Shop manua máy đào KOMATSU PW75R-2

Nội dung PW75R-2 00-1 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

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

Pages having no marks are those previously revised

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LIST OF REVISED PAGES

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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 chine on hard, level ground, and block the wheels

ma-to prevent the machine from moving

8 Before starting work, lower outrigger, bucket orany other work equipment to the ground If this

is not possible, use blocks to prevent the workequipment from falling down In addition, be sure

to lock all the control levers and hang warningsign on them

9 When disassembling or assembling, support themachine with blocks, jacks or stands before star-ting work

10 Remove all mud and oil from the steps or otherplaces used to get on and off the machine Alwaysuse 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 orsteps, use a stand to provide safe footing

PRECAUTIONS DURING WORK

11 When removing the oil filler cap, drain plug or draulic pressure measuring plugs, loosen themslowly to prevent the oil from spurting out.Before disconnecting or removing components ofthe hydraulic circuit and engine cooling circuit,first remove the pressure completely from the cir-cuit

hy-12 The water and oil in the circuits are not hot whenthe engine in stopped, so be careful not to getburned

Wait for the oil water to cool before carrying outany work on the cooling water circuits

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 effectiveand safe methods of operation Some of these operations require the use of tools specially designed byFKI for the purpose

To prevent injury to workers, the symbols and are used to mark safety precautions in this 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

ma-SAFETY

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

19 Be sure to assemble all parts again in their nal places Replace any damage parts with newparts

origi- When installing hoses and wires, be sure thatthey will not be damaged by contact with otherparts when the machine is being operated

20 When installing high pressure hoses, make surethat they are not twisted Damaged tubes are dan-gerous, so be extremely careful when installingtubes for high pressure circuits Also, check thatconnecting parts are correctly tightened

21 When assembling or installing parts, always usespecified tightening torques

When installing the parts which vibrate violently orrotate at high speed, be particulary careful tocheck that they are correctly installed

22 When aligning two holes, never insert your fingers

or hand

23 When measuring hydraulic pressure, check thatthe measuring tool is correctly assembled beforetaking any measurement

24 Take sure when removing or installing tracks of inparticular rubber tracks When removing thetrack, the track separates suddenly, so never letanyone stand at either end of the wheel

This shop manual has been prepared as an aid to improve the quality of repairs by giving the operator an 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

ac-This shop manual mainly contains the necessary technical information for operations performed in a serviceworkshop

The manual is divided into chapters on each main group of components; these chapters are further divided intothe following sections

STRUCTURE AND FUNCTION

This section explains the structure and function of each component It serves not only to give an ding of the structure, but also serves as reference material for troubleshooting

understan-TESTING AND ADJUSTING

This sections explains checks to be made before and after performing repairs, as well as adjustments to bemade 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 assemblingeach component, as well as precautions to be taken for these operations

MAINTENANCE STANDARD

This section gives the judgement standards when inspecting disassembled parts

NOTEThe specifications contained in this shop manual are subject to change at any time and without anynotice

Contact your FKI distributor for the latest information

Shop manual are issued as a guide to carry out

re-pairs These various volumes are designed to avoid

duplicating the same information

DISTRIBUTION AND UPDATING

Any additions, amendments or other changes will

be sent to FKI distributors

Get the most up-to-date information before you start

any work

FILING METHOD

1 See the page number on the bottom of the page

File the pages in correct order

2 Following examples show you how to read the

pa-ge number

Example

3 Additional pages: additional pages are indicated

by a hyphen (-) and number after the page

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

SYMBOLS

In order to make the shop manual greatly chelpful,important points about safety and quality are markedwith the following symbols

Safety

Special safety precautions are cessary when performing the work.

ne-Extra special safety precautions are necessary when performing the work because it is under inter- nal pressure.

Caution

Special technical precautions or other precautions for preserving standards are necessary when performing the work.

Weight

Weight of parts or systems Caution necessary when selecting hoisting wire, or when working po- sture is important, etc.

Tightening torque

Parts that require special attention for the tightening torque during as- sembly.

Coat Parts to be coated with adhesivesand lubricants etc.Oil, water Places where oil, water or fuelmust be added, and their quantity.

Drain

Places where oil or water must be drained, and quantity to be drai- ned.

HOW TO READ THE SHOP MANUAL

HOW TO READ THE SHOP MANUAL

Numero dell'articolo (10 Struttura efunzionamento)

Numero di pagina progressivo perogni articolo

10 - 3

Heavy parts (25 kg or more) must be lifted

with a hoist etc In the Disassembly and

As-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:

WIRE ROPES(Standard «S» or «Z» twist ropes

without galvanizing)Rope diameter (mm) Allowable load (tons)

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-ing, and a serious accident can result

Hooks have maximum strength at the middleportion

3) Do not sling a heavy load with one rope alone,but sling with two or more ropes symmetricallywound on to the load

Slinging with one rope may cause turning ofthe load during hoisting, untwisting of the ro-

pe, or slipping of the rope from its originalwinding position on the load, which can cau-

The table below shows the variation of ble load (kg) when hoisting is made with two ro-pes, each of which is allowed to sling up to

allowa-1000 kg vertically, at various handing angles.When two ropes sling a load vertically, up to

2000 kg of total weight can be suspended.This weight becomes 1000 kg when two ropesmake a 120ë hanging angle

On the other hand, two ropes are subjected to

an excessive force as large as 4000 kg if theysling a 2000 kg load at a lifting angle of 150ë.HOISTING INSTRUCTIONS

HOISTING INSTRUCTIONS

STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE

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

«Di-1 STANDARD TIGHTENING TORQUE OF BOLTS AND NUT

Thread diameter

of bolts

(mm)

Pitch ofbolts(mm)

Width across flat(mm)

1013171922

5681012

0,96w0,12,3w0,24,6w0,57,8w0,812,5w1

9,5w123w245w4,977w8122w13

1,3w0,153,2w0,36,5w0,611w117,5w2

13,5w1,532,2w3,563w6,5108w11172w18

2427303236

1414171719

19,5w227w338w452w666w7

191w21262w28372w40511w57644w70

27w337w453w673w892w10

268w29366w36524w57719w80905w98

4146505560

19222427Ð

96w10131w14177w20230w25295w33

945w1001287w1401740w2002250w2502900w330

135w15184w20250w27320w35410w45

1329w1401810w1902455w2703150w3504050w450

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

STANDARD TIGHTENING TORQUE

Superficie di tenuta Sealing surface

2 TIGHTENING TORQUE FOR NUTS OF FLARED

Use these torques for nut part of flared

2.6w0.54w0.56.7w28w29.7w317w320w58w220w5

25.5w4.939.2w4.965.7w19.678.5w19.695.15w29.4166.7w29.4196.2w4978.5w19.6196.2w49

2.3 ± 2.53.4 ± 3.95.2 ± 5.88.2 ± 9.212.2 ± 13.315.3 ± 17.318.4 ± 20.420.4 ± 24.4

COATING MATERIALSThe recommended coating materials prescribed in FKI Shop Manuals are listed below:

Adhesives

ASL800010 Used to apply rubber pads, rubber gaskets and cork plugs.

ASL800020 Used to apply resin, rubber, metallic and non-metallic parts when a fast, strongseal is needed.Loctite 222 Used for low resistance locking of screws, check nuts and adjustment nuts.

Loctite 242 To prevent the loosening of bolts, nuts and plugs and the leakage of oil Used formedium 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.

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.

Loctite 573 Used for sealing rather exact plane surfaces when the option of possible futuredismantling is required.Loctite 601 Used for high resistant locking of mechanical components that can be removedonly after heatingLoctite 675 Used to lock cylindrical couplings and for the permanent locking of threaded parts,and also to lock shafts to bearings, gears, pulleys, pins, bushings, etc.

(Lithium grease) ASL800050 Applied to bearings, sliding parts and oil seals for lubrication, rust prevention andfacilitation of assembling work.

ELECTRIC WIRE CODE

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

Nominal

number

(mm) Current rating(A)

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

WEIGHT TABLEThis weight table is a guide for use when transporting or handling components.

TABLE OF OIL AND COOLANT QUANTITIESRESERVOIR KIND OFFLUID

AMBIENT TEMPERATURE CAPACITY (<)

Transmission API GL5OIL

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

FKI 907 10WFKI 907 20W-20

FKI 907 SAE 30FKI 907 SAE 40FKI 907 10W

(1) When fuel sulphur content is less than 0.5%,

change oil in the oil pan ebery periodic

maintenan-ce hours described in operation and maintenanmaintenan-ce

manual Change oil according to the following

ta-ble if fuel sulphur content is above 0.5%

(2) When starting the engine is weathers temperaturebelow 0ëC, be sure to use engine oil SAE 10W,SAE 20W-20, even if weather temperature goes

up to 10ëC day time

(3) Use classification CD as engine oil, if use cation CC, reduce the engine oil change interval tohalf

classifi-(4) Use original products, which have characteristicsspecifically formulated and approved for the engi-

ne, the hydraulic circuit of equipment and for ductions

re-P.T.O 2

Power train 3

Front axle 4

Transmission (2WS) 8

Hydraulic circuit (2WS) 10

Steering system (2WS) 14

Transmission (4WS) 16

Rear axle (4WS) 18

Steering system (4WS) 23

Steering unit 27

Swing circle 28

Swing machinery 29

Hydraulic circuit (2WS) 31

Hydraulic circuit (4WS) 33

Hydraulic circuit (lower equipment) 35

Hydraulic pump 36

Priority valve 62

Control valve 64

Swing motor 92

Swivel joint 96

Travel motor 97

Displacement automatic control high pressure 98

Related 98

Travel motor brake valves 99

Cylinders 100

Servocontrol feed unit 104

Accumulators 109

PPC valve 110

PPC valve (blade, boom swing, 2-piece boom) 114

Travel ppc valve 117

Brake pump 118

Boom and arm safety valve 119

2-piece boom safety valve 120

Blade or outrigger safety valve 121

Over load sensor switch 122

Solenoid valve group ST1 (Y5-Y6-Y7-Y11) 123

Solenoid valve group ST2 (Y4-Y10-Y12) 124

Solenoid valve group ST3 (Y1-Y2) 125

Solenoid valve group OP1 (Y21-Y22-Y23-Y24) 126

Solenoid valve group OP2 (Y26) 127

Solenoid valve group OP3 (Y8-Y9) 128

Electrical diagram (2WS) (1/5) 129

Electrical diagram (2WS) (2/5) 131

Electrical diagram (2WS) (3/5) 133

Electrical diagram (2WS) (4/5) 135

Electrical diagram (2WS) (5/5) 137

Electrical diagram (4WS) (1/5) 139

Electrical diagram (4WS) (2/5) 141

Electrical diagram (4WS) (3/5) 143

Electrical diagram (4WS) (4/5) 145

Electrical diagram (4WS) (5/5) 147 STRUCTURE AND FUNCTION

3 2

Z=51

Z=73

Z=39 Z=18

RKP08830 Front of machine

11 12 13

14 15 16

14

RKP08840

1 Brake bleeding screw

2 Disk release spring

4

17 18 19

20 21

22 23

RKP08860

a b Port - From swivel joint (2 Port)

b a Port - From swivel joint (1 Port)4WS version

a b Port - From swivel joint (2 Port)

b a Port - From OP1 solenoid valve group

4 3

6 5

a e Port - From swivel joint (3 Port)

b f Port - From swivel joint (4 Port)

1 Flange

2 Filler and level oil plug

3 Oil drain plug

4 Neutral manual control

5 Low speed selector piston

6 High speed selector piston

7 6

1

3 2

A A

Sezione B - B

RKP08880Section B - B

12 High speed drive gear (Z=47)

13 Oil drain plug

7

8

9

10 11

12 13

14 15 16 17

18 19

RKP08890

Reduction ratio: 8:2.9

REAR AXLE

Differential

7 8 9 10

11

12 13 14

12

RKP08900

12 13 14 15

RKP08910

a From swivel joint (8 Port)

1 Brake bleeding screw

10

7

RKP08920Section A - A

14 Cylinder fulcrum lever

15 Cylinder fulcrum pin

OPERATIONWhen 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 connectedwhen the machine is idle

When push-button is pushed Y11 is energized and lows oil to flow into chamber b of the cylinder (16);when the pressure exceeds the loading on the spring(18), it is compressed and the piston (19) moves, thuslengthening side B-C of the parallelogram A-B-C-Dformed by the swing centers of the levers (8) and(14), the cylinder fulcrum B (16) and the fulcrum C ofthe lever (8) connected to the piston (19)

al-The swing of levers (8) and (14), coupled directly to ver (10), cancels out the action on the push rods (4)joined to the push disks (9)

le-The limit of the swing and the distribution of the loadgenerated by the pressure in the cylinder (16) are gov-erned by adjustable screws (2) that act directly on le-vers (8) and (14)

When the engine stops, Y11 is de-energized, and leases pressure in the circuit As pressure drops thespring (18) commences the thrusting action that ro-tates the levers (8) and (14) The force of the spring

re-is transferred to the push rods of the push dre-isks (9)which act on the brake disks (7) on the rear axle

12 13

14

15

21 22

D A

7

Motore

8 Front axle steering cylinder

9 Front axle cylinder piston

DESCRIPTION The steering system is completely hydraulic Theoil required, supplied by the pump (2) driven bythe motor (1), is sent to the priority valve (4) whichfunctions by Load Sensing, and sends the neces-sary quantity of oil to the steering system (5), evenwhen other oleodynamic components supplied bythe same circuit are in operation The oil passesfrom this group (5) into the swivel joint (7) and fromthere into the steering cylinder (8)

The hydraulic power supplied by the pump (2) istransferred to cylinder (8) and transformed into me-chanical steering power

STEERING SYSTEM (2WS)

2

1 4

3

6 5

L R

P T

(P2)

1 2 2 1

RKP08950

a e Port - From swivel joint (14 Port)

b f Port - From swivel joint (5 Port)

1 Flange

2 Filler and level oil plug

3 Oil drain plug

4 Neutral manual control

5 Low speed selector piston

6 High speed selector piston

7 6

1

3 2

A A

Sezione B - B

RKP08880Detail B - B

12 High speed drive gear (Z=47)

13 Oil drain plug

7

8

9

10 11

12 13

14 15 16 17

18 19

RKP08970

12 13 14

12

RKP08980

17 18 19

20 21

22 23

RKP08860

a d Port - From OP1 solenoid valve group

3 5

4

1

RKP08960

a From swivel joint (8 Port)

1 Brake bleeding screw

10

7

RKP08920Section A - A

14 Cylinder fulcrum lever

15 Cylinder fulcrum pin

OPERATIONWhen 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 connectedwhen the machine is idle

When push-button is pushed Y11 is energized and lows oil to flow into chamber b of the cylinder (16);when the pressure exceeds the loading on the spring(18), it is compressed and the piston (19) moves, thuslengthening side B-C of the parallelogram A-B-C-Dformed by the swing centers of the levers (8) and(14), the cylinder fulcrum B (16) and the fulcrum C ofthe lever (8) connected to the piston (19)

al-The swing of levers (8) and (14), coupled directly to ver (10), cancels out the action on the push rods (4)joined to the push disks (9)

le-The limit of the swing and the distribution of the loadgenerated by the pressure in the cylinder (16) are gov-erned by adjustable screws (2) that act directly on le-vers (8) and (14)

When the engine stops, Y11 is de-energized, and leases pressure in the circuit As pressure drops thespring (18) commences the thrusting action that ro-tates the levers (8) and (14) The force of the spring

re-is transferred to the push rods of the push dre-isks (9)which act on the brake disks (7) on the rear axle

12 13

14

15

21 22

D A

7

Engine