WB97R-5 S
Uploaded by
Ahmad Bik ElhaysWB97R-5 S
Uploaded by
Ahmad Bik ElhaysWEBM006300
SHOP MANUAL
WB97R -5
WB97R-5 F50003 and up
CONTENTS
CONTENTS
Page
10. STRUCTURE AND FUNCTION............................................................................... 10-1
20. TESTING AND ADJUSTING ................................................................................... 20-1
30. DISASSEMBLY AND ASSEMBLY ......................................................................... 30-1
40. STANDARD MAINTENANCE ................................................................................. 40-1
90. OTHER..................................................................................................................... 90-1
WB97R-5 00-1
PAGE INTENTIONALLY
LEFT BLANK
REVISED PAGES
REVISED PAGES
The affected pages are indicated by the use of the fol-
lowing marks. It is requested that necessary actions be
taken to these pages according to table below. Mark Indication Action required
Q Page to be newly Add
q Page to be replaced Replace
( ) Page to be delete Discard
Pages having no marks are those previously revised or
made additions.
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 10-30 10-84 20-25 30-6
00-2 10-31 10-85 20-26 30-7
00-3 10-32 10-86 20-27 30-8
00-4 10-33 10-87 20-28 30-9
00-5 10-34 10-88 20-29 30-10
00-6 10-35 10-89 20-30 30-11
00-7 10-36 10-90 20-31 30-12
00-8 10-37 10-91 20-32 30-13
00-9 10-38 10-92 20-33 30-14
00-10 10-39 10-93 20-34 30-15
00-11 10-40 10-94 20-35 30-16
00-12 10-41 10-95 20-36 30-17
00-13 10-42 10-96 20-37 30-18
00-14 10-43 10-97 20-38 30-19
00-15 10-44 10-98 20-39 30-20
00-16 10-45 10-99 20-40 30-21
00-17 10-46 10-100 20-41 30-22
00-18 10-47 10-101 20-42 30-23
00-19 10-48 10-102 20-43 30-24
00-20 10-49 10-103 20-44 30-25
00-21 10-50 10-104 20-45 30-26
00-22 10-51 10-105 20-46 30-27
00-23 10-52 10-106 20-47 30-28
00-24 10-53 10-107 20-48 30-29
10-54 10-108 20-49 30-30
10-1 10-55 10-109 20-50 30-31
10-2 10-56 10-110 20-51 30-32
10-3 10-57 10-111 20-52 30-33
10-4 10-58 10-112 20-53 30-34
10-5 10-59 20-54 30-35
10-6 10-60 20-1 20-55 30-36
10-7 10-61 20-2 20-56 30-37
10-8 10-62 20-3 20-57 30-38
10-9 10-63 20-4 20-58 30-39
10-10 10-64 20-5 20-59 30-40
10-11 10-65 20-6 20-60 30-41
10-12 10-66 20-7 20-61 30-42
10-13 10-67 20-8 20-62 30-43
10-14 10-68 20-9 20-63 30-44
10-15 10-69 20-10 20-64 30-45
10-16 10-70 20-11 20-65 30-46
10-17 10-71 20-12 20-66 30-47
10-18 10-72 20-13 20-67 30-48
10-19 10-73 20-14 20-68 30-49
10-20 10-74 20-15 20-69 30-50
10-21 10-75 20-16 20-70 30-51
10-22 10-76 20-17 20-71 30-52
10-23 10-77 20-18 20-72 30-53
10-24 10-78 20-19 30-54
10-25 10-79 20-20 30-1 30-55
10-26 10-80 20-21 30-2 30-56
10-27 10-81 20-22 30-3 30-57
10-28 10-82 20-23 30-4 30-58
10-29 10-83 20-24 30-5 30-59
WB97R-5 00-3
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
30-60 30-138 30-216 30-294 40-41
30-61 30-139 30-217 30-295 40-42
30-62 30-140 30-218 30-296 40-43
30-63 30-141 30-219 30-297 40-44
30-64 30-142 30-220 30-298 40-45
30-65 30-143 30-221 30-299 40-46
30-66 30-144 30-222 30-300
30-67 30-145 30-223 30-301 90-1
30-68 30-146 30-224 30-302 90-2
30-69 30-147 30-225 30-303 90-3
30-70 30-148 30-226 30-304 90-4
30-71 30-149 30-227 30-305
30-72 30-150 30-228 30-306
30-73 30-151 30-229 30-307
30-74 30-152 30-230 30-308
30-75 30-153 30-231 30-309
30-76 30-154 30-232 30-310
30-77 30-155 30-233 30-311
30-78 30-156 30-234 30-312
30-79 30-157 30-235 30-313
30-80 30-158 30-236 30-314
30-81 30-159 30-237 30-315
30-82 30-160 30-238 30-316
30-83 30-161 30-239 30-317
30-84 30-162 30-240 30-318
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30-88 30-166 30-244 30-322
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30-90 30-168 30-246 30-324
30-91 30-169 30-247 30-325
30-92 30-170 30-248 30-326
30-93 30-171 30-249 30-327
30-94 30-172 30-250 30-328
30-95 30-173 30-251 30-329
30-96 30-174 30-252 30-330
30-97 30-175 30-253
30-98 30-176 30-254 40-1
30-99 30-177 30-255 40-2
30-100 30-178 30-256 40-3
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30-108 30-186 30-264 40-11
30-109 30-187 30-265 40-12
30-110 30-188 30-266 40-13
30-111 30-189 30-267 40-14
30-112 30-190 30-268 40-15
30-113 30-191 30-269 40-16
30-114 30-192 30-270 40-17
30-115 30-193 30-271 40-18
30-116 30-194 30-272 40-19
30-117 30-195 30-273 40-20
30-118 30-196 30-274 40-21
30-119 30-197 30-275 40-22
30-120 30-198 30-276 40-23
30-121 30-199 30-277 40-24
30-122 30-200 30-278 40-25
30-123 30-201 30-279 40-26
30-124 30-202 30-280 40-27
30-125 30-203 30-281 40-28
30-126 30-204 30-282 40-29
30-127 30-205 30-283 40-30
30-128 30-206 30-284 40-31
30-129 30-207 30-285 40-32
30-130 30-208 30-286 40-33
30-131 30-209 30-287 40-34
30-132 30-210 30-288 40-35
30-133 30-211 30-289 40-36
30-134 30-212 30-290 40-37
30-135 30-213 30-291 40-38
30-136 30-214 30-292 40-39
30-137 30-215 30-293 40-40
00-4 WB97R-5
k SAFETY
k IMPORTANT SAFETY NOTICE
Proper service and repair is extremely important for the safe operation of your machine.
The service and repair techniques recommended by Komatsu 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 Ko-
matsu for the purpose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The cautions
accompanying these symbols should always be carefully followed. If any danger arises or may possibly arise,
first consider safety, and take necessary steps to face.
k SAFETY
GENERAL PRECAUTIONS PREPARATIONS FOR WORK
Mistakes in operation extremely dangerous. 7. Before adding or making any repairs, park the ma-
Read all the Operation and Maintenance Manual carefully chine on hard, level ground, and block the wheels to
BEFORE operating the machine. prevent the machine from moving.
1. Before carrying out any greasing or repairs, read all 8. Before starting work, lower outrigger, bucket or any
the precautions written on the decals which are suck other work equipment to the ground. If this is not pos-
on the machine. sible, use blocks to prevent the work equipment from
2. When carrying out any operation, always wear safety falling down. In addition, be sure to lock all the control
shoes and helmet. Do not wear loose work clothes, or levers and hang warning sign on them.
clothes with buttons missing. 9. When disassembling or assembling, support the ma-
• Always wear safety glasses when hitting parts chine with blocks, jacks or stands before starting
with a hammer. work.
• Always wear safety glasses when grinding parts 10. Remove all mud and oil from the steps or other places
with a grinder, etc. used to get on and off the machine. Always use the
3. If welding repairs are needed, always have a trained, handrails, ladders or steps when getting on or off the
experienced welder carry out the work. When carrying machine.
out welding work, always wear welding gloves, apron, Never jump on or off the machine.
glasses, cap and other clothes suited for welding If it is impossible to use the handrails, ladders or steps,
work. use a stand to provide safe footing.
4. When carrying out any operation with two or more
PRECAUTIONS DURING WORK
workers, always agree on the operating procedure be-
fore starting. Always inform your fellow workers be- 11. When removing the oil filler cap, drain plug or hydrau-
fore starting any step of the operation. Before starting lic pressure measuring plugs, loosen them slowly to
work, hang UNDER REPAIR signs on the controls in prevent the oil from spurting out.
the operator’s compartment. Before disconnecting or removing components of the
hydraulic circuit and engine cooling circuit, first re-
5. Keep all tools in good condition and learn the correct
move the pressure completely from the circuit.
way to use them.
6. Decide a place in the repair workshop to keep tools 12. The water and oil in the circuits are not hot when the
and removed parts. Always keep the tools and parts in engine in stopped, so be careful not to get burned.
their correct places. Always keep the work area clean Wait for the oil water to cool before carrying out any
and make sure that there is no dirt or oil on the floor. work on the cooling water circuits.
Smoke only in the areas provided for smoking. Never
13. Before starting work, remove the leads from the bat-
smoke while working.
tery. Always remove the lead from the negative ( – )
terminal first.
WB97R-5 00-5
k SAFETY
14. When raising heavy components, use a hoist or 19. Be sure to assemble all parts again in their original
crane. Check that the wire rope, chains and hooks places. Replace any damage parts with new parts.
are free from damage. When installing hoses and wires, be sure that they
Always use lifting equipment which has ample ca- will not be damaged by contact with other parts
pacity. Install the lifting equipment at the correct when the machine is being operated.
places.
20. When installing high pressure hoses, make sure
Use a hoist or crane and operate slowly to prevent
that they are not twisted. Damaged tubes are dan-
the component from hitting any other part.
gerous, so be extremely careful when installing
Do not work with any part still raised by the hoist or
tubes for high pressure circuits. Also, check that
crane.
connecting parts are correctly tightened.
15. When removing covers which are under internal
21. When assembling or installing parts, always use
pressure or under pressure from a spring, always
specified tightening torques.
leave two bolts in position on opposite sides. Slowly
When installing the parts which vibrate violently or
release the pressure, then slowly loosen the bolts to
rotate at high speed, be particulary careful to check
remove.
that they are correctly installed.
16. When removing components, be careful not to
22. When aligning two holes, never insert your fingers or
break or damage the wiring.
hand.
Damage wiring may cause electrical fires.
23. When measuring hydraulic pressure, check that the
17. When removing piping, stop the fuel or oil from spill-
measuring tool is correctly assembled before taking
ing out. If any fuel or oil drips on to the floor, wipe it up
any measurement.
immediately.
Fuel or oil on the floor can cause you to slip, or can 24. Take sure when removing or installing wheels.
even start fires.
18. As a general rule, do not use gasoline to wash parts.
In particular, use only the minimum of gasoline when
washing electrical parts.
00-6 WB97R-5
FOREWORD
FOREWORD
This shop manual has been prepared as an aid to improve the quality of repairs by giving the operator an accurate
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 work-
shop.
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 understanding
of the structure, but also serves as reference material for troubleshooting.
TESTING AND ADJUSTMENTS
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.
REMOVAL AND INSTALLATION
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.
STANDARD MAINTENANCE
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 no-
tice.
Contact your Komatsu distributor for the latest information.
WB97R-5 00-7
HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL
VOLUMES SYMBOLS
Shop manual are issued as a guide to carry out repairs. In order to make the shop manual greatly chelpful, im-
These various volumes are designed to avoid duplicat- portant points about safety and quality are marked with
ing the same information. the following symbols.
DISTRIBUTION AND UPDATING Symbol Item Remarks
Any additions, amendments or other changes will be
sent to Komatsu distributors. Special safety precautions
Get the most up-to-date information before you start any are necessary when
k
work. performing the work.
Safety
FILING METHOD Extra special safety precautions
are necessary when performing
1. See the page number on the bottom of the page. the work because it is under in-
File the pages in correct order. ternal pressure.
2. Following examples show you how to read the page
Special technical precautions or
number.
other precautions for preserving
Example: a Caution
standards are necessary when
10 - 3 performing the work.
Weight of parts or systems.
4
Item number (10. Structure and Caution necessary when select-
Weight
Function) ing hoisting wire, or when work-
ing posture is important, etc.
Consecutive page number for each
3 Tightening
item Parts that require special atten-
3. Additional pages: additional pages are indicated by torque tion for the tightening torque dur-
ing assembly.
a hyphen (–) and number after the page number.
2
Fle as in the example. Parts to be coated with adhe-
Coat
Example: sives and lubricants etc.
5
10-4 Places where oil, water or fuel
Oil, water must be added, and their quan-
10-4-1 tity.
Added pages
6
10-4-2 Places where oil or water must
10-5 Drain be drained, and quantity to be
drained.
REVISED EDITION MARK
When a manual is revised, an edition mark is recorded
on the bottom outside corner of the pages.
REVISIONS
Revised pages are shown on the LIST OF REVISED
PAGES between the title page and SAFETY page.
00-8 WB97R-5
HOISTING INSTRUCTIONS
4
HOISTING INSTRUCTIONS
Hooks have maximum strength at the middle por-
k Heavy parts (25 kg or more) must be lifted with a
tion.
hoist etc. In the Disassembly and Assembly section,
every part weighing 25 kg or more is clearly indicated
with the symbol 4
1. If a part cannot be smoothly removed from the ma-
chine by hoisting, the following checks should be
made: 3) Do not sling a heavy load with one rope alone, but
sling with two or more ropes symmetrically wound
• Check for removal of all bolts fastening the part to
on to the load.
k Slinging with one rope may cause turning of the load
the relative parts.
• Check for any part causing interference with the
during hoisting, untwisting of the rope, or slipping of
part to be removed.
the rope from its original winding position on the
load, which can cause dangerous accidents.
2. Wire ropes
1) Use adequate ropes depending on the weight of 4) Do not sling a heavy load with ropes forming a wide
parts to be hoisted, referring to the table below: hanging angle from the hook.
When hoisting a load with two or more ropes, the
WIRE ROPES force subjected to each rope will increase with the
(Standard «S» or «Z» twist ropes hanging angles.
without galvanizing)
The table below shows the variation of allowable
Rope diameter (mm) Allowable load (tons) load (kg) when hoisting is made with two ropes,
each of which is allowed to sling up to 1000 kg ver-
10.0 1.0
tically, at various handing angles.
11.2 1.4 When two ropes sling a load vertically, up to 2000 kg
of total weight can be suspended.
12.5 1.6
This weight becomes 1000 kg when two ropes
14.0 2.2 make a 120° hanging angle.
On the other hand, two ropes are subjected to an ex-
16.0 2.8
cessive force as large as 4000 kg if they sling a 2000
18.0 3.6 kg load at a lifting angle of 150°.
20.0 4.4
22.4 5.6
30.0 10.0
40.0 18.0
50.0 28.0
60.0 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 hoisting, and a se-
rious accident can result.
WB97R-5 00-9
STANDARD TIGHTENING TORQUE
3
STANDARD TIGHTENING TORQUE
The following charts give the standard tightening torques of bolts and nuts.
Exceptions are given in section of «Disassembly and Assembly».
1. STANDARD TIGHTENING TORQUE OF BOLTS AND NUT
Width across flat
Thread Pitch of (mm)
diameter of bolts bolts
(mm) (mm) kgm Nm kgm Nm
6 1 10 8 0.96±0.1 9.5±1 1.3±0.15 13.5±1.5
8 1.25 13 6 2.3±0.2 23±2 3.2±0.3 32.2±3.5
10 1.5 17 8 4.6±0.5 45±4.9 6.5±0.6 63±6.5
12 1.75 19 10 7.8±0.8 77±8 11±1 108±11
14 2 22 12 12.5±1 122±13 17.5±2 172±18
16 2 24 14 19.5±2 191±21 27±3 268±29
18 2.5 27 14 27±3 262±28 37±4 366±36
20 2.5 30 17 38±4 372±40 53±6 524±57
22 2.5 32 17 52±6 511±57 73±8 719±80
24 3 36 19 66±7 644±70 92±10 905±98
27 3 41 19 96±10 945±100 135±15 1329±140
30 3.5 46 22 131±14 1287±140 184±20 1810±190
33 3.5 50 24 177±20 1740±200 250±27 2455±270
36 4 55 27 230±25 2250±250 320±35 3150±350
39 4 60 ---- 295±33 2900±330 410±45 4050±450
This torque table does not apply to bolts or nuts which have to fasten nylon or other parts non-ferrous metal washer.
a Nm (newton meter): 1 Nm = 0.102 kgm
00-10 WB97R-5
STANDARD TIGHTENING TORQUE
3
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 2.6±0.5 25.5±4.9
9/16” - 18 17 4±0.5 39.2±4.9
3/4” - 16 22 6.7±2 65.7±19.6
7/8” - 14 27 8±2 78.5±19.6
1.1/16 - 12 32 9.7±3 95.15±29.4
1.5/16 - 12 38 17±3 166.7±29.4
1.5/8 - 12 50 20±5 196.2±49
22 27 8±2 78.5±19.6
33 41 20±5 196.2±49
Sealing surface
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
WB97R-5 00-11
COATING MATERIALS
2
COATING MATERIALS
The recommended coating materials prescribed in Komatsu 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 Used for high resistant locking and for sealing threaded parts, bolts and stud
Loctite 270
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
Loctite 675
parts, 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
ASL800060
fittings 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
(Lubricant including ASL800040
sticking, burning or rusting.
Molybdenum disulfide)
Grease Applied to bearings, sliding parts and oil seals for lubrication, rust prevention
ASL800050
(Lithium grease) and facilitation of assembling work.
Vaseline ----- Used for protecting battery electrode terminals from corrosion
00-12 WB97R-5
ELECTRIC
ELECTRIC
ELECTRIC
In the wiring diagrams various colour 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 Ø of strands Cross section (mm) (A)
strands (mm) (mm)
0.5 16 0.20 0.35 1.55 3.5
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–B A/B A–G – A–N A/N A–R A/R A–V A/V
Colour Light Blue Light Blue – White Light Blue–Yellow Light Blue–Black Light Blue–Red Light Blue–Green
Code B B–G – B–N B/N B–R B/R – B/V – –
Colour White White–Yellow White–Black White–Red White–Green –
Code C C–B C/B C–L – C–N – – – – –
Colour Orange Orange–White Orange–Blue Orange–Black – –
Code G G–N G/N G–R – G–V – – – – –
Colour Yellow Yellow–Black Yellow–Red Yellow–Green – –
Code H H–L – H–N H/N – – – – – –
Colour Grey Grey–Blue Grey–Black – – –
Code L L–B L/B L–G – – L/N – – – –
Colour Blue Blue–White Blue–Yellow Blue–Black – –
Code M M–B – M–N M/N M–V – – – – –
Colour Brown Brown–White Brown–Black Brown–Green – –
Code N – – – – – – – – – –
Colour Black – – – – –
Code R R–G – R–N R/N R–V – – – – –
Colour Red Red–Yellow Red–Black Red–Green – –
Code S S–G – S–N – – – – – – –
Colour Pink Pink–Yellow Pink–Black – – –
Code V V–B – V–N V/N – – – – – –
Colour Green Green–White Green–Black – – –
Code Z Z–B Z/B Z–N 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 symbol listed.
Example: G–V = Yellow-Green with longitudinal colouring
G/V = Yellow-Green with transversal colouring
WB97R-5 00-13
WEIGHT TABLE
WEIGHT TABLE
k This weight table is a guide for use when transporting or handling components.
Unit: kg
Machine model WB97R-5
Engine assembly - Muffler - Exhaust pipe 394
Radiator - exchanger
Hydraulic oil tank (empty) 10
Fuel tank (empty) 68
Front counterweight 372
Engine hood 32
Cabin (without seat)
Seat
Engine-gear box-pump group
Piston pump 36.8
Transmission 254
Front axle 295
Rear axle 435
Front wheel
Rear wheel
Work equipment 1100
• Boom 313
• Shovel 436
• Fulcrum lever 13x4
• Tilt lever 32.5x2
• Raise cylinder 46x2
• Tilt cylinder 35x2
Work equipment
• with standard arm 850
• with long arm 885
• with jig arm 1030
Boom 248
Arm
Long arm
Boom swing bracket 162.5
Backframe 246
Control valve (8-spool)
Control valve (10-spool)
Jig arm 460
Outriggers 39x2
Boom cylinder 87.5
Arm cylinder 67
Bucket cylinder 52.5
Outriggers cylinder 27.5x2
Swing cylinder 34x2
Bucket 158
00-14 WB97R-5
TABLE OF OIL AND COOLANT QUANTITIES
TABLE OF OIL AND COOLANT QUANTITIES
AMBIENT TEMPERATURE CAPACITY (l)
TANK /
FLUID
RESERVOIR 1st filling Change
-30 -20 -10 0 10 20 30 40 50 °C
OIL
ACEA E5 - E4 SAE 5W-30
Engine oil pan 13 13
OIL
API CI-4 SAE 15W-40
ACEA E7
Hydraulic OIL API
SAE 10W-30 98 40
system CF - CF2 - CD
Hydraulic system
with 98 40
biodegradable oil
Front axle:
7 7
Differential
Final reduction
OIL 0.75 0.75
gear (ea)
UTTO FLUID
Rear axle:
Differential and fi- 15 15
nal reduction gears
Hydraulic OIL GM
20 20
transmission DEXRON® II D
®
(DEXRON is a reg-
Braking istered trademark of
General Motors Cor- 0.8 0.8
system poration)
Fuel a
DIESEL OIL 150 –
tank ASTM D975 N. 2
Engine PERMANENT
cooling COOLANT 15 –
system (aa)
a ASTM D975 N. 1
aa Special red permanent antifreeze suitable for aluminium radiators. If pure, dilute with water
(50%).
WB97R-5 00-15
TABLE OF OIL AND COOLANT QUANTITIES
ASTM: America Society of Testing and Materials
SAE: Society of Automotive Engineers
API: American Petroleum Institute
MIL: Military Specification
CCMC: Common Market Constructors Committe
First filling quantity:
total quantity of oil, including the oil for the components and pipes.
Oil change quantity:
quantity of oil necessary to fill the system or unit during the normal inspection and maintenance operations.
NOTE:
(1) When the diesel oil sulphur content is less then 0.5%, change the engine oil according to the periodic maintenance
intervals indicated in the operation and maintenance manual. In the diesel oil sulphur content exceeds 0.5% change
the engine oil according to the following table:
Sulphur content Engine oil change interval
from 0.5 to 1.0% 1/2 of regular interval
over 1.0% 1/4 of regular interval
(2) When starting the engine at temperatures below 0 °C, use engine oil SAE 10W, 20W-20, even if during the day the
temperature increases by 10 °C.
(3) Use engine oil with CD classification; if oil with CC classification is used, reduce the engine oil change interval by a
half.
(4) Use original products, which have characteristics specifically formulated and approved for the engine, the hydraulic
circuit of equipment and for reductions.
00-16 WB97R-5
CONVERSION TABLE
CONVERSION TABLE
METHOD OF USING THE CONVERSION TABLE
The conversion table in this section is provided to enable simple conversion of figures.
For details of the method of using the conversion table, see the example given below.
EXAMPLE
• Method of using the conversion table to convert from millimeters to inches.
1. Convert 55 mm into inches.
1 - Locate the number 50 in the vertical column at the left side, take this as A , then drow a horizontal line from
A.
2 - Locate the number 5 in the row across the top, take this as , then draw a perpendicular line down from B .
3 - Take the point where the two lines cross as C . This point C gives the value when converting from mil-
limeters to inches. Therefore, 55 mm =2.165 in.
2. Convert 550 mm into inches
1 - The number 550 does not appear in the table, so divide by 10 (move the decimal point one place to the left) to
convert it to 55 mm.
2 - Carry out the same procedure as above to convert 55 mm to 2.165 in.
3 - The original value (550 mm) was divided by 10, so multiply 2.165 in. by 10 (move the decimal point one place to
the right) to return to the original value. This gives 550 mm = 21.65 in.
From millimeters to inches B
1 mm = 0.03937 in.
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
C
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
A
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
WB97R-5 00-17
CONVERSION TABLE
From mm to in.
1 mm = 0.03937 in.
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
From kg to lb.
1 kg = 2.2046 lb.
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.24 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
00-18 WB97R-5
CONVERSION TABLE
From liter to U.S. Gall.
1 ᐉ = 0.2642 U.S. Gall.
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
From liter to U.K. Gall.
1 ᐉ = 0.21997 U.K. Gall.
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.969 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 12.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
WB97R-5 00-19
CONVERSION TABLE
From Nm to lb.ft.
1 Nm = 0.737 lb.ft.
0 1 2 3 4 5 6 7 8 9
0 0 0.737 1.474 2.211 2.948 3.685 4.422 5.159 5.896 6.633
10 7.370 8.107 8.844 9.581 10.318 11.055 11.792 12.529 13.266 14.003
20 14.740 15.477 16.214 16.951 17.688 18.425 19.162 19.899 20.636 21.373
30 22.110 22.847 23.584 24.321 25.058 25.795 26.532 27.269 28.006 28.743
40 29.480 30.217 30.954 31.691 32.428 33.165 33.902 34.639 35.376 36.113
50 36.850 37.587 38.324 39.061 39.798 40.535 41.272 42.009 42.746 43.483
60 44.220 44.957 45.694 46.431 47.168 47.905 48.642 49.379 50.116 50.853
70 51.590 52.327 53.064 53.801 54.538 55.275 56.012 56.749 57.486 58.223
80 58.960 59.697 60.434 61.171 61.908 82.645 63.382 64.119 64.856 65.593
90 66.330 67.067 67.804 68.541 69.278 70.015 70.752 71.489 72.226 72.963
100 73.700 74.437 75.174 75.911 76.648 77.385 78.122 78.859 79.596 80.333
110 81.070 81.807 82.544 83.281 84.018 84.755 85.492 86.229 86.966 87.703
120 88.440 89.177 89.914 90.651 91.388 92.125 92.862 93.599 94.336 95.073
130 95.810 96.547 97.284 98.021 98.758 99.495 100.232 100.969 101.706 102.443
140 103.180 103.917 104.654 105.391 106.128 106.865 107.602 108.339 109.076 109.813
150 110.550 111.287 112.024 112.761 113.498 114.235 114.972 115.709 116.446 117.183
160 117.920 118.657 119.394 120.131 120.868 121.605 122.342 123.079 123.816 124.553
170 125.290 126.027 126.764 127.501 128.238 128.975 129.712 130.449 131.186 131.923
180 132.660 133.397 134.134 134.871 135.608 136.345 137.082 137.819 138.556 139.293
190 140.030 140.767 141.504 142.241 142.978 143.715 144.452 145.189 145.926 146.663
00-20 WB97R-5
CONVERSION TABLE
From Nm to kgm
1 Nm = 0.102 kgm
0 1 2 3 4 5 6 7 8 9
0 0 0.102 0.204 0.306 0.408 0.510 0.612 0.714 0.816 0.918
10 1.020 1.222 1.224 1.326 1.428 1.530 1.632 1.734 1.836 1.938
20 2.040 2.142 2.244 2.346 2.448 2.550 2.652 2.754 2.856 2.958
30 3.060 3.162 3.264 3.366 3.468 3.570 3.672 3.774 3.876 3.978
40 4.080 4.182 4.284 4.386 4.488 4.590 4.692 4.794 4.896 4.998
50 5.100 5.202 5.304 5.406 5.508 5.610 5.712 5.814 5.916 6.018
60 6.120 6.222 6.324 6.426 6.528 6.630 6.732 6.834 6.936 7.038
70 7.140 7.242 7.344 7.446 7.548 7.650 7.752 7.854 7.956 8.058
80 8.160 8.262 8.364 8.466 8.568 8.670 8.772 8.874 8.976 9.078
90 9.180 9.282 9.384 9.486 9.588 9.690 9.792 9.894 9.996 10.098
100 10.200 10.302 10.404 10.506 10.608 10.710 10.812 10.914 11.016 11.118
110 11.220 11.322 11.424 11.526 11.628 11.730 11.832 11.934 12.036 12.138
120 12.240 12.342 12.444 12.546 12.648 12.750 12.852 12.954 13.056 13.158
130 13.260 13.362 13.464 13.566 13.668 13.770 13.872 13.974 14.076 14.178
140 14.280 14.382 14.484 14.586 14.688 14.790 14.892 14.994 15.096 15.198
150 15.300 15.402 15.504 15.606 15.708 15.810 15.912 16.014 16.116 16.218
160 16.320 16.422 16.524 16.626 16.728 16.830 16.932 17.034 17.136 17.238
170 17.340 17.442 17.544 17.646 17.748 17.850 17.952 18.054 18.156 18.258
180 18.360 18.462 18.564 18.666 18.768 18.870 18.972 19.074 19.176 19.278
190 19.380 19.482 19.584 19.686 19.788 19.890 19.992 20.094 20.196 20.298
WB97R-5 00-21
CONVERSION TABLE
From kgm to lb.ft.
1 kgm = 7.233 lb.ft.
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.2 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 876.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
00-22 WB97R-5
CONVERSION TABLE
From bar to psi (lb/in2)
1 bar = 14.503 psi
0 1 2 3 4 5 6 7 8 9
0 0 14.5 29.0 43.5 58.0 72.5 87.0 101.5 116.0 130.5
10 145.0 159.5 174.0 188.5 203.0 217.5 232.0 246.5 261.0 275.6
20 290.0 304.6 319.1 333.6 348.1 362.6 377.1 391.6 406.1 420.6
30 435.1 449.6 464.1 478.6 493.1 507.6 522.1 536.6 551.1 565.6
40 580.1 594.6 609.1 623.6 638.1 652.6 667.1 681.6 696.1 710.6
50 725.1 739.6 754.1 768.6 783.2 797.7 812.2 826.7 841.2 855.7
60 870.2 884.7 899.2 913.7 928.2 942.7 957.2 971.7 986.2 1000.7
70 1015.2 1029.7 1044.2 1058.7 1073.2 1087.7 1102.2 1116.7 1131.2 1145.7
80 1160.2 1174.7 1189.2 1203.7 1218.2 1232.7 1247.2 1261.8 1276.3 1290.8
90 1305.3 1319.8 1334.3 1348.8 1363.3 1377.8 1392.3 1406.8 1421.3 1435.8
100 1450.3 1464.8 1479.3 1493.8 1508.3 1522.8 1537.3 1551.8 1566.3 1580.8
110 1595.3 1609.8 1624.3 1638.8 1653.3 1667.8 1682.3 1696.8 1711.3 1725.8
120 1740.4 1754.9 1769.4 1783.9 1798.4 1812.9 1827.4 1841.9 1856.4 1870.8
130 1885.4 1899.9 1914.4 1928.9 1943.4 1957.9 1972.4 1986.9 2001.4 2015.9
140 2030.4 2044.9 2059.4 2073.9 2088.4 2102.9 1217.4 2131.9 2146.4 2160.9
150 2175.4 2189.9 2204.4 2218.9 2233.5 2248.0 2262.5 2277.0 2291.5 2306.0
160 2320.5 2335.0 2349.5 2364.0 2378.5 2393.0 2407.5 2422.0 2436.5 2451.0
170 2465.5 2480.0 2494.5 2509.0 2523.5 2538.0 2552.5 2567.0 2581.5 2596.0
180 2610.5 2625.0 2639.5 2654.0 2668.5 2683.0 2697.7 2712.1 2726.6 2641.1
190 2755.6 2770.0 2784.6 2799.1 2813.6 2828.1 2842.6 2857.1 2871.6 2886.1
200 2900.6 2915.1 2929.6 2944.1 2958.6 2973.1 2987.6 3002.1 3016.6 3031.1
210 3045.6 3060.1 3074.6 3089.1 3103.6 3118.1 3132.6 3147.1 3161.6 3176.1
220 3190.7 3205.2 3219.7 3234.2 3248.7 3263.2 3277.7 3192.2 3306.7 3321.2
230 3335.7 3350.2 3364.7 3379.2 3393.7 3408.2 3422.7 3437.2 3451.7 3466.2
240 3480.7 3495.2 3509.7 3524.2 3538.7 3553.2 3567.7 3582.2 3596.7 3611.2
WB97R-5 00-23
CONVERSION TABLE
TEMPERATURE
Fahrenheit-Centigrade conversion; a simple way to convert a Fahrenheit temperature reading into a Centigrade tem-
perature reading or vice versa is to enter the accompanying table in the center or boldface column of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit tem-
peratures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of Centigrade val-
ues and read the corresponding Fahrenheit temperature on the right.
1 °C = 33.8°F
°C °F °C °F °C °F °C °F
–40.4 –40 –40.0 –11.7 11 51.8 7.8 46 144.8 27.2 81 117.8
–37.2 –35 –31.0 –11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
–34.4 –30 –22.0 –10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
–31.7 –25 –13.0 –10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
–28.9 –20 –4.0 –9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
–28.3 –19 –2.2 –8.9 16 60.8 10.6 51 123.8 30.0 86 186.8
–27.8 –18 –0.4 –8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
–27.2 –17 1.4 –7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
–26.7 –16 3.2 –7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
–26.1 –15 5.0 –6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
–25.6 –14 6.8 –6.1 21 69.8 13.3 56 132.8 32.8 91 195.8
–25.0 –13 8.6 –5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
–24.4 –12 10.4 –5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
–23.9 –11 12.2 –4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
–23.3 –10 14.0 –3.9 25 77.0 15.6 60 140.0 35.0 95 203.0
–22.8 –9 15.8 –3.3 26 78.8 16.1 61 141.8 35.6 96 204.8
–22.2 –8 17.6 –2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
–21.7 –7 19.4 –2.2 28 72.4 17.2 63 145.4 36.7 98 208.4
–21.1 –6 21.2 –1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
–20.6 –5 23.0 –1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
–20.0 –4 24.8 –0.6 31 87.8 18.9 66 150.8 40.6 105 221.0
–19.4 –3 26.6 0.0 32 89.6 19.4 67 152.6 43.3 110 230.0
–18.9 –2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
–18.3 –1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
–17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
–17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0
–16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
–16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
–15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 2930
–15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
–14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0
–13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
–13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
–12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
–12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
00-24 WB97R-5
10 STRUCTURE AND FUNCTION
POWER TRAIN...............................................................2 AIR-CONDITIONING UNIT .......................................... 98
TRANSMISSION (4WD) .................................................4 OPERATION OF THE AIR CONDITIONING UNIT ...... 99
TRANSMISSION.............................................................6 FUSE AND RELAY CENTRE..................................... 101
CONTROL VALVE BLOCK.............................................8 DRIVER SEAT WIRING ............................................. 102
DRIVE SHAFTS ..............................................................9 SWITCH PANEL WIRING .......................................... 103
FRONT AXLE................................................................11 FRONT DASH WIRING.............................................. 104
REAR AXLE ..................................................................14 LATERAL DASH WIRING .......................................... 105
HYDRAULIC CIRCUIT..................................................19 ROOF WIRING........................................................... 106
HYDRAULIC PUMP ......................................................21 ENGINE WIRING ....................................................... 107
8-SPOOL CONTROL VALVE .......................................36 SPEED SELECTOR WIRING .................................... 108
10-SPOOL CONTROL VALVE .....................................42 BACKHOE WIRING ................................................... 109
CLSS.............................................................................49 JIG ARM WIRING ...................................................... 110
STEERING UNIT ..........................................................68 WIRING DIAGRAM (STANDARD VERSION)
PPC VALVES................................................................69 (see also Group 90).................................................... 111
SOLENOID VALVE GROUP (EV1)...............................86
SAFETY VALVES .........................................................88
SHOVEL CYLINDERS ..................................................92
BACKHOE CYLINDERS ...............................................94
WB97R-5 10-1
STRUCTURE AND FUNCTION POWER TRAIN
POWER TRAIN
1 2
3 4
5 7 8
6
RKZ09600
DESCRIPTION
• The driving power for the engine (1) is transmitted • The driving power is transmitted from the
through the flywheel to the converter (2). transmission (3) to the front (5) and rear (6) axles
The converter (2) uses hydraulic oil to convert the through the cardan drive shafts (7 and 8).
torque transmitted by the engine (1) into driving • The driving power transmitted to the front (5) and rear
power. The converter (2) transmits motion to the drive (6) axles is reduced by the differentials and then
shaft of the transmission (3) and to the drive shaft of transmitted to the planetary gear through the
the hydraulic pump (4). differential shafts.
• The transmission (3) is electro-hydraulic in all its
functions (power shuttle); direction and speed can be
selected manually from a dedicated control unit and is
managed by solenoid valves.
10-2 WB97R-5
STRUCTURE AND FUNCTION POWER TRAIN
Front axle Rear axle
Gears
Transmission Differential Planetary Total Transmission Differential Planetary Total
1st gear 5.533 81.722 5.533 97.338
2nd gear 3.360 49,627 3.360 59.136
2.462 6.000 2.750 6.400
3rd gear 1.532 22.627 1.532 26.963
4th gear 0.810 11.963 0.810 14.256
8
4
2 7 10
RKZ09610
1. Diesel engine 5. Front axle 9. Rear wheels
2. Convertor 6. Rear axle 10. Front wheels
3. Transmission 7. Front cardan drive shaft
4. Hydraulic pump 8. Rear cardan drive shaft
WB97R-5 10-3
STRUCTURE AND FUNCTION TRANSMISSION (4WD)
TRANSMISSION (4WD)
Hydraulic convertor-transmission circuit diagram
12 13 14
FWD REV 4WD
rpm 900 13.5-16 bar rpm 900 13.5-16 bar
rpm 2200 14.5-17.5 bar rpm 2200 14.5-17.5 bar
17 TUBE
10 11
15
18
TRANSMISSION CONTROL TUBE TUBE TUBE TUBE
VALVE UNIT
19 20 21 22
8
1st 2nd 3rd 4th
rpm 900 14-16.5 bar
rpm 2200 15.5-18 bar rpm 900 11.5-14.5 bar rpm 900 14-16.5 bar rpm 900 14-16.5 bar rpm 900 14-16.5 bar
rpm 2200 13-15.5 bar rpm 2200 15.5-18 bar rpm 2200 15.5-18 bar rpm 2200 15.5-18 bar
4
2 NOT SUPPLIED 25
BY-PASS
6
OPENS AT
3.45 BAR
5
Ø3.5 mm
LOCATED IN
OIL PUMP
LOCATED IN
OIL PUMP
HOSE HOSE
OPENS AT FLOW TO COOLER
1
23.0 BAR RPM 900 13-25 L/1°
26.0 RPM 2200 20-35 L/1°
PRIMARY SHAFT
OUTPUT SHAFT
7
INPUT SHAFT
3 9
LOCATED IN OIL PUMP
OPENS AT 5.5 BAR
AIR
BREATHER
TRASMISSION SUMP 24 23 16
RKZ11120
10-4 WB97R-5
STRUCTURE AND FUNCTION TRANSMISSION (4WD)
1. Suction filter (250 µm)
2. Pump
3. Oil screen drain valve
4. Spin-on filter (10 µm)
5. Convertor
6. Radiator
7. Torque converter pressure relief valve
8. Pressure control/flow divider valve
9. Vent
10. FORWARD engagement pressure check
11. REVERSE engagement pressure check
12. FORWARD engagement
13. REVERSE engagement
14. 4WD engagement/disengagement
15. Modulating valve
16. Input shaft lubrication (A pivot)
17. Backhoe oil feed port
18. Drive engagement pressure check
19. 1st gear engagement
20. 2nd gear engagement
21. 3rd gear engagement
22. 4th gear engagement
23. Main shaft lubrication (B shaft)
24. Output shaft lubrication (C/E shafts)
25. Oil temperature thermostat port from oil cooler
WB97R-5 10-5
STRUCTURE AND FUNCTION TRANSMISSION
TRANSMISSION
1
2
a b
5 8
10
11
7 12 RKZ11130
a. To the oil cooler
b. From the oil cooler
1. Control valve group 7. Vent plug
2. Convertor 8. Revolution sensor
3. Oil filter 9. Converter input pressure check port
4. Oil refilling port 10. Reverse engagement pressure check port
5. Oil drain plug 11. Forward engagement pressure check port
6. Oil temperature sensor 12. PPC valve feed pressure check port
10-6 WB97R-5
STRUCTURE AND FUNCTION TRANSMISSION
Kinematics diagram
Axis D
L
L
Axis A
Axis B
Axis C
Axis E
D
Input shaft A
Output shaft C
Output shaft E
RKZ11140
WB97R-5 10-7
STRUCTURE AND FUNCTION CONTROL VALVE BLOCK
CONTROL VALVE BLOCK
1 3 7 6
2 4 5
RKZ11150
ELECTRICAL COMPONENTS
1. C24 – 2nd gear solenoid valve (ED6)
2. C27 - 4WD solenoid valve(ED5)
3. C26 – 4th gear solenoid valve (ED2)
4. C21 - Reverse gears command solenoid valve (ED4)
5. C22 – Forward gear solenoid valve (ED3)
6 - C25 – 3rd gear solenoid valve (ED7)
7. C23 – 1st gear solenoid valve (ED1)
10-8 WB97R-5
STRUCTURE AND FUNCTION DRIVE SHAFTS
DRIVE SHAFTS
Drive shaft for forward and reverse movement
1 2
a b c
6
5
RKZ11160
4 3
a. Port commanding reverse clutch 1. Reverse gear clutch (Z=37)
b. Port commanding forward clutch 2. Forward gear (Z=37)
c. Lubrication port 3. Reverse clutch piston
4. Forward clutch piston
5. Shoulder ring
6. Driven shaft
Drive shaft
3
1
2
4
a
5 RKZ11170
a. 2nd gear port 1. 3rd drive gear (Z=45)
2. 2nd drive gear (Z=28)
3. 4th drive gear (Z=58)
4. 1st drive gear (Z=17)
5. 2nd gear piston
WB97R-5 10-9
STRUCTURE AND FUNCTION DRIVE SHAFTS
Driven gear shaft
5
2
4
1
3
c a b 6
7
9 8 RKZ11180
a. 4th gear port 4. 4WD drive gear (Z=51)
a. 3rd gear port 5. 1st gear driven gear (Z=60)
a. 1st gear port 6. Rear output shaft
1. 3rd gear driven gear (Z=44) 7. 1st gear piston
2. 2nd gear driven gear (Z=60) 8. 4th gear piston
3. 4th gear driven gear (Z=30) 9. 3rd gear piston
4WD driven shaft
3
2
1 a
RKZ11190
5
4
a. 4WD disengagement command port 3. 4WD gear driven (Z=41)
1. Front output shaft 4. Piston (n°3).
2. 4WD disengagement piston 5. Spring
10-10 WB97R-5
STRUCTURE AND FUNCTION FRONT AXLE
FRONT AXLE
Differential
1 2 3 4
16
15
7
8
14
9
13
10
12 11
RKZ09700
1. Planetary gear 9. Spacer
2. Ring gear (Z=32) 10. Bearing
3. Planetary gear pin 11. Sealing ring
4. Planetary gear 12. Cover
5. Ring nut 13. Ring nut
6. Half-axle 14. Bearing
7. Pin 15. Bevel pinion (Z=13)
8. Differential housing 16. Oil refilling plug
WB97R-5 10-11
STRUCTURE AND FUNCTION FRONT AXLE
Final reduction gear - Joint
7
3
2
1 5 8
6 9
4
10
11
13
22 12
17
14
18 16
21 15
20 19
RKZ09710
1. Planetary gear 12. Axle body
2. Planetary (Z=23) 13. Bearing
3. Ring gear (Z=32) 14. Joint
4. Crown wheel holder 15. Pin
5. Wheel hub 16. Protection
6. Sealing ring 17. Sealing ring
7. Pin 18. Bearing
8. Shim 19. Snap ring
9. Protection 20. Centering bushing
10. Bushing 21. Stud bolt
11. Sealing ring 22. Plug
10-12 WB97R-5
STRUCTURE AND FUNCTION FRONT AXLE
Steering unit cylinder
B 1
C 2 3
A
A
a b
7 7
5
4 6
Section B - B
Section A - A Detail C
RKZ09720
1. Steering cylinder Port a - From the steering unit (L Port)
2. Oil refilling plug Port b - From the steering unit (R Port)
3. Oil drain plug
4. Nut
5. Adjusting screw
6. Nut
7. Bushing
WB97R-5 10-13
STRUCTURE AND FUNCTION REAR AXLE
REAR AXLE
Differential
3
4
2
1 5
6
7 7
14
13
12 8
9
11 10 RKZ09730
1. Bearing 8. Bearing
2. Planetary gear 9. Ring nut
3. Ring gear (Z=32) 10. Sealing ring
4. Planetary gear 11. Flange
5. Differential housing 12. Spacer
6. Ring nut 13. Bevel pinion (Z=13)
7. Half-axle 14. Planetary gear
10-14 WB97R-5
STRUCTURE AND FUNCTION REAR AXLE
Final reduction gear
1
3 4
11
5
10 9 8 7
RKZ09740
1. Stud bolt 7. Snap ring
2. Planetary gear 8. Ring nut
3. Bell 9. Bearing
4. Planetary gear 10. Gasket
5. Half-axle (Z=15) 11. Wheel hub
6. Ring gear (Z=32)
WB97R-5 10-15
STRUCTURE AND FUNCTION REAR AXLE
Brakes
1
2
3 4
6
7
Detail A A
Particolare
A
RKZ09750
1. Bleed screw 6. Pressure disk
2. Piston 7. Bushing
3. Brake disk 8. Parking brake control caliper
4. Intermediate disk 9. Spring retaining pin
5. Pressure disk
10-16 WB97R-5
STRUCTURE AND FUNCTION REAR AXLE
Differential lock
3
8 7 6 5 4
RKZ09760
a. From servocontrol solenoid valve group EV1 1. Pin
(Port B2) 2. Sleeve
3. Cover
4. Piston
5. Guide bushing
6. Control rod
7. Fork
8. Spacer
WB97R-5 10-17
PAGE INTENTIONALLY
LEFT BLANK
2.5 bar
5 bar
16
µm
WB97R-5
T
E
Ø0,5
PLS
Pen
P1L
qMAX
LS
PRIORITY VALVE
VALVOLA PRIORITARIA
qMIN
LS VALVE
CLOCKWISE
P 8 bar
160 bar
270bar 80 l/min
Pp
STRUCTURE AND FUNCTION
PC VALVE
HYDRAULIC CIRCUIT
P1
2xØ1
80L/min MARTELLO
2xØ1 A0 HAMMER
OUT
IN
B0
80L/min
160
PB0 bar
10 PA0
0µ
m
PS
Pd
PM
P1c
140L/min
Pd2
A1
DIGGING DUMP B1
PB1 2° BRACCIO
140L/min
Ø0,6 ARM
Ø0,6
PA1
D
Ø1.5 Ø1.3
PRIORITY DLs
VALVE
LS Ø0,5
P
275bar
170 bar
0
T
+5
SELF REDUCING 5 bar
218 bar
225 bar 0
VALVE
+20
37,3bar
LS
Ø0.62
PPPC Ts
Cilindro di sterzo
Steering cylinder
215
225 bar 0
T
bar
+20
*100L/min
A2
LEFT (BH) RIGHT (BH)
ROTAZIONE 1° BRACCIO
R
B2
PB2 BOOM SWING
215 *100L/min
Ø0,6 bar
Ø0,6
PA2
220
bar
120L/min
A3
T
BENNA ANTERIORE
DIGGING DUMP B3 FRONT BUCKET
110L/min
PB3 PA3
LOCK
DIFFERENTIAL
P2
1° BRACCIO
0,5mm
120L/min
10
BOOM
A4
P1
RAISE LOWER
A1
B1
A2
B2
UL
LOCK
1
Acc
PM
B4
UBH
PB4
BH BOOM
0.32L-10bar
344 120L/min
EV1 Solenoid valve group
Gruppo elettrovalvole EV1
Ø0,6 bar
Ø0,6
2
PA4
100L/min
3
A5
7 4 8 5 9 6
DIGGING DUMP B5
PB5 120L/min BENNA RETROESC.
11
REAR BUCKET
T
PA5
P1
P1
CN-S1
100 µm
100 µm
P
90L/min
0,6mm
A6 BENNA 4 in 1
P2
OPEN CLOSED B6 4 in 1 BUCKET
P2
T
Ø0,6 75L/min
PB6 PA6
Manipolatore pala
P3
P3
Ø0,6
Stabilizer ppc valve
Loader ppc valve P1
0,6mm
RKZ10360
P4
2° BRACCIO
P3
P4
Manipolatore stabilizzatori
100L/min
P4
A7
TELESCOPICO
P2
0,6mm TELESCOPIC ARM
P4
P3
CLOSED EXTENDED B7
CN-S4
PB7 80L/min
P2
P1
PA7
0,6mm
120L/min SOLLEVAMENTO
0,6mm
A8
FLOAT PALA
OPTION LOWER RAISE B8
Ø0,6 100L/min LIFT FRONT ARM
PB8 PA8
STABILIZZATORE
50L/min DESTRO
A9 R.H. STABILIZER
PB9 RAISE LOWER B9
50L/min
PA9
Ø0.5
STABILIZZATORE
SS SINISTRO
50L/min
A10 L.H. STABILIZER
BLOCCAGGIO PIASTRA
SIDE SHIFT RAISE LOWER B10
2
50L/min
3
PB10 PA10
1
3
4
T1
2
CILINDRI
L.H. ppc valve
P
CLAMP CYLINDERS
BLOCCAGGIO PIASTRA
4
Manipolatore sinistro
2
3
1
3
4
T1
2
P
R.H. ppc valve
4
Manipolatore destro
T
P
B2
A2
A1
EV2 Solenoid valve group
Gruppo elettrovalvole EV2
HYDRAULIC CIRCUIT
10-19
PAGE INTENTIONALLY
LEFT BLANK
STRUCTURE AND FUNCTION HYDRAULIC PUMP
HYDRAULIC PUMP
Pd2
Ps
View X
P1L PLS
Pd P1c
Z
X
3 2
PM Pen P1
1
RKZ09410
View Z
COMPONENTS PORT FUNCTIONS
1. Hydraulic pump Port P1 - Pump delivery
2. Delivery control valve Port Pd - Drain
3. Oil refilling plug Port Ps - Intake of oil
Port P1L - Pump delivery pressure input
CONNECTIONS
Port P1C - Quick connect for pump delivery pressure
Port P1 - To the shovel control valve (Port P)
Port Pd2 - Drain plug
Port Pd - To hydraulic tank
Pen port - Delivery control pressure check
Port Ps - From hydraulic tank
Port PLS - Load Sensing signal input
Port P1L - From control valve (Port Pp)
Port PM - Operating mode control signal input
Port PLS - From control valve (Port LS)
Port PM - From EV1 solenoid valve group (Port PM)
WB97R-5 10-21
STRUCTURE AND FUNCTION HYDRAULIC PUMP
1. MAIN PUMP
A
View X
Z X
B B
D Pd4 Pa PM2
C C
D Pe Pd5
View Z
RKZ09420
PORT FUNCTIONS
Port Pa - Delivery control group feed
Port Pe - Delivery control signal
Port Pd4 - Drain
Port Pd5 - Drain
Port PM2 - Operating mode signal
10-22 WB97R-5
STRUCTURE AND FUNCTION HYDRAULIC PUMP
1 1 14
Section A - A Section C - C
4 5 6 7 8
3
13
Section D - D
RKZ09520
12 11 10 9
Section B - B
1. Bearing 8. Swash plate
2. Input shaft 9. Cover
3. Hydraulic pump 10. Shoe guide
4. Swash plate 11. Control piston
5. Shoe 12. Spring
6. Piston 13. Sealing ring
7. Cylinder block 14. Ball
WB97R-5 10-23
STRUCTURE AND FUNCTION HYDRAULIC PUMP
FUNCTION
The rotation and torque transmitted to the pump shaft is converted into hydraulic energy and pressurized oil is delivered
according to the load requirements.
The amount of oil delivered can be modified by changing the angle of the swash plate.
8 7 6 5 1 10
3
4
9 A a RKZ09790
STRUCTURE
• Groove a supports and makes cylinder block (1) an integral part of shaft (2), and shaft (2) is supported by front and
rear bearings (3), (4).
• The end of piston (5) is a concave ball, and shoe (6) is caulked to it to form one unit. Piston (5) and shoe (6) form a
spherical bearing.
• Swash plate (7) is supported by pump body (8) and ball (9), and has a flat surface A.
Shoe (6) remains in contact with swash plate (7) and slides in a circular movement.
Pressurised oil is introduced between shoe (6) and swash plate (7) forming a static bearing that allows shoes (6) to
slip.
• The pistons (5) perform their relative movements in an axial direction, inside cylindrical chambers fashioned in the
cylinder block (1).
• The rotation of the cylinder block (1) pressurises the oil inside the chambers of the block; pressure is adjusted by the
valve plate (10). The surface of the swash plate (10) is so designed that the oil pressure always remains within
acceptable limits. The oil in each chamber is drawn in and discharged through holes in the valve plate (10).
10-24 WB97R-5
STRUCTURE AND FUNCTION HYDRAULIC PUMP
OPERATION
7 6 1
1. Pump operation
1 - The cylinder block (1) rotates with the shaft (2), and
the shoe (6) slides on the flat surface A.
When this happens, the swash plate (7) rotates on X
the ball (9), and the angle a between the axis of the
cylinder block (1) and the axis X of the swash plate a
(3) changes. The angle a is known as the swash
plate angle.
2 - When the axis X of the swash plate (7) retains the
angle a in relation to the axis of the cylinder block
(1), flat surface A acts as a cam for the shoe (6).
This is why the piston (5) slides inside the
cylinder block (1), creating a difference between 9 A RKZ09530
volumes E and F and therefore causing the
suction and delivery of oil in a quantity that is
equivalent to the difference between those
volumes (F–E = delivery).
In other words, when cylinder block (1) rotates, 7 6 5 1 E
chamber F decreases in volume causing oil to be
delivered to the circuits, while chamber E
increases in volume causing oil to be suctioned.
(The illustration shows the state of the pump
when suction at chamber F and delivery at X
chamber E are complete). a
3 - When the center line X of the swash plate (7) and
the center line of the cylinder block (1) are
perfectly aligned (the swash plate angle a = 0),
the difference between the volumes E' and F'
within the cylinder block (1) becomes 0 and the
pump does not take in or deliver any oil.
4 - In brief, the angle of the swash plate a is 9 A F RKZ09540
proportional to pump delivery.
3 6 E
F RKZ09550
WB97R-5 10-25
STRUCTURE AND FUNCTION HYDRAULIC PUMP
2. Control of Delivery
1 - When angle a of the swash plate increases, the 8 9 7 E
difference between volumes E and F increases too,
and this makes delivery Q increase accordingly.
Angle a of the swash plate is varied by the servo- X
piston (11).
a
2 - The servo-piston (11) moves in a reciprocating
linear motion caused by pressure signals from the
PC and LS valves. The linear motion is transmitted
to the swash plate (7). The swash plate is supported 9
by the pump body (8) through the ball (9), and this is
the reason why the swash plate (7) moves in a 11
semicircular alternate motion.
F RKZ09560
10-26 WB97R-5
STRUCTURE AND FUNCTION HYDRAULIC PUMP
2. DELIVERY CONTROL VALVE
Pe Pd5
Ad4 Pa PM
A A
B B
RKZ09430
PORT FUNCTIONS
T port - Drain
P1 port - Delivery control group feed
Pd4 port - Drain
PE port - Delivery control signal output
PM port - Operating mode signal input
WB97R-5 10-27
STRUCTURE AND FUNCTION HYDRAULIC PUMP
2.1 PC VALVE
2 3 4 5
6 7 8
1
9
Pd4 PPL Pa PM Pa
RKZ09770
Section A - A
COMPONENTS PORT FUNCTIONS
1. Lever T port - Drain
2. Spring PA Port - Pump delivery pressure
3. Retainer PM port - Operating mode signal input
4. Seat PPL port - Delivery control signal output
5. Spool
6. Sleeve
7. Piston
8. Gasket
9. Piston
10-28 WB97R-5
STRUCTURE AND FUNCTION HYDRAULIC PUMP
2.2 LS VALVE
1 2 4
3 5
6
PPLS PPL Pe Pa Pd4 PLS RKZ09780
Section B - B
COMPONENTS PORT FUNCTIONS
1. Spool T port - Drain
2. Plug PA Port - Pump delivery pressure
3. Seat PE port - Delivery control signal
4. Spring PLS port - LS signal input
5. Nut PPL port - Delivery control signal input
6. Plug PPLS port - LS pump signal input
WB97R-5 10-29
STRUCTURE AND FUNCTION HYDRAULIC PUMP
LS VALVE FUNCTION
• The LS valve controls the pump delivery according
to the stroke of the control valve lever, i.e., in
function of the delivery demands made by the
actuators.
Pump delivery Q
• The LS valve detects the actuator’s delivery
needs by means of the differential pressure
DPLS existing between pressure PPLS (control
valve input pressure) and pressure PLS (control
valve output pressure). The sensing of this
differential pressure permits control of the main
pump delivery Q. (PPLS, PLS and DPLS are, LS differential pressure dPLS bar
respectively, the pump pressure, the Load
Sensing pressure, and the difference in pressure
between these two values). RKZ09570
• In other words, the LS valve detects the pressure
difference DPLS generated by the passage of
the oil flow through the surface freed by the
control valve spool, and controls the pump
delivery Q so as to keep the pressure drop
constant.
It can therefore be assumed that the pump
delivery is proportional to the demands made
known by the control valve.
• Pump pressure PPLS (pump pressure at control
valve input) and pressure PLS (Load Sensing
pressure) are introduced into the LS valve. The
relation between differential pressure DPLS and
pump delivery varies as shown in the diagram on
the right.
10-30 WB97R-5
STRUCTURE AND FUNCTION HYDRAULIC PUMP
PC (Power Control) VALVE FUNCTION
• The PC valve performs an approximate power 5
check, and ensures that the hydraulic horse-power
absorbed by the pump does not exceed the horse-
power delivered by the endothermal engine.
• This is achieved by limiting the pump delivery Q
in function of the delivery pressure PPLS, even if
the LS valve requests an increase in delivery Q
due to the larger section freed by the control
valve spool, in the presence of high pressure
pump delivery.
• In other words, when during operation the
delivery Q increases and the delivery pressure RKZ09800
PPLS also increases simultaneously, the PC
valve reduces the pump delivery Q. When the
delivery pressure PPLS decreases, the PC valve
increases the pump flow.
1
Pump delivery Q
• As pressure PC increases, the relation between
p r e s s u r e P A a n d d e l i v e r y Q i s c h a ng e d i n
accordance with the force applied by pressure PC.
• In other words, when the force applied by 2
pressure PC is added to the force applied by the
pump's delivery pressure against the spool (5), Pump pressure PA bar
the relation between pump delivery pressure and
delivery is switched from "1" to "2" in accordance
with increment "X". RKZ09580
WB97R-5 10-31
STRUCTURE AND FUNCTION HYDRAULIC PUMP
PC VALVE OPERATION
1. Spring operation
• PC valve spring loading (3) is defined by swash
plate position.
• If control piston (6) moves to the right, spring (3)
is compressed by lever (2) and spring loading
increases.
2. When pump pressure PA is low
1 5 4 PA
Check valve
D C B
PT
Engine
C B 3
F
LS valve
Solenoid
valve
G
J
RKZ09490
• The force applied by the pressure against the spool • When the control piston (2) moves, the lever (3)
(4) decreases, and the spool (5) shifts slightly to the moves to the left, and the spring (1) expands,
right. thereby reducing its load on the spool (5).
At the same time, a connection opens between Consequently, the spool (5) moves to the left and
passages C and D, and pressurised oil from valve LS stops the oil flow between C and D, and a passage
is sent for relief (PT). opens between ports B and C.
• Simultaneously, passages F and G on valve LS are • As a result of that, the pressure in C increases, and
interconnected: pressure at passage J is sent for the control piston (2) stops.
relief (PT), and the control piston (2) shifts to the
left.
• Pump delivery increases as a result.
10-32 WB97R-5
STRUCTURE AND FUNCTION HYDRAULIC PUMP
3. When pump pressure PA is high
1 5 4 PA
Check valve
D C B
PT
Engine
C B 3
2
LS valve
Solenoid
valve
J G
RKZ09500
• The force applied by the pressure against the spool • When the control piston (2) moves, the lever (3)
(4) increases, and the spool (5) shifts slightly to the moves to the right, and the spring (1) compresses,
left. At the same time, a connection opens C and B, thereby increasing its load on the spool (5).
and the pressure of the oil sent to valve LS becomes Consequently, the spool (5) moves to the right and
equivalent to the pump's delivery pressure (PA). stops the oil flow C and B, and a passage opens D and
• Simultaneously, passages F and G in valve LS are C.
interconnected, and pressure at port J becomes • As a result of that, the pressure in C decreases, and
equivalent to the pump's delivery pressure (PA), and the control piston (2) stops.
the control piston (2) shifts to the right.
• Pump delivery decreases as a result.
WB97R-5 10-33
STRUCTURE AND FUNCTION HYDRAULIC PUMP
4. When equilibrium has been reached
1 5 4 PA
Check valve
D C B
PT
Engine
C B 3
LS valve
Solenoid
valve
G
J
RKZ09510
• The equilibrium between the force applied by
pressure PA against spool (4) and the force applied
by spring (1) against spool (5) is what determines
the position at which the control piston (2) (hence
pump delivery) stops.
10-34 WB97R-5
PAGE INTENTIONALLY
LEFT BLANK
STRUCTURE AND FUNCTION 8-SPOOL CONTROL VALVE
8-SPOOL CONTROL VALVE
AC
Komatsu Ltd.
AC
PA1 B1 A1
AB AB
DLS T
PPPC
AA AA
LS P D
N N
PA2 B2 A2
B3 M M
PA3 A3
X L L A4
B4
PA4
K K
B5 A5
PA5
J J
B6 A6
PA6
F F
E E
D
PA7 PA8
Z
B7 SS A7
RKZ09060
B8 A8
ViewZ
10-36 WB97R-5
STRUCTURE AND FUNCTION 8-SPOOL CONTROL VALVE
AE
C B A
PP
PB1
PB2
PB3
PB4
PB5
PB6
PB8 C B A PB7 RKZ09070
AE
View X
A1 - To the arm cylinder (Head side) T- To hydraulic tank
A2 - To the boom (LH-RH) swing cylinder (Bottom side) TS - To hydraulic tank
A3 - To the shovel cylinders (Bottom side) PPPC - To solenoid valve group EV1 (P Port)
A4 - To the boom cylinder (Bottom side) SS - To the backhoe plate lock cylinders
A5 - To the backhoe bucket cylinder (Head side) PA1 - From backhoe LH PPC valve (port 3)
A6 - To the shovel arm raise cylinder (Bottom side) PA2 - From backhoe LH PPC valve (port 4)
A7 - To the RH outrigger cylinder (bottom side) PA3 - From the shovel PPC valve (P2 port)
A8 - To the LH outrigger cylinder (bottom side) PA4 - From backhoe RH PPC valve (port 3)
B1 - To the arm cylinder (Bottom side) PA5 - From backhoe RH PPC valve (port 4)
B2 - To the boom (LH-RH) swing cylinder (Head side) PA6 - From the shovel PPC valve (P3 port)
B3 - To the shovel cylinders (Head side) PA7 - From the outriggers PPC valve (P1 port)
B4 - To the boom cylinder (Head side) PA8 - From the outriggers PPC valve (P3 port)
B5 - To the backhoe bucket cylinder (Bottom side) PB1 - From backhoe LH PPC valve (port 1)
B6 - To the shovel arm raise cylinder (Head side) PB2 - From backhoe LH PPC valve (port 2)
B7 - To the RH outrigger cylinder (Head side) PB3 - From the shovel PPC valve (P1 port)
B8 - To the LH outrigger cylinder (Head side) PB4 - From backhoe RH PPC valve (port 1)
LS - To the hydraulic pump (PLS port) PB5 - From backhoe RH PPC valve (port 2)
P- From hydraulic pump (P1 port) PB6 - From the shovel PPC valve (P4 port)
D- To the steering unit (P Port) PB7 - From the outriggers PPC valve (P2 port)
DLS - From the steering unit (LS Port) PB8 - From the outriggers PPC valve (P4 port)
PP - To the hydraulic pump (P1L port)
WB97R-5 10-37
STRUCTURE AND FUNCTION 8-SPOOL CONTROL VALVE
6
7
18
17
19 8
20
16 4
3
15 9
2 10
14
1 11
13
12
B-B A-A RKZ09080
1. Anticavitation valve 12. Spool (shovel arm control)
(backhoe bucket curl) 13. Spool (backhoe bucket control)
2. Anti-shock/anticavitation valve 14. Spool (boom control)
(boom raise) 15. Spool (front bucket control)
3. Anticavitation valve (shovel dump) 16. Spool (boom swing control)
4. Anti-shock/anticavitation valve (LH swing) 17. LS by-pass plug
5. Anticavitation valve (arm out) 18. Spool (arm control)
6. Safety valve 19. Spool (priority valve)
7. Anticavitation valve (arm in) 20. Unloading valve
8. Anti-shock/anticavitation valve (RH swing)
9. Anti-shock/anticavitation valve
(shovel curl)
10. Anticavitation valve (boom lower)
11. Anticavitation valve
(backhoe bucket dump)
10-38 WB97R-5
STRUCTURE AND FUNCTION 8-SPOOL CONTROL VALVE
AD
7
16
6 13
17
8
18 9
5
19
4
10
20 3 11
21 2
1
12
AD
15 14
D-D C-C
22
23
AD - AD RKZ08340
PRESSURE REDUCING VALVE 11. Backhoe bucket
1. Shovel arm 12. Shovel arm
2. Backhoe bucket 13. Max. pressure valve
3. Boom 14. Check valve
4. Front bucket 15. Check valve
5. Boom swing 16. Check valve
6. Arm 17. Check valve
18. Check valve
DELIVERY CONTROL VALVE 19. Check valve
7. Arm 20. Check valve
8. Boom swing 21. Check valve
9. Front bucket 22. LS, DLS pressure check valve
10. Boom 23. LS by-pass plug
WB97R-5 10-39
STRUCTURE AND FUNCTION 8-SPOOL CONTROL VALVE
3 4
2 7
1
E-E K-K
5 8
F-F L-L
6 9
J-J M-M RKZ09100
1. Spool (right outrigger control)
2. Spool (left outrigger control)
3. Backhoe plate lock solenoid valve
4. Backhoe plate lock valve
5. Spool (shovel arm control)
6. Spool (backhoe bucket control)
7. Spool (Boom control)
8. Spool (front bucket control)
9. Spool (boom swing control)
10-40 WB97R-5
STRUCTURE AND FUNCTION 8-SPOOL CONTROL VALVE
5 6
AC - AC
N-N
3
1
AA - AA
AB - AB
RKZ09110
AE - AE
1. Servocontrol max. pressure valve
2. Max. pressure valve spool
3. Sequential reducing valve
4. Blow out plug
5. Unloading valve
6. LS by-pass plug
7. Spool (Arm control)
WB97R-5 10-41
STRUCTURE AND FUNCTION 10-SPOOL CONTROL VALVE
10-SPOOL CONTROL VALVE
AC
Komatsu Ltd.
AC
PA1 B1 A1
AB AB
DLS PPPC T
AA AA
LS P D
R R A2
PA2 B2
B3 N N
PA3 A3
X M M A4
B4
PA4
L L
B5 A5
PA5
K K
B6 A6
PA6
B7 J J
PA7 A7
B8 A8
PA8
F F
E E
D
PA7 PA8 Z
B9 A9
RKZ09120
B10 A10
ViewZ
10-42 WB97R-5
STRUCTURE AND FUNCTION 10-SPOOL CONTROL VALVE
AE
C B A
PP
PB1
PB2
PB3
PB4
PB5
PB6
PB7
PB8
PB10 C B A PB9 RKZ09590
AE
WB97R-5 10-43
STRUCTURE AND FUNCTION 10-SPOOL CONTROL VALVE
A1 - To the arm cylinder (Head side)
A2 - To the boom (LH-RH) swing cylinder (Bottom side)
A3 - To the shovel cylinders (Bottom side)
A4 - To the boom cylinder (Bottom side)
A5 - To the backhoe bucket cylinder (Head side)
A6 - To the 4 in 1 bucket cylinder (Bottom side)
A7 - To the jig arm cylinder (Bottom side)
A8 - To the shovel arm raise cylinder (Bottom side)
A9 - To the RH outrigger cylinder (Bottom side)
A10 - To the LH outrigger cylinder (Bottom side)
B1 - To the arm cylinder (Bottom side)
B2 - To the boom (LH-RH) swing cylinder (Head side)
B3 - To the shovel cylinders (Head side)
B4 - To the boom cylinder (Head side)
B5 - To the backhoe bucket cylinder (Bottom side)
B6 - To the 4 in 1 bucket cylinder (Head side)
B7 - To the jig arm cylinder (Head side)
B8 - To the shovel arm raise cylinder (Head side)
B9 - To the RH outrigger cylinder (Head side)
B10 - To the LH outrigger cylinder (Head side)
LS - To the hydraulic pump (PLS port)
P- From hydraulic pump (P1 port)
D- To the steering unit (P Port)
DLS - From the steering unit (LS Port)
PP - To the hydraulic pump (P1L port)
T- To hydraulic tank
TS - To hydraulic tank
PPPC -To solenoid valve group EV1 (P Port)
SS - To the backhoe plate lock cylinders
PA1 - From backhoe LH PPC valve (port 3)
PA2 - From backhoe LH PPC valve (port 4)
PA3 - From the shovel PPC valve (P2 port)
PA4 - From backhoe RH PPC valve (port 3)
PA5 - From backhoe RH PPC valve (port 4)
PA6 - From solenoid valve group EV1 (A1 Port)
PA7 - From solenoid valve group EV2 (A2 Port)
PA8 - From the shovel PPC valve (P3 port)
PA9 - From the outriggers PPC valve (P1 port)
PA10 - From the outriggers PPC valve (P3 port)
PB1 - From backhoe LH PPC valve (port 1)
PB2 - From backhoe LH PPC valve (port 2)
PB3 - From the shovel PPC valve (P1 port)
PB4 - From backhoe RH PPC valve (port 1)
PB5 - From backhoe RH PPC valve (port 2)
PB6 - From solenoid valve group EV1 (B1 Port)
PB7 - From solenoid valve group EV2 (B2 Port)
PB8 - From the shovel PPC valve (P4 port)
PB9 - From the outriggers PPC valve (P2 port)
PB10 -From the outriggers PPC valve (P4 port)
10-44 WB97R-5
STRUCTURE AND FUNCTION 10-SPOOL CONTROL VALVE
7
22
8
6
25
9
23
24
21 5
20 4 10
3 11
19
2 12
18
1 13
17
14
16
15
B-B A-A
17
16
K-K J-J
RKZ09130
1. Anticavitation valve 13. Anticavitation valve (jig arm retract)
(jig arm extend) 14. Anticavitation valve (4 in 1 bucket dump)
2. Anticavitation valve (backhoe bucket curl) 15. Spool (shovel arm control)
3. Anti-shock/anticavitation valve (boom raise) 16. Spool (Jig arm control)
4. Anticavitation valve (shovel dump) 17. Spool (4 in 1 bucket control)
5. Anti-shock/anticavitation valve (LH swing) 18. Spool (backhoe bucket control)
6. Anticavitation valve (arm out) 19. Spool (boom control)
7. Safety valve 20. Spool (front bucket control)
8. Anticavitation valve (arm in) 21. Spool (boom swing control)
9. Anti-shock/anticavitation valve (RH swing) 22. Spool (arm control)
10. Anti-shock/anticavitation valve (shovel curl) 23. Spool (priority valve)
11. Anticavitation valve (boom lower) 24. Unloading valve
12. Anticavitation valve (backhoe bucket dump) 25. LS by-pass plug
WB97R-5 10-45
STRUCTURE AND FUNCTION 10-SPOOL CONTROL VALVE
AD
20 9
8
17
21
10
22 11
7
23
6 12
24 5 13
25
4 14
3 15
26 2
1
16
AD
19 18 D-D C-C
RKZ09140
27
28
AD - AD
PRESSURE REDUCING DELIVERY CONTROL 19. Check valve
VALVE VALVE 20. Check valve
1. Shovel arm 9. Arm 21. Check valve
2. Jig arm 10. Boom swing 22. Check valve
3. 4 in 1 bucket 11. Front bucket 23. Check valve
4. Backhoe bucket 12. Boom 24. Check valve
5. Boom 13. Backhoe bucket 25. Check valve
6. Front bucket 14. 4 in 1 bucket 26. Check valve
7. Boom swing 15. Jig arm 27. LS, DLS pressure check
8. Arm 16. Shovel arm valve
17. Max. pressure valve 28. LS by-pass plug
18. Check valve
10-46 WB97R-5
STRUCTURE AND FUNCTION 10-SPOOL CONTROL VALVE
3 4
2 7
1
E-E M-M
5 8
F-F N-N
6 9
L-L P-P RKZ09101
1. Spool (right outrigger control)
2. Spool (left outrigger control)
3. Backhoe plate lock solenoid valve
4. Backhoe plate lock valve
5. Spool (shovel arm control)
6. Spool (backhoe bucket control)
7. Spool (Boom control)
8. Spool (front bucket control)
9. Spool (boom swing control)
WB97R-5 10-47
STRUCTURE AND FUNCTION 10-SPOOL CONTROL VALVE
5 6
AC - AC
R-R
3
1
AA - AA
AB - AB
RKZ09111
AE - AE
1. Servocontrol max. pressure valve
2. Max. pressure valve spool
3. Sequential reducing valve
4. Blow out plug
5. Unloading valve
6. LS by-pass plug
7. Spool (Arm control)
10-48 WB97R-5
STRUCTURE AND FUNCTION CLSS
CLSS
1. DESCRIPTION
1.1 CHARACTERISTICS
The term CLSS means Closed Center Load Sensing System, which has the following characteristics:
a) High precision control that is independent of the load applied to the movement;
b) High precision control of digging action even during delicate manoeuvres;
c) Ability to perform complex operations, guaranteed by control of oil flow in function of the aperture surfaces of the
shuttles;
d) Energy savings guaranteed by control of pump delivery.
1.2 STRUCTURE
• The CLSS system includes the variable flow pump, the control valve and the working equipment.
• The pump includes the main pump, the TCC valve and the LS. valve.
Actuator
PLS
Control valve
TCC valve
LS valve
PP
Servo
piston
RKP00661
WB97R-5 10-49
STRUCTURE AND FUNCTION CLSS
2. OPERATING PRINCIPLES
2.1 CONTROL OF THE ANGLE OF THE PUMPING PLATE
• The angle of the swash plate (and hence the pump delivery) is controlled in such a way that the differential pressure
DPLS between the delivery pressure PP of the pump and the pressure PLS at the outlet of the control valve towards
the actuator is maintained at a constant value. (DPLS=Pump delivery pressure PP – pressure PLS of delivery to the
actuator.
• If the differential pressure DPLS becomes lower than the set pressure of the LS, valve, the angle of the swash plate
increases.
If the differential pressure DPLS increases, the angle of the swash plate decreases.
a For details about this movement, see the description of the "HYDRAULIC PUMP".
Actuator
Max.
Swash plate angle Q
Control valve
Min.
PLS
Pump passage
LS passage 0 LS differential
pressure ∆PLS Set differential
pressure of LS valve
Main pump
PP RKP02931
Min. Max.
Servo piston
∆ PLS
LS valve
Differential
pressure high Differential
pressure
low
PC valve
Pump pressure Pump pressure
high low
RKP02921
10-50 WB97R-5
STRUCTURE AND FUNCTION CLSS
2.2 PRESSURE COMPENSATION CONTROL
• The pressure compensation valves are installed downstream from the control valve in order to balance the
differential pressure between the loads.
When two or more movements (cylinders) are activated simultaneously, the pressure differences DP between the
delivery at the control valve inlet and outlets of the control valve are compensated by these valves.
We obtain the distribution of the pump flow in proportion to the areas of passage 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
WB97R-5 10-51
STRUCTURE AND FUNCTION CLSS
3. OPERATION FOR EACH CIRCUIT AND VALVE
3.1 HYDRAULIC CIRCUIT DIAGRAM AND NAMES OF VALVES
3.1.1 8-spool control valve
1. Unloading valve:
3
pressure LS + 27.5 bar
PP
2. Max. pressure valve: 218 bar
4 3. Safety valve: 270 bar
Arm
4. Check valve
A1
PB1 B1
5. Anti-shock/anticavitation valve: 215 bar
8 PA1 6. Anti-shock/anticavitation valve: 220 bar
4 7. Anti-shock/anticavitation valve: 350 bar
9 D
8. Pressure compensation valves
DLS
9. Priority valve
LS
P
T
10. Servocontrols reducing valve
10 1
11. Backhoe plate lock valve
2
Ts
PPPC
5
A2 Boom
PB2 B2 swing
8 PA2
5
6
A3 Shovel
PB3 B3
8 PA3
A4
Boom
B4
7
PB4
8 PA4
4
A5 Bucket
PB5 B5
8 PA5
A6 Shovel
raising
PB6 B6
PA6
8
11 A7
Right
outrigger
PB7 B7
PA7
A8
Left
SS outrigger
B8
PB8
PA8
RKZ09170
10-52 WB97R-5
STRUCTURE AND FUNCTION CLSS
3.1.1 10-spool control valve
3 1. Unloading valve:
PP
pressure LS + 27.5 bar
4 2. Max. pressure valve: 218 bar
3. Safety valve: 270 bar
A1 Arm 4. Check valve
PB1
8
B1
5. Anti-shock/anticavitation valve: 215 bar
PA1
4
6. Anti-shock/anticavitation valve: 220 bar
7. Anti-shock/anticavitation valve: 350 bar
9 D
DLS 8. Pressure compensation valves
P
LS 9. Priority valve
T
10 1 10. Servocontrols reducing valve
2 11. Backhoe plate lock valve
Ts
PPPC
5
Boom
A2
swing
PB2 B2
8 PA2
5
6
A3 Shovel
PB3 B3
8 PA3
A4 Boom
B4
PB4
7
8 PA4
4
A5
Bucket
PB5 B5
8 PA5
A6 Bucket 4 in 1
PB6 B6
8 PA6
A7
Jig arm
PB7 B7
8 PA7
A8 Shovel
raising
PB8 B8
PA8
8
11 A9 Right
outrigger
PB9 B9
PA9
A10 Left
SS outrigger
B10
PB10 PA10
RKZ09180
WB97R-5 10-53
STRUCTURE AND FUNCTION CLSS
3.2 UNLOADING VALVE
3.2.1 When the control valve is in "NEUTRAL" position
Function
• When the control valve is in “NEUTRAL” position, pump delivery Q (resulting from the swash plate being at its min.
angle) is sent into the tank circuit.
When this happens, the pump's delivery pressure PP is regulated at 27.5 bar (28 kg/cm2) by means of the spring (2)
inside the valve.
(LS signal with PLS pressure=0 bar (0 kg/cm2)
PP
S1 1 S2
S3
T 2 PL
RKZ09190
Functioning
• Pump pressure PP acts on spool (1) – left, on surface PP = Pump circuit
S1, and right, on surface S2 – whereas Load Sensing PLS = Load Sensing circuit
pressure PLS acts on surface S2. T= Tank circuit
• Since no LS signal with PLS pressure is generated A = To control valve spools
when the control valve is in “NEUTRAL” position, the
only pressure acting on spool (1) in this condition is
the pump's delivery pressure PP as regulated by
spring compression (2).
• As the pump's delivery pressure PP increases and the
resulting force equals spring loading (2), the spool (1)
shifts to the right. The pump's delivery circuit PP is
then connected to the tank circuit T by means of the
holes in spool (1).
• This ensures that the pump delivery pressure PP
stays regulated at 27.5 bar (28 kg/cm2).
10-54 WB97R-5
STRUCTURE AND FUNCTION CLSS
3.2.2 Control valve fine control
Function
• When the actuators' delivery needs during fine control are within the delivery values related to the minimum angle
of the swash plate, the pump's delivery pressure PP is regulated by pressure PLS at +27.5 bar (28 kg/cm2).
Since the unloading valve opens when the differential pressure between the pump's delivery pressure PP and
pressure PLS of the LS equals spring loading (2) (27.5 bar (28 kg/cm2)), the differential pressure DPLS becomes
27.5 bar (28 kg/cm2).
PP
S1 1 A S2
B
S3
T 2 PL
RKZ09200
Functioning
• When fine controls are performed at the control valve,
a PLS pressure is generated. This pressure acts on
surface S3 on the right hand side of the spool (1).
Since pressure PLS of LS is low – because the control
valve passage is small – the difference with the
pump's delivery pressure PP is great.
• When the differential pressure between the pump's
delivery pressure PP and pressure PLS of the LS
equals spring loading (2) (27.5 bar (28 kg/cm2)), the
spool (1) shifts to the right and, in turn, the pump
circuit PP connects to the tank circuit T.
• The pump's delivery pressure PP is regulated by the
combination of the pressure from the spring (27.5 bar
(28 kg/cm 2 )) and the pressure PLS of the LS, i.e.
when the differential pressure DPLS reaches a value
of 27.5 bar (28 kg/cm2).
WB97R-5 10-55
STRUCTURE AND FUNCTION CLSS
3.2.3 When the control valve is in use
Function
• When the request for oil flow from the actuators exceeds the minimum delivery of the pump during use of the control
valve, the connection to the tank circuit is eliminated and the entire pump delivery Q is sent to the actuators.
PP
S1 1 S2
S3
T 2 PL
RKZ09210
Functioning • The result is that the connection between the pump
• When the control valve spool is caused to perform a delivery circuit PP and the tank circuit T is excluded
longer travel, this generates a pressure PLS of the and the entire pump delivery Q is sent to the
LS, which acts on the right hand side of the spool (1). actuators.
Since the control valve passage is wide, the
difference between the pressure PLS of the LS and
the pump's delivery pressure PP is small.
• For this reason, since the differential pressure
between the pump's delivery pressure PP and the
pressure PLS of the LS fails to reach the spring
loading pressure value of spring (2) (27.5 bar (28 kg/
cm2), the spool (1) is pushed to the left by the spring
(2).
10-56 WB97R-5
STRUCTURE AND FUNCTION CLSS
3.3 INTRODUCTION OF THE LS PRESSURE
Function
• LS pressure is the actuator's pressure at control valve output.
• This pressure actually reduces the pump's PP pressure – via the pressure compensation group reducing valve (3)
– to the same A pressure of the actuator circuit and then sends it into the PLS circuit of the LS.
• In the outriggers control valve, the actuator's pressure A is introduced directly into circuit PLS of the LS
3.3.1 Control valve (working equipment not including outriggers).
A b a
SLS
PLSS
2 3
PLS
c
PP 4
SA PA
RKZ09220
Functioning • The pressure acting on the left side of the reducing
• When the spool (1) is operated, pump pressure PP valve (3) is pressure PA (= A) of the actuator, whereas
starts flowing into the circuit of actuator A – from the the pressure acting on the right hand side is the
delivery control valve (2) and from the notch a via the reduced pressure PP of pump delivery.
duct b. • The reducing valve (3) therefore balances out when
• At the same time, the pressure reducing valve (3) pressure PA of the actuators and pressure PLSS of
moves to the right thereby making the pump's the spring chamber are balanced. This in turn allows
pressure PP drop as it flows through the bottleneck c, the pressure PP – now reduced by the bottleneck c –
and causing the pressure to flow into the circuit PLS of to be introduced into the PLS circuit of the LS at the
the LS and into the chamber of spring PLSS. same pressure A as the actuator's circuit.
• At this point, the PLS circuit of the LS is connected to
the tank circuit T by means of the by-pass plug (4).
(See the description of the LS by-pass plug).
WB97R-5 10-57
STRUCTURE AND FUNCTION CLSS
3.3.2 Outriggers control valve
A a PP
RKZ09240
b PLS
Functioning a The outriggers circuit differs from the working
• When the spool (1) is operated, pump pressure PP equipment circuit in that the operating pressure of
starts flowing into the circuit of actuator A through the actuator A is introduced directly into the PLS circuit of
duct a. the LS.
• At the same time, pressurised oil is introduced into the
PLS circuit of the LS through holes b.
10-58 WB97R-5
STRUCTURE AND FUNCTION CLSS
3.4 LS BY-PASS PLUG
Description
• The LS by-pass plug unloads residual pressure from the Load Sensing's PLS circuit.
• This makes the increment rate of Load Sensing's PLS pressure smoother.
Moreover, by eliminating oil (through the bottleneck), a loss of pressure is generated in the flow that is controlled by
the spool, and stability is increased as a result, thereby reducing the actual differential pressure LS.
b a
T PLS
RKZ09250
T PP
Functioning PP = Pump circuit
• Pressurised oil in the Load Sensing PLS circuit flows PLS = Load Sensing circuit
through filter a, through orifice b and into the tank T = Drain circuit
circuit T.
WB97R-5 10-59
STRUCTURE AND FUNCTION CLSS
3.5 PRESSURE COMPENSATION VALVES
Function
• Pressure compensation occurs during simultaneous operation of several movements, specifically when the
pressure of an actuator becomes lower than the pressure of the actuator on the opposite side, and pump delivery is
on the verge of being increased.
In this specific case, the RH actuator withstands a higher pressure than the LH actuator.
Side receiving
compensation
Side giving
compensation
T
W A W A
aB aB
PLSS PPA PA
2 PA
1
PPA
PLS RKZ09260
PP
Functioning • The delivery control valve (2) and the pressure
• During simultaneous operation, when RH actuator reducing valve (1) are balanced out at a point where
pressure increases, delivery in circuit A of the LH the differential pressure between PA and PLS (these
actuator tends to increase. two acting on both surfaces of the pressure reducing
• In this case, the PLS pressure of the LS for the RH valve (1)), equals the loss of pressure between PP
actuator acts on chamber PLS1 of the spring and and PPA (these two acting on both surfaces of the
pushes the pressure reducing valve (1) and the delivery control valve (1)).
delivery control valve (2) to the left. • The differential pressure between the upstream
• The delivery control valve (2) produces a bottleneck pressure PPA and the downstream pressure of both
between the pump's delivery PP circuit and the PPA spools in the control valves concerned in the
circuit upstream of the control valve spool. simultaneous movements are equalised, and pump
This bottleneck generates a pressure loss between delivery is distributed proportionally to the sections a
circuits PP and PPA. that are responsible for opening the notches of each
spool.
10-60 WB97R-5
STRUCTURE AND FUNCTION CLSS
3.6 PRESSURE COMPENSATION VALVE SURFACE/SURFACE RATIO
Function
• In order to equalize the characteristics of each actuator, the pressure compensation valve will determine the
compensation characteristics by performing a micrometer adjustment of the surface ratio S1/S2. This is the ratio of
area S1 (delivery control valve (2) end) to area S2 (pressure reducing valve (1) end).
S1 = surface of the delivery control valve (2) – Surface of piston (3).
S2 = surface of pressure reducing valve (1) – Surface of piston (3).
T
A b
S1
S2
PPA 1
2 3
PP PA PLS
RKZ09230
Surface ratio (S1:S2) and compensation characteristics
• When the ratio is 1.00 :
[Pump pressure PP – Pressure PPA upstream of spool] C [Load Sensing PLS pressure – Actuator PA pressure (=
A)]
Delivery is distributed proportionally to the opening surfaces of the spool.
• When the ratio is greater than 1.00: PP – PPA > PLS – PA (= A)
Delivery distribution is lower than the proportion of the opening surfaces of the spool.
• When the ratio is lower than 1.00: PP – PPA < PLS – PA (= A)
Delivery distribution is higher than the proportion of the opening surfaces of the spool.
WB97R-5 10-61
STRUCTURE AND FUNCTION CLSS
3.7 PRIORITY VALVE
Function
• The purpose of the priority valve is to feed pressurised oil to the steering unit and to the other actuators.
• Oil distribution is determined by the position of the spool (1) of the priority valve, which is in turn determined by LS
signal, pump delivery, steering circuit pressure, and hydraulic circuit pressure.
• The position of the spool (1) is determined in such a way as to ensure that the oil delivered to the steering unit
matches the delivery needs at any time.
PP DLS
D
1
P LS RKZ09270
1= Priority valve spool
PP = Pump circuit
D = Steering unit feed circuit
DLS = Steering unit LS signal
10-62 WB97R-5
STRUCTURE AND FUNCTION CLSS
3.8 SERVOCONTROLS REDUCING VALVE
Function
• This valve regulates the servocontrol feed pressure at 29 bar (30 kg/cm2).
• When actuator pressure is low, the sequential valve closes to permit an increase in the pump's delivery pressure PP
in order to supply pressure to the servocontrols.
3.8.1 When all actuators are in a neutral condition
PPPC
4
PP 5
2
TO ACTUATORS
1 PLS
TS
RKZ09280
Functioning
• The spool (1) of the unloading valve moves, and delivery pressure is regulated at 29 bar (30 kg/cm2).
(For details, see 3.2 UNLOADING VALVE).
• The spool (2) and valve (3) reduce the pump's delivery pressure PP to 29 bar (30 kg/cm2) .
Pressure is then sent to the servocontrols via port PC.
WB97R-5 10-63
STRUCTURE AND FUNCTION CLSS
3.8.2 When the control valve is operated
PPPC
4
PP 5
2
TO ACTUATORS
1 PLS
TS
T RKZ09290
Functioning
• The spool (1) of the unloading valve moves to the left, and the pump's delivery pressure exceeds the pressure of the
actuator circuit (5) by an amount equivalent to LS differential pressure.
(For details, see 3.2 UNLOADING VALVE).
• If the pump's delivery pressure PP exceeds 29 bar (30 kg/cm2), valves (2) and (3) reduce pressure PP to 29 bar (30
kg/cm2).
The reduced pressure is then sent to the servocontrols via port PC.
• When this occurs, the sequential reducing valve (4) stays open.
10-64 WB97R-5
STRUCTURE AND FUNCTION CLSS
PPPC
4
PP 5
2
TO ACTUATORS
1 PLS
TS
RKZ09300
• When the pump's delivery pressure PP is lower than 29 bar (30 kg/cm2), the sequential reducing valve shifts to the
right, thereby reducing the flow of the PP pressure to the actuator circuit (5).
This generates a pressure gap between PP pressure and actuator pressure.
PP pressure is incremented in excess of 29 bar (30 kg/cm2) and is then reduced to 29 bar (30 kg/cm2) by valves (2)
and (3) to guarantee pressure feed to the servocontrols.
WB97R-5 10-65
STRUCTURE AND FUNCTION CLSS
3.9 BACKHOE PLATE LOCK SOLENOID VALVE
Function
• The purpose of this solenoid valve is to send pump delivery pressure PP to backhoe plate lock cylinders.
3.9.1 When the solenoid valve is deenergized
Lock cylinder
SS
1 4
T
PP
RKZ09310
Functioning
• When the solenoid valve is deenergized, pump delivery pressure PP flows through orifice (2) and check valve (3)
and into the SS circuit of the plate lock cylinders.
• When the entire circuit reaches pump delivery pressure PP, the check valve (3) lowers, thereby dividing the circuit,
which is therefore kept at the maximum pressure reached by the delivery circuit.
10-66 WB97R-5
STRUCTURE AND FUNCTION CLSS
3.9.2 When the solenoid valve is energized
Lock cylinder
SS
1 4
T
PP
RKZ09320
Functioning
• When the solenoid valve is energized, pressurised oil in the SS circuit is sent to the tank circuit through spool (4).
• As a result, the SS circuit pressure decreases, and the plate is released, so it can be shifted.
WB97R-5 10-67
STRUCTURE AND FUNCTION STEERING UNIT
STEERING UNIT
a e b
LS
L R
T P
c d RKP03740
a. Port L - To steering cylinder (a Port) TECHNICAL DATA
b. Port R - To steering cylinder (b Port) Steering unit type: OSPC200LS
c. Port T - To hydraulic tank Nominal flow: 20 l
d. Port P - From control valve (D port)
OPERATION
e. Port LS - To control valve (DLS port)
• The steering unit is composed of a control valve and a
rotating oil dispenser, and is of the hydrostatic type.
• When the steering wheel is turned, the control valve
sends oil from the pump (by means of the rotating oil
dispenser) to one of the sides of the steering cylinder.
The rotating dispenser ensures that the volume of oil
supplied to the cylinder is proportionate to the angle of
rotation of the steering wheel.
• In the event of malfunction, the oil dispenser will
function automatically as a hand-pump, thus
guaranteeing emergency steering.
10-68 WB97R-5
STRUCTURE AND FUNCTION PPC VALVES
PPC VALVES
SHOVEL PPC VALVE (STANDARD)
P2 P4
P3 P1
Z
E E
D D
B
T P
A C
C A
View Z RKZ09330
P1 port - To control valve (PB3 port)
P2 port - To control valve (PA3 port)
P3 port - To control valve (PA8 port)
P4 port - To control valve (PB8 port)
P port - From EV1 solenoid valve group (VL port)
Port T - To hydraulic tank
WB97R-5 10-69
STRUCTURE AND FUNCTION PPC VALVES
5 7
4
8
3
9
2
1 10
A-A B-B
D-D
C-C
E-E
RKZ09340
1. Spool 6. Nut
2. Adjusting screw (inner) 7. Joint
3. Adjusting screw (outer) 8. Cover
4. Piston 9. Retainer
5. Disk 10. Body
10-70 WB97R-5
STRUCTURE AND FUNCTION PPC VALVES
OPERATION
1. Control lever in neutral position
Control valve ducts A and B and PPC valve ducts
P1 and P2 are connected to discharge chamber D
by means of the calibrated hole f in spool (1).
D
f
T
P
2. During fine control (NEUTRAL o Actuator)
When the disk (5) starts pushing down on the piston
(4), the retainer (9) moves as a result. This A Control B
movement will compress the spring (2) which will in valve
turn act on the spool (1) and push it downwards. RKZ09450
As a result of this action, the calibrated hole f will be
isolated from the discharge chamber D and at
almost at the same time it will be put in connection 5
with the PP chamber, which is directly connected to
the servocontrols circuit. 4
Pressure in the servocontrols circuit will flow
through the calibrated holef and into the circuit 9
thereby increasing the pressure in duct P1-A.
When pressure P1 increases, spool (1) is pushed 2 D
upwards, and calibrated hole f is connected back to
f T
discharge chamber D thereby compressing the
spring (2). P
The floating of the spool (1) will continue until
calibrated hole f is halfway between discharge
chamber D and pressure chamber PP, in other 1 PP
words until the pressure in duct P1 – the pressure P1 P2
acting on the section of stem (1) – offsets the force
applied by the spring (2).
The spring (2) is compressed proportionally to the
movement of the disk (5) and therefore, pressure at
A Control B
P1 increases in proportion to the travel of the disk valve
(5).
The equilibrium position is then kept until the RKZ09470
position of piston (4) is changed, i.e.:
a) as long as pressures at ports A and P1 are
perfectly balanced;
b) until pressure in section A-P1 – i.e. the
pressure acting on stem (1) – is enough to
counteract the force of the spring (2).
This ensures proportionality between control lever
position, A-P1 circuit pressure, and main control
valve stem displacement.
WB97R-5 10-71
STRUCTURE AND FUNCTION PPC VALVES
3. During fine control
(Actuatoro NEUTRAL) 5
When the disk (5) is released and moved to neutral 4
position, the piston (4) is pushed upwards by the
spring (3) acting on the retainer (9), and spool (1) is 9
thrusted upwards both by the force of spring (2) and
by the force that the pressure in section A-P1 3
applies against the stem. D
This movement moves the calibrated hole f of spool 2
(1) into the discharge chamber D, thereby allowing f T
pressure in section A-P1 to be released. P
If pressure P1 drops too quickly, spool (1) is pushed
downwards by spring (2) and the calibrated hole f f
becomes cut off from the discharge chamber D; at 1
almost the same time, the calibrated hole f is put in PP
connection with pressure chamber PP and starts P1 P2
supplying pressure to section P1 until the pressure
corresponding to the control lever position is
balanced.
When the spool of the control valve returns, oil flows A Control B
valve
back into chamber D, through calibrated hole f', and
into chamber B of the control valve spool opposite
the operating one. RKZ09480
Oil flows through duct P2 and into chamber B to
ensure it is filled properly.
4. During fine control
(NEUTRAL o Full stroke) 5
When the disk (5) pushes down on the piston (4), 4
and the retainer (9) pushes down on the spool (1),
calibrated hole f is put in direct connection with
chamber PP, which is in turn connected to a 9
constantly pressurised servocontrols circuit.
Oil is then allowed to flow directly into section A-P1, D
thereby pushing the stem of the main control valve f
to the end of its travel. This causes the main control T
valve to send the oil contained in chamber B P
towards input P2, through calibrated hole f' and into
discharge chamber D. f
1 PP
P1 P2
A Control B
valve
RKZ09460
10-72 WB97R-5
STRUCTURE AND FUNCTION PPC VALVES
SHOVEL PPC VALVE (FLOAT + RETURN TO DIG)
P2 P4
P3 P1
D D
T P
B A
C C
A B
RKZ08920
View Z
P1 port - To control valve (PB3 port)
P2 port - To control valve (PA3 port)
P3 port - To control valve (PA8 port)
P4 port - To control valve (PB8 port)
P port - From EV1 solenoid valve group (VL port)
Port T - To hydraulic tank
WB97R-5 10-73
STRUCTURE AND FUNCTION PPC VALVES
6
5 7
4 8
3
9
2
10
1
11
A-A C-C
D-D
B-B RKZ08980
1. Spool 7. Joint
2. Adjusting screw (inner) 8. Cover
3. Adjusting screw (outer) 9. Retainer
4. Piston 10. Piston
5. Disk 11. Body
6. Disk
10-74 WB97R-5
STRUCTURE AND FUNCTION PPC VALVES
OPERATION
1. Control lever in neutral position
• Shovel PPC valve • Shovel raise PPC valve
Control valve ducts A and B and PPC valve ducts P1 Control valve ducts A and B and PPC valve ducts P3
and P2 are connected to discharge chamber D by and P4 are connected to discharge chamber D by
means of the calibrated hole f in spool (1). means of the calibrated hole f in spool (1).
D D
f f
T T
P P
1 1
P2 P1 P3 P4
A Control B A Control B
valve valve
RKZ08990
WB97R-5 10-75
STRUCTURE AND FUNCTION PPC VALVES
2. During fine control (NEUTRAL o Actuator)
When the disk (5) starts pushing down on piston (4)
and piston (10), the retainer (9) moves as a result. 5
This movement will compress the spring (2) which
will in turn act on the spool (1) and push it 4
downwards.
As a result of this action, the calibrated hole f will be
isolated from the drain chamber D and at almost at
the same time it will be put in connection with the PP
chamber, which is directly connected to the
servocontrols circuit.
10
Pressure in the servocontrols circuit will flow
through the calibrated holef and into the circuit
9
thereby increasing the pressure in duct P1-B.
When pressure P1 increases, spool (1) is pushed
D
upwards, and calibrated hole f is connected back to
discharge chamber D thereby compressing the T
spring (2). P
The floating of the spool (1) will continue until
f
calibrated hole f is halfway between discharge PP
chamber D and pressure chamber PP, in other 1
words until the pressure in duct P1 – the pressure P2 P1
acting on the section of stem (1) – offsets the force
applied by the spring (2).
The spring (2) is compressed proportionally to the
movement of the disk (5) and therefore, pressure at
A Control B
valve
P1 increases in proportion to the travel of the disk
(5).
RKZ09000
The equilibrium position is then kept until the
position of piston (4) is changed, i.e.:
a) as long as pressures at ports B and P1 are
perfectly balanced;
b) until pressure in section B-P1 – i.e. the
pressure acting on stem (1) – is enough to
counteract the force of the spring (2).
This ensures proportionality between control lever
position, B-P1 circuit pressure, and main control
valve stem displacement.
10-76 WB97R-5
STRUCTURE AND FUNCTION PPC VALVES
3. During fine control
(Actuatoro NEUTRAL) 5
When the disk (5) is released and moved to neutral
position, the piston (4) is pushed upwards by the
spring (3) acting on the retainer (9), and spool (1) is 4
thrusted upwards both by the force of spring (2) and
by the force that the pressure in section B-P1
applies against the stem.
This movement moves the calibrated hole f of spool
(1) into the discharge chamber D, thereby allowing
pressure in section B-P1 to be released.
If pressure P1 drops too quickly, spool (1) is pushed
9
downwards by spring (2) and the calibrated hole f
becomes cut off from the discharge chamber D; at 3
almost the same time, the calibrated hole f is put in D
connection with pressure chamber PP and starts 2
supplying pressure to section P1 until the pressure p
T
corresponding to the control lever position is
P
balanced.
When the spool of the control valve returns, oil flows
f
back into chamber D, through calibrated hole f', and
into chamber B of the control valve spool opposite PP 1
the operating one. P2 P1
Oil flows through duct P2 and into chamber B to
ensure it is filled properly.
A Control B
valve
4. During fine control RKZ09010
(NEUTRAL o Full stroke)
When the disk (5) pushes down on the piston (4),
and the retainer (9) pushes down on the spool (1),
calibrated hole f is put in direct connection with
chamber PP, which is in turn connected to a 5
constantly pressurised servocontrols circuit.
Oil is then allowed to flow directly into section B-P1 4
thereby pushing the stem of the main control valve
to the end of its travel. This causes the main control
valve to send the oil contained in chamber AB
towards input P2, through calibrated hole f' and into
relief chamber D.
D
p
T
P
f
PP
P2 P1
A Control B
valve
RKZ09020
WB97R-5 10-77
STRUCTURE AND FUNCTION PPC VALVES
5. When control lever is moved to float position
If piston (4) and piston (10) of the spool controlling
the arm (port P4) are pushed downwards by disk 5
(5), the mechanism inside the PPC valve will start 4
locking the spool halfway along its travel.
4
If piston (4’) is pushed upwards and the solenoid in
the PPC valve is energized, the force generated by
the solenoid will retain the piston (4’) in place and
the arm float condition will be retained – even if the
lever is released.
At the same time, the control valve will also be
activated and retained in the arm float position.
11
6. When control lever is moved from float back 10
to neutral position
The disk (5) can be moved back to neutral position D
by applying a force that exceeds the force applied T
by the solenoid. P
The floating state can also be cancelled, and the
lever can move back to neutral position,
denergizing the solenoid.
PP
P3 P4
A Control B
valve
RKZ09021
10-78 WB97R-5
STRUCTURE AND FUNCTION PPC VALVES
OUTRIGGERS PPC VALVE
P2 P4
P4
P2
P1 P3
P T
RKZ09360
P1 P3
RKZ09350
Z
P1 port - To control valve (8 spools) (PA7 port)
To control valve (10 spools) (PA9 port)
P2 port - To control valve (8 spools) (PB7 port)
To control valve (10 spools) (PB9 port)
P3 port - To control valve (8 spools) (PA8 port)
To control valve (10 spools) (PA10 port)
P4 port - To control valve (8 spools) (PB7 port)
To control valve (10 spools) (PB10 port)
P port - To EV1 solenoid valve group (P2 port)
Port T - To hydraulic tank
WB97R-5 10-79
STRUCTURE AND FUNCTION PPC VALVES
2
3
4 5
RKZ09370
6 7
1. knob
2. Nut
3. Lever
4. Boot
5. Plate
6. LH PPC valve body
7. RH PPC valve body
10-80 WB97R-5
STRUCTURE AND FUNCTION PPC VALVES
OPERATION
1. Control lever in neutral position
P2 P1
A Control B
valve
RKZ09380
• Ports A and B of control valve and ports P1 and P2 of PPC valves are connected to the tank circuit.
• Hence, the spool is in neutral position.
WB97R-5 10-81
STRUCTURE AND FUNCTION PPC VALVES
2. During fine control (NEUTRAL o Actuator)
P2 P1
A Control B
valve
RKZ09390
• When the lever (1) is moved in the direction shown by the arrow, the valves (2) are rotated and a passage is opened
between delivery duct a and port P1, while port P2 remains conected to the tank circuit.
• Pressure at port P1 increases as the travel of lever (1) increases. Consequently, the spool of the control valve moves
to the left by a distance that is proportional to the travel of the lever (1).
10-82 WB97R-5
STRUCTURE AND FUNCTION PPC VALVES
3. Control lever at full stroke (Actuator o NEUTRAL)
P2 P1
A Control B
valve
RKZ10610
• When lever (1) is moved fully to the left, the valves (2) are fully rotated.
• Port P1 is then connected directly to delivery duct a whereas port P2 is connected to tank circuit only, and the spool
of the control valve performs its full travel.
WB97R-5 10-83
STRUCTURE AND FUNCTION PPC VALVES
BACKHOE LH PPC VALVE
P
T
2 4
3 View A
A
RKZ10250
1 port - To control valve (Port PB1) (Out arm)
Port T - To hydraulic tank
4 port - To backhoe control valve (Port PA2) (LH swing boom)
3 port - To backhoe control valve (Port PA1) (In arm)
P port - To EV1 solenoid valve group (VBH port)
2 port - To backhoe control valve (Port PB2) (swing boom)
10-84 WB97R-5
STRUCTURE AND FUNCTION PPC VALVES
BACKHOE RH PPC VALVE
1 T
P
2 4
3 View A
RKZ10260
Port 1 - To control valve (Port PB4) (raise boom)
Port T - To hydraulic tank
Port 4 - To control valve (Port PA5) (dump bucket)
Port 3 - To backhoe control valve (Port PA4) (lower boom)
Port P - To solenoid valve group (VBH port)
Port 2 - To control valve (Port PB5) (curl bucket)
WB97R-5 10-85
STRUCTURE AND FUNCTION SOLENOID VALVE GROUP (EV1)
SOLENOID VALVE GROUP (EV1)
BACKHOE VERSION WITHOUT 4 IN 1 BUCKET
ACC P1
2 3 4
5
1
A2
P2 P
PM T
B2 UL B1
RKZ10290
1. Y94 - Differential lock solenoid valve Port Acc - Accumulator
2. Y95 - Boom unlock solenoid valve Port P1 - Pressure tap
3. Y90 - Backhoe PPC solenoid valve Port P2 - To outriggers PPC valve
4. Y93 - PPC solenoid valve (Port P)
5. Y91 - Ecopower solenoid valve Port A2 - To boom unlock cylinder
Port B2 - To rear axle
Port VBH - To backhoe PPC valves
(Port P)
Port VL - To shovel PPC valve (Port P)
Port PM - To hydraulic pump (Port PM)
Port P - From control valve (Port PPPC)
Port T - To hydraulic tank
10-86 WB97R-5
STRUCTURE AND FUNCTION SOLENOID VALVE GROUP (EV1)
BACKHOE VERSION WITH 4 IN 1 BUCKET
ACC P1
2 3 4 5
6
1
7
A2
A1
P2 P
PM T
B2 UL B1
Hydraulic circuit
ACC B2 A2 PM UL B1 A1 UBH
P1
S2
S2
ORF1
CV1
P2 ø0.5mm
SV2
S1
S1 SV1 SV5
SV3 SV4
P T
RKZ10300
1. Y94 - Differential lock solenoid valve Port Acc - Accumulator
2. Y95 - Boom unlock solenoid valve Port P1 - Pressure tap
3. Y90 - Backhoe PPC solenoid valve Port P2 - To outriggers PPC valve
4. Y93 - PPC solenoid valve (Port P)
5. Y98 - Bucket curl solenoid valve Port A2 - To boom unlock cylinder
6. Y99 - Bucket dump solenoid valve Port B2 - To rear axle
6. Y91 - Ecopower solenoid valve Port VBH - To backhoe PPC valves
(Port P)
Port VL - To shovel PPC valve (Port P)
Port A1 - To control valve (Port PA6)
Port B1 - To control valve (Port PB6)
Port PM - To hydraulic pump (Port PM)
Port P - From control valve (Port PPPC)
Port T - To hydraulic tank
WB97R-5 10-87
STRUCTURE AND FUNCTION SAFETY VALVES
SAFETY VALVES
SHOVEL RAISE
a
A
b b
3 4
2
5
Pressione ∆p (bar)
Pressure ∆p (bar)
50
45
40
35
30
25 a
20 b
15
c
1 10
5
0 0
10 20 30 40 50 60 70 80 90 100
Portata Q (l / min)
Flow Q (l / min)
RKZ08040 SectionAA- -AA
Sezione RKZ08050
a. Port PiL - To the raise cylinders (Head side) COMPONENTS
b. Port V2 - From control valve (8-spool) 1 - Solenoid valve
(Port A6) 2 - Adjusting screw
From control valve (10-spool) 3 - Spring
(Port A8)
4 - Spool
c. Port C2 - To the raise cylinders (Bottom side)
5 - Unlock screw
CHARACTERISTICS
Safety valve calibration: 220 +0 10 bar
10-88 WB97R-5
STRUCTURE AND FUNCTION SAFETY VALVES
SHOVEL DUMP
c b
RKZ08060
Pressione Dp (bar)
Pressure Dp (bar)
24
20
16
b
a
12
0 12 24 36 48 60
Portata Q (l / min)
Flow Q (l / min)
RKZ08070
a. Port PiL - To the dump cylinder (Bottom side) CHARACTERISTICS
b. Port C2 - To the dump cylinder (Head side) Safety valve calibration: 220 +0 10 bar
b. Port V2 - From control valve (8-spool)
(B3 port)
WB97R-5 10-89
STRUCTURE AND FUNCTION SAFETY VALVES
BOOM
a
b
RKZ08080
Pressione Dp (bar)
Pressure Dp (bar)
35
28
21
a b
14
0 15 30 45 60 75 90 105 120 135 150
Portata Q (l / min)
Flow Q (l / min)
RKZ08090
a. PiL port - To the boom cylinder (bottom side) CHARACTERISTICS
b. V2 port - From control valve (B4 port) Safety valve calibration 1: 250 +0 15 bar
c. C2 port - To the boom cylinder (Head side) Safety valve calibration 2: 200 +0 20 bar
10-90 WB97R-5
STRUCTURE AND FUNCTION SAFETY VALVES
ARM
b
RKZ08100
24
Pressione Dp (bar)
Pressure Dp (bar)
20
16
b
12
a
0 25 50 75 100 125 150 175
Portata Q (l / min)
Flow Q (l / min)
RKZ08110
a. PiL port - To the arm cylinder (bottom side) CHARACTERISTICS
b. V2 port - From control valve (A1 port) Safety valve calibration 1: 300 +0 10 bar
c. C2 port - To the arm cylinder (Head side)
WB97R-5 10-91
STRUCTURE AND FUNCTION SHOVEL CYLINDERS
SHOVEL CYLINDERS
RAISING CYLINDER
7 2 6 1
5 4 3
8
707-00-0y891
1. Bottom bushing 4. Gasket 7. Head
2. Cylinder 5. Piston 8. Head bushing
3. Nut 6. Stem
DUMPING CYLINDER
7 2 6 5 4 3 1
8
707-00-0y920
1. Bottom bushing 4. Gasket 7. Head
2. Cylinder 5. Piston 8. Head bushing
3. Nut 6. Stem
10-92 WB97R-5
STRUCTURE AND FUNCTION SHOVEL CYLINDERS
4 IN 1 BUCKET
2 3 4 5 1
6 7
8
42N-6C-12800
1. Cylinder 4. Piston 7. Head bushing
2. Nut 5. Stem
3. Gasket 6. Head
CHARACTERISTICS
Cylinder Lifting Dump 4 in 1 bucket
Piston rod diameter 50 45 40
Internal cylinder diameter 90 70 70
Piston stroke 570 745 230
Max. cylinder length 1740 2145 705
Min. cylinder length 1170 144 475
Key size for piston safety nut 55 40 36
WB97R-5 10-93
STRUCTURE AND FUNCTION BACKHOE CYLINDERS
BACKHOE CYLINDERS
BOOM CYLINDER
11 8
7 6
3 5 9
2 4
1
707-02-0Y941
10
1. Bottom bushing 5. Piston 9. Bottom bushing
2. Stem 6. Gasket 10. Dowel
3. Head 7. Guide ring 11. Ball-bearings (no. 10)
4. Cylinder 8. Cushion plunger
ARM
7 8
6
3 5
2 4 10
1
9
707-00-0y871
1. Bottom bushing 5. Brake bushing 9. Nut
2. Stem 6. Gasket 10. Bottom bushing
3. Head 7. Guide ring
4. Cylinder 8. Piston
10-94 WB97R-5
STRUCTURE AND FUNCTION BACKHOE CYLINDERS
BUCKET CYLINDER
8
7 6
5
3 2 4 9
1
707-00-0y901
1. Bottom bushing 4. Cylinder 7. Guide ring
2. Stem 5. Piston 8. Nut
3. Head 6. Gasket 9. Bottom bushing
OUTRIGGER CYLINDER
3
2 6 4 5 7
707-00-0Y0910
1. Stem 4. Gasket 7. Nut
2. Head 5. Guide ring
3. Cylinder 6. Piston
WB97R-5 10-95
STRUCTURE AND FUNCTION BACKHOE CYLINDERS
BOOM SWING CYLINDER
5
1 2
11
8 4
3 7
6
12
707-02-07730
9 10
1. Retaining ring 5. Bushing 9. Guide ring
2. Restriction ring 6. Head 10. Piston seal
3. Stem 7. Bottom bushing 11. Spacer
4. Cylinder 8. Piston 12. Cushion plunger
JIG ARM CYLINDER
2 6 5
4
1 3
42N-6C-13301
1. Stem 3. Cylinder 5. Gasket
2. Head 4. Piston 6. Guide ring
10-96 WB97R-5
STRUCTURE AND FUNCTION BACKHOE CYLINDERS
CHARACTERISTICS
Cylinder Boom Arm Bucket
Piston rod diameter 60 55 55
Internal cylinder diameter 120 115 90
Piston stroke 850 700 765
Max. cylinder length 2160 1765 1850
Min. cylinder length 1310 1065 1085
Key size for piston safety nut – 55 55
CHARACTERISTICS
Cylinder Outriggers Boom swing Jig arm
Piston rod diameter 40 50 40
Internal cylinder diameter 70 100 70
Piston stroke 635 230 1140
Max. cylinder length 1690 319.5 2590
Min. cylinder length 1055 89.5 1450
Key size for piston safety 46 -- 46
nut
WB97R-5 10-97
STRUCTURE AND FUNCTION AIR-CONDITIONING UNIT
AIR-CONDITIONING UNIT
2
Low steam pressure
Low steam/fluid pressure
High steam pressure
AMBIENT AIR
Fluid high pressure
1a
3 1
8
5
7
9
CAB INTERIOR
RKZ03130
1. Compressor TECHNICAL DATA
2. Condenser • Circuit operating pressure with engine
3. Filter – dehydrator tank 2500 rpm at an ambient temperature of 25–30°C:
4. Safety pressure switch Regular pressure: 15–17 bar
Low pressure: 1.6-1.8 bar
5. Expansion valve
• Safe pressures:
6. Evaporator
High pressure: 26 bar
7. Clutch thermostat sensor Low pressure: 2.5 bar
8. Cab air circulation fans • Coolant fluid: R134a
9. Air feeder • Coolant quantity: 2250 ±150 g
10-98 WB97R-5
STRUCTURE AND FUNCTION OPERATION OF THE AIR CONDITIONING UNIT
OPERATION OF THE AIR CONDITIONING UNIT
The compressor (1) receives drive directly from the On leaving the evaporator (6), the coolant is drawn once
driving shaft through a belt, and compressor rotation is more into the compressor (1), and a new cycle starts.
caused by a pulley with electromagnetic clutch (1a). The extraction of heat from the atmosphere in which the
Clutch engagement and disengagement are controlled evaporator is located leads to the condensation of the
by the thermostatic sensor (7). When the evaporator water suspended in the air, and hence to
reaches the lower limit temperature, the thermostatic dehumidification. The condensate is deposited on the
sensor comes into operation to command clutch evaporator fins where, if a temperature higher than 0°C
disengagement. When the evaporator reaches the is not maintained, it freezes and inhibits the functioning
higher limit temperature, the thermostatic sensor of the evaporator.
commands clutch engagement. The task of keeping the temperature of the evaporator
The coolant fluid (in gaseous phase) is drawn into the above 0°C (and thus within the optimum limits for heat
compressor where it is subjected to compression and an exchange) is entrusted to a thermostatic sensor (7).
intense heating process; the compressed and heated The condensate that forms on the evaporator fins (6)
fluid is then sent into the condenser (2). Here, it reaches also contains dust, pollens and particles suspended in
condensation temperature as a result of heat extraction the air. Continual condensation therefore effectively
due to the air flowing through the condenser fins, and the purifies the air, and the droplets of condensate are
fluid switches to a high-pressure liquid state. released to the exterior.
Subsequently the coolant passes into the drying-filter A fixed quantity of anti-freeze oil is also introduced into
assembly (3) which performs three functions: it filters out the circuit, with the function of lubricating all the
impurities, absorbs any moisture from the circuit and, mechanical parts of the A/C system. A percentage of this
finally, also functions as a reserve tank. oil circulates constantly throughout the A/C system in
The coolant in its liquid state is then transferred to the atomised form, lubricating the compressor (pistons and
evaporator (6), first passing through an expansion bearings) and the expansion valve.
valve(5). The task of this valve is the constant metering A pressure switch (4) has been inserted in the electrical
of the quantity of fluid in order to maintain optimum control circuit to protect the A/C system in the case of a
evaporation. lack of coolant fluid or if the quantity of fluid becomes
In the evaporator, the coolant fluid is subjected to insufficient due to leakages. This switch will inhibit the
expansion, bringing it up to the critical evaporation point engagement of the electromagnetic clutch and hence
at a temperature of approximately -- 8°C. the functioning of the air-conditioning system.
The flow of air generated by centrifugal fan (8), which
passes through the evaporator (6) at ambient
temperature is considerably warmer than -- 8°C. For this
reason it yields heat to the coolant fluid, bringing it up to
boiling point and complete evaporation.
WB97R-5 10-99
PAGE INTENTIONALLY
LEFT BLANK
STRUCTURE AND FUNCTION FUSE AND RELAY CENTRE
FUSE AND RELAY CENTRE
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
POS CODICE DESCRIZIONE
1 00105013 INTERMITTENZA ELETTRONICA 12V 1
2 01171064 CENTRALINA ANTIRIPETIZIONE AVV. 12V 1
2 ITALY ITALY
1
3 1B020459 CIRCUITO STAMPATO 1 ART 01171064 ART 00105013
ANTIPETIZIONE AVV.
ING.IN FREQUENZA INT.ELETTRONICA
4 120231 TERMINALE DI POTENZA M6 1 53M I
TENSIONE 53M I
TENSIONE 6
12V 12V
53S 53S
15 15
5 120232 TERMINALE DI POTENZA M5 2
T 31 T 31
3
6 124004 CONNETTORE PORTARELE'SCHEDE 2
7 124526 CONNETTORE PORTAFUFIBILE 5 VIE 5
25
8 125188 CONNETTORE MARK II 11V SCHEDE 1
9 125191 CONNETTORE MARK II 9V SCHEDE 1 26
18
10 125223 CONNETTORE MARKII 7VIE SCHEDE 1 9 8 15 17 16 11 14 12 24
11 125224 CONNETTORE MARKII 17VIE SCHEDE 1
12 125225 CONNETTORE MARKII 21VIE SCHEDE 1
13 157137 RELE' CM1-DP-12V 9
14 163005 FUSIBILE A LAMA 7.5 A 5 10
15 163006 FUSIBILE A LAMA 15 A 6
7.5
7.5
7.5
10
10
10
10
10
15
15
15
15
3
5
16 163007 FUSIBILE A LAMA 10 A 11
17 163010 FUSIBILE A LAMA 3 A 2 21 19 5
18 163031 FUSIBILE A LAMA 5 A 257005 1
22 20 4
19 190288 ROND.EL.SP.5,3X8,9X1,2 UNI1751 INOX 2
7.5
7.5
10
10
15
15
10
10
10
10
REV.B
20 190289 ROND.EL.SP.6,4X11,3X1,6 UNI1751INOX 1
21 19 5
21 190468 DADO M5 UNI 5588-65 INOX 2
22 190479 DADO M6 UNI 5588 INOX A2 1
23
NAiS
NAiS
NAiS
NAiS
NAiS
NAiS
NAiS
NAiS
NAiS
23 190534 DADO M4 BLOK UNI 7473 INOX A2 4
12V
12V
12V
12V
12V
12V
12V
12V
12V
24 191368 RONDELLA 3,5X13,6X2 CERTENE 4
25 191369 RONDELLA 4,4X10X1,1 NYLON 4
26 191804 ANTIVIBRANTE M/F M4X10 H15 INOX 4 7 13 42N-06-15140
WB97R-5 10-101
STRUCTURE AND FUNCTION DRIVER SEAT WIRING
DRIVER SEAT WIRING
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
X61
Rele servizi
X56
Rele cons. avviamento
X159 X5.s
Centralina ATC 26 X158 85
87
85
X17.1
A CENTRALINA
30
BUZZER
87
Centralina ATC26 86 86
30
6
5
7
7
3
X17.2
8
2
+15
4 6
9
1
5
10
3
1
11
2
2
12
1
12
3
11
4
10
5
BUZZER
6
8
7
21
X3.s
11
20
10
19
9
18
A CENTRALINA
8
X555 X8.p
17
7
2.5A
16
Diodo A linea cambio
15
X44.p
14
3
13
2
12
A linea cabina
1
10
7
4
11 1
8
5
12 2
X47
9
6
3
X43 16 13
10 7
11 8
4 1
5 2
X46
Pannello strumenti
17 14
18 15
12 9
6 3
Manipolatore
Freno di stazionamento
1 7 8 9 10
11 12
X6
X11.p
11
6 5 4
17 16
3 2
X48 A CENTRALINA
1 2 1
9 8
X2.s
10
20
15
FUNZIONI MACCHINA A linea elettrovalvole
14
Ev flottante
6
A CENTRALINA
13 12
4 3
1
13
2
3
4
5
1
6
7
8
2 10
11 10
A
X42
14 7
2 1
A
B 11 4
15 8 1
B 12
C 5
C 9 2
6
3
Tergi posteriore
1
2
3
4
5
6
7
8
4
3 2
X1.s
1
11 10
6
1
5
2
A CENTRALINA
4
X49 Gnd1.3
9
3
8
2
X41.s
7
1
Ev return to d.a.g.
Pulsante posteriore claxon X7.p
2
A linea motore
1
13
14
10
15
11
7
12
4
9
1
6
2
5
X4.s
3
4
Gnd1.2
8
3
2
A CENTRALINA
7
1
6
X40
Micro sedile
1
2
4
3
B
A
X13
C
Gnd1.1 Sensore retorn to dig
X30.1
Accendisigari
X30.2
Luce servizio
+15Key
21
20
18
19
+15 KEY scheda fusibili
17
15
16
14
12
13
X10.p
11
10
9
8
6
7
5
3
4
2
X28.s X68.1 A linea cruscotto anteriore
1
X65.p
A
Alimentazione gruppo +30
B
+50 start
riscaldamento X24.br
Alim. fusibile
X27.s elettrostop
1
2
A/C X45 15
18
17
86 rele preriscaldo
1 2 12 14 16
9 11 13
6
2.5A
8 10
3 5 7
X15.p
2
X24.r1 X24.b
4
1
X9.p
Quadro avviamento X24.acc Quadro avviamento Alimentazione OPT X23 A linea cruscotto anteriore
vpos. R1 pos. B
Quadro avviamento
pos. Acc
+30 Diodo
+30 centralina rele 3
2
6
5
9
8
X24.c
1 4 7
6
3
Quadro avviamento
5
2
X77.p
4
1
pos. C
X68.2 A linea ATC 26
Alimentazioni +30 X12.p
3
X61.1 A linea posteriore
2
6
1
9
4
12
7
11
15
30 rele servizi
X26.p
10
14
18
13
17
21
16
20
19
Pannello SW
X56.1
6 9
42N-06-11870
2 5 12
8 9
1 6
4 3 11
7 8
5
30 rele preriscaldo
2
Gnd10
10
Gnd11
7
4
1
X25.p
Pannello SW X160 X68.3 B
A linea interruttore +30 rele candelette +30 rele preriscaldo
Gnd9 X24.gnd
10-102 WB97R-5
STRUCTURE AND FUNCTION SWITCH PANEL WIRING
SWITCH PANEL WIRING
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
3
5
2
4
1
X80
8
1
4
INTERRUTTORE RIDE CONTROL
5
3
6
X85
PULSANTE AVV. ACUSTICO POSTERIORE X25.s
A L. POSTO GUIDA
9 6 3
8 5 2
7 4 1
3
5
2
4
1
X81
8
8
PULSANTE SBLOCCO BRACCIO
1
4
2
5
3
X86
INTERRUTTORE GENERALE LUCI
7
8
4
1
5
2
6
3
X87
INTERRUTTORE 4WD
3
5
2
4
1
7
8
X82
INTERRUTTORE SBLOCCO PIASTRA
19 16
7
13
4 20 17
7
8 14
11 10 4
1
5 21 18
1
8
15 5
6 12 2
2
9
6
3
3
X88
PULSANTE PPC X26.s
A L. POSTO GUIDA
3
5
2
4
1
X83
8
PULSANTE E/C POWER
8
7
1
4
2
X89
3
INTERRUTTORE WARNING
150
OH
M1
/4 W X181
1A LIMITATORE DI CORRENTE
X180
6
LIMITATORE DI CORRENTE PER SPIA
3
5
2
4
1
7
X84
8
INTERRUTTORE VALVOLE EMPI 42N-06-11850
WB97R-5 10-103
STRUCTURE AND FUNCTION FRONT DASH WIRING
FRONT DASH WIRING
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
X59.1
Livello olio freni
X60
Devio luci
7
8
9
10
X59.2
6 11
5 12
4
3
2
Livello olio freni 1
X58
1
X10.s Motore tergi anteriore
2
3
A linea posto guida
4
3
5
6
2
9
1
12
4
15
11
7
18
14
10
21
17
13
X63
20
16
19
Strumento anteriore
8
16
7
15
6
14
5
13
4
12
3
11
2
10
1
9
12
11
6
10
5
9
4
8
3
X64
2
1
1
Strumento anteriore
2
4
3
7
6
10
8
11
9
13
12
14
16
X9.s
15
17
_
18
A linea posto guida X55
I
Pompetta
X54.2
Sw luce stop
6
5
4
3
2 7
1 8
9
10
11
12
X57
X53.1 X54.1 Devio cambio 42N-06-11520
Sw stop Sw luce stop
X53.2
Sw stop
10-104 WB97R-5
STRUCTURE AND FUNCTION LATERAL DASH WIRING
LATERAL DASH WIRING
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
X25.s
14
15
12 A L. POSTO GUIDA
13 11 9
10 8 6
5 3
7
7
X85 4 2
4
1
5
PULSANTE AVV. ACUSTICO POSTERIORE
6
X167
INTERRUTTORE GIROFARO
X86 3
2
1 8
8
X168
7
7
INTERRUTTORE GENERALE LUCI
4
5
6
4
2
INTERUTTORE FARI LAVORO ANTERIORI
5
3
3
2
6
6
1
5
8
4
7
X87
8
7
1
INTERRUTTORE 4WD
2
5
3
19 16 13
20 17 14 11 8
21 18 15 12
X26.s
a
10
A L. POSTO GUIDA
9
4
6
5
1
3
2
6
3
5
X169
7
2
4
8
1
1
X88 INTERRUTTORE FARI LAVORO POSTERIORI
5
8
2
PULSANTE PPC
3
7
8
4
9
5
1
6
2
3
X166.s
A L. POSTO GUIDA
X80
8
6
1
INTERRUTTORE RIDE CONTROL
4
7 3
2
2
1
3
X83
PULSANTE E/C POWER
X181
LIMITATORE DI CORRENTE
/4 W
M1
OH
7
150
4
8
5
1
X81
1A
6
2
3
6
PULSANTE SBLOCCO BRACCIO
4 5
7
2 3
8 1
X84
INTERRUTTORE VALVOLE EMPI
X180
LIMITATORE DI CORRENTE PER SPIA
7
4
8
5
1
X89
6
2
42N-06-11950 INTERRUTTORE WARNING
WB97R-5 10-105
STRUCTURE AND FUNCTION ROOF WIRING
ROOF WIRING
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
X141
Interruttore girofaro
X140
Interruttore fari lavoro X138
posteriori
Faro di lavoro posteriore
SX laterale
4 1
3 2
X142 X136
Interruttore fari lavoro Faro di lavoro posteriore
anteriori DX laterale
4
3
1
X147.2
2
3
8 2
1
1 8
Faro anteriore SX 2 6
3 7 5
4
4 7
X147.1 5
X147.3 Faro anteriore SX
6
Faro anteriore SX
2
6
X147.4
1
5
Faro anteriore SX
8
4
7
X147.5
Faro anteriore SX
X148.2 Gnd8
Presa girofaro
X151.1
Faro ant. DX
16
17
18
13
X148.1
14
15
10
11
12
Presa girofaro
7
8
4
9
X44.s
5
6
1
2
2
A linea posto guida
1
3
X151.2
2
1
3
4
Faro ant. DX
4
X146 X143 X151.5
Faro di lavoro
anteriore SX laterale
Faro lavoro ant. DX lat. Faro ant. DX Gnd7.3
X151.3
Faro ant. DX
X151.4
Faro ant. DX
Gnd7.1
X152.2
3
2
Plafoniera
1
X152.1
4
5
6
Plafoniera 42N-06-11830
a Gnd7.2
10-106 WB97R-5
STRUCTURE AND FUNCTION ENGINE WIRING
ENGINE WIRING
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
X117
Elettrostop
X115
Sensore press. olio motore
X116
Elettrofrizione compressore
X114
Candelette
X112
Termistore
B
A
X128.s
+50 avviamento
X113
X126.4
1
Filtro aria
2
87 rele preriscaldo
X121
Avvisatore acustico
1
2
Gnd6
GND
13
14
10
15
11
7
12
8
X7.s
9
5
1
6
2
3
A linea cabina
2
1
2
X118.1
1
+50 START
X60 B
Valvole emp. Conn.DT 2 vie F.
Conn. DT 2 vie M.
Gnd5
X119.1 Punto di massa
W alternatore
X119.2
D+ alternatore
42N-06-11160
WB97R-5 10-107
STRUCTURE AND FUNCTION SPEED SELECTOR WIRING
SPEED SELECTOR WIRING
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
X203
X200
Ev 2° marcia Ev 4° marcia
1 1
2 2
X8.s
A linea posto guida X202
Ev 1° velocità
X77.s
3
1
9 6
2
12 2
5
X207
8
11
A CENTRALINA ATC 24 10
7 4
1
Pompa travaso
3
1
2
6
2
1
5
9
4
8
7
X206 X208
Ev 3° marcia Seg. troppo pieno
1
2
X210
Temp. olio trasmissione
Gnd 1.1
Occhiello di massa
B
A
X209
Galleggiante
1
X201
2
X211 Ev marcia avanti
Sensore cardano
1
2
1
2
X204
Ev doppia trazione X205
Ev retromarcia
42N-06-11280
10-108 WB97R-5
STRUCTURE AND FUNCTION BACKHOE WIRING
BACKHOE WIRING
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
X90
2
Ev. PPC retro
1
Gnd2.2
Gnd2.1
X91
2
Ev ecopower
1
Gnd2.3
X94
2
Ev blocco differenziale
15
14
12
13
11
9
10
6
7
X11.s
3
4
2
1
X95 A linea posto guida
2
Ev sblocco braccio
1
X99
Ev apertura benna 2
1
X98
4
5
1
6
2
2
3
Ev. chiusura benna
1
X12.s
X92 A linea posto guida
2
Back-up allarm
1
X93
2
Ev. PPC
1
X96
2
Ev sblocco piastra
1
X100
Fanale posteriore DX
1
2
X97
Sw avvisatore acustico posteriore
X101
Fanale pesteriore SX
X103
42N-06-11450 Luce targa
WB97R-5 10-109
STRUCTURE AND FUNCTION JIG ARM WIRING
JIG ARM WIRING
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
X5
2
Ev rientro
1
X6
2
Ev sfilo
1
X1.p
A linea cabina telescopico
X7
2
Ev martello
1
4
1
bb
2
3
5
Gnd
42N-06-11340
10-110 WB97R-5
STRUCTURE AND FUNCTION WIRING DIAGRAM (STANDARD VERSION) (see also Group 90)
WIRING DIAGRAM (STANDARD VERSION) (see also Group 90)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
42-N-06 42-N-06 42-N-06
15120 11850 11830
V-Z1
42N-06-15510
G-V1.5
A-G1
A-G1
V/N1
M-B1.5
G-V1
M-N1.5
C-L1
C-L1
L-N1.5
G-N1
L-R1
L-R1
A 1 2 3 4
G-M1
C-L1
C-L1
L-R1
L-R1
A/B1
C-B1
G/R1
G-L1
R-N1
L-B1
H-V1
N1
N1
N1
H1.5
N1
N1
M1
R/N1
A/R1
A/R1
H-V1
R/N1
C-L1
L/R1
V-N1
V-N1
V-Z1
A1
R1
N1
N1
N1
N1
N1
N1
4 2 8 5 7 4 1 9 10 12 8 7 2 P63 1
7 1 3 4 6 7 1 3 4 6 4 6 1 3 7
X57 X57 X57 X57 X57 X60 X60 X60 X60 X60 X60 X180 1 1 1 1
X142
X142
X142
X142
X142
X141
X141
X141
X141
X141
X140
X140
X140
X140
X140
1 3 4 6 7 X146 X143 X136 X138
R N F Out1 Out2 56 1 L R 31b 53 15 53c 7 1 3 7 1 3 7 1 3
WASHER X89 X89 X89 X89 X89
N F 0 X80 X80 X80 X81 X81 X81 X82 X82 X82 7 1 3 4 6 7 1 3 4 6
R I 2 Dx LAVACRISTALLO I
1 3 4 6 7
0 1 4 6 1 3 7 E146 E143 E136 E138
7 1 3 7 1 3 7 1 3 II I 0 II I 0
HORN V180 1 0 0 1 1 0 0 1 5 2 8
Sx CLAXON
X146 X143 X136 X138
H 8 2 5 8 2 5
X141 X141 X141 Nome/Item Descrizione Description KUE P/N
+ 56b 56a 49 H
S89 8 2 5
S80 8 2
S81 8 2
S82 8 2 S140 X140 X140 X140 S142 X142 X142 X142 S141 A6 FUNCTION MACHINE UNIT
S57 9 S60 5 3 11 6
8 2 5
8 2
8 2 8 2 8 2 5 8 2 5 5 2 8 4 4 4 4 A CENTRALINA FUNZIONI MACCHINA
X89 X89 X81 X81 X82 X82 B13 SENSORE RETURN TO DIG RETURN TO DIG SENDER
X60 X60 X60 X60 1 X89 X80 X80
A-G1.5
A-G1.5
G-N1.5
G-N1.5
A-G1
A-G1
G-V1
G-V1
B59 Livello olio freni BRAKE OIL LOW LEVEL SWITCH
L-R1
C-L1
C-L1
X181
R1
N1
N1
N1
N1
H-R1
G-M1
A-G1
A-B1
A-G1
G/R1
A/R1
A/R1
A/R1
A/R1
B112 Termistore Thermistor switch
C-L1
C-L1
L/R1
V/N1
V-N1
V-Z1
H1
C1
V1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 9 10 11 12 B113 Filtro aria Air filter blocked switch
X64 B115 Sensore press. olio motore Engine oil low pressure switch
X63
42-N-06 B121 Avvisatore acustico Horn
L-B0.5
C-L0.5
V0.35
G-M1
M/B1
M-N1
A-R1
B-V1
A-V1
S-G1
A/V1
S-N1
H-V1
R-V1
Z-B1
S/N1
V-N1
G1
N1
H1
S1
V1
B209 Galleggiante Fuel level sender
11520 B210 Temp. olio trasmissione Gearing oil temperature sensor
B211 Sensore cardano Cardan sensor
A-B1
B-N1
B-N1
A-N1
A-N1
R/N1
S-N1
R/N1
N1
N1
N1
N1
E100 Fanale podteriore DX Right rear beam
E101 Fanale posteriore SX Left rear beam
7 1 3 7 1 3 7 1 3 E103 Luce targa Plate light
X83 X83 X83 X85 X85 X85 X84 X84 X84 E136 Faro di lavoro posteriore DX laterale Lateral right rear working light
7 1 3 7 1 3 7 1 3 E138 Faro di lavoro posteriore SX laterale Lateral left rear working light
0 0 0 1
1 1 E143 Faro lavoro ant. DX lat. Lateral right front working light
E146 Faro di lavoro anteriore SX laterale Lateral left front working light
8 2 8 2
S83 8 2 S85 S84 E147 Faro anteriore SX Left front light
X83 X83 X85 X85 X84 X84 E148 Girofaro Beacon lamp
8 2 8 2 8 2
E151 Faro ant. DX Right front light
A-B1
A-B1
A-N1
E152 Plafoniera Room lamp
R/N1
R/N1
S-N1
R/N1
R/N1
Z-N1
F1 FUSIBILE FARI LAVORO ANTERIORI CENTRALI 15A Central front working light fuse 15A
F2 FUSIBILE FARI LAVORO POSTERIORI CENTRALI 15A Central rear working light fuse 15A
F3 FUSIBILE LUCE POSIZIONE DX 3A Right position light fuse 3A
F4 FUSIBILE LUCE POSIZIONE SX 3A Left position light fuse 3A
F5 FUSIBILE AVVISATORE ACUSTICO 10A Horn fuse 10A
M-N1
B-G1
A-B1
A-B1
G-L1
H-L1
S/N1
Z/N1
G1
N1
N1
N1
N1
N1
F6 FUSIBILE FARI LAVORO POSTERIORI LATERALI 15A Lateral rear working light fuse 15A
L/R1
F7 FUSIBILE TERGI POSTERIORE + AVVISATORE ACUSTICO POSTERIORE 7,5A Winshield wiper-washer + rear horn fuse 7,5A
7 1 3 4 6 7 1 3 4 6 1 3 7 F8 FUSIBILE SWITCH LUCI STOP 7,5A Stop light swicth fuse 7,5A
X86 X86 X86 X86 X86 X88 X88 X88 F9 FUSIBILI FARI LAVORO ANTERIORI LATERALI 15A Lateral front working light fuse 15A
G-V1.5
X87 X87 X87 X87 X87
A-B1
G-N1
H1.5
H1.5
V1.5
V1.5
G1
A1
7 1 3 7
R1
7 1 3 4 6 F10 FUSIBILE ALIM. TERGI ANTERIORE 10A Front windhield-motor supply fuse 10A
L-N1
0 1 4 6 1 3
N1
N1
A/B1
H1.5
II I 0 0
R-G1
R-N1
F11 FUSIBILE OPTIONAL 7,5A Optional fuse 7,5A
A/V1
1
2 4 3 1 5 2 8 F12 FUSIBILE BUZZER+STR.ANTERIORE+STR.LATERALE 5A Front + lateral instruments + buzzer fuse 5A
S87
56a X147.2
8 2
X151.2
1 1 1 X58 X58 X58 X55 UNIT A6 S86 8 2 5
S88 X87 X87 X87 - - - - - - - - 1 1 F13 FUSIBILE ALIM. MANIPOLATORE10A Supply level grip fuse 10A
X59.1 X86 X86 X86 X88 X88 5 2 8 X148.1 X152.1
X53.1 X54.1 F14 FUSIBILE LAMPADE SWITCH + SWTCH OPTIONAL 10A Light switch + swicth optional fuse 10A
8 2 5 8 2
S53 S54 B59 53a
MULTIFUNCTION 01171079 F15 Fusibile elettrostop + sicurezza avviamento 10A ELETTROSTOP + SAFETY STARTER FUSE 10A
G1.5
M
56b
56a
56b
G1
53 M 53b
57
57
R
L
M-N1
A-B1
A-B1
31b F16 FUSIBILE GIROFARO 10A Beacon light fuse 10A
H-L1
H-L1
Z/N1
Z/N1
M
31 F17 FUSIBILE SWITCH EMERGENZA 10A Warning swicth fuse 10A
M55
31
31
1 1 1 F18 FUSIBILE PLAFONIERA+ACCENDISIGARI 10A Cabin lamp + cigarette lighter fuse 10A
M58
X53.2 X54.2 X59.2 E147 - - E151
NEUTRAL POSITION STEERING COLUMN
1 2 F19 FUSIBILE ANABBAGLIANTI 15A Low beam fuse 15A
X58 X55
X147.1 X151.1 1 E148 E152
N1.5
N1.5
N1.5
X148.2 X152.2 F20 FUSIBILE ABBAGLIANTI 15A Main beam light 15A
R-G1
B-R1
C-B1
FUNCTION MACHINE UNIT SUPPLY
N1
N1
N1
N1
N1
+15 MULTIFUNCTION UNIT SUPPLY
SELF CONTROL SOLENOID VALVE
N1
F21 FUSIBILE ALIM. SENSORE RETURN + DIG 10A Return sender supply + DIG fuse 10A
REVERSE PPC SOLENOID VALVE
MULTIFUNCTION UNIT SUPPLY
F22 FUSIBILE EC POWER 7,5A EC POWER FUSE 7,5A
DIFFERENTIAL LOCK SWITCH
EC POWER SOLENOID VALVE
CONSENT TOGETHER PEDAL
LIGHT PPC SOLENOID VALVE
F23 FUSIBILE +15 CENTRALINA STERZATURA 10A +15 STEERING UNIT FUSE 10A
M-B1.5
L-B0.5
LIGHTS AND SWITCH 4WD
L-N1.5
C-L0.5
A-G1.5
A-G1.5
G-N1.5
G-N1.5
G-M1
G-M1
M/B1
M-N1
A-G1
M-N1
A-B1
A-G1
A-B1
A-B1
R-G1
C-B1
A-R1
A-N1
B-N1
G-N1
B-V1
H-R1
G/R1
S-G1
R-N1
H-R1
G/R1
L-B1
A-V1
G-L1
A/R1
G-V1
Z-B1
H-V1
R-V1
S-N1
H-V1
C-L1
H-L1
R/N1
S/N1
S/N1
V/N1
V-N1
V-N1
V-N1
G1.5
Z/N1
Gnd7.1
H1.5
H1.5
V-Z1
V1.5
V1.5
M1
A1
H/R1
A1
G1
PPC CONTROL SWITCH
H1
N1
C1
N1
R1
R1
N1
S1
F24 FUSIBILE ALIM. INTERMITTENZA 7,5A FLASHER FUSE 7,5A
4WD SOLENOID VALVE
EC POWER SWITCH
F25 FUSIBILE SIRENA RETRO + ALIM. DEVIO 10A REVERSE SPEED BUZZER + STEERING COLUMN 10A
PPC SEAT SWITCH
2nd GEAR SIGNAL
X10.s 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 X9.s 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 X25.s X26.s 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 19 20 21 X44.s 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
1st GEAR SIGNAL
F27 FUSIBILE GENERALE 175A General fuse 175A
SEAT SWITCH
4WD SWITCH
OUT BUZZER
G1 Batteria Battery
X10.p 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 X9.p 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 1 2 3 4 5 6 7 8 9 X25.p X26.p 1 2 3 4 5 6 X44.p G118 Motorino avviamento Starter
R1 ACC BR R2 C 7 8 9 10 11 12 13 14 15 16 17 19 20 21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
R1OFF ACC
G119 Alternatore Generetor
A-G1.5
A-G1.5
G-N1.5
G-N1.5
CAVO1 V0.35
R-N1.5
L-B0.5
L-N1.5
C-L0.5
M-N1
G-M1
G-M1
ST
M/B1
M-N1
M-N1
A-B1
A-B1
B-R1
R-G1
C-B1
B/G1
B-N1
G-N1
B-V1
H-R1
G/R1
A-V1
G-L1
G/R1
G-L1
A/R1
G-V1
GND
H-L1
H/R1
H-V1
R-V1
H-V1
R/N1
H/R1
S/N1
V/N1
V-N1
V-N1
V-N1
V-N1
G1.5
Z/N1
N1.5
N1.5
R1.5
H1.5
H1.5
N2.5
V-Z1
V1.5
V1.5
M1
G1
A1
G1
H1
C1
R1
N1
V1
H17 BUZZER BUZZER
S24 B
X6 A1 A2 A3 A4 A5 A6 A7 A8 B1 B2 B4 B5 B6 B7 B8 C1 C2 C3 C4 C5 C6 C7 C8 K1 CENTRALINA ANTIRIPETIZIONE AVVIAMENTO Unrepeat start unit
K2 INTERMITTENZA Flasher
X24.r1 X24.acc X24.b X24.br X24.c X24.gnd
B-R1.5
G-M1
A-B1
A-B1
S1 S2 S3 S4 S5 S6
M-V1
M-V1
C-B1
B-N1
B/G1
B-R1
C-N1
K3 RELE' ANABBAGLIANTI Low beam relay
Z-B1
H-L1
S-N1
H/R1
H/N1
S/N1
Z-N1
Z/N1
L/R1
M1
N1
S1
M/N1
M/N1
N1.5
K4 RELE' ABBAGLIANTI Main beam relay
B1
R6
L6
K5 RELE' avvisatore acustico anteriore Front horn relay
K6 RELE' ELETTROVALVOLA RETURN TO DIG Return to DIG solenoid valve relay
K7 RELE' LUCI STOP Light stop relay
K8 RELE' CONSENSO AVVIAMENTO Assent start relay
C-B1
M-V1
M-N1
A-B1
M-B1
C/B1
C-N1
Z-N1
N1
N1
K9 RELE' MARCIA AVANTI Forword speed relay
K10 RELE' MARCIA INDIETRO Reverse speed relay
K11 RELE' STACCO TRASMISSIONE Stop drive relay
X158 1 N1
M-N1 X47 1 K45 Rele' preriscaldo Preheating Relay
2 A1
M-B1
C-B1 2 K56 Rele' consenso avviamento Starting relay
3 M-N1
M1
C/B1 3 K61 Rele' servizi Service realy
4 C-N1
M-B1 4 M42 Tergi posteriore Rear Windshield-washer
5 CAVO3 V0.35
C-N1 5 M55 Pompetta Motor pump
6 L-B1
Z-N1 6 M58 Motore tergi anteriore Front windshild-washer
7 G/R1
A-B1 7 M116 ElettrofrIzione compressore Compressor Electonic cluch
8 B-V1
N1 8 R114 Candelette Preheating
9 M-B1
9 S1 INTERRUTTORE FUNZIONE KICK DOWN KICK DOWN SWITCH
10 L/B1
M-V1 10 S2 INTERRUTTORE ELETTROVALVOLA EC POWER SOLENOID VALVE E.C. POWER SWITCH
11 A-R1
11 S3 INTERRUTTORE CHIUSURA BENNA LOCK GRAB SWITCH
12 H-R1
12 S4 INTERRUTTORE STACCO TRASMISSIONE DECLUCH SWITCH
42-N-06
S5 INTERRUTTORE APERTURA BENNA OPEN GRAB SWITCH
15720 S6 INTERRUTTORE BLOCCO DIFFERENZIALE DIFFERENTIAL LOCK SWITCH
H97 CLAXON POSTERIORE REAR HORN
S24 Quadro avviamento Starting switch
S40 Micro sedile Seating switch
S41 PULSANTE POSTERIORE CLAXON Rear horn Switch
L-N1.5
C-B1
C-B1
M/N1
C-B1
S46 Freno di stazionamento Parking brake switch
N1.5
A-R1
M-B1
M-B1
A-G1
B-G1
M/B1
C-L1
N1
V6
N1
B-N1
S53 Interruttore luci stop Stop light switch
C-L1
S/N1
X15p 2
B6
N1 1 2 3
S54 Interruttore stop 4wd Stop 4wd witch
M16
A-N1.5 X17.1 1 2 1 S40 86 87 X42
X15p 1 1 B A C 86 87 1 2
X61 X61 1 S57 Devio cambio Steering column gear switch
1 Y49 X49 X13 X13 X13 X555 Y48 X48 X23 X23 K45 M42
K56 X56 X56 K61 86 87 X45 S60 Devio luci Steering column light switch
V555 86 87 86 87 M M
S80 INTERRUTTORE RIDE CONTROL Ride control switch
85 30 S81 PULSANTE SBLOCCO BRACCIO Arm unlock switch
85 30
H17 B13 1 2 3 4
85 X61.1
85 30 S82 INTERRUTTORE SBLOCCO PIASTRA Plate unlock switch
2 85 X56.1 2 B S83 PULSANTE E/C POWER E/C Power Switch
P43 1 X40 V23
R6
B-N1
R16
N1
R6
S84 INTERRUTTORE VALVOLE EMPI EMPI solenoid valve switch
M-V1
X17.2
H/N1
N1
N1
N1
S85 PULSANTE AVV. ACUSTICO POSTERIORE Rear horn switch
R-G1
S86 INTERRUTTORE GENERALE LUCI General light switch
X43 1 R-G1 S87 INTERRUTTORE 4WD 4WD Switch
2 G-N1 S88 PULSANTE PPC PPC switch
15
10 20 3 R1 S89 INTERRUTTORE WARNING WARNING switch
RPM x 100
5 25 4 B-N1 S140 Interruttore fari lavoro posteriori Rear working light switch
A-G1
H-R1
G/R1
H-R1
5 H-N1 H-L1 S141 Interruttore girofaro Beacon light switch
N1.5
0 30 X160.p
6 Z-N1 H/R1 1 S142 Interruttore fari lavoro anteriori Front working light switch
R6
L6
V6
7 C-L0.5 7 6 5 4 3 2 1 G-N1 2 Y48 Ev flottante Float solenoid valve
X5.s +15Key +30 +15Service
8 C-B1 3 Y49 Ev return to d.i.g. Return to Dig solenoid valve
9 A-V1 X3.s 1 H-G1 Y60 Valvole emp. EMP Solenoid Valve
42N-06-15140 X4.s 1 R1 M-B1
4
10 B-V1 R-N1.5 2 5 Y90 Ev. PPC retro Rear PPC solenoid valve
11L-B0.5 B-R1.5 3 F25 F14 F13 F12 F24 F21 F7 F22 F18 F16 F17 2 R-N1.5 N1 6 Y91 Ev ecopower EC power Solenoid valve
13 M/N1 4 10A 10A 10A 5A 7,5A 10A 7,5A 7,5A 10A 10A 10A 3 H1 CAVO3 V0.35 7 Y92 ELETTROVALVOLA ALLARME MARCIA INDIETRO Back-up allarm solenoid valve
14 Z-B1 Z-N1 5 4 V1 8 Y93 Ev. PPC PPC solenoid valve
17 V1 B1 6 5 C1 L/B1 9 Y94 Ev blocco differenziale Lock Differential gear solenoid valve
18 V-B1 7 6 R1.5 B/N1 10 Y95 Ev sblocco braccio Arm unlock solenoid valve
19 G-V1 8 7 R1.5 B-V1 11 Y96 Ev sblocco piastra Plate unlock solenoid valve
20 N1 9 8 A-G1.5 12 Y98 Ev. chiusura benna Grab close solenoid valve
10 9 G-N1.5 Y99 Ev apertura benna Grab open solenoid valve
B-G1 11 Y117 Elettrostop Elettrostop
H-R1 12 Y200 Ev 4° marcia 4th gear solenoid valve
K2 K1
13 F23 F2 F9 F1 Y201 Ev marcia avanti Forword solenoid valve
42N-06-15130 14
F8 F11 F10 15 F15 15
Y202 Ev 1° velocita' 1st gear solenoid valve
M-B1 31 T 31 T
X27s A-R1
G1.5 15 53S53M Y203 Ev 2° marcia 2nd gear solenoid valve
1 7,5A 7,5A 10A 10A 10A
53S53M 15A 15A 15A
R/N1
A-N1
X27s C-B2.5 R/N1 16 1 Y204 Ev doppia trazione Doble traction solenoid valve
2 A-N1.5 17 X46 Y205 Ev retromarcia Reverse speed solenoid valve
S46
R-V1 18 2 1 Y206 Ev 3° marcia 3rd gear solenoid valve
X28s R4 19 X41.s X41.s X12.s CONNETTORE a linea posto guida TO DRIVER SITE HARNESS CONNECTOR
1 R-G1
20 X25.s CONNETTORE a linea posto guida TO DRIVER SITE HARNESS CONNECTOR
X28s 2 N4 21 2 X30 X26.s CONNETTORE a linea posto guida TO DRIVER SITE HARNESS CONNECTOR
S41 X44.s CONNETTORE a linea posto guida TO DRIVER SITE HARNESS CONNECTOR
X2.s 1
L/R1 I _ 1
K11 K5 K3 X77.s CONNETTORE A CETRALINA ATC26 TO ATC 26 UNIT CONNECTOR
A-G1.5 2 F5 K4
F6 F3 F4 F19 F20 X30.1 X30.2 X8.s CONNETTORE a linea posto guida TO DRIVER SITE HARNESS CONNECTOR
86 87a 87 10A 86 87a 87 86 87a 87 86 87a 87
N1
R1.5
N1.5
B-R1
G1
X10.s CONNETTORE a linea posto guida TO DRIVER SITE HARNESS CONNECTOR
R-N1 4 85 30 85 30 85 30 85 30 15A 3A 3A 15A 15A X9.s CONNETTORE a linea posto guida TO DRIVER SITE HARNESS CONNECTOR
X159 1 G-N1 L-N1.5 5
X1.s X1.s CONNETTORE a linea posto guida TO UNIT 01171062 CONNECTOR
2 H-L1 A-B1 6 1 V1.5 X10.p CONNETTORE a linea cruscotto anteriore TO FRONT DASHBOARD HARNESS CONNECTOR
3 B-L1 G-N1.5 7 2 H1.5 X11.p CONNETTORE a linea telaio TO CHASSIS HARNESS CONNECTOR
4 8 3 G1 X12.p CONNETTORE a linea telaio TO CHASSIS HARNESS CONNECTOR
5 A-N1.5 9 4 G-N1 X15.p CONNETTORE a linee optional TO OPTIONAL HARNESS
6 L1 L-N1.5 10 5 M-V1
K10 K6 K8 K9 K7 X158 CONNETTORE A LINEA CENTRALINA ATC26 TO ATC26 UNIT CONNECTOR
7 M-B1 11 D2 D3 D1 86 87a 87 86 87a 87 86 87a 87 86 87a 87 86 87a 87 6 G1 X159 CONNETTORE A LINEA CENTRALINA ATC26 TO ATC26 UNIT CONNECTOR
8 H1 H-G1 12 7
85 30 85 30 85 30 85 30 85 30 X160.p CONNETTORE A LINEA PANNELLO INTERRUTTORI TO SWITCHES PANEL HARNESS CONNECTOR
9 H-N1 M1 13 8 H1.5 X2.s CONNETTORE A LINEA CENTRALINA 01171062 TO UNIT 01171062 CONNECTOR
10 H/R1 14 9 G-N1 X25.p CONNETTORE A LINEA PANNELLO INTERRUTTORI TO SWITCHES PANEL HARNESS CONNECTOR
11 H-R1 R-G1 15 10 G-N1 X26.p CONNETTORE A LINEA PANNELLO INTERRUTTORI TO SWITCHES PANEL HARNESS CONNECTOR
12 B/N1 A-G1 16 11 G1 X27.s CONNETTORE ARIA CONDIZIONATA A/C HARNES CONNECTOR
S/N1 17
X28.s CONNETTORE RISCALDAMENTO HEATING CONNECTOR
X3.s CONNETTORE A LINEA CENTRALINA 01171062 TO UNIT 01171062 CONNECTOR
X30 Accendisigari CIGARETTE LIGHTER
X4.s CONNETTORE A LINEA CENTRALINA 01171062 TO UNIT 01171062 CONNECTOR
X44.p CONNETTORE A LINEA CABINA TO CABIN HARNESS CONNECTOR
X5.s CONNETTORE A LINEA CENTRALINA 01171062 TO UNIT 01171062 CONNECTOR
X6 CONNETTORE A LINEA CENTRALINA FUNZIONI MACCHINA TO FUNCTION MACHINE UNIT
X65.p CONNETTORE A LINEA MOTORE TO MOTOR HARNESS CONNECTOR
X7.p CONNETTORE A LINEA MOTORE TO MOTOR HARNESS CONNECTOR
X77.p CONNETTORE A LINEA ATC26 ATC26 HARNESS CONNECTOR
X8.p CONNETTORE A LINEA ATC26 ATC26 HARNESS CONNECTOR
X9.p CONNETTORE a linea cruscotto anteriore TO FRONT DASHBOARD HARNESS CONNECTOR
X11.s CONNETTORE a linea posto guida TO DRIVER SITE HARNESS CONNECTOR
42-N-06 P43 PANNELLO STRUMENTI INSTRUMENTS PANEL
N10
P63 PANNELLO DI CONTROLLO ANTERIORE FRONT CONTROL PANEL
11290
R4
R6
R6
R6
X68.2
X68.1 X68.3
Gnd11 Gnd10 Gnd9 Gnd1.3 Gnd1.2 Gnd1.1
C-B2.5
A-N1.5
R-N1.5
F27
175A 42-N-06
G-M1
B-N1
H-N1
H-L1
V-N1
N1.5
M-N1
A-B1
C-B1
A-N1
G-N1
B-R1
C/B1
C-N1
Z-B1
Z-N1
V/N1
V-N1
N1.5
N1.5
H1
L1
G1
A1
N1
11870
H-N1
Z-B1
S-N1
V-B1
A1
V1
M16
B6
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1 2 3 4 5 6 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 10 11 12
X7.p X65.p 1 X11.p X12.p X77.p X8.p
X7.s 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 X128.s 1 X126.4 X11.s 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 X12.s 1 2 3 4 5 6 X77.s 1 2 3 4 5 6 7 8 9 X8.s 1 2 3 4 5 6 7 8 9 10 11 12
G-M1
M-N1
A-B1
C-B1
A-N1
G-N1
G-N1
B-N1
42-N-06
C/B1
C-N1
H-N1
B-L1
Z-B1
H-L1
H/R1
H-L1
Z-N1
V/N1
V-N1
N1.5
N1.5
N1.5
V-Z1
C-B2.5
A-N1.5
R-N1.5
Gnd6
G1
A1
A1
B2
H1
L1
M-V1
H-N1
Z-B1
S-N1
V-B1
Z-N1
M16
42-N-06
M1
M1
B6
N6
V1
11450
11160 B0.35
V0.35
B2 X207
1
X207
2
X208
G-M1
G-N1
B-N1
H-N1
1
B-L1
B-V1
A-B1
H-L1
H/R1
G-N1
G-N1
B-R1
G-N1
B-R1
V-N1
A1
H1
N1
L1
G1
A1
N1
N1
A-N1.5
C-B2.5
R-N1.5
M-V1
H-N1
Z-B1
S-N1
V-B1
Z-N1
M16
R25
R70
R70
R25
R25
B0.35
V0.35
B6
N1
V1
X100.3
X101.3
X101.4
M-N1
C-B1
A-N1
C-N1
C/B1
Z-B1
H-L1
Z-N1
V/N1
V-Z1
X100.1
X100.2
X101.2
X100.4
X101.1
1 1 B A C
1 1 1 1 1 1 1 1 1 1 1 1 1
X103.1
- 1 1 1 1 1 X209 X209 X209 1
X119.2
X119.1 1 1 A B C 1 1 X116 1
X118.1 1 Y90 X90 Y91 X91 Y92 X92 Y93 X93 Y94 X94 Y95 X95 Y96 X96 Y98 X98 Y99 X99 X97 Y200 X200 Y201 X201 Y202 X202 Y203 X203 Y204 X204 Y205 X205 Y206 X206 X211
X117 X115 X112 X112 X112 X121
Y60 X60 M116 X210 B209
G1 R114 X114 X113 E101 B210 B211
59c
59c
57
57
E103
L
30
M
50 D+
30 G W
Y117 B115 B113 B112 B121 M
p p t
12Vcc 3 t
H97
31
31
U
G118 G119 31
2
t 2 2
2 2 2 2 2 2 2 2 2 2 - E100 2 2 2 2 2 2 2 2
X113 X90 X91 X92 X93 X94 X95 X96 X98 X99 X97 X103.2 X200 X201 X202 X203 X204 X205 X206 X211
N70
X121 X60
N1.5
N6
N1
N1
N1
N1
N1
N1
N1
N1
N1
N1
N2
N1.5
N1.5
N1
N1
N1
N1
N1
N1
N1
N1
N1
N1
N1
N1
N1
GND2.1
Gnd5 GND1.1 42-N-06
Gnd3.1 GND2.2
11280
E34000-059U
WB97R-5 10-111
PAGE INTENTIONALLY
LEFT BLANK
20 TESTING AND ADJUSTMENTS
NORMAL OR STANDARD TECHNICAL DATA ............3 ADJUSTING THE PC VALVE ..................................... 43
SPECIAL TOOLS .........................................................18 TESTING AND SETTING STEERING CONTROL
ADJUSTING VALVE CLEARANCE.............................19 SYSTEM PRESSURE .................................................. 44
• Control .................................................................... 44
ENGINE SPEED TESTS...............................................20 • Setting..................................................................... 44
TENSIONING THE AIR-CONDITIONING CHECKING FOR LEAKS IN THE STEERING
COMPRESSOR BELT..................................................22 CYLINDERS................................................................. 45
BLEEDING AIR FROM CIRCUITS - TESTING PRESSURES IN THE POWER TRAIN
ELIMINATING RESIDUAL PRESSURE.......................23 GROUP ........................................................................ 46
• Bleeding air from cylinders ......................................23 • Converter oil pressure ............................................ 46
• Air bleeding from braking circuit ..............................23 • Clutch engagement pressure.................................. 47
• Releasing residual pressure from the circuits .........24 • Supply pressure...................................................... 47
ADJUSTING ACCELERATOR PEDAL TRAVEL AND TESTING THE CORRECT FUNCTIONING OF
ACCELERATOR LEVER..............................................25 THE POWER TRAINCLUTCHES ................................ 48
• Accelerator pedal travel adjusting ...........................25 • Preparation of the machine..................................... 48
• Accelerator lever travel adjusting ............................26 • Control .................................................................... 48
ADJUSTING BRAKE PEDAL SLACK/ALIGNMENT...27 ANALYSIS OF CAUSES HYDRAULIC DRIFT............ 49
• Control.....................................................................27 • FRONT EQUIPMENT ............................................. 49
• Adjustment ..............................................................27 • Shovel raise check.................................................. 49
BRAKING SYSTEM CHECKS .....................................28 • Shovel dump check ................................................ 50
• Checking brake pumps and brake system for leaks28 • BACKHOE .............................................................. 51
• Checking individual pumps......................................29 • Boom testing........................................................... 51
• Checking the braking groups for leaks. ...................30 • Arm testing.............................................................. 51
• Bucket testing ......................................................... 52
PARKING BRAKE ADJUSTMENT ..............................31
• Outriggers testing ................................................... 53
• Functional check .....................................................31
TESTING THE AIR-CONDITIONING UNIT ................. 54
CHECKING AND SETTING PRESSURE IN THE ATTA-
CHMENTS EMPTYING THE AIR-CONDITIONING UNIT .............. 56
HYDRAULIC CIRCUIT .................................................32 TROUBLESHOOTING ................................................. 57
• Introduction..............................................................32
• 8-spool control valve + Hammer..............................33
• 10-spool control valve + Hammer............................33
CHECKING THE SETTING OF MAIN RELIEF AND
SECONDARY VALVES................................................34
SETTING THE MAIN RELIEF VALVES AND THE
REDUCING VALVES....................................................38
CHECKING AND ADJUSTING THE LS DIFFERENTIAL
PRESSURE - ADJUSTING THE LS VALVE................40
• Control.....................................................................40
• Adjusting the LS valve .............................................41
CHECKING AND ADJUSTING SERVOCONTROLS
SUPPLY PRESSURE ...................................................42
• Checking servocontrols supply pressure.................42
• Adjusting the servocontrol valve..............................42
WB97R-5 20-1
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA
NORMAL OR STANDARD TECHNICAL DATA
Machine model WB97R-5
Unit: Standard Normal
Check item Test conditions
value value
High idling rpm 2400±50 2350–2450
Engine speed
Low idling rpm 1050±50 1000–1100
(without load):
Calibration speed rpm – –
Exhaust gas Sudden acceleration Bosch – <3.0
colour At high idling speed index <1.5 <3.0
Intake valve (20°C) mm 0.30±0.05 0.30±0.05
Valve clearance
Exhaust (20°C) mm 0.55±0.05 0.55±0.05
Compression
Oil temperature: 69–72°C bar 34.3±1 27.5±1
pressure
(Engine speed) rpm 250 250
(SAE30 oil)
Engine oil
With blow-by 5–10 5–10
pressure mm H2O
Free exhaust 50.0 50.0
(SAE30 oil)
Engine oil At high idling speed bar (kPa) 3.5 (350)
–
pressure At Low idling bar (kPa) 0.7 (70)
Engine oil
Entire speed range °C Max. 120 Max. 120
temperature
Fuel
B.T.D.C. mm 1.00 1.00±0.05
injectiontiming
WB97R-5 20-3
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA
Machine model WB97R-5
Classifi Standard Normal
Check item Test conditions Unit
cation value value
• Hydraulic oil temperature: 45–55 °C
Max. 2400±50 2350–2450
• Converter oil temperature: 80 °C
• Engine oil temperature cooling circuit:
Accelerator pedal
in the limits
• Measurement taken on drive shaft
Engine speed
Min. 1050±50 1000–1100
pulley with stroboscopic rev counter.
rpm
• Hydraulic oil temperature: 45–55 °C
• Converter oil temperature: 80 °C Max. 1900±50 1850–1950
• Engine oil temperature cooling circuit:
Accelerator fuel in the limits
• Measurement taken on drive shaft
pulley with stroboscopic rev counter. Min. 1050±50 1000–1100
l a b c l a b c
Control valve
Arm shovel, shovel,
boom, boom swing, 4 in 1 mm
bucket, arm, jig arm • See Fig. A – 6 5.5 2 -- -- -- --
cylinder, outrigger,
backhoe bucket
Shovel arm Raise 95 80–110
Neutral o
control lever Lower 95 80–110
Shovel control Dump 95 80–110
Neutral o
lever Curl 95 80–110
Boom b a c k h o e • Engine stopped Raise 50 40–60
Neutral o
Travel of levers and pedals
controllever • Knob lever: at the center Lower 50 40–60
and at 90° from the lever
• Value reading Opening 50 40–60
Arm backhoe control lever Neutral o
at the end of Closing 50 40–60
working stroke plus half
Bucket backhoe control measured backlash Opening mm 50 40–60
Neutral o
lever • Attachments on the Curl 50 40–60
ground
Boom swing • Instrument Right 50 40–60
backhoe control metre w/ millimetre Neutral o
Left 50 40–60
lever divisions
Outriggers control Up 35 25–45
Neutral o
lever Down 35 25–45
Fuel control
Min. o Max. 40 30–50
lever
20-4 WB97R-5
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA
Machine model WB97R-5
Classifi Standard Normal
Check item Test conditions Unit
cation value value
• Engine stopped
Travel of levers and
• Knob lever: at the center
Accelerator pedal and at 90° from the lever
Min. o Max. mm 80 65–95
• Value reading
pedals
at the end of
working stroke
Wheel swing • Attachments on the RightoLeft rev.
3.5 3.1–3.9
ground LeftoRight 3.5 3.1–3.9
• Instrument:
Shovel arm
1.5 1.0–2.0
control lever
Shovel control lever 1.5 1.0–2.0
Force for lever, pedal and steering wheel operation
Control lever
• Engine speed: min. 1.8 1.3–2.3
Boom • Oil temperature: 45–55 °C
Arm control • Tool connection at centre of knob and 80 mm
away from handle base (see Fig. B) 1.8 1.3–2.3
lever
• Value reading at the 10 mm before end of working
Bucket control stroke.
• Instrument force gauge. 1.3 0.8–1.8
lever kg
• Ambient temperature: 15-35 °C
Boom swing
1.3 0.8–1.8
control lever
Outriggers control
1.5 1.0–2.0
lever
Fuel control
6.0 5.0–7.0
lever
Accelerator
4.0 2.5–5.5
pedal
• Force measured on steering wheel knob at min.
Steering wheel RPM for approx. half a revolution under steady – –
motion at a speed of 2.5” per rev.
WB97R-5 20-5
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA
Machine model WB97R-5
Classifi Standard Normal
Check item Test conditions Unit
cation value value
• Engine speed: 2200 rpm
• Oil temperature: 45-55 °C
Main valve pressure
• Move arm cylinder to end of stroke and measure
Control valve the pressure 245 235–260
• Instrument: 0-600 bar pressure gauge
mounted on adapters at port “P1C”. bar
• Working mode switch: POWER
Steering unit • Engine speed: 1500±50 rpm 175 170–185
Shovel
270 260–280
(curled)
Shovel
240 230–255
(Dump)
4 in 1 bucket
270 260–280
(opens-closes)
Boom
345 320–360
(raising)
Pressures of secondary valves circuits
Boom (lowering) 270 260–280
Arm (Closing) • Engine speed: min. 270 260–280
• Oil temperature: 45-55 °C
• Check one circuit at the time
Arm (Out) bar 270 260–280
• Instrument: 0-600 bar pressure gauge
mounted on adapters at port “P1C”.
Boom swing • Working mode switch: POWER 230 220–245
Bucket (curled) 270 260–280
Bucket (Dump) – –
Jig arm
– –
(out - in)
Hammer (delivery) 190 180–210
Steering unit (safety) 225 225–245
20-6 WB97R-5
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA
Machine model WB97R-5
Classifi Standard Normal
Check item Test conditions Unit
cation value value
• Engine speed (without load): 2400±50
• Hydraulic oil temperature: 45-55 °C
With converter • Machine in 3rd gear 2175±50 2125–2225
• Working brakes: engaged.
• Working mode switch: POWER
Engine speed (with load) -
• Engine speed (without load): 2400±50
• Hydraulic oil temperature: 45-55 °C
Converter
• Machine in 3rd gear
With converter and
• Working brakes: engaged. rpm 2075±50 2025–2125
hydraulic circuit • Shovel raise bottom of stroke
• Steering held at the end of stroke
• Working mode switch: POWER
• Engine speed: 1050±50
• Hydraulic oil temperature: 45-55 °C
Hydraulic circuit • Vehicle in neutral
600 Min. 600
at Low idling • Parking brake: applied
• Bucket dump bottom of stroke
• Working mode switch: POWER
WB97R-5 20-7
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA
★ The technical data of follow table are referred to a machine with max. 500 kg shovel, 600 mm (max. 160 kg) backhoe
bucket and standard arm (or jig arm) closed.
Machine model WB97R-5
Classifi Standard Normal
Check item Test conditions Unit
cation value value
Complete
working equipment Measuring posture: see Fig. C
150 300
(Shovel teeth tip • In this position check in feedback of each cylinder
lower) and the leakage with applied load on the tip of
shovel teeth.
• On level ground.
Shovel
Raise cylinder • Shovel: load 1800 Kg
4 in 1 bucket: load 1550 kg mm 12 20
(Cylinder in)
• Engine stopped
• Oil temperature: 45-55 °C
• Check measures as soon as
engine stops.
Shovel cylinder
Hydraulic drift working equipment
• Check changes every 5 min. and the
35 50
(Cylinder out) total change in 15 min.
Complete
working equipment
200 350
(Bucket teeth tip
lower) Measuring posture: see Fig. D
• In this position check the extension of each
cylinder and the leakage with normal load on the
Boom cylinders bucket.
10 20
(Cylinder out) • On level ground.
• Bucket: load with standard arm: 340 kg
Backhoe
Bucket load with jig arm: 0 kg mm
Fully extend jig arm
• Engine stopped
Arm cylinders • Oil temperature: 45-55 °C 10 20
(Cylinder out) • Check measures as soon as
engine stops.
• Check changes every 5 min. and the
total change in 15 min.
Bucket cylinder
8 15
(Cylinder in)
20-8 WB97R-5
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA
★ The technical data of follow table are referred to a machine with max. 500 kg shovel, 600 mm (max. 160 kg) backhoe
bucket and standard arm (or jig arm) closed.
Machine model WB97R-5
Classific Standard Normal
Check item Test conditions Unit
ation value value
Measuring posture: see Fig. E
• Oil temperature: 45-55 °C
• Backhoe balanced on the guides
bucket in transport condition.
• Fully retract arm and bucket
cylinder Lift the bucket
Hydraulic drift working equipment
Boom swing fulcrum pin 1 m off the ground and swing 15 25
boom to bottom of stroke in either
direction.
• Move the machine on a slope of
15° and apply the parking brake.
Backhoe
• Stop the engine and, after 1 minute, check the
mm
inner cylinder feed back opposite to the boom
Measuring posture: see Fig. F
• Oil temperature: 45-55 °C
• Backhoe balanced.
• Boom and arm cylinders in,
Outriggers bucket cylinder out 7 15
• Outriggers at maximum extension.
• Engine stopped
• Check the frame lowering for each side
every 5 min. for a total of
15 minutes.
2.0
Boom Max. 8.0
(each cylinder)
Shovel
1.6
Shovel Max. 6.0
(each cylinder)
Boom 3.3 Max. 13.5
Arm • Engine: Max. speed 3.0 Max. 12.0
Cylinder leaking
• Oil temperature: 45-55 °C
• Leaking check: on the cylinder
cm³/
opposite side to the pressure one.
Bucket • Check 1 cylinder at a time. min 2.4 Max. 9.5
• For arm shovel, shovel and for swing, check the
Backhoe
two cylinders separately.
Boom swing 3.2 Max. 13.0
Outriggers 3.3 Max. 13.5
Side digging boom 2.0 Max. 8.0
Jig arm 1.6 Max. 6.0
WB97R-5 20-9
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA
★ The technical data of follow table are referred to a machine with max. 500 kg shovel, 600 mm (max. 160 kg) backhoe
bucket and standard arm (or jig arm) closed.
Machine model WB97R-5
Classific Standard Normal
Check item Test conditions Unit
ation value value
Lifting
Arm shovel
3.6 3.1–4.1
Measuring posture: see Fig. G
Cylinders
• Engine speed: max.
fully out
• Oil temperature: 45-55 °C
Lowering
• Shovel speed button: applied
2.6 2.2–3.0
Shovel at the ground
Shovel
shovel Curl
2.3 2.0–2.6
Cylinders
Measuring posture: see Fig. H
fully
• Engine speed: max.
out
• Oil temperature: 45–55 °C
• Shovel speed button: applied
Dump
2.8 2.4–3.2
Cylinders
fully in
Work equipment speed
Boom
Lifting q
2.7 2.3–3.1
Measuring posture: see Fig. J
Cylinders
fully in • Engine speed: 1700 +0 50 rpm
• Oil temperature: 45-55 °C sec.
• Backhoe balanced
Lowering
• Power mode ON
Teeth bucket on level 2.0 1.7–2.3
ground
Opening
Arm
3.8 3.2–4.3
Measuring posture: see Fig. K
Cylinders
Backhoe
0
• Engine speed: 1700 + 50 rpm
fully in
• Oil temperature: 45-55 °C
• Backhoe balanced
Closing q
• Power mode ON
Cylinders 4.4 3.7–5.1
fully out
Bucket
Dump
2.4 2.0–2.8
Measuring posture: see Fig. L
Cylinders
• Engine speed: 1700 +0 50 rpm
fully in
• Oil temperature: 45-55 °C
• Backhoe balanced
• Power mode ON
Curl
Cylinders 3.1 2.6–3.6
fully out
20-10 WB97R-5
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA
★ The technical data of follow table are referred to a machine with max. 500 kg shovel, 600 mm (max. 160 kg) backhoe
bucket and standard arm (or jig arm) closed.
Machine model WB97R-5
Classific Standard Normal
Check item Test conditions Unit
ation value value
Right q
3.2 2.7–3.7
Work equipment speed
Boom swing
Measuring posture: see Fig. M
Backhoe
Right end travel • Engine speed: 1700 +0 50 rpm
• Oil temperature: 45-55 °C sec.
• Arm vertical
• Power mode ON
Left end travel
Left q
3.2 2.7–3.7
q Times are referred to the cylinder stroke whitout the brake phase.
NOTE. The engine speed (1700 +0 50 rpm) has to be checked with the procedure described at paragraph
«MEASURING ENGINE SPEED» in this section.
WB97R-5 20-11
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA
★ The technical data of follow table are referred to a machine with max. 500 kg shovel, 600 mm (max. 160 kg) backhoe
bucket and standard arm (or jig arm) closed.
Machine model WB97R-5
Classific Standard Normal
Check item Test conditions Unit
ation value value
Measuring posture: see Fig. N
• Engine speed: Min.
Arm shovel • Oil temperature: 45-55 °C 0 Max. 2
• Check the time necessary to lift shovel from level
ground.
Measuring posture: see Fig. P
• Engine speed: Min.
• Oil temperature: 45-55 °C
Boom • With attachments fully extended, 0 Max. 2
lower the boom and check the necessary time
from the beginning of machine lifting until bucket is
on level ground.
Measuring posture: see Fig. Q
Work equipment
• Engine speed: Min.
Time lags
• Oil temperature: 45-55 °C
Arm • Put boom at 45°, open completely sec. 0 Max. 2
the arm with curled bucket. Extend arm cylinder
and check the time passing between arm stop at
dead centre and the restart movement.
Measuring posture: see Fig. R
• Engine speed: Min.
• Oil temperature: 45-55 °C
Bucket • Put arm in horizontal position. Tilt back bucket 0 Max. 2
cylinder an then extend it. Check the time passing
between bucket stop at dead centre and the restart
movement.
Measuring posture: see Fig. S
• Engine speed: Min.
• Oil temperature: 45-55 °C
Outriggers • Boom, arm and bucket fully retracted and putted in 0 Max. 2
machine centre position.
• Check the time necessary for outriggers to raise
the machine from when they lean on level ground.
• Check each outrigger at a time.
20-12 WB97R-5
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA
Fig. A Fig. B
a b c 80mm
RKZ10840
RKZ10860
Fig. C Fig. D
~10°
1m 1m
RKZ10680 RKZ10690
WB97R-5 20-13
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA
Fig. E Fig. F
RKZ10700
RKZ10830
Fig. G Fig. H
RKZ10730
RKZ10720
20-14 WB97R-5
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA
Fig. J Fig. K
RKZ10740
RKZ10750
Fig. L Fig. M
RKZ10780 RKZ10760
WB97R-5 20-15
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA
Fig. N Fig. P
RKZ10800
RKZ10790
Fig. Q Fig. R
45°
RKZ10820
RKZ10810
20-16 WB97R-5
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA
Fig. S
RKZ10830
WB97R-5 20-17
TESTING AND ADJUSTMENTS SPECIAL TOOLS
SPECIAL TOOLS
Measurement check point Symbol Code Name Q.ty Note
Engine speed C 1 Stroboscopic tachometer 1 6 - 30000 rpm
Commercially
1 Pressure gauge 2 Full scale 60 bar
available
Commercially
2 Pressure gauge 1 Full scale 250 bar
available
Commercially
3 Pressure gauge 1 Full scale 400 bar
E available
Hydraulic pressure Commercially
4 Pressure gauge 1 Full scale 600 bar
available
5 Servocontrol kit
Differential digital 1 0-1000 bar
6 pressure gauge
ATR800200
1 Flow-meter 1 Delivery 0–300 l/min.
F
2 Pipe fitting kit 1 –
Commercially
1 Maintenance station 1 For coolant R134a
available
Air-conditioning Commercially Sampling every 15
M 2 Thermometer-hygrometer 1
unit available seconds
Commercially
3 Leak detector 1 For coolant R134a
available
20-18 WB97R-5
TESTING AND ADJUSTMENTS ADJUSTING VALVE CLEARANCE
ADJUSTING VALVE CLEARANCE
1 -Park the machine on solid, level ground, apply the
parking brake, and remove the ignition key.
2 -Remove the intake filter and muffler. 1
(For details see "30 REMOVAL AND INSTALLATION"). 2
3 -Release from straps and disconnect the wiring harness
(1) of the coolant liquid temperature sensor (2).
4 -Adjust valve clearance according to the instructions
provided in the engine shop manual (code
WHBMNEF000).
RKZC3150
WB97R-5 20-19
TESTING AND ADJUSTMENTS ENGINE SPEED TESTS
ENGINE SPEED TESTS
k When checking engine speeds, be careful not to touch
high temperature parts and not to get caught in rotating
parts.
1 -Start the engine and heat the hydraulic oil by performing
all normal working motions, including travel.
a Check hydraulic oil temperature with a probe
plunged in the reservoir or with a probe applied to
the reservoir wall.
Temperature should be at 50±5°C.
2 -Place the machine on solid level ground with the
transmission in NEUTRAL.
1
3 -Stop the engine and apply a reading notch “B” to the
engine pulley (1) for the stroboscopic rev counter.
RKZC3160
• CHECKING ENGINE WITHOUT LOAD
1 -Start engine and check:
Low idling speed without load (accelerator pedal
released).
• Minimum speed: 1050±50 rpm
High idling speed without load (accelerator pedal at the
travel end).
• Maximum speed: 2400±50 rpm
a If low and high idling speed with engine without load are
not within permissible value, before going on with other
operations, check accelerator pedal stoppers and
wiring sheathings.
(See "ADJUSTING ACCELERATOR PEDAL TRAVEL
AND ACCELERATOR LEVER").
20-20 WB97R-5
TESTING AND ADJUSTMENTS ENGINE SPEED TESTS
• CHECKING ENGINE WITH LOAD
1. With the machine in Power mode at MIN.
1 -With the transmission in neutral, idle the engine.
2 -Dump shovel and force the movement; let the engine
stabilize and then read the engine speed.
a Normal speed: 600 rpm
Minimum speed: 600 rpm
2. With converter stalled
1 -Increase speed to high idling and brake with the working
brakes.
2 -Hold the brakes while simultaneously engaging 3rd
gear; let the engine stabilize, and read the rpm value.
a Minimum speed: 2125 rpm
Maximum speed: 2225 rpm
k Hold the machine stalled as long as necessary, in any
case for not more than 30 sec., and carry out the tests at
least 15 sec one from the other.
3. With converter stalled and hydraulic pump under
load
1 -Increase speed to high idling and brake with the working
brakes.
2 -While holding the brakes:
a - engage 3rd FORWARD;
b - raise shovel the full travel span and hold in this
position;
c - steer the wheels fully;
3 -In the above conditions, let the engine stabilize, then red
the engine rpm.
a Minimum speed: 2025 rpm
Maximum speed: 2125 rpm
k Hold the machine stalled as little as necessary, in any
case for not more than 30 sec., and carry out the tests at
least 15 sec one from the other.
• ANALYSIS
1 -If readings are not within the required interval, check the
engine according to the instructions provided in manual
code WHBMNEF000.
2 -If the engine has no conditions, adjust the pump's power
absorption (PC valve).
WB97R-5 20-21
TESTING AND ADJUSTMENTS TENSIONING THE AIR-CONDITIONING COMPRESSOR BELT
TENSIONING THE AIR-CONDITIONING COMPRESSOR
BELT
1 -Loosen the screw (1) and the nut (2).
2 -Turn the screw (3) clockwise to tension the belt (4).
3 2
1
4
RKTA1204
3 -Apply a 10 kg force halfway between compressor pulley
(5) and engine pulley (6). 4
10 kg
4 -Check the resulting arrow “F”.
a F = 4-6 mm normal tensioning
F
F = 3 mm new belt
k Check belt tension again after 15 minutes of
operation.
5
6
RKT01261
5 -Once proper tension is reached, retain the position of
the adjustment bolt (3) with the nut (2).
3 2
RKTA1205
6 -Retain the adjustment bracket (7) with the screw (1).
7
1
RKTA1221
20-22 WB97R-5
TESTING AND ADJUSTMENTS BLEEDING AIR FROM CIRCUITS - ELIMINATING RESIDUAL
BLEEDING AIR FROM CIRCUITS - ELIMINATING RESIDUAL
PRESSURE
• Bleeding air from cylinders
a When hydraulic cylinders or associated pipes have
been removed, it is necessary to bleed air before using
the machine again.
a Perform bleeding on one movement at a time starting
from the main cylinders (boom out and boom raise).
1 -Start the engine and run the engine at high speed for
about 5 minutes to heat the oil.
2 -Reduce speed to low idling and extend and retract the
1st piston to be bled several times.
a Extend, lower and retract pistons until about 100
mm from their end of stroke.
3 -Stop the engine, check and top up the oil in the tank.
4 - Bring again the engine at high idling speed and repeat
operation of point 2; return the engine at low idling
speed and make a complete travel of piston until the
hydraulic pump reaches its maximum pressure.
5 - Repeat steps (from Step 2) for all cylinders, frequently
checking the oil level in the tank.
• Air bleeding from braking circuit
a Above operation is to be carried out every time 1
maintenance is made on braking circuit to remove or
replace a component, or when air entered into the
circuit.
a Machine must be stopped with attachments on level
ground.
1 -Make sure that oil in brake system tank (1) is at
maximum level.
RKZC3170
2 -Remove safety plugs and applied to bleeding screws
(2) a vinyl hose (3) to catch oil. 2 3
3- Push brake pedal to bottom and, while keeping it
pushed, loosen the bleeding screw (2) of the braking
unit that is being bled until the pedal reaches the end of
its stroke.
4 -Keeping pedal at the end stroke, tighten bleeding screw
(2).
RKZC3180
WB97R-5 20-23
TESTING AND ADJUSTMENTS BLEEDING AIR FROM CIRCUITS - ELIMINATING RESIDUAL
5 -Release brake pedal, wait for few seconds and repeat
above operations two or three times until from bleeding
screw, oil flows out without air bubbles. 4
2
6 -Repeat the same steps for the opposite braking unit.
a Check frequently the oil level in the tank and carry
out filling every time level approaches to minimum.
a After air bleeding apply on screws (2) safety plugs
(4).
RKZC3190
• Releasing residual pressure from the
circuits
1 -Put work attachments on level ground, stop the engine.
2- Move all control levers in all directions to fully release
cylinder and servocontrol circuit residual pressure.
20-24 WB97R-5
TESTING AND ADJUSTMENTS ADJUSTING ACCELERATOR PEDAL TRAVEL AND ACCELERATOR
ADJUSTING ACCELERATOR PEDAL TRAVEL AND ACCELERATOR
LEVER
a Working condition:
• Machine in safety conditions.
• Engine stopped but at operating temperature.
• Low and high idling speed: within permissible
values.
a In order to check high speed engine idling, push the
accelerator pedal (1) manually.
• Accelerator pedal travel adjusting
1 -Make sure that accelerator pedal (1) is fully raised and 2
accelerator lever (2) is at minimum stroke.
1
RKZC3200
2 -Tighten the nut (3) until spring slack is eliminated (4) and
spring is preloaded to about 1 mm.
5
4
3
RKTA2255
3- Push accelerator pedal until accelerator lever (3)
contacts the injection pump high idling adjusting screw. 1
4 -Adjust the end travel stopper (6) of accelerator pedal (1)
in this position and lock it with nut (7).
7
5 -Release the accelerator pedal (1).
RKZC3210
WB97R-5 20-25
TESTING AND ADJUSTMENTS ADJUSTING ACCELERATOR PEDAL TRAVEL AND ACCELERATOR
• Accelerator lever travel adjusting
1 -Remove the front mat.
2
2 -Remove the metal sheet (1) closing the bottom of the
cab and the upright guard (2).
1
RKZC3220
3 -Check that the hand accelerator (3) is at end of travel at
MIN.
4 -Loosen and unscrew the locking nut (4).
3
RKZC3230
5 -Start the engine and move the hand accelerator (3) to
MAX. 4
6 -Tighten the nut (5) to the required speed for hand
accelerator.
5
a Engine idling speed: 1900±50 rpm
RKZC3240
7 -Return to engine low idling speed and retain the position
of the nut (5) with the locking nut (4).
8 -Check MAX speed once more by pushing the hand
accelerator to end of travel.
20-26 WB97R-5
TESTING AND ADJUSTMENTS ADJUSTING BRAKE PEDAL SLACK/ALIGNMENT
ADJUSTING BRAKE PEDAL SLACK/ALIGNMENT
a Working condition:
• Set the machine on level surface with attachments
on ground level
• Apply the parking brake and remove the ignition key
• Pedal connection pin (1) inserted.
RKZC3251
• Control
1 -Remove mat. 1
2 -Check height “A” between floor and pedal lower edge.
3 -Depress pedals by hand and check height “B” to G
determine slack “G”.
a Standard clearance: 3-8 mm
A
B
RKZ11390
• Adjustment
4 -Remove the front cover (2). 2
(For details see "30 REMOVAL AND INSTALLATION").
RKZC6050
5 -Loosen nuts (3) and adjust slack using stoppers (4).
6 -When adjustment is complete, secure the stoppers (4). 3
4
a When stoppers are secured, double check to
ensure that slack “G” is within range and that the
pedals touch the stoppers simultaneously.
RKZC3460
WB97R-5 20-27
TESTING AND ADJUSTMENTS BRAKING SYSTEM CHECKS
BRAKING SYSTEM CHECKS
a Working condition:
• Engine stopped
• Place the vehicle on firm level ground with the
equipment raised and the safety devices activated.
• Independent brake pedals and oil pan at maximum
level.
a The brake system checking procedure consists of two
steps:
• checking the brake pumps;
• checking the braking groups for leaks.
• Checking brake pumps and brake system for
leaks
1
1 -Disconnect hoses (1) from the hoses (2) connecting to
the axle braking groups.
2 -Seal either hose (1).
a Plug all pipes/hoses (2) to prevent contamination.
RKZC2072
3 -Connect a pressure gauge E2 (250 bar) to the other
hose (1). 1
4 -Apply either brake pedal until a pressure of approx. 120
bar is reached.
a Do not exceed maximum permitted pressure
(150±5 bar).
E2
5 -Hold the pressure on the pedal for at least 2 minutes and
verify that pressure and pedal position remain
unchanged.
a If the position of the pedal needs to be changed in RKZC6070
order to hold the pressure, then the loss of pressure
is to be blamed on leaks inside either pump.
To confirm whether this is the case, check the oil. If
a leak condition exists, the oil will be stirred.
20-28 WB97R-5
TESTING AND ADJUSTMENTS BRAKING SYSTEM CHECKS
• Checking individual pumps
1 -Remove the front lining (3). 3
RKZC6051
2 -Disconnect the pressure equalizer hose (5) from the
brake circuit pump (4) that is being inspected.
3 -Seal the hole of the equalizer (plug “A”).
4
A
5
7 RKZC6080
4 -Remove the clamp (6).
RKZC6090
5 -Disconnect the delivery hoses (7) from the pump that is
being tested. Connect a pressure gauge E2 (250 bar) to
the pump during the inspection.
6 -Apply the brake pedal corresponding to the pump and
pressurize the circuit to approx. 120 bar.
a Do not exceed maximum permitted pressure
(150±5 bar).
E2
7
RKZC6100
WB97R-5 20-29
TESTING AND ADJUSTMENTS BRAKING SYSTEM CHECKS
7 -Hold the pressure on the pedal for at least 2 minutes and
verify that pressure and pedal position remain
unchanged.
a If the position of the pedal needs to be changed in
order to hold the pressure, then the loss of pressure
is to be blamed on leaks inside the pump, and in this
case the pump needs to be changed. To confirm
whether this is the case, check the oil. If a leak
condition exists, the oil will be stirred.
8 -Repeat for the other pump.
• Checking the braking groups for leaks.
From brake pump
1
1 -Disconnect the delivery hose (1) from the braking group
that is being inspected.
9
2 -Connect a suitable tool between the delivery hose (1)
and the braking group.
100 150
50 200
0 250
a Check to ensure that the pressure tap (8) is installed 8
between the braking group and the cut out valve (9). E2
3 -Connect a pressure gauge E2 (250 bar) to the tool
pressure tap and open the cut out valve (9).
RKZ11400
4 -Operate the brake pump and pressurize the circuit to
150±55 bar maximum.
5 -Hold the pressure while simultaneously closing the
valve (9) to keep the braking circuit that is being
inspected under pressure.
6 -Release the brake pedal and monitor pressure gauge
E2 for two minutes.
a If the pressure reading changes in the negative,
then there is a brake piston seal failure.
k Further evidence of leak is an increase in the level
of oil in the axle, and the fact that the oil is stirred as
a result. Replace all sealing rings in the various
ax l e s e c ti o n s a n d c o m p l et e ly c h an ge t he
lubricant.
7 -Repeat the test for the other braking group using the
same procedure as above.
8 -Restore the braking circuit to operating condition.
k When checks and repair (if any) are complete,
bleed the air from the braking groups (See
"BLEEDING AIR FROM CIRCUITS -
ELIMINATING RESIDUAL PRESSURE").
20-30 WB97R-5
TESTING AND ADJUSTMENTS PARKING BRAKE ADJUSTMENT
PARKING BRAKE ADJUSTMENT
• Functional check
a Test conditions:
• Tire pressure within the prescribed range.
• Machine in operating conditions without load and on
level ground. 1
• Working brake pedals: connected by a cotter pin.
1 -Remove the screws (1) and remove PPC valve and 2
parking brake casing (2).
RKZC6110
2 -Engage the parking brake.
3 -Press and hold the microswitch (3) while engaging 2nd
gear and selecting a direction of movement.
4 -Accelerate engine revs gradually up to 1530±50 RPM. 3
k If machine attempts to move, release the
microswitch to return to N (Neutral).
RKZC6120
5 -Rotate the end of the lever (4) by 2 or 3 turns
counterclockwise.
a Direction of rotation is from the operator’ point of
view when the operator is sitting on the driver’s seat. 4
6 -Re-apply the parking brake and repeat the test.
a If a normal braking condition is not achieved after
two attempts to adjust the lever, check control cable
for slackness and braking disc for wear and replace
components as necessary.
(See "30 REMOVAL AND INSTALLATION" for
details). RKZC6130
WB97R-5 20-31
TESTING AND ADJUSTMENTS CHECKING AND SETTING PRESSURE IN THE ATTACHMENTS
CHECKING AND SETTING PRESSURE IN THE ATTACHMENTS
HYDRAULIC CIRCUIT
STEERING UNIT
SAFETY VALVE
Komatsu Ltd. LS
TRANSMISSION
HYDRAULIC PUMP
DIESEL
CONTROL VALVE
RKZ10890
NOTE 2 -The full pump delivery supplies the control valve.
Shown in this section is the servocontrolled version
3 -Pump delivery is shut by the priority valve (inside the
of the control valve.
control valve) when the steering unit is used for a
• Introduction steering manoeuvre.
1 -The machine is equipped with a single control valve
with hydraulically controlled spools. The control
valve is protected against overpressure by a single
upper valve (or main valve, referred to as "LS safety
valve") with adjustable pressure setting.
20-32 WB97R-5
TESTING AND ADJUSTMENTS CHECKING AND SETTING PRESSURE IN THE ATTACHMENTS
• 8-spool control valve + Hammer
Set
Cylinder and movement Port
(bar)
Hammer B0 190 B7 A7
Opens A1 270
Arm
Closes B1 270 B8 A8
Right A2 230
Boom swing
Left B2 230
Dump A3 240
Shovel
Curl B3 270 B0 Komatsu Ltd.
A1
Lowering A4 270
Boom B1
Lifting B4 345
Backhoe Dump A5 – B2 A2
bucket Curl B5 270 B3 A3
Lifting A6 –
Shovel arm B4 A4
Lowering B6 –
Down A7 – B5 A5
Right outrigger
Up B7 –
Down A8 – B6 A6
Left outrigger
Up B8 –
RKZ11100
• 10-spool control valve + Hammer
Set
Cylinder and movement Port
(bar)
Hammer B0 190
B9
Opens A1 270 A9
Arm
Closes B1 270
B10 A10
Right A2 230
Boom swing
Left B2 230
Dump A3 240
Shovel
Curl B3 270
B0
Lowering A4 270
Boom
Lifting B4 345 B1 Komatsu Ltd.
A1
Dump A5 –
Backhoe bucket
Curl B5 270 A2
B2
Closes A6 270
4 in 1 bucket B3 A3
Opens B6 270
Out A7 – B4 A4
Jig arm
In B7 – A5
B5
Lifting A8 –
Shovel arm
Lowering B8 – B6 A6
Down A9 – A7
Right outrigger B7
Up B9 –
Down A10 – B8 A8
Left outrigger RKZ11110
Up B10 –
WB97R-5 20-33
TESTING AND ADJUSTMENTS CHECKING THE SETTING OF MAIN RELIEF AND SECONDARY
CHECKING THE SETTING OF MAIN RELIEF AND SECONDARY
VALVES
• Checking the operating pressure
of the unloading valve
E1
1 -Connect a pressure gauge E1 (60 bar) to the pressure
tap P1C on the pump.
2 -Start the engine and run the engine at low idling with all
levers in neutral position.
P1C
RKZC3260
3 -In this condition, check the pressure in the hydraulic
circuit.
a Normal pressure: 41±4 bar
a The unloading valve cannot be pressure set; if
pressure changes from its normal value, replace the
valve.
• Checking main relief valve setting
a Test conditions: E3
• Engine: at operating temperature.
• Hydraulic oil: 45-55 °C
• Working brakes applied
1 -Connect a pressure gauge E3 (600 bar) to pressure tap
P1C of the pump.
P1C
RKZC3270
2 -Start the engine, move the hand accelerator lever to full
throttle and check setting pressure for main relief valve
by forcing the shovel arm raise movement the full travel
span.
a Nominal pressure: 235-260 bar
a If the main relief valve pressure does not
correspond to the nominal pressure value, it must
be re-set (For details, see "SETTING THE MAIN
RELIEF VALVES AND THE REDUCING
VALVES").
20-34 WB97R-5
TESTING AND ADJUSTMENTS CHECKING THE SETTING OF MAIN RELIEF AND SECONDARY
• Checking secondary valves setting
(for boom swing, shovel dump, and hammer
E3
movements)
a Test conditions:
• Engine: at operating temperature.
• Hydraulic oil: 45-55 °C
• Working brakes applied
P1C
a The pressure readings are to be operated from the same
check point.
1 -Connect a pressure gauge E3 (600 bar) to pressure tap RKZC3270
P1C of the pump.
2 -Start the engine and bring the hand accelerator lever up
to 2200 rpm.
3 -Check pressure for each movement, with the control
lever at the end of its travel and at stabilized pressure.
a Move piston to the end of stroke to check the
pressure.
a Normal pressure values:
Set
Cylinder and movement
(bar)
Hammer 180–210
Right 225–250
Boom swing
Left 225–250
Shovel Dump 235–260
WB97R-5 20-35
TESTING AND ADJUSTMENTS CHECKING THE SETTING OF MAIN RELIEF AND SECONDARY
• Checking secondary valve setting
(for boom raise movement)
a Test conditions:
• Engine: at operating temperature.
• Hydraulic oil: 45-55 °C
• Working brakes applied
1 -Set the machine with arm in vertical position and with
bucket on level ground leaned on the side.
2 -Stop the engine and release residual hydraulic
pressures. RKZ10900
3 -Disconnect the hose (1) and connect a tee fitting (2) with
adapter.
2
4 -Connect a pressure gauge E3 (600 bar) to the adapter.
E3
RKZC6170
5 -Start the engine, connect a weight of approx. 1500 kg to
the bucket, and fully lower the outriggers.
RKZ10910
6 -Slowly extend the arm and boom and take the pressure
when the boom lowers.
a Normal pressure: 320-360 bar
RKZ10920
20-36 WB97R-5
TESTING AND ADJUSTMENTS CHECKING THE SETTING OF MAIN RELIEF AND SECONDARY
• Checking secondary valve setting (for arm
in, shovel loading, backhoe bucket loading,
boom raise, and 4-in-1 bucket movements)
a Test conditions:
• Engine: at operating temperature.
• Hydraulic oil: 45-55 °C
• Working brakes applied
a The pressure readings are to be operated from the same
check point.
1 -Connect a pressure gauge E3 (600 bar) to pressure tap
P1C of the pump.
E3
2 -Start the engine and bring the hand accelerator lever up
to 2200 rpm.
P1C
RKZC3270
3 -Set the main relief valve to a value 30 bar higher than the
maximum pressure to be tested.
(For details, see "Setting the main relief valve").
4 -Check pressure for each movement, with the control
lever at the end of its travel and at stabilized pressure.
a Move piston to the end of stroke to check the
pressure of the working equipment.
a Normal pressure values:
Set
Cylinder and movement
(bar)
RKZC3290
Arm Closing 260–280
Shovel Curl 260–280
Boom Lowering 260–280
Backhoe bucket Curl 260–280
Closes 260–280
4 in 1 bucket
Opens 260–280
a If one movement fails to reach the setting pressure,
then the malfunction is in the tested element.
a If all movements fail to reach the setting pressure,
then you need to pressure set or replace the
secondary valve.
WB97R-5 20-37
TESTING AND ADJUSTMENTS SETTING THE MAIN RELIEF VALVES AND THE REDUCING VALVES
SETTING THE MAIN RELIEF VALVES AND THE REDUCING VALVES
• Setting the main relief valve
1 -Loosen lock nut (1). 1
RKZC3291
2 -Adjust the pressure using the screw (2).
• To INCREASE pressure turn in CLOCKWISE 1
direction.
• To DECREASE pressure turn in
COUNTERCLOCKWISE direction.
3 -Lock the nut (1).
3 Nut: 29.4-39.2 Nm
a When adjustment is complete, check the setting of 2
the main relief valve using the procedures used for
measurements. RKZ10930
20-38 WB97R-5
TESTING AND ADJUSTMENTS SETTING THE MAIN RELIEF VALVES AND THE REDUCING VALVES
• Adjusting secondary valves (for boom
swing, shovel dump, hammer, and boom
raise movements)
1
1 -Loosen nut (1)
RKZC3300
2 -Adjust the pressure using the nut (2).
• To INCREASE pressure turn in CLOCKWISE 1 2
direction.
• To DECREASE pressure turn in
COUNTERCLOCKWISE direction.
3 -Tighten nut (1) while holding nut (2).
3 Nut (1): 39-49 Nm
RKZ10940
• Adjusting the secondary valve (for arm in,
D C
shovel curl, backhoe bucket curl, boom
raise, and 4-in-1 bucket movements)
1 -Loosen nut (1).
A = hammer secondary valve
B = LH swing secondary valve
Komatsu Ltd.
C = shovel dump secondary valve
D = RH swing secondary valve
A B RKZ10950
2 -Adjust the pressure using the nut (2).
• To INCREASE pressure turn in CLOCKWISE
2 1
direction.
• To DECREASE pressure turn in
COUNTERCLOCKWISE direction.
3 -Tighten nut (1) while holding nut (2).
3 Nut (1): 39-49 Nm
RKZ10960
WB97R-5 20-39
TESTING AND ADJUSTMENTS CHECKING AND ADJUSTING THE LS DIFFERENTIAL PRESSURE -
CHECKING AND ADJUSTING THE LS DIFFERENTIAL PRESSURE -
ADJUSTING THE LS VALVE
• Control
a Test conditions:
E4
• Engine: stopped but at working temperature.
• Hydraulic oil: 45-55 °C.
• Machine: front equipment on the ground, parking
brake applied and boom and arm fully extended. 1
• Working mode: POWER
2
1- Disconnect hose (1) from the Load Sensing line, Install a
tee with pressure tap (2) and reconnect hose (1).
RKZC3310
2 -Connect a differential pressure gauge E4 to adaptor (2)
and to pressure tap P1C of the pump.
3- Start the engine and run it at low idling (1050±50 rpm)
and, without any movement (lever in neutral position),
read the DP pressure.
P1C
a Normal value: 41±4 bar
a If DPLS pressure is not within the permissible
range, replace the control valve unloading valve.
E4
E4
RKZC3320
4 -Simultaneously perform a boom raise and a backhoe
bucket curl movement to end of travel and then read the
DP pressure.
a Normal value: 27.5±1.5 bar
a If the DPLS value is not within the permissible
range, set the unloading valve.
20-40 WB97R-5
TESTING AND ADJUSTMENTS CHECKING AND ADJUSTING THE LS DIFFERENTIAL PRESSURE -
• Adjusting the LS valve
a If the DPLS value is not within the specified range,
adjust the LS valve as follows:
1 -Loosen the retaining nut (1) and turn the adjustment 1
screw (2).
• To INCREASE pressure turn in CLOCKWISE
direction.
• To DECREASE pressure turn in
COUNTERCLOCKWISE direction.
a Each turn of the adjustment screw (2) will change RKZC3330
the pressure by approx. 13 bar.
2 -Lock the nut (3).
3 Nut: 27.4-34.3 Nm 1
2
3 -When adjustment is complete, check the setting of the
LS valve (1) using the procedures used for checking.
RKZ10970
WB97R-5 20-41
TESTING AND ADJUSTMENTS CHECKING AND ADJUSTING SERVOCONTROLS SUPPLY
CHECKING AND ADJUSTING SERVOCONTROLS SUPPLY
PRESSURE
• Checking servocontrols supply pressure
1
a Test conditions:
E1
• Engine: at operating temperature.
• Hydraulic oil temperature: 45-55 °C
1 -Connect a pressure gauge E1 (60 bar) to the pressure
2
tap (1) of the solenoid valve group (2).
2 -Start the engine and run the engine at low idling with all
levers in neutral position.
3 -Check the pressure.
RKZC3340
a Normal pressure: 37.3±3 bar
• Adjusting the servocontrol valve
a If the pressure value is not within the tolerance range,
adjust the valve (1) as follows:
1 -Loosen the retaining nut (2) and turn the adjustment
screw (3).
• To INCREASE pressure rotate in CLOCKWISE
direction. 1
• To DECREASE pressure rotate in
COUNTERCLOCKWISE direction.
a Each turn of the screw (3) will change the pressure RKZC3350
by _____ bar.
2 -Lock the nut (2).
3 Nut: 22 ± 2.5 Nm 2
3
RKZ10980
20-42 WB97R-5
TESTING AND ADJUSTMENTS ADJUSTING THE PC VALVE
ADJUSTING THE PC VALVE
a If pump delivery and LS differential pressure are within
permissible values, but you notice that the engine rpm 1
drops as a result of a change in the load, or that working
equipment is very slow, it is time to adjust the PC valve.
1 -Loosen the nut (1) and turn the adjustment screw (2).
a To decrease the pump's torque absorption, turn the
adjustment screw (2) counterclockwise
a To increase the pump's torque absorption (i.e. to
increase the speed of working equipment) turn the
adjustment screw (2) clockwise.
2
RKZ10990
a Turn the adjustment screw by not more than 180° in
relation to the 0° line, in both directions
a Adjustment screw position on first installation
shown
MAX 180
2 -Lock the nut (1). 0°
3 Nut: 27.4-34.4 Nm MAX 180
RKZ11000
WB97R-5 20-43
TESTING AND ADJUSTMENTS TESTING AND SETTING STEERING CONTROL SYSTEM PRESSURE
TESTING AND SETTING STEERING CONTROL SYSTEM PRESSURE
a Test conditions:
• Engine: operating temperature
• Hydraulic oil: 45-55 °C
• Control
1 -Connect a pressure gauge E3 (600 bar) to the pressure E3
tap P1C on the backhoe control valve.
2 -Start the engine and bring it to idle speed 1500±50 rpm
and carry out a total steering.
3 -Forcing the steering wheel at the end of stroke, check
pressure.
P1C
a Normal pressure: 175-185 bar
4 -Check for the other steering direction too. RKZC3270
• Setting
3
a If pressure is not within permissible value, carry out
setting acting on upper valve (1) of the steering unit (2). 5
1 -Remove the plug (3).
4
2 -Insert a wrench of 4 mm and loosen screw (4).
• To INCREASE pressure rotate in CLOCKWISE
direction. 1
• To DECREASE pressure rotate in
COUNTERCLOCKWISE direction. 2
3 -Stop the engine and replace the plug (3); ensure that the RKPB1360
seal (5) is in its proper position.
3 Plug: 50±10 Nm
20-44 WB97R-5
TESTING AND ADJUSTMENTS CHECKING FOR LEAKS IN THE STEERING CYLINDERS
CHECKING FOR LEAKS IN THE STEERING CYLINDERS
a Test conditions:
• Engine: at operating temperature.
1
• Hydraulic oil: 45-55°C. 2
• Working brakes: engaged.
• Maximum steering pressure: within permissible
limits.
1 -Start the engine and fully steer the wheels in either
direction. 3
2 -Stop the engine.
3 -Disconnect the supply hose (2) from the cylinder (1) on RKZC3360
the side where the rod is fully out (3); plug the hose
tightly.
4 -Connect a provisional hose to the cylinder (1) to collect
any leaking fluid.
5 -Start the engine and operate the engine at high idling
speed.
6 -Force the steering wheel to the end of its travel and
retain the position for 30 seconds; measure any leak
during the following minute.
7 -Release the steering wheel, run the engine at low idling,
and then stop the engine.
8 -Check if leakage is normal (see «NORMAL OR
STANDARD TECHNICAL DATA).
a Test cylinder on one side only, as there is only one
gasket separating the two chambers.
9 -Restore the hydraulic connection, steer the wheel
several times in both directions to remove any air from
the circuit.
WB97R-5 20-45
TESTING AND ADJUSTMENTS TESTING PRESSURES IN THE POWER TRAIN GROUP
TESTING PRESSURES IN THE POWER TRAIN GROUP
The power train group can be used to perform pressure tests
on the internal hydraulic circuit. These are useful for
identifying malfunctions.
Specifically, the tests involve:
1 - Converter oil pressure.
2 - Clutch engagement pressures for both directions of
travel.
a Test condition:
• Engine: stopped.
• Brake pedals: connected by a cotter pin. RKZ11010
• Machine: on solid and level ground with the
equipment raised and safety devices engaged.
• Lower cab closeout removed.
• Converter oil pressure
1 -Remove the plug (P3) and connect the pressure gauge
E6. P3
2 -Start the engine and heat the engine and all the fluids up
to working temperature. In particular make sure that the
power train oil reaches a temperature of 80±5 °C.
3 -With the engine at MIN, check the pressure on the
pressure gauge E6.
a Idle pressure: 3 bar
RKZC6140
4 -Gradually increase engine speed to 2200 rpm; take a
new reading on pressure gauge E6.
a Normal pressure: 3-9 bar
5 -Bring the engine back to MIN and compare the pressure
with the normal value.
a Min. pressure: 3 bar
a If the pressure value drops to below the permissible
lower limit, the power train pump needs an
replacement.
3 Plug: 30 Nm
20-46 WB97R-5
TESTING AND ADJUSTMENTS TESTING PRESSURES IN THE POWER TRAIN GROUP
• Clutch engagement pressure
1 -Remove the plug (P18) and connect the pressure gauge
E6. P18 P17
2 -Start the engine and heat the engine and all the fluids up
to working temperature. In particular make sure that the
power train oil reaches a temperature of 80±5 °C.
3 -Bring the engine up to MIN (idling) and check the
pressure on the pressure gauge E6.
a Normal pressure: Max. 0.3 bar
RKZC6150
4 -With the working brakes applied, select reverse gear
and gradually increase rev speed up to MAX, then take a
new reading from the pressure gauge E6.
a Normal pressure: 13.5-16.5 bar
5 -Bring the engine back to MIN and the transmission in
neutral position; compare the pressure with the normal
value.
a Normal pressure: Max. 0.3 bar
6 -Remove the pressure adapter and replace the plug
(P19).
3 Plug: 30 Nm
7 -Repeat the same test for the FORWARD gear, reading
the pressure from the orifice protected by the plug (P17).
• If the pressures are different for the two travel
directions, there is a loss of pressure on the clutch
piston with lower pressure.
• Supply pressure
1 -Remove the plug (P21) and connect the pressure gauge
E6.
2 -Start the engine and heat the engine and all the fluids up
to working temperature. In particular make sure that the
power train oil reaches a temperature of 80±5 °C.
3 -Bring the engine up to MIN (idling) and check the
pressure on the pressure gauge E6.
a Normal pressure: 14-17 bar
P21
4 -Gradually increase engine speed to 2.200 rpm; take a
new reading on pressure gauge E6.
a Min. pressure: 14 bar
a If reading drops below minimum, the transmission
pump needs replacing.
3 Plug: 30 Nm
RKZC6160
WB97R-5 20-47
TESTING AND ADJUSTMENTS TESTING THE CORRECT FUNCTIONING OF THE POWER
TESTING THE CORRECT FUNCTIONING OF THE POWER
TRAINCLUTCHES
a Test conditions:
• Engine: stopped.
• Brake pedals: connected by a cotter pin.
• Machine: on solid and level ground with the
equipment raised and safety devices engaged.
a This test must be performed after having checked
the pressures of the power train group.
RKZ11010
• Preparation of the machine
1 -Prepare a rev. counter C1 to measure the engine rpm.
k Make sure that the brake pedals are fastened
C1
together by the cotter pin (1).
k During the following tests, during the engine
acceleration phase with the gear engaged, the
condition of the brake disks can also be checked If,
while force is being exerted on the brake pedals,
the machine starts to travel (even slowly):
a - Release the accelerator immediately and stop the RKZC3161
engine.
b - Check the wear on the brake disks and change them
before completing the tests. (For details, see "30
REMOVAL AND INSTALLATION").
• Control
1 -Start the engine and heat the engine and all the fluids up
to working temperature. In particular make sure that the
power train oil reaches a temperature of 80±5 °C.
2 -With the engine in idling condition, accelerate to MAX.
and check that in this condition the revs remain within
permissible limits. 1
(See "ENGINE SPEED TESTS").
3 -Brake hard and bring the engine up to MAX.
4 -Engage the 3rd gear while braking and accelerating as RKZC3251
above; confirm that engine speed decreases to the
permissible range (See "CHECKING ENGINE WITH
LOAD").
5 -Repeat this test in REVERSE gear.
a If the revs are high than the permissible limits, the
clutches are worn, and must be replaced.
20-48 WB97R-5
TESTING AND ADJUSTMENTS ANALYSIS OF CAUSES HYDRAULIC DRIFT
ANALYSIS OF CAUSES HYDRAULIC DRIFT
a If working attachments have a hydraulic drift, it is
necessary to check if reason is due to cylinders gaskets
or to control valve.
a All testing conditions:
• Engine: at operating temperature
• Hydraulic oil: 45-55 °C
• Removal and installation of pipes only after remain
pressure removal.
FRONT EQUIPMENT
• Shovel raise check
1 -Put the machine with the shovel teeth on blocks “A” of
about 10 cm and in vertical position in relation to the
ground.
2 -Stop the engine and release residual hydraulic
pressures.
3- Disconnect pipes (1) and (2) from lift cylinders (3) and
A
plug them.
RKZC3440
4 -Plug cylinders, base side, and apply a temporary pipe,
head side, to catch possible oil leakage.
5 -Start the engine and curl shovel until the teeth are in tilt
position by about 10°.
2
6 -Stop the engine and check shovel link position for 5
minutes.
• If bucket link has no lowering movement, drift is due
1
to control valve.
To test the individual cylinders, proceed as follows: 3
7 -Carry out with shovel a dump movement to let teeth lean
on ground in vertical position.
RKZC3380
8 -Remove from one of the cylinders the plug fitted on the
cylinder bottom side in Phase 4.
9 -Start the engine and retract the shovel until to bring the
teeth in tilt position of about 10° towards upper.
10 -Stop the engine and check the shovel position for 5
minutes.
• If shovel link has a lowering movement, drift is due to
gaskets of plugged cylinder.
11 -Repeat operation from stage 8 to stage 10 to check the
other cylinder.
RKZC3450
WB97R-5 20-49
TESTING AND ADJUSTMENTS ANALYSIS OF CAUSES HYDRAULIC DRIFT
• Shovel dump check
1 -Put the machine with shovel on level ground and teeth
tilted of about 10°.
Put in the bucket a weight of 1500 kg.
1500 kg
RKZ02130
2 -Disconnect pipes (1) and (2) from both dump cylinders
(3) and plug them to prevent contamination of the ducts.
3 -Plug dump cylinder hole, base side, and apply a 3
temporary pipe on head side to catch possible oil
leakage.
2
RKZC3390
4 -Start the engine and raise the shovel until shovel hinge
pin is aligned with shovel arm hinge pin. 1500 kg
5 -Stop the engine and check the position of the shovel
teeth for 5 minutes.
• If shovel has no swing movement, drift is due to
control valve.
To test the individual cylinders, proceed as follows:
6 -Lower the shovel to the ground.
7 -Remove from one of the cylinders the plug fitted on the
cylinder bottom side in Phase 3. RKZ02630
8 -Start the engine and raise the shovel as indicated in
phase 4.
9 -Stop the engine and check the position of the shovel
teeth for 5 minutes.
• If the shovel teeth turn, the drift is due to the gasket
seals of the plugged cylinder.
10 -Repeat operation from stage 6 to stage 9 to check the
other cylinder.
20-50 WB97R-5
TESTING AND ADJUSTMENTS ANALYSIS OF CAUSES HYDRAULIC DRIFT
BACKHOE
a Test condition:
• Backhoe aligned
• Lifted outriggers
• Boom testing
1 -Set the machine with arm in vertical position and with
bucket on level ground leaned on the side.
2 -Stop the engine and release residual hydraulic
pressures.
RKZ11020
3 -Disconnect hoses (1) and (2) that feed cylinder (3).
4 -Plug the two hoses to avoid impurity inlet. 3
5 -Plug the cylinder head side. 4
6 -Apply a temporary pipe on pipe (3) base side to catch
possible oil leakage.
2
1
RKZC3400
7 -Start the engine and extend completely the arm.
8 -Stop the engine and check the boom position for 5
minutes.
• If boom has a lowering movement, drift is due to
cylinder gaskets.
• If boom has no lowering movement, drift is due to
control valve.
RKZ11030
• Arm testing
1 -Set the machine with arm fully extended and with bucket
teeth on ground.
2 -Stop the engine and release residual hydraulic
pressures.
RKZ11040
WB97R-5 20-51
TESTING AND ADJUSTMENTS ANALYSIS OF CAUSES HYDRAULIC DRIFT
3 -Disconnect pipes (1) and (2) pipes from arm cylinder (3)
and plug them to avoid impurity inlet.
2
a If safety valve is fitted, provide to removal.
1
3
4 -Plug arm cylinder hole on head side and fit a temporary
pipe on base side to catch possible oil leakage.
RKZC3410
5 -Start the engine and raise the boom.
6 -Stop the engine and check the arm position for 5
minutes.
• If arm has a lowering movement, drift is due to
cylinder gaskets.
• If arm has no movement, drift is due to control valve.
RKZ11050
• Bucket testing
1 -Set the machine with vertical arm and horizontal bucket
leaned at level ground on the side.
Put in the bucket a weight of 450 kg or fill it with earth.
450 kg
RKZ11060
2 -Stop the engine and release residual hydraulic
pressures. 2
3 -Disconnect bucket cylinders (3) pipes (1) and (2) and
plug them to avoid impurity inlet.
1
4 -Plug bucket cylinder hole on base side and fit a
temporary pipe on head side to catch possible oil
leakage.
3
RKZC3420
20-52 WB97R-5
TESTING AND ADJUSTMENTS ANALYSIS OF CAUSES HYDRAULIC DRIFT
5 -Start the engine and raise the boom.
6 -Stop the engine and check the bucket position for 5
minutes.
• If bucket has an opening movement, drift is due to
cylinder gaskets.
• If bucket has no movement, drift is due to control
valve.
RKZ11070
• Outriggers testing
1 -Set the machine with arm in vertical position and with
bucket on level ground leaned on the side.
2 -Put blocks of about 20 cm under the outriggers.
3 -Without forcing them, lower the outriggers onto the
trestles.
RKZ11080
4 -Stop the engine and release residual hydraulic
pressures.
5 -Remove clamp (1) and disconnect from cylinders (4) the 3
pipes (2) and (3).
2 3
6 -Plug cylinders pipes (2) base side and apply on head
sides temporary pipes to catch possible oil leakage.
7 -Start the engine, use force on the boom to raise the 1 2
machine, and remove the trestles supporting the
outriggers.
4
RKZC3430
8 -Lower the machine and stop the engine.
9 -Check the outriggers position for 5 minutes.
• If one or both outriggers have a lowering movement,
drift is due to single or both cylinders.
• If there is no lowering, drift is due to control valve.
RKZ11090
WB97R-5 20-53
TESTING AND ADJUSTMENTS TESTING THE AIR-CONDITIONING UNIT
TESTING THE AIR-CONDITIONING UNIT
a Test conditions:
• Machine on level ground with the working
equipment raised and in safety conditions
• Parking brake engaged
1. Testing the working temperature
1 -Connect the maintenance station to the high pressure
valve (H.P.) and the low pressure valve (L.P.)
2 -Start the engine and bring it up to a speed of 1500 rpm.
RKZ11010
3 -Switch on the A/C unit using the switch in the cab.
4 -Select an intermediate ventilation speed inside the cab.
5 -Use the thermometer/hygrometer M2 to check that the
temperature inside the cab is equal to or lower than the
ambient temperature.
a If the temperature of the cab is higher than the
ambient temperature, open the doors and widows
and wait until the cab temperature stabilizes at the
outside value.
6 -Close the doors and windows and let the A/C unit
operate in these conditions for 5 - 10 minutes.
7 -Use the thermometer M2 to check the temperature of
the air at the central outlets.
a Position the probe as close as possible to the air
outlets.
8 -Compare the average value of the measured
temperatures using the following table:
Ambient
20 25 30 35
temperature (°C)
Outgoing
air temperature 6 -- 8 8 -- 10 8 -- 12 9 -- 14
(°C)
9 -f the average value of the temperature measured does
not fall within the values given in the table, it will be
necessary to thoroughly check the unit.
20-54 WB97R-5
TESTING AND ADJUSTMENTS TESTING THE AIR-CONDITIONING UNIT
2. Checking the unit
Check the unit after the point 1., 2., 3., 4. and 6. of the
precedent paragraph.
A diagnosis of faults in the unit is based on the working
pressures.
When the pressures do not fall within the values given in the
following table, the causes must be sought by checking the
high-pressure (H.P.) and low pressure (L.P.) pressure
gauges.
Unit with R134a
Outside
L.P. (kg/cm²) H.P. (kg/cm²)
Temperature (°C)
Min. Max. Min. Max.
20 1.2 2.5 6.0 9.0
25 1.0 2.5 7.5 10.5
30 1.1 2.4 9.5 13.0
35 1.3 2.4 12.0 15.5
40 1.5 1.8 18.0 18.8
45 1.8 1.9 21.5 22.0
The following conditions may be found:
Conditions Causes - Faults
• Electromagnetic pulley that slips or does not engage correctly
L.P. high - H.P. normal or low • Expansion valve blocked in open position
• Compressor damaged
• Expansion valve blocked in closed position or obstructed
• Filter saturated with moisture
L.P. low - A.P. high or normal
• Obstruction in the L.P. line or in the H.P. line between the filter and the
evaporator L.P.
• Infiltration of hot air into the evaporator group, the pipes or the cab
L.P.normal - H.P. normal • Hot air circulating in the heating group
• Formation of ice on the evaporator
• Normal condition with very high ambient temperature (higher than 43°C)
• Excess coolant (30÷35% more)
• Overheating of condenser
L.P. high - H.P. high
• Air present in the unit
• Obstruction in the H.P. line between the compressor and the condenser-
filter tube, behind the measurement point of the H.P
• Normal condition with very low temperature (lower than 5°C)
• Lack of coolant (70 - 75% less) (probable leakages)
L.P. normal or low - H.P. low • Obstruction in the H.P. line between the compressor and the condenser-
filter tube, before the measurement point of the H.P.
• Compressor damaged
• Compressor belt missing
L.P. roughly equal to H.P. • Electromagnetic pulley that slips or does not engage
• Compressor damaged
WB97R-5 20-55
TESTING AND ADJUSTMENTS EMPTYING THE AIR-CONDITIONING UNIT
EMPTYING THE AIR-CONDITIONING UNIT
1 -Connect the maintenance station M1 to the service
valves (1) and (2) and follow the specific maintenance
station instructions relative to the drainage of the unit.
2 -Disconnect the group to be substituted or reconditioned
immediately after switching off the maintenance 2
station.Plug the removed or disconnected
connection tubes tightly and with a minimum of
delay.
1
3 -Carefully check the quantity of anti-freeze oil recovered
and contained in the disassembled parts, since the
same quantity must be replaced when the air- RKZC3032
conditioning unit is refilled.
20-56 WB97R-5
TESTING AND ADJUSTMENTS TROUBLESHOOTING
TROUBLESHOOTING
FRONT AXLE TROUBLESHOOTING
Wheel vibration; front tyre resistance; halfshaft breakage
CAUSES REMEDY
Incorrect installation Correct installation
Defective axle Replace the differential in case it does not survive any one of the test phases
Remove excessive weight and redistribute load, following instructions
Bent halfshaft
related to the vehicle
Different rotation radius of the tyres Replace the tyre or adjust pressure to have same radius on both tyre
Remove excessive weight and redistribute load, following instructions
Bent halfshaft
related to the vehicle
Steering is difficult; vehicle goes straight while its turning.
CAUSES REMEDY
Incorrect installation Correct installation
Replace the differential in case it does not survive any one
Defective axle
of the test phases
Remove excessive weight and redistribute load, following
Bent halfshaft
linstructions related to the vehicle
Different rotation radius of the tyres Replace the tyre or adjust pressure to have same radius on both tyre
Remove excessive weight and redistribute load, following instructions
Broken halfshaft
related to the vehicle
No differential action; jamming while steering.
CAUSES REMEDY
Incorrect installation Correct installation
Replace the differential in case it does not survive any one of the
Defective axle
test phases
Remove excessive weight and redistribute load, following instructions
Overloading/ incorrect weight distribution
related to the vehicle
Excess of noise
CAUSES REMEDY
Incorrect installation Correct installation
Replace the differential in case it does not survive any one of the
Defective axle
test phases
Remove excessive weight and redistribute load, following
Bent halfshaft
instructions related to the vehicle
Different rotation radius of the tyres Replace the tyre or adjust pressure to have same radius on both tyre
Remove excessive weight and redistribute load, following instructions
Overloading/ incorrect weight distribution
related to the vehicle
Incorrect wheel adjustment Verify group integrity and wheel side bearings.
Contamination in the axle box or Look for foreign particles. Check assembly of the
incorrect assemblyof parts various parts of the axle.
WB97R-5 20-57
TESTING AND ADJUSTMENTS TROUBLESHOOTING
Uneven wear of tyre
CAUSES REMEDY
Incorrect installation Correct installation
Replace the differential in case it does not survive any one of the
Defective axle
test phases
Remove excessive weight and redistribute load, following
Bent halfshaft
instructions related to the vehicle
Different rotation radius of the tyres Replace the tyre or adjust pressure to have same radius on both tyre
Remove excessive weight and redistribute load, following instructions
Overloading/ incorrect weight distribution
related to the vehicle
Blocked halfshaft:
Blocked halfshaft:
• Abnormal functioning of the differential or
breakage/blockage of command device. • Verify assembly and all components
• Vehicles with wide steering angle may • Reduce the steering angle to minimum and decelerate when the
p r o c ee d w i t h k i c k s , h a v e s t e e r i n g vehicle begins to kick.
difficulty or cause pneumatic wearing at
sharp turns.
Incorrect wheel adjustment Verify group integrity and wheel side bearings.
Friction noise
CAUSES REMEDY
Incorrect installation Correct installation
Replace the differential in case it does not survive any one of the
Defective axle
test phases
Remove excessive weight and redistribute load, following instructions
Overloading/ incorrect weight distribution
related to the vehicle
Check the condition of ring gear, pinion gear, bearings etc.
Spoiled or worn out axle parts
Replace when ever necessary.
Contamination in the axle box or Look for foreign particles. Check assembly of the
incorrect assemblyof parts various parts of the axle.
Incorrect adjustment of bevel gearset:
Parts of the transmission worn out. Replace or adjust as required.
(transmission gears, U joints, etc.)
Vibration during forward drive, intermittent noise
CAUSES REMEDY
Incorrect installation Correct installation
Replace the differential in case it does not survive any one of the
Defective axle
test phases
Remove excessive weight and redistribute load, following
Bent halfshaft
instructions related to the vehicle
Different rotation radius of the tyres Replace the tyre or adjust pressure to have same radius on both tyre
20-58 WB97R-5
TESTING AND ADJUSTMENTS TROUBLESHOOTING
Noise while driving
CAUSES REMEDY
Excessive backlash between pinion and ring
Replace
gear
Worn out pinion and gear ring Replace
Worn out pinion bearings Replace
Pinion bearings loosened Replace
Excessive pinion axial backlash Replace
Worn out differential bearings Replace
Differential bearings loosened Replace
Ring gear out of roundness Replace
Low lubricant level Top up
Poor or wrong lubricant Replace
Bent halfshaft Replace
Noise while driving in neutral
CAUSES REMEDY
Noise coming from axle are usually heard
when vehicle moves in neutral gear but are not Replace or adjust (see above)
loud.
Incorrect backlash between pinion and ring
(sound heard while decelerating disappears Replace
while increasing the speed)
Pinion or input flange worn out Replace
Intermittent noise
CAUSES REMEDY
Ring gear damaged Replace bevel gear set
Differential box bolts loosened Tighten to torque
Constant noise
CAUSES REMEDY
Ring gear teeth or pinion damaged Replace bevel gear set
Worn out bearings Replace
Pinion spline worn out Replace
Bent halfshaft Replace
Noise while steering
CAUSES REMEDY
Worn out differential gears Replace
Worn out differential box
Replace
or spider
Differential thrust washers worn out Replace
Half shaft spline worn out Replace
WB97R-5 20-59
TESTING AND ADJUSTMENTS TROUBLESHOOTING
FRONT AXLE CHECKING AND TROUBLESHOOTING
Ring gear tooth broken at the outer side
CAUSES REMEDY
Excessive gear load compared to the one foreseen
Replace bevel gear set
Incorrect gear adjustment (excessive backlash)
Adjust bevel gear set freebacklash
Pinion nut loosened
Ring gear tooth broken side
CAUSES REMEDY
Load bump
Replace bevel gear set
Incorrect gear adjustment (insufficient backlash)
Adjust bevel gear set freebacklash
Pinion nut loosened
Pinion or ring gear teeth or worn
CAUSES REMEDY
Insufficient lubrication; contaminated oil; Replace bevel gear set.
incorrect lubrication or depleted additives Use correct lubrication, fill up to the right level and substitute
at recommended intervals
Worn out pinion bearings Use correct lubricants, fill up to the right levels and
replace according to the recommended program.
Overheated ring and pinion teeth
CAUSES REMEDY
Prolong ed functioning at high temperatures Replace bevel gear set.
Insufficient lubrication; contaminated oil; Use correct lubrication, fill up to the right level and substitute
incorrect lubrication at recommended intervals
Pinion teeth pitting
CAUSES REMEDY
Excessive use axial pinion Replace bevel gear set.
Use correct lubrication, fill up to the right level and substitute
Insufficient lubrication at recommended intervals
Axle beam body bent
CAUSES REMEDY
Vehicle over loaded
Vehicle's accident Replace axle beam body
Load bump
Worn out or pitted bearings
CAUSES REMEDY
Insufficient lubrication; contaminated oil
Excessive use axial pinion Replace bearings.
Use correct lubrication, fill up to the right level and substitute
Normal wear out at recommended intervals
Pinion nut loosened
20-60 WB97R-5
TESTING AND ADJUSTMENTS TROUBLESHOOTING
Oil leakage form gaskets and seals
CAUSES REMEDY
Prolonged functioning at high temperature
of the oil Replace the gasket or seal and matching surface
Oil gasket assembled incorrectly if damaged.
Use correct lubrication, fill up to the right level and substitute
Seal lip damaged at recommended intervals
Contaminated oil
Excessive wearing out of input flange spline
CAUSES REMEDY
Excessive use axial pinion Replace the flange.
Pinion nut loosened Check that the pinion spline is not excessively
worn out.
Pinion axle backlash Replace bevel gear set if required.
Fatigue failure of pinion teeth
CAUSES REMEDY
Excessive use axial pinion
Replace bevel gear set
Continuous overload
Pinion and ring teeth breakage
CAUSES REMEDY
Check and/or replace other differential
Crash load of differential components
components
Side gear spline worn out
CAUSES REMEDY
Replace differential gear group.
Excessive use axial pinion
Replace halfshaft if required
Thrust washer surface worn out or scratched
CAUSES REMEDY
Replace all scratched washers and those with 0.1mm thickness
Insufficient lubrication; contaminated oil; lower than the new ones.
incorrect lubrication Use correct lubrication, fill up to the right level and substitute
at recommended intervals
Inner diameter of tapered roller bearing worn out
CAUSES REMEDY
Excessive use axial pinion Replace bearing.
Excessive pinion axial backlash Check pinion axial backlash.
Use correct lubrication, fill up to the right level and substitute
Insufficient lubrication; contaminated oil at recommended intervals
Bent or broken halfshaft or halfshaft broken at wheel side
CAUSES REMEDY
Vehicle intensively operated or overloaded Replace the axle shaft
Wheel support loosened Check beam body distortion.
Beam body bent Check wheel bearing and replace if necessary.
WB97R-5 20-61
TESTING AND ADJUSTMENTS TROUBLESHOOTING
REAR AXLE TROUBLESHOOTING
Wheel vibration; front tyre resistance; halfshaft breakage
CAUSES REMEDY
Incorrect installation Correct installation
Defective axle Replace the differential in case it does not survive any one of the test phases
Remove excessive weight and redistribute load, following instructions
Bent halfshaft
related to the vehicle
Different rotation radius of the tyres Replace the tyre or adjust pressure to have same radius on both tyre
Remove excessive weight and redistribute load, following instructions
Bent halfshaft
related to the vehicle
Steering is difficult; vehicle goes straight while its turning.
CAUSES REMEDY
Incorrect installation Correct installation
Replace the differential in case it does not survive any one
Defective axle
of the test phases
Remove excessive weight and redistribute load, following
Bent halfshaft
linstructions related to the vehicle
Replace the tyre or adjust pressure to have same radius
Different rotation radius of the tyres
on both tyre
Remove excessive weight and redistribute load, following instructions
Broken halfshaft
related to the vehicle
No differential action; jamming while steering.
CAUSES REMEDY
Incorrect installation Correct installation
Replace the differential in case it does not survive any one of the
Defective axle
test phases
Remove excessive weight and redistribute load, following instructions
Overloading/ incorrect weight distribution
related to the vehicle
Excess of noise
CAUSES REMEDY
Incorrect installation Correct installation
Replace the differential in case it does not survive any one of the
Defective axle
test phases
Remove excessive weight and redistribute load, following
Bent halfshaft
instructions related to the vehicle
Different rotation radius of the tyres Replace the tyre or adjust pressure to have same radius on both tyre
Remove excessive weight and redistribute load, following instructions
Overloading/ incorrect weight distribution
related to the vehicle
Incorrect wheel adjustment Verify group integrity and wheel side bearings.
Contamination in the axle box or Look for foreign particles. Check assembly of the
incorrect assemblyof parts various parts of the axle.
20-62 WB97R-5
TESTING AND ADJUSTMENTS TROUBLESHOOTING
Uneven wear of tyre
CAUSES REMEDY
Incorrect installation Correct installation
Replace the differential in case it does not survive any one of the
Defective axle
test phases
Remove excessive weight and redistribute load, following
Bent halfshaft
instructions related to the vehicle
Different rotation radius of the tyres Replace the tyre or adjust pressure to have same radius on both tyre
Remove excessive weight and redistribute load, following instructions
Overloading/ incorrect weight distribution
related to the vehicle
Blocked halfshaft:
• Abnormal functioning of the differential
or breakage/blockage of command • Verify assembly and all components.
device.
• Vehicles with wide steering angle may • Reduce the steering angle to minimum and decelerate when the
proceed with kicks, have steering vehicle begins to kick.
difficulty or cause pneumatic wearing at
sharp turns.
Incorrect wheel adjustment Verify group integrity and wheel side bearings.
Friction noise
CAUSES REMEDY
Incorrect installation Correct installation
Replace the differential in case it does not survive any one of the
Defective axle
test phases
Remove excessive weight and redistribute load, following instructions
Overloading/ incorrect weight distribution
related to the vehicle
Check the condition of ring gear, pinion gear, bearings etc.
Spoiled or worn out axle parts
Replace when ever necessary.
Contamination in the axle box or Look for foreign particles. Check assembly of the
incorrect assemblyof parts various parts of the axle.
Incorrect adjustment of bevel gearset:
Parts of the transmission worn out. Replace or adjust as required.
(transmission gears, U joints, etc.)
Vibration during forward drive, intermittent noise
CAUSES REMEDY
Incorrect installation Correct installation
Replace the differential in case it does not survive any one of the
Defective axle
test phases
Remove excessive weight and redistribute load, following instructions
Overloading/ incorrect weight distribution
related to the vehicle
Remove excessive weight and redistribute load, following
Bent halfshaft
instructions related to the vehicle
Different rotation radius of the tyres Replace the tyre or adjust pressure to have same radius on both tyre
WB97R-5 20-63
TESTING AND ADJUSTMENTS TROUBLESHOOTING
Noise while driving
CAUSES REMEDY
Excessive backlash between pinion and ring
Replace
gear
Worn out pinion and gear ring Replace
Worn out pinion bearings Replace
Pinion bearings loosened Replace
Excessive pinion axial backlash Replace
Worn out differential bearings Replace
Differential bearings loosened Replace
Ring gear out of roundness Replace
Low lubricant level Top up
Poor or wrong lubricant Replace
Bent halfshaft Replace
Noise while driving in neutral
CAUSES REMEDY
Noise coming from axle are usually heard
when vehicle moves in neutral gear but are not Replace or adjust (see above)
loud.
Incorrect backlash between pinion and ring
(sound heard while decelerating disappears Replace
while increasing the speed)
Pinion or input flange worn out Replace
Intermittent noise
CAUSES REMEDY
Ring gear damaged Replace bevel gear set
Differential box bolts loosened Tighten to torque
Constant noise
CAUSES REMEDY
Ring gear teeth or pinion damaged Replace bevel gear set
Worn out bearings Replace
Pinion spline worn out Replace
Bent halfshaft Replace
Noise while steering
CAUSES REMEDY
Worn out differential gears Replace
Worn out differential box
Replace
or spider
Differential thrust washers worn out Replace
Half shaft spline worn out Replace
20-64 WB97R-5
TESTING AND ADJUSTMENTS TROUBLESHOOTING
REAR AXLE CHECKING AND TROUBLESHOOTING
Ring gear tooth broken at the outer side
CAUSES REMEDY
Excessive gear load compared to the one foreseen
Replace bevel gear set
Incorrect gear adjustment (excessive backlash)
Adjust bevel gear set freebacklash
Pinion nut loosened
Ring gear tooth broken side
CAUSES REMEDY
Load bump
Replace bevel gear set
Incorrect gear adjustment (insufficient backlash)
Adjust bevel gear set freebacklash
Pinion nut loosened
Pinion or ring gear teeth or worn
CAUSES REMEDY
Insufficient lubrication; contaminated oil; Replace bevel gear set.
incorrect lubrication or depleted additives Use correct lubrication, fill up to the right level and substitute
at recommended intervals
Worn out pinion bearings Use correct lubricants, fill up to the right levels and
replace according to the recommended program.
Overheated ring and pinion teeth
CAUSES REMEDY
Prolong ed functioning at high temperatures Replace bevel gear set.
Insufficient lubrication; contaminated oil; Use correct lubrication, fill up to the right level and substitute
incorrect lubrication at recommended intervals
Pinion teeth pitting
CAUSES REMEDY
Excessive use axial pinion Replace bevel gear set.
Use correct lubrication, fill up to the right level and substitute
Insufficient lubrication at recommended intervals
Axle beam body bent
CAUSES REMEDY
Vehicle over loaded
Vehicle's accident Replace axle beam body
Load bump
Worn out or pitted bearings
CAUSES REMEDY
Insufficient lubrication; contaminated oil
Excessive use axial pinion Replace bearings.
Use correct lubrication, fill up to the right level and substitute
Normal wear out at recommended intervals
Pinion nut loosened
WB97R-5 20-65
TESTING AND ADJUSTMENTS TROUBLESHOOTING
Oil leakage form gaskets and seals
CAUSES REMEDY
Prolonged functioning at high temperature
of the oil Replace the gasket or seal and matching surface
Oil gasket assembled incorrectly if damaged.
Use correct lubrication, fill up to the right level and substitute
Seal lip damaged at recommended intervals
Contaminated oil
Excessive wearing out of input flange spline
CAUSES REMEDY
Excessive use axial pinion Replace the flange.
Pinion nut loosened Check that the pinion spline is not excessively
worn out.
Pinion axle backlash Replace bevel gear set if required.
Fatigue failure of pinion teeth
CAUSES REMEDY
Excessive use axial pinion
Replace bevel gear set
Continuous overload
Pinion and ring teeth breakage
CAUSES REMEDY
Check and/or replace other differential
Crash load of differential components
components
Side gear spline worn out
CAUSES REMEDY
Replace differential gear group.
Excessive use axial pinion
Replace halfshaft if required
Thrust washer surface worn out or scratched
CAUSES REMEDY
Replace all scratched washers and those with 0.1mm thickness
Insufficient lubrication; contaminated oil; lower than the new ones.
incorrect lubrication Use correct lubrication, fill up to the right level and substitute
at recommended intervals
Inner diameter of tapered roller bearing worn out
CAUSES REMEDY
Excessive use axial pinion Replace bearing.
Excessive pinion axial backlash Check pinion axial backlash.
Use correct lubrication, fill up to the right level and substitute
Insufficient lubrication; contaminated oil at recommended intervals
Bent or broken halfshaft or halfshaft broken at wheel side
CAUSES REMEDY
Vehicle intensively operated or overloaded Replace the axle shaft
Wheel support loosened Check beam body distortion.
Beam body bent Check wheel bearing and replace if necessary.
20-66 WB97R-5
TESTING AND ADJUSTMENTS TROUBLESHOOTING
TRANSMISSION TROUBLESHOOTING
Vehicle does not move
CAUSES REMEDY
Faulty supply to solenoid valves Check/Replace
Damaged wiring connections between
Repair/Replace
transmission and vehicle
Oxidised contacts in
Clean
electrical wiring
Break in electric cable Replace
Damaged solenoids Replace
Damaged sensors Replace
Short circuits or false contacts Check/replace fuses
Gear selector and direction of movement selector
Replace selector
malfunction
Shift electronic control malfunction Replace
Incorrect oil level Top up
Check for leaks Repair/Top up
Blocked intake filter Clean
Damaged oil pump Replace
Damaged oil pump relief valve Replace oil pump
Blocked/damaged transmission filter Replace
Damaged/jammed control valve Replace
Damaged converter Replace
Oil temperature below 0ûC Wait for oil to reach working temperature (stall test)
Damaged rotary seals Replace
Reverser locking Repair
Worn clutch unit Replace/Repair clutch unit
No drive transmission
Check/Repair/Replace
(broken gears, shafts, bearings, etc.)
Vehicle has reduced power transmission
CAUSES REMEDY
Incorrect oil temperature Wait for oil to reach working temperature (stall test)
Transmission oil overheating Restore acceptable temperature values
Check hydraulic circuit and replace
Incorrect operating pressure
(oil pump, filters, control valve)
Damaged converter Replace
Incorrect oil level Top up
Worn clutch unit Replace/Repair
4WD clutch failure Repair/Replace 4WD shaft group
Overheated solenoids/solenoid valves Replace
Damaged wiring connections between
Repair/Replace
transmission and vehicle
Damage to shift electronic control logic Replace
Damaged sensors Replace
WB97R-5 20-67
TESTING AND ADJUSTMENTS TROUBLESHOOTING
Overheating
CAUSES REMEDY
Damaged hydraulic cooling system Repair
Dirty heat exchanger Clean
Parking brake inadvertently activated Release
Excessive dirt on axle wheel hubs Clean
Seizing (broken gears, shafts, bearings, etc.) Check/Repair/Replace
Braking force outside transmission:
Check/Repair axle
irregular axle operation
Clutch plate drag Repair/Replace
Damaged converter Replace
Damaged oil thermostat Replace
Incorrect oil level Top up
Worn oil pump Replace
Wheels rotate when vehicle is raised
CAUSES REMEDY
Clutch plate drag Repair/Replace
Low oil temperature (high oil viscosity) Wait for oil to reach working temperature (stall test)
Incorrect oil specifications Replace oil and filters
Damaged control valve Replace
Faulty reverser locking Repair/Replace
Noise
CAUSES REMEDY
Damaged converter Replace
Damaged oil pump Replace
Aeration/Cavitation Check oil level / Check oil specifications
Seizing (broken gears, shafts, bearings, etc.) Check/Repair/Replace
Worn clutch plates Replace
Irregular actuation
CAUSES REMEDY
Damaged control valve Replace
Electrical system fault Repair/Replace
Worn clutch plates Replace
Damaged converter Replace
Low oil temperature (high oil viscosity) Wait for oil to reach working temperature (stall test)
Overheating See "overheating"
Gear selector or direction of movement selector
Replace
malfunction
Control module malfunction Replace
Shift electronic control malfunction Replace
Damaged hydraulic system Repair/Replace
20-68 WB97R-5
TESTING AND ADJUSTMENTS TROUBLESHOOTING
Gear remains engaged
CAUSES REMEDY
Damaged/jammed shuttleshaft lever Repair/Replace
Electrical system fault Repair/Replace
Damaged control valve Replace
Damaged hydraulic system Repair/Replace
Damaged clutch unit Repair/Replace
Selector malfunction Replace
Control module malfunction Replace
Shift electronic control malfunction Replace
No 4WD power transmission
CAUSES REMEDY
Damaged 4WD clutch Replace
Hydraulic system fault Repair/Replace
Damaged control valve Replace
Faulty brake sensor Check/Replace
Electrical system fault Repair/Replace
Selector malfunction Replace
Control module malfunction Replace
Shift electronic control malfunction Replace
Gear shift won’t engage
CAUSES REMEDY
Damage to clutch engagement assembly Repair/Replace
Damaged hydraulic system Repair/Replace
Damaged control valve Replace
Damage to pressure sensors Check/Replace
Electrical system fault Repair/Replace
Selector malfunction Replace
Control module malfunction Replace
Shift electronic control malfunction Replace
WB97R-5 20-69
30 REMOVAL AND INSTALLATION
HOW TO READ THE MANUAL .....................................5 STEERING WHEEL AND TRANSMISSION-REVERSE,
PRECAUTIONS TO BE TAKEN WHILE WORKING .....6 DIRECTION INDICATOR AND HEADLIGHT DIPPER
BEAM CONTROL GROUP .......................................... 38
SPECIAL TOOLS ...........................................................7
• Removal.................................................................. 38
ENGINE HOOD.............................................................11 • Installation............................................................... 39
• Removal ..................................................................11
WORKING BRAKE PUMP GROUP ............................ 40
• Installation ...............................................................12
• Removal.................................................................. 40
FRONT GUARD............................................................13 • Installation............................................................... 42
• Removal ..................................................................13
STEERING UNIT.......................................................... 43
• Installation ...............................................................13
• Removal.................................................................. 43
RADIATOR GROUP .....................................................14 • Installation............................................................... 44
• Removal ..................................................................14
CAB.............................................................................. 45
• Installation ...............................................................17
• Removal.................................................................. 45
CONDENSER (For machines equipped with an air- • Installation............................................................... 51
conditioning unit)........................................................18
HYDRAULIC OIL TANK .............................................. 53
• Removal ..................................................................18
• Removal.................................................................. 53
• Installation ...............................................................18
• Installation............................................................... 59
MUFFLER .....................................................................19
PISTON PUMP............................................................. 60
• Removal ..................................................................19
• Removal.................................................................. 60
• Installation ...............................................................19
• Installation............................................................... 61
AIR FILTER ..................................................................20
TRANSMISSION .......................................................... 62
• Removal ..................................................................20
• Removal.................................................................. 62
• Installation ...............................................................20
• Installation............................................................... 66
TURBOCHARGER .......................................................21 • Disassembly and assembly .................................... 67
• Removal ..................................................................21
CONVERTOR ............................................................ 175
• Installation ...............................................................22
• Removal................................................................ 175
AIR-CONDITIONING UNIT COMPRESSOR................23 • Installation............................................................. 175
• Removal ..................................................................23
ENGINE...................................................................... 176
• Installation ...............................................................24
• Removal................................................................ 176
AIR-CONDITIONING UNIT COMPRESSOR BELT .....25 • Installation............................................................. 180
• Removal ..................................................................25
CONTROL VALVE..................................................... 181
• Installation ...............................................................26
• Removal................................................................ 181
EXHAUST PIPE............................................................27 • Installation............................................................. 183
• Removal ..................................................................27
FRONT AXLE ............................................................ 184
• Installation ...............................................................27
• Removal................................................................ 184
FAN AND HEATING GROUP.......................................28 • Installation............................................................. 186
• Removal ..................................................................28 • Disassembly and assembly .................................. 187
• Installation ...............................................................33
REAR AXLE............................................................... 220
BATTERY .....................................................................34 • Removal................................................................ 220
• Removal ..................................................................34 • Installation............................................................. 222
• Installation ...............................................................35 • Disassembly and assembly .................................. 223
FUEL TANK..................................................................36 SHOVEL PPC VALVE ............................................... 273
• Removal ..................................................................36 • Removal................................................................ 273
• Installation ...............................................................37 • Installation............................................................. 274
WB97R-5 30-1
SHOVEL LIFT CYLINDERS ...................................... 275 BACKHOE BOOM SAFETY CYLINDER ...................304
• Removal................................................................ 275 • Removal ................................................................304
• Installation............................................................. 276 • Installation .............................................................305
SHOVEL DUMP CYLINDERS ................................... 277 CYLINDER..................................................................306
• Removal................................................................ 277 • SHOVEL ARM, SHOVEL, BOOM, ARM, BUCKET,
• Installation............................................................. 278 OUTRIGGERS ......................................................306
SHOVEL..................................................................... 279 • Disassembly ..........................................................306
• Removal................................................................ 279 • Assembly...............................................................308
• Installation............................................................. 279 • BACKHOE SWING CYLINDERS ..........................311
• Disassembly ..........................................................311
FRONT WORKING EQUIPMENT .............................. 280
• Assembly...............................................................314
• Removal................................................................ 280
• Installation............................................................. 281 BACKHOE WORKING EQUIPMENT.........................317
• Removal ................................................................317
BACKHOE PPC VALVES.......................................... 282
• Installation .............................................................318
• Removal................................................................ 282
• Installation............................................................. 283 BACKHOE BUCKET..................................................319
• Removal ................................................................319
PPC VALVE SUPPORT RELEASE CABLES ........... 284
• Installation .............................................................319
• Removal................................................................ 284
• Installation and adjusting ...................................... 286 BACKHOE BOOM CYLINDER ..................................320
• Removal ................................................................320
PPC VALVE SUPPORT RETURN GAS SPRING ..... 287
• Installation .............................................................320
• Removal................................................................ 287
• Installation............................................................. 288 ARM............................................................................321
• Removal ................................................................321
SOLENOID VALVE GROUP (servocontrol and optional
• Installation .............................................................321
attachment) ............................................................... 289
• Removal................................................................ 289 JIG ARM .....................................................................322
• Installation............................................................. 290 • Removal ................................................................322
• Installation .............................................................322
BACKHOE BOOM CYLINDER.................................. 291
• Removal................................................................ 291 2nd ARM ....................................................................323
• Installation............................................................. 293 • Removal ................................................................323
• Installation .............................................................323
ARM CYLINDER ........................................................ 294
• Removal................................................................ 294 2nd ARM GUIDES......................................................324
• Installation............................................................. 295 • Removal ................................................................324
• Installation .............................................................324
JIG ARM CYLINDER ................................................. 296
• Removal................................................................ 296 BACKHOE SWING BRACKET ..................................325
• Installation............................................................. 296 • Removal ................................................................325
• Installation .............................................................325
OUTRIGGER CYLINDER .......................................... 297
• Removal................................................................ 297 COMPLETE BACKHOE BACKFRAME.....................326
• Installation............................................................. 298 • Removal ................................................................326
• Installation .............................................................327
BACKHOE SWING CYLINDERS .............................. 299
• Removal................................................................ 299 BACKFRAME LOCK PISTONS.................................328
• Installation............................................................. 301 • Removal ................................................................328
• Installation .............................................................329
BACKHOE BUCKET CYLINDER .............................. 302
• Removal................................................................ 302
• Installation............................................................. 303
30-2 WB97R-5
REMOVAL AND INSTALLATION 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 [*1]; 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 OF THE GROUP ● ● ● : .........................................Title of operation
k: ............................................................................................Safety precautions to be followed when
carryingout the operation.
1 - Remove XXXX (1): ..............................................................Step in removal procedure
a: ........................................................................................Technique or important point to remember
whenremoving XXXX (1)
2 - eee (2): ...................................................................... [*1] This sign means that information is given\line
for the installation procedure
3 - Remove ttt (3):
6........... l: ....................................................................Recovery of oil or water, and the quantity to be
recovered.
INSTALLATION OF THE GROUP qqq: ..................................Title of operation
q To install, reverse removal procedure.
[*1]: .............................................................................................Technique to be used for installation
a: ........................................................................................Technique or important point to remember when
installing eee (2)
q Addition of water or oil: ........................................................Step in removal procedure
a: 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 WHILE WORKING".
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 2,3 , 4, 5, 6; 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 LUBRICATION», «LUBRICATING GREASE».
NOTE
If no symbol is indicated, the values to be used are those given in the introductory sections of this manual.
WB97R-5 30-5
REMOVAL AND INSTALLATION PRECAUTIONS TO BE TAKEN WHILE WORKING
PRECAUTIONS TO BE TAKEN WHILE WORKING
a 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.
• Always use the safety devices when working with the working equipment raised.
• 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.
• Use a receptacle of adequate capacity to collect the oil.
• Before removing a part from the machine, check the alignment reference marks which show the correct
installation 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.
• Replace the O-rings, cotter pins and stop rings with new ones.
• 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 hoisting
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 engine to
circulate the oil in the hydraulic circuits, and then top up to the indicated level.
• Fill with lubricant when installing mechanical assemblies.
• 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.
a For details, see «20. TESTING AND ADJUSTMENTS».
• After having re-assembled cylinder joints or cylinders, or work equipment articulations, lubricate thoroughly.
30-6 WB97R-5
REMOVAL AND INSTALLATION SPECIAL TOOLS
SPECIAL TOOLS
Nature of work Symbol Code Name Q.ty
Removal of piston pump 1 Pump support tool 1
B
Removal of transmission 2 Transmission support tool 1
1 CA715655 Plunger 1
2 CA119097 Plunger 1
3 CA715360 Plunger 1
4 CA715035 Plunger 1
5 CA715026 Plunger 1
6 CA715077 Plunger 1
7 CA715034 Plunger 1
8 CA715163 Plunger 1
9 CA119043 Plunger 1
10 CA715779 Plunger 1
Disassembly - assembly
D 11 CA715164 Plunger 1
front axle
12 CA119030 Ring nut spanner wrench 1
13 CA119230 Plunger 1
14 CA119099 Closed end wrench 1
15 CA715170 Closed end wrench 1
16 CA119225 Plunger 1
17 CA715023 False pinion 1
18 CA119182 False differential box 1
19 CA119206 False differential box 1
20 CA715179 Plunger 1
21 CA715701 Plunger 1
WB97R-5 30-7
REMOVAL AND INSTALLATION SPECIAL TOOLS
Nature of work Symbol Code Name Q.ty
1 CA715550 Plunger 1
Removal/installation tool
2 CA715902 1
self adjusting kit
3 CA715167 Plunger 1
4 CA715901 Bushing 1
5 CA715026 Plunger 1
6 CA715477 Plunger 1
Removal/installation tool
7 CA715900 1
Disassembly - assembly differential ring nut
E
rear axle 8 CA715391 Plunger 1
9 CA715170 Closed end wrench 1
10 CA119099 Closed end wrench 1
Outer ring installation tool
11 CA715092 1
pinion bearing
Outer ring installation tool
12 CA119225 1
pinion bearing
13 CA715128 False pinion 1
14 CA119198 False differential box 1
30-8 WB97R-5
REMOVAL AND INSTALLATION SPECIAL TOOLS
Nature of work Symbol Code Name Q.ty
1 CA715409 Plunger 1
2 CA715004 Plunger 1
3 CA715623 Plunger 1
4 CA715494 Control 1
5 CA715495 Protection + shims 1
6 CA715497 Plunger 1
7 CA715356 Calibrator 1
8 CA715501 Plunger 1
Installation/assembly tool
9 CA715358 1
clutches
10 CA715499 Protection 1
11 CA715046 Plunger 1
12 CA715743 Protection + shims 1
Disassembly - assembly
F
transmission 13 CA715746 Plunger 1
14 CA715745 Calibrator 1
15 CA715732 Lifting of B, C, and E shafts 1
16 CA715149 Plunger 1
17 CA715744 Protection + shims 1
18 CA715747 Calibrator 1
19 CA715748 Plunger 1
20 CA716009 Calibrator 1
21 CA716010 Protection 1
22 CA716018 Protection + shims 1
23 CA716019 Plunger 1
24 CA716020 Calibrator 1
25 CA716021 Extractor 1
WB97R-5 30-9
REMOVAL AND INSTALLATION SPECIAL TOOLS
Nature of work Symbol Code Name Q.ty
790-502-1003 Equipment 1
1
790-101-1102 Pump 1
2 790-102-3802 Key 1
790-302-1310 Key 65 mm 1
790-302-1280 Key 55 mm 1
3
790-302-1270 Key 50 mm 1
790-302-1390 Key 46 mm 1
4 790-102-4300 Expander 1
796-720-1670
Calibrator for boom cylinder 1
07281-01279
796-720-1660
Calibrator for arm and swing cylinders 1
07281-01159
5
796-720-1650 Calibrator for bucket and shovel arm
1
07281-01029 cylinders
796-720-1640 Calibrator for outriggers and
1
07281-00909 shovel cylinders
790-201-1702 Driver kit 1
Disassembly - assembly 790-101-5021 . Handle 1
U
cylinder
01010-50816 . Screw 1
790-201-1781 . Driver for boom cylinder 1
6 790-201-1771 . Driver for bucket cylinder 1
. Driver for swing and shovel arm
790-201-1761 1
cylinder
790-201-1751 . Driver for shovel cylinder 1
790-201-1741 . Driver for outrigger cylinder 1
790-201-1500 Driver kit 1
790-101-5021 . Handle 1
01010-50816 . Screw 1
790-201-1590 . Driver for boom cylinder 1
7 790-201-1580 . Driver for bucket cylinder 1
. Driver for swing and shovel arm
790-201-1570 1
cylinder
790-201-1560 . Driver for shovel cylinder 1
790-201-1550 . Driver for outrigger cylinder 1
790-102-4300 Key 1
8
790-102-4310 Pin 2
30-10 WB97R-5
REMOVAL AND INSTALLATION ENGINE HOOD
ENGINE HOOD
Removal
k Lower the working equipment completely until it is
3
resting on the ground.
Stop the engine and remove the ignition key.
1
1 -Loosen and remove the screws (1) and washers and
remove the front grille (2). 2
1
RKZC0740
2 -Fully raise the engine hood (3), remove the safety pins
(4) and disconnect the gas springs (5) from the chassis.
RKZC0750
3 -Remove the snap rings (6) and washers (7).
8
7
RKZC0760
4 -Attach lifting equipment to engine hood (3); pull out
fulcrum pins (8) and remove hood (3).
4 Engine hood: 32 kg
3
RKZC0770
WB97R-5 30-11
REMOVAL AND INSTALLATION ENGINE HOOD
Installation
• To install, reverse removal procedure.
a Check catch (9) for proper centring.
9
RKZC0780
30-12 WB97R-5
REMOVAL AND INSTALLATION FRONT GUARD
FRONT GUARD
Removal
k Lower the working equipment completely until it is
resting on the ground.
Stop the engine and remove the ignition key.
1
1 -Loosen and remove the screws (1) and washers and
remove the front grille (2). 2
1
RKZC0741
2 -Loosen the screws (3) retaining the guard (4) to
eliminate torque. [*1]
4
3
RKZC0790
3 -Connect the guard (4) to the lifting equipment and
slightly tension the rope.
4 -Take out the screws (1) and remove the protection (4).
RKZC0800
Installation
• To install, reverse removal procedure.
[*1]
2 Screw: Loctite 242
3 Screw: 300 Nm
WB97R-5 30-13
REMOVAL AND INSTALLATION RADIATOR GROUP
RADIATOR GROUP
Removal
k Fully raise the front working equipment and engage the
safety stop.
Also place the backhoe in its secure position. 1
k Remove the ignition key.
1 -Remove the engine hood (1).
(For details see "ENGINE HOOD").
RKZC0771
2 -Remove the front guard (2).
(For details see "FRONT GUARD").
k Release all residual pressure in all circuits.
RKZC0801
3 -Open the cock (3) and drain the coolant liquid. [*1]
6 Coolant liquid: approx. 15 l
3
For machines equipped with an air-conditioning unit.
4- Drain the air conditioning unit.
(For details see "20 TESTING AND ADJUSTMENTS").
5
[*2]
5 -Disconnect the connector (4) and remove the horn (5).
4
RKZC0810
6 -Disconnect hose (7) from radiator (6) and remove surge
tank (8).
7
6
RKZC0820
30-14 WB97R-5
REMOVAL AND INSTALLATION RADIATOR GROUP
7 -Loosen and remove four screws and fan guards (9) and
(10).
9 10
RKZC0830
8 -Partly loosen fittings (11) and (12) to drain the hydraulic
oil from the oil cooler; once the oil is drained, fully 12
disconnect hoses (13), (14) and plug them to prevent 11
contamination. [*3]
6 Hydraulic oil: 40 l
13
14
RKZC0840
9 -Disconnect gearbox oil hoses (15) and (16) from the oil
cooler and plug them to prevent contamination.
k Mark the hoses and their respective positions for
connection.
[*4]
15
16
RKZC0850
For machines equipped with an air-conditioning unit.
10 -Disconnect the tubes (17) and (18).
a Immediately plug the tubes and the orifices to prevent to
prevent moisture from entering into the circuit. 17
18
RKZC0860
WB97R-5 30-15
REMOVAL AND INSTALLATION RADIATOR GROUP
11 -Disconnect the tubes (19) and (20).
19
20
RKZC0870
12 -Loosen and remove the self-locking nuts (21) (n°2),
washers (22) and anti-vibration dampers (23).
23
22
21
RKZC0880
13 -Loosen and remove the screws (24) retaining the
holders (25).
25
24
RKZC0890
14 -Move the radiator group (6) to the front of the machine so
as to disengage it from the cooling fan.
[*5]
6
15 -Attach lifting equipment to the group (6) and remove the
group.
4 Radiator group: 37 kg
RKZC0900
30-16 WB97R-5
REMOVAL AND INSTALLATION RADIATOR GROUP
Installation
• To install, reverse removal procedure.
[*1]
a Refill the coolant liquid circuit.
5 Coolant liquid: 15 l
[*2]
a Refill the air-conditioning unit.
5 Quantity of fluid (R134a): 2250 ±150 g
Quantity of oil: see the amount recovered.
[*3]
a Fill the tank with hydraulic oil up to maximum level.
5 Hydraulic oil: 40 l
[*4]
a Ensure that the level of transmission oil is at maximum.
1 -Start the engine at low idling to circulate all the fluids and
to fill up the systems.
2 -Accelerate gradually up to 1700 rpm; after about one
minute, stop the engine and check or top up the level.
a After about one minute, stop the engine and top up
all levels.
[*5] 25±2 mm
a Align radiator (6) with fan (26), making sure the fan
protrudes from fan shroud by 25±2 mm. 6
26
RKZ10741
WB97R-5 30-17
REMOVAL AND INSTALLATION CONDENSER (For machines equipped with an air-conditioning unit)
CONDENSER
(For machines equipped with an air-conditioning unit)
Removal
k Fully raise the front working equipment and engage the
safety stop.
Also place the backhoe in its secure position.
1 -Drain the air conditioning unit.
(For details see "20 TESTING AND ADJUSTMENTS").
2 -Remove the front grille and the front guard
(For details see "FRONT GUARD").
3 -Disconnect the tubes (1) and (2).
a Immediately plug the tubes and the condenser
tightly to prevent moisture from entering into the air-
conditioning circuit. 2
1
RKZC0861
4 -Disconnect the connector (3) and remove the horn (4).
5 -Loosen and remove four screws (5) and washers, and
remove condenser (6) together with dehydrating filter. 3 5
5
6
4
RKZC0910
Installation
• To install, reverse removal procedure.
1 -Refill the air-conditioning unit. (For details, see "20
TESTING AND ADJUSTMENTS").
30-18 WB97R-5
REMOVAL AND INSTALLATION MUFFLER
MUFFLER
Removal
k Fully raise the front working equipment and engage the
safety stop. 1
Also place the backhoe in its secure position.
k Remove the ignition key and fully raise the engine
hood. 2
1 -Loosen the nuts (1) on the jumper pin (2) retaining the
muffler pipe (3) to the exhaust pipe. 3
1
RKZC0920
2 -Loosen the jumper pin (4), disconnect the pipe (3) from
the muffler (5) and remove pipe.
5
RKZC0930
3 -Loosen the tie strap (6) retaining the muffler pipe to the
turbocharger.
RKZC0940
4 -Loosen and remove the four screws (7) and washers.
5 -Remove the muffler (5).
Installation 7
5 7
• To install, reverse removal procedure.
RKZC0950
WB97R-5 30-19
REMOVAL AND INSTALLATION AIR FILTER
AIR FILTER
Removal
2
1 -Park the machine on hard, level ground, apply the
parking brake, stop the engine and remove the ignition
key.
1
2 -Fully open engine hood, loosen straps (1) and (2), and
disconnect pipes (3) and (4). 4
1
RKZC0960
3 -Disconnect connector (6) from filter clogging sensor (5).
5
6
RKZC0970
4 -Loosen and remove the screws (7) and remove the filter
(8) together with the filter holder.
7
8
RKZC0980
Installation
• To install, reverse removal procedure.
30-20 WB97R-5
REMOVAL AND INSTALLATION TURBOCHARGER
TURBOCHARGER
Removal
k Fully raise the front working equipment and engage the
safety stop.
Also place the backhoe in its secure position.
k Remove the ignition key.
2
1 -Disconnect the vapour recovery pipe (2) from the
suction pipe (1).
1
2 -Disconnect the suction pipe (1) from the turbocharger
(3). 3
RKZC0961
3 -Disconnect the connector (4) from the filter clogging
lamp.
RKZC0971
4 -Loosen and remove the screws (5) and the air filter (6).
5
6
RKZC0981
5 -Loosen and remove screw (7) and nut (8), and remove
heat guard (9). 7 8
RKZC0990
WB97R-5 30-21
REMOVAL AND INSTALLATION TURBOCHARGER
6 -Remove the muffler (10)
(For details see "MUFFLER").
10
RKZC1000
7 -Remove the turbocharger (3) according to the
instructions provided in the engine manual (manual
code WHBMNEF000).
3
RKZC0962
Installation
• To install, reverse removal procedure.
30-22 WB97R-5
REMOVAL AND INSTALLATION AIR-CONDITIONING UNIT COMPRESSOR
AIR-CONDITIONING UNIT COMPRESSOR
Removal
k Fully raise the front working equipment and engage the
safety stop.
Also place the backhoe in its secure position.
k Remove the ignition key.
1 -Connect the outlets (1) and (2) to the maintenance
station for air-conditioning units and drain the cooling
fluid.
2
(For details see "20 TESTING AND ADJUSTMENTS").
2 -Release the tie strap and disconnect the connector (3). 1
RKZC3000
3 -Disconnect fluid delivery and return pipes (5), (6) from
compressor (4). [*1]
5
a Collect the O-rings.
RKZC3010
4 -Remove the air filter (8).
RKZC0982
WB97R-5 30-23
REMOVAL AND INSTALLATION AIR-CONDITIONING UNIT COMPRESSOR
5 -Remove the left fan guard (7).
RKZC3020
6 -Loosen the screw (9) retaining the tensioner (10).
7 -Loosen the nut (11) and turn the screw (12) to loosen the
belt.
12 11
9 10
RKTA1206
8 -Disengage belt (13) from pulley (14).
9 -Loosen the screws (15) retaining the compressor (4).
10 -Take out the screws (15) and remove the compressor 15
(4). 15
13
4
14
15
Installation RKZC3030
• To install, reverse removal procedure.
[*1]
a Check O-rings for damage.
2 O-rings and fittings: coolant oil
1 -Tension the compressor belt.
(For details see "AIR-CONDITIONING UNIT
COMPRESSOR BELT").
2 -Connect the unit to the maintenance station and refill it.
(For details see "20 TESTING AND ADJUSTMENTS").
30-24 WB97R-5
REMOVAL AND INSTALLATION AIR-CONDITIONING UNIT COMPRESSOR BELT
AIR-CONDITIONING UNIT COMPRESSOR BELT
Removal
k Fully raise the front working equipment and engage the 1 1
safety stop.
Also place the backhoe in its secure position.
k Remove the ignition key.
1 -Take out the screws and remove the fan guards (1).
RKZC0831
2 -Remove the air filter (2).
RKZC0983
3 -Loosen the screw (3) retaining the tensioner bracket (4).
4 -Loosen nut (5) and screw (6) for belt tension.
6 5
3 4
RKTA1207
5 -Loosen the screws (7) retaining the compressor (8) and
remove the belt (9).
7
7
9
8
7
RKZC3031
WB97R-5 30-25
REMOVAL AND INSTALLATION AIR-CONDITIONING UNIT COMPRESSOR BELT
Installation
• To install, reverse removal procedure.
[*1]
3 Bracket lock nut: 117.6 Nm
[*2]
3 Fan fastening nuts: 42 Nm
1 -Carry out the belt tensioning procedure.
(For details see "20 TESTING AND ADJUSTMENTS").
30-26 WB97R-5
REMOVAL AND INSTALLATION EXHAUST PIPE
EXHAUST PIPE
Removal
1 -Loosen the nuts (1) on the jumper pin (2) retaining the
muffler pipe (3) to the exhaust pipe. 1
3
1
RKZC0920
2 -Loosen the screws (4) on the attachment flange;
remove one screw but leave the second screw in place
for added safety.
RKZC1010
3 -Remove the screw (5) and washer from the upper
vibration damper.
4 -Remove the second screw (4) and remove the exhaust
pipe (6). 6
RKZC1020
Installation
• To install, reverse removal procedure.
WB97R-5 30-27
REMOVAL AND INSTALLATION FAN AND HEATING GROUP
FAN AND HEATING GROUP
Removal
NOTEIf no air-conditioning unit is included, perform
only those operations relating to the heating unit.
k Lower the working equipment completely until it rests 3
on the ground, and stop the engine.
k Disconnect the cable from battery negative terminal (-).
(For details see "BATTERY"). 2
a Drain the engine cooling liquid.
6 Coolant liquid: 15 l 1 RKZC1030
a Drain the air conditioning unit.
(For details see "20 TESTING AND ADJUSTMENTS").
1 -Remove the floor-mat (1); disconnect the connector (2)
and remove the seat (3).
2 -Take out the screws (4) and remove the control unit
protection (5).
5
4
RKZC6230
3 -Remove four screws (6) and remove PPC valve and
parking brake casing (7).
7
RKZC6380
4 -Remove four screw covers and screws (8).
10 8
5 -Remove the lower side instrument board (9).
a Cut the wiring harness strap and position the
instrument board (9) inside the RH case (10).
• To install, reverse removal procedure.
9
RKZC6530
30-28 WB97R-5
REMOVAL AND INSTALLATION FAN AND HEATING GROUP
6 -Remove four screw covers and screws (11).
7 -Remove the upper side instrument board (12). 12
11
RKZC1070
8 -Disconnect the connector (13) from the instrument
board (12).
9 -Disconnect connectors (14) and (15) from the lighter.
13
14 15 12
RKZC1080
10 -Extract screws (16) and remove the hand accelerator
handle (17).
17
11 -Remove screws (18) from the accelerator lever
assembly.
16
18
RKZC1090
12 -Loosen and remove the screws (19) and (20).
19 20
RKZC1100
WB97R-5 30-29
REMOVAL AND INSTALLATION FAN AND HEATING GROUP
13 -Loosen nuts and remove knobs (21) from outrigger PPC
valves.
14 -Remove PPC valve mounting plate (22).
21
22
RKZC1110
15 -Extract screws (23) and remove contact carrier plate
(24) for rear wiper.
23
24
RKZC1120
16 -Extract the lower screws (25) retaining the right hand
case (10).
25
25
10
RKZC6520
17 -Extract three screw covers (26) and screws retaining the
right hand case (10) at the rear. 26 26
10
RKZC1140
30-30 WB97R-5
REMOVAL AND INSTALLATION FAN AND HEATING GROUP
18 -Extract two screw covers (27) and screws; extract the
lower screw (28) and washer.
27
28
RKZC6190
19 -Extract the upper screw (29) retaining the right hand
case (10) and its washer.
10
29
RKZC1160
20 -Move the rear of the right hand case (10) towards the
middle of the cab, remove pin (30), and disconnect hand
30
accelerator cable (31).
21 -Loosen nut and disconnect sheath (32). 31
32
RKZC1170
22 -Disconnect the contact carrier plate connector (33).
33
RKZC2990
WB97R-5 30-31
REMOVAL AND INSTALLATION FAN AND HEATING GROUP
24 -Engage the parking brake.
25 - Raise right hand case (10) until PPC valve control and 10
parking brake lever are disengaged; fully remove the
case.
RKZC6180
FAN
35
26 -Disconnect the connector (34).
36
27 - Remove screw (35), then rotate fan group (36)
counterclockwise.
34
RKZC1190
28 -Extract the fan group (36).
36
RKZC1200
29 -Remove the clamp (37).
30 -Disconnect connectors (38) and (39); slide off and move
to one side the fuse and relay group (40). 40
39
38
37
RKZC1210
30-32 WB97R-5
REMOVAL AND INSTALLATION FAN AND HEATING GROUP
31 -Disconnect the heating system liquid inlet and outlet
pipes (42) from the oil cooler (41).
42
41
RKZC1220
32 -Only for machines with air-conditioning.
44 47
Disconnect the pressure switch connector (43).
Remove the screw (44), the washer and the plate (45);
disconnect delivery and return hoses (46), (47).
a Collect the O-rings.
45
43
46
RKZC6200
OIL COOLER GROUP
33 -Loosen and remove the four screws (48) and remove
the group (41).
48 48
41
Installation RKZC1231
1 - Refill the coolant liquid.
5 Coolant liquid: approx. 15 l
2 -Drain and refill the air-conditioning unit.
5 Quantity of fluid (R134a): 2250 ±150 g
Quantity of oil: see the amount recovered.
3 -Start the engine and use a leak detector to check the
leaktightness of the air-conditioning unit.
4 -Complete installation by reversing the removal
procedure.
WB97R-5 30-33
REMOVAL AND INSTALLATION BATTERY
BATTERY
Removal
k Lower the working equipment completely until it is
resting on the ground.
Engage the parking brake, stop the engine and remove
the ignition key.
1
1 -Lift the door (1) and disconnect the catch (2).
2
RKZC1240
2 -Remove the lower right-hand guard (3) of the cab.
3 -Remove the protection (4).
4
RKZC1250
4 -Take out the screws and remove the platform (5) and
door.
RKZC1260
5 -Disengage battery negative (–) terminal (6) from shield
and disconnect from battery (7). 6
6 -Use the same procedure as above to disconnect the 8
battery positive terminal (8). [*1]
7
RKZC1270
30-34 WB97R-5
REMOVAL AND INSTALLATION BATTERY
7 -Loosen wing nut (9) and remove tie rod (10) and bracket
(11). 11
8 -Remove the battery (8).
8 9
10
RKZC1280
Installation
• To install, reverse removal procedure.
[*1]
k Connect the battery positive (+) cable first, and then the
battery negative (–) cable.
WB97R-5 30-35
REMOVAL AND INSTALLATION FUEL TANK
FUEL TANK
Removal
k Lower the working equipment completely until it is
resting on the ground.
Engage the parking brake, stop the engine and remove
the ignition key.
1 -Take the cap (2) off the filling inlet of the fuel tank (3) and
remove also the bottom plug in order to drain the fuel.
6 Fuel: max. 150 l 3
2 -Reinstall the fill plug (1) and the drain plug (3).
1 2
RKZC1290
3 -Remove the lower left-hand guard (4) of the cab.
RKZC1300
4 -Disconnect the connector (5) from the level gauge (6).
5 8
5 -Mark and disconnect the fuel inlet and return hoses (7),
(8).
a Plug all pipes/hoses to prevent contamination.
RKZC1310
30-36 WB97R-5
REMOVAL AND INSTALLATION FUEL TANK
6 -Place a hoist under the fuel tank (2); remove four
retaining screws (9) and washers, and remove the tank.
[*1]
4 Fuel tank: 68 kg
9
RKZC1320
Installation
• To install, reverse removal procedure.
[*1]
3 Tank retaining screws: 120 Nm
1 -Refill the fuel tank.
5 Fuel: max. 150 l
2 -Bleed the air from the fuel circuit.
3 -Start the engine.
WB97R-5 30-37
REMOVAL AND INSTALLATION STEERING WHEEL AND TRANSMISSION-REVERSE, DIRECTION
STEERING WHEEL AND TRANSMISSION-REVERSE, DIRECTION
INDICATOR AND HEADLIGHT DIPPER BEAM CONTROL GROUP
Removal
k Lower the working equipment completely until it rests
on the ground.
Engage the parking brake and stop the engine.
k Disconnect the cable from battery negative terminal (–).
(For details see "BATTERY"). 1
1
1 -Use a thin bladed screwdriver placed under each spoke
of the steering wheel to pry away the cover (1).
RKZC1330
2 -Loosen and remove the retaining nut (2) and remove the
steering wheel (3). 3
RKZC1340
3 -Remove four screw covers (4) and loosen four screws
(5) retaining the instrument panel.
4
5
RKZC1350
4 -Slide off instrument panel (6) from steering column;
disconnect connectors (7) and (8), and remove
instrument panel. 6
RKZC1360
30-38 WB97R-5
REMOVAL AND INSTALLATION STEERING WHEEL AND TRANSMISSION-REVERSE, DIRECTION
5 -Loosen and remove screws (9) and (10) and release
direction indicator group (11)and transmission reverse 12
9
control group (12).
10
11
RKZC1370
6 -Disconnect connectors (13) and (14) and remove
groups (11) and (12). [*1] 13
14
12
11
RKZC1380
Installation
• To install, reverse removal procedure. 16
[*1]
a Before attempting to tighten the screws, check the
antirotation stake (15) for proper engagement into the
steering column (16).
15
RKZC1390
WB97R-5 30-39
REMOVAL AND INSTALLATION WORKING BRAKE PUMP GROUP
WORKING BRAKE PUMP GROUP
Removal
k Lower the working equipment completely until it rests
on the ground.
Engage the parking brake, stop the engine and remove
the ignition key.
1 -Remove the steering wheel and the direction indicator
and transmission reverse control groups
(For details, see "STEERING WHEEL AND
TRANSMISSION-REVERSE, DIRECTION
INDICATOR AND HEADLIGHT DIPPER BEAM
CONTROL GROUP").
2 -Disconnect the connector (1) and remove the seat (2).
3 -Remove the front mat (3).
RKZC1031
4 -Loosen and remove the upper screws (4) retaining the
instrument panel holder (5).
RKZC1400
5 -Remove the guards (6) and extract the upper screws (7)
retaining the front trim cover (8).
RKZC1410
30-40 WB97R-5
REMOVAL AND INSTALLATION WORKING BRAKE PUMP GROUP
6 -Loosen and remove the lower screws (9) retaining the
front trim cover (8). 8
7 -Fully lower the steering column; extract the knob (10).
10
RKZC1420
8 -Slide the front trim cover (8) up to remove it.
8
RKZC1430
9 -Take out the lower screws (11) and remove the
instrument panel holder (5).
5
11
RKZC6220
10 -Remove the plug and (12) and draw oil from the tank
(13). 14
12
11 -Reinstall the plug and disconnect connectors (14) and
pressure switch connectors (15) and (16).
12 -Remove the tank (13).
13
16
15
RKZC1450
WB97R-5 30-41
REMOVAL AND INSTALLATION WORKING BRAKE PUMP GROUP
13 -Disconnect the delivery pipes (18) from the pumps (17).
[*1]
a Plug all pipes/hoses to prevent contamination. 17
19
14 -Take out four screws (19) and remove the pump group.
[*2]
20
a If only one pump is to be removed, also disconnect
the pressure equalizing pipe (20).
[*3]
18 RKZC1460
Installation
• To install, reverse removal procedure.
[*1]
a Bleed the air from the braking circuit.
(For details, see "20 TESTING AND ADJUSTMENTS").
[*2]
21
a Make sure that the push-rods (21) center the seating of
the pistons.
a When installation is complete, inspect for proper brake
pedal pre-travel and alignment.
(For details, see "20 TESTING AND ADJUSTMENTS").
[*3]
3 Union: 20 Nm
RKZ10750
30-42 WB97R-5
REMOVAL AND INSTALLATION STEERING UNIT
STEERING UNIT
Removal
k Lower the working equipment completely until it rests
on the ground.
Engage the parking brake, stop the engine and remove
the ignition key. 3
k Eliminate residual pressure from all circuits by moving
all control levers in all directions. 2
1 -Remove the front mat (1).
2 -Disconnect the connector (2) and remove the seat (3). 1 RKZC1030
3 -Remove the steering wheel and the direction indicator,
transmission reverse and headlight dipper beam control
groups
(For details, see "STEERING WHEEL AND
TRANSMISSION-REVERSE, DIRECTION
INDICATOR AND HEADLIGHT DIPPER BEAM
CONTROL GROUP").
RKZC1381
4 -Loosen and remove the upper screws (4) retaining the
instrument panel holder (5).
RKZC1400
5 -Remove the steering column lock knob (6).
6 -Remove the screws (7) retaining the side of the
instrument panel holder.
6
RKZC6210
WB97R-5 30-43
REMOVAL AND INSTALLATION STEERING UNIT
7 -Slide the instrument panel holder (5) up to remove it.
RKZC6221
8 -Loosen screw (6) and remove two screws (7); remove
the front guard (8).
7
8
RKZC1480
9 -Mark the respective positions of and disconnect five
pipes (10) from steering unit. 9
a Plug all pipes to prevent contamination.
[*1]
10
10
RKZC1490
10 -Loosen the screws (11) fastening the column (12) and
steering unit (9); remove the steering unit. 12
Installation
• To install, reverse removal procedure.
[*1]
11
a Start the engine and perform several complete steering
manoeuvres in both directions, to bleed the air out of the
steering system.
RKZC1500
30-44 WB97R-5
REMOVAL AND INSTALLATION CAB
CAB
Removal
k Lower the working equipment completely until it rests
on the ground.
Engage the parking brake and stop the engine.
k Disconnect the cable from battery negative terminal (–).
(For details see "BATTERY").
k Release all residual pressure in all circuits.
a Drain the engine cooling liquid.
6 Coolant liquid: 15 l
a Only for machines equipped with an air-
conditioning unit.
Drain the air conditioning unit.
(For details see "20 TESTING AND ADJUSTMENTS").
[*1]
1 -Remove the exhaust pipe.
(For details see "EXHAUST PIPE").
2 -Disconnect the injection pump control rod (2) from the
pitman arm (1).
1
RKZC1531
3 -Remove the front mat, remove screws (3) and loosen
screw (4). 3
3
4 -Remove the steering unit guard (5).
4
RKZC3040
WB97R-5 30-45
REMOVAL AND INSTALLATION CAB
5 -Disconnect pipes (7) from steering unit. [*2]
a Mark the positions of the pipes to prevent 6
exchanging positions when reconnecting.
a Plug the pipes and pipe-fittings to prevent entry of
impurities.
7
7
RKZC1491
6 -Remove nut (8) and disconnect strap (9) from frame.
7 -Disconnect the tubes (10) and (3). [*3]
a Plug the pipes and pipe-fittings to prevent entry of
10
impurities.
8
9
RKZC1532
8 -Take out the screws (11) and remove the hood (12).
12
11
RKZC6231
9 -Disconnect lower frame harness connectors (14) from
fuse block (13).
13
14
14
RKZC6240
30-46 WB97R-5
REMOVAL AND INSTALLATION CAB
10 -Lift rear window (15) to the top and remove the rear mat.
15
RKZC1871
11 -Take out the screws (16) and remove the platform (17).
16
16
17
RKZC1973
12 -Snly if equipped.
Disconnect connectors (19) and (20) from foot button
(18). 18
a Mark the position of connectors to avoid mixing
them during installation.
19
20
RKZC6540
13 -Disconnect the servocontrols upper and lower pipes
(21) from the control valve. [*4] 21 21
a Check that all the hoses are marked and note down
the bends and routing patterns.
a Cap pipes, hoses and holes to prevent
contamination.
a Lay the hoses inside the cab to gain access to the
feed and exhaust hoses.
21
21
RKZC1992
WB97R-5 30-47
REMOVAL AND INSTALLATION CAB
14 -Disconnect servocontrol supply hoses (23) and (24)
from solenoid valve group (22).
a Mark the pipes to avoid exchanging them during
installation.
22
a Cap pipes, hoses and holes to prevent
contamination. 24
23
RKZC2322
15 -Disconnect parking brake cable (25) from brake caliper.
[*5]
25
RKZC2073
16 -Take out the screws (26) and remove the protection
(27).
27
26 26
RKZC1302
17 -Remove nuts (28) as well as front and rear screws.
[*6]
28
28
RKZC3061
30-48 WB97R-5
REMOVAL AND INSTALLATION CAB
• Version with air-conditioning unit
18 -Disconnect the suction pipe (30) from the compressor
(29). [*7]
a Cap the hose and hole to ward off humidity.
a Release the hose and route it under the cab.
30
29
RKZC3012
19 -Take out the screws (31) and remove the protection
(32).
31
32
31
RKZC0743
20 -Disconnect hose (34) from condenser (33). [*8]
a Cap the hose and hole to ward off humidity.
a Release the hose and route it under the cab.
34
33
RKZC3071
WB97R-5 30-49
REMOVAL AND INSTALLATION CAB
21 -Remove the hole plugs and tighten two lifting eyes into
the lifting holes provided.
Connect the cab (35) to the lifting equipment and apply
light tension. 35
22 -Lift the cab by about 30 cm and place some safety blocks
“A” under it.
A A
RKZC3081
23 -Remove the screw (36) and disconnect the ground wire
(37). 38
24 -Pull out screws (38) and remove cable guard (39).
36
37
39
RKZC3091
25 -Loosen straps (40) and disconnect heating hoses (41).
a Mark the pipes to avoid exchanging them during
installation.
a Cap pipes, hoses and holes to prevent 41
contamination.
26 -Ensure that all hoses, harnesses and wires are free, and
remove the cab.
40
RKZC3101
30-50 WB97R-5
REMOVAL AND INSTALLATION CAB
Installation
• To install, reverse removal procedure.
[*1]
a Drain and refill the air-conditioning unit
5 Quantity of fluid (R134a): 2250 ±150 g
Quantity of oil: see the amount recovered.
[*2]
a Bleed the air from the steering circuit. (For details, see
"20 TESTING AND ADJUSTMENTS").
[*3]
a Bleed the air from the braking circuit.
(For details, see "20 TESTING AND ADJUSTMENTS").
[*4]
a Perform all possible backhoe movements to bleed the
servocontrol system.
[*5]
a Adjust the stroke of the parking brake lever. (For details,
see "20 TESTING AND ADJUSTMENTS").
[*6]
3 Cab retaining screws: 200 Nm
[*7]
3 Suction pipe union: _________ Nm
[*8]
3 Union (34): 16 Nm
1 - Refill the coolant liquid.
5 Coolant liquid: approx. 15 l
WB97R-5 30-51
PAGE INTENTIONALLY
LEFT BLANK
REMOVAL AND INSTALLATION HYDRAULIC OIL TANK
HYDRAULIC OIL TANK
Removal
k Lower the working equipment completely until it rests
on the ground.
Engage the parking brake, stop the engine and remove
the ignition key.
k Eliminate residual pressure from all circuits by moving
all control levers in all directions.
k Disconnect the cable from battery negative terminal (–).
(For details, see "BATTERY").
1 -Remove the plug (1) and drain the hydraulic oil.
6 Hydraulic oil: approx. 40 l
RKZC1510
2 -Remove the front mat (2).
3 -Disconnect the connector (3) and remove the seat (4).
2 RKZC1032
4 -Remove the steering wheel and remove the
transmission reverse control group (5) and the direction
indicator and headlight dipper beam control group (6)
(For details, see "STEERING WHEEL AND 5
TRANSMISSION-REVERSE, DIRECTION
INDICATOR AND HEADLIGHT DIPPER BEAM
CONTROL GROUP").
RKZC1382
WB97R-5 30-53
REMOVAL AND INSTALLATION HYDRAULIC OIL TANK
5 -Loosen and remove the upper screws (7) retaining the
instrument panel holder (8).
RKZC1401
6 -Remove the guards (9) and extract the upper screws
(10) retaining the front trim cover (11).
11
10
RKZC1411
7 -Loosen and remove the lower screws (12) retaining the
front trim cover (11). 11
8 -Fully lower the steering column; extract the knob (13).
13
12
RKZC1421
9 -Slide the front trim cover (11) up to remove it.
11
RKZC1431
30-54 WB97R-5
REMOVAL AND INSTALLATION HYDRAULIC OIL TANK
10 -Take out the lower screws and remove the instrument
panel holder (8).
8
RKZC6222
11 -Remove the fill plug (14) and draw the brake fluid.
15
a Replace plug to prevent contamination. 14
12 -Disconnect oil level and pressure switch connectors
(15) and (16).
16
16
RKZC1451
13 -Disconnect the brake fluid delivery tubes (17). [*1]
a Plug all pipes/hoses to prevent contamination.
17 RKZC1461
14 -Loosen mounting bolt (18).
15 -Pull out the screws (19) and remove the protection (20).
19
20
18
RKZC1481
WB97R-5 30-55
REMOVAL AND INSTALLATION HYDRAULIC OIL TANK
16 -Loosen and remove five screws (21) and remove the
metal sheet (22) closing off the cab floor. 21
22
21
RKZC6250
17 -Loosen and remove nuts (23) and disconnect the hand
accelerator cable (25) from the relay rod (24). [*2] 23
24
18 -Disconnect the injection pump rod (26) from the relay
rod (24). 26
19 -Disconnect the strap (27) holding the steering unit and 25
working brake hoses.
27
RKZC1530
20 -Loosen and remove nut (28) and washer.
30
21 -Disconnect the washer hoses (29) and remove the
complete wiper arm (30).
28
29
RKZC1540
22 -Disconnect connector (32) from washer pump (31).
31
32
RKZC1550
30-56 WB97R-5
REMOVAL AND INSTALLATION HYDRAULIC OIL TANK
23 -Disconnect connector (33) from wiper (34).
34
33
RKZC1560
24 -Loosen and remove screws (35) and washers.
Remove the complete bulkhead (36) and move it to the
rear of the machine.
35 35
36
RKZC6260
25 -Take out the screws (37) and remove the conveyor (38).
37
38
RKZC1580
26 -Lift the rubber bulkhead and disconnect the discharge
hose (40) from the tank (39).
a Plug the pipe to prevent contamination.
40
39
RKZC1590
WB97R-5 30-57
REMOVAL AND INSTALLATION HYDRAULIC OIL TANK
27 -Disconnect the draining union (41) and pipe (42).
a Plug the union to prevent contamination.
42
41
RKZC1600
28 -Disconnect the pump suction pipe (43).
a Plug the pipe to prevent contamination.
43
RKZC1610
29 -Disconnect the vent hose (44) and filter and remove.
30 -Remove the screws and remove the fill sleeve (45).
a Collect the O-ring. 45
44
RKZC1620
31 -Remove screws (46) and washers and remove the
tank's front holder (47).
47
46
RKZC1630
30-58 WB97R-5
REMOVAL AND INSTALLATION HYDRAULIC OIL TANK
32 -Remove screws (48) and washers and remove the
tank's rear holder (49).
49
48
RKZC1640
33 -Remove two screws (50) and washers to release the
complete tank (39).
39
50
RKZC1650
34 -Extract the tank (39).
39
Installation
• To install, reverse removal procedure.
[*1]
a Bleed the air from the braking circuit. (For details, see
"20 TESTING AND ADJUSTMENTS").
RKZC1660
[*2]
a Check and adjust the stroke of the hand accelerator.
1 -Refill the hydraulic oil.
5 Hydraulic oil: approx. 40 l
2 -Start the engine and check for leaks.
3 -Bleed the air from the cylinders. (For details, see "20
TESTING AND ADJUSTMENTS").
4 -Stop the engine, check the oil level in the tank and, if
necessary, top it up.
WB97R-5 30-59
REMOVAL AND INSTALLATION PISTON PUMP
PISTON PUMP
Removal
k Lower the working equipment completely until it rests
on the ground.
Stop the engine and remove the ignition key.
k Eliminate all residual pressure from all circuits by
moving all hydraulic controls in all directions. 1
1 -Remove the plug (1) and drain the hydraulic oil.
6 Hydraulic oil: approx. 40 l
a Replace plug to prevent contamination. RKZC1510
2 -Disconnect rear cardan shaft (3) from transmission (2).
[*1]
3
RKZC1670
3 -Disconnect the delivery hose (5) and the LS and pump
delivery pressure control hoses (6) and (7) from the
7
pump (4).
a Cap pipes, hoses and holes to prevent
contamination.
4 5
RKZC1680
4 -Disconnect the suction pipe (8) and the draining hose (9)
from the pump.
a Cap pipes, hoses and holes to prevent
contamination.
8
9
RKZC1511
30-60 WB97R-5
REMOVAL AND INSTALLATION PISTON PUMP
5 -Loosen and remove the lower screw (10) retaining the
pump (4) and its washer. 11
6 -Loosen upper screw (11) but leave it in place. 4
a Do not remove the screw at this stage. [*2]
10
RKZC6270
7 -Install pump holding tool “B1” to a hydraulic jack.
8 -Place tool “B1” under the pump until the pump fully
supported.
B1
RKZC6280
9 -Take out the upper screw (11) and remove the pump (4).
4 Piston pump: 36.8 kg 4
Installation
• To install, reverse removal procedure.
RKZC1710
[*1]
3 Screw: 38±1 Nm
[*2]
3 Pump screws: 220 Nm
1 -Refill the hydraulic oil.
5 Hydraulic oil: approx. 40 l
2 -Start the engine and run it at MIN. to bleed any air.
3 -Stop the engine and check the oil level in the tank.
WB97R-5 30-61
REMOVAL AND INSTALLATION TRANSMISSION
TRANSMISSION
Removal
k Lower the working equipment completely until it rests
on the ground.
Stop the engine and remove the ignition key.
k Eliminate all residual pressure from all circuits by
moving all hydraulic controls in all directions.
k Disconnect the cable from battery negative terminal (–).
a Drain the hydraulic oil.
6 Hydraulic oil: approx. 40 l RKZC1271
a Drain the oil from the gearbox.
6 Hydraulic oil: approx. 20 l
1
[*1]
1 -Remove the piston pump (1).
(For details see "PISTON PUMP"). [*2]
RKZC1711
2 -Remove the front mat and remove the metal sheet (2)
closing off the cab floor.
RKZC1521
3 -Disconnect rear cardan shaft (4) from transmission (3).
[*4]
4
RKZC1672
30-62 WB97R-5
REMOVAL AND INSTALLATION TRANSMISSION
4 -Remove front cardan shaft (5). [*4]
RKZC1731
5 -Disconnect seven solenoid valve connectors (6) and
6
shift oil temperature sensor connector (7) from gearshift 8
(3).
6 -Take out the screws (8) and remove the harness holder 8
(9).
9
3 7
RKZC6290
7 -Disconnect the connector (10) from the rev sensor (11).
11
10
RKZC6310
8 -Disconnect delivery hose (12) to oil cooler and return
hose (13) from gearbox (3).
9
9 -Remove the clamp (14). 12
13 14
RKZC6300
WB97R-5 30-63
REMOVAL AND INSTALLATION TRANSMISSION
10 -Remove the screws and remove the cover (15) giving
access to the converter coupling flange.
15
11 -Slowly rotate the engine flywheel until the converter
retaining screws (16) are centred in the hole; remove the
four screws. [*5]
16
RKZC1760
12 -Procure to support the engine (17) with a stand “C”
placed under the flywheel bell.
17
RKZC1781
13 -Disconnect the gearbox oil load and oil level control pipe
(18), remove the screw (19) and remove the complete
pipe (18). 18
18
19
RKZC6320
14 -Remove the nuts (20) on the vibration dampers (21), the
screws (22) and remove the gearbox supports (23). 21
[*6] [*7] 23 21
23
20
20
22
22
RKZC6330
30-64 WB97R-5
REMOVAL AND INSTALLATION TRANSMISSION
15 -Install the gearbox holding tool “B2” to a stand that is
capable of descending by about 60 cm.
Using the holes on the supports, secure the tool “B2” to
the gearbox.
B2
RKZC6340
16 -Loosen and remove the two screws (24) retaining the
gearbox (3) to the engine (17). [*8]
24
24
17
RKZC6350
17 -Move the gearbox group (3) towards the rear of the
machine and extract the group.
4 Transmission: 254 kg
RKZC6360
WB97R-5 30-65
REMOVAL AND INSTALLATION TRANSMISSION
Installation
• To install, reverse removal procedure.
[*1]
5 Hydraulic oil: approx. 20 l
[*2]
5 Hydraulic oil: approx. 40 l
[*3]
3 Screw: 120 Nm
[*4]
3 Cardan shaft screws: 38 Nm
[*5]
2 Screw: Loctite 242
3 Screw: 64 Nm
[*6]
3 Anti-vibration nuts: 195±20 Nm
[*7]
2 Support screws: Loctite 262
3 Support screws: 90±5 Nm
[*8]
2 Engine-gearbox screws: Loctite 262
3 Engine-gearbox screws: 50±5 Nm
a Tighten the screws using the alternating crosswise
method.
1 -Start the engine to circulate the oil. Check that there are
no leaks.
2 -Bleed the air from the working equipment circuits.
(For details see "20 TESTING AND ADJUSTMENTS").
3 -Stop the engine, check the levels and, if necessary, top
them up.
30-66 WB97R-5
REMOVAL AND INSTALLATION TRANSMISSION
TRANSMISSION
Disassembly and assembly
1. Plugs and filters
1.1 Disassembly
6 11
13 12
7 14
16
2
10
5 9
3
8
4
1 18
15
RKZ11200
1 -Remove the drain plug (1) and drain the oil from the
transmission.
RKZC3490
2 -Remove the two cap screws (2) which fasten the cover
for the oil screen.
RKZC3500
WB97R-5 30-67
REMOVAL AND INSTALLATION TRANSMISSION
3 -Remove the cover (3), the oil screen (4) and the ring (5).
5
RKZC3510
4 -Unscrew the oil filter (6).
If necessary, remove the connector (7) for the oil filter 6
(6).
RKZC3520
5 -Unscrew and remove the oil filter protection valve (8).
RKZC3530
6 -Check the valve (8) condition.
a Clean with care the valve and replace the O-ring (9)
and (10) if necessary.
9
10
8
RKZC3540
30-68 WB97R-5
REMOVAL AND INSTALLATION TRANSMISSION
7 -Remove the breather (11) from the transmission
housing only if this part is leaking or damaged.
11
RKZC3550
8 -To check the FORWARD clutch pressure, remove the
plug (12).
12
RKZC3560
9 -To check the REVERSE clutch pressure, remove the
plug (13).
13
RKZC3570
10 -To check the lubrication pressure, remove the plug (14).
14
RKZC3580
WB97R-5 30-69
REMOVAL AND INSTALLATION TRANSMISSION
11 -Remove the speed sensor (15).
15
RKZC3590
12 -Rimuovere il termostato olio (16).
16
RKZC3600
1.2 Assembly
1 -Assemble the speed sensor (15) to the prescribed
torque
3 Sensor: 50 Nm
15
RKZC3590
2 -Assemble the thermostat (16) to the prescribed torque.
3 Thermostat: 30 Nm
16
RKZC3600
30-70 WB97R-5
REMOVAL AND INSTALLATION TRANSMISSION
3 -Assemble the plugs (12), (13) and (14) to the prescribed
torque after the pressure check.
3 Caps: 30 Nm
13
12
RKZC3571
4 -Assemble by hand the breather (11) to the transmission
housing and tighten it strongly.
11
RKZC3550
5 -Clean with care the oil filter protection valve (8).
Assemble the new O-ring (9) and (10).
10
8
RKZC3540
6 -Assemble the oil filter protection valves (8).
Tighten the valve (8) to the prescribed torque
3 Valve: 23 Nm
RKZC3530
WB97R-5 30-71
REMOVAL AND INSTALLATION TRANSMISSION
7 -Assemble the connector (7) for the oil filter (6) then
tighten it to the prescribed torque.
3 Union: 50 Nm
7
RKZC3610
8 -Assemble new oil filter (6).
a Put a thin coat of oil or grease on the filter gasket,
6
turn clockwise until the gasket makes contact with
the base, continue to turn the filter 2/3 turn.
RKZC3521
9 -Assemble new O-ring (5) to the filter (4).
Insert the filter (4) with O-ring (5) and assemble the
cover (3).
4
5
RKZC3620
10 -Assemble the two cap screws (2) at prescribed torque to
fasten the cover (3).
3 Screw: 23 Nm 3
2
RKZC3501
30-72 WB97R-5
REMOVAL AND INSTALLATION TRANSMISSION
11 -Assemble the drain plug (1) to the prescribed torque.
3 Plug: 80 Nm
RKZC3490
WB97R-5 30-73
REMOVAL AND INSTALLATION TRANSMISSION
2. Torque converter and oil pump
2.1 Disassembly
4
3
2
5 6
1
RKZ11210
1 -Remove torque converter (1).
(For details see "CONVERTOR"). 1
RKZC3630
2 -Remove screws (2).
a Make reference mark on the pump and bell housing
before untightening the screws.
2
RKZC3640
30-74 WB97R-5
REMOVAL AND INSTALLATION TRANSMISSION
3 -Extract the pump (3) by means of two levers.
RKZC3650
4 -Remove the oil pump (3).
k Do not disassemble the oil pump (3)
RKZC3660
5 -Remove O-ring (4).
a Replace the O-ring at each disassembly.
RKZC3670
6 -If replacement is necessary, remove the seal ring (5).
a This is a destructive operation for the seal ring.
5
RKZC3680
WB97R-5 30-75
REMOVAL AND INSTALLATION TRANSMISSION
2.2 Assembly
1 -Assemble new seal ring (5) on the oil pump (3).
Use tool F1.
F1
5
3
RKZC3690
2 -Assemble new O-ring (4).
RKZC3670
a If the oil pump is being replaced, verify that the oil
passage holes between the pump and the half housing,
and the marks on the side in view match.
RKZC3700
3 -Grease the ring (5) to keep it centred/coaxial with
respect to the shaft slot centre line and to make the
introduction onto the pump easier.
RKZC3710
30-76 WB97R-5
REMOVAL AND INSTALLATION TRANSMISSION
4 -Apply a thin film of grease on the coupling seat with the
transmission housing (6). Assemble the oil pump (3).
3
6
RKZC3720
5 -Assemble the screws (2) to prescribed torque.
3 Screw: 23 Nm
a Check that reference marks made on the oil pump
2
and on the bell housing coincide.
RKZC3640
6 -To prevent damage to the pump sealing ring, install the
converter to the transmission by hand. The two teeth on 1
the converter that are responsible for driving the pump
can cut the lip of the sealing ring.
7 -Couple transmission and converter to the engine
flywheel with the screws of the bell converter drive plate.
RKZC3630
WB97R-5 30-77
REMOVAL AND INSTALLATION TRANSMISSION
3. Hydraulic control valve
3.1 Disassembly
1 6 4
2
5
7
3
11
10
9
8
RKZ11220
1 -Drain oil from transmission hydraulic circuit, disconnect
all electrical connections.
Remove screws (1). 1
1
1
RKZC3730
2 -Lift control valve (2).
RKZC3740
30-78 WB97R-5
REMOVAL AND INSTALLATION TRANSMISSION
3 -Remove the gasket (3).
RKZC3750
4 -Place the control valve unit on a clean workbench.
Remove fastening screws (4) from the valves (5) and 6
(6). 5
4
RKZC3760
5 -Extract with care the valves (5) and (6) with a
screwdriver.
5
RKZC3770
6 -Remove the valves (5) and (6).
RKZC3780
WB97R-5 30-79
REMOVAL AND INSTALLATION TRANSMISSION
7 -Check the valves (5) and (6) condition.
5
RKZC3790
8 -Unscrew and remove the valve (7).
RKZC3800
9 -Check the valve (7) condition.
7
RKZC3810
10 -Unscrew and remove the oil filter protection valve (8).
RKZC3530
30-80 WB97R-5
REMOVAL AND INSTALLATION TRANSMISSION
11 -Check the valve (8) condition.
Clean with care the valve and replace the O-ring (9) and
(10) if necessary.
10
8
RKZC3540
3.2 Assembly
1 -Clean with care the oil filter protection valve (8) and
assemble the new O-ring (9) and (10).
9
10
8
RKZC3540
2 -Assemble the oil filter protection valves (8).
Tighten the valve (8) to the prescribed torque
3 Valve: 23 Nm
RKZC3530
3 -Assemble the ON/OFF (6) and proportional (5) valves
using the locations shown on the side. 6 6 6 6
6 5 5
RKZ11230
WB97R-5 30-81
REMOVAL AND INSTALLATION TRANSMISSION
4 -Assemble the valve mounting screws (4).
4
RKZC3761
6 -Assemble the new gasket (3).
RKZC3750
7 -Assemble the control valve unit (2) to the transmission
(11).
11
RKZC3820
8 -Tighten the bolts (1) to the prescribed torque.
3 Screws: 23 Nm 1
1
1
RKZC3830
30-82 WB97R-5
REMOVAL AND INSTALLATION TRANSMISSION
4. Hydraulic system lines
4.1 Disassembly
1
5
3
7
RKZ11240
1 -Drain oil from transmission hydraulic circuit.
Unscrew the connections of pipe (1) (shaft lubrication)
and remove the pipe (1).
RKZC3840
2 -Remove the pipe (2) (2nd speed) unscrewing related
connections.
RKZC3850
WB97R-5 30-83
REMOVAL AND INSTALLATION TRANSMISSION
3 -Remove the pipes (3) (4th speed), (4) (4WD), (5) (1st
speed) and (6) (3rd speed) unscrewing related
connections.
6
3
a Collect connection gaskets.
4
5
RKZC3860
4 -Remove the pipe (7) (shaft lubrication) unscrewing
related connections.
RKZC3870
4.1 Assembly
1 -Assemble the pipe (1) tightening the connections to the
prescribed torque.
3 Unions: 30 Nm
RKZC3840
2 -Assemble the pipe (2) tightening torques the
connections to the prescribed torque.
3 Unions: 30 Nm
RKZC3850
30-84 WB97R-5
REMOVAL AND INSTALLATION TRANSMISSION
3 -Assemble the pipes (3), (4), (5) and (6) then tighten
related connections to the prescribed torque.
3 Unions: 30 Nm 3
6
4
5
RKZC3860
4 -Assemble the pipe (7) tightening torques the
connections to the prescribed torque.
3 Unions: 30 Nm
RKZC3870
WB97R-5 30-85
REMOVAL AND INSTALLATION TRANSMISSION
5. Transmission housing
5.1 Disassembly
8 6
18 11
10
19 7
20
12
14
15
13
16
17
4
3
5
2
1 RKZ11250
1 -Drain oil from transmission.
Unscrew flange (2) fastening bolt (1).
2
RKZC3880
30-86 WB97R-5
REMOVAL AND INSTALLATION TRANSMISSION
2 -If necessary use a screwdriver and two screws to stop
flange rotation.
RKZC3900
3 -Collect the washer (3).
RKZC3910
4 -Remove flange (2) and O-ring (4).
a Replace the O-ring at each disassembly. 2
RKZC3920
5 -Remove seal ring (5).
a This is a destructive operation for the seal ring.
5
RKZC3930
WB97R-5 30-87
REMOVAL AND INSTALLATION TRANSMISSION
6 -Remove the fastening screws (6) from the flange (7).
RKZC3940
7 -Remove flange (7).
RKZC3950
8 -Extract transmission shaft PTO (8).
RKZC3960
9 -If to be replaced, remove teflon seal ring (9) by cutting it.
a This is a destructive operation for the seal ring.
9
RKZC3970
30-88 WB97R-5
REMOVAL AND INSTALLATION TRANSMISSION
10 -Remove snap ring (10).
10
RKZC3980
11 -Extract bearing (11) with tool F2.
11
RKZC3990
12 -Unscrew flange (13) fastening bolt (12).
Use a screwdriver and two screws to stop flange
13
rotation.
RKZC3901
13 -Remove the bolt (12) and washer (14).
12 14
RKZC3911
WB97R-5 30-89
REMOVAL AND INSTALLATION TRANSMISSION
14 -Remove flange (13) and O-ring (15).
13
a Replace the O-ring at each disassembly. 15
RKZC4000
15 -Remove seal ring (16).
a This is a destructive operation for the seal ring.
16
RKZC4010
16 -Remove fastening bolts (17) from the rear (18) and front
(19) half housings. 19
18
17
RKZC4020
17 -Insert a lever in the special slot to detach the cover.
RKZC4030
30-90 WB97R-5
REMOVAL AND INSTALLATION TRANSMISSION
18 -Lift the front half housing (19) by means of two hooks.
19
RKZC4040
19 -Remove the three O-rings (20).
20
20
RKZC4050
5.2 Assembly
1 -Assemble three new O-rings (20) to the rear half
housings (18). 20
a Accurately remove from mating surfaces any 20
residual of sealant and clean them with a detergent.
RKZC4050
2 -Assemble all the transmission internal parts.
Apply a thin film of prescribed sealant on the edge of the
rear half-housing.
2 Loctite 510
RKZC4060
WB97R-5 30-91
REMOVAL AND INSTALLATION TRANSMISSION
3 -Install front half housing (19) to rear half housing. Make
sure that the bearings on the shafts go straight into the
bores in the front half housing. Push the front half 19
housing all the way down on the rear half housing.
RKZC4040
4 -Assemblare fastening bolts (17) to the rear (18) and
front (19) half housings.
Tighten the bolts to the prescribed torque.
3 Screws: 50 Nm
17
RKZC4070
5 -Assemble seal ring (5) on front shaft output.
Use tool F8.
5
RKZC4080
6 -Assemble flange (2) and a new O-ring (4).
2
RKZC3920
30-92 WB97R-5
REMOVAL AND INSTALLATION TRANSMISSION
7 -Assemble the washer (3) and bolt (1).
1 3
RKZC3912
8 -Tighten the bolt (1) to the prescribed torque.
Use screwdriver and two screws to stop flange rotation.
3 Screws: 139 Nm
RKZC4090
9 -Assemble seal ring (16) on rear shaft output.
Use tool F8.
16
RKZC4100
10 -Assemble flange (13) and a new O-ring (15).
13
15
RKZC3921
WB97R-5 30-93
REMOVAL AND INSTALLATION TRANSMISSION
11 -Assemble the washer (14) and bolt (12).
12 14
RKZC3911
12 -Tighten the bolt (12) to the prescribed torque.
Use screwdriver and two screws to stop flange rotation.
3 Screws: 139 Nm
RKZC4090
13 -Assemble bearing (11) on transmission shaft PTO (8).
11
RKZC4110
14 -Assemble snap ring (10).
10
RKZC4120
30-94 WB97R-5
REMOVAL AND INSTALLATION TRANSMISSION
15 -Install the Teflon sealing ring (9) according to steps 21 to
25 of the procedure described in paragraph "6.2
Assembly", using tools F5 - F6 - F7.
9
RKZC4130
16 -Insert transmission shaft PTO (8) to the stroke.
RKZC3960
17 -Apply a thin film of sealant to the flange (7).
2 Loctite 510
7
a Verify that the two holes for oil passage (A) match.
A
A RKZC4140
18 -Assemble the screws (6) to prescribed torque.
3 Screw: 50 Nm
6
RKZC3940
WB97R-5 30-95
REMOVAL AND INSTALLATION TRANSMISSION
6. Shafts A - D
6.1 Disassembly
33
37 17 18 32
11 34
16 10
8 38
6 39
40
7 27
4
3
2
1
31
21
20
19 22
23
9 24
5 25
12
26
28
15 30
14 29
13 35
36
RKZ11260
1 -Grasp with pliers the input shaft assembly A . Remove
with shaft assembly D and lift.
D
A
RKZC4150
2 -If to be replaced, remove the teflon seal ring (1).
RKZC4160
30-96 WB97R-5
REMOVAL AND INSTALLATION TRANSMISSION
3 -Remove the snap ring (2).
RKZC4170
4 -Install a bearing separator under the gear.
Use a puller on the bearing separator and insert a shaft
protector between the puller and the end of the input
shaft.
Operate with the puller between bearing separator and
shaft protector and pull only until the bearing is free.
Pulling any farther can damage the parts.
k Do not install the separator between gear and
bearing.
RKZC4180
5 -Remove bearing (3).
RKZC4190
6 -Remove spacer (4).
RKZC4200
WB97R-5 30-97
REMOVAL AND INSTALLATION TRANSMISSION
7 -Remove gear (6).
RKZC4210
8 -Remove needle cage (7).
RKZC4220
9 -Remove spacer (8).
RKZC4230
10 -Remove split pin (9).
RKZC4240
30-98 WB97R-5
REMOVAL AND INSTALLATION TRANSMISSION
11 -Remove the snap ring (10).
10
RKZC4250
12 -Use prybars to lift and to remove the thrust plate lock ring
(11) evenly.
11
RKZC4260
13 -Remove the clutch plates (18) and the clutch drive
plates (17).
17
18
RKZC4270
14 -Place a mark below the groove on the friction bell.
RKZC4280
WB97R-5 30-99
REMOVAL AND INSTALLATION TRANSMISSION
15 -Place a mark on each thrust plate lock ring (11), clutch
plate (18) and clutch drive plate (17). 11
These marks will be used for reference during the
reassembly procedure.
17
18
RKZC4290
Lower the spring (15) lock washer (13).
Use tool F9.
F9
13
RKZC4300
17 -Remove snap ring (14).
14
RKZC4310
18 -Loosen the handles of the threaded rods to release the
tension from the spring.
Remove the top piece of the F9 special tool.
F9
RKZC4301
30-100 WB97R-5
REMOVAL AND INSTALLATION TRANSMISSION
19 -Remove lock spring cover (13) and spring (15).
13
15
RKZC4320
20 -Remove sleeve (5).
RKZC4330
21 -Remove clutch piston (19) by blowing in compressed air
through the delivery hole.
19
RKZC4340
22 -If to be replaced, remove teflon seal ring (20) and
relevant inner O-ring (20) from outer seat of piston and
teflon seal rings (21) and relevant inner O-ring (21) from
inner of piston. To remove the rings it is necessary to cut
them.
21 20
RKZC4350
WB97R-5 30-101
REMOVAL AND INSTALLATION TRANSMISSION
23 -Turn the shaft.
If Teflon seal rings (22) are to be replaced, remove the
rings by cutting them.
22
RKZC4360
24 -Remove snap ring (23).
23
RKZC4370
25 -Remove bearing (24) by means of an extractor.
24
RKZC4380
26 -Remove bearing (24) and thrust washer (25).
24
25
RKZC4390
30-102 WB97R-5
REMOVAL AND INSTALLATION TRANSMISSION
27 -Remove gear (26) and needle cage (12).
28 -Repeat steps 9 to 22 in this section to disinstall the other
components.
29 -Check: 26
- the sealing ring grooves (large and small) for wear and
damage if necessary.
- on the output shaft for wear and damage.
- oil passages in the output shaft to be sure that the 12
passages are open and free of foreign material.
- ball bearings and roller bearings for smooth areas, pits
or other damage. RKZC4400
Use new parts as required.
30 -If the clutch discs are to be used again, keep the clutch
packs in the same previous assembly order separate
and record which clutch pack goes with each clutch.
31 -At each disassembly, use a gauge bar to check that total
thickness of clutch unit is within the permissible wear
limit. If it is not, replace the clutch unit (18) with a new
one.
Check all clutch plates for burns and inspect the friction
material for damage. Inspect the grooves in the friction
material for being well traced.
Verify also that all the clutch drive plates (17) are
perfectly plane and inspect for pitting or scoring. RKZC4410
In the case that at least one of the above problems
occurs, replace the complete clutch kit with a new one. If
using a new clutch kit soak the clutch plates in clean
transmission oil for at least an hour before assembly.
Lubricate the contact surfaces of clutch drive plates with
clean transmission oil before assembly.
Number of clutch plates (each side) 6
Number clutch steel plate (each side) 6
Nominal clutch plate thickness 2.40±0.05 mm
Nominal clutch kit thickness * 29.0-29.2 mm
RKZC4420
Maximum clutch plate wear (each side) 0.25 mm
Maximum clutch kit wear 1.5 mm
* Under load of 163 kg 17
RKZC4430
WB97R-5 30-103
REMOVAL AND INSTALLATION TRANSMISSION
32 -Inspect the bore of the shaft in the input shaft housing for
damage that will cause leakage when the clucth is
assembled. 18
Check the slots in the side of the input shaft housing for
damage from the tangs on the steel discs.
Use new parts as required during assembly.
RKZC4440
SHAFT D
1 -Remove bearing (16) of shaft D by means of an
extractor.
16
RKZC4450
2 -Remove bearing (37) of shaft D by means of an
extractor.
37
RKZC4460
6.2 Assembly
SHAFT A
1 - Assemble new teflon ring (20) and relevant inner O-
rings (20),new teflon ring (21) and relevant inner O-rings
(21) respectively into the piston outer and inner seats.
21 20
RKZC4350
30-104 WB97R-5
REMOVAL AND INSTALLATION TRANSMISSION
2 - Apply a thin film of grease on the sealing rings just
inserted.
RKZC4470
3 -Insert clutch piston (19) with special tool F10 as
protection of seal rings (21).
19
F10
RKZC4480
4 -Assemble sleeve (5).
RKZC4330
5 -Assemble spring (15) and washer (13).
13
15
RKZC4320
WB97R-5 30-105
REMOVAL AND INSTALLATION TRANSMISSION
6 -Lower the spring (15) lock washer (13).
Use tool F9.
F9
13
RKZC4300
7 -Insert snap ring (14).
a Ensure that the snap ring (14) is well fitted.
14
RKZC4310
8 -Loosen the handles of the threaded rods to release the
tension from the spring.
Remove the top piece of the F9 special tool.
F9
RKZC4301
9 -Remove tool F9 and assemble split pin (9).
RKZC4490
30-106 WB97R-5
REMOVAL AND INSTALLATION TRANSMISSION
10 -Insert thrust washer (8)
RKZC4500
11 -Insert needle cage (7).
RKZC4220
12 -To assemble the clutch pack start with the gear (6) on
the bench.
Install the thrust plate (11) so that the reference mark on 11
top of the plate made during disassembly is facing
towards the gear.
RKZC4510
13 -Assemble clutch plates (18) and clutch drive plates (17)
on the gear (6).
The assembled clutch pack must contain seven clutch 18
drive plates and six clutch plates.
17
RKZC4520
WB97R-5 30-107
REMOVAL AND INSTALLATION TRANSMISSION
14 -Locate the pack assembly by means of two
screwdrivers.
RKZC4530
15 -Assemble snap ring (10).
10
RKZC4540
16 -Assemble washer (4).
RKZC4200
17 -Heat the bearing (3) to 80÷100 °C (176° to 212 °F).
Assemble bearing (3).
Use tool F2. F2
RKZC4550
30-108 WB97R-5
REMOVAL AND INSTALLATION TRANSMISSION
18 -Install the snap ring (2).
NOTA .
For clarity of the Teflon sealing ring installation
procedure the following photos do not show the
clutch pack, gear, spacer, bearing, and snap ring
installed on the input shaft.
RKZC4170
19 -Insert the teflon seal ring (1) as follows.
RKZC4560
20 -Install the F5a spacer onto the input shaft with the
chamfered end facing in.
F5a
RKZC4570
21 -Slide the F5b expander/protector onto the input shaft
and on the spacer.
The expander/protector will stop in the correct position
to install the seal ring in the groove.
F5b
RKZC4580
WB97R-5 30-109
REMOVAL AND INSTALLATION TRANSMISSION
22 -Heat the Teflon seal ring to 60°-80°C (140°-176° F) for 5
minutes.
Install the teflon seal ring onto the expander/protector.
RKZC4590
23 -Install the F6 pusher over the expander/protector and
slide the seal ring until it reaches the groove in the shaft.
Remove the pusher, expander/protector, and spacer
F6
from the shaft.
RKZC4600
24 -Install the end of the F7 seal compressor with the deep
chamfer onto the shaft and over the sealing ring.
Use a back and forth twisting motion to allow the seal
F7
compressor to slip over the top of the sealing ring and
seat the sealing ring into the groove. Be careful not to
damage the seal ring. After the sealing ring is seated in
the groove, remove the seal compressor from the shaft.
RKZC4610
25 -Turn the seal compressor around and slide the end with
the narrow chamfer over the shaft and over the seal ring.
Leave the seal compressor in place for 15 minutes until
the sealing ring has cooled and is properly sized and
seated in the groove. After the seal ring has cooled,
remove the seal compressor from the shaft.
RKZC4620
30-110 WB97R-5
REMOVAL AND INSTALLATION TRANSMISSION
26 -Measure the clutch discs clearance for each clutch
assembly.
The thrust plate lock ring must be all the way up against
the lock ring.
Use a feeler gauge to measure the distance between the
thrust plate lock ring and the first clutch drive plate (17).
a Distance: 1.60-2.45 mm.
a If the distance is not within specification, the clutch is
probably assembled wrong. 17
RKZC4630
27 -Turn shaft upside down and carry out steps from 1 to 15
in this section .
Lubricate the washer (25) with transmission oil.
Install the thrust washer ensuring that the notch on the
inner edge goes onto the pin. 25
Make sure that the side with the holes in it for oil passage
is at the bottom.
RKZC4640
27 -Heat the bearing (24) to 80÷100 °C (176° to 212 °F)
Use driver F11 to drive the bearing (24) onto the input
shaft until the bearing makes contact with the thrust
washer.
24
RKZC4650
28 -Assemble snap ring (23).
23
RKZC4660
WB97R-5 30-111
REMOVAL AND INSTALLATION TRANSMISSION
29 -Assemble the teflon seal rings (22) as follows: place the
F12a spacer into the F12b expander/protector. F12b
F12a
RKZC4670
30 -Slide the F12 expander/protector and the spacer onto
the shaft.
The expander/protector will stop in the correct position F12b
to install the seal ring in the groove.
RKZC4680
31 -Heat the Teflon seal ring to 60°-80°C (140°-176° F) for 5
minutes.
Install the teflon seal ring onto the expander/protector.
RKZC4690
32 -Install the F13 pusher over the expander/protector and
slide the seal ring until it reaches the groove in the shaft. F13
Remove the pusher, expander/protector, and spacer
from the shaft.
RKZC4700
30-112 WB97R-5
REMOVAL AND INSTALLATION TRANSMISSION
33 -Install the end of the F14 seal compressor with the deep
chamfer onto the shaft and over the sealing ring.
Use a back and forth twisting motion to allow the seal
compressor to slip over the top of the sealing ring and
F14
seat the sealing ring into the groove. Be careful not to
damage the seal ring. After the sealing ring is seated in
the groove, remove the seal compressor from the shaft.
RKZC4710
34 -Turn the seal compressor around and slide the end with
the narrow chamfer over the shaft and over the seal ring.
Leave the seal compressor in place for 15 minutes until
the sealing ring has cooled and is properly sized and
seated in the groove. Once the sealing ring has cooled,
remove the seal compressor from the shaft.
To install the three Teflon rings remaining, carry out
steps 29 to 33 in this section using the other spacers of
tool F12.
RKZC4720
WB97R-5 30-113
REMOVAL AND INSTALLATION TRANSMISSION
7 4
6 5
8 1
3 2
6 5
RKZ11270
1. Lubrication oil passage
2. Forward clutch oil passage
3. Reverse clutch oil passage
4. Forward gear
5. Forward clutch pack
6. Reverse clutch pack
7. Reverse gear
8. Input shaft
36 -Apply compressed air at about 6 bar for forward gear 37 -Apply compressed air at about 6 bar for reverse gear
clutch passage. clutch passage.
Feel the forward gear piston move to lock its Feel the reverse gear piston move to lock its
respective clutch pack. Try to move the forward respective clutch pack. Try to move the reverse
gear. The forward gear must not turn on the input gear. The forward gear must not turn on the input
shaft. Try to move the reverse gear. The reverse shaft. Try to move the forward gear. The reverse
gear must turn freely on the input shaft. If the gear must turn freely on the input shaft. If the
clutches do not work correctly, disassemble the clutches do not work correctly, disassemble the
clutches to find the problem. clutches to find the problem.
30-114 WB97R-5
REMOVAL AND INSTALLATION TRANSMISSION
SHAFT D
38 -Assemble D shaft bearing (16).
Use tool F3. 16
RKZC4730
39 -Assemble D shaft bearing (37).
Use tool F3.
37
RKZC4740
40 -Lubricate with oil the shaft seat A.A.
RKZC4750
41 -Fit shaft assembly D and shaft assembly A.
The operation is correct only if the two shafts are fitted at
the same time.
RKZC4760
WB97R-5 30-115
REMOVAL AND INSTALLATION TRANSMISSION
7. AXIS B
7.1 Disassembly
12
10 11
9
8
B
xis
7 /A
6 se
As
4 5
3 26
22
2
1 25
B 18
xis
se
/A 24
As
16 21 23
14
20
19
17
15
13 RKZ11280
1 -Remove screws (28) and protection (29).
28
29
RKZC4770
2 -Lift the three shafts B-C-E, at the same time B-C-E.
Use tool F15. F15
RKZC4780
30-116 WB97R-5
REMOVAL AND INSTALLATION TRANSMISSION
3 -Remove seals (1) and (2).
a This is a destructive operation for the seal rings. 1
RKZC4790
4 -By means of an extractor remove bearing (3) and gear
(4).
RKZC4800
5 -Remove The bearing (3) and the gear (4).
3
4
RKZC4810
6 -Remove snap ring (5).
RKZC4820
WB97R-5 30-117
REMOVAL AND INSTALLATION TRANSMISSION
7 -Remove spacer (6).
RKZC4830
8 -Remove the spring pin (23).
23
RKZC4840
9 -Remove gear (8).
RKZC4850
10 -Remove roller retainers (7) and washer (13).
7
13
RKZC4860
30-118 WB97R-5
REMOVAL AND INSTALLATION TRANSMISSION
11 -Remove spring pin (24) and spacer (14).
24
14
RKZC4870
12 -Slightly press thrust plate (10).
10
RKZC4880
13 -Remove snap ring (9).
9
RKZC4890
14 -Remove thrust plate (10) by means of two screwdrivers.
10
RKZC4900
WB97R-5 30-119
REMOVAL AND INSTALLATION TRANSMISSION
15 -Remove disc (11) and counterdiscs (12) pack.
12 11
RKZC4910
16 -Lower the spring (17) retaining washer (16).
Use tool F9.
F9
RKZC4920
17 -Remove snap ring (15).
15
RKZC4930
18 -Loosen the handles of the threaded rods to release the
tension from the spring.
Remove the top piece of the F9 special tool.
F9
RKZC4920
30-120 WB97R-5
REMOVAL AND INSTALLATION TRANSMISSION
19 -Remove the washer (16) and spring (17).
16
17
RKZC4940
20 -Remove sleeve (18).
18
RKZC4950
21 -Remove clutch piston (19) by blowing in compressed air
through the delivery hole.
19
RKZC4960
22 -If to be replaced, remove teflon seal ring (20) and
relevant inner O-ring from outer seat of piston and teflon
seal rings (21) and relevant inner O-ring from inner of
piston. To remove the rings it is necessary to cut them.
21 20
RKZC4350
WB97R-5 30-121
REMOVAL AND INSTALLATION TRANSMISSION
23 -Remove the teflon seal ring (26).
26
RKZC4970
24 -Remove bearing (25) by means of an extractor.
25
RKZC4980
25 -Check:
- the sealing ring grooves (large and small) for wear and
damage if necessary.
- on the output shaft for wear and damage.
- the oil passages in the output shaft to be sure that the
passages are open and free of foreign material.
- the ball bearings and the needle bearings for flat areas,
pitting, and other damage.
Use new parts as required.
26 -If the clutch discs are to be used again, keep the clutch
packs in the same previous assembly order separate
and record which clutch pack goes with each clutch. RKZC4420
30-122 WB97R-5
REMOVAL AND INSTALLATION TRANSMISSION
27 -At each disassembly:
- verify with a caliper that the total thickness of the clutch
kit is within the wear limit. 12
- Verify that all the clutch plates do not appear burned or
that the friction material it is not damaged and that
splines are well traced.
- Verify also that all the clutch drive plates (12) are
perfectly plane and inspect for pitting or scoring.
In the case that at least one of the above problems
occurs, replace the complete clutch kit with a new one.
If using a new clutch kit soak the clutch plates in clean
transmission oil for at least an hour before assembly. In
RKZC4431
any case lubricate the contact surfaces of clutch drive
plates with clean transmission oil before assembly.
11
Number of clutch plate 8
Number clutch steel plate 8
Nominal clutch plate thickness 2.00±0.05 mm
Nominal clutch kit thickness * 30.5-30.7 mm
Maximum clutch plate wear (each side) 0.20 mm
Maximum clutch kit wear 1.6 mm
RKZC4441
* Under load of 163 kg
28 -Inspect the bore of the shaft in the input shaft housing for
damage that will cause leakage when the clucth is
assembled.
Check the slots in the side of the input shaft housing for
damage from the tangs on the steel discs.
Use new parts as required during assembly.
7.2 Assembly
1 -Assemble bearing (25).
Use tool F2. F2
25
RKZC4990
WB97R-5 30-123
REMOVAL AND INSTALLATION TRANSMISSION
2 -Assemble a new Teflon sealing ring (26).
To install the ring (26), repeat steps 29 to 34 in
section"6.2 Assembly" using tool F5.
RKZC5000
3 -Assemble new teflon ring (20) and relevant inner O-ring,
new teflon ring (21) and relevant inner O-rings
respectively into the piston outer and inner seats.
21 20
RKZC4350
4 -Apply a thin film of grease on the sealing rings just
inserted.
RKZC4470
5 -Insert clutch piston (19) with special tool F10 as
protection of seal rings (21).
19
F10
RKZC4480
30-124 WB97R-5
REMOVAL AND INSTALLATION TRANSMISSION
6 -Assemble sleeve (18).
18
RKZC4950
7 -Assemble spring (17) and washer (16).
16
17
RKZC4940
8 -Lower the spring (16) lock washer (17).
Use tool F9.
F9
17
RKZC4302
9 -Insert snap ring (15).
a Ensure that the snap ring (15) is well fitted.
15
RKZC4311
WB97R-5 30-125
REMOVAL AND INSTALLATION TRANSMISSION
10 -Loosen the handles of the threaded rods to release the
tension from the spring.
Remove the top piece of the F9 special tool.
F9
RKZC4301
11 -Assemble clutch pack to shaft (22).
22
RKZC4911
12 -Assemble spacer (14) and spring pin (24).
24
14
RKZC5010
13 -Insert washer (13) and roller bearing (7).
13
RKZC5020
30-126 WB97R-5
REMOVAL AND INSTALLATION TRANSMISSION
14 -Assemble thrust plate (10) and press it against the
clutch pack.
10
RKZC5030
15 -Assemble snap ring (9).
RKZC5040
16 -Apply compressed air at low pressure in hole in order to
push the thrust plate (10) against the retaining ring (9),
then align the clutch plate (11) spline.
9
10
11
RKZC5050
17 -Assemble gear (8) paying attention it completely fit in its
seat.
RKZC5060
WB97R-5 30-127
REMOVAL AND INSTALLATION TRANSMISSION
18 -Assemble spring pin (23).
23
RKZC5070
19 -Assemble the washer (6) and lock ring (5).
6
RKZC5080
20 -Measure the clutch discs clearance for each clutch
assembly.
The clutch plate lock ring must be all the way up against
the lock ring.
Use a feeler gauge to measure the distance between
the clutch plate lock ring and the first clutch plate (11).
a Distance: 2.20-3.05 mm.
a If the distance is not within specification, the clutch is
probably assembled wrong. 11
RKZC4631
21 -Assemble gear (4) taking care to orientate the shelf
facing the clutch and bearing (3).
Use tool F16.
4 3
RKZC5090
30-128 WB97R-5
REMOVAL AND INSTALLATION TRANSMISSION
4 5
3
RKZ11290
1. Lubrication oil passage
2. 2nd speed clutch oil passage
3. 2nd speed gear
4. 2nd speed clutch pack
5. Input shaft
22 -Try to rotate the 2nd speed gear. The 2nd speed gear
must turn freely on the input shaft.
Apply compressed air of approximately 6 bar to the 2nd
speed gear clutch passage.
Hear the 2nd speed gear piston moving to lock the 2nd
speed gear clutch pack. Try to move the 2nd speed
gear. The 2nd speed gear must not turn on the input
shaft.
If the clutch does not work correctly, disassemble the
clutch to find the problem.
WB97R-5 30-129
REMOVAL AND INSTALLATION TRANSMISSION
23 -Assemble Teflon sealing rings (1) and (2).
To install the sealing rings, repeat steps 29 to 34 in
section "6.2 Assembly" using the spacer rings of tool 1
F17.
2
RKZC5100
24 -Lift the three shafts B-C-E at the same time and insert
into the half-housing. F15
Use tool F15.
RKZC4780
25 -Assemble protection (29) and tighten screws (28) to the
prescribed torque.
3 Screw: 50 Nm
28
29
RKZC4770
30-130 WB97R-5
REMOVAL AND INSTALLATION TRANSMISSION
8. AXIS C
8.1 Disassembly
8 9 29 31
6 7 28
27
5 26
4 25 45
3 30 44
24
2
1 23
43
42
20 41
19 22
17 40
15
14 39
13
38 57
12
21 37 55
10
18
16 36
35 53
34 51 58
33 56
49
11 47
52 54
50
48
32 46 RKZ11300
1 -Remove screws (59) and protection (60).
59
60
RKZC4771
2 -Lift the three shafts B-C-E, at the same time B-C-E.
Use tool F15. F15
RKZC4780
WB97R-5 30-131
REMOVAL AND INSTALLATION TRANSMISSION
3 -By means of an extractor remove bearing (58).
58
RKZC5110
4 -Remove the spacer (57).
57
RKZC5120
5 -Remove the gear (54) with its inner parts.
54
RKZC5130
6 -Overturn the group.
Push down the thrust plate (39).
39
RKZC5140
30-132 WB97R-5
REMOVAL AND INSTALLATION TRANSMISSION
7 -Remove snap ring (38).
38
RKZC5150
8 -Remove the thrust plate (39) by means of two
screwdrivers.
39
RKZC5160
9 -Remove clutch kit (40).
40
RKZC5170
10 -Push down the thrust washer (42) to allow lock ring
removal (41).
Use the special tool F9. 41
RKZC5180
WB97R-5 30-133
REMOVAL AND INSTALLATION TRANSMISSION
11 -Loosen the handles of the threaded rods to release the
tension from the spring. F9
Remove the top piece of the F9 special tool.
RKZC5190
12 -Remove the lock ring (41), the thrust washer (42) and
spring (43).
17
RKZC5800
13 -Remove clutch piston (44) by blowing in compressed air
through the delivery hole.
44
RKZC5210
14 -If to be replaced, remove teflon seal ring (45) and
relevantimer O-ring from outer seat of piston (44).
45
RKZC5220
30-134 WB97R-5
REMOVAL AND INSTALLATION TRANSMISSION
15 -If to be replaced, remove the teflon sealving (53) and
relevant inner O-ring from seat of gear (54).
53
RKZC5230
16 -Remove gear (37) with an extractor.
Remove bushing (47) and (56), roller bearing (46) and
(55) and spacer (50).
46
50
37
RKZC5240
17 -Chech the condition of removed parts (46), (47), (50),
(55) and (56). 47 50
56
46
55
RKZC5250
18 -Remove the O-rings (48) and (52) from the bush (50).
destructive operation for the seal rings
50
52
48
RKZC5260
WB97R-5 30-135
REMOVAL AND INSTALLATION TRANSMISSION
19 -Check the wear condition of the teflon seal rings (49)
and (51).
If replacement is necessary, cut the teflon seal rings (49) 51
and (51) to remove they from the bush (50).
destructive operation for the seal rings
49
RKZC5270
20 -Remove gear (35).
35
RKZC5280
21 -Remove roller retainer (36).
36
RKZC5290
22 -Remove spacer (31).
31
RKZC5300
30-136 WB97R-5
REMOVAL AND INSTALLATION TRANSMISSION
23 -Push down the counterdisk (33) to set free the lock ring
(34).
33 34
RKZC5310
24 -Remove snap ring (34).
34
RKZC5320
25 -Remove the thrust plate (33) by means of two
screwdrivers.
33
RKZC5330
26 -Remove clutch kit (32).
32
RKZC5340
WB97R-5 30-137
REMOVAL AND INSTALLATION TRANSMISSION
27 -Remove the spring pin (22).
22
RKZC5350
28 -Lower the spring (28) lock washer (29).
Use tool F9.
F9
29
RKZC4303
29 -Remove snap ring (30).
30
RKZC4312
30 -Loosen the handles of the threaded rods to release the
tension from the spring.
Remove the top piece of the F9 special tool.
F9
RKZC4301
30-138 WB97R-5
REMOVAL AND INSTALLATION TRANSMISSION
31 -Remove the lock ring (30), the thrust washer (29) and
spring (28). 30
29
22
RKZC5360
32 -Extract clutch piston (26) from its seat by blowing in
compressed air through the delivery hole.
RKZC5370
33 -Remove the bush (27) and clutch piston (26).
27
26
RKZC5380
34 -If to be replaced, remove teflon seal ring (25) and
relevant inner O-ring from outer seat of piston and teflon
seal rings (24) and relevant inner O-ring from inner of
piston.
To remove the rings it is necessary to cut them.
25 24
RKZC4351
WB97R-5 30-139
REMOVAL AND INSTALLATION TRANSMISSION
35 -Overturn the shaft (23).
Cut and remove the seal rings (16), (17), (18) and (19). 16
17
18
19
RKZC5390
36 -By means of an extractor remove bearing (1).
RKZC5400
37 -Remove spacer (2).
RKZC5410
38 -Remove gear (3).
RKZC5420
30-140 WB97R-5
REMOVAL AND INSTALLATION TRANSMISSION
39 -Remove roller retainers (7) and washer (8).
RKZC5430
40 -Remove the spring pin (21).
21
RKZC5440
41 -Push down the thrust plate (5) to set free the lock ring (4).
4 5
RKZC5311
42 -Remove snap ring (4).
RKZC5321
WB97R-5 30-141
REMOVAL AND INSTALLATION TRANSMISSION
43 -Remove the thrust plate (5) by means of two
screwdrivers.
5
RKZC5331
44 -Remove clutch kit (6).
RKZC5341
45 -Lower the spring (11) lock washer (10).
Use tool F9.
F9
10
RKZC4304
46 -Remove snap ring (9).
RKZC4313
30-142 WB97R-5
REMOVAL AND INSTALLATION TRANSMISSION
47 -Loosen the handles of the threaded rods to release the
tension from the spring.
Remove the top piece of the F9 special tool.
F9
RKZC4301
48 -Remove the lock ring (9), the thrust washer (10) and
spring (11). 9
10
11
RKZC5361
49 -Extract clutch piston (13) from its seat by blowing in
compressed air through the delivery hole.
RKZC5370
50 -Remove the bush (12) and clutch piston (13).
12
13
RKZC5381
WB97R-5 30-143
REMOVAL AND INSTALLATION TRANSMISSION
51 -If to be replaced, remove teflon seal ring (15) and
relevant inner O-ring from outer seat of piston and teflon 14
seal rings (14) and relevant inner O-ring from inner of
piston.
To remove the rings it is necessary to cut them.
15
RKZC5450
52 -Check:
- the sealing ring grooves (large and small) for wear and
damage if necessary.
- on the output shaft for wear and damage.
- the oil passages in the output shaft for restrictions or
foreing matter.
- the ball bearings and the needle bearings for flat areas,
pitting, and other damage.
Use new parts as required.
53 -If the clutch discs are to be used again, keep the clutch
packs in the same previous assembly order separate
and record which clutch pack goes with each clutch. RKZC4420
54 -At each disassembly:
- verify with a caliper that the total thickness of the clutch
kit is within the wear limit.
- Verify that all the clutch plates do not appear burned or
A
that the friction material it is not damaged and that
splines are well traced.
- Verify also that all the clutch drive plates (A) are
perfectly plane and inspect for pitting or scoring.
In the case that at least one of the above problems
occurs, replace the complete clutch kit with a new one.
If using a new clutch kit soak the clutch plates (B) in
clean transmission oil for at least an hour before
assembly. In any case lubricate the contact surfaces of
RKZC4432
clutch drive plates with clean transmission oil before
assembly.
RKZC4442
30-144 WB97R-5
REMOVAL AND INSTALLATION TRANSMISSION
1st GEAR CLUTCH
Number of clutch plate 6
Number clutch steel plate 6
Nominal clutch plate thickness 2.20±0.05 mm
Nominal clutch kit thickness * 27.5-27.7 mm
Maximum clutch plate wear (each side) 0.15 mm
Maximum clutch kit wear 0.9 mm
* Under load of 163 kg
3rd GEAR CLUTCH
Number of clutch plate 6
Number clutch steel plate 6
Nominal clutch plate thickness 2.00±0.05 mm
Nominal clutch kit thickness * 30.5-30.7 mm
Maximum clutch plate wear (each side) 0.20 mm
Maximum clutch kit wear 1.6 mm
* Under load of 163 kg
4th GEAR CLUTCH
Number of clutch plate 6
Number clutch steel plate 6
Nominal clutch plate thickness 2.00±0.05 mm
Nominal clutch kit thickness * 15.9-16.1 mm
Maximum clutch plate wear (each side) 0.2 mm
Maximum clutch kit wear 0.8 mm
* Under load of 163 kg
55 -Inspect the bore of the shaft in the input shaft housing for
damage that will cause leakage when the clucth is
assembled.
Check the slots in the side of the input shaft housing for
damage from the tangs on the steel discs.
Use new parts as required during assembly.
WB97R-5 30-145
REMOVAL AND INSTALLATION TRANSMISSION
8.2 Assembly
54
1 -Assemble new teflon ring (53) and relevant inner O-
Ring on gear (54) using special tool F21.
. Assemble the O-Ring (52).
RKZC5460
2 -Calibrate the teflon ring (53) using special tool F20.
RKZC5470
3 -Assemble new teflon ring (45) with relative O-ring on
clutch piston (44).
44
45
RKZC5480
4 -Apply a thin film of grease on the outer edge and in the
inner part of clutch piston (44) and assemble in gear 44
(54).
54
RKZC5490
30-146 WB97R-5
REMOVAL AND INSTALLATION TRANSMISSION
5 -Insert spring (43), thrust washer (42) and snap ring (41).
41
42
43
RKZC5500
6 -Lower the spring (43) lock washer (42).
Use tool F9.
F9
42 43
RKZC5191
7 -Insert snap ring (41).
a Ensure that the snap ring (41) is well fitted. 41
RKZC5180
8 -Loosen the handles of the threaded rods to release the
tension from the spring. Remove the top piece of the F9
special tool.
F9
RKZC5510
WB97R-5 30-147
REMOVAL AND INSTALLATION TRANSMISSION
9 -Insert clutch kit (40) and thrust plate (39) into the gear
(54).
39
40
54
RKZC5520
10 -Assemble retaining ring (38) making sure it is correctly
seated. 38
RKZC5150
11 -Measure the clutch discs clearance for each clutch
assembly.
The clutch plate lock ring must be all the way up against
the lock ring.
Use a feeler gauge to measure the distance between
the clutch plate lock ring and the first clutch plate (40).
a Distance: 1.725-2.375 mm.
40
a If the distance is not within specification, the clutch is
probably assembled wrong.
RKZC5530
12 -Assemble new teflon ring (25) and relevant inner O-ring,
new teflon ring (24) and relevant inner O-rings
respectively into the piston (26) outer and inner seats. 26
25 24
RKZC4352
30-148 WB97R-5
REMOVAL AND INSTALLATION TRANSMISSION
13 -Apply a thin film of grease on the sealing rings just
inserted.
RKZC4470
14 -Insert clutch piston (26) with special tool F10 as
protection of seal rings (24).
26
F10
RKZC4481
15 -Assemble sleeve (27).
27
RKZC4951
16 -Assemble spring (28) and retainer washer (29).
29
28
RKZC5540
WB97R-5 30-149
REMOVAL AND INSTALLATION TRANSMISSION
17 -Lower the spring (28) lock washer (29).
Use tool F9.
F9
29
RKZC4303
18 -Insert snap ring (30).
a Ensure that the snap ring (30) is well fitted.
30
RKZC4312
19 -Loosen the handles of the threaded rods to release the
tension from the spring.
Remove the top piece of the F9 special tool.
F9
RKZC4301
20 -Remove tool F9 and assemble spring pin (22).
22
RKZC5550
30-150 WB97R-5
REMOVAL AND INSTALLATION TRANSMISSION
21 -Insert the thrust washer (31) into the shaft (23).
Apply a thin film of grease under washer (31) to avoid its
falling when overturning the shaft.
31
RKZC5560
22 -Assemble the washer (31) on the pin (22).
31
22
RKZC5590
23 -Insert clutch kit (32) on main shaft (23).
23
32
RKZC4912
24 -Insert the roller bearing (36) and thrust plate (33).
36
33
RKZC5600
WB97R-5 30-151
REMOVAL AND INSTALLATION TRANSMISSION
25 -Assemble snap ring (34).
34
RKZC5610
26 -Apply compressed air at low pressure in hole (a) in order
to push the thrust plate (33) against retaining ring (34),
then align the clutch plate (32) spline.
32
34
A
33
RKZC5620
27 -Measure the clutch discs clearance for each clutch
assembly.
The clutch plate lock ring must be all the way up against
the lock ring.
Use a feeler gauge to measure the distance between
the clutch plate lock ring and the first clutch plate (32).
a Distance: 1.50-1.95 mm.
a If the distance is not within specification, the clutch is
probably assembled wrong. 32
RKZC4632
28 -Insert gear (35) paying attention it completely fit in its
seat.
35
RKZC5280
30-152 WB97R-5
REMOVAL AND INSTALLATION TRANSMISSION
29 -Insert gear (37) on the shaft (23) by side shown in figure.
37
23
RKZC5630
30 -Assemble the gear assembly (54) on main shaft (23).
54
RKZC5640
31 -Assemble the bush (47) and needle bearing (46) with
special tool F2. 46
F2
47
RKZC5650
32 -Assemble the new O-rings (48) and (52) to the bush
(50).
50
52
48
RKZC5260
WB97R-5 30-153
REMOVAL AND INSTALLATION TRANSMISSION
33 -Install new sealing rings (49) and (51) to bushing (50)
using tools F22, F23 and F24. Carry out steps 29 to 34 in
section "6.2 Assembly" to install.
RKZ11310
35 -Assemble the bush (50) on main shaft (23) with special
tool F2.
k The reference mark must be on the top surface
50
23
RKZC5660
36 -Assemble the bush (56) and needle bearing (55) with
special tool F2. 55
F2
56
RKZC5670
36 -Assemble the spacer (57).
57
RKZC5120
30-154 WB97R-5
REMOVAL AND INSTALLATION TRANSMISSION
37 -Assemble bearing (58).
Use tool F2.
58
RKZC5680
38 -Turn the shaft.
Assemble new O-ring with relative teflon ring (14) into
the piston (13) outer seat. 13
Assemble new O-ring with relative teflon ring (15) into
the piston (13) inner seat.
14 15
RKZC4353
39 -Apply a thin film of grease on the sealing rings just
inserted.
RKZC4470
40 -Inseryt the clutch piston (13) with the special tool F10 as
protection of seal rings (15).
13
F10
RKZC4482
WB97R-5 30-155
REMOVAL AND INSTALLATION TRANSMISSION
41 -Assemble sleeve (12).
12
RKZC4331
42 -Assemble spring (11) and washer (10).
10
11
RKZC4321
43 -Lower the spring (11) lock washer (10).
Use tool F9.
F9
10
RKZC4304
44 -Insert snap ring (9).
a Ensure that the snap ring (9) is well fitted.
RKZC4313
30-156 WB97R-5
REMOVAL AND INSTALLATION TRANSMISSION
45 -Loosen the handles of the threaded rods to release the
tension from the spring.
Remove the top piece of the F9 special tool.
F9
RKZC4301
46 -Assemble spring pin (21).
21
RKZC5580
47 -Insert clutch kit (6) on main shaft (23).
23
6
RKZC4913
48 -Assemble thrust plate (5).
RKZC5570
WB97R-5 30-157
REMOVAL AND INSTALLATION TRANSMISSION
49 -Assemble snap ring (4).
RKZC5690
50 -Apply compressed air at low pressure in hole in order to
push the thrust plate (5) against the retaining ring (4),
then align the clutch plate (6) spline.
4
5
RKZC5051
51 -Measure the clutch discs clearance for each clutch
assembly.
The clutch plate lock ring must be all the way up against
the lock ring.
Use a feeler gauge to measure the distance between
the clutch plate lock ring and the first clutch plate (6).
a Distance: 2.20-3.05 mm.
a If the distance is not within specification, the clutch is
probably assembled wrong. 6
RKZC4633
52 -Assemble the thrust washer (8) and roller bearing (7).
RKZC5430
30-158 WB97R-5
REMOVAL AND INSTALLATION TRANSMISSION
53 -Assemble the gear (3).
RKZC5700
54 -Assemble the thrust washer (2).
RKZC5710
55 -Assemble bearing (1) with the special tool F2.
F2
RKZC5720
56 -Install Teflon sealing rings (16), (17), (18) and (19).
Use special tool F5 and carry out steps 29 to 34 in
section "6.2 Assembly" to install. F5
RKZC4681
WB97R-5 30-159
REMOVAL AND INSTALLATION TRANSMISSION
9
8
4 5 6
7
1 2 3 10
11
RKZ11330
1. 1st clutch oil passage
2. 3rd clutch oil passage
3. 4th clutch oil passage
4. 3rd gear
5. 3rd gear clutch pack
6. 4th gear clutch pack
7. 4th gear
8. 1st gear
9. 1st gear clutch pack
10. Main shaft
11. Lubrication oil passage
57 -Verify that all the gears can freely rotate on the main 3rd speed gear clutch pack. Try to move the 3rd
shaft. speed gear. The 3rd speed gear must not turn on the
Apply compressed air of approximately 6 bar to the input shaft.
1st speed gear clutch passage. If the clutch does not work correctly, disassemble
Hear the 1st speed gear piston moving to lock the 1st the clutch to find the problem.
speed gear clutch pack. Try to move the 1st speed Apply compressed air of approximately 6 bar to the
gear. The 1st speed gear must not turn on the input 4th speed gear clutch passage.
shaft. Hear the 4th speed gear piston moving to lock the
If the clutch does not work correctly, disassemble 4th speed gear clutch pack. Try to move the 4th
the clutch to find the problem. speed gear. The 4th speed gear must not turn on the
Apply compressed air of approximately 6 bar to the input shaft.
3rd speed gear clutch passage. If the clutch does not work correctly, disassemble
Hear the 3rd speed gear piston moving to lock the the clutch to find the problem.
30-160 WB97R-5
REMOVAL AND INSTALLATION TRANSMISSION
58 -Hook the three shafts B-C-E using the special tool F15.
Lift the shafts B-C-E at the same time and insert the unit F15
into the half-housing.
Use tool F15.
RKZC4780
59 -Assemble protection (60) and tighten screws (59) to the
prescribed torque.
3 Screw: 50 Nm
59
60
RKZC4771
WB97R-5 30-161
REMOVAL AND INSTALLATION TRANSMISSION
9. AXIS E
9.1 Disassembly
5
18
E 4 13 17
3
2 16
1
15
E
14
12 23
11 22
10 21
9 20
7 19
8
RKZ11340
1 - Remove screws (24) and protection (25).
24
25
RKZC4772
2 - Lift the three shafts B-C-E at the same time.
Use tool F15. F15
RKZC4780
30-162 WB97R-5
REMOVAL AND INSTALLATION TRANSMISSION
3 -Remove seals (22) and (23).
a This is a destructive operation for the seal rings.
23
22
RKZC5730
4 -By neans of an extractor, remove bearings (21) and (1).
Remove spacer (20).
20
1 21
RKZC5740
5 -Assemble the gear (18).
18
RKZC5750
6 -Remove roller bearing (19).
19
RKZC5760
WB97R-5 30-163
REMOVAL AND INSTALLATION TRANSMISSION
7 -Overturn the shaft (12).
Press the Belleville washers (5) and remove retaining
ring (2).
Use tool F25.
F25
5
12
2
RKZC5770
8 -Remove the shim (3) and washers (4).
3
4
RKZC5780
9 -Remove the Belleville washers (5) and spacer (6).
5
RKZC5790
10 -Remove snap ring (17).
17
RKZC5800
30-164 WB97R-5
REMOVAL AND INSTALLATION TRANSMISSION
11 -Remove the thrust plate (16) and clutch kit (15).
16
RKZC5810
12 -Remove brake counter disk (14).
14
RKZC5820
13 -Estract piston (8) using pins (10) as pusher.
RKZC5830
14 -Remove the O-rings, inner (7) and outer (9).
a Replace the O-rings at each disassembly.
8
9
RKZC5840
WB97R-5 30-165
REMOVAL AND INSTALLATION TRANSMISSION
15 -Remove the O-rings (11) from pins (10).
a Replace the O-rings at each disassembly. 10
10
10 11
11
RKZC5850
16 -If the clutch discs are to be used again, keep the clutch
packs in the same previous assembly order separate
and record which clutch pack goes with each clutch.
17 -At each disassembly:
- verify with a caliper that the total thickness of the clutch
kit is within the wear limit.
- verify that all the clutch plates do not appear burned or
that the friction material it is not damaged and that
splines are well traced.
- verify also that all the clutch drive plates (12) are RKZC4420
perfectly plane and inspect for pitting or scoring.
In the case that at least one of the above problems
occurs, replace the complete clutch kit with a new one.
If using a new clutch kit soak the clutch plates in clean
12
transmission oil for at least an hour before assembly. In
any case lubricate the contact surfaces of clutch drive
plates with clean transmission oil before assembly.
18 -Inspect the bore of the shaft in the input shaft housing for
damage that will cause leakage when the clucth is
assembled.
Check the slots in the side of the input shaft housing for
damage from the tangs on the steel discs. RKZC4431
Use new parts as required during assembly.
Number of clutch plate 9
11
Number clutch steel plate 9
Nominal clutch plate thickness 2.00±0.05 mm
Nominal clutch kit thickness * 33.8-34.0 mm
Maximum clutch plate wear (each side) 0.15 mm
Maximum clutch kit wear 1.35 mm
* Under load of 163 kg
RKZC4441
30-166 WB97R-5
REMOVAL AND INSTALLATION TRANSMISSION
9.2 Assembly
1 -Insert inner (7) and outer (9) O-rings on clutch piston (8).
9
RKZC5840
2 -Insert O-rings (11) on the relative pins (10).
10
10
10 11
11
RKZC5850
3 -Insert pins (10) on clutch piston (8).
10
8
10
10
RKZC5860
4 -Apply a thin film of grease on O-Rings and position the
pins on clutch piston (8) in correspondence with the
holes on output shaft.
RKZC5870
WB97R-5 30-167
REMOVAL AND INSTALLATION TRANSMISSION
5 -Overturn the shaft (12) and fully insert the clutch piston
(8).
12
RKZC5880
6 -Insert brake counter disk (14) on shaft (12) with with
tapered edge facing down.
14
12
RKZC5890
7 -Mount the clutch kit (15) starting with a drive plate (A)
followed by a clutch plate (B). A
RKZC5900
8 -Mount thrust plate (16) on shaft (12).
16
RKZC5910
30-168 WB97R-5
REMOVAL AND INSTALLATION TRANSMISSION
9 -Assemble retaining ring (17).
17
RKZC5920
10 -Assemble gear (18).
18
RKZC5930
11 -Assemble roller bearing (19) and spacer (20).
20
19
RKZC5940
12 -Assemble bearing (21) using special tool F2.
F2
21
RKZC5950
WB97R-5 30-169
REMOVAL AND INSTALLATION TRANSMISSION
13 -Turn shaft (12). Make sure that the disk/counterdisk
pack and the piston are correctly seated.
12
RKZC5960
14 -Preassemble spacer (6), washer (4) and lock ring (2).
2
6
RKZC5970
15 -Using a thickness gauge measure quote X between
washer (4) and lock ring (2).
Subtract from quote X fixed quote S1 (S1=1.80mm).
The result S is the thickness of shims (3) which has to be 2
inser to between washer (4) and locking (2). X
S=X-S1=X-1.80mm
6
4
RKZ11350
16 -Pick the (S) shim (3) from the range of shims available.
a Choose a shim that will provide a piston travel of
1.70-1.90 mm.
SHIM RANGE
Shim (mm) 0.1 0.3 0.5
RKZ11360
30-170 WB97R-5
REMOVAL AND INSTALLATION TRANSMISSION
17 -Disassemble the washer (4) and lock ring (2).
RKZC5990
18 -Insert Belleville washer (5).
a Check the Belleville washer (5) orientation.
5
RKZC6000
19 -Mount washer (4) and shims (3) with thickness S defined
at sequence 14.
3
4
RKZC6010
20 -Lower Belleville washers (5) and assemble retaining
ring (2). Use tool F25.
F25
2
RKZC5771
WB97R-5 30-171
REMOVAL AND INSTALLATION TRANSMISSION
21 -Assemble bearing (1) using tool F16.
F16
RKZC6020
22 -Install Teflon sealing rings (22) and (23).
Use special tool F5 and carry out steps 29 to 34 in
section "6.2 Assembly" to install. F5
RKZC4681
23 -Use tool F4 for piston operation check and correct
adjustment check.
F4
RKZC6030
24 -In order to verify the seal of rings (7) and (9) feed the
piston chamber with oil at 10 bar and check with a dial
gauge located as shown in the photo if the real stroke is
included between 1.7 and 1.9 mm.
RKZC6040
30-172 WB97R-5
REMOVAL AND INSTALLATION TRANSMISSION
1
4
1.7 1.9
RKZ11370
1. 4WD oil passage.
2. 4WD drive gear.
3. 4WD lubricant oil passage.
4. Shaft
5. Belleville washers.
25 -Apply compressed oil pressure of approximately 10 bar
to the 4WD clutch passage.
Listen to hear the piston moving to unlock the clutch
pack. The belleville washers compressing.
Try to move the 4WD gear.
The 4WD gear must turn freely on the 4WD shaft.
If the clutches do not work correctly, disassemble the
clutches to find the problem.
WB97R-5 30-173
REMOVAL AND INSTALLATION TRANSMISSION
26 -Lift the three shafts B-C-E at the same time and insert
into the half-housing. F15
Use tool F15.
RKZC4780
26 -Assemble protection (25) and tighten screws (24) to the
prescribed torque.
3 Screw: 50 Nm
24
25
RKZC4772
30-174 WB97R-5
REMOVAL AND INSTALLATION CONVERTOR
CONVERTOR
Removal
k Lower the working equipment completely until it rests
on the ground.
Stop the engine and remove the ignition key.
k Eliminate all residual pressure from all circuits by
moving the hydraulic controls in all directions.
a Drain the hydraulic oil.
6 Hydraulic oil: approx. 40 l
a Drain the oil from the gearbox.
6 Gearbox oil: approx. 20 l
1 -Remove the piston pump.
(For details see "PISTON PUMP"). 1
2 -Remove the engine hood.
(For details see "TRANSMISSION").
3 -Remove the converter (1). [*1]
RKZC1840
Installation
• To install, reverse removal procedure.
a Ensure that the mating surfaces are clean and free of A
dents.
[*1]
a To aid in mating flywheel and joint, before mating engine
and transmission, tighten a threaded shank “A” as guide
to the joint:
2 Screw: Loctite 262
3 Screw: 39 Nm
RKZC1850
WB97R-5 30-175
REMOVAL AND INSTALLATION ENGINE
ENGINE
Removal
1 -Remove:
• ENGINE HOOD
• FRONT GUARD
• FRONT COUNTERWEIGHT
• RADIATOR GROUP
• CONDENSER (For machines equipped with an air-
conditioning unit)
• MUFFLER
• AIR FILTER
• PISTON PUMP
• TRANSMISSION
For details, see the individual removal procedures.
2 -Disconnect the fuel inlet and return pipes (1) and (2),
release them from the tie straps and position them
aside.
a Cap pipes, hoses and holes to prevent
contamination.
1
2
RKZC2860
3 -Remove the screws and release the straps (1) and (2)
retaining the heating system hoses.
1 2
2 RKZC2870
4 -Disconnect the heating system hoses (3) and (4) and
remove the tie strap (5) retaining the gearbox oil hoses.
3
a Cap pipes, hoses and holes to prevent
contamination.
RKZC2880
30-176 WB97R-5
REMOVAL AND INSTALLATION ENGINE
5 -Lift the cover (6) and disconnect wiring harnesses (7)
and (8) from starter.
8
6
7
RKZC2890
Only if equipped
6 -Disconnect suction and delivery hoses (10) and (11) 11
from air-conditioning group compressor (9).
a Cap the hoses and holes to prevent contamination.
10
9
RKZC2900
Only if equipped
7 -Release the wiring harness (12) to the compressor (9)
from the tie straps and disconnect.
12 RKZC2910
8 -Disconnect wiring harness (13) from thermal starter and
disconnect connector (14) from the coolant liquid 14
temperature sensor. 13
RKZC2930
WB97R-5 30-177
REMOVAL AND INSTALLATION ENGINE
9 -Disconnect the ground plait (15) from the engine.
15
RKZC2920
10 -Disconnect connector (16) from the engine stop
solenoid valve, disconnect connector (17) from the
engine oil temperature sensor (17), and disconnect
connector (18) from the oil pressure sensor. 17
18
16
RKTA0811
11 -Disconnect wiring harness (20) and ground wire (21)
from generator (19).
19
20
21
RKZC2940
12 -Disconnect heating system connector and fuel
temperature sensor connector (22) and (23) from the
filter holder.
23
22
RKTA0801
30-178 WB97R-5
REMOVAL AND INSTALLATION ENGINE
13 -Release the entire engine harness from the tie straps
and route the harness down, and use some straps on
the inner sides of the frame to let the wiring hang
termporarily.
14 -Check to ensure that all hoses to the engine are
released from straps or ties.
RKZC2950
15 -Tighten a revolving lifting eye “A” to the muffler inner
mounting hole.
A
RKZC2960
16 -Attach a lifting device to lifting eye “A” and to engine front
bracket (24), and apply a slight tension to the chains or
cables.
28 A
24
RKZC2970
17 -Loosen and remove nuts (25), screws (26) and vibration
dampers (27) from front engine mounts. [*1] 27
18 -Remove the engine (28).
4 Engine: approx. 370 kg 25
26
28
RKZC2980
WB97R-5 30-179
REMOVAL AND INSTALLATION ENGINE
Installation
• To install, reverse removal procedure.
[*1]
3 Nuts: 200 Nm
a Check transmission oil level before starting the
engine.
a Thoroughly check the connectors to ensure that
they are properly connected.
1 -Start the engine and let it idle for a couple of minutes.
2 -Stop the engine and check all levels.
30-180 WB97R-5
REMOVAL AND INSTALLATION CONTROL VALVE
CONTROL VALVE
Removal
1 -Move backhoe fully to the right and swing the boom by
about 45° to the right leaving the backhoe plate
unlocked.
2 -Lower the outriggers to the ground, curl the bucket and
allow it to rest on the ground on its back.
Apply the parking brakes, stop the engine.
3 -Release all residual pressure.
(For details see "20 TESTING AND ADJUSTMENTS").
RKZC6370
4 -Lift rear window (1) to the top and remove the rear mat.
1
RKZC1870
5 -Take out the screws (2) and remove the platform (3).
3
RKZC1970
6 -Loosen the clamp (4) on the control valve support frame
(5) (4 screws).
4
RKZC1922
WB97R-5 30-181
REMOVAL AND INSTALLATION CONTROL VALVE
7 -Disconnect lower servocontrol and actuator hoses (6)
together will all accessible side hoses (7) from control
valve.
a Check that all the hoses are marked and note down
the bends and routing patterns.
6
a Cap pipes, hoses and holes to prevent
contamination. 7
RKZC1980
8 -Disconnect upper servocontrol hoses (8) and actuator
hoses (9) from control valve. 8 8
a Check that all the hoses are marked and note down
the bends and routing patterns.
a Cap pipes, hoses and holes to prevent
contamination.
a Lay the servocontrol hoses inside the cab to gain
access to the delivery, exhaust, and actuator hoses.
9 9
RKZC1990
9 -Turn the tubes (10) that provide direct connection away
fro m control valve and retain their position by
temporarily tightening clamp (4) on frame (5). 10 4
5
10
RKZC1923
10 -Disconnect connector (11) from backhoe plate lockout
solenoid valve (12).
11
12
RKZC1951
30-182 WB97R-5
REMOVAL AND INSTALLATION CONTROL VALVE
11 -Support control valve (13) by means of two ropes
connected to a lift arm to be introduced through the cab
opening.
Apply a slight tension to the ropes. 13
a Pay special attention to rope routing to prevent
damaging the unions.
RKZC6550
12 -Loosen and remove the four screws (14) (n° 3) and the
relative washers.
14 14
RKZC1981
13 -Lower the control valve (13) onto a lift. [*1]
4 8-spool control valve: _______ kg
4 10-spool control valve: _______ kg
13
Installation
• To install, reverse removal procedure. RKZC3131
[*1]
a Install control valve from top.
1 -Start the machine to circulate the oil; check to ensure
that there are no leaks.
2 -Bleed the air from the working equipment circuits.
(For details see "20 TESTING AND ADJUSTMENTS").
3 -Stop the engine, check the hydraulic oil level and top up
as necessary.
WB97R-5 30-183
REMOVAL AND INSTALLATION FRONT AXLE
FRONT AXLE
Removal
1- Start the engine and force the shovel downwards in
order to raise the machine and the front wheels.
2 -Place two stands “A” and some blocks beneath the
chassis.
3 -Slowly lower the machine onto the blocks, checking that A
the wheels remain at least 5 cm above the ground.
k Fully raise the front working equipment and engage the
safety stop.
Also place the backhoe in its secure position. RKZC2000
4 -Engage the parking brake.
5 -Stop the engine and eliminate residual pressure from all
circuits.
(For details see "20 TESTING AND ADJUSTMENTS"). 1
Remove the ignition key.
6 -Remove the engine hood (1) and the front guard (2).
(For details, see "ENGINE HOOD" and "FRONT
GUARD").
2
7 -If equipped, remove the front counterweight.
[*1]
4 Counterweight: 372 kg
RKZC0772
8 -Remove the front wheels. [*2]
4 Wheel: _________ kg
9 -Disconnect the cardan shaft (4) from the axle (3).
[*3] 6 7
5 4
10 -Disconnect the lines (5) from the steering cylinder and
plug them to prevent entry of impurities. [*4]
3
11 -Disconnect the lubrication tube (6) for the axle
oscillation pin (7).
5
RKZC2010
30-184 WB97R-5
REMOVAL AND INSTALLATION FRONT AXLE
12 -Position a jack “B” and some blocks “C” beneath the
axle. Raise the jack until the blocks can be forced under
the axle arms (3).
3
a It should be possible to lower the jack 10 cm in order
to disengage the axle from the fulcrum supports.
C
B
RKZC2020
13 -Take out the nut and remove the retaining screw (8) of
the axle oscillation pin (7). 7
14 -Tighten a hammer puller into the central hole of the axle
oscillation pin (7); pull out the axle oscillation pin. [*5]
15 -Lower the jack until the axle is disengaged.
8
16 -Extract the entire axle (3).
4 Front axle: 295 kg
RKZC2030
WB97R-5 30-185
REMOVAL AND INSTALLATION FRONT AXLE
Installation
• To install, reverse removal procedure.
[*1]
3 Nuts for front wheels: 370 Nm
[*2]
3 Front closing screws: 300 Nm
[*3]
3 Screws on gearbox side: 38 Nm
[*4]
a Bleed the air from the Load Sensing circuit.
(For details, see "20 TESTING AND ADJUSTMENTS").
[*5]
2 Axle oscillation pin - bushings: ASL800050
1 -Check the oil level in the tank and start the engine.
2 -Perform a few complete steering manoeuvres in both
directions to bleed the air from the steering circuit.
30-186 WB97R-5
REMOVAL AND INSTALLATION FRONT AXLE
FRONT AXLE
Disassembly and assembly
1. CYLINDER GROUP DISASSEMBLY
1.1 Disassembly
21 10
9
20
8
19
18
6
17
16 7
11
15 12
13 14
5
4
3
2
1
RKZ09810
1 -Unloose the guide rod (2) locknut (1) of some turns till it
is over the end of the threaded pin. 3
Beat on the nut (1) with a hammer in order to disjoin the
guide rod (2) from the swivel housing (3).
a Don’t beat on the end of the threaded pin.
a This is a destructive operation for the nut (1). 2
1
3
RKZB5581
2 -Loosen the nuts (4) and (9) and remove the tie rods (3)
and (10). 4
3 -Remove the fastening screws (6) of the cylinder, then 7
take the cylinder (7) out of its housing using a rubber 6
hammer.
5
a Remove only those parts that need to be 4
overhauled and/or replaced.
5
RKZ07111
WB97R-5 30-187
REMOVAL AND INSTALLATION FRONT AXLE
4 -Detach the cylinder head (15) from the cylinder case
(19). 19
Remove off the cylinder head and the rod (17) from the
cylinder case (19). 17
20 21
5 -Recover all sealing rings (16) and (18), O-rings (14) and
(20), and scrapers (21) and (13) from cylinder body (19) 14 15
and rod (17). 13 18
16
RKZ07121
1.2 Assembly
19
1 -Install new sealing rings (16) and (18), O-rings (14) and
(20), and scrapers (21) and (13) to cylinder head (15), to 17
rod piston (17) and into cylinder body (19). 20 21
14 15
13 18
16
RKZ07121
2 -Slide pre-assembled (17) rod into the cylinder body (19).
19
17
RKZB0093
3 -Install ball joints (5) and (8), nuts (4) and (9) and tie rods
(3) and (10) at the rod (17) ends and tighten. 4
3 Tie rods: 300 Nm 7
6
5
4
5
RKZ07111
30-188 WB97R-5
REMOVAL AND INSTALLATION FRONT AXLE
4 -Install steering cylinder to centre body (7) together with
tie rods. 6
5 -Assemble and tighten the steering cylinder fastening
screws (6) with torque wrench.
3 Screw: 120 Nm
7
RKZB5461
6 -Align the swivel housing with the axle (parallel wheel
hub).
Screw the guide rod (5) so that the ball joint can be
inserted into the swivel housing arm. 10
a It is important to unscrew the locking nut (9) to carry
out this operation.
11
RKZB1163
7 -Insert the ball joint (8) (into its own housing on the swivel
housing.
Assemble and tighten the lock nut (1) with
2 3
dynamometric wrench.
3 Nut: 220 Nm
8 -Repeat the operation for the opposite side.
1
RKZB1173
9 -Screw in the lock nuts (4) and (9) of the tie rods (3) and
(10) only when the toe-in adjustment has been carried
out.
WB97R-5 30-189
REMOVAL AND INSTALLATION FRONT AXLE
Toe-in adjustment
1 -Put two equal one-meter-long linear bars “A” on the
A
wheel sides and lock them with two nuts on the wheel
hub stud bolt.
a The two bars should be fixed on their middle so that
they are perpendicular to the supporting surface
and parallel to the pinion shaft axis.
a Align the two bars.
50 cm 50 cm
RKZB1190
2- Using a measuring tape, measure the distance in mm
“M” from the farthest bar ends, and tighten or loosen the
guide rods until the distance is the same on both sides.
a Keep the minimum value, swinging the M
measurement point.
RKZB1200
3 -Check that the difference of the measurements between
the wheel hubs diameters ends is within the requested A -0 2 mm
tolerance range.
The nominal toe-in (A) value is referred to the external
diameter of the wheel hubs flange, therefore the
measured toe-in value (M) at the bars ends must be
related to the ratio between length of the bar and flange
diameter.
nominal toe-in = A --0 2 mm A
measured toe-in = M --0 5 mm
M -0 5 mm
RKZ09820
30-190 WB97R-5
REMOVAL AND INSTALLATION FRONT AXLE
4- If toe-in is incorrect, operate with two wrenches on the
guide rods screwing in and out the two joint tie rods
equally till the toe-in is within the required tolerance.
RKZB1210
5 -Once adjustment is complete, tighten the retaining nuts
on the guide tie rods.
3 Nuts: 250 Nm
RKZB1221
Steering angle adjustment
A
1 -Use the same bars “A” assembled for the toe-in
adjustment and a long bar perfectly leant over the
machined part of the central body (pinion side), so that
the two bars form an acute angle at the maximum
steering.
RKZB1230
2 -Adjust a goniometer to the angle of 65° and position it on
the long bar.
Move a wheel side till it forms, with the two bars, the
angle fixed by the goniometer.
RKZB1240
WB97R-5 30-191
REMOVAL AND INSTALLATION FRONT AXLE
3 -Adjust the steering mechanical retainer, screwing in or
out the special screws (1) on the bar body, locking them
with a locknut (2).
3 Lock nut: 150 Nm
Steer completely towards the other side and repeat the
same operations.
RKZB1251
30-192 WB97R-5
REMOVAL AND INSTALLATION FRONT AXLE
2. EPICYCLIC REDUCTION GEAR
2.1 Disassembly
7
6
9
3
8
10
2
1
RKZ09830
k Before draining the oil, position the epicyclic reduction
gear (3) with the plug (2) on the upper part and loosen it
of some turns in order to eliminate any possible inner 2
pressure, then remove it completely.
Turn the hub upside-down till the hole is in the lowest 3
point.
Drain the oil completely.
RKZB0102
1 -Remove the fastening screws (1).
RKZC0600
WB97R-5 30-193
REMOVAL AND INSTALLATION FRONT AXLE
2 -Remove the planetary carrier (3) from the epicyclic
reduction gear and remove the O-ring (10). 3
10
RKZC0610
• Replacements of the planetary gears
(if necessary) 8
1 -Remove stop ring (9) from each pin (4). 7
2 -Remove the gears (6) out of the pins.
3 -Recover rollers (7) and (5) and inspect their condition. 7 5
4 -Remove the thrust washers (8).
6
a With new planetary gears is advisable to assembly
new roller bearings.
RKZ09840
2.2 Assembly
8
1 -Recover all epicyclic reduction gear components: the
planetary gears carrier (3), the gears (6), the needle 7
bearings (5) and (7), washer (8) and the snap rings (9) of
every pin (4).
7 5
a With new gears, it is advisable to install new needle
rollers.
6
RKZ09840
2 - Insert the needles (5) and (7) into the gears (6).
a Grease well the needles (5) and (7).
Insert the gears (6) with assembled needles in the
planetary carrier pins.
6
RKZC0620
30-194 WB97R-5
REMOVAL AND INSTALLATION FRONT AXLE
3 -Assemble the washer (8) and snap ring (9) on every
pin (4). 9
8
RKZ09850
4 -Install a new O-ring (10).
Install planetary gear carrier (3) to epicyclic reduction
gear.
Install retaining screws (1).
3 Screws: 25 Nm
RKZC0600
5 - Use recommended oil in epicyclic reduction gear and
axle body.
Install plug (2) to epicyclic reduction gear. 2
3 Plug: 80 Nm
3
RKZB0102
WB97R-5 30-195
REMOVAL AND INSTALLATION FRONT AXLE
3. WHEEL HUB GROUP
3.1 Disassembly
19 27
18
14
13 26
11 23
12
22 25
10
15
7
4 21
20
16
3
9 17
1
8
6
2 5
RKZ09860
k Before disassembling the wheel hub, it is advisable to
secure it with a belt or a rope on a hoist or any other
supporting device, in order to avoid its accidental fall
that could damage either the operator or the wheel hub
group.
1 -Insert a lever between the swivel housing (14) and the
axle beam and fit it into the double U-Joint.
With the lever push the double U-Joint in the direction of
the wheel hub to allow the lock ring (1) removal.
a Do not damage the double U-Joint.
RKZC0630
2 -Remove the lock ring (1) from the double U-Joint shaft
and collect the washers (2), (3).
1
RKZB0133
30-196 WB97R-5
REMOVAL AND INSTALLATION FRONT AXLE
3 -Unscrew and remove the fastening screws (5) from the
wheel carrier (7) group.
7 5
RKZB0141
4 -In order to remove the wheel carrier group (7) from its
housing, screw (5) at least two of the just removed
screws in the threaded extraction holes. 7
5 -Extract and remove the hub-lock ring gear (7) together
5
with the epicyclic ring gear (4).
5
5
RKZB0152
6 -Remove the stop ring (4) and disjoin the hub-lock ring
gear (7) from the epicyclic ring gear (3).
a Check the wear conditions of the components. 6
Only if necessary
7 -Remove the centering bushes (6) of the hub lock ring
7
gear with a hammer and the special tool D1.
4
RKZC0640
8 -Remove the hub (11), using levers and a hammer to
facilitate the operation.
11
a Collect the bearing (9) cone.
RKZB0172
WB97R-5 30-197
REMOVAL AND INSTALLATION FRONT AXLE
9 -Position on a flat surface the hub and take the seal ring
out (13) with a lever. 12
a This is a destructive operation for the seal ring.
10 -Take the bearing cups out (9) and (12), on both sides of
the hub, using a hammer and a suitable tool to be 9
beaten. 13
11 -Remove the bearing cone (12) from the swivel housing
using a suitable, commercially available puller.
11
RKZ09870
12 -Unscrew and remove the fastening screws (19) from the
upper (18) and (17) lower (16) king pin. 19
k Before removing the king pins, secure the swivel
housing with a belt or a rope to a hoist or any other
supporting device. 18
13 -Remove the king pins (18) and (16) and collect he
belleville washers (25), (27).
16
RKZB5621
14 -Remove the swivel housing (14) from the axle beam and
from the shaft (24).
14
24
RKZB0212
15 -Position the swivel housing (14) on a flat surface and
take the seal ring (23) out with a lever.
14
a This is a destructive operation for the seal ring.
23
22
16 -Turn the swivel housing (14) and take the bush (22) out,
using a driver and a hammer.
RKZB5631
30-198 WB97R-5
REMOVAL AND INSTALLATION FRONT AXLE
3.2 Assembly
1 -Force the bush (22) into the swivel housing (14) with the
special tool D2. and a hammer or a press.
D2 D3
2 -Assemble the seal ring (23) on the swivel housing (14) 22 23
with the special tool D3.
and a hammer. Lubricate the ring with grease
ASL800050. 14
RKZB1013
3 -Position the lower king pin (16) on a workbench and
assemble the cone of the spherical joint (15) with the 27
15
special tool D4 under a press. Grease well the king pin
housings with grease ASL800050.
4 -Position the Belleville washers (25) and (27) on the king
pin housings (16) and (18). 16
25 RKZB5661
5 -Secure the swivel housing (7) group with a rope.
Lubricate the seal ring lip and protect the splined end of
the axle shaft by winding it with thin adhesive tape to 18
avoid damage to the seal ring. After assembly, remove
completely the adhesive tape. Assemble the swivel
housing on the axle beam.
19
6 -Assemble the two king pins, the upper (16) and the lower
(18), and tighten the retaining screws (17) and (19).
3 Screw: 190 Nm 16 14
a Make sure that the Belleville washers (25) and (27)
remain in their position. RKZB1412
7 -If bearings (9) and (12) need to be replaced, make sure
that distances “A”, “B” and “C” are within the permissible
range.
A = 5.900 – 5.905 mm
B = 52.229 – 52.279 mm 9 12
C = 23.072 – 23.173 mm C A C
RKZ05743
WB97R-5 30-199
REMOVAL AND INSTALLATION FRONT AXLE
8 -Position the wheel hub (11) on a workbench and force
both cups of the taper roller bearings (9) e (12) in 12 13
position with the special tool D5 under a press or with a 9
hammer.
9 -Insert the seal ring (13) into the wheel hub (11) with the
special tool D6 and a hammer.
D5 D6
D5 11
RKZB1424
10 -Assemble the cone of the taper roller bearing (12) on the
swivel housing end (14). 14 14
11 -Assemble the wheel hub (11) on the swivel housing (14) 12
and fit the other cone of the taper roller bearing (9) in
position.
RKZB1433
12 -Position the wheel carrier (7) on a workbench and force
the bushes (6) to the carrier surface level with the
special tool D1.
6
At least two bushes (diametrically-opposed) should be
set slightly higher than the carrier surface level to be
used as dowel pins.
7
RKZB1093
13 -Preassemble the wheel carrier - (7) epicyclic ring gear
group (7) and (4) with the special locking ring (8) shown 4
in figure.
RKZ05733
30-200 WB97R-5
REMOVAL AND INSTALLATION FRONT AXLE
14 -Assemble the wheel carrier group on the wheel hub
using the two projecting bushes (6) as dowel pins.
Screw the relative screws (5) in order to put in contact
the ring bevel gear with the wheel hub.
RKZB1103
15 -Force all the hub dowel bushes completely with the
special tool D1 and a hammer.
7
Assemble the wheel carrier (7) fastening screws (5) and 5
tighten.
3 Screw: 120 Nm
RKZB1443
16 -Install washers (2) and (3) to the axle shaft and install the
stop ring (1) by pushing it from the end of the serrated
hub to its seat while counteracting with a lever inserted
1
between beam and swivel housing and engaged onto
the double U joint.
RKZB0133
WB97R-5 30-201
REMOVAL AND INSTALLATION FRONT AXLE
4. AXLE BEAM GROUP
4.1 Disassembly
7
8
1
2
8
7 4 5
RKZ09880
1 -Remove the U-Joint (6) from the axle beam (1).
RKZC0650
2 -Take the seal ring (5) out of the axle (1) beam with a
lever.
a This is a destructive operation for the seal rings. 4
3 -Remove the bush (3) from the beam with a suitable
extractor.
a Examine the bush before the removal and replace it
only if the wear conditions require this.
5
5
RKZC0660
30-202 WB97R-5
REMOVAL AND INSTALLATION FRONT AXLE
4 -Extract the upper bushings (2) and cup (3) from the king
pin housings. 2
a Examine the bushing and housing before removal
and replace depending on wear conditions.
1
3
RKZ09890
5 -Take the seal ring (7) out of the axle (1) beam with a
suitable tool.
7
a This is a destructive operation for the seal rings.
Only if necessary, remove the bushings with a standard 8 1
three-gripping point extractor or a suitable driver and a
hammer.
a Do not damage the bushing housing. 8
7
RKZ09900
4.2 Assembly
1 -Using tool D7 and a hammer, install bushing (2) and cup 2 D7
(3). 2
a To make installation easier, allow the bushings and
cups to cool in liquid nitrogen at less than -100°C (-
148°F)
D7
3
3
RKZC0670
2 -Assemble the bush (4) on the axle beam with the special
tool D9 and a hammer.
3 -Assemble the seal ring (5) on the beam with the special
tool D10 and a hammer. 4 5
Fill 3/4 of the seal ring cavity with grease ASL800050.
RKZ09910
WB97R-5 30-203
REMOVAL AND INSTALLATION FRONT AXLE
4 -Lubricate the bush (5) and the seal ring lip (6). Insert the
U-Joint (7) inside the axle beam.
a Take care not to damage the sealing ring. 6
RKZC0650
5 -Assemble two new bushings (8) respectively and two
new seal rings (7) in the central unit (1) pivot by using
special tools D8 and D11. 7
8 1
8
7
RKZ09900
30-204 WB97R-5
REMOVAL AND INSTALLATION FRONT AXLE
5. DIFFERENTIAL SUPPORT
5.1 Disassembly
6
12
5 7 11 14
10
13
4
3
1
RKZ09920
1 -Loosen and remove the screws (2) on the differential
support (1). Remove the differential support (1) from the
axle beam (14).
k Support the differential carrier with a rope or other
appropriate means. 14
2 1
RKZ09930
2 -Loosen and remove the screws (6) to remove the two
ring nut retainers (5). 6 6
5
5
RKZ09940
WB97R-5 30-205
REMOVAL AND INSTALLATION FRONT AXLE
3 -Before removing bolts, mark halfbridles (10) and the
differential carrier with permanent reference marks to
avoid inverting them when re-assembling the unit. Mark
the area between the ring (3), (7) buts and the 10
differential (1) carrier as well. 1
RKZ09950
4 -Unscrew the adjuster ring nuts (3), (7) using tool D12
and a wrench.
7 3
D12 RKZ09960
5 -Loosen and remove the 4 screws (11) and remove the 2
half-collar (10). 11
a Ensure that the centre bushings (9) remain seated.
10
RKZ09970
6 -Take out the differential case (13).
a Take care not to loose the cups bearing (13) that are
removed together with the differential case (1).
4 4
a Do not mismatch the cups of the bearings (4) if
bearings are not to be replaced.
RKZ09980
30-206 WB97R-5
REMOVAL AND INSTALLATION FRONT AXLE
5.2 Assembly
1 -Position the complete differential box (13), with the outer
cups (4) of the tapered roller bearings already
assembled, on the differential carrier (1).
k Take care not to invert the outer races of the tapered 4
4
roller bearings and check you are working on the right
side of the bevel crown assembly.
13
RKZ09990
2 -Place the differential (1) group and the two halfbridles
(3) and bolts in their seat. 11
Check the positions of the bushings and halfbridles
using the reference marks on them and on the
10
differential support (1).
Install the halfbridles and secure with their respective
screws (11).
9
RKZ09970
3 -Assemble and tighten the two adjustment ring nuts (3)
(7) in the differential support with tool D12, so as to pre-
load the differential bearings slightly. Knock lightly with a
soft hammer in order to properly set the bearings in
position.
7 3
a Take care not to reverse the ring nuts; align the
previously-traced reference marks.
D12 RKZ09960
4 -Install a magnetic comparator “A” to the differential
support so that the checkhead is at right angles with the
side of a tooth from the ring gear. A
RKZ10000
WB97R-5 30-207
REMOVAL AND INSTALLATION FRONT AXLE
5 -Lock the pinion and move the crown gear alternatively
and note the pinion-ring gear backlash, measured with
the comparator.
Repeat the operation on 2 or more points (teeth),
rotating the crown gear, so that to obtain an average
value.
Check if the measured backlash value is within the
requested range:
0.18 – 0.28 mm
Adjust by operating the ring nuts (3), (7) by means of tool
D12. RKZ09951
6 -If the measured backlash is lesser than the given
tolerance range, screw the ring nut (7) from the side
opposite to the ring gear and unscrew (3) the opposite
one of the same measure.
6a -If the measured backlash is higher than the given
tolerance range, screw the ring nut (3) from the side of 13
the ring gear and unscrew the opposite (7) one of the
same measure.
RKZ10100
7 -Make sure that the bearings are slightly preloaded; if
necessary, repeat previous adjustment until the
specified conditions are reached. A
RKZ10000
8 -Once pinion/ring gear backlash is determined, measure
total bearing preload (T) (pinion/ring gear system) using
a force gauge with the cable wound around the splined
pinion end. The reading should be within the following
values:
T=(P+3.75)–(P+5.75) daN
where P is the effectively measured pinion preloading
(For details, see "6. DIFFERENTIAL GROUP")
a All preloadings should be measured without the
seal ring.
RKZ10020
30-208 WB97R-5
REMOVAL AND INSTALLATION FRONT AXLE
9 -If the measurement is not within the requested range,
check well the assembly of each component and b b
operate on the adjuster ring nuts (3) and (7) of the
differential support:
a - if total preload is less than the specified values,
tighten the adjuster ring nuts (3) and (7) by the same
amount, while keeping the pinion/ring gear
backlash unchanged;
b - if total preload is greater than the specified a a
values, loosen the adjuster ring nuts (3) and (7) by
the same amount, while keeping the pinion/ring
gear backlash unchanged; RKZ10010
10 -When all adjustments are complete, install the ring
nut retainers (5) and their respective screws (6), and 6
tighten to the specified torque. 6
5
3 Screw: 266 Nm 5
RKZ09940
11 -Tighten the screws (11) the 2 half-collar (10).
3 Screw: 266 Nm
11
10
RKZ10030
12 -Before matching surfaces, make sure that they are
perfectly clean, degrease and clean them with
appropriate detergents.
Spread a film of adhesive on the contact surface
between the axle beam (14) and the differential carrier
(1).
2 Loctite: 510
14
a check that two dowel pins (12), (8) are in their seats.
12
RKZ10040
WB97R-5 30-209
REMOVAL AND INSTALLATION FRONT AXLE
13 - Assemble the differential support (1) to the axle
housing (14), and tighten the retaining bolts (2) to the
requested torque.
Refill the tank with oil.
3 Screw: 169 Nm 14
2 1
RKZ09930
• Bevel gear marking test
1 -To test the marks of the bevel gear teeth, paint the ring
gear with red lead paint.
The marking test should be always carried out on the
ring bevel gear teeth and on both sides.
RKZ10050
2 -OK - Correct contact:
If the bevel gear is well adjusted, the mark on the teeth OK Z
surfaces will be regular.
Z - Excessive contact on the tooth tip:
Approach the pinion to the ring bevel gear and then
move the ring bevel gear away from the pinion in order to
adjust the backlash. X
X - Excessive contact at the tooth base:
Move the pinion away from the ring bevel gear and then
approach the ring bevel gear to the pinion in order to
adjust the backlash. RKZ10060
3 -Movements to correct:
1 - move the pinion for type X contact adjustment X.
2 - move the pinion for type Z contact adjustment.
RKZ10070
30-210 WB97R-5
REMOVAL AND INSTALLATION FRONT AXLE
6. DIFFERENTIAL GROUP
6.1 Disassembly
7 4 1
6
3
5
9
11
13 8
10
12
RKZ10080
1 -Pry the cover (13) away from the differential support
using a lever.
13
RKZ10100
2 -Remove the seal rings (12) and (11) from the cover (13).
11
a This is a destructive operation for the seal rings.
13
12
RKZ10110
WB97R-5 30-211
REMOVAL AND INSTALLATION FRONT AXLE
3 -Fit the differential carrier (1) in a vise.
Unscrew the lock nut (10) using special tools D14-D15.
a This operation will irretrievably damage the ring nut
D14
(10).
10
D15
RKZ10170
4 -Remove the ring nut (10) and collect its retaining washer
(9).
9
10
RKZ10120
5 -Tap the shaft with a soft hammer to remove the bevel
pinion (1). 8
a Take care not to drop the bevel pinion (1).
Recover washers (4) and (6), collapsible spacer (5) and 5
bearing cone (8).
1
6
4
RKZ10090
6 - Place differential support (7) on a firm flat surface and
extract bearing outer rings (3) and (8).
3
RKZ10180
30-212 WB97R-5
REMOVAL AND INSTALLATION FRONT AXLE
7 -To remove bearing inner ring (3) from bevel pinion (1),
use a commercially available grip puller.
Recover bearing inner ring (3) and the shim (2) under 3
it.
RKZ10190
8 -Check all pinion components for wear.
a The ring nut (10) and the snap spacer (5) must be
replaced when reassembling the unit.
5
10
RKZ10200
6.2 Assembly
1 -Place differential support (7) on a work bench. 3
Force bearing outer rings (3) and (8) into it using
special tool D16 and a hammer.
RKZ10180
2 -Use the kit consisting of the special tools called “false
pinion” D17 and “false differential box D18 and D19 and
a deep gauge.
D19
D18
D17
10 RKZ10210
WB97R-5 30-213
REMOVAL AND INSTALLATION FRONT AXLE
3 -Introduce bearing rings (3) and (8) to their respective
seats.
7
Assemble the “false pinion” and ring nut (10).
Tighten ring nut – but do not overtighten – until backlash
is eliminated.
8
10 3
RKZ10130
4 -Install tool D18, D19 to bearing seats in differential
support (7) and retain with halfbridles. D18
D19
RKZ10220
5 -Installation method D18, D19.
Use a depth gauge to measure distance “X” (distance D18 D19
between the axis of the differential bearings and the
point at which the pinion head, or base of bearing, is X
supported).
RKZ10230
6 -In order to determine the thickness (S) required
between the pinion and the bearing, subtract the value
(V), stamped on the pinion head (V=requested bevel
distance), from the measured value (X). V
S=X-V mm
RKZ10150
30-214 WB97R-5
REMOVAL AND INSTALLATION FRONT AXLE
7 -Pick the (S) shim (2) from the range of shims available.
SHIM RANGE
Shims 2.5 2.6 2.7 2.8 2.9 3.0 3.1 3.2 3.3 3.4
RKZ10160
8 -Remove special tool D18, D19 from differential support.
Remove ring nut (10), false pinion, and bearing cones
7
(3) and (8).
8
10 3
RKZ10130
9 -Install the selected shim (2) to the pinion shaft (1) with
the chamfer facing the gear.
3 6
Force bearing (3) onto the pinion shaft (1) using a press
and driver D20, and ensure that the bearing is fully
locked into position.
5 4
Install shims (4) and (6), and a new collapsible spacer
(5). 2
1
a Use only one new spacer at any time.
RKZ10240
10 -Install preassembled bevel pinion group (1) to the
differential support (7), and install bearing inner ring (8) 8
to pinion end as shown.
To force bearing (8), use driver D20 and a hammer.
a Oppose a resistance to the striking force (e.g. a sledge 5
hammer).
1
6
4
RKZ10090
WB97R-5 30-215
REMOVAL AND INSTALLATION FRONT AXLE
11 -Insert a ring nut washer (9) and screw a new lock ring nut
(10) on the pinion end.
9
10
RKZ10120
12 -Screw the ring nut in (10), using the wrench for ring nut
D14 and for pinion retainer D15.
a The torque setting is given by the preloading
D14
measurement on bearings (3) and (8); Tighten the ring
nut (10) step by step.
a If it is tightened too much, the elastic spacer (5) should
10
be replaced and the procedure repeated.
When you check the preloading, it is advisable to beat D15
slightly both pinion (1) ends with a soft hammer, so as to
help setting the bearings (3) and (8).
RKZ10170
13 -Measure preload P of tapered bearings (3) and (8) using
a force gauge with the string wound around the splined
end of pinion (1).
Adjustment is carried out by gradually increasing the
tightening torque of the ring nut (10), paying attention
not to overtighten.
a All preloadings should be measured without the seal
ring.
P=9.2-13.7 daN
RKZ10140
14 - Once you got the requested preloading value, caulk
the ring nut (10).
10
RKZC0680
30-216 WB97R-5
REMOVAL AND INSTALLATION FRONT AXLE
a Do not carry out the steps below until you have
completed the adjustment of preload T. 11
15 -Assemble sealing ring (11) to cover (13) using tool D21
and a hammer. 13
Install a new O-ring (12) to cover (13).
Lubricate O-ring (12) and sealing ring (11).
12
RKZ10110
16 - Install cover (13) to differential support.
13
RKZ10100
WB97R-5 30-217
REMOVAL AND INSTALLATION FRONT AXLE
7. DIFFERENTIAL GROUP
7.1 Disassembly
11
1 7
2
5 9
4 10
4
8
2
7
6
3
RKZ10250
1 Lock the differential in a clamp.
2 -Unscrew all the fastening screws (1) on ring bevel gear
(11).
a This will make both differential half boxes (3), (10)
free, so take care not to drop the internal 11
components.
3 -Remove the bevel gear crown (11).
1
RKZB0571
4 -Disassemble the differential box in two half boxes (3),
(10) complete with the relevant components.
a Scribble some match marks before separating the
two half housings.
5 -Recover the components from both half boxes. 3
6 -heck the operating and wear conditions of the 10
components.
RKZ10260
30-218 WB97R-5
REMOVAL AND INSTALLATION FRONT AXLE
7 -Take the bearing (2) out of the differential half box (3) e
(10), using two levers or a three-hold extractor.
3
2
10 2
RKZ10270
7.2 Assembly
1 -Assemble the cones of the new taper roller bearings (2) 3
on the half boxes (3), (10) using the special tool D13 and 2
a hammer.
10 2
RKZ10270
2 -Position a half housing (3) on a workbench and
assemble all inner components: locking differential
counterdiscs (4), sun gears (5), spider (9), spider gears
(7), thrust washers (6), pin (8), as shown in figure.
Join the two half boxes, aligning the reference marks
made during disassembly. 3
10
RKZ10260
3 -Position the ring bevel gear (3) and then fix the whole by
tightening the screws (4). 11
3 Screw: 95 Nm
2 Screw: Loctite 270 1
RKZB1291
WB97R-5 30-219
REMOVAL AND INSTALLATION REAR AXLE
REAR AXLE
Removal
1 -Lower the backhoe outriggers (1) and force them
downwards in order to raise the rear wheels.
2 -Place jacks or stands "A” under backhoe frame with non
slip blocks that are 50–52 cm high.
3 -Start the engine and slowly retract the outriggers until
the machine rests on jacks “A”, then move frame back to
its horizontal position.
1 1
A
RKZC2040
4 -For added safety, place the backhoe bucket with its back
on the ground while holding the arm in its upright
position.
Lower shovel to the ground as well.
RKZC6390
5 -Remove the rear wheels (2). [*1]
6 -Stop the engine and completely release residual
pressures from all the circuits.
(For details, see "20 TESTING AND ADJUSTMENTS").
RKZC2050
7 -Disconnect cable (3) from parking brake (4).
[*2]
RKZC2070
30-220 WB97R-5
REMOVAL AND INSTALLATION REAR AXLE
8 -Disconnect differential lock hose (5).
a Cap the hose and hole to prevent contamination.
5
RKZC2080
9 -Disconnect service brake pipes (7) from axle (6).
[*3] 8
7
a Disconnect pipes (7) from hoses (8); loosen and
remove clamp (9) and pipes (7).
a Cap pipes, hoses and holes to prevent 9
contamination.
7
RKZC2090
10 -Disconnect the cardan shaft (10) from the rear axle.
[*4]
10
RKZC2100
11 -Position a jack “C” and some blocks beneath the axle
(6). Raise the jack until the blocks can be forced under 6
the axle arms.
a It should be possible to lower the jack by approx. 20
cm.
RKZC2110
WB97R-5 30-221
REMOVAL AND INSTALLATION REAR AXLE
12 -Loosen and remove the screws (11) and (4). [*5]
13 -Lower the jack until the axle (6) is disengaged from the
chassis.
14 -Extract the entire axle.
4 Rear axle: 435 kg
11 11
6
RKZC2120
Installation
• To install, reverse removal procedure.
[*1]
3 Wheel nuts: 500±9.8 Nm
[*2]
a Bleed the air from the braking circuits. (For details,
see "20 TESTING AND ADJUSTMENTS").
[*3]
a Adjust the stroke of the parking brake lever. (For
details, see "20 TESTING AND ADJUSTMENTS").
[*4]
3 Cardan shaft screws: 38 Nm
[*5]
3 Axle retaining screws: 1000 Nm
2 Axle retaining screws: Loctite 262
30-222 WB97R-5
REMOVAL AND INSTALLATION REAR AXLE
Disassembly and assembly
1. PARKING BRAKE GROUP
1.1 Disassembly
10
9
5 3
2
6
12
11
4
1
7
RKZ08460
1 -Loosen nut (1) (n°2).
1
RKZB7100
2 -Loosen and remove the screws (2) (n°2).
a Proceed with care, in order to avoid damaging the
brake pads. 2
3
3 -Remove the brake caliper (3).
RKZB7110
WB97R-5 30-223
REMOVAL AND INSTALLATION REAR AXLE
4 -Remove the snap ring (4) and the input flange (5).
a Collect the shim (6) and the O-ring (7). 5 7
RKZ08470
5 -Loosen and remove the screws (8) retaining the brake
caliper support (9). 9
6 -Remove the support (9) from the centre body.
RKZ08480
7 -Remove the seal ring (10) from the central housing (11)
with a puller. 11
a This is a destructive operation for the seal ring.
10
RKZ08490
1.2 Assembly
11
1 -Introduce a new seal (10) into in the central body using
special tool E1.
10
RKZ08490
30-224 WB97R-5
REMOVAL AND INSTALLATION REAR AXLE
2 -Insert the dowel pin (10) and the brake caliper support
(7) on the central body (9).
Screw in and tighten the fastening screws (8). 11
3 Support screws: 80 Nm 9
12
RKZ08500
3 -Lubricate O-ring (7).
2 O-ring: ASL800050 5 7
4 -Insert the thickness (6) on the splined pinion end, a new
O-Ring (7), the input flange (5) and the lock ring (4).
4
RKZ08470
5 -Position the brake caliper (3) on the flange disc (9).
a Be careful to avoid damaging the brake pads.
3 9
RKZB7120
6 -Screw in the bolts (2) and tighten the nuts (1) to the
prescribed torque.
1±0.5 mm
a Once the nuts are tightened, check to make sure
that a 1 ± 0.5 mm gap remains between nuts (1) and
the spacers shown.
3 Nuts: 115 Nm
3 Screw: 45 Nm
1
2 2 RKZ08520
WB97R-5 30-225
REMOVAL AND INSTALLATION REAR AXLE
1.3 Maintenance
10
5
18 2
3 6
4
20
18
11 9 19
16
13 8
15
1
17
12
RKZ08530
1 -Insert mounting bolts through sleeves (9) and thread 4 -Tighten outer Locking Nut (13) against inner
brake mounting locking nuts as far as possible on Adjustment Nut (12) to lock Adjustment Bolt (2) in
mounting bolts. This is not required if brake assembly place. Tighten at 62 – 76 Nm.
comes with the sleeve/bolt sub-assy. Position the
brake over disc align with mounting holes in
mounting bracket. Ball and Cam Replacement
2 -Thread mounting bolts (9) into mounting bracket, 1 -Remove both Adjustment Locking Nuts (12, 13),
adjusting bolts until a 0.5 – 1.5 mm exists between Thrust, stainless steel and Hardened Washer (11,
the Sleeves and the Locking Nuts. Tighten the 16, 17), Lever (11), and Boot (3) from Adjustment
Locking Nuts to 115 Nm of torque against the Bolt (2).
bracket. 2 -Remove outer cam (4) and Ball Assembly (8) from
Adjustment Bolt (2).
3 -Refer to Adjustment Procedure to set backlash of
installed brake assembly. 3 -Use a screwdriver, or similar tool, to gently pry inner
Cam (4) protrusions on back of cam, loose from
Brake pad looseness adjustment procedure Torque Plate (5), and remove from Adjustment Bolt
1 -Loosen adjustment nuts (12, 13). (2). Remove Seal (15) from Adjustment Bolt (2).
2 -Tighten inner Adjustment Nut (12) until firm contact is 4 - Install new Seal (15) on Adjusting Bolt (2), inserting
made with the disc by the linings. Torque to 160÷ 170 through inner Cam (4) until Seal (15) bottoms out on
Nm. Torque plate.
Ensure that the control lever is in the brake apply a We recommend lubricating the cams' thrust
position. surfaces before installing the cams (4).
3 -Back off inner Adjustment nut (12) 4 to 6 turns and 2 Cam surface: ASL800050
check that disc is free to move.
30-226 WB97R-5
REMOVAL AND INSTALLATION REAR AXLE
5 -Install new Cam (4) on Adjustment Bolt (2), taking Sleeve seal replacement
care to orient protrusions into Holes in Torque Plates
(5). 1 -Loosen the two locking nuts on the mounting bolts
and remove the mounting bolt/sleeve assembly (9)
6 -Install Ball Assembly (8) onto Adjusting Bolt (2), from the brake.
orienting balls into pockets of Inner Cam (4). Install
outer Cam (4) onto Adjustment Bolt (2), orienting 2 -Insert sleeve seals (18) between the torque (5, 7) and
pockets onto Balls of Balls Assembly (8). Install boot align with the sleeve bores.
(3) over cam assembly.
a Lubricate the mounting bolt/sleeve fit before
7 -Install Lever (1), using protrusions on back of outer installing
2 Bushings: ASL800050.
Cam (4) and holes in Lever (1) to orient lever to
proper operating position.
8 -Install remaining washer and nuts and follow 3 -Install the mounting bolt / sleeve assembly through
adjustment procedure at paragraph 1.2. the front pad support (5), the sleeve seals (18) and
the rear pad support (7).
a Check to ensure that the coated side of shim (11)
is oriented towards the steel washer (17). 4 -Mount brake per paragraph 1.1 and adjust per
section 1.2.
Lining Replacement
Replacing the cable attachment bracket
1 -Loosen two adjustment Locking Nuts (12, 13)
enough to remove each Torque Plate (5, 7) away 1 -Remove the screws (19) of the bracket (20) from pad
from disc far enough to provide backlash to remove support (5).
old carrier and lining assemblies and install new Remove the bracket (20).
ones. (It may be necessary to remove one or both
2 -Position the bracket (20) in correspondence with the
Nuts)
threaded holes of the pad support (5).
2 -Collapse the two Lining retraction Springs (10) and Fix the bracket (20) to the front torque plate (5) with
remove them from brake Head Assembly. the appropriate screws (19).
3 -Remove Torque Plates (5, 7) away from disc, move 3 Screw: 63 Nm
Carrier and Lining Assemblies (6) out of pockets, and
remove from the Brake Head Assembly from the
side.
4 -Before installing new pads, it is necessary to
introduce grease between bushings (9) and pad
supports (5, 7).
2 Bushings: ASL800050
a Once grease has been applied, slide the
supports onto the bushings so as to distribute
grease evenly.
5 -Install new Carrier and Lining Assemblies (6) in each
Torque Plate (5, 7).
6 -Install the two Lining Retention springs (10) into
Brake Head Assembly. Be sure spring’s “feet” are
positioned properly in holes in both Lining Carrier
Assemblies (6).
7 -Adjust brake at paragraph 1.2.
WB97R-5 30-227
REMOVAL AND INSTALLATION REAR AXLE
2. SERVICE BRAKE GROUP
2.1 Disassembly
11
12 8 10
9 16
13 17
14 3
15
18
19
2 4
5
6
5
6 RKZ08540
1 -Drain the oil completely from the differential.
2 Differential oil: approx. 15 l.
RKZB7130
2 -Remove all but two of the cap screws (1).
RKZB7140
30-228 WB97R-5
REMOVAL AND INSTALLATION REAR AXLE
3 -Connect the hub (2) to a lifting device and tension the
rope.
a insert two dowel rod to enable removal.
3
2 RKZB7150
4 -Remove last two cap screws (1) and separate the hub
(2) from the axle (3).
3
2 RKZB7150
5 -Slowly pull hub (2) away from axle and the half shaft (4),
make sure that brake disks (5) and plates (6) stay with
the hub. 5
6
4
RKZB7160
6 -Stand the hub up, mark the reaction plat (5) that was
against the axle housing (3). Remove the reaction (6)
and brake disks (5) and pins (7). 5
a Check friction plate and brake separator thickness.
For details, see ("40MAINTENANCE
STANDARD")
a If brake discs are to be replaced, soak the new discs
(for each differential) in oil for at least 24 hours 6 7
RKZB7170
WB97R-5 30-229
REMOVAL AND INSTALLATION REAR AXLE
7 -Remove axle shaft (4) from wheel hub assembly (2).
RKZB7180
8 -Remove screws (8) and Belleville washers (9) from
brake cylinder (10).
10
RKZB7190
9 -Check to ensure that screws (8) and Belleville washers
(9) are not damaged.
8 9
a If brake discs are being replaced, replace screws
and washers with the new kit.
RKZB7200
10- Remove the lock ring (11) and remove the self adjuster
(12).
11
12
RKZB7210
30-230 WB97R-5
REMOVAL AND INSTALLATION REAR AXLE
11 -Place self adjuster (12) onto special tool E2 and drive
out the spring clips (13) from the adjuster.
12 E2
13
E2
RKZB7220
12 -Inspect adjuster bushing (14) for wear.
a Repeat procedure for the remaining 2 kit self adjust.
14
RKZB7230
13 -Use an acceptable flat bars and pry the brake piston (10)
up from the hub.
10
RKZB7240
14 -Remove from the brake complete piston (10) the inner
cylinder (15).
10
15
RKZB7250
WB97R-5 30-231
REMOVAL AND INSTALLATION REAR AXLE
15 -Remove O-rings (16) and (17) from the brake piston
(10).
16
17
10
RKZB7260
16 -Remove O-ring (18) from inner cylinder (15).
18
15
RKZB7270
17 -Remove and replace O-Ring (19).
a This is a destructive operation for the O-ring.
19
RKZB7280
2.2 Assembly
1 -Install a new O-Ring (19) onto hub (2).
19
RKZB7280
30-232 WB97R-5
REMOVAL AND INSTALLATION REAR AXLE
2 -Install O-ring (18) onto inner cylinder (15).
18
15
RKZB7290
3 -Install O-rings (16) and (17) onto brake piston (10).
16
17
10
RKZB7260
4 - Lubricate O-rings (16), (17) and (18), and install
complete piston (15) to brake cylinder (10)
2 O-ring: ASL800050 17
15
16
10
RKZB7300
5 -Use hydraulic oil to lubricate the brake cavity of the hub
housing (2) and mount pins (7). 7
2 Cylinder cavity: ASL800050
2
RKZB7310
WB97R-5 30-233
REMOVAL AND INSTALLATION REAR AXLE
6 -Install the complete brake cylinder (10) and remove pins
(7).
7
10
RKZB7320
7 -Place bushing (14) inside calibrated ring E2 with the
chamfer facing upwards.
Place pin E2 into brake adjuster (14).
14 E2
E2 14
RKZB7330
8 -Mount spring clips (13) taking care to rotate them 90°
clockwise respect to the one mounted before.
13
RKZB7330
9 -Using driver E2, push the rings (13) until solid contact
against calibrated ring E2 is obtained.
a Repeat procedure for the remaining 2 self adjust.
E2 13
RKZB7350
30-234 WB97R-5
REMOVAL AND INSTALLATION REAR AXLE
10 -Insert the adjuster (12) into the brake piston, make sure
that the chaffered side is up.
14
12
RKZB7360
11 -Install the snap rings (11) into the self adjuster bore.
a Check to ensure that spring ring teeth are facing the
self adjust kit as shown in the following illustration.
11
RKZB7211
12 -Snap ring (11) orientation and Belleville washers (9).
9 11
RKZ08550
13 - Install Belleville washers (9) to screws (8) taking care to
orient them as shown in the previous illustration.
9
RKZB7380
WB97R-5 30-235
REMOVAL AND INSTALLATION REAR AXLE
14 -Mount the shouldered bolts (8) and spring washers (9)
and tighten to the requested torque
3 Screw: 16 Nm
8
RKZB7390
15 -Put the half shaft (4) and brake separator plate pins (7)
into the axle housing.
7
RKZB7400
16 -Using the reference mark made during disassembly,
place the inner brake separator plate (5) into the axle
housing (3).
3
5 RKZB7410
17 - Place the inner brake disk (6) and the second brake
separator (5).
6
a If brake discs (6) are replaced, soak discs (for each
differential) in oil at least 24 hours prior to
installation.
5 RKZB7440
30-236 WB97R-5
REMOVAL AND INSTALLATION REAR AXLE
18 -Place the outer brake disk (6) and make sure the slots of
the inner and outer brake disks are aligned with each
other.
6
RKZB7420
19 -Attach lifting equipment to hub assembly (2) and guide
onto the axle (3).
a Use a piece of rope and lift and rotate the half shaft 3
while pushing the hub onto the axle.
4
2 RKZB7430
20 -Install screws (1) tighten to the required torque
2 Screw: Loctite 270
3 Screw: 226 Nm
1
a Tighten using the alternating crosswise method.
RKZB7140
21 -Fill axle with oil.
5 Differential oil: approx. 15 l
RKZB7130
WB97R-5 30-237
REMOVAL AND INSTALLATION REAR AXLE
3. WHEEL HUB
3.1 Disassembly
8
14
11
13
12
10
2
1
3
4
5
RKZ08540
1 -Loosen the screws (1).
a replace screw with a new set. 6
1
RKZB7450
2 -Mark side gears (2), retaining washer (3) and indexed
washer (4).
RKZB7460
30-238 WB97R-5
REMOVAL AND INSTALLATION REAR AXLE
3 -Remove screws (1), retaining washer (3) and indexed
washer (4).
3
RKZB7470
4 -Mark the mounting position of retaining washer (3) and
indexed washer (4) on the planetary carrier (5).
RKZB7480
5 -Attach lifting equipment to planetary carrier (5).
RKZB7490
6 -Locate the snap ring (6) slot and open it while raising the
planetary carrier (5).
5
RKZB7500
WB97R-5 30-239
REMOVAL AND INSTALLATION REAR AXLE
7 -Only if necessary: only if necessary, remove from the
planetary carrier (5) the side gears (2) and their related 7
rollers (7) (n° 66 per gear).
2
a stock all the components of each gear together as a
set.
5 RKZB7510
8 -Using spanner E4, loosen and remove the ring nut (8).
8
E4
RKZB7520
9 -Use suitable puller and separate hub housing (9) from
wheel flange (10)
10
9
RKZB7530
10 -Attach lifting equipment to hub housing (9) and remove
from the wheel flange (10).
Collect the bearing cone (11)
11
RKZB7540
30-240 WB97R-5
REMOVAL AND INSTALLATION REAR AXLE
11 -Remove from hub housing (9) the outer race of the
bearing (11).
11 9
RKZB7550
12 -Remove from hub housing (9) the outer race of the
bearing (12).
a This is a destructive operation for the seal ring. 12
9
RKZB7560
13 -Remove from hub housing (9) the outer race of the
bearing (13).
13
RKZB7570
14 -Remove from whell flange (10) spacer (14).
14
10
RKZB7580
WB97R-5 30-241
REMOVAL AND INSTALLATION REAR AXLE
15 -Using an angle grinder, cut the cage and etch the
bearing ring (13).
Use a chisel to cut and remove bearing inner race (13).
10
13
RKZB7590
3.2 Assembly
1 -Install bearing outer races (13) and (11) to hub (9) using
special tool E5 and a press. Using special tool E6 install
the hub seal (12). E6
12
RKZB7600
2 -Install bearing inner race (13) to wheel flange (10) using
a suitable driver and a press.
10
13
RKZB7590
3 -Install spacer (14) on wheel flange (10
14
10
RKZB7580
30-242 WB97R-5
REMOVAL AND INSTALLATION REAR AXLE
4 -Attach lifting equipment to hub (9) and carefully install
onto wheel flange (10).
a Clean accurately all sealing surfaces.
a Take care not to damage the hub seal (12).
9
10
RKZB7541
5 -Install bearing inner race (11) using a suitable driver and
a hammer.
Install ring nut (8).
8
11
RKZB7610
6 -Using spanner E4, tighten ring nut (8) to the required
torque.
3 Ring nut: 1000 Nm
E4
8
RKZB7620
7 -Apply a light coat of Lithium based grease to the
planetary carrier (5) stud to hold the needle bearings (7)
(n° 33) in place.
5
2 Grease: ASL 800050 7
a Use all the components corresponding to the marks
made during disassembly.
RKZB7630
WB97R-5 30-243
REMOVAL AND INSTALLATION REAR AXLE
8 -Install the side gear (2) and the remaining needle rollers
(7) (N° 33) into the side gear.
7
2
RKZB7640
9 -Attach lifting equipment to planetary carrier (5) and
lower into hub (9).
5
RKZB7650
10 -During installation the locking ears of the planetary
carrier (5) must engage the ring nut (8) as shown in
figure and in next one. 5 8
RKZB7660
11 -In order to simplify the installation, align the hole on the
planetary carrier (5) with the ring nut (8) as shown.
RKZ08570
30-244 WB97R-5
REMOVAL AND INSTALLATION REAR AXLE
12 -Open the snap ring (6) and slowly lower the planetary
carrier (5).
5
RKZB7500
13 -Install washers (3) and (4) and tighten screws (1); apply
the specified sealant and tighten to the required torque.
a Replace bolts with new ones. 4
2 Screw: Loctite 270
3 Screw: 79 Nm
1
3
RKZB7470
WB97R-5 30-245
REMOVAL AND INSTALLATION REAR AXLE
4. DIFFERENTIAL SUPPORT GROUP
4.1 Disassembly
6 9
7
1 4
3 5
8
1
RKZ08460
1 -Drain the oil completely from the differential.
6 Differential oil: approx. 15 l
RKZB7130
2 -Remove the all screws (1).
1
RKZB7670
30-246 WB97R-5
REMOVAL AND INSTALLATION REAR AXLE
3 -Separate from axle (2) the differential housing (3) using
pry bars in slots.
3
2
RKZB7680
4 -Attach lifting eyes to differential housing (3) and remove
it.
RKZB7690
5 -Remove the bolts (4) securing the ring nuts (5) and (6).
RKZB7700
6 -Use the tool E7, unscrew the adjuster ring nuts (5) e (6).
E7
7
5
RKZB7720
RKZB7710
WB97R-5 30-247
REMOVAL AND INSTALLATION REAR AXLE
7 -Remove out the differential case (7). The external rings
(8) and (9) are removed together with the differential
housing.
a Try not to mismatch bearings if bearings are not to
be replaced. 8
7
RKZB7720
4.2 Assembly
1 -Using driver E8, install bearing outer races (8) and (9) to
E8
differential housing (7).
8
a Try not to mismatch bearings if bearings are not to
be replaced.
RKZB7730
2 -Position the complete differential box (7) with bearings
on the differential carrier (3).
7
RKZB7721
3 -Insert and tighten adjustment ring nuts (5) and (6) in the
differential support with tool E7, so as to pre-load the
differential bearings slightly.
E7
a Knock lightly with a soft hammer in order to properly
set the bearings in position.
5
RKZB7710
30-248 WB97R-5
REMOVAL AND INSTALLATION REAR AXLE
4 -Place a magnetic comparator the differential support so
that the checkhead is at right angles with the side of a
tooth from the ring gear.
RKZB7740
5 -Lock the pinion and move the crown gear alternatively
and note the pinion-ring gear backlash, measured with
the comparator.
Repeat the operation on 2 or more points (teeth),
rotating the crown gear, so that to obtain an average
value.
Check if the measured backlash value is within the
requested range:
0.21–0.29 mm
Adjust by operating the adjuster ring nuts. (5) and (6),
using tool E7.
RKZB7750
6 -Adjust the ring nuts (5) and (6) remembering that:
a - if the measured backlash is less than the given
tolerance range, unscrew the adjuster ring nut (6)
and screw in the adjuster ring nut (5) by the same 5 6
measure;
a - if the measured backlash is greater than the given
tolerance range, unscrew the adjuster ring nut (5)
and screw in the adjuster ring nut (6) by the same
measure.
RKZ08590
7 -Repeat the whole sequence of the above mentioned
operations till the indicated conditions are reached.
RKZB7740
WB97R-5 30-249
REMOVAL AND INSTALLATION REAR AXLE
8 -Once the pinion-ring gear backlash has been
established, measure the total rolling torque Tr of the
bearings (pinion-crown bevel gear system), using a
torque wrench and special tool E9.
a Total rolling torque should be measured without
pinion retaining ring. E9
Rolling torque Tr must be within the following range:
Tr = (Pr+0.58) – (Pr+0.87) Nm
where Pr is the actual rolling torque of pinion alone.
RKZB7760
9 -If the reading is not within the requested range,
thoroughly check the assembly of each component and
operate the adjuster ring nuts (5) and (6) of the
differential support:
5 6
a - if total preload is less than the specified value,
tighten the adjuster ring nuts (5) and (6) by the same
amount, while keeping the pinion/ring gear
backlash value unchanged;
b - if total preload is greater than the specified value,
loosen the adjuster ring nuts (5) and (6) by the same
amount, while keeping the pinion/ring gear
backlash value unchanged; RKZ08590
10 -To test the marks of the bevel gear teeth, paint the ring
gear with red lead paint.
The marking test should be always carried out on the
ring bevel gear teeth and on both sides.
RKZ08340
11 -Contact:
OK-Correct contact: Z
OK
If the bevel gear is well adjusted, the mark on the
teeth surfaces will be regular.
Z - Excessive contact on the tooth tip:
Approach the pinion to the ring bevel gear and then
move the ring bevel gear away from the pinion in
order to adjust the backlash. X
X - Excessive contact at the tooth base:
Move the pinion away from the ring bevel gear and
RKZ08350
30-250 WB97R-5
REMOVAL AND INSTALLATION REAR AXLE
then approach the ring bevel gear to the pinion in order to adjust the backlash.
12 -Movements to correct:
1 - move the pinion for type X contact adjustment.
2 - move the pinion for type Z contact adjustment.
RKZ08360
13 -When all adjustment procedures are complete, lock
adjuster ring nuts (5) and (6) into position with screws
(4). Tighten screws (4) to the required torque.
3 Screw: 10Nm
4
RKZB7700
14 -Before matching surfaces, make sure that they are
perfectly clean, degrease and clean them with
appropriate detergents. Spread a film of adhesive on the
contact surface between the axle beam (2) and the
differential carrier (3).
2 Contact surfaces: Loctite 510
RKZB7770
15 - Assemble the differential support (3) to the axle housing
(2).
3
2
RKZB7691
WB97R-5 30-251
REMOVAL AND INSTALLATION REAR AXLE
16 -Tighten all screws (1) to the required torque.
3 Screw: 169 Nm
1
17 -Refill the hydraulic oil. 1
5 Differential oil: approx. 15 l
RKZB7670
30-252 WB97R-5
REMOVAL AND INSTALLATION REAR AXLE
5. DIFFERENTIAL LOCKING GROUP
5.1 Disassembly
9
10
5
4 1
12
2
11
6
3
8
13
7
RKZ08620
1 -Loose plug (1) but do not remove it.
RKZB7780
2 -Hold the differential lock fork (2) down to catch a block
inside of the housing, remove the plug (1).
RKZB7790
WB97R-5 30-253
REMOVAL AND INSTALLATION REAR AXLE
3 -Pull the differential lock fork (2) up, place a flat piece of
steel under the shaft (3) to keep it from moving down.
3
RKZB7800
4 -Compress spring (4) until snap ring (5) is released.
Remove snap ring (5).
4
RKZB7810
5 -Remove the bushing (6).
RKZB7820
6 -Remove the spring (4).
RKZB7830
30-254 WB97R-5
REMOVAL AND INSTALLATION REAR AXLE
7 -Remove the shaft (3) from differential housing.
RKZB7840
8 -Remove the fork (2), spring (7) and bushing (8) from the
shaft (3).
2 8 7
3
RKZB7850
9 -Remove O-Ring (9) from plug (1) and O-rings (11) and
(12) from the piston (10).
10 11
12
1
9
RKZB7860
5.2 Assembly
1 -Install new O-rings (11) and (12) on the piston (10) and
O-Ring (9) on plug (1). Lubricate the O-rings. 10 11
12
1
9
RKZB7860
WB97R-5 30-255
REMOVAL AND INSTALLATION REAR AXLE
2 -Lubricate the shaft (3) with clean hydraulic oil.
Install the fork (2) on the shaft (3) like shown in figure. 8
Install bushing (8) and spring (7) onto shaft.
13
a Mount the spacer (8) with the chamfer towards the
snap ring (13).
2 3 8 7
RKZB7870
3 -Insert in the differential housing the shaft (3) complete.
RKZB7840
4 -Mount the spring (4).
RKZB7830
5 -Place the bushing (6) on the shaft, make sure the
chamfer in the bushing is facing out.
RKZB7820
30-256 WB97R-5
REMOVAL AND INSTALLATION REAR AXLE
6 -Pull the differential lock fork (2) up, place a flat piece of
steel under the shaft (3) to keep it from moving down.
3
RKZB7800
7 -Compress the spring (4) using a proper tool and install
the snap ring (5).
Remove the piece of steel under the shaft (3). 4
RKZB7810
8 -Hold the differential lock fork (2) down to catch a block
inside of the housing, remove the plug (1).
Hand screw the plug (1).
2
RKZB7790
9 -Tighten plug (1) to the requested torque.
3 Plug: 180 Nm
1
RKZB7780
WB97R-5 30-257
REMOVAL AND INSTALLATION REAR AXLE
6. DIFFERENTIAL
6.1 Disassembly
11 2
17
3
16
10
9
13
21 20 22
10 9
18
8 23 24
7 25
5 9
4 10
1 18 21
19 20
14
6 15
RKZ08630
1 -If differential bearings are to be replaced, remove
bearing outer rings (1) and (2). 1
Remove sleeve (3).
RKZB7890
2 -Remove snap ring (4).
RKZB7900
30-258 WB97R-5
REMOVAL AND INSTALLATION REAR AXLE
3 -Remove the differential housing cover (5), remove the
anti rotation pin (6) and the thrust washer (7).
5 7
RKZB7910
4 -Remove the side gear (8).
RKZB7920
5 -Remove three plugs (9) from the differential.
RKZB7930
6 -Remove the three pins (10) securing the spider pins in
the differential.
10
RKZB7940
WB97R-5 30-259
REMOVAL AND INSTALLATION REAR AXLE
7 -Remove the ring gear cap screws (11), remove the ring
gear (12).
11
12
RKZB7950
8 -Push the pin (13) towards the flat surface side (14).
a the pin can be pushed in only one direction.
13
14
RKZB7960
9 -Remove the planetary gear (14) and thrust washer (15).
15
14
RKZB7970
10 -Push the pin (13) out of the housing and remove the
planetary gear (16) and thrust washer (17).
13
16 17
RKZB7980
30-260 WB97R-5
REMOVAL AND INSTALLATION REAR AXLE
11 -Push the short spider pins (18) out of the spacer (19) by
pushing them through the hole in the spacer (19).
19
18
18
RKZB7990
12 -Remove pins (18), spider gears (20) and thrust washers
(21).
18
18
20
21
RKZB8000
13 -Remove side gear (22) and thrust washer (23) from the
housing.
22 23
RKZB8010
14 -Remove the differential locking pins (25) from the
housing (24).
25
24
RKZB8020
WB97R-5 30-261
REMOVAL AND INSTALLATION REAR AXLE
6.2 Assembly
1 -Install and lubricate new O-rings (26) on the pins (25).
2 Gaskets O-ring: ASL800050
26
25
RKZB8030
2 - Install the pins (25) in the differential housing (24).
25
24
RKZB8020
3 -Lubricate and install sun gear (22) and thrust washer
(23).
2 Gear: differential oil
22 23
RKZB8010
4 -Lubricate and install planetary gear (20) and its
respective thrust washer (21) and introduce the pins
(18) forward enough to support them.
18
a Orientate the flats on the pins facing up. 18
2 Gear and pin: differential oil
20
21
RKZB8000
30-262 WB97R-5
REMOVAL AND INSTALLATION REAR AXLE
5 -Install spacer (19) and introduce pins (18), taking care to
align the holes with those on the differential housing
(24). 19
18
18
24
RKZB7991
6 -Lubricate and install the sun gear (16) and thrust washer
(17).
Introduce the pin (13) as far as it will go.
a Orient pin (13) with the flats on the pin facing up.
2 Gear and pin: differential oil
13
16 17
RKZB7980
7 -Lubricate and install the planetary gear (14) and thrust
washer (15) and introduce the pin (13). Orient the hole
so as to align with the hole on the differential housing
(24).
2 Gear and thrust washer: differential oil
15
24
14
RKZB7971
8 -Install the differential ring gear (12), apply sealant and
tighten screws (11) to the required torque.
2 Screw: Loctite 270 11
3 Screw: 155 Nm
12
RKZB8040
WB97R-5 30-263
REMOVAL AND INSTALLATION REAR AXLE
9 -Install pins (10) and tighten caps (9) to the prescribed
torque.
3 Caps: 25 Nm
RKZB7930
10 -Install the planetary gear (8).
RKZB7920
11 -Apply a thin coat of grease to the cover (5) and install the
shoulder ring (7).
2 Cover: ASL800050
5 7
RKZB7910
12 -Install antirotation pin (6) to cover (5) and install cover
(5) to differential housing.
RKZB8050
30-264 WB97R-5
REMOVAL AND INSTALLATION REAR AXLE
13 -Lock cover (5) into position with snap ring (4).
RKZB7901
14 -Install sleeve (3) and make sure that sleeve fits snugly
into position.
22
a To make installation easier, rotate the side gear
(22).
3
RKZB7891
15 -Install bearing outer rings (1) and (2) using driver E8.
a Do not invert bearings.
E8
1
RKZB8070
WB97R-5 30-265
REMOVAL AND INSTALLATION REAR AXLE
7. DIFFERENTIAL GROUP
7.1 Disassembly
8
9
10
6
7
2
1
5
RKZ08640
1 -Fit the differential carrier (1) in a vise.
Unscrew the lock nut (1) using special tools E9 - E10. E9
a This operation will irretrievably damage the ring nut
(1).
E10
RKZB7751
2 -Remove the ring nut (1) and collect its retaining washer
(2).
2 1
RKZB8080
30-266 WB97R-5
REMOVAL AND INSTALLATION REAR AXLE
3 -Tap the shaft with a soft hammer to remove the bevel
pinion (3). 3
a Take care not to drop the bevel pinion (3).
Recover washers (4) and (5), collapsible spacer (6) and
bearing inner ring (7).
4
6
7
5 RKZ08650
4 -Remove bearing outer rings (7) and (8) from differential
support (9) using a driver and a hammer.
RKZB8090
5 -To remove bearing inner ring (8) from bevel pinion (3),
use a commercially available grip puller.
Recover bearing inner ring (8) and the shim (10) under it. 3
10
RKZB8100
6 -Check all pinion components for wear.
a The ring nut (1) and the snap spacer (6) must be
replaced.
5
RKZ08660
WB97R-5 30-267
REMOVAL AND INSTALLATION REAR AXLE
7.2 Assembly
1 -Place the differential support (9) on a workbench. E11
Introduce bearing outer rings (7) and (8) using special
tools E11 - E12 and a hammer.
9
7
RKZB8110
2 -Insert inner rings (7) and (8) in their housings. Assemble
the false pinion E13 and its ring nut (1). 8
Tighten without exceeding the ring nut, till the backlash
is eliminated. 9
7
E13
1
RKZ08670
3 -Install special tool E14 to the differential group supports
(9).
E14
RKZB8120
4 -Use a depth gauge to measure distance “X” (distance
between the axis of the differential bearings and the
point at which the pinion head is supported, or base of
the bearing).
9 RKZB8130
30-268 WB97R-5
REMOVAL AND INSTALLATION REAR AXLE
5 -To adjust bevel gear/pinion measure the distance “A”
with a depth gauge.
Calculate the value “X” as follows:
X =(A+C)-B mm
where “B” and “C” are known. C
X
A
B
RKZ08680
6 -In order to determine the necessary thickness value (S)
between the pinion and the bearing, subtract the value
(V), stamped on the pinion head (V=requested
distance), from the measured value (X).
S = (X–V) mm
RKZB8140
7 -Select the shim with the thickness value (S) among the
range of available shims (10), and fit to shaft under the
pinion head.
a The chamfer on the ID of the shim (10) must be
toward the pinion gear (3).
10
SHIM RANGE
Shims 2.5 2.6 2.7 2.8 2.9 3.0 3.1 3.2 3.3 3.4 3
RKZB8150
8 -Remove the special tool E14 to the differential group
supports (9). 8
Remove the ring nut (10), the false pinion E13 and the
bearing cones (7) and (8). 9
7
E13
1
RKZ08670
WB97R-5 30-269
REMOVAL AND INSTALLATION REAR AXLE
9 -Select a suitable shim (10) and install with the chamfer
facing the gear, then install bearing inner ring (8) to
pinion (3) with the help of a press and tool E3, and check
to ensure that it fits snugly in place.
8
10
RKZB8160
10 -Install the washers (4) and (9) and a new collapsible
spacer (6) on the pinion gear (3).
a Use always a new collapsible spacer (6).
4
6
5
RKZB8170
11 -Install bearing outer ring (7) to pinion end.
To install bearing (8), use special tool E3 and a hammer.
RKZB8180
12 -Insert a ring nut washer (2) and screw a new lock ring nut
(1) on the pinion end.
2 1
RKZB8080
30-270 WB97R-5
REMOVAL AND INSTALLATION REAR AXLE
13 -Screw the ring nut in (1), using the wrench for ring nut
E10 and for pinion retainer E9. E9
a The torque setting is given by the preloading
measurement on bearings (7) and (8); Tighten the
ring nut (1) step by step.
1
a If it is tightened too much, the elastic spacer (6)
should be replaced and the procedure repeated.
When you check the preloading, it is advisable to
beat slightly both pinion (3) ends with a soft
E10
hammer, so as to help setting the bearings (7) and
(8). RKZB7751
14 -To measure the rolling torque (Pr) of tapered bearings
(7) and (8), use a torque wrench and tool E9.
Adjustment is carried out by gradually increasing the
tightening torque of ring nut (1), paying attention not to
overtighten.
a All preloadings should be measured without the
seal rings.
Rolling torque should be within the following range:
Pr = 2.0–2.4 Nm
RKZB8190
15 -Once you got the requested preloading value, caulk the
ring nut (1).
RKZB8200
WB97R-5 30-271
PAGE INTENTIONALLY
LEFT BLANK
REMOVAL AND INSTALLATION SHOVEL PPC VALVE
SHOVEL PPC VALVE
Removal
k Lower the working equipment completely until it rests
on the ground; engage the parking brake, stop the
engine and remove the ignition key.
k Release all residual pressure from all circuits.
(For details, see "20 TESTING AND
ADJUSTMENTS").
RKZC2130
1 -Remove four screws (1) and remove PPC valve and
parking brake casing (2).
2
RKZC6381
2 -Disconnect the connector (3).
3 -Disconnect five hoses (5) from PPC valve (4).
a Check to ensure that hoses are marked; scribble 3
match marks if necessary. [*1]
a Cap the hoses and holes to prevent contamination.
4
5 RKZC2140
4 -Loosen and remove screws (6) and remove the
complete PPC valve (4).
6 4
RKZC2150
WB97R-5 30-273
REMOVAL AND INSTALLATION SHOVEL PPC VALVE
Installation
P3 P
• To install, reverse removal procedure.
Front
[*1] 3
a Carefully inspect the hoses for the proper position P2
P
1
when connecting them.
(For details, see "10 STRUCTURE AND P1
2
FUNCTION").
T
T
4
P4
RKZ10760
30-274 WB97R-5
REMOVAL AND INSTALLATION SHOVEL LIFT CYLINDERS
SHOVEL LIFT CYLINDERS
Removal
k Fully lower the front working equipment until it rests on 3
the ground; apply the parking brake, and stop the
engine. A
1 -Introduce non-slip blocks “A” between the shovel dump 1
tie bar (1) and the spacer (2) of the fulcrum lever (3) on
removal side.
2
RKZC2160
2 -Take off the snap-ring (4) and the internal retaining
spacer (5) for the piston attachment pin (6).
6
5
RKZC2170
3 -Remove the tie strap (7) retaining the piston return hose
(8).
4 -Place a sling around the cylinder and connect it to a
hoisting device. 8
a Do not engage the piston return hose with the sling. 9
5 -Extract pin (6) to expose piston eye and safety rod (9).
6 -Remove rod.
7
6
RKZC2180
7 -Lower cylinder (10) until it rests on blocks “B”.
8 -Start the engine to retract the piston.
[*1] [*2]
8
k Stop the engine and eliminate residual pressure. 10
B
RKZC2190
WB97R-5 30-275
REMOVAL AND INSTALLATION SHOVEL LIFT CYLINDERS
8 -Remove hoses (8) and (11), and remove hose clamp
(12). 12
a Cap pipes, hoses and holes to prevent 14
contamination.
9 -Remove the snap-ring (13) and the spacer (14).
10 -Remove cylinder (10).
4 Cylinder: approx. 46 kg
11
8 13
RKZC2200
Installation
• To install, reverse removal procedure.
[*1]
k When aligning the positions between the hole and the
pin, turn the engine over at low idling speed.
Do not insert fingers into the holes to check alignment.
[*2]
2 Internal bushing: ASL800050
1 -Start the engine and bleed the air from the cylinders.
(For details, see "20 TESTING AND ADJUSTMENTS").
a After bleeding the air, check the oil level in the tank.
30-276 WB97R-5
REMOVAL AND INSTALLATION SHOVEL DUMP CYLINDERS
SHOVEL DUMP CYLINDERS
Removal
2
k Fully lower the working equipment to the ground; apply
3
the parking brake, and stop the engine.
1 -Remove the strap retaining the piston return hose (1).
For the right-hand cylinder only
a If installed, disconnect the return-to-dig sensor, mark its A 5 1
location, and then remove the lift bracket. 6
2 -Remove shovel position rod (2). 4
3 -Place a sling round the cylinder (3) and insert a block “A”
RKZC2210
between the spacer (4) of the piston fulcrum lever (5)
and the link (6).
a Do not engage the piston return hose with the sling.
4 -Take off the snap-ring (7) and the internal retaining
spacer (8) for the piston attachment pin (9).
8 9
5 -Extract pin (9) to expose piston eye.
6 -Start the engine to retract the piston(10).
[*1] [*2]
k Stop the engine and eliminate completely residual
pressure from all circuits.
10 7
RKZC2240
7 -Remove hoses (1) and (11), and remove hose clamp
(12).
a Cap the hoses and holes to prevent contamination.
12
11
RKZC2250
8 -Remove the snap-ring (13) and the spacer (14).
9 -Remove cylinder (3).
4 Tilt cylinder; approx 35 kg
a Recover spacer (15) between frame and cylinder.
15
13
14
RKZC2260
WB97R-5 30-277
REMOVAL AND INSTALLATION SHOVEL DUMP CYLINDERS
Installation
• To install, reverse removal procedure.
[*1]
k When aligning the positions between the hole and the
pin, turn the engine over at low idling speed.
Do not insert fingers into the holes to check alignment.
[*2]
2 Internal bushing: ASL800050
1 -Start the engine and bleed the air from the cylinders.
(For details, see "20 TESTING AND ADJUSTMENTS").
a After bleeding the air, check the oil level in the tank.
Machines equipped with return-to-dig only
2 -Check sensor position and adjust as necessary.
(For details, see "20 TESTING AND ADJUSTMENTS").
30-278 WB97R-5
REMOVAL AND INSTALLATION SHOVEL
SHOVEL
Removal
k Lower the shovel to the ground, resting on its back, but
without forcing it downwards.
1 -Stop the engine and release residual pressures.
RKZC2130
2 -Take out the screws (1) and remove the pins (2) of the
lever (3).
Rest the lever (3) on the boom. [*1] [*2]
1
RKZA1461
3 -Take out the screws (4) and remove the pins (5) of the
shovel fulcrum. [*1] [*2]
4 -Start the engine and put the machine into reverse gear in 4
order to disengage the boom (6).
4 Shovel: 436 kg
6
5
RKZA1471
Installation
• To install, reverse removal procedure.
[*1]
k When aligning the positions between the hole and the
pin, turn the engine over at low idling speed.
Do not insert fingers into the holes to check alignment.
[*2]
2 Internal bushing: ASL800050
WB97R-5 30-279
REMOVAL AND INSTALLATION FRONT WORKING EQUIPMENT
FRONT WORKING EQUIPMENT
Removal
k Lower the working equipment completely until it rests
on the ground stop the engine and remove the ignition
wrench.
k Release all residual pressure in all circuits.
(For details, see "20 TESTING AND
ADJUSTMENTS").
1 -Remove the tilt cylinders. (See "SHOVEL DUMP
CYLINDERS").
RKZC2270
2 -Disconnect the cylinders from the boom (1) and rest
them on wooden blocks «A» placed on the front axle.
(See "SHOVEL LIFT CYLINDERS").
A
RKZC2191
3 -Open the front hood and take out the screws (2) that lock
the axle oscillation pins (3) of the boom (4).
Close the front hood.
4 3
RKZC2290
4 -Put a sling round the boom (4) as shown in the figure,
and attach it to the hoisting tackle. Apply a slight tension
to the cables.
4
RKZC2280
30-280 WB97R-5
REMOVAL AND INSTALLATION FRONT WORKING EQUIPMENT
5 -Using a puller, remove the oscillation pins (5) of the arm
(4) together with snap ring and spacer.
[*1] [*2]
6 -Start the engine and put the machine into reverse gear
travel until the boom is disengaged.
4
a If the working equipment is to be detached while the
engine or gearshift is out of order and the machine
cannot travel automatically, it can be towed using
the towing hooks of the backhoe. 5
7 -Place two stands in position and lower the boom until it is
resting on them.
4 Front equipment: approx. 1100 kg
RKZC2300
Installation
• To install, reverse the removal procedure, if necessary
using the front towing hook.
[*1]
k When aligning the positions between the hole and the
pin, turn the engine over at low idling speed.
Do not insert fingers into the holes to check alignment.
[*2]
2 Internal bushing: ASL800050
• Start the engine and bleed the air from the cylinders.
(For details, see "20 TESTING AND ADJUSTMENTS").
a After bleeding the air, check the oil level in the tank.
WB97R-5 30-281
REMOVAL AND INSTALLATION BACKHOE PPC VALVES
BACKHOE PPC VALVES
Removal
k The following removal procedure applies to both PPC
valves.
1 -Lower the outriggers to the ground: fold the bucket and
rest the arm on an “A” block, keeping it at right angles
with the ground.
2 -Release the backhoe plate and stop the engine.
k Release all residual pressure in all circuits. (For details,
see "20 TESTING AND ADJUSTMENTS").
3 -Lift cab rear window up to the top.
RKZC6390
4 -Fully raise the boot (1).
5 -Loosen and remove the screws (2) retaining the PPC 1
valve (3) and armrest (4).
2
4 RKZB6813
6 -Raise the armrest from the rear side and remove the
screw (5) retaining the rear guard (6). 5 8
7 -Cut the retaining clamp and lower the lower boot (7). 7
8 -Loosen and remove screw (8), and remove rear guard
(6).
6
RKZB6823
9 -Disconnect the connector (9).
10 -Ensure that the hoses are marked (10), then disconnect
the hoses from the PPC valve. [*1]
a Mark the hoses, if necessary. 9
a Plug all pipes/hoses to prevent contamination.
10
RKZB6831
30-282 WB97R-5
REMOVAL AND INSTALLATION BACKHOE PPC VALVES
11 -Remove the PPC valve (11).
11
RKZB6841
Installation
• To install, reverse removal procedure.
a Carefully inspect the hoses for the proper position
when connecting them. (For details, see "10
STRUCTURE AND FUNCTION").
WB97R-5 30-283
REMOVAL AND INSTALLATION PPC VALVE SUPPORT RELEASE CABLES
PPC VALVE SUPPORT RELEASE CABLES
Removal
1 - Lower the outriggers and the equipment to the ground;
stop the engine.
RKZC6390
2 -Remove the rear mat (1).
RKZC6400
3 -Take out the screws (2) and remove the platform (3).
3
2
RKZC6410
4 -Fully raise the boot (4).
5 -Loosen and remove the screws (5) that retain the PPC 4
valve and armrest (6).
5
6 RKZB6814
30-284 WB97R-5
REMOVAL AND INSTALLATION PPC VALVE SUPPORT RELEASE CABLES
6 -Raise the armrest from the rear side and remove the
screw (7) retaining the rear guard (8). 9 10
7 -Cut the retaining clamp and release the lower boot (9). 7
8 -Loosen and remove the screws (10) and remove the
rear guard (8).
8
RKZB6824
9 -Loosen and remove the screws (11) and raise the boot
(12) and the retaining edge (13). 12
a Raise until the lower fulcrum and locking assembly
become fully disengaged.
13 11
RKZB6852
10 -Remove the retaining screws (14) from the lock-
actuating lever assembly (15).
11 -Remove the entire lever assembly (15). 15
14
RKZB6861
12 -Loosen the nut (16) and disengage the sheath (18) from
the support (17).
13 -Disconnect the cable (20) from the lower locking lever
(19).
17 20
18
19
16
RKZB6871
WB97R-5 30-285
REMOVAL AND INSTALLATION PPC VALVE SUPPORT RELEASE CABLES
14 -Loosen the nut (21) and unscrew the tensioner (22);
disengage the control cable (20) from the release
control lever (15).
21
15
22
20
RKZB6971
Installation and adjusting
• To install, reverse removal procedure.
1 -Using the tensioner (22), adjust cable tension to obtain
safe locking and friction-free unlocking of the column.
2 -Lock the nut while holding the tensioner into position
(21).
21
22
RKZB7071
30-286 WB97R-5
REMOVAL AND INSTALLATION PPC VALVE SUPPORT RETURN GAS SPRING
PPC VALVE SUPPORT RETURN GAS SPRING
Removal
1 - Lower the outriggers and the equipment to the ground;
stop the engine.
RKZC6390
2 -Remove the rear mat (1).
RKZB6772
3 -Take out the screws (2) and remove the platform (3).
3
2
RKZC6410
4 -Fully loosen the stop knob (4) of the PPC valve support
(5) you are working on.
RKZC6420
WB97R-5 30-287
REMOVAL AND INSTALLATION PPC VALVE SUPPORT RETURN GAS SPRING
5 -Fully raise the boot (6).
6 -Loosen and remove the screws (7) that retain the PPC 6
valve and armrest (8).
7
8 RKZB6815
7 -Raise the armrest from the rear side and remove the
screw (9) retaining the rear guard (10). 11 12
8 -Cut the retaining clamp and release the lower boot (11). 9
9 -Loosen and remove screw (12), and remove rear guard
(10).
10
RKZB6825
10 -Loosen and remove the screws (13) and raise the boot
(14) and the retaining edge (15). 14
a Raise until the gas spring (16) becomes fully
disengaged.
15 13
RKZB6853
11- Loosen the nut (17) and remove the snap ring (18) and
washer (19). 17 19
12- Disconnect the gas spring (16) and remove it.
18
Installation
• To install, reverse removal procedure.
16
RKZB7081
30-288 WB97R-5
REMOVAL AND INSTALLATION SOLENOID VALVE GROUP (servocontrol and optional attachment)
SOLENOID VALVE GROUP (servocontrol and optional attachment)
Removal
1 -Lower the outriggers and the equipment to the ground;
engage the parking brake, stop the engine and extract
the ignition key.
k Release residual pressure from all circuits by moving all
control levers in all directions.
RKZC6390
2 -Disconnect the connector (1) and remove the seat (2).
RKZC1031
3 -Remove the rear mat and remove the metal sheet (3)
closing off the floor.
3
RKZC1974
4 -Disconnect all connectors (4) from the solenoid valves .
a Check to ensure that all connectors have marks 4
scribbled on, and note down their plugging
positions.
7
5 -Mark and disconnnect all hoses (5).
5
a Cap pipes, hoses and holes to prevent
contamination.
6 -Loosen and remove two screws (6) and washers; 5
remove the solenoid valve group (7) together with the 6
accumulator. RKZC2323
WB97R-5 30-289
REMOVAL AND INSTALLATION SOLENOID VALVE GROUP (servocontrol and optional attachment)
Installation
• To install, reverse removal procedure.
1 -Start the engine and perform all possible manoeuvres to
eliminate the air from all circuits.
30-290 WB97R-5
REMOVAL AND INSTALLATION BACKHOE BOOM CYLINDER
BACKHOE BOOM CYLINDER
Removal
1 -Fully extend the arm (1) and fully open the bucket (2). 3 1
Manoeuvre the boom until the outer end of the boom is in
a level position.
2
2 -Place and force a jack stand “A” and a non-slip block
under the boom.
3 -Lower the arm until the bucket teeth touch the ground.
A
RKZC6430
4 -Lower the outriggers to the ground, apply the parking
brake, and stop the engine.
6
k Release residual pressure from all circuits by
operating the control levers in all directions.
4
5 -Remove pins (4) and disconnect tie rod (6) from boom
retaining lever (5).
5
RKZC2340
6 -Loosen and remove the screws, remove the group (7)
controlling the levers (5) and position it aside.
7
RKZC2350
7 -Remove snap rings (8), shims (9), and levers (5).
8
9
RKZC2360
WB97R-5 30-291
REMOVAL AND INSTALLATION BACKHOE BOOM CYLINDER
8 -Remove springs (10), and remove the nut and screw
(11) retaining the piston attachment pin.
11
10
RKZC2370
9 -Place a safety block "B" under the cylinder (12)
controlling the arm. 12
RKZC2380
10 -Sling the cylinder (12) in a band and connect it to a
hoisting device; apply a slight tension. 14
12
a Do not engage the hoses with the band.
11 -Pull out pin (13) and recover spacers (14).
[*1] [*2]
13
RKZC6440
12 -Start the engine and retract the piston.
Stop the engine and release residual pressures.
13 -Remove snap ring (15). 15
RKZC2400
30-292 WB97R-5
REMOVAL AND INSTALLATION BACKHOE BOOM CYLINDER
14 -Disconnect hoses (13) and (14) from cylinder (12).
a Cap pipes, hoses and holes to prevent 12
contamination.
14
13
RKZC2410
15 -Pull out pin (15) and remove cylinder (12).
16
a Recover shims (16) and note down their position of
installation between boom and cylinder and
between boom and arm. [*1] [*2] 15
4 Cylinder: 87.5 kg
RKZC2420
Installation
• To install, reverse removal procedure.
[*1]
k When aligning the positions between the hole and the
pin, turn the engine over at low idling speed.
Do not insert fingers into the holes to check alignment.
[*2]
2 Internal bushing: ASL800050
1 -Start the engine and bleed the air from the cylinders.
(For details, see "20 TESTING AND ADJUSTMENTS").
a After bleeding the air, check the oil level in the tank.
WB97R-5 30-293
REMOVAL AND INSTALLATION ARM CYLINDER
ARM CYLINDER
Removal
1 -Fully extend the arm (1) and fully open the bucket (2). 3
Manoeuvre the boom until the outer end of the boom is in
1
a level position.
2
2 -Place and force a jack stand “A” and a non-slip block
under the boom.
3 -Lower arm (3) until bucket teeth touch the ground.
4 -Lower the outriggers to the ground, apply the parking A
brake, and stop the engine.
k Release residual pressure from all circuits by
RKZC6430
operating all hydraulic controls in all directions.
5 -Force a block “B” under the boom cylinder (4).
4
RKZC6450
6 -Remove the strap (5) retaining the hoses.
7 -Sling the cylinder (4) in a band and connect it to a
hoisting device; apply a slight tension. 7 6
8
a Do not engage the hoses with the band.
5
8 -Remove the snap ring (6) retaining the cylinder fulcrum
pin (7) and the screw (8) retaining the piston pin (9).
RKZC2440
9 -Disconnect hoses (10) and (11) from cylinder (4).
a Cap pipes, hoses and holes to prevent
contamination.
4 11
10
RKZC2450
30-294 WB97R-5
REMOVAL AND INSTALLATION ARM CYLINDER
10 -Pull out the piston attachment pin (9).
[*1] [*2]
RKZC2460
11 -Pull out the cylinder attachment pin (7) until the eye of
cylinder (4) is exposed. [*1] [*2]
7
4
12 -Remove cylinder (4) and recover shims (if any).
4 Arm cylinders: 67 kg
RKZC2470
Installation
• To install, reverse removal procedure.
[*1]
k When aligning the positions between the hole and the
pin, turn the engine over at low idling speed.
Do not insert fingers into the holes to check alignment.
[*2]
2 Internal bushing: ASL800050
1 -Start the engine and bleed the air from the cylinders.
(For details, see "20 TESTING AND ADJUSTMENTS").
a After bleeding the air, check the oil level in the tank.
WB97R-5 30-295
REMOVAL AND INSTALLATION JIG ARM CYLINDER
JIG ARM CYLINDER
Removal
k Open the arm (1) completely and lower it until it rests on 1
a trestle “A” that is roughly 40 cm high. Extend the jig 4
arm (2) until it rests on a block “B”, and let the bucket
teeth rest on the ground.
1 -Stop the engine and release the cylinder (3) pressures,
2
by moving the command pedal several times.
2 -Place a sling around the cylinder (3).
A
3 -Take off the snap ring and remove the pin (4).
B
[*1] [*2] RKZA7931
4 -Start the engine to retract the piston.
5 -Stop the engine and release residual hydraulic pressure
from all circuits by operating the control levers in all
directions. 4
6 -Take out the safety pin (5).
7 -Disconnect the tubes (6), (7), (8) and (9).
a Cap pipes, hoses and holes to prevent
contamination. 3
8 -Remove the clamp (10).
9 -Remove the screws (11) and the pin (12). [*1] [*2] RKZA7941
10 -Remove cylinder (3).
5
11 10
6
Installation
8
• To install, reverse removal procedure. 12
[*1]
k When aligning the positions between the hole and the
pin, turn the engine over at low idling speed. 9 7
Do not insert fingers into the holes to check alignment. RKZA7951
[*2]
2 Internal bushing: ASL800050
1 -Start the engine and bleed the air from the cylinders.
(For details, see "20 TESTING AND ADJUSTMENTS").
a After bleeding the air, check the oil level in the tank.
30-296 WB97R-5
REMOVAL AND INSTALLATION OUTRIGGER CYLINDER
OUTRIGGER CYLINDER
Removal
k Set the backhoe with the centered attachments with the
arm in vertical position and the bucket leaned on the
back at level ground.
1 -Extend the outriggers (1) of about 15 cm, stop the
engine and release the cylinders pressures.
1 RKZC6460
2 -Place a lifting platform “A” beneath outrigger (2) of
cylinder to be remove.
Raise this until it is forced up against the outrigger.
RKZC2490
3 -Remove the clamps (3) retaining the pipes (4).
4 -Disconnect from cylinder (5) the pipes (4) and plug them
to avoid impurity entry. 3 4
a Plug also the union to avoid the movement of piston.
RKZC2500
5 -Take off snap ring (6) and slide pin (7) out until cylinder
(5) is disengaged. [*1] [*2]
7 6
RKZC2510
WB97R-5 30-297
REMOVAL AND INSTALLATION OUTRIGGER CYLINDER
6 -Raise the lifting platform “A” to disengage the cylinder
head (5) from frame.
Place a sling round the cylinder (5) and apply slight
tension to the cables.
5
RKZC2520
7 -Take out the screws and remove the pin (10).
[*1] [*2]
8 -Remove the cylinder(5).
8
4 Cylinder: approx. 27.5 kg
RKZC2530
Installation
• To install, reverse removal procedure.
[*1]
k Do not insert fingers into the holes to check alignment.
[*2]
2 Internal bushing: ASL800050
1 -Start the engine and bleed the air from the cylinders.
(For details, see "20 TESTING AND ADJUSTMENTS").
a After bleeding the air, check the oil level in the tank.
30-298 WB97R-5
REMOVAL AND INSTALLATION BACKHOE SWING CYLINDERS
BACKHOE SWING CYLINDERS
Removal
k Set the backhoe with the centered attachments with the
arm in vertical position and the bucket leaned on the
back at level ground.
1 -Stop the engine and release all cylinder pressure by
moving the lockout control several times.
RKZC6390
2 -Loosen and remove screws (1) and release hose clamp
(2). 1
RKZC2540
3 -Loosen and remove the four screws (3) and washers.
[*1]
RKZC2550
4 -Lift the hoses (4) to the backhoe cylinders and retain
them in position with a band.
RKZC2560
WB97R-5 30-299
REMOVAL AND INSTALLATION BACKHOE SWING CYLINDERS
5 -Remove the upper support (5) with a vertical movement.
[*3]
RKZC2570
6 -Disconnect four tubes (6) from cylinders (7).
a Cap pipes, hoses and holes to prevent 7
7
contamination.
6 RKZC2580
7 -Take out the screws (8) and remove the pins (9).
9
8 -Rotate the cylinders to disengage the piston heads from 8
the swing bracket (10) and remove the cylinders (6).
4 Cylinder: approx. 34 kg
10
RKZC2590
30-300 WB97R-5
REMOVAL AND INSTALLATION BACKHOE SWING CYLINDERS
Installation
1 -Mount the cylinders (6) and the upper cylinder fulcrum
support (2). Secure the support with the four screws (3). 5 3
[*1]
2 Support screws: Loctite 262
3 Support screws: 981±98 Nm
2 -Connect the four tubes (7) to the cylinders.
7
3 -Start the engine and swing the boom in order to center
6
one of two pins (6). Secure the 1st pin with the screw. RKZC2551
Perform the same operation for the other pin.
[*2]
k When aligning the positions between the hole and the
9
8
pin, turn the engine over at low idling speed.
Do not insert fingers into the holes to check alignment.
[*3]
2 Internal bushing: ASL800050
4 -Bleed the air from the cylinders. (For details, see "20
TESTING AND ADJUSTMENTS").
a After bleeding the air, check the oil level in the tank.
RKZC2591
WB97R-5 30-301
REMOVAL AND INSTALLATION BACKHOE BUCKET CYLINDER
BACKHOE BUCKET CYLINDER
Removal
2
1 -Extend the arm (1). 1
2 -Operate the boom (2) and bucket (3) until bottom of
bucket sits level.
3 -Lower the outriggers to the ground, apply the parking
brake, and stop the engine.
k Release residual pressure from all circuits by operating
the control levers in all directions.
RKZC6470
4 -Sling the cylinder (4) in a band and connect it to a
hoisting device; apply a slight tension.
a Do not engage the hoses with the band.
RKZC2610
5 -Take out the lock-nut (5) and the washer and remove the
pin (6). [*1] [*2] [*3]
6 -Start the engine and retract the piston.
5
k Stop the engine and release residual pressures.
RKZC2620
7 -Disconnect the tubes (7) and (8).
a Cap pipes, hoses and holes to prevent 8 7
contamination.
8 -Take off the snap ring (9) and remove the pin (10).
[*1] [*2] 10
RKZC2630
30-302 WB97R-5
REMOVAL AND INSTALLATION BACKHOE BUCKET CYLINDER
Versions with jig arm only
9 -Disconnect the tubes (11) and (12).
10 -Take out screw (13) and remove pin (14).
[*1] [*2] 12 11
11 -Remove cylinder (4).
4 Standard cylinder: approx. 52.5 kg 14
13
4
RKZA9951
Installation
• To install, reverse removal procedure.
[*1]
k When aligning the positions between the hole and the
pin, turn the engine over at low idling speed.
Do not insert fingers into the holes to check alignment.
[*2]
2 Internal bushing: ASL800050
[*3]
a Tighten the locknut completely, then release it half a
turn.
1 -Start the engine and bleed the air from the cylinders.
(For details, see "20 TESTING AND ADJUSTMENTS").
a After bleeding the air, check the oil level in the tank.
WB97R-5 30-303
REMOVAL AND INSTALLATION BACKHOE BOOM SAFETY CYLINDER
BACKHOE BOOM SAFETY CYLINDER
Removal
2
1 -Extend the arm (1). 1
2 -Operate the boom (2) and bucket (3) until bottom of
bucket sits level.
3 -Lower the outriggers to the ground, apply the parking
brake, and stop the engine.
k Release residual pressure from all circuits by operating
the control levers in all directions.
RKZC6470
4 -Remove pins (4) and disconnect yokes (6) from boom
retaining levers (5).
6
4
5
RKZC2341
5 -Loosen and remove nut (7) and remove tie rod (8).
8
8 7
RKZC2640
6 -Disconnect feed hose (9).
a Cap the hose and hole to prevent contamination.
7 -Loosen and remove the screws (10) and the cylinder 11
(11).
9
10
RKZC2650
30-304 WB97R-5
REMOVAL AND INSTALLATION BACKHOE BOOM SAFETY CYLINDER
Installation
• To install, reverse removal procedure.
1 -Start the engine and operate the cylinder several times
to eliminate the air from the circuit.
2 -Lift the boom and check to ensure that the safety
connection is correct.
WB97R-5 30-305
REMOVAL AND INSTALLATION CYLINDER
CYLINDER
SHOVEL ARM, SHOVEL, BOOM, ARM, BUCKET, OUTRIGGERS
Disassembly
1 -Position cylinder to be disassembled (1) to equipment
U1.
U2 2 1
2 -Using wrench U2 with torque amplifier, fully unscrew the
head (2). U1
RKZ11420
3 -Extract the complete piston (3).
a Place a receptacle to collect the oil.
3
U1
RKZ11640
4 -Position the complete piston (3) to equipment U1.
5 -Using a wrench U3 with torque amplifier, remove the nut
(4) retaining the piston (5) from the following cylinders: 4 3
- Shovel raise: Key 55 mm
-Shovel dump: Key 55 mm
- Boom: Key 65 mmq U1
- Arm: Key 65 mm
- Bucket: Key 55 mm
-Outriggers: Key 46 mm U3
- Jig arm: Key 46 mm Q
q Remove safety dowel first
RKZ11440
Q Lift calking first
6 -Slide piston (6) and head (2) off rod (5).
5
a Arm only:
Note down direction of installation of brake bushing 2
(5a).
6
5a
RKZ11620
30-306 WB97R-5
REMOVAL AND INSTALLATION CYLINDER
7 -Boom cylinder rod only.
Remove plug (7) and rotate end (8) to let the balls (9) out.
8 -Remove end (8). 7 9 8
RKZ11580
9 -All cylinders.
Remove guide ring (10) and seal (11) from piston (5). 5
11
10
RKZ11600
10 -Remove O-ring (12) with anti-extrusion ring, O-ring (13),
snap ring (14) and scraper ring (15) from head. 18
11 -Remove gaskets (16) and (17). 12
17
a Note down direction fo installation of anti-extrusion
ring and position of ring (12).
12 -Boom head 16
Remove bushing (18). 13
15
14
RKZ11460
WB97R-5 30-307
REMOVAL AND INSTALLATION CYLINDER
Assembly
a Lubricate surfaces to prevent damage to the gaskets, U6 U7
seals, O-rings, scraper, etc.
2 Surface: engine oil
18 15
a Do not force sealing rings into place; heat them instead
in hot water at 50-60°C before installing.
Boom head only
1 -Using tool U6, install bushing (18).
RKZ11520
All cylinders
2 -Using tool U7, install scraper ring (15) and snap ring
(14).
3 -Assemble seals (16) and (17). 12
18
a Check direction of installation.
17
16
13
14
15
RKZ11510
Assembly piston
1 –Using tool U4 expand seal (11) and fit it on the piston.
U5
2 -Calibrate seal (11) using calibrator U5.
U4 11
3 -Boom cylinder only.
Install anti-extrusion rings and O-ring (12).
4 -Assemble the guide ring (10). 11
RKZ11530
11 10
12
RKZ11470
30-308 WB97R-5
REMOVAL AND INSTALLATION CYLINDER
5 -Boom cylinder only.
Introduce rod (6), end (8), and ten balls (9); install plug
(7).
2 Plug: Loctite 262
9 8
3 Plug: 23±2 Nm
7
RKZ11630
6 -Install piston (5) to rod (6).
5a 5
a Arm cylinder only.
Check orientation of brake bushing (5a).
6 RKZ11610
Assembly complete piston
1 -Install rod (6) to equipment U1.
2 -Remove any existing dirt from the rod and install the
4 6 2
head (2).
U1
U3
RKZ11441
3 -Boom cylinder only.
Thread piston (5) onto rod (6) and lock into position with
19
a wrench U3 with torque amplifier.
3 Piston: 280–290 kgm
4 -Install safety dowel (19) and tighten until snug.
2 Dowel: Loctite 542
RKZ11590
WB97R-5 30-309
REMOVAL AND INSTALLATION CYLINDER
5 -All cylinders: install head (2) and piston (5); coat piston
thread with sealant.
2 Piston: Loctite 262 4 5 2
6 -Install nut (4) and, using wrench U3 with torque
amplifier, lock piston in place using the following U1
torques:
2 Shovel raise: 170±17 kgm
Shovel dump: 127±12.7 kgm U3
Arm backhoe 170±17 kgm
Bucket: 170±17 mm
Outriggers: 93±9.3 kgm RKZ11442
Jig arm: 110±11 kgm Q
Q Calk after tightening.
Final assembly
1 -Lubricate piston seals (5) and head gaskets (2) and
introduce piston into cylinder (1). 1 3
2 -Position cylinder (1) to equipment U1 and tighten head
U1
(2) using tool U2; tighten to the following torque:
3 Shovel raise: 69±6.9 kgm
Shovel dump: 55±5.5 kgm
arm: 98±9 kgm
Bucket: 120±140 kgm E
Outriggers: 55±6.5 kgmm
Jig arm: 55±5.5 kgm RKZ11641
Boom: 100±10 kgm
E Loosen down to 0 kg, tighten up to 40 kgm, and then
tighten angle-wise for 3.5–4.5 mm
3 -When assembly is complete, plug union fitting holes to
prevent contamination. U2 2 1
U1
RKZ11420
30-310 WB97R-5
REMOVAL AND INSTALLATION CYLINDER
BACKHOE SWING CYLINDERS
Disassembly
1 -Position cylinder (1) to equipment U1.
U2 2 1
2 -Using wrench U2 with torque amplifier, fully unscrew the
head (2).
U1
RKZ11420
3 -Extract the complete piston (3).
a Place a receptacle to collect the oil.
3
U1
RKZ11430
4 -Position the complete piston (3) to equipment U1.
U1
RKZ11540
5 -Remove safety screw (4) (M8x1.25).
4
a If removal is awkward, tighten screw until snug and
work thread with a tap.
4
RKZ11450
WB97R-5 30-311
REMOVAL AND INSTALLATION CYLINDER
6 -Using a wrench U8, remove the complete piston (6).
a If no U8 tool is used, drill 4 holes ( Ø 10) and loosen
the complete piston.
U8
4
DH
RKZ11490
7 -Slide piston (6) and head (2) off rod (5).
2
RKZ11480
8 -Remove guide ring (7), seal (8), O-ring (9) and their
respective anti-extrusion rings from piston. 8 7
RKZ11650
9 -Remove the snap-ring (10), the spacer (11) and the ring
(12).
a Note down orientation of ring (12) and position of
spacer (11).
12 11 10
RKZ11660
30-312 WB97R-5
REMOVAL AND INSTALLATION CYLINDER
10 -Remove O-ring (13) with anti-extrusion ring, O-ring (14),
snap ring (15) and scraper ring (16) from head. 13
19
11 -Remove gaskets (17) and (18).
a Note down direction fo installation of anti-extrusion 18
ring and position of ring (13).
17
12 -Remove the bushing (19).
14
15
16
RKZ11511
WB97R-5 30-313
REMOVAL AND INSTALLATION CYLINDER
Assembly
a Lubricate surfaces to prevent damage to the gaskets,
seals, O-rings, scraper, etc.
2 Surface: engine oil
U6 U7
19 16
a Do not force sealing rings into place; heat them in hot
water at 50-60°C before installing.
Assembling the head
1 -Using tool U6, install bushing (19).
2 -Assemble seals (17) and (18).
a Check direction of installation. RKZ11521
3 -Using tool U7, install scraper ring (16) and snap ring
(15).
4 -Assemble O-ring (14). 13
19
5 -Install anti-extrusion ring and O-ring (13).
18
17
14
15
16
RKZ11511
Assembly piston
1 -Using tool U4 expand seal (8) and fit it on the piston. U5
2 -Calibrate seal (8) using calibrator U5. U4 8
3 -Install anti-extrusion rings and O-ring (9).
8
4 -Assemble the guide ring (7).
5 -Install ring (12), spacer (11) and snap ring (10) to rod (5).
a Pay attention to the orientation of ring (12).
RKZ11531
8 7
12 11 10 RKZ11500
30-314 WB97R-5
REMOVAL AND INSTALLATION CYLINDER
Assembly complete piston
1 -Install rod (5) to equipment U1.
2 -Remove any existing dirt from the rod and install the 2 5 6
head (2).
3a - With original parts only: U1
Thread piston (6), and tighten with wrench U8 until
threaded hole H of safety screw (4) is perfectly aligned.
3b -With new parts:
a - Thread the piston (6) in, ensure it contacts the rod
(5), and then tighten. RKZ11541
3 Piston: 734±49 Nm
b - Drill hole H for safety screw (4) on the seam of
thread between rod and piston.
H
a Hole Ø 6.8 – depth 31 mm U8
Thread: M8x1.25 - depth 25 mm
5
4 -Remove any dirt or shaving and install the safety screw
(4).
2 Screw: Loctite 262
3 Screw: 13.25±1.45 Nm
6
5 -Calk screw (4) in four locations. RKZ11550
5
RKZ11560
RKZ11570
WB97R-5 30-315
REMOVAL AND INSTALLATION CYLINDER
Final assembly
1 -Lubricate piston seal (6) and head gasket (2) and
introduce piston into cylinder (1).
U2 2 1
2 -Position cylinder (1) to equipment U1 and tighten head
(2) using tool U2; tighten to torque. U1
3 Head: 785±78.5 Nm
a When assembly is complete, plug cylinder union
fittings to prevent contamination.
RKZ11420
30-316 WB97R-5
REMOVAL AND INSTALLATION BACKHOE WORKING EQUIPMENT
BACKHOE WORKING EQUIPMENT
Removal
1 -Fully extend the arm (1) and fully open the bucket (2); 3
operate the boom (3) until the outer end of the boom is in
1
a horizontal position.
2
2 -Place and force a jack stand “A” and a non-slip block
under the boom (3).
3 -Lower the arm until the bucket teeth touch the ground.
4 -Lower the outriggers to the ground, apply the parking A
brake, and stop the engine.
k Release residual pressure from all circuits by operating
RKZC6430
all hydraulic controls in all directions.
5 -Position a lift “B” and some non-slip blocks under boom
fulcrum.
A B
RKZC6480
6 -Place a sling around the boom lift cylinder (4), connect it
to a hoisting device and apply a slight tension to the 4
cable.
RKZC2411
7 -Pull out the piston attachment pin (5).
8 4
8 -Release boom and arm cylinder hoses and bucket 7
cylinder hoses from the three hose clamps (6).
5
9 -Disconnect hoses (7) and (8) from boom and arm
cylinder.
a Mark the pipes to avoid exchanging them during
installation. 6 6
a Plug all pipes/hoses to prevent contamination.
6
RKZC6560
WB97R-5 30-317
REMOVAL AND INSTALLATION BACKHOE WORKING EQUIPMENT
9 -Disconnect hoses (9) from bucket cylinder.
9
a Cap pipes, hoses and holes to prevent 9
contamination.
a Mark the pipes to avoid exchanging them during
installation.
10 -Slide all hoses off and place them aside.
RKZC2680
11 -Position a non-slip block “C” under the boom lift cylinder
and disconnect the hoisting device
C
RKZC6490
12 -Remove the screw (10) and the pin (11).
13 -Start the engine, draw in the outriggers and move the
machine rearward.
a Recover the shims between boom and swing 10
11
bracket.
4 Backhoe working equipment
with standard arm: 850 kg
RKZC2700
Installation
• To install, reverse removal procedure.
1 -Start the engine and bleed the air from all circuits.
(For details, see "20 TESTING AND ADJUSTMENTS").
2 -Stop the engine, check the level in the tank and, if
necessary, top it up.
30-318 WB97R-5
REMOVAL AND INSTALLATION BACKHOE BUCKET
BACKHOE BUCKET
Removal
7
k Place the bucket on a level surface, resting on its back. 4
1 -Take out the safety pin (1) and remove the connecting 6
pin (2) between bucket (3) and tie-rods (4). [*1] [*2] 2
2 -Take out the safety pin (5) and remove the pin (6) that 5
attaches the bucket to the arm (7).
[*1] [*2] 1
3
4 Bucket: 158 kg
RKZA1350
Installation
• To install, reverse removal procedure.
[*1]
k When aligning the positions between the hole and the
pin, turn the engine over at low idling speed.
Do not insert fingers into the holes to check alignment.
[*2]
2 Internal bushing: ASL800050
WB97R-5 30-319
REMOVAL AND INSTALLATION BACKHOE BOOM CYLINDER
BACKHOE BOOM CYLINDER
Removal
1 -Remove the arm cylinder.
(For details see "ARM CYLINDER").
2 -Remove the arm.
(For details see "ARM").
3 -Start the engine and rest the boom on the ground.
4 -Remove the boom cylinder. 1 1
(For details see "BACKHOE BOOM CYLINDER").
5 -Remove the hose clamps (1) retaining the boom, arm 1
and bucket hoses.
a Mark the tubes to prevent exchanging positions
RKZC6500
during re-connection.
6 -Hook the boom (2).
7 -Take out the retaining screw and remove the pin (3). 2
[*1] [*2]
a Recover the shims (4) between boom and swing
bracket.
8 -Remove the boom (2).
4 Boom: 248 kg
RKZC6510
Installation
• To install, reverse removal procedure.
[*1]
k When aligning the positions between the hole and the 4
pin, turn the engine over at low idling speed.
Do not insert fingers into the holes to check alignment.
[*2]
2 Internal bushing: ASL800050
1 -Start the engine and bleed the air from the cylinders. 3
(For details, see "20 TESTING AND ADJUSTMENTS"). RKZC2720
a After bleeding the air, check the oil level in the tank.
30-320 WB97R-5
REMOVAL AND INSTALLATION ARM
ARM
Removal 4
1 -Remove the bucket.
(For details see "BACKHOE BUCKET").
2 -Remove the bucket cylinder and the link (1).
1
(For details, see "BACKHOE BUCKET CYLINDER"). 3
3 -Take out the lock nut (2), and the washer and remove the
pin (3) and the links (4). [*1] [*2]
2
4 -Start the engine, bring the arm into a vertical position
and lower it to the ground.
5 -Stop the engine and release residual pressures from the RKZA1360
cylinder.
6 -Put a sling around the arm cylinder (5), remove the
screws (6) and remove the pin (7). [*2] [*3] 7
7 -Start the engine and retract the piston completely.
6 5
8 -Rest cylinder (5) on a block “A” and disconnect from the
hoisting device.
9 -Stop the engine.
10 -Connect the arm (8) to the hoisting device and apply a
slight tension to the cable.
RKZC2441
11 -Take out the screws (9) and remove the pin (10).
[*1] [*2]
8 5
a Recover the shims.
12 -Remove the arm (8).
4 Arm: ______ kg
Installation A
• To install, reverse removal procedure. RKZC2730
[*1]
k When aligning the positions between hole and pin, do
not insert fingers into the holes to check on alignment. 10
[*2]
2 Internal bushing: ASL800050
8 9
a Tighten the locknut completely, then release it half a
turn.
[*3]
k When aligning the positions between the hole and the
pin, turn the engine over at low idling speed.
Do not insert fingers into the holes to check alignment. RKZC2740
WB97R-5 30-321
REMOVAL AND INSTALLATION JIG ARM
JIG ARM
Removal 4
1 -Remove the bucket.
(For details see "BACKHOE BUCKET").
2 -Remove the bucket cylinder and the link (1). 1
(For details, see "BACKHOE BUCKET CYLINDER"). 3
3 -Take out the lock nut (2), and the washer and remove the
pin (3) and the links (4). [*1] [*2]
2
RKZA1360
4 -Disconnect the jig arm hoses (5) and (6), the bucket
cylinder hoses (7) and (8), and the hoses of the auxiliary
equipment (9) and (10).
a Mark the hoses to avoid exchanging them during 11
6
INSTALLATION.
5 -Remove the clamp (11).
6 -Proceed with the removal as for the arm 7 10
. (See "ARM").
4 Jig arm cylinder: 460 kg
9 8
5
RKZA7970
Installation
• To install, reverse removal procedure.
[*1]
k When aligning the positions between hole and pin, do
not insert fingers into the holes to check on alignment.
[*2]
2 Internal bushing: ASL800050
a Tighten the locknut completely, then release it half a
turn.
30-322 WB97R-5
REMOVAL AND INSTALLATION 2nd ARM
2nd ARM
Removal
1 -Remove the bucket (1).
(For details see "BACKHOE BUCKET").
2 -Remove the bucket cylinder (2) and the link (3). 1 2
(For details, see "BACKHOE BUCKET CYLINDER"). 3
3 -Remove the 2nd arm cylinder.
(For details see "JIG ARM CYLINDER").
a For safety, tightly plug all the disconnected hoses.
7
RKZA7980
4 -Take out the lock nut (4), and the washer and remove the
pin (5) and the links (6). [*1] [*2] [*3]
6
5 -Connect the 2nd arm (7) to some hoisting tackle.
a Use the bucket pin hole and the safety pin holes.
5
6 -Start the engine and, maintaining constant tension on 3
the section of cable or chain connected to the bucket
coupling, slowly raise the boom until both sections of 4
cable or chain are under slight tension.
RKZA7990
7 -Stop the engine and loosen by several turns the gib
adjustment screws.
a Loosen the screws on both sides.
8 -Slide out the 2nd arm (7).
4 2nd arm: _______ kg
7
RKZA8000
Installation
• To install, reverse removal procedure.
[*1]
k When aligning the positions between hole and pin, do
not insert fingers into the holes to check on alignment.
[*2]
2 Internal bushing: ASL800050
[*3]
a Tighten the locknut completely, then release it half a
turn.
WB97R-5 30-323
REMOVAL AND INSTALLATION 2nd ARM GUIDES
2nd ARM GUIDES
Removal
2
1 -Remove the bucket. 1
(For details see "BACKHOE BUCKET").
2 -Partially extend the 2nd arm (1).
3 -Rest the arm (2) on a trestle “A” about 80 cm high.
A
RKZA8010
4 -Loosen and remove the screws (3), the spring washers
and remove the upper guides (4). [*1]
5 -Connect the 2nd arm (1) to some hoisting tackle.
a Use the bucket pin hole and the safety pin holes.
6 -Slowly raise the 2nd arm (1) until it rests on the 3
supporting surfaces of the upper guides.
5 6
RKZA8020
7 -Loosen the nuts (5) and remove the adjustment dowel
bolts (6). 3
8 -Raise the lower guides (7) and slide them out. [*1]
4
6
7
RKZ02390
Installation
2
• To install, reverse removal procedure.
1
[*1]
2 Guides and 2nd arm guides: ASL800040
1 -Adjust the clearances, keeping the jig arm (1) aligned
with respect to the 2nd arm (2).
(For details, see "20 TESTING AND ADJUSTMENTS").
RKZA8030
30-324 WB97R-5
REMOVAL AND INSTALLATION BACKHOE SWING BRACKET
BACKHOE SWING BRACKET
Removal
2
1 -Remove the equipment. (For details see "BACKHOE 1
WORKING EQUIPMENT").
2 -Take out the screws (1) and remove the pins (2) that
connect the swing cylinders (3). [*1] [*2]
3
3 -Remove boom safety cylinder (4). (For details see
"BACKHOE BOOM SAFETY CYLINDER").
RKZC2592
4 -Sling the swing bracket (5)
5 -Take out screws (6) and (7) and remove pins (8) and (9)
4
from swing bracket. [*1] [*2]
6 -Remove swing bracket (5) and shims (10) and slide the
hoses off. [*3]
4 Bracket: 162.5 kg
RKZC2351
Installation
8
• To install, reverse removal procedure. 5
[*1]
k When aligning the positions between the hole and the 6
pin, turn the engine over at low idling speed.
Do not insert fingers into the holes to check alignment.
[*2]
2 Internal bushing: ASL800050 9 7
RKZC2750
[*3]
a Insert the shims.
1 -Start the engine and bleed the air from the cylinders.
(For details, see "20 TESTING AND ADJUSTMENTS").
13
a After bleeding the air, check the oil level in the tank.
13
13
RKZ01330
WB97R-5 30-325
REMOVAL AND INSTALLATION COMPLETE BACKHOE BACKFRAME
COMPLETE BACKHOE BACKFRAME
Removal
1
1 -Remove the equipment. 2
(For details see "BACKHOE WORKING
EQUIPMENT").
2 -Remove the swing bracket.
(For details see "BACKHOE SWING BRACKET").
3 -Disconnect the backhoe backframe lock piston feeding
hose (2) from union (1); plug hose and union to prevent
contamination.
RKZC2760
4 -Disconnect feed hoses (4) from swing cylinders (3).
3 4
RKZC2770
5 -Connect the backframe (5) to a hoisting device.
6 -Loosen nuts (6) and remove washers and four screws
(7).
Loose partially lateral nuts (4) to remove backframe (3) 6 5
from frame (8). [*1]
6
8
7
RKZC2780
7 -Put a sling round the backframe (5) and apply slight
tension to the cables.
10
9
8 -Remove external nuts (6), washers and screws (7). 10
[*1]
9 -Remove slide block (9) and spacers (10). 7
RKZC2790
30-326 WB97R-5
REMOVAL AND INSTALLATION COMPLETE BACKHOE BACKFRAME
10 -Lower backframe (5) and remove backframe together
with swing cylinders.
4 Complete backframe: approx. 246 kg 5
RKZC2800
Installation
• To install, reverse removal procedure.
[*1]
2 Nuts: Loctite 262
3 Nuts: 980±98 Nm
1 -Start the engine and bleed the air from the cylinders.
(For details, see "20 TESTING AND ADJUSTMENTS").
a After bleeding the air, check the oil level in the tank.
WB97R-5 30-327
REMOVAL AND INSTALLATION BACKFRAME LOCK PISTONS
BACKFRAME LOCK PISTONS
Removal
1 -Remove the complete backframe (1).
1
(For details see "COMPLETE BACKHOE
BACKFRAME").
RKZC2801
UPPER PISTON
1 -Remove two pipes (2) and (3).
2 -Plug the horizontal union (4).
3 -Introduce compressed air at low pressure (max. 2 bar)
through lower union (5) and recover piston (6).
k Be aware that the piston may be ejected rapidly. 2
6
Use a rag or non-slip gloves to accompany the 4
piston as it is being ejected. 3
RKZC2810
LOWER PISTON
1 -Remove pipe (3).
2 -Introduce compressed air at low pressure (max. 2 bar)
through union (7) and recover piston (6).
3
k Be aware that the piston may be ejected rapidly.
Use a rag or non-slip gloves to accompany the
piston as it is being ejected.
RKZC2820
REPLACING SEALS
8 9 10
1 -Remove seal (8), guide ring (9), and seal (10).
a Note down direction of installation of seal (10).
10
RKZC2830
30-328 WB97R-5
REMOVAL AND INSTALLATION BACKFRAME LOCK PISTONS
2 -Thoroughly clean the seats and install new seals and the
guide ring.
3 -Lubricate the seals, guide ring, and piston seat.
2 Seal and seat: Hydraulic oil: A
6
RKZC2840
4 -Apply a band “A” for seal compression and install piston
(6). A
RKZC2850
Installation
• To install, reverse removal procedure.
WB97R-5 30-329
40 STANDARD MAINTENANCE
TRANSMISSION.............................................................2 SHOVEL CYLINDERS ................................................. 34
FRONT AXLE..................................................................5 BACKHOE CYLINDERS .............................................. 36
REAR AXLE ....................................................................9 FRONT WORKING EQUIPMENT ................................ 40
HYDRAULIC PUMP ......................................................13 SWING BRACKET ....................................................... 42
CONTROL VALVE ........................................................16 BACKHOE WORKING EQUIPMENT ........................... 44
PPC VALVES................................................................32
WB97R-5 40-1
STANDARD MAINTENANCE TRANSMISSION
TRANSMISSION
3 23 Nm
3 30 Nm
3 30 Nm
X
3 30 Nm
A
3 30 Nm
3 30 Nm 3 50 Nm
3 30 Nm
View X
3 30 Nm
3 30 Nm
K
3 23 Nm
3 30 Nm
3 30 Nm
View Z
K-K RKZ11670
40-2 WB97R-5
STANDARD MAINTENANCE TRANSMISSION
2 Loctite 510
3 50 Nm
2 Loctite 510
3 50 Nm
L
L
3 139 Nm
3 139 Nm
3 50 Nm
2 Loctite 542
A-A
3 50 Nm
RKZ11410 2 Loctite 542
WB97R-5 40-3
STANDARD MAINTENANCE TRANSMISSION
3 23 Nm
3 30 Nm
3 50 Nm
3 23 Nm
gr40_003
3 50 Nm
2 Loctite 542
B-B RKZ11680
40-4 WB97R-5
STANDARD MAINTENANCE FRONT AXLE
FRONT AXLE
Differential
3 95 Nm
2 Loctite 270
3 13 Nm
3 169 Nm
2 Loctite 510
2
2 Loctite 638
3
4
RKZ10380
WB97R-5 40-5
STANDARD MAINTENANCE FRONT AXLE
3 266 Nm
3 60 Nm RKZ10390
Unit: mm
No. Check item Criteria Remedy
Standard clearance Clearance limit
1 Axle clearance
---- ----
Backlash of crown wheel and
2 0.18–0.28 0.28
pinion
Pinion rotation force Adjust
3 (without sealing ring) 92-137 Nm
As measured on pinion Ø 34.8
Pinion-crown
rotation force
4 129.5-194.5 Nm
(without sealing ring)
As measured on pinion Ø 34.8
40-6 WB97R-5
STANDARD MAINTENANCE FRONT AXLE
Planetary - Joint
3 190 Nm
3 8 Nm
3 120 Nm
1
3 70 Nm
3 8 Nm
2 Loctite 270
RKZ10400
Unit: mm
No. Check item Criteria Remedy
1 Hub rotation torque ---- Adjust
2 Drive shaft axle clearance ---- Replace
WB97R-5 40-7
STANDARD MAINTENANCE FRONT AXLE
Steering unit cylinder
3 350 Nm 3 120 Nm B
39,32°
50°
A
A 3 300 Nm
3 250 Nm
1920 -02
3 150 Nm
A-A 3 220 Nm B-B
Detail C C
Particolare RKZ10410
Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance Replace
Clearance between bushing and size Shaft Hole clearance limit bushing
1 pin and
50 ---- 50.19+0 0.04 ---- ---- pin
40-8 WB97R-5
STANDARD MAINTENANCE REAR AXLE
REAR AXLE
Differential
A
3 10 Nm
3 155 Nm
A 2 Loctite 270
3 169 Nm
3 80 Nm
2
3 80 Nm 2 Loctite 638
3 25 Nm
2 Loctite 270
3
4
2 Loctite 542
A-A
RKZ10420
Unit: mm
No. Check item Criteria Remedy
Standard
Clearance limit
1 Axle clearance clearance
---- ----
2 Backlash of crown wheel and pinion 0.21–0.29 0.29 Adjust
Pinion rotation force (without sealing ring)
3 115-138 Nm
As measured on pinion Ø 34.8
Pinion-crown rotation force (without sealing ring)
4 148-188 Nm
As measured on pinion Ø 34.8
WB97R-5 40-9
STANDARD MAINTENANCE REAR AXLE
Planetary
3 70 Nm 3 8-12 Nm
3 500 Nm 2 Loctite 270
3 1000 Nm
3 79 Nm
2 Loctite 270
3 226 Nm 3 60 Nm
2 Loctite 270
RKZ09741
Unit: mm
No. Check item Criteria Remedy
1 Hub rotation torque ---- Adjust
2 Drive shaft axle clearance ---- Replace
40-10 WB97R-5
STANDARD MAINTENANCE REAR AXLE
Brakes
3 16 Nm
Detail A A
Particolare
RKZ10430
Unit: mm
No. Check item Criteria Remedy
Standard thickness Min. thickness
1 Disc thickness Replace
6.73 -- 0.1
0
5.8
WB97R-5 40-11
STANDARD MAINTENANCE REAR AXLE
Differential lock
3 180 Nm
RKZ09761
40-12 WB97R-5
STANDARD MAINTENANCE HYDRAULIC PUMP
HYDRAULIC PUMP
3 19.6-24.5 Nm
View X
3 157-196 Nm
A A
3 68.6-83.4 Nm
Z
X
3 27.4-34.3 Nm
3 7.8-9.8 Nm
3 68.6-83.4 Nm
3 19.6-27.4 Nm
3 11.8-14.7 Nm RKZ10440
View Z
WB97R-5 40-13
STANDARD MAINTENANCE HYDRAULIC PUMP
3 27.4-34.3 Nm Z
3 27.4-34.3 Nm
X
3 27.4-34.3 Nm 3 27.4-34.3 Nm
A-A
RKZ10450
40-14 WB97R-5
PAGE INTENTIONALLY
LEFT BLANK
STANDARD MAINTENANCE CONTROL VALVE
CONTROL VALVE
8-SPOOL VERSION
3 9.8-12.7 Nm
AC
Komatsu Ltd.
AC
AB AB
AA AA
3 9.8-12.7 Nm N N
M M
X L L
K K
J J
3 9.8-12.7 Nm
F F
E E
3 9.8-12.7 Nm
D
3 58.8-73.5 Nm
3 29.4-34.3 Nm
RKZ09062
40-16 WB97R-5
STANDARD MAINTENANCE CONTROL VALVE
AE
C B A
C B A RKZ09071
AE
View X
WB97R-5 40-17
STANDARD MAINTENANCE CONTROL VALVE
3 49-58.8 Nm
3
3 39.2-49 Nm
39.2-49 Nm
3 39.2-49 Nm
3
39.2-49 Nm
3 39.2-49 Nm
5 6
A-A RKZ09080
10
3
4
3 2
2 2
1
7
8
B-B
40-18 WB97R-5
STANDARD MAINTENANCE CONTROL VALVE
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free
Installed Installed Free Installed
installed
length load installed load
x Øe
Spool return spring
1 (shovel arm raise 27.1x16.2 26.7 14.7N – 11.8N
control)
Spool return spring
2 (in arm control) 41.1x19.3 40.5 34.3N – 27.4N
Spool return spring
3
(out arm control)
42.3x19.2 40.5 54.9N – 43.9N
Spool return spring
4
(boom swing control)
29x17.5 28.5 22.5N – 18N
Replace
Spool return spring spring
5
(shovel control)
27.2x16.6 26.7 30.38N – 24.3N
Spool return spring
6 (backhoe bucket 24.2x16.7 23.7 30.4N – 24.3N
boom control)
Spool return spring
7 (shovel arm 19.4x17.6 19 14.7N – 11.8N
float control)
Spool return spring
8 (shovel arm 38.7x18 27.6 355.7N – 284.6N
lower control)
9 Priority valve spring 56.8x15.2 48.5 29.6N – 23.7N
10 Unloading valve spring 25.5x19.3 18 121.5N – 97.2N
WB97R-5 40-19
STANDARD MAINTENANCE CONTROL VALVE
AD
2
7
3 117.6-161.8 Nm
8
3
1 4
8
8
1
8 5
3 19.6-24.5 Nm
1 3
5
3 14.7-19.6 Nm
AD
3 24.5-34.3 Nm
6 6
D-D C-C
3 14.7-19.6 Nm
3 24.5-34.3 Nm
AD - AD
RKZ08341
40-20 WB97R-5
STANDARD MAINTENANCE CONTROL VALVE
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free
Installed Installed Free Installed
installed
length load installed load
x Øe
Pressure compensation valve
spring
1
(Shovel arm, backhoe bucket,
15.4x6 8 7.44N – 5.96N
boom, shovel, boom swing)
Pressure compensation valve
2
spring (arm)
31.4x14.4 21.8 63.7N – 51.0N
Pressure compensation valve
3 spring. 18.9x8.4 15 15.7N – 12.5N Replace
(Boom swing, backhoe bucket) spring
Pressure compensation valve
4 spring. 37.1x8.6 24 34.3N – 27.4N
(Front bucket)
Pressure compensation valve
5 spring. 20x8.4 15 4.32N – 3.45N
(Boom, shovel arm)
6 Check valve spring 27.2x6.9 21 4.70N – 3.76N
7 Check valve spring 27.2x6.9 22 3.92N – 3.14N
8 Check valve spring 21.9x5 15.8 1.96N – 1.57N
9 Check valve spring 11.3x4.3 7.5 1.72N – 1.38N
WB97R-5 40-21
STANDARD MAINTENANCE CONTROL VALVE
3
3 65.7-82.3 Nm
2 2
1 1 7
1 2 E-E 2 1 K-K
F-F L-L
J-J M-M RKZ09102
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free
Installed Installed Free Installed
installed
length load installed load
x Øe
Spool return spring Replace
1 18.0x18 17.5 39.2N – 31.4N
(Outrigger control) spring
Spool return spring
2 20.2x14.2 10.4 30.4N – 24.3N
(Outrigger control
Control valve spring
3 13.0x8.8 11 3.92N – 3.1N
plate lock
40-22 WB97R-5
STANDARD MAINTENANCE CONTROL VALVE
3 34-44 Nm
3 34.3-44.1 Nm
AC - AC
N-N
3 65.7-82.3 Nm
1
AA - AA
AB - AB AE - AE
RKZ08892
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free
Installed Installed Free Installed
installed Replace
length load installed load
x Øe spring
Pressure compensation
1 31.7x9.2 27.5 43.1N – 34.5N
valve spring.
WB97R-5 40-23
STANDARD MAINTENANCE CONTROL VALVE
10-SPOOL VERSION
3 9.8-12.7 Nm
AC
Komatsu Ltd.
AC
AB AB
AA AA
3 9.8-12.7 Nm
R R
N N
M M
X
L L
K K
J J
3 9.8-12.7 Nm F F
E E
3 9.8-12.7 Nm
D
Z
3 29.4-34.3 Nm
3 58.8-73.5 Nm RKZ09121
ViewZ
40-24 WB97R-5
STANDARD MAINTENANCE CONTROL VALVE
AE
C B A
C B A
RKZ09591
AE
ViewX
WB97R-5 40-25
STANDARD MAINTENANCE CONTROL VALVE
3 49-58.8 Nm
5 6
9 3
3 39.2-49 Nm
10 39.2-49 Nm
4
3
3 3
3
2 39.2-49 Nm
2
39.2-49 Nm
3
39.2-49 Nm
11
7
8
B-B A-A
K-K J-J
RKZ09131
40-26 WB97R-5
STANDARD MAINTENANCE CONTROL VALVE
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free
Installed Installed Free Installed
installed
length load installed load
x Øe
Spool return spring
1 (shovel arm raise 27.1x16.2 26.7 14.7N – 11.8N
control)
Spool return spring
2 (in arm control) 41.1x19.3 40.5 34.3N – 27.4N
Spool return spring
3
(out arm control)
42.3x19.2 40.5 54.9N – 43.9N
Spool return spring
4
(boom swing control)
29x17.5 28.5 22.5N – 18N
Spool return spring
5
(shovel control)
27.2x16.6 26.7 30.38N – 24.3N Replace
spring
Spool return spring
6 (backhoe bucket 24.2x16.7 23.7 30.4N – 24.3N
boom control)
Spool return spring
7 (shovel arm 19.4x17.6 19 14.7N – 11.8N
float control)
Spool return spring
8 (shovel arm 38.7x18 27.6 355.7N – 284.6N
lower control)
9 Priority valve spring 56.8x15.2 48.5 29.6N – 23.7N
10 Unloading valve spring 25.5x19.3 18 121.5N – 97.2N
Spool return spring
11 (jig arm control, 29x17.5 28.5 22.5N 18.0N
4 in 1 bucket control)
WB97R-5 40-27
STANDARD MAINTENANCE CONTROL VALVE
AD
7 2
3 24.5-34.3 Nm
8
3
1 4
8
8 1 5
3 47-58.8 Nm
8 3
1
3 19.6-24.5 Nm
5
AD
6 6
3 24.5-34.3 Nm
D-D C-C RKZ09141
3 14.7-19.6 Nm
3 24.5-34.3 Nm
AD - AD
40-28 WB97R-5
STANDARD MAINTENANCE CONTROL VALVE
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free
Installed Installed Free Installed
installed
length load installed load
x Øe
Pressure compensation valve
spring
1 (Shovel arm, backhoe bucket, 15.4x6 8 7.44N – 5.96N
boom, shovel, boom swing, jig
arm, 4 in 1 bucket)
Pressure compensation valve
2
spring (arm)
31.4x14.4 21.8 63.7N – 51.0N
Pressure compensation valve
3 spring. 18.9x8.4 15 15.7N – 12.5N Replace
(Boom swing, backhoe bucket) spring
Pressure compensation valve
4 spring. 37.1x8.6 24 34.3N – 27.4N
(Front bucket)
Pressure compensation valve
spring.
5
(Boom, shovel arm jig arm, 4 in 1
20x8.4 15 4.32N – 3.45N
bucket)
6 Check valve spring 27.2x6.9 21 4.70N – 3.76N
7 Check valve spring 27.2x6.9 22 3.92N – 3.14N
8 Check valve spring 21.9x5 15.8 1.96N – 1.57N
9 Check valve spring 11.3x4.3 7.5 1.72N – 1.38N
WB97R-5 40-29
STANDARD MAINTENANCE CONTROL VALVE
3
3 65.7-82.3 Nm
2 2
1 1 7
1 2 E-E 2 1 K-K
F-F L-L
J-J M-M RKZ09102
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free
Installed Installed Free Installed
installed
length load installed load
x Øe
Spool return spring Replace
1 18.0x18 17.5 39.2N – 31.4N
(Outrigger control) spring
Spool return spring
2 20.2x14.2 10.4 30.4N – 24.3N
(Outrigger control
Control valve spring
3 13.0x8.8 11 3.92N – 3.1N
plate lock
40-30 WB97R-5
STANDARD MAINTENANCE CONTROL VALVE
3 34-44 Nm
3 34.3-44.1 Nm
AC - AC
N-N
3 65.7-82.3 Nm
1
AA - AA
AB - AB AE - AE
RKZ08892
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free
Installed Installed Free Installed
installed Replace
length load installed load
x Øe spring
Pressure compensation
1 31.7x9.2 27.5 43.1N – 34.5N
valve spring.
WB97R-5 40-31
STANDARD MAINTENANCE PPC VALVES
PPC VALVES
SHOVEL CONTROL
1 2
3 3
RKZ10460
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free
Installed Installed Free Installed
installed
length load installed load
x Øe
Return spring (outer) Replace
1
(for ports P1 and P2)
Return spring (outer)
2
(for ports P3 and P4)
3 Adjusting screw (inner)
40-32 WB97R-5
STANDARD MAINTENANCE PPC VALVES
1 2
3 3
RKZ10470
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free
Installed Installed Free Installed
installed
length load installed load
x Øe
Return spring (outer) Replace
1
(for ports P1 and P2)
Return spring (outer)
2
(for ports P3 and P4)
3 Adjusting screw (inner)
WB97R-5 40-33
STANDARD MAINTENANCE SHOVEL CYLINDERS
SHOVEL CYLINDERS
DUMP CYLINDER
3 1250±130 Nm 3 539±54 Nm
1 3
2
707-00-0y920-1
RAISE CYLINDER
3 1670±170 Nm 3 677±67.5 Nm
1 3
2
707-00-0y891-1
Unit: mm
Criteria
No. Check item Cylinder Standard Tolerance Standard Clearance Remedy
size Shaft Hole clearance limit
Lifting 50
-- 0.030 + 0.162
0.035 0.238
Tolerance between -- 0.076 + 0.005
1 Replace
piston rod and head -- 0.025 + 0.141
Dump 45 -- 0.064 + 0.004
0.029 0.205
Lifting 60
-- 0.060 + 0.174
0.160 0.280
Tolerance between -- 0.106 + 0.100
2 bushing and piston
head mounting pin Dump 45
-- 0.050 + 0.142
0.130 0.231
-- 0.089 + 0.080 Replace
pin and
Lifting 60
-- 0.060 + 0.174
0.160 0.280 bushing
Tolerance between -- 0.106 + 0.100
3 bushingn and cylin
der mounting pin Dump 50
-- 0.050 + 0.142
0.130 0.231
-- 0.089 + 0.080
40-34 WB97R-5
STANDARD MAINTENANCE SHOVEL CYLINDERS
4 IN 1 BUCKET
3 690±69 Nm 3 540±54 Nm
1
42N-6C-12800-1
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free
Installed Installed Free Installed
installed
length load installed load
x Øe
Tolerance between -- 0.025 + 0.064 Replace
1 40 0.05 0.114
piston rod and head -- 0.050 + 0.025
Tolerance between
2 bushing and piston head 40 -- 0.150
0
mounting pin
WB97R-5 40-35
STANDARD MAINTENANCE BACKHOE CYLINDERS
BACKHOE CYLINDERS
BOOM
3 2740-2840 Nm
with Loctite 262
3 981±98 Nm 3
1
2
ARM
3 1670±170 Nm 3
3 961±96.1 Nm
1
2
707-00-0y871-1
BUCKET
31670±170 Nm
3 1176-1372 Nm
1 3
2
707-00-0y901-1
40-36 WB97R-5
STANDARD MAINTENANCE BACKHOE CYLINDERS
BOOM SWING
3 44.1-53.9 Nm 3 785±78.5 Nm
3 297±29.4 Nm
1 2
707-02-07730-1
Unit: mm
Criteria
No. Check item Cylinder Tolerance Remedy
Standard Standard Clearance
size clearance limit
Shaft Hole
Boom 60
-- 0.030 + 0.051
0.035 0.227
-- 0.076 + 0.005
Arm 55 -- 0.030 + 0.046
0.030 0.132
Clearance between
-- 0.076 0
1
piston rod and head
Bucket 55
-- 0.030 + 0.051
0.035 0.227 Replace
-- 0.076 + 0.005
Boom swing 50
- 0.030 + 0.164
0.037 0.240
-- 0.076 + 0.007
Boom 60
-- 0.060 + 0.174
0.160 0.280
-- 0.106 + 0.100
Arm 50
-- 0.050 + 0.142
0.130 0.231
Tolerance between -- 0.089 + 0.080
2 bushing and piston
head mounting pin -- 0.050 + 0.142
Bucket 45 -- 0.089 + 0.080
0.130 0.231
Boom swing 55
-- 0.060 + 0.174
0.160 0.280
-- 0.106 + 0.100 Replace
pin and
-- 0.060 + 0.174 bushing
Boom 60 0.160 0.280
-- 0.106 + 0.100
Tolerance between
3 bushing and cylinder Arm 60
-- 0.060 + 0.174
0.160 0.280
mounting pin
-- 0.106 + 0.100
Bucket 45
-- 0.050 + 0.142
0.130 0.231
-- 0.089 + 0.080
WB97R-5 40-37
STANDARD MAINTENANCE BACKHOE CYLINDERS
OUTRIGGERS
3 911±91.1 Nm
3 539±54 Nm with Loctite 262
1
707-00-0Y0910-1
JIG ARM
3 1080±100 Nm
3 539±54 Nm
1
42N-6C-13301-1
Unit: mm
Criteria
No. Check item Cylinder Tolerance Remedy
Standard Standard Clearance
size clearance limit
Shaft Hole
Outriggers 40 -- 0.025 + 0.132
0.031 0.196
-- 0.064 + 0.006
Clearance between
1 Replace
piston rod and head
Jig arm 40
-- 0.025 + 0.064
0.050 0.114
-- 0.050 + 0.025
40-38 WB97R-5
PAGE INTENTIONALLY
LEFT BLANK
STANDARD MAINTENANCE FRONT WORKING EQUIPMENT
FRONT WORKING EQUIPMENT
E
C E
C
D
B
B D
A
A
1 3
2
A-A B-B
C-C
5
4
D-D E-E
RKZ10480
40-40 WB97R-5
STANDARD MAINTENANCE FRONT WORKING EQUIPMENT
Unit: mm
Criteria
No. Check item Tolerance Remedy
Standard Standard Clearance
size clearance limit
Shaft Hole
Clearance between
1 bushings and bucket 45 -- 0.050 + 0.080
0.130–0.329
mounting pin -- 0.089 + 0.240
Clearance between bushing -- 0.050 + 0.080
2 45 0.130–0.329
and link mounting pin -- 0.089 + 0.240
Clearance between
3 bushing and fulcrum link 45
-- 0.050 + 0.080
0.130–0.208 Replace
mounting pin
-- 0.089 + 0.119
Clearance between -- 0.060
4 bushing and link 60 + 0.137
0.143–0.303
mounting pin -- 0.106 + 0.197
Clearance between bushing -- 0.050
5 50
and boom mounting pin -- 0.089
WB97R-5 40-41
STANDARD MAINTENANCE SWING BRACKET
SWING BRACKET
B
A
C
A C
1
3 4
B-B
2
1
A-A 5
C-C
RKZ10490
40-42 WB97R-5
STANDARD MAINTENANCE SWING BRACKET
Unit: mm
Criteria
No. Check item Tolerance Remedy
Standard Standard Clearance
size clearance limit
Shaft Hole
Clearance between
1 rotating bushing and boom 60 -- 0.010 + 0.090
0.070–0.175
swing cylinder bushing -- 0.085 + 0.060
Clearance between
2 bushing and (lower) swing 65 -- 0.060 + 0.190
0.250–0.370
bracketrotating pin -- 0.106 + 0.264
Clearance between -- 0.060 + 0.190 Replace
3 bushing and (upper) swing 65 -- 0.106 + 0.264
0.250–0.370 bushing
bracketrotating pin and pin
Standard size Limit size
Upper shim
4
thickness
2.50 --0 0.1
5 Central shim thickness 4.75 --0 0.1
6 Lower shim thickness 4.75 --0 0.1
WB97R-5 40-43
STANDARD MAINTENANCE BACKHOE WORKING EQUIPMENT
BACKHOE WORKING EQUIPMENT
C
C
D B
A
A
D
3
2
1
4
A-A
B-B
5
6 6
D-D
C-C RKZ10500
40-44 WB97R-5
STANDARD MAINTENANCE BACKHOE WORKING EQUIPMENT
Unit: mm
Criteria
No. Check item Tolerance Remedy
Standard Minimum Clearance
size clearance limit
Shaft Hole
Clearance between
1 link bushings and bucket 45 -- 0.050 --- 0.080 0.130–0.329
mounting pin -- 0.089 --- 0.240
Clearance between -- 0.050 --- 0.080
2 arm bushings and bucket 45 0.130–0.329
mounting pin
-- 0.089 --- 0.240
Clearance between -- 0.050 --- 0.080
3 arm bushings and lever 45 -- 0.089 --- 0.240 0.130–0.329
mounting pin
Replace
Clearance between
4 bushings and tilt 45 -- 0.050 --- 0.080 0.130–0.329
lever mounting pin
-- 0.089 --- 0.240
Clearance between -- 0.050 --- 0.080
5 bushings and arm 50 -- 0.089 --- 0.119 0.130–0.208
mounting pin
Clearance between -- 0.060 --- 0.137
6 bushings and boom 60 -- 0.106 --- 0.197 0.197–0.303
mounting pin
WB97R-5 40-45
90 VARIE
SCHEMA ELETTRICO (VERSIONE STANDARD) ... 3
WB97R-5 90-1
OTHER ELECTRICAL DIAGRAM (STANDARD VERSION)
ELECTRICAL DIAGRAM (STANDARD VERSION)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
42-N-06 42-N-06 42-N-06
15120 11850 11830
V-Z1
42N-06-15510
G-V1.5
A-G1
A-G1
V/N1
M-B1.5
G-V1
M-N1.5
C-L1
C-L1
L-N1.5
G-N1
L-R1
L-R1
A 1 2 3 4
G-M1
C-L1
C-L1
L-R1
L-R1
C-B1
A/B1
G/R1
R-N1
G-L1
L-B1
H-V1
N1
N1
N1
H1.5
N1
N1
M1
R/N1
A/R1
A/R1
H-V1
R/N1
C-L1
L/R1
V-N1
V-N1
V-Z1
A1
R1
N1
N1
N1
N1
N1
N1
4 2 8 5 7 4 1 9 10 12 8 7 2 P63 1
7 1 3 4 6 7 1 3 4 6 4 6 1 3 7
X57 X57 X57 X57 X57 X60 X60 X60 X60 X60 X60 X180 1 1 1 1
X142
X142
X142
X142
X142
X141
X141
X141
X141
X141
X140
X140
X140
X140
X140
1 3 4 6 7 X146 X143 X136 X138
R N F Out1 Out2 56 1 L R 31b 53 15 53c 7 1 3 7 1 3 7 1 3
WASHER X89 X89 X89 X89 X89
N F 0 X80 X80 X80 X81 X81 X81 X82 X82 X82 7 1 3 4 6 7 1 3 4 6
R I 2 Dx LAVACRISTALLO I
1 3 4 6 7
0 1 4 6 1 3 7 E146 E143 E136 E138
7 1 3 7 1 3 7 1 3 II I 0 II I 0
HORN V180 1 0 0 1 1 0 0 1 5 2 8
Sx CLAXON
X146 X143 X136 X138
H 8 2 5 8 2 5
X141 X141 X141 Nome/Item Descrizione Description KUE P/N
+ 56b 56a 49 H
S89 8 2 5
S80 8 2
S81 8 2
S82 8 2 S140 X140 X140 X140 S142 X142 X142 X142 S141 A6 FUNCTION MACHINE UNIT
S57 9 S60 5 3 11 6
8 2 5
8 2
8 2 8 2 8 2 5 8 2 5 5 2 8 4 4 4 4 A CENTRALINA FUNZIONI MACCHINA
X89 X89 X81 X81 X82 X82 B13 SENSORE RETURN TO DIG RETURN TO DIG SENDER
X60 X60 X60 X60 1 X89 X80 X80
A-G1.5
A-G1.5
G-N1.5
G-N1.5
A-G1
A-G1
G-V1
G-V1
B59 Livello olio freni BRAKE OIL LOW LEVEL SWITCH
L-R1
C-L1
C-L1
X181
R1
N1
N1
N1
N1
H-R1
G-M1
A-G1
A-G1
A-B1
G/R1
A/R1
A/R1
A/R1
A/R1
B112 Termistore Thermistor switch
C-L1
C-L1
V/N1
L/R1
V-N1
V-Z1
H1
C1
V1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 9 10 11 12 B113 Filtro aria Air filter blocked switch
X64 B115 Sensore press. olio motore Engine oil low pressure switch
X63
42-N-06 B121 Avvisatore acustico Horn
L-B0.5
C-L0.5
V0.35
G-M1
M-N1
M/B1
A-R1
S-G1
B-V1
A-V1
A/V1
S-N1
H-V1
R-V1
Z-B1
S/N1
V-N1
G1
N1
H1
S1
V1
B209 Galleggiante Fuel level sender
11520 B210 Temp. olio trasmissione Gearing oil temperature sensor
B211 Sensore cardano Cardan sensor
A-B1
B-N1
B-N1
A-N1
A-N1
R/N1
S-N1
R/N1
N1
N1
N1
N1
E100 Fanale podteriore DX Right rear beam
E101 Fanale posteriore SX Left rear beam
7 1 3 7 1 3 7 1 3 E103 Luce targa Plate light
X83 X83 X83 X85 X85 X85 X84 X84 X84 E136 Faro di lavoro posteriore DX laterale Lateral right rear working light
7 1 3 7 1 3 7 1 3 E138 Faro di lavoro posteriore SX laterale Lateral left rear working light
0 0 0 1
1 1 E143 Faro lavoro ant. DX lat. Lateral right front working light
E146 Faro di lavoro anteriore SX laterale Lateral left front working light
8 2 8 2
S83 8 2 S85 S84 E147 Faro anteriore SX Left front light
X83 X83 X85 X85 X84 X84 E148 Girofaro Beacon lamp
8 2 8 2 8 2
E151 Faro ant. DX Right front light
A-B1
A-B1
A-N1
E152 Plafoniera Room lamp
R/N1
R/N1
S-N1
R/N1
R/N1
Z-N1
F1 FUSIBILE FARI LAVORO ANTERIORI CENTRALI 15A Central front working light fuse 15A
F2 FUSIBILE FARI LAVORO POSTERIORI CENTRALI 15A Central rear working light fuse 15A
F3 FUSIBILE LUCE POSIZIONE DX 3A Right position light fuse 3A
F4 FUSIBILE LUCE POSIZIONE SX 3A Left position light fuse 3A
F5 FUSIBILE AVVISATORE ACUSTICO 10A Horn fuse 10A
M-N1
B-G1
A-B1
A-B1
G-L1
H-L1
S/N1
Z/N1
G1
N1
N1
N1
N1
N1
F6 FUSIBILE FARI LAVORO POSTERIORI LATERALI 15A Lateral rear working light fuse 15A
L/R1
F7 FUSIBILE TERGI POSTERIORE + AVVISATORE ACUSTICO POSTERIORE 7,5A Winshield wiper-washer + rear horn fuse 7,5A
7 1 3 4 6 7 1 3 4 6 1 3 7 F8 FUSIBILE SWITCH LUCI STOP 7,5A Stop light swicth fuse 7,5A
X86 X86 X86 X86 X86 X88 X88 X88 F9 FUSIBILI FARI LAVORO ANTERIORI LATERALI 15A Lateral front working light fuse 15A
G-V1.5
X87 X87 X87 X87 X87
A-B1
G-N1
H1.5
H1.5
V1.5
V1.5
G1
A1
7 1 3 7
R1
7 1 3 4 6 F10 FUSIBILE ALIM. TERGI ANTERIORE 10A Front windhield-motor supply fuse 10A
L-N1
0 1 4 6 1 3
N1
N1
A/B1
H1.5
II I 0 0
R-G1
R-N1
F11 FUSIBILE OPTIONAL 7,5A Optional fuse 7,5A
A/V1
1
2 4 3 1 5 2 8 F12 FUSIBILE BUZZER+STR.ANTERIORE+STR.LATERALE 5A Front + lateral instruments + buzzer fuse 5A
S87
56a X147.2
8 2
X151.2
1 1 1 X58 X58 X58 X55 UNIT A6 S86 8 2 5
S88 X87 X87 X87 - - - - - - - - 1 1 F13 FUSIBILE ALIM. MANIPOLATORE10A Supply level grip fuse 10A
X59.1 X86 X86 X86 X88 X88 5 2 8 X148.1 X152.1
X53.1 X54.1 F14 FUSIBILE LAMPADE SWITCH + SWTCH OPTIONAL 10A Light switch + swicth optional fuse 10A
8 2 5 8 2
S53 S54 B59 53a
MULTIFUNCTION 01171079 F15 Fusibile elettrostop + sicurezza avviamento 10A ELETTROSTOP + SAFETY STARTER FUSE 10A
G1.5
M
56b
56a
56b
G1
53 M 53b
57
57
R
L
M-N1
A-B1
A-B1
31b F16 FUSIBILE GIROFARO 10A Beacon light fuse 10A
H-L1
H-L1
Z/N1
Z/N1
M
31 F17 FUSIBILE SWITCH EMERGENZA 10A Warning swicth fuse 10A
M55
31
31
1 1 1 F18 FUSIBILE PLAFONIERA+ACCENDISIGARI 10A Cabin lamp + cigarette lighter fuse 10A
M58
X53.2 X54.2 X59.2 E147 - - E151
NEUTRAL POSITION STEERING COLUMN
1 2 F19 FUSIBILE ANABBAGLIANTI 15A Low beam fuse 15A
X58 X55
X147.1 X151.1 1 E148 E152
N1.5
N1.5
N1.5
X148.2 X152.2 F20 FUSIBILE ABBAGLIANTI 15A Main beam light 15A
R-G1
B-R1
C-B1
FUNCTION MACHINE UNIT SUPPLY
N1
N1
N1
N1
N1
+15 MULTIFUNCTION UNIT SUPPLY
SELF CONTROL SOLENOID VALVE
N1
F21 FUSIBILE ALIM. SENSORE RETURN + DIG 10A Return sender supply + DIG fuse 10A
REVERSE PPC SOLENOID VALVE
MULTIFUNCTION UNIT SUPPLY
F22 FUSIBILE EC POWER 7,5A EC POWER FUSE 7,5A
DIFFERENTIAL LOCK SWITCH
EC POWER SOLENOID VALVE
CONSENT TOGETHER PEDAL
LIGHT PPC SOLENOID VALVE
F23 FUSIBILE +15 CENTRALINA STERZATURA 10A +15 STEERING UNIT FUSE 10A
M-B1.5
L-B0.5
LIGHTS AND SWITCH 4WD
L-N1.5
C-L0.5
A-G1.5
A-G1.5
G-N1.5
G-N1.5
G-M1
G-M1
M-N1
M-N1
M/B1
A-G1
A-G1
A-B1
A-B1
A-B1
R-G1
G-N1
C-B1
A-R1
A-N1
B-N1
H-R1
G/R1
S-G1
R-N1
H-R1
G/R1
G-V1
B-V1
A-V1
G-L1
A/R1
L-B1
H-V1
R-V1
S-N1
H-V1
R/N1
Z-B1
C-L1
H-L1
S/N1
S/N1
V/N1
V-N1
V-N1
V-N1
G1.5
Z/N1
Gnd7.1
H1.5
H1.5
V-Z1
V1.5
V1.5
M1
H/R1
G1
PPC CONTROL SWITCH
A1
A1
H1
N1
C1
N1
R1
R1
N1
S1
F24 FUSIBILE ALIM. INTERMITTENZA 7,5A FLASHER FUSE 7,5A
4WD SOLENOID VALVE
EC POWER SWITCH
F25 FUSIBILE SIRENA RETRO + ALIM. DEVIO 10A REVERSE SPEED BUZZER + STEERING COLUMN 10A
PPC SEAT SWITCH
2nd GEAR SIGNAL
X10.s 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 X9.s 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 X25.s X26.s 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 19 20 21 X44.s 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
1st GEAR SIGNAL
F27 FUSIBILE GENERALE 175A General fuse 175A
SEAT SWITCH
4WD SWITCH
OUT BUZZER
G1 Batteria Battery
X10.p 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 X9.p 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 1 2 3 4 5 6 7 8 9 X25.p X26.p 1 2 3 4 5 6 X44.p G118 Motorino avviamento Starter
R1 ACC BR R2 C 7 8 9 10 11 12 13 14 15 16 17 19 20 21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
R1OFF ACC
G119 Alternatore Generetor
A-G1.5
A-G1.5
G-N1.5
G-N1.5
CAVO1 V0.35
R-N1.5
L-B0.5
L-N1.5
C-L0.5
M-N1
G-M1
G-M1
M-N1
M-N1
ST
M/B1
A-B1
A-B1
R-G1
G-N1
B-R1
C-B1
B/G1
B-N1
H-R1
G/R1
G/R1
G-V1
B-V1
A-V1
G-L1
G-L1
A/R1
GND
H/R1
H-V1
R-V1
H-V1
R/N1
H/R1
H-L1
S/N1
V/N1
V-N1
V-N1
V-N1
V-N1
G1.5
Z/N1
N1.5
N1.5
R1.5
H1.5
H1.5
N2.5
V-Z1
V1.5
V1.5
M1
G1
G1
A1
H1
C1
R1
N1
V1
H17 BUZZER BUZZER
S24 B
X6 A1 A2 A3 A4 A5 A6 A7 A8 B1 B2 B4 B5 B6 B7 B8 C1 C2 C3 C4 C5 C6 C7 C8 K1 CENTRALINA ANTIRIPETIZIONE AVVIAMENTO Unrepeat start unit
K2 INTERMITTENZA Flasher
X24.r1 X24.acc X24.b X24.br X24.c X24.gnd
B-R1.5
G-M1
A-B1
A-B1
S1 S2 S3 S4 S5 S6
M-V1
M-V1
C-B1
B-N1
B/G1
B-R1
C-N1
K3 RELE' ANABBAGLIANTI Low beam relay
S-N1
H/R1
H/N1
Z-B1
H-L1
S/N1
Z-N1
Z/N1
L/R1
M1
N1
S1
M/N1
M/N1
N1.5
K4 RELE' ABBAGLIANTI Main beam relay
B1
R6
L6
K5 RELE' avvisatore acustico anteriore Front horn relay
K6 RELE' ELETTROVALVOLA RETURN TO DIG Return to DIG solenoid valve relay
K7 RELE' LUCI STOP Light stop relay
K8 RELE' CONSENSO AVVIAMENTO Assent start relay
C-B1
M-N1
M-V1
A-B1
M-B1
C/B1
C-N1
Z-N1
N1
N1
K9 RELE' MARCIA AVANTI Forword speed relay
K10 RELE' MARCIA INDIETRO Reverse speed relay
K11 RELE' STACCO TRASMISSIONE Stop drive relay
X158 1 N1
M-N1 X47 1 K45 Rele' preriscaldo Preheating Relay
2 A1
M-B1
C-B1 2 K56 Rele' consenso avviamento Starting relay
3 M-N1
M1
C/B1 3 K61 Rele' servizi Service realy
4 C-N1
M-B1 4 M42 Tergi posteriore Rear Windshield-washer
5 CAVO3 V0.35
C-N1 5 M55 Pompetta Motor pump
6 L-B1
Z-N1 6 M58 Motore tergi anteriore Front windshild-washer
7 G/R1
A-B1 7 M116 ElettrofrIzione compressore Compressor Electonic cluch
8 B-V1
N1 8 R114 Candelette Preheating
9 M-B1
9 S1 INTERRUTTORE FUNZIONE KICK DOWN KICK DOWN SWITCH
10 L/B1
M-V1 10 S2 INTERRUTTORE ELETTROVALVOLA EC POWER SOLENOID VALVE E.C. POWER SWITCH
11 A-R1
11 S3 INTERRUTTORE CHIUSURA BENNA LOCK GRAB SWITCH
12 H-R1
12 S4 INTERRUTTORE STACCO TRASMISSIONE DECLUCH SWITCH
42-N-06
S5 INTERRUTTORE APERTURA BENNA OPEN GRAB SWITCH
15720 S6 INTERRUTTORE BLOCCO DIFFERENZIALE DIFFERENTIAL LOCK SWITCH
H97 CLAXON POSTERIORE REAR HORN
S24 Quadro avviamento Starting switch
S40 Micro sedile Seating switch
S41 PULSANTE POSTERIORE CLAXON Rear horn Switch
L-N1.5
M/N1
C-B1
C-B1
C-B1
S46 Freno di stazionamento Parking brake switch
N1.5
A-R1
M-B1
M-B1
A-G1
B-G1
M/B1
C-L1
N1
V6
N1
B-N1
S53 Interruttore luci stop Stop light switch
C-L1
S/N1
X15p 2
B6
N1 1 2 3
S54 Interruttore stop 4wd Stop 4wd witch
M16
A-N1.5 X17.1 1 2 1 S40 86 87 X42
X15p 1 1 B A C 86 87 1 2
X61 X61 1 S57 Devio cambio Steering column gear switch
1 Y49 X49 X13 X13 X13 X555 Y48 X48 X23 X23 K45 M42
K56 X56 X56 K61 86 87 X45 S60 Devio luci Steering column light switch
V555 86 87 86 87 M M
S80 INTERRUTTORE RIDE CONTROL Ride control switch
85 30 S81 PULSANTE SBLOCCO BRACCIO Arm unlock switch
85 30
H17 B13 1 2 3 4
85 X61.1
85 30 S82 INTERRUTTORE SBLOCCO PIASTRA Plate unlock switch
2 85 X56.1 2 B S83 PULSANTE E/C POWER E/C Power Switch
P43 1 X40 V23
R6
B-N1
R16
N1
R6
S84 INTERRUTTORE VALVOLE EMPI EMPI solenoid valve switch
M-V1
X17.2
H/N1
N1
N1
N1
S85 PULSANTE AVV. ACUSTICO POSTERIORE Rear horn switch
R-G1
S86 INTERRUTTORE GENERALE LUCI General light switch
X43 1 R-G1 S87 INTERRUTTORE 4WD 4WD Switch
2 G-N1 S88 PULSANTE PPC PPC switch
15
10 20 3 R1 S89 INTERRUTTORE WARNING WARNING switch
RPM x 100
5 25 4 B-N1 S140 Interruttore fari lavoro posteriori Rear working light switch
A-G1
H-R1
G/R1
H-R1
5 H-N1 H-L1 S141 Interruttore girofaro Beacon light switch
N1.5
0 30 X160.p
6 Z-N1 H/R1 1 S142 Interruttore fari lavoro anteriori Front working light switch
R6
V6
L6
7 C-L0.5 7 6 5 4 3 2 1 G-N1 2 Y48 Ev flottante Float solenoid valve
X5.s +15Key +30 +15Service
8 C-B1 3 Y49 Ev return to d.i.g. Return to Dig solenoid valve
9 A-V1 X3.s 1 H-G1 Y60 Valvole emp. EMP Solenoid Valve
42N-06-15140 X4.s 1 R1 M-B1
4
10 B-V1 R-N1.5 2 5 Y90 Ev. PPC retro Rear PPC solenoid valve
11L-B0.5 B-R1.5 3 F25 F14 F13 F12 F24 F21 F7 F22 F18 F16 F17 2 R-N1.5 N1 6 Y91 Ev ecopower EC power Solenoid valve
13 M/N1 4 10A 10A 10A 5A 7,5A 10A 7,5A 7,5A 10A 10A 10A 3 H1 CAVO3 V0.35 7 Y92 ELETTROVALVOLA ALLARME MARCIA INDIETRO Back-up allarm solenoid valve
14 Z-B1 Z-N1 5 4 V1 8 Y93 Ev. PPC PPC solenoid valve
17 V1 B1 6 5 C1 L/B1 9 Y94 Ev blocco differenziale Lock Differential gear solenoid valve
18 V-B1 7 6 R1.5 B/N1 10 Y95 Ev sblocco braccio Arm unlock solenoid valve
19 G-V1 8 7 R1.5 B-V1 11 Y96 Ev sblocco piastra Plate unlock solenoid valve
20 N1 9 8 A-G1.5 12 Y98 Ev. chiusura benna Grab close solenoid valve
10 9 G-N1.5 Y99 Ev apertura benna Grab open solenoid valve
B-G1 11 Y117 Elettrostop Elettrostop
H-R1 12 Y200 Ev 4° marcia 4th gear solenoid valve
K2 K1
13 F23 F2 F9 F1 Y201 Ev marcia avanti Forword solenoid valve
42N-06-15130 14
F8 F11 F10 15 F15 15
Y202 Ev 1° velocita' 1st gear solenoid valve
M-B1 31 T 31 T
X27s A-R1
G1.5 15 53S53M Y203 Ev 2° marcia 2nd gear solenoid valve
1 7,5A 7,5A 10A 10A 10A
53S53M 15A 15A 15A
R/N1
A-N1
X27s C-B2.5 R/N1 16 1 Y204 Ev doppia trazione Doble traction solenoid valve
2 17 X46 Y205 Ev retromarcia Reverse speed solenoid valve
A-N1.5 S46
R-V1 18 2 1 Y206 Ev 3° marcia 3rd gear solenoid valve
X28s R4 19 X41.s X41.s X12.s CONNETTORE a linea posto guida TO DRIVER SITE HARNESS CONNECTOR
1 R-G1
20 X25.s CONNETTORE a linea posto guida TO DRIVER SITE HARNESS CONNECTOR
X28s 2 N4 21 2 X30 X26.s CONNETTORE a linea posto guida TO DRIVER SITE HARNESS CONNECTOR
S41 X44.s CONNETTORE a linea posto guida TO DRIVER SITE HARNESS CONNECTOR
X2.s 1
L/R1 I _ 1
K11 K5 K3 X77.s CONNETTORE A CETRALINA ATC26 TO ATC 26 UNIT CONNECTOR
A-G1.5 2 F5 K4
F6 F3 F4 F19 F20 X30.1 X30.2 X8.s CONNETTORE a linea posto guida TO DRIVER SITE HARNESS CONNECTOR
86 87a 87 10A 86 87a 87 86 87a 87 86 87a 87
N1
R1.5
N1.5
B-R1
G1
X10.s CONNETTORE a linea posto guida TO DRIVER SITE HARNESS CONNECTOR
R-N1 4 85 30 85 30 85 30 85 30 15A 3A 3A 15A 15A X9.s CONNETTORE a linea posto guida TO DRIVER SITE HARNESS CONNECTOR
X159 1 G-N1 L-N1.5 5
X1.s X1.s CONNETTORE a linea posto guida TO UNIT 01171062 CONNECTOR
2 H-L1 A-B1 6 1 V1.5 X10.p CONNETTORE a linea cruscotto anteriore TO FRONT DASHBOARD HARNESS CONNECTOR
3 B-L1 G-N1.5 7 2 H1.5 X11.p CONNETTORE a linea telaio TO CHASSIS HARNESS CONNECTOR
4 8 3 G1 X12.p CONNETTORE a linea telaio TO CHASSIS HARNESS CONNECTOR
5 A-N1.5 9 4 G-N1 X15.p CONNETTORE a linee optional TO OPTIONAL HARNESS
6 L1 L-N1.5 10 5 M-V1
K10 K6 K8 K9 K7 X158 CONNETTORE A LINEA CENTRALINA ATC26 TO ATC26 UNIT CONNECTOR
7 M-B1 11 D2 D3 D1 86 87a 87 86 87a 87 86 87a 87 86 87a 87 86 87a 87 6 G1 X159 CONNETTORE A LINEA CENTRALINA ATC26 TO ATC26 UNIT CONNECTOR
8 H1 H-G1 12 7
85 30 85 30 85 30 85 30 85 30 X160.p CONNETTORE A LINEA PANNELLO INTERRUTTORI TO SWITCHES PANEL HARNESS CONNECTOR
9 H-N1 M1 13 8 H1.5 X2.s CONNETTORE A LINEA CENTRALINA 01171062 TO UNIT 01171062 CONNECTOR
10 H/R1 14 9 G-N1 X25.p CONNETTORE A LINEA PANNELLO INTERRUTTORI TO SWITCHES PANEL HARNESS CONNECTOR
11 H-R1 R-G1 15 10 G-N1 X26.p CONNETTORE A LINEA PANNELLO INTERRUTTORI TO SWITCHES PANEL HARNESS CONNECTOR
12 B/N1 A-G1 16 11 G1 X27.s CONNETTORE ARIA CONDIZIONATA A/C HARNES CONNECTOR
S/N1 17
X28.s CONNETTORE RISCALDAMENTO HEATING CONNECTOR
X3.s CONNETTORE A LINEA CENTRALINA 01171062 TO UNIT 01171062 CONNECTOR
X30 Accendisigari CIGARETTE LIGHTER
X4.s CONNETTORE A LINEA CENTRALINA 01171062 TO UNIT 01171062 CONNECTOR
X44.p CONNETTORE A LINEA CABINA TO CABIN HARNESS CONNECTOR
X5.s CONNETTORE A LINEA CENTRALINA 01171062 TO UNIT 01171062 CONNECTOR
X6 CONNETTORE A LINEA CENTRALINA FUNZIONI MACCHINA TO FUNCTION MACHINE UNIT
X65.p CONNETTORE A LINEA MOTORE TO MOTOR HARNESS CONNECTOR
X7.p CONNETTORE A LINEA MOTORE TO MOTOR HARNESS CONNECTOR
X77.p CONNETTORE A LINEA ATC26 ATC26 HARNESS CONNECTOR
X8.p CONNETTORE A LINEA ATC26 ATC26 HARNESS CONNECTOR
X9.p CONNETTORE a linea cruscotto anteriore TO FRONT DASHBOARD HARNESS CONNECTOR
X11.s CONNETTORE a linea posto guida TO DRIVER SITE HARNESS CONNECTOR
42-N-06 P43 PANNELLO STRUMENTI INSTRUMENTS PANEL
N10
P63 PANNELLO DI CONTROLLO ANTERIORE FRONT CONTROL PANEL
11290
R4
R6
R6
R6
X68.2
X68.1 X68.3
Gnd11 Gnd10 Gnd9 Gnd1.3 Gnd1.2 Gnd1.1
C-B2.5
A-N1.5
R-N1.5
F27
175A 42-N-06
G-M1
B-N1
H-N1
H-L1
V-N1
N1.5
M-N1
A-B1
C-B1
A-N1
G-N1
B-R1
C-N1
C/B1
Z-B1
Z-N1
V/N1
V-N1
N1.5
N1.5
H1
L1
G1
A1
N1
11870
H-N1
S-N1
Z-B1
V-B1
A1
V1
M16
B6
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1 2 3 4 5 6 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 10 11 12
X7.p X65.p 1 X11.p X12.p X77.p X8.p
X7.s 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 X128.s 1 X126.4 X11.s 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 X12.s 1 2 3 4 5 6 X77.s 1 2 3 4 5 6 7 8 9 X8.s 1 2 3 4 5 6 7 8 9 10 11 12
G-M1
M-N1
A-B1
G-N1
G-N1
C-B1
A-N1
B-N1
42-N-06
C-N1
H-N1
C/B1
B-L1
H/R1
Z-B1
H-L1
H-L1
Z-N1
V/N1
V-N1
N1.5
N1.5
N1.5
V-Z1
C-B2.5
A-N1.5
R-N1.5
Gnd6
G1
A1
A1
B2
H1
L1
M-V1
H-N1
S-N1
Z-B1
V-B1
Z-N1
M16
42-N-06
M1
M1
B6
N6
V1
11450
11160 B0.35
V0.35
B2 X207
1
X207
2
X208
G-M1
G-N1
B-N1
1
H-N1
B-V1
B-L1
A-B1
H/R1
H-L1
G-N1
G-N1
G-N1
B-R1
B-R1
V-N1
A1
H1
N1
L1
G1
A1
N1
N1
A-N1.5
C-B2.5
R-N1.5
M-V1
H-N1
S-N1
Z-B1
V-B1
Z-N1
M16
R25
R70
R70
R25
R25
B0.35
V0.35
B6
N1
V1
X100.3
X101.3
X101.4
M-N1
C-B1
A-N1
C-N1
C/B1
Z-B1
H-L1
Z-N1
V/N1
V-Z1
X100.1
X100.2
X101.2
X100.4
X101.1
1 1 B A C
1 1 1 1 1 1 1 1 1 1 1 1 1
X103.1
- 1 1 1 1 1 X209 X209 X209 1
X119.2
X119.1 1 1 A B C 1 1 X116 1
X118.1 1 Y90 X90 Y91 X91 Y92 X92 Y93 X93 Y94 X94 Y95 X95 Y96 X96 Y98 X98 Y99 X99 X97 Y200 X200 Y201 X201 Y202 X202 Y203 X203 Y204 X204 Y205 X205 Y206 X206 X211
X117 X115 X112 X112 X112 X121
Y60 X60 M116 X210 B209
G1 R114 X114 X113 E101 B210 B211
59c
59c
57
57
E103
L
30
M
50 D+
30 G W
Y117 B115 B113 B112 B121 M
p p t
12Vcc 3 t
H97
31
31
U
G118 G119 31
2
t 2 2
2 2 2 2 2 2 2 2 2 2 - E100 2 2 2 2 2 2 2 2
X113 X90 X91 X92 X93 X94 X95 X96 X98 X99 X97 X103.2 X200 X201 X202 X203 X204 X205 X206 X211
N70
X121 X60
N1.5
N6
N1
N1
N1
N1
N1
N1
N1
N1
N1
N1
N2
N1.5
N1.5
N1
N1
N1
N1
N1
N1
N1
N1
N1
N1
N1
N1
N1
GND2.1
Gnd5 GND1.1 42-N-06
Gnd3.1 GND2.2
11280
E34000-059U
WB97R-5 90-3
© 2006 KOMATSU UTILITY EUROPE S.p.A.
All Rights Reserved
Printed in Europe 03-06
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