Komatsu PW75R-2 Hydraulic Excavator Shop Manual WEBM001602 PDF
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Komatsu PW75R-2 Hydraulic Excavator Shop Manual WEBM001602 – PDF DOWNLOAD
- SERIAL NUMBER
PW75R-2 22E0210001 and up
Description
Komatsu PW75R-2 Hydraulic Excavator Shop Manual WEBM001602 – PDF DOWNLOAD
FILE DETAILS:
Komatsu PW75R-2 Hydraulic Excavator Shop Manual WEBM001602 – PDF DOWNLOAD
Language : English
Pages : 524
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Komatsu PW75R-2 Hydraulic Excavator Shop Manual WEBM001602 – PDF DOWNLOAD
- SERIAL NUMBER
PW75R-2 22E0210001 and up
COVER 1
CONTENTS 3
LIST OF REVISED PAGES 5
SAFETY 7
FOREWORD 9
HOW TO READ THE SHOP MANUAL 10
HOISTING INSTRUCTIONS 11
STANDARD TIGHTENING TORQUE 12
COATING MATERIALS 14
ELECTRIC WIRE CODE 15
WEIGHT TABLE 16
TABLE OF OIL AND COOLANT QUANTITIES 17
CONVERSION TABLE 19
10 STRUCTURE AND FUNCTION 27
P T O 28
POWER TRAIN 29
FRONT AXLE 30
TRANSMISSION 34
REAR AXLE 36
STEERING SYSTEM 41
STEERING UNIT 45
SWING CIRCLE 46
SPECIFICATIONS 47
HYDRAULIC DIAGRAM STANDARD 49
HYDRAULIC CIRCUIT (WORK EQUIPMENT) 51
HYDRAULIC PUMP 52
MAIN PUMP 53
PRIORITY VALVE 78
CONTROL VALVE 80
SWING VALVE 86
BLADE VALVE 87
TRAVEL VALVE – BOOM VALVE 88
ARM VALVE – BUCKET VALVE 89
OUTRIGGER VALVE – BOOM SWING VALVE 90
2-PIECE BOOM VALVE – ATTACHMENT VALVE 91
CONTROL VALVE 93
SWING MOTOR 108
SWIVEL JOINT 114
TRAVEL MOTOR 115
DISPLACEMENT AUTOMATIC CONTROL HIGH PRESSURE RELATED 116
TRAVEL MOTOR BRAKE VALVES 117
CYLINDERS 118
AXLE LOCKING CYLINDER 120
SERVOCONTROL FEED UNIT 122
ACCUMULATOR 127
SHUTTLE VALVE 128
PPC VALVES 129
TRAVEL PPC VALVE 138
BRAKE PUMP 139
BOOM AND ARM SAFETY VALVE 140
BLADE OR OUTRIGGERS SAFETY VALVE 141
2-PIECE BOOM SAFETY VALVE 142
OVERLOAD SENSOR SWITCH 143
SOLENOID VALVES 144
AIR-CONDITIONING UNIT 150
ELECTRICAL DIAGRAM (1/8) 153
ELECTRICAL DIAGRAM (2/8) 155
ELECTRICAL DIAGRAM (3/8) 157
ELECTRICAL DIAGRAM (4/8) 159
ELECTRICAL DIAGRAM (5/8) 161
ELECTRICAL DIAGRAM (6/8) 163
ELECTRICAL DIAGRAM (7/8) 165
ELECTRICAL DIAGRAM (8/8) 167
CONTROL UNIT FUSES – RELAIS (1/2) 169
CONTROL UNIT FUSES – RELAIS (2/2) 171
20 TESTING AND ADJUSTMENTS 173
NORMAL OR STANDARD TECHNICAL DATA 174
SPECIAL TOOLS 186
MEASURING THE ENGINE SPEED 187
ADJUSTING VALVE CLEARANCE 188
MEASURING COMPRESSION PRESSURE 189
TESTING AND ADJUSTING FUEL INJECTION TIMING 190
TESTING AND ADJUSTING FAN BELT TENSION 192
CHECKING AND TIGHTENING THE COMPRESSOR FAN-BELT 193
ADJUSTING THE STROKE OF THE ACCELERATOR LEVER 194
ADJUSTING PPC VALVES CLEARANCE 195
ADJUSTING THE SAFETY MICROSWITCH 196
MEASURING THE SWING CIRCLE AXIAL CLEARANCE 197
AIR BLEEDING FROM HYDRAULIC CIRCUITS 198
RELEASING RESIDUAL PRESSURE FROM THE CIRCUITS 201
CHECKING AND REGULATING PRESSURE IN THE HYDRAULIC CIRCUITS 202
TESTING AND SETTING OF MAIN VALVES 203
ADJUSTING PC VALVE 205
MEASURING LS DIFFERENTIAL PRESSURE AND ADJUSTING LS VALVE 206
CHECKING AND ADJUSTING PRESSURES IN THE SERVOCONTROL FEED UNIT 208
MEASURING PUMPS DELIVERY AND FLOW CONTROL STARTING POINT PUMP P1 209
CHECKING THAT THE PRIORITY VALVE IS FUNCTIONING CORRECTLY 210
CHECKING AND REGULATING THE PRESSURE OF THE STEERING SYSTEM 211
CHECKING LEAKAGES IN THE STEERING CYLINDERS 212
CHECKING THE BRAKING SYSTEM 213
CHECKING WEAR IN THE BRAKE DISKS 218
BLEEDING AIR FROM THE BRAKE LINES 219
ADJUSTING THE PARKING BRAKE 220
TRAVEL HYDRAULIC EQUIPMENT CHECKING PROCEDURE 221
CHECKING AND ADJUSTING THE AUTOMATIC DISPLACEMENT CONTROL SYSTEM OF THE TRAVEL MOTOR 222
CHECKING FOR LEAKAGES IN THE TRAVEL MOTOR 223
CHECKING AND ADJUSTING THE SPEED OF THE TRAVEL PROPELLER SHAFT 224
ADJUSTMENT OF THE SPEED SURVEYOR 225
ADJUSTING BOOM AND ARM SAFETY VALVES 226
ADJUSTING 2nd BOOM SAFETY VALVES 227
MEASURING AND SETTING OF PRESSURE SWITCH SIGNAL OVERLOAD OPERATION 228
MEASUREMENT OF INTERNAL OIL LEAKAGES IN THE SWING MOTOR 229
CHECKING FOR LEAKAGES INSIDE THE SWIVEL JOINT 230
ANALYSIS OF THE CAUSES OF HYDRAULIC DRIFTS 233
TESTING THE AIR-CONDITIONING UNIT 243
EMPTYING THE AIR-CONDITIONING UNIT 245
30 REMOVAL AND INSTALLATION 247
HOW TO READ THE MANUAL 249
PRECAUTIONS TO BE TAKEN WHEN WORKING 250
SPECIAL TOOLS 251
STARTER MOTOR 261
ALTERNATOR 262
AIR-CONDITIONING UNIT COMPRESSOR 263
INJECTION PUMP 265
NOZZLE HOLDER 269
CYLINDER HEAD 270
THERMOSTAT 273
MUFFLER 274
SEAT 275
CABIN 276
ENGINE HOOD 279
CONDENSER UNIT 280
FRONT HOOD 282
HEATING FAN UNIT 283
AIR CONIDTIONING FAN UNIT 285
RADIATOR 288
FUEL TANK 290
HYDRAULIC OIL TANK 292
ENGINE-PUMP GROUP 293
PUMP GROUP 297
ENGINE-PUMP COUPLING JOINT 299
MAIN PUMP INPUT SHAFT OIL SEAL 300
GEAR-PUMP 301
SWIVEL JOINT 302
SWING MOTOR 303
SWING MACHINERY 305
CONTROL VALVE 319
REVOLVING FRAME 320
COUNTERWEIGHT 322
SWING CIRCLE 323
TRANSMISSION – REVERSER, DIRECTION INDICATOR AND HEADLIGHT DIPPER BEAM CONTROL GROUP 324
R H PPC VALVE (BOOM-BUCKET) 325
L H PPC VALVE (ARM-SWING) 327
OUTRIGGER AND BLADE PPC VALVE 329
BOOM SWING PPC VALVE 330
TRAVEL AND 2nd BOOM PPC VALVE 331
BRAKE PUMP 332
STEERING UNIT 333
PRIORITY VALVE 350
TRAVEL MOTOR 352
TRANSMISSION 362
AXLE LOCKING CYLINDERS 377
FRONT AXLE 378
REAR AXLE 381
AXLES 384
BOOM CYLINDER (For 1-piece boom) 446
REMOVAL OF BOOM CYLINDER (For 2-piece boom) 447
2nd BOOM CYLINDERS 449
ARM CYLINDER 451
BUCKET CYLINDER 452
BOOM SWING CYLINDER 453
CYLINDERS FOR OUTRIGGERS OR BLADE 454
WORK EQUIPMENT CYLINDERS 455
WORK EQUIPMENT (For 1-piece boom) 460
WORK EQUIPMENT (For 2-piece boom) 461
BUCKET 463
ARM 464
2nd BOOM 467
BOOM (For 1-piece boom) 469
BOOM (For 2-piece boom) 470
SWING SUPPORT 472
BLADE AND OUTRIGGERS 473
BLADE AND OUTRIGGER ARMS 474
40 STANDARD MAINTENANCE 475
P T O 476
FRONT AXLE 477
TRANSMISSION 482
REAR AXLE 484
SWING CIRCLE 490
SWING MACHINERY 492
HYDRAULIC PUMP 494
CONTROL VALVE 496
SWING MOTOR 506
SWIVEL JOINT 507
TRAVEL MOTOR 508
TRAVEL MOTOR BRAKE VALVES 510
SERVOCONTROL FEED UNIT 511
TRAVEL PPC VALVE 512
PPC VALVES 513
BLADE SAFETY VALVE 515
CYLINDERS 516
WORK EQUIPMENT 518
DESCRIPTION:
Komatsu PW75R-2 Hydraulic Excavator Shop Manual WEBM001602 – PDF DOWNLOAD
- SERIAL NUMBER
PW75R-2 22E0210001 and up
Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully BEFORE operating the machine.
1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine.
2. When carrying out any operation, always wear safety 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 trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, glasses, cap and other clothes 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 correct way to use them.
PREPARATIONS FOR WORK:
7. Before adding oil or making any repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving.
8. Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them.
9. When disassembling or assembling, sup- port the machine with blocks, jacks or stands before starting 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.
11. When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out.
Before disconnecting or removing components of the oil, water or air circuits, first remove the pressure completely from the circuit.
12. The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned.
Wait for the oil and water to cool before carrying out any work on the oil or water circuits.
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 capacity.
Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly to prevent the component from hit- ting 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. Damaged 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.
G.B 18/12/24
