐÐ

PERMANENT
18 ÐÐ
LIQUID

] ASTM D975 N. 1

ASTM: America Society of Testing and Materials


SAE: Society of Automotive Engineers
API: American Petroleum Institute
MIL: 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.

PW75R-2 00-13
NOTE:
(1) When fuel sulphur content is less than 0.5%, (2) When starting the engine is weathers temperature
change oil in the oil pan ebery periodic maintenan- below 0ëC, be sure to use engine oil SAE 10W,
ce hours described in operation and maintenance SAE 20W-20, even if weather temperature goes
manual. Change oil according to the following ta- up to 10ëC day time.
ble if fuel sulphur content is above 0.5%. (3) Use classification CD as engine oil, if use classifi-
cation CC, reduce the engine oil change interval to
Oil change interval in engine oil half.
Fuel sulphur content
pan
(4) Use original products, which have characteristics
0.5 to 1.0% 1/2 of regular interval specifically formulated and approved for the engi-
ne, the hydraulic circuit of equipment and for re-
Above 1.0% 1/4 of regular interval
ductions.

00-14 PW75R-2
STRUCTURE AND FUNCTION

P.T.O. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 2 Accumulators . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . 109


Power train . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 3 PPC valve . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . 110
Front axle . . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 4 PPC valve (blade, boom swing, 2-piece boom).. . 114
Transmission (2WS) . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 8 Travel ppc valve . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . 117
Hydraulic circuit (2WS) . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 10 Brake pump .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . 118
Steering system (2WS) . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 14 Boom and arm safety valve . . . . .. . . . . .. . . . . .. . . . .. . 119
Transmission (4WS) . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 16 2-piece boom safety valve . .. . . . .. . . . . .. . . . . .. . . . .. . 120
Rear axle (4WS). . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 18 Blade or outrigger safety valve. .. . . . . .. . . . . .. . . . .. . 121
Steering system (4WS) . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 23 Over load sensor switch . . . .. . . . .. . . . . .. . . . . .. . . . .. . 122
Steering unit . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 27 Solenoid valve group ST1 (Y5-Y6-Y7-Y11).. . . . .. . 123
Swing circle. . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 28 Solenoid valve group ST2 (Y4-Y10-Y12) . . .. . . . .. . 124
Swing machinery . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 29 Solenoid valve group ST3 (Y1-Y2). . . .. . . . . .. . . . .. . 125
Hydraulic circuit (2WS) . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 31 Solenoid valve group OP1 (Y21-Y22-Y23-Y24) .. . 126
Hydraulic circuit (4WS) . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 33 Solenoid valve group OP2 (Y26). . . . . .. . . . . .. . . . .. . 127
Hydraulic circuit (lower equipment). . . . .. . . . . .. . . . .. . 35 Solenoid valve group OP3 (Y8-Y9) . . .. . . . . .. . . . .. . 128
Hydraulic pump . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 36 Electrical diagram (2WS) (1/5) . .. . . . . .. . . . . .. . . . .. . 129
Priority valve. . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 62 Electrical diagram (2WS) (2/5) . .. . . . . .. . . . . .. . . . .. . 131
Control valve . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 64 Electrical diagram (2WS) (3/5) . .. . . . . .. . . . . .. . . . .. . 133
Swing motor . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 92 Electrical diagram (2WS) (4/5) . .. . . . . .. . . . . .. . . . .. . 135
Swivel joint . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 96 Electrical diagram (2WS) (5/5) . .. . . . . .. . . . . .. . . . .. . 137
Travel motor . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 97 Electrical diagram (4WS) (1/5) . .. . . . . .. . . . . .. . . . .. . 139
Displacement automatic control high pressure. . .. . 98 Electrical diagram (4WS) (2/5) . .. . . . . .. . . . . .. . . . .. . 141
Related. . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 98 Electrical diagram (4WS) (3/5) . .. . . . . .. . . . . .. . . . .. . 143
Travel motor brake valves. . . .. . . . . .. . . . .. . . . . .. . . . .. . 99 Electrical diagram (4WS) (4/5) . .. . . . . .. . . . . .. . . . .. . 145
Cylinders .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . 100 Electrical diagram (4WS) (5/5) . .. . . . . .. . . . . .. . . . .. . 147
Servocontrol feed unit . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . 104

PW75R-2 10-1
P.T.O.

5
4
RKP08290

1. Disc
2. Flywheel
3. Damper (No. 4)
4. Hub
5. Pump

10-2 PW75R-2
POWER TRAIN

REDUCTION RATIO

Transmission Differential Planetary Axle Total


High speed 1.30 24.73
3.625 5.25 19.03
Low speed 4.06 77.26

Front ofmacchina
Fronte machine 10

Z=29
Z=51 8

Z=12

Z=19

Z=8

7 2
5
3
4
Z=51
Z=39

Z=73
Z=18

6 Z=51

Z=12

Z=19

Z=8 Z=29 9

11
RKP08830
1. Engine 7. Propeller shaft
2. Pump 8. Front axle
3. Control valve 9. Rear axle
4. Swivel joint 10. Front wheel
5. Travel motor 11. Rear wheel
6. Transmission

PW75R-2 10-3
FRONT AXLE

Differential

1 2 3 4 5 1 6

16
10 9 8 7
14
15
11
14
12
13 RKP08840

1. Bearing 11. Seal


2. Differential gear 12. Flange
3. Dowel pin 13. Nut
4. Pin 14. Bearing
5. Bevel gear 15. Spacer
6. Ring nut 16. Differential housing cover
7. Drive shaft
8. Plug SPECIFICATIONS
9. Differential housing Amount of oil: 4.8 ,
10. Ring bevel gear Reduction ratio: 8:29

10-4 PW75R-2
Brakes

1
2 3

6 4

RKP08850

1. Brake bleeding screw


2. Disk release spring
3. Adjusting screw
4. Brake disk
5. Pressure disk
6. Brake piston

PW75R-2 10-5
Final reduction

4 5 6 7 8

1 2 3 9 10

11

12

13

14

23 22 16 15

21 20 19 18 17
RKP08860

1. Bearing 13. Bearing


2. Dowel 14. Plug
3. Cardan shaft (Z=12) 15. Ring gear (Z=51)
4. Bearing 16. Ring gear carrier
5. Pin 17. Stud bolt
6. Seal 18. Nut
7. Wheel hub 19. Seal
8. Screw 20. Seal
9. Bearing 21. Housing
10. Support 22. Seal
11. Bevel gear (Z=19) 23. Bearing
12. Pin

SPECIFICATIONS
Amount of oil: 0.7 ,
Reduction ratio: 1:5.25

10-6 PW75R-2
Steering cylinder

A
A
a 2 b

Only for 2WS with Only for 2WS with front


Solo Solo per 2WS con
rearper 2WS con
attachment attachment
attrezzaturaand for 4WS
anteriore
attrezzatura posteriore
e per 4WS

5 6
Section A - A
Sezione A - A

3 4
Detail B B
Particolare Detail B B
Particolare

RKP08870

1. Steering cylinder 2WS version


2. Sensor (only for 4WS) a. b Port - From swivel joint (2 Port)
3. Nut b. a Port - From swivel joint (1 Port)
4. Spacer
5. Nut 4WS version
6. Pin cotter a. b Port - From swivel joint (2 Port)
b. a Port - From OP1 solenoid valve group
(T Port)

PW75R-2 10-7
TRANSMISSION (2WS)

B
B

1
3 A

6 7

9
14

10
a b 12 13 11
SectionB B
Sezione - B- B
RKP08880
a. e Port - From swivel joint (3 Port)
b. f Port - From swivel joint (4 Port)

1. Flange 8. Selecting fork


2. Filler and level oil plug 9. Speed sensor
3. Oil drain plug 10. Safety switch
4. Neutral manual control 11. Selector shaft
5. Low speed selector piston 12. Spring
6. High speed selector piston 13. Ball
7. Selector gear 14. Piston

10-8 PW75R-2
1 2 3 4 5

19

18

17

16
9
15

14 13 12 11 10 RKP08890

1. Flange 11. Protection


2. Breather 12. High speed drive gear (Z=47)
3. High speed drive gear (Z=43) 13. Oil drain plug
4. Rear housing 14. Cover
5. Low speed drive gear (Z=18) 15. Bearing
6. Bearing 16. Flange
7. Low speed driven gear (Z=73) 17. Output shaft
8. Roller bearing 18. Nut
9. Bearing 19. Bearing
10. Front housing

PW75R-2 10-9
REAR AXLE

Differential

1 2 3 4 5 1 6

14
10 9 8 7
12
13

12 11
RKP08900

1. Bearing 10. Ring bevel gear


2. Differential gear 11. Ring nut
3. Dowel pin 12. Bearing
4. Pin 13. Spacer
5. Bevel gear 14. Differential housing cover
6. Ring nut
7. Drive shaft SPECIFICATIONS
8. Plug Amount of oil: 4,8 ,
9. Differential gear Reduction ratio: 8:2.9

10-10 PW75R-2
Final reduction

1 2 3 4 5 6 7

10

11

15

14 13 12

RKP08910

1. Seal 11. Plug


2. Bearing 12. Ring gear carrier
3. Wheel hub 13. Nut
4. Screw 14. Stud bolt
5. Bearing 15. Seal
6. Ring gear
7. Bevel gear SPECIFICATIONS
8. Pin Amount of oil: 0.7 ,
9. Shim Reduction ratio: 1:5.25
10. Support

PW75R-2 10-11
Brakes and parking brake cylinder

1 2 3 4 5 6

A A

10 9
11 10 7

Section A - A
Sezione A - A
a 8 RKP08920

a. From swivel joint (8 Port)

1. Brake bleeding screw 8. Brake lever


2. Adjusting screw 9. Pressure disk
3. Nut 10. Pressure lever
4. Push-rod 11. Brake piston
5. Disk release spring 12. Bracket
6. Adjusting screw 13. Bushing
7. Brake disk

10-12 PW75R-2
15
16 17 18 19 20
21
22
14

2
23

RKP08930
13 3 12
14. Cylinder fulcrum lever
15. Cylinder fulcrum pin
16. Cylinder
17. Gasket
18. Spring
19. Piston SYSTEM DESCRIPTION
20. Filter
The parking brake is of the «negative» type, e.i. it pro-
21. Piston fulcrum pin vides full mechanical braking in the absence of pres-
22. Ball joint sure in the circuits that make the machine safe to
23. Scraper ring drive.
b 16 18 19 OPERATION
When the engine is started up the pump (P1) con-
nected to the servocontrol circuit pressurizes the sys-
tem to which the solenoid valve Y11 is connected
B C when the machine is idle.
14 8 When push-button is pushed Y11 is energized and al-
17 lows oil to flow into chamber b of the cylinder (16);
A D when the pressure exceeds the loading on the spring
(18), it is compressed and the piston (19) moves, thus
7 7 lengthening side B-C of the parallelogram A-B-C-D
formed by the swing centers of the levers (8) and
(14), the cylinder fulcrum B (16) and the fulcrum C of
the lever (8) connected to the piston (19).
The swing of levers (8) and (14), coupled directly to le-
9 4 4 9 ver (10), cancels out the action on the push rods (4)
joined to the push disks (9).
The limit of the swing and the distribution of the load
Y11 generated by the pressure in the cylinder (16) are gov-
P1 erned by adjustable screws (2) that act directly on le-
vers (8) and (14).
When the engine stops, Y11 is de-energized, and re-
Alimentazione
servocomandi
leases pressure in the circuit. As pressure drops the
spring (18) commences the thrusting action that ro-
tates the levers (8) and (14). The force of the spring
Motore is transferred to the push rods of the push disks (9)
which act on the brake disks (7) on the rear axle.
RKP08940

PW75R-2 10-13
STEERING SYSTEM (2WS)

4 1
3

9 T P
a
5
A 2 (P2)
11 6
B

b 7
R L
1 1

2 2

RKP08950

DESCRIPTION
. The steering system is completely hydraulic. The
oil required, supplied by the pump (2) driven by
1. Engine the motor (1), is sent to the priority valve (4) which
2. Pump (P2) functions by Load Sensing, and sends the neces-
3. Tank sary quantity of oil to the steering system (5), even
4 Priority valve when other oleodynamic components supplied by
the same circuit are in operation. The oil passes
5. Steering unit from this group (5) into the swivel joint (7) and from
6. Steering wheel there into the steering cylinder (8).
7. Swivel joint . The hydraulic power supplied by the pump (2) is
8. Front axle steering cylinder transferred to cylinder (8) and transformed into me-
9. Front axle cylinder piston chanical steering power.

10-14 PW75R-2
PW75R-2 10-15
TRANSMISSION (4WS)

B
B

1
3 A

6 7

9
14

10
a b 12 13 11
Detail B - B
Sezione B - B
RKP08880

a. e Port - From swivel joint (14 Port)


b. f Port - From swivel joint (5 Port)

1. Flange 8. Selecting fork


2. Filler and level oil plug 9. Speed sensor
3. Oil drain plug 10. Safety switch
4. Neutral manual control 11. Selector shaft
5. Low speed selector piston 12. Spring
6. High speed selector piston 13. Ball
7. Selector gear 14. Piston

10-16 PW75R-2
1 2 3 4 5

19

18

17

16
9
15

14 13 12 11 10 RKP08970

1. Flange 11. Protection


2. Breather 12. High speed drive gear (Z=47)
3. High speed drive gear (Z=43) 13. Oil drain plug
4. Rear housing 14. Cover
5. Low speed drive gear (Z=18) 15. Bearing
6. Bearing 16. Flange
7. Low speed driven gear (Z=73) 17. Output shaft
8. Roller bearing 18. Nut
9. Bearing 19. Bearing
10. Front housing

PW75R-2 10-17
REAR AXLE (4WS)

Differential

1 2 3 4 5 1 6

14
10 9 8 7
12
13

12 11
RKP08980

1. Bearing 10. Ring bevel gear


2. Differential gear 11. Ring nut
3. Dowel pin 12. Bearing
4. Pin 13. Spacer
5. Bevel gear 14. Differential housing cover
6. Ring nut
7. Drive shaft SPECIFICATIONS
8. Plug Amount of oil: 0.7 ,
9. Differential gear Reduction ratio: 8:29

10-18 PW75R-2
Final drive

4 5 6 7 8

1 2 3 9 10

11

12

13

14

23 22 16 15

21 20 19 18 17
RKP08860

1. Bearing 13. Bearing


2. Dowel 14. Plug
3. Cardan shaft (Z=12) 15. Ring gear (Z=51)
4. Bearing 16. Ring gear carrier
5. Pin 17. Stud bolt
6. Seal 18. Nut
7. Wheel hub 19. Seal
8. Screw 20. Seal
9. Bearing 21. Housing
10. Support 22. Seal
11. Bevel gear (Z=19) 23. Bearing
12. Pin
SPECIFICATIONS
Amount of oil: 0.7 ,
Reduction ratio: 1:5.25

PW75R-2 10-19
Steering cylinder

A
A
a 2 b

4 5 3
Section A --AA
Sezione A Detail B B
Particolare
RKP08960

a. d Port - From OP1 solenoid valve group


(B Port)
b. c Port - From OP1 solenoid valve group
(A Port)

1. Steering cylinder
2. Sensor
3. Spacer
4. Nut
5. Pin cotter

10-20 PW75R-2
Brakes and parking brake cylinder

1 2 3 4 5 6

A A

10 9
11 10 7

Section
Sezione A
A -- A
A
a 8 RKP08920

a. From swivel joint (8 Port)

1. Brake bleeding screw 8. Brake lever


2. Adjusting screw 9. Pressure disk
3. Nut 10. Pressure lever
4. Push-rod 11. Brake piston
5. Disk release spring 12. Bracket
6. Adjusting screw 13. Bushing
7. Brake disk

PW75R-2 10-21
15
16 17 18 19 20
21
22
14

2
23

RKP08930
13 3 12
14. Cylinder fulcrum lever
15. Cylinder fulcrum pin
16. Cylinder
17. Gasket
18. Spring
19. Piston SYSTEM DESCRIPTION
20. Filter The parking brake is of the «negative» type, e.i. it pro-
21. Piston fulcrum pin vides full mechanical braking in the absence of pres-
sure in the circuits that make the machine safe to
22. Ball joint
drive.
23. Scraper ring
b 16 18 19 OPERATION
When the engine is started up the pump (P1) con-
nected to the servocontrol circuit pressurizes the sys-
tem to which the solenoid valve Y11 is connected
B C when the machine is idle.
14 8 When push-button is pushed Y11 is energized and al-
lows oil to flow into chamber b of the cylinder (16);
17 when the pressure exceeds the loading on the spring
A D (18), it is compressed and the piston (19) moves, thus
7 7 lengthening side B-C of the parallelogram A-B-C-D
formed by the swing centers of the levers (8) and
(14), the cylinder fulcrum B (16) and the fulcrum C of
the lever (8) connected to the piston (19).
The swing of levers (8) and (14), coupled directly to le-
9 4 4 9 ver (10), cancels out the action on the push rods (4)
joined to the push disks (9).
The limit of the swing and the distribution of the load
generated by the pressure in the cylinder (16) are gov-
Y11
erned by adjustable screws (2) that act directly on le-
P1 vers (8) and (14).
When the engine stops, Y11 is de-energized, and re-
Servocontrol
leases pressure in the circuit. As pressure drops the
feed unit
spring (18) commences the thrusting action that ro-
tates the levers (8) and (14). The force of the spring
is transferred to the push rods of the push disks (9)
Engine
which act on the brake disks (7) on the rear axle.
RKP08941

10-22 PW75R-2
STEERING SYSTEM (4WS)

4 1
3
10
9 T P
a d
5
A D
2 (P2)
11 6 12
B C

7 Y22 Y24 c
b
R L
1 1 P B

2 2 T A
Y21 Y23

RKP10410

DESCRIPTION
. The steering system is completely hydraulic. The
1. Engine oil required, supplied by the pump (2) driven by
2. Pump (P2) the motor (1), is sent to the priority valve (4) which
3. Tank functions by Load Sensing, and sends the neces-
sary quantity of oil to the steering system (5), even
4 Priority valve
when other oleodynamic components supplied by
5. Steering unit the same circuit are in operation. The oil passes
6. Steering wheel from this group (5) into the swivel joint (7) and from
7. Swivel joint there into the steering cylinders (10) and (11).
8. OP1 Solenoid valve group: The solenoid valve group (8) can switch the oil flow
to provide three types of steering:
± YS1: Rear steering cut out
1 - 2 wheels steering
± YS2: Front/rear steering
Steering condition in which the rear axle is ex-
± YS3: Phase coincidence steering cluded.
± YS4: Crab steering 2 - 2 wheels steering and 2 wheels counter-
9. Front axle steering cylinder steering. Steering condition in which rear
10. Rear axle steering cylinder steering is activated and the direction of the
11. Front axle cylinder piston rear wheels is contrary to that of the front
12. Rear axle cylinder piston wheels.
3 - 4 wheels steering in the same direction.
Steering condition in which rear axle steering
is activated and the direction of the rear
wheels agrees with that of the front wheels.
. The hydraulic power supplied by the pump (2) is
transferred to cylinders (10) and (11) and trans-
formed into mechanical steering power.

PW75R-2 10-23
OPERATION
1 - Steering with front wheels, only.

b 12 a 10 b 10 12 a

B A B A

e R T e R T
h h
5 3 5 3
g g
L P L P

4 4
f f
7 7
6 2 6 2
(P2) (P2)
Y21 Y22 Y21 Y22

Y23 Y24 Y23 Y24

RKP10420 RKP04390

STEERING TO THE RIGHT STEERING TO THE LEFT


Turning the steering wheel (6) clockwise causes rota- Turning the steering wheel (8) anti-clockwise causes
tion of the steering metering group (5) and prepares rotation of the steering metering group (5) and pre-
the control valve (port R) to send oil through line e to pares the control valve (port L) to send oil through
solenoid valve group and thence through line g, into lines f and h directly into chamber b of the cylinder
chamber a of the cylinder (10); the pressurized oil (10); the pressurized oil moves the piston (12) which
moves the piston (12) which then steers the wheels. then steers the wheels.
The oil in chamber b of cylinder (10) is impelled into The oil in chamber a of cylinder (10) is impelled into
line h and thence into line f which is coupled to the line g to solenoid valve group and thence into line e
control valve of the steering group (5) (port L); from which is coupled to the control valve of the steering
the control valve the oil passes out of Port T and group (5) (port R); from the control valve the oil passes
drains into the tank (3). out of Port T and drains into the tank (3).

10-24 PW75R-2
2 - Steering with 2 wheels steering and 2 wheels countersteering.

b 12 a 10 b 10 12 a

B A B A

h e R T h e R T

g 5 3 g 5 3
L P L P

f 4 f 4
7 7
6 2 6 2
(P2) (P2)
Y21 Y22 Y21 Y22

Y23 Y24 Y23 Y24


m m
n n

C D C D

c 13 11 d c d
11 13

RKP04410 RKP04420

STEERING TO THE RIGHT STEERING TO THE LEFT


Turning the steering wheel (6) clockwise causes rota- Turning the steering wheel (6) anti-clockwise causes
tion of the steering metering group (5) and prepares rotation of the steering metering group (5) and pre-
the control valve (port R) to send oil (through line e) pares the control valve (port L) to send oil through line
to solenoid valve group and thence through line m into f directly to chamber b of cylinder (10).
chamber d of cylinder (11). The pressurized oil moves the piston (12) of cylinder
The pressurized oil moves the piston (13) of the cylin- (10) which in turn steers the wheels while simulta-
der (11) that steers the wheels and at the same time neously impelling the oil in chamber a (at the same
impels the oil in chamber c (at the same pressure as pressure as chamber b, through lines g - n into cham-
chamber d), through lines n and g into chamber a of ber c of cylinder (11).
cylinder (10). The oil in chamber d of cylinder (11) is impelled
The oil in chamber b of cylinder (10) is impelled through lines m and e to the control valve of the steer-
through lines h and f to the control valve of the steer- ing group (port R) from which it passes (port T) to drain
ing group (5) (port L), from which it passes (port T) to into the tank (3).
drain into the tank (3).

PW75R-2 10-25
3 - Steering with 4 wheels steering in the same direction.

b 12 a 10 b 10 12 a

B A B A

h e R T h e R T

g 5 3 g 5 3
L P L P

f 4 f 4
7 7
6 2 6 2
(P2) (P2)
Y21 Y22 Y21 Y22

Y23 Y24 Y23 Y24


m m
n n

C D C D

c d c 13 11 d
11 13

RKP04430 RKP04450

STEERING TO THE RIGHT STEERING TO THE LEFT


Turning the steering wheel (6) clockwise causes rota- Turning the steering wheel (6) anti-clockwise causes
tion of the steering metering group (5) and prepares rotation of the steering metering group (5) and pre-
the control valve (port R) to send oil (through line e) pares the control valve (port L) to send oil through
to solenoid valve group and thence through line m into lines f and h into chamber b of cylinder (10).
chamber c of cylinder (11). The pressurized oil moves the piston (12) of cylinder
The pressurized oil moves the piston (13) of the cylin- (10) which in turn steers the wheels while simulta-
der (11) that steers the wheels while simultaneously neously impelling the oil in chamber a (at the same
impelling the oil in chamber d (at the same pressure pressure as chamber b) through lines g and m into
as chamber c) through lines m and g into chamber a chamber d of cylinder (11).
of the cylinder (10). The oil in chamber c of cylinder (11) is impelled
The oil in chamber b of cylinder (10) is sent through through lines n and e to the control valve of the steer-
lines h and f to the control valve of the steering group ing group (5) (port R) from which it passes (port T) to
(5) (port L) from which the oil passes (port T) to drain drain into the tank (3).
into the tank (3).

10-26 PW75R-2
STEERING UNIT

a e b

LS

L R

T P

c d RKP03740

a. L Port - To swivel joint (2 Port) SPECIFICATIONS


b. R Port - To swivel joint (1 Port) Steering unit type: OSPC200LS
c. T Port - To tank Rated discharge: 20 ,/min
d. P Port - From priority valve (CF Port)
e. LS Port - From priority valve (LS Port)
OPERATION
. The steering unit consists of a control valve and a
rotating oil dispenser and functions hydrostatically.
. When the steering wheel is moved, the control
valve sends oil from pump P2 (through the rotating
oil dispenser) to one or other of the chambers of the
steering cylinder. The rotating oil dispenser en-
sures that the amount of oil supplied to the cylinder
is proportional to the rotation angle of the steering
wheel.
. If the steering unit pump malfunctions the oil dis-
penser functions automatically like a hand-pump
to ensure emergency steering.

PW75R-2 10-27
SWING CIRCLE

7
4 5

1
3
1 6
2
Section B - B Section A - A
Sezione B - B Sezione A- A

5 C
D

8
1 C
D A
Section
Sezione C
C -- C
C
B

B
1 B
6
Section
Sezione D
D -- DD
C

C RKP08990

1. Swing circle outer race SPECIFICATIONS


2. Swing circle inner race Amount of grease: 25 kg
3. Ball bearing 81
Reduction ratio: ------------ =8.1
4. Pin 10
5. Screw
6. Screw
7. Nut
8. Grease nipple

10-28 PW75R-2
SWING MACHINERY

7
9

6
10
5

11
3

12

RKP08180

1. Swing pinion (Z=10) 10. 2nd reduction sun gear (Z=24)


2. Case 11. Nipple
3. No. 2 planetary carrier 12. Plug
4. Drive gear (Z=68)
5. 2nd reduction central gear (Z=19)
6. No. 1 planetary carrier SPECIFICATIONS
7. 1st reduction central gear (Z=22) Reduction ratio: 1:18.73
8. Gauge oil level
9. 1st reduction sun gear (Z=23)

PW75R-2 10-29
10-30 PW75R-2
HYDRAULIC CIRCUIT (2WS)
Boom swing 2-piece boom
PPC valve PPC valve

L.H. PPC valve


R.H. PPC valve
T P T P T P Rear axle
T OP3 solenoid
Travel PPC valve valve group
B A
P T
T
P
A 2 4 3 1 P2 P1 P1 P2
P
2 4 1 3
T P Ø 0,6 Ø 0,6 Transmission

Ø 0,6
ST2 solenoid valve group Ø 0,6
B A
A

A1

Travel motor
B1

T P
TS PDB PA1 PA2 PA3 PA4 PA5 PA6 PA7 PA8 PA9 PA10
ST1 solenoid valve
group

265 bar

L.H. swing
A2

Forward
Travel
B2
P1
A1 Front axle

31 bar

294 bar
A3

R.H. swing

Reverse

196 bar

196 bar

Locking oscillation
A4
PLS

cylinder
P T

TC TB TWS PB1 B1 A1 P2 PB2 B2 A2 PB3 B3 A3 PB4 B4 A4 PB5 B5 A5 PB6 B6 A6 PB7 B7 A7 PB8 B8 A8 PB9 B9 A9 PB10 B10 A10

R.H. swing

L.H. swing
Lower
Oil cooler

Close

Close
Raise

Open

Open

Retract
Extend
exchange

R.H. side equipment

L.H. side equipment


Exhaust
filter: 25 m
Ø 0,5

(Ø100xØ60-650)
(Ø110xØ70-765)

Bucket cylinder
Boom cylinder

(Ø95xØ60-905)

(Ø95xØ55-665)

Boom swing
14 12 10 8 6 4 2 Swivel joint

2-piece boom
9 7 5 3 1

Arm cylinder
13 11

cylinder

cylinder
70 ø
Hydraulic
tank

Filter: 10 m MA S MB
Suction
filter: 90 m

PLS PDA T
P2
Ø0,3min

E B
Swing motor F R2 R1
39,4 kg/cm2

PC Brake unlocked pressure


18,5±2,5kg/cm2 Brake pump
Ø0,9

T'1

PR P R
T1
Ø1

B T'2
38 kg/cm2

50 kg/cm2

T2
PS CF
P T L
PA3 PM PPLS PD1
PGS PGA T
EF LS
N
Priority valve Steering unit
LS

RKP09001

PW75R-2 10-31
10-32
HYDRAULIC CIRCUIT (4WS)
Boom swing 2-piece boom
PPC valve PPC valve

L.H. PPC valve T P T P T P


R.H. PPC valve OP3 solenoid
T valve group
Rear axle
P
Travel PPC valve B A
T
T
P
A 2 4 3 1 P2 P1 P1 P2
P
2 4 1 3
T P Ø 0,6 Ø 0,6

ST2 solenoid valve group Ø 0,6


Ø 0,6 Transmission
B A
A OP1 solenoid
valve group

A1

B1 EVS2 EVS1

P T

Travel motor
T P
TS PDB PA1 PA2 PA3 PA4 PA5 PA6 PA7 PA8 PA9 PA10 B A
ST1 solenoid valve
group
EVS3 EVS4

265 bar

L.H. swing
A2

Forward
Travel
B2
P1
A1

31 bar

294 bar
Front axle

R.H. swing
A3

Reverse

196 bar

196 bar
216 bar
A4
PLS PLS

Locking oscillation
P T

cylinder
TC TB TWS PB1 B1 A1 P2 PB2 B2 A2 PB3 B3 A3 PB4 B4 A4 PB5 B5 A5 PB6 B6 A6 PB7 B7 A7 PB8 B8 A8 PB9 B9 A9 PB10 B10 A10

R.H. swing
Oil cooler

L.H. swing
Lower
exchange

Close

Close
Raise

Open

Open
Exhaust

R.H. side equipment

L.H. side equipment


filter: 25 m Ø 0,5
13 11 9 7 5 3 1 Swivel joint

(Ø100xØ60-650)
(Ø110xØ70-765)

Bucket cylinder
Boom cylinder

(Ø95xØ60-905)

(Ø95xØ55-665)
14 12 10 8 6 4 2

Boom swing

2-piece boom
Arm cylinder

cylinder
70 ø

cylinder
Hydraulic
tank

Filter: 10 m MA S MB
Suction
filter: 90 m

PLS PDA T
P2
Ø0,3min

E B
Swing motor F R2 R1
39,4 kg/cm2

PC Brake unlocked pressure


18,5±2,5kg/cm2 Brake pump
Ø0,9

T'1

PR P R
T1
Ø1

B T'2
38 kg/cm2

50 kg/cm2

T2
PS CF
P T L
PA3 PM PPLS PD1
PGS PGA T
Priority valve EF LS
N
Steering unit
LS

RKP09011

PW75R-2 10-33
10-34
HYDRAULIC CIRCUIT (LOWER EQUIPMENT)

REAR OUTRIGGER AND


FRONT BLADE VERSION 4 OUTRIGGER VERSION

T P T P T P T P

P1 P2 P1 P2

P2 P1 P2 P1

P2 P1 P2 P1 P2 P1 P2 P1

REAR BLADE VERSION REAR OUTRIGGER VERSION

T P T P
T P
PA2 P B2 P A7 P B7 PA2 PB2 PA7 PB7
P2 P1 P2

P1 P2 P1

P2 P1 P2 P1
P2 P1

A2 A7 A2 B2 A7 B7 PA2 PB2
B2 B7
PA2 PB2 PA7 PB7

FRONT BLADE FRONT OUTRIGGER

Left Right Left Right

10 9 3 10 9 3

A2 B2
A2 B2 A7 B7

C2 C1 C2 C1 C2 C1 C2 C1
10 9 3

V2 V1 V2 V1 V2 V1 V2 V1 10 9 3

To travel motor To travel motor


(T port) (T port)

V2 V1 V2 V1
D C2 C3 D C2 C3

P1 P1 V2 V1 V2 V1
C2 C1 C2 C1
P2 P2

C2 C1 C2 C1

C4 C1 C4 C1

V2 V1 V2 V1 V2 V1 V2 V1 Left Right
REAR BLADE

Left Right
C2 C1 C2 C1 C2 C1 C2 C1
REAR OUTRIGGER

Left Right Left Right

REAR OUTRIGGER REAR OUTRIGGER


RKP09021

PW75R-2 10-35
HYDRAULIC PUMP
d
a b c

View
Vista Z
Z
e f 1 g 2

h j

View YY
Vista

RKP08210

a. PPLS Port - From control valve (PLS port) g. PA Port - To servocontrol feed unit (P1 port)
b. PLS Port - From control valve (P1 port) and from h. PA3 Port - From gear pump (PGA port)
servocontrol feed unit (P2 port) j. PGS Port - From hydraulic tank
c. PGA Port - From control valve (P2 port) k. PS Port - From hydraulic tank
d. PM Port - From ST1 solenoid valve group
(A3 port)
e. PDA Port - Air breeder port 1. Hydraulic pump
f. PD Port - Main pump drain 2. Gear pump

10-36 PW75R-2
1. MAIN HYDRAULIC PUMP

a b c

A A

Y
View
Vista Z
Z

B
d e f
C

B
g
h

View YY
Vista

RKP08220

a. PS Port - From hydraulic tank f. PPLS Port - From control valve (P1 port) and from
b. PDA Port - Air breeder port servocontrol feed unit (P2 port)
c. PD Port - Main pump drain g. PA3 Port - From gear pump (PGA port)
d. PA Port - To servocontrol feed unit h. PM Port - From ST1 solenoid valve group
e. PLS Port - From control valve (PLS port) (A3 port)

PW75R-2 10-37
1 2 3 4 5 6 7 8

10

Section A --AA
Sezione A Section
Sezione C
C -- C
C

Section
Sezione B
B -- B
B
RKP08230

1. Shaft 6. Piston
2. Cradle 7. Cylinder block
3. Case 8. Valve plate
4. Rocker cam 9. Spring
5. Shoe 10. Servo piston

10-38 PW75R-2
FUNCTION
. The engine rotation and torque transmitted to the
pump shaft is converted into hydraulic energy,
and pressurized oil is discharged according to the
load.
. It is possible to change the delivery amount by
changing the swash plate angle.

1 2 3 4 A 5 6 7 8

B a RKP10430

STRUCTURE . The piston (6) carries out relative motion in the axial
. The cylinder block (7) is supported to the shaft (1) direction inside each cylinder chamber of the cylin-
by the spline a, and the shaft (1) is supported by der block (7).
the front and rear bearings. . The cylinder block (7) seals the pressure oil to the
. Tip of the piston (6) is a concave ball, and shoe (5) valve plate (8), and carries out relative rotation.
is caulked to it to form one unit. The piston (6) and This surface is so designed that the oil pressure
the shoe (5) form a spherical bearing. balance is maintained at a suitable level. And oil in-
. The rocker cam (4) has a flat surface A, and the side each cylinder of the cylinder block (7) is
shoe (5) is always pressed against this surface sucked in and discharged through the valve plate
while sliding in a circular movement. (8).

. The rocker cam (4) brings high pressure oil at the


cylindrical surface B with the cradle (2), which is se-
cured to the case, and forms a static pressure bear-
ing when it slides.

PW75R-2 10-39
OPERATION
1. Pump operation
1 - The cylinder block (7) rotates together with the 1 4 5 A 7
shaft (1), and the shoe (5) slides on the flat sur-
face «A».
At this time, the rocker cam (4) moves along
the cylindrical surface «B», so the angle «a»
between the center line X of the rocker cam
(4) and the inclination of the cylinder block
(7) in the axial direction changes.
This angle «a» is called the swash plate angle.
2 - When the center line X of the rocker cam (4) a
maintains the swash plate angle «a» in rela-
tion to the axial direction of the cylinder block X
(7), the flat surface «A» acts as a cam for the
shoe (5). B RKP10440
By this, the piston (6) slides on the inside of
the cylinder block (7), creates a difference be-
tween capacities E and F, then suction and
discharge of oil for the amount of the differ-
ence (F±E) will be carried out.
In other words, oil is discharged as the capa-
city of the chamber E decreases when the cy- 4 5 A 6 F
linder block (7) rotates.
In the mean time, the capacity of the chamber
F increases, and the oil is sucked at this pro-
cess.
(The figure shows the state of the pump when
suction of the chamber F and discharge of the
chamber E have completed).
3 - When the center line X of the rocker cam (4) a
becomes in line with the axial direction of the
cylinder block (7) (swash plate angle = 0), X
the difference between capacities of E and F
inside the cylinder block (7) becomes 0, so
the pump does not carry out any suction or dis- 7 E
charge action of oil. RKP10450
(In actual fact, the swash plate angle never be-
comes 0).
4 - In other words, discharge amount of the pump
is directly proportional to the swash plate an-
gle «a».
F

1 7 E
RKP10460

10-40 PW75R-2
2. Control of Discharge Amount
. As the swash plate angle «a» becomes larger,
difference between the capacities E and F be-
comes larger, so the discharge amount Q in-
creases. 2 4
The swash plate angle «a» is changed by the
servo piston (10).
. The servo piston (10) moves in a linear recipro-
cating motion ( × ) under the signal pressure of
PC and LS valve.
This linear motion is transmitted to the rocker
cam (4), which is supported by the cylindrical
surface of the cradle (2), and the rocker cam
slides in the semi-circular reciprocating direc-
tion ( ).
. The upper and lower pressure receiving area of
the servo piston (10) are different from each
other, and to the pressure chamber of the smal-
ler piston side (upper), discharge pressure (self
pressure) PP of the main pump is always intro- RKP10470
duced.
To the pressure chamber of the larger piston
side (lower), output pressure PEN of the LS valve
is introduced.
Movement of the servo piston (10) is controlled
by the relationship between pressures PP and
PEN and the proportion of the pressure receiving
areas of the smaller and larger pistons.

PW75R-2 10-41
2. PC VALVE, LS VALVE, SERVO PISTON

4 5 6 7 8 a 9 10 11 b

A A

1 B B

e 15 14 d 13 12

Section A - A Section B - B
Sezione A - A Sezione B - B

RKP08240

a. PA3 Port - From gear pump (PGA port) PC VALVE


b. PM Port - From ST1 solenoid valve group 4. Piston
(A3 port) 5. Spring
c. PA Port - To servocontrol feed unit (P1 port) 6. Seat
d. PLS Port - From control valve (P1 port) and from 7. Spring
servocontrol feed unit (P2 port) 8. Piston
e. PPLS Port - From control valve (PLS port) 9. Sleeve
10. Piston
11. Union
SERVO PISTON
1. Servo piston
2. Lever LS VALVE
3. Spring 12. Plug
13. Sleeve
14. Spring
15. Piston

10-42 PW75R-2
LS VALVE
FUNCTION
. The LS valve control the pump discharge accord-

(,/min)
ing to the stroke of the control lever, in other words,

/ min)
the flow demand of the actuator.

Q (< Q
amount
. The LS valve detects the flow demand of the actua-
tor from the differential pressure DPLS of the dis-

Portata pompa
charge amount of the main pump PPLS (from self

Pump discharge
valve) and the outlet pressure of the control valve
PLS, and controls the discharge amount Q of the
main pump. (PPLS, PLS and DPLS are the pump
pressure, LS pressure and LS differential pressure
respectively). 21.5
21,5
Differential
Differenza dipressure
pressioneDp
Dp (bar)
. In other words, the LS valve detects the pressure (bar)

loss (LS differential pressure DPLS) generated ac- RKP08250

cording to pump flow passing through the opening


area of the spool of the control valve, and controls
the discharge amount Q of the pump so that the
pressure loss becomes constant. Thus, the dis-
charge amount of the pump is kept proper for the
demand of the control valve.
. To the LS valve, the pump pressure (from self re-
duce valve) P and LS pressure PLS are introduced.
The relationship between the LS differential pres-
sure DPLS and the pump discharge amount Q
changes as shown in the right chart.

PW75R-2 10-43
OPERATION
1. When the control valve is at «NEUTRAL» position

To the actuator
All'utilizzo

PLS
Control valve
Distributore

PPLS

Unità di alimentazione
Self reduce valve
servocomandi

PP

Minimum
Minimo

(Small diameter
(Lato sezione size)
minore)

Y 3

PP

PP

a
b 14
PEN d c

1
PLS
PPLS 15
x
(Large diameter
(Lato sezione size)
maggiore)

RKP08260

10-44 PW75R-2
. To the spring chamber a of the LS valve, LS pres-
sure PLS is introduced from the outlet of the control
valve, and to the chamber b at the end of the sleeve
on the opposite side, pump pressure PPLS is intro-
duced through the self reduce valve.
. Position of the piston (15) is determined by the
combined force of LS pressure PLS and force of
the spring (14) and the volume of the pump pres-
sure PPLS.
. Before the engine is started, the servo piston (1) is
pushed to the lower direction (swash plate angle
max. side) by the spring (3).
. When the engine is started, if all the control valves
are at the «NEUTRAL» positions, the LS pressure
PLS becomes 0 bar (0 kg/cm2) because no pressure
oil flows to the outlet side of the control valve.
(The spring chamber a is open to the drain circuit
through the spool of the control valve).
At the same time, the pump pressure PPLS is main-
tained at the unload pressure of approx. 26 bar (ap-
prox. 27 kg/cm2).
. Therefore, the piston (15) is pushed to the right side
( ), a path is formed between the ports c and d,
and then the pump pressure PP is led to the cham-
ber X at the large diameter side of the servo piston
from the Port d.
. Though the pump pressure PP is always introduced
to the chamber Y of the small diameter side of the
servo piston (1), because the force to the large dia-
meter side is larger due to the difference of the
areas at two ends of the servo piston (1), the servo
piston (1) is moved to the minimum swash plate an-
gle side ( ).

PW75R-2 10-45
2. When the opening of the control valve is large (lever stroke large)

To All'utilizzo
the actuator

PLS
Control valve
Distributore

PPLS

Unità di alimentazione
Self reduce valve
servocomandi

PP

Maximum
Massimo

(Small diameter
(Lato sezione size)
minore)

Y 3

PP

f PP

a
b 14
PEN ed c

1
PLS
PPLS 15
x
(Lato sezione maggiore)
(Large diameter size)

RKP08270

10-46 PW75R-2
. When the control lever is moved to full-stroke, in
other words, as the opening area of the control
valve becomes large, the difference of the pump
pressure PPLS and the LS pressure PLS (LS differ-
ential pressure DPLS) becomes smaller.
. LS pressure PLS introduced to the spring chamber
a of the LS valve becomes more or less the same
as the pump pressure PPLS and the piston (15) is
pushed to the left side ( ) by the combined force
of the LS pressure and the spring (14), closing the
Port c and forming a path between the ports d and
e.
. Therefore, the pressure oil functioning to the cham-
ber X at the large diameter side of the servo piston
(1) flows to the Port e from the Port d, and then to
the Port f of the PC valve.
. At this time, since the Port f of the PS valve is open
to the drain inside the pump case through the in-
side of the piston, pressure in the chamber X of
the large diameter side of the servo piston also be-
comes to the drain pressure.
. By this, the servo piston (1) is moved to the max.
swash plate angle side ( ) by the pump pressure
PP functioning to the chamber Y at the small dia-
meter side.

PW75R-2 10-47
3. When the opening of the control valve is small (lever stroke small)

To the actuator
All'utilizzo

PLS
Control valve
Distributore

PPLS

Unità
Selfdireduce
alimentazione
valve
servocomandi

PP

Minimum
Minimo

(Small diameter
(Lato sezione size)
minore)

Y 3

PP

PP

a
b 14
PEN d c

1
PLS
PPLS 15
x
(Large
(Lato diameter
sezione size)
maggiore)

RKP08280

10-48 PW75R-2
. When the control lever is fine-controlled or moved
to the «NEUTRAL» position, in other words, as the
opening area of the control valve becomes small,
the difference of the pump pressure PPLS and the
LS pressure PLS (LS differential pressure DPLS) be-
comes larger.
. Function at this time is same as that at "1. When
the control valve is at «NEUTRAL» position, that
is, the pump pressure PPLS pushes the piston (14)
to the right side ( ) and the servo piston (1) is
moved to the minimum swash plate angle side.
In other words, when the control valve is in the
range from the «NEUTRAL» to the opening area
small (fine control), if the LS differential pressure
DPLS is 21 bar (21.5 kg/cm2) (LS setting differential
pressure of the LS valve) and above, the pump
swash plate angle functions to the minimum side,
and if the LS differential pressure DPls becomes
below 21 bar (21.5 kg/cm2) when the control valve
opening becomes larger, the pump swash plate an-
gle functions to the maximum side.

PW75R-2 10-49
4. When the pump flow is proper the demand of the control valve

To All'utilizzo
the actuator

PLS
Control valve
Distributore

PPLS

Unità di alimentazione
Selfservocomandi
reduce valve

PP
Fermo
Hold

(Small
(Lato diameter size)
sezione minore)

Y 3

PP

A2
f PP

a
b 14
A1
PEN ed c

1
PLS
PPLS 15
x
(Large
(Lato diameter
sezione size)
maggiore)

RKP08390

10-50 PW75R-2
. Let us take the pressure receiving area at the large
diameter side of the servo piston (1) as A1, pres-
sure receiving area at the small diameter side as
A2, pressure functioning to the large diameter side
as PEN, and the pressure to the small diameter side
as PP.
. When the pump flow rate reaches the flow demand
of the control valve, the pump pressure PPLS func-
tioning to the Port b of the LS valve balances with
the combined force of the LS pressure PLS func-
tioning to the spring chamber a and the spring
(14), and the piston (15) stops at the center posi-
tion.
. By this, ports c, d and e open almost equally, and
while flowing to the Port d, a part of the pump pres-
sure from the Port c also flows into the chamber X
at the large diameter side of the servo piston (1)
after reduced to about half pressure by partially
drained into the tank case from the Port e.
. At this time, because the relationship of the pres-
sure receiving areas on the servo piston (1) is
A2 : A1=1 : 2, the pressure functioning to two ends
of the servo piston (1) becomes PP : PEN=2 : 1, so
the forces to the two ends of the servo piston (1) be-
comes 1 : 1, and the servo piston (1) stops at the
position, balancing the flow demand of the control
valve and the pump discharge.
. Spring force is so adjusted that the piston (15)
is balanced when
PPLS ± PLS=DPLS=21 bar (21.5 kg/cm2).
. In other words, the pump discharge is maintained
as the opening area of the control valve by main-
taining the LS differential pressure DPLS as 21
bar (21.5 kg/cm2) because when the opening area
of the control valve is 1/2, the pump swash plate
angle becomes 1/2, and when the opening area is
1/4, then the pump swash plate angle becomes
also 1/4.
. For example, if the opening of the control valve is
moved to 3/4 after the piston balanced with the
opening of 1/4, the LS differential pressure DPLS
once lowers.
So, the LS valve is activated to increase the pump
discharge, and when the pump swash plate angle
rises to 3/4, since the LS differential pressure DPLS
rises to 21 bar (21.5 kg/cm2), the piston is balanced
at this point.

PW75R-2 10-51
10-52 PW75R-2
PC VALVE (Power Control)
FUNCTION
. The PC valve carries out an approximate equal
horse-power control so that the hydraulic horse-
power sucked by the pump does not exceed the en-
gine horse-power by limiting the discharge amount
Q to a specified about in relation with the discharge
pressure PP, even if the LS valve tries to increase
the pump discharge amount Q when the discharge
pressure PP becomes high and opening area of the
control valve is large.
. In other words, when a load becomes large during
operation and the pump discharge pressure PP
rises, the PC valve reduces the pump discharge
amount Q, and when the pump discharge pressure
PP lowers, it increases the pump discharge amount
Q.
Mode systemPP
Mode system
. Relationship between the pump discharge pres- ,/min)
sure PP and the pump discharge amount Q is as Mode system EE
Mode system
(< /(min)

shown in the chart. Mode system P with


Mode system
swing pump inP con pompa
operation
pompa Q Q

Normally, it is set to the pump suction torque of the di rotazione sotto carico
Portata amount

standard mode, but when a signal from the mode Mode system E with
Mode system
swing pump inE con pompa
operation
switching solenoid valve is inputted, the pump suc- di rotazione sotto carico
tion horsepower lowers by approximately 20% as
Pump discharge

shown by the light-load mode curve.


. Since the swing pump is mounted directly on the
main pump, when the swing pump is in operation,
suction torque of the main pump is reduced by
the amount sucked by the swing pump so that the
sum of the main pump suction torque and the Pump discharge
Pressionepressure PP (bar)
pompa PP (bar)
swing pump suction torque becomes the total suc- RKP08400
tion torque (100%).

PW75R-2 10-53
FUNCTION
1. When load on the actuator is large (pump discharge pressure is high)

W
PLS
Control valve
Distributore

PPLS

Mode switch
Elettrovalvola
Unità di alimentazione solenoid
Mode valve
System
Self reduce valve
servocomandi

PP

PA3

M Swing
Pompa
pump
rotazione

f g
(Small diameter
(Lato sezione size)
minore)

y
4 5 7
8
PA3
PP

PM
2
PP

e d

PEN

1
PLS
PPLS 15
x
(Large
(Lato diameter
sezione size)
maggiore)

RKP08410

10-54 PW75R-2
. When a load on the actuator is large and the pump
discharge pressure PP rises, the piston (8) is
pushed to the left ( ) due to the relationship of
the section areas of S1 and S2 of the piston
(S1>S2).
. By this action, path is formed between the ports f
and g, at the same time when the pump pressure
PP of flows to the Port f from the Port g, when the
shut out Port f and drain circuit.
. If the LS valve works to increase the pump dis-
charge amount, the spool (15) of the LS valve is
shifted to the left side ( ) and the path is formed
between the ports d and e.
. Therefore, the pump pressure PP from the Port f of
the PC valve flows to the Port d from the Port e of
the LS valve, enters into the chamber X at the large
diameter side of the servo piston (1), and stops the
movement of the servo piston (1).
. If the pump discharge pressure PP rises further, the
piston (8) moves to the left side ( ), and the servo
piston (1) is shifted to the minimum swash plate an-
gle side ( ) by the pressure in the chamber X at
the large diameter side.
. When the servo piston (1) is shifted to the upper
( ), side, the piston (4) is shifted to the right
( ) side via the lever (2). Because of this, the
springs (5) and (7) move to the contraction side,
and push back the piston (8) to the right side.
. When the piston (8) is pushed back to the right and
the path between the ports f and g is shut out, the
upward ( ) movement of the servo piston is
stopped.
. At this time, the stopping position of the servo pis-
ton (1) is higher (close to the minimum swash plate
angle side) than that when the pump discharge
pressure is lower.

PW75R-2 10-55
2. When load on the actuator becomes small (pump discharge pressure lowers)

W
PLS

Control valve
Distributore

PPLS
PM

Unità di alimentazione
Self reduce valve
servocomandi

PP

PA3

M
Swing
pump
Pompa
rotazione

(Small diameter size) f g


(Lato sezione minore)
Y
5 7
8
PA3
PP

PM
2
PP

e d

PEN

1
PLS
x
(Large
(Lato diameter
sezione size)
maggiore)

RKP08420

10-56 PW75R-2
. When the load on the actuator becomes small and
the pump discharge pressure PP lowers, the piston
(8) is pushed to the right ( ) side by the spring
force of the springs (5) and (7).
. By this action, at the same time when the path be-
tween the ports g and f is shut out, the Port f be-
comes open to the drain circuit.
. At this time, if the LS valve is working to increase
the pump discharge amount, because control of
the PC valve becomes ineffective, pressure oil the
chamber X of the large diameter side of the servo
piston (1) flows from the Port d through the Port e
of the LS valve and drains into the drain circuit from
the Port f of the PC valve.
. Therefore, the servo piston (1) is shifted to the max-
imum swash plate angle ( ) side by the pressure
PP in the chamber Y at the small diameter side.

PW75R-2 10-57
3. When the signal pressure is inputted from the mode switch solenoid valve
When the swing is operated

PLS
Control valve
Distributore

PPLS
PM
Mode switch
Elettrovalvola
Unità di alimentazione solenoid
Mode valve
System
Self reduce valve
servocomandi

PP

PA3

M Swing
Pompa
pump
rotazione

S3<S4

(Small diameter
(Lato sezione size)
minore)

5 7 8
10
PA3
PP

PM

PP

e d

PEN

PLS
PPLS

(Large diameter
(Lato sezione size)
maggiore)

RKP08430

10-58 PW75R-2
When the signal pressure is inputted from the
mode switch solenoid valve
. When the mode switch solenoid valve is turned ON
and the signal pressure PM is inputted into the Port
PM, it activates the piston (10), and the piston (10)
pushes the piston (8) to the left ( ) side.
. By this action, the springs (5) and (7) are contracted
and, because the spring load increases, the pump
suction torque lowers by about swing.

When the swing is operated


. When the swing is not being used, in other words
when no load is applied on the swing pump, the
pump suction torque is same as the standard mode
or the light-load mode.
. Once the swing is activated, thus, a load is applied
on the swing pump, the signal pressure PA3 is in-
putted to the Port PA3, and the piston (8) is pushed
to the left ( ) side according to the volume of the
signal pressure PA3.
. By this action, the springs (5) and (7) are contracted
and, because the spring load increases, the pump
suction torque lowers according to the volume of
the load on the swing pump.

PW75R-2 10-59
4. Function of the spring

PLS
Control valve
Distributore

PPLS
PM
Mode switch
Elettrovalvola
solenoid
Mode valve
System
Unità di alimentazione
Selfservocomandi
reduce valve

PP

PA3

M Swing
pump
Pompa
rotazione

(Small
(Lato diameter size)
sezione minore)

4 5 6 7
8
PA3
PP

PM
2
PP

e d

PEN

1
PLS
PPLS

(Large diameter
(Lato sezione size)
maggiore)

RKP08440

10-60 PW75R-2
. The spring load of the springs (5) and (7) in the PC
valve is changed in proportion to the swash plate
angle of the pump.
. As the servo piston (1) moves, the lever (2) moves,
and then the piston (4) moves according to the
semi-rotating movement of the lever (2).
. When the piston (4) moves to the right ( ) side,

pompaQQ((,</min)
/ min)
the springs (5) and (7) are contracted at first. If
the piston (4) moves further to the right ( ), the
spring (5) touches the seat (6), so only the spring
(7) functions as a spring.

amount
In other words, the spring load is changed by the

Portata
piston (4) expanding/contracting the springs (5)

Pump discharge
and (7).
. The pump absurption torque curve which indicates
the relationship between the pump discharge pres-
sure PP and the discharge amount Q forms a bent
line as shown in the chart because the springs (5)
and (7) have separate spring loads.
. Furthermore, when the signal pressure PM of the Pump discharge pressure
Pressione pompa PP P (bar)
P (bar)

mode switch solenoid valve is inputted, or when RKP08450


the signal pressure PA3 of the swing pump
changes, since the springs (5) and (7) are pushed
from the right side by the piston (8), the spring load
changes.
The position where the piston (8) stops, that is the
pump absurption torque, is determined as the posi-
tion where the total pressure of the pump pressure
/min)

PP which applies onto the piston (8), the mode


pompa QQ(<(/,min)

switch pressure PM and the swing pump signal


pressure PA3 balances with the spring force of the
Portataamount

springs (5) and (7).


b a
. In other words, as the pump discharge pressure PP
rises, the pump discharge amount Q reduces, and
Pump discharge

as the pump discharge pressure PP lowers, the


pump discharge amount Q increases.
. The pump absurption torque curve which indicates
the relationship between the pump discharge pres-
sure PP and the discharge amount Q is shifted in
Pump Pressione
discharge pressure
pompa PP (bar)
PP (bar)
parallel from a to b as increase of each signal pres-
sure. RKP08460

PW75R-2 10-61
PRIORITY VALVE

d c

RKP09030

a. P Port - From P2 pump (PGA Port) OPERATION


b. LS Port - To steering unit (LS Port)
. The oil from the pump is distributed through the
c. CF Port - To steering unit (P Port) priority valve to the steering unit (Port CF) and to
d. EF Port - To by-pass valve (C Port) the other hydraulic components (Port EF).
. Distribution is determined by the position of the
SPECIFICATIONS priority valve slider in function of:
Type: OLS40 a - the Load Sensing signal coming from the
steering unit (Port LS);
b - the pump oil delivery;
c - the pressure in the steering system;
d - the pressure in the connected hydraulic circuit.
. The slider position is such as to ensure that deliv-
ery to the steering unit always corresponds to the
actual requirements.

10-62 PW75R-2
PW75R-2 10-63
CONTROL VALVE

A
C B
D A
aa
AA AA
Ps
Pt
Pq O O
v N x Pr
N
Po Pp
t u
M M
Pm r Pn
L L s
Pk p Pi
B K K q
Pi n Pj
J J o
Pg l Ph
H H m
Pe j k Pf
G G
Pc h Pd
F F i
P Pa Pb
f g
E E xx
d e
BB BB
c
C D A
Pu
a b P B

View
VistaAA
y

w
View
Vista B
B
RKP03160

10-64 PW75R-2
a. Tc Port - To exchanger
b. Tsw Port - To swing motor (S Port)
c. TB Port - To hydraulic tank
d. A1 Port - To swing motor (MB Port)
e. B1 Port - To swing motor (MA Port)
f. A2 Port - See hydraulic circuit
g. B2 Port - See hydraulic circuit
h. A3 Port - To swivel joint (13 Port)
i. B3 Port - To swivel joint (12 Port)
j. A4 Port - To boom cylinder (bottom side)
k. B4 Port - To boom cylinder (head side)
l. A5 Port - To arm cylinder (head side)
m. B5 Port - To arm cylinder (bottom side)
n. A6 Port - To bucket cylinder (head side)
o. B6 Port - To bucket cylinder (bottom side)
p. A7 Port - See hydraulic circuit
q. B7 Port - See hydraulic circuit
r. A8 Port - To boom swing cylinder (head side)
s. B8 Port - To boom swing cylinder (bottom side)
t. A9 Port - To 2-piece boom cylinder (head side)
u. B9 Port - To 2-piece boom cylinder (bottom side)
v. A10 Port - To attachment (L.H. side)
w. P1 Port - From servocontrol unit (P2 Port) and to pump (PPLS Port)
x. B10 Port - To attachment (R.H. side)
y. P2 Port - From priority valve (EF Port)
aa. PLS Port - To hydraulic pump (PLS Port)
xx. TS Port - To hydraulic tank
Pa. PA1 Port - From L.H. PPC valve (P3 Port)
Pb. PB1 Port - From L.H. PPC valve (P4 Port)
Pc. PA2 Port - See hydraulic circuit
Pd. PB2 Port - See hydraulic circuit
Pe. PA3 Port - From ST3 solenoid valve group (A Port)
Pf. PB3 Port - From ST3 solenoid valve group (B Port)
Pg. PA4 Port - From R.H. PPC valve (P2 Port)
Ph. PB4 Port - From R.H. PPC valve (P1 Port)
Pi. PA5 Port - From L.H. PPC valve (P1 Port)
Pj. PB5 Port - From L.H. PPC valve (P2 Port)
Pk. PA6 Port - From R.H. PPC valve (P4 Port)
Pl. PB6 Port - From R.H. PPC valve (P3 Port)
Pm.PA7 Port - See hydraulic circuit
Pn. PB7 Port - See hydraulic circuit
Po. PA8 Port - From boom swing PPC valve (P1 Port)
Pp. PB8 Port - From boom swing PPC valve (P2 Port)
Pq. PA9 Port - From 2-piece boom PPC valve (P1 Port)
Pr. PB9 Port - From 2-piece boom PPC valve (P2 Port)
Ps. PA10 Port - From OP3 solenoid valve group (B Port)
Pt. PB10 Port - From OP3 solenoid valve group (A Port)
Pu. PDB Port - From R.H. PPC valve (P2 Port)

PW75R-2 10-65
1

15 16

13 14

11 12

9 10

7 8

5 6

3 4

1 2

18

Section
Sezione A
A -- AA RKP03170

1. L.H. travel suction valve (A3 port) 10. R.H. outrigger suction valve (B7 Port)
2. L.H. travel suction valve (B3 port) 11. Boom swing suction valve (Head side) (A8 port)
3. Boom suction valve (Bottom side) (A4 port) 12. Boom swing suction valve (Bottom side) (B8 port)
4. Boom suction valve (Head side) (B4 port) 13. 2-piece boom suction valve (A9 Port)
5. Arm suction valve (Head side) (A5 port) 14. 2-piece boom suction valve (B9 Port)
6. Arm suction valve (Bottom side) (B5 port) 15. Attachment safety valve (R.H. side) (A10 port)
7. Bucket suction valve (Head side) (A6 port) 14. Attachment safety valve (L.H. side) (B10 port)
8. Bucket suction valve (Bottom side) (B6 port) 17. Safety valve
9. R.H. outrigger suction valve (A7 Port) 18. Lift check valve

10-66 PW75R-2
11

10

Section
SezioneBB -- B
B
RKP03180

1. Main relief valve (P1 port) 7. Spool (bucket)


2. Spool (swing) 8. Spool (R.H. outrigger)
3. Spool (blade or outriggers) 9. Spool (boom swing)
4. Spool (travel) 10. Spool (2-piece boom)
5. Spool (boom) 11. Spool (attachment)
6. Spool (arm)

PW75R-2 10-67
18

8 16

7 15

6 14

5 13

4 12

3 11

2 10

1 9

17

19

SectionCC- C
Sezione -C
RKP03190

Flow compensation valve: Reducing pressure compensation valve:


1. Travel 9. Travel
2. Boom 10. Boom
3. Arm 11. Arm
4. Bucket 12. Bucket
5. R.H. outrigger 13. R.H. outrigger
6. Boom swing 14. Boom swing
7. 2-piece boom 15. 2-piece boom
8. Attachment 16. Attachment
17. Main relief valve (P2 Port)
18. Plug
19. Spool (boom raise at joining pump discharge)

10-68 PW75R-2
9

Section D - D
Sezione D - D RKP03200

1. Swing check valve 6. Outrigger check valve


2. Blade check valve 7. Boom swing check valve
3. Boom check valve 8. 2-piece boom check valve
4. Arm check valve 9. Attachment check valve
5. Bucket check valve

PW75R-2 10-69
2

Section
SezioneBB
BB-- BB
BB RKP02820

5 3

4 Section E - E
Sezione E - E RKP02810

1. Main relief valve (P1 port)


2. Lift check valve

SWING VALVE
3. Spool (swing)
4. Spool (boom raise at joining pump discharge)
5. Check valve (swing)

10-70 PW75R-2
2

3
SectionAA
Sezione AA- AA
- AA
RKP02840

Section F - F 6
Sezione F - F RKP02830

1. Pump pressure detection plug


2. Pressure relief plug
3. LS bypass plug
4. Safety relief valve

BLADE VALVE
5. Spool (blade)
6. Main relief valve (P2 port)

PW75R-2 10-71
1 2

5 4
Section
Sezione G
G -- G
G
RKP02850

6 7

10 9
Section
SezioneHH -- H
H
RKP02860

TRAVEL VALVE BOOM VALVE


1. Suction valve (A3 port) 6. Suction valve (Head side)
2. Suction valve (B3 port) 7. Suction valve (Bottom side)
3. Spool 8. Spool
4. Reducing pressure compensation valve 9. Reducing pressure compensation valve
5. Flow compensation valve 10. Flow compensation valve

10-72 PW75R-2
1 2

RKP02870

5 4
Section J -- JJ
Sezione J

1 2

RKP02880
5 4
Section K - K
Sezione K - K

ARM VALVE BUCKET VALVE


1. Suction valve (Head side) 6. Suction valve (Head side)
2. Suction valve (Bottom side) 7. Suction valve (Bottom side)
3. Spool 8. Spool
4. Reducing pressure compensation valve 9. Reducing pressure compensation valve
5. Flow compensation valve 10. Flow compensation valve

PW75R-2 10-73
1 2

5 4
Section
Sezione LL-L
-L RKP03210

6 7

10 9
Section M-M
Sezione M-M RKP03220

OUTRIGGER VALVE BOOM SWING VALVE


1. Suction valve (A7 Port) 6. Suction valve (Head side)
2. Suction valve (B7 Port) 7. Suction valve (bottom side)
3. Spool 8. Spool
4. Reducing pressure compensation valve 9. Reducing pressure compensation valve
5. Flow compensation valve 10. Flow compensation valve

10-74 PW75R-2
1 2

5 4
Section
SezioneNN-N
-N RKP03230

6 7

10 9
Section O - O RKP03240
Sezione O-O

11

RKP03250
Section P - P-P
Sezione P

2-PIECE BOOM VALVE ATTACHMENT VALVE


1. Suction valve (A9 Port) 6. Safety valve (L.H. side)
2. Suction valve (B9 Port) 7. Safety valve (R.H. side)
3. Spool 8. Spool
4. Reducing pressure compensation valve 9. Reducing pressure compensation valve
5. Flow compensation valve 10. Flow compensation valve
11. Unload valve

PW75R-2 10-75
10-76 PW75R-2
2. FUNCTION PRINCIPLE
1. Control of pump swash plate angle
. The pump swash plate angle (pump discharge amount) is so controlled that the LS differential pressure DPLS,
which is the difference between the pump discharge pressure PP and the LS pressure PLS at the outlet Port of
the control valve (actuator load pressure), is maintained at a constant level.
(LS differential pressure DPLS=Pump discharge pressure PP ± LS pressure PLS).
. If the LS differential pressure DPLS becomes lower than the setting pressure of the LS valve, the pump swash
plate angle becomes larger, and if it becomes higher, the pump swash plate angle becomes smaller.
H For the details of this action, refer to the descriptions of "HYDRAULIC PUMP".

Max.

Swash plate angle Q


Actuator

Min.

Control valve
0 LS differential
pressure ∆PLS Set differential
pressure of LS valve
RKP02931

PLS
Pump passage
LS passage

Main pump
PP

Min. Max.

Servo piston

∆ PLS
LS valve

Differential
pressure high Differential
pressure
low
PC valve

Pump pressure Pump pressure


high low
RKP02921

PW75R-2 10-77
2. Pressure compensation control
. Valves (pressure compensation valves) are installed at the inlet Port side of the spools of the control valves to
balance the loads.
When the actuators are complex-operated, the pressure differences DP at the upstream (inlet) and down-
stream (outlet) are made equal by these valves.
In this way, the flow from the pump are distributed in proportion to the opening areas S1 and S2 of each
valve.

Load
Load
W W

Actuator Actuator

∆P ∆P
S1 S2

Pressure Pressure
compensation compensation
valve valve

LS valve RKP02941

10-78 PW75R-2
3. Operation for each function and valve

Hydraulic circuit diagram and names of valves

Ls
294 bar
5
1. Unload valve
Ls ø0,5
9
LS pressure+31 bar (32 kg/cm2)
A10
B10 2. Main relief valve (P1 port)
Attachment 265 bar (270 kg/cm2)
3. Pressure compensation valve
Pa10 Pb10
9
3 4. Suction valve
4
A9
5. Safety valve
Pa9
B9 2-piece boom 294 bar (300 kg/cm2)
Pb9
4 6. Main relief valve (P2 port):
3 4 216 bar (220 kg/cm2)
A8 7. Lift check valve
B8 Boom swing
Pa8 Pb8 8. Cooler bypass valve
4
9 - Safety valve (hammer element):
3 4 196 bar (200 kg/cm2)
A7

Pa7
B7 L.H. outrigger
Pb7
4
3 4
A6
B6
Pa6 Bucket
Pb6
4
3 4
A5

Pa5
B5 Arm
Pb5
4
3 4
A4

Pa4
B4
Boom
Pb4
4
3 4
A3
B3 Travel
Pa3 Pb3
4
3
A2
B2 Blade and/or
Pb2
Pa2
R.H. outrigger
P2
216bar 6
A1
B1 Swing
Pa1 Pb1

TS
PDB

2 265 bar 1 31 bar 8 TSW


7 TB
TC
P1
RKP10131

PW75R-2 10-79
1. Unload valve

FUNCTION
1. When the control valve is at «NEUTRAL», pump discharge amount Q for the minimum swash plate angle is re-
leased to the tank circuit.
At this time, the pump discharge pressure PP is set at 23 bar (25 kg/cm2) by the spring (2) inside the valve.
(LS pressure PLS=0 bar (0 kg/cm2)

PP PLS

T
1 2 3

RKP02960

OPERATION
When the control valve is at «NEUTRAL»
. In this way, the pump discharge pressure PP is set
. To two end surfaces of the spool (1), the pump dis-
to 23 bar (25 kg/cm2).
charge pressure PP is acting on the left and the LS
pressure PLS is acting on the right side.
. Since no LS pressure PLS is generated when the
control valve is at «NEUTRAL», only the pump dis-
charge pressure PP is acting, and PP is set only by
the load of the spring (2).
. As the pump discharge pressure PP rises and
reaches the spring load of the spring (2) (23 bar
(25 kg/cm2)), the spool (1) is shifted to the right
( ) side and the pump circuit PP becomes open
to the tank circuit T through the drill holes in the
sleeve (3).

10-80 PW75R-2
2. When the flow demand from the actuator is within the discharge amount for the pump minimum swash angle
plate during fine control of the control valve, the pump discharge pressure PP is set to the LS pressure PLS +23
bar (25 kg/cm2).
Since the unload valve opens when the differential pressure between the pump discharge pressure PP and the
LS pressure PLS reaches the spring load of the spring (2) (23 bar (25 kg/cm2)), the LS differential pressure DPLS
at this time becomes 23 bar (25 kg/cm2).

PP PLS

T
1 2 3

RKP02970

OPERATION
Fine control of the control valve
. Thus, the pump discharge pressure PP is set to the
. When the control valve is fine-controlled, the LS
combined pressure of the spring force (23 bar (25
pressure PLS is generated and acts on the right
kg/cm2)) and the LS pressure PLS, and the LS dif-
end of the spool (1).
ferential pressure DPLS becomes 23 bar (25 kg/
At this time, since the LS pressure PLS is small be-
cm2).
cause the opening area of the spool of the control
valve is small, there is big difference from the pump
discharge pressure PP.
. When the differential pressure between the pump
discharge pressure PP and LS pressure PLS
reaches the spring load of the spring (2) (23 bar
(25 kg/cm2)), the spool (1) moves to the right ( )
side and a path is formed between the pump circuit
PP and the tank circuit T.

PW75R-2 10-81
3. When the flow demand from the actuator becomes greater than the pump flow for the minimum swash plate
angle during operation of the control valve, the flow to the tank circuit T is cut off, and all the pump discharge
Q flows into the actuator circuit.

PP PLS

T
1 2 3

RKP02980

OPERATION
When the control valve is operated
. As the result, the path between the pump circuit PP
. When the control valve is operated to a bigger
and the tank circuit T is shut off, and whole pump
stroke, the LS pressure PLS is generated and acts
discharge Q flows to the actuator circuit.
on the right end surface of the spool (1).
At this time, since the opening area of the spool of
the control valve is large, the difference between
the LS pressure PLS and the pump discharge pres-
sure PP is small.
. For this reason, because the differential pressure
between the pump discharge pressure PP and the
LS pressure PLS noes not reach the spring load of
the spring (2) 23 bar (25 kg/cm2)), the spool (1) is
pushed to the left ( ) side by the spring (2).

10-82 PW75R-2
2. Introduction of LS pressure
FUNCTION
. The LS pressure denotes the actuator load pressure at the outlet Port of the control valve.
. Actually, in the control valves, the pump pressure PP is reduced to the same pressure of the actuator circuit
pressure A by the pressure reducing valve (3) in the pressure compensation valve before introducing into the
LS circuit PLS.
Furthermore, the orifice C is provided in the middle of the circuit from the pump circuit PP to the pressure
reducing valve (3) for damper function.
. In the travel valves, the actuator circuit pressure A is directly introduced into the LS circuit PLS.

A
b
1

a d

PP SA PA 3 PLS1 SLS
2

C 4 PLS
RKP02990

OPERATION
1. Control valves (boom, 2-piece boom, arm,
bucket, boom swing, attachment)
. Areas of the both ends of the pressure reducing
. When the spool (1) is operated, the pump pres- valve (3) are same (SA=SLS), and on the SA
sure PP starts to flow to the actuator circuit A side, the actuator circuit pressure PA (=A) is
from the flow control valve (2) and the spool acting, and on the opposite SLS side, the re-
notch a through the bridge path b. duced pump pressure PP is acting.
. At the same time, the pressure reducing valve . Therefore the pressure reducing valve (3) bal-
(3) moves to the right ( ) side, so the pump ances at the point where the actuator circuit
pressure PP introduced from the orifice c is de- pressure PA and the spring chamber pressure
pressurized by the pressure loss at the notch d PLS1 are balanced, and the pump pressure PP
and introduced to the LS circuit PLS, and then, reduced by the notch d is introduced to the LS
further introduced to the spring chamber PLS1. circuit PLS as the actuator circuit pressure A.
. At this time, the LS circuit PLS is open to the
tank circuit T through the LS bypass plug (4) (re-
fer to the description of the LS bypass plug).

PW75R-2 10-83
A
b

a d

PP 2 PA 3

PLS
RKP03270

2. Travel valves
. When the spool (1) is operated, the pump pres-
sure PP starts to flow to the actuator circuit A
from the flow control valve (2) and the spool
notch a through the bridge path b.
. At the same time, the pressure reducing valve
(3) is moved to the right ( ) side by the actua-
tor circuit PA, and paths are made between the
notches c and d to the LS circuit PLS respec-
tively.
. By this, the actuator circuit pressure PA (=A) is
introduced to the LS circuit PLS from the notch c
through the notch d.
H In the travel circuits, unlike the work equipment
circuits, the actuator circuit pressure PA is di-
rectly introduced to the LS circuit PLS.

10-84 PW75R-2
3. LS bypass plug
DESCRIPTION
1 - The LS bypass plug releases the residual pressure of the LS pressure PLS.
2 - This makes the pressure-rising speed of the LS pressure PLS more gentle, and with this discarded throttled
flow, it creases a pressure loss in the throttled amount of the spool or shuttle valve and increases the stability
to lowering the effective LS differential pressure.

1 T

PLS

RKP03010

OPERATION

. The pressurized oil in the LS circuit PLS flows from


the clearance filter a, which is formed by the clear-
ance between the LS bypass plug (1) and the body,
to the tank circuit T through the orifice b.

PW75R-2 10-85
4. Pressure compensation valve

FUNCTION
1. During complex operation, if the load pressure at one side becomes lower than that of the other actuator and
the oil flow is about to increase, pressure compensation is carried out.
(In this case, the other actuator (right side) of the complex operation has higher load pressure than that of this
side (left side).

W W
A A
PA
PPA

a a

T
PLS1
PPA PA
2 1
PP

PLS PP
RKP03020

OPERATION

. During complex operation, when the load pressure . The flow control valve and the pressure reducing
of the other actuator side (right side) becomes high- valve (1) are balanced at the point where the differ-
er, the flow in the actuator circuit A at this (left) side ential pressure between PA and PLS, which act on
tends to increase. the both end surfaces of the pressure reducing
valve (1), becomes equal to the pressure loss in be-
. In this case, the LS pressure PLS at the other actua- tween PP and PPA before and after the flow control
tor acts on the spring chamber PLS1, and pushes valve (2).
the pressure reducing valve (1) and the flow control
valve (2) to the left ( )side. . By this operation, the differential pressures be-
tween the upstream pressure PPA and the down
. The flow control valve (2) throttles the opening area stream pressure PA of both spools in the complex
between the pump circuit PP and the upstream side operation are made same, and the pump flow is
of the spool PPA, and generates a pressure loss in distributed in proportion to the opening areas of
between PP and PPA. notches a of each spool.

10-86 PW75R-2
5. Area ratio of pressure compensation valve

FUNCTION

. The pressure compensation valve determines the compensation characteristics by carrying out fine adjustment
of the area ratio (S1/S2) between the area S1 of the flow control valve (2) side and the area S2 of the pressure
reducing valve (1) side to match the characteristics of each actuator.
S1=Area of the flow control valve (2) ± Area of the piston (3)
S2=Area of the pressure reducing valve (1) ± Area of the piston (3)

S1 PPB PP 2 1 PA 3 S2

PLS
RKP03030

Area ratio (S1/S2) and compensation characteristics


. When the ratio is 1.00 : [Pump pressure PP - Upstream pressure of the spool notch PPB]6[LS circuit pressure PLS
- Actuator circuit pressure PA (=A)] Thus, the flow is distributed in proportion of opening areas of the spool.
. When the ratio is larger than 1.00 : PP ± PPB>PLS ± PA (=A)
Thus, the flow is divided less than the proportion of opening areas of the spool.
. When the ratio is smaller than 1.00 : PP ± PPB<PLS ± PA
Thus, the flow is divided more than the proportion of opening areas of the spool.

PW75R-2 10-87
6. Travel LS bypass circuit

FUNCTION
. When the travel and another actuator are operated at the same time, by increasing the LS throttle amount in the
LS circuit PLS which is discarded, and relaxing the pressure compensation precision in the travel circuit, drop in
the travel speed is minimized.
. The bypass circuit is closed when the travel or another actuator is operated individually.

A1 1 A2 PA

PLS
PLS1
a

PB 4
3 2 c

RKP03060

OPERATION
Normal operation
. When the boom spool (1) is operated, the pressure
in the LS circuit PLS becomes same as the boom
circuit pressure A1.
. At the same time, the LS circuit pressure PLS is also
introduced to the spring chamber PLS1 of the pres-
sure reducing valve (2) in the travel valve.
. Since the travel spool is not operated, the travel ac-
tuator circuit is closed, and the check valve (4) in
the reducing valve (2) is also closed.
. Thus, during individual operation of the boom, the
travel LS bypass circuit is closed.

10-88 PW75R-2
A1 1 A2 PA

PLS
PLS1
a

PB 4
2 c

RKP03070

When the travel and another actuator are operated


together

. When the boom spool (1) is operated, the pressure . Thus, the LS circuit pressure PLS, which has been
in the LS circuit PLS becomes same as the boom the same as the boom circuit pressure A1, flows
circuit pressure A1. to the travel circuit A2 and lowers.
. Since the pressure in the boom RAISE actuator cir-
cuit is normally higher than that of the travel actua-
tor (A1>A2), the pressure in the spring chamber
PLS1 in the reducing valve (2) at the travel side is
higher than the travel circuit pressure (PA).
. Therefore, the pressure reducing valve (2) moves to
the left ( ) side, and the LS pressure in the spring
chamber PLS1 from the orifice a pushes and opens
the check valve (4), and flows to the travel circuit PA
through the path b and the path c.

PW75R-2 10-89
7. Boom and arm regeneration circuit

FUNCTION (Explanation by boom)


1. When the boom is being lowered, if the bottom pressure A of the cylinder (1) is higher than the head pressure
B, and there is hydraulic drift, this sends the return flow at the bottom end to the head end to increase the cy-
linder speed by that amount.

1
B
A
4
2

T
3
a

PP PLS

RKP03080

OPERATION
. When there is hydraulic drift when lowering the
boom, the pressure A at the bottom end of the
boom cylinder (1) becomes higher than the pres-
sure B at the head end.
. At this time, a part of the return flow at the bottom
end passes the regeneration passage a of the
boom spool (2), pushes the check valve (3) open,
and flows to the head end.
. As the result, the boom lowering speed is in-
creased.

10-90 PW75R-2
2. When lowering the boom, if the head pressure B of the cylinder (1) is greater than the bottom pressure A, and
the operation is in the load process, the check valve (3) closes to shut off the circuit between the head and the
bottom sides.

B
A
4
2

T
3
a

PLS
PP

RKP03090

OPERATION

. During a load process such as lowering the boom,


etc., the pressure B at the head side of the boom
cylinder (1) becomes higher than the pressure A
at the bottom side.
. At this time, the check valve (3) is closed by the
pressure B at the head side and the spring (4),
and the passage between the head circuit and
the bottom circuit is shut off.

PW75R-2 10-91
SWING MOTOR

a A
B

C C

B A

b c

RKP08470

a. S Port - From control valve (TSW Port) SPECIFICATIONS


b. T Port - To hydraulic tank Type: LMF40AB-2
c. B Port - From ST1 solenoid valve group Motor capacity: 40.8 cc/rev
(A1 Port) Rated speed: 1500 rpm
d. MB Port - From control valve (A1 Port) Safety valve set pressure:
e. MA Port - From control valve (B1 Port) 206 bar (210 kg/cm2)
Suction valve cracking pressure:
max. 0.3 bar (0.3 kg/cm2)
Brake releasing pressure: 18.1w2.5 bar
(18.5w2.5 kg/cm2)

10-92 PW75R-2
2

3 4 5 6 7 8 9

SectionBB- -BB
Sezione
13 12 11 10
Section
Sezione A
A -- AA

Section C --CC
Sezione C RKP08480

1. Output shaft 8. Valve plate


2. Case 9. End cover
3. Thrust plate 10. Brake spring
4. Shoe 11. Brake piston
5. Piston 12. Disc
6. Center spring 13. Plate
7. Cylinder 14. Safety valve with suction

PW75R-2 10-93
SAFETY VALVE WITH SUCTION
FUNCTION
. When swing operation is stopped, outlet circuit of
the motor is closed by the control valve. However,
the motor will run for a while by inertial force, so
pressure at the outlet side of the motor will abnor-
mally rise, which may cause damage to the motor.
. To avoid such danger, the safety valve releases the
abnormally high pressure oil from the outlet side of
the motor to the Port S, as well as performing swing
brake function.
. The suction valve supplies oil of equivalent amount
to the oil released by the safety valve from the Port
S to the inlet side of the motor to avoid cavitation.
S
OPERATION
1. When swing starts
. When the swing control lever is operated to SWING
LEFT, pressure oil from the pump will be sent to the
Port MA through the control valve.
. By this, pressure in the Port MA rises, which gener- MB MA
ates starting force to the motor, and the motor
starts to run.
. Oil coming out of the outlet Port returns to the tank Control valve
Distributore
from the Port MB though the control valve. RKP08490

2. When swing stops


. When the swing control lever is returned to the
NEUTRAL position, pressure oil from the control
valve is not sent to the Port MA.
At the same time, return circuit for the oil coming
out of the outlet of the motor to the tank is shut 1 2
off by the control valve.
. At the Port MB, pressure rises, which generates ro-
tational resistance to the motor, which then acts as
braking force to the motor.
. When the pressure at the Port MB reaches the set
pressure of the safety valve (1), B of the safety
valve (1) opens to release the pressure oil in the
Port MB to the Port S.
. At the Port MA, since the motor runs without being
supplied with pressure oil, negative pressure will
be generated. S
When this negative pressure lowers to the set pres-
sure of the suction valve (2), the suction valve (2)
opens and oil is sent from the Port S to avoid cavi-
tation.

MB MA

Control valve
Distributore
RKP08500

10-94 PW75R-2
SWING BRAKE
OPERATION
Servocontrol
Unità di
1. When swing brake solenoid valve is deactivated feed unit
alimentazione
servocomandi
. When the swing brake solenoid valve is deacti-
vated, the pressurized oil from the servocontrol Deactivated
feed unit is shut off and Port B is connected to Non eccitata
M
the tank circuit.
. Because of this, brake piston (11) is pushed down Swing brake freno
Elettrovalvola
in the direction of the arrow by brake spring (10), solenoid
di valve
rotazione
so disc (12) and plate (13) are pushed together 10
and the brake is applied.
11

a 12

A 13

RKP08510

2. When swing brake solenoid valve is excited Unità di


Servocontrol
alimentazione
. When the swing brake solenoid valve is excited, the feed unit
servocomandi

valve is switched, and the pressurized oil from the


servocontrol feed unit enters Port B and flows to
brake chamber a. Excited
Eccitata M
. The pressurized oil entering chamber a overcomes
the force of brake spring (10), and brake piston (11) Elettrovalvola
Swing brake freno
is pushed up in the direction of the arrow. solenoid
di valve
rotazione

. Because of this, disc (12) and plate (13) separate, 10


and the brake is released.
11

a 12
A 13

RKP08520

PW75R-2 10-95
SWIVEL JOINT

Front
Fronteofmacchina
machine

Asse ingressi
1 Inlet axis
3A-7A-11A
3A-7A-11A
2
4a 7a
3 8a
13a
1
1a
11a
14A
6a
3a
13A
5
Asse ingressi Asse ingressi
Inlet axis
4A-8A-12A Inlet axis
2A-6A-10A-11A
4A-8A-12A 2A-6A-10A-11A
11A 2a
14a
12 10A
12a 9a
6 9A 5a 10a

8A 7A Asse ingressi
Inlet axis
2A-6A-10A-11A
6A 2A-6A-10A-11A

5A View Z
Vista Z
4A 3A RKP03780

2A 1. 14 slip ring collector


2. Collector support
1A
7 3. Screw
10 4. Screw
5 9 5. Anti-friction ring
6. Seal
7. O-Ring seal
8 8. Body
9. Guard ring
Z
10. Rotor

1A. From steering unit (R Port) 1a. See hydraulic circuit


2A. From steering unit (L Port) 2a. See hydraulic circuit
3A. See hydraulic circuit 3a. See hydraulic circuit
4A. From ST1 solenoid valve group (B2 Port) 4a. To brake cylinder
5A. From ST2 solenoid valve group (B1 Port) 5a. To transmission (f Port)
6A. To hydraulic tank 6a. From travel valve (T Port)
7A. From brake pump (T1 Port) 7a. To axle brake
8A. From brake pump (T2 Port) 8a. To axle brake
9A. See hydraulic circuit 9a. See hydraulic circuit
10A. See hydraulic circuit 10a. See hydraulic circuit
11A. From ST2 solenoid valve group (A Port) 11a. To locking axle cylinder (B Port)
12A. From control valve (B3 Port) 12a. To travel motor (B Port)
13A. To control valve (A3 Port) 13a. To travel motor (A Port)
14A. From ST2 solenoid valve group (A1 Port) 14a. To transmission (e Port)

10-96 PW75R-2
TRAVEL MOTOR

5
c 1

2 4 a b 4

3 View X
Vista X

RKP04460

1. Motor SPECIFICATIONS
2. Brake valve Min. displacement: 33 cc/rev.
3. Displacement automatic control Max. displacement: 80 cc/rev.
4. Relief/anti-cavitation Check valve rated pressure: 350 bar
5. Travel speed increment solenoid valve (Y25)
a. A Port - To swivel joint (13 Port)
b. B Port - To swivel joint (12 Port)
c. T Port - To swivel joint (6 Port)

PW75R-2 10-97
DISPLACEMENT AUTOMATIC CONTROL HIGH PRESSURE
RELATED

3
b

1 1 6

5
4
4
a
7
5

Section X X
Particolare
RKP04470

FUNCTION . The pressure moves the positioning piston (2)


. This device automatically varies the displacement which, because it is connected mechanically to
in function of the working pressure. the engine cylinder, causes this to move and in-
A displacement increase leads to a reduction in the crease the displacement.
engine shaft rpm and an increase in the torque. The movement of the positioning piston (2) con-
tinues until equilibrium has been reached between
OPERATION the delivery pressure acting on the smaller surface
of the piston and the pressure acting on the larger
. The pressurized oil coming from the control valve surface. Once equilibrium has been reached the
arrives through the brake valve (1) on the smaller spring (6) returns the measuring piston (5) to its
surface of the positioning piston (2), thus pushing neutral position.
it towards the minimum displacement limit stop. Maximum displacement is determined by the me-
The smaller surface is connected hydraulically to chanical limit stop (7).
the pilot system bushing (4), which contains a mea-
suring piston with two different surfaces. The avail- . When delivery line pressure diminishes there is no
able pressure therefore acts in a differential man- longer equilibrium between the forces acting on the
ner and, with the spring (6), causes the piston (5) positioning piston; the measuring piston moves,
to perform the function of governing the pressure and opens passage c to release the existing pres-
flows. sure in chamber b.
Under this new pressure the positioning piston (2)
. When delivery line pressure increases the mea- gradually returns to the minimum displacement po-
surement piston (5) moves, compresses the spring sition. The movement stops when a new equili-
(6), and allows oil to pass through line a into cham-
brium is reached between the forces acting on
ber b of the larger surface of the positioning piston
(2). the measurement piston (5) and the positioning pis-
ton (2).

10-98 PW75R-2
TRAVEL MOTOR BRAKE VALVES

8 9 10 11 f 11 10 9 2

5
5
3

6
4

7 c

b a RKP04550

FUNCTION
. The brake valves control loading in order to prevent . When the pressure in line a drops due to loading
the cavitation phenomenon which occurs when the changes or due to the movement of the controls,
rotation speed of the hydraulic motor exceeds the there is an immediate reduction of pressure in the
speed determined by pump delivery through the spring housing e; pressure from the spring (4)
control valve. and residual pressure from the drainage lines
. The brake valves are not a substitute for the ma- cause the piston (3) to return, leading to a reduction
chine duty brakes. in the amount of oil draining through the throttle (6),
and thus provoking an automatic braking action.
OPERATION . Valves (2) and (8) protect the engine against both
. Pressurized oil from the control valve enters line a pressure peaks and the cavitation phenomenon.
causing valve (1) to open, and acts through the pilot . When the pressure in line f exceeds the calibration
system channel c the ring chamber d and valve (2) value of the spring (9), the pilot valve (10) opens to
to feed the piston motor. eliminate pressure inside the main valves (11). The
The pilot system oil acts on the surface of piston (3) pressure in line d acts on the outside of the main
and causes it to move to compress the spring (4) valves (11) which causes them to open and allow
while the throttles (5) control the passages to obtain communication between their lines of delivery a
slow and regular piston movement. and drainage b.
The piston movement (3) releases a progressive
throttling action (6) and allows the oil drained out
of the motor to return to the tank through the valve
opening (7).

PW75R-2 10-99
CYLINDERS

BOOM

2 3 4 5 6 7 8 9 10 12
1

19 18 17 16 15 14 RKP08710

ARM

2 3 4 5 6 7 8 9 10 11 12
1

19 18 17 16 15 14 13 RKP08720

BUCKET

2 3 4 5 6 8 9 10 12
1

RKP08730
19 18 17 16 15 14

10-100 PW75R-2
BOOM SWING, BLADE OR OUTRIGGERS, 2-PIECE BOOM
(H The figure shows the blade cylinder)

2 3 4 5 6 8 9 20 12
1

RKP08740
19 18 17 16 14 15

1. Head bushing 8. Gasket 15. Gasket


2. Snap ring 9. Guide ring 16. Cylinder
3. Gasket 10. Nut 17. Cylinder head
4. Gasket 11. Bottom cushion plunger 18. Gasket
5. Guide ring 12. Bottom bushing 19. Clamping flange
6. Piston rod 13. Ball (No. 12) 20. Half flange (No. 2)
7. Head cushion plunger 14. Piston

Blade or
Cylinder Boom 2-piece-boom Arm Bucket Boom swing
outriggers
Piston rod size
70 50 60 55 60 60
diameter
Cylinder inside
110 90 95 85 100 100
diameter
Piston stroke 765 580 905 730 650 185
Max. cylinder
1965 1510 2245 1810 1650 710
length
Min. cylinder
1200 930 1340 1080 1000 525
length
Piston nut width
70 Ð Ð 55 Ð Ð
across flat

PW75R-2 10-101
Axle locking cylinder

B
2

3 4 5 6

Section BB
Sezione - B- B
Section
SezioneAA- -AA
RKP03770

a. B Port - From swivel joint (11 Port)

1. Cylinder
2. Piston
3. Cover
4. Plunger
5. Valve seat
6. Screw
7. Oil seal
8. Gasket

10-102 PW75R-2
PW75R-2 10-103
SERVOCONTROL FEED UNIT

a b
B
A A

d
RKP03961

a. P2 Port - To control valve (P1 Port)


b. Pc Port - To brake pump (P Port)
c. PR Port - To ST1 solenoid valve group (P Port)
d. T Port - To hydraulic tank

10-104 PW75R-2
2

11 6 5 4
Detail Z Z
Particolare
1

8 7 Z
Section
SezioneAA -- A
A

10 9
Section B
Sezione B --BB RKP03970

1. Pump case
2. Valve
3. Spring
4. Screw
5. Poppet
6. Spring (reducing valve pilot)
7. Spring (reducing valve main)
8. Spool (reducing valve)
9. Spring (safety valve)
10. Ball

PW75R-2 10-105
OPERATION
1. When engine is stopped
PC
. Poppet (5) is pushed against the seat by spring
(6), and the passage from Port PR T is P1 P2
closed.
. Valve (8) is pushed to the left by spring (7), and
the passage from Port P1 PR is open.
. Valve (2) is pushed to the left by spring (3), so
the passage between Port P1 P2 is closed.
(See Fig. 1)

T
PR
Hydraulic diagram
RKP03861

Control valve
P2
PC 2 3

P1

PR

8 7 5 6

PC valve PPC valve

LS valve

RKP03871

10-106 PW75R-2
2. At neutral
3. When load pressure P2 is low (when moving Control valve

down under own weight (boom LOWER or arm P2


IN)
PC d 2 3
Note: When load pressure P2 is lower than output
pressure PR of the self-reducing pressure
valve.
. Valve (2) receives force in the direction to close P1
the passage from Port P1 P2 from spring (3)
and pressure PR (when the engine is stopped,
the pressure is 0 bar (0 kg/cm2)).
However, when hydraulic oil flows in from Port T
P1, the pressure is balanced so that pressure
P16 force of spring (7) + (area ùd x pressure
PR), and the opening from Port P1 P2 is ad-
justed so that pressure P1 is kept at a certain
value above pressure PR.
PR
. When pressure PR goes above the set pres-
8 a 7 5
sure, poppet (5) opens, and the hydraulic oil
flows in the following circuit: Port PR hole
a inside spool (8) opening of poppet (5)
tank Port T.
As a result, a pressure difference is created on M
both sides of hole a inside spool (8), so spool (8)
moves in the direction to close the opening from PC valve PPC valve
Port P1 PR.
LS valve
Pressure P1 is reduced to a certain pressure
(set pressure) by the amount of opening at this RKP03881

point, and is supplied as pressure PR.


(See Fig. 2)
Control valve
4. When load pressure P2 is high P2
If load pressure P2 increases and the pump dis- PC d 2 3
charge amount also increases because of digging
operations, pressure P1 also increases (pressure
P1> force of spring (7) + (area ùd x pressure
PR), so valve (2) moves to the right to the end of P1
the stroke.
As a result, the amount of opening from Port
P1 P2 increases and the resistance in the pas-
sage is reduced, so the loss of engine horsepower T
is reduced.
. If pressure PR goes above the set pressure,
poppet (5) opens and the hydraulic oil flows in
the following circuit: Port PR hole a in-
side spool (8) a opening of poppet (5)
tank Port T. PR
As a result, a pressure difference is created on 8 a 7 5
both sides of hole a is inside spool (8), so spool
(8) moves in the direction to close the opening
from Port P1 PR.
Pressure P1 is reduced to a certain pressure M
(set pressure) by the amount of opening at this
point, and is supplied as pressure PR. PC valve PPC valve
(See Fig. 3)
LS valve
RKP03891

PW75R-2 10-107
5. When there is abnormal high pressure
When pressure PR of the self-reducing pressure
valve becomes abnormally high, ball (10) pushes
against the force of spring (9), separates from
the seat, and allows hydraulic oil to flow from out- M
put Port PR T, so pressure PR goes down.
This action protects the equipment at the destina-
tion for the hydraulic pressure supply (PPC valve, PPC valve
electromagnetic valve, etc.) from abnormally high
pressure. (See Fig. 4) PR P1 T

10 9
RKP03901

10-108 PW75R-2
ACCUMULATORS

RKP03910

TECHNICAL DATA FUNCTION


Servocontrol feed group: . A rubber bag (1) containing nitrogen gas is used in
the accumulator. Its function is to maintain oil pres-
Nominal volume: 0.35 , sure in the circuit to which the accumulator is con-
Pre-set pressure: 12 1 bar nected.
Working pressure: 35 ± 45 bar
OPERATION
Braking system
. When the engine is running, the chamber A of the
Nominal volume: 0.70 , rubber bag (1) (containing nitrogen) is compressed
Pre-set pressure: 70 bar by the pressurized oil from line B.
Working pressure: 65 ± 150 bar . If the oil pressure in line B falls below the maximum
calibration pressure (even after intensive use), the
rubber bag (1) will expand due to the pressure of
the nitrogen inside it.

PW75R-2 10-109
PPC VALVE

WORK EQUIPMENT

a b

d c

E E
D D
e
B f

A C

C A RKP01070

L.H. PPC VALVE R.H. PPC VALVE


a. P2 Port - To control valve (PB5 port) a. P2 Port - To control valve (PA4 port)
(arm close) (boom raise)
b. P4 Port - To control valve (PB1 port) b. P4 Port - To control valve (PA6 port)
(R.H. swing) (bucket open)
c. P1 Port - To control valve (PA5 port) c. P1 Port - To control valve (PB4 port)
(arm open) (boom lower)
d. P3 Port - To control valve (PA1 port) d. P3 Port - To control valve (PB6 port)
(L.H. swing) (bucket close)
e. T Port - To ST1 solenoid valve e. T Port - To ST1 solenoid valve
(T port) (T port)
f. P Port - From ST1 solenoid valve f. P Port - From ST1 solenoid valve
(A4 port) (A4 port)

10-110 PW75R-2
6

5 7
4
8

3
9

2 10

SectionAA- -AA
Sezione Section B
Sezione B --B
B

Section
Sezione D
D --D
D

Section CC--C
Sezione C

Section
Sezione EE -E
-E

RKP01080

1. Spool 7. Joint
2. Adjusting spring (internal) 8. Cover
3. Return spring (external) 9. Pin
4. Plunger 10. Body
5. Disc
6. Nut

PW75R-2 10-111
FUNCTION
1. At neutral
Ports A and B of the control valve and ports P1
and P2 of the PPC valve are connected to drain
chamber D through fine control hole f in spool
(1). (Fig. 1)

D
f T
P

1
P3 (P1) P4 (P2)

A Control valve
B

RKP01091

Fig. 1

2. During fine control (NEUTRAL fine control)


When piston (4) starts to be pushed by disc (5), re-
tainer (7) is pushed; spool (1) is also pushed by
metering spring (2), and moves down.
When this happens, fine control hole f is shut off
from drain chamber D, and at almost the same
time, it is connected to pump pressure chamber
5
PP, so pilot pressure oil from the control pump
passes through fine control hole f and goes from
4
port P1 to port A.
When the pressure at port P1 becomes higher,
3
spool (1) is pushed back and fine control hole f
is shut off from pump pressure chamber PP.
2
D
At almost the same time, it is connected to drain f
chamber D to release the pressure at port P1. T
When this happens, spool (1) moves up or down P
so that the force of metering spring (2) is balanced
with the pressure at port P1. The relationship in
the position of spool (1) and body (8) (fine control 1 PP
hole f is at a point midway between drain hole D
and pump pressure chamber PP) does not change P1 P2 10
until retainer (7) contacts spool (1).
Therefore, metering spring (2) is compressed pro-
portionally to the amount of movement of the con-
trol lever, so the pressure at port P1 also rises in A B
Control valve
proportion to the travel of the control lever. In this
way, the control valve spool moves to a position
where the pressure in chamber A (the same as RKP01101

pressure at port P1) and the force of the control


valve spool return spring are balanced. (Fig. 2) Fig. 2

10-112 PW75R-2
3. During fine control (when the lever is returned)
When disc (5) starts to be returned, spool (1) is
pushed up by the force of centering spring (3)
and the pressure at port P1.
When this happens, fine control hole f is con-
nected to drain chamber D and the pressure oil 5
at port P1 is released.
If the pressure at port P1 drops too far, spool (1) is 4
pushed down by metering spring (2), and fine con-
trol hole f is shut off from drain chamber D. At al- 3
most the same time, it is connected to pump pres-
sure chamber PP, and the pump pressure is sup- 2
D
plied until the pressure at port P1 recovers to a
f T
pressure that corresponds to the lever position.
When the spool of the control valve returns, oil in P
drain chamber D flows in from fine control hole f' f
in the valve on the side that is not working.
The oil passes through port P2 and enters cham- 1 PP
ber B to fill the chamber with oil. (Fig. 3)
P1 P2

A B
Control valve

Fig. 3 RKP01111

4. At full stroke
When disc (5) pushes down piston (4), and retai-
ner (7) pushes down spool (1), fine control hole f
is shut off from drain chamber D, and is con-
nected with pump pressure chamber PP. There-
fore, the pilot pressure from the control pump 5
passes through fine control hole f and flows to
chamber A from port P1, and pushes the control
valve spool.
4
The oil returning from chamber B passes from
port P2 through fine control hole f' and flows to
9
drain chamber D. (Fig. 4)
D
f T
P
f

1 PP
P1 P2

A Control valve
B

RKP01121

Fig. 4

PW75R-2 10-113
PPC VALVE
(Blade, boom swing, 2-piece boom)
(H Be careful about mounting direction)

T
P

P1 P2
a
RKP03920

5
4
c d 6

3 7

2
8
1
9
Section A- -A
Sezione A A
RKP00960

a. T Port - To hydraulic tank


b. P Port - From ST1 solenoid valve group 1. Spool
(A4 Port) 2. Metering spring
c. P1 Port - For boom swing: 3. Centering spring
to control valve (PA8 Port) 4. Piston
For 2-piece boom:
to control valve (PA9 Port) 5. Lever
For L.H. outrigger: 6. Plate
to control valve (PB2 Port) 7. Retainer
For R.H. outrigger or blade: 8. Body
to control valve (PA7 Port)
d. P2 Port - For boom swing:
to control valve (PB8 Port)
For 2-piece boom:
to control valve (PB9 Port)
For blade or R.H. outrigger:
to control valve (PA2 Port)
For L.H. outrigger:
to control valve (PB7 Port)

10-114 PW75R-2
FUNCTION
1. At neutral
Ports A and B of the control valve and ports P1
and P2 of the PPC valve are connected to drain
chamber D through fine control hole f in spool
(1). (Fig. 1)

D
T

f P

1
P1 P2

2. During fine control (NEUTRAL fine control)


When piston (4) starts to be pushed by lever (5), A Control valve B
retainer (7) is pushed; spool (1) is also pushed
by metering spring (2), and moves down. RKP00971

When this happens, fine control hole f is shut off Fig. 1


from drain chamber D, and at almost the same
time, it is connected to pump pressure chamber
PP, so pilot pressure oil from the control pump
passes through fine control hole f and goes from
Port P1 to Port A.
When the pressure at Port P1 becomes higher,
spool (1) is pushed back and fine control hole f
is shut off from pump pressure chamber PP. 5
At almost the same time, it is connected to drain
chamber D to release the pressure at Port P1. 4
When this happens, spool (1) moves up or down
so that the force of metering spring (2) is ba-
lanced with the pressure at Port P1. The relation-
ship in the position of spool (1) and body (8) (fine
control hole f is at a point midway between drain 7 D
hole D and pump pressure chamber PP) does not
change until retainer (7) contacts spool (1). T
Therefore, metering spring (2) is compressed pro- 2
portionally to the amount of movement of the con- 8
trol lever, so the pressure at Port P1 also rises in
proportion to the travel of the control lever. In this f P
way, the control valve spool moves to a position
where the pressure in chamber A (the same as
pressure at Port P1) and the force of the control 1 P1 P2
valve spool return spring are balanced. (Fig. 2)
PP

A Control valve B

RKP00981
Fig. 2

PW75R-2 10-115
3. During fine control
(when the lever is returned)
When lever (5) starts to be returned, spool (1) is
pushed up by the force of centering spring (3) 5
and the pressure at Port P1.
When this happens, fine control hole f is con-
nected to drain chamber D and the pressure oil 4
at Port P1 is released.
If the pressure at Port P1 drops too far, spool (1) is
pushed down by metering spring (2), and fine con-
trol hole f is shut off from drain chamber D. At al- 7 D
most the same time, it is connected to pump pres-
sure chamber PP, and the pump pressure is sup- T
plied until the pressure at Port P1 recovers to a 2
pressure that corresponds to the lever position.
When the spool of the control valve returns, oil in P
drain chamber D flows in from fine control hole f' f
in the valve on the side that is not working. The oil f'
passes through Port P2 and enters chamber B to
fill the chamber with oil. (Fig. 3) 1 P1 P2 PP

A Control valve B

RKP00991
4. At full stroke Fig. 3
When lever (5) pushes down piston (4), and retai-
ner (7) pushes down spool (1), fine control hole f is
shut off from drain chamber D, and is connected
with pump pressure chamber PP. Therefore, the
pilot pressure from the control pump passes
through fine control hole f and flows to chamber
A from Port P1, and pushes the control valve
spool. 5
The oil returning from chamber B passes from
Port P2 through fine control hole f' and flows to
drain chamber D. (Fig. 4) 4

7 D

T
2
8
P
f
f'
1 P1 P2 PP

A Control valve B

RKP01001
Fig. 4

10-116 PW75R-2
TRAVEL PPC VALVE

25
°
a
4
6 2 3
1
1

2
b
a 5

3
4

Z c
ANGLE ADJUSTABLE

Hole a
1 25ë
2 30ë
3 35ë
4 40ë

RKP09040

1. Pedal
2. Pedal adjustment
3. Adjustable stop
4. Control unit
5. Support
6. Rubber jacket

a. P Port - From servocontrol feed unit (PR Port)


b. T Port - To tank
c. A Port - To ST3 solenoid valve group (P Port)

PW75R-2 10-117
BRAKE PUMP

1
2

b c d
5

3 g f a
e 4

i h

View
VistaAA
RKP04530

1. Pedal SPECIFICATIONS
2. Pedal angle adjustment Feed pressure: 70w5 bar
3. Pump Unitary displacement: 70 cc
4. Service brake locking solenoid valve (Y3)
5. Pedal movement adjustment

a. P Port - From servocontrol feed unit (PC Port)


b. N Port - To hydraulic tank
c. T1 Port - Brake light pressure switch port
d. F Port - Accumulator pressure switch port
e. B Port - To pump (PLS Port)
f. R2 Port- To A1 accumulator
g. R1 Port- To A2 accumulator
h. T1 Port - To swivel joint (7 Port)
i. T2 Port - To swivel joint (8 Port)

10-118 PW75R-2
BOOM AND ARM SAFETY VALVE

a b

c d

1 2

3
4
5
e

RKP04170

1. Screw
2. Valve
3. Rod SPECIFICATIONS
4. Nut Pilot ratio: 22:1
5. Nut
(bar)
Dp(bar)

20
a. T Port - To hydraulic tank
b. P Port - For boom: From control valve
pressione Dp

16
Differenza dipressure

(PB4 Port)
2
C

For arm: From control valve 12 V2


V2


(PB5 Port) C2
Differential

8
c. V2 Port - For boom: From control valve
(A4 Port) 4
For arm: From control valve
(A5 Port) 0
0 25 50 75 100 125 150
d. M Port - For boom: To the overload PortataQQ ((,
Amount < //min)
min)
sensor switch
RKP04160
e. C2 Port - For boom: To the cylinder
(Bottom side)
For arm: To the cylinder
(Head side)

PW75R-2 10-119
2-PIECE BOOM SAFETY VALVE

a b
A A

1 1

2 3 3 2
Section
SezioneAA -- A
A

c d

RKP04070

1. Screw SPECIFICATIONS
2. Plug Pilot ratio: 4.25:1
3. Valve

a. C1 Port - To 2-piece boom (Head side) 24


(bar)

b. C2 Port - To 2-piece boom (Bottom side)


Dp(bar)

c. V1 Port - From control valve (A9 Port) 20


pressione Dp

V2

d. V2 Port - From control valve (B9 Port)


pressure

16
C2

C2

12 V2
Differenza di
Differential

0
0 12 24 36 48 60
Amount Q (Q,/min)
Portata (< / min)
RKP04080

10-120 PW75R-2
BLADE OR OUTRIGGER SAFETY VALVE

a b

A A

Section A - A
Sezione A - A
c a

RKP03760

a. V2 Port - See hydraulic circuit SPECIFICATIONS


b. V1 Port - See hydraulic circuit Start opening: 8 bar (8.1 kg/cm2)
c. C2 Port - To blade or outrigger (Bottom side)
d. C1 Port - To blade or outrigger (Head side)
(bar)
(bar)

16
14
DpDp
di pressione

12
10
pressure

2
8 ➔C
V2
6 ➔
V2
C2
Differenza

4
Differential

2
0
0 6 12 18 24 30
Amount Q (Q,/min)
Portata (l / min)

RKP04540

PW75R-2 10-121
OVER LOAD SENSOR SWITCH

2
3

4
5

3
1
2

RKP03930

a. From boom safety valve (M port) TECHNICAL DATA


Setting valve: 130 bar
1. Connector
2. Pressure sensor switch FUNCTION
3. Adjusting screw The overload sensor switch is connected through the
4. Nut boom safety valve to boom cylinder (bottom side).
5. Connection plate When the pressure rises over the setting valve, the
sensor close the electrical circuit and the actives the
horn.

10-122 PW75R-2
SOLENOID VALVE
Solenoid valve group ST1 (Y5-Y6-Y7-Y11)
Swing brake, parking brake, mode system, servocontrol

1 2 3 4

b
a

f e d c

RKP10490

a. P Port - From servocontrol feed unit (PR Port) 1. Y11 Parking brake
b. B2 Port - To swivel joint (4 Port) 2. Y5 Swing brake
c. A4 Port - Tp PPC valves (P Port) 3. Y6 Mode System
d. A3 Port - To hydraulic pump (PM Port) 4. Y7 Servocontrols
e. A1 Port - To swing motor (B Port)
f. T Port - To hydraulic tank

PW75R-2 10-123
Solenoid valve group ST2 (Y4-Y10-Y12)
Locking axle and travel speed change

2
1

b c

RKP10720

1. Y10 Locking axle


2. Y4 Low speed
3. Y3 High speed

a. T Port - To hydraulic tank


b. P Port - From servocontrol feed unit (PR Port)
c. A1 Port - To swivel joint (14 Port)
d. B1 Port - To swivel joint (5 Port)
e. A Port - To swivel joint (11 Port)

10-124 PW75R-2
Solenoid valve group ST3 (Y1-Y2)
Travel direction

1 a b 2

d c

RKP04570

2
Measured
Misurate conat V=41
V=41 mm
mm2/s /s and t=50ë
e t=50°C 1 2
(bar)

1. Y1 Reverse 10
(bar)

2. Y2 Forward
pressione DpDp

8
Differenza dipressure

a. Port P - From travel PPC valve (A Port) 6

b. Port B - To control valve (PB3 Port) 4


Differential

c. Port T - To hydraulic tank


2
d. Port A - To control valve (PA3 Port)
0
0 20 40 60 80
Amount QQ
Portata (,(/lmin)
/ min)

RKP04490

PW75R-2 10-125
Solenoid valve group OP1 (Y21-Y22-Y23-Y24)
For steering (With 4WS only)

2 3

a b

T A

P B

c 5 d

1 4
RKP03670

Fig. 1

2
Measured at V=41 mm2/s and t=50ë
Misurate con V=41 mm /s e t=50°C
5 3 Misurate con V=41 mm2/s e t=50°C
Measured at V=41 mm2/s and t=50ë 6
(bar)(bar)

9
(bar)(bar)

10
10
pressione DpDp

Dp Dp

8
Differenza dipressure

8
pressure
Differenza di pressione

6
6
4
Differential

4
Differential

2
2
0
0 20 40 60 80 0
Amount Q (,/min)
Portata Q (l / min) 0 20 40 60 80
Amount QQ(,
Portata (l // min)
min)
RKP04500
RKP04510

1. Y21: Rear steering cut out


2. Y22: Front/rear steering
3. Y23: Phase coincidence steering
4. Y24: Crab steering
5. Blocks connection

a. T Port - To front steering cylinder (a Port)


b. A Port - To rear steering cylinder (c Port)
c. P Port - From swivel joint (1 Port)
d. B Port - To rear steering cylinder (d Port)

10-126 PW75R-2
Solenoid valve group OP2 (Y26)
Front outriggers or blade and rear outrigger selection

c d

b e

(bar)
Dp (bar)

10
di pressione Dp

8
Differenzapressure

a f 4
Differential

C
P➔
2

RKP05460
0
10 30 50 70 90
Amount QQ((,<//min)
Portata min)
RKP04520

a. P1 Port - From swivel joint (10 Port) e. C4 Port- To R.H. rear outrigger safety valve
b. C1 Port- To L.H. rear outrigger safety valve (V2 Port)
(V1 Port) f. P2 Port - From swivel joint (9 Port)
c. C2 Port- With 4 outriggers:
To L.H. front outrigger safety valve
(V1 Port)
- For front blade and rear outrigger:
Not used
d. C3 Port- With 4 outriggers:
To R.H. front outrigger safety valve
(V2 Port)
- For front blade and rear outrigger:
To blade cylinder safety valve
(V2 Port)

PW75R-2 10-127
Solenoid valve group OP3 (Y8-Y9)
For breaker, rotating grab bucket control

a b
1 2

d c

RKP03940

1. Y8 L.H. optional equipments control


2. Y9 R.H. optional equipments control

a. T Port - To hydraulic tank


b. A Port - To control valve (PB10 Port)
c. P Port - From ST1 solenoid valve group (A4 Port)
d. B Port - To control valve (PA10 Port)

10-128 PW75R-2
ELECTRICAL DIAGRAM (2WS) (1/5)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

M-B1 M-B1
STRUMENTO MULTIFUNZIONALE 4.1
R-G1 R-G1
R1 ACC BR R2 C MULTIFUNCTION INSTRUMENT 4.1

OFF ACC H/R1 H/R1


R1 4.1
ST
XS XS XS XS XS XS XS XS XS XS XS XS XS XS XS XS H-N1.5 H-N1.5
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 4.1

G/R1

H-L1
B

A-V1
V1

S1
M-N1 M-N1

G1
S6

H/R1

V/B1
Z/B1

R-V1
Z-B1
2.1
HA5

A2.5

M-V1
Z-B1

G4
MANIPOLATORE 4.14
JOYSTICK A-V1
XC 1 G1
S7
3.1

H-N1

A-V1
Z-B1
R4
R-N1
2.1
L/R1
2.1

5 16 7 19 20 4 9 5 11 4 8 2 12 4

X7 X7 X4 X9 X9 X7 X9 X3 X3 X4 X11 X4 X4
3.15
X16

X16
X17
+30 +15 F1B F4B F2B +15
1 X17 X17 X17 X17 X17 X17 X17 X17
5 8 2 9 6 3 1 2 7 4
3A
7.5A 3A

M1

V-B1

V1
G4

L/R1

H-N1
3.9

3.4

K4 86 87a 87
K8
86 87a 87

85 30 85 30
1
R6
R4

KT1 86 87a 87 X12 L/R1 +15


K1 86 87a 87 K2 86 87a 87 K3 86 87a 87
B-R1

Z-N1
Z-B1

+30
85 30
F4C F3B F6A
B-N1

85 30

R-N1.5
85 30 85 30
R6 5A 7.5A 15A

R4

L-R1
M-N1
K01 K03 K02
FUG2 FUG4 FUG1 FUG3 86 87 86 87 86 87 DIODO
50A 40A 30A 60A

85 30 85 30 85 30

X5 X5 X5 X5 X6 X6 X8 X6 X9 X8 X9 X8 X7
A2.5 10 5 11 3 3 6 9 4 3 3 13 13 14

H2.5

A-N1
A-N1

A-N1.5
4.6
G4

R4
R10

R2.5 A-N1.5
3.1

H-G1.5
M6

3 2 2

H-R1

A-G1
B-N1
R50

H-G1.5

B-R1.5
XA
XA

XAM XAM 10 X20


M1 G2 1
M2

S1
G1 R1 R3 X18
30 50 D+ XW R4 S21 HA4
M 30 G W Y0 S16 S17 S20 Y2 Y1 X1 M S5
Y6 p p p
12Vcc 3 t
U
t
31

B-G1
XAM X18 X20
2
N50

1 9 1
N1

N1

N1

N1

N1

N1

N1

N1

N1

N1

N1

N1

N1
N1.5

N1.5

N1.5
2.1

RKP10210
COMPONENTS
G1 - Battery M1 - Starter motor Y2 - Forward speed solenoid valve F6A - Right lateral dashboard line 12
- Pliers valve - horn - current intake - X4 X12 - Diode 2 way connector
G2 - Generator M2 - Transfer pump Y6 - Working mode solenoid valve way connector
solenoid valve fuse 15A X16 - Power 3 way connector
HA4 - Horn R1 - Heating start FUG1 X5 - Engine line 11 way connector
- Fuel shut off fuse 30A X17 - Lateral dashboard 9 way con-
R3 - Engine water temperature sender FUSES FUG2 - General fuse 50AX6 - Lights switch-gear shift line 13 way nector
HA5 - Buzzer
K01 - Starter relay R4 - Fuel level sender F1B - Gear valve fuse 7.5A FUG3 - Generator fuse 60A connector X18 - Rear line 8 way connector
K02 - Fuel shut off relay S5 - Transfer pump sensor F2B - Joystick button-instrument power FUG4 X7 - Steering interface line 21 way con-
- Preheating fuse 40A X20 - Transfer pump 2 way connector
K03 - Preheating relay S6 - Starting switch fuse 3A nector XA - Generator 2 way connector
K1 - Forward speed valve relay S16 - High water temperature switch F3B - Safety start-fuel shut off fuse 7.5A CONNECTORS X8 - Loom line 21 way connector XAM - Fuel shut off 3 way connector
K2 - Reverse speed solenoid valve relay S17 - Air filter switch F4B - Right traffic light and instrument X1 - Interface line 5 way connector X9 - Lights switch-gear shift line 21 way XC - 1 way connector
K3 - Speed connection relay S20 - Engine oil low pressure switch light fuse 3A X3 - Right lateral dashboard line 18 way connector XS - Multifunction instrument 16 way
K4 - Key safety start relay S21 - Brakes pressure switch F4C - Generator and timers connector X11 - Lateral dashboard line 13 way con- connector
K8 - Horn relay Y0 - Fuel shut off solenoid valve (preheating and startif) 5A nector XW - Economy power valve 2 way con-
KT1 - Preheating timer Y1 - Reverse speed solenoid valve nector

PW75R-2 10-129
10-130
ELECTRICAL DIAGRAM (2WS) (2/5)

PULSANTIERA PRINCIPALE MANIPOLATORE


PULSANTIERA PRINCIPALE PULSANTIERA SECONDARIA
JOYSTICK
MAIN SWITCHES PANEL MAIN SWITCHES PANEL SECONDARY SWITCHES PANEL

XP1 S11 S10 XP2


1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 2 3 4 5 6 7 8 9 10 11 12

G/N1
R-N1

C-N1

G-R1

M-B1
G-N1

V-B1

V-N1

A-G1
R-G1

C-B1

S-N1

G-V1

A/V1
R/N1

R-V1
M-N1

L/R1
C/N1
M-N1
1.20
R-N1
1.20
L/R1
1.20

R1.5

R1.5
3.16

10 12 5 7 8 6 1 2 18 3 9 10 15 12 13 16 14 9 11 17

X4 X11 X4 X3 X3 X3 X3 X3 X3 X3 X4 X3 X3 X3 X3 X3 X3 X3 X3 X3

4.10
4.8 4.1
4.10
4.8

4.8
+15 +15 +15 OP +15 1
4.5

X13
F7A K9 F2C F2A F3A
86 87a 87
15A 7.5A 5A 7.5A

85 30

X5 X6 X6 X5 X6 X6 X6 X8 X8 X8 X8 X8 X8 X9 X8
4 2 8 1 13 12 11 15 7 20 8 19 6 21 18

G1

S1

A-V1
L/G1

G/N1
S-G1
Z-N1

G-N1

M1
C-L1
M-N1

M-V1
S14

R1 R1
3.13

S13 Y9 Y8 Y3 1 2 Y10 Y11 S15 Y7 S8 S9 S22


N1.5

p p
X19 X19
N1

N1

N1

N1

N1

N1

N1

N1

N1

N1
1.20 3.1

RKP10220

COMPONENTS CONNECTORS
K9 -
Stop light relay Y7 - Servocontrol solenoid valve X3 - Right lateral dashboard line 18 way X11 - Lateral dashboard line 3 way connec-
S8 -
Hammer pedal button Y8 - Hammer solenoid valve connector tor
S9 -
Pliers button Y9 - Grab solenoid valve X4 - Right lateral dashboard line 12 way X13 - Power 3 way connector
S10 -
Hammer button Y10 - Axle lock solenoid valve connector X19 - Optional pliers solenoid valve 2 way
S11 -
Joystick grab button Y11 - Parking brake solenoid valve X5 - Engine line 11 way connector connector
S13 -
Brake light switch FUSES X6 - Light switch-gear shift line 13 way con- XP1 - Switches panel 18 way connector
S15 -
Anti overturning pressure nector XP2 - Switches panel 12 way connector
F2A - Servocontrol valve fuse 5A
switch X8 - Loom line 21 way connector
F2C - Buttons relays fuse 7.5A
S22 - Brakes pressure switch X9 - Lights switch-gear shift line 21 way
F3A - Buttons relays fuse 7.5A
Y3 - Working brake solenoid valve connector
F7A - Stop light and heater 15A

PW75R-2 10-131
10-132
ELECTRICAL DIAGRAM (2WS) (3/5)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

SPIE DEVIO DEVIO LUCI G1


B C F 15/1 30/3 R/7 B C F 15/1 30/3 L/6
GEAR SHIFT LAMPS LIGHTS SWITCH 0
1
2 0 1 0
1
2 0 1

XD1

XD1

XD1

XD1

XD2

XD2

XD2

XD2

XD2

XD2

XD2

XD2

XD2

XD2

XD2

XD2
1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12
S3 A E S1 49/4 49a/5 L/6 S4 A E S2 49/4 30b/2 R/7

H1

V1

A1

B1
G-V1

G-L1

L-N1

A-B1

A-N1

A-N1.5
H-L1
C-B1
R1.5
2.20

A-V1
1.20

A-N1.5
1.20

R1

A1
V1.5

H1.5

L1.5
B-G1

H-R1

A-B1

S-G1

A-N1

B/R1

G1.5

B1.5
C-V1.5

A-R1.5
8 11 6 16 15 10 10 5 3 14 18 2 9 7 6 17 6 12 1 3 8 11 13 2 4 1

X9 X9 X9 X9 X9 X9 X11 X11 X4 X9 X9 X9 X11 X11 X11 X9 X4 X9 X4 X11 X11 X11 X11 X11 X11 X11

+15
1.20 4.1

F5A F5C
3A 10A

+30
+15 +30 +15
K5 86 87a 87 K6 86 87a 87 K10
+15
F3C F5B F4A F7B F6C F6B +

7.5A 15A 15A 85 30 85 30 10A 10A 7.5A F7C


C R
4.10
10A

4.5

4.5 1.20
1.20

27
4.15 4.10 4.1

X8 X8 X8 X8 X8 X8 X8 X8 X8 X8 X6 X6 X9 X6 X5 X5 X5 X6 X6 X10 X10
10 4 21 11 1 2 12 17 14 16 5 7 1 10 6 8 9 7 9 1 1 4
B1

S1

R1

G1

A1
A/V1

B1.5

A-B1

B1.5

G1.5

H1.5
M-V1

G-R1

G-R1

A-B1
M1.5

M1.5
G-N1.5

C-V1.5

A-R1.5
G1

A1

R1
1 3 2 1 4 6

X29

X29

X29

X24

X24

X24
1 2 1 2 5 4 1 2 3 6 8 7

X32

X32

X33

X33

X18

X18

X18

X18

X18
H7
H2 H3 H4 H5
56a

56b

57

56a

56b

57

57

59c

57

59c
Y12 Y4 Y5 S18 S19 1 2 H1 H6 H10 H8
5 5 5 5 5 5 5 M3 M M
X31

X31

p p
31

31

31

31
X32 X33
3 3 R1
2.20
N1

N1

N1

N1

N1

N1

N1
N1.5

N1.5

N1.5

N1.5

N1.5
2.20 4.1

COMPONENTS FUSES CONNECTORS RKP10290

G1 - Battery K10 - Flasher unit F3C -


Radio and cabin power fuse 7.5A X4 - Right lateral dashboard line 12 way X18 -
Rear line 8 way connector
H1 - Working light M3 - Heater motor F4A Main beam fuse 15A - connector X24 -
Cabin 7 way connector
H10 - Number plate lamp S1 - Hazard F5A -
Left traffic light fuse 3A X5 - Engine line 11 way connector X29 -
Heater 4 way connector
H2 - Front right light S2 - Rotating lamp switch F5B Low beam fuse 15A - X6 - Lights switch-gear shift line 13 way X31 -
Radio 2 way connector
H3 - Front left light S3 - Working light switch F5C -
Lights switch power fuse 10A connector X32 -
Right front light 3 way connector
H4 - Rear left light S4 - Blower motor switch F6B -
Direction indicators power X8 - Loom line 21 way connector X33 -
Left front light 3 way connector
H5 - Rear right light S18 - 1st rotation pressure switch fuse 7.5A X9 - Lights switch-gear shift line 21 way XD1 -
Gear shift warning light 4 way
H6 - Number plate lamp S19 - 2nd rotation pressure switch F6C - Hazard power fuse 10A connector connector
H7 - Beacom lamp Y4 - High speed solenoid valve F7B - Working lights fuse 10A X10 - Cabin line 5 way connector XD2 - Lights switch 12 way connector
H8 - Working light Y5 - Rotation solenoid valve F7C - Cabin power (+15) and beacon X11 - Lateral dashboard line 13 way
K5 - Main beam relay Y12 - Slow speed valve fuse 10A connector
K6 - Low beam relay

PW75R-2 10-133
10-134
ELECTRICAL DIAGRAM (2WS) (4/5)

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

DEVIO GUIDA CENTRALINA CONTROLLO STERZATURA


GEAR SHIFT STEERING CONTROL UNIT

XD3

XD3

XD3

XD3

XD3

XD3

XD3

XD3

X21

X21

X21

X21

X21

X21

X21

X22

X22

X22

X22

X22

X22

X22

X22

X22

X22

X22

X22

X22

X23

X23

X23

X23

X23

X23

X23

X23

X23
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 1 2 3 4 5 6 7 8 9 10 11 12 13 1 2 3 4 5 6 7 8 9

C-L1

R-V1

B-R1
B1

H1

C1

R1

V1
S1.5
H/R1

S-N1

N1.5
B-G1

B-G1

B-N1

V-B1

Z-B1

A/V1
R-G1

C-N1

S-N1

M-V1

G-R1

G-V1

M-B1

R/N1

R-N1
H-N1.5
H/R1
1.20
H-N1.5
1.20
R-G1 Z-B1
1.20 1.20
M-B1
1.20

2 7 7 4 5 15 5 4 21 9 2 13 3 8 1 1 3 10 20 6 12 19 17 18 11

X1 X9 X7 X9 X9 X7 X1 X1 X7 X7 X7 X7 X7 X7 X7 X7 X7 X7 X7 X7 X7 X7 X7 X7 X7

2.13 2.7 2.7 3.4


+15 +15
3.3 2.7 3.5
F1C F1A
3.3 2.7 2.15
3A 7.5A
2.16

3.4
3.6

3.19

X10 X10
A1

H1

S1

V1

R1
V-B1

G-R1

R/N1

R-N1

R-V1
A-N1
1.20
2 3
9 8 13 10 12 11 6 2 3 5 7 1 4 2 3 4

X26

X26

X26
XG XG XG XG XG XG XG XG XG XG XG

GIUNTO

Z1

B1
C/B1
JOINT
B-R1

3 1 2 4
C1

X25 X25 X26 X25 X25 X25 X25 X25 X25 X25 X25 X25 X25

X27

X27

X27

X27
9 8 1 10 12 11 6 2 3 5 7 1 4

S1

S1
L1

H1
A/V1

3 2 5

X24 X24 X24

N1
S12
H9
M4
1

M Y26 Y25 SENSORE DI


MOVIMENTO
MOVEMENT
SENSOR
N1.5

N2.5
N1

N1

N1

N1

N1

N1
3.20

RKP10300
COMPONENTS FUSES CONNECTORS
H9 - Cabin lamp F1A - Steering valves fuse 7.5A X1 - Interface line 5 way connector X23 - Steering unit 9 way connector
M4 - Washer motor F1C - Proximity and steering unit X7 - Steering interface line 21 way con- X24 - Cabin 7 way connector
S12 - Speed connection micro- power fuse 3A nector X25 - Inferior cart line 12 way connector
switch X9 - Lights switch-gear shift line 21 way X26 - Inferior cart line 4 way connector
Y25 - Engine power change so- connector X27 - Optional 4 way connector
lenoid valve X10 - Cabin line 5 way connector XD3 - Gear shift 8 way connector
Y26 - Bracket solenoid valve X21 - Steering unit 7 way connector XG - Joint 17 way connector
X22 - Steering unit 13 way connector

PW75R-2 10-135
10-136
ELECTRICAL DIAGRAM (2WS) (5/5)

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

57/58 SX DX WARNING ABBAGL.


CMV MI MA ML MV LENTA VELOCE
DX 0 0
MV M M

SX
ML

56a 56b 30 L -
+ + -

DEVIO LUCI DEVIO GUIDA

LIGHTS SWITCH GEAR SHIFT

RKP10310

PW75R-2 10-137
10-138
ELECTRICAL DIAGRAM (4WS) (1/5)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

M-B1 M-B1
STRUMENTO MULTIFUNZIONALE 4.1
R-G1 R-G1
R1 ACC BR R2 C
MULTIFUNCTION INSTRUMENT 4.1

OFF ACC H/R1 H/R1


R1 ST 4.1
XS XS XS XS XS XS XS XS XS XS XS XS XS XS XS XS H-N1.5 H-N1.5
4.1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
B M-N1 M-N1

G1

S1
A-V1

G/R1

H-L1
S6 2.1

HA5 Z-B1

V/B1
G4

V1
A2.5

Z-B1

Z/B1
M-V1

H/R1

R-V1
MANIPOLATORE 4.14
JOYSTICK A-V1
XC 1 G1 S7 3.1

A-V1
Z-B1
H-N1
BUZZER
R4

R-N1
2.1

L/R1
2.1

5 16 7 19 20 4 9 5 11 4 8 2 12 4

X7 X7 X4 X9 X9 X7 X9 X3 X4 X3 X4 X11 X4 X4
3.15
X16

X17
X17

X16

X17

X17

X17

X17

X17

X17

X17
+30 +15 F1B F4B F2B +15
1 7.5A 3A 3A
5 8 2 9 6 3 1 2 7 4

G4

M1

V1
V-B1

L/R1

H-N1
3.9

3.4

K4 K8
86 87a 87 86 87a 87

85 30 85 30
R4

R6

1
KT1
86 87a 87 X12
L/R1 +15
K1 86 87a 87 K2 86 87a 87 K3 86 87a 87
B-N1
B-R1

Z-B1

Z-N1

+30
85 30
F4C F3B F6A

R-N1.5
85 30 85 30 85 30
R6 5A 7.5A 15A

R4

L-R1
K01 K03 M-N1 K02
FUG2 FUG4 FUG1 FUG3 85 87 86 87 86 87
50A 40A 30A 60A

86 30 85 30 85 30

X5 X5 X5 X5 X6 X6 X8 X6 X9 X8 X9 X8 X7
A2.5 10 5 11 3 3 6 9 4 3 3 13 13 14

A-N1
H2.5
A-N1
4.6
G4

R4
R10

R2.5 A-N1.5
3.1

H-R1

B-N1

A-G1
H-G1.5

H-G1.5

A-N1.5

B-R1.5
M6

3 2 2
R50
XAM

XAM
XA
XA

10 X20
1
M1 G2 S1
X18 M2
G1 50 R1 XW R3 R4 HA4

1
30 D+
Y0 S16 S17 S20 S21
ALTERNATORE

M 30
G W Y2 Y1 X1 M S5
Y6 p p p
12Vcc 3 t
U
CANDELETTE t

B-G1
BATTERIA 31

XAM 2
X18 X20
1 9 1
N1

N1

N1

N1

N1

N1

N1

N1

N1

N1

N1

N1
N50

N1.5

N1.5

N1.5
2.1

RKP10320
COMPONENTS
G1 - Battery M1 - Starting motor Y0 - Fuel shut off solenoid valve F4C - Generator and timers (preheating and X4 - Right lateral dashboard line 12 way X16 - Power 3 way connector
G2 - Generator M2 - Pliers Y1 - Reverse speed solenoid valve start) fuses 5A connector X17 - Lateral dashboard 9 may con-
HA4 - Horn R1 - Heating start Y2 - Forward speed solenoid valve F6A - Pliers valve - horn - current intake - X5 - Engine line 11 way connector nector
HA5 - Buzzer R3 - Engine water temperature sender Y6 - Working mode solenoid valve solenoid valve fuse 15A X6 - Lights switch-gear shift line 13 way X18 - Rear line 8 way connector
K01 - Starter relay R4 - Fuel level sender FUG1 - Fuel shut off fuse 30 A connector X20 - Transfer pump 2 way connector
K02 - Fuel shut off relay S5 - Transfer pump sensor FUSES FUG2 - General fuse 50A X7 - Steering interface line 21 way con- XA - Generator 2 way connector
K03 - Preheating relay S6 - Starting switch F1B - Gear valve fuse 7.5A FUG3 - Generator fuse 60A nector XAM - Fuel shut off 3 way connector
K1 - Forward speed valve relay S7 - Joystick horn button F2B - Joystick button-instrument power FUG4 - Preheating fuse 40A X8 - Loom line 21 way connector XC - 1 way connector
K2 - Reverse speed solenoid valve relay S16 - High water temperature switch fuse 3A CONNECTORS X9 - Lights switch-gear shift line 21 way XS - Multifunction instrument 16 way
K3 - Speed connection relay S17 - Air filter switch F3B - Safety start - fuel shut off fuse 7.5A connector connector
K4 - Key safety start relay S20 - Engine oil low pressure switch F4B - Right traffic light and instrument X3 - Right lateral dashboard line 18 way X11 - Lateral dashboard line 13 way con- XW - Economy power valve 2 way con-
K8 - Horn relay S21 - Brakes pressure switch light fuse 3A connector nector nector
KT1 - Preheating timer X1 - Current intake X12 - Diode 2 way connector

PW75R-2 10-139
10-140
ELECTRICAL DIAGRAM (4WS) (2/5)

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

PULSANTIERA PRINCIPALE MANIPOLATORE PULSANTIERA SECONDARIA


JOYSTICK PULSANTIERA PRINCIPALE
MAIN SWITCHES PANEL MAIN SWITCHES PANEL SECONDARY SWITCHES PANEL

XP1

XP1

XP1

XP1

XP1

XP1

XP1

XP1

XP1

XP1

XP1

XP1

XP1

XP1

XP1

XP1

XP1

XP1

XP2

XP2

XP2

XP2

XP2

XP2

XP2

XP2

XP2

XP2

XP2

XP2
S11 S10
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 2 3 4 5 6 7 8 9 10 11 12

C/N1

R/N1

L/R1

V-B1

V-N1

A/V1
M-N1

R-N1

R-G1

C-B1

S-N1

C-N1

G-N1

G-V1

R-V1

G-R1

A-G1

M-B1

G/N1
M-N1
1.20
R-N1
1.20
L/R1
1.20

R1.5

R1.5
3.16

10 12 5 7 8 6 1 2 18 3 9 10 15 12 13 16 14 9 11 17

X4 X11 X4 X3 X3 X3 X3 X3 X3 X3 X4 X3 X3 X3 X3 X3 X3 X3 X3 X3

4.10
4.8 4.1
4.10
4.8

4.8
+15 +15 +15 OP +15 1
4.5

X13
F7A K9 86 87a 87 F2C F2A F3A
15A 7.5A 5A 7.5A

85 30

X5 X6 X6 X5 X6 X6 X6 X8 X8 X8 X8 X8 X8 X9 X8
4 2 8 1 13 12 11 15 7 20 8 19 6 21 18
R1

G1

S1

M1
Z-N1

C-L1

L/G1
M-N1

G-N1

A-V1

S-G1

M-V1

G/N1
S14

R1 R1
3.13

S13 Y9 Y8 Y3 1 2 Y10 Y11 S15 Y7 S8 S9 S22

X19

X19
p p
N1

N1

N1

N1

N1

N1

N1

N1

N1

N1
N1.5

1.20 3.1

RKP10330

COMPONENTS FUSES CONNECTORS


K9 - Stop light relay Y3 - Working brake solenoid valve F2A - Servocontrol valve X3 - Right lateral dashboard line 18 way X11 - Lateral dashboard line 13 way connec-
S8 - Hammer pedal button Y7 - Servocontrol solenoid valve fuse 5A connector tor
S9 - Pliers button Y8 - Hammer solenoid valve F2C - Buttons relays fuse X4 - Right lateral dashboard line 12 way X13 - Power 3 way connector
S10 - Hammer button Y9 - Grab solenoid valve 7.5A connector X19 - Optional pliers solenoid valve 2 way
S11 - Joystick grab button Y10 - Axle lock solenoid valve F3A - Buttons relays fuse X5 - Engine line 11 way connector connector
S13 - Brake light switch Y11 - Parking brake solenoid valve 7.5A X6 - Lights switch-gear shift line 13 way XP1 - Switches panel 18 way connector
S14 - Arm micro switch F7A - Stop light and heater connector XP2 - Switches panel 12 way connector
S15 - Anti overturning pressure switch 15A X8 - Loom line 21 way connector
S22 - Brakes pressure switch X9 - Lights switch-gear shift line 21 way
connector

PW75R-2 10-141
10-142
ELECTRICAL DIAGRAM (4WS) (3/5)

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

SPIE DEVIO DEVIO LUCI G1


B C F 15/1 30/3 R/7 B C F 15/1 30/3 L/6
GEAR SHIFT LAMPS LIGHTS SWITCH 0
1
2 0 1 0
1
2 0 1

XD2

XD2

XD2

XD2

XD2

XD2

XD2

XD2

XD2

XD2

XD2

XD2
XD1

XD1

XD1

XD1
A E 49/4 49a/5 L/6 A E 49/4 30b/2 R/7
1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 S3 S1 S4 S2

H1

V1

A1

B1
C-B1

G-V1

H-L1

G-L1

L-N1

A-B1

A-N1

A-N1.5
R1.5
2.20

A-V1
1.20

A-N1.5
1.20

R1

A1
V1.5

H1.5

L1.5
B-G1

G1.5

B1.5
H-R1

A-B1

A-N1

B/R1
S-G1

C-V1.5

A-R1.5
8 11 6 16 15 10 10 5 3 14 18 2 9 7 6 17 6 12 1 3 8 11 13 2 4 1

X9 X9 X9 X9 X9 X9 X11 X4 X9 X9 X9 X11 X11 X11 X9 X4 X9 X4 X11 X11 X11 X11 X4 X11 X11

+15
1.20 4.1

F5A F5C
3A 10A

+30
+15 +30 +15
K5 86 87a 87
K6 86 87a 87 K10
+15
F3C F5B F4A F7B F6C F6B +

7.5A 15A 15A 85 30 85 30 10A 10A 7.5A


C R F7C
4.10
10A

4.5

15
4.5 1.20
1.20

4.15 4.10 4.1

X8 X8 X8 X8 X8 X8 X8 X8 X6 X6 X9 X6 X5 X5 X5 X5 X6 X6 X10 X10
10 4 21 11 1 2 12 17 14 16 5 7 1 10 6 8 9 7 9 1 1 4
B1

S1

R1

G1

A1
A/V1

B1.5

M1.5

A-B1

B1.5

M1.5

H1.5
M-V1

G-R1

G-R1

A-B1

G1.5
G-N1.5

C-V1.5

A-R1.5
A1

R1
G1
1 3 2 1 4 6

X29

X29

X29

X24

X24

X24
1 2 1 2 5 4 1 2 3 6 8 7

X32

X32

X33

X33

X18

X18

X18

X18

X18

X18

X18

X18
H7
H2 H3 H4 H5
M3
56a

56b

56a

56b

59c

59c
57

57

57

57
Y12 Y4 Y5 S18 S19 H6 H10
R

R
H1 H8

L
1 2 M
M
X31

X31

p p
31

31

31

31
X32 X33
3 3
R1
N1

N1

N1

N1

N1

N1

N1
N1.5

N1.5

N1.5

N1.5

N1.5
2.20

2.20 4.1

COMPONENTS FUSES CONNECTORS RKP10340


G1 - Battery K10 - Flasher unit F3C - Radio and cabin power fuse 7.5A X4 - Right lateral dashboard line 12 way X18 -
Rear line 8 way connector
H1 - Working light M3 - Heater motor F4A - Main beam fuse 15A connector X24 -
Cabin 7 way connector
H2 - Front right light S1 - Hazard F5A - Left traffic light fuse 3A X5 - Engine line 11 way connector X29 -
Heater 4 way connector
H3 - Front left light S2 - Rotating lamp switch F5B - Low beam fuse 15A X6 - Lights switch-gear shift line 13 way X31 -
Radio 2 way connector
H4 - Rear left light S3 - Working light switch F5C - Light switch power fuse 10A connector X32 -
Right front light 3 way connector
H5 - Rear right light S4 - Blower motor switch F6B - Direction indicators power fuse 7.5A X8 - Loom line 21 way connector X33 -
Left front light 3 way connector
H6 - Number plate lamp S18 - 1st rotation pressure switch F6C - Hazard power fuse 10A X9 - Lights switch-gear shift line 21 way XD1 -
Gear shift warning light 4 way
H7 - Beacom lamp S19 - 2nd rotation pressure switch F7B - Working lights fuse 10A connector connector
H8 - Working light Y4 - High speed solenoid valve F7C - Cabin power (+15) and beacon X10 - Cabin line 5 way connector XD2 - Lights switch 12 way connector
H10 - Number plate lamp Y5 - Rotation solenoid valve fuse 10A X11 - Lateral dashboard line 13 way
K5 - Main beam relay Y12 - Slow speed valve connector
K6 - Low beam relay

PW75R-2 10-143
10-144
ELECTRICAL DIAGRAM (4WS) (4/5)

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

DEVIO GUIDA CENTRALINA CONTROLLO STERZATURA


GEAR SHIFT STEERING CONTROL UNIT

XD3

XD3

XD3

XD3

XD3

XD3

XD3

XD3

X21

X21

X21

X21

X21

X21

X21

X22

X22

X22

X22

X22

X22

X22

X22

X22

X22

X22

X22

X22

X23

X23

X23

X23

X23

X23

X23

X23

X23
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 1 2 3 4 5 6 7 8 9 10 11 12 13 1 2 3 4 5 6 7 8 9

B1

H1

C1

R1

V1
S1.5
H/R1

S-N1

B-G1

B-G1

C-L1

V-B1

G-V1

Z-B1

A/V1
R-G1

B-N1

C-N1

S-N1

M-V1

G-R1

M-B1

R/N1

R-N1

R-V1

B-R1
N1.5
H-N1.5
H/R1
1.20
H-N1.5
1.20
R-G1 Z-B1
1.20 1.20
M-B1
1.20

2 7 7 4 5 15 5 4 21 9 2 13 3 8 1 1 3 10 20 6 12 19 17 18 11

X1 X9 X7 X9 X9 X7 X1 X1 X7 X7 X7 X7 X7 X7 X7 X1 X1 X7 X7 X7 X7 X7 X7 X7 X7

2.13 2.7 2.7 3.4 +15 +15

3.3 2.7 3.5


F1C F1A
3.3 2.7 2.15
3A 7.5A
2.16

3.4
3.6

3.19

X10 X10
A1

H1

S1

V1

R1
V-B1

G-R1

R/N1

R-N1

R-V1
A-N1
2 3 1.20

9 8 13 10 12 11 6 2 3 5 7 1 4 2 3 4

X26

X26

X26
XG XG XG XG XG XG XG XG XG XG XG XG XG

GIUNTO

Z1

B1
C/B1
JOINT
3 1 2 4

X25

X25
X25

X25
C1

B-R1

X25 X25 X26 X25 X25 X25 X25 X25 X25

X27

X27

X27

X27
R1
9 8 1 10 12 11 6 2 3 5 7 1 4

V-B1

G-R1
3 2 5
L1

H1

S1

S1

V1
A/V1

R/N1

R-V1
R-N1
C B A C B A
X24 X24 X24 S12

X28

X28

X28

X30

X30

X30
H9
M4

L1

L1
M1

N1

M1
N1
M Y26 Y25 SENSORE DI Y21 Y22 Y24 Y23
MOVIMENTO SENSORE PONTE SENSORE PONTE
MOVEMENT ANTERIORE POSTERIORE
SENSOR FRONT AXLE REAR AXLE
SENSOR SENSOR
N1

N1

N1

N1

N1

N1

N1

N1

N1

N1

N1

N1
N1.5

N2.5

3.20

COMPONENTS FUSES CONNECTORS RKP10350

H9 -
Cabin lamp F1A - Steering valves fuse 7.5A X1 - Interface line 5 way connector X23 - Steering unit 9 way connector
M4 -
Washer motor F1C - Proximity and steering unit power X7 - Steering interface line 21 way X24 - Cabin 7 way connector
S12 -
Speed connection microswitch fuse 3A connector X25 - Inferior cart line 12 way connector
Y21 -
2W steering solenoid valve X9 - Lights switch-gear shift line 21 way X26 - Inferior cart line 4 way connector
Y22 -
Double steering solenoid valve connector X27 - Optional 4 way connector
Y23 -
Round steering solenoid valve X10 - Cabin line 5 way connector X28 - Front axle sensor 3 way connector
Y24 -
Crab steering solenoid valve X21 - Steering unit 7 way connector X30 - Rear axle sensor 3 way connector
Y25 -
Engine power change solenoid X22 - Steering unit 13 way connector XD3 - Gear shift 8 way connector
valve XG - Joint 17 way connector
Y26 - Bracket solenoid valve

PW75R-2 10-145
10-146
ELECTRICAL DIAGRAM (4WS) (5/5)

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

57/58 SX DX WARNING ABBAGL.


CMV MI MA ML MV LENTA VELOCE
DX 0 0
MV MI MA

SX
- ML
-
56a 56b 30 L + +

DEVIO LUCI DEVIO GUIDA

LIGHTS SWITCH GEAR SHIFT

RKP10360

PW75R-2 10-147
10-148
TESTING AND ADJUSTMENTS

Normal or standard technical data . . . . .. . . . . .. . . . .. . . 2 Checking and regulating the pressure of the
Special tools . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 19 steering system. . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 45
Measuring the engine speed. . . . . . .. . . . .. . . . . .. . . . .. . 21 Checking leakages in the steering cylinders . . .. . . . 46
Adjusting valve clearance . . . .. . . . . .. . . . .. . . . . .. . . . .. . 22 Checking the braking system . . .. . . . . .. . . . . .. . . . .. . . . 47
Measuring compression pressure .. . . . .. . . . . .. . . . .. . 23 Adjusting braking disks clearance . . . .. . . . . .. . . . .. . . . 52
Testing and adjusting fuel injection timing . .. . . . .. . 24 Checking wear in the brake disks . . . .. . . . . .. . . . .. . . . 52
Testing and adjusting fan belt tension .. . . . . .. . . . .. . 26 Bleeding air from the brake lines . . . . .. . . . . .. . . . .. . . . 53
Adjusting the stroke of the accelerator lever . . . . .. . 27 Adjusting the parking brake . . . . .. . . . . .. . . . . .. . . . .. . . . 54
Adjusting ppc valves clearance. . . .. . . . .. . . . . .. . . . .. . 28 Travel hydraulic equipment checking procedure . . . 55
Adjusting the safety microswitch . .. . . . .. . . . . .. . . . .. . 29 Checking and adjusting the automatic
Measuring the swing circle axial clearance. .. . . . .. . 30 displacement control system of the travel motor . . . 56
Air bleeding from hydraulic circuits . . . .. . . . . .. . . . .. . 31 Checking for leakages in the travel motor . . . . . .. . . . 57
Releasing residual pressure .. . . . . .. . . . .. . . . . .. . . . .. . 34 Checking and adjusting the speed of the travel
propeller shaft . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 58
Checking and regulating pressure in the
hydraulic circuits . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 35 Adjustment of the speed surveyor . . . .. . . . . .. . . . .. . . . 59
Testing and setting of main valves . . . . .. . . . . .. . . . .. . 36 Adjusting boom and arm safety valves. . . . .. . . . .. . . . 60
Adjusting pc valve .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 38 Adjusting 2nd boom safety valves. . . . .. . . . . .. . . . .. . . . 61
Measuring ls differential pressure Measuring and setting of pressure switch signal
and adjusting ls valve . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 39 overload operation . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 62
Checking and adjusting pressures in the Measurement of internal oil leakages
servocontrol feed unit. . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 41 in the swing motor . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 63
Measuring pumps delivery and flow Checking for leakages inside the swivel joint. . .. . . . 64
control starting point pump p1 . . . . .. . . . .. . . . . .. . . . .. . 42 Analysis of the causes of hydraulic drifts . .. . . . .. . . . 67
Checking that the priority valve is functioning
correctly . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 44

When carrying out controls, adjustments or analyses for troubleshooting, park the machine on firm, level
ground. Apply all the machine safety devices and use blocks to prevent any machine movement.
When more than one person is engaged in the work, use the prescribed notices that indicate that the machine
is undergoing maintenance. Do not allow any unauthorised persons to remain in the vicinity.
When checking the level of the cooling liquid, wait until this liquid has cooled. If the radiator cap is removed
while the liquid is still hot and under pressure, it may cause severe burns.
Take great care not to get entangled in moving parts (fan, alternator belt or any of the rotating elements).

PW75R-2 20-1
NORMAL OR STANDARD TECHNICAL DATA
. FOR ENGINE
Machine model PW75R-2

Engine 4D98E-1FB

Check item Test Conditions Unit Standard Permissible


value value

High idling rpm 2470 2470w50


Engine speed Low idling rpm 1000 1000 50
Set speed rpm 2300 Ð

Sudden acceleration Index 0.9 1.5


Exhaust gas colour Bosch 1.8
At high idling speed 0.5

Intake valve (20ëC) mm 0.20 Ð


Valve clearance
Exhaust valve (20ëC) mm 0.20 Ð

Compression Oil temperature 69 ± 72ëC kg/cm2 35w1 28w1


pressure
(SAE30 oil) (Engine speed) rpm 250 250

Blow-by Water temperature in


operating range Ð Ð
pressure mm H2O
(SAE30 oil) Ð Ð
At high idling speed

Max. idling (in cold state) kg/cm2 max. 6 Ð


Engine oil With water temperature in operating range
pressure High idling kg/cm2 3±4 Ð
At low idling kg/cm2 min. 0.6 Ð

Oil temperature Entire speed range ëC 120 Max. 120

Fuel injection timing B.T.D.C. degrees 10 ± 12 Ð

Fan-belt tension Deflection when pressed mm 10 ± 15 Ð


with finger force of approx. 10 kg

20-2 PW75R-2
. FOR MACHINE
All tests, if not otherwise specified, should be performed with WORKING MODE in position P

Machine model PW75R-2


Classifi- Check item Test conditions Unit Standard Permissible
cation value value

Engine speed with


pump P1 2296 2296w50
at max. pressure
. Hydraulic oil temp.: 45 ± 55ëC
Engine speed with . Engine oil pressure: in correct range
pump P1 and P2 . Cooling water temp.: in correct range 2285 2285w50
at max. pressure . Swing lock pin inserted
Engine

. Max. pressure P1: with boom rpm


Engine speed with
pump P2 . Max. pressure P1-P2: with boom and 2300 2300w50
at max. pressure swing boom
. Max. pressure P2: with arm and
Engine speed when pumps swing boom
P1-P2 are at max. pressure 2250 2250w50
and the WORKING MODE
selector is in pos. E
Boom , a b , a b

Arm ᐉ
a b
Bucket
Swing
Spool travel

Blade-outriggers mm
45 6.5w0.3 6.5w0.3 45 6.5w0.3 6.5w0.3
Boom swing
2nd boom
RKP08070

Travel
Attachment
. At centre of Raise
Boom control lever lever knob
Neutral Lower 80 60 ± 100
. Reading at
end of travel Neutral Extended
Arm control lever Retracted 80 60 ± 100
. Engine
stopped Open
Bucket control lever . Equipment on Neutral Curled 80 601 ± 100
the ground
Travel of levers and pedals

Swing right
Swing control lever Neutral Swing left 80 60 ± 100

Blade outriggers Neutral


Raise
90 68 ± 112
control lever Lower mm
Fuel control lever Min. Max. 150 130 ± 170
Swing
Boom swing pedal Neutral right 20 15 ± 25
Swing left

Open
2nd boom pedal Neutral Closed 30 25 ± 35

Travel control pedal Neutral Max. 60 50 ± 70

Brakes pedal Zero Max. 30 25 ± 35

PW75R-2 20-3
. FOR MACHINE

Machine model PW75R-2


Classifi- Check item Test conditions Unit Standard Permissible
cation value value

Raise boom . Engine speed: high idling 2.0 1.8 ± 2.2


Operating force for control of levers and pedals

. Oil temperature: 45 ± 55ëC


Lower boom . Instrument coupling at centre 2.0 1.8 ± 2.2
of control lever knob
Bucket curled-open . Instrument coupling on outside 1.5 1.1 ± 1.9
edge of pedal control
Arm open-close 2.0 1.8 ± 2.2
Swing (R.H.-L.H.) 1.5 1.1 ± 1.9
Blade control and outriggers kg 1.2 1.0 ± 1.4
Fuel control lever 3.0 2.5 ± 3.5
Boom swing pedal 10 9.0 ± 11
nd
2 boom pedal 10 9.0 ± 11
Travel pedal . A 150 mm
4w0.5 3.5 ± 4.5
from fulcrum
Brake pedal 50 2 50 2

P1 pump (Safety) 300 7

. Engine speed: max.


Main valve
pressure

P2 pump (Safety) . Oil temperature: 45 ± 55ëC kg/cm2 300 7


. Check one circuit at a time
Servocontrols (Safety) 38/50 w3

Raise 270 7
Boom
Lower 270 7

Arm . Engine speed: max. 270 7


. Oil temperature: 45 ± 55ëC
Bucket . Check one circuit at a time 270 7

Swing 220 7

Blade 220 7

Outriggers (R.H. side) 220 7

Outriggers (L.H. side) 270 7


Hydraulic pressure

Boom swing 270 7


kg/cm2
nd
2 boom 270 7

Travel 270 7

Servocontrols 32 3.5 28.5 ± 32

. Engine: . Levers at NEUTRAL 25 ± 40 Ð


high idling
LS differential pressure
. Oil temperature: . Travel speed: Hi
21.5w1 Ð
45 ± 55ëC . Wheels: raised

. Engine speed: low idling


Steering 170 5 168 ± 177
. Oil temperature: 45 ± 55ëC
. Engine speed: low idling
Braking 70 1 69 ± 72
. Oil temperature: 45 ± 55ëC

20-4 PW75R-2
. FOR MACHINE

Machine model PW75R-2

Classifi- Check item Test conditions Unit Standard Permissible


cation value value

Work equipment at max. reach

Braking angle RKP06000 Degrees Max. 60ë Max. 90ë


(mm) (400) (600)
. Load in the bucket: 475 kg
. Engine speed: high idling.
. Oil temperature: 45 ± 55ëC
. Make centring marks on the outer swing
circle rings. Rotate the upper turret 360ë
and stop. Measure the difference between
the marks after stopping.

Working equipment at max. reach

90ë Ð Ð

Time taken to start swing sec

RKP06000

. Engine speed: high idling 180ë 5 Max. 5.5


. Oil temperature: 45 ± 55ëC
. Time taken also from starting posi-
Swing

tion at 90ë and 180ë.

Working equipment at max. reach

Time taken to swing sec 35 31 ± 39


RKP06000

. Engine speed: high idling


. Oil temperature: 45 ± 55ëC
. Make one turn to settle machine.
. Measure the time taken to make 5 full
swings.

15°

RKP06010

Hydraulic drift of swing Degrees 0 Ð


. Engine switched off (mm)
. Oil temperature: 45 ± 55ëC
. Brake disengaged (with specific tool)
. Park the machine on a 15ë slope and set
the boom at 90ë with respect to the ground
surface
. On the outer swing circle, mark the posi-
tion between turret and track frame.
. After 15 minutes measure the drift.

PW75R-2 20-5
. FOR MACHINE

Machine model PW75R-2

Classifi- Check item Test conditions Unit Standard Permissible


cation value value

. Engine speed: high idling


Swing

Internal leakage from swing . Oil temperature: 45 ± 55ëC


,/min 0 0
motor . Swing block: engaged
. Measure the leakage

20-6 PW75R-2
. FOR MACHINE

Machine model PW75R-2

Classifi- Check item Test conditions Unit Standard Permissible


cation value value

Work equipment at max. reach

For TUV approval


(20 km/h) (20 km/h)
2225 2175
(25 km/h) (25 km/h)
2780 2730
Travel speed (1) rpm
(without load) RKP06020

. Engine speed: 2000 rpm


. Oil temperature: 45 ± 55ëC
. Axle blocked

Normal
. Rest the front work equipment on
the ground and push it down to rai- 3590 Min. 3540
se the machine
. Measure the speed of the propeller
shaft in 2nd fast gear.

Work equipment at max. reach

For TUV approval


45°
18 16 ± 20

Working travel speed (2) sec

RKP06030
. On road travel configuration
. Engine speed: high idling
Travel

.
Normal

Oil temperature: 45 ± 55ëC


. On flat ground 8 7±9
. 2nd fast gear
. Travel for at least 20 metres and
then check on the time needed to
cover 50 metres.

Work equipment at max. reach

Hydraulic drift mm 0 0
of travel motor
15°

RKP06040

. Engine switched off


. Oil temperature: 45 ± 55ëC
. After 1 minute, mark the position; measure
drift for every 5 minutes and then check to-
tal drift in 15 minutes.

PW75R-2 20-7
. FOR MACHINE

Machine model PW75R-2

Classifi- Check item Test conditions Unit Standard Permissible


cation value value

. Engine speed: 2000 rpm


Travel

Leakage from . Oil temperature: 45 ± 55ëC


travel motor . Working brakes: engaged ,/min Ð Ð
. 2nd fast gear engaged
. After 30 seconds start to measure for full
minute

20-8 PW75R-2
. FOR MACHINE

Machine model PW75R-2


Classifi- Check item Test conditions Unit Standard Permissible
cation value value
Measuring posture
Boom
Total work equipment A 400 450
(Standard boom)
(Downward movement
bucket teeth tips) A Boom
B
B 400 90

RKP06050 Boom
A 75 100
. In this position, measure exten-
Boom cylinder sion or retraction of each cylinder,
(Retraction) and any leakages occurring when
a load is applied to the tips of the Boom mm
B 80 60
bucket teeth.
. Horizontal levelled ground
. Bucket: rated load (475 kg)
Boom
. Levers: neutral
A 50 75
Arm cylinder . Engine: switched off
(Extension) . Oil temperature: 45 ± 55ëC
. Safety valve disengaged Boom
B 60 40
. Take measurements as soon as
the engine stops
Hydraulic drift of working equipment

. Measure the variations every 5 mi-


Bucket cylinder nutes and check the total variation 30 800
(Retraction) after 15 mins.

Boom
Total work equipment Measuring posture 600 800
A
(Downward movement
of tips of bucket teeth)
(2-piece boom) Boom
B 600 800
A
B
Boom
A 80 100
RKP06060
Boom cylinder
(Retraction)
Boom
B 90 115
. In this position, measure extension
and retraction of each cylinder, and
any leakages when a load is ap- Boom mm
plied to the tips of the bucket teeth. A 60 75
nd
2 boom cylinders . Horizontal levelled ground
(Retraction) . Bucket: rated load (475 kg)
Boom
. Levers: neutral 75 100
B
. Engine: switched off
. Oil temperature: 45 ± 55ëC
. Safety valve disengaged Boom
A 50 60
. Take measurements as soon as
Arm cylinder the engine stops
(Extension) . Measure the variations every 5 mi-
nutes and check the total variation Boom
B 60 75
after 15 mins.

Bucket cylinder 30 40
(Retraction)

PW75R-2 20-9
. FOR MACHINE

Machine model PW75R-2


Classifi- Check item Test conditions Unit Standard Permissible
cation value value
A
B Boom
A 30 35
Boom swing
(Standard boom)
15° Boom
B 35 40
RKP06070 mm
. Engine: switched off
. Oil temperature: 45 ± 55ëC Boom
40 45
. In the same position as above, A
Boom swing park the machine on a 15ë slope
(boom) and bring the turret round to 90ë.
Measure the extension and retrac- Boom
B 45 50
tion of the cylinder after 15 mins.
Hydraulic drift of working equipment

Outriggers RKP06080
mm Max. 20 Max. 30

. Engine speed: high idling


. Oil temperature: 45 ± 55ëC
. Safety valve cut out
. Bring the outriggers to half stroke and
measure their height from the ground.
Measure the downward after 15 mins.

Blade
(measure the downward mm Max. 20 Max. 30
movement of the edge of RKP06090

the blade) . En