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
00-2-1 10-27 10-68 10-109 20-3
00-2-2 10-28 10-69 10-110 20-4
00-3 10-29 10-70 10-111 20-5
00-4 10-30 10-71 10-112 20-6
00-5 10-31 10-72 10-113 20-7
00-6 10-32 10-73 10-114 20-8
00-7 10-33 10-74 10-115 20-9
00-8 10-34 10-75 10-116 20-10
00-9 10-35 10-76 10-117 20-11
00-10 10-36 10-77 10-118 20-12
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00-12 10-38 10-79 10-120 20-14
00-13 10-39 10-80 10-121 20-15
00-14 10-40 10-81 10-122 20-16
10-41 10-82 10-123 20-17
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10-2 10-43 10-84 10-125 20-19
10-3 10-44 10-85 10-126 20-20
10-4 10-45 10-86 10-127 20-21
10-5 10-46 10-87 10-128 20-22
10-6 10-47 10-88 10-129 20-23
10-7 10-48 10-89 10-130 20-24
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10-9 10-50 10-91 10-132 20-26
10-10 10-51 10-92 10-133 20-27
10-11 10-52 10-93 10-134 20-28
10-12 10-53 10-94 10-135 20-29
10-13 10-54 10-95 10-136 20-30
10-14 10-55 10-96 10-137 20-31
10-15 10-56 10-97 10-138 20-32
10-16 10-57 10-98 10-139 20-33
10-17 10-58 10-99 10-140 20-34
10-18 10-59 10-100 10-141 20-35
10-19 10-60 10-101 10-142 20-36
10-20 10-61 10-102 10-143 20-37
10-21 10-62 10-103 10-144 20-38
10-22 10-63 10-104 10-145 20-39
10-23 10-64 10-105 10-146 20-40
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
Mark Page Mark Page Mark Page Mark Page Mark Page
revision revision revision revision revision

20-42 30-22 30-79 30-136 40-22

20-43 30-23 30-80 30-137 40-23
20-44 30-24 30-81 30-138 40-24
20-45 30-25 30-82 30-139 40-25
20-46 30-26 30-83 30-140 40-26
20-47 30-27 30-84 30-141 40-27
20-48 30-28 30-85 30-142 40-28
20-49 30-29 30-86 30-143 40-29
20-50 30-30 30-87 30-144 40-30
20-51 30-31 30-88 30-145 40-31
20-52 30-32 30-89 30-146 40-32
20-53 30-33 30-90 30-147 40-33
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20-56 30-36 30-93 30-150 40-36
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20-58 30-38 30-95 30-152 40-38
20-59 30-39 30-96 30-153 40-39
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20-61 30-41 30-98 30-155 40-41
20-62 30-42 30-99 30-156 40-42
20-63 30-43 30-100 30-157 40-43
20-64 30-44 30-101 30-158 40-44
20-65 30-45 30-102 30-159 40-45
20-66 30-46 30-103 30-160 40-46
20-67 30-47 30-104 30-161 40-47
20-68 30-48 30-105 30-162 40-48
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20-71 30-51 30-108 30-165 40-51
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20-73 30-53 30-110 30-167
20-74 30-54 30-111 30-168
20-75 30-55 30-112 30-169
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30-9 30-66 30-123 40-9
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30-12 30-69 30-126 40-12
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30-16 30-73 30-130 40-16
30-17 30-74 30-131 40-17
30-18 30-75 30-132 40-18
30-19 30-76 30-133 40-19
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
Mistakes in operation extremely dangerous.
Read all the Operation and Maintenance Manual care-
fully BEFORE operating the machine.
1. Before carrying out any greasing or repairs, read
all the precautions written on the decals which
are suck on the machine.
2. When carrying out any operation, always wear sa-
fety shoes and helmet. Do not wear loose work
clothes, or clothes with buttons missing.
. Always wear safety glasses when hitting parts
with a hammer.
. Always wear safety glasses when grinding
parts with a grinder, etc.
3. If welding repairs are needed, always have a trai-
ned, experienced welder carry out the work.
When carrying out welding work, always wear
welding gloves, apron, glasses, cap and other clo-
thes suited for welding work.
4. When carrying out any operation with two or more
workers, always agree on the operating procedure
before starting. Always inform your fellow workers
before starting any step of the operation. Before
starting work, hang UNDER REPAIR signs on
the controls in the operator's compartment.
5. Keep all tools in good condition and learn the cor-
rect way to use them.
6. Decide a place in the repair workshop to keep
tools and removed parts. Always keep the tools
and parts in their correct places. Always keep
the work area clean and make sure that there is
no dirt or oil on the floor.
Smoke only in the areas provided for smoking.
Never smoke while working.
PREPARATIONS FOR WORK
7. Before adding or making any repairs, park the ma-
chine on hard, level ground, and block the wheels
to prevent the machine from moving.
8. Before starting work, lower outrigger, bucket or
any other work equipment to the ground. If this
is not possible, use blocks to prevent the work
equipment from falling down. In addition, be sure
to lock all the control levers and hang warning
sign on them.
9. When disassembling or assembling, support the
machine with blocks, jacks or stands before star-
ting work.
10. Remove all mud and oil from the steps or other
places used to get on and off the machine. Always
use the handrails, ladders or steps when getting
on or off the machine.
Never jump on or off the machine.
If it is impossible to use the handrails, ladders or
steps, use a stand to provide safe footing.
PRECAUTIONS DURING WORK
11. When removing the oil filler cap, drain plug or hy-
draulic pressure measuring plugs, loosen them
slowly to prevent the oil from spurting out.
Before disconnecting or removing components of
the hydraulic circuit and engine cooling circuit,
first remove the pressure completely from the cir-
cuit.
12. The water and oil in the circuits are not hot when
the engine in stopped, so be careful not to get
burned.
Wait for the oil water to cool before carrying out
any work on the cooling water circuits.

PW75R-2 00-3
13. Before starting work, remove the leads from the
battery. Always remove the lead from the negative
( ± ) terminal first.
14. When raising heavy components, use a hoist or
crane. Check that the wire rope, chains and hooks
are free from damage.
Always use lifting equipment which has ample ca-
pacity. Install the lifting equipment at the correct
places.
Use a hoist or crane and operate slowly to prevent
the component from hitting any other part.
Do not work with any part still raised by the hoist
or crane.
15. When removing covers which are under internal
pressure or under pressure from a spring, always
leave two bolts in position on opposite sides.
Slowly release the pressure, then slowly loosen
the bolts to remove.
16. When removing components, be careful not to
break or damage the wiring.
Damage wiring may cause electrical fires.
17. When removing piping, stop the fuel or oil from
spilling out. If any fuel or oil drips on to the floor,
wipe it up immediately.
Fuel or oil on the floor can cause you to slip, or
can even start fires.
18. As a general rule, do not use gasoline to wash
parts. In particular, use only the minimum of gaso-
line when washing electrical parts.
00-4
19. Be sure to assemble all parts again in their origi-
nal places. Replace any damage parts with new
parts.
. When installing hoses and wires, be sure that
they will not be damaged by contact with other
parts when the machine is being operated.
20. When installing high pressure hoses, make sure
that they are not twisted. Damaged tubes are dan-
gerous, so be extremely careful when installing
tubes for high pressure circuits. Also, check that
connecting parts are correctly tightened.
21. When assembling or installing parts, always use
specified tightening torques.
When installing the parts which vibrate violently or
rotate at high speed, be particulary careful to
check that they are correctly installed.
22. When aligning two holes, never insert your fingers
or hand.
23. When measuring hydraulic pressure, check that
the measuring tool is correctly assembled before
taking any measurement.
24. Take sure when removing or installing tracks of in
particular rubber tracks. When removing the
track, the track separates suddenly, so never let
anyone stand at either end of the wheel.
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.
2. Wire ropes
1) Use adequate ropes depending on the weight
of parts to be hoisted, referring to the table be-
low:
3) Do not sling a heavy load with one rope alone,
but sling with two or more ropes symmetrically
wound on to the load.
Slinging with one rope may cause turning of
the load during hoisting, untwisting of the ro-
pe, or slipping of the rope from its original
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-
tion of the steering metering group (5) and prepares
the control valve (port R) to send oil through line e to
solenoid valve group and thence through line g, into
chamber a of the cylinder (10); the pressurized oil
moves the piston (12) which then steers the wheels.
The oil in chamber b of cylinder (10) is impelled into
line h and thence into line f which is coupled to the
control valve of the steering group (5) (port L); from
the control valve the oil passes out of Port T and
drains into the tank (3).
Turning the steering wheel (8) anti-clockwise causes
rotation of the steering metering group (5) and pre-
pares the control valve (port L) to send oil through
lines f and h directly into chamber b of the cylinder
(10); the pressurized oil moves the piston (12) which
then steers the wheels.
The oil in chamber a of cylinder (10) is impelled into
line g to solenoid valve group and thence into line e
which is coupled to the control valve of the steering
group (5) (port R); from the control valve the oil passes
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-
tion of the steering metering group (5) and prepares
the control valve (port R) to send oil (through line e)
to solenoid valve group and thence through line m into
chamber d of cylinder (11).
The pressurized oil moves the piston (13) of the cylin-
der (11) that steers the wheels and at the same time
impels the oil in chamber c (at the same pressure as
chamber d), through lines n and g into chamber a of
cylinder (10).
The oil in chamber b of cylinder (10) is impelled
through lines h and f to the control valve of the steer-
ing group (5) (port L), from which it passes (port T) to
drain into the tank (3).
Turning the steering wheel (6) anti-clockwise causes
rotation of the steering metering group (5) and pre-
pares the control valve (port L) to send oil through line
f directly to chamber b of cylinder (10).
The pressurized oil moves the piston (12) of cylinder
(10) which in turn steers the wheels while simulta-
neously impelling the oil in chamber a (at the same
pressure as chamber b, through lines g - n into cham-
ber c of cylinder (11).
The oil in chamber d of cylinder (11) is impelled
through lines m and e to the control valve of the steer-
ing group (port R) from which it passes (port T) to 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-
tion of the steering metering group (5) and prepares
the control valve (port R) to send oil (through line e)
to solenoid valve group and thence through line m into
chamber c of cylinder (11).
The pressurized oil moves the piston (13) of the cylin-
der (11) that steers the wheels while simultaneously
impelling the oil in chamber d (at the same pressure
as chamber c) through lines m and g into chamber a
of the cylinder (10).
The oil in chamber b of cylinder (10) is sent through
lines h and f to the control valve of the steering group
(5) (port L) from which the oil passes (port T) to drain
into the tank (3).
Turning the steering wheel (6) anti-clockwise causes
rotation of the steering metering group (5) and pre-
pares the control valve (port L) to send oil through
lines f and h into chamber b of cylinder (10).
The pressurized oil moves the piston (12) of cylinder
(10) which in turn steers the wheels while simulta-
neously impelling the oil in chamber a (at the same
pressure as chamber b) through lines g and m into
chamber d of cylinder (11).
The oil in chamber c of cylinder (11) is impelled
through lines n and e to the control valve of the steer-
ing group (5) (port R) from which it passes (port T) to
drain 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 cylinder block (7) is supported to the shaft (1)
by the spline a, and the shaft (1) is supported by
the front and rear bearings.
. Tip of the piston (6) is a concave ball, and shoe (5)
is caulked to it to form one unit. The piston (6) and
the shoe (5) form a spherical bearing.
. The rocker cam (4) has a flat surface A, and the
shoe (5) is always pressed against this surface
while sliding in a circular movement.
. The piston (6) carries out relative motion in the axial
direction inside each cylinder chamber of the cylin-
der block (7).
. The cylinder block (7) seals the pressure oil to the
valve plate (8), and carries out relative rotation.
This surface is so designed that the oil pressure
balance is maintained at a suitable level. And oil in-
side each cylinder of the cylinder block (7) is
sucked in and discharged through the valve plate
(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)
2. Suction valve (Bottom side)
3. Spool
4. Reducing pressure compensation valve
5. Flow compensation valve
6. Suction valve (Head side)
7. Suction valve (Bottom side)
8. Spool
9. Reducing pressure 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)
. 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) moves to the right ( ) side, so the pump
pressure PP introduced from the orifice c is de-
pressurized by the pressure loss at the notch d
and introduced to the LS circuit PLS, and then,
further introduced to the spring chamber PLS1.
. 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).
. Areas of the both ends of the pressure reducing
valve (3) are same (SA=SLS), and on the SA
side, the actuator circuit pressure PA (=A) is
acting, and on the opposite SLS side, the re-
duced pump pressure PP is acting.
. Therefore the pressure reducing valve (3) bal-
ances at the point where the actuator circuit
pressure PA and the spring chamber pressure
PLS1 are balanced, and the pump pressure PP
reduced by the notch d is introduced to the LS
circuit PLS as the actuator circuit pressure A.

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
of the other actuator side (right side) becomes high-
er, the flow in the actuator circuit A at this (left) side
tends to increase.
. In this case, the LS pressure PLS at the other actua-
tor acts on the spring chamber PLS1, and pushes
the pressure reducing valve (1) and the flow control
valve (2) to the left ( )side.
. The flow control valve (2) throttles the opening area
between the pump circuit PP and the upstream side
of the spool PPA, and generates a pressure loss in
between PP and PPA.
. The flow control valve and the pressure reducing
valve (1) are balanced at the point where the differ-
ential pressure between PA and PLS, which act on
the both end surfaces of the pressure reducing
valve (1), becomes equal to the pressure loss in be-
tween PP and PPA before and after the flow control
valve (2).
. By this operation, the differential pressures be-
tween the upstream pressure PPA and the down
stream pressure PA of both spools in the complex
operation are made same, and the pump flow is
distributed in proportion to the opening areas of
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
1 1
4
a
5
Section X X
Particolare
FUNCTION
. This device automatically varies the displacement
in function of the working pressure.
A displacement increase leads to a reduction in the
engine shaft rpm and an increase in the torque.
OPERATION
. The pressurized oil coming from the control valve
arrives through the brake valve (1) on the smaller
surface of the positioning piston (2), thus pushing
it towards the minimum displacement limit stop.
The smaller surface is connected hydraulically to
the pilot system bushing (4), which contains a mea-
suring piston with two different surfaces. The avail-
able pressure therefore acts in a differential man-
ner and, with the spring (6), causes the piston (5)
to perform the function of governing the pressure
flows.
. When delivery line pressure increases the mea-
surement piston (5) moves, compresses the spring
(6), and allows oil to pass through line a into cham-
ber b of the larger surface of the positioning piston
(2).
10-98
3
b
6
5
4
7
RKP04470
. The pressure moves the positioning piston (2)
which, because it is connected mechanically to
the engine cylinder, causes this to move and in-
crease the displacement.
The movement of the positioning piston (2) con-
tinues until equilibrium has been reached between
the delivery pressure acting on the smaller surface
of the piston and the pressure acting on the larger
surface. Once equilibrium has been reached the
spring (6) returns the measuring piston (5) to its
neutral position.
Maximum displacement is determined by the me-
chanical limit stop (7).
. When delivery line pressure diminishes there is no
longer equilibrium between the forces acting on the
positioning piston; the measuring piston moves,
and opens passage c to release the existing pres-
sure in chamber b.
Under this new pressure the positioning piston (2)
gradually returns to the minimum displacement po-
sition. The movement stops when a new equili-
brium is reached between the forces acting on
the measurement piston (5) and the positioning pis-
ton (2).
PW75R-2
TRAVEL MOTOR BRAKE VALVES
8 9 10 11 f 11
5
6
7 c
b a
FUNCTION
. The brake valves control loading in order to prevent
the cavitation phenomenon which occurs when the
rotation speed of the hydraulic motor exceeds the
speed determined by pump delivery through the
control valve.
. The brake valves are not a substitute for the ma-
chine duty brakes.
OPERATION
. Pressurized oil from the control valve enters line a
causing valve (1) to open, and acts through the pilot
system channel c the ring chamber d and valve (2)
to feed the piston motor.
The pilot system oil acts on the surface of piston (3)
and causes it to move to compress the spring (4)
while the throttles (5) control the passages to obtain
slow and regular piston movement.
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 9 2
5
3
4
RKP04550
. When the pressure in line a drops due to loading
changes or due to the movement of the controls,
there is an immediate reduction of pressure in the
spring housing e; pressure from the spring (4)
and residual pressure from the drainage lines
cause the piston (3) to return, leading to a reduction
in the amount of oil draining through the throttle (6),
and thus provoking an automatic braking action.
. Valves (2) and (8) protect the engine against both
pressure peaks and the cavitation phenomenon.
. When the pressure in line f exceeds the calibration
value of the spring (9), the pilot valve (10) opens to
eliminate pressure inside the main valves (11). The
pressure in line d acts on the outside of the main
valves (11) which causes them to open and allow
communication between their lines of delivery a
and drainage b.
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

COMPONENTS
H9 - Cabin lamp
M4 - Washer motor
S12 - Speed connection micro-
switch
Y25 - Engine power change so-
lenoid valve
Y26 - Bracket solenoid valve
RKP10300
FUSES CONNECTORS
F1A - Steering valves fuse 7.5A X1 - Interface line 5 way connector X23 - Steering unit 9 way connector
F1C - Proximity and steering unit X7 - Steering interface line 21 way con- X24 - Cabin 7 way connector
power fuse 3A nector X25 - Inferior cart line 12 way connector
X9 - Lights switch-gear shift line 21 way X26 - Inferior cart line 4 way connector
connector X27 - Optional 4 way connector
X10 - Cabin line 5 way connector XD3 - Gear shift 8 way connector
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
Special tools . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 19
Measuring the engine speed. . . . . . .. . . . .. . . . . .. . . . .. . 21
Adjusting valve clearance . . . .. . . . . .. . . . .. . . . . .. . . . .. . 22
Measuring compression pressure .. . . . .. . . . . .. . . . .. . 23
Testing and adjusting fuel injection timing . .. . . . .. . 24
Testing and adjusting fan belt tension .. . . . . .. . . . .. . 26
Adjusting the stroke of the accelerator lever . . . . .. . 27
Adjusting ppc valves clearance. . . .. . . . .. . . . . .. . . . .. . 28
Adjusting the safety microswitch . .. . . . .. . . . . .. . . . .. . 29
Measuring the swing circle axial clearance. .. . . . .. . 30
Air bleeding from hydraulic circuits . . . .. . . . . .. . . . .. . 31
Releasing residual pressure .. . . . . .. . . . .. . . . . .. . . . .. . 34
Checking and regulating pressure in the
hydraulic circuits . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 35
Testing and setting of main valves . . . . .. . . . . .. . . . .. . 36
Adjusting pc valve .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 38
Measuring ls differential pressure
and adjusting ls valve . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 39
Checking and adjusting pressures in the
servocontrol feed unit. . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 41
Measuring pumps delivery and flow
control starting point pump p1 . . . . .. . . . .. . . . . .. . . . .. . 42
Checking that the priority valve is functioning
correctly . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 44
Checking and regulating the pressure of the
steering system. . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 45
Checking leakages in the steering cylinders . . .. . . . 46
Checking the braking system . . .. . . . . .. . . . . .. . . . .. . . . 47
Adjusting braking disks clearance . . . .. . . . . .. . . . .. . . . 52
Checking wear in the brake disks . . . .. . . . . .. . . . .. . . . 52
Bleeding air from the brake lines . . . . .. . . . . .. . . . .. . . . 53
Adjusting the parking brake . . . . .. . . . . .. . . . . .. . . . .. . . . 54
Travel hydraulic equipment checking procedure . . . 55
Checking and adjusting the automatic
displacement control system of the travel motor . . . 56
Checking for leakages in the travel motor . . . . . .. . . . 57
Checking and adjusting the speed of the travel
propeller shaft . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 58
Adjustment of the speed surveyor . . . .. . . . . .. . . . .. . . . 59
Adjusting boom and arm safety valves. . . . .. . . . .. . . . 60
Adjusting 2nd boom safety valves. . . . .. . . . . .. . . . .. . . . 61
Measuring and setting of pressure switch signal
overload operation . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 62
Measurement of internal oil leakages
in the swing motor . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 63
Checking for leakages inside the swivel joint. . .. . . . 64
Analysis of the causes of hydraulic drifts . .. . . . .. . . . 67

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) . Engine: switched off

. Oil temperature: 45 ± 55ëC
. Safety valve disengaged
. Raise the blade and measure the height of
the edge from the ground.
Measure the downward after 15 mins.
H Check one cylinder at a time.

Boom Max. 3.5 Max. 12

2nd boom Max. 2.2 Max. 8.0

Internal cylinder leankage

(2 cylinders) (each cylinder)

. Engine speed: high idling
Arm . Oil temperature: 45 ± 55ëC Max. 2.5 Max. 12
. Check leakages: on the cylinder on the si-
de opposite to the one under pressure
cc/
Bucket min Max. 2.2 Max. 8.0
H Check one cylinder at a time
Boom swing H For the 2-piece boom check the two cylin- Max. 2.5 Max. 10
ders individually but simultaneously.
Blade - outriggers Max. 3.5 Max. 15
(each cylinder)

Steering Max. 1.5 Max. 5.0

(each cylinder)

20-10 PW75R-2
. FOR MACHINE

Machine model PW75R-2

Classifi- Check item Test conditions Unit Standard Permissible

cation value value

. Measuring posture
Boom

Raise
2.1 Max. 2.5
Bucket teeth on the ground

RKP06100

Lower
Cylinder completely 2.5 Max. 3.0
extended
. Engine speed: high idling
. Oil temperature: 45 ± 55ëC

. Measuring posture
2nd boom

Closed
4.5 Max. 5.5
Cylinders completely
retracted

Inout
Cylinders completely
RKP06110 5.0 Max. 6.0
extended . Engine speed: high idling
. Oil temperature: 45 ± 55ëC

. Measuring posture
Arm
Closed

3.5 Max. 4.0

Work equipment

Cylinder completely
retracted
Speed

sec
Inout

Cylinders completely
RKP06120 2.6 Max. 3.0
extended . Engine speed: high idling
. Oil temperature: 45 ± 55ëC

. Measuring posture
Bucket
Curled

3.0 Max. 3.5

Cylinder completely
retracted
Dump

Cylinder completely
RKP06130 2.2 Max. 2.5
extended . Engine speed: high idling
. Oil temperature: 45 ± 55ëC

. Measuring posture
Boom swing
L.H.

6.0 Max. 7.0

Cylinder completely
retracted

RKP06140
R.H.

Cylinder completely 6.0 Max. 7.0

extended . Engine speed: high idling
. Oil temperature: 45 ± 55ëC

PW75R-2 20-11
. FOR MACHINE

Machine model PW75R-2

Classifi- Check item Test conditions Unit Standard Permissible

cation value value

. Measuring posture

Raise
Outriggers
2.2 Max. 2.5

Resting on ground

Lower
RKP06150
1.8 Max. 2.2
Work equipment

Fully raised
. Engine speed: high idling
Speed

. Oil temperature: 45 ± 55ëC

sec
. Measuring posture

Raise
Blade 1.6 Max. 2.0
Blade on the ground

Lower
Blade raised to max.
RKP06160
2.3 Max. 2.5
height
. Engine speed: high idling
. Oil temperature: 45 ± 55ëC

20-12 PW75R-2
. FOR MACHINE

Machine model PW75R-2

Classifi- Check item Test conditions Unit Standard Permissible

cation value value
Measuring posture

Boom Max. 2 Max. 3

(Standard)
RKP06170

. Engine speed: low idling

. Oil temperature: 45 ± 55ëC
. Retract fully the cylinders of the arm and
bucket.
Lower bucket to ground and measure time
taken for chassis to rise from ground.

Measuring posture
Work equipment

Boom Max. 2 Max. 3

Time lags

(2-piece boom)
sec
RKP06180

. Engine speed: low idling

. Oil temperature: 45 ± 55ëC
. Retract fully the cylinders of the arm and
bucket.
Extend the 2nd boom fully.
Lower bucket to ground and measure time
taken for chassis to rise from ground.

Measuring posture

2nd boom Max. 2 Max. 3

RKP06190

. Engine speed: low idling

. Oil temperature: 45 ± 55ëC
. Retract fully the cylinders of the arm and
bucket. Extend the 2nd boom fully. Bring
the boom into a vertical position. Close
completely the 2nd boom and measure
the time taken to increase the pressure.

PW75R-2 20-13
. FOR MACHINE

PW75R-2
Machine model

Classifi- Check item Test conditions Unit Standard Permissible

cation value value
Measuring posture A
B

Boom
A Max. 2 Max. 3

RKP06200
Arm

. Engine speed: low idling

. Oil temperature: 45 ± 55ëC
. Bring the boom into a horizontal posi- Boom
Max. 2 Max. 3
tion. B
Retract the cylinder of the arm com-
pletely and then extend it.
Amount of time when arm stops for a
moment.

Measuring posture
Work equipment

Time lags

Bucket RKP06210 Max. 2 Max. 3

sec

. Engine speed: low idling

. Oil temperature: 45 ± 55ëC
. Bring the arm into a horizontal position.
Retract the bucket cylinder completely, then
extend it.
Measure the time that elapses between the
bucket stopping at dead centre and then
starting to move again.

Measuring posture

RKP06220
Outriggers Max. 1 Max. 2

. Engine: low idling

. Oil temperature: 45 ± 55ëC
. Raise the outriggers to their max. height and
then lower them. Measure the time it takes
for the front of the machine to be lifted off
the ground, starting from the time the outrig-
gers contacts the ground.

20-14 PW75R-2
. FOR MACHINE

Machine model PW75R-2

Classifi- Check item Test conditions Unit Standard Permissible

cation value value

Measuring posture
Work equipment

Time lags

Blade RKP06230
sec Max. 1 Max. 2

. Engine speed: low idling

. Oil temperature: 45 ± 55ëC
. Raise the blade to its max. height, then lo-
wer it.
Measure the time it takes for the rear of the
machine to be lifted off the ground, starting
from the time the blade contacts the
ground.

Machine model PW75R-2

Classifi- Check item Test conditions Unit Standard Permissible

cation value value
Pump delivery

. Oil temperature: 45 ± 55ëC

. Measure with engine at rated speed
Pumps

Gear pump P2 . At relief valve set pressure 64.4 Min. 58

(29.4 bar (30 Kg/cm2)) ,/min
. Measure the deliveries for
WORKING MODE in position P
and with the 3 - circuit valve functioning.

Piston pumps P1 See following pages

PW75R-2 20-15
 Machine model PW75R-2

Classifi- . Delivery of individual piston pumps P1

cation . WORKING MODE selector: position P
. Pump speed: 2300 rpm.
. Oil temperature: 45 ± 55ëC.

(kgm)
torque(kgm)
Q (ᐍ/min)

pompa
200

shaft
Coppia
Input
178
(144.6
174.8 ,/min )
bar

25
170

21,4
150 ( 137.2
161.2 ,/min )
bar
20
(137.5 ,/min )
172.8 bar

Maximum
Portata massima
delivery
(teorica) 15

( 172.8
117 ,/min )
bar
Pump characteristics

100 10

Minimum
Portata minima
delivery
ammessa ( 264.6
88.3 ,/min )
bar

( 264.6
65.2 ,/min )
bar

50 0

2
Gear pump
Pressione P2 ad
pompa pressure: 19.6
ingranaggi bar (20
: 19,6 bar kg/cm ) 2)
(20 kg/cm

0
49 98 147 196 245 265 294 P(bar)
(50) (100) (150) (200) (250) (270) (300) (kg/cm2)

RKP08060

H When measuring the deliveries with the pumps mounted on the machine, it becomes difficult to use
the accelerator to set the number of engine rpm corresponding to the test speed prescribed for the
pump.
Measure the delivery with the engine set to 2300 rpm, and perform a proportional calculation to find
the delivery value required for the test.

20-16 PW75R-2
 Machine model PW75R-2

Classifi- . Delivery of individual piston pumps P1

cation . WORKING MODE selector: position E
. Pump speed: 2300 rpm.
. Oil temperature: 45 ± 55ëC.

(kgm)
torque(kgm)
Q (ᐍ/min)

200

Coppia
Input pompa
shaft
170,2 178 ( 174.8 ,/min )
78.2 bar

25
170

( 62.2
165.1 ,/min )
bar
( 104.8
138.7 ,/min )
150 bar 20

16,2

( 99.9
118.7 ,/min )
bar 15

Maximum
Portata massima
Pump characteristics

delivery
(teorica)
100 10

Minimum
Portata minima 5
delivery
ammessa

( 264.6
57 ,/min )
bar

50 0

( 264.6
28.4 ,/min )
bar

2
Gear pumppompa
Pressione P2 pressure: 19.8 bar
ad ingranaggi (20 bar
: 19,8 kg/cm
(20 )kg/cm2)

0
49 98 147 196 245 265 294 P(bar)
(50) (100) (150) (200) (250) (270) (300) (kg/cm2)

RKP08050

H When measuring the deliveries with the pumps mounted on the machine, it becomes difficult to use
the accelerator to set the number of engine rpm corresponding to the test speed prescribed for the
pump.
Measure the delivery with the engine set to 2300 rpm, and perform a proportional calculation to find
the delivery value required for the test.

PW75R-2 20-17
 Machine model PW75R-2

Classifi- . Delivery of individual piston pumps P1

cation . WORKING MODE selector: position P
. Pump speed: 2300 rpm.
. Oil temperature: 45 ± 55ëC.

(kgm)
torque(kgm)
Q (ᐍ/min)

pompa
200

shaft
Coppia
Input
(5.8
174.8 ,/min )
bar

25
170

(30.3
141.2 ,/min )
155,7 bar
21,3

150 20

15
Pump characteristics

100 (25.5
122.3 ,/min )
bar
10
Maximum
Portata massima
delivery
(teorica)

Minimum
Portata minima
delivery
ammessa
50 0

( 256.6
21.5 ,/min )
bar

2
( 264.6
21 ,/min )
bar

Gear pump
Pressione P2ad
pompa pressure: 215.6
ingranaggi bar (220
: 215,6 kg/cm
bar (220 ) 2)
kg/cm

( 264.6
4.6 ,/min )
bar

0
49 98 147 196 245 265 294 P(bar)
(50) (100) (150) (200) (250) (270) (300) (kg/cm2)

RKP08040

H When measuring the deliveries with the pumps mounted on the machine, it becomes difficult to use
the accelerator to set the number of engine rpm corresponding to the test speed prescribed for the
pump.
Measure the delivery with the engine set to 2300 rpm, and perform a proportional calculation to find
the delivery value required for the test.

20-18 PW75R-2
SPECIAL TOOLS

Measurement check points Symbol Code Name Q.ty Remarks

Valve clearance - Adjusting A 1 Commercially Feeler gauge 1 Ð

parking brake available

1 ATR800090 Compression gauge 1 0-70 kg/cm2

Compression pressure B
2 ATR800130 Adapter 1 Ð

1 ATR800070 Multi-scale tachometer 1 20 - 4000 rpm

Engine speed C
2 ATR800060 Stroboscopic tachometer 1 6 - 30000 rpm

D 1 Commercially Digital temperature 1

Water and oil temperature available gauge ± 50 - 1200 ëC

1 ATR800170 Pressure gauge 2 Full scale 60 bar

2 ATR800150 Pressure gauge 1 Full scale 250 bar

3 ATR800140 Pressure gauge 1 Full scale 400 bar

E
4 ATR800010 Pressure gauge 1 Full scale 600 bar
Hydraulic pressures and
deliveries
Kit servocontrol
5 ATR800200 (differential pressure gau- 1 Ð
ge)

1 Flowmeter 1
F ATR800120 Ð
2 Tube union kit 1

Thickness of brake disks G 1 ATR500930 Feeler gauge 1 4.5/4.3 mm

1 ATR200380 Tool for checking 1 Ð

Brakes and swing motor drifts and brake line
H
drift test
2 ATR201310 Union kit 1 Ð

Hydraulic drift of boom L 1 21D-62-15530 Flange 1 Mount with O-Ring

and arm cylinders code 21D-09-69870

PW75R-2 20-19
TESTING AND ADJUSTMENTS

20-20 PW75R-2
TESTING AND ADJUSTMENTS MEASURING THE ENGINE SPEED

MEASURING THE ENGINE SPEED

When measuring the speed (rpm) of the engine, do

not touch heated parts and take care not to become
entangled in rotating elements.

H Do not start to measure engine speed until the follow-

ing conditions have been met: C1
. Engine cooling water temperature: 68 ± 80ëC
. Hydraulic system oil temperature: 45 ± 55ëC
1 - Install and connect the tachometer C1.
H If a stroboscopic tachometer C2 is used, make a
distinct mark on the motor pulley to facilitate the
reading. RKPA5120

2 - Start the engine and check:

. Low idling without load (accelerator lever in «mini-
mum» position).
. High idling without load (accelerator lever in
«maximum» position).
H Low idling: 1000 50 rpm
H High idling: 2470w50 rpm

H If the minimum and maximum engine speeds

without load do not fall within the correct range,
check the position stops of the accelerator lever
and the accelerator cable sheathing (See «AC-
CELERATOR LEVER ADJUSTMENT») before RKPA5130

performing the stress tests.

. Engine rpm with the pumps working.

H Max. speed with the P1 pump working:
2290w50 rpm
H Max. speed with the P1 and P2 pumps working:
2285w50 rpm
H If the efficiency is not within the permissible limits,
call the Authorised Repair Shop to come and give
the engine a diagnostic check.

PW75R-2 20-21
TESTING AND ADJUSTMENTS ADJUSTING VALVE CLEARANCE

ADJUSTING VALVE CLEARANCE

H Adjust clearance between valves and rocker levers as

follows: 1
Unit: mm

Intake valve Exhaust valve 2

At cold
engine
0.20 0.20

H Ignition order 1-3-4-2-1.....

H Normal rotation sense: counterclockwise from fly-
wheel view.

. Adjusting procedure RKPB0552

1 - Remove the suction pipe (1) and the valves cover

(2).
2 - Rotate crankshaft in normal direction as long as 4
cylinder piston to be checked is at compression
Top Dead Center (TDC).
3
H In this position intake and exhaust valves are
closed.
3 - Loose lock nut (3) and unscrew tappet (4) of about
1 turn. 5
YES
SI NO
NO
H Check that valve insert (5) is laying flat on
valve stem and that it is not worn askew.
1 - If valve inserts (5) are damaged, replaced
them with new ones. RKP10490
5
2 - Make sure that inserts feet and lay flat on
valve stem.
4 - Connect A1 feeler gauge between insert and rock-
er lever to adjust; rotate the tappet (4) until touch- 4 3
ing A1 feeler gauge.
Tight tappet (4) with lock nut (3). A1
H After tightening the lock nut, check the clear-
ance again.
5 - Adjust with same procedures second cylinder
valve and repeat same operation for the other cy-
linders, according to the ignition order.

RKP10500

. Cover valves installation

2 8
1 - Check condition of cover valves (2), gasket (6), O-
Rings (7) and lock nuts (8); clean carefully contact 7
surface on cylinder head.
2 - Install valves cover (2), fit O-Rings (7) and lock
nuts (8).
Cover lock nut: 25w3 Nm

6
RKP10510

20-22 PW75R-2
TESTING AND ADJUSTMENTS MEASURING COMPRESSION PRESSURE

MEASURING COMPRESSION PRESSURE

. When measuring the compression pressure be

careful not to get caught in cooling fan, in the al- 1
ternator belt or in other rotating parts.
. Check all cylinders.
H Test condition: 2
. Engine: at operating temperature
. Hydraulic oil: 55 ± 60 ëC
. Battery: at full charge
. Valve clearance:
adjusted (see «ADJUSTING VALVE»)
1 - Disconnect high pressure pipe (1).
RKPA5140

2 - Remove nozzle holder assembly (2) of cylinder to be

checked.
3 - Disconnect connector (3) of fuel cut-off solenoid valve
(4). 3
4 - Crank engine with starting motor.

RKPA5150

5 - Install B2 adapter and connect B1 pressure gauge.

H Check that seal is installed in the adapter and that
it is not damaged.
6 - Crank engine with starting motor and measure com- B2
pression pressure.
H Measure the compression pressure at the point
where the pressure gauge indicator remains stea-
dy.
H When measuring the compression pressure, B1
check also engine speed with C2 stroboscopic
tachometer; if speed is not within the specified
range, refer to diagram. RKPA5160

H Compression value:
Normal: 35w1 kg/cm2 at 250 rpm/min
Minimum permissible:
28w1 kg/cm2 at 250 rpm/min
pressure
di compressione

H Difference between cylinders: 40

2 ± 3 kg/cm2 35
Compression

7 - After measuring, install the nozzle holder assembly 30

(2), connect high pressure pipe, feedback pipe and
Pressione

connector (3). 25

Nozzle holder collar bolts: 6.9 ± 8.8 Nm 20

2
High pressure union: 19.6 ± 24.5 Nm (kg/cm
(kg/cm 2
) )
200 250 300 350 400
Engine speed
Velocità motore(rpm)
(giri/min)
RKP10520

PW75R-2 20-23
TESTING AND ADJUSTMENTS TESTING AND ADJUSTING FUEL INJECTION TIMING

TESTING AND ADJUSTING FUEL INJECTION TIMING

H Check fuel injection timing of No. 1 cylinder by means

of No. 1 delivery valve of injection pump.
H Cylinders are numbered 1-2-3-4 starting from flywheel
side. Counter-
Senso
H On the flywheel there are marked the notches corre-
clockwise
antiorario 1
sponding \to injection time of 0ë- 10ë - 15ë - 20ë; to
note the intermediate values, divide in equal parts
the sector between two notches.
1 - Remove plug (1) from flywheel housing.

Senso
Clockwise
orario
RKPA5170

2 - Using a screwdriver putted between teeth, rotate the

crankshaft in clockwise direction (from flywheel side
view) until to align the mark on flywheel with mark
(2) located inside the inner housing hole. Mark
Riferimento
2
H In this position, No. 1 and No. 4 cylinder pistons
are both at Top Dead Centre (TDC); check that
No. 1 cylinder is at the end of compression stroke,
with both intake and exhaust valves closed.
If valves are not closed, rotate the crankshaft of 1 Flywheel
Tacca volano
turn. (TDC)
(PMS)
H After recognition of TDC, rotate the crankshaft in
clockwise direction (from flywheel side view) of
about 25 teeth. RKPA5180

3 - Disconnect all fuel delivery pipes (3) from injection

pump.
4 - Move externally the stop engine lever (4) and fix the
position with a temporary string. 4

5 - Rotate crankshaft slowly in counterclockwise direc- 3

tion (from flywheel side view), checking carefully fuel
level into the No. 1 delivery union of injection pump;
stop the rotation as soon as fuel level starts to in-
crease.

RKPA5190

6 - Check the 10ë ignition timing notch position on fly-

wheel \against the notch on housing hole. 15°
If both notches are aligned, the injection timing is of
10ë; if the notch on flywheel exceeds the notch of 20°
10°
hole, the injection timing value is lower. 15°
H Standard fuel injection timing: 10-12ë
10°

1/4
Notch
Riferimento
2

RKPA5200

20-24 PW75R-2
TESTING AND ADJUSTMENTS TESTING AND ADJUSTING FUEL INJECTION TIMING

7 - If injection timing is not within standard value, rotate

\the injection pump (5) toward external or toward en-
gine after loosening pump nuts (6) and bolt (7) fixing 5
the bracket to injection pump. 6
. To RETARD injection, rotate the pump (5) toward
external.
. To ADVANCE injection, rotate the pump (5) to-
ward cylinders block. 7 8

8 - Tight the pump lock nuts (6) at cylinder block and the
\bolt (7) fixing injection pump to bracket (8).
Nuts: 34.2 ± 44.1 Nm
Bracket bolt: 44.1 ± 53.9 Nm RKPA5210

9 - Connect fuel delivery pipes (3) to pump.

Delivery pipe unions: 19.6 ± 24.5 Nm
10 - Release the stop engine lever and carry out air bleed-
ing.

PW75R-2 20-25
TESTING AND ADJUSTMENTS TESTING AND ADJUSTING FAN BELT TENSION

TESTING AND ADJUSTING FAN BELT TENSION

1. Tension check
1 - Push fan belt (1) at midway point between alterna-
tor (2) and pulley operating water pump; check the 1
deflection. 2
With a pressure of 10 kg (98 N), deflection should
be of 10 ± 15 mm; if this value is not reached, ten-
sion fan belt.
H With new belt, deflection must be of 7 ± 9 mm.

RKPA5220

2. Fan belt tension

1 - Loosen mounting bolt (3) of the alternator (2) and
4
mounting bolt (4) of adjustment plate.
2 - Rotate the alternator (2) to give correct tension to
fan belt (1) and tighten mounting bolts (3) and (4).
3 - Check fan belt (1) tension.
H If belt has been replaced, check tension again
after about 20 operating hours.
3
Mounting bolt (3): 44.1 ± 53.9 Nm
Mounting bolt (4): 22.5 ± 28.4 Nm RKPA5230

10kg (98 N)
Water pump
Puleggia pompa
acqua

10
15mm

Alternatore

Puleggia
albero motore
RKP10530

20-26 PW75R-2
TESTING AND ADJUSTMENTS ADJUSTING THE STROKE OF THE ACCELERATOR LEVER

ADJUSTING THE STROKE OF THE ACCELERATOR LEVER

H Test conditions:
. Engine: Switched off, but at working temperature.
. Low idling: within correct range.
. Hydraulic oil: 45 ± 55ëC
. Accelerator lever at the mid-point of its stroke.
1 2
1 - Use the stretcher (2) to eliminate clearance in the
jacket (1).

RKPA5240

2 - Raise the right-hand cover in order to reach the

screws (3) and (4).
3 - Unscrew the nuts (5) and (6) and tighten the screws
(3) and (4) in the support.
4 - Move the accelerator lever (9) slowly towards low id- 9
ling position. Stop this movement when the lever (7) 5 3 9 6 4
on the cover of the injection pump comes into contact
with the low idling adjustment screw (8).
5 - Adjust the screw (3) until it is 0.1 mm from the lever
(9) and lock it in this position with the nut (5).
6 - Move the lever (9) towards the high idling position. RKPA5250
Stop this movement when the lever (7) on the cover
of the injection pump rests against the lead-sealed
high idling adjustment screw (10).
7 - Adjust the screw (4) to 0.1 mm from the lever (9) and 8 10
lock it in this position with the nut (6).
H After adjustment, replace the right-hand cover
and check that the aperture does not impede
the movement of the lever (9) towards its extreme
positions.

RKPA5260

PW75R-2 20-27
TESTING AND ADJUSTMENTS ADJUSTING PPC VALVES CLEARANCE

ADJUSTING PPC VALVES CLEARANCE

The clearance of the PPC valve (hand and foot) levers is

adjusted as follows.

Lower the working equipment to the ground and stop

the engine.
2
Turn the ignition key to the «I» position and move the
command levers in all directions in order to release 1
all pressure in the hydraulic circuits. 3
Return the ignition key to the «O» (OFF) position and
remove it. 4
Push the lever of the safety device into the
«LOCKED» position.
Slowly loosen the oil-tank refuelling cap to eliminate
residual pressure.

1. Work equipment PPC valve

1 - Remove cap (1).
2 - Loosen the nut (2) that retains the disc (3).
3 - Tighten the disc (3) until it makes light contact with
the 4 push-rods (4).
H During this adjustment, take care not to acti-
vate any of the push-rods (4) individually.
4 - Secure this position by tightening the retaining nut
(2) to the specific torque.
RKP06380
Retaining nut: 113w15 Nm

2. Travel PPC valve

1 - Tighten the screw (1) until all clearances are elimi-
nated. Tighten a further quarter of a turn (90ë).
H While making this adjustment, take care not to
activate the plunger (2).
2 - Check that the pedal stroke is 25ë. To adjust this
stroke, act on the end-of-stroke screw (3), after
having loosened the nut (4).
25

3 - Block the set position by tightening the nut (4) to

°

the specified torque.

Retaining screws: 8w1 Nm
2
4

3
1

RKP11020

20-28 PW75R-2
TESTING AND ADJUSTMENTS ADJUSTING THE SAFETY MICROSWITCH

ADJUSTING THE SAFETY MICROSWITCH

H Test conditions:
. Engine: switched off but at working temperature.
. Hydraulic oil: 45 ± 50ëC. 2
1 - Unscrew the nut (1) that secures the microswitch (2).
2 - Tighten or unscrew the microswitch (2) to the extent
indicated.
H Projection of microswitch: 16 1 mm
3 - Secure it in position with the nut (1).
1

RKPA5270

2
1

16 0+1

RKP07480

PW75R-2 20-29
TESTING AND ADJUSTMENTS MEASURING THE SWING CIRCLE AXIAL CLEARANCE

MEASURING THE SWING CIRCLE AXIAL CLEARANCE

1. Test procedure
1 - Park the machine on firm, flat ground, and align
the revolving frame with the wheels.
2 - Extend the boom, the arm and the bucket, in such
a way that they cover the maximum radius of ac-
tion when the teeth of the bucket are at the same
height as the lower platform of the revolving
frame.
3 - Use the working brakes to block the machine.

RKP09250

4 - Attach a comparator with a magnetic base (1) to

the rear surface of the under carriage (2), and rest 3
the tracer on the part machined to support the 1
swing circle (3).
H Place the tracer as close as possible to the
swing circle.
5 - Preload the comparator by about 3 mm and set
this measurement to zero.

2
RKPB0920

6 - Close the bucket, position the arm perpendicular

to the ground and rest the back of the bucket on Crankshaft
Zona lavorata
the ground.
7 - Force the boom down until the front of the ma-
chine rises, in order to transfer the weight of the
under carriage onto the rear wheels.
8 - Check the movement of the comparator (1) in
these conditions. The value read corresponds to
the value of the swing circle axial clearance. 1
While the machine is raised, take care not to
place hands or feet beneath the wheels.
RKP09260
9 - Return the machine to phase 2 conditions and
check that the comparator returns to «zero». If it
does not, repeat the test, starting at phase 4.

150 ÷ 200 mm

RKP09270

20-30 PW75R-2
TESTING AND ADJUSTMENTS AIR BLEEDING FROM HYDRAULIC CIRCUITS

AIR BLEEDING FROM HYDRAULIC CIRCUITS

Order for operations and procedure for bleeding air
Air bleeding procedure
Air bleeding item 1 2 3 4 5 6 7

Bleeding Bleeding Bleeding Bleeding

Bleeding Start air air from air from air from Start
Nature of work air from steering opera-
pump engine from swing travel unit LS tions
cylinder motors motor circuit

. Replace hydraulic oil

p p p p p p
. Clean strainer ,1 ,1
. Replace return filter element p p

. Replace, repair pump

p p p p
. Remove suction piping

. Replace, repair control valve p p p p

. Replace cylinder
p p p
. Remove cylinder piping

. Replace swing motor

p p p
. Remove swing motor piping

. Replace travel motor, swivel

p p p
. Remove travel motor, swivel piping

. Replace steering unit or priority

valve p p p
. Remove steering unit or priority
valve piping

,1: Bleed the air from the swing motors or travel motors only when the oil inside the motor case has been drained.

1. Bleeding air from pump P1

H When the hydraulic oil tank is drained, or when the
main pumps are removed for revision or replacement, 1
air must be bled from the intake circuit as follows:
1 - Loosen air bleed plug (1) from body pump (2).
2 - Fill the tank with oil up to the level of the hole in
the plug (1). 2
3 - Tighten plug (1).
Plug: 7.35w1.47 Nm (0.75w0.15 kgm)
4 - Continue to fill the tank until the maximum level is
RKPA7700

reached.
5 - Starting the engine and run the engine at low id-
ling for 10 minutes.
(See «Bleeding air from hydraulic cylinders»)

PW75R-2 20-31
TESTING AND ADJUSTMENTS AIR BLEEDING FROM HYDRAULIC CIRCUITS

2. Bleeding air from hydraulic cylinders

H Once the hydraulic cylinders or the tubes connected
to them have been removed, the air must be bleed
as follows:
1 - Start the engine and run at idling for approx. 5
minutes.
2 - Run the engine at low idling, then raise and lower
the boom 4-5 times in succession.
H Operate the piston rod to approx. 100 mm be-
fore the end of its stroke.
3 - Increase engine speed to high idling and repeat
the operations described at point 2. Reduce en-
gine speed to low idling and take the piston
through its entire stroke until the hydraulic pump
has reached maximum pressure.
4 - Repeat the operations (starting from point 2) for
the cylinders of the 2nd boom, the arm and the
bucket.

3. Bleeding air from swing motor

1
1 - Connect hoses (1), drain hose (2) and brake swing
release hose (3).
2 - Fill the swing motor case with hydraulic oil from
union (4) 3

RKPA5320

3 - Connect hose (5).

4 - Start engine at low idling for approx. 10 minutes. 5 4
5 - Slowly swing in both direction few times.
1

2
RKPA5330

20-32 PW75R-2
TESTING AND ADJUSTMENTS AIR BLEEDING FROM HYDRAULIC CIRCUITS

4. Bleeding air form the travel motor

1 - Connect motor feed pipes (1). 4
3
2 - Using the union (2) of the draining pipe, fill the
casing with hydraulic oil (4) up to the bottom level
of hole.
3 - Connect the draining pipe (3).
1
4 - Start the engine and let it run for about 10 minutes
in order to heat the oil.
5 - Execute some slow travel actions in both ways. 2
RKPA7710

5. Bleeding air from the Load Sensing circuit

H When removing the priority valve or the steering unit
on starting up the machine, air must be bled from
the Load Sensing circuit. The procedure is as follows:
1 - Start the engine and leave it running at low idling
speed. 1
2 - Loosen the outgoing union (1) of the steering unit
(2).
3 - Start turning the steering wheel slowly, and con- 2
tinue until oil runs out of the union (1) without a
trace of air.
4 - Stop turning the steering wheel and tighten the RKPA7720

union (1).
H After the bleeding operation and before start-
ing to travel, execute a complete steering ac-
tion with both axles.

PW75R-2 20-33
TESTING AND ADJUSTMENTS RELEASING RESIDUAL PRESSURE

RELEASING RESIDUAL PRESSURE

1. From the hydraulic circuits
1 - Rest the work equipment on the ground and stop the
engine. 0 1
2 - Put the ignition key at position «I» and move the con-
trol lever in all directions to relieve all pressure in the
main hydraulic circuits and the PPC valves.
3 - Turn the ignition key to position «O» (OFF) and re- 0 1
move it.
4 - Put the lever of the safety device into the «LOCKED»
position.
5 - Slowly loosen the oil-tank filler-cap to release any re-
RKP10570

sidual pressure.

2. From the brake line accumulators

1 - Rest the work equipment on the ground and stop the
engine.
2 - Turn the ignition key to position «I».
3 - Push the button that engages the working brakes
several times until the accumulators are completely
emptied. This condition has been achieved when
the brake pedal will no longer move.
4 - Return the ignition key to position «O» (OFF).

20-34 PW75R-2
 CHECKING AND REGULATING PRESSURE IN THE
TESTING AND ADJUSTMENTS HYDRAULIC CIRCUITS

CHECKING AND REGULATING PRESSURE IN THE

HYDRAULIC CIRCUITS
INTRODUCTION
. The control valve is divided into two normally indepen-
dent sections, supplied by pumps P1 e P2 respec-
tively. 3
. Each section is protected against overpressures by a
main (or primary) relief valve with a regolable car-
tridge.
. Each section is protected by safety valve with pre-set-
ting cartridge.

1- Main relief valve (Section 1)

SEZIONE 1
2- Main relief valve (Section 2)
3- Safety valve

pulley
SEZIONE 2
P2

Altenator
P1 P2 2
DIESEL
zone SERBATOIO
Worked

P1

1
RKP10580

. The sections consist of the spools that govern:

Sec- Control Ports

tion

A3 - B3 10
Travel motor (Forward-Backward) 10
A4 - B4
Boom (Raise-Lower) A5 - B5 9 9
Arm (Open-Close) A6 - B6 8 8
Bucket (Curl-Dump) A7 - B7
1 7 7
Blade and/or R.H. outriggers [ (Down-Up)
Boom swing (Left-Right) A8 - B8 6 6
2-piece boom (Down-Up) A9 - B9 5 5
H Attachment (L.H. side - R.H. side) A10 - B10
4 4
3 3
Swing (Left-Right) A1 - B1 2 2
2 A2 - B2
Blade and/or R.H. outriggers [ (Down-Up) 1 1

[ If expected SECTION
UTILIZZI A B RKP10591
H Optional

PW75R-2 20-35
TESTING AND ADJUSTMENTS TESTING AND SETTING OF MAIN VALVES

TESTING AND SETTING OF MAIN VALVES

H Check condition:
. Engine: at working temperature
. Engine idling MIN. and MAX.: within standard
values
. Hydraulic oil: 45 ± 55ëC
. WORKING MODE selector: position P
. Swing lock pin: applied.

Release the remain pressure from circuits.

(See «REMAIN PRESSURE REMOVAL FROM CIR-
CUITS»).

1. Main valve Section 1

1 - Connect to pressure port M1 the gauge E3 (400
bar).
M1
2 - Start the engine and bring the accelerator on high E3
idling speed position.
3 - Acting on one of upper attachments (boom, arm,
bucket) bring the piston rod at the end of its stroke
and check that the pressure value reading on
gauge is 265w5 bar (270w5 kg/cm2).
H If the reading values on gauge are not the same
as shown, proceed to main valves setting.
RKPB1250

2. Main valve Section 2

1 - Connect to pressure port M1 the gauge E3 (400
bar).
2 - Start the engine and bring the accelerator on high
idling speed position.
3 - Raise the blade or L.H. outrigger up to the end of
stroke and check that the gauge connected to port
M2 shows a pressure of 216w5 bar (220w5 kg/
cm2). E3

4 - Put the blade on the ground and make the upper

structure swing on both directions; check that the
gauge connected to port M2 shows a pressure va-
lue of 216w5 bar (220w5 kg/cm2). M2
H If the pressure values are lower than the value
shown, check the safety valves of swing motor.

RKPB1300

20-36 PW75R-2
TESTING AND ADJUSTMENTS TESTING AND SETTING OF MAIN VALVES

3. Main valves setting

To make the valve setting, prepare the machine in
the same way as for pressure testing.
2a Sezione
1 - Loosen the locking nut (1).
2 - Adjust the pressure with screw (2).
1a Sezione
. To INCREASE the pressure turn in CLOCKWISE
direction.
. To DECREASE the pressure turn in COUNTER-
CLOCKWISE direction.
3 - Lock the position with nut (1).
Locking nut: 49 ± 59 Nm (5 ± 6 kgm) RKPA5360

RKP10600

PW75R-2 20-37
TESTING AND ADJUSTMENTS ADJUSTING OF PC VALVE

ADJUSTING PC VALVE

H In case the engine speed lowers as a load becomes

larger, or in case the work equipment speed is slow
even though the engine speed, pump discharge pres-
sure and LS differential pressure are normal, adjust
the PC (1) valve according to the following procedure.
1 - Loosen the lock nut (2). For the cases of slow speed,
turn the sleeve (3) clockwise, and for the cases of low-
1
ering of engine speed, turn the sleeve counterclock-
wise.
H Clockwise rotation of the sleeve «increases» the
suction torque of the pump, and counterclockwise
rotation «decreases» the absurption torque.
RKPB1310

H Rotation range of the sleeve (3) shall be within

180ë for both clockwise and counteclockwise.
2 - After adjustment finished, tighten the lock nut (2).
Lock nut: 100.5w12.3 Nm (10.25w1.25 kgm)
2

3
RKP10610

20-38 PW75R-2
 MEASURING LS DIFFERENTIAL PRESSURE
TESTING AND ADJUSTMENTS AND ADJUSTING LS VALVE

MEASURING LS DIFFERENTIAL PRESSURE

AND ADJUSTING LS VALVE
1. Measuring DPLS differential pressure
1 - Measurement using a differential pressure
gauge E5. 1

i) Remove the oil pressure measurement plug (1)

(PT 1/8) and connect an adapter (2).
ii) Connect the pressure gauge E5 to adapter (2)
on control valve and to adapter M1 (delivery
pump P1).
iii) Measure the DPLS differential pressure accord-
ing to the conditions shown in table 1.
Table 1 RKPA5370

Work Fuel Differential

Operation pressure
mode lever bar (kg/cm2)

P Full Lever at NEUTRAL 25 - 39

(25 - 40)

P Full Travel speed: Hi 21w1 2

Travel idling (lever full) (21.5w1)

NOTE: Raised machine - Front axle locked.

E5

RKPB0930

2 - Measurement using a hydraulic pressure gauge

E3.
H Use a same gauge.
i) Remove the oil pressure measurement plug (1)
(PT 1/8) on control valve and connect an adap-
ter (2). M1

RKPB1010

ii) Connect the pressure gauge E3 (400 bar) to

adapter M1 of pump.
H Reading of the gauge shall be 10 bar.
H If a pressure gauge of 400 bar is not available,
may be used one of 600 bar. M1
E3
iii) Measure the pump discharge pressure accord-
ing to the conditions shown in table 1.
H Stand directly in front of the indicator and be
sure to read it correctly.

RKPB1250

PW75R-2 20-39
 MEASURING LS DIFFERENTIAL PRESSURE
TESTING AND ADJUSTMENTS AND ADJUSTING LS VALVE

iV) Remove from the pump P1 the oil pressure gauge

E3 and install it to the adapter (2).
V) Measure the LS pressure according to the condi-
tions shown in table 1.
H Stand directly in front of the indicator and be
sure to read it correctly.
VI) Subtract to pump discharge pressure PP the LS
pressure to obtain the differential pressure DPLS.
(PP-LS=DPLS) 2
E3

RKPA5380

2. Adjusting of the LS valve

If the values obtained during the measurement of the
differential pressure according to the foregoing condi-
tions are not in the standard value range, adjust the
LS valve (3) according to the following procedure. 3
1 - Loosen the lock nut (4) and turn the screw (5) to
adjust.
. Turn the screw:
CLOCKWISE to increase the differential pres-
sure;
COUNTERCLOCKWISE to decrease the dif-
ferential pressure.
RKPB1311
. Adjusting amount for one turn of the screw:
(13.2 kg/cm2).
2 - After-the adjustment finished, tighten the locknut
(4).
4
Lock nut: 56.4w7.4 Nm (5.75w0.75 kgm)

NOTE: Make sure to adjust the LS valve with measur-

ing the differential pressure.

RKP10620

20-40 PW75R-2
 CHECKING AND ADJUSTING PRESSURES IN THE
TESTING AND ADJUSTMENTS SERVOCONTROL FEED UNIT

CHECKING AND ADJUSTING PRESSURES IN THE

SERVOCONTROL FEED UNIT
H Test conditions:
. Hydraulic oil: 45 ± 55ëC

Release any residual pressures from the circuits M3

(See «RELEASING RESIDUAL PRESSURES FROM
THE CIRCUITS»).

1 - Connect the pressure gauge E1 to the adapter

M3. E1
2 - Start the engine and move the accelerator into its
maximum position.
3 - Put the lever of the safety device in its working po-
RKPB0650

sition, (UNLOCKED).
4 - Bring a servocontrol circuit up to pressure by op-
erating the work equipment (i.e. bucket).
5 - Check the working pressure on the pressure
gauge E1.
H Working pressure: 30 3.5 bar.
H If the working pressure is lower that the per-
missible value, check servocontrol feed unit
valve

RKP10630

PW75R-2 20-41
 MEASURING PUMPS DELIVERY AND FLOW
TESTING AND ADJUSTMENTS CONTROL STARTING POINT PUMP P1

MEASURING PUMPS DELIVERY AND FLOW

CONTROL STARTING POINT PUMP P1
H Test conditions:
. Engine: at working temperature.
. Hydraulic oil: 45 ± 55ëC.
. WORKING MODE selector: position P.
. Work equipment on the ground and made safety.
. Swing lock pin inserted

1. Connecting the flowmeter

1 - Disconnect the delivery tube of the pump to be
tested.
2 - Connect the delivery outlet of the pump to the inlet
port of the flowmeter F1.
3 - Connect the discharge port of the flowmeter to the
tube disconnected in phase 1.
1
Al distributore
4 - Mount a rev. counter (C1 or C2) to measure that
the delivery from the tested pump is within the tol-
erances allowed for the rated engine rpm.
1
H If an electronic pressure-transducer type rev.
counter is installed on a diesel supply tube SECTION 2
Dalla pompa
to the nozzle, make sure that it is mounted
at a distance from the hose-clamps.
H When measuring deliveries with the pumps
mounted on the machine, it is difficult to use
the accelerator to count the precise number F1
of revs needed for this test.
RKP10640

Make delivery measurements with the engine

running at a speed close to the test speed and
then make a proportional calculation.
Example:
MEASUREMENT
Engine speed: 2275 rpm
Delivery: 108.80 ,/min
PROPORTIONAL DELIVERY AT 2300 rpm
108.80 x 2300 = 110 ,/min
ÐÐÐÐ
2275

2. Measurement for pump P1

1 - Start the engine and bring it up to a speed of 2300
rpm.
2 - Adjust the delivery pressure with the flowmeter
knob (1) and measure the effective delivery of
the pump.
H Perform this test several times, varying the
pressure to cover the entire duty range
(max. 265 bar (270 kg/cm2)). F1
H Measure the flow values at each 9.8 bar 1
(10 kg/cm2) of pressure variation.

RKPB0660

20-42 PW75R-2
 MEASURING PUMPS DELIVERY AND FLOW
TESTING AND ADJUSTMENTS CONTROL STARTING POINT PUMP P1

3 - Check the flow ± pressure values against the va-

Q (ᐍ /min)
lues of «P MODE» diagram as shown on «TECHNI- 200

CAL SPECIFICATION» making if necessary, the

proportional calculating to obtain the flow values
referred to 2300 rpm/min. necessary to make the 178
170
control. Maximum
Portata massima
delivery
(teorica)
If the measured values are lower than those Point ofinizio
Punto di initial
permissible, it is necessary to overhaul or to 150 regulation
regolazione

replace the pump.

NOTE: Making the flow readings each 9.8 bar
(10 kg/cm2), also the initial pump regu-
lation is made, that, in the operating
mode «P», corresponds to a pressure
of 137w4 bar (140 kg/cm2). 100
Minimum
Portata minima
delivery
ammessa
4 - Turn the WORKING MODE selector on position E
and repeat the checks comparing the flow values
with «E MODE» curve.
5 - Raise the working attachments, turn the WORK-
ING MODE selector on position S and start the 50

upper structure rotation; keeping the lever to the

end of stroke, make the flow-pressure measure-
ments and compare the values with the «S Gear pump
Pressione pompapressure: (20 kg/cm
ad ingranaggi:(20kg/cm 2)
2
)
MODE» curve.

0
50 100 140 150 200 250 270 300
P(kg/cm2)
RKP10650

3. Measurement of pump P2
1 - Start the engine and bring it at idling of 2300 rpm/
F1
min.
2 - Adjust the delivery pressure with flowmeter knob
(1) at 29.4 bar (30 kg/cm2).
3 - Check the flow ± pressure values against the va-
lues shown on «TECHNICAL SPECIFICATION»
making if necessary, the proportional calculating
to obtain the flow values referred to 2300 rpm/
min necessary to make the control.
If the measured value is lower than that per-
1
missible, it is necessary to overhaul or to re-
RKPB0670

place the pump.

PW75R-2 20-43
 CHECKING THAT THE PRIORITY VALVE
TESTING AND ADJUSTMENTS IS FUNCTIONING CORRECTLY

CHECKING THAT THE PRIORITY VALVE IS FUNCTIONING

CORRECTLY
H Test conditions:
. Engine: at working temperature. E3
. Hydraulic oil: 45 ± 55ëC
. Working brakes: engaged.

1. Checking the Load Sensing signal M2

1 - Connect pressure gauge E3 (400 bar) to the adap-
ter M2.
2 - Start the engine and put it into swing speed of
2000 rpm.
RKPB1300
3 - Use the pressure gauge E3 to check the pressure
value when the steering wheel is not moving.
4 - Start to turn the wheel very slightly and see
whether the pressure increases.
5 - Complete the steering action and check that the
pressure increases up to the normal value
(170 5 bar) when force is applied to the steering
wheel.
H If the pressure as measured by the pressure
gauge shows no variation when the steering
wheel is turned, or if excessive effort is re-
quired on the steering wheel to execute the
steering movement, check that the priority 1
valve (1) is functioning correctly.
RKPB0810

2. Checking that the priority valve is functioning

correctly
2 3
1 - Remove the priority valve (1).
(See «30. DISASSEMBLY AND ASSEMBLY»).
2 - Remove the cap (2) of the «PP» port and check (by
pushing with a rod) that the spool (3) moves freely
along the entire length of the stroke.
3 - Check that the nozzle (4) inside the spool is free of 4
obstructions.
4 - Re-assemble the priority valve (1). 1
5 - Start the engine and bleed the Load Sensing cir-
RKP09280
cuit. (See «BLEEDING AIR FROM THE LOAD
SENSING CIRCUIT»).
6 - Execute several steering operations and, if the dif-
ficulty persists, overhaul or replace the steering
unit.

20-44 PW75R-2
 CHECKING AND REGULATING THE PRESSURE
TESTING AND ADJUSTMENTS OF THE STEERING SYSTEM

CHECKING AND REGULATING THE PRESSURE OF THE

STEERING SYSTEM
H Test conditions:
. Engine: at working temperature E3
. Hydraulic oil: 45 ± 55ëC

Test
1 - Connect pressure gauge E3 (400 bar) to the adapter
M2
M2.
2 - Start the engine and put it into high idling and turn the
steering wheel as far as it will go.
3 - Apply extra force to the steering wheel in its fully
turned position. RKPB1300

H Normal pressure: 170 5 bar

4 - Repeat this check while steering in the other direc-
tion. 3
5
Adjustment
4
If the pressure is not within permissible limits, it can be ad-
justed from the safety valve (1) of the steering unit (2).
1 - Remove the cap (3). 1
2 - Using a 4 mm screw wrench, adjust the maximum
pressure through the screw (4). 2
. To INCREASE pressure turn in a CLOCKWISE di- RKPB1360
rection.
. To DECREASE pressure, turn in a COUNTER-
CLOCKWISE direction.
3 - Stop the engine and replace the cap (3), making sure
that the washer (5) is properly seated.
Cap: 50w10 Nm

PW75R-2 20-45
TESTING AND ADJUSTMENTS CHECKING LEAKAGES IN THE STEERING CYLINDERS

CHECKING LEAKAGES IN THE STEERING CYLINDERS

H Test conditions:
. Engine: at working temperature.
. Hydraulic oil: 45 ± 55ëC
. Working brakes: engaged. 1
. Maximum steering pressure: within permissible
limits.
H First check the front axle cylinder and then the rear
3
axle cylinder.

1 - Start the engine and execute a full steering move-

ment in one of the two directions.
2
RKPA7730

2 - Stop the engine.

3 - Disconnect the supply hose (2) from the cylinder (1)
on the side of the fully extended piston rod (3). Seal
the hose securely.
4 - Connect a provisional hose to the cylinder (1) to col-
lect any leaking oil.
5 - Start the engine and put it into high idling.
6 - Apply maximum force to the steering wheel and hold
that position for 30 seconds; measure any oil lea-
kages for another full minute.
7 - Release the steering wheel, bring the engine back to
low idling, then switch off.
8 - Check whether the amount of leakage is normal (See
«NORMAL OR STANDARD TECHNICAL DATA»).
H Check the cylinder for one side only, since just
one seal separates the two chambers.
9 - Re-assemble the hydraulic connections and execute
several full steering movements in both directions to
release air from the circuit.
10 - Use the same procedure to check the rear axle cylin-
der after having selected one of the two types of
steering.

20-46 PW75R-2
TESTING AND ADJUSTMENTS CHECKING THE BRAKING SYSTEM

CHECKING THE BRAKING SYSTEM

H Test conditions:
. Engine: at working temperature
1
. Hydraulic oil: 45 ± 55ëC
E3
1. Checking accumulator recharging pressure
1 - Connect pressure gauge E3 (400 bar) to the adap- M5
ter M5 of the accumulator line (1).
2 - Start the engine and put it into low idling.
3 - Depress the brake pedal completely to fully re-
charge the accumulators. Check that the maxi-
mum accumulator recharging pressure corre- RKPA7740

sponds to the normal value (150w5 bar).

4 - Using the push-button that engages the working
brakes, perform several braking actions to check
whether or not the accumulators start to recharge
when the normal minimum pressure is reached
(120 5 bar).

Adjustment
If the pressures are not within normal values, proceed
as follows:

Pressure at which to start recharging the accumu-

lators 2

This setting also causes variation in the maxi-

mum recharging pressure of the accumulators.
It will therefore also be necessary to perform
the adjustment described in the next paragraph.

1 - Loosen and remove the protective cap (2) and the

washer (3).
3
2 - Depress the brake pedal several times to reduce
pressure in the accumulators and then measure RKPA7750

the pressure at which the recharging operation

will start.
3 - Loosen the nut (4) and adjust the initial recharging
pressure using the adjustment screw (5).
H Initial recharging pressure: 120 5 bar.
. To INCREASE pressure turn in a COUNTER-
CLOCKWISE direction.
. To DECREASE pressure, turn in a CLOCK-
WISE direction.
4 - Secure the adjustment screw (5) with the nut (4). 5
4

RKPA7760

PW75R-2 20-47
TESTING AND ADJUSTMENTS CHECKING THE BRAKING SYSTEM

Maximum accumulator recharging pressure

1 - Loosen the nut (6) and adjust the pressure by
screwing or unscrewing the screw (7). 6
H Maximum pressure: 150w5 bar.
. To INCREASE pressure turn in a COUNTER-
CLOCKWISE direction.
. To DECREASE pressure, turn in a CLOCK-
WISE direction.
2 - Secure the screw (7) with the nut (6). 7
3 - Re-assemble the washer (3) and the cap (2).
RKPA7761

2. Checking the braking pressure

1 - Connect the pressure gauge E2 (250 bar) to the
adapter of the brake line M6.
2 - Start the engine and put it into low idling.
E2
M6
3 - Recharge the accumulators.
4 - Completely depress the brake pedal and check
whether or not the pressure is normal (70 1 bar).

RKPA7770

Adjustment of braking pressure

If the pressure is not within normal values, proceed as
follows:
1 - Raise the rubber sleeve (8) and loosen the nut (9)
that secures the end-of-stroke screw (10).
10
2 - With the pedal fully depressed, adjust the braking
pressure using the screw (11).
H Braking pressure: 70 1 bar.
. To INCREASE pressure turn in a CLOCK-
WISE direction. 9 8
. To DECREASE pressure, turn in a COUN-
TERCLOCKWISE direction. RKPA7780

3 - Secure the position of the screw (10) with the nut

(9).
Lock nut: 45w4 Nm
10

11

RKPA7790

20-48 PW75R-2
TESTING AND ADJUSTMENTS CHECKING THE BRAKING SYSTEM

3. Check the leaktightness of the hydraulic braking

circuit
1 - Connect the pressure gauge E2 (250 bar) to the
adapter of the braking line M6. E2
2 - Start the engine and put it into low idling.
M6

3 - Execute several braking actions to empty the ac-

cumulators and then recharge them completely
(150 5 bar).
4 - Stop the engine and return the ignition key to po-
sition «I» in order to supply voltage to the electric
circuits. RKPA7770

5 - Use the working brake engagement button to exe-

cute a braking action.
6 - Watch the pressure shown by pressure gauge E2
for two minutes. During this period the pressure
value should not vary with respect to the first read-
ing.
H If variations in the braking pressure are observed,
verify in the following sequence:
1 - Any visible leakages in the system.
2 - Internal leakages in the swivel joint (For de-
tails, see «MEASUREMENT OF INTERNAL
OIL LEAKAGES IN THE SWIVEL JOINT»).
3 - The leaktightness of the brake groups (For de-
tails, see «4. Checking the leaktightness of the
brake groups»).

4. Checking the leaktightness of the brake groups

This test envisages two phases:
1 - Identification of the defective axle.
2 - Identification of the defective brake group.

Identification of the defective axle

We shall describe here the procedure for the axles is
identical.
1 - Release all residual pressure in the accumulators.
2 - Disconnect the flexible hose (12), leading out of
the swivel joint (branch 7 for front axle, branch 8
for rear axle), from the rigid front axle supply tube
(11) (on the LH side of the lower frame). 11
3 - Insert apparatus H1 between the two tubes, con- H1
necting it in such a way that the cut-off cock (13) 12
is connected to the flexible hose leading out of
the swivel joint.

E2 13

RKPA7800

PW75R-2 20-49
TESTING AND ADJUSTMENTS CHECKING THE BRAKING SYSTEM

4 - Attach the pressure gauge E2 (250 bar) to the

adapter and open the cock (13) of apparatus H1.
5 - Start the engine and put it into low idling.
6 - Push the working brake engagement button to re-
charge the accumulators.
7 - Check that the braking pressure indicated by the
pressure gauge E2 is 70 1 bar.
8 - Close the cock (13) of apparatus H1 in order to
maintain pressure in the branch under examina-
tion, then stop the engine.
9 - Watch the pressure indicated by pressure gauge
E2 for 2 minutes.
. If the pressure value goes down, it means that
at least one piston in one of the two brake
groups under examination is defective. Test
the defective group, following the procedure
described in the next paragraph.
. If the pressure value remains constant, the
leakages are occurring in the rear axle.

Identification of the defective brake group

1 - Insert apparatus H1, complete with the pressure
gauge E2, into the supply line of the defective
axle.
2 - Disconnect the supply tube (15) of one of the two
brake groups from the Tee (14). Seal the free side
of the Tee (14) securely.
3 - Following the same procedure indicated for identi- 11
fication of the defective axle (from point 5 to point H1
8), pressurise the brake group that is still con- 12
nected and close the cock (13).
4 - Watch the pressure indicated by the pressure
gauge E2 for two minutes.
. If the pressure value goes down, it means that E2 13
at least one brake piston is defective.
. If the pressure value remains constant, the
other brake group is defective.
RKPA7800

1 - Further confirmation of the leakage of one or

more brake pistons can also be found
through an increase in the level of oil in the
central body of the axle, or in the planetary.
2 - If such an oil increase, and hence mixing of 14
oils, are found as a result of brake piston 15
leakage, change all sealing rings between
axle sections and carry out a complete
change of the lubrication oil.

RKPA7810

20-50 PW75R-2
TESTING AND ADJUSTMENTS CHECKING THE BRAKING SYSTEM

5. Checking the alarm pressure switch setting for

insufficient braking pressure
Before performing this test, first verify that there are 1
no leakages in the brake lines.
E3
1 - Connect pressure gauge E3 (400 bar) to the adap-
ter M3 of the accumulator line (1).
M5
2 - Start the engine and put it into low idling.
3 - Execute several braking actions with the pedal un-
til the accumulators are completely recharged
(150 5 bar).
4 - Stop the engine and return the ignition key to po- RKPA7740

sition «I», in order to supply voltage to the electri-

cal circuits.
5 - Using the working brake engagement button, exe-
cute several braking actions (count them) while
keeping a check on both the warning light that in-
dicates insufficient braking pressure and the pres-
sure gauge E3.
The warning light should come on when the fol-
lowing conditions have been reached:
. residual pressure: 90 2 bar.
. minimal number of braking actions: 15.

Adjustment
If the warning light comes on at values higher or lower
than 90 2 bar, adjust the intervention setting of the
pressure switch (16) that causes the warning lamp
to light up.
The setting is obtained by turning the screw (17).

. Switching pressure: 90 2 bar

. To INCREASE pressure turn in a CLOCKWISE di-
rection.
. To DECREASE pressure, turn in a COUNTER-
CLOCKWISE direction. 16
17

RKPA7820

PW75R-2 20-51
TESTING AND ADJUSTMENTS CHECKING WEAR IN THE BRAKE DISKS

CHECKING WEAR IN THE BRAKE DISKS

1 - Start the engine and put it into low idling.

2 - Execute several braking actions with the working
brakes, until the braking system accumulators are
completely recharged.
3 - Stop the engine. 1 1
4 - Return the ignition key to the «I» position and press
the button that engages the working brakes.
5 - Remove the filling cap (1) and use the tool G1 to
check the thickness «S».
H Minimum thickness «S»: 4.5 mm
RKPA7830

6 - Following the same procedure, check all the brake

groups.
1 - If the thickness «S» of one of the two brake
groups of an axle is equal to or less than
the minimum permissible thickness, change
the disks on both brake groups.
2 - After changing the brake disks, bleed air
from the brake line.
(See «BLEEDING AIR FROM THE BRAKE
LINES»).

G1
ADJUSTING BRAKING DISKS RKPA7840

CLEARANCE
H Adjustment conditions:
. Engine: not running
. Machine: on solid, flat ground, and in safe condi-
tions 1
H Before performing adjustment, make sure that the
braking disks are not worn (see «CHECKING
WEAR IN THE BRAKING DISKS»)
1 - Loosen check nuts (1) of the adjusting screws (2)
(No. 3).
2 - Turn adjusting screws (2) anti-clockwise to lock the
braking disks.
RKPA7850

3 - Turn the adjusting screws clockwise by 180ë (3/4

turn) to provide disks with the correct adjustment
clearance
H Adjustment clearance: 0.75 mm
4 - Keeping the position of screws (2) as it is, tighten the
nuts (1).

RKPA7860

20-52 PW75R-2
TESTING AND ADJUSTMENTS BLEEDING AIR FROM THE BRAKE LINES

BLEEDING AIR FROM THE BRAKE LINES

H Bleed air from both axles.

1 - Start the engine and put it into low idling.
2 - Engage and release the working brakes several 2
times, until the accumulators of the brake line are
completely recharged.
3 - Stop the engine.
4 - Return the ignition key to position «I» and press the 1
button that engages the working brakes.
5 - Attach a transparent flexible hose (1) to the bleeding
screws (2) in order to collect the oil. RKPA7870

6 - Slowly loosen by a half turn the bleeding screw (2) of

one brake group until oil runs out of the screw without
any trace of air.
7 - Tighten the screw (2).
8 - Repeat the bleeding operation for the other brake 2
group.
1
H If the level in the accumulators drops during the
bleeding operation, and the warning light for low
brake oil pressure comes on, interrupt the bleed-
ing operation and recharge the accumulators.
H Once the bleeding operation is concluded, re-
place the protective caps over the screws (2).
RKPA7880

PW75R-2 20-53
TESTING AND ADJUSTMENTS ADJUSTING THE PARKING BRAKE

ADJUSTING THE PARKING BRAKE

H Conditions for the adjustment:

. Engine at working temperature 7
. Hydraulic oil: 45 ± 55ëC 12 6 8
While carrying out this adjustment, the engine
must be running to maintain pressure in the
parking brake line. Rest the work equipment, 8
the blade and, if necessary, the outriggers on
the ground.
Place safety wedges beneath the wheels.
8 4 5
1 - Adjust the clearance between the braking disks (For RKP09290
details see «ADJUSTING BRAKING DISKS CLEAR-
ANCE»).
2 - Start the engine and put it into low idling.
11 10 10 11
3 - Press the button that releases the parking brake in or-
der to bring the circuit up to pressure.
4 - Disconnect the cylinder (1) from the levers (2-3), re-
moving in sequence the lock nut (4), the nut (5), the
screw (6), and finally the pin (7) of the cylinder ful-
crum (1).
H Check the positions of the washer (13).
2 3
5 - Move the cylinder (1) to a position that allows access
to the cylinder coupling lever. 1
6 - Pull the lever (2) outwards and apply light pressure RKPA7890

until the internal eccentric lever rests on the springs.

7 - Adjust the register (10) until a distance of 0.2 mm has
been obtained between the lever (2) and the register
(10). Secure this position with the nut (11).
12 13
Nut: 25 3 Nm
8 - Follow the same adjustment procedure for the other
lever (3)
9 - Fit the cylinder (1) in between the two levers (2) and
(3) checking that the fulcrum pin (7) and the connect-
ing screw (6) are engaged in the levers without being
too tight.
H Pace the shim washers (8) into correct position.
H If the fulcrum pin and screw are too tight, loosen RKP09300

the check nut (12) of the articulation (13) and ad-

just distance between the centres of cylinder con-
nections (1) until the cylinder is engaged without it
being too tight. 5
6 mm
Fulcrum pin (7): 75 Nm
Stem connection screw nut (5): 49 4 Nm
Lock nut (4): 30 2 Nm
Articulation nut (12): 82v91 Nm
10 - Stop the engine and check that when the parking
brake is on, the stem (14) juts out 5 ± 6 mm from the
head of cylinder (1).

1 14 RKP09310

20-54 PW75R-2
TESTING AND ADJUSTMENTS TRAVEL HYDRAULIC EQUIPMENT CHECKING PROCEDURE

TRAVEL HYDRAULIC EQUIPMENT CHECKING PROCEDURE

H Check conditions:
. Engine: at working temperature
. Hydraulic oil: 45 ± 55 ëC
. Service brakes: on

This test id divided into two sections to facilitate identifica-

tion of the faulty member or part that is to be set.
1. Top portion of the equipment
Check that:
. Servo-control pressure is normal (for details, see
«CHECKING AND ADJUSTING PRESSURES IN
THE SERVOCONTROL FEED UNIT»).
. That spools receive pressure from servo-controls.
. The distributor spool involved in travel executes
the whole travel (See «TECHNICAL DATA»).
. The valve in section 1 of the distributor is set. (For
details, see «TESTING AND SETTING OF MAIN
VALVES»).
. The pressure of differential unit DPLS of the LS is
normal (For details, see «MEASURING LS DIF-
FERENTIAL PRESSURE AND ADJUSTING LS
VALVE»).
. There is no internal blow-by in the swing joint (for
details, see «CHECKING FOR LEAKAGES IN-
SIDE THE SWIVEL JOINT»).
. The safety valves of the travel motor are set
(320w10 bar, bench controlled).

2. Bottom part of the equipment:

Check:
. The operating point of the travel motor automatic
displacement change device.
For details, see «CHECKING AND ADJUSTING
THE AUTOMATIC DISPLACEMENT CONTROL
SYSTEM OF THE TRAVEL MOTOR»).
. Blow-by in the travel motor.
For details, see «CHECKING FOR LEAKAGES IN
THE TRAVEL MOTOR».

PW75R-2 20-55
 CHECKING AND ADJUSTING THE AUTOMATIC
TESTING AND ADJUSTMENTS DISPLACEMENT CONTROL SYSTEM OF THE TRAVEL MOTOR

CHECKING AND ADJUSTING THE AUTOMATIC DISPLACEMENT

CONTROL SYSTEM OF THE TRAVEL MOTOR
H Test conditions:
. Engine at working temperature
. Hydraulic oil: 45 ± 55ëC
. Working brakes: engaged M1
E3

Test
1 - Connect the adapter M1 to the pressure gauge E3
(400 bar).
2 - Take off the cap and connect pressure gauge E4 (600
bar) to the automatic displacement control system (1).
RKPB1250
3 - Select the 2nd fast forward gear.
4 - Bring the engine up to a speed of 2000 rpm.
5 - Press lightly on the travel pedal and watch whether
the pressure gauge E4 connected to the control sys-
tem starts to move when the pressure gauge E3 con- 1
nected to the adapter M1 indicates a pressure of
200 10 bar.

Adjustment
1 - Take off the safety cap (2).
E4
2 - Loosen the nut (3).
3 - Adjust the intervention point with the screw (4). RKPA7900

H Intervention point: 200 10 bar

. To INCREASE pressure turn in a COUNTER-
CLOCKWISE direction
. To DECREASE pressure, turn in a CLOCKWISE
direction
4 - Secure the position of the screw (4) with the nut (3).
Lock nut: 10 Nm
5 - Replace the cap of the control system (1). 2
Cap: 30 Nm
6 - Replace the safety cap (2) to protect against un-
authorised tampering.

RKPA7910

4
3

RKP09320

20-56 PW75R-2
TESTING AND ADJUSTMENTS CHECKING FOR LEAKAGES IN THE TRAVEL MOTOR

CHECKING FOR LEAKAGES IN THE TRAVEL MOTOR

Before carrying out this control, check the efficiency

of the working brakes.
1
H Test conditions:
. Engine at working temperature
. Hydraulic oil: 45 ± 55ëC
. Selector in WORKING MODE: position P
3
. Working brakes: engaged
1 - Disconnect the drainage tube (1) from the lower union
(2) of the motor (3) and plug it.
2
2 - Attach a provisional tube to collect the draining oil.
RKPA7920

3 - Start the engine and bring it up to 2000 rpm.

4 - Select the 2nd fast forward gear and press the travel
pedal slowly to the end of its stroke.
5 - Hold the travel pedal in this position for 30 seconds
and then measure the oil drainage from the motor
for the next minute.
6 - Check whether the amounts of drainage oil are nor-
mal (see «NORMAL OR STANDARD TECHNICAL
DATA»).
7 - Stop the engine and re-assemble the hydraulic con-
nections.

PW75R-2 20-57
 CHECKING AND ADJUSTING THE SPEED
TESTING AND ADJUSTMENTS OF THE TRAVEL PROPELLER SHAFT

CHECKING AND ADJUSTING THE SPEED OF THE TRAVEL

PROPELLER SHAFT
H Test conditions:
. Engine at working temperature
. Hydraulic oil: 45 ± 55ëC
. Machine: completely raised
. Front axle: blocked BLOCK
BLOCCO BLOCK
BLOCCO

Test
H Make a distinct mark (1) on the propeller shaft to facil-
itate the reading of the speed indicator C2.
1 - Position the machine with the arm vertical and the
back of the bucket resting on the ground. 10 cm
RKPB0820

2 - Push down the boom and the rear outriggers until the
machine is completely raised.
If the blade is mounted on the machine, rest it on
the ground after the machine has been raised.

3 - Place safety blocks, height 10 cm, beneath the centre

of the axles to prevent the machine from dropping ac-
cidentally.
After having lowered the axles gently onto the
blocks, check that the wheels are raised approxi- C2
mately 10 cm above the ground. 1
4 - Use blocks to stop the front axle from turning.
5 - Select the 2nd fast forward gear.
6 - Bring the engine up to high idling (2470w50 rpm) mea- RKPA7930

suring it with instrument C1.

7 - Press the travel pedal down to the end of its stroke.
8 - Use the speed indicator C2 to check the rev. speed of
the propeller shaft.
Unit: rpm

Normal speed: 3590w50

Speed for TUV approval: TBG: 20 km/h 2225w50

25 km/h 2780w50
2
Adjustment
1 - Take off the safety cap (2).
2 - Loosen the nut (3).
RKPB2130

3 - Regulate the speed with the minimum displacement

adjustment screw (4).
. To INCREASE the speed turn in a COUNTER-
CLOCKWISE direction.
. To DECREASE the speed, turn in a CLOCKWISE
direction.
4 - Secure this position with the nut (3).
Lock nut: 69 Nm
5 - Apply a new safety cap (2) to protect against un-
authorised tampering.

4 3
RKP10070

20-58 PW75R-2
TESTING AND ADJUSTMENTS ADJUSTMENT OF THE SPEED SURVEYOR

ADJUSTMENT OF THE SPEED SURVEYOR

When dismantling or substituting the speed surveyor, pro- 0

ceed as follows for the final positioning: 0,5 + 0,2
1 2 3
1 - Screw the sealing washer (2) onto the sensor (1) and 4
screw the sensor (1) into the casing of the transmis-
sion (3) by hand until it rests on the toothed wheel (4).
H Check the condition of the sealing washer (2) with
care.
2 - Unscrew the sensor (1) until a space of 0.5 0.2 mm is
obtained between the sensor and the toothed wheel
(4) (0.5 ± 0.6 turns).
5
3 - Secure the sensor with the nut (5). RKP09340
Lock nut: 22w2 Nm
4 - Connect the electric cabling and mount the protective
rubber sleeve (6).
Turn the protective sleeve (6) so that the cable
opening points towards the ground, in order to 6
prevent accumulations of water or condensates.

RKPA7940

PW75R-2 20-59
TESTING AND ADJUSTMENTS ADJUSTING BOOM AND ARM SAFETY VALVES

ADJUSTING BOOM AND ARM SAFETY VALVES

H Test conditions Boom

V2
. Engine: at working temperature
. Hydraulic oil: 45 ± 55ëC
. WORKING MODE selector: position P
. Main safety valves: set to 370w5 bar
. Valves in section 2 of the distributor: set at normal
value. (See «TESTING AND SETTING OF MAIN 2 1
VALVES»)
1 - Rest the work equipment on the ground, stop the en- C2
gine and release any residual pressures (See «RE-
LEASING RESIDUAL PRESSURES FROM THE CIR-
CUITS»). RKPB1040

2 - Disconnect the pipe (1) from the coupling V2 and the

pipe (2) from coupling C2.
Arm 1
H Disconnect the safety valve from the arm cylinder.
3 - Cap the pipe (2) to prevent entry of impurities.
H For the arm, cap the cylinder.
C1
4 - Connect the tube (1) to the coupling C2, using a tube
with equal section.
H For the arm, connect the flange V2 to the coupling
C2.
5 - Unscrew the nut (6) and remove the threaded rod (5) V2
and the nut (4).
6 - Start the engine and bring it up to high idling speed. RKPB1050

7 - Bring the boom cylinder bottom side or the arm cylin-

der head side slowly up to maximum pressure (320
bar), checking that no oil leaks out of the valve. 5
8 - Maintaining pressure, adjust the valve with the screw 6 10
(3), until a slight leakage of oil (just a few drops every Nm 70 Nm 4
minute) is seen coming from the flange V2.
3
140 Nm
. To INCREASE pressure, turn in a CLOCKWISE
Nm

direction. 7
. To DECREASE pressure, turn in an COUNTER-
CLOCKWISE direction.
H Every turn of the screw (3) changes the pressure V2
by 110 bar.
9 - Block the screw (3) in position with the nut (4).
Locknut: 70 Nm
10 - Screw the rod in (5) until it comes into contact with the C2
retaining element (7) and then turn it back for 5-6
turns. Secure it in position with the nut (6).
11 - Rest the equipment on the ground, stop the engine,
and release any residual pressures. T
12 - Re-assemble the valve connections.

RKP07440

20-60 PW75R-2
TESTING AND ADJUSTMENTS ADJUSTING 2nd BOOM SAFETY VALVES

ADJUSTING 2nd BOOM SAFETY VALVES

H Test conditions:
. Engine: at working temperature 4
. Hydraulic oil: 45 ± 55ëC 6
. WORKING MODE selector: position P 5
. Main safety valve of the 2nd section of the control 2
valve: set to 370w5 bar 3
. Secondary valves: set to normal values. 8
(See «2. Valves with a fixed setting»).
1
1 - Rest the work equipment on the ground, stop the en-
gine and release any residual pressures (See «RE- 7
LEASING RESIDUAL PRESSURES FROM THE CIR-
RKPA5460

CUITS»).
H Adjust the valves of one cylinder at a time.
2 - Disconnect the pipes (1), (2), (3) and (4).
3 - Use hoses of equal section to connect up the pipes in 10 9
the following manner:
pipe (1) port (5).
pipe (2) port (6)
4 - Cap pipes (3) and (4) to prevent entry of any impuri-
ties.
5 - Remove the access caps (9) to the adjustment screws 13
(10-11). 7
6 - Start the engine and bring it up to high idling speed.
7 - Move the 2nd boom pedal to the end of its opening
stroke.
5
8 - Using the screw (11) adjust the valve (12) until a slight
leakage of oil can be seen from the flange (8).
. To INCREASE pressure, turn in a CLOCKWISE
direction.
. To DECREASE pressure, turn in an COUNTER-
CLOCKWISE direction.
H Every turn of the screw changes the pressure by
165 bar.
9 - Move the 2nd boom pedal to the end of its closing
stroke.
10 - Using the procedure indicated in point 8 adjust the 6
valve (13) until a slight leakage of oil is visible from
the port (7).
11 - Stop the engine and release any residual pressures. 8 12
12 - Replace the caps (9) and re-assemble the hydraulic
circuits.
Locknut 20 Nm
13 - Repeat the same regulation operations for the valves
of the other cylinder.

11 9

RKP07430

PW75R-2 20-61
 MEASURING AND SETTING OF PRESSURE
TESTING AND ADJUSTMENTS SWITCH SIGNAL OVERLOAD OPERATION

MEASURING AND SETTING OF PRESSURE SWITCH SIGNAL

OVERLOAD OPERATION
H NOTE: The illustration shows the pressure switch
without guard.
H Check condition:
. Engine: at working temperature M1
E3
. Hydraulic oil: 45 ± 55ëC

1 - Connect to pressure port M1 the gauge E3 ( 400 bar).

2 - Start the engine and bring it at medium throttle.
3 - Apply the overload alarm.
4 - Raise boom until the lift end of stroke and increase RKPB1250

lowly the pressure; check the pressure value when

appear the overload signal.
H Standard operating pressure: 130 bar
(132.6 kg/cm2)

Setting
If the operating pressure in not within the standard limits,
make the pressure switch setting as follows:
1 - Loosen the locking nut (1).
2 - Raise the boom checking on gauge E3 that hydraulic 2 1
cylinder approach the operating pressure.
3 - Turn the adjusting screw (2) until to obtain the over-
load alarm signal.
. To INCREASE the operating pressure, turn the
screw in CLOCKWISE direction.
. To DECREASE the operating pressure, turn the RKPA7950

screw in COUNTERCLOCKWISE direction.

4 - Lock the position with nut (1).
5 - Release the pressure and repeat several times the
measuring to check the setting stability.

20-62 PW75R-2
 MEASUREMENT OF INTERNAL OIL
TESTING AND ADJUSTMENTS LEAKAGES IN THE SWING MOTOR

MEASUREMENT OF INTERNAL OIL LEAKAGES

IN THE SWING MOTOR
H Test conditions:
. Engine: at working temperature
. Hydraulic oil: 45 ± 55ëC
. WORKING MODE selector: position P
. Revolving frame: secured by the rotation-blocking
pin.
1 - Disconnect the drainage hose (1) of the motor (2).
2 - Attach a provisional hose to collect the drainage oil. 2
1
3 - Start the engine and bring it up to high idling speed.
4 - Push the swing control lever as far as it will go. RKPA5321

5 - Hold it in this position for 30 seconds and then mea-

sure the oil leakage for the next minute.
6 - Reduce motor speed to low idling, swing the revol-
ving frame 180ë and repeat the measurement.
7 - Check that the average between the two measure-
ments falls within the normal range. (See «TECHNI-
CAL DATA»).
8 - Re-assemble the hydraulic drainage circuit.

PW75R-2 20-63
 MEASUREMENT OF INTERNAL OIL
TESTING AND ADJUSTMENTS LEAKAGES IN THE SWING MOTOR

CHECKING FOR LEAKAGES INSIDE THE SWIVEL JOINT

H Test conditions:
. Engine: at working temperature. 14 Slow gear insertion
. Hydraulic oil: 45 ± 55ëC. 13 Travel motor (Forward)
. WORKING MODE selector: position P.
12 Travel motor (Backward)
1. Functionality test 11 Axle locking

1 - When one of the lower-level tools (blade, travel
motors, speed increment, brakes) is found to be
defective, one of the causes of the failure may
be the swivel joint.
2 - To confirm the defect it is sufficient to by-pass the
joint by connecting (using an additional length of
tubing) the input and output hoses of the joint of
the branch to be checked.
If the defect disappears, it is certainly due to the
swivel joint.
If the defect remains, it can be due to other
causes, but not to the swivel joint.
10 Blade-outrigger command (Descent) (R.H. side)
9 Blade-outrigger command (Descent) (L.H. side)
8 Rear axle braking
7 Front axle braking
6 Drainage (travel motor)
5 Inserimento marcia veloce
4 Parking brake
3 Blade-outrigger command (Rise)
2 Front steering to the left
1 Front steering to the right

2. Identification of defective seal

These tests should be performed on those
branches subjected to working pressures. Tests
on unstressed or unused branches are therefore
excluded.
The test method consists in pressurising the branch
under examination and measuring any leakage from
adjacent branches, as set out in the following table:

Në Branch to be tested (under pressure) Adjacent parts (Leakages) Në

External leakage (visible) Ð
14 Slow gear insertion
Travel motor (Forward) 13
Slow gear insertion 14
13 Travel motor (Forward)
Travel motor (Backward) 12
Travel motor (Forward) 13
12 Travel motor (Backward)
Axle locking 11
Travel motor (Backward) 12
11 Axle locking
Blade-outrigger command (Descent) (R.H. side) 10

Blade-outrigger command (Descent) Axle locking 11

10
(R.H. side) Blade-outrigger command (Descent) (L.H. side) 9

Blade-outrigger command (Descent) Blade-outrigger command (Descent) (R.H. side) 10

9
(L.H. side) Rear axle braking 8
Blade-outrigger command (Descent) (L.H. side) 9
8 Rear axle braking
Front axle braking 7
Rear axle braking 8
7 Front axle braking
Drainage (travel motor + EVOP2) 6
Front axle braking 7
6 Drainage (travel motor + EV OP2)
Fast gear insertion 5

20-64 PW75R-2
 MEASUREMENT OF INTERNAL OIL
TESTING AND ADJUSTMENTS LEAKAGES IN THE SWING MOTOR

Në Branch to be tested (under pressure) Adjacent parts (Leakages) Në

Drainage (travel motor and EV OP2) 6
5 Fast gear insertion
Parking brake 4
Fast gear insertion 5
4 Parking brake
Blade-outrigger command (Rise) 3
Parking brake 4
3 Blade-outrigger command (Rise)
Front steering to the left 2
Blade-outrigger command (Rise) 3
2 Front steering to the left
Front steering to the right 1
Front steering to the left 2
1 Front steering to the right
External leakage (Visible) ±

The numbers correspond to the numbers stamped on the input and output ports of the swivel joint.

3. Preparation for testing:

. travel motors 1
. travel brakes
2
. speed increment
1 - Relieve all residual hydraulic pressures (See «RE-
LEASING RESIDUAL PRESSURES FROM THE CIR-
CUITS»). 3
2 - Identify the branch involved in the test (1).
3 - Disconnect the hoses (2) from the branches adjacent
to the part to be tested and cap them tightly.
Make sure that the detached tubes are securely
sealed, to prevent jets of high-pressure oil es-
caping if circuits that are not undergoing tests RKP09350

should accidentally become pressurised.

H The tubes of the adjacent branches must be dis-
connected from the upper parts of the swivel
joint.
4 - Provisional hoses (3) for collecting any oil leakages
3
should be connected to the inlets of the branches ad-
jacent to the one being tested.

4. Preparation for testing the blade

1 - Relieve all residual hydraulic pressures (See «RE-
LEASING RESIDUAL PRESSURES FROM THE CIR- 1
CUITS»).
2 - Identify the branch involved in the test.
3 - Disconnect the tube corresponding to the branch to
be tested from the safety valve input and cap it.
Make sure that the detached tubes are securely
sealed, to prevent the escape of jets of oil at high
pressure.
3
4 - Cap the valve to prevent entry of impurities.
5 - Disconnect from the swivel joint the hoses (2) of the
branches adjacent to the branch to be tested, and
cap them tightly. RKP09360

PW75R-2 20-65
 MEASUREMENT OF INTERNAL OIL
TESTING AND ADJUSTMENTS LEAKAGES IN THE SWING MOTOR

Make sure that the detached hoses are securely

sealed, to prevent jets of high-pressure oil es-
caping if the circuits that are not undergoing
tests should accidentally become pressurised.
H The tubes of adjacent branches must be discon-
nected from the upper parts of the swivel joint.
6 - Provisional hoses (3) to collect any leaking oil should
be connected to the inlets of the branches adjacent to
the one being tested.

5. Test
1 - Start the engine and bring it up to the test speed de-
scribed for each group or component.
2 - Pressurise the branch to be tested.
3 - After 30 seconds, watch for another minute if there
are any leakages.
H If oil leaks out of one of the two provisional hoses,
it means that there is a leakage in the intermedi-
ate gasket between the branch connected to the
provisional hose and the pressurised branch.

20-66 PW75R-2
TESTING AND ADJUSTMENTS ANALYSIS OF THE CAUSES OF HYDRAULIC DRIFTS

ANALYSIS OF THE CAUSES OF HYDRAULIC DRIFTS

H If hydraulic drift occurs in the work equipment, a

check must be carried out to see if the cause is due
to a cylinder gasket or to the control valve.
H Conditions for all checks:
. Engine: at working temperature.
. Hydraulic oil: 45 ± 55ëC
. Removal and connection of tubes only after relief
of residual pressures. (See «RELEASING RESI-
DUAL PRESSURES FROM THE CIRCUITS»).

RKP09370

1. Boom test
1 - Position the machine with the arm vertical and the 3
bucket on the ground, resting on its back.
2 - Stop the engine and release any residual hydrau-
lic pressure.
3 - Disconnect the hose (1) that feeds the cylinder on 4
the head side.
H Plug the hose to keep out impurity
4 - Disconnect the hose (2) and plug it to keep out im- 1
purity. 2
RKPB1041
5 - Remove safety valve (3) together with the pipe (4)
and plug the bottom side under port using flange
L1.
H Plug the pipe to keep out impurity.
6 - Start the engine and extend the arm completely.
7 - Stop the engine and check the position of the
boom for 5 minutes.
. If the boom drops, the drift is due to the cylin-
der gasket.
. If the boom does not drop, the drift is due to
the control valve.

2. Arm test
1 - Position the machine with the arm completely ex-
tended and the bucket teeth on the ground.
2 - Stop the engine and release any residual hydrau-
lic pressure.

RKP09380

PW75R-2 20-67
TESTING AND ADJUSTMENTS ANALYSIS OF THE CAUSES OF HYDRAULIC DRIFTS

3 - Disconnect the hoses (1) and (2) from the pipes

and plug them to keep out impurity.
2
Standard 3
4 - Plug the hose (1) feeding the cylinder on the head
side and connect a provisional hose on the bottom
side to collect any leaking of oil.
Safety valve version
5 - Remove the safety valve (3) from the cylinder and
plug it to keep out impurity. 1
6 - Plug the head side cylinder port using flange L1. RKPB1060

All version
7 - Start the engine and raise the boom.
8 - Stop the engine and check the position of the arm
for 5 minutes.
. If the arm drops, the drift is due to the cylinder
gasket.
. If the arm does not drop, the drift is due to the
control valve.

3. Testing the functionality of the boom and arm

safety valve. V2
H This test should be carried out after having
checked that the drift is not due to the cylinder
gaskets (See «BOOM TEST» and «ARM TEST»),
and after having checked the valve settings
(See «ADJUSTING BOOM AND ARM SAFETY
VALVES»). 2 1

1 - Depending upon which valve is to be checked, po-

sition the machine as for the «Boom test» or for the C2
«Arm test».
2 - Disconnect the hose (1) that supplies the valve RKPB1040

(port V2).
3 - Disconnect:
For the boom, the head side pipe.
For the arm, the bottom side pipe.
1
4 - Start the engine and extend the arm completely
for the «Boom test», or raise the boom for the V2
«Arm test».
5 - Stop the engine and check for leakages from the
valve for 5 minutes.
. If there is any leakage, the valve is defective.

RKPB1051

20-68 PW75R-2
TESTING AND ADJUSTMENTS ANALYSIS OF THE CAUSES OF HYDRAULIC DRIFTS

4. 2nd boom test

1 - Position the machine with the arm and the 2nd
boom completely extended. Rest the bucket teeth
on the ground.
2 - Stop the engine and release any residual hydrau-
lic pressures.

RKP09390

3 - Disconnect the two pipes (1) and (2) and cap them
to prevent entry of impurities.
H If a safety valve has been installed, remove it.
4 - Cap the cylinder couplings on the bottom side and
1
attach provisional hoses on the head side to col-
lect any leaking oil.

2
RKPA5540

5 - Start the engine and raise the boom.

6 - Stop the engine and check the position of the 2nd
boom for 5 minutes.
. If the 2nd boom closes, the drift is due to the
cylinder gasket.
. If the 2nd boom does not close, the drift is due 50 cm
to the control valve.
To check one cylinder at a time, proceed as follows:
7 - Rest the bucket on the ground and release any re-
sidual hydraulic pressures.
8 - From one cylinder remove the cap mounted on the RKP09400
bottom side during phase 4.
9 - Start the engine, raise the boom and then stop the
engine.
10 - Check the position of the 2nd boom for 5 minutes.
. If the 2nd boom closes, the drift is due to the
gaskets of the cylinder that has been capped.
11 - Repeat the operation from phase 8 to phase 10 to
test the other cylinder.

PW75R-2 20-69
TESTING AND ADJUSTMENTS ANALYSIS OF THE CAUSES OF HYDRAULIC DRIFTS

5. Testing the functionality of the 2nd boom safety

valves

H This test should be performed after having ascer- V2

tained that the drift is not due to the cylinders.
(See «2nd BOOM TEST») and after having checked
the adjustment of the safety valves (See «AD- V1
JUSTING 2nd BOOM SAFETY VALVES»).
1 - Position the machine with the arm and 2nd boom
fully extended. Rest the bucket teeth on the
ground.
2 - Stop the engine and relieve any residual hydraulic RKPA5530
pressures.
3 - Disconnect the connecting tubes of the safety
valves (two pipes of ports V1 and V2 for each
valve).
4 - Start the engine and raise the boom.
5 - Stop the engine and check the position of the 2nd
boom for 5 minutes.
50 cm
. If the 2nd boom tends to close, both safety
valves are defective.

RKP09400

6. Bucket test
1 - Position the machine with the arm vertical and the
bucket horizontal and resting on the ground. Put a
weight in the bucket, or fill it with earth.
2 - Stop the engine and release any residual hydrau-
lic pressure.
3 - Disconnect the pipes (1 and 2) of the bucket cylin-
der and cap them to prevent entry of impurities.
4 - Cap the hole in the bucket cylinder on the bottom
side and attach a provisional hose on the head
side to collect any oil leakages. RKP09430

RKPA5520

20-70 PW75R-2
TESTING AND ADJUSTMENTS ANALYSIS OF THE CAUSES OF HYDRAULIC DRIFTS

5 - Start the engine and raise the boom.

6 - Stop the engine and check the position of the
bucket for 5 minutes.
. If the bucket tends to open, the drift is due to
the cylinder gasket.
. If the bucket does not tend to open, the drift is
due to the control valve.
50 cm

RKP09420

7. Boom swing test

1 - Position the machine with the boom, arm and
bucket raised and with the revolving frame turned
90ë to the right.
2 - Stop the engine and release any residual hydrau-
lic pressure.
3 - Disconnect the pipes (1 and 2) of the boom swing
cylinder and cap them. 15°
4 - Cap the hole in the boom swing cylinder on the
bottom side and attach a provisional hose to the
head side to collect any oil leakages. RKP09510

5 - Start the engine and move the machine onto a 15ë

slope.
6 - Stop the engine and check the position of the
boom for 5 minutes.
. If the boom tends to swing, the drift is due to
the cylinder gasket.
. If the boom does not tend to swing, the drift is
due to the control valve.

1 2

RKPA5490

8. Test for the outriggers

H Test one outriggers at a time.
1 - Swing the revolving frame to bring the work equip-
ment to the same side as the outriggers. Position
the machine with the arm vertical and the back of
the bucket resting on the ground.
2 - Lower the outriggers to be tested to about half its
possible stroke and support it on a block of height
25 cm. 25 cm

3 - Stop the engine and release all residual hydraulic

pressures.
RKP09450

PW75R-2 20-71
TESTING AND ADJUSTMENTS ANALYSIS OF THE CAUSES OF HYDRAULIC DRIFTS

4 - Disconnect the tubes (2) and (3) that connect the

safety valves (1) to the cylinder (4). Plug the valves 2
to prevent entry of any impurities. 2
5 - Plug the tube (3) of the cylinder (4) on the head
side and attach a provisional tube on the base 3
side to collect any leakages. 3
6 - Start the engine, push down with the boom to
raise the machine and remove the supporting 4
block from beneath the outriggers. 4 1
7 - Lower the machine and stop the engine.
8 - Check the position of the outriggers for 5 minutes. RKPA7960

. If the outriggers drops, the drift is due to the

cylinder (4).
. If the outriggers does not drop, the drift is due
to the safety valve (1).
H To discover whether the drift is due to the swi-
vel joint, see «CHECKING FOR LEAKAGES
INSIDE THE SWIVEL JOINT - CIRCUITS
FOR OUTRIGGERS AND BLADE».

RKP09460

20-72 PW75R-2
TESTING AND ADJUSTMENTS ANALYSIS OF THE CAUSES OF HYDRAULIC DRIFTS

9. Blade test
1 - Position the machine with the arm vertical and
resting on the ground, and with the bucket resting
on its back.
2 - Bring the blade to roughly half its potential stroke
and support it on a block, height 28 cm, placed in
the centre.
3 - Stop the engine and release any residual hydrau- 28 cm
lic pressure.
4 - Disconnect both safety valves (1) and the tubes (2)
and (3) that connect them to the cylinder (4). Plug RKP09470
the valves to prevent entry of any impurities.
5 - Plug the tube (3) on the head side of just one cy-
linder (4) and attach a provisional tube on the 2 2
base side of the same cylinder to collect any lea-
kages.
H The second cylinder should be left completely
free.
6 - Start the engine, push down with the boom to
3
raise the machine in order to remove the block
3 1
on which the blade is resting.
4
7 - Lower the machine and stop the engine.
4
8 - Check the position of the blade for 5 minutes.
. If the blade tends to sink, the drift is due to the RKPA7970

cylinder (4).
. If the blade does not tend to sink, the drift is
due to the safety valve group (1).
H To discover whether or not the drift is due to
the swivel joint, see «CHECKING FOR LEA-
KAGES INSIDE THE SWIVEL JOINT - CIR-
CUITS FOR OUTRIGGERS AND BLADE».
9 - To test the other cylinder repeat these operations,
starting from point 5.

RKP09480

PW75R-2 20-73
TESTING AND ADJUSTMENTS ANALYSIS OF THE CAUSES OF HYDRAULIC DRIFTS

10. Swing motor test

1 - Position the machine with boom, arm and bucket
raised as in the figure, and with the revolving
frame turned 90ë.
2 - Stop the engine and release any residual hydrau-
lic pressure.

RKP09490

3 - Disconnect the hoses (1 and 2) from the motor

and cap them to prevent entry of impurities. At-
tach some provisional hoses to the motor to col- 1
lect any oil leakages.
4 - Disconnect brake swing hose (3) from motor.
2
5 - Connect equipment H1 between motor and hose
(3). 3
Check that cock is open and near the hose (3).

RKPA5322

6 - Connect gauge E1 to the equipment H1.

7 - Start engine and start swing. E1
H In this way the swing brake will be disen-
gaged.
8 - With the swing brake circuit under pressure (30
bar) close the cock of the equipment H1.
3

H1 RKP08081

9 - Let the machine travel onto a 15ë slope, and stop

the engine.
8 - Mark the position between revolving frame and
track frame on the swing circle. Check on any
swinging movement of the revolving frame for 5
minutes.
. If the revolving frame tends to swing, the drift
is due to the swing motor.
. If the revolving frame does not tend to swing,
15°
the drift is due to the control valve
H During this test, the pressure indicated on the
pressure gauge E1 should not drop below the
limit value of 18 bar. (*18 kg/cm2). RKP09440

20-74 PW75R-2
TESTING AND ADJUSTMENTS ANALYSIS OF THE CAUSES OF HYDRAULIC DRIFTS

11. Checking the travel motor

1 - Position the machine with the arm vertical and the
back of the bucket resting on the ground. Stop the
engine.
2 - Disconnect the supply tube (2) from the parking
brake (1).
3 - Insert apparatus H1 between the brake (1) and the
tube (2). Attach the pressure gauge E1 (60 bar) to
the adapter of apparatus H1 to keep a check on
the parking brake release pressure throughout
the test.
RKP09520

4 - With the cock (3) of test apparatus H1 open, start

the engine and engage and release the parking
brake several times.
5 - Raise the front work equipment and travel the ma-
2
H1
chine over a surface with a 15ë slope. 1
H The articulated axle should be facing towards
the lower part of the slope.
6 - Using the working brakes to hold the machine in 3
position, close the cock of apparatus H1 in order
to maintain pressure (35 3.5 bar) and thus to keep
the parking brake released. Stop the engine.
7 - After 5 minutes, mark the position of the machine.
E1
8 - Check whether or not the machine has moved RKPA7980

every 5 minutes for a total of 15 minutes.

H During this test the pressure indicated on the
pressure gauge E1 should not drop below a
minimum limit of 22 bar.

15°

RKP09530

PW75R-2 20-75
TESTING AND ADJUSTMENTS ANALYSIS OF THE CAUSES OF HYDRAULIC DRIFTS

12. Test for the axle-locking valve

H Use the same method to check both cylinders.
1 - Start the engine and lock the axle.
2 - Fully extend the entire front work equipment and
lower it to approx. 70 cm above the ground.
3 - Swing the frame approx. 45ë to bring the work
equipment over the axle-locking cylinder (1-3) 70 cm
being tested.
4 - Stop the engine and check to see for 5 minutes,
whether the work equipment has dropped at all.
H If cylinder yields and there is no visible leak- RKP09540

age, drift comes from the check valve inside

the cylinder; check valve should be over-
hauled.

RKP09410

20-76 PW75R-2
 DISASSEMBLY AND ASSEMBLY
HOW TO READ THE MANUAL . . . . . . . . . . . . . . . . . . . . . . . . 3
PRECAUTIONS TO BE TAKEN
WHEN WORKING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
STARTER MOTOR
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
ALTERNATOR
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
INJECTION PUMP
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
NOZZLE HOLDER
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
CYLINDER HEAD
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
SEAT
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
CABIN
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
ENGINE HOOD
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
REMOVAL OF FRONT HOOD
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
RADIATOR
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
HYDRAULIC OIL COOLER
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
FUEL TANK
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
HYDRAULIC OIL TANK
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
PW75R-2
ENGINE-PUMP GROUP
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
PUMP GROUP
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
ENGINE-PUMP COUPLING JOINT
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
MAIN PUMP INPUT SHAFT OIL SEAL
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
GEAR-PUMP
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
SWIVEL JOINT
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
SWING MOTOR
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
SWING GEARED MOTOR
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
SWING MACHINERY ASSEMBLY
Disassembly . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 41
Assembly . . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 44
CONTROL VALVE
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
REVOLVING FRAME
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
COUNTERWEIGHT
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
SWING CIRCLE
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
TRANSMISSION - REVERSER, DIRECTION
INDICATOR AND HEADLIGHT DIPPER
BEAM CONTROL GROUP
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
30-1
R.H. PPC VALVE (BOOM - BUCKET) BOOM CYLINDER (For 2-piece boom)
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
L.H. PPC VALVE (ARM-SWING) 2nd BOOM CYLINDERS
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
OUTRIGGER AN\D BLADE PPC VALVE ARM CYLINDER
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
BOOM SWING PPC VALVE BUCKET CYLINDER
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
TRAVEL AND 2nd BOOM PPC VALVE BOOM SWING CYLINDER
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
BRAKE PUMP CYLINDERS FOR OUTRIGGERS OR BLADE
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
STEERING UNIT WORK EQUIPMENT CYLINDERS
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
STEERING UNIT WORK EQUIPMENT (For 1-piece boom)
Disassembly. .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . 62 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Assembly . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . 68 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
PRIORITY VALVE WORK EQUIPMENT (For 2-piece boom)
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
PRIORITY VALVE BUCKET
Assembly . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . 79 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Disassembly. .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . 79
ARM
TRAVEL MOTOR
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Disassembly. .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . 82 2nd BOOM
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Assembly . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . 85
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
TRANSMISSION
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
1st BOOM
Disassembly. .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . 91
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Assembly . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . 98
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
AXLE LOCKING CYLINDERS
SWING BRACKET
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
FRONT AXLE
BLADE AND OUTRIGGERS
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
BLADE AND OUTRIGGERS ARMS
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
AXLES Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
Disassembly. .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 112
Assembly . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 124
BOOM CYLINDER (For 1-piece boom)
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

30-2 PW75R-2
DISASSEMBLY AND ASSEMBLY HOW TO READ THE MANUAL

HOW TO READ THE MANUAL

1. Removal and Installation of the groups
(1) The procedures and information needed to carry out the work of removing or Installing units or groups are
given in the removal procedure. The sequence of operations is not repeated in the installation procedure.
(2) Information needed for installation is marked with the symbol . The same symbol is repeated at the
end of each removal procedure for the same item, to indicate to which installation item it refers.
(Example)
REMOVAL GROUP : *** : . . . . . . . . . . . . . . . . . . . . . . . . Title of operation

:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety precautions to be followed when carrying

out the operation.
1 - Remove XXXX (1):. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Step in removal procedure.
H : . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Technique or important point to remember when re-
moving XXXX (1)
2 - ~ ~ ~ (2): . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . This sign means that information is given for
the installation procedure
3 - Remove &&&& (3):
........... ,: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Recovery of oil or water, and the quantity to be re-
covered.

INSTALLATION GROUP *** : . . . . . . . . . . . . . . . . . . . . . Title of operation.

. To install, reverse removal procedure.
: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Technique to be used for installation.
H : . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Technique or important point to remember when re-
moving ~ ~ ~ (2).
. Addition of water or oil: . . . . . . . . . . . . . . . . . . . . . . Step in removal procedure.
H : . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Point to remember when adding water or oil.

2. To the precautions to be taken during the removal or installation of the groups, must be added the specific
«PRECAUTIONS TO BE TAKEN DURING THE OPERATIONS».
Always make sure that these precautions are taken.

3. List of special tools.

(1) For details of the descriptions, codes and quantities of each tool (A1; A2 etc.) mentioned in the operational
procedures, see the list «SPECIAL TOOLS» supplied in this section.

4. List of the tightening torques and weights, and the quantities oil, liquids or grease needed to fill
tanks and containers
(1) In the operating procedures, you will find the symbols , , , . In the following order, these
represent the values of «TIGHTENING TORQUES», «WEIGHT OF PARTS OR GROUPS», «QUANTITIES
OF OIL OR LIQUIDS TO BE INTRODUCED», «SCREW LOCKING MATERIAL, SEALANTS AND LUBRICA-
TION», «LUBRICATING GREASE».
NOTE
If no symbol is indicated, the values to be used are those given in the introductory sections of this manual.

PW75R-2 30-3
DISASSEMBLY AND ASSEMBLY PRECAUTIONS TO BE TAKEN WHEN WORKING

PRECAUTIONS TO BE TAKEN WHEN WORKING

H When dismantling or installing a part, always take the following general precautions.

1. Precautions for removal operations

. If not otherwise indicated, lower the work equipment until it rests on the ground.
. If the coolant liquid contains an anti-freeze substance, follow the instructions given for drainage.
. After having removed flanges and tubes, insert plugs to prevent impurities from entering.
. Before removing a cylinder, fully retract the piston and tie it with wire.
. Use a sufficiently large container to collect the oil.
. Before removing a part from the machine, check the alignment reference marks which show the correct in-
stallation position. If necessary add further marks to avoid incorrect installation.
. While dismantling the connectors, always grasp them firmly to avoid undue strain on the wiring.
. If necessary, attach markers to the wires and tubes to avoid muddling them up during installation.
. Check the number and height of the adjustments to a given clearance and store them in a safe place.
. When raising the machine or some parts of it, use adequate equipment for the weight of the part concerned.
. When using screws or eyebolts to remove items of the machinery, screw them alternately, and as deeply as
they will go.
. Before removing a piece, clean the surrounding area and, after removal, cover the area to prevent dirt or
dust from gaining entrance.
2. Precautions to be taken during installation
. Tighten nuts and screws with the specified tightening torques.
. Install the flexible hoses, taking care not to entangle or twist them.
. Bend the cotter pins and stops in such a way as to secure them.
. When coating the threads with adhesives, clean the piece to remove oil and grease, then apply just enough
adhesive to cover the threading in a uniform manner.
. When applying a liquid sealant, clean the surface involved, remove residual oil and grease, check that there
are no dents or dirt, then apply the liquid sealant in a uniform manner.
. Clean all the parts, remove dirt, rust, burrs, or dents.
. Apply a film of engine oil over all the moving parts.
. Apply a film of anti-friction grease (ASL800040) over all surfaces assembled with pressure, to avoid sticking.
. After having mounted the snap-rings, check that they are firmly positioned in their seatings.
. When installing electrical system jacks, remove any oil, dust or water that may have penetrated into them,
then connect them firmly.
. If using eyebolts, check that they are not distorted, screw them in fully, and then align the eye with the hoist-
ing hook.
. Mount the flanges in a uniform manner, and tighten the screws in criss-cross sequence, to avoid excessive
pull on one side only.
3. Precautions to be taken on completion of removal and installation operations.
. If the coolant liquid has been drained away, close the drainage plug and add new liquid up to normal level.
Start the engine to circulate the liquid throughout the cooling system and then top up the level once more.
. When the hydraulic equipment has been dismantled, add engine oil to the indicated level. Start up the en-
gine to circulate the oil in the hydraulic circuits, and then top up to the indicated level.
. If hoses or hydraulic equipment, such as hydraulic cylinders, pumps, motors, solenoid valves and valves,
are removed for repairs or substitution, bleed air from the hydraulic circuits after having re-assembled the
machine.
H For details, see «20. TESTING AND ADJUSTMENTS».
. After having re-assembled cylinder joints or cylinders, or work equipment articulations, lubricate thoroughly.

30-4 PW75R-2
DISASSEMBLY AND ASSEMBLY SPECIAL TOOLS

SPECIAL TOOLS

Nature of work Symbol Code Description Q.ty Notes

Removal/Installation 1 ATR201320 Coupling for brake 1 Ð

revolving frame and swing release
A 2 ATR200400 Rear raising equipment 1 Ð
Installation of swing
machinery for revolving frame 3 ATR200410 Front raising equipment 1 Ð
Removal/Installation of
counterweight
Removal of wheels B 1 ATR800230 Dynamometric wrench 1 Max. 700 kgm (700 dNm)
with multiplier
Disassembly/Assembly of
cylinder nut
1 ATR501290 Tool 1 Rotating unit assembly

2 ATR501300 Tool For central pin clearance

Assembly travel motor C checking

3 ATR501310 Tool Gasket, spacer, circlip

assembly
Removal/Installation of D 1 ATR200420 Swing circle raising 1 Ð
swing circle equipment
Removal of wheels E 1 ATR200650 Raising support 1 Ð

1 ATR200470 Pliers for mounting 1 All cylinders

gaskets
ATR200480 ù 50 calibrator 1
ATR201330 ù 55 calibrator 1 To calibrate piston rod
2 gaskets
ATR200490 ù 60 calibrator 1
ATR200500 ù 70 calibrator 1
ATR201030 ù 85 plunger 1
ATR200510 ù 90 plunger 1
3 ATR200520 ù 100 plunger 1 To assemble piston
gaskets
ATR201340 ù 110 plunger 1
ATR200530 ù 120 plunger 1
ATR201030 ù 85 calibrator ring 1
ATR200540 ù 90 calibrator ring 1
4 ATR200550 ù 100 calibrator ring 1 To calibrate piston
gaskets
Disassembly/Assembly F ATR201350 ù 110 calibrator ring 1
the cylinders
ATR200560 ù 120 calibrator ring 1

ATR200570 ù 50 insertion bushing 1

for piston rod

ATR201360 ù 55 insertion bushing 1

for piston rod To mount flange
5
ù 60 insertion bushing and head
ATR200580 for piston rod 1

ATR200590 ù 70 insertion bushing 1

for piston rod

6 ATR200600 Pliers for mounting 1 All cylinders

snap-ring

ATR800240 Socket wrench 1 Bucket cylinder

(6-point 55)
7
ATR800250 Socket wrench 1 Boom and arm cylinder
(6-point 70)

8 ATR200610 Tool for disassembly and 1 All cylinders

assembly cylinders

PW75R-2 30-5
DISASSEMBLY AND ASSEMBLY SPECIAL TOOLS

Type of work Symbol Code Description Q.ty Notes

1 796T-267-1110 Plunger 1
Replace of pump seal G Replace of pump seal
2 790-201-2730 Spacer 1
Disassembly/Assembly
the swing bracket H 1 ATR201370 Raising equipment 1 Ð

1 ATR501340 Plunger 1 Removal ring

2 ATR501350 Support 1 Removal pinion
3 ATR501360 Plunger 1 Removal pinion
4 ATR501370 Plunger 1 Removal bearing
5 ATR501380 Plunger 1 Mounting seal
Disassembly/Assembly
the cylinders L 6 ATR501390 Plunger 1 Mounting ring
7 ATR501400 Plunger 1 Mounting bearing
8 ATR501410 Plunger 1 Mounting bearing
9 ATR501420 Dynamometer 1 Full scale 20 kg
10 ATR501430 Plunger 1 Place of pinion
11 ATR501440 Plunger 1 Fitting guard
1 ATR501570 Tool 1 Disassembly and assembly
2 ATR501580 Wrench 1 front axle bevel pinion

3 ATR501020 Wrench 1 Disassembly and assembly

4 ATR501040 Tool 1 rear axle bevel pinion

Fitting tapered bearing

5 ATR500960 Tool 1 thrust blocks on front and
rear axle pinion (4WS)

6 ATR501600 Tool 1 Adjusting front and rear axle

bevel pinion (4WS)

7 ATR500990 Tool 1 Adjusting front and rear axle

bevel pinion (4WS)

8 ATR501610 Tool 1 Fitting front and rear axle

Disassembly/Assembly M bevel pinion (4WS)
axles
9 ATR500930 Tool 1 Fitting front axle sealing
ring
Fitting tapered roller
10 ATR501010 Tool 1 bearing thrust blocks on
rear axle pinion (2WS)
11 ATR501050 Wrench 1 Bevel gear adjusting

12 ATR500940 Tool 1 Fitting seals on rear axle

hub (2WS)
Fitting sealing ring and
13 ATR501550 Tool 1 centre square in rear
axle (4WS)

14 ATR500950 Tool 1 Fitting bearing on rear axle

hub (2WS)

30-6 PW75R-2
DISASSEMBLY AND ASSEMBLY SPECIAL TOOLS

Type of work Symbol Code Description Q.ty Notes

Fitting sealing ring on front
15 ATR501560 Tool 1 and rear axle articulation
(4WS)
Disassembly/Assembly M
axles A Guide 1
Assembling seals, piston
16 ATR501590 B Guide 1 and head of steering
cylinder
C Pin 1
To determine clearance
1 ATR501070 Distance piece 1 of central pin
Assembly travel motor P
2 ATR501080 Special tool 1 To determine clearance
of central pin

1 ATR200640 Special wrench 1 To remove the hydraulic

guide from the machine
Guide
Removal - Installation of
hydraulic guide Q 2 ATR501090 Plunger 1 Spool seal assembly
Assembly of steering unit Push rod
3 ATR501100 Fork 1 Control shaft check
4 ATR501110 Plunger 1 Mounting guard

PW75R-2 30-7
DISASSEMBLY AND ASSEMBLY

30-8 PW75R-2
DISASSEMBLY AND ASSEMBLY STARTER MOTOR

REMOVAL OF STARTER MOTOR

Disconnect the lead from the negative (±) battery
terminal.
2
1 - Remove upper cover (1) with exhaust pipe (2).
2 - Remove lower guard. 1

RKPA5550

3 - Remove heat-guard (3).

RKPB1320

4 - Disconnect electrical cable (4).

5 - Remove screw (5) and starter motor (6). 5
4

6 5
RKPA5561

INSTALLATION OF STARTER
MOTOR
. To install, reverse the removal procedure.

Screw: 78.4 ± 98 Nm

PW75R-2 30-9
DISASSEMBLY AND ASSEMBLY ALTERNATOR

REMOVAL OF ALTERNATOR
Disconnect the lead from the negative (±) battery
terminal.
2
1 - Remove upper cover (1) with exhaust pipe (2).

RKPA5550

2 - Remove union (3) of the exhaust pipe.

RKPB0680

3 - Disconnect cable (4) and connector (5).

4 - Loosen bolts (6), (7) and (8) sufficiently to allow the al- 7
ternator (9) to be rotate.
5
5 - Free the pulley from the fan-belt (10) and remove al-
ternator (9).
4

6
RKPA5231

INSTALLATION OF ALTERNATOR
. To install, reverse the removal procedure.
10
9
H Check the union gasket of exhaust pipe.

H Adjust the tension of the fan-belt. (For details, see

«20. TESTING AND ADJUSTMENTS). 8

RKPA5221

30-10 PW75R-2
DISASSEMBLY AND ASSEMBLY INJECTION PUMP

REMOVAL OF INJECTION PUMP

Disconnect the cable from accumulator negative
terminal (±).
H Close the cock (1) of separator (2) to prevent fuel leak-
age. 1
H Plug removed or disconnected pipes to avoid impurity
entry. 2

RKPB0690

1 - Disconnect pipe (3) from fuel filter.

2 - Disconnect high pressure pipes (5) from injection
pump (4). 5

4
RKPA5570

3 - Disconnect from injection pump (4) fuel feeding pipes

(6) and return pipes (7).

7 6

RKPA5580

4 - Disconnect pipes (9) and (10) from fuel feed-pump (8).

5 - Disconnect the engine stop solenoid (11) from injec-
10
tion pump (4) and remove the complete unit.
11

RKPA5191

PW75R-2 30-11
DISASSEMBLY AND ASSEMBLY INJECTION PUMP

6 - Disconnect control cable (13) from accelerator lever

(12).
12

13

RKPA5241

7 - Remove the bolt and bracket (14) of injection pump

lubricating pipe.
8 - Remove injection pump lubricating pipe (15).
15
14

RKPA5590

9 - Remove coolant tank support (16).

10 - Remove fan guard (17).

17

16

RKPB1080

11 - Remove the inlet cover (18) to ignition gear system

and the filler oil plug (19).

19
18

RKPA5600

30-12 PW75R-2
DISASSEMBLY AND ASSEMBLY INJECTION PUMP

12 - Loosen and remove nut (20) and lock washer (21) of

pump driving gear (22).
H Be careful not to let lock washer drop in the hous- 22
ing.

21
20

RKPA5610

13 - Remove pump (4) driving gear (22).

H Before removing pump driving gear, mark posi- X2
tion compared to idling gear. 25
H For removal, use a puller (X1) and tighten its
screws (X2) directly in the gear (22). 23
H Be careful not to damage pump shaft thread.
H During removal be careful not to let key drop (23)
in the housing.
22 X1

X2
RKP07800

14 - Remove nuts (24) (No. 4) and injection pump (4) with

relative OR rings (25).

4 24

RKPA5591

PW75R-2 30-13
DISASSEMBLY AND ASSEMBLY INJECTION PUMP

INSTALLATION OF INJECTION PUMP

. To install, reverse the removal procedure.

Feed and return pipes: 19.6 ± 24.5 Nm

High pressure pipes: 19.6 ± 24.5 Nm

H Replace safety cotter pin.

Lubrication pipe pump side: 9.8 ± 12.7 Nm

Lubrication pipe cylinders side: 12.7 ± 16.7 Nm
Stiffening bolt: 22.5 ± 28.4 Nm

Cover gasket: ASL800070

Timing gear system cover bolts:17.6 ± 22.5 Nm

Ingranaggio pompa
Injection pump
H Align marks among gears before to install pump d'iniezione
gear
and nut.
Gear lock nut: 83.3 ± 93.1 Nm

Reference
Riferimento

Idling gear folle

Ingranaggio

RKP07810

Pump lock nuts: 34.3 ± 44.1 Nm

1 - Check fuel injection timing.
(For details, see «20. TESTING AND ADJUSTMENTS»).

30-14 PW75R-2
DISASSEMBLY AND ASSEMBLY NOZZLE HOLDER

REMOVAL OF NOZZLE HOLDER

1 - Remove suction pipe (1) with union (2). 2

1
2 - Disconnect connector (3) of clogging indicator and re-
move union (4) and filter (5).

5 3

RKPB1090

3 - Remove electrical cable bridge (6).

RKPA5141

4 - Loosen clips (7) and remove high pressure pipes (8)

and fuel recovery pipes (9).
9
5 - Remove collar (11) lock nut (10) and remove nozzle
holder (12), seat (13) and guard (14).

7
8

RKPA5620

INSTALLATION OF NOZZLE 11
HOLDER
. To install, reverse the removal procedure.
10
High pressure pipe fittings: 19.6 p 24.5 Nm

12 14
Collar lock nuts: 6.9 p 8.8 Nm 13
RKP07790

PW75R-2 30-15
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD

REMOVAL OF CYLINDER HEAD

Disconnect the cable from accumulator negative
terminal (±).
H Drain the coolant liquid.
1
Coolant liquid: 18 ,

1 -Remove coolant tank (1).

RKPB1081

2 - Remove suction pipe (2) with air filter union (3).

3 2
3 - Remove air filter (4) with union (5)

4
5

RKPB1091

4 - Disconnect the cable (6) from the thermostat.

7
5 - Remove the fastening screws of both electrical cable
bridge (7) and lifting brackets; turn the assembly over
towards the piston pump.

6 - Re-position the previously removed screws and tight-

en them up.
Screw: 22.5 ± 28.4 Nm (2.3 ± 2.9 kgm)

RKPA5630

7 - Remove the alternator adjustment bracket (8); disen-

gage the belt and rotate the alternator (9) towards the
stationary hood. 8
10
8 - Remove nut (10), screw (11) and remove muffler (12)
with support (13).
12
13

11
9
RKPA5640

30-16 PW75R-2
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD

9 - Remove fuel filter (14).

10 - Remove clip (15).

15

14

RKPA5571

11 - Disconnect coolant pipe (16) and heating pipe (17)

from cylinder head.
16
12 - Remove nozzle holder. (For details, see «REMOVAL
OF NOZZLE HOLDER»).

18
17

14

RKPA5581

13 - Remove the valve-tappets cover (18). 19

14 - Remove the rocker shaft (19).
21
H Loosen lock nut and unscrew valve tappets of 2-3
turns.
22
15 - Remove the push rods (20).

20

RKP07780

16 - Remove screw (21) and the cylinder head (22) follow-

ing the indicated order for bolts loosening.
BOLT LOOSENING ORDER

H Bolts loosening order: see illustration

7 16 14 6
Loosen cylinder head bolts in two stages. 1 9 18 12 4

3 11 17 10 2
5 13 15 8

RKP07820

PW75R-2 30-17
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD

INSTALLATION OF CYLINDER HEAD

. To install, reverse the removal procedure.

1 - Fill the cooling circuit.

Coolant liquid: 18 ,
2 - Start engine to allow liquid circulation in all circuits;
stop the engine and check the level.

Screw: 22.5 ± 28.4 Nm (2.3 ± 2.9 kgm)

H Adjust fan belt tension (for details see «20. TEST-

ING AND ADJUSTMENTS»).

H Replace exhaust pipe gasket.

Nut and screw: 22.5 ± 28.4 Nm (2.3 ± 2.9 kgm)

3 - Check the condition of valves cover gasket and of

lock nuts OR rings, clean carefully contact surface
on cylinders head.
Cover lock nuts: 25w3 Nm

H Check that tappets are firmly engaged in the rods

and that the valves collar are correctly as-
sembled.
H Start the rocker shaft tightening starting from the
center to external.
Rocker shaft bolts: 44.1 ± 53.9 Nm

H Adjust valves clearance. (For details, see «20.

TESTING AND ADJUSTMENTS»).

H Assemble a new gasket.

H Lubricate with engine oil bolts thread and cylinder
block.
H Tighten screws, first manually and after in two
stages, according to assigned order.
Cylinder head bolts:
1st Tightening: 49 ± 59 Nm BOLT LOOSENING ORDER
Final tightening: 103 ± 113 Nm

12 3 5 13
18 10 1 7 15

16 8 2 9 17
14 6 4 11

RKP07830

30-18 PW75R-2
DISASSEMBLY AND ASSEMBLY SEAT

REMOVAL OF SEAT
Lower the work equipment until it is resting on the
ground, switch off the engine and remove the ignition
key.
1

1 - Raise the front window (1) completely.

2 - Remove the lower window (2) and place it in the sup-
ports provided at the back of the cabin.
3 - Remove the four screws (3) that secure the seat.
H Slide the seat forwards and backwards in order to
reach the screws.
4 - Remove the seat.
Seat: 32 kg

INSTALLATION OF SEAT 2

. To install, reverse the removal procedure.

RKPB1280

RKPB0940

PW75R-2 30-19
DISASSEMBLY AND ASSEMBLY CABIN

REMOVAL OF CABIN
Lower the work equipment until it is resting on the
ground and switch off the engine.

1 - Disconnect the connector (1) and hose (2) from the

windshield-washer tank and remove all the clamps 4
fixing them.
4
2 - Disconnect the heating hose (3) from the diffuser (4).
3 - Move the back of the operator's seat completely for-
3
ward and remove the panel (6) fixing screw (5).
4 - Raise the pane (6), disconnect the heating hose (7) 2
RKPB1110

from the diffuser (8) and remove the panel (6).

5 - Remove the knob (9), remove the screws (10) (Në 3)
and remove the panel (11). 5
8
6 - Disconnect the connector (12). 6 6

7 - Remove the cable fixing screws (13) (në 7). 7

8 - Remove the upper protective caps and mount the
hoisting eyebolts (7).
9 - Attach the eyebolts (7) to the hoisting tackle and
move the cabin.
Cabin: 250 kg
RKPB1120

INSTALLATION OF CABIN
. To install, reverse the removal procedure. 7
7
H Make sure that the short screw (8) is placed on the
LH side.

10

12 8
9
13

11

RKPB1130 RKPB1100

30-20 PW75R-2
DISASSEMBLY AND ASSEMBLY ENGINE HOOD

REMOVAL OF ENGINE HOOD

Lower the work equipment until it is resting on the
ground and switch off the engine.

1 - Disconnect the rear light supply connector (1).

1
2 - Detach the gas cylinder (2) from the engine hood.
3 - While holding up the engine hood (3) remove the
screws (4) that attach the hood to the hinges (5).

H Mark the position of any shims.

Engine hood: ........ kg
RKPB0840

INSTALLATION OF ENGINE HOOD

. To install, reverse the removal procedure.
1
H Check the centering and adjustment of the clos-
ing hook (6).
H Position any shims.
Replace the cotter pins (7). 2
RKPB0560

RKPB0570

6
5

RKPB0950

PW75R-2 30-21
DISASSEMBLY AND ASSEMBLY FRONT HOOD

REMOVAL OF FRONT HOOD

Lower the work equipment until it is resting on the
ground and switch off the engine.
2
1 - Detach the gas cylinder (2) from the support (1).

RKPA5660

2 - While holding up the hood (3) remove the screws (4)

that attach the hood (3) to the hinges (5). 4

H Mark the position of any shims.

Engine hood: ........ kg

RKPA5670

INSTALLATION OF FRONT HOOD

. To install, reverse the removal procedure.

H Check the centering and adjustment of the closing

hook (6).
H Position any shims.
Replace the cotter pins (7).
6

RKPA5680

30-22 PW75R-2
DISASSEMBLY AND ASSEMBLY HEATING FAN

REMOVAL OF HEATING FAN

Lower the work equipment until it is resting on the
ground and switch off the engine.

Disconnect the lead from the negative (±) battery

2
terminal. 3

Drain the coolant liquid to a level below that of the

connecting tubes (2-3) between the engine and the
1
heating fan.

Cooling liquid: approx. 5 ,

1 - Disconnect the hose clamp (1) and pipes (2) and (3) RKPA5631

from engine and lower the terminals to thoroughly

drain the liquid from the heating radiator.
5 7
Cooling liquid: approx. 1.5 ,
2 - Move the back of the operator's seat completely for- 5
ward and remove the panel (5) fixing screws (4). 6
3 - Raise the panel (5), disconnect the heating hose (6)
from the diffuser (7).

RKPB1121

4 - Remove the knob (8), remove screw (9) (në 3) and re-
move the panel (10).
5 - Move the seat forwards as far as it will go.
10
6 - Disconnect the pipes (11), remove the side screws
(12) that lock the fan unit (13) and disconnect the con-
nector (14).
9
7 - Extract the fan unit (9) backwards. 8

RKPB1140

INSTALLATION OF HEATING FAN

13
. To install, reverse the removal procedure.
1 - Make sure that the heating cock is fully open. 14
11
2 - Fill up with coolant liquid.

Quantity of coolant liquid: approx. 7.5 ,

3 - Start the engine to circulate the coolant liquid. 12

4 - Switch off the engine and top up the level.
RKPB1150

PW75R-2 30-23
DISASSEMBLY AND ASSEMBLY RADIATOR

REMOVAL OF RADIATOR
Lower the work equipment until it is resting on the
ground and switch off the engine.
1
Drain the engine coolant liquid.
2
Coolant liquid: 18 ,

1 - Remove the engine hood.

(For details, see «REMOVAL OF ENGINE HOOD»). 6
2 - Remove the container (1) together with the relative
tubing and support (2).
RKPB1082

3 - Disconnect the engine cooling pipes (3) and (4) from

the radiator.
4 - Remove the suction pipe (5).
7
5 - Remove the fan guard (6).
6 - Remove the fan guard (6)

3
RKPB0581

7 - Remove the top vibration-damper (8).

8 - Remove the top fastener (9) of the radiator-exchan-
ger.
9 - Move the radiator and pull it out upwards.
5
Radiator: ......... kg

RKPB1160

INSTALLATION OF RADIATOR
9
. To install, reverse the removal procedure. 8
1 - Fill up the coolant liquid circuit.

Coolant liquid: approx. 18 ,

2 - Start the engine to circulate the coolant liquid and

check that there are no leakages.
3 - Switch off the engine, check the level of the liquid in
the container and, if necessary, top it up. RKPB0700

30-24 PW75R-2
DISASSEMBLY AND ASSEMBLY HYDRAULIC OIL COOLER

REMOVAL OF HYDRAULIC OIL COOLER

Lower the work equipment until it is resting on the
ground and switch off the engine.
1 2

Release residual pressures from all circuits. (For de-

tails, see «20. TESTING AND ADJUSTMENTS»).
Drain the hydraulic oil. 7

Hydraulic oil: 70 ,
1 - Remove the front hood (For details, see «REMOVAL
OF FRONT HOOD»).
2 - Remove the top cover (1) together with the exhaust RKPB1161

pipe (2).
3 - Disconnect the top return pipe (3) from the exchan-
ger; also remove the connection(4).
4 - Disconnect the bottom pipe (5) and the connection (6) 9
8
from the exchanger. 3
5 - Remove the air suction pipe (7).
6 - Remove the vibration-damper (8).
7 - Remove the top fastener (9) of the radiator-exchan-
ger. 4
8 - Move the exchanger (10) and extract it upwards.
10
H To facilitate removal, screw the bottom connec- RKPB0600

tion (6) into the top hole.

Exchanger: .......... kg

INSTALLATION OF HYDRAULIC
OIL COOLER
. To install, reverse the removal procedure. 5 6
During the filling operation, bleed air from the piston
pump (For details, see «20. TESTING AND ADJUST- RKPA5720

MENTS»).

H Fill up the hydraulic oil tank.

Hydraulic oil needed: approx. 70 ,

1 - Start the engine to fill up the oil cooler and check that
there are no leakages.
2 - Switch off the engine, check the oil level of the hy-
draulic oil tank and, if necessary, top it up.

PW75R-2 30-25
DISASSEMBLY AND ASSEMBLY FUEL TANK

REMOVAL OF FUEL TANK

Lower the work equipment until it is resting on the
ground and switch off the engine.

Disconnect the lead from the negative (±) battery

terminal. 1
H Turn the turret by 45ë towards the right.
2
1 - Remove the front hood (For details, see «REMOVAL
OF FRONT HOOD»).
2 - Turn the cock (1) of separator (2).

RKPB0690

3 - Remove the cap of the fuel tank, open the tank drai-
nage cock (5), and drain the fuel.
5
4 - Disconnect the fuel suction pipe (6).

RKPB0850

5 - Disconnect the fuel return pipe (7) and the connector

(8) of the level gauge (9).
3

9
8

RKPB0720

6 - Disconnect the plate (10) that joins the tanks.

10

RKPB1170

30-26 PW75R-2
DISASSEMBLY AND ASSEMBLY FUEL TANK

7 - Hook the tank (4) to the hoisting equipment and

slightly put the rope under tension.
8 - Remove the bolts and the fuel tank.

Tank: 40 kg 4

RKPB0620

INSTALLATION OF FUEL TANK

. To install, reverse the removal procedure.
H Fill the fuel tank and start the engine.

PW75R-2 30-27
DISASSEMBLY AND ASSEMBLY HYDRAULIC OIL TANK

REMOVAL OF HYDRAULIC OIL TANK

Lower the work equipment until it is resting on the
ground and switch off the engine.

Release residual pressures from all circuits. (For de-

tails, see «20. TESTING AND ADJUSTMENTS»).

. Drain the hydraulic oil.

Quantity of oil: approx. 70 , 2
1 - Remove the front hood (For details, see «REMOVAL 1
OF FRONT HOOD»).
2 - Remove the top cover (1) together with the exhaust
RKPB1180
pipe (2).
3 - Disconnect the top return pipe (3) from the exchan-
ger; also remove the connection(4).
4 - Disconnect the bottom pipe (5) and the connection (6)
6
from the exchanger.
5 - Remove the air suction pipe (7).
6 - Remove the vibration-damper (8).
7 - Remove the top fastener (9) of the radiator-exchan-
ger.
8 - Move the exchanger (10) and extract it upwards. 4
H To facilitate removal, screw the bottom connec-
3
RKPB1330
tion (6) into the top hole.

Exchanger: 60 kg

INSTALLATION OF HYDRAULIC
OIL TANK
. To install, reverse the removal procedure.
4
1 - Fill the oil tank up to max. level.
During the filling operation, bleed the air from RKPA5721

the pump (For details, see «20. TESTING AND

ADJUSTMENTS»).

Hydraulic oil required: approx. 70 ,

2 - Start the engine to circulate the oil and check that 7
there are no leakages.
3 - Switch off the engine, check the level and, if neces-
sary, top it up.

RKPB0740

30-28 PW75R-2
DISASSEMBLY AND ASSEMBLY ENGINE-PUMP GROUP

REMOVAL OF ENGINE-PUMP GROUP

Lower the work equipment until it is resting on the
ground and switch off the engine.

Release residual pressures from all circuits. (For de- 1

tails, see «20. TESTING AND ADJUSTMENTS»).

Disconnect the lead from the negative (±) battery

terminal.

. Drain the hydraulic oil.

Quantity of oil: approx. 70 ,
RKPB0691

. Drain the engine coolant liquid.

Quantity of coolant liquid: 18 ,
2
. Close the feed cock of fuel tank and separator (1).
3

1 - Remove the engine-hood.

(For details, see «REMOVAL OF ENGINE-HOOD»).
2 - Remove the top cover (2) complete with the exhaust 4
pipe (3).
5
3 - Remove the suction pipe (4) complete with the rubber
elbow (5) for filter connection.

RKPB1162

4 - Remove bottom left and bottom rear guards.

5 - Open the door (6) of the electric board, remove the 9
panel (7) and disconnect the engine cable connector
8
(8) and the earth cable (9).
H Free the engine cable from any clip placed be-
tween the board and the flywheel.

7
6
RKPB0750

6 - Disconnect the pipe (11) coming from the separator

from the fuel pump (10).
13
7 - Disconnect the return tube (13) from the fuel filter
(12).

10

11 12

RKPB0760

PW75R-2 30-29
DISASSEMBLY AND ASSEMBLY ENGINE-PUMP GROUP

8 - Disconnect the cable (14) and the sheathing (15) of

the accelerator as well as the earth plait (16) from
the engine.

14
15

16
RKPB0630

9 - Remove the complete support of the compensating

tank (17) and move it to one side.
10 - Remove the fan guard (18).
22
11 - Remove the fastening screws (19) of the conveyor.
Push the conveyor towards the engine in order to dis- 18 19
engage it from the radiator supports.

17

RKPB1083

12 - Disconnect the pipes (20) and (21) that connect to the

radiator and the heating pipes (22) from the engine.
13 - Disconnect the supporting and guiding clamps of the
heating pipes (22) from the engine and extract the
pipes from the left opening.

20

21

RKPB0582

14 - Remove the heat guard (23).

24

RKPB1321

30-30 PW75R-2
DISASSEMBLY AND ASSEMBLY ENGINE-PUMP GROUP

14 - Disconnect the flanges of the suction pipes and all

delivery pipes (24) from pumps.
H Mark the position of Load Sensing, Mode System
and servo-control feed pipes in order to avoid mix- 24
ing them up during installation.
24

RKPB0641

15 - Hook the engine (25) to the hoisting equipment using

the specific brackets and slightly put the chains under
tension. 25

RKPB0771

16 - Remove the central screws (26) (No. 4) of the engine

supports (27). 26 27
17 - Slowly lift the unit drawing cables and pipes to and re-
move the engine (25).

Engine - pumps: 460 kg

RKP10711

PW75R-2 30-31
DISASSEMBLY AND ASSEMBLY ENGINE-PUMP GROUP

INSTALLATION OF ENGINE-PUMP GROUP

. To install, reverse the removal procedure.

H Before connecting the flanges, check the state of

seals and keep them in position by applying grease
ASL800050.

Piston pump flange screws:

63w6.5 Nm (6.5w0.6 kgm)

Gear pump flange screws:

35w3.5 Nm (3.6w0.3 kgm)

Supports central screws: 157 Nm (16 kgm)

1 - Fill the hydraulic tank up to its maximum level.

While filling the tank, bleed air from pump.

(For details, see «20. TESTING AND ADJUST-
MENTS»).

Hydraulic oil needed: approx. 70 ,

2 - Fill the cooling circuit up to its maximum level.

Coolant liquid needed: approx. 18 ,

3 - Start the engine to circulate oil and coolant liquid, and

check that there are no leakages.
4 - Switch off the engine, check the levels and, if neces-
sary, top them up.

30-32 PW75R-2
DISASSEMBLY AND ASSEMBLY PUMP GROUP

REMOVAL OF PUMP GROUP

Lower the work equipment until it is resting on the
ground and switch off the engine.

Release residual pressures from all circuits. (For de-

tails, see «20. TESTING AND ADJUSTMENTS»).
. Drain the hydraulic oil.
Quantity of oil: approx. 70 ,
1 - Remove the engine hood.
(For details, see «REMOVAL OF ENGINE HOOD»).
2 - Remove left and centre rear guards.
3 - Disconnect the suction flanges and all delivery pipes
from the pumps (1) and (2).
H Mark the position of Load Sensing, Mode System
and servo-control feed pipes in order to avoid mix-
ing them up during installation.

RKPB1032

6 - Hook the assembly by the eyebolt (3) placed on the

piston pump and slightly put the rope under tension.
H Pass a harness under the gear pump to prevent
tilting of the unit.
7 - Pull out the screws (4) and remove the pump group;
disengage the group from the coupling joint shifting
4
it to one side.
3
Pump group: approx. 57 kg

RKPB0780

PW75R-2 30-33
DISASSEMBLY AND ASSEMBLY PUMP GROUP

INSTALLATION OF PUMP GROUP

. To install, reverse the removal procedure.

H Before connecting the suction flanges, check the con-

dition of seals and keep them in position applying
grease ASL800050.

Piston pump flange screws:

63w6.5 Nm (6.5w0.6 kgm)

Gear pump flange screws:

35w3.5 Nm (3.6w0.3 kgm)

H Coat the coupling surfaces thinly:

Coupling surfaces: ASL800050

Pump check screws: Loctite 262
Pump check screws: 50w5 Nm (5.1w0.5 kgm)

1 - Fill the hydraulic oil tank to maximum level.

While filling tank, bleed air from pump. (For de-
tails, see «20. TESTING AND ADJUSTMENTS»).
Hydraulic oil: 70 ,
2 - Start the engine to circulate the oil and check that
there are no leakages.
3 - Switch off the engine, check the level and, if neces-
sary, top it up.

30-34 PW75R-2
DISASSEMBLY AND ASSEMBLY ENGINE-PUMP COUPLING JOINT

REMOVAL OF ENGINE-PUMP COUPLING JOINT

Lower the work equipment until it is resting on the
ground and switch off the engine.

1 - Remove the pump group. (For details, see «RE- 1

MOVAL OF PUMP GROUP»).

Half joint on pump

2 - Loosen dowel pin (1) fixing half joint (2) in more
stages and alternatively.
H Heat dowel pins to 85 ± 100 ëC. 2
3 - Remove pump half joint (2).
RKPA5730

H If necessary, use a puller.

Half joint on flywheel

4 - Remove blots (5) and drive flange (6). 3

4
INSTALLATION OF ENGINE-PUMP RKPA5740

COUPLING JOINT
. To install, reverse the removal procedure.

Pump half joint mounting bolts: Loctite 262

Pump half joint mounting bolts: 50 Nm

Drive flange bolts: Loctite 262

Drive flange bolts: 50 Nm

1 - Fill up the tank until maximum level.

During the filling operation, bleed air from the
piston pump (For details, see «20. TESTING
AND ADJUSTMENTS»).

Hydraulic oil: 70 ,
2 - Start the engine to allow oil circulation in all systems
and check the seal.
3 - Stop the engine and, if necessary, restore oil level in
the tank.

PW75R-2 30-35
DISASSEMBLY AND ASSEMBLY MAIN PUMP INPUT SHAFT OIL SEAL

REMOVAL OF MAIN PUMP INPUT SHAFT OIL SEAL

1 - Remove main pump assembly. (For details, see «RE-

MOVAL OF MAIN PUMP ASSEMBLY»). 1
2 - Remove PTO assembly (1). (For details, see «RE-
MOVAL OF ENGINE - PUMP COUPLING JOINT»).
3 - Remove snap ring (2), then remove spacer (3).
4 - Lever up oil seal (4) with a screwdriver to remove.

H When removing the oil seal, be extremely careful

not to damage the shaft.
RKP07840

INSTALLATION OF MAIN PUMP

INPUT SHAFT OIL SEAL 4
. To install, reverse the removal procedure. 2

Lip of oil seal: ASL800050

Coat the outside circumference of the oil seal
thinly with ASL800050. then press fit.

H Use tools G1 e G2 to press fit oil seal (4).

3 RKP07850

G1

4 G2

RKP10680

30-36 PW75R-2
DISASSEMBLY AND ASSEMBLY GEAR-PUMP

REMOVAL OF GEAR-PUMP
Lower the work equipment until it is resting on the
ground and switch off the engine.

Release residual pressures from all circuits. (For de-

tails, see «20. TESTING AND ADJUSTMENTS»). 2
. Drain the hydraulic oil.
3
Quantity of oil: 70 ,
4
1 - Disconnect the suction flange (1) and the delivery
pipe (2) from the pump.
1
2 - Remove the bolts (3) and the pump (4), the joint (5)
and the gasket (6).
RKPB0280

6
4

5
INSTALLATION OF GEAR-PUMP
3
To install, reverse the removal procedure.
RKP07860
.

H Before connecting the suction flange, check the con-

dition of the seal and keep it in its seat by applying
grease ASL800050.

Flange screws: 35w3.5 Nm (3.6w0.3 kgm)

Joint: ASL800050
Pump fastening screws:
98 ± 123 Nm (10 ± 12.5
kgm)
1 - Fill the hydraulic oil tank to maximum level.
While filling, bleed air from the main pump. (For
details, see «20. TESTING AND ADJUST-
MENTS»).

Hydraulic oil needed: 70 ,

2 - Start the engine to circulate the oil and check that
there are no leakages.
3 - Switch off the engine, check the level and, if neces-
sary, top it up.

PW75R-2 30-37
DISASSEMBLY AND ASSEMBLY SWIVEL JOINT

REMOVAL OF SWIVEL JOINT

Lower the work equipment until it is resting on the
ground and switch off the engine. 3
Release residual pressures from all circuits. (For de-
tails, see «20. TESTING AND ADJUSTMENTS»). 1 2
Disconnect the lead from the negative (±) battery
terminal.

1 - Remove the front hood (For details, see «REMOVAL

OF FRONT HOOD»).
4
2 - Remove the cabin (For details, see «REMOVAL OF
CABIN»).
RKPB0290
3 - Disconnect the tubes (1) on the lower side of the joint
(2) and plug them.
H Mark the tubes before disconnecting them, to
avoid errors when re-assembling. 6
4 - Disconnect the stay bolt (3) from the joint (2) and
place it to one side. 2
5 - Disconnect the bottom connectors (4).
5
6 - Disconnect the tubes (5) on the top of the joint (2) and
plug them.
H Mark the tubes before disconnecting them, to
avoid errors when re-assembling.
7
7 - Disconnect from the electric box the connectors (6) of
cables coming out on the top portion of joint. RKPB0300

8 - Unscrew and remove the four crews (7) of the swivel

joint.
9 - Hook the joint (2) to the hoisting equipment and re-
move it.
Swivel joint: 54 kg

INSTALLATION OF THE SWIVEL

JOINT
. To install, reverse the removal procedure.

H Before connecting the top pipes, introduce hydraulic

oil into the draining branch (branch 6).
1 - Start the engine and bleed air from the circuits by fol-
lowing the procedure given below:
a - Move the outriggers and blade (if mounted) sev-
eral times to the end of their stroke.
b - Perform several steering actions on both axles
and in both directions.
c - Bleed air from the brake line (For details, see «20.
TESTING AND ADJUSTMENTS»).

30-38 PW75R-2
DISASSEMBLY AND ASSEMBLY SWING MOTOR

REMOVAL OF SWING MOTOR

Lower the work equipment until it is resting on the
ground and switch off the engine.
1
Release residual pressures from all circuits. (For de-
tails, see «20. TESTING AND ADJUSTMENTS»).
3
1 - Disconnect the feed pipes (1), exhaust pipe (2), the
break release pipe (3) and the drain line connection
(4). 4

2 - Remove the screws (5) (No. 14) that attach the motor
(6) to the swing machinery (7).
RKPB0310

3 - Fasten two screws in the holes opposite to each other

(8) and remove the motor.
Motor: 22 kg
2
1
INSTALLATION OF
SWING MOTOR
. To install, reverse the removal procedure.

H Fill the motor with hydraulic oil through the top drain 4
line connection.
RKPA5331

Screw: 58.8 ± 73.5 Nm (6 ± 7.5 kgm)

6
Coupling surface: ASL800070
1 - Start the engine to allow oil circulation in all systems
and check the seals.
8
2 - Bleed the air from engine (For details, see «20. TEST-
ING AND ADJUSTMENTS»).

7
5
RKPA5780

PW75R-2 30-39
DISASSEMBLY AND ASSEMBLY SWING GEARED MOTOR

REMOVAL OF SWING GEARED MOTOR

Lower the work equipment until it is resting on the
ground and switch off the engine.
1
Release residual pressures from all circuits. (For de-
tails, see «20. TESTING AND ADJUSTMENTS»).
3
1 - Remove the front hood (For details, see «REMOVAL
OF FRONT HOOD»).
2 - Disconnect the feed pipes (1), the exhaust pipe (2), 4
the brake release pipe (3) and the drain line connec-
tion (4).

3 - Remove the check screws (5) (No. 10) of the reduction RKPB0310

gear (6).

4 - Fasten two screws into the opposing holes and force

the reduction gear out.

5 - Sling the complete assembly and remove it.

2
H During removal, slowly lift the assembly and pay
particular attention not to damage the pipes or
other parts.

Complete group: 43 kg

4
INSTALLATION OF THE SWING
GEARED MOTOR RKPA5332

. To install, reverse the removal procedure.

H In order to centre the pin holes and the fastening
screw holes, connect tool A1 to the hydraulic motor
and slowly rotate the motor until the correct angular
position of reduction gear is obtained.

H Fill the motor with hydraulic oil through the drain line 6
connection (2) and lubricate the bearings through the 7
lubricating nipple (7).

Bearing: ASL800050
5
RKPB0270

Screw: 58.8 ± 73.5 Nm (6 ± 7.5 kgm)

Coupling surface: ASL800070

A1
1 - Start the engine to allow oil circulation in all systems
and check the seals.
2 - Bleed the air from engine (For details, see «20. TEST-
ING AND ADJUSTMENTS»).

A1

RKPB0320

30-40 PW75R-2
DISASSEMBLY AND ASSEMBLY SWING MACHINERY ASSEMBLY

DISASSEMBLY SWING MACHINERY ASSEMBLY

1 - Remove drain plug (1) and drain oil from swing ma-
chinery case. 3
Remove screws (2) (No. 12) and remove swing motor
assembly (3).
Swing machinery case: approx. 1.5 , 2

RKP07740

2 - Remove No. 1 sun gear (4) and No. 1 carrier (5).

RKP07750

3 - Remove snap ring (6), the remove thrust washer (7),

gear (8), bearing (9) and thrust washer (10).
7 6
8 9

10

RKP07590

4 - knock in pin (11) and remove shaft (12).

H After removing the shaft (12), remove pin (11).
Remove thrust washer (13) from carrier (14). 12
14 13

11

RKP07770

PW75R-2 30-41
DISASSEMBLY AND ASSEMBLY SWING MACHINERY ASSEMBLY

5 - Remove No. 2 sun gear (15), ring gear (16) and re-
move No. 2 carrier assembly (17). 15 17

16

RKP07710

6 - Remove snap ring (18), then remove thrust washer

19 18
(19), gear (20), bearing (21) and thrust washer (22).
20
Knock in pin (23) and remove shaft (24).
H After removing the shaft (24), remove pin (23). 21
26 25
Remove thrust washer (25) from carrier (26).

22

23

24
RKP07720

7 - Set shaft and case assembly (27) to press, and push

bearing (28) with tool L1. L1
H Operate the press slowly and push the bearing to 27
a point where the split collar (29) can be removed. 29
Remove split collar (29).

28
RKP07760

8 - Set block L2 to shaft and case assembly (27), and

using push tool L3, remove shaft assembly (30) with
press.
Remove bearing (28). 30 L3

27
L2 28
RKP07730

30-42 PW75R-2
DISASSEMBLY AND ASSEMBLY SWING MACHINERY ASSEMBLY

9 - Set shaft assembly (30) to press, and using push tool

L4, remove bearing (31), and collar (32) from shaft L4
(33).

32

30 31

33
RKP07680

10 - Remove dust seal (34) and oil seal (35) from case
(36).
35

34 36

RKP07690

11 - Using puller, remove bearing outer races (37) and

(38) from case (36).

37
38 36
RKP07700

PW75R-2 30-43
DISASSEMBLY AND ASSEMBLY SWING MACHINERY ASSEMBLY

ASSEMBLY OF SWING MACHINERY ASSEMBLY

H Clean all parts, and check for dirt or damage.

H Coat the sliding surfaces of all parts with engine oil
before installing.
H Replace the oil seal with a new part.

1 - Using push tool L5, press fit oil seal (35) to case (36).
Lip of oil seal: ASL800050 L6
2 - Using push tool L6, press fit outer races (37) and (38) L5
to case (36). 36 38

33 37 RKP07650

3 - Install collar (32) to shaft (33).

L7
Using the tool L7, press fit bearing (31) with press.
Set case assembly (39) to shaft assembly (30).
Using push tool L8, press fit bearing (28) to a point
where split collar (29) can be inserted.
H Press fitting force: 11768 N (1200 kg) 31
H Rotate the case and gradually press fit the bear- 30
ing.
Install split collar (29). 32

33
RKP07660

L8 39
29
28

30
RKP07670

30-44 PW75R-2
DISASSEMBLY AND ASSEMBLY SWING MACHINERY ASSEMBLY

4 - Using push tool L10, press fit shaft (30) with press un-
til split collar (29) is fixed in position.
Screw bolt (thread dia.=10mm, pitch=1.5mm) in L10
case, and using push-pull scale L9, measure tangen- 26
tial force in direction of rotation.
H Tangential force: Max. 147 N (15 kg)
H The tangential force is the maximum reading
when starting rotation.

L9
33
RKP07610

5 - Using push tool L11, press fit dust seal (34).

L11 34

RKP07620

6 - Install thrust washer (25) to carrier (26).

Align position of pin holes of shaft (24) and carrier (26), 19 18
then tap with a plastic hammer to install shaft (24) and
20
insert pin (23).
26 25 21
H After inserting the pin (23), caulk the pin portion of
the carrier.
H Check that the stepped difference between the 22
shaft (24) and carrier (26) in less than 0.2 mm.
Assemble thrust washer (22), bearing (21), gear (20) 23
and thrust washer (19), then install snap ring (18).
Install No. 2 carrier assembly (17) to shaft and case Max 0,2mm 24
assembly.
RKP07630

PW75R-2 30-45
DISASSEMBLY AND ASSEMBLY SWING MACHINERY ASSEMBLY

7 - Install ring gear (16). 15

Ring gear mating surface: Loctite 510 17
Install No. 2 sun gear (15).

16

RKP07640

8 - Install thrust washer (13) to carrier (14).

Align position of pin holes of shaft (12) and carrier
(14), then tap with a plastic hammer to install shaft
(12).
12
14 13
Insert pin (11).
H After inserting the pin (11) caulk the pin portion of
the carrier.
H Check that the stepped difference between the
shaft (14) and carrier (12) is less than 0.2 mm. Max 0,2mm
11

RKP07580

9 - Assemble thrust washer (7), bearing (9), gear (8) and

thrust washer (10), then install snap ring (6).
7 6
8 9

10

RKP07590

10 - Install No. 1 carrier assembly (5).

Install No. 1 sun gear (4). 3
Install swing motor assembly (3) and tighten screws 4
(2) (No. 12).
Tighten drain plug and add oil through oil filter. 2
Mounting bolt: 66.2w7.4 Nm (6.75w0.75 kgm)
Motor mating surface: Loctite 510
Swing machinery case: approx. 1.5 ,

Swing machinery case: 5

ASL800050 (approx. 110 cc)
RKP07600

30-46 PW75R-2
DISASSEMBLY AND ASSEMBLY CONTROL VALVE

REMOVAL OF CONTROL VALVE

Lower the work equipment until it is resting on the
ground and switch off the engine. 1 4
1
Release residual pressures from all circuits. (For de-
tails, see «20. TESTING AND ADJUSTMENTS»).

H Mark all pipes before removal.

2
1 - Disconnect pipes in the following sequence: servo
control pipes (1), feed pipes (2), exhaust pipes (3), 3
function pipes (4) and LS pipes (5).
H Plug all holes so as to keep out impurities.
5
2 - Fit the unit with two eyebolts (6). (M8x1.25) RKPA5810

3 - Hook the unit (7) to the hoisting equipment and

slightly put the ropes under tension.
6
4 -Remove the three screws (8) and lift out the control
valve.
Control valve: approx. 60 kg

INSTALLATION OF
CONTROL VALVE 7

. To install, reverse the removal procedure.

RKPA5820

Distributor check screws: 190 Nm (19.5 kgm)

Counterweight screws: Loctite 262
1 - Check the level of the tank; start the engine to allow
oil to circulate to all parts of the equipment.
Switch off the engine and top up the oil level.
2 - Bleed air from the circuits. (For details, see «20.
TESTING AND ADJUSTMENTS»).

8
RKPA5830

PW75R-2 30-47
DISASSEMBLY AND ASSEMBLY REVOLVING FRAME

REMOVAL OF REVOLVING FRAME

Disconnect the lead from the negative (±) battery
terminal.

1 - Remove the upper work equipment (For details, see

«REMOVING UPPER WORK EQUIPMENT»). 2 1
2 - Remove the front hood (For details, see «REMOVAL
OF FRONT HOOD»).
3 - Remove the cabin and the seat (For details, see «RE-
MOVAL OF CABIN AND REMOVAL OF SEAT»).
4 - Remove the boom cylinder. (For details, see «RE-
MOVAL OF BOOM CYLINDER»).
RKPB0291

5 - Disconnect all the lower tubes (2) from the swivel joint
(1) and plug them. Also plug the fittings left on the
joint.
6 - Remove the lower left-hand protective casing (3) of
the revolving frame (4) to gain access to the retaining 6
nuts of the LH area.
7 - Start the engine, swing the revolving frame (4) about
5 7
90ë to the left, until a screw (5) is accessible on the
under carriage (6) side.
8 - Remove the screw (5) and its nut.
9 - Leave the next screw in place and remove the other
thirty three screws. RKPB0330

Leave two screws in position for reasons of

safety, one at the front and one at the rear.

10 - Using the equipment A2 and A3 attach the revolving

frame to a hoisting tackle and apply slight tension to A3
the chains.

11 - Loosen and disengage the two screws, leaving them

A2
inserted in the bearing ring (7).
12 - Raise the revolving frame (4) slowly.

H While raising the revolving frame, take great care

not to damage the swivel joint. 4
RKPB0790

Revolving frame: 765 kg

RKP07570

30-48 PW75R-2
DISASSEMBLY AND ASSEMBLY REVOLVING FRAME

INSTALLATION OF REVOLVING FRAME

. To install, reverse the removal procedure.

Revolving frame attachment screws

(without nut): Loctite 262
Revolving frame attachment screws
(with nut): 314 Nm 8
Revolving frame attachment screws
(without nut): 314 Nm
7

H Align the two positions corresponding to the cen- RKPA5850

tering pins (9), then assemble.

Sealant and swing circle platform gaskets:
ASL800050
Internal swing circle grease: approx. 25 kg 10
9
H After connecting up all the hydraulic tubes, start
the engine and move all parts of the equipment 12
several times to bleed air from the circuits, while
checking for leakages.
11
H Switch off the engine and check level of the hy-
draulic oil.

Installation Procedure
In order to swing the revolving frame for centering
RKPB0311

the reference pins (8), the pinion-swing circle cou-

pling and for mounting the screws (5):

1 - Disconnect the feed pipes (10), the drain line con-

A1
nection (11) and the brake release tube (12) from
the swing motor (9).
H Plug connections to avoid impurity entry.
2 - Connect tool A1 and slowly rotate the turret until
correct centring is obtained.
3 - Insert the two screws (5) left in the swing circle (7)
and secure them.
4 - Insert all the other screws (5). RKPA5800

5 - After having secured all the screws that join the

swing circle to the revolving frame, reconnect
the delivery tubes (10) of the swing motor (9),
the brake release tube (12) and union (11).
6 - Detach the hoisting tackle.

PW75R-2 30-49
DISASSEMBLY AND ASSEMBLY COUNTERWEIGHT

REMOVAL OF COUNTERWEIGHT
Lower the work equipment until it is resting on the
ground and switch off the engine.

1 - Remove the engine-hood. 1

(For details, see «REMOVAL OF ENGINE HOOD»).
2 - Remove the engine-hood hook support (1).
3 - Remove the protective caps and firmly tighten the
hoisting eyebolts (2).
4 - Attach the hoisting tackle and apply slight tension to
the cables. RKPB0860

5 - Using the tool B1, loosen the screws (3) and their
safety washers.
6 - Remove the counterweight (4).
Counterweight: 1050 kg

2 2
INSTALLATION OF
COUNTERWEIGHT
. To install, reverse the removal procedure. 4
RKPB0870

Counterweight screws: Loctite 262

Counterweight screws: 580 Nm (59 kgm)

H Carefully check that the vertical positioning mea-

surement (A) is 100w2 mm with respect to the re-
A
volving frame. 3

RKPB0880

30-50 PW75R-2
DISASSEMBLY AND ASSEMBLY SWING CIRCLE

REMOVAL OF SWING CIRCLE

1 - Remove the upper revolving frame. (For details, see

«REMOVAL OF UPPER REVOLVING FRAME»). S
3
2 - Completely remove all contaminated grease.
3 - Remove the screws (1) that secure the swing circle
(2).
4 - Remove the swing circle (2) using the tool D1.

Swing circle: 89 kg. 1

2
RKPB0340

INSTALLATION OF
SWING CIRCLE
H Before installing the swing circle, check the condition D1
of the central gasket (3).
For reasons of safety, when installing the swing cir-
cle, insert two screws into the front and back holes 2 S
in the frame.
. To install, reverse the removal procedure.

Before attaching the swing circle, check that the area

marked with an «S» is positioned on the right-hand RKPB0350

side of the chassis.

Attachment screws: Loctite 242
Attachment screws: 314 Nm
Lubricating grease: approx. 25 kg

PW75R-2 30-51
 TRANSMISSION - REVERSER, DIRECTION INDICATOR
TESTING AND ADJUSTMENTS AND HEADLIGHT DIPPER BEAM CONTROL GROUP z

REMOVAL OF THE TRANSMISSION - REVERSER, DIRECTION

INDICATOR AND HEADLIGHT DIPPER BEAM CONTROL GROUP
Lower the work equipment until it rests on the ground
and stop the engine. 1
Disconnect the lead from the negative (±) battery
terminal.

1 - Take out check screws (1) (No. 2) and remove the

front guard (2) of the steering column. 2
2 - Free cables from clamps and disconnect the connec-
tors (3).
3 - Remove the two connecting screws (4) of the switch-
ing groups (5-6).
RKPB0360

4 - Remove the RH half-clamp (7).

5 - Remove the LH half-clamp (8).

6 - Remove the switching group (5 and 6) complete with

wiring assemblies.

INSTALLATION 3

. To install, reverse the removal procedure.

H Check that the reference pin (9) can be fully inserted

into the steering column (10) and that the R.H. half- RKPB0370

clamp (7) adheres perfectly.

4
6

4
5
RKPB0380

9 7

10
RKPB0400 RKPB0390

30-52 PW75R-2
DISASSEMBLY AND ASSEMBLY R.H. PPC VALVE (BOOM - BUCKET)

REMOVAL OF R.H. PPC VALVE (BOOM - BUCKET)

Lower the work equipment until it is resting on the
ground and switch off the engine and remove the
starting key. 1 3
Release residual pressures from all circuits. (For de- 2
tails, see «20. TESTING AND ADJUSTMENTS»).
Disconnect the lead from the negative (±) battery 1
terminal.
5
1 - Remove screws (1) and remove cover (2).
2 - Disconnect connectors (3), remove screws (4) and re-
move the dashboard (5). 4
RKPB1190

3 - Take out cover (6) and disconnect connector (7).

4 - Remove screws (8) and armrest (9).
5 - Remove retaining screws (10) (në 3) of R.H. dash- 9
board (11).
H To remove the inside screw, lower the seat and
push it right back. 11
10

8
RKPB1201

6 - Disconnect the catch (12) from the R.H. dashboard

(11).
7 - Move backward the R.H. dashboard. Disconnect 7
hoses (13) (në 6) from the PPC valve (12) and plug
6
them to prevent entry of impurities.
H Mark the position to avoid errors during assembly.
8 - Remove screws (15) and remove the PPC valve (14).
If there is a slack on the control lever, adjust the
unit (See «20: TESTING AND ADJUSTMENTS -
Adjustment of manual control slacks»)

RKPB1340

12
15

14

13

RKPB1211

PW75R-2 30-53
DISASSEMBLY AND ASSEMBLY R.H. PPC VALVE (BOOM - BUCKET)

INSTALLATION OF
R.H. PPC VALVE
T
. To install, reverse the removal procedure.

P P2
H Check the positions carefully when reconnecting
the tubes
P4
P - Pressure
T - Unload P1
P3
P1 - Boom descent RKPA3120

P4 - Bucket opening
P2 - Boom rising
P3 - Bucket closing
1 - Start the engine to allow oil circulation in all systems
and check the seals

30-54 PW75R-2
DISASSEMBLY AND ASSEMBLY L.H. PPC VALVE (ARM-SWING)

REMOVAL OF L.H. PPC VALVE (ARM-SWING)

Lower the work equipment until it is resting on the
ground and switch off the engine.

Release residual pressures from all circuits. (For de-

tails, see «20. TESTING AND ADJUSTMENTS»).
Disconnect the lead from the negative (±) battery
terminal.

1 - Remove the knob (1) and loosen the heating control

fixing nut (2)
2 - Disconnect the catch (3) from the L.H. dashboard (4).

3 - Remove the arm rest (6) fixing screws (5).

2
4 - Remove screws (7) and L.H. dashboard (4). 1
4
H To remove the inside screw, lower the seat and
push it right back. RKPB1220

5
6

5 - Disconnect the six tubes (8) from the PPC valve (9) 4
and plug them to prevent entry of impurities. 7
H Mark the positions to avoid errors during assem-
bly. RKPB1230

6 - Remove screws (10) and remove PPC valve (9).

If there is a slack on the control lever, adjust the
unit (See «20: TESTING AND ADJUSTMENTS -
10 9
Adjustment of manual control slacks»)

8
RKPB1240

PW75R-2 30-55
DISASSEMBLY AND ASSEMBLY L.H. PPC VALVE (ARM-SWING)

INSTALLATION OF
L.H. PPC VALVE
T
. To install, reverse the removal procedure.
P P2
H Check the positions carefully when reconnecting
the tubes P4
P - Pressure
T - Unload P3 P1
P1 - Boom descent RKPB1290

P4 - Bucket opening
P2 - Boom rising
P3 - Bucket closing
1 - Start the engine to circulate the oil and check the
seals.

30-56 PW75R-2
DISASSEMBLY AND ASSEMBLY OUTRIGGER AND BLADE PPC VALVE

REMOVAL OF OUTRIGGER AND BLADE PPC VALVE

Lower the work equipment until it is resting on the
ground and switch off the engine.
1
Release residual pressures from all circuits. (For de-
tails, see «20. TESTING AND ADJUSTMENTS»).
4

1 - Remove the cabin (For details, see «REMOVAL OF 4

CABIN»). 5

2 - Remove the casing (1) from right-hand PPC valve

support.
2 3
1. Blade version
RKPA7090

1 - Disconnect tubes (2) and (3) and plug them.

H Place an identifying mark on each tube to prevent
mixing them up during installation.
2 - Take out screws (4) and remove PPC valve (5). 10
11
2. Blade - stabiliser version
9 10
1 - Disconnect feed and exhaust pipes (6) and (7).
H Place an identifying mark on each tube to prevent
mixing them up during installation. 7
6 8
2 - Remove pipes (8) and (9).
3 - Take out the screws (10) and remove the PPC valve
(11) for reconditioning or replacement.. RKPB0410

INSTALLATION OF OUTRIGGER
AND BLADE PPC VALVE
. To install, reverse the removal procedure.
1 - Start the engine to allow oil circulation in all systems .
2 - Bleed the air from the cylinders (For details, see «20.
TESTING AND ADJUSTMENTS»).

PW75R-2 30-57
DISASSEMBLY AND ASSEMBLY BOOM SWING PPC VALVE

REMOVAL OF BOOM SWING PPC VALVE

. Rotate the turret by 90ë to the left.

Lower the work equipment until it is resting on the
ground and switch off the engine.

Release residual pressures from all circuits. (For de-

tails, see «20. TESTING AND ADJUSTMENTS»).
1 - Remove the bottom left cover (1). 1
2 - Disconnect the pipes (2) (No. 4 tubes) from the PPC
valve.
H Place an identifying mark on the pipes to avoid
mixing them up during installation. RKP07970

3 - Remove the connections (3) from the PPC valve.

4 - Pull out the screws (4) and remove the PPC valve (5)
with the operation pedal (6). 3

INSTALLATION OF BOOM SWING

PPC VALVE
. To install, reverse the removal procedure.
2
1 - Start the engine to allow oil circulation in all systems .
2 - Bleed the air from boom swing cylinder (For details,
see «20. TESTING AND ADJUSTMENTS»). RKPA7140

5
4

RKPA7150

30-58 PW75R-2
DISASSEMBLY AND ASSEMBLY TRAVEL AND 2nd BOOM PPC VALVE

REMOVAL OF TRAVEL AND 2nd BOOM PPC VALVE

. Rotate the turret by 90ë to the left.

Lower the work equipment until it is resting on the
ground and switch off the engine.

Release residual pressures from all circuits. (For de-

tails, see «20. TESTING AND ADJUSTMENTS»).
1 - Remove the bottom left cover (1). 1
2 - Disconnect the pipes (2) (No. 4 tubes) from the PPC
valve concerned.
H Place an identifying mark on the pipes to avoid
mixing them up during installation. RKP07970

3 - Remove the connections (3) from the PPC valve.

2nd BOOM
4 - Pull out the screws (4) and remove the PPC valve (5)
or (6) with the operation pedal (6).
2

INSTALLATION OF TRAVEL AND

2nd BOOM PPC VALVE
. To install, reverse the removal procedure.
3
1 - Start the engine to allow oil circulation in all systems .
2 - Bleed the air from boom swing cylinder (For details, 2
see «20. TESTING AND ADJUSTMENTS»).
RKPB0420

2nd BOOM

4
RKPB0430

TRAVEL

4
RKPB0440

PW75R-2 30-59
DISASSEMBLY AND ASSEMBLY BRAKE PUMP

REMOVAL OF BRAKE PUMP

Lower the work equipment completely until it rests it
on the ground and stop the engine.

Release all residual pressures from all circuits, and

in particular from the brake line (See «20. TESTING
AND ADJUSTMENTS»).
1 - Disconnect the seven hoses (1) from the brake pump
and plug them.
H Make an identifying mark on the hoses to avoid
mixing them up during installation.
1

2 - Disconnect the solenoid valve (2) connector.

RKPB0450

3 - Disconnect the terminals of pressure switches (3) and

(4).
H Make an identifying mark on the cables to avoid
mixing them up during installation.
4 - Remove the fastening screws (5) of the brake pump,
which are located on the cabin platform.
5 - Remove the brake pump (6).

INSTALLATION OF THE 4
BRAKE PUMP 3
. To install, reverse the removal procedure. 2
RKPB0460

Start the engine and bleed air from the brake lines
(See «20. TESTING AND ADJUSTMENTS»).
6
After re-connection, make sure that the protective
sleeves are positioned correctly and firmly.

5
RKPB0431

30-60 PW75R-2
DISASSEMBLY AND ASSEMBLY STEERING UNIT

REMOVAL OF THE STEERING UNIT

Lower the work equipment until it is resting on the
ground and stop the engine.
Release all residual pressures from all circuits (For
details, see «20. TESTING AND ADJUSTMENTS»).
1 - Remove the LH guard (1) of the revolving frame.

RKP07970

2 - Disconnect the tubes (3) from the steering unit (2).

H Make some identifying marks on the tubes before
disconnecting them, to avoid mixing up the posi- 4
tions when reconnecting.

2
RKPA8290

3 - Using the special wrench Q1, remove the screws that

fasten the steering unit group (2) to the steering col-
umn (4).
H In order to remove the front screws, attach the
5
special wrench Q1 to the steering unit (2) and
move it with a normal wrench inserted in the lou-
Q1
ver provided between the cabin (5) and the revol-
ving frame (6).
2

6 RKP09570

INSTALLATION OF THE
STEERING UNIT
. To install, reverse the removal procedure.
1 - Start the engine and bleed air from the Load Sensing
circuit (See «20. TESTING AND ADJUSTMENTS»).

RKPB0470

PW75R-2 30-61
DISASSEMBLY AND ASSEMBLY STEERING UNIT

DISASSEMBLY THE STEERING UNIT

Disassembly the body of the steering unit
1 - Loosen and remove the screws (1-3) that hold the 3
cover (2) in place (six screws plus one special screw). 1

RKPA7990

2 - Remove the cover (2) by sliding it sideways.

RKPA8000

3 - Raise the rotating gear (4) complete with the O-rings

(34). Also remove the spacer (5).
4

5
34

RKPA8010

4 - Remove the drive shaft (6).

RKPA8020

30-62 PW75R-2
DISASSEMBLY AND ASSEMBLY STEERING UNIT

5 - Remove the control lens (7).

RKPA8030

6 - Remove the threaded bush (8) of the safety valve.

RKPA8040

7 - Remove the O-ring (9).

RKPA8050

8 - Lift out the ball (10) of the check valve, and the pins
(11) and balls (12) of the anticavitation valves.

11

10

12

RKPA8060

PW75R-2 30-63
DISASSEMBLY AND ASSEMBLY STEERING UNIT

9 - While watching through the central hole of the spool,

position the spool-bushing connecting pin horizon-
tally. 13
Push the entire group (13) and the entire bearing until
they can be extracted from the body of the steering
unit (14).

14

RKPA8070

10 - Remove the outside ring (15), the inside ring (16), and
the roller bearing (17) from the spool. Also remove the
ring (33).
H The inside ring (16) sometimes gets left in the
body of the steering unit. Make sure that it has 33
been removed.
16

15 17

RKPA8080

11 - Lift out the cross pin (18), the bushing (19) and the
spool (20).
H Use the special cover-fastening screw (3) for total 19
extraction.
3

18

20

RKPA8090

12 - Slowly slide the spool (20) out of the bushing (19).

20

19

RKPA8100

30-64 PW75R-2
DISASSEMBLY AND ASSEMBLY STEERING UNIT

13 - Push the neutral position springs (21) and extract

them from the spool (20).
21

20

RKPA8110

14 - Remove the dust-guard washer (22) and the compo-

site leaktight seal (23) (O-ring + washer).
23
22

RKPA8120

15 - Remove the caps (24) from the safety valves.

24

RKPA8130

16 - Remove the cup springs (25).

25

RKPA8140

PW75R-2 30-65
DISASSEMBLY AND ASSEMBLY STEERING UNIT

17 - Remove the adjustment screws (26) (6 mm screw

wrench).

26

RKPA8150

18 - Extract the springs (27) and the two balls (28).

H The valve seatings are fixed in the body of the
steering unit and cannot be removed.

27

RKPA8160

19 - Check that the dismantled pieces resemble those in-

dicated in the figure. 26
25
27

28 24

27 25
26
RKPA8170

Removal of the safety valve

20 - Remove the cap (29) and its gasket (30) (8 mm screw
wrench).

29

30

RKPA8180

30-66 PW75R-2
DISASSEMBLY AND ASSEMBLY STEERING UNIT

Disassembly the safety valve

21 - Remove the safety valve (31) and its washer (32).
22 - Make sure that the steering unit is completely dis- 31 32
mantled.

NOTE
Cleaning
H Clean all the components with an aliphatic solvent
(white spirits or similar).

Inspections and substitutions

RKPA8190
H Change all the cup springs and seals.
H Inspect all the pieces and change those in a doubtful
state of wear.

PW75R-2 30-67
DISASSEMBLY AND ASSEMBLY STEERING UNIT

ASSEMBLY THE STEERING UNIT

H Before assembly, lubricate all the components

with hydraulic oil.
1 - There is only one possible and correct way to assem-
a
ble of the spool (20) and bushing (19).
Assemble with the three holes (a) of the bushing (19) 20
opposite the slots (b) in the spool (20). 19
Check that the holes in the bushing are at least par-
tially visible through the slots (b) in the spool.
b

RKPA8200

2 - Insert the two flat springs (21a) in the seating and

centre them with respect to the diameter of the spool
(20). Insert the four curved springs (21b) between the
two flat springs (21a) , arranged in pairs, and push
them completely home.

21a
20
21b

RKPA8210

3 - Align the springs (21).

21

RKPA8220

4 - Insert the spool (20) into the bushing (19).

H Make sure that the position between bushing and
spool is as described in phase 1 of the assembly 20
instructions.

21 19

RKPA8230

30-68 PW75R-2
DISASSEMBLY AND ASSEMBLY STEERING UNIT

5 - Push the springs (21) and the spool (20) down to-
gether until the springs are engaged in the seating
of the bushing (19).
21

20

19

RKPA8240

6 - Align the springs (21) with each other and centre

them with respect to the diameter of the bushing (19).
21

19

RKPA8250

7 - Install the ring (33) in the seating of the bushing (19).

H The ring (33) should be free to rotate without inter-
fering with the springs (21).

19

33

RKPA8260

8 - Insert the cross pin (18).

18

RKPA8270

PW75R-2 30-69
DISASSEMBLY AND ASSEMBLY STEERING UNIT

9 - Assemble the thrust bearing according to the se-

quence indicated at point 10.

16

17

15

RKPA8280

10 - Sequence for assembly the bearing.

15 - Outside ring 16
16 - Inside ring
17 - Needle bearing 17
19 - Bushing
15
20 - Spool

20

19
RKP09580

11 - Place the body of the steering unit (14) with the hole
horizontal.
Insert the guide of tool Q2 into the hole of the spool/
14
bushing group.

Q2

RKPA8300

12 - Lubricate the seal ring (23a) and the O-ring (23b) and
mount them on the push-rod of tool Q2.

23a Q2
23b

RKPA8310

30-70 PW75R-2
DISASSEMBLY AND ASSEMBLY STEERING UNIT

13 - Mount the tool Q2 and insert it in the guide already

inserted in the hole of the steering unit.

23
Q2

RKPA8320

14 - Push the gasket (23) into the seating of the body of

the steering unit (14), assisting the movement with
slight rotatory movements.

14

RKPA8330

15 - Extract the guide from the body of the steering unit

(14) using the tool Q2, and leaving in position the
push-rod carrying the gaskets.

14

RKPA8340

16 - Insert the bushing/spool group (13) into the hole of

the steering unit (14).
Assist the insertion with slight rotatory movements.
H Insert the group while keeping the cross pin hori-
zontal. 13

14

RKPA8350

PW75R-2 30-71
DISASSEMBLY AND ASSEMBLY STEERING UNIT

17 - Push the group (13) as far as it will go in order to push

out the push rod that was left in position during phase
15.
14

13

RKPA8360

18 - Rotate the body of the steering unit (14) until the cen-
tral hole is vertical.
Insert the ball (10) of the safety valve into the hole in-
dicated by the arrow.
10

14

RKPA8370

19 - Screw the valve threaded bush (8) into the hole in the
safety valve.
H The upper part of the threaded bush should be
lower than the surface of the body of the steering
unit (14). 8

14

RKPA8380

Assembly of the anticavitation valve

20 - Insert the balls (12) into the two holes indicated by the
arrows.
12

RKPA8390

30-72 PW75R-2
DISASSEMBLY AND ASSEMBLY STEERING UNIT

21 - Insert the pins (11) into the same holes.

11

RKPA8400

22 - Lubricate the O-ring (9) and mount it in the seating.

Mineral oil: viscosity approx. 500 cSt at 20ëC
9

RKPA8410

23 - Position the control lens (7) so that the holes corre-

spond to those in the body of the steering unit (14).
7

14

RKPA8420

24 - Insert the drive shaft (6) in the hole and engage the
cross pin; check that the pin engagement is parallel
to the connection flange between the steering unit
6
and the steering column.

RKPA8430

PW75R-2 30-73
DISASSEMBLY AND ASSEMBLY STEERING UNIT

25 - Place the drive shaft in a vertical position and hold it

steady with the tool Q3.

Q3

RKPA8440

26 - Lubricate the two O-rings (34) and mount them in the

two seatings of the ring bevel gear of the gear rim (4).
Mount the gear rim (4) on the drive shaft (6).
Mineral oil: viscosity approx. 500 cSt at 20ëC 4 34

RKPA8450

Positioning the motor

27 - Install the motor (4a) on the drive shaft (6) in such a
way that the bottom of a motor tooth corresponds to
the tooth base on the drive shaft.
Then rotate the external ring bevel gear (4b) in order 6
to align the attachment holes.

4a

RKPA8460

28 - Install the spacer (5).

4b

RKPA8470

30-74 PW75R-2
DISASSEMBLY AND ASSEMBLY STEERING UNIT

29 - Mount the cover (2).

RKPA8480

30 - Insert the special screw (3) complete with washer in

the hole indicated in the figure.

RKPA8490

31 - Insert the six screws (1) complete with their cup

springs.
Tighten the screws (1) crosswise with a torque of
30w6 Nm.

RKPA8500

32 - Position the dust-guard seal (22) in the body of the

steering unit (14).

22

14

RKPA8510

PW75R-2 30-75
DISASSEMBLY AND ASSEMBLY STEERING UNIT

33 - Press the dust-guard seal (22) into the body of the

steering unit, using the tool Q4 and a plastic hammer.
Q4

22

RKPA8520

34 - Close the holes of the hydraulic couplings with plastic

caps to prevent the entry of impurities.
H Push the caps on by hand, without using the ham-
mer.

RKPA8530

Assembly of the main valve

35 - Mount the seal (32) on the main valve (31) and screw
the cartridge into the body of the steering unit (14)
using a 12 mm screw wrench.
31
Cartridge: 50w1 Nm
14

32

RKPA8540

36 - Screw the cap (29) complete with washer (30), using

an 8 mm. Screw wrench.
Cap: 50w1 Nm

29

30

RKPA8550

30-76 PW75R-2
DISASSEMBLY AND ASSEMBLY STEERING UNIT

Assembly of the safety valve

37 - Insert the balls (28) of the safety valves into the holes 28
indicated by the arrows.

RKPA8560

38 - Insert the springs (27) of the safety valves into the

holes.
27

RKPA8570

39 - Screw the pressure adjustment screws (26) into the

holes.
26

RKPA8580

40 - Mount the sealing cup springs (25) on the caps (24)

and screw the entire group into the two holes of the
safety valves. 24
Use a 6 mm screw wrench.
Caps: 30 Nm
25

RKPA8590

PW75R-2 30-77
DISASSEMBLY AND ASSEMBLY PRIORITY VALVE

REMOVAL OF THE PRIORITY VALVE

Lower the work equipment until it is resting on the
ground and stop the engine.
Release all residual pressures from all circuits (For
details, see «20. TESTING AND ADJUSTMENTS»).
1 - Disconnect the four tubes (2) and the priority valve
(1).
2 - Remove screw (3) and washer.
Remove the priority valve (1).

1
RKPA8600

2
RKP09870

INSTALLATION OF THE
PRIORITY VALVE
. To install, reverse the removal procedure.
1 - Start the engine and bleed air from the Load Sensing
circuit. (See «20. TESTING AND ADJUSTMENTS»).

30-78 PW75R-2
DISASSEMBLY AND ASSEMBLY PRIORITY VALVE

DISASSEMBLY THE PRIORITY VALVE

1 - Unscrew the cap (1) (PP port) and take it off together
with its aluminium washer.
2 - Loosen the cap (2) (LS port).
3 - Lift off the cap (2) complete with the aluminium
2
washer and the spring (3).
4 - Using a nylon plunger, extract the spool (4).
3

ASSEMBLY OF THE
PRIORITY VALVE
H Before assembly:
1 - Wash the pieces thoroughly in kerosene or similar
product.
2 - Make sure that the spool throttle is clean.
3 - Lubricate the pieces before assembly.
4 - Change the aluminium washers.
1 - Insert the spool (4) using the nylon plunger to keep it
centred.
1 4
2 - Screw the cap (1) complete with its aluminium
washer, into the PP port.
3 - Screw the cap (2), complete with its aluminium RKP10200
washer and the spring (3) into the LS port.
4 - Tighten caps (2) and (1) firmly, and in that sequence.
Caps (1) and (2): 50w10 Nm

PW75R-2 30-79
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR

REMOVAL OF TRAVEL MOTOR

Lower the work equipment until it is resting on the
ground and stop the engine.
Release all residual pressures from all circuits. (For
details, see «20. TESTING AND ADJUSTMENTS»).
1 - Remove the steps leading to the cabin (1).

RKPA8610

2 - Disconnect the front drive shaft (2) from the transmis-

sion (3).
3

RKPA8620

3 - Disconnect the supply tubes (4), the motor drainage

tubes (5) and the drainage tube. Plug the tubes and
the motor to prevent entry of impurities.
6

4 - Disconnect the connector (6).

5 - Loosen the four screws (8) that hold the motor (7).
6 - Place a hydraulic jack underneath the motor to sup-
port it.
RKPA8630

7
5
7 - Remove the screws (8).
8 - With the help of levers and a soft-headed mallet,
move the motor (7) and slide the shaft off the trans-
mission coupling.
4
H Take great care not to damage the coupling sur-
faces. 8

RKPA8641

30-80 PW75R-2
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR

INSTALLATION OF THE TRAVEL MOTOR

. To install, reverse the removal procedure.

H Before connecting the drainage tube (5), fill the

motor casing with hydraulic oil.

H Carefully check the O-ring seal between motor

and transmission. If there are any doubts as to
its condition, change it.
Sealant: ASL800050
1 - Start the motor and travel both forwards and back-
wards at low speed to bleed the system and to check
the leaktightness of the tubing.
2 - Stop the motor and check the level of oil in the tank.
If the travel motor is to be dismantled for any form of 9
inspection or overhaul, before using the machine
again check: 7
1 - The setting of the automatic displacement control
system.
2 - The speed of the travel propeller shaft.
H For test and adjustment procedures, see «20.
TESTING AND ADJUSTMENTS».

RKP09590

PW75R-2 30-81
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR

DISASSEMBLY OF THE TRAVEL MOTOR

1 - Remove circlip (1) and spacer (2).

1

RKP09640

2 - Install two screws in gasket (3) holes and extract it

using pliers.

RKP09880

3 - Remove oil exchange valve (4).

RKP09600

4 - Remove recognition of travel direction device and

automatic displacement device (5), guide pin (6),
spring (7), bushing (8) and spring (9).
Remove brake valve (35).
Remove safety valve (36) (në 2).

9
8 36 35
7
5 6

RKP09610

30-82 PW75R-2
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR

5 - Set the motor on a work bench, mark measure «A» of

minimum displacement adjusting screw (34) and re-
move it. A

34

RKP09750

6 - Push positioning piston (10) until to bring the cylinder

barrel to position zero. 10
H Mark the measure «B» of maximum displacement
adjusting screw.

RKP09760

7 - Mark position between motor case (11) and displace-

ment adjusting case (12), and after removed bolts 12
(13) (No. 8) remove the adjusting case. 13

11

RKP09620

8 - Remove screw (14) and piston (15) complete with

gaskets. 15 16
Loosen locking screw (16) and positioning pin (17).
H For an easy removal, make a pin (17) and screw
(16) heating at about 120 ëC.

14
17
RKP09780

PW75R-2 30-83
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR

9 - Stop with threaded pin (18) a washer (19) and a nut

(20) the cylinder barrel in zero position. 20
Remove maximum displacement adjusting screw 19
(21).
18
H Threaded pin: M5x71

21

RKP09890

10 - Using a puller, remove the complete swing unit (22).

22

RKP09900

11 - Tighten the complete swing unit into a vice and re-

move nut (20), washer (19) and threaded pin (18). 20
Remove cylinder barrel (23).
H Use a vice provided with soft jaws.
19
18

23

RKP09910

12 - Loosen mounting bolts (24) of valve plate (25).

24

25

RKP09920

30-84 PW75R-2
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR

ASSEMBLY OF THE TRAVEL MOTOR

1 - Tighten the swing unit (26) in a vice and install pis-

tons (27), valve plate (25) and screws (24).

24

27

26 25

RKP09930

2 - Install cylinder block (23).

H Check that all components are oriented correctly
and in the right position.

RKP09790

3 - Block cylinder block (23) in vertical position using the

threaded pin (18), and washer (19) and nut (20).
H Threaded pin: M5X71
23

RKP09940

4 - Install tool C1 on swing unit (22).

22
C1

RKP09800

PW75R-2 30-85
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR

5 - Heat the motor case (11) at 80 ëC and insert complete

swing unit.

11

RKP09810

6 - Lock cylinder barrel in zero position using maximum

displacement adjusting screw (21).
Loosen nut (20) used to lock cylinder barrel and re-
move washer (19) and threaded pin (18).
Install O-ring gasket (28).
28
21

RKP09950

7 - Set valve plate (29) on cylinder barrel (23) and dowel

it with dowel pin of tool C2.
29

23
8 - Prepare tool C2 assembling the travel motor compo-
nents as shown in the illustration. RKP09960

452010 452269
083105
Useful
Posizioni
position
utili detail
per
for
particolari
452271 C2
452271
083010
452269
452271
452021
RKP10920 452014
RKP09970

30-86 PW75R-2
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR

9 - Assemble and set tool C2 on motor case (11).

Check and bring to zero dial gauge when knob has
been rotated in counterclockwise direction till end of C2
stroke.

11

RKP09980

10 - Rotate the knob for 4 turns in clockwise direction and

make sure with a caliper that the dial gauge has a
clearance of 2 mm and that pointer is in zero position.
H This is the starting zero for checking.

RKP10030

11 - Rotate the knob in clockwise direction till end of

stroke and check the central pin (30) clearance value
that corresponds to dial gauge indicated value.
H Pin clearance: 0.2w0.05 mm C2
H If central pin clearance is not within the tolerance,
replace springs guide plate (31).
30 31
11

RKP10080

12 - Remove tool C2.

PW75R-2 30-87
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR

13 - Assemble positioning piston (32) into the displace-

ment adjusting case (12). 32 16
Assemble the positioning pin (17) and locking bolt
(16).
H Use a new locking bolt.
H Tighten the bolt to recommended tightening tor-
que.

17
RKP09820

14 - Assemble rings (33) into the piston (15).

Assemble complete piston on positioning piston (32)
and tighten the bolt (14).
33
H Assemble rings (33) with opposed notch. 15
14

RKP09990

15 - Assemble displacement adjusting case (12) on pump

case (11) and tighten mounting bolts (13) (No. 8). 12
Restore the measures «A» and «B» of maximum (21) 13
and minimum (34) displacement adjusting bolts.
H Align marks made on pump case and on displace-
ment adjusting case before the disassembly.
11

RKP09620

16 - Assemble the spring (9), bushing (8), spring (7), guide

pin (6) and the recognition travel direction device (5).
Assemble the safety valve (36) (në 2).
Assemble the brake valve (35).

9
8 36 35
7
5 6

RKP09610

30-88 PW75R-2
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR

17 - Assemble the oil exchange valve (4).

RKP09600

18 - Using tool C3, fit the gasket (3), spacer (2) and circlip
(1).

1 2
3

RKP09830

PW75R-2 30-89
DISASSEMBLY AND ASSEMBLY TRANSMISSION

REMOVAL OF THE TRANSMISSION

Lower the work equipment until it is resting on the
ground and stop the engine.
2
Release all residual pressures from all circuits (For
details, see «20. TESTING AND ADJUSTMENTS»).
. Drain the transmission oil.
Transmission oil: approx. 1.5 ,
1 - Remove the travel motor (See «REMOVAL OF TRA-
VEL MOTOR»).
2 - Disconnect the rear drive shaft (2) from the transmis- 3
sion (1).
RKPA8621

3 - Disconnect the movement sensor (3) and the micro- 11

6
switch (4).
5
10 4 3
4 - Disconnect the gear-change tubes (4-5) and plug
them.
H Make some identifying marks on the tubes, to
avoid mixing up the position when reconnecting.
5 - Place a supporting jack underneath the transmission
(1).
6 - Loosen the screw (7) (No. 8) and remove complete
group.
H Take great care not to damage the sensor (3) and RKPA8652

the microswitch (4).

Transmission: ............. kg

INSTALLATION OF THE 1 8
TRANSMISSION
. To install, reverse the removal procedure.
7
H Adjust the position of the transmission sensor.
(For details, see «20. TESTING AND ADJUST-
MENTS»).
H Position the protective sleeve with the cable outlet
pointing towards the ground to prevent accumula- RKPA8660

tions of water or condensates.

Screw: Loctite 270

Screw: 69 ± 71 Nm

H Fill the transmission with lubricating oil.

Transmission oil: 1.5 <
1 - Start the engine to circulate the oil and, with the ma-
chine stationary, put it into gear several times to
bleed air from the circuit.

30-90 PW75R-2
DISASSEMBLY AND ASSEMBLY TRANSMISSION

DISASSEMBLY OF THE TRANSMISSION

3
View of gear cilindro
Particolare
2 1 cylinder
comandocontrol
marce
4
5 6 8 29
16 44 31
23
22 7
21 24
35 30
18
17 36 32
19
20
13
12 26
14
34
11
10
38
9 28
37
27
33 39 25

38
41

40

RKP09630

1 - Unscrew and take out the gear control shaft (6).

RKPA8670

PW75R-2 30-91
DISASSEMBLY AND ASSEMBLY TRANSMISSION

2 - Remove the gear control cylinder assembly (7) and

guard plate (8).

7
8
RKPA8680

3 - Disassemble the gear control cylinder (7).

7
H Check carefully the O-rings position.
H Arrange the components in reassembly order.

RKPA8690

4 - Remove the breather (3) and mount the eyebolt (A).

Apply a slight tension to the chain an remove the A
screws fixing the gear box (B) to the axle (C).
B
C

RKPA8700

5 - Using a plastic hammer, remove the gear box (B).

RKPA8710

30-92 PW75R-2
DISASSEMBLY AND ASSEMBLY TRANSMISSION

6 - Remove the gear position microswitch (9), washer

(10) and O-ring (11).

10
RKPA8720

7 - Remove the screw (12), spring (13) and ball (14) for
neutral position.

14 13
12

RKPA8730

8 - Remove the flange (1) with oil seal (4) and spacer (5).
H Note the spacers thickness.

RKPA8740

9 - Remove the nut (16).

H To remove the nut (16) heat it at about 120 ëC.
H Make unit cold before continuing in disassembly.

16 17

RKPA8750

PW75R-2 30-93
DISASSEMBLY AND ASSEMBLY TRANSMISSION

10 - Remove the ring (18) and the flange (17).

16 18

17

RKPA8760

11 - Remove the cover (19) complete with seal (20) and

thrust ring (22). X
H Note that notch «X» must be turned upwards.

20
22
19

RKPA8770

12 - Remove the bolts (23) and lightly the cover (24).

23 24

RKPA8790

13 - Using some levers, force the cover (24) to divide it

from housing (25).
H Prise the cover by the locating dowels.
H Take great care not to ruin surfaces. 24

25
RKPA8800

30-94 PW75R-2
DISASSEMBLY AND ASSEMBLY TRANSMISSION

14 - Pull out gear (39), needle bearings (38) and distance

piece (40) from the cover (25). 39

40 25

38
RKPA8810

15 - Take out bearing (36).

H Do not take out the bearing (36) if does not need
replacement.

36

RKPA8820

16 - Remove the oil shield plate (41).

H Operation to be carried on only if necessary.

41

RKPA8830

17 - Remove the bolts of cut flow housings (26) and (27)

27

RKPA8840

PW75R-2 30-95
DISASSEMBLY AND ASSEMBLY TRANSMISSION

18 - Remove the cut flow housing (27) and, in one time,

the hub (28) and the fork (29) complete with pads
(30) and transmission shaft (31).
29
27

31 28

RKPA8850

19 - Check sliding block (30), pin (32) and sliding coupling

(28) wear; replace if worn.

30

32
28
RKPA8860

20 - Using a plastic hammer, remove the output shaft (37)

with needle bearings (38), gear (33) and cut flow
housing (26). 38
37

26
33
RKPA8870

21 - Remove the output shaft (37), gear (33), needle bear-

ing (38), distance piece (34) and bearing (21).
H Replace worn or damaged components.

37 21
34

38
RKPA8880

30-96 PW75R-2
DISASSEMBLY AND ASSEMBLY TRANSMISSION

22 - Remove input shaft (35) from the cover (24).

35

24
RKPA8890

23 - Remove bearing (44) from carter (24).

24

44

RKPA8900

24 - Remove all the oil seal and clean and dry with accu-
racy all the components before reassembling.

PW75R-2 30-97
DISASSEMBLY AND ASSEMBLY TRANSMISSION

ASSEMBLY OF THE TRANSMISSION

Removed gaskets and O-rings cannot be used
again.
H Check carefully that contact surfaces are not damaged.
H Remove from contact surfaces each sealing residual.
H Lubricate the coupling surfaces of bearings and
seals.
Surfaces: ASL800050

1 - Install the bearing (44) into the casing (24) and fit seal
(4) and spacer (5) into the flange (1).
H Lock the spacers into position using grease.
Spacers: ASL800050

4
44
24 1

RKPA8910

2 - Install the flange (1) onto the casing (24) and bolt it.
Flange surface: Loctite 510
Flange screws: 49 ± 51 Nm

24

RKPA8920

3 - Lubricate the threaded portion of seal and fit the com-

plete shaft (35).
Seal: ASL800050
35

RKPA8930

30-98 PW75R-2
DISASSEMBLY AND ASSEMBLY TRANSMISSION

4 - Assemble the complete outlet shaft (37) and the flow

regulator casing (26) at the same time.
H Stop assembly at approx. 5mm from the final po-
sition.
37

26
RKPA8940

5 - Provisionally fit cover (19) and screw it down.

H Hold niche «X» turned to the top side of reduction
gear.

X
19

RKPA8950

6 - Install coupling (28), the complete fork (29) and the

flow regulator casing (27) all at the same time.

29
27

28

RKPA8851

7 - Bolt the assembly with screws.

Screws: Loctite 270
Screws: 25 ± 26 Nm

RKPA8970

PW75R-2 30-99
DISASSEMBLY AND ASSEMBLY TRANSMISSION

8 - Install the needle bearings (38), the gear (39) and the
distance piece (34). 34

39 38

RKPA8960

9 - Coat the outer rim of the flow regulator plate (41).

Flow-regulator: Loctite 510

41

RKPA8980

10 - Fit the flow regulator plate (41) into the reduction gear
housing (25) turning the oil inlet (Y) upwards.
Place it 5 ± 5.5 mm from the surface of the body.

41
Y
25

5ⴜ5,5mm
RKPA8990

11 - Fit the bearing (36) into the housing (25).

25

36

RKPA9000

30-100 PW75R-2
DISASSEMBLY AND ASSEMBLY TRANSMISSION

12 - Fit the housing (25) onto the casing (24) making sure
to centre the pins. 24
H Apply sealant to the surface of cover.
H Use a plastic hammer to mate.
Cover: Loctite 510

25

RKPA9010

13 - Bolt casing (24) and (25) with screws (23).

Screws: 48 ± 62 Nm

24
23

25
RKPA9020

14 - Lubricate the ball (14), spring (13) and the screw (12)
and install the neutral position assembly.
Ball and spring: ASL800050
Screw: 80 ± 100 Nm 13
14 12

RKPA8730

15 - Fit the in-gear-position microswitch (9), the O-ring (11)

and washer (10).
Microswitch: Max. 54.2 Nm
9

10
RKPA8720

PW75R-2 30-101
DISASSEMBLY AND ASSEMBLY TRANSMISSION

16 - Hook transmission (B) to the hoisting equipment and

fit it onto axle (C ). B
Coat supporting surfaces.
Bolt units with the relative screws. C
Surfaces: Loctite 510
Screws: Loctite 270
Screws: 52 ± 63 Nm

RKPA9030

17 - Pull out screws and remove the provisionally fitted

cover (19).

19

RKPA9040

18 - Push the bearing (21) to end of travel.

21

RKPA9050

19 - Using a depth gauge, measure jut «A» of bearing (21)

on flange surface.
21

RKPA9060

30-102 PW75R-2
DISASSEMBLY AND ASSEMBLY TRANSMISSION

20 - Measure dimension «B» between the surface of the

cover (19) and the edge of the seat of bearing. B
Calculate the required dimension of distance washers
so as to leave a slack of 0.2 ± 0.3 mm, i.e.: B ± 19
(A+0.2 ± 0.3)= dimension of distance washer.

19

RKPA9070

21 - Insert the required distance washers (22) in the cover,

greasing them to keep them in position.
Distance washers: ASL800050

X 19

22

RKPA9080

22 - Coat the supporting surfaces and fit the flange.

H Keep niche «X» upwards.
Surfaces: Loctite 510
Screws: Loctite 270
Screws: 48 ± 62 Nm

RKPA9090

23 - Fit the flange (17), the O-ring (18) and bolt them with
the nut (16).
Nut: Loctite 270
16
Nut: 260 ± 300 Nm

17

RKPA9100

PW75R-2 30-103
DISASSEMBLY AND ASSEMBLY TRANSMISSION

24 - Assemble the gear control cylinder (7).

7
H Carefully check position of O-rings.

RKPA8690

25 - Fit the protection plate (8) onto the transmission (B)

after coating the surface touching the transmission.
Plate: Loctite 510

8
B
RKPA9110

26 - Install the gear control cylinder (7) complete with O-

ring and bolt it with the relative screws.
Screws: 94 ± 51 Nm

RKPA8681

27 - Run the gear control rod (6) and tighten.

Rod: Loctite 242
Rod: 24 ± 26 Nm

RKPA8670

30-104 PW75R-2
DISASSEMBLY AND ASSEMBLY AXLE LOCKING CYLINDERS

REMOVAL OF AXLE LOCKING CYLINDERS

Lower the bucket (1) until level ground and make it
lean on the back.
Release all residual pressures from all circuits (For 2
1
details, see «20. TESTING AND ADJUSTMENTS»).
1 - Bring the ignition key to the «I» position and operate
the axle release push-button; move the key to the
«O» (off) position and remove it.
2 - Disconnect the pipe (2) from the cylinder (1) and plug 3
it.
3 - Loosen the screws (3).
RKPA9120

4 - Sling the cylinder (1) and remove the screws (3).

Cylinder: 22 kg

INSTALLATION OF AXLE
LOCKING CYLINDERS
. To install, reverse the removal procedure.
1 - Start the engine, then lock and release the axle sev-
eral times to restore the circuit and check it is leak
tight.

PW75R-2 30-105
DISASSEMBLY AND ASSEMBLY COMPLETE FRONT AXLE

REMOVAL OF COMPLETE FRONT AXLE

1 - Remove the cabin access steps (1) from both sides of

the machine.

RKPA8610

2 - Disconnect the drive shaft (32) from the axle (3).

RKPB0010

3 - Start the engine and raise the front of the machine by

pushing down vertically with the boom, until the
wheels are about 20 cm above the ground.

20 cm

RKP09850

4 - Place a trestle (A) underneath the machine and some

blocks (B), roughly 15 cm high, at points correspond-
ing to the chassis.
5 - Lower the machine slowly onto the blocks (B) and that
the wheels remain raised above the ground.
Lower the lower work equipment until it rests on the
ground and stop the engine. B
Completely release all residual pressures from all
circuits, and in particular from the brake line. (For A
details, see « 20. TESTING AND ADJUSTMENTS»).

RKPA9130

30-106 PW75R-2
DISASSEMBLY AND ASSEMBLY COMPLETE FRONT AXLE

6 - Mount the tool E1 on the wheel group (5) and apply a

slight tension to the hoisting cables. Using the dyna-
mometric wrench B1, take off the nuts and remove
E1
the entire wheel group.
Wheel group: 150 kg 4

RKPA9140

7 - Disconnect the tubes (5) from the steering cylinder

and plug both the tubes and the cylinder.
8 - Disconnect the brake-group tubes (6) and plug both 6
the tubes and the axle couplings.
7 8
Only for version 4WS
9 - Remove the guard (7) and disconnect the steering
sensor cable (8).
H Protect both the sensor and the connector with vi-
nyl bags and insulating tape.
5
RKPA9150

10 - Take away the cotter pin (9), the nut (10), the pin (11)
9
and its washer (12).

11
10

12
RKPA9160

11 - Place a lifting platform (C) and some blocks (D) be-

neath the axle. Raise this until the blocks are being
forced up against the arms of the axle (13).
H The lifting platform should be capable of an excur-
sion of about 15 cm in descent.

13 D

C
RKPA9170

PW75R-2 30-107
DISASSEMBLY AND ASSEMBLY COMPLETE FRONT AXLE

12 - Remove the screws (14) and take away the pin (11)
and the cup springs between the axle and the chas-
sis.
13 - Lower the lifting platform (C) until the axle is free of 14
the chassis.
14 - Extract the axle (13).
11
Front axle: 357 kg

RKPA9180

INSTALLATION OF FRONT AXLE 15 9

. To install, reverse the removal procedure.

Wheel lock nuts: 550w20 Nm (56w2 kgm) 14 10

H Insert the cup springs (15) between chassis and
axle. 12
11
1 - Refill the axle with lubricating oil and check tightness.
2 - Start the engine to circulate the oil, recharge the ac-
13
cumulators of the brake line, and check the leaktight-
ness. RKP10010

3 - Execute several complete steering manoeuvres with

the front axle.
4 - Bleed air from the front brake line.
(See «20. TESTING AND ADJUSTMENTS»).
5 - Stop the engine and check the level of the oil in the
tank.

30-108 PW75R-2
DISASSEMBLY AND ASSEMBLY COMPLETE REAR AXLE

REMOVAL OF COMPLETE REAR AXLE

1 - Remove the cabin access steps (1) from both sides of

the machine.

RKPA8610

2 - Disconnect the drive shaft (3) from the axle (2).

2

RKPA8621

3 - Start the engine and raise the front of the machine by

pushing down vertically with the boom, until the
wheels are about 20 cm above the ground.

20 cm

RKP09840

4 - Place a trestle (A) underneath the machine and some

blocks (B), roughly 15 cm high, at points correspond-
ing to the chassis.
5 - Lower the machine slowly onto the blocks, making
sure that the wheels remain raised above the ground.

Lower the lower work equipment until it rests on the

ground and stop the engine.
Release all residual pressures from all circuits in
particular from brake circuit. (For details, see « 20. A
TESTING AND ADJUSTMENTS»).
RKPA9190

PW75R-2 30-109
DISASSEMBLY AND ASSEMBLY COMPLETE REAR AXLE

6 - Mount the tool E1 on the wheel group (4) and apply a

slight tension to the hoisting cables.
E1
Using the dynamometric wrench B1, take off the nuts
and remove the entire wheel group.
Wheels group: 150 kg
7 - Remove the travel motor (for details, see «REMOVAL
OF TRAVEL MOTOR»).

RKPA9200

8 - Disconnect the tubes (5) of the braking units and plug

both pipes and cylinder. A

9 - Disconnect the brake group tubes (6) and plug both 6

the tubes and the axle couplings.

Only for version 4WS

5
10 - Disconnect sensor (8).
H Protect both sensor (8) and connector (9) with vi-
nyl bags and tape. 9 8

11 - Disconnect the steering cylinder tubes (5) and plug 7

both the tubes and the cylinder. A RKPA9210

12 - Disconnect pipes (10) and (11) from transmission and

plug them.
H Place an identifying mark on each tube to prevent 11
mixing them up during installation. 13 12
Disconnect the position sensor (12) and the mi- 10
croswitch (13).

RKPA8651

13 - Sling the axle (14) with ropes and hook it to a piece of

hoisting equipment.
17
14 - Loosen and take away the nuts (10), and plates (11)
and the fastening screws (12).
H Loosen screws a little at a time and using the
criss-cross method.
15 - Lower the axle (14) and extract it.
Complete stationary axle: 301 kg 16 14
Complete steering axle: 378 kg
15
RKPA9230

30-110 PW75R-2
DISASSEMBLY AND ASSEMBLY REAR AXLE

INSTALLATION OF REAR AXLE

. To install, reverse the removal procedure.

Wheel lock nuts: 550w20 Nm (56w2 kgm)

1 - Refill the axle with lubricating oil and check tightness.
2 - Start the engine to circulate the oil, recharge the ac-
cumulators of the brake line, and check the leaktight-
ness.
3 - If the machine is a 4WS version, execute a few full
steering manoeuvres.
4 - Bleed air from the rear brake line.
(See «20. TESTING AND ADJUSTMENTS»).
5 - Stop the engine and check the level of the oil in the
tank.

PW75R-2 30-111
DISASSEMBLY AND ASSEMBLY AXLES

DISASSEMBLY OF AXLES
1. Final reducing unit
1 - Loosen the screws (1) and remove the support of the
planetary gears (2). 2
1

RKPA9240

2 - Take away the snap ring (3).

Using a press, remove the planetary carrier pins (4).
Remove the planetary gears (5) complete with their 3
roller bearings and cup springs.

4
5
RKPA9250

3 - Loosen screws (7) (No. 8).

Only for 2WS rear axle
Loosen brake clearance adjusting screws (No. 3 on 6
each side) all the way and then remove the axle shaft 7
(6). Loosen screws (7) (No.8).

RKPA9260

4 - Use a puller to remove the toothed ring bevel gear (8)

and the wheel hub (9).
H Use the slightly loosened retaining screws of the
toothed ring bevel gear and a plate as a support- 8 9
ing surface for the puller.

RKPA9270

30-112 PW75R-2
DISASSEMBLY AND ASSEMBLY AXLES

5 - Use a puller to extract the bearing (10) 11

10
Remove seal (11).
Remove the bearing (10).

11
10

RKPA9280

6 - Only for 2WS rear axle

Using an extractor, remove the sealing ring (12) and
the centring ring (13) from the arm.

12 13
RKPA9290

2. Joint
1 - Remove the cotter pin (14) and the nut (15).
Use a puller to remove the ball and socket joint (16).

16
15 14

RKPA9300

2 - Loosen the six screws and remove the upper pin (17).
Repeat this operation for the lower pin.
H Replace the sealing ring (18). 17

18
RKPA9310

PW75R-2 30-113
DISASSEMBLY AND ASSEMBLY AXLES

3 - Remove the final reducing unit (19) and pull out the
outer races of roller bearings (20).
H Check (using a micrometer for inner parts) that
the seats of outer races are not deformed. 19 20

RKPA9320

4 - Remove snap ring (22) sealing ring (23), ring (24) and
bearings (25) from the articulation box. 21

22

23

24
25

RKPA9330

3. Drive shaft
H Before proceeding to the removal of the drive shaft,
lock the brakes by loosening the clearance adjusting
screws (No. 3 on each side) all the way so as to lock
the position of the braking disks.
Maintain this position until re-assembly of the drive
shaft.
1 - Dismantle the joint (See «2. Joint»).

2 - Loosen the nut (26) and the screw (27).

26
27

RKPB0260

30-114 PW75R-2
DISASSEMBLY AND ASSEMBLY AXLES

3 - Use levers to remove the drive shaft (28).

28

RKPA9340

4. Brakes
29
1 - Loosen nuts (29) (No. 16) on each side and remove 30
the complete arms (30).
Loosen nuts (31) (No.3) on each side.

31
RKPA9350

2 - Remove the adjusting screws (32) (No.3).

Remove the thrust plate (33). 33

32
RKPA9360

3 - Remove the friction disks (34) and intermediate disks

(35). 35
H If there is no need to change the disks, remove 34
the entire stack without altering their positions.

RKPA9370

PW75R-2 30-115
DISASSEMBLY AND ASSEMBLY AXLES

4 - Introduce compressed air and extract the pistons (35)

from the intermediate cover (36).

36

37

RKPA9380

5 - Remove the anti-extrusion ring (38) and the O-ring

(31) from the pistons (37). 39 38

RKP09860

30-116 PW75R-2
DISASSEMBLY AND ASSEMBLY AXLES

5. Differential group

42 54
51
55

46 47
45
48
52 54
51
53 47 49
44
50 42
49
54 51 51 45
46
54

43
RKP10090

1 - Remove the complete arms. (See «2. Brakes»).

Remove the stud bolts (40) (two horizontal bolts op-
posed for each side). 40

RKPA9390

2 - Take off the intermediate covers (36).

Remove the complete differential group (41). 41
36
H Take care not to damage the sealed areas of the
O-rings.

RKPA9400

PW75R-2 30-117
DISASSEMBLY AND ASSEMBLY AXLES

3 - Extract the bearings (42) and take out the twelve

44
screws (43).
Remove the cover (44) complete with the planetary
gear (45) and the shim (46).

42
43

RKPA9410

4 - Fully insert the three centering pins (47) into the sup-
porting pins (48-49). Draw out the supporting pins (48- 52
49), the cross journal (50), the planetary gears (51),
the shims (54) and the second planetary gear (45),
complete with its shim (46). 48 49
Loosen the screws (52) and lift out the bevel ring gear
(53).
H Replace screws (52) at each disassembly.

53

RKPA9420

30-118 PW75R-2
DISASSEMBLY AND ASSEMBLY AXLES

6. Bevel pinion
1 - Remove the differential. 58 61 65 68 63 62
56 57
(See «5. Differential group»).

59 60 67 64
RKP09650

2 - Using tools M1 and M2, loosen the nut (56), remove

the O-ring (57), the flange (58) together with guard 66
(59), the sealing ring (60) and the distance piece (61).
Extract the bevel pinion (62) complete with roller M2
bearing (63), distance piece (64) and distance washer
(65).

M1

RKPA9430

3 - Remove the roller bearing (63) from the bevel pinion

(62).
Extract the thrust blocks of bearings (63) and (67) and 66
the shim (68) from the main body (66).
62

63

RKPA9440

4 - Remove the snap ring (69) and the cover (70).

69

70

RKP09660

PW75R-2 30-119
DISASSEMBLY AND ASSEMBLY AXLES

7. Bevel pinion (Only for 2WS rear axle)

62

71 75

65

63

74 64

72
67

73

RKP10170

1 - Remove the differential gear.

(See «5. Differential unit»).
Loosen screws (71) (No. 8) and remove the complete 72
pinion support (72).

71

72
RKPA9450

2 - Remove bearing (73) and using tools M3 and M4,

loosen the ring nut (74).
Remove the bevel pinion (62) complete with roller
bearing (63). M3
Remove bearing (67) from the pinion support. 72
Remove shim (65) and distance piece (64) from the
bevel pinion.

62
M4

RKPA9470

30-120 PW75R-2
DISASSEMBLY AND ASSEMBLY AXLES

3 - Remove bearing (63) from the bevel pinion (62). Re-

move the thrust block of bearing (63) and the sealing
ring (75) from the bevel pinion support (72). 62

63

72

RKPA9460

4 - Remove the snap ring (69) and cover (70).

69

70

RKP09660

8. Bevel pinion (for 4WS rear axle)

1 - Remove the differential gear (See «5. Differential 74
unit»).
Extract bearing (73). 62

73

67 65 64 68 63
RKP09670

2 - Using tools M3 and M4, loosen the ring nut (74).

Extract bevel pinion (62) with roller bearing (63), dis-
tance piece (64) and distance washer (65). M3
62

M4

RKPA9480

PW75R-2 30-121
DISASSEMBLY AND ASSEMBLY AXLES

3 - Remove the roller bearing (63) from the bevel pinion.

From the main body (66) extract the thrust blocks of 66
bearings (63) and (67), the shim (68) and the sealing
ring (75). 62

63

RKPA9490

4 - Remove the snap ring (69) and the cover (70).

69

70

RKP09660

9. Steering cylinder
1 - Disconnect the tie-rods of the steering mechanism
(16) from the joints (see «2. Joint») and from the piston
rods of the steering cylinder (76). 16 76
Remove the four screws (77).

77

RKPA9500

2 - Extract the complete cylinder (76) from the axle body.

76

RKPA9510

30-122 PW75R-2
DISASSEMBLY AND ASSEMBLY AXLES

3 - Remove the snap ring (78).

78

RKPA9520

4 - Push the head-piece (79) inside the cylinder (80) and

remove the snap ring (81). 81 80
5 - Slide the piston (82) complete with head-piece (79) off
the cylinder (80).
6 - Remove all the cup springs and guide rings from the
cylinder (80), from the piston (82), and from the head-
piece (79).

82 79
RKP10160

10. Removal of the negative brake cylinder

1 - Introduce oil into the cylinder at a pressure of 20 ± 22 87 86
bar.
83 88
2 - Disconnect the cylinder from the levers (83), remov-
ing in sequence the lock nut (84), the nut (85), the
screw (86) and finally the dowel (87) of the cylinder
fulcrum.
H Check the positions of the shims (88).
83
88
H When the operation is completed, release all 85 84 88
pressure from the cylinder.
RKP10060

PW75R-2 30-123
DISASSEMBLY AND ASSEMBLY AXLES

ASSEMBLY OF AXLES
1. Bevel pinion
(For 4WS front and rear axle) 75
1 - Only for 4WS rear axle
Fit the oil seal (75) into the main body.

RKP09680

2 - Use the tool M5, assemble the outside rings of the

roller bearings (63-67) without shims in the central
body. M5

RKPA9530

3 - Return tool M6 to zero on a surface plane.

M6

RKPA9540

4 - Using tool M7, assemble the roller bearings (63-67).

M7 63 67
RKP09690

30-124 PW75R-2
DISASSEMBLY AND ASSEMBLY AXLES

5 - Insert tool M6 into the central housing and take mea-

surement «A».
H Measurement «A» corresponds to the shim (68)
that should be inserted beneath the outside ring
of the roller bearing.
68

M6
RKPA9550

6 - Extract the outside ring of the bearing (63), insert the

shim (68), then use tool M5 to replace the ring.
Mount the bearings (63-67) and the spacer (64) on C
tool M7 and take measurement «C».
63

63 64
67
64
67 M7

RKPA9560

7 - Use tool M7 to insert the roller bearings without the

spacer (64) and take measurement «B».
B
H The measurement «B-C + X» corresponds to the
shim that should be inserted between the spacer
(55) and the roller bearing (56). M7
H X=0.07 ± 0.09 mm

M7

RKPA9570

8 - Fit the roller bearing (63) onto the bevel pinion (62).
Install the distance piece (64) and the distance
washer (65) onto the bevel pinion. 62

63

RKPA9580

PW75R-2 30-125
DISASSEMBLY AND ASSEMBLY AXLES

9 - Use tool M8 to mount the complete bevel pinion (62)

and the roller bearing (67).
M8

62

RKPA9590

10 - Only for front axle

Fit the distance piece (61)
Fit the flange (58) with guard (59), O-ring (57) and,
using tool M1 tighten nut (56).
Nut: 260 ± 300 Nm

M1

RKPA9600

11 - Only for front axle

Check that the torque of bevel pinion is within permis-
sible values.
H Pinion torque: 120 ± 170 Ncm
If pinion torque is not within permissible values,
change the dimension of distance washer (65).
. An INCREASE in dimension of 0.02 mm reduces
the pinion torque by * 10 Ncm.
. A REDUCTION in dimension of 0.02 mm increases
pinion torque by * 10 Ncm.
H If changing the dimension of distance washer
does not lead to the minimum permissible torque, RKPA9610

replace the distance piece (64).

12 - Only for front axle
Loosen nut (56) and remove the flange (58) with
guard (59).
Using tool M9, insert the sealing ring (60).
Fit the flange (58) complete with guards (59) and
using tool M1 tighten nut (56).
Nut: Loctite 270
Nut: 260 ± 300 Nm

M9

RKPA9620

30-126 PW75R-2
DISASSEMBLY AND ASSEMBLY AXLES

13 - Only for 4WS rear axle

Using tools M3 and M4 tighten the ring nut (74).
Ring nut: 600 ± 700 Nm
14 - Only for 4WS rear axle M3
Check that the torque of bevel pinion is within permis-
sible values.
H Pinion torque: 170 ± 220 Ncm
If pinion torque is not within permissible values, M4
change the dimension of distance washer (65).
. An INCREASE in dimension of 0.02 mm reduces
the pinion torque by * 10 Ncm. RKPA9630

. A REDUCTION in dimension of 0.02 mm increases

pinion torque by * 10 Ncm.
Tighten ring nut (74) thoroughly. Fit bearing (73).
Ring nut: Loctite 270
Ring nut: 600 ± 700 Nm

RKPA9610

2. Bevel pinion support

(Only for 2WS rear axle)
1 - Fit the sealing ring (75) into pinion support (72).
Using tool M10 fit the thrust blocks of bearings (63) M10
and (67) into the pinion support (72).

72

M10
RKPA9640

2 - Fit bearing (63) and (67) into pinion support. Measure

dimension «A».
Dimension «A» corresponds to the distance between
the face of the bevel pinion support and the outer sur-
face of bearing (63).

63

RKPA9650

PW75R-2 30-127
DISASSEMBLY AND ASSEMBLY AXLES

3 - Using tool M7, measure dimension «B».

B
M7

M7
RKPA9660

4 - Fit the bearings (63) and (67) and the distance piece
(64) onto tool M7; measure dimension «C».

M7
63
64
67
M7
RKPA9670

5 - Using a press, fit the bearing (63) onto the bevel pi-
nion (62).
Fit the distance piece (64) and the shim (65) onto the
65
bevel pinion.
H Shim dimension: S1=B ± C+X 64
H X=0.05 ± 0.07 mm 63

RKPA9680

6 - Fit the bearing (67) into the pinion support (72) and
using a press, assemble the complete bevel pinion 62
(62). M3
Tighten the ring nut (74) using tools M3 and M4.

72
M4

RKPA9690

30-128 PW75R-2
DISASSEMBLY AND ASSEMBLY AXLES

7 - Check that the torque of bevel pinion is within permis-

sible values.
H Pinion torque: 170 ± 220 Ncm
M3
If pinion torque is not within permissible values,
change the dimension of distance washer (65).
. An INCREASE in dimension of 0.02 mm reduces
the pinion torque by *10 Ncm.
. A REDUCTION of 0.02 mm increases pinion torque
by *10 Ncm.
M4
Tighten ring nut (74) thoroughly. Fit bearing (73).
Nut: Loctite 270 RKPA9700

Nut: 600 ± 700 Nm

3. Differential
1 - Insert into the differential case (55) the thrust washer 48
(46) and pinion gear (45).

33 mm
Insert the thrust washers (54) (No. 4), sun gears (51)
(No. 4) and spinder (50).
Insert the shafts (48) and (49) and dowels (47).
H Check that shafts holes are aligned with dowels
holes.
H Insert the dowels until 33 mm depth. 49
49

RKPA9710

2 - Insert the pinion gear (45) and thrust washer (46) into
the differential case. 42
Assemble cover (44) on differential case and tighten 43
the bolts (43) (No. 12).
Using a press, assemble bearings (42) inner rings. 44
Bolt: Loctite 270
Bolts: 69 ± 72 Nm

42

RKPA9720

PW75R-2 30-129
DISASSEMBLY AND ASSEMBLY AXLES

3 - Insert the bevel gear ring (53) and tighten the bolts
(52) (No. 12).
Bolt: Loctite 270
Bolts: 73 ± 76 Nm
52

53

RKPA9730

4. Measuring pinion carrier position shim (only for

rear axle)
1 - Measure distances «E» and «F».
H Determine measure «S2» of shim (89).
H S2=(98+A) ± (E+F)

F F E
S2
RKP09700

2 - Assemble complete pinion carrier (72) and spacer

(89).
Tighten the bolts (71).
Bolt: Loctite 270
Bolts: 69 ± 71 Nm

72 89 71
5. Adjustment of the bevel gear RKPA9740

(Only for rear axle)

1 - Mount the intermediate cover (36) of the side oppo-
site the ring bevel gear and tighten the stud bolts
(40) (two stud bolts, horizontal and opposite).
36
Use a rod to insert the complete differential group.
Mount the intermediate cover (36) on the ring bevel
gear side and tighten the stud bolts (40) (two horizon-
tal and opposite).
Remove the safety plates (90) from the intermediate
covers and take out the lock nuts (91) using tool M11.
H Take care not to damage the sealing areas of the M11
O-ring.
H Clean the lock nuts very thoroughly.
RKPA9750

30-130 PW75R-2
DISASSEMBLY AND ASSEMBLY AXLES

2 - Tighten the lock nuts (91) and check the clearance

between the bevel pinion and the ring bevel gear.
91
Once the prescribed clearance has been obtained,
tighten the lock nut on the side opposite to the ring
bevel gear, until the rotation torque of the bevel pi-
nion has been increased by 35 ± 45 Ncm.
Chamfer the safety plates.
Lock nuts: Loctite 222
H Clearance between pinion and ring bevel gear:
0.15 ± 0.18 mm
H If the clearance measured is found to be LESS RKPA9760
than the prescribed value, LOOSEN the lock nut
on the RING BEVEL GEAR SIDE and tighten
the lock nut on the side opposite the ring bevel
gear to the same value.
H If the clearance measured is found to be MORE
than the prescribed value, LOOSEN the lock nut
on the SIDE OPPOSITE TO THE RING BEVEL
GEAR and tighten the lock nut on the ring bevel
gear side to the same value.
H Take care not to pre-load the differential roller
bearings.

RKPA9770

6. Drive shaft
1 - Mount the drive shaft (28).

28

RKPA9780

2 - Screw the dowel bolt (27) home and tighten the nut
(26). 26
27
Nut: 86 ± 89 Nm

RKPA9790

PW75R-2 30-131
DISASSEMBLY AND ASSEMBLY AXLES

7. Final drive
1 - Using a press, assemble the thrust washers and in-
ner bearing (10) into the hub (9).
10 10
9

RKPA9800

2 - Using a press and tool M12, assemble seal (11) into

the hub (9).
M12
11

RKPA9810

3 - Using tool M13, assemble the seal (12) and ring (13)
into the axle housing (15).
Seat the hub (9) on the axle housing (15). M13
13

12
9

RKPA9820

4 - Using tool M14 and a soft hammer, beat on outer

bearing (92).

M14

92

RKPA9830

30-132 PW75R-2
DISASSEMBLY AND ASSEMBLY AXLES

5 - Assemble the gear (8), insert the centering bushing

(93) (No. 8) and tight the bolts (7) (No. 8). 8
Bolts: 76 ± 81 Nm 7

RKPA9840

6 - Check that hub rotation torque is within the permissi-

ble value.
H Hub rotation torque: 7 ± 20 Nm

RKPA9850

7 - Assemble on pinion gear (4) the bearings (94) and

spacer (95).
Insert the sun gear (5) and thrust washer (96) from
4
95
sun gear carrier (2) central hole and using a press in-
sert the pinion gear (4). 4
94 2

RKPA9860

8 - Insert the circlip (3).

H Check carefully the circlip correct introduction.
H Caulk the sun gear carrier in the area not inter- 3
ested by the circlip.

5
96

RKPA9870

PW75R-2 30-133
DISASSEMBLY AND ASSEMBLY AXLES

9 - Introduce the drive shaft (6) and assemble the sun

gear carrier assembly (2).
Tighten the bolts (1). 6
Bolts: 86 ± 89 Nm
1
2

RKPA9880

8. Final reducing unit

(For 4WS front and rear axle)
M14
1 - Using tool M15, fit the sealing ring (11) into the articu- 11 M15
lation box (21).
Using tool M14 fit the bearing (10) 10
21

RKPA9890

2 - Fit the outer races of bearings (10) and (92) into the
hub (9).
Using tool M14 fit the hub onto the articulation box
M14
(21).
9
9 21

RKPA9900

3 - Fit bearings (25), ring (24), sealing ring (23) and snap
ring (22) into the articulation box (21).
21
25 23

RKPA9910

30-134 PW75R-2
DISASSEMBLY AND ASSEMBLY AXLES

4 - To continue final reducing unit assembly procedure,

execute points 5 ± 9 of section «7. Final reducing unit
(for 2WS rear axle)».

9. Articulation (for 4WS front and rear axle)

1 - Fit the outer races of bearings (20).

20

RKPA9920

2 - Fit the complete final reducing unit (19) into position.

19
RKPA9930

3 - Fit the bottom pin (17) with bearing (20) and sealing
ring; tighten screws (No. 6).
Screws: 120 ± 123 Nm
Fit the complete top pin (17) and tighten screws.
20
H Tighten screws (No. 4) up to a torque of 10 ± 12
Nm.

RKPA9940

PW75R-2 30-135
DISASSEMBLY AND ASSEMBLY AXLES

4 - Using a feeler gauge, determine the dimension of dis-

tance washers to be inserted.
Insert distance washers and tighten nuts (No. 4).
Screws: 120 ± 123 Nm

RKPA9950

5 - Fit the ball articulation (16), tighten nut (15) and insert
the cotter pin (14). 16
Nut: 260 ± 290 Nm

15 14

RKPA9960

10. Brakes
1 - Assemble O-rings (39) and thrust rings (38) on pis-
tons.
38
H Make sure that gasket (39) and anti thrust ring
(38) assemblies are correct.

39

RKPA9970

2 - Introduce pistons assembly (37) (No. 3 each side) into

the intermediate cover (36). 36
Raise the pressure into the brake circuit for about ten
minutes with compressed air at 0.5 ± 1 bar.
Repeat the test for the other side.
37

RKPA9980

30-136 PW75R-2
DISASSEMBLY AND ASSEMBLY AXLES

3 - Introduce brake discs (34) and (35) into their seat.

35
H Make sure that lubricating holes are all aligned.
34
H Make sure discs are assembled in the right order.

RKPA9370

4 - Introduce thrust plate (97), the spring (33), the adjust-

ing bolts (32) complete with O-ring. 33
Tight the adjusting screws (32).

32
RKPA9360

5 - Assemble the axle housings (30) on differential case

and lock the nuts (29). 32
Adjust brake discs clearance, loosening the adjusting 30
bolts (32) of 3/4 turn.
Tight the lock nuts (31) (No. 3 each side).

31
RKPA9351

PW75R-2 30-137
DISASSEMBLY AND ASSEMBLY AXLES

11. Steering cylinder

79

82

101 100 99
98 99 100 101
80
98
104 82

106 106

79 102 103 105 80 RKP10140

1 - Mount the gaskets (99), the anti-extrusion rings (100)

and the gasket seal (101) in the cylinder (80) and in
the head-piece (79).
Mount the O-ring (103) and the anti-extrusion ring
(102) on the head-piece (79).
H Verify the correct assembly position for the seals
of the anti-extrusion rings and the O-ring.

2 - Use tool M16B to mount the O-ring (104) and the seal
ring (105) on the piston (82).
H To facilitate assembly, heat the O-ring (104) and
the seal ring (105) to 60 ± 80 ëC.

105
104 M16 M16

82
82
RKPA9990

30-138 PW75R-2
DISASSEMBLY AND ASSEMBLY AXLES

3 - Mount the guide rings (106).

Mount tool M16A and wait about 15 minutes be-
fore proceeding with the next operation. M16
H Mount tool M16A from the bevel side.

106

RKPA8780

4 - Insert tool M16C on the piston from the same side as

the bevel of tool M16A.
Then push the piston (82) complete with tools M16 82
M16A and M16C into the cylinder (80), until tool
80
M16A is completely free.
H Grease the contact areas between tool M16C and
the piston (82).

RKPB0020

5 - Remove tool M16C and insert it on the opposite side

of the piston (82).
Then assemble the head-piece (79) complete with 79
cup springs.
H Grease the contact areas between tool M16C and
the head-piece (79). M16

82

RKPB0030

6 - Mount the two snap rings (81) and (78).

81 78

RKPB0040

PW75R-2 30-139
DISASSEMBLY AND ASSEMBLY AXLES

7 - Push the complete steering cylinder (76) into the cen-

tral housing.
Then tighten the four screws (77).
H Take care not to damage the O-ring mounted in
the steering cylinder tube.
77
Screws: 86 ± 89 Nm 76

RKPB0050

8 - Fasten the tie-rods of the steering (16) to the piston

rods of the cylinder (76) and chamfer them at the
joints (See «9. Joint»).
Tie-rods: Loctite 242 16 76
Tie-rods: 240 ± 270 Nm

RKPB0060

12. Toe-in adjustment

1 - Position the piston rod of the steering cylinder (76) at
half-stroke and check the position with a gauge.
76

RKPB0070

2 - Verify that measurement «A» is equal on both sides.

Check the parallelism of both front and rear wheel
hubs. // 0,5 cm

A A
500 mm

RKP10040

30-140 PW75R-2
DISASSEMBLY AND ASSEMBLY AXLES

3 - If the parallelism of the hubs is outside permissible

limits, loosen the clamp (107) and loosen or tighten
the RH and LH tie-rods to the same extent. 107

107

RKPB0080

13. Steering angle adjustment

1 - Adjust the adjustment screw (a) to a measurement of
50 mm and after having completed a steering action
from one side, screw down the end-of-stroke screw
(b) on the opposite side. Repeat this operation with
the other adjustment screw (b).

b a A a
50

RKP10190 d C

14. Assembly of parking brake cylinder

1 - Introduce a pressure of 20 ± 30 bar in the cylinder and
proceed with re-assembly by following the removal
operation in the reverse order.
Adjust the end-of-stroke screws (See «20. TESTING
AND ADJUSTMENTS» - Adjustment of parking
brake).

PW75R-2 30-141
DISASSEMBLY AND ASSEMBLY BOOM CYLINDER (For 1-piece boom)

REMOVAL OF BOOM CYLINDER (For 1-piece boom)

Extend the arm fully and open the bucket comple-
tely. Lower the work equipment until it is resting on 2
the ground

1 - Put a sling around the cylinder (1).

2 - Switch off the engine, release pressure in the cylinder
by moving the RH PPC valve lever several times.
3
3 - Remove the screw (2) and draw out the pin (3).
4
4 - Start the engine to retract the piston (4). 1
5 - Lower the cylinder (1) until it rests on a stand «A». RKPA7160

H To hold the piston rod in its fully retracted position

tie it with wire.
6 - Switch off the engine and release any residual hy-
draulic pressures. (For details, see «20. TESTING
AND ADJUSTMENTS»).
1
7 - Disconnect the tubes (5-6) and plug them. Also plug
the holes in the safety valve to avoid entry of impuri-
ties.
8 - Remove pipe (7) and plug the cylinder port and the
pipe to keep out impurities.
A
9 - Remove the screw (8) and safety valve (9).
RKPA7170

10 - Remove screw (10) and draw out the pin (11).

11 - Remove cylinder (1).
9 8

INSTALLATION OF BOOM
7
CYLINDER (For 1-piece boom)
. To install, reverse the removal procedure.

H Insert the adjustments to a given clearance (dis- 5

tributed on both sides of the cylinder rod) until a 6
clearance of 1 ± 2 mm is obtained.
RKPB1042

When aligning the positions between hole and

pin, let the engine run at minimum idling.
Do not insert fingers into the hole to check the
alignment.

Inside bushings : ASL800050

10

H Insert the adjustments to a given clearance (dis-

tributed on both sides of the piston rod) until a
clearance of 0.5 ± 1 mm is obtained.
. Start the engine and bleed air from the cylinder. (For
details, see «20. TESTING AND ADJUSTMENTS»). 11
H After bleeding the air, check the oil level in the
tank. RKPA7180

30-142 PW75R-2
DISASSEMBLY AND ASSEMBLY BOOM CYLINDER (For 2-piece boom)

REMOVAL OF BOOM CYLINDER (For 2-piece boom)

1 - Fully extend the front work equipment, raise the

boom and 2-piece boom and position a supporting
stand (A) between them.
H The stand should be 1.60 m high.
2 - Manoeuvre the arm until the bucket is resting on the
ground. Switch off the engine.
A

RKPB0100

3 - Put a sling round the RH cylinder (1) of the 2-piece

boom and remove the self-locking nut (2), the screw 1 1
(3) and the adjustment to a given clearance (4).

4
4
2

5
5 3
RKPA7210

4 - Slide off the pin (5) that connects the RH cylinder (1)
to the 2-piece boom, until the piston rod is completely
disconnected.
5 - Start the motor and retract the RH cylinder piston. 6

H To secure the piston rod in this position, tie it with

wire and switch off the engine.
1
6 - Disconnect the tubes (6) from the RH cylinder (1) and
plug them.
7 - Slide out the pin (7) until the cylinder (1) is free and 7
remove it. RKPA7220

8 - Put the boom cylinder in a sling.

9 - Slide the pin (7) out until the boom cylinder piston rod
(8) is disconnected.
H To hold the piston rod it its fully retracted position,
tie it with wire and switch off the engine.
8
10 - Start the engine and retract the piston.
11 - Lower the cylinder (8) and rest it on a stand (B). 7

B
RKPA7230

PW75R-2 30-143
DISASSEMBLY AND ASSEMBLY BOOM CYLINDER (For 2-piece boom)

12 - Disconnect the tubes (9) and (10) and plug them. Also
plug hole in the safety valve (11) to prevent impurities
11 13
from entering.
13 - Remove pipe (12) and plug the cylinder port and the
pipe (12) to keep out impurities.
12
14 - Remove the screw (13) and take out safety valve (11)
15 - Remove the screws (14) and take out the pin (15).
9
10
16 - Remove the cylinder.
RKPB1043

8 14
INSTALLATION OF THE BOOM
CYLINDER (For 2-piece boom)
. To install, reverse the removal procedure.

15
Self-locking nut: 118 Nm.
RKPA7240

Inside bushings: ASL800050.

When aligning the positions between hole and

pin, run the engine at minimum idling.
Do not insert fingers in the holes to check the
alignment.

H Insert the adjustments to a given clearance (dis-

tributed on both sides of the piston rod) until a
clearance of 0.5 ± 1 mm is obtained.

H Insert the adjustments to a given clearance (dis-

tributed on both sides of the cylinder) until a clear-
ance of 0.5 ± 1 mm is obtained.
. Start the engine and bleed the air from the cylinders
(For details, see «20. TESTING AND ADJUST-
MENTS»).
H After bleeding the air, check the level of the oil
tank.

30-144 PW75R-2
DISASSEMBLY AND ASSEMBLY 2nd BOOM CYLINDERS

REMOVAL OF 2nd BOOM CYLINDERS

1 - Fully extend the front work equipment, raise the

boom and 2-piece boom and position a supporting
stand (A) between them.
H The stand should be 1.60 m high.
2 - Manoeuvre the arm until the bucket is resting on the
ground. Switch off the engine.
A

RKPB0100

3 - Put a sling round the RH cylinder (1) of the 2-piece

boom and remove the self-locking nut (2), the screw 1 1
(3) and the adjustment to a given clearance (4).

4
4
2

5
5 3
RKPA7210

4 - Slide off the pin (5) that connects the RH cylinder (1)
to the 2-piece boom, until the piston rod is completely
disconnected.
5 - Start the motor and retract the RH cylinder piston. 6
H To hold the rod in its fully retracted position, tie it
with wire and switch off the engine.
6 - Disconnect the tubes (6) from the RH cylinder (1) and 1
plug them.
7 - Slide out the pin (7) to free the cylinder (1) and re-
move it. 7
RKPA7220
8 - Put the boom cylinder in a sling.
9 - Slide the pin (7) out to disconnect the boom cylinder
piston rod (8).
10 - Start the engine and retract the piston.
H To hold the rod in its fully retracted position, tie it
with wire and switch off the engine.
11 - Lower the cylinder and rest it on a stand (B). 8

B
RKPA7230

PW75R-2 30-145
DISASSEMBLY AND ASSEMBLY 2nd BOOM CYLINDERS

12 - Repeat the procedure from points 3-7 to remove the

LH cylinder of the 2-piece boom.
6

7
9

RKPA7250

INSTALLATION OF 2nd
BOOM CYLINDERS
. To install, reverse the removal procedure.

Self-locking nut: 118 Nm.

Inside bushings: ASL800050.

When aligning the positions between hole and pin,

run the engine at minimum idling.
Do not insert fingers in the holes to check the align-
ment.

H Insert the adjustments to a given clearance (dis-

tributed on both sides) until a clearance of
0.5 ± 1 mm is obtained for each cylinder.

H Insert the adjustments to a given clearance (dis-

tributed on both sides of the cylinder) until a clear-
ance of 0.5 ± 1 mm is obtained.
. Start the engine and bleed the air from the cylinders
(For details, see «20. TESTING AND ADJUST-
MENTS»).
H After bleeding the air, check the level of the oil
tank.

30-146 PW75R-2
DISASSEMBLY AND ASSEMBLY ARM CYLINDER

REMOVAL OF ARM CYLINDER

Open the front work equipment completely, then
raise it and place a supporting stand between the
boom and the 2-piece boom.
H The stand should be 1.60 m high.
1 - Manoeuvre the bucket until its teeth are resting on
the ground, together with the arm.
2 - Put a sling around the cylinder (1).
A
3 - Switch off the engine, release pressure in the cylinder
by moving the LH PPC valve lever several times.
4 - Remove the screw (2) and draw out the pin (3). RKPA7260

5 - Start the engine to retract the piston (4).

H To hold the piston in its fully retracted position, tie 5
the rod with wire.
6 - Switch off the engine and release any residual hy-
1
draulic pressures. (For details, see «20. TESTING 4
AND ADJUSTMENTS»). 3
7 - Disconnect the tubes (5) and plug them.
If a safety valve has been installed, disconnect
the tubes (6-7) from the valve.
2
8 - Remove the screw (8) and draw out the pin (9).
RKPA7050

9 - Lift out the cylinder (1).

INSTALLATION OF
ARM CYLINDER
. To install, reverse the removal procedure.

H Insert the adjustments to a given clearance (dis-

tributed on both sides of the piston rod) until a 7
clearance of 1 ± 2 mm is obtained. 6
When aligning the positions between hole and
RKPB1052

pin, let the engine run at minimum idling.

Do not insert fingers into the hole to check the
alignment.

Inside bushings: ASL800050

9 8
1
H Insert the adjustments to a given clearance (dis-
tributed on both sides of the cylinder) until a clear-
ance of 0.5 ± 1 mm is obtained.
. Start the engine and bleed air from the cylinder. (For
details, see «20. TESTING AND ADJUSTMENTS»).
H After bleeding the air, check the oil level in the
tank.
RKPA7010

PW75R-2 30-147
DISASSEMBLY AND ASSEMBLY BUCKET CYLINDER

REMOVAL OF BUCKET CYLINDER

Extend the arm fully and open the bucket comple-
tely. Lower the work equipment until it is resting on 4
the ground

1 - Switch off the engine and release pressure in the cy-

2
linder by moving the RH PPC valve lever several
times.
2 - Remove the ring nut (2) and draw out the pin (3).

3 - Switch off the engine and retract the piston rod (4).
H To hold the piston rod in its fully retracted posi- 3
tion, tie it with wire. RKPA7690

4 - Switch off the engine and release any residual hy-

draulic pressures. (For details, see «20. TESTING
AND ADJUSTMENTS»).
6
5 - Disconnect the hoses (5) and plug them. Also plug
7
the holes of the rigid tubes to avoid entry of impuri-
ties. 1

6 - Put a sling around the cylinder (1).

7 - Remove the screw (6) and draw out the pin (7).

8 - Lift out the cylinder (1).

5
RKPA7270

INSTALLATION OF BUCKET 5
CYLINDER
. To install, reverse the removal procedure. 6
7
H Insert the adjustments to a given clearance (dis-
tributed on both sides of the piston rod) until a
clearance of 1 ± 2 mm is obtained.

When aligning the positions between hole and

pin, do not insert fingers into the hole to check RKPA7280

the alignment.

Inside bushings: ASL800050

H Insert the adjustments to a given clearance (dis-

tributed on both sides of the cylinder) until a clear-
ance of 0.5 ± 1 mm is obtained.

. Start the engine and bleed air from the cylinder. (For
details, see «20. TESTING AND ADJUSTMENTS»).
H After bleeding the air, check the oil level in the
tank.

30-148 PW75R-2
DISASSEMBLY AND ASSEMBLY BOOM SWING CYLINDER

REMOVAL OF BOOM SWING CYLINDER

1 - Swing the boom to the right to extend the cylinder

fully.
2 - Swing the revolving frame 45ë and rest the work
equipment on the ground.
3 - Switch off the engine and move the PPC valve sev-
eral times to release all residual pressures. 1
4 - Remove the RH front guard (1) from the revolving
frame (2). 2
5 - Disconnect the tubes (3) from the cylinder and plug
them. Also plug the flanges (4) of the cylinder (5). RKP07980

6 - Disconnect the lubricator tube (6).

7 - Place a block beneath the cylinder head to prevent
the edge of the frame making dents in the piston
5
rod. Also place a support beneath the cylinder. 4 4
8 - Remove the screw (7), draw out the pin (8) and detach
the piston rod from its support (9).
9 - Remove the screws (10) and draw out the stop (11)
and the pin (12).
3
10 - Slide the cylinder out partially from the front and, as
soon as possible, put it in a sling and lift it off.
H During this operation take great care not to dent RKPA5491
the piston rod.

INSTALLATION OF BOOM SWING

CYLINDER 7
8
. To install, reverse the removal procedure.

H Insert the adjustments to a given clearance (dis-

tributed on both sides of the piston) until a clear-
ance of 1 ± 2 mm is obtained.
9
When aligning the positions between hole and RKPB0990

pin, let the engine run at minimum idling.

Do not insert fingers into the hole to check the
alignment.
10
12
Inside bushings: ASL800050

H Insert the adjustments to a given clearance (dis- 11

tributed on both sides of the cylinder) until a clear-
ance of 0.5 ± 1 mm is obtained. 6

. Start the engine and bleed air from the cylinder. (For
details, see «20. TESTING AND ADJUSTMENTS»).
H After bleeding the air, check the oil level in the
tank.
RKPA7290

PW75R-2 30-149
DISASSEMBLY AND ASSEMBLY CYLINDERS FOR OUTRIGGERS OR BLADE

REMOVAL OF CYLINDERS FOR OUTRIGGERS OR BLADE

1 - Bring the arm into a vertical position and rest the back
of the bucket on the ground.
2 - Rest the blade and/or the outriggers on the ground.
3 - Stop the engine and release all residual pressures
from the blade and/or outriggers.
4 - Take away the screw (1), remove the dowel (2), and
disengage the piston rod from the blade or from the
outrigger.

5 - Start the engine and retract the piston rod (3). RKP10050

H Secure the totally retracted position by binding

both sides of the piston rod with wire.

6 - Stop the engine and release all residual pressures. 10

7 - Disconnect the tubes (4) and (5) and plug them. Also
plug the safety valve (6) couplings. 9
8 - Put a sling around the cylinder (7).
H Take care not to distort the valve tube (8).
3
9 - Take out the screw (9) and remove the dowel (10). 2

1
10 - Take out the cylinder complete with valve.
RKPB0120

INSTALLATION OF CYLINDERS 5
FOR OUTRIGGERS OR BLADE
. To install, reverse the removal procedure. 8
4
H Insert the shims on both sides of the piston rod.

6
When aligning the positions between hole and
pin, let the engine run at low idling.
Do not insert fingers into the holes to check on
alignment. RKPB0130

Internal bushings: ASL800050

H Insert the shims on both sides of the piston rod. 7

. Start the engine and bleed air from the cylinder. (For
details, see «20. TESTING AND ADJUSTMENTS»).
H After bleeding the air, check the level of oil in the
tank.

RKPB0140

30-150 PW75R-2
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT CYLINDERS

DISASSEMBLY OF WORK EQUIPMENT CYLINDERS

1. All cylinders
1 - Place the cylinder on the tool F8 and partially extract 3
the piston. F8 5
2 - Loosen the retaining screws of the flange (1) that se-
cures the head (2) and take it away. Move the flange
(1) towards the piston rod.
3 - Push the head (2) into the cylinder (3) and remove the
snap ring (4).
H Take great care not to damage the inside of the
cylinder.
RKPA7310
4 - Slide the piston rod (5) out of the cylinder (3), com-
plete with the flange (1), the snap ring (4), the head
(2) and the piston (6).

1
2. 2nd boom, boom swing and blade cylinders: 2 4

5 - Remove the screws (7) and remove the two half- 8

flanges (8).

4 6 7
RKPA7320

3. Boom, arm and bucket cylinders

1 - Heat the end nut (10) to a temperature of 140 ± 150 ëC. 10
9
2 - Only for the arm cylinder: loosen and remove the
safety screw (9).
3 - Loosen and remove the end nut (10). Use the key F7
and the dynamometric key B1.
H Before continuing with the dismantling opera-
tions, allow the piston rod to cool down.

RKPA7330

4. All cylinders
1 - Take the group to pieces.
For the arm cylinder, first take away the twelve
brake pin (12) retaining balls (11).
12
2 - Remove the seals from the piston rod.

11
RKPA7340

PW75R-2 30-151
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT CYLINDERS

ASSEMBLY OF WORK EQUIPMENT CYLINDERS

H Take care not to damage the seals or the sliding sur-

faces.
H Prepare each individual component before final as-
3
2
sembly.
1 2

1. Assembly of the head-retaining flange.

1
1 - Mount the scraper (1) in the external seating of the
flange (2), making sure that it is positioned correctly.
Drive home the scraper using the press.
2 - Mount the O-ring seal (3). RKP07300
RKPA7350

H Use grease to hold the washer in place.

Sealant: ASL800050

6 5
7 1
2. Head assembly
1 - Mount the internal central retaining ring, positioning 4 2
first the O-ring (1) and then the sealing ring (2).
H Make sure that the lowering of the retaining ring is
turned towards the inside of the cylinder.
3 4
2 - Use the tool F1, mount the lip seal (3).
H Check that the lips are facing towards the inside RKP09710

of the cylinder.
3 - Mount the guide rings (4).
6 5 1 6 5 6
4 - Mount the O-rings (5) and relative anti-extrusion rings 7
(6) on the outside of the head (7).
H Check the position of the anti-extrusion rings (6).

4
3 2 4 RKP09720

1 2 F1

7 2

RKPA7360 RKPA7370

30-152 PW75R-2
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT CYLINDERS

5 - Gauge the diameter of the internal seals, mounting

the group underneath the press and using the speci-
fic gauging knuckle pin F2 for the diameter of the pis-
ton rod.

F2

RKPA7380

3. Piston assembly
1 - Using the tool F3, mount the piston seal. Mount in the
correct sequence the rubber ring (1), the external seal
(2), and the rings wear (3).
2 - Mount the guide rings (4).
1 2 F3
3 - Only for boom, arm and bucket piston: Mount the
O-ring (5) and the rings wear (6) for the sealing be-
tween piston rod and piston.

RKPA7390

4 3 2 3 4

6 5 6
RKP09730

4 - Gauge the diameter of the seal (2) of the piston (7),

mounting the group under the press and using the
specific gauging ring F4 for the piston diameter.
7

F4

RKPA7400

PW75R-2 30-153
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT CYLINDERS

4. Piston rod group assembly

1 - Mount on the end of the piston rod (1) the bushing F5
of the correct diameter. 2
1 4
2 - Slide the head-retaining flange (2), the snap ring (3)
and the head (4) onto the piston rod.
H Check carefully the positioning of the head-retain-
ing flange.
3 - Remove the bushing F5 from the end of the piston.
F5 3
RKPA7410

4 - Mount the O-ring (5) and the rings wear (6) in the end-
seating, for the sealing between the piston ring and 5
piston.
H For boom, arm and bucket piston ring, the seal is
7 8
housed in the piston itself. 6
5 - Mount in the correct sequence the brake bushing (7)
(for the boom and arm cylinders only) and the piston
(8).

RKPA7420

6 - For the arm piston only: mount the brake pin (9) and
slide the twelve retaining balls (11) into the hole (10).
8 12
7 - Mount the half-flanges (12) that hold the piston (8) in 10
place, and secure them with the screws (1).
Flange retaining screws:
5w0.5 kgm (49w5 Nm)

13
11 9
Only for boom, arm and bucket piston: RKPA7430

1 - Mount the nut (14) that holds the piston (8) in

place, and tighten with the socket wrench F7
and the dynamometric tool with multiplier G1.
Piston retaining nut: Loctite 262
8
Piston retaining nut: 14
Boom: 530w53 kgm (520w52 daNm)
Arm: 300w20 kgm (294w19.5 daNm) 15
Bucket: 290w29 kgm (284w28.4 daNm)

Only for boom cylinder:

2 - Mount the safety screw (15).
Safety screws: Loctite 262
Safety screws: 9w0.9 kgm (88w8.8 Nm)
RKPA7331

30-154 PW75R-2
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT CYLINDERS

5. Cylinder assembly
1 - Place the cylinder (1) and the piston rod group (2) on 1 3
the equipment F8 and align their axes. 4
2
2 - Lubricate the external seals and insert the piston (3)
in the cylinder (1).
Piston sealants: Grease ASL800050
H Before inserting the piston, check that the seals
are not damaged and that they fit perfectly in their
seatings.
3 - Lubricate the external seals of the head (4) and insert 5
it completely into the cylinder (1). F8 RKPA7311

Head sealants: Grease ASL800050

H Before inserting the head, check that the seals
are not damaged and that they fit perfectly in their
seatings.
4 - Using the tool F6, position the snap ring (5) that holds
8
the head (4) in the cylinder seating. 6
H Check that the snap ring is completely inserted in
the seating.
5 - Position the flange (6) that holds the head in place,
and secure it with the screws (7). F6
H Before positioning the flange, check that the O-
ring flange seal (8) is in its seating.
Flange blocking screws: 5w0.5 kgm (49w5 Nm)
RKPA7460

7
RKPA7470

PW75R-2 30-155
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT (For 1-piece boom)

REMOVAL OF WORK EQUIPMENT (For 1-piece boom)

Extend the arm fully and open the bucket comple-
tely. Lower the work equipment until it is resting on 2
the ground
1 - Put a sling around the cylinder (1) of the boom. 7
2 - Switch off the engine, release pressure in the cylinder
by moving the PPC valve lever several times.
3 - Remove the screw (2) and draw out the pin (3). 3
6
4 - Start the engine to retract the piston (4). 4
H To hold the piston in its fully retracted position, tie 1
it with wire.
RKPA7161

5 - Lower the cylinder (1) until it comes to rest on blocks

(A).
6 - Switch off the engine and release any residual hy-
draulic pressures. (For details, see «20. TESTING
AND ADJUSTMENTS»).
7 - Remove the overload sensor (For details, see «RE-
MOVAL OF OVERLOAD SENSOR»). 1
8 - Disconnect the hoses (5) and plug them. Also plug
the rigid tubes.
9 - Put the equipment in a sling and apply slight tension
to the cables.
10 - Remove the screw (6) and the pin (7). Lift off the work
equipment (8). A

Work equipment: ........ kg RKPA7170

INSTALLATION OF WORK
EQUIPMENT (For 1-piece boom)
. To install, reverse the removal procedure.

H Insert the adjustments to a given clearance (dis-

tributed on both sides of the piston) until a clear-
ance of 1 ± 2 mm is obtained. 5 5

When aligning the positions between holes and

pin, let the engine run at minimum idling.
Do not insert fingers into the hole to check the RKPA7480
alignment.

Inside bushings: ASL800050.

H Insert the adjustments to a given clearance (dis-

tributed on both sides of the arm) until a clearance
of 0.5 ± 1 mm is obtained.
. Start the engine to circulate the oil, and bleed air from
the cylinder.
H After bleeding the air, switch off the engine and
check oil level in the tank.

8
RKPB0150

30-156 PW75R-2
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT (For 2-piece boom)

REMOVAL OF WORK EQUIPMENT (For 2-piece boom)

Fully extend the arm and the 2-piece boom and com-
pletely curl up the bucket. Position a stand (A)
(height 1.90 m.) between the boom and the 2-piece
boom, and rest the back of the bucket on the ground.
Stabilise the machine by resting the blade and/or the
stabilisers on the ground.
Completely eliminate residual pressures from all the A
circuits. (For details, see «20. TESTING AND AD-
JUSTMENTS»).

RKPA7500

1 - Disconnect the boom cylinder (1) from the 2-piece

boom and rest it on a stand (B).
H In order to disconnect the boom cylinder, it is ne-
cessary to remove the RH cylinder of the 2-piece
boom. (See «REMOVAL OF 2-PIECE BOOM CY- 2
LINDERS up to point 11).
A 1
After having disconnected the boom cylinder, re-
assemble the RH cylinder of the 2-piece boom
with the pin (2) and fasten it with its own screws.

B
RKPB0160

2 - Disconnect the eight hoses (3) that control the front

work equipment cylinders, and plug them. Also plug
the union fittings of the hoses (4).
3
3 - Remove the overload sensor (See «REMOVAL OF
OVERLOAD SENSOR»).

RKPA7520

4 - Put the boom (5) in a sling and apply slight tension to

the cables.
H Pass the cables through the rigid tubes to avoid
distortion.
2
5 - Remove the screws (6) and take out the pin (7).
A 1

6 - Raise the boom (5) until it is disengaged from the swi-

vel support (8) and take away the stand (A).

B
RKPA7530

PW75R-2 30-157
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT (For 2-piece boom)

7 - Swing the group to the side of the machine and rest

the boom on a stand (C).
5
Work equipment: ............ kg

RKP08030

INSTALLATION OF WORK EQUIPMENT

(For 2-piece boom)
. To install, reverse the removal procedure.

H Insert the shims (distributed on both sides of the

top of the cylinder) until a clearance of 1 ± 2 mm
is obtained.

When aligning the positions between holes and

pin, let the engine run at minimum idling.
Do not insert fingers into the hole to check the
alignment.

Inside bushings: ASL800050

H Insert the shims (distributed on both sides of the

top of the piston rod) until a clearance of 1 ± 2
mm is obtained.

. Start the engine to circulate the oil, and bleed air from
the cylinder. (For details, see «20. TESTING AND AD-
JUSTMENTS»).
H After bleeding the air, switch off engine and check
oil level in the tank.

30-158 PW75R-2
DISASSEMBLY AND ASSEMBLY BUCKET

REMOVAL OF BUCKET
Lower the bucket to the ground, resting with its back
on a flat surface. 7
4
1 - Take out the safety pin (1) and the connecting pin (2)
between bucket (3) and tie-rod (4).
6
2
5
2 - Take out the safety pin (5) and the pin (6) that con-
nects the bucket to the arm (7).
1 3

INSTALLATION OF BUCKET RKPA7540

. To install, reverse the removal procedure.

H Insert the adjustments to a given clearance be-

tween bucket (3) and tie-rod (4).

When lining up the hole and the pin, let the en-
gine turn at low idling speed.
Do not insert fingers into the holes to check
alignment.

Inside bushings: ASL800050

H Insert the adjustments to a given clearance (on

both sides) between the bucket (3) and the arm
(7), until a play of 0.5 ± 1 mm is obtained.

PW75R-2 30-159
DISASSEMBLY AND ASSEMBLY ARM

REMOVAL OF ARM

1 - Remove the bucket (For details, see «REMOVAL OF

BUCKET»).
2 - Remove the bucket cylinder. (For details, see «RE- 1
MOVAL OF BUCKET CYLINDER»).
3 - If the machine is designed for the application of op-
tional front equipment, disconnect the boom (or the 2-
piece boom), the tubes (1) and remove the supports (2).

2
RKPA7550

4 - Loosen the ring nut (3) and pin (4) and remove the
thrust lever (5).
3

4
RKPA7560

5 - Raise the boom and bring the arm (6) into a vertical
position and then lower it to the ground.
6

RKP09740

6 - Switch off the engine and release residual pressures.

10 7
7 - Put the arm cylinder (7) in a sling, remove the screw 9
(8) and take out the pin (9).
8 - Start the engine and fully retract the piston (10).

H To hold the piston rod in its fully retracted posi-

tion, tie it with wire.
8

RKPA7570

30-160 PW75R-2
DISASSEMBLY AND ASSEMBLY ARM

9 - Rest the cylinder (7) on a block (A).

10 - Switch off the engine. 7

A
RKPA7580

11 - Connect the arm (6) to the hoisting tackle and apply

slight tension to the cable.
12 - Remove the cotter-pin (11) and the nut (12).

12
11

RKPA7590

13 - Take out the screw (13) and pull out the pin (14).
14 - Lift off the arm (6). 6
Arm: 125 kg
Long arm: 167 kg

14

13
RKPA7600

15 - Start the engine and, for reasons of safety, lower the

boom or 2-piece boom until it rests on the ground.

RKPB0890

PW75R-2 30-161
DISASSEMBLY AND ASSEMBLY ARM

INSTALLATION OF ARM

. To install, reverse the removal procedure.

Inside bushings: ASL800050

H Insert shim

When aligning the positions between holes and

pin, do not insert fingers into the hole to check
the alignment.

H Insert the adjustments to a given clearance (dis-

tributed on both sides of the piston) until a clear-
ance of 1 ± 2 mm is obtained.
When aligning the positions between holes and
pin, let the engine run at minimum idling.
Do not insert fingers into the holes to check the
alignment.

Inside bushings: ASL800050

H Insert the adjustments to a given clearance (dis-
tributed on both sides) until a clearance of 0.5 ±
1 mm is obtained.
When aligning the positions between hole and
pin, do not insert fingers into the holes to check
the alignment.

30-162 PW75R-2
DISASSEMBLY AND ASSEMBLY 2nd BOOM

REMOVAL OF 2nd BOOM

1 - Remove the bucket, the bucket cylinder, the arm cy-

linder and the arm. For details see:
. REMOVAL OF BUCKET
1
. REMOVAL OF BUCKET CYLINDER
. REMOVAL OF ARM CYLINDER
. REMOVAL OF ARM
2 - Start the engine and bring the 2-piece boom (1) into a
vertical position. Lower it until it rests on the ground
and switch off the engine.
RKPB0891

3 - Put a sling round the RH cylinder (2) of the 2-piece

boom and remove the nut (3), the screw (4) and the 2 2
shim (5).
4 - Slide out the pin (6) that connects the RH cylinder (2)
to the 2-piece boom (1) until the piston rod is comple- 5
tely disconnected. 5
3

6 4
RKPA7211

5 - Start the engine and completely retract the piston rod

of the RH cylinder.
H To hold the piston rod in a fully retracted position,
tie it with wire and switch off the engine.
6 - Lower the cylinder until it is in a vertical position, leav-
ing the boom tied up.
7 - Repeat these operations from point 3 to point 6 in or-
der to disconnect the LH cylinder (7).

RKPA7221

8 - Hook the 2-piece boom to the hoisting tackle.

9 - Remove the screws and take out the pin (8).

10 - Take off the 2-piece boom. 8

2-piece boom: 162 kg

7
RKPA7610

PW75R-2 30-163
DISASSEMBLY AND ASSEMBLY 2nd BOOM

INSTALLATION OF 2nd BOOM

. To install, reverse the removal procedure.To install,

reverse the removal procedure.

Self-locking nut: 118 Nm.

Inside bushings: ASL800050.

When aligning the positions between holes and

pin, let the engine run at minimum idling.
Do not insert fingers into the hole to check the
alignment.

. Insert the shims (distributed on both sides of the

boom) until a clearance of 0.5 ± 1 mm is obtained.
. Start the engine to circulate the oil, and bleed air from
the cylinder. (For details, see «20. TESTING AND AD-
JUSTMENTS»).
H After bleeding the air, switch off the engine and
check the oil level in the tank.

30-164 PW75R-2
DISASSEMBLY AND ASSEMBLY BOOM

REMOVAL OF BOOM

1 - Remove the arm (For details, see «REMOVAL OF 2

ARM»).
2 - Remove the arm cylinder. (For details, see «RE-
MOVAL OF ARM CYLINDER»).
3 - Start the engine and lower the boom to the ground.
4 - Switch off the engine and move the PPC valve sev-
eral times to release pressures in the cylinder. 3
5 - Put the boom cylinder in a sling (1).
6 - Take out the screw (2) and pull out the pin (3). 4

1
7 - Start the engine and fully retract the piston (4). RKPA7162

H To hold the piston rod in its fully retracted posi-

tion, tie it with wire.
8 - Switch off the engine and release all pressures. (For 9
details, see «20. TESTING AND ADJUSTMENTS»).
9 - Lower the piston until it is resting on blocks (A).
10 - Remove the overload sensor. (For details, see «RE- 1
MOVAL OF OVERLOAD SENSOR»).
8
11 - Put the boom (5) in a sling, using the attachment hole
in the arm cylinder. Apply slight tension to the cable.
12 - Disconnect the front equipment hoses (6) and plug
them. Also plug the rigid tubes (7).
13 - Take out the screw (8) and pull out the pin (9). A
14 - Lift off the boom (5).
RKPA7171

Boom: 300 kg

INSTALLATION OF BOOM 5
. To install, reverse the removal procedure.

H Insert the adjustments to a given clearance (dis-

tributed on both sides of the piston rod) until a
clearance of 1 ± 2 mm is obtained.

When aligning the positions between holes and

pin, let the engine run at minimum idling.
Do not insert fingers into the hole to check the
alignment. RKPB1350

Inside bushings: ASL800050

7 7
H Insert the adjustments to a given clearance (dis-
tributed on both sides of the boom) until a clear-
ance of 0.5 ± 1 mm is obtained.
. Start the engine to circulate the oil and bleed air from
the cylinders.
6 6
H After bleeding the air, switch off the engine and
check the oil level in the tank.

RKPA7481

PW75R-2 30-165
DISASSEMBLY AND ASSEMBLY 1st BOOM

REMOVAL OF 1st BOOM

1 - Remove the bucket, the bucket cylinder, the arm cy-

linder, the arm, and the 2-piece boom. For details
see:
. REMOVAL OF BUCKET
. REMOVAL OF BUCKET CYLINDER
. REMOVAL OF ARM CYLINDER
. REMOVAL OF ARM
. REMOVAL OF 2-PIECE BOOM

2 - Replace the fulcrum pin (1) of the 2-piece boom and

secure it with the proper screws.
2 1
3 - Manoeuvre the boom (2) until the fulcrum pin is rest-
ing on a stand (A), 1.60 m high.
A
4 - Switch off the engine and release any residual pres-
sures in the boom cylinder.
5 - Remove the 2-piece boom cylinders (3) and let the
3
boom cylinder (4) rest on a stand. (For details, see
«REMOVAL OF 2-PIECE BOOM CYLINDER»).
4
RKPB0180

6 - Remove the overload sensor. (For details, see «RE-

MOVAL OF OVERLOAD SENSOR»).
7
7 - Disconnect the six connecting hoses of the front work 6
5
equipment cylinders (5) and the two tubes (6) of the
optional equipment.
H Plug the hoses and rigid tubes to prevent entry of im-
purities.

RKPA7521

8 - Take out the four screws (7) and lift away the com-
plete rack of tubes. 7

RKPA7440

30-166 PW75R-2
DISASSEMBLY AND ASSEMBLY 1st BOOM

9 - Screw four M10 UNI 2947 eyebolts (8) as far as they

will go into the holes of the rack of tubes.
8 10
10 - Attach the hoisting tackle to the eyebolts and apply
slight tension to the cables.
11 - Take out the screws (9) and remove the pin (10).
12 - Lift away the entire boom (2).
Boom: 245 kg.
2
9
RKPB0900

INSTALLATION OF 1ST BOOM

. To install, reverse the removal procedure.

Inside bushings: ASL800050

Do not insert fingers in the holes in order to

check the alignment.

H Insert shims on both sides of the boom, until a

clearance of 0.5 ± 1 mm is obtained.
. Start the engine to let the oil circulate and bleed air
from the cylinders.
H After bleeding the air, switch off the engine and
check the level in the oil tank.

PW75R-2 30-167
DISASSEMBLY AND ASSEMBLY SWING BRACKET

REMOVAL OF SWING BRACKET

Extend the work equipment fully and rest it on the
ground.
1 - Remove the front work equipment. (For details see
«REMOVAL OF WORK EQUIPMENT»). 1 H1
2 - Remove the boom cylinder (For details, see «RE-
MOVAL OF BOOM CYLINDER»).
3 - Remove the swing boom cylinder from the swing
bracket (1). For details, see «REMOVAL OF BOOM
SWING CYLINDER».
4 - Attach the swing bracket to the hoisting tackle (1) and
RKPA7450
apply slight tension to the cable.
5 - Place a jack (3) beneath the lower pin (2).
6 - Take out the retaining screws and pull out the pin (2).

7 - Take out the retaining screws and, with the help of a

lever, pull out the upper pin (4).
8 - Lift out the swing bracket (1).
Swing bracket: 170 kg 2

INSTALLATION OF SWING RKPA7650

BRACKET
. To install, reverse the removal procedure.

Lower pin: ASL800050

Upper pin: ASL800050 4

H Insert the adjustments to a given clearance be-

tween the chassis and the support.
Unit: mm

Pos. Code No. Thick- Quantity

RKPA7660

ness
1 21D-09-39170 5 2
2 21D-09-39160 0.5 2 1
2
H Insert the shims (spread over two sides of the pis-
ton) until a clearance of 1 ± 2 mm is obtained.

Supporting surfaces and adjustments to a 1

given clearance: ASL800050 2
When aligning hole and pin, engine should be idle.
Do not introduce fingers into the holes to check align-
ment.
RKP10020

30-168 PW75R-2
DISASSEMBLY AND ASSEMBLY BLADE AND OUTRIGGERS

REMOVAL OF BLADE AND OUTRIGGERS

1 - Raise the blade (1) or the outriggers (2) and place 1

blocks (A) under the arms (3); Lower the equipment
until the arms rest lightly on the blocks.

A
RKPB0210

2 - Attach the blade (1) or the outriggers (2) to the lifting

equipment and apply slight tension to the cables.
3
3 - Take out the screws and remove the pins (4).

4 - Remove the blade (1) or the outriggers (2).

4

Blade: 191 kg
Outrigger: 28 kg
A

2
RKPB0220

INSTALLATION OF BLADE
AND OUTRIGGERS
. To install, reverse the removal procedure.

Internal bushings: ASL800050

Do not insert fingers into the holes to check on

alignment.

H Insert the shims on both sides of the arm, in order

to obtain a clearance of 0.5 ± 1 mm.

PW75R-2 30-169
DISASSEMBLY AND ASSEMBLY BLADE AND OUTRIGGER ARMS

REMOVAL OF BLADE AND OUTRIGGER ARMS

1 - Remove the blade or the outriggers.

(For details, see «REMOVAL OF BLADE AND OUT-
RIGGERS»).
2 - Take out the screw (1) and remove the dowel (2).

3 - Start the engine and retract the piston (3). Stop the
engine. 2
3

1
RKPB0230

4 - Attach the arm (4) to the hoisting equipment and ap-

ply slight tension to the cables. 5
5 - Take out the screw (5) and remove the dowel (6).
6
6 - Remove the arm (4).

INSTALLATION OF BLADE
AND OUTRIGGERS ARMS RKPB0240

. To install, reverse the removal procedure.

Internal bushings: ASL800050

Do not insert fingers into the holes to check on

alignment.

H Insert the shims on both sides of the arm, in order

to obtain a clearance of 0.5 ± 1 mm.

30-170 PW75R-2
 MAINTENANCE STANDARD
PTO . . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 2
Front axle . . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 3
Transmission (2WS) . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 8
Rear axle (2WS). . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 10
Transmission (4WS) . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 14
Rear axle (4WS). . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 16
Swing circle. . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 22
Swing machinery . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 23
Hydraulic pump . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 24
Control valve . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 26
Swing motor . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 37
Swivel joint . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 38
PW75R-2
Travel motor . . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 39
ravel motor brake valves. . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 41
Servocontrol feed unit . . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 42
Travel ppc valve . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 43
Boom, arm, bucket, swing. .. . . . .. . . . . .. . . . . .. . . . .. . . . 44
PPC valve (blade, boom swing, 2-piece boom).. . . . 45
Blade safety valve. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 46
Boom swing 2-piece boom blade - outrigger . . .. . . . 47
Cylinders . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 47
Work equipment (1-piece boom) . . . . . .. . . . . .. . . . .. . . . 49
Work equipment (2-piece boom) . . . . . .. . . . . .. . . . .. . . . 51
40-1
PTO

44 Nm

50 Nm

50 Nm

RKP08291

40-2 PW75R-2
FRONT AXLE

Differential

67 ± 72 Nm 73 ± 76 Nm
with Loctite 270 with Loctite 270
10 Nm
with Loctite 222 Loctite 222

2 1

260 ± 300 Nm
with Loctite 270 RKP09050

Unit: mm

No . Check item Criteria Remedy

Standard clearance Clearance limit

1 Bearing axial clearance
0 ± 0.05 Ð
Adjust
Backlash of crow wheel
2 0.15 ± 0.18 Ð
and pinion

Tightening torque of slew

3 120 ± 170 Ncm
pinion (w/o seal)

PW75R-2 40-3
Brakes
1 ............Nm

69 ± 72 Nm
Loctite 270 3 with Loctite 242

.......... Nm 69 ± 72 Nm
with Loctite 242 RKP09060

Unit: mm

No . Check item Criteria Remedy

Standard size Repair limit

Free Installated Installated Free Installated

1 Returning spring
length length load length load

Ð Ð Ð Ð Ð

Standard thickness Min. thickness

2 Disk thickness Replace
Ð Ð

Standard clearance Max. clearance

3 Disk clearance Adjust
0.75 Ð

40-4 PW75R-2
Final drive

120 ± 123 Nm 86 ± 89 Nm
1

76 ± 81 Nm

2
RKP09070

Unit: mm

No . Check item Criteria Remedy

1 Articulation box torque 10 ± 12 Nm
Hub torque Adjust
2 7 ± 20 Nm
(with sealing ring)

PW75R-2 40-5
Steering cylinder

2
240 ± 270 Nm 240 ± 270 Nm
Nm
with 4 270 Nm
240Loctite 242 1 1 Nm
with 4 270 Nm
240Loctite 242
con Loctite 242 con Loctite 242

86 ASL800070
Nm 86±489
89 Nm
Nm ASL 800070 RKP09080

Unit: mm

No . Check item Criteria Remedy

Standard Tolerance Standard Clearance

Clearance between shaft size clearance limit
1 Shaft Hole Replace
and bushing
45 Ð Ð Ð Ð
Clearance between bushing
2 Ð Ð Ð Ð Ð
and pin

40-6 PW75R-2
Steering and convergency angle

A Fronte
Front ofmacchina
machine A

a a

A
A
Frontanteriore
Assale axle

105 ± 110 Nm

32

Detail A1
Particolare A1

136 ± ....... Nm

260 ± 290 Nm 45

Section A--AA
Sezione A Detail A2
Particolare A2

= =
......

......

......

......

RKP09090

PW75R-2 40-7
TRANSMISSION (2WS)

A 25 Nm

50w2.5 Nm

50w2.5 Nm

35 ± 50 Nm 50w2.5 Nm

A
35 ± 50 Nm 50w2.5 Nm

24 ± 25 Nm
25 Nm
Loctite 510

80 ± 100 Nm 30 Nm

Sezione B - B
RKP09100

40-8 PW75R-2
 25 Nm Loctite 510

260 ± 300 Nm
with Loctite 270

Loctite 510
Loctite 510 69 ± 71 Nm
with Loctite 270 RKP09110

Unit: mm

No . Check item Criteria Remedy

Standard clearance Clearance limit

1 Bearing axial clearance
0.25 ± 0.35 Ð Adjust

2 Bearing axial clearance 0.20 ± 0.30 Ð

PW75R-2 40-9
REAR AXLE (2WS)

Differential

69 ± 72 Nm 73 ± 76 Nm
with Loctite 270 with Loctite 270
10 Nm
with Loctite 222 Loctite 222

2 1
69 ± 71 Nm
with Loctite 270

3 600 ± 700 Nm
with Loctite 270 RKP09120

Unit: mm

No . Check item Criteria Remedy

Standard clearance Clearance limit

1 Bearing axial clearance
0 ± 0.05 Ð
Adjust
Backlash of crow wheel
2 Ð Ð
and pinion

Tightening torque of slew

3 170 ± 220 Ncm
pinion (w/o seal)

40-10 PW75R-2
Brakes
10 ± 11 Nm 25 ± 28 Nm

1 ..........11 Nm

2
Loctite 270 69 ± 72 Nm
with Loctite 242

30 ± 35 Nm 3
with Loctite 242

............. Nm
69 ± 72 Nm
with Loctite 242

RKP09130

Unit: mm

No . Check item Criteria Remedy

Standard size Repair limit

Free Installated Installated Free Installated

1 Returning spring
length length load length load

Ð Ð Ð Ð Ð

Standard thickness Min. thickness

2 Disk thickness Replace
Ð 4.5

Standard clearance Max. clearance

3 Disk clearance Adjust
0.75 Ð

PW75R-2 40-11
Parking brake and cylinder
............. Nm ............. Nm

10 kg

Loctite 270 1 49 ± 51 Nm

2
Detail A - AA
Particolare A 3

RKP09140

Unit: mm

No . Check item Criteria Remedy

Standard size Repair limit

Replace if
Free Installated Installated Free Installated
1 Brake locking spring damage or
length length load length load
deformed
Ð Ð Ð Ð Ð

2 Clearance with 10 kg force 0.2 Ð Set

3 Piston jut 5±6 Min. 3 Set

40-12 PW75R-2
Final drive

86 ± 89 Nm

76 ± 81 Nm

RKP09150

Unit: mm

No . Check item Criteria Remedy

1 Hub torque 7 ± 20 Nm Adjust
2 Axle shaft axial clearance 2 Replace spacer

PW75R-2 40-13
TRANSMISSION (4WS)

A 25 Nm

50w2.5 Nm

50w2.5 Nm

35 ± 50 Nm
50w2.5 Nm

A
35 ± 50 Nm 50w2.5 Nm

24 ± 26 Nm

25 Nm
Loctite 510

80 ± 100 Nm 30 Nm

Detail B - B
Sezione B - B
RKP09100

40-14 PW75R-2
 25 Nm Loctite 510

260 ± 300 Nm
with Loctite 270

2
69 ± 71 Nm
with Loctite 270

Loctite 510 Loctite 510

RKP09160

Unit: mm

No . Check item Criteria Remedy

Standard clearance Clearance limit

1 Inlet shaft axial clearance
0.25 ± 0.35 Ð Adjust

2 Outlet shaft axial clearance 0.2 ± 0.3 Ð

PW75R-2 40-15
REAR AXLE (4WS)

Differential

69 ± 72 Nm 73 ± 76 Nm
with Loctite 270 with Loctite 270
10 Nm
with Loctite 222 Loctite 222

2 1

RKP09170

Unit: mm

No . Check item Criteria Remedy

Standard clearance Clearance limit

1 Bearing axial clearance
0 ± 0.05 Ð
Adjust
Backlash of crow wheel
2 Ð Ð
and pinion

Tightening torque of slew

3 170 ± 220 Ncm
pinion (w/o seal)

40-16 PW75R-2
Brakes
10 ± 11 Nm 25 ± 28 Nm

1 ............. Nm

Loctite 270
2 69 ± 72 Nm
with Loctite 242

30 ± 35 Nm 3
with Loctite 242

............. Nm
69 ± 72
with Loctite 242

RKP09130
Unit: mm

No . Check item Criteria Remedy

Standard size Repair limit

Free Installated Installated Free Installated

1 Returning spring
length length load length load

Ð Ð Ð Ð Ð

Standard thickness Min. thickness

2 Disk thickness Replace
Ð 4.5

Standard clearance Max. clearance

3 Disk clearance Adjust
0.75 Ð

PW75R-2 40-17
Parking brake cylinder

............. Nm ............. Nm

10 kg

Loctite 270 1 49 ± 51 Nm

2
Detail A A 3
Particolare A

RKP09140

Unit: mm

No . Check item Criteria Remedy

Standard size Repair limit

Free Installated Installated Free Installated

1 Brake locking spring
length length load length load

Ð Ð Ð Ð Ð

2 Clearance with 10 kg force 0.2 Ð Set

3 Piston jut 5±6 Min. 3 Set

40-18 PW75R-2
Final drive

120 ± 123 Nm 1 86 ± 89 Nm

76 ± 81 Nm

2
RKP09070

Unit: mm

No . Check item Criteria Remedy

1 Articulation box torque 10 ± 12 Nm
Hub torque Adjust
2 7 ± 20 Nm
(with sealing ring)

PW75R-2 40-19
Steering cylinder

240 ± 270 Nm 240 ± 270 Nm

with Loctite 242 1 1 with Loctite 242

86 ± 89 Nm ASL800070 RKP09180

Unit: mm

No . Check item Criteria Remedy

Standard Tolerance Standard Clearance

Clearance between shaft size clearance limit
1 Shaft Hole Replace
and bushing
45 Ð Ð Ð Ð

40-20 PW75R-2
Steering and convergency angle

A Front ofmacchina
Fronte machine
A
27°

27°
A
A

136 ± ...... Nm

45
260 ± 290 Nm
Section A
Section
Sezione A
A -- AA Particolare A

= =
......

......

......

......

RKP09190

PW75R-2 40-21
SWING CIRCLE

314 Nm
with Loctite 262

1
Section A - A Section B - B
Sezione A - A Sezione B- B

C
D

C
D B
Section C --CC
Sezione C
A

314 Nm A

B
B

Section D - D B
Sezione D - D

C RKP09200

Unit: mm

No . Check item Criteria Remedy

Standard clearance Clearance limit

1 Axial bearing clearance Replace
0.04 ± 0.20 1.50

40-22 PW75R-2
SWING MACHINERY

1
58.8 ± 73.5 Nm
(6 ± 7.5 kgm)
2

ASL800070
4

6 3

7
5

RKP08780

Unit: mm

No . Check item Criteria Remedy

Backlash between No. 1 Standard clearance Clearance limit

1 sun gear and No. 1
planetary gear 0.11 ± 0.31 0.6

Wear of distance piece sealing

2 0.12 ± 0.40 0.6
surface

Backlash between No. 2 Replace

3 sun gear and No. 2 0.11 ± 0.31 0.6
planetary gear

Backlash between planetary

4 0.12 ± 0.40 0.6
gear and crown wheel

Backlash between swing

5 0.22 ± 0.85 2.0
pinion and swing circle gear

Standard Repair
Wear of swing pinion shaft Tolerance
side limit
6 surface contacting with oil
seal Repair hard
65 0.074 64.8 chrome
plating or
replace
Wear of swing pinion collar
± 0.043
7 surface contacting with 125 124.8
± 0.106
dust seal

PW75R-2 40-23
HYDRAULIC PUMP

Y
68.6w9.8 Nm 17.2w2.5 Nm
(7w1 kgm) (1.75w0.25 kgm) View Z
Vista Z

7.35w1.47 Nm 110.3w12.3 Nm
(0.75w0.15 kgm) (11.25w1.25 kgm)

View
Vista Y
Y

RKP08211
12.3w7.4 Nm
(1.25w0.75 kgm)

40-24 PW75R-2
PW75R-2 40-25
CONTROL VALVE

A
C B
D A

AA AA
O O
N N

M M
L L

K K
J J

H H

G G

F F
P
E E xx

BB BB

C D A
Pu
P B

9.8 ± 12.7 Nm 29.4 ± 39.2 Nm

(1 ± 1.3 kgm) (3 ± 4 kgm)

1 3

4 2

1st tightening: 19.6 ± 29.4 Nm View A

Vista A
(2 ± 3 kgm) Tightening
following
2nd tightening: 39.2 ± 49 Nm 1-2-3-4 order
(4 ± 5 kgm) in 3 times
3rd tightening: 58.8 ± 73.5 Nm
(6 ± 7.5 kgm)

View
Vista B
B RKP03280

40-26 PW75R-2
 39 ± 49 Nm 39 ± 49 Nm
(4 ± 5 kgm) (4 ± 5 kgm)

39 ± 49 Nm 39 ± 49 Nm
(4 ± 5 kgm) (4 ± 5 kgm)

39 ± 49 Nm 39 ± 49 Nm
(4 ± 5 kgm) (4 ± 5 kgm)

107.8 ± 147 Nm
(11 ± 15 kgm)
Section
Sezione A
A -- A
A RKP03290

Unit: mm

No . Check item Criteria Remedy

Standard size Repair limit

Free Installed Installed Installed

Cooler by-pass Free length
1 length length load load Replace
valve spring
231.4 N
Ð 33 Ð Ð
(23.6 kg)

PW75R-2 40-27
 1 1

1 1

1 1

1 1

1 1

1 2

1 3

1 1

1 1

3 3

Section
SezioneBB-- B
B RKP03370

Unit: mm

No . Check item Criteria Remedy

Standard size Repair limit

Spool return spring
(Work equipment, swing, Free Installed Installed Installed
Free length
1 boom, arm, bucket, length length load load
boom swing, blade,
travel, equipment) 34.7 N
Ð 40.5 Ð Ð
(3.5 kg) Replace

Spool return spring 54.6 N

2 Ð 40.5 Ð Ð
(Arm) (5.6 kg)

Spool return spring 4.9 N

3 Ð 40.5 Ð Ð
(Boom, swing) (5 kg)

40-28 PW75R-2
 118 ± 162 Nm
(12 ± 16.5 kgm) 1

1
4
2

Section C - C RKP03300
Sezione C - C
Unit: mm

No . Check item Criteria Remedy

Standard size Repair limit

Free
Installed Installed Installed
Pressure compensation length Free length
1 length load load
valve spring x O.D.

13.72 N
Ð 14.5 Ð Ð
(1.4 kg)
Replace
Pressure compensation 55.9w3 N
2 Ð 21.5 Ð Ð
valve spring (boom) (5.7w0.34 kg)

Spool (boom raise at joining 238.3 N

3 Ð 36 Ð Ð
pump discharge) (24.3 kg)

Flow compensation valve 27.6 N

4 Ð 20 Ð Ð
spring (boom) (2.82 kg)

PW75R-2 40-29
 1

Section
SezioneDD -- D
D RKP03310

Unit: mm

No . Check item Criteria Remedy

Standard size Repair limit

Free Installed Installed Installed

Free length
1 Check valve spring length length load load
Replace
3.92 N
Ð 22 Ð Ð
(0.4 kg)

Check valve spring 13.7 N

2 Ð 11.5 Ð Ð
(Swing) (1.4 kg)

40-30 PW75R-2
 107.8 ± 147 Nm
(11 ± 15 kgm)

49 ± 59 Nm 1
(5 ± 6 kgm)

Section BB - BB
Sezione BB - BB RKP02821

19.6 ± 27.4 Nm
(1.5 ± 2 kgm) 65.7 ± 85.3 Nm
with Loctite 638 (6.1 ± 8.4 kgm)
Section E-E
Sezione E - E RKP02811

Unit: mm

No . Check item Criteria Remedy

Free length Installed Installed Installed

Free length
x O.D. length load load
1 Lift check valve spring Replace
36.3 N
Ð 44.9 Ð Ð
(3.7 kg)

PW75R-2 40-31
 34 ± 44 Nm
(3.5 ± 4.5 kgm)
7.9 Nm
(9 ± 11 kgm)

34 ± 44 Nm
(3.5 ± 4.5 kgm)

19.6 ± 27.5 Nm
(2 ± 2.8 kgm)
34 ± 44 Nm
(3.5 ± 4.5 kgm)

Section
Sezione AA
AA -- AA
AA RKP02841

39 ± 49 Nm
(4 ± 5 kgm)

49 ± 59 Nm
(5 ± 6 kgm)
Section FF --FF
Sezione RKP02831

40-32 PW75R-2
 RKP02851

Section G - G
Sezione G - G

14.7 ± 19.6 Nm
(1.5 ± 2 kgm)
with Loctite 638 14.7 ± 19.6 Nm
(1.5 ± 2 kgm)
with Loctite 638

Section
Sezione H
H -- H
H RKP02861

PW75R-2 40-33
 14.7 ± 19.6 Nm 14.7 ± 19.6 Nm
(1.5 ± 2 kgm) (1.5 ± 2 kgm)
with Loctite 638 with Loctite 638

Section
Sezione J - JJ - J
RKP02871

14.7 ± 19.6 Nm
(1.5 ± 2 kgm)
with Loctite 638

SectionK K- K- K
Sezione RKP02881

40-34 PW75R-2
 14.7 ± 19.6 Nm
(1.5 ± 2 kgm)
with Loctite 638

Section
SezioneLL-L
-L RKP03320

14.7 ± 19.6 Nm
(1.5 ± 2 kgm)
with Loctite 638

Section
SezioneMM-M
-M RKP03330

PW75R-2 40-35
 14.7 ± 19.6 Nm
(1.5 ± 2 kgm)
with Loctite 638

Section N - N RKP03340
Sezione N-N

14.7 ± 19.6 Nm
(1.5 ± 2 kgm)
with Loctite 638

30 ± 25 Nm
(2 ± 45 kgm)
Section O - O
RKP03350
Sezione O-O

147 ± 186 Nm
(15 ± 19 kgm)

Section P - P RKP03360
Sezione P-P

40-36 PW75R-2
SWING MOTOR

250 ± 253 Nm
with ASL800 .........

RKP10390

Unit: mm

No . Check item Criteria Remedy

Installed Installed Installed

Free length Free length
length load load
1 Suction valve spring Replace
3.42 N
Ð 21.9 Ð Ð
(0.35 kg)

PW75R-2 40-37
SWIVEL JOINT

RKP03790

Unit: mm

No . Check item Criteria Remedy

Standard Tolerance Standard Clearance

Backlash between rotor size Shaft Hole clearance limit
1 Replace
and stator
± 0.02 +0.10 0.12±
Ð 0.25
± 0.05 +0.15 0.20

40-38 PW75R-2
TRAVEL MOTOR

.......... Nm

.......... Nm
2

.......... Nm
RKP04600

Në Check item Criteria Remedy

Standard size Repair limit

Free
Installed Installed Free Installed
1 Valve guide retain spring length
length load length load

Ð Ð Ð Ð Ð

2 Measure piston spring Ð Ð Ð Ð Ð

3 Centre spring of cylinder unit Ð Ð Ð Ð Ð

PW75R-2 40-39
 1

.......... Nm

.......... Nm

.......... Nm .......... Nm
Section A - A RKP04590
Sezione A - A

40-40 PW75R-2
TRAVEL MOTOR BRAKE VALVES

1 2 200 Nm
20 Nm 100 Nm

20 Nm

600 Nm

200 Nm
650 Nm

10 Nm 4

RKP04560

Unit: mm

No . Check item Criteria Remedy

Standard size Repair limit

Free Installed Installed Installed

1 Pilot valve spring Free length Replace
length length load load

Ð Ð Ð Ð Ð

2 Main valve spring Ð Ð Ð Ð Ð Replace

3 Piston return spring Ð Ð Ð Ð Ð Replace

4 Single-acting valve spring Ð Ð Ð Ð Ð Replace

5 Check valve spring Ð Ð Ð Ð Ð Replace

PW75R-2 40-41
SERVOCONTROL FEED UNIT

3 22.0 w4.9 Nm 29.4w4.9 Nm

9.8w2 Nm

1 2 9.8w2 Nm 4
66.2 w7.3 Nm

Section A
Sezione A--AA Section
SezioneBB- -BB
RKP04090

Unit: mm

No . Check item Criteria Remedy

Standard size Repair limit

Free Installed Installed Installed

Free length
1 Pilot valve spring length length load load

19.6 N 17.7 N
19.2x7.2 16.1 Ð
(2 kg) (1.8 kg)
Replace
Reduction box pilot 20.6 N 18.6 N
2 16.5x7.2 12.7 Ð
valve spring (2.1 kg) (1.9 kg)

199.8 N 186.2 N
3 Spring 71x18 59 Ð
(20.4 kg) (19 kg)

61.7 N 58.8 N
4 Relief valve spring 16.1x7.8 13.4 Ð
(6.3 kg) (6 kg)

40-42 PW75R-2
TRAVEL PPC VALVE

1.8 Nm

1 2

RKP03720

Unit: mm

No . Check item Criteria Remedy

Standard size Repair limit

Free Installed Installed Installed

1 Metering spring Free length Replace
length length load load

Ð Ð Ð Ð Ð

2 Centering spring Ð Ð Ð Ð Ð Replace

PW75R-2 40-43
PPC VALVE

BOOM, ARM, BUCKET, SWING

112.8w14.7 Nm
(11.5w1.6 kgm)
13.2w1.5 Nm
(1.35w0.15 kgm)

1
44.1 w4.9 Nm
(4.5w0.5 kgm)

Section
Sezione A
A -- AA Section B
Sezione B --BB

8.3w 2.5 Nm
(0.85w0.25 kgm)

2
Section
Sezione D
D -- DD

3 6.4w 2.5 Nm
(0.65w0.25 kgm)

Section C - C
Sezione C - C

Section EE- -EE

Sezione RKP01331

Unit: mm

No Check item Criteria Remedy

Standard size Repair limit

Free length Installed Installed Free length Installed

Metering spring
1 x O.D. length load x O.D. load
(For P3 and P4 port))
Replace if
9.8 N 7.8 N
38.7x15.5 34 Ð damaged
(1.0 kg) (0.8 kg)
or
deformed
Centering spring 17.6 N 13.7 N
2 42.5x15.5 34 Ð
(For P1 and P2 port) (1.8 kg) (1.4 kg)

15.2 N 11.8 N
3 Metering spring 26,1x8.2 24.7 Ð
(1.55 kg) (1.2 kg)

40-44 PW75R-2
PPC VALVE

(Blade, boom swing, 2-piece boom)

RKP04110

Unit: mm

No . Check item Criteria Remedy

Standard size Repair limit

Free length Installed Installed Installed

Free length
1 Centering spring x O.D. length load load
Replace
124.5 N 100.0 N
33.9x15.3 28.4 Ð
(12.7 kg) (10.2 kg)

16.7 N 13.7 N
2 Metering spring 22.7x8.1 22.0 Ð
(1.7 kg) (1.4 kg)

PW75R-2 40-45
BLADE SAFETY VALVE

83 Nm

33 Nm

RKP04580

Unit: mm

No . Check item Criteria Remedy

Standard size Repair limit

Free length Installed Installed Installed

1 Check valve spring Free length Replace
x O.D. length load load

16.5 11.12 2.464 kg 13.5 1.1 kg

40-46 PW75R-2
CYLINDERS

Boom: 5194w519 Nm (530w53 kgm)

BOOM BUCKET Bucket: 2842w284 Nm (290w29 kgm)
with Loctite 262
1

RKP08711
49 Nm (5 kgm)
with Loctite 262

ARM 88 Nm (9 kgm)
with Loctite 262
1

RKP08721

49 Nm (5 kgm) 2940w196 Nm (300w 20 kgm)

with Loctite 262

BOOM SWING 2-PIECE BOOM BLADE - OUTRIGGER

1

RKP08741

49 Nm (5 kgm) 49 Nm (5 kgm)

PW75R-2 40-47
 Unit: mm

No . Check item Criteria Remedy

Tolerance
Standard Standard Clearance
Cylinder
size clearance limit
Shaft Hole

±0.03 +0.2 0.23

Boom 70 0.46
±0.06 +0.3 0.36

2nd boom ±0.025 +0.2 0.225

50 0.45
(2-pieces) ±0.05 +0.3 0.35
Clearance
between
1 ±0.03 +0.2 0.23
piston rod Arm 60 0.46
and bushing ±0.06 +0.3 0.36

±0.03 +0.2 0.23

Bucket 55 0.46
±0.06 +0.3 0.36

±0.03 +0.2 0.23

Boom swing 60 0.46
±0.06 +0.3 0.36

±0.03 +0.2 0.23

Blade-outrigger 60 0.46
±0.06 +0.3 0.36

±0.06 +0.1 0.16

Boom 60 1
±0.106 +0.146 0.252

2nd boom ±0.05 +0.08 0.13

50 1
(2-pieces) ±0.089 +0.119 0.208

±0.05 +0.08 0.13

Clearance Arm 50 1
±0.089 +0.119 0.208
between cylinder
2
head bushing
and pin ±0.05 +0.08 0.13
Bucket 50 1
±0.089 +0.119 0.208

±0.05 +0.08 0.13

Boom swing 50 1
±0.089 +0.119 0.208

±0.05 +0.08 0.13

Blade-outrigger 50 1
±0.089 +0.119 0.208

±0.06 +0.1 0.16

Boom 60 1
±0.106 +0.146 0.252

2nd boom ±0.06 +0.1 0.16

60 1
(2-pieces) ±0.106 +0.146 0.252

±0.05 +0.08 0.13

Clearance Arm 50 1
±0.089 +0.119 0.208
between cylinder
3
bottom bushing
and pin ±0.05 +0.08 0.13
Bucket 50 1
±0.089 +0.119 0.208

±0.05 +0.08 0.13

Boom swing 50 1
±0.089 +0.119 0.208

±0.05 +0.08 0.13

Blade-outrigger 50 1
±0.089 +0.119 0.208

40-48 PW75R-2
WORK EQUIPMENT

(1-piece boom)

G
E
B
A

7 6 4 5 3

Section A - A Section B - B Section C - C

Sezione A - A Sezione B - B Sezione C - C

Section D - D Section E - E Section F - F

Sezione D - D Sezione E - E Sezione F - F

RKP09210

PW75R-2 40-49
 9

Section G - G
Sezione G - G
RKP09220

Unit: mm

No . Check item Criteria Remedy

Standard Tolerance Standard Clearance

Clearance between swing size clearance limit
Shaft Hole
1 bracket-to-revolving
frame mounting and pin bushing ±0.072 +0.145 0.116±
100 0.8
±0.0126 +0.044 0.271
Clearance between boom-to-swing ±0.060 +0.047 0.107±
2 60 0.8
bracket mounting pin and bushing ±0.106 +0.127 0.233
Clearance between boom-to-arm ±0.060 +0.047 0.107±
3 60 0.8
mounting pin and bushing ±0.106 +0.127 0.233
Clearance between bucket
±0.050 +0.095 0.066±
4 cylinder-to-link mounting pin 50 1
±0.089 +0.016 0.184
and link bushing Replace
Clearance between arm-to-link ±0.050 +0.095 0.066±
5 50 1
mounting pin and bushing ±0.089 +0.016 0.184
Clearance between bucket-to-arm ±0.050 +0.095 0.066±
6 50 1
mounting pin and bushing ±0.089 +0.016 0.184
Clearance between bucket-to-link ±0.050 +0.095 0.066±
7 50 1
mounting pin and bushing ±0.089 +0.016 0.184
Clearance between bushing and ±0.050 +0.095 0.066±
8 50 1
connecting pin of outrigger ±0.089 +0.016 0.184
Clearance between bushing and ±0.050 +0.095 0.066±
9 50 1
bracket pin ±0.089 +0.016 0.184

40-50 PW75R-2
WORK EQUIPMENT

(2-piece boom)
D

H
F
F

B
A

7 6 4 5 3

Section B - B Section
Section
SezioneA
A -- A
A Sezione B - B Sezione C
C -- C
C

8 2

Section D - D Section
Sezione D - D SezioneEE -- E
E SectionFF- F- F
Sezione

RKP09230

PW75R-2 40-51
 9 10

Section G - G
Sezione G - G Section H - HH - H
Sezione
RKP09240

Unit: mm

No . Check item Criteria Remedy

Standard Tolerance Standard Clearance

Clearance between swing size clearance limit
Shaft Hole
1 bracket-to-revolving
frame mounting and pin bushing ±0.072 +0.145 0.116±
100 0.8
±0.126 +0.044 0.271
Clearance between boom-to-swing ±0.060 +0.047 0.107±
2 60 0.8
bracket mounting pin and bushing ±0.106 +0.127 0.233
Clearance between boom-to-arm ±0.060 +0.047 0.107±
3 60 0.8
mounting pin and bushing ±0.106 +0.127 0.233
Clearance between bucket
±0.050 +0.095 0.066±
4 cylinder-to-link mounting pin 50 1
±0.089 +0.016 0.184
and link bushing
Clearance between arm-to-link ±0.050 +0.095 0.066± Replace
5 50 1
mounting pin and bushing ±0.089 +0.016 0.184
Clearance between bucket-to-arm ±0.050 +0.095 0.066±
6 50 1
mounting pin and bushing ±0.089 +0.016 0.184
Clearance between bucket-to-link ±0.050 +0.095 0.066±
7 50 1
mounting pin and bushing ±0.089 +0.016 0.184
Clearance between bushing and ±0.060 +0.047 0.107±
8 60 0.8
connecting pin of 2nd boom ±0.106 +0.127 0.233
Clearance between bushing and ±0.050 +0.095 0.066±
9 50 1
connecting pin of outrigger ±0.089 +0.016 0.184
Clearance between bushing and ±0.060 +0.047 0.066±
10 60 1
bracket pin ±0.106 +0.127 0.184

40-52 PW75R-2