komatsu WB97 S-2 _SF10001_WEBM002400_U0512

7/16/2019 komatsu WB97 S-2 _SF10001_WEBM002400_U0512

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CONTENTS

WB97S-2

No. of page

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

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

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

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



00-2 WB97S-2

PAGE INTENTIONALLY LEFT BLANK



Pages having no marks are those previously revisedor made additions.

00-3WB97S-2

Mark Indication Action required

C Page to be newly Add

c Page to be replaced Replace

( ) Page to be delete Discard

LIST OF REVISED PAGES

The affected pages are indicated by the use of thefollowing marks. It is requested that necessary ac-tions be taken to these pages according to tablebelow.

Mark PageTime of

revision

Mark PageTime of

revision

Mark PageTime of

revision

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revision

Mark PageTime of

revision

00-100-200-300-400-500-600-700-800-900-1000-1100-12

00-1300-1400-1500-16

10-110-210-310-410-510-610-710-810-910-1010-1110-1210-1310-1410-1510-1610-1710-1810-1910-2010-2110-22

10-2310-24

10-2510-2610-2710-2810-2910-3010-3110-3210-3310-3410-3510-36

10-3710-3810-3910-4010-4110-4210-4310-4410-4510-4610-4710-4810-4910-5010-5110-5210-5310-5410-5510-5610-5710-5810-5910-6010-6110-6210-63

10-6410-65

10-6610-6710-6810-6910-7010-7110-7210-7310-7410-7510-7610-77

10-7810-7910-8010-8110-8210-8310-8410-8510-8610-8710-8810-8910-9010-9110-9210-9310-9410-9510-9610-9710-98

20-120-220-320-420-5

20-620-7

20-820-920-1020-1120-1220-1320-1420-1520-1620-1720-1820-19

20-2020-2120-2220-2320-2420-2520-2620-2720-2820-2920-3020-3120-3220-3320-3420-3520-3620-3720-3820-3920-4020-4120-4220-4320-4420-4520-46

20-4720-48

20-4920-5020-5120-5220-5320-5420-5520-56

30-130-230-3

30-430-530-630-730-830-930-1030-1130-1230-1330-1430-1530-1630-1730-1830-1930-2030-2130-2230-2330-2430-2530-2630-2730-2830-2930-30

30-3130-32



00-4 WB97S-2

Mark PageTime of

revisionMark Page

Time of

revisionMark Page

Time of

revisionMark Page

Time of

revisionMark Page

Time of

revision

30-3330-3430-3530-3630-3730-3830-3930-4030-4130-4230-4330-4430-4530-46

30-4730-4830-4930-5030-5130-5230-5330-5430-5530-5630-5730-5830-5930-6030-6130-6230-6330-6430-6530-6630-6730-6830-6930-7030-7130-7230-73

30-7430-7530-7630-7730-7830-7930-8030-8130-8230-8330-8430-8530-8630-8730-8830-89

30-9030-9130-9230-9330-9430-9530-9630-9730-9830-9930-10030-10130-102

40-140-240-340-440-540-640-740-840-940-1040-1140-1240-1340-1440-1540-1640-1740-1840-1940-2040-2140-2240-2340-2440-2540-2640-27

40-2840-2940-3040-3140-3240-3340-3440-3540-3640-3740-3840-3940-4040-4140-4240-43

40-44



GENERAL PRECAUTIONS

Mistakes in operation extremely dangerous.Read all the Operation and Maintenance Manual care-fully BEFORE operating the machine.

1. Before carrying out any greasing or repairs, read

all the precautions written on the decals which

are suck on the machine.

2. When carrying out any operation, always wear sa-

fety shoes and helmet. Do not wear loose work

clothes, or clothes with buttons missing.

. Always wear safety glasses when hitting partswith a hammer.

.

Always wear safety glasses when grindingparts with a grinder, etc.

3. If welding repairs are needed, always have a trai-

ned, experienced welder carry out the work.

When carrying out welding work, always wear

welding gloves, apron, glasses, cap and other clo-

thes suited for welding work.

4. When carrying out any operation with two or more

workers, always agree on the operating procedure

before starting. Always inform your fellow workers

before starting any step of the operation. Before

starting work, hang UNDER REPAIR signs on

the controls in the operator's compartment.

5. Keep all tools in good condition and learn the cor-

rect way to use them.

6. Decide a place in the repair workshop to keep

tools and removed parts. Always keep the tools

and parts in their correct places. Always keep

the work area clean and make sure that there is

no dirt or oil on the floor.

Smoke only in the areas provided for smoking.

Never smoke while working.

PREPARATIONS FOR WORK

7. Before adding or making any repairs, park the ma-chine on hard, level ground, and block the wheels

to prevent the machine from moving.

8. Before starting work, lower outrigger, bucket or

any other work equipment to the ground. If this

is not possible, use blocks to prevent the work

equipment from falling down. In addition, be sure

to lock all the control levers and hang warning

sign on them.

9. When disassembling or assembling, support the

machine with blocks, jacks or stands before star-

ting work.

10. Remove all mud and oil from the steps or other

places used to get on and off the machine. Always

use the handrails, ladders or steps when getting

on or off the machine.

Never jump on or off the machine.

If it is impossible to use the handrails, ladders or

steps, use a stand to provide safe footing.

PRECAUTIONS DURING WORK

11. When removing the oil filler cap, drain plug or hy-

draulic pressure measuring plugs, loosen them

slowly to prevent the oil from spurting out.

Before disconnecting or removing components of

the hydraulic circuit and engine cooling circuit,

first remove the pressure completely from the cir-

cuit.

12. The water and oil in the circuits are not hot when

the engine in stopped, so be careful not to get

burned.

Wait for the oil water to cool before carrying out

any work on the cooling water circuits.

00-5WB97S-2

IMPORTANT SAFETY NOTICE

Proper service and repair is extremely important for the safe operation of your machine.The service and repair techniques recommended by Komatsu Utility and describe in this manual areboth effective and safe methods of operation. Some of these operations require the use of tools specially

designed by Komatsu Utility for the purpose.To prevent injury to workers, the symbols and are used to mark safety precautions in this ma-nual. The cautions accompanying these symbols should always be carefully followed. If any danger ari-ses or may possibly arise, first consider safety, and take necessary steps to face.

SAFETY



13. Before starting work, remove the leads from the

battery. Always remove the lead from the negative

( ± ) terminal first.

14. When raising heavy components, use a hoist or

crane. Check that the wire rope, chains and hooks

are free from damage.

Always use lifting equipment which has ample ca-

pacity. Install the lifting equipment at the correct

places.

Use a hoist or crane and operate slowly to prevent

the component from hitting any other part.

Do not work with any part still raised by the hoist

or crane.

15. When removing covers which are under internal

pressure or under pressure from a spring, alwaysleave two bolts in position on opposite sides.

Slowly release the pressure, then slowly loosen

the bolts to remove.

16. When removing components, be careful not to

break or damage the wiring.

Damage wiring may cause electrical fires.

17. When removing piping, stop the fuel or oil from

spilling out. If any fuel or oil drips on to the floor,

wipe it up immediately.

Fuel or oil on the floor can cause you to slip, or

can even start fires.18. As a general rule, do not use gasoline to wash

parts. In particular, use only the minimum of gaso-

line when washing electrical parts.

19. Be sure to assemble all parts again in their origi-

nal places. Replace any damage parts with new

parts.

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

20. When installing high pressure hoses, make sure

that they are not twisted. Damaged tubes are dan-gerous, so be extremely careful when installing

tubes for high pressure circuits. Also, check that

connecting parts are correctly tightened.

21. When assembling or installing parts, always use

specified tightening torques.

When installing the parts which vibrate violently or

rotate at high speed, be particulary careful to

check that they are correctly installed.

22. When aligning two holes, never insert your fingers

or hand.

23. When measuring hydraulic pressure, check thatthe measuring tool is correctly assembled before

taking any measurement.

24. Take sure when removing or installing tracks of in

particular rubber tracks. When removing the

track, the track separates suddenly, so never let

anyone stand at either end of the wheel.

00-6 WB97S-2



00-7WB97S-2

FOREWORD

This shop manual has been prepared as an aid to improve the quality of repairs by giving the operator an ac-curate understanding of the product and by showing him the correct way to perform repairs and make judgements.

Make sure you understand the contents of this manual and use it to full effect at every opportunity.

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

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

STRUCTURE AND FUNCTIONThis section explains the structure and function of each component. It serves not only to give an understan-ding of the structure, but also serves as reference material for troubleshooting.

TESTING AND ADJUSTINGThis sections explains checks to be made before and after performing repairs, as well as adjustments to bemade at completion of the checks and repairs.Troubleshooting charts correlating «Problems» to «Causes» are also included in this section.

DISASSEMBLY AND ASSEMBLYThis section explains the order to be followed when removing, installing, disassembling or assemblingeach component, as well as precautions to be taken for these operations.

MAINTENANCE STANDARDThis section gives the judgement standards when inspecting disassembled parts.

NOTICE

The specifications contained in this shop manual are subject to change at any time and without anynotice.Contact your Komatsu Utility distributor for the latest information.



VOLUMESShop manual are issued as a guide to carry out re-

pairs. These various volumes are designed to avoidduplicating the same information.

DISTRIBUTION AND UPDATING

Any additions, amendments or other changes willbe sent to Komatsu Utility distributors.Get the most up-to-date information before you startany work.

FILING METHOD

1. See the page number on the bottom of the page.

File the pages in correct order.

2. Following examples show you how to read the pa-

ge number.

Example

3. Additional pages: additional pages are indicated

by a hyphen (-) and number after the page num-

ber.

Fle as in the example.

Example:10-4

10-4-1

10-4-2

10-5] Added pages

REVISED EDITION MARK

( 1 2 3 ....)

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

REVISIONS

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

SYMBOLS

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

Symbol Item Remarks

Safety

Special safety precautions are ne-

cessary when performing the

work.

Extra special safety precautions

are necessary when performing

the work because it is under inter-

nal pressure.

Caution

Special technical precautions or

other precautions for preserving

standards are necessary when

performing the work.

Weight

Weight of parts or systems.

Caution necessary when selecting

hoisting wire, or when working po-

sture is important, etc.

Tightening

torque

Parts that require special attentionfor the tightening torque during as-

sembly.

CoatParts to be coated with adhesives

and lubricants etc.

Oil, waterPlaces where oil, water or fuel

must be added, and their quantity.

Drain

Places where oil or water must be

drained, and quantity to be drai-

ned.

HOW TO READ THE SHOP MANUAL

HOW TO READ THE SHOP MANUAL

00-8 WB97S-2

Item number (10. Structure and

Function)

Consecutive page number for eachitem.

10 - 3



Heavy parts (25 kg or more) must be liftedwith a hoist etc. In the Disassembly and As-sembly section, every part weighing 25 kg ormore is clearly indicated with the symbol

1. If a part cannot be smoothly removed from the

machine by hoisting, the following checks should

be made:

. Check for removal of all bolts fastening the partto the relative parts.

. Check for any part causing interference with

the part to be removed.

2. Wire ropes

1) Use adequate ropes depending on the weightof parts to be hoisted, referring to the table be-low:

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

without galvanizing)

Rope diameter (mm) Allowable load (tons)

10

11.2

12.5

14

16

18

20

22.4

30

40

50

60

1.0

1.4

1.6

2.2

2.8

3.6

4.4

5.6

10.0

18.0

28.0

40.0

The allowable load value is estimated to beone-sixth or one-seventh of the breakingstrength of the rope used.

2) Sling wire ropes from the middle portion of thehook. Slinging near the edge of the hook maycause the rope to slip off the hook during hoist-

ing, and a serious accident can result.Hooks have maximum strength at the middleportion.

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

Slinging with one rope may cause turning ofthe load during hoisting, untwisting of the ro-pe, or slipping of the rope from its originalwinding position on the load, which can cau-se dangerous accidents.

4) Do not sling a heavy load with ropes forming awide hanging angle from the hook.When hoisting a load with two or more ropes,

the force subjected to each rope will increasewith the hanging angles.The table below shows the variation of allowa-ble load (kg) when hoisting is made with two ro-pes, each of which is allowed to sling up to1000 kg vertically, at various handing angles.When two ropes sling a load vertically, up to2000 kg of total weight can be suspended.This weight becomes 1000 kg when two ropesmake a 120ë hanging angle.On the other hand, two ropes are subjected toan excessive force as large as 4000 kg if theysling a 2000 kg load at a lifting angle of 150ë.

HOISTING INSTRUCTIONS

HOISTING INSTRUCTIONS

00-9WB97S-2



STANDARD TIGHTENING TORQUE


00-10 WB97S-2

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

1. STANDARD TIGHTENING TORQUE OF BOLTS AND NUT

Thread diameterof bolts

(mm)

Pitch ofbolts(mm)

Width across flat(mm)

kgm Nm kgm Nm

6

8

10

12

14

1

1.25

1.5

1.75

2

10

13

17

19

22

5

6

8

10

12

0.96w0.1

2.3w0.2

4.6w0.5

7.8w0.8

12.5w1

9.5w1

23w2

45w4.9

77w8

122w13

1.3w0.15

3.2w0.3

6.5w0.6

11w1

17.5w2

13.5w1.5

32.2w3.5

63w6.5

108w11

172w18

16

18

20

22

24

2

2.5

2.5

2.5

3

24

27

30

32

36

14

14

17

17

19

19.5w2

27w3

38w4

52w6

66w7

191w21

262w28

372w40

511w57

644w70

27w3

37w4

53w6

73w8

92w10

268w29

366w36

524w57

719w80

905w98

27

30

33

36

39

3

3.5

3.5

4

4

41

46

50

55

60

19

22

24

27

Ð

96w10

131w14

177w20

230w25

295w33

945w100

1287w140

1740w200

2250w250

2900w330

135w15

184w20

250w27

320w35

410w45

1329w140

1810w190

2455w270

3150w350

4050w450

This torque table does not apply to bolts or nuts which have to fasten nylon or other parts non-ferrous metal washer.

. Nm (Newton meter): 1 Nm = 0.102 kgm




00-11WB97S-2

Superficie di tenutaSealing surface

2. TIGHTENING TORQUE FOR NUTS OF FLARED

Use these torques for nut part of flared.

Thread diameterof nut part

(mm)

Width across flatsof nut part

(mm)

TIGHTENING TORQUE

kgm Nm

1/2" - 20

9/16" - 18

3/4" - 16

7/8" - 14

1.1/16" - 12

1.5/16" - 12

1.5/8" - 12

2233

17

17

22

27

32

38

50

2741

2.6w0.5

4w0.5

6.7w2

8w2

9.7w3

17w3

20w5

8w220w5

25.5w4.9

39.2w4.9

65.7w19.6

78.5w19.6

95.15w29.4

166.7w29.4

196.2w49

78.5w19.6196.2w49

Thread diameterof nut part

(mm)

Width across flatsof nut part

(mm)

TIGHTENING TORQUE

kgm Nm

9/16" - 18

11/16" - 16

13/16" - 16

1" - 14

1.3/16" - 12

1.7/16" - 12

1.11/16" - 12

2" - 12

17

22

24

30

36

41

50

57

2.3±2.5

3.4±3.9

5.2±5.8

8.2±9.2

12.2 ± 13.3

15.3 ± 17.3

18.4 ± 20.4

20.4 ± 24.4

23±25

33±38

51±57

80±90

120±130

150±170

180±200

200±240



00-12 WB97S-2

COATING MATERIALS

The recommended coating materials prescribed in Komatsu Utility Shop Manuals are listed below:

Nomenclature Code Applications

Adhesives

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

ASL800020Used to apply resin, rubber, metallic and non-metallic parts when a fast, strongseal is needed.

Loctite 222 Used for low resistance locking of screws, check nuts and adjustment nuts.

Loctite 242To prevent the loosening of bolts, nuts and plugs and the leakage of oil. Used formedium resistance locking of screws and nuts of every type, and for locking keysand bearings.

Loctite 262 Used for high resistant of threaded parts that can be removed with normal tools.

Loctite 270 Used for high resistant locking and for sealing threaded parts, bolts and stud bolts.

Loctite 542 Used for sealing the union threads for hydraulic tubes.

Loctite 573Used for sealing rather exact plane surfaces when the option of possible futuredismantling is required.

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

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

Gasket sealant

ASL800060Used by itself to seal grease fittings, tapered screw fittings and tapered screw fit-tings in hydraulic circuits of less than 50 mm in diameter.

Loctite 510Used by itself on mounting flat surface(Clearance between surfaces within 0.2 mm)

Loctite 518Used by itself on mounting flat surface(Clearance between surfaces within 0.5 mm)

Antifriction compound(Lubricant includingMolybdenum disulfide)

ASL800040Applied to bearings and taper shaft to facilitate press-fitting and to prevent stic-king, burning or rusting.

Grease(Lithium grease)

ASL800050Applied to bearings, sliding parts and oil seals for lubrication, rust prevention andfacilitation of assembling work.

Vaseline ± Used for protecting battery electrode terminals from corrosion.



ELECTRIC WIRE CODE

ELECTRIC WIRE CODE

00-13WB97S-2

ELECTRIC

n the wiring diagrams various colours and symbols are employed to indicate the thickness of wires.This wire code table will help you understand WIRING DIAGRAMS.Example: R -N 1.5 indicates a cable having a nominal number 1.5 and red coating with black stripe.

CLASSIFICATION BY THICKNESS

Nominalnumber

Copper wireCable O.D.

(mm)Current rating

(A)Numberstrands

ù of strands(mm)

Cross section(mm2)

1 14 0.30 0.99 2.80 11

1.5 21 0.30 1.48 3.32 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 5350 399 0.40 50.11 14.00 160

CLASSIFICATION BY COLOUR AND CODE

Primary Auxiliary

Code A 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 H-R ± ± ± ± ±

Colour Gray Gray - Blue Gray - Black Gray - Pink ± ±

Code L L-B L/B ± L/N L-G ± ± ± ± ±

Colour Blue Blue - White Blue - Black Blue - Yellow ± ±

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-N ± S-G ± ± ± ± ± ± ±

Colour Pink Pink - Black Pink - Yellow ± ± ±

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 COLOURSThe coloration of two-colour wires is indicated by the composition of the symbols listed.

Example: G-V = Yellow-Green with longitudinal colouring.G/V = Yellow-Green with transversal colouring.



WEIGHT TABLE

00-14 WB97S-2

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

Unit: kg

Machine model WB97S-2

From serial no. 97SF10001-

Engine assembly - Muffler - Exhaust pipe 410

Radiator - exchanger 37

Hydraulic tank (without hydraulic oil) 77

Fuel tank (without fuel) 73

Front counterweight 300

Engine hood 27

Cab (without seat) 595

Seat 34

Engine - gear-box - pump group 740

Piston pump 38

Transmission 230

Front axle 530

Rear axle 540

Front wheel

Rear wheel

163

163

2-spool control valve 24


Front work equipment assy.:

. Boom

. Shovel

. Fulcrum lever

. Tilt lever

. Raise cylinder

. Tilt cylinder

960

370

427

13x4

48x2

40x2

45x2

Backhoe

Work equipment assy.:

. with standard arm

. with long arm

. with jig arm

850

885

1030

Boom 323

Arm 213

Long arm 245

Boom swing bracket 133Backframe 237




Jig arm 392

Outriggers 57

Boom cylinder 78

Arm cylinder 69

Bucket cylinder 49

Outrigger cylinder 42Swing cylinder 30

Standard bucket 156



TABLE OF OIL AND COOLANT QUANTITIES

00-15WB97S-2

RESERVOIRKIND OF

FLUID

AMBIENT TEMPERATURE CAPACITY ( < )

±20 ±10 0 10 20 30ëCSpecified Refill

Crankcase sumpOIL

. API CD8.6 8.6

Hydraulic circuitOIL

. API CD150 92

Front axle

. differential

OIL

. UTTO FLUID

10.5 10.5

. final red. gear(each) 1.3 1.3

Rear axle:

. differential9 9

. final red. gear(each) 1.3 1.3

Hydraulictransmission

OIL

. GM DEXRONt

II D(DEXRONt is a registe-red trademark of GeneralMotors Corporation)

19 16

Brakingsystem 0.8 0.8

Fuel tank DIESEL OIL 130 Ð

Engine coolantsystem

WATER+ANTI-FREEZE

18 Ð

WATER 18 Ð

PERMANENTLIQUID 18 Ð

] ASTM D975 N. 1

ASTM: America Society of Testing and MaterialsSAE: Society of Automotive EngineersAPI: American Petroleum InstituteMIL: USA Military SpecificationCCMC: 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 mainte-

nance operations.

SAE 10W

SAE 20W-20

SAE 30

SAE 40

SAE 10W-30

SAE 10W-30

]

ASTM D975 N. 2



00-16 WB97S-2

NOTE:

(1) When the diesel oil sulphur content is less then 0.5%, change the engine oil according to the periodic mainte-nance intervals indicated in the operation and maintenance manual. In the diesel oil sulphur content exceeds0.5% 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 ëC, use engine oil SAE 10W, 20W-20 and 10W-30, even ifduring the day the temperature increases by 10 ëC.

(3) Use engine oil with CD classification; if oil with CD classification is used, reduce the engine oil change intervalby a half.

(4) Use original products, which have characteristics specifically formulated and approved for the engine, the hy-draulic circuit of equipment and for reductions.



10-1WB97S-2

STRUCTURE AND FUNCTION

Power train ............................................. 2

Transmission . ..... ..... ..... ..... ..... ..... ..... ..... .. 4

Drive shafts............................................. 8

Control valve block..... ... ... ... ... ... ... ... ... ... ... . 10

Front axle.............................................. 12Rear axle .............................................. 15

Steering system (4WS) ............................... 19

Steering unit....... ..... ..... ..... ..... ..... ..... ..... . 23

Hydraulic pump ....................................... 24

Hydraulic circuit....................................... 45

Shovel control valve .. ... ... ... ... ... ... ... ... ... ... .. 46

Backhoe control valve ................................ 52

CLSS... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Solenoid valve......................................... 73

Safety valve.... ..... ..... .... ..... ..... ..... ..... ..... .75

Brake pump............................................77

Shovel cylinders.......................................78

Backhoe cylinders.....................................79

Air-conditioning unit... ... ... ... ... ... ... ... ... ... ... .. 83How the air-conditioning unit functions..............84

Electrical circuit diagram (1/7)........................85









DESCRIPTION

. The driving power for the engine (1) is transmittedthrough the flywheel to the converter (2).The converter (2) uses hydraulic oil to convert thetorque transmitted by the engine (1) into driving po-wer. The converter (2) transmits motion to the driveshaft of the transmission (3) and to the drive shaftof the hydraulic pump (4).

. The transmission (3) has two hydraulically-activa-ted clutches that can be selected by an electrical-

ly-controlled gear selector. It also has manual gearselection (four forward gears and four reversegears).

. The driving power is transmitted from the transmis-sion flanges (3) to the front (5) and rear (6) axlesthrough the Cardan drive shafts (7 and 8).

. The driving power transmitted to the front (5) andrear (6) axles is reduced by the differentials andthen transmitted to the planetary gear through thedifferential shafts.

POWER TRAIN

10-2 WB97S-2

RKZ04450

1 2

3 4

5 687



Gears Transmission Differential Planetary Total

1st gear 4.374

2.75 6.923

83.273

2nd

gear 2.436 46.3773rd gear 1.232 23.455

4th gear 0.651 12.394

10-3WB97S-2

4

10

RKZ04460

6

9

8

7

5

2

3

1

1. Diesel engine

2. Convertor3. Transmission

4. Hydraulic pump

5. Front axle

6. Rear axle7. Front Cardan drive shaft

8. Rear Cardan drive shaft

9. Rear wheels

10. Front wheels



Diagram of the power train

1. Engine

2. Convertor

3. Transmission

4. Hydraulic pump

5. Rear flange

6. Front flange

TRANSMISSION

10-4 WB97S-2

RKZ04470

1

2

3

4

6

5

Z=37

Z=27

Z=27 Z=37

Z=58

Z=17

Z=51

Z=59

Z=41

Z=30

Z=58

Z=44Z=30

Z=45



1. 1st gear antishock valve

2. 1st gear filling pressure sensor (C08)

3. 1st gear clutch solenoid valve (C23)

4. 3rd gear filling pressure sensor (C10)

5. 3rd gear antishock valve

6. 3rd gear clutch solenoid valve (C25)

7. Forward clutch proportional solenoid valve (C22)

8. Reverse clutch proportional solenoid valve (C21)

9. 4th gear filling pressure sensor (C11)

10. 4th gear clutch solenoid valve (C26)

11. 4WD disengagement clutch solenoid valve (C27)

12. 2nd gear filling pressure sensor (C09)

13. 2nd

gear antishock valve14. 2nd gear clutch solenoid valve (C24)

15. Oil pressure sensor (alarm) (C07)

16. Control valve group

17. Delivery filter (10 mm)

18. Check valve: set 23 ± 26 bar

19. Plug

20. By-pass filter valve: set 3.45 bar

21. Pressure control

22. Pump

23. Engine

24. Suction filter (250 mm)

25. Convertor pressurization valve: set 5.5 bar

26. Convertor

27. Exchange

28. Transmission oil temperature sensor

Hydraulic Convertor-Transmission Circuit Diagram

10-5WB97S-2

RKZ03030

13

12 11

10

8

7

6

3

12

4

5

28

26 27

23

23

23

24

25

2120

17

1615

14

18

19

Ø 3 ,

5

Albero lato posteriore

Albero conduttore

Albero comandotrasmissione

9

Rear shaft

Drive shaft

Transmission shaft



a. From the oil cooler

b. To the oil cooler

c. To the solenoid valve group ST1 (Port P)

d. From the solenoid valve group ST1 (Port T)

1. Control valve group

2. Convertor

3. Filter

4. Plug5. Plug

6. Suction filter

7. Oil temperature sensor (C16)

8. 4th gear filling pressure sensor (C11)

9. 1st gear filling pressure sensor (C08)

10. Speedmeter sensor (C02)

11. 3rd gear filling pressure sensor (C10)

12. 2nd gear filling pressure sensor (C09)

TRANSMISSION

Views

10-6 WB97S-2

RKZ04250

Vista X

A

7

A

1 2

8

X

3

B

12

11

10

B

6

59

a

b c

d

4

View X



1. Hydraulic pump drive shaft

2. Propeller shaft

3. Reverse gears idler shaft

4. Drive shaft

5. Driven shaft

6. Flange

7. Rear output shaft

8. Front output shaft

9. 4WD engagement device

10. Flange

10-7WB97S-2

RKZ04270

1

2 3

4

5

7

6

9

Sezione A - A

10

8

Section A ± A



Drive shaft for forward and reverse movement

Drive shaft

DRIVE SHAFTS

10-8 WB97S-2

RKZ03070

1

a

5

2

b c

34

6

RKZ03090

1

a

2

3

5

4

a. Port commanding reverse clutch

b. Port commanding forward clutch

c. Lubrication port

1. Reverse gear clutch (Z=37)

2. Forward gear clutch (Z=37)

3. Reverse clutch piston

4. Forward clutch piston

5. Thrust ring

6. Driven shaft

a. Drive gear for 2nd gear

1. Drive gear 3rd gear (Z=45)

2. Drive gear 2nd gear (Z=30)

3. Drive gear 4th gear (Z=58)

4. Drive gear 1st gear (Z=17)

5. Control piston 2nd gear



Driven gear shaft

Front shaft and 4WD

10-9WB97S-2

RKZ04280

1

a

c

68

b

2

3

4

5

7

9

RKZ04290

1

6

a

23

5

4

a. Port commanding 4th gear

b. Port commanding 3rd gear

c. Port commanding 1st gear

1. Driven gear for 3rd gear (Z=44)

2. Driven gear for 2nd gear (Z=58)

3. Driven gear for 4th gear (Z=30)

4. Drive gear for 4WD (Z=51)

5. Driven gear for 1st gear (Z=59)

6. Control piston 1st gear

7. Control piston 4th gear

8. Control piston 3rd gear

9. Speedmeter disc

a. 4WD disengagement command port

1. Front output shaft

2. 4WD disengagement command piston

3. 4WD driven gear

4. Rear output shaft

5. Piston (No. 3)

6. Spring



CONTROL VALVE BLOCK

10-10 WB97S-2

ELECTRICAL COMPONENT

1. C24 - 2nd gear clutch solenoid valve

2. C27 - 4WD disengagement clutch solenoid valve

3. C26 - 4th gear clutch solenoid valve

4. C21 - Reverse clutch proportional solenoid valve

5. C22 - Forward clutch proportional solenoid valve

6. C25 - 3rd gear clutch solenoid valve

7. C23 - 1st gear clutch solenoid valve

8. C07 - Oil pressure sensor (alarm)

CHECK POINT

a. 2nd gear pressure

b. Torque converter pressure

c. 4WD disengagement pressure

d. 4th gear pressure

e. General oil clucth pressure

f. Reverse clucth pressure

g. Forward clucth pressure

h. 3rd gear pressure

l. 1st gear pressure

RKZ03100

b

7654321

8

e f g

a c d h l



10-11WB97S-2




1. Planetary gear

2. Ring bevel gear (Z=31)

3. Bevel gear

4. Lock nut

5. Half-axle

6. Pin

7. Differential housing8. Spacer

9. Bearing

10. Seal

11. Flange

12. Lock nut

13. Bearing

14. Bevel pinion (Z=13)

15. Pin16. Oil drain plug

FRONT AXLE

Differential

10-12 WB97S-2

RKZ04260

2

1

3

1

4

5

6

7

8

9

1011

12

13

14

15

16



1. Planetary carrier

2. Planetary

3. Ring gear

4. Ring gear carrier

5. Wheel hub

6. Seal

7. Pin

8. Shim

9. Protection10. Bushing

11. Seal

12. Axle body

13. Bearing

14. Joint

15. Pin

16. Protection

17. Seal

18. Bearing

19. Snap ring

20. Steady pin21. Stud bolt

22. Plug

Final reduction-Joint

10-13WB97S-2

RKZ04300

2

3

21 4 5

69

8

10

11

7

12

13

14

141617181920

22

1



1. Steady pin

2. Oil refilling plug

3. Oil drain plug

4. Nut

5. Adjustment screw

6. Nut7. Bushing

8. Bushing

Port a - From the steering unit (Port L)

Port b - From the steering unit (Port R)

Steering cylinder

10-14 WB97S-2

RKZ04380

A

7

8

A

A

ab

B

B

4

Sezione A - A

1

2 3

56

Particolare ASezione B - BSection A ± A Section B ± B Detail A



1. Bearing

2. Planetary gear

3. Bevel gear

4. Ring bevel gear

5. Differential housing

6. Lock nut

7. Half-axle

8. Pin

9. Bearing

10. Lock nut

11. Seal

12. Flange

13. Spacer

14. Bevel pinion (Z=13)

15. Differential housing

16. Friction disc

17. Steel disc

REAR AXLE

Differential

10-15WB97S-2

RKZ04400

1 2 34 5 6

77

8

9

10

12 11

13

14

15 1716



1. Support

2. Planetary gear

3. Crown

4. Support

5. Hub

6. Gasket

7. Pin

8. Washer

9. Protection10. Bushing

11. Gasket

12. Axle body

13. Bearing

14. Joint

15. Pin

16. Protection

17. Gasket

18. Bearing

19. Ring

20. Centering pin21. Stud

22. Plug

Final Reduction

10-16 WB97S-2

RKZ04410

2

3

21 4 5

6 98

10

11

12

13

14

141617181920

22

1

7



1. Spring

2. Bushing

3. Parking brake control rod

4. Bleeder valve

5. Parking brake lever

6. Parking brake control cam

7. Brake disk

8. Bushing

9. Service brake piston

10. Pressure disk

11. Center reaction plate

12. Spacer

Brakes

10-17WB97S-2

RKZ04420

2

3 1 A

4 5

6 10 11 712 8

9

Particolare ADetail A



1. Steering cylinder

2. Nut

3. Screw

4. Nut

c Port - From ST2 solenoid valve group (A port)

d Port - From ST2 solenoid valve group (B port)

e Port - From brake pump

Steering cylinder

10-18 WB97S-2

RKZ04440

A

A

Acd

e e

2

Sezione A - A

1

34

Particolare ASection A ± A Detail A



1. Engine

2. Pump (P2)

3. Tank

4 Priority valve

5. Control valve

6. Steering unit

7. Steering wheel

8. ST2 Solenoid valve group:

± Y1: Rear steering cut out

± Y2: Front/rear steering

± Y3: Phase coincidence steering

± Y4: Crab steering

9. Front axle steering cylinder

10. Rear axle steering cylinder

DESCRIPTION. The steering system is completely hydraulic. The

oil required, supplied by the pump (2) driven bythe motor (1), is sent to the priority valve (4) whichfunctions by Load Sensing, and sends the neces-sary quantity of oil to the steering system (6), evenwhen other oleodynamic components supplied bythe same circuit are in operation. The oil passesfrom this group (6) into the steering cylinders (9)and (10).The solenoid valve group (8) can switch the oil flowto provide three types of steering:

1 - 2 wheels steering

Steering condition in which the rear axle is ex-cluded.

2 - 2 wheels steering and 2 wheels counter-steering. Steering condition in which rearsteering is activated and the direction of therear wheels is contrary to that of the frontwheels.

3 - 4 wheels steering in the same direction.Steering condition in which rear axle steeringis activated and the direction of the rearwheels agrees with that of the front wheels.

. The hydraulic power supplied by the pump (2) istransferred to cylinders (9) and (10) and transfor-

med into mechanical steering power.

STEERING SYSTEM (4WS)

10-19WB97S-2

9

b

a

B

A

PT

5

7

6

Y2

L R

T

Y4

Y3Y1

8

B

A

c

d

C

D

10

RKZ04480

DLS

3

2

4

1

P



STEERING TO THE RIGHT

Turning the steering wheel (7) clockwise causes rota-tion of the steering metering group (6) and prepares

the control valve (port R) to send oil through line e di-rectly into chamber b of the cylinder (9); the pressuri-zed oil moves the piston which then steers thewheels.The oil in chamber a of cylinder (9) is impelled into linef to solenoid valve group and thence into line g whichis coupled to the control valve of the steering group (6)(port L); from the control valve the oil passes out ofPort T and drains into the tank (3).

STEERING TO THE LEFT

Turning the steering wheel (7) anti-clockwise causesrotation of the steering metering group (6) and prepa-

res the control valve (port L) to send oil through line gto solenoid valve group and thence through line f, intochamber a of the cylinder (9); the pressurized oil mo-ves the piston which then steers the wheels.The oil in chamber b of cylinder (9) is impelled into linee which is coupled to the control valve of the steeringgroup (5) (port R); from the control valve the oil passesout of Port T and drains into the tank (3).

OPERATION

1 - Steering with front wheels, only.

10-20 WB97S-2

Y2

Y4Y3

Y1

RKZ04490

9

AB

ab

e

f

L

R P

T

7

4

6 3

2

5

g

Y2

Y4Y3

Y1

RKZ04500

9 ab

e

f

L

R P

T

7

4

6 3

2

5

g

AB




Turning the steering wheel (7) clockwise causes rota-tion of the steering metering group (6) and preparesthe control valve (port R) to send oil through line e di-

rectly to chamber b of cylinder (9).The pressurized oil moves the piston of cylinder (9)which in turn steers the wheels while simultaneouslyimpelling the oil in chamber a (at the same pressureas chamber b, through lines f - h into chamber d of cy-linder (10).The oil in chamber c of cylinder (9) is impelled throughlines i and g to the control valve of the steering group(port L) from which it passes (port T) to drain into thetank (3).


Turning the steering wheel (7) anti-clockwise causesrotation of the steering metering group (6) and prepa-res the control valve (port L) to send oil (through line g)

to solenoid valve group and thence through line i intochamber c of cylinder (10).The pressurized oil moves the piston of the cylinder(10) that steers the wheels and at the same time im-pels the oil in chamber d (at the same pressure aschamber c), through lines h and f into chamber a ofcylinder (9).The oil in chamber b of cylinder (9) is impelled throughline e to the control valve of the steering group (portR), from which it passes (port T) to drain into the tank(3).

2 - Steering with 2 wheels steering and 2 wheels countersteering

10-21WB97S-2

Y2

Y4Y3

Y1

RKZ04510

9

AB

ab

e

f

L

R P

T

7

4

6 3

2

5

g

DC

10c d

h

i

Y2

Y4Y3

Y1

RKZ04520

9

AB

ab

e

f

L

R P

T

7

4

6 3

2

5

g

DC

10c d

h

i




Turning the steering wheel (7) clockwise causes rota-tion of the steering metering group (6) and preparesthe control valve (port R) to send oil through line e into

chamber b of cylinder (9).The pressurized oil moves the piston of cylinder (9)which in turn steers the wheels while simultaneouslyimpelling the oil in chamber a (at the same pressureas chamber b) through lines f and i into chamber cof cylinder (10).The oil in chamber d of cylinder (10) is impelledthrough lines h and g to the control valve of the stee-ring group (5) (port L) from which it passes (port T) todrain into the tank (3).


Turning the steering wheel (7) anti-clockwise causesrotation of the steering metering group (6) and prepa-res the control valve (port L) to send oil (through line g)

to solenoid valve group and then through line h intochamber d of cylinder (10).The pressurized oil moves the piston of the cylinder(10) that steers the wheels while simultaneously impel-ling the oil in chamber c (at the same pressure aschamber d) through lines i and f into chamber a ofthe cylinder (9).The oil in chamber b of cylinder (9) is sent through linee to the control valve of the steering group (port R)from which the oil passes (port T) to drain into the tank(3).

3 - Steering with 4 wheels steering in the same direction

10-22 WB97S-2

Y2

Y4Y3

Y1

RKZ04530

9

AB

ab

e

f

L

R P

T

7

4

6 3

2

5

g

DC

10c d

h

i

Y2

Y4Y3

Y1

RKZ04540

9

AB

ab

e

f

L

R P

T

7

4

6 3

2

5

g

DC

10c d

h

i



a. Port L - To the steering cylinder (Port a)

b. Port R - To the steering cylinder (Port b)

c. Port T - To the hydraulic oil tank

d. Port P - From control valve (Port D)e. Port LS - From control valve (Port DLS)

TECHNICAL DATASteering unit type: OSPC160LSDelivery: 16 ,/min

OPERATION

. The steering unit is composed of a control valveand a rotating oil dispenser, and is of the hydrosta-tic type.

. When the steering wheel is turned, the control val-ve sends oil from the pump P2 (by means of the ro-tating oil dispenser) of the steering cylinder. The ro-tating dispenser ensures that the volume of oil sup-plied to the cylinder is proportionate to the angle ofrotation of the steering wheel.

. In the event of malfunction, the oil dispenser willfunction automatically as a hand-pump, thus gua-

ranteeing emergency steering.

STEERING UNIT

10-23WB97S-2

RKP03740

L

T

R

P

LS

a e b

c d



1. Delivery variation group

2. Working mode selection solenoid valve (Y1)

3. Delivery control valve

a. Port L1 - To the intake flange (Spool Port)

b. Port B - To the shovel control valve (Port P)

c. Port X2 - From the shovel control valve(Port LS)

d. Port L - To the hydraulic oil tanke. Port S - To the hydraulic oil tank

HYDRAULIC PUMP

10-24 WB97S-2

3A

A

BB

D

RKZ00401

b

e

a

c

d

D

2

1



1. Seal

2. Bearing

3. Central spring

4. Bearing5. Control rod

6. Swash plate

7. Positioning piston

8. Spring

9. Cylinder block

10. Positioning piston11. Piston

12. Guide shoe

10-25WB97S-2

RKZ00380101112

7 8 9

6

2

1

5

43C C

Sezione B - B

Sezione A - ASection A ± A

Section B ± B



POWER GOVERNOR

1. Spring

2. Piston rod

3. Bushing

4. Initial adjustment spring

5. Spring

6. Pressure cut calibration screw

7. Initial adjustment calibration screw

PC VALVE

8. Spool9. Spring (internal)

10. Spring (external)

LS VALVE

11. External spring

12. Internal spring

13. Throttles

14. Throttles

15. Spool

10-26 WB97S-2

RKZ00640

Sezione C - C

Sezione D - D

1 4

6

5

1112131415

3

10

7

98

2

Section C ± C

Section D ± D



FUNCTION

. The rotation and torque transmitted to the pumpshaft is converted into hydraulic energy and pres-surized oil is delivered according to the load requi-rements.

. The amount of oil delivered can be modified bychanging the angle of the swash plate.

STRUCTURE

. The cylinder block (6) is supported and connectedto the shaft (1) by the spline a and the shaft (1) issupported by the front and rear bearings.

. The tip of the piston (6) is ball-shaped. The shoe (4)is caulked to it to form one unit in such a way thatthe piston (5) and the shoe (4) together form a sphe-rical bearing.

. The swash plate (3) has a flat surface A and theshoe (4) remains pressed against this surface whilesliding in a circular movement.The swash plate brings highly pressurized oil ontothe cylindrical surface B fashioned in the pump bo-dy (2), which means that the swash plate (3) slides

on a hydrostatically-supported bearing.

. The pistons (5) perform their relative movements inan axial direction, inside cylindrical chambers fas-hioned in the cylinder block (6).

. The oil is brought up to pressure in the chambers ofthe cylinder block (6) by the rotatory movement ofthe block itself. The areas of pressure and suctionare determined by the swash plate (7).The surface of the swash plate is so designed thatthe oil pressure always remains within acceptablelimits.The oil in each chamber is drawn in and dischargedthrough holes in the valve plate (7).

10-27WB97S-2

RKZ01120

1 2 3 4 5 6 7

B A a



OPERATION

1. Pump operation

1 - The cylinder block (7) rotates together with theshaft (1) and the shoe (4) slides on the flat sur-face «A». The swash plate (3) moves along thecylindrical surface «B». The angle «a» formedbetween the center line of the shaft (1) andthe center line X of the swash plate (3) chan-ges, thus modifying the axial position of the pi-stons in relation to the cylinder block.The angle «a» is known as the swash plate an-gle.

2 - When the center line X of the swash plate (3)maintains the angle «a» in relation to the cen-ter line of the shaft (1), and hence also of thecylinder block (6), the flat surface A acts as a

cam for the shoe (4). As the piston (5) rotatesand slides inside the cylinder block (6), it the-refore creates a difference between the volu-mes C and D which provokes intake and di-scharge of the oil in quantities equal to the dif-ference between the volumes (D ± C=delive-ry).In other words, as the cylinder block (6) rota-tes, chamber D loses volume while the volumeof chamber C is increased, thus provoking anintake of oil.(The figure indicates the state of the pumpwhen the intake of chamber D and the deliveryof chamber C have been completed).

3 - When the center line X of the swash plate (3)and the center line of the cylinder block (6)are perfectly aligned (the swash plate angle«a»=0), the difference between the volumesC and D within the cylinder block (6) becomes0 and the pump does not take in or deliver anyoil. (In practice the swash plate angle «a» ne-ver becomes=0)

4 - In other words, pump delivery is directly pro-portional to the swash plate angle «a».

10-28 WB97S-2

RKZ01100

5 61 43 A D

B C

␣

X

RKZ01110

2 5 D

C

X

␣ = 0



2. Control of Delivery

. As the swash plate angle «a» grows larger, thedifference between volumes C and D increases,and the delivery Q also increases.The swash plate angle is modified by servo-pi-stons (8) and (9).

. The servo-piston (8) moves in a reciprocating li-near motion ( ) caused by pressure signalsfrom the PC and LS valves.The linear movement is transmitted to theswash plate (3), which is supported by the cylin-drical surface of the cradle (7). The swash platetherefore has a semi-circular reciprocating mo-vement ( ).

. The surfaces of the servo-pistons receiving the

pressures PP

and LS are dissimilar. The delive-ry pressure PP of the main pump is always pas-sed into the smaller (upper) pressure chamber,whereas the pressure PEN coming from the LSvalve is passed into the larger (lower) pressurechamber.The movement of the servo-piston is governedby the relationship between pressures PP andPEN, as well by the proportions between the sur-faces (larger and smaller) of the servo-piston.

10-29WB97S-2

RKZ01130C

2 3

8

D

␣

9



SERVO-PISTON

1. Spring

2. Servo-piston

3. Servo-piston

LS VALVE4. Piston

5. Spring

PC VALVE

6. Servo-piston

7. Spring

2. PC VALVE, LS VALVE SERVO-PISTON

10-30 WB97S-2

RKZ01140

Distributore

4

6

5

7

1

3

2

All'utilizzo

Control valve

To the actuator



LS VALVE

FUNCTION

. The LS valve controls the pump delivery accordingto the stroke of the control valve level, i.e., in func-tion of the delivery demands made by the actua-tors.

. The LS valve detects the actuator's delivery needsby means of the differential pressure DPLS existingbetween the pump delivery pressure PP and thepressure PLS coming from the control valve. Thisreading permits control of the main pump deliveryQ.(PP, PLS and DPLS are, respectively, the pumppressure, the Load Sensing pressure, and the diffe-rence in pressure between these two values).

. In other words, the LS valve detects the pressuredifference DPLS generated by the passage of theoil flow through the surface freed by the control val-ve spool, and controls the pump delivery Q so as tokeep the pressure drop constant.

. It can therefore be assumed that the pump deliveryis proportional to the demands made known by thecontrol valve.

10-31WB97S-2



. The pressure PLS of the LS coming from the controlvalve outlet passes into chamber a of the spring of

the LS valve. The pressure PP of the pump passesinto chamber b of the opposite side.

. The piston rod movement (4) is determined by thecombination of the force generated by the pressurePLS, the force of the spring (6) and the force gene-rated on the side opposite the piston rod by thepressure PP.

. Before the engine is started the servo-piston (3) ispushed to the right by the spring (1) (correspondingto the maximum angle of the swash plate).

. If all the control valve spools are in their «NEU-TRAL» position when the engine is started, the

pressure PLS of the LS will remain at 0 bar (0 bar)because no oil is flowing through the control valve.

At the same time the pump pressure PP increasesand is maintained at a value of about 21 bar (21.3

kg/cm2).

. For this reason the piston (4) is thrust to the right( ) and a passage is formed between the deliverylines c and d. This opening enables the pump pres-sure PP to enter chamber X of the servo-piston (3).

. Although the pump pressure PP is always passedinto chamber Y of the servo-piston (2), since the for-ce exerted by that pressure on piston (3) exceedsthe force exerted on piston (2), the servo-piston(1) moves to the right ( ), i.e. towards the sideof the minimum angle of the swash plate.

OPERATION

1. When the control valve is in a «NEUTRAL» position.

10-32 WB97S-2

RKZ01150

All'utilizzo

T PLSPP

PP

Min Max

Distributore

c

4

b

d a 6

1

2

3

Y

XM

To the actuator

Control valve



2. When a control valve lever is activated

. When the control valve lever is moved out of itsNEUTRAL position, the opening f is determined, al-lowing an LS signal to be generated.

. Until the DPLS generates a force less than the forceexerted by the spring (6) on the spool (4), the sy-stem will remain stable.When the opening f is such as to provoke a reduc-tion in DPLS, the spool (4) moves to the left ( ) toform a passage between delivery lines d and e. Thechamber X loses pressure and the servo-piston

causes the swash plate to move towards maximumdisplacement.

. Equilibrium is re-established in the system whenthe pressure DPLS generates on the spool (4) thedifference in force exerted by the spring (6), andthe passage between delivery lines c and d is re-opened.

10-33WB97S-2

RKZ01160

c

4

b

d a 6

1

2

3

Y

X

PP

M

Min Max

T PLSPP

e

All'utilizzo

Distributore

To the actuator

Control valve



3. When the control valve opening is at its maximum (lever at the end of its stroke)

. When the control lever is moved to full stroke, inother words, when the spool opening reaches itsmaximum, the difference between the pump pres-sure PP and the LS pressure PLS becomes smaller(differential pressure DPLS).

. The LS pressure PLS introduced into the chamber aof the LS valve becomes about the same as thepump pressure PP and the piston (4) is moved tothe left ( ) by the combined forces generatedby the pressure PLS and the spring (6).The piston movement closes the delivery line c andforms a passage between lines d and e.

. The pressurized oil present in the chamber X of theservo-cylinder (3) flows through the lines d and eand reaches the pump drainage chamber, so thatthe pressure in chamber X of the servo-cylinder(1) becomes equal to the drainage pressure.

. The servo-piston (3) is thus moved to the right ( )by swash plate movement due to the pressure PP inthe chamber Y of the servo-cylinder (2).In other words, it is drawn in the direction of the in-crease in angle of the swash plate.

10-34 WB97S-2

RKZ01160

c

4

b

d a 6

1

2

3

Y

X

PP

M

Min Max

T PLSPP

e

All'utilizzo

Distributore

To the actuator

Control valve



4. When the spool makes very small movements (fine-control)

. When the control valve lever moves in very smallincrements towards the «NEUTRAL» position, i.e.when the control valve opening f diminishes, thedifferential pressure DPLS between the pump pres-sure PP and the LS pressure PLS increases.

. If the differential pressure DPLS generates on thespool (4) a difference in force that exceeds the for-ce exerted by the spring (6), the spool moves to theright ( ) and a passage is formed between the de-livery lines c and d. The pressure PP is introducedinto the chamber X and the swash plate moves to-wards its minimum angle.

. When the control valve lever performs small move-ments towards the position of maximum opening,

i.e. when the opening f of the control valve increa-ses, the differential pressure DPLS diminishes.

. If the differential pressure DPLS generates on thespool (4) a force difference that does not exceedthe force exerted by the spring (6), the spool (4) mo-ves to the left ( ) and a passage is formed bet-ween the delivery lines d and e.The chamber X loses pressure and the servo-pistonprovokes a movement of the swash plate towardsmaximum displacement.

. Equilibrium is re-established in the system whenthe pressure DPLS generates on the spool (4) the

difference in force exerted by the spring (6), andhence the passage between delivery lines c andd is also re-opened.

10-35WB97S-2

RKZ01170

c

4

b

d a 6

1

2

3

Y

X

PP

M

Min Max

T PLSPP

e

All'utilizzo

Distributore f

To the actuator

Control valve



5. When pump flow matches the demands of the control valve

. Let A1 be the surface of the servo-piston (3), A2 thesurface of the servo-piston (2), PEN the pressure ac-ting on the piston (1) and PP the pressure acting onthe piston side (2).

. When pump delivery reaches the quantity deman-ded by the control valve, the pump pressure PP inchamber b of the LS valve is in equilibrium withthe combined forces of the LS pressure PLS inchamber a, and the force exerted by the spring (6).Once equilibrium has been reached the piston (4)stops in the central position.

. In this condition the passage from chamber c tochamber d remains only slightly open in order to

maintain pressure in chamber d.

A flow of oil is introduced into the servo-cylinder (3)

at a pressure that balances the force generated by

the pump pressure PP in the cylinder (2)(PEN x A1=PP x A2).

. The stability of the equilibrium is guaranteed by aflow stabilized by the throttle g.

. The force of the spring (6) is regulated so that thepiston (4) is in equilibrium whenPP ± PLS=DPLS=18 bar (18.4 kg/cm2).

. In practice, the pump flow is made proportional tothe section of the opening of the control valve,which maintains the differential pressureDPLS=18 bar (18.4 kg/cm2).

10-36 WB97S-2

RKZ01180

A1

A2

c

4

b

da 6

1

2

3

Y

X

PP

M

Fermo

T PLSPP

e

PEN

PP

All'utilizzo

g

Distributore

To the actuator

Control valve

Hold



PC VALVE

FUNCTION

. The PC valve performs an approximate powercheck, and ensures that the hydraulic horse-powerabsorbed by the pump does not exceed the horse-power delivered by the endothermal engine.This is achieved by limiting the pump delivery Q infunction of the delivery pressure PP, even if the LSvalve requests an increase in delivery Q due to thelarger section freed by the control valve spool, inthe presence of high pressure pump delivery.

. In other words, when during operation the deliveryQ increases and the delivery pressure PP also in-creases simultaneously, the PC valve reduces thepump delivery Q. When the delivery pressure PP

decreases, the PC valve increases the pump flow.. The relationships between the pump delivery pres-

sure PP and the delivery Q are shown in the dia-gram.

10-37WB97S-2

RKP01180

Pressione pompa

P o r t a t a p o m p a Q

PP

P u m p d i s c h a r g e a m o u n t Q

Pump discharge pressure PP



OPERATION

1. When the load on the actuators is heavy (high pump delivery pressure)

. When a higher delivery is required, the LS valve re-ceives a signal from the control valve to bring thepump up to maximum displacement.When the swash plate moves it also moves the bus-hing (2) joined to it (by the pin (1)), which releasesthe spring (3). As the pressure of the actuators in-creases, pressure also increases in the delivery li-ne c. When the calibrated setting of the spring (3)is reached, the piston rod (4) is thrust to the left( ) and the passage between chamber b and

the pump drainage chamber a is opened.. The opening of the passage between the chambers

b and a generates a flow of oil and hence, due tothe calibrated hole (6), a DP is generated betweenchambers f and g at the sides opposite the spool(5). (DP=PP ± PPC)

. When the value of PP exceeds the value of thespring loading (7) the spool (5) moves to the right( ), opening the passage between the delivery li-nes d and e and sending the pump pressure PP to-wards the servo-cylinder (8).

. The pressure PP introduced into chamber X of thecylinder (8) pushes it towards the minimum angleof the swash plate ( ).

10-38 WB97S-2

RKZ01190

TPENPP LS

5 7

Max

PP

Min

M

PPC

PPC

∆ p6f

e

d

g

3 a b 4

2 1

8 X

All'utilizzo

c

Distributore

To the actuator

Control valve



2. When equilibrium has been reached

. When the piston (8) is pushed to the left ( ) thebushing (2) is also moved.The oil flow between the chambers b and a is redu-ced and the PPC pressure tends to approach the PP

pressure value.The DP decreases and the spool (5) is pushed tothe left ( ) by the force of the spring (7).

. Equilibrium is reached when the force generated bythe PP pressure, the force generated by the PPC

pressure, and the force of the spring (7) are all ba-lanced. (The force generated by PP=the force ge-nerated by the PPC+ the spring force (7)).

. In this condition the passage from chamber d tochamber e remains only slightly open in order tomaintain pressure in chamber e. A flow of oil is in-troduced into the cylinder (8) at a pressure that ba-lances the force generated by the pump pressurePP acting on the cylinder (9). (PEN x A1=PP x A2)

. The stability of this equilibrium is generated by acontinuous stabilized flow from the throttle (10).

10-39WB97S-2

RKZ01200

A1

A2

5 7

PP

Fermo

M

PPC

PPC

∆ p6f

e

d

g

a b 42

8 X

PENPP LS

9

10

c

All'utilizzo

Distributore

To the actuator

Control valve

Hold



3. When the load on the actuators decreases (pump delivery pressure drops)

. When the load on the actuators diminishes and thepump delivery pressure PP drops, the PPC. pressu-re also drops.

. The reduction in the PPC causes the spool (4) tomove and the passage between chambers b, dand a is closed.The PPC pressure and the PP pressure of the pumpare equalised due to the interruption of the oil flowthrough the calibrated hole (6) and hence the DP

becomes zero (DP=PP ± PPC=0).

. The spring (7) pushes the spool (5) to the left ( ),closing the passage between the chambers d and eand opening the passage between chambers e and g.

. The pressurized oil present in chamber X of theservo-cylinder (8) passes through chambers e andg and reaches the pump drainage chamber, so thatthe pressure in chamber X of the servo-cylinder (7)becomes equal to the drainage pressure.

. Therefore the servo-piston (7) is caused to move bythe PP pressure in chamber Y of the servo-cylinder(9), i.e. in the direction of the increase in the angleof the swash plate.

10-40 WB97S-2

RKZ01210

5 7

PP

Fermo

M

PPC

PPC

6

e

d

a b 4

8 X

PENPP LS

c

g

9Y

All'utilizzo

Distributore

To the actuator

Control valve

Hold



4. The function of the spring

. The loading on the springs (3) and (11) of the PCvalve changes in proportion to the angle of inclina-tion of the pump swash plate.

. The compression of the spring (3) varies with themovements of the servo-piston (8).

. When the piston (8) moves to the left ( ) thespring (3) is compressed.If the piston (8) moves even further to the left ( ),the spring (11) comes into action to increase theloading.In other words, the overall loading of the springs isvaried by the piston (8), which either compresses orreleases them.

. The pump absorption torque curve, which indicates

the relationship between the pump delivery pressu-re PP and the delivery Q, is a broken line (as illu-strated in the diagram).

10-41WB97S-2

TPLSPP LS

RKZ01220

8

3 11 4

All'utilizzo

Distributore

M

To the actuator

Control valve

RKZ01240

Pressione pompa

P o r t a t a p o m p a Q

Molla (3) + molla (11)

Molla (3)

PP

P u m p d i s c h a r g e a m o u n t Q


Spring (3)+spring (11)

Spring (3)



. The position in which the piston (8) stops, i.e. thepump absorption torque, is determined by the posi-tion in which the PPC pressure applied to the spool

(4) is balanced by the force exerted by the springs(3) and (11).

. In practice, as the pump delivery pressure PP in-creases, the delivery Q decreases, and as the pres-sure PP diminishes the pump delivery Q increases.

10-42 WB97S-2



WORKING MODE SOLENOID VALVE

FUNCTION

. Calibration of the pump absorption torque is nor-mally performed for the working mode E.When the solenoid valve of the working mode iscommutated the absorbed power of the pump is in-creased, as indicated by the working mode curve.

OPERATION1. WORKING MODE E (Economy)

. During normal operation (Working mode E), the PCvalve intervenes when a DP1 is generated equal tothe loading on the spring (4).

. The DP1 is generated by the calibrated hole (3) inthe spool of the PC valve (2) when, at a determinedpump delivery pressure P1, the valve (1) puts the

delivery line a into discharge, thus generating aflow F1 in the delivery line a.

10-43WB97S-2

RKZ01250

P o r t a t a p

o m p a Q

Pressione pompa PP

Working mode P

Working mode E

P u m p d i s c h a r g e a m

o u n t Q


RKZ01230

∆P1

a

3 42

5

1

6



2. WORKING MODE P (Power)

. When the solenoid valve (6) is commutated (Wor-king Mode P) the pressurized oil coming from thepump changes its route and passes through thethrottle (5), which has a larger diameter than the ca-librated hole (3).

. Because the throttle (5) has a larger diameter, theDP2 generated is less than is needed to overcomethe force generated by the spring (4). The spoolof the PC valve (2) is therefore pushed to the left( ) by the force of the spring (4).

. This shift obliges the pump to increase displace-ment and hence the delivery (See «PC VALVE: 3.When the load on the actuators decreases» thirdparagraph).

. The increase in flow causes an increment of theDP2 which, when the loading value of the springis reached, allows the spool to shift to the right( ).

. The pump starts to work in normal fashion onceagain, and all the valves recommence normal func-tioning.

10-44 WB97S-2

RKZ01320

∆P2

3 42

5

1

6



HYDRAULIC CIRCUIT

WB97S-2

S L1 L

B

X1 X2

Arm Bucket

DLS

T P

Hammer Arm Boom swing L.H. outrigger Bucket

Addiequip

L R

R.H. outrigger

21bar

245bar

235bar

240bar

5 bar

5 bar

230bar

-50200

bar

DLS

P

T

LS D B1 A1 B2 A2 B3

b

a

b

aa

T B A T T B

b

b

a

A6B6

A

B

T

T

A5B5

b

a

A4B4A3B3

b

a

b

a

AB TTA T

A2B2

b

a

A1B1

b

a

A T

LS1MP2T1

PT

LST

T2

235bar

175bar

240bar

175bar

245bar

235bar

165bar



o

SHOVEL CONTROL VALVE

2-Spool

10-46

1 2

a

B

B

Sezione A - ASection A± A

a. Port D - To the hydraulic steering unit (P

b. Port A2 - To the bucket cylinders (Head si

c. Port A1 - To the shovel-raising cylinders(Base side)

d. Port LS - To the pump (Port X2)

e. Port T - To the hydraulic oil tank

f. Port P - From the pump (Port B)

g. Port B1 - To the shovel-raising cylinders(Head side)

h. Port B2 - To the bucket cylinders (Base si



1. Plug

2. Raising command spool

3. Spool return spring

4. Compensator

5. Antishock/anticavitation valve

6. Bucket dump command spool

7. Spring

8. Check valve

10-47WB97S-2

6

5

5

RKZ00660

Sezione C - C

Sezione D - D

E

E

Sezione E - E

E

E

4

1

3

2

3

4

7 8

87

Section C ± CSection D ± D

Section E ± E



a. Port D - To the hydraulic steering unit (Port P)

b. Port A3 - To the auxiliary equipment (Left side)

c. Port A2 - To the bucket cylinders (Head side)

d. Port A1 - To the shovel-raising cylinders(Base side)

e. Port LS - To the pump (Port X2)

f. Port T - To the hydraulic oil tank

g. Port P - From the pump (Port B)

h. Port B1 - To the shovel-raising cylinders(Head side)

i. Port B2 - To the bucket cylinders (Base side)

l. Port B3 - To the auxiliary equipment(Right side)

1. Plug

2. Plug

3. Ball

4. Spring

5. Priority valve piston rod

6. Priority valve spring

7. Plug

3-Spool control valve

10-48 WB97S-2

1 2

a c

f

g

A

A

B

C

C

D

D

B

b

E

E

RKZ01070

hi

Sezione A - A Sezione B - B

d e

l

6

4

5

3

7

Section A ± A Section B ± B



1. Plug



4. Spring

5. Ball6. Ball

7. Compensator




11. Optional equipment command spool

12. Spring13. Check valve

10-49WB97S-2

8

92

1

1

8

8

8

7

15

15

F

RKZ00691

Sezione C - C

Sezione D - D

F

F

Sezione F - F

Sezione E - E

FF

11

10

7

5

6

3

4

14

14

7

12

13

F

Section C ± C

Section D ± D

Section E ± E

Section F ± F



a. Port D - To the hydraulic steering unit (Port P)

b. Port A3 - To the auxiliary equipment (Left side)

c. Port A2 - To the bucket cylinders (Head side)

d. Port A1 - To the shovel-raising cylinders(Base side)

e. Port LS - To the pump (Port X2)

f. Port T - To the hydraulic oil tank

g. Port P - From the pump (Port B)

h. Port B1 - To the shovel-raising cylinders(Head side)

i. Port B2 - To the bucket cylinders (Base side)

l. Port B3 - To the auxiliary equipment(Right side)

1. Plug

2. Plug

3. Ball

4. Spring

5. Priority valve piston rod

6. Priority valve spring

7. Plug

3-spool control valve (with return to dig)

10-50 WB97S-2

1 2

ac

f

g

A

A

C

C

D

D

b

E

E

B

B

RKZ01090

hi

d e

l

Sezione A - A Sezione B - B

6

4

5

3

7




1. Plug



4. Spring

5. Ball

6. Ball

7. Compensator




11. Coil

12. Optional equipment command spool

13. Spring

14. Check valve

10-51WB97S-2

8

9

2

1

1

8

8

8

7

15

15

F

RKZ00691

Sezione C - C

Sezione D - D

F

F

Sezione F - F

Sezione E - E

FF

11

10

7

5

6

3

4

14

14

7

12

13

F

Section C ± C

Section D ± D

Section E ± E

Section F ± F



a. Port P - From the pump (Port B)

b. Port T - To the hydraulic oil tank

c. Port B1 - To the arm cylinder (Base side)

d. Port B2 - To the arm LH swing cylinder(Base side)

e. Port B3 - To the RH outrigger cylinder(Base side)

f. Port B4 - To the LH outrigger cylinder(Base side)

g. Port B5 - To the bucket cylinder (Base side)

h. Port B6 - To the boom cylinder (Head side)

i. Port C - To the backhoe backframe lockcylinders

l. Port A6 - To the boom cylinder (Base side)

m. Port A5 - To the bucket cylinder (Head side)

n. Port A4 - To the LH outrigger cylinder(Head side)

o. Port A3 - To the RH outrigger cylinder(Head side)

p. Port A2 - To the RH boom swing cylinder(Base side)

q. Port A1 - To the arm cylinder (Head side)

r. Port T1 - To the hydraulic oil tank

s. Port LS - To the pump (Port X2)

BACKHOE CONTROL VALVE

6 Ports

10-52 WB97S-2

RKZ00230

Sezione A - A

Sezione B - B

1

2

3

4

5

6

3

A

A

B

B

C

C

D

D

D

D

E

E

F

F

L

H

H

L

G

G

c

q

i

l

a

d e f g hb

mnopr

s

Section A ± A

Section B ± B



1. Ball

2. Backhoe backframe lock solenoid valve


4. Boom command spool

5. Spool return spring6. Compensator

7. Bucket command spool

8. Anticavitation valve

9. Plug

10. Outrigger command spool

11. Boom swing command spool

12. Arm command spool13. Spring

14. Check valve

10-53WB97S-2

RKZ00760

Sezione C - C Sezione D - D Sezione E - E

Sezione F - F

Sezione G - G

G

G

G

G

G

G

G

G

9

8

37

3

6

311

5

6

9

9 10

5

12

6

35

13

13 14

14

5

6

Section C ± C Section D ± D Section E ± E

Section F ± F

Section G ± G



10-54 WB97S-2

RKZ00790

Sezione H - H Sezione L - L

4 5

23

1

Section H ± H Section L ± L

1. Valve

2. Spring

3. Plug

4. Pressure cut-out valve

5. Unloading valve



10-55WB97S-2




a. Port B7 - To the jig arm cylinder (Base side)

b. Port A7 - To the jig arm cylinder (Head side)c. Port B7 - To the side digging boom cylinder

(Base side)

d. Port A7 - To the side digging boom cylinder

(Head side)e. Port B7 - To the hydraulic hammer (Left side)

7-spool control valve

10-56 WB97S-2

RKZ00240

a

b

A

A

For jig arm

RKZ00250

B

B

c

d

Side digging boom

RKZ00260

C

C

e

For Hammer



1. Anticavitation valve

2. Jig arm command spool


4. Plug

5. Compensator

6. Anti-shock/anticavitation valve

7. Side digging boom command spool

8. Hammer command spool

10-57WB97S-2

RKZ00960

Sezione B - B

Sezione C - C

Sezione A - A

4

64

5

67

3

8

5

6 3

5

1 2

3


Section C ± C



a. Port B7 - To the hydraulic hammer (L.H. side)

b. Port B8 - To the jig arm cylinder (Base side)

c. Port A8 - To the jig arm cylinder (Head side)

d. Port B7 - To the side digging boom cylinder(Base side)

e. Port A7 - To the side digging boom cylinder(Head side)

8-spool control valve

10-58 WB97S-2

RKZ00270

a b

c

For hammer and jig arm

RKZ00280

d

e

b

c

For side digging boom and jig arm



1. DESCRIPTION

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 theshuttles;

d) Energy savings guaranteed by control of pump delivery.

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.

CLSS

10-59WB97S-2

RKZ01710

Attrezzature di lavoro

Distributore

Valvola TCC

Valvola LS

Pistone dicontrollo

PLS

PP Pistone dicontrollo

Attachment

Control valve

TCC Valve

LS Valve

Piston

Piston



2. OPERATING PRINCIPLES

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 pres-sure DPLS between the delivery pressure PP of the pump and the pressure PLS at the outlet of the control valvetowards the actuator is maintained at a constant value. (DPLS=pump delivery pressure PP ± pressure PLS of de-livery to the actuator).

. If the differential pressure DPLS becomes lower than the set pressure of the LS valve, the angle of the swashplate increases (delivery increasing).If the differential pressure DPLS increases, the angle of the swash plate decreases.

H For details about this movement, see the description of the «HYDRAULIC PUMP».

10-60 WB97S-2

Attrezzatura di lavoro

Distributore

Mandata pompa

Pistone diposizionamento POMPA

Pistone di

posizionamento

Valvola TCC

Valvola LS

Altapressione

Altapressione

RKZ01720

Attachment

Control valve

Pump delivery

PistonPUMP

Piston

TCC Valve

Highpressure

LS Valve

Highpressure



2. Pressure compensation control

. The pressure compensation valves are installed downstream from the control valve in order to balance the dif-ferential pressure between the loads..When two or more movements (cylinders) are activated simultaneously, the pressure differences DP between thedelivery 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.

10-61WB97S-2

Carico

Utilizzo Utilizzo

Carico

Compensatore Compensatore

S1 S2

POMPA

⌬P⌬P

RKZ01730

Load

Actuator

Load

Actuator

Pressurecompensationvalve

Pressurecompensationvalve

PUMP



3. Unloading valve

FUNCTION

1. When the control valve is in «NEUTRAL» position, the flow Q of the pump (due to the swash plate being in theminimum angle position) is sent to the control valve.In these conditions, the pump delivery pressure PP is regulated to 21 bar (21.4 kg/cm2) by the spring (2) insidethe valve.(LS signal with pressure PLS=0 bar (0 kg/cm2))

OPERATION

When the control valve is in «NEUTRAL» position.

. On the two surfaces of the shuttle (1), the pumppressure PP acts on the right-hand side, while theLS signal with pressure PLS acts on the left-hand si-de.

. Because no LS signal is generated with a pressurePLS, when the control valve is in «NEUTRAL» posi-tion, only the pump delivery pressure PP regulatedby the compression of the spring (2), acts on theshuttle (1).

. While the pump delivery pressure PP increases un-til it compensates for the loading on the spring (2)(21 bar (21.4 kg/cm2)), the shuttle (1) moves to

the left ( ) and the PP circuit is put into communi-cation with the tank circuit T.

. This system ensures that the pump delivery pressu-re PP stays regulated at 21 bar (21.4 kg/cm 2).

10-62 WB97S-2

RKZ01740

12

PLS T

PP



2. If, during the precision regulations of the control valve, the request for oil flow to the actuators in equal or lessthan the delivery values given by the minimum angle of the swash plate, the pump delivery pressure PP is re-gulated by the pressure PLS+21 bar (21.4 kg/cm2).

Because the unloading valve opens when the differential pressure between the pump delivery pressure PP andthe PLS LS pressure becomes equivalent to the loading of the spring (2) (21 bar (21.4 kg/cm2)), the differential LSpressure DPLS del LS becomes 21 bar (21.4 kg/cm2).

OPERATION

Final control of control valve

. When final control are performed with the controlvalve, a pressure PLS is generated that pressurizingthe spring chamber, acts on the left-hand extremityof the valve (1).The actuator pressure is introduced into the LS cir-cuit and then into the spring chamber.As a result, the pump pressure PP tends to increa-se.

. When the differential pressure between the pumpdelivery pressure PP and the LS pressure PLS hasthe same value as the loading on the spring (2)(21 bar (21.4 kg/cm2)), the shuttle (1) moves tothe left ( ) and the pump circuit PP puts itself intocommunication with the tank circuit T.

Consequently the exceeding pump delivery Q, rela-tive to the actuator request, is sent to the tank cir-cuit.

. The pump delivery pressure PP is regulated by thecombination of the pressure provided by the spring(21 bar (21.4 kg/cm2)) and by the LS pressure PLS,i.e. when the pressure differential DPLS reaches thevalue of 21 bar (21.4 kg/cm2).

10-63WB97S-2

RKZ01750

12

PLS T

PP



3. When the request for oil flow from the actuators exceeds the minimum delivery of the pump during use of thecontrol valve, the connection to the tank circuit is eliminated and the entire pump delivery Q is sent to the ac-tuators.

OPERATION

When the control valve is in use

. When the control valve shuttle is operated to exe-cute a bigger stroke, the opening section of spoolbecomes bigger and consequently the controlleddelivery.Because the control valve passage is large, the dif-ference between the LS pressure PLS and the pumpdelivery pressure PP is reduced up to 16 bar (16.3kg/cm2) (LS pump valve setting).

. Because the differential pressure between thepump delivery pressure PP and the LS pressurePLS is not equal to the pressure given by the springloading (2) (21 bar (21.4 kg/cm2)), the shuttle (1) ispushed to the right ( ) of the spring (2).

. The result is that the connection between the pumpdelivery circuit PP and the tank circuit T is excludedand the entire pump delivery Q is sent to the actua-tors.

10-64 WB97S-2

RKZ01760

12

PLS T

PP



4. Introduction of the LS pressure

. The LS pressure is the pressure generated by external forces acting on the actuators at the outlet of the controlvalve.

OPERATION

. When the shuttle (1) is activated, the pump

pressure PP

starts to flow into the actuator cir-cuit A through the duct b.

. At the same time the compensator (2) movesupwards ( ) so that the flow controlled by spool(1) can flow towards the actuator A.Check valve (4) do not allow any flow up to whenpressure in chamber c is higher than pressurein chamber b.Pressure downstream spool (1) flows in the PLS

circuit downstream the compensator valvethrought the orifice d.

. The PLS circuit of the LS is thus in communica-tion with the tank circuit T by means of the LSdecompression valve (3). (See the description

of the LS decompression valve).

. The system stabilizes when a pressure differen-ce of 18 bar (18.3 kg/cm2) is generated acrossthe shuttle (1) between pump pressure PP andPLS pressure.

10-65WB97S-2

RKZ01780

2

3

A

b

PP

1

Alla pompa4

c d

To the pump



INTRODUCTIONThe flow sent to each actuator is controlled by the opening area of each spool.While performing complex control, in traditional control valves the difference between actuators pressure might cau-

se sudden and unexpected movements acceleration in those actuators operal at lower pressure.The adoption of the pressure compensation valve allow to control those situation guaranting the proportionality bet-ween each actuator

FUNCTION

Compensation of actuator deliveries occurs when, during the simultaneous activation of two or more movements,the pressure of one actuator drops lower than that of the other, and pump delivery, if not controlled, tends to besupplied the actuator operating at lower. (In the diagram the actuator on the right is requesting higher pressure).

OPERATION

1. When activating an actuator at a pressure lower than the one already working.(While operating actuator A starts operating actuator B)

. Until the pressure PBV downstream from the shuttle(1) reaches the same value requested by actuatorB, no oil passes.

. When the pressure requested by actuator B is ex-ceeded, movement can commence. This createsa flow that adding to the one controlled by spool(3) reduces the pressure upstream of spool (1)and (3) and therefore the DP between PLS and PP.

. The pump compares the delivery pressures PP and

PLS and senses that the difference DP<18 bar

(18.3 kg/cm2). This variation in DP causes an in-crease in oil flow increasing the swash plate angle.(For the detail see «Hydraulic pump»).

. Until the pump does not realize a DP of 18 bar (18.3kg/cm2), i.e. until the increase in oil flow compensa-tes the requirements of the two actuators, the pumpwill continue to increase delivery.

. DP of 18 bar (18.3 kg/cm2) will stabilize as soon as itis restored to.

. The compensator (2) is moved upwards by the oilflow and stops when the aperture between thechambers a and b reduces the passage sufficientlyto reduce the pressure in chamber a to be sent to

the actuator.

5. DELIVERY COMPENSATION

10-66 WB97S-2

RKZ02310

A B

PA

PAV

PP

PBV

PB

PLS

C

d

4

3

1

b

a

2



2. When a low pressure actuator needs to work at a higher pressure than the other

. If the actuator B needs to work at a higher pressure

(PB>PA), the pressure PB will start to increase.

. Since pressure PB is increasing, the compensator(2) moves upwards to restore the DP between thechambers a and b, and therefore the DP does notvary upstream or downstream from the shuttle (1).

. When pressure PB exceeds pressure PA, the com-pensator (2) is fully open and the pressure PB is in-troduced into the LS circuit.

. The increase in pressure in the LS circuit obligesthe pump to increase delivery until the DP is resto-red to 18 bar (18.3 kg/cm2).

. Simultaneously the increase in pressure upstream

from the shuttle (3) generates an increase in DP up-stream and downstream from the shuttle.(PAV<PLS<PP)

. Because the pressure PLS which is equal to the

pressure PB acts on the upper side of the compen-sator (4), and since the pressure PAV is lower, thecompensator (4) is pushed downwards.

. The compensator stops when the aperture betweenthe chambers c and d generates a reduction of thepassage sufficient to reduce the pressure to besent to the actuator, and to increase the pressurePAV until the DP is restored to the 18 bar (18.3 kg/cm2) necessary for equilibrium.

10-67WB97S-2

RKZ02320

A B

PA

PAV

PP

PBV

PB

PLS

C

d

4

3

1

b

a

2



3. When an increase in delivery is required by an actuator

. When an increased delivery is required by actuatorA, i.e. when the shuttle (3) is asked to execute abigger movement, the section of the aperture in-creases.

. The increase in aperture provokes a drop in DP bet-ween the two sides of the shuttles (2) and (3), be-cause the flow, which has remained unchanged un-til now, is divided between both the actuators.

. At the same time the pump senses the variation inDP and increases the oil flow until the DP is restoredto DP of 18 bar (18.3 kg/cm2) between the two sides

of the shuttle (1) and the compensator (4) changesposition in order to restore the DP upstream anddownstream from the shuttle (3).

10-68 WB97S-2

RKZ02330

A B

PA

PAV

PP

PBV

PB

PLS

C

d

4

3

1

b

a

2



FUNCTION

. The Load Independence Flow Divider (LIFD) intervenes automatically when the oil-flow requested by the actua-tors exceeds the maximum delivery guaranteed by the pump.In this case, the oil-flow is divided between the various actuators in proportion to their requirements.

OPERATION

. When, during the simultaneous operation of morethan one actuator, one of them needs a higherpressure and the characteristics of the pump are

exceeded, the pump guarantees a delivery limitedby its calibration curve.

. At this point less oil than requested is distributed toall the actuators.

. Because the sections of the apertures remain un-changed, the pressure upstream and downstreamfrom the shuttles drops. Since the position of thecompensator (4) is determined by the pressure ofthe LS signal, by the pressure PBV downstreamfrom the shuttle (3) and by the flow of oil neededfor the movement, the compensator is pusheddownwards by the higher pressure in the upperchamber until the pressure PBV downstream from

the shuttle becomes equal to the pressure PAV

downstream from the shuttle (1). This equalizesthe pressure DP of the shuttle (1).

. Thus the flow of each actuator is reduced by a per-centage equal to the reduction or absence of pumpdelivery.

. In other words, when the request for performance isexcessive, the system can nevertheless guaranteeproportionality and graduality for the movements inany load conditions.

. If an increase in delivery is requested, rather thanan increase in pressure, and the characteristics ofthe pump are exceeded, the system will functionin the same way as described for the above case.

6. LIFD CONTROL SYSTEM

10-69WB97S-2

RKZ02340

PCV PBV PAV

ABC

6 4 2

5 3 1



DESCRIPTION

The LS decompression valve is a throttle that continuously releases a small quantity of oil from the LS circuit andthat, when the shuttles are brought back to a neutral position, releases the residual LS pressure.

This continued flow renders the PLS pressure increment more gentle and gradual, and increases stability and controlduring the phases of reducing the LS pressure.

OPERATION

.

When the LS pressure reaches chamber a of thevalve, it generates a force that opposes the forceof the spring (2).

. Until the force generated by the LS pressure ex-ceeds the force of the spring (2) (LS pressure low)the shuttle (1) remains «at rest» and oil flowsthrough the calibrated orifice a in the tank circuit.

. When the force generated by the LS pressure ex-ceeds the force of the spring (2), the shuttle is pus-hed upwards ( ) and the passages c are closed.Oil continues to flow into the chamber d until theforce generated by the pressure contained inchamber d, together with the force of the spring

(2), exceeds the force generated by the LS pressu-re.

.

The shuttle is pushed downwards ( ) and passagec is opened.

. The system is in equilibrium (i.e. the shuttle is atrest), when the quantity of oil allowed to flow intothe tank circuit is equivalent to the quantity that ge-nerates a pressure difference DP such that(PLSxS)=[(PLS1xS)+F] where:PLS= LS pressurePLS1= LS pressure contained in chamber dS= section of the shuttleF= force of the spring.

7. LS DECOMPRESSION VALVE

10-70 WB97S-2

RKZ02350

c

a

d2

b

RKZ02360

1,3

P (bar)

Q (ᐍ / min)

0,8

0 20 250



DESCRIPTION

The function of the pressure cut-off valve is to regulate the maximum pressure of the Load Sensing signal and hen-ce also the pressure of the pump.

OPERATION

. The pressurized oil of the LS reaches the chambera of the valve.

. When the force generated by the LS pressure onthe valve (1) exceeds the force of the spring (2),the valve (1) is pushed upwards ( ) opening the

passage between the chamber a and the tank cir-cuit.

8. PRESSURE CUT-OFF VALVE

10-71WB97S-2

RKZ01770

1

2

1b

a



FUNCTION

The function of the priority valve is to distribute oil to the steering unit and to the other hydraulic components. Di-stribution is determined by the position of the valve of the priority valve in function of the LS signal, oil delivery from

the pump, the pressure of the steering unit and the pressure of the hydraulic circuit. The position of the valve is suchas to guarantee that delivery to the steering unit will always correspond to the actual need.

9. PRIORITY VALVE (ONLY FOR THE 2-3 SPOOL CONTROL VALVE)

10-72 WB97S-2

RKZ02370

P LS

P

Agli utilizzi

DLSD

To the actuator



1. EV4 - Backhoe boom locking

a. Port 3 - To the transmission

b. Port 1 - From the transmission

c. Port 2 - Boom-locking cylinder

SOLENOID VALVE

Solenoid valve block ST1

Differential locking - backhoe boom locking

10-73WB97S-2

RKZ04640

a

b

c

1



1. Y1 Rear steering cut out

2. Y2 Front/rear steering3. Y3 Phase coincidence steering

4. Y4 Crab steering

5. Blocks connection

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

b. A Port - To rear steering cylinder (c Port)

c. P Port - From steering unit (Port r)

d. B Port - To rear steering cylinder (d Port)

Solenoid valve group ST2

10-74 WB97S-2

RKP03670

1 4

a b

c d5

AT

P B

2 3

10

8

6

4

2

0

0 20 40 60 80

Measured at V=41 mm2 /s e t=50°C5 3

RKP04501

D i f f e r e n t i a l p r e s s u r e ⌬ p

( b a r )

Amount Q (ᐍ / min)

6 9

10

8

6

4

2

00 20 40 60 80

Measured at V=41 mm2 /s e t=50°C

RKP04511

D i f f e r e n t i a l p r e s s u r e ⌬ p ( b a r )

Amount Q (ᐍ / min)

RKZ04571

Y3

Y4

Y1

Y2

Direction of travel

c

d

rearcylinder



Shovel raise

a. Port Y - to the raising cylinders (Head side)

b. Port A - From the shovel control valve (Port A1)

c. Port X - To the raising cylinders (Base side)

d. Port B - From the shovel control valve (Port B1)

Bucket Dump

a. Port Y - To the dump cylinders (Head side)

b. Port A - From the shovel control valve (Port B2)

c. Port X - To the dump cylinders (Base side)

d. Port B - From the shovel control valve (Port A2)

Boom

a. Port Y - To the boom cylinder (Head side)

b. Port A - From the backhoe control valve(Port A6)

c. Port X - To the boom cylinder (Base side)d. Port B - From the backhoe control valve

(Port B6)

Arm

a. Port Y - To the arm cylinder (Head side)

b. Port A - From the backhoe control valve(Port B1)

c. Port X - To the arm cylinder (Base side)

d. Port B - From the backhoe control valve(Port A1)

CHARACTERISTICS

Safety valve calibration

Shovel dump: 230 bar

Boom: 350 bar

Arm: 230 bar

SAFETY VALVE

10-75WB97S-2

a b

c

d

A

A RKZ00850



1. Plug

2. Check valve spring

3. Check valve

4. Check valve spring

5. Check valve

6. Plug

7. Protection8. Over-ride screw (Safety)

9. Spool

10. Safety valve spring

11. Safety valve

12. Spool

13. Spring

14. Housing

15. Plug

H The drawing represents the boom safety valve

10-76 WB97S-2

RKZ01050Sezione A - A

1

2 3 4

6

5

7

8

91011121314

15

Section A ± A



1. Pump body

2. Main piston

3. Seal

4. Differential piston

5. Spring

6. Pump spring

7. Spring

8. Check valve

9. Ball

10. Seal

11. Pin

12. Seal

13. Seal

14. Seal

15. Ball

16. Spring17. Seal

CHARACTERISTICS:

Stroke: 36 mm

Displacement: 15 ± 28 cc

Max. pressure: 150 bar

BRAKE PUMP

10-77WB97S-2

RKZ00932

1

1011121314151617

9

7

8

2 3 4 5 6



RAISING CYLINDER

DUMPING CYLINDER

CHARACTERISTICS

Cylinder Raising Dumping

Piston rod diameter 50 50

Internal cylinder diameter 85 85

Piston stroke 730 755

Max. cylinder length 1880 2145

Min. cylinder length 1150 1390

Key size for pistonsafety nut

55 55

SHOVEL CYLINDERS

10-78 WB97S-2

RKZ00300

4 65

1

32 7

8

RKZ00310

4 65

1

32 7

8

1. Bushing, base side

2. Cylinder

3. Nut

4. Piston seal

5. Piston

6. Piston rod

7. Cylinder

8. Bushing, head side



BOOM

ARM

BUCKET

BACKHOE CYLINDERS

10-79WB97S-2

RKZ00200

4

1

32 7

8

65

9

1011

RKZ00220

4

1

3

2

7 865 910

RKZ00290

4

1

32 765 8 9

1. Head bushing, piston rod side2. Piston rod

3. Cylinder head

4. Cylinder

5. Piston6. Piston ring

7. Guide ring

8. Cushion plunger

9. Bottom bushing10. Dowel bolt

11. Ball-bearings (9)

1. Head bushing

2. Piston rod

3. Cylinder head

4. Cylinder

5. Bushing

6. Piston ring

7. Guide ring

8. Piston

9. Nut

10. Bottom bushing

1. Head bushing

2. Piston rod

3. Cylinder head

4. Cylinder

5. Piston

6. Piston ring

7. Guide ring

8. Nut

9. Bottom bushing



OUTRIGGERS

BOOM SWING

ARM (for side digging boom)

10-80 WB97S-2

RKZ00410

41 32 765 8

RKZ00361

41 326

5

7

101112 9 8

11 10 RKZ00210

31 3

2

754

86

9

1. Piston rod

2. Cylinder head

3. Cylinder

4. Spacer

5. Piston ring

6. Guide ring

7. Piston

8. Nut

1. Retaining ring

2. Throttling ring

3. Piston rod

4. Cylinder

5. Swing bushing

6. Cylinder head

7. Head bushing

8. Piston

9. Guide ring

10. Piston ring

11. Spacer

12. Cushion plunger

1. Head bushing

2. Cylinder head3. Throttling ring

4. Piston ring

5. Guide ring

6. Nut7. Bearing

8. Piston

9. Piston

10. Piston rod11. Cylinder



SIDE DIGGING BOOM

JIG ARM

10-81WB97S-2

1 2

RKZ00390

3 4 5 6 7 8 9 10

11

1 2 3 54 67 7 8

RKZ04580

1. Head bushing

2. Piston rod

3. Ring nut

4. Gasket

5. Cylinder head

6. Cylinder

7. Piston ring

8. Ring

9. Nut

10. Bottom bushing

11. Spacer

1. Head bushing

2. Piston rod

3. Cylinder head

4. Cylinder

5. Piston

6. Piston ring

7. Guide ring

8. Bottom bushing



CHARACTERISTICS

Cylinder Boom

Arm

BucketStandard

With sidedigging boom

Piston rod diameter 60 60 60 60

Internal Cylinder diameter 120 110 110 95

Piston stroke 849 920 910 765

Max. cylinder length 2050 2175 2170 1850

Min. cylinder length 1040 1255 1260 1085

Key size for pistonsafety nut 65 55 55 55

CHARACTERISTICS

Cylinder Outriggers Boom swing Side digging boom Jig arm

Piston rod diameter 40 50 45 40

Internal Cylinder diameter 80 100 85 70

Piston stroke 635 230 365 1140

Max. cylinder length 1690 319 830 2590

Min. cylinder length 1055 89 565 1450

Key size for pistonsafety nut

46 Ð 46 Ð

10-82 WB97S-2



1. Compressor

2. Condenser

3. Drying-filter tank

4. Safety pressure

5. Expansion valve

6. Evaporator

7. Thermostatic clutch control sensor

8. Air-circulation fan in cab

9. Air conveyor

TECHNICAL DATA

. Operating pressure in circuit with engine at 2500rpm and ambient temperature at 25 ± 30ëC:Normal pressure: 15 ± 17 barLow pressure: 1.6 ± 1.8 bar

. Safety pressures:High pressure: 26 bar

Low pressure: 2.5 bar. Coolant fluid: R134a

. Quantity of coolant: 970w15 g

AIR-CONDITIONING UNIT

10-83WB97S-2

RKZ03130

4

3

5

2

1

6

7

9

1a

8

Low pressure steam

Low pressure liquid/steam

High pressure steam

High pressure liquid

INTERIOR OF CAB

AIR AT AMBIENT TEMPERATURE



The compressor (1) is driven directly by the engineshaft by means of a belt, and made to rotat by a pulleyfitted with an electromagnetically-engaged clutch (1a).

A thermostatic sensor (7) controls the engagementand disengagement of the clutch. It disengages theclutch when the evaporator reaches the lower tempe-rature limit and engages the clutch when the evapora-tor reaches the upper temperature limit.

The coolant fluid (in gaseous phase) is drawn into thecompressor where it is subjected to compression andan intense heating process. In these conditions thefluid is then sent into the condenser (2) where, dueto the heat extracted by ambient temperature air flo-wing over fins, it reaches condensation temperature,and passes into a high-pressure liquid state.

Subsequently the coolant passes into the drying-filter

group (3) which performs three functions: it filters outimpurities, absorbs any moisture present in the circuitand, finally, also functions as a reserve tank.

The coolant in its liquid state is then transferred to theevaporator (6), first passing through an expansion val-ve (5). The task of this valve is the constant meteringof the quantity of fluid in order to maintain optimumevaporation.

In the evaporator the coolant fluid is subjected to ex-pansion, bringing it up to the critical evaporation pointat a temperature of approximately ± 8ëC.

The flow of air generated by centrifugal fan (8) whichpasses through the evaporator (6) at ambient tempera-ture is considerably warmer than ± 8ëC. For this rea-son it yields heat to the coolant fluid, bringing it upto boiling point and complete evaporation.

On leaving the evaporator (6) the coolant is drawn on-ce more into the compressor (1) and a new cycle com-mences.

The yielding of heat from the atmosphere in which theevaporator is positioned leads to the condensation ofthe water suspended in the air, and hence to dehumi-dification. The condensate is deposited on the evapo-rator fins where, if a temperature higher than 0ëC isnot maintained, it freezes and inhibits the functioningof the evaporator.

The task of keeping the temperature of the evaporatorabove 0ëC (and thus within the optimum limits for heatexchange) is entrusted to a thermostatic sensor (7).

The condensate that forms on the evaporator fins (6)also contains dust, pollens and particles suspendedin the air. Continual condensation therefore effectively

purifies the air, and the droplets of condensate are di-scharged to the exterior.

A fixed quantity of anti-freeze oil is also introduced intothe circuit, with the function of lubricating all the me-chanical parts of the unit. A percentage of this oil cir-culates constantly throughout the unit in nebulizedform, lubricating the compressor (pistons and bea-rings) and the expansion valve.

A pressure switch (4) has been inserted in the electri-cal control circuit to protect the unit in the case of alack of coolant fluid or if the quantity becomes insuffi-cient due to leakages. This switch will inhibit the enga-gement of the electromagnetic clutch and hence the

functioning of the air-conditioning unit.

HOW THE AIR-CONDITIONING UNIT FUNCTIONS

10-84 WB97S-2



ELECTRICAL CIRCUIT DIAGRAM (1/7)

WB97S-2

R / N 1

H / N 1

X173

t_

P4-

S i+

X1714

X S

6

X S

5

q

P3-

S+

i

X179

R/N13.1

X4

8

G 1

V - B 1

A - G 1

X8

5

X8

7

X8

3

X8

11

R / N 1

X8

12

D19

7

D 1 8

+15

F3A

7.5A

R25

1/4W

+15

F7C

7.5A

X8

2

Z / N 1

X8

9

X8

6

X8

8

+30

+15

X8

10

D 2 0

K4 86 87a 87

85 30

D5

R3

1/4W

X178

X17

D

1 0

X15

B/V12.4

t

S21

X21

2

X21

1

X213

R31 S24

B / V 1

B / N 1

134.15

24.18

B - R 1

Z - N 1

X16

X19

L4

B-N1

X111

Z - B 1

R - N 1 . 5

N 1

R4

1/4W

L 2 5

L3

XS1

XS4

rpm

P1-

S i+

H8

X 1 7

2

V 1

6 5

H4 H5 H6 H7

S 1

11113 12

H1 H2

N 1 . 5

A 2 . 5

3 4

G2.5

M - V 1

H3

4

R - N 1 . 5

X 1 0

5

A-R1

3 4 X T 1

1 2

KT1

5 3 S

5 3 M

3 1

1 5

A-R12.19

M - V 1

R - V 1

M - V 1

10

R - V 1

3X

1 012

X 1 8

5 4 X A Dl

4 X T 2

1

KT2

5 3 S

1 5

5 3 M 3 1

2

X 1 94 5

X10

9

X10

11

X 1 07

R - V 1

M - V 1

A 2 . 5

A 2 . 5

Z / B 1

X177

X152

R6

X151

L42.13

AL KIT

G 2 . 5

B - R 1

X11

2

X142

R 4

L 4

X 1 22

X10

13

L 4 X 1 3

l

A - V 1

X 1 08

X 1 4

1

L 4

A - V 1

COND.

R 4

R 4

R 4

X11

1

X12

1

R 6

G 2 . 5

R1ST

OFF ACC

S6

R1 ACC BR R2 C

B

A - V 1

G 1

M 1

K03

86 87

85 30

B1.5

B1.5

X16

A

B

3

R30

2

Y0

1

M10G2.5

K01

86 87

85 30

K0286 87

85 30

N 1

N 1

N 1

Z - B 1

G 2 . 5

R 1 0

R50

FUG4

70A

FUG3

30A

X A

-

X Al

U

3

G

G2

30D+

W

31

M

M1

30 50

FUG1

60A

G1

12Vcc

FUG2

80A

R 5 0

N 5 0

G / N 1 R

- V 1

B / R 1 M

- V 1

Z / B 1

-

Z / N 1

B - N 1

h

P2 -

S i+

X 1 7

X 1 7

X 1 7

X 1 7

X 1 7

X 1 7

X 1 7

X 1 5

X 1 5

X A D

X T 2

X T 2

X 1 0

X 1 8

X 1 9

X T 1

X T 1

X T 1

XAM XAM

X16XAM

D 1 1

R 1 . 5

B - N 1

3.18R/N1

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

COMPONENTS

G1 BatteryG2 GeneratorH1 Preheating warning lightH2 Generator warning lightH3 Engine water high temperature

warning lampH4 Air filter warning lampH5 Hydraulic oil filter warning lampH6 Optional warning lampH7 Optional warning lampH8 Optional warning lampHA1 HornK01 Starter relay

K02 Preheating relayK03 Fuel shut off relayK4 Safety start relayKT1 Fuel shut off timerKT2 Preheating timerM1 Starter motorP1 RPM instrumentP2 Hour counterP3 Fuel level indicatorP4 Water temperature instrumentR30 Heating startR31 Fuel level senderR32 Water temperature sender

S6 Starting switchS21 Engine water high temperature switchS22 Air filter blocked switchS23 Engine oil low pressure switchS24 Fuel gaugeY0 Fuel shut off solenoid valve

CONNECTORS

X1 Front line (engine) 11 way connectorX4 Monitor 11 way connectorX8 Lateral dashboard 17 way connectorX10 Front line-engine line 13 way connectorX11 Power 3 way connectorX12 Front line-cross line 3 way connectorX13 Front line-engine line 2 way connectorX14 Front line-cross line 4 way connectorX15 Start key 4 way connectorX16 Conditioner clutch 2 way connectorX17 Lateral dashboard 21 way connectorX18 Power box 5 way connectorX19 Front dashboard 9 way connector

X21 Fuel level indicator 3 wXA Generator 2 way conneXAD Diode 2 way connectorXAM Fuel shut off valve 3 waXS Multifunction instrumenXT1 Fuel shut off timer 4 waXT2 Preheating timer 4 way



10-86





WB97S-2

87a

30

R0ohm

NON MONTATO

RELE' K7

G - V 1

X288

X29

M - B 1

X284

X286

X285

X287

MANIPOLATORE

C - B 1

C / B 1

M - N 1

X282

X281

V / N 1

X283

D14

X5

7

X5

8

X5

3

X8

1 M - N 1

M-N1

V2.5

X9

1

X9

9

+15

L26

F5A

15A

R26

1/4W

L 1 7

R17

1/4W

K04

86 87

85 30

3

V / N 1

E

X

5

X27

1

L41.2

2V - N 2 . 5

C / B 1

C - B 1

EV1

43

X201

X27

6 2

EV2

L4

X27

3

N 1

N 1

N 1

N 1

A1.5

V - B 1

N14.1

10

23

S4

2 3 4

+ 1

V - N 1 S

1

H11H10H9 H12

B 1 . 5

R 1 . 5 N

1

Z - B 1

X2

4

X9

10

X2

7

324.17

314.17

D4

183.1

L5

R5

1/4W

C - L 1

M / N 1

X5

10

X5

5

X5

11

203.7

X9

16

D8

+15

F3C

7.5A

A - N 1

L - B 1

R/N12.19

R/N1

II0I

S2A

2 6 7 9

3 5 10

X 1 9

7 A - R 1

X9

8

L/B13.9

11.20

111.20

X8

4

X 1 8

3

L 1 4

+15

R14

1/4W

F4A

7.5A

L 2 7

R27

1/4W

X9

15

X813

Z-N1.5

X37

X 1 4

4

R 1 . 5

R 1

R 1 . 5S20

B - R 1 . 5

B - R 1

S19

X 1 4

3

B - R 1

G - N 1

A - G 1

X51

X34

121.20

S - N 1

X35

S15

X 2 32

X 2 3

1

OPTIONAL

N 1

p

S16

S18

S17

154.16

16

4.6

N 1

N 1

N 1 B

- R 1

B

/ V 1

B/V11.15

L - B 1

X33

X 2 43

X241

X22

l

X22-

MM2

X 2 44

MM3 53

53a53b

31b

31

311.20

N 1

D22 D21

403.1

MM4

Z - N 1

N 2 . 5

X 2 0

2

X 2 5

1

V2.5

V - N 2 . 5

10

S2

1 5/1 3 0/3 L /6

49/4 30b/2 R/7

K3

86 87a 87

85 30

X 2 0

X 2 0

X27

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

COMPONENTSEV1 Opened grab solenoid valveEV2 Closed grab solenoid valveEV4 Rear 1^ boom unlock solenoid valveH9 4WD warning lampH10 Engine water high temperature warning lightH11 Engine oil high temperature warning lightH12 Fuel reserve warning lightK04 Powered blower motor relayK3 Insert double traction relayM2 Washer pumpS1 Economy power switchS2 Rear 1^ boom unlock switchS4 Blower motor switchS10 Hammer button

S15 Hand brake switchS16 Brake oil low level switchS17 Stop switchS18 Stop switchS19 Stop light switchS20 Stop light switchS2A Winshield wiper-washer switch

on front dashboardY5 Economy power solenoid valve

CONNECTORSX2 Lights switch and gear shift line9 way connector

X3 Front line 11 way connectorX5 Cabin command 11 way connectorX6 Solenoid valves line 9 way connectorX8 Lateral dashboard 17 way connectorX9 Front dashboard 17 way connectorX14 Front line-cross line 4 way connectorX18 Power box 5 way connectorX19 Front dashboard 9 way connectorX20 Blower motor 4 way connectorX22 Windshield washer pump 2 way connectorX23 Optional 2 way connectorX24 Windshield wiper 4 way connector

X25 Powered blower motor 2 way connectorX27 Valves line 6 way connectorX28 Joystick way connectorX29 Convert detachment button 2 way conneX43 Pred. 2 way connector



10-88





WB97S-2

NON MONTATO

RELE' K1

C1

22uF

A - N 1

G1.5

G / N 1

HA2

R / N 1 1 0

S3A

1 9

5 10

X3

3

X9

7

X33

6

L19

+15

R19

1/4W

+30

L11

R8

1/4W

L8 R11

1/4W

F2B

7.5A

F5C

15A

X 1

9

1

G-V1

X 1

9

2

G / N 1

G / N 1

X2

1

X1719

R/N12.20

81.20

X9

12

R7

1/4W

L7

+30

L10

F2A

10A

R10

1/4W

F1C

3A

G-V14.8

F1B

3A

III

S

B 1

L - G 1 . 5

N 0 . 5 M

1

R-V1

X54

A

X39B

X39C

Y6

G14.1

X316

124.5

G-R14.7

X 3 11

X 3 12

N1

H18H17

3

X31

4

2

H16

S27

N 1 . 5

N 1

L. CABINAN

1

L . 0 5

H19

L-G1.5

L/B1

L1.5

1 0

S1L

1 9

5 10

1 0

S5L

1 9

5 10

B-R1

L / N 1

X1710

X8

16

X2

9

71.16

L/B12.2

+15

F5B

15A

R1

1/4W

L1

D1

L 1 . 5

X2

5

194.19

L2

R2

1/4WD3

K286 87a 87

85 30

X8

14

X1717

B - R 1

A - N 1

10

S3

15/1 30/3 L /6

49/4 30b/2 R/7

C-L12.20

R/N11.14

X1716

X1718

X8

15

S - G 1

+15

A - N 1

+15

3

J2

21

F6A

15A

R15

1/4W

F4B

10A

L15

402.9

182.8

R20

1/4W

L20

1 0

S4L

1 9

5 10

B-R1.5

G 1

X598 2 6 17

R - V 1

X1 H15 1MM5

X302

X30

1

R - N 1 . 5

202.5

X61

P4

X67

X64

X65

31.20

X63

N 1 . 5

N 1 . 5

H - L 1

X52

HA4Y7

HA3

312.20

N 1

N 1

N 1

1 0

S3L

1 9

5 10

L18

R18

1/4W

R - N 1 . 5

G14.9

AUTORADIO

ALIM.

X6 X6 X6 X8 X5

X 3 2

X 3 2

X31

X 3 9

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

COMPONENTSH13 Dashboard lightH14 Dashboard lightH15 Cigarette lighter lampH16 Cabin lampH17 Front working lampH18 Front working lampH19 Beacon lampH20 Rear working lightH21 Rear working lampHA2 BuzzerHA3 Rear hornHA4 BuzzerK05 Return to dig relayK2 Reverse speed relayM5 Fuel pump

M8 Windshield wiper motorS1L Rear working light switch on lat. dashboardS27 Npn sensorS2L Windshield wiper-washer switch on lat. dashboardS3A Front working light switch on front dashboardS3L Beacon switch on lat. dashboardS4L Horn switch on lat. dashboardS5L Optional switch on lat. dashboardY6 Return to dig solenoid valveY7 Plate unlock solenoid valve

CONNECTORSX1 Front line (engine) 11 way connectorX2 Lights switch and gear shift line 9 way connectorX3 Front line 11 way connectorX5 Cabin command 11 way connectorX6 Solenoid valves line 9 way connectorX8 Lateral dashboard 17 way connectorX9 Front dashboard 17 way connectorX17 Lateral dashboard 21 way connectorX19 Front dashboard 9 way connectorX30 Fuel pump 2 way connectorX31 Cabin 5 way connectorX32 Radio power 2 way connectorX33 Windshield wiper and beacon 7 way connectorX39 Proximity 3 way connector

FUSESF1B Right traffic F1C Left traffic liF2A Beacon fuseF2B Radio and cF4B Forward-revF5B Rear workinF5C Front workinF6A Windshield



10-90





WB97S-2

G - V 1

86 7

C 1

A / B 1

432

DEVIO LUCI

5 9

2.7

X9

14

131.12

X2

2

R - N 1

X2

6

L21

D9

K8

86 87a 87

85 30

L24

91.20

R - G 1

L 1

9 1075 6 8

+15+15

3

N 1

N 1

X40

1

N 1

28

A 1

4

N 1

F7B

10A

R24

1/4W

R21

1/4W

N 1

G-V13.14

H22 H23 H24

M-N12.20

R/N1R/N13.20

H25

2

X199 A

- V 1

X9

11

1 X 1 9

8

X9

3

K9

C

+

R

X9

5

A / V 1

X2

3

X9

17

X9

6

V 1

R - N 1

B 1

162.7

F4C

15A

R29

1/4W

D7L22

R16

1/4W+15

R22

1/4W

K6

86 87a 87

85 30

+30

X 1 8

2

A / N 1

B / R 1

A / N 1

B - R 1

A-N1

N12.8

X9

4

+30

R 1 . 5

X2

8

H - N 1

L12

+30

R12

1/4W

F2C

10AR28

1/4W

D6

F1A

15A

K586 87a 87

85 30

1 0

S4A

2 8 5 10

4 6 3 1 7

F6C

10A

A 1

R1

A - B 1

G13.10

X 2 64

X266

H31

7

X 2 6

3 1

X265

H30

5 7 L

5 9 c

3 1

G-R1

A 1

A - B 1

123.12

G - R 1

M 1

102 9

X 3 54

X 3 5

6

X 3 532

X351

G-R13.12

R12.20

N 1

N 1

N 1 . 5

P1

G1

X36

M 1

B 1

11

X38

463

X 3 42

X341

H26

5 6 a

5 6 b R 5

7

3 1

G13.13

313.20

N 1 . 5

N 1 . 5

H27

5 6 a

5 6 b L 5

7

3 1

B 1

L9

R9

1/4W L28 L29

L16

H32

5 7 R

5 9 c

3 1

F6B

7.5

XD11

2

XD1 XD1 XD1 XD1 XD1 XD1 XD1 XD1

X 1 8

X9

X3 X3 X3 X3

X 3 4

X 3 4

X 3 4

X 3 5

X 2 6

X 2 6

X 2 6

X 2 6 X40 X40 X40 X40 X40 X40 X40 X40 X4

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

COMPONENTSH22 Indicators warning lampH23 Main beam warning lampH24 Low level brake oil warning lampH25 Differential lock warning lampH26 Right front lampH27 Left front lampH30 Left rear lampH31 Number plate lampH32 Right rear lampK5 Low beam relayK6 Main beam relayK8 Horn relayK9 Flasher unitS4A Warning switch on front dashboard

CONNECTORSX2 Lights switch and gear shift line 9 way connectorX3 Front line 11 way connectorX7 Not connected 9 way connectorX9 Front dashboard 17 way connectorX18 Power box 5 way connectorX19 Front dashboard 9 way connectorX26 Rear line 8 way connectorX34 Right front light 6 way connectorX35 Left front light 6 way connectorX40 Flasher unit 13 way connectorXD1 Lights switch 9 way connector

FUSESF1A Low beam fuse 15AF2C Warning fuse 10AF4C High beam fuse 15AF6B Lights switch fuse 7.5AF6C Warning power fuse 10AF7B Horn fuse 10A



10-92





WB97S-2

14 15 11 2 3 4 5 6 7 8 9 10 11 12 13

654321

N 0 . 5

H34

N 0 . 5

H33

N 0 . 5

N 0 . 5

N 0 . 5

S7

N 2 . 5

X E

X E

1

M - B 1

L - G 1

A - R 1

S - G 1

M - N 1

L - B 1

S28

X 5 5

B

X 5 5

C

X 5 5

A

X 5 4

C

X 5 4

B

X 5 4

A

X 5 6

3

X 5 6

2

X 5 6

1

N 1

M - V 1

M 1

N 1

X 5 1

11

N 1

X 5 1

6

X 5 1

7

M 1

M - V 1

X 6 4

2

X 6 4

1

R - N 1

X 5 1

4

R - N 1

X 6 3

2

X 6 3

1

X 6 2

2

X 6 2

1

X 6 1

2

X 6 1

1

R - V 1

X 5 1

3

R - V 1

V 1

X 5 1

2

V 1

N 1

N 1

N 1

N 1

314.20

R / N 1

X 5 1

1

R / N 1

Y4Y3Y2Y1

N 1

N 1

R 1

X 5 1

10 R 1

B - R 1

X 5 1

8

B - R 1

R11.20

R 1

R 1

X53

1

X 5 1

9 R 1

Z - B 1

X 5 1

5

Z - B 1

G - V 1

S - N 1

C - N 1

G - R 1

A - B 1

N11.20

S11.20

G11.20

Z-N11.20

H - R 1

X 5 2

X 5 2

X 5 2

X 5 2

X 5 2

X 5 2

X 5 2

S 1

G 1

Z - N 1

B-N11.20

A-V11.20

N1.51.20

R1.51.20

V-N11.20

A-G11.20

V-B11.20

B - N 1

A - V 1

N 1 . 5

R 1 . 5

V - N 1

A - G 1

V - B 1

X M 1

POTENZIOMETRO

POSTERIORE

MONITOR

1817161514131211109876543212019181716151413121110987654321

X M 2

S29

COMPONENTSH33 2WS warning lampH34 Round steering warning lampH35 Crab steering warning lampS7 2WS steering buttonS8 Round steering buttonS9 Crab steering buttonS28 Front axle alignment sensorS29 Rear axle alignment sensorY1 4WS solenoid valveY2 2WS solenoid valveY3 Round steering solenoid valveY4 Crab steering solenoid valve

CONNECTORSX51 Chassis cable 12 way connectorX52 Steering buttons 13 way connectorX53 Extension 1 way connectorX54 Front axle 3 way connectorX55 Rear axle 3 way connectorX56 Rear potentiometer 3 way connectorX61 4WS solenoid valve 2 way connectorX62 2WS solenoid valve 2 way connectorX63 Round steering solenoid valve 2 way connectorX64 Crab steering solenoid valve 2 way connectorXE EDM 7 way connectorXM1 Monitor 20 way connectorXM2 Monitor 18 way connector



10-94





WB97S-2

8 9754 62 3

X D 11

54D49 54S57/58

L3156b56a 30

DEVIO LUCI

DX

SX

X D 1

X D 1

X D 1

X D 1

X D 1

X D 1

X D 1

X D 1

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

CONNECTORSXD1 Lights switch 9 way connector



10-96





WB97S-2

X1 X4 X6 X8

X2 X3 X5 C04 X9

F1A

F1B

F1C

F2A

F2B

F2C

F3A

F3B

F3C

F4A

F4B

F4C

F5A

F5B

F5C

F6A

F6B

F6C

F7A

F7B

F7C

K2 K4 K6 K8

K1 K3 K5 K7

COMPONENTS

K1 Forward speed relayK2 Reverse speed relayK3 Insert DT relayK4 Safety start relayK5 Low beam relayK6 Main beam relayK7 Lights switch relayK8 Horn relayK9 Flasher unit

FUSES

F1A Low beam fuse 15AF1B Right traffic light fuse 3AF1C Left traffic light 3AF2A Beacon fuse 10AF2B Radio and cabin lamp fuse 7.5AF2C Warning fuse 10AF3A Safety start fuse 7.5AF3B Switch + warning light + return to dig fuse 7.5AF3C Optional valve fuse 7.5AF4A 4WD-windshield wiper/washer fuse 7.5AF4B Forward-reverse speed fuse 10AF4C High beam fuse 15AF5A Blower motor switch fuse 15A

F5B Rear working light switch fuse F5C Front working light switch fuseF6A Windshield wiper-washer switcF6B Lights switch fuse 7.5AF6C Warning power fuse 10AF7A Monitor fuse 7.5AF7B Horn fuse 10AF7C Fuel shut off fuse 7.5A



10-98



Normal or standard technical data ................... 2

Special tools... ..... .... ..... ..... ..... ..... ..... ..... . 16

Measuring engine speed .. .. .. .. .. .. .. .. .. .. .. .. .. .. . 17

Adjusting valve clearance .. .. .. .. .. .. .. .. .. .. .. .. .. .. 18

Measuring compression pressure .. .. .. .. .. .. .. .. .. . 19Testing and adjusting fuel injection timing . .. .. . .. . 20

Checking and tightening the fan - belt .. .. .. .. .. .. .. 22

Checking and tightening the compressorfan - belt ..... ..... ..... ..... ..... ..... ..... ..... .... ... 23

Measuring accelerator pedal operating traveland accelerator lever ... ... ... ... ... ... ... ... ... ... ... 24

Adjusting brake pedal travel, brake alignment,microswitches ......................................... 26

Air bleeding - releasing residual pressure .. .. .. . .. . 27

Checking and setting pressure in the attachmentshydraulic circuit ..... ... ... ... ... ... ... ... ... ... ... ... . 30

Testing and adjusting of load sensing signal(LS valve) ..............................................36

Checking unloading valve functionality .............37

Testing pump delivery . ... ... ... ... ... ... ... ... ... ... .38

Testing priority valve operation ......................40Testing and setting steeringcontrol system pressure ..............................41

Testing brake system ... ... ... ... ... ... ... ... ... ... ... 42

Control of the engine speed under load ............44

Testing pressures in the power train group.........46

Testing the correct functioning of thepower train clutches... ... ... ... ... ... ... ... ... ... ... .. 48

Adjusting the sensor for Return to Dig device.. .. . . 49

Analysis of causes hydraulic drift....................50

Testing the air-conditioning unit .....................55

TESTING AND ADJUSTMENTS

20-1

When carrying out controls, adjustments or analyses for troubleshooting, park the machine on firm, levelground. Apply all the machine safety devices and use blocks to prevent any machine movement.

When more than one person is engaged in the work, use the prescribed notices that indicate that the machineis undergoing maintenance. Do not allow any unauthorised persons to remain in the vicinity.

When checking the level of the cooling liquid, wait until this liquid has cooled. If the radiator cap is removedwhile the liquid is still hot and under pressure, it may cause severe burns.

Take great care not to get entangled in moving parts (fan, alternator belt or any of the rotating elements).

WB97S-2




Engine S4D106-1FA

Check item Test conditions Unit Standardvalue

Permissiblevalue

Engine speed

High idling

Low idling

Set speed

rpm

rpm

rpm

2375w50

1050w50

2200

2375 ± 2425

1000 ± 1100

Ð

Exhaust gascolour

Sudden acceleration

At high idling speed

Bosch

index

0.9

0.5

1.5

1.0

Valve clearanceIntake valve (20ëC)

Exhaust valve (20ëC)

mm

mm

0.3w0.5

0.3w0.5

Max. 0.35

Max. 0.35

Compressionpressure(SAE30 oil)

Oil temperature 69 ± 72ëC

(Engine speed)

kg/cm2

rpm

35w1

250

28w1

250

Blow - bypressure(oil SAE30)

Water temperature in operating range

At high idling speedmm H2O

Ð

Ð

Ð

Ð

Engine oilpressure

Max. idling (in cold state)

At set speed

At low idling

kg/cm2

kg/cm2

kg/cm2

Max. 6

4.5

1

Max. 6

4 ± 5

Min. 1

Oil temperature Entire speed range ëC 120ë Max. 120ë

Fuel injectiontiming B.T.D.C. degrees 12.5 11.5 ± 13.5

Fan belttension Deflection when pressed with finge forceof approx. 10 kg mm 10 10 ± 15

NORMAL OR STANDARD TECHNICAL DATA. FOR ENGINE

20-2 WB97S-2




Classifi-cation

Check item Test conditions UnitStandard

valuePermissible

value

Accelerator pedal

. Hydraulic oil temperature:45± 55 ëC.

. Converter oil temperature:80 ëC

. Engine oil temperaturecooling circuit:in the limits.

Max.

rpm

2375w50 2325 ± 2425

Min. 1050w50 1000 ± 1100

Accelerator fuel

. Hydraulic oil temperature:45± 55 ëC.

. Converter oil temperature:80 ëC

. Engine oil temperaturecooling circuit:in the limits.

Max. 1700w50 1650 ± 1750

Min. 1050w50 1000 ± 1100

All controls(front bucket andbackhoe)

mm

,a b c

,a b c

41.5 8 8 5 Ð Ð Ð Ð

For front shovel armcommand only(with floating arm)

41.5 8 8 5 Ð Ð Ð Ð

Front bucket tilt levercontrol

. Engine stopped

. At the centreof knob lever

. Valve readingat the end ofworking stroke

. Attachmentson the ground

Neutral RaiseLower

mm

80 60 ± 100

Front bucket controllever Neutral Dump

Curled 115 90 ± 140

Front bucket controllever Neutral Raise

Lower 100 80 ± 120

Arm backhoe controllever Neutral

OpeningClosing 100 80 ± 120

Bucket backhoecontrol lever Neutral Opening

Closing 100 80 ± 120

Boom swing backhoecontrol lever Neutral Right

Left 100 80 ± 120

Outriggers controllever Neutral Up

Down 50 35 ± 65

Fuel control lever Min. Max. 70 50 ± 90

Jig arm control pedal Neutral OutIn

15

30

10±20

20±40

Hammer and side diggingboom control pedal Neutral Right

Left15

30

10±20

20±40

. FOR MACHINE

20-3WB97S-2

E n g i n e s p e e d

C o n t r o l v a l v e

T r a v e l o f l e v e r s a n d

p e d a l s

RKZ02580

ᐉa b c




Classifi-cation


valuePermissible

value

Accelerator pedal. Engine

stopped

. At the centreof knob lever

. Valve readingat the end ofworking stroke

. Attachmentson the ground

Min. Max. mm 80 60 ± 100

Wheel swing RightLeft

LeftRight rev. Max. 2.5 2.2 ±2.5

Front bucket tilt levercontrol

. Engine speed: max.

. Oil temperature: 45 ± 55ëC

. Tool connection at the centre of knob(for levers)

. Tool connection on edge(for pedals)

kg

2.5 2 ± 3

Front bucket controllever 2.5 2 ± 3

Boom controllever 1.5 1 ± 2

Arm controllever

1.5 1 ± 2

Bucket control lever 1.5 1 ± 2

Boom swingcontrol lever 1.5 1 ± 2

Outriggers controllever 3 2.5 ± 3.5

Fuel control lever 12 10 ± 14

Jig arm control pedalIn 4

8

3 ± 4

6 ± 1 0Out

Hammer and sidedigging boom controlpedal

8 6 ± 10

Accelerator pedal 3 2 ± 4

Brake pedal 30 Max. 60

. FOR MACHINE

20-4 WB97S-2

T r a v e l o f l e v e r s a n d

p e d a l s

F o r c e f o

r l e v e r s a n d p e d a l s o p e r a t i o n




Classifi-cation


valuePermissible

value

2-3-Spool control valve . Engine speed: max.

. Oil temperature: 45± 55ëC± 55 ëCbar

200 200w7

6-7-8-Spool control valve 200 200w7

Steering unit (safety) . Check on test bench 240 240w7

Front bucket(curled) ]

. Engine speed: max.


. Check one circuit at the time

] Check on test bench

bar

235 235w7

Optional 230 230w7

Front bucket (dump) 175 175w7

Boom (raising) ] 305 305w7

Boom (lowering) 235 235w7

Arm (Closing) 235 235w7

Boom swing 245 245w7

Bucket (curled) 235 235w7

Side digging boom(right-left) 275 275w7

Hammer (delivery) 165 165w7

Steering unit 175 175w7

. FOR MACHINE

20-5WB97S-2

M a i n v a l v e

p r e s s u r e

P r e s s u r e s o f s e c o n d a r y v a l v e s c i r c u i t s




Classifi-cation


valuePermissible

value

With converter

. Engine speed (without load): 2375w50

. Hydraulic oil temperature: 45 ± 55ëC

. Converter oil temperature: 80ëC

. Machine in 4th gear

. Working brakes applied

rpm

2275w50 2225 ± 2525

With converter andhydraulic circuit

. Engine speed: 2375w50

. Hydraulic oil temperature: 45 ± 55ëC

. Converter oil temperature: 80ëC

. Machine in 4th gear


. Front bucket curled stop

. Steering stop

2200w50 2150 ± 2250

With converter(TBG version)

. Engine speed: 2375w50

.Hydraulic oil temperature: 45 ± 55 ëC. Converter oil temperature: 80 ëC

. Machine in 3rd gear


2200w50 2150 ± 2250

With converter andhydraulic circuit(TBG version)

. Engine speed (without load): 2375w50

. Hydraulic oil temperature: 45 ± 55 ëC

. Converter oil temperature: 80 ëC

. Machine in 3rd gear


. Front bucket curled stop

. Steering stop

2200w50 2150 ± 2250

. FOR MACHINE

20-6 WB97S-2

E n g i n e

s p e e d ( w i t h l o a d )

C o n v e r t e r




Classifi-

cationCheck item Test conditions Unit

Standardvalue

Permissiblevalue

Complete workingequipment

(Tip lowering ofbucket teeth)

Measuring posture

. In this position check in feedback of eachcylinder and the leakage with applied

load on the tip of bucket teeth.. Ground level.

. Bucket: normal load (1500 kg)

. Engine stopped


. Check measures as soon as enginestops.

. Check changes every 5 min. and the totalchange in 15 min.

mm

250 400

Cylinders

(cylinder in)30 45

Bucket cylinder

(cylinder in)15 25

Complete workingequipment

(Tip lowering ofbucket teeth)

Measuring posture

. In this position check the extension ofeach cylinder and the leakage with nor-mal load on the bucket.

. On level ground.

. Bucket : normal load (450 kg)

. Engine stopped


. Check measures as soon as enginestops.

. Check changes every 5 min. and the totalchange in 15 min.

mm

300 450

Boom cylinders

(cylinder out)35 50

Arm cylinder

(cylinder out)15 25

Bucket cylinder

(Cylinder in)10 15

. FOR MACHINE

20-7WB97S-2

H y

d r a u l i c d r i f t w o r k i n g e q u i p m e n t

B a c k h o e

F r o n t b u c k e t

RKZ04310

~10°

RKZ00420

1m




Classifi-cation


valuePermissible

value

Boom swing

. Oil temperature: 45 ± 55 ëC

. Backhoe balanced on the guides bucketin transport condition.

. Arm and bucket cylinder in. Put the buc-ket link pin at 1 meter from ground andswing at end of boom stroke in one ofthe two direction.

. Move the machine on a chute of 15ë andapply the parking brake.

. Stop the engine and, after 1 minute,check the cylinder feed back oppositeto the boom every 5 min. for a total of15 minutes.

H Make the test for each swing direction.

mm

15 25

Outriggers


. Backhoe balanced.

. Boom and arm cylinders in,bucket cylinder out

. Outriggers at maximum extension.

. Engine stopped.

. Check the frame lowering for each sideevery 5 min. for a total of 15 minutes.

15 25

. FOR MACHINE

20-8 WB97S-2

H y d r a u l i c

d r i f t w o r k i n g e q u i p m e n t

B a c k h o e

RKZ00490

Max

RKZ04320




Classifi-

cationCheck item Test conditions Unit

Standardvalue

Permissiblevalue

Boom

. Engine: Max. speed


. Leaking check: on the cylinder oppositeside to the pressure one.

H Check 1 cylinder at a time.

H For tilt front bucket, front bucket and forswing, check the two cylinders separate-

ly.

mm

2.0(each cylinder) Max. 8.0

Bucket 1.6(each cylinder) Max. 6.0

Boom 3.3 Max. 13.5

Arm 3.0 Max. 12.0

Bucket 2.4 Max. 9.5

Boom swing 3.2 Max. 13.0

Outriggers 3.3 Max. 13.5

Side digging 2.0 Max. 8.0

Jig arm 1.6 Max. 6.0

. FOR MACHINE

20-9WB97S-2

C y l i n d e r l e a k i n g

B a

c k h o e

F r o n t b u c k

e t




Classifi-cation


valuePermissible

value

Tilt lever frontbucket

Bucket on level ground

Cylinders extended out

Measuring posture

. Engine speed: Max.


sec.

3.9 3.3 ± 4.5

2.6 2.2 ± 3.0

Front bucket

Cylinder extended out

Cylinder in

Measuring posture

. Engine speed: Max.


2.6 2.2 ± 3.0

3.5 3.0 ± 4.0

Boom

Teeth bucket on level

ground

Cylinder in

Measuring posture

. Engine speed: 1900 rpm


. Backhoe balanced

2.6 2.2 ± 3.0

1.9 1.6 ± 2.2

Arm

Cylinder in


Measuring posture



. Backhoe balanced

4.5 3.9 ± 5.1

3.6 3.1 ± 4.1

Bucket

Cylinder in


Measuring posture

.Engine speed: 1900 rpm


. Backhoe balanced

3.1 2.7 ± 3.5

2.6 2.2 ± 3.0

. FOR MACHINE

20-10 WB97S-2

W o r k e q u i p m e n t s p e e d

B

a c k h o e

F r o n t b u c k e t

D u m p

C u r l e d

O p e n i n g

C l o s i n g

L o w e r e d

R a i s e d

D u m p

C u

r l e d

L o w e r e d

R a i s e d

RKZ04330

RKZ04340

RKZ00430

RKZ00440

RKZ00450




Classifi-cation


valuePermissible

value

Boom swing

Left end travel

Right end travel

Measuring posture



. Backhoe balanced

. Arm verticalsec.

4.5 3.9 ± 5.1

4.5 3.9 ± 5.1

Outriggers

All extended

All raised

Measuring posture



. Backhoe balanced

. Dowel joint locking: applied

. Rear wheels raised

. Outriggers at maximum extension

2 1.8 ± 2.2

2 1.8 ± 2.2

. FOR MACHINE

20-11WB97S-2

W o r k e q u i p m e

n t s p e e d

B a c k h o

e

L o w e r i n g

L i f t i n g

L e f t

R i g h t

RKZ00520

RKZ02570




Classifi-cation


valuePermissible

value

Tilt lever frontbucket

Measuring posture

. Engine speed: Min.


. Check the time necessary to lift bucketfrom level ground.

sec.

0 Max. 2

Boom

Measuring posture



. With attachments fully extended, lowerthe boom and check the necessary timefrom the beginning of machine lifting untilbucket is on level ground.

0 Max. 2

Arm

Measuring posture



. Put boom at 45ë, open completely thearm with curled bucket. Extend arm cylin-der and check the time passing betweenarm stop at dead centre and the restartmovement.

0 Max. 2

. FOR MACHINE

20-12 WB97S-2

W o r k e

q u i p m e n t

T i m

e l a g s

RKZ04330

RKZ00460

RKZ00471

45°




Classifi-cation


valuePermissible

value

Bucket

Measuring posture



. Put arm in horizontal position. Tilt backbucket cylinder an then extend it.Check the time passing between bucketstop at dead centre and the restart move-ment.

sec.

0 Max. 2

Outriggers

Measuring posture



. Boom, arm and bucket fully retracted andputted in machine centre position.

. Check the time necessary for outriggersto raise the machine from when they leanon level ground.

H Check each outrigger at a time.

0 Max. 2

. FOR MACHINE

20-13WB97S-2

W o r k e q u i p m e n t

T i m e l a g s

RKZ00480

RKZ00520




Classifi-cation

. Piston pump P1 delivery.

. Working mode: Economy.

. Pump speed: 2200 rpm

. Hydraulic oil temperature: 45 ± 55ëC.

H When measuring deliveries with the pump mounted on the machine, it becomes difficult to use theaccelerator to set the number of engine rpm corresponding to the test speed prescribed for the pump.

Measure the delivery with the engine set to 2200 rpm, and perform a proportional calculation to findthe delivery value required for the test.

20-14 WB97S-2

P u m p s c h a r a c t e r i s t i c s

Portata massima(teorica)

Portata minimaammessa

0

200(204)

280(285,7)

Q (ᐍ /min)40 12080

P ( b a r )

( k g / c m 2 )

40(40,8)

80(81,6)

160

(163,2)

120(124,5)

240(244,9)

320(326,5)

160

RKZ02611

Max. delivery(theoretical)

Delivery(lower limit)




Classifi-cation

. Piston pump P1 delivery.

. Working mode: Power

. Pump speed: 2200 rpm


H When measuring deliveries with the pump mounted on the machine, it becomes difficult to use theaccelerator to set the number of engine rpm corresponding to the test speed prescribed for the pump.

Measure the delivery with the engine set to 2200 rpm, and perform a proportional calculation to findthe delivery value required for the test.

20-15WB97S-2

0

200(204)

280(285,7)

Q (ᐍ /min)40 12080

P ( b a r )

( k g / c m 2 )

Portata massima(teorica)

Portata minimaammessa

40(40,8)

80(81,6)

160(163,2)

120(124,5)

240(244,9)

320(326,5)

160

RKZ02621

Max. delivery(theoretical)

Delivery(lower limit)

P u m p s c h a r a c t e r i s t i c s



Measurement check point Symbol Code Name Q.ty Note

Valve clearance A 1Commercially

available Feeler gauge 1 Ð

Compression pressure B1

ATR800280Compression gauge 1 Ð

2 Adapter 1 Ð

Engine speed C1 Commercially

available Multiscale tachometer 1 20 - 4000 rpm

2 ATR800060 Stroboscopic tachometer 1 6 - 30000 rpm

Oil and water temperature D 1 Commerciallyavailable Digital thermometer 1 ± 50 - 1200 ëC

Hydraulic pressure

E

1 ATR800170 Pressure gauge 2 Full scale 60 bar




5

ATR800200

(Only for Europe)

Servocontrol kitDifferential digitalpressure gauge

1 0 ± 1000 bar6

F1 Flow-meter 1 Delivery: 0 ± 300 ,/min

2 Pipe fitting kit 1 Ð

G 1 ATR201490 Tank cap 1 Pump air bleeding

Braking group H1

ATR201500Tool to checkleaktightness of brakes 1 Ð

2 Union kit 1 Ð

Hand brake L 1 Commerciallyavailable Spring dynamometer 1 Full scale 20 kg

Air-conditioning unit M

1Commercially

available Maintenance station 1 For Coolant R134a

2 Commerciallyavailable Thermometer-Hygrometer 1 Sampling every 15

seconds

3 Commerciallyavailable

Leak detector 1 For coolant R134a

SPECIAL TOOLS

20-16

TESTING AND ADJUSTMENTS SPECIAL TOOLS

WB97S-2



TESTING AND ADJUSTMENTS MEASURING ENGINE SPEED

20-17

MEASURING ENGINE SPEED

When checking engine speed, be careful not totouch high temperature parts and not to get caughtin rotating parts.

H Check speed when following condition are reached:

. Engine water cooling temperature: 68 ± 80ëC.


1 - Remove the air filter (1) and release the heating linesfrom the hose-clamp (2).

2 - Install and connect C1 tachometer.

H If using C2 stroboscopic tachometer, mark a lightnotch on, engine pulley for an easier reading.

3 - Start engine and check:

. Low idling speed without load (accelerator pedal

released in «minimum» position).. High idling speed without load (accelerator pedal

at the travel end).

H Low idling speed: 1050w50 rpm

H High idling speed: 2375w50 rpm

H If low and high idling speed with engine withoutload are not within permissible value, beforegoing on with other operations, check acceleratorpedal stoppers and wiring sheathings. (See «AC-CELERATOR LEVER ADJUSTING»).

WB97S-2

RKZA1763

1

2

RKZA5300

C1



ADJUSTING VALVE CLEARANCE

H Engine: in cold state.

H Adjust clearance between valves and rocker levers as

follows:Unit: mm

At coldengine

Intake-exhaust

0.30w0.05

H Firing order: 1-3-4-2-1..... at 180ë step.

H Normal rotation sense: counterclockwise from flyw-heel

H The cylinder Në 1 is on the opposite fan side.

. Adjusting procedure

1 - Remove air cleaner (1), intake manifold (2) andvalves cover (3).

2 - Rotate crankshaft in normal direction as long ascylinder piston to be checked is at compressionTop Dead Center (PMS).

H In this position intake and exhaust valves areclosed.

3 - Loose lock nut (4) and unscrew tappet (5) of about1 turn.

H Check that valve insert (6) is laying flat on val-ve stem and that it is not worn askew.

1 - If valve inserts (6) are damaged, replaced

them with new ones.2 - Make sure that inserts feet and lay flat on

valve stem.

4 - Connect A1 feeler gauge between insert and roc-ker lever to adjust; rotate the tappet (5) until tou-ching A1 feeler gauge.Tight tappet (5) with lock nut (4).

Nut: 14.7 ± 19.6 Nm

H After tightening the lock nut, check the clea-rance again.

5 - Adjust with same procedures second cylinder val-ve and repeat same operation for the other cylin-

ders, according to the firing order.

. Cover valves installation

1 - Check condition of cover valves (3), gasket (7), O-Rings (8) and lock nuts (9); clean carefully contactsurface on cylinder head.

2 - Install valves cover (3), fit O-Rings (8) and locknuts (9).

Cover lock nut: 25w3 Nm

20-18

TESTING AND ADJUSTMENTS ADJUSTING VALVE CLEARANCE

WB97S-2

RKZA5310

1

3

2

RKZ019106

6

4

5

SI NOYES NO

RKZ01920

54

A1

RKZ01930

8

93

7



TESTING AND ADJUSTMENTS MEASURING COMPRESSION PRESSURE

20-19

MEASURING COMPRESSION PRESSURE

. When measuring the compression pressure becareful not to get caught in cooling fan, in the al-ternator belt or in other rotating parts.

. For this measurement the engine should be up toworking temperature. Take every precautionagainst burns.

. Check all cylinders.

H Test condition:

. Engine: at operating temperature

. Hydraulic oil: 55 ± 60 ëC.

. Battery: at full charge

. Valve clearance:adjusted (see «ADJUSTING VALVE»)

1 - Disconnect high pressure pipe (1).

2 - Remove nozzle holder assembly (2) of cylinder to bechecked.

3 - Disconnect connector (3) of fuel cut-off solenoid valve(4).

4 - Crank engine with starting motor.

5 - Install B2 adapter and connect B1 pressure gauge

H Check that seal is installed in the adapter and thatit is not damaged.

6 - Crank engine with starting motor and measure com-pression pressure.

H Measure the compression pressure at the pointwhere the pressure gauge indicator remains stea-dy.

H When measuring the compression pressure,check also engine speed with C2 stroboscopictachometer; if speed is not within the specified

range, refer to diagram.H Compression value:

Normal: 35w1 kg/cm2 at 250 rpmMinimum permissible: 28w1 kg/cm2 at 250 rpm

H Difference between cylinders: 2 ± 3 kg/cm2

7 - After measuring, install the nozzle holder assembly(2), connect high pressure pipe, feedback pipe andconnector (3).

Nozzle holder collar bolts: 9.8 ± 11.8 Nm

High pressure union: 19.6± 24.5 Nm

WB97S-2

RKZA5320

2

1

RKZA5330

4

3

RKZA5340

B1

B2

RKZ01940

35

40

30

25

20

200 250 300 350 400Velocità motore (giri/min)

P r e s s i o n e d i c o m p r e s s i o n e

( k g / c m 2 )

C o m p r e s s i o n p r e s s u r e

Engine speed (rpm)



TESTING AND ADJUSTING FUEL INJECTION TIMING

H Check fuel injection timing of N.1 cylinder bymeans of N.1 delivery valve of injection pump.

H Cylinders are numbered 1-2-3-4 starting from fly-wheel side.

1 - Rotate crankshaft using engine pulley and put N. 1cy-linder piston at top dead centre (PMS).

H Top dead centre (PMS) is shown by notch (4) on

pulley (1) positioned on «zero» of the scale (5)and by closing of both cylinder N. 1 valves.

H If the notch (4) of pulley (1) is in «zero» position onthe scale (5) but cylinders N. 1 valves are notclosed, rotate the crankshaft of 1 turn.

H After recognition of PMS, rotate the crankshaft incounterclockwise direction (from pulley side view)of about 20ë.

2 - Disconnect cylinder N.1 high pressure pipe (2) frominjection pump.

3 - Rotate crankshaft slowly in clockwise direction frompulley side view, checking fuel level into the N. 1 de-livery of injection pump.

4 - Stop pulley (1) rotation as soon as fuel level starts toincrease.

20-20

TESTING AND ADJUSTMENTS TESTING AND ADJUSTING FUEL INJECTION TIMING

WB97S-2

RKZ01960

Volano

Cilindro Nº1

1

N. 1 Cylinder

Flywheel

RKZA5350

1

5

4

Nº1

RKZA0071

2

RKZ01970

RaccordoNº1

LivelloN. 1 Union

Level



TESTING AND ADJUSTMENTS TESTING AND ADJUSTING FUEL INJECTION TIMING

20-21

5 - Check notch (4) position on crankshaft pulley (1) com-pared with scale (5); reading value corresponds to an-

gle of fuel injection timing.H Standard fuel injection timing: 12.5ëw1ë

NOTE. Repeat checking more than once.

6 - If injection timing is not on standard value, rotate in-

jection pump (6) toward external or toward engineafter loosening pump nuts (7) (quantity 4) and pumplock nuts (8) fixing the bracket (9) to injection pump.

. To RETARD injection, rotate pump (6) toward ex-ternal.

. To ADVANCE injection, rotate pump (6) towardcylinders block.

7 - Tight the pump lock nuts (7) at cylinder block andpump lock nut (8) at bracket (9).

Nuts: 34.2 ± 44.1 Nm

Bracket lock nut: 44.1 ± 53.9 Nm

8 - Connect fuel delivery pipe (2) to pumpDelivery pipe union: 19.6 ± 24.5 Nm

WB97S-2

RKZA5360

1

4

5

RKZA5370

9

8

6

7

Lato pompa

Lato carter

Controllo anticipod'iniezione

Pump side

Carter side

Testing advanceinjector



CHECKING AND TIGHTENING THE FAN - BELT

1. Tension check

1 - Push fan belt (1) at midway point between alterna-

tor (2) and pulley (3) operating water pump; checkthe deflection.With a pressure of 10 kg, deflection should be of10 ± 15 mm; if this value is not reached, tensionfan belt.

H With new belt, deflection must be of 7 ± 9 mm.

2 . Fan belt tension

1 - Loosen mounting bolt (4) of the alternator (2) andmounting bolt (5) of adjustment plate.

2 - Rotate the alternator (2) to give correct tension tofan belt (1) and tighten mounting bolts (4) and (5).

3 - Check fan belt (1) tension.

H If belt has been replaced, check tension againafter about 20 operating hours.

Bolts (4): 44.1 ± 53.9 Nm

Bolts (5): 22.5 ± 28.4 Nm

20-22

TESTING AND ADJUSTMENTS CHECKING AND TIGHTENING THE FAN - BELT

WB97S-2

RKZA5700

1

32

RKZA5690

4

5

RKZ01980

Alternatore

Puleggiaalbero motore

Puleggia pompaacqua

10÷15 mm

Water pumppulley

Crankshaftpulley

Alternator

10±15 mm



TESTING AND ADJUSTMENTS CHECKING AND TIGHTENING THE COMPRESSOR FAN - BELT

20-23

CHECKING AND TIGHTENING THE COMPRESSOR FAN - BELT

1. Checking tension

1 - Push fan belt (1) at midway point between com-

pressor (2) and pulley (3).Check the deflection.With a pressure of 10 kg, deflection should be of7 ± 10 mm; if this value is not reached, tensionfan belt.

H With new belt, deflection must be of 4 ± 6 mm.

2 . Fan belt tension

1 - Loosen mounting bolt (4) of the eccentric (5).

2 - Apply tube on eccentric (5), give correct tension tofan belt and lock with bolt (4).

3 - Check fan belt (1) tension

H If belt has been replaced, check tension againafter about 20 operating hours.

Bolt: 123 Nm

WB97S-2

RKZO3260

1

23

7÷10 mm

RKZA8560

5

4

1



MEASURING ACCELERATOR PEDAL OPERATING TRAVELAND ACCELERATOR LEVER

H Work condition:

. Machine: in safety conditions.

. Engine stopped and at working temperature

. Low and high idling speed: within permissible va-lue.

H In order to check high speed engine idling,push the accelerator pedal (1) manually.

1. Accelerator pedal travel adjusting

1 - Make sure that accelerator pedal (1) is fully raisedand accelerator lever (2) is at minimum stroke.

2 - Check that accelerator lever (3) is in contact withlow idling speed adjusting screw (4).

3 - Adjust nut (5) and lock nut (6) of accelerator pedal

cables and hand accelerator at a distance of

0.2 ± 0.3 mm from lever (7).

4 - Push accelerator pedal until accelerator lever (3)contacts the high idling adjusting screw (8).

5 - Adjust the end travel stopper (9) of accelerator pe-dal (1) in this position and lock it with nut (10).

6 - Release the accelerator pedal (1).

20-24

TESTING AND ADJUSTMENTSMEASURING ACCELERATOR PEDAL OPERATING

TRAVEL AND ACCELERATOR LEVER

WB97S-2

RKZA8150

1

2

RKZA5390

4 8

3

RKZA5400

7

5 6

RKZA8160

1

9

10



TESTING AND ADJUSTMENTSMEASURING ACCELERATOR PEDAL OPERATING

TRAVEL AND ACCELERATOR LEVER

20-25

2. Accelerator lever travel adjusting

1 - Remove knob (1), accelerator lever (2) and lateral

cover (3).

2 - Temporally, re-assembly accelerator lever (2); loo-

sen nut (4) and tight the end lever travel bolt (5) ofsome turns.

3 - Start engine and bring it to the defined idlingspeed for accelerator lever.

H Check using the stroboscopic tachometer C2.

H Engine idling speed: 1900w50 rpm

4 - Loosen end lever travel bolt (5) up to it is in con-tact with lever (2) and looked with nut (4).

5 - Bring engine at low idling and check acceleratorlever idling speed again pushing lever at end stro-ke.

WB97S-2

RKZA8750

3

1

2

RKZA5430

4

5

2



ADJUSTING BRAKE PEDAL TRAVEL, BRAKE ALIGNMENT,MICROSWITCHES

H Working condition:

. Engine stopped

. Machine with attachments on ground level

1 - Check that pedal (1) is near to the stopper (2) and thepedals side are at "A" measure from cab level.If necessary, adjust height acting on the stopper (2).

H "A" measure: 313w3 mm

H Check that pin (3) can freely run and lock the ped-als (1).

Master cylinder rod adjustment

2 - Loosen nut (4) locking the adjusting rod (5) and loos-en until it touches the brake pump piston seat.

3 - Tighten the adjusting rod (5) of one turn (360ë) andlock it with nut (4).

4 - Repeat operations 3. and 4. for the other pedal.

H After tightened nuts (4), check that the adjustingrod (5) touch the brake pump piston seat simulta-neously.

Microswitches adjustment

5 - Loosen microswitches (7) locking nuts (6).

6 - Adjust microswitches (7) paying attention to guaran-tee (at pedals in neutral position) a minimum clear-ance (about 1 mm) between microswitches bodyand the pedal.

Checking adjustment

7 - Verify measure like shown in figure.

H "A" measure: at pedal in neutral position

"B" measure: at master cylinder rod touching thepump

"C" measure: with pedal releases microswitch rod.

20-26

TESTING AND ADJUSTMENTSADJUSTING BRAKE PEDAL TRAVEL,

BRAKE ALIGNMENT, MICROSWITCHES

WB97S-2

RKZA8172

1

3

RKZ03671

6

A = 313±3 mm

C = 292 mm

B = 302 mm

1 mm( 0 .0 39 4 i n.)

7

1

2

RKZ019515

2

4



TESTING AND ADJUSTMENTS AIR BLEEDING - RELEASING RESIDUAL PRESSURE

20-27

AIR BLEEDING - RELEASING RESIDUAL PRESSURE

1. Air bleeding from pump

H Air bleeding from pump (that means the filling ofpump body) is necessary:

1 - When removing pump.

2 - When removing or replacing connection hosesbetween pump and hydraulic tank.

3 - When replacing hydraulic oil and hydraulictank overhaul.

The air bleeding is obtained as follows:

1 - Carry out tank oil filling and close hydraulic tankwith plug G1.

2 - Remove plug (1) of breather pipe (2).

3 - Connect plug G1 to low pressure air compressed

connection.4 - Introduce slowly and intermittently air compressed

in the hydraulic tank until when flows out oil wi-thout air bubbles.

H Max. pressure in tank: 0.5 bar

5 - Mount plug (1) and lock it.

6 - Depressurize slowly hydraulic tank, check leveland, if necessary, refill tank oil at correct level.

7 - Start engine and run it for few minutes beforebleeding air from the whole system.

2. Air bleeding from cylinders

H When hydraulic cylinders or pipe fitting have beenremoved, it is necessary to bleed air before to useagain the machine.

H Operate on a movement at a time starting frommain cylinders (lifting).

1 - Start engine and run it at high idling speed forabout 5 min. to worm up oil and to pressurise hy-draulic system.

2 - Return engine at low idling speed, extend and re-tract the interested piston 4-5 times.

H Extend, lower and retract pistons until about100 mm from their end of stroke.

3 - Bring again the engine at high idling speed andrepeat operation of point 2; return the engine atlow idling speed and make a complete travel of pi-ston until the hydraulic pump reaches its maxi-mum pressure.

4 - Repeat above operation (starting from point 2) forall cylinders.

WB97S-2

RKZA8180

G1

RKZA8090

1

2



3. Air bleeding from oil tank

1 - Put the machine in oil level check position and re-

move the tank plug.H If necessary add oil until reaching the correct

level.

2 - After stopping the engine wait for some minutes,until air bubbles on oil surface are fully disappea-red.

3 - Install tank plug.

4. Hydraulic oil tank pressurization

1 - With engine at low idling speed extend slowly, upto end of stroke, all cylinders.

2 - Stop the engine and remove tank plug.3 - Check the condition of gasket and reassemble

plug.

H Avoid to increase the engine speed beforecompleting all air bleeding procedures and af-ter the pressurization of oil tank.

H After air bleeding procedures, operate engineat low Idling speed for about 10 minutes befo-re starting to work.

5. 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 release

completely cylinders and main circuit remain pres-sure.

3 - Loosen slowly oil filler tank to remove remainpressure.

6. Air bleeding from braking circuit

H Above operation is to be carried out every timemaintenance is made on braking circuit to removeor replace a component, or when air entered into

the circuit.H Machine must be stopped with attachments on le-

vel ground.

1 - Make sure that oil in brake system tank (1) is atmaximum level.

2 - Remove pedal lock pin.

3 - Remove safety plugs and applied to bleedingscrews (2) a vinyl hose (3) to catch oil.

4 - Push brake pedals to bottom and, keeping it pus-hed, loosen bleeding screw (2) of the left brakingunit until the pedals reach end of their stroke.

5 - Keeping pedal at the end stroke, tighten bleedingscrew (2).

20-28


WB97S-2

RKZA5460

1

RKZA90502

3




20-29

6 - Release brake pedals, wait for few seconds andrepeat above operations two or three times until

from bleeding screw, oil flows out without air bub-bles.

7 - Repeat same operations for the right braking unit.

8 - Disconnect pedal lock pin.

9 - Push one brake pedal to bottom and, keeping itpushed, loosen bleeding screw (2) of one of twobraking units until the pedal reaches end of itsstroke.

H Check that oil flows out without air bubblesfrom bleeding screw (2).

10 - Repeat same operations for the other braking unit.

H Check frequently the oil level in the tank andcarry out filling every time level approachesto minimum.

H After air bleeding apply on screws (2) safetyplugs.

7. Checking air bleeding from braking circuit

1 - Start engine, remove block from wheels.Lower the backhoe outrigger and force themdownwards in order to raise the rear wheels.

2 - Engage forward/reverse gear in order to movewheels.

3 - Return the machine in neutral and lower it andstop the engine.

4 - Apply 50 kg on the pedal and verify measure "D".

5 - Insert pedal lock pin and applying the same massverify the measure "D".

H "D" measure with one pedal pushed:not less than 165 mm

H "D" measure with both pedal pushed:not less than 170 mm

8. Emptying the air-conditioning unit

1 - Connect the maintenance station M1 to the servi-ce valves (1) and (2) and follow the specific main-tenance station instructions relative to the draina-ge of the unit.

2 - Disconnect the group to be substituted or recondi-tioned immediately after switching off the mainte-nance station. Plug the removed or disconnec-ted connection tubes tightly and with a mini-mum of delay.

3 - Carefully check the quantity of anti-freeze oil reco-

vered and contained in the disassembled parts,since the same quantity must be replaced whenthe air-conditioning unit is refilled.

WB97S-2

RKZ03680

D

RKZA8570

2

1



CHECKING AND SETTING PRESSURE IN THE ATTACHMENTSHYDRAULIC CIRCUIT1. Introduction

. On the machine configuration, one or two spool.Mechanical control valves have been installedwith following function:

Control valve No. 1 (2-3-spools):for front work attachments control.

Control valve No. 2 (6-7-8-spools):for rear work attachments control.

. The two control valves are protected against over-pressure by a main relief valve (or general andnamed Pressure cut off valve) with fixed setting.

. Control valves are feeded by P1 pump total deliv-ery.

. P1 pump delivery is checked by a priority valve(internal to the control valve N. 1) when steering

unit is used.

. Control valves include spools controlling:

2-SPOOL CONTROL VALVE

Control Port

Front bucket (curled - dump) A1-B1

Front bucket (lifting - lowering) A2-B2

20-30

TESTING AND ADJUSTMENTSCHECKING AND SETTING PRESSURE IN

THE ATTACHMENTS HYDRAULIC CIRCUIT

WB97S-2

RKZ02490

DISTRIBUTOREPALA ANTERIORE

(2-3 ELEMENTI)

DISTRIBUTORERETROESCAVATORE

(6-7-8 ELEMENTI)

VALVOLAGENERALE

DIESEL

P1

IDROGUIDA

TRASMISSIONE

STEERING UNIT

FRONT SHOVELCONTROL VALVE

(2-3 SPOOLS)

POWER TRAIN

DIESEL

P1

MAIN RELIEFVALVE

BACKHOECONTROL VALVE

(6-7-8 SPOOLS)

RKZ02040

A1 2

B





20-31


Control Port

Optional attachment A1-B1

Front bucket (curled - dump) A2-B2

Front bucket (lifting - lowering) A3-B3


Control Port

Arm (opening - closing) A1-B1

Boom swing (left - right) A2-B2

R.H. outrigger (up - down) A3-B3

L.H. outrigger (up - down) A4-B4

Bucket cylinder (dump - curled) A5-B5

Boom cylinder (lifting - lowering) A6-B6


(For jig arm)

Control Port

Jig arm (in - out) A7-B7


(For hammer - side digging boom)

Control Port

Hammer (R.H. side - L.H. side) A7-B7

Side digging boom (left - right) A7-B7

WB97S-2

RKZ02060

A1 2

B3

RKZ02070

1 2 3 4 5 6

A

B

RKZ02080

7

A

B

RKZ02090

7

A

B




(For hammer and jig arm)

Control Port

Hammer (R.H. side - L.H. side) A7-B7

Jig arm (in - out) A8-B8

2. Testing and setting general valves

(Pressure cut off valve)

H Test condition:


. Hydraulic oil: 45 ± 55 ëC


1 - Connect the pressure gauge E3 (400 bar) to thepressure adapter (1) of the front shovel control val-ve (2).

2 - Start the engine, bring the hand accelerator leverup to 1050 rpm and check the nominal pressure ofthe main relief valve (pressure cut-off valve) by for-

cing the front bucket to rise to the end of its stroke.H Nominal pressure: 221

± 1+6

H If the main relief valve pressure do not corre-spond to the nominal values, they must bere-set (See «SETTING THE MAIN RELIEFVALVES AND THE REDUCING VALVES»).

3. Testing and setting secondary valves

H Test condition:

. Engine: at operating temperature.

. Hydraulic oil: 55 ± 60 ëC.

. Parking brake: applied.

H The pressure readings are to be operated fromthe same check point.

1 - Connect the pressure gauge E3 (400 bar) tothe pressure adapter (1) of the backhoe con-trol valve (2).

2 - Start the engine and bring the hand accelera-tor lever up to 1050 rpm.

20-32



WB97S-2

RKZ02050

7

A8

B

A

B

RKZA5480

1

2

E3

RKZA5480

1

2

E3





20-33

3 - Set the main relief valve (pressure cut-off val-ve) to a value 30 bar higher than the maximum

pressure to be tested.4 - Check the single movements pressure.

The secondary valve of backhoe boom lif-ting, must be checked and settled ontest bench only.

Setting 2-spool control valve secondary valvesUnit: bar

Cylinder and movement Port Setting

Frontbucket

Lifting A1 Ð

Lowering B1 Ð

Front

bucket

Curled A2 235w7

Dump ] B2 175w7

] This setting can be carried without modifing the general valve pres-

sure.



Frontbucket

Lifting A1 Ð

Lowering B1 Ð

Frontbucket

Curled A2 235w7

Dump ] B2 175w7

Optionalattachment

A3 230w7

B3 230w7

] This setting can be carried without modifing the general valve pres-

sure.



ArmClosing A1 235w7

Opening B1 Ð

Boom swing Left A2 245w7Right B2 245w7

Right outriggerUp A3 Ð

Down B3 Ð

Left outriggerUp A4 Ð

Down B4 Ð

Bucket Dump A5 Ð

Curled B5 235w7

Boom Lifting ] A6 305w7

Lowering B6 235w7

] The setting must be carried on test bench only.

WB97S-2



Nominal values of the reducing valves of the 7-8 element control valve(for the other settings, please refer to the 6-element control valve).

Unit: barNo. of spools Cylinder and movement Port Setting

7

HammerR.H. side A7 165w7

L.H. side ] B7 Ð

Side digging boomRight A7 275w7

Left B7 275w7

Jig armIn A7 Ð

Out B7 Ð

8

HammerR.H. side A7 Ð

L.H. side ] B7 Ð

Jig armIn A8 Ð

Out B8 Ð

] This setting can be carried without modifing the general valve pressure.

H If valve setting pressure do not correspond to theindicated ones, provide to set them (see «SET-TING MAIN AND SECONDARY VALVES»).

4 - Set the general valve pressure to the standard va-lue.

4. Main and secondary valves setting

. General valves (Pressure cut off valve (1)For setting, prepare machine as per pressure te-sting.

1 - Loosen lock nut (2).

2 - Force to the end of its stroke the lever commandingwhichever movement is being used for the tests.

3 - Adjust pressure with adjusting screw (3).

. To INCREASE pressure, rotate in CLOCKWI-SE direction.

. To DECREASE pressure, rotate in COUN-

TERCLOCKWISE direction.4 - Lock position with nut (2).

20-34



WB97S-2

RKZA8100

1

RKZ02241

2

3





20-35

. Secondary valves

For setting, prepare machine as per pressure te-

sting.

H This setting is valid for all the secondary valveand has to be carried forcing the movement tobe checked at its end of stroke.

1 - Loosen lock nut (1).

2 - Adjust pressure with adjusting screw (2).


. To DECREASE pressure, rotate in COUN-TERCLOCKWISE direction.

3 - Lock position with nut (1).

Lock nut: 10w1 Nm.

When terminated the setting, Apply safetyplug (3) to avoid not authorised tamperings.

4 - Set the general valve pressure to the standard va-lue.

WB97S-2

12

3

RKZ02010



TESTING AND ADJUSTING OF LOAD SENSING SIGNAL(LS VALVE)

H Testing conditions.

. Engine: stopped but at working temperature.

. Hydraulic oil: 45 ± 55ëC.

. Machine: front equipment on the ground, parkingbrake applied and boom and arm fully extended.

1 - Disconnect hose(1) from the Load Sensing line. In-stall an thee (2) and reconnect hose (1).

2 - Connect to thee (2) a pressure port and gauge E3(400 bar).

3 - Connect to rear control valve pressure port a pres-

sure gauge E3 (400 bar).

4 - Start the engine and bring it to 2000 rpm; check thatwith no movements the Load Sensing pressure is6w2 bar.

5 - Raise boom up to middle of stroke; force the move-ment and read the pressure on both gauges.

6 - Calculate the differential pressure (iP) substractingthe reading from the two gauges (control valve P -Load Sensing PLS).

H Normal DP: P ± PLS= 18w1 bar

H If the iP value is not inside the limits, carry out

the Load sensing valve (3) setting.

1. Adjusting of the Load Sensing valve

1 - Remove nut (4).

2 - Loosen nut (5).

3 - Adjust pressure using adjusting screw (6).


. To DECREASE pressure, rotate in COUN-TERCLOCKWISE direction.

4 - Lock the position with nut (5).Lock nut: 21 Nm

5 - Check gasket (7) and mount nut (4).

Nut: 21 Nm

20-36

TESTING AND ADJUSTMENTS LOAD SENSING SIGNAL (LS VALVE)

WB97S-2

RKZA5501

1

E3

2

RKZA5480

1

2

E3

RKZA5710

RKZ02270

1 3

4 56

7



TESTING AND ADJUSTMENTS CHECKING UNLOADING VALVE FUNCTIONALITY

20-37

CHECKING UNLOADING VALVE FUNCTIONALITY

H Test condition:


. Low idling: in the permissible limit.


. Machine: in safety condition, parking brake ap-plied.

. Control valve lever at neutral position.

1 - Disconnect hose (1) from the Load Sensing line. In-stall an thee (2) and reconnect hose (1).

2 - Connect to thee (2) a pressure port and gauge E1 (60bar).

3 - Connect gauge E1 (60 bar) to rear control valve pres-

sure port (3).

4 - Start the engine at low idling and without any move-ment check pressure on both gauges.

H Normal pressure (P) control valve gauge27w3 bar

H Normal pressure Load Sensing line gauge (PLS):6w2 bar

(This value is due to the influence of the counter-pressure present in the steering circuit).

H If any variations are found, they do not representa problem provided that the difference of 21w1bar between the two readings is respected.

5 - If the difference between the two readings is higherthan 21w1 bar, stop the engine and release residualpressures.

6 - Thoroughly clean the valve (4) and re-install it.

Valve: 20 Nm

7 - If, in spite of cleaning the valve (4), the value of 21w1bar still does not fall within the tolerance limits, installa new valve.

WB97S-2

RKZA8740

E1

1

2

RKZA5511

E1

3

RKZA8102

4



TESTING PUMP DELIVERY

H Test condition:



. General valve (Pressure cut off valve) and sec-ondary valve: within normal limits.

. Machine: front equipment on the ground, boomand arm fully extended and bucket fully curledand on the ground.

. Parking brake: applied.

1. Flow-meter connection

1 - Release residual pressure.

2 - Disconnect bucket bottom side hose (1) and headside (2).

H Plug holes to avoid impurity inlet.

3 - Connect cylinder bottom side hose (1) to the flow-meter F1 inlet port and connect the cylinder headside hose to the outlet port.

4 - Use a tachometer C2 to control that pump deliveryis within the rpm limits during the test.

H If using a multiscale tachometer C1 mountedon fuel delivery pipe, check that it is mountedfar from the pipes retainer.

H Pumps diagrams are refereed to constantidling for all the use range.

H When measuring the deliveries with the pumpmounted on the machine it becomes difficultto use the accelerator to set the engine idling.Make delivery measurements with the enginerunning at a speed close to the test speed andthen make a proportional calculation.

2. Measurement

1 - Start the engine and bring it up to 2200 rpm.

2 - Move the bucket curling lever up to end of strokeand, with the lever in this condition, adjust the de-livery pressure with the flowmeter F1 knob (3).

20-38

TESTING AND ADJUSTMENTS TESTING PUMP DELIVERY

WB97S-2

RKZA5520

F1

12

RKZA5300

C1

Example:

MEASUREMENT

Engine speed: 2144 rpm

Delivery: 153.97 ,/min

PROPORTIONAL DELIVERY AT 2200 rpm

153.97 x 2200 = 158 ,/minÐÐÐÐ

2144

RKZA5530

F1

3

PRESSURE

DELIVERY



TESTING AND ADJUSTMENTS TESTING PUMP DELIVERY

20-39

3 - Check the effective delivery flow and the engineidling speed at each pressure increment, perfor-

ming different reading each 20 bar pressure in-creasing, extending the readings to all the wor-king range (up to the maximum value set by thegeneral valve).

H Perform more than once the reading to have amedia of the values.

H Those tests check the Economy mode curve.

H After checked the pump characteristic curve ispossible to carry out the check of the point ofpump initial regulation, that means the pointwhere the pump starts reducing the deliveryto preserve the pressure required.To obtain the exact position of this diagram

point, perform the pressure-delivery-enginespeed tests each 10 bar a zone close to thepoint found in the preceding test.

4 - Release pressure to the minimum value using theflowmeter F1 knob (3) and insert the Power mode(«Speed control» push-button).

5 - Repeat phase 3 procedure to check Power modecurve (Power mode).

6 - Release the «Speed control» push-button, reducepressure and stop the engine.

7 - Check the flow - pressure against the value shown

on «TECHNICAL SPECIFICATION».H If the measured value is lower of more the 7%

than the permissible, it is necessary to over-haul of the pump.

8 - Release the residual pressure.

9 - Restore the bucket hoses connection to the cylin-der.

WB97S-2

RKZ02260

00

b a r

ᐍ /min

Power

Economy

Inizio regolazione

Power

Economy

Initial regulation



TESTING PRIORITY VALVE OPERATION

H Test condition:

. Engine: operating temperature


. Parking brakes: applied

1. Testing Load Sensing signal

1 - Connect a pressure gauge E2 (250 bar) to thepressure adapter (1) of the backhoe control valve.

2 - Start the engine and bring it to idle speed of1500 ± 50 rpm.

3 - Check on gauge E2 pressure value with stoppedsteering wheel (21 bar).

4 - Start a slight steering and check that pressure in-creases.

5 - Continue the steering up to end of stroke andcheck that, forcing the steering wheel, pressureincreases till normal value.

H Normal pressure: 175w7 bar.

H If the pressure does not reach the normal va-lue, re-set the pressure of the steering unit.

H If turning the steering wheel the pressureshown by gauge does not change and stresson steering wheel necessary to carry out stee-ring is high, check the priority valve (2).

2. Testing priority valve operation

1 - Remove priority valve plug (3), spring (4) and rod(5).

H Check and make notes on the direction of as-sembly.

2 - Dismantle the plug (6) and remove the ball (7) ofthe inside valve and the spring (8).

3 - Check that the hole (9) and the nozzle (10) are per-fectly clean.

4 - Replace the spring (8), the ball (7) and the plug(6).

Plug: Loctite 542

Plug: 20 Nm

H Do not allow any Loctite to enter the hole (9).

H Remove all excess Loctite from the rod (5).

5 - Lubricate the rod (5) and mount it in its seating,ensuring that it slides freely.

6 - Insert the spring (4) and mount the plug (3).

Plug: 100 Nm

7 - Start the motor, execute several steering manoeu-vres and, if the fault is not corrected, replace the

complete steering column with a new one.

20-40

TESTING AND ADJUSTMENTS TESTING PRIORITY VALVE OPERATION

WB97S-2

RKZA5540

E2

1

RKZA5550

2

RKZ02220

3

9

4

6

8

7

5

10



TESTING AND ADJUSTMENTS TESTING AND SETTING STEERING CONTROL SYSTEM PRESSURE

20-41

TESTING AND SETTING STEERING CONTROL SYSTEM PRESSURE

H Test condition:

. Engine: operating temperature


Testing

1 - Connect a pressure gauge E2 (250 bar) to the pres-sure adapter (1) of the backhoe control valve.

2 - Start the engine and bring it to idle speed of 1500w50 rpmand carry out a total steering.

3 - Forcing the steering wheel at the end of stroke, checkpressure.

H Normal pressure: 175w7 bar

4 - Check for the other steering direction too.

Setting

If pressure is not within permissible value, carry out set-ting acting on upper valve (3) of the steering unit.

1 - Remove plug (4).

2 - Insert a wrench of 4 mm and loosen screw (5).

3 - Adjust pressure with screw (6).

. To INCREASE pressure rotate in CLOCKWISE di-rection.

. To DECREASE pressure rotate in COUNTER-CLOCKWISE direction.

4 - Stop engine, lock the adjusting screw (6) positiontightening screw (5).

5 - Reassemble plug (4) checking that gasket (7) is on itsseat.

WB97S-2

RKZA5540

E2

1

RKZA5560

3

5 4 76



TESTING BRAKE SYSTEM

H Test condition:

. Engine: stopped

. Machine: on solid and level ground, with equip-ment raised and safety devices engaged.

. Brake pedals: independent, with the container le-vel at maximum.

The system testing provides in two stages:

1 - Testing circuit and brake pump tightness.

2 - Leaktightness test of the braking group.

If both the tests give a positive result, the leaksmust be sought in the pipelines of the brakingsystem.

1. Testing circuit and brake pump tightness

1 - Disconnect the connecting pipe (2) of the equali-zers from the brake pumps (1) of the circuit tobe tested.

2 - Securely plug the equalizer orifice (plug A).

3 - Remove the clamp (3) and disconnect the deliverylines (4) from the pumps. Connect a pressure gau-ge E2 (250 bar) to the pump (1) being tested.

4 - Move the brake pedal corresponding to the pumpand bring the circuit up to a pressure of approxi-mately 120 bar.

H Do not exceed maximum permissible valuethat is of 150w5 bar.

5 - Keep the pedal pushed for at least 2 minutes andcheck that pedal pressure and position remainsteady.

H If the position of the pedal must be changed tomaintain pressure, the pressure loss is due toleakages inside the pump.This can be confirmed by checking the oil. Ifthere are leakages, it will show signs of mi-xing.

6 - Repeat test for the other brake pump.

2. Testing braking group leaktightness

1 - Disconnect the delivery tube (5) of the brakinggroup being tested.

2 - Connect the tool H1 between the delivery line (5)and the braking group.

H Check that the pressure adapter (6) is insertedbetween the braking group and the exclusionvalve (7).

3 - Connect a pressure gauge E2 (250 bar) to the

pressure adapter of the tool H1 and open the cock(7).

20-42

TESTING AND ADJUSTMENTS TESTING BRAKE SYSTEM

WB97S-2

RKZA5570

1

3

2

RKZA5580

2

4

A

RKZA5590

1

E2

RKZA9190

E2

H1

5

6

7



TESTING AND ADJUSTMENTS TESTING BRAKE SYSTEM

20-43

4 - Operate brake pump to feed pressure into the circuitto maximum pressure of 150w5 bar.

5 - Maintaining pressure, close the valve (7) to main-tain pressure in the braking group being tested.

6 - Release the brake pedal and check for 2 minutesthe pressure indicated by gauge E2.

H If the pressure value shows a negative chan-ge, it means that the braking piston sealsare defective.

Further confirmation of the leak can also be ob-tained by an increase in the oil level in the axle,which leads to a mixing of the oils. Change allthe sealing rings between the axle sections,and carry out a complete lubrication oil change.

7 - Repeat the test for the other braking group, follo-wing the same method.

8 - Re-assemble the braking circuit.

After testing and possible repairs, bleed air frombrake units (see «AIR BLEEDING OF BRAKECIRCUIT»).

WB97S-2



CONTROL OF THE ENGINE SPEED UNDER LOAD

H Test conditions:



. Power train oil: up to working temperature.

. Brake pedals: connected by a cotter-pin.

. Machine: on solid and level ground with theequipment raised and safety devices engaged.

Two tests must be performed:

1 - Speed test with the torque converter under stress.

2 - Speed test with the torque converter and the hydrau-lic system under stress.

H The tests must be performed after a no-load testof the engine speed.

(For details, see «ENGINE SPEED TESTS»).

During the following tests, while accelerating theengine with the gear engaged, the condition ofthe brake disks can also be checked.If, while force is being exerted on the brake pe-dals, the machine starts to travel (even slowly):

a - Release the accelerator immediately andstop the engine.

b - Check the wear on the brake disks andchange them before completing the tests(See: «30. DISASSEMBLY AND ASSEM-BLY - REAR AXLE»).

1. Preparing the machine

1 - Prepare the rev. counter C1 to measure the engi-ne rpm.

H If mounting an electronic pressure transducerrev. counter on a diesel delivery line to the in-

jection nozzles, make sure that it is placed faraway from the clamp.

H If using a stroboscopic tachometer C2, make aclearly visible notch on the engine pulley to fa-cilitate the reading.

Make sure that the brake pedals are fastenedtogether by the cotter pin (1).

2. Testing with the torque converter under stress

1 - Start the motor at MIN. Engage the highest FOR-WARD gear and brake hard.

2 - Keeping the machine on the brake, accelerate theengine gradually up to high idling and measurethe speed reached.

H Normal speed: 2275w50 rpm

TBG version: 2200w50 rpm

3 - Release the accelerator pedal and move on to thenext test.

20-44

TESTING AND ADJUSTMENTS CONTROL OF THE ENGINE SPEED UNDER LOAD

WB97S-2

RKZA9070

RKZA5300

C1

RKZA8171

1



TESTING AND ADJUSTMENTS CONTROL OF THE ENGINE SPEED UNDER LOAD

20-45

3. Testing the torque converter and hydraulic sys-

tem under stress

1 - Start the motor at MIN. Engage the highest FOR-WARD gear and brake hard.

2 - Keeping the machine on the brake, engage theupper FORWARD gear, accelerate the engine gra-dually and at the same time act on the front bucketclosed (curled) command control valve lever.

3 - Once the maximum engine speed and the maxi-mum pressure of the bucket circuit have been rea-ched, measure the speed reached by the engine.

H Normal speed: 2200w50 rpm

TBG version: 2200w50 rpm

. If the revs of the engine are higher than the per-

missible limit, in both tests, check the pressureof delivery to the converter and the clutch pres-sures. (See «TESTING PRESSURES OF THEPOWER TRAIN GROUP»).

. If the revs of the engine are lower than the permis-sible limit, check the condition of the air filter, andthe conditions of the engine compression, the tim-ing, the injection pump, and the valve clearances.

WB97S-2



TESTING PRESSURES IN THE POWER TRAIN GROUP

The power train group can be used to perform pressuretests 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 oftravel.

H Test conditions:

. Engine: stopped.

. Brake pedals: connected by a cotter pin.

. Machine: on solid and level ground with the equip-ment raised and safety devices engaged.

1. Preparing the machine

1 - Prepare the rev. counter C1 to measure the engi-ne rpm.

H If mounting an electronic pressure transducerrev. counter on a diesel delivery line to the in-

jection nozzles, make sure that it is placed faraway from the line-clamp.

H If using a stroboscopic tachometer C2, make aclearly visible notch on the engine pulley to fa-cilitate the reading.

Make sure that the brake pedals are fastenedtogether by the cotter pin (1).

2. Converter oil pressure

1 - Remove the plug (P28) and connect the pressuregauge E6.

2 - Start the engine and heat the engine and all thefluids up to working temperature. In particular ma-ke sure that the power train oil reaches a tempera-ture of 80w5 ëC.

3 - With the engine at MIN, check the pressure on thepressure gauge E6.

H Normal pressure: MIN. 1 bar - MAX. 6 bar

4 - Gradually increase the rev speed to 2200 rpm. Ta-ke a new reading from the pressure gauge E6.

5 - Bring the engine back to MIN and compare thepressure with the normal value.

H Normal pressure: MIN. 6 bar - MAX. 11 bar

H If the maximum pressure value drops to belowthe permissible lower limit, the power trainpump needs an overhaul.

20-46

TESTING AND ADJUSTMENTS TESTING PRESSURES IN THE POWER TRAIN GROUP

WB97S-2

RKZA9070

RKZA5300

C1

RKZA8171

1

RKZO4430

P20

P19

P28



TESTING AND ADJUSTMENTS TESTING PRESSURES IN THE POWER TRAIN GROUP

20-47

3. Clutch engagement pressure

1 - Remove the cab floor.

2 - Remove the plug (P20) and connect the pressuregauge E6.


4 - Bring the engine up to MIN (idling) and check thepressure on the pressure gauge E6.

H Normal pressure: max 14 ± 16 bar

5 - Gradually increase the rev speed up to 2200 rpm.Take a new reading from the pressure gauge E6.

6 - Bring the engine back to MIN and compare thepressure with the normal value.

H Normal pressure: 15± 17 bar

7 - Remove the pressure adapter and replace theplug (P20).

Cap: 23 Nm

8 - Repeat the same test for the FORWARD gear,reading the pressure from the orifice protectedby the plug (P19).

. If the pressures are different for the two traveldirections, there is a loss of pressure on the

clutch piston with lower pressure.

WB97S-2

RKZA8590

P20P19

E6



TESTING THE CORRECT FUNCTIONING OF THEPOWER TRAIN CLUTCHES

H Test conditions:

. Engine: stopped.

. Brake pedals: connected by a cotter pin.

. Machine: on solid and level ground with theequipment raised and safety devices engaged.

H This test must be performed after having checkedthe pressures of the power train group.

1. Preparation of the machine

1 - Prepare a rev. counter to measure the engine rpm.

H If mounting an electronic pressure transducer rev.counter on a diesel delivery line to the injectionnozzles, make sure that it is placed far away fromthe line-clamp.

H If using a stroboscopic tachometer C2, make aclearly visible notch on the engine pulley to facil-itate the reading.

Make sure that the brake pedals are fastened toge-ther by the cotter pin (1).

During the following tests, during the engine accele-ration phase with the gear engaged, the condition ofthe 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 theengine.

b - Check the wear on the brake disks and changethem before completing the tests (See: «30. DIS-ASSEMBLY AND ASSEMBLY - REAR AXLE»).

2. Testing


2 - With the engine in idling condition, accelerate toMAX and check that in this condition the revs re-main within permissible limits. (See «TESTINGENGINE SPEED»).

3 - Brake hard and bring the engine up to MAX.

4 - Maintaining the braking action and the accelera-tion, engage the FORWARD gear and check thatthe engine speed decreases until it is once againwithin permissible limits (See «TESTING THE EN-GINE SPEED UNDER STRESS»).

5 - Repeat this test in REVERSE gear.

H If the revs are high than the permissible limits,the clutches are worn, and must be replaced.

20-48

TESTING AND ADJUSTMENTSTESTING THE CORRECT FUNCTIONING

OF THE POWER TRAIN CLUTCHES

WB97S-2

RKZA9070

RKZA5300

C1

RKZA8171

1



TESTING AND ADJUSTMENTS ADJUSTING THE SENSOR FOR RETURN TO DIG DEVICE

20-49

ADJUSTING THE SENSOR FOR RETURN TO DIG DEVICE

H Adjustment conditions:

. Machine: on solid and level ground.

. Engine: stopped.

. Hydraulic oil: 45± 55ëC

. Parking brake: engaged.

1 - Rest the bucket on the ground, making sure that thebottom is perfectly parallel to the surface.

2 - Stop the engine and remove the sensor guard (1).

3 - Check that there is a distance 3 ± 4 mm between the

sensor (2) and the rod (3)

H If necessary loosen the nuts (4) and adjust the dis-tance, until the indicated measurement is ob-tained, and secure that position.

4 - Loosen the locking nuts (5) and (6) of the position-in-dicating rod (3) and shift the rod towards the front ofthe machine until it has passed beyond the sensoraxis (2).

5 - Start the engine at MIN., tighten the rear nut (6) andat the same time unscrew the front nut (5) until thesensor (2) is engaged.

H When the rod engages the sensor, the pilot light(7) comes on.

6 - Secure the position of the rod (2) by tightening thenuts (5) and (6) behind the bracket (8).

7 - Perform several tests by raising the bucket and simu-lating some dumping manoeuvres. If the bucket isable to rest flat on the ground, replace the sensorguard (1).

WB97S-2

RKZA9080

RKZA5620

1

RKZA5630

33 ÷ 4 mm

2

2

7

4

3

RKZA5640

8

3 6 5



ANALYSIS OF CAUSES HYDRAULIC DRIFT

H If working attachments have a hydraulic drift, it is ne-cessary to check if reason is due to cylinders gaskets

or to control valve.H All testing conditions:


. Hydraulic oil: 45± 55ëC

. Removal and installation of pipes only after re-main pressure removal.(See «REMOVAL OF REMAIN PRESSUREFROM CIRCUIT»).

FRONT EQUIPMENT

1. Testing of front bucket lifting

1 - Put the machine with bucket teeth on blocks ofabout 10 cm and in vertical position compared toground.

2 - Stop the engine and remove the remain hydraulicpressure.

3 - Disconnect pipes (1) and (2) from lift cylinders (3)and plug them.

4 - Plug cylinders, base side, and apply a temporarypipe, head side, to catch possible oil leakage.

5 - Start the engine and retract the bucket until tobring the teeth in tilt position of about 15ë.

6 - Stop the engine and check bucket link position for5 minutes.

. If bucket link has no lowering movement, driftis due to control valve.

To check each cylinders, proceed as follow:

7 - Carry out with bucket a dump movement to letteeth lean on ground in vertical position.

8 - Remove from one of cylinders the plug as instal-led on base side at stage 4.

9 - Start the engine and retract the bucket until tobring teeth in tilt position of about 15ë towards up-

per.

10 - Stop the engine and check the bucket position for5 minutes.

. If bucket link has a lowering movement, drift isdue to gaskets of plugged cylinder.

11 - Repeat operation from stage 8 to stage 10 tocheck the other cylinder.

20-50

TESTING AND ADJUSTMENTS ANALYSIS OF CAUSES HYDRAULIC DRIFT

WB97S-2

RKZA9090

BlocchiBlocks

RKZA9180

2

1

3

RKZA9100

15°




20-51

2. Testing of front bucket dumping

1 - Put the machine with bucket on level ground and

teeth tilted of about 15ë.Put in the bucket a weight of 1500 kg.

2 - Disconnect pipes (1) and (2) from dump cylinder

(3) and plug them to avoid impurity inlet.

3 - Plug dump cylinder hole, base side, and apply atemporary pipe on head side to catch possibleoil leakage.

4 - Start the engine and raise the bucket up to thealignment of the bucket hinge and shovel arm hin-ge.

5 - Stop the engine and check bucket teeth positionfor 5 minutes.

. If bucket has no swing movement, drift is dueto control valve.

To test the individual cylinders, proceed as follows:

6 - Lower the bucket to the ground.

7 - Remove from one of the cylinders the plug fitted

on the cylinder bottom side in Phase 3.

8 - Start the engine and raise the bucket as indicatedin phase 4.

9 - Stop the engine and check the position of the buc-ket teeth for 5 minutes.

. If the bucket teeth turn, the drift is due to thegasket seals of the plugged cylinder.

10 - Repeat the operations from phase 6 to phase 9 inorder to test the other cylinder.

WB97S-2

RKZ04350

1500 kg

RKZA5660

3

2

1

RKZ04360

1500 kg



BACKHOE

H Test condition:

. Backhoe aligned

. Lifted outriggers

1. Boom testing

1 - Set the machine with arm in vertical position andwith bucket on level ground leaned on the side.


3 - Disconnect hoses (1) and (2) that feed cylinder (5).

4 - Plug the two hoses to avoid impurity inlet.

5 - Plug the cylinder head side.

6 - Apply a temporary pipe on pipe (3) base side tocatch possible oil leakage.

7 - Start the engine and extend completely the arm.

8 - Stop the engine and check the boom position for 5minutes.

. If boom has a lowering movement, drift is dueto cylinder gaskets.

. If boom has no lowering movement, drift isdue to control valve.

2. Arm testing

1 - Set the machine with arm fully extended and withbucket teeth on ground.


20-52


WB97S-2

RKZ02510

RKZA1341

2

1

3

RKZ02520

RKZ02530




20-53

3 - Disconnect pipes (1) and (2) pipes from arm cylin-der (3) and plug them to avoid impurity inlet.

H If safety valve is fitted, provide to removal.

4 - Plug arm cylinder hole on head side and fit a tem-porary pipe on base side to catch possible oil lea-kage.

5 - Start the engine and raise the boom.

6 - Stop the engine and check the arm position for 5minutes.

. If arm has a lowering movement, drift is due tocylinder gaskets.

. If arm has no movement, drift is due to controlvalve.

3. Bucket testing

1 - Set the machine with vertical arm and horizontalbucket leaned at level ground on the side.Put in the bucket a weight of 450 kg or fill it withearth.

2 - Stop the engine and remove the remain hydraulicpressures.

3 - Disconnect bucket cylinders (3) pipes (1) and (2)and plug them to avoid impurity inlet.

4 - Plug bucket cylinder hole on base side and fit atemporary pipe on head side to catch possibleoil leakage.

WB97S-2

RKZA5680

31

2

RKZ02540

RKZ02550

450 kg

RKZA5670

3

2

1



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 isdue to cylinder gaskets.

. If bucket has no movement, drift is due to con-trol valve.

4. Outriggers testing

1 - Set machine with vertical arm and with bucket lea-ned at ground on the side.

2 - Put blocks of about 20 cm under the outriggers.

3 - Without forcing them, lower the outriggers ontothe trestles.

4 - Stop the engine and release residual hydraulicpressures.

5 - Remove clamp (1) and disconnect from cylinders(4) the pipes (2) and (3).

6 - Plug cylinders pipes (2) base side and apply onhead sides temporary pipes to catch possible oilleakage.

7 - Start the engine, use force on the boom to raisethe machine, and remove the trestles supportingthe outriggers.

8 - Lower the machine and stop the engine.

9 - Check the outriggers position for 5 minutes.

. If one or both outriggers have a lowering mo-vement, drift is due to single or both cylinders.

. If there is no lowering, drift is due to controlvalve.

20-54


WB97S-2

RKZ02560

RKZ02200

20 cm

RKZA1251

2

4

3

1

RKZ02210



TESTING AND ADJUSTMENTS TESTING THE AIR-CONDITIONING UNIT

20-55

TESTING THE AIR-CONDITIONING UNIT

H Test conditions:

. Machine on level ground with the working equip-

ment raised and in safety conditions. Parking brake engaged

1. Testing the working temperature

1 - Connect the maintenance station to the high pressurevalve (H.P.) and the low pressure valve (L.P.)

2 - Start the engine and bring it up to a speed of 1500rpm.

3 - Switch on the A/C unit using the switch in the cab.

4 - Select an intermediate ventilation speed inside thecab.

5 - Use the thermometer/hygrometer M2 to check thatthe temperature inside the cab is equal to or lowerthan the ambient temperature.

H If the temperature of the cab is higher than theambient temperature, open the doors and widowsand wait until the cab temperature stabilizes atthe outside value.

6 - Close the doors and windows and let the A/C unit op-erate in these conditions for 5 - 10 minutes.

7 - Use the thermometer M2 to check the temperature ofthe air at the central outlets.

H Position the probe as close as possible to the airoutlets.

8 - Compare the average value of the measured tem-peratures using the following table:

Ambienttemperature (ëC) 20ë 25ë 30ë 35ë

Outgoing airtemperature (ëC) 6ë± 8ë 8ë± 10ë 8ë± 12ë 9ë± 14ë

9 - If the average value of the temperature measureddoes not fall within the values given in the table, it willbe necessary to thoroughly check the unit.

WB97S-2

RKZA9070



2. Checking the unit

A diagnosis of faults in the unit is based on the workingpressures.When the pressures do not fall within the values given inthe following table, the causes must be sought by chec-king the high-pressure (H.P.) and low pressure (L.P.) pres-sure gauges.

OutsideTemperature (ëC)

Unit with R134a

L.P. (kg/cm2) H.P. (kg/cm2)

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

L.P. high - H.P. normal or low

. Electromagnetic pulley that slips or does not engage correctly

. Expansion valve blocked in open position

. Compressor damaged

L.P. low - H.P. high or normal

. Expansion valve blocked in closed position or obstructed

. Filter saturated with moisture

. Obstruction in the L.P. line or in the H.P. line between the filterand the evaporator

L.P. normal - H.P. normal

. Infiltration of hot air into the evaporator group, the pipes or thecab

. Hot air circulating in the heating group

. Formation of ice on the evaporator

L.P. high - H.P. high

. Normal condition with very high ambient temperature (higherthan 43ëC)

. Excess coolant (30 - 35% more)

. Overheating of condenser

. Air present in the unit

. Obstruction in the H.P. line between the compressor and thecondenser-filter tube, behind the measurement point of the H.P.

L.P. normal or low - H.P. low

. Normal condition with very low temperature (lower than 5ëC)

. Lack of coolant (70 - 75% less) (probable leakages)

. Obstruction in the H.P. line between the compressor and thecondenser-filter tube, before the measurement point of the H.P.


L.P. roughly equal to H.P.

. Compressor belt missing

. Electromagnetic pulley that slips or does not engage


20-56

TESTING AND ADJUSTMENTS TESTING THE AIR-CONDITIONING UNIT

WB97S-2



REMOVAL AND INSTALLATION

30-1

HOW TO READ THE MANUAL....................... 3

PRECAUTIONS TO BE TAKEN WHILE WORKING 4

SPECIAL TOOLS . ..... ..... ..... ..... ..... ..... ..... .. 5

STARTING MOTOR

Removal and installation .......................... 7ALTERNATOR

Removal............................................. 8

Installation ..... ..... ..... ..... ..... ..... ..... ..... .. 9

AIR-CONDITIONING UNIT COMPRESSOR

Removal............................................ 10

Installation ......................................... 11

INJECTION PUMP

Removal............................................ 12

Installation ......................................... 15

INJECTION NOZZLES

Removal and installation . .. .. .. .. .. .. .. .. .. .. .. .. 16

THERMOSTAT


COOLING LIQUID PUMP

Removal............................................ 18

Installation ......................................... 19

TURBOCOMPRESSOR


CYLINDER HEAD

Removal............................................ 22

Installation ......................................... 25

FRONT COUNTERWEIGHT


RADIATOR-OIL COOLER UNIT

Removal............................................ 27

Installation ......................................... 29

CONDENSER


HYDRAULIC OIL COOLER

Removal............................................ 31

Installation ......................................... 32

TRANSMISSION OIL COOLER


MUFFLERRemoval and installation . .. .. .. .. .. .. .. .. .. .. .. .. 34

EXHAUST PIPE

Removal and installation..........................34

ENGINE HOOD

Removal............................................35

Installation........ ..... ..... ..... ..... ..... .... ..... 36

CAB

Removal............................................37

Installation........ ..... ..... ..... ..... ..... .... ..... 40

HEAT AND AIR-CONDITIONING GROUP

Removal............................................41

Installation........ ..... ..... ..... ..... ..... .... ..... 42

FUEL TANK


HYDRAULIC OIL TANK


ENGINE-GEARBOX-PUMP GROUP

Removal............................................45

Installation........ ..... ..... ..... ..... ..... .... ..... 50

PISTON PUMP

Removal............................................51

Installation........ ..... ..... ..... .... ..... ..... ..... 52

TRANSMISSION

Removal............................................53

Installation........ ..... ..... ..... .... ..... ..... ..... 56

CONVERTOR


TRANSMISSION-REVERSE, DIRECTION

INDICATOR AND HEADLIGHT DIPPER BEAMCONTROL GROUP


STEERING UNIT


WORKING BRAKE PUMP GROUP


FRONT WORKING EQUIPMENT

CONTROL VALVE


FRONT AXLE

Removal............................................62

Installation........ ..... ..... ..... ..... ..... .... ..... 63

WB97S-2



30-2

REAR AXLE

Removal........................................... 64

Installation..... ..... ..... .... ..... ..... ..... ..... .. 65

STEERING SOLENOID VALVE GROUPRemoval and installation......................... 66

FRONT BUCKET BOOM-RAISING CYLINDER

Removal and installation......................... 67

FRONT BUCKET TILT CYLINDERS


FRONT BUCKET



Removal........................................... 70

Installation..... ..... ..... .... ..... ..... ..... ..... .. 71

BACKHOE CONTROL VALVERemoval........................................... 72

Installation..... ..... ..... .... ..... ..... ..... ..... .. 73

BACKHOE BOOM CYLINDER


BACKHOE ARM CYLINDER


JIG ARM CYLINDER


BACKHOE BUCKET CYLINDER


OUTRIGGER CYLINDERS

Removal........................................... 78

Installation..... ..... ..... .... ..... ..... ..... ..... .. 79

BACKHOE SWING CYLINDERS


BACKHOE BACKFRAME LOCK CYLINDER


CYLINDERS

(Front bucket raise and tilt, boom, arm, bucket,outriggers and jig arm)

Disassembly.. ..... ..... ..... .... ..... ..... ..... ... 82Assembly ........ ..... ..... ..... ..... ..... ..... .... 84

BOOM SWING CYLINDER

Disassembly.. ..... ..... ..... .... ..... ..... ..... ... 88

Assembly ........ ..... ..... ..... ..... ..... ..... .... 89

BACKHOE BACKFRAME LOCK CYLINDER

Disassembly.. ..... ..... ..... .... ..... ..... ..... ... 91

Assembly ........ ..... ..... ..... ..... ..... ..... .... 91

BOOM SAFETY CYLINDER

Removal ........................................... 92

Installation ..... ..... ..... ..... ..... ..... .... ..... .. 92

BACKHOE WORKING EQUIPMENT

Removal and installation. .. .. .. .. .. .. .. .. .. .. .. .. 93

BACKHOE BUCKET


ARM


JIG ARM


2nd ARM


2nd ARM GUIDES


BACKHOE BOOMRemoval and installation. .. .. .. .. .. .. .. .. .. .. .. .. 99

BACKHOE SWING BRACKET

Removal and installation. .. .. .. .. .. .. .. .. .. .. .. . 100

BACKHOE BACKFRAME

Removal and installation. .. .. .. .. .. .. .. .. .. .. .. . 101

WB97S-2



HOW TO READ THE MANUAL

1. Removal and Installation of the groups

(1) The procedures and information needed to carry out the work of removing or Installing units or groups are

given in the removal procedure. The sequence of operations is not repeated in the installation procedure.

(2) Information needed for installation is marked with the symbol . The same symbol is repeated at the

end of each removal procedure for the same item, to indicate to which installation item it refers.

(Example)

REMOVAL GROUP : *** : . . . . . . . . . . . . . . . . . . . . . . . . T itle of operation

: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety p recautions t o be f ollowed when c arrying

out the operation.

1 - Remove XXXX (1):. .. .. .. .. .. . .. .. .. .. . .. . .. . .. . .. Step in removal procedure.

H :. .. .. .. .. . .. .. .. .. . .. .. .. . .. .. .. .. . .. .. .. .. . .. Technique or important point to remember when re-

moving XXXX (1)

2 - ~~~ (2): . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . This sign means that information is given for

the installation procedure

3 - Remove&&&& (3):

........... ,: .. .. . .. .. .. .. . .. .. .. .. . .. . .. . .. . .. Recovery of oil or water, and the quantity to be re-

covered.

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

. To install, reverse removal procedure.

: ....................................... Technique to be used for installation.

H : ......................................... Technique or important point to remember when re-

moving~~~ (2).

. Addition of water or oil: ...................... Step in removal procedure.

H : .. .. . .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. . .. Point to remember when adding water or oil.

2. To the precautions to be taken during the removal or installation of the groups, must be added the specific

«PRECAUTIONS TO BE TAKEN DURING THE OPERATIONS».

Always make sure that these precautions are taken.

3. List of special tools.

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

4. List of the tightening torques and weights, and the quantities oil, liquids or grease needed to fill

tanks and containers

(1) In the operating procedures, you will find the symbols , , , . In the following order, these

represent the values of «TIGHTENING TORQUES», «WEIGHT OF PARTS OR GROUPS», «QUANTITIES

OF OIL OR LIQUIDS TO BE INTRODUCED», «SCREW LOCKING MATERIAL, SEALANTS AND LUBRICA-

TION», «LUBRICATING GREASE».

NOTE

If no symbol is indicated, the values to be used are those given in the introductory sections of this manual.

30-3

REMOVAL AND INSTALLATION HOW TO READ THE MANUAL

WB97S-2



PRECAUTIONS TO BE TAKEN WHILE WORKING

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

1. Precautions for removal operations

. If not otherwise indicated, lower the work equipment until it rests on the ground.

. If the coolant liquid contains an anti-freeze substance, follow the instructions given for drainage.

. After having removed flanges and tubes, insert plugs to prevent impurities from entering.

. Before removing a cylinder, fully retract the piston and tie it with wire.

. Use a sufficiently large container to collect the oil.

. Before removing a part from the machine, check the alignment reference marks which show the correct in-stallation position. If necessary add further marks to avoid incorrect installation.

. While dismantling the connectors, always grasp them firmly to avoid undue strain on the wiring.

. If necessary, attach markers to the wires and tubes to avoid muddling them up during installation.

. Check the number and height of the adjustments to a given clearance and store them in a safe place.

. When raising the machine or some parts of it, use adequate equipment for the weight of the part concerned.

. When using screws or eyebolts to remove items of the machinery, screw them alternately, and as deeply asthey will go.

. Before removing a piece, clean the surrounding area and, after removal, cover the area to prevent dirt ordust from gaining entrance.

2. Precautions to be taken during installation

. Tighten nuts and screws with the specified tightening torques.

. Install the flexible hoses, taking care not to entangle or twist them.

. Bend the cotter pins and stops in such a way as to secure them.

. When coating the threads with adhesives, clean the piece to remove oil and grease, then apply just enoughadhesive to cover the threading in a uniform manner.

. When applying a liquid sealant, clean the surface involved, remove residual oil and grease, check that thereare 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 hoi-sting hook.

. Mount the flanges in a uniform manner, and tighten the screws in criss-cross sequence, to avoid excessivepull on one side only.

3. Precautions to be taken on completion of removal and installation operations.

. If the coolant liquid has been drained away, close the drainage plug and add new liquid up to normal level.Start the engine to circulate the liquid throughout the cooling system and then top up the level once more.

. When the hydraulic equipment has been dismantled, add engine oil to the indicated level. Start up the en-gine to circulate the oil in the hydraulic circuits, and then top up to the indicated level.

. If hoses or hydraulic equipment, such as hydraulic cylinders, pumps, motors, solenoid valves and valves,are removed for repairs or substitution, bleed air from the hydraulic circuits after having re-assembled themachine.H For details, see «20. TESTING AND ADJUSTMENTS».

. After having re-assembled cylinder joints or cylinders, or work equipment articulations, lubricate thoroughly.

30-4

REMOVAL AND INSTALLATION PRECAUTIONS TO BE TAKEN WHILE WORKING

WB97S-2



SPECIAL TOOLS

Nature of work Symbol Code Description Q.ty Notes

Disassembly and assembly

cylindersA

1 ATR200620 Attachment 1Cylinders disassembly -

assembly

2

ATR200760 Plunger é 40 2Assembly cylinder androd bushingsCylinder and rod lockingon ATR200620

ATR200770 Plunger é 45 2



3 ATR201420 Bushing é 45 2Blocking swing cylinderson ATR200620

4

ATR800040

Notched wrench forcylinders é 70

1

Head disassembly-assembly


1

Notched wrench forcylinders é 85 1


1

Notched wrench forcylinders é 115-120

1


1

5Notched wrench forside digging boom cylinders

1Head disassembly-assembly

6 ATR200300

Notched wrench 1Disassembly ring nutside digging boomcylinder

Notched wrench 1 Boom swing headdisassembly-assembly

7

ATR800270 Socket wrench (6-point 46) 1Pistons removal-installation

ATR800240 Socket wrench (6-point 55) 1

ATR800030 Socket wrench (6-point 65) 1

8


Dust seal assemblyATR200980 Plunger é 50 1



9

ATR201000 Expander é 70 1

Piston gaskets assembly

ATR201020 Expander é 80 1ATR201030 Expander é 85 1





10

ATR201160 Bushing for rod é 40 1

Head assembly on rod





30-5

REMOVAL AND INSTALLATION SPECIAL TOOLS

WB97S-2



Nature of work Symbol Code Description Q.ty Notes

Disassembly and assemblycylinders

A 11

ATR201200 Bushing for piston é 70 1

Piston-cylinder assembly







Disassembly and assemblypiston pump

B 1 ATR201450 Tool 1 Pump bracket

Disassembly and assemblytransmission

C 1 ATR201460Tool 1

Transmission supportSet of spacers 1

Air-conditioning unit E 1 Commerciallyavailable

Maintenance station 1 Adjustment differentiallock nuts

30-6

REMOVAL AND INSTALLATION SPECIAL TOOLS

WB97S-2



REMOVAL OF THE STARTING MOTOR

Fully raise the front working equipment and engagethe safety stop.

1 - Stop the engine and engage the parking brake.

2 - Remove guard (1) from tank (2).

3 - Remove the cover (3).

Disconnect the clamp (5) from accumulator (4) nega-

tive terminal (±).

4 - Disconnect the electric wiring (6).

5 - Loosen the two screws (7) and remove the starting

motor (8).

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

Starting motor mounting screws:78.4±98 Nm (8±10 kgm)

30-7

REMOVAL AND INSTALLATION STARTING MOTOR

WB97S-2

RKZA1822

1

2

RKZA7793

3

4

5

RKZA0021

7

8

6

7



REMOVAL OF THE ALTERNATOR

Fully raise the front working equipment and engagethe safety stop.

1 - Stop the engine and engage the parking brake.

2 - Remove guard (1) from tank (2).

3 - Remove the cover (3).

Disconnect the clamp (5) from accumulator (4) nega-

tive terminal (±).

4 - Disconnect the cable (6), the connector (7) and thecotter pin (8).

5 - Loosen the screws (9), (10) and (11) to leave the alter-

nator (12) free to rotate.

30-8

REMOVAL AND INSTALLATION ALTERNATOR

WB97S-2

RKZA1822

1

2

RKZA7793

3

4

5

RKZA0032

7

8

6

RKZA0042

10

13

9



6 - Release the belt (13) from the pulley and remove the

alternator (12).

INSTALLATION OF THEALTERNATOR. To install, reverse the removal procedure.

H Adjust the fan-belt tension. (For details, see «20. TE-STING AND ADJUSTMENTS ± Fan-belt tension».)

30-9

REMOVAL AND INSTALLATION ALTERNATOR

WB97S-2

RKZA0052

13

1211



REMOVAL OF THE AIR-CONDITIONING UNIT COMPRESSOR

Disconnect the cable from accumulator negative ter-minal (±).

1 - Remove lateral guard (1).

2 - Connect the outlets (2) and (3) to the maintenance

station for air-conditioning units E1 and drain the coo-

ling fluid.

3 - Disconnect the connector (4).

4 - Loosen the screw (5) and remove the belt (6) that dri-

ves the compressor (7).

5 - Loosen and remove the screw (8) that holds the brac-

ket (9) that supports the delivery and suction lines

(10), (11).

H Be careful to avoid damaging the seals.

30-10

REMOVAL AND INSTALLATION AIR-CONDITIONING UNIT COMPRESSOR

WB97S-2

RKZA8790

1

RKZA8571

3

27

RKZA8561

6

5

RKZA8600

7

8

11

109



6 - Remove the front screws (12), the rear nuts (13) and

lift out the compressor (7) complete with its support

(14).

INSTALLATION OF THE AIR-CON-DITIONING UNIT COMPRESSOR. To install, reverse the removal procedure.

Belt-tightening screw: 123 Nm

H Apply tension to the compressor belt.(For details, see «TESTING AND APPLYINGTENSION TO THE COMPRESSOR BELT»).

H Tighten until the flanges rest on the compressor.

Compressor retaining screws: 32 Nm

1 - Connect the unit to the maintenance station E1

and refill it.

H Quantity of fluid: 970w15 g

30-11

REMOVAL AND INSTALLATION AIR-CONDITIONING UNIT COMPRESSOR

WB97S-2

RKZA8610

7

14

13

12



REMOVAL OF THE INJECTION PUMP

Fully raise the front working equipment and engagethe safety stop. Also make the backhoe safe.


H Plug all tubes that have been removed or disconnec-ted to prevent entry of impurities.

1 - Remove the engine coolant liquid container (1).

2 - Disconnect the fuel supply (3) and flow-back (4) hoses

from the injection pump (2).

3 - Disconnect the high-pressure pipes (5).

4 - Disconnect the fuel feed hose (7) and delivery tube (9)

from the feed pump (6).

5 - Disconnect the tube (9) from the oil level dip-stick and

remove it.

6 - Remove the support-bracket (10) of the pump.

7 - Disconnect the accelerator control cable support (12)

from the lever (11).

30-12

REMOVAL AND INSTALLATION INJECTION PUMP

WB97S-2

RKZA8800

1

RKZA0070

2

3

4

5

RKZA0080

6

7

89

10

RKZA0090

11

12



8 - Disconnect the engine-stopping solenoid (13) from

the injection pump (2). Lift out the entire group.

9 - Remove the retaining clip (14) of the injection pump

lubrication tube.

10 - Disconnect the lubrication tube (15).

11 - Remove the cover (16) that gives access to the distri-

bution gear and the oil filler plug (17).

12 - Loosen and lift off the retaining nut (18) and safety

washer (19) of the pump driving gear (20).

H Take great care not to drop the safety washer (19)into the pump casing.

30-13


WB97S-2

RKZA0100

2

13

RKZA0110

14

15

RKZA0120

16

17

RKZA0130

1820

19



13 - Remove the driving gear (20) of the pump (2).

H Before removing the pump driving gear, mark its

position with respect to the idling gear.H For removal use a puller (X1). The puller screws

(X2) screw directly into the gear (20).

H Take great care not to damage the pump shaftthread.

H During removal, be careful not to let the wrench(21) drop into the housing.

14 - Take out the four nuts (22) and remove the injection

pump (2) with its O-ring seal (23).

30-14


WB97S-2

23

RKZ00030

20

X2

X1

X2

21

RKZA0081

22

2



INSTALLATION OF THE INJECTION PUMP

. To install, reverse the removal procedure.

Fuel feed hoses: 24.5 ± 34.3 Nm (2.5 ± 3.5 kgm)

High pressure hoses:24.5 ± 34.3 Nm (2.5± 3.5 kgm)

Stiffening bolt screw, pump side:44.1 ± 53.9 Nm (4.5 ± 5.5 kgm)

Stiffening bolt screw, pump side:22.5 ± 8.4 Nm (2.3± 2.9 kgm)

H Put in a new safety cotter pin.

Cover gasket: ASL800070

Cover bolts for ignition gear system:18 Nm (1.84 kgm)

H Align the marks between the gears before instal-ling the pump and mounting the nut.

Gear-locking nut:83.3 ± 93.1 Nm (8.5± 9.5 kgm)

Pump-locking nut:35.2 ± 43.1 Nm (34.4± 42.2 kgm)

1 - Check fuel injection timing.

(For details, see «20. TESTING AND ADJUSTMENTS»)

30-15


WB97S-2

RKZ00130

Riferimento

Ingranaggio folle

Ingranaggio pompad'iniezione (20)Injection pump gear

Reference

Idling gear



REMOVAL OF THE INJECTION NOZZLES



1 - Disconnect the sensor (1) for a clogged air-filter.

2 - Remove the air-filter (2), the supporting bracket (3)

and the intake sleeve (4).

3 - Remove and place to one side the bulldog clip (5) that

secures the cab heating pipes.

4 - Loosen the clip (7) and remove the high-pressure pi-

pes (8).

5 - Disconnect the fuel flow-back pipes (9).

6 - Take out the nuts (10) that secure the collar (11) and

take out the injector (12), the seating (13) and the pro-

tection piece (14).

INSTALLATION OF THEINJECTION NOZZLES. To install, reverse the removal procedure.

High-pressure pipe:24.5 ± 34.3 Nm (2.5± 3.5 kgm)

Hose-clamp screws: 9.8 ± 11.8 Nm (1 ± 1.2 kgm)

Collar lock nuts: 9.8 ± 11.8 Nm (1 ± 1.2 kgm)

30-16

REMOVAL AND INSTALLATION INJECTION NOZZLES

WB97S-2

RKZA1750

1

2

RKZA1760

5

4

3

8

76

RKZA0170

8

9

10

11

RKZ00140

11

10

12

13

14



REMOVAL OF THE THERMOSTAT



H Drain the engine coolant liquid.

Coolant liquid: 18 ,

1 - Disconnect the cable (1) of the clogged filter indicator

(2) and remove the entire suction filter (3).

2 - Remove the fan guard (4).

3 - Disconnect the radiator connection sleeve (6) from

the thermostat cover (5).

4 - Take out the screws and remove the thermostat cover

(5).

5 - Remove the gasket (7), the thermostat (8) and the

ring seal (9).

Put in new seals.

INSTALLATION OF THETHERMOSTAT. To install, reverse the removal procedure.

1 - Refill the coolant liquid tank.


2 - Start the engine at low idling to circulate the coolant

liquid through all circuits.

3 - Accelerate gradually up to 1700 rpm. After about one

minute, stop the engine and check or top up the level

in the container.

H Check that there are no leaks.

Cover screws: 22 ± 27.8 Nm

30-17

REMOVAL AND INSTALLATION THERMOSTAT

WB97S-2

RKZA1770

1

2

34

RKZA1780

6

RKZ00151

5

8

9

7

RKZA1790

5



REMOVAL OF THE COOLING LIQUID PUMP





1 - Remove the engine coolant liquid container (1).


3 - Disconnect the cable (3) of the clogged filter indicator

and remove the air filter (4).

4 - Remove the alternator and its support (5) (For details,

see «REMOVAL OF THE ALTERNATOR»).

5 - Only for machines equipped with a compressor

Remove the air-conditioning unit compressor (14) and

its supports. Put the compressor to one side.

(For details, see «REMOVAL OF THE AIR-CONDI-

TIONING UNIT COMPRESSOR»).

30-18

REMOVAL AND INSTALLATION COOLING LIQUID PUMP

WB97S-2

RKZA8800

1

RKZA1771

3

42

7

RKZA1800

5

RKZA8572

14



6 - Disconnect the cab heating pipes (6).

7 - Disconnect the temperature sensor cables (7) and (8).

8 - Remove the radiator/oil-cooler group. (For details,

see «REMOVAL OF THE RADIATOR - OIL COO-

LERS»).

9 - Remove the fan (9), the spacer (10) and the pulley

(11).

10 - Remove the four screws (12) and then the complete

pump (13).

Replace all seals with new ones.

INSTALLATION OF THE COOLANTLIQUID PUMP. To install, reverse the removal procedure.

Locking screws for alternator support:22,5v28,4 Nm

H Apply tension to the alternator belt.(For details, see «20. TESTING AND ADJUST-MENTS»).

Locking screws for pulley and fan:44,1v53,9 Nm

Pump screws: 22,5v28,4 Nm

Locking screw for compressor: 64 Nm

H Apply tension to the compressor belt.

(For details, see «TESTING AND APPLYINGTENSION TO THE COMPRESSOR BELT»).

1 - Refill the coolant liquid circuit.





minute, stop the engine and check or top up the level

in the container.

H Check that there are no leaks.

30-19

REMOVAL AND INSTALLATION COOLING LIQUID PUMP

WB97S-2

RKZA7770

6

8

RKZA1810

9

1011

RKZA2450

12

13



REMOVAL OF THE TURBOCOMPRESSOR



1 - Disconnect the clogged air-filter indication cable (1)

and remove the entire suction filter (3).

2 - Remove the muffler.

(For details, see «REMOVAL OF THE MUFFLER»).

3 - Disconnect the turbocompressor delivery coupling

sleeve (4) from the suction manifold.

4 - Take the screws out of the clips (5) and disconnect

the tube (6) that delivers the turbocompressor lubrica-

tion oil.

5 - Take out the tube-retaining screws (7) and the two

screws (8) that secure the flange of the lubrication

oil drainage tube (9).

30-20

REMOVAL AND INSTALLATION TURBOCOMPRESSOR

WB97S-2

RKZA1751

23

1

RKZA0210

4

16

RKZA0220

5

6

5

RKZA0230

7

98



6 - Take out the screws (10) that join the turbocompres-

sor to the coupling sleeve, and remove the coupling

sleeve (11).

7 - Take out the screws (12) and remove the bracket (13).

8 - Take out the nuts (14), and the washers (15) and lift

off the turbocompressor (16).

H Carefully check the state of all the sealing ga-skets. Replace them if there is any sign of dama-ge.

INSTALLATION OF THE TURBOCOMPRESSOR. To install, reverse the removal procedure.

Tube retaining screws: 22.5 ± 28.4 Nm

Flange screws: 8 ± 9 Nm

Coupling joint screws: 22.5 ± 28.4 Nm

Bracket screws: 22.5 ± 28.4 Nm

1 - Start the engine and check that there are no leaks in

the turbocompressor lubrication tubes.

30-21

REMOVAL AND INSTALLATION TURBOCOMPRESSOR

WB97S-2

RKZA1621

12

13

10

11

RKZA0240

14 15

16



REMOVAL OF THE CYLINDER HEAD





1 - Remove the container (1).

2 - Disconnect the cable (2) of the clogged air-filter sen-

sor and remove the entire suction filter (4) and its sup-port (5).

H Remove the turbocompressor. (For details, see«REMOVE THE TURBOCOMPRESSOR»).

3 - Only for machines equipped with an air-conditio-

ning unit

Remove the alternator (24), the compressor (25) and

the supporting bracket (26).

(For details, see «REMOVAL OF THE ALTERNA-

TOR» and «REMOVAL OF THE AIR-CONDITIONING

UNIT»).

4 - Remove the support (27).

30-22

REMOVAL AND INSTALLATION CYLINDER HEAD

WB97S-2

RKZA8800

1

RKZA0182

2 3

45

RKZA8573

2526

24

RKZA8562

27



5 - Disconnect the cable (6) of the cold-start equipment.

6 - Remove the suction manifold (7) and the cold-start

equipment (8).

7 - Remove the diesel fuel filter (9) and place it to one si-

de.

8 - Disconnect the clips that secure the heating pipes.

9 - Disconnect the breather tube (11) from the engine

head.

10 - Remove the muffler (12).

(For details, see «REMOVAL OF THE MUFFLER»).

11 - Remove the muffler support bracket (13).

12 - Disconnect the cables (14) from the temperature sen-

sors (15).

13 - Disconnect the heating pipes (16).

14 - Remove the radiator connection pipes (17).

15 - Remove the coolant liquid pump. (For details, see

«REMOVAL OF THE COOLANT LIQUID PUMP»).

30-23


WB97S-2

7

9

8

10

8 6

RKZA7781

RKZA0221

11

RKZA0250

12

13

RKZA1782

14

15

16

17



16 - Disconnect the fuel return hose (18) from the injector

nozzles and remove the nozzles. (For details, see

«REMOVAL OF THE INJECTOR NOZZLES»).

17 - Remove the cover of the tappets (19).

18 - Remove the valve rocker-arm shaft (20).

H Loosen the nuts and unscrew the tappets by 2-3turns.

19 - Take out the rocker-arm control rods (21).

20 - Take out the screws (22) and remove the entire cylin-

der head (23). Follow the indicated sequence for loo-

sening the screws.

H Sequence to be followed: see drawing.

Loosen the cylinder head retaining screws in twostages.

30-24


WB97S-2

RKZA0171

18

19

RKZ00160

20

21

22

23

RKZ00170

1

3

7

5

9

11

1618

17

13

14

12

10

15

6

4

2

8

BOLT LOOSENING ORDER



INSTALLATION OF THE CYLINDER HEAD


H Fill up the cooling circuit.


H Check carefully that there are no leaks.

Support screws: 35.2 Nm (3.6 kgm)

Frontal screw (M8): 32 NmLateral screws (M10): 64 Nm

Frontal screws (M10): 64 NmLateral screw (M8): 32 Nm

Bracket screws: 45 ± 55 NmScrews for intake line: Loctite 262Screws for intake line: 45 ± 55 Nm

High-pressure pipe fittings:24.5 ± 34.3 Nm (2.5± 3.5 kgm)

Collar lock nuts: 9.8 ± 11.8 Nm (1 ± 1.2 kgm)

H Check the condition of the seals of the tappet coverand the O-rings of the fastening nuts. Thoroughly

clean the contact surfaces on the cylinder heads.Cover fastening nuts: 25w3 Nm

H Check that the tappets are firmly engaged in their rodsand that the valve collars are correctly assembled.

Rods - tappets: Engine oil

H Start tightening the rocker-arm shaft from the centertowards the outside.

Screws and nuts for the rocker-arm shaft:22.5 ± 28.4 Nm (2.3 ± 2.9 kgm)

H Adjust the valve clearances (For details, see «20. TE-

STING AND ADJUSTMENTS»).

H Assemble a new gasket.

Bolt and cylinder block threadings: Engine oil.

H Tighten the screws, manually at first, and then in twostages, following the sequence indicated.

Cylinder head bolts.first tightening: 88.3 ± 98.1 Nm (9± 10 kgm)Final tightening: 181.4± 191.2 Nm

(18.5 ± 19.5 kgm)



2 - Accelerate gradually up to 1700 rpm. After about oneminute, stop the engine and check or top up the level

in the container.

30-25


WB97S-2

RKZ00180

8

31

2

6

5

7

9

4

18

12

10

14

16

13

15

17

11

BOLTS TIGHTENING ORDER



REMOVAL OF THE FRONT COUNTERWEIGHT


1 - Partially loosen the screws (1) to eliminate the tighte-ning torque, and thus to facilitate the subsequent di-

smantling procedure.

2 - Insert the prongs of a fork-lift truck into the ventilation

slits, and force them gently upwards to compensate

for the weight of the counterweight (2).

3 - Remove the screws (1) and the washers (3).

4 - Remove the Front counterweight (2).

Counterweight: 300 kg

INSTALLATION OF THE FRONT COUNTERWEIGHT. To install, reverse the removal procedure.

Screws: 300w30 Nm

30-26

REMOVAL AND INSTALLATION FRONT COUNTERWEIGHT

WB97S-2

RKZA9220

32 1



REMOVAL OF THE RADIATOR-OIL COOLER UNIT



1 - Disconnect the safety gas cylinders (1) for opening

the engine hood. Accompany the hood until it is com-

pletely open.

H Place some soft material between the enginehood and the front closing mechanism.

Completely eliminate all residual pressures in all cir-cuits. (For details, see «20. TESTING AND ADJUST-MENTS»).

H Drain the cooling liquid.

Cooling liquid: 18 ,


3 - Disconnect the cable (3) and remove the acoustic

alarm (4).

4 - Remove the air filter suction line (5).


ning unit

Drain the air conditioning unit, and disconnect the tu-

bes (19), (20).

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

MENTS»).

6 - Remove the container (6).

7 - Disconnect the engine coolant circuit hoses (8) and

(9) from the radiator (7).

8 - Remove the brackets (10).

30-27

REMOVAL AND INSTALLATION RADIATOR-OIL COOLER UNIT

WB97S-2

RKZA1860

2

1

RKZA1870

3

4

5

7

RKZA8620

20

19

RKZA1741

6

8

9

10



9 - Slowly loosen the hoses (11) and (12) to drain the hy-

draulic oil from the oil cooler (13). When the oil is fully

drained, complete disconnection of the hoses, andplug them to prevent entry of impurities.

10 - Slowly loosen the hoses (14) to drain the oil from the

transmission oil cooler (15). When the oil is fully drai-ned, complete disconnection of the hoses, and plug

them to prevent entry of impurities.

11 - Disconnect the conveyor (17) from the radiator (7) and

move it towards the engine.

12 - Take out the nuts (18) of the lower anti-vibration units

and remove the entire radiator - oil cooler group (7).

13 - Remove the rubber conveyor situated between chas-

sis and radiator.

30-28


WB97S-2

RKZA1880

13

11

12

RKZA7820

14

16

15

RKZA7830

7

17

RKZA7840

718 18



INSTALLATION OF THE RADIATOR ± OIL COOLER GROUP


. Refill the coolant liquid circuit.


H Refill the air-conditioning unit.

Quantity of fluid (R134a): 970w15 gQuantity of oil: See the amount recovered.

. Ensure that the level of hydraulic oil in the tank is atmaximum.

. Ensure that the level of transmission oil is at maxi-mum.

1 - Start the engine at low idling to circulate all the fluids

and to fill up the oil coolers.


minute, stop the engine and top up all levels.

H Check carefully that there are no leaks.

3 - Stop the engine and replace the rubber conveyor.

30-29


WB97S-2



REMOVAL OF THE CONDENSER (Only for machines equipped with an air-conditioning unit)

Completely raise the front working equipment andengage the parking brake.Also place the backhoe in its secure position.

1 - Drain the air-conditioning unit.


MENTS»).

2 - Disconnect the cable (1) and remove the klaxon (2).

3 - Disconnect the tubes (3) and (4).

H Immediately plug the tubes and the condensertightly to prevent moisture from entering into theair-conditioning circuit.

4 - Loosen the upper retaining screw (5) of the conden-

ser (6), leaving it in position for reasons of safety.

5 - Loosen the screws (7) and remove the locknuts.

6 - Remove the screws (5) and (7) and take out the con-

denser.

INSTALLATION OF THECONDENSER. To install, reverse the removal procedure.

1 - Refill the air-conditioning unit.


30-30

REMOVAL AND INSTALLATION CONDENSER

WB97S-2

RKZA8630

6 1

5

2

RKZA8621

3

4

RKZA86407

6



REMOVAL OF HYDRAULIC OIL COOLER



1 - Disconnect the safety gas cylinders (1) from the engi-

ne hood. Accompany the hood until it is completely

open.

H Place some soft material between the enginehood and the front closing mechanism.

Completely release residual pressures from all cir-cuits.(For details, see «20. TESTING AND ADJUST-MENTS»).

2 - Disconnect the cable (2) and remove the acousticalarm (3).


ning unit

Remove the condenser (11) without detaching the tu-

bes, and put it to one side.

4 - Slowly loosen the hoses (4) and (5) to drain the hy-

draulic oil from the cooler (6). When all the oil has

been drained, disconnect the hoses completely and

plug them to prevent entry of impurities.

30-31

REMOVAL AND INSTALLATION HYDRAULIC OIL COOLER

WB97S-2

RKZA1862

1

RKZA1871

2

3

8

7

RKZA8650

11

RKZA1881

5

6

4



5 - Remove the screws (7) that fasten the oil cooler (6) to

the radiator group (8).

6 - Take out the nuts and washers (9) and remove the ful-

crum screws and washers (10).

7 - Remove the rubber conveyor.

INSTALLATION OF THEHYDRAULIC OIL COOLER. To install, reverse the removal procedure.

. Make sure that the level of the hydraulic oil in the tankis at maximum.

1 - Start the engine at low idling in order to circulate the

oil and fill up the cooler.


minute stop the engine and, if necessary, top up the

level of oil in the tank.

3 - Replace the rubber conveyor.

30-32

REMOVAL AND INSTALLATION HYDRAULIC OIL COOLER

WB97S-2

RKZA7841

6

7

8910



REMOVAL OF THE TRANSMISSION OIL COOLER


1 - Remove the radiator - oil cooler group. (For details,see «REMOVAL OF THE RADIATOR - OIL COOLER

GROUP»).

2 - Loosen the retaining clip (1) of the coupling (2) on the

radiator (3).

3 - Take out the nuts (4) and remove the oil cooler (5).

INSTALLATION OF THETRANSMISSION OIL COOLER. To install, reverse the removal procedure.

. Make sure that the levels of the transmission oil, thehydraulic oil and the engine cooling liquid are all atmaximum.

1 - Start the engine at low idling to let the fluids circulate,

and fill up the oil coolers.

2 - Gradually accelerate up to 1700 rpm. After about one

minute, stop the engine and top up the levels.

30-33

REMOVAL AND INSTALLATION TRANSMISSION OIL COOLER

WB97S-2

RKZA0321

1 2

3

5

RKZA7850

5

4



REMOVAL OF THE MUFFLER


1 - Take out the retaining screws (1) of the flexible outlethose (2).

2 - Take out the two screws (3), the screws (4) and remo-

ve the muffler (5).

INSTALLATION OF THE MUFFLER. To install, reverse the removal procedure.

H Put in a new sealant.

REMOVAL OF THE EXHAUST PI-PE

1 - Loosen the clip (6) and disconnect the flexible hose

(2).

2 - Take out two of the three lower screws (7) of the con-

necting flange (8).

H Loosen the third screw and leave it in place for sa-fety.

3 - Take out the nut (9) and the washer of the upper anti-

vibration unit (10).

4 - Take out the last screw (7) and remove the exhaust

pipe (11).

INSTALLATION OF THEEXHAUST PIPE. To install, reverse the removal procedure.

30-34

REMOVAL AND INSTALLATION MUFFLER - EXHAUST PIPE

WB97S-2

RKZA0330

6 2 1

RKZA0251

3

4

5

RKZA1890

8

7

RKZA1900

9

10

11



REMOVAL OF THE ENGINE HOOD

Lower the working equipment completely until it is re-sting on the ground. Stop the engine and remove theignition key.

1 - Open the engine hood (1) take out the safety pins (2)

and disconnect the hood from the gas cylinders (3).

2 - Raise the hood (1) to a vertical position and attach it

to some hoisting tackle.

H To attach it, use the hole in the opening cavity.

3 - Take out the screws (4) and remove the hood (1).

Engine hood: 27 kg

30-35

REMOVAL AND INSTALLATION ENGINE HOOD

WB97S-2

RKZA7860

3

2

1

RKZA7880

1

RKZA7871

1

4



INSTALLATION OF THE ENGINE HOOD


H Check that the hood (1) closes perfectly, and re-attach

the screws (5).

30-36

REMOVAL AND INSTALLATION ENGINE HOOD

WB97S-2

RKZA1913

5



REMOVAL OF THE CAB

Lower the working equipment completely until itrests on the ground and stop the engine and removethe ignition key.


Release all residual pressure in all circuits. (For de-tails, see «20. TESTING AND ADJUSTMENTS»).

H Only for machines equipped with an air-conditio-ning unitDrain the air conditioning unit.(For details, see «20. TESTING AND ADJUST-MENTS»).

1 - Disconnect the pedal accelerator and hand accelera-

tor cables (1) from the injection pump. Disengage the

sheathings from the support (2).

2 - Disconnect the parking brake cable (4) from the rear

axle (3) and pipe (5).

3 - Disconnect the braking circuit pipes (6) from the rear

axle.

H Mark the positions of the pipes to prevent exchan-ge of positions when reconnecting.

H Plug the pipes and pipe-fittings to prevent entry ofimpurities.

4 - Disconnect the steering cylinder pipe (7) from the rear

axle.

H Plug the pipe and pipe-fitting to prevent entry ofimpurities.

30-37

REMOVAL AND INSTALLATION CAB

WB97S-2

RKZA0091

1

2

RKZA92916

5

4

3

5

RKZA9130

7



5 - Disconnect the pipes (8, 9 and 10) of the R - L - T ports

from the steering unit.

H Mark the positions of the pipes to prevent exchan-ging positions when reconnecting.

H Plug the pipes and pipe-fittings to prevent entry ofimpurities.

6 - Disconnect the connectors (11) and (12) and the

grounding cable (13).

7 - Disconnect the connectors (14), (15) and (16) from the

gearbox.

8 - Disconnect from grounding stud two connectors (17).

9 - Disconnect the connector (18) of the auxiliary controls

set into the bucket control lever.

10 - Disconnect the converter disengagement connector

(19) set into the gear lever.

11 - Disconnect the connector (20) of the backhoe boom

disengagement solenoids.

12 - Disconnect the power increment solenoid connector

(21) installed on the piston pump.

13 - Disconnect the connectors (22) of the rear acoustic

alarm, the connector (23) of the rear lights and finally

the connector (24) of the solenoid of the backhoe con-

trol valve.

14 - Disconnect the control steering connector.

30-38


WB97S-2

RKZA0410

8

9

10

RKZA8760

11

12

13

16

14

1415

17

RKZA0430

18

2120

19

RKZA0440

23

22 24



15 - Disconnect the heating unit tubes (25) and (26).

(For details, see «REMOVAL OF THE CAB HEATING

GROUP»).


ning unit.

Disconnect the tubes (27), (28) connecting the unit to

the drying filter (29) and the expansion valve (30).

H Immediately plug the tubes and the orifices tightlyto prevent moisture from entering into the air-con-ditioning circuit.

17 - Lift off the lower left-hand guard of the cab and di-

sconnect the connector (31) of the fuel level indicatorand the connector of the self-supply pump, if any.

18 - Also lift off the lower right-hand guard.

19 - Remove the grip (32) of the hand accelerator and

then the inspection cover (33). Push the protective

sleeve (34) of the gearbox lever down into the side co-

ver (35).

20 - Remove the grips (36) of the outrigger control levers

and the grip (37) of the lever-locking device. Lift off

the cover (38) of the control levers.

21 - Take off the self-locking nuts (39) and the four screws

that secure the cab.

30-39


WB97S-2

RKZA8710

25

26

27

28

29

30

RKZA1922

31

RKZA8752

32

33

35

34

RKZA0471

36

37

38

39



22 - Take off the protective plugs and screw two eyebolts

«A» into the holes supplied for hoisting purposes.

Attach the cab (40) to the hoisting tackle and apply aslight tension.

23 - Slowly raise the cab, directing its movement in such

way that the gear lever slides out.

H Make sure that all the electrical leads and the ac-celerator cables are free.

Cab: 630 kg

INSTALLATION OF THE CAB. To install, reverse the removal procedure.

H Drain and refill the air-conditioning unit.


H Check and adjust the stroke of the hand and pedal ac-celerators. (For details, see «20. TESTING AND AD-JUSTMENTS»).

H Adjust the stroke of the parking brake lever. (For de-tails, see «20. TESTING AND ADJUSTMENTS»).

H Bleed the air from the braking circuit. (For details, see

«20. TESTING AND ADJUSTMENTS»).

H Bleed the air from the steering circuit. (For details, see«20. TESTING AND ADJUSTMENTS»).

Cab retaining screws: 169w9.8 Nm

30-40


WB97S-2

RKZA0481

40

A



REMOVAL OF THE HEAT AND AIR-CONDITIONING GROUP

NOTE. If no air-conditioning unit is included, perform onlythose operations relating to the heating unit.

Lower the working equipment completely until itrests on the ground, and stop the engine.


H Drain the engine cooling liquid.


1 - Drain the air-conditioning unit.


MENTS»).

2 - Disconnect the flexible hose (1) of the heating water

cock.

3 - Disconnect the connector of the power-supply cabling

(2) and the clamp.

4 - Disconnect the pipes (4) from the fan-cooler (3).

5 - Disconnect the tubes (5) and (6) that connect with the

engine.

6 - Disconnect the connector (8) from the pressure

switch (7).

7 - Disconnect the delivery pipe(11) and the return pipe

(12) from the expansion valve (9) and the dryer filter

(10).

H Immediately plug the tubes and the orifices tightlyto prevent moisture from entering into the air-con-ditioning circuit.

H Re-use the O-ring.

8 - Loosen the clip and remove the drying filter (10).

H Immediately plug the delivery tube (11) and theexpansion valve (9) tightly to prevent moisturefrom entering into the air-conditioning circuit.

H Re-use the O-ring.

9 - Remove the four screws (13) and remove the group

(3).

30-41

REMOVAL AND INSTALLATION HEAT AND AIR-CONDITIONING GROUP

WB97S-2

RKZA8820

1

6

5

RKZA8830

2

10 9

RKZA8840

4

5

6 3

RKZA8711

6

8

7

9

12

10

11

13



INSTALLATION OF THE HEATING AND AIR-CONDITIONING GROUP


1 - Refill the cooling liquid.


2 - Drain and refill the air-conditioning unit.


3 - Start the engine and use a leak detector to check

the leaktightness of the air-conditioning unit.

30-42

REMOVAL AND INSTALLATION HEAT AND AIR-CONDITIONING GROUP

WB97S-2



REMOVAL OF THE FUEL TANK

Lower the working equipment completely until itrests on the ground and stop the engine.


1 - Remove the lower left-hand guard (1) of the cab.

2 - 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.

Fuel: max. 130 ,

3 - Remove the nut (4) in order to free the clips (5).

4 - Take off the guard (6) and lift off the accumulator co-

ver (7).

Disconnect from positive terminal (+) the clamps (8)

and, using handle (10), left out the accumulator (9).

5 -Disconnect the connector (11) of the level indicator

(12) and the connector (13) of the self-supply pump,

if fitted.

6 - Disconnect the fuel suction and flow-back hoses (14)

and (15) and the pipe of the self-supply pump, if fitted.

H Plug the pipes to prevent entry of impurities.

H Mark the pipes to avoid exchanging them duringinstallation.

7 - Remove the screws (16) and the guard (17).

8 - Support the fuel tank (3) with hoisting tackle and re-

move the four retaining screws (18).

9 - Remove the fuel tank (3).

Fuel tank: 73 kg

INSTALLATION OF THEFUEL TANK . To install, reverse the removal procedure.

Retaining screws for fuel tank: 120 Nm

1 - Refill the fuel tank.

Fuel: max. 130 ,

2 - Bleed the air from the fuel circuit.

3 - Start the engine.

30-43

REMOVAL AND INSTALLATION FUEL TANK

WB97S-2

RKZA1940

12

6

3

4

5

RKZA7794

7

8

9

10

RKZA1921

11

12

1314 15

16

17

RKZA1950

18



REMOVAL OF HYDRAULIC OIL TANK


Eliminate completely any residual pressures from allcircuits.(For details, see «20. TESTING AND ADJUST-MENTS»).

1 - Take off the lower right-hand guard (1) of the cab.

2 - Remove the guard (2).

3 - Raise the guard (3) and remove the oil drainage cap

(4).

H Drain the hydraulic oil.

Hydraulic oil: 92 ,

4 - Disconnect the lower suction (6) and drainage (7) ho-ses from the tank (5).

H Leave the check valve (8) on the tank.

H Plug the hoses to prevent entry of impurities.

5 - Disconnect the upper pipes (9), (10) and (11), remove

the check valve (12) and the T-piece (13).

H Make a note of the assembly sequence.

6 - Support the tank (5) with hoisting tackle and remove

the four retaining screws (14).

7 - Remove the tank (5).

Oil for the tank: 77 kg

INSTALLATION OF THEHYDRAULIC OIL TANK . To install, reverse the removal procedure.

Tank retaining screws: 120 Nm

1 - Refill the tank.

Hydraulic oil: 92 ,

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

ADJUSTMENTS»).

3 - Start the engine to let the oil circulate through all the

hydraulic systems and check for leaks.

4 - Bleed the air from the hydraulic systems. (For details,

see «20. TESTING AND ADJUSTMENTS»).

5 - Stop the engine, check the oil level in the tank, andtop it up if necessary.

30-44

REMOVAL AND INSTALLATION HYDRAULIC OIL TANK

WB97S-2

RKZA1960

14

2

3

1

RKZA1970

34

5

RKZA1980

6

7 8

7

RKZA1990

9

10

11

12

13



REMOVAL OF THE ENGINE-GEARBOX-PUMP GROUP



Release all residual pressure in all circuits.(For details, see «20. TESTING AND ADJUST-MENTS»).


Hydraulic oil: 92 ,

H Drain the engine cooling liquid.


H Drain the oil from the gearbox.

Gearbox oil: 16 ,


ning unit.

Drain the air conditioning unit.


MENTS»).

2 - Remove the front working equipment. (For details,

see «REMOVAL OF THE FRONT WORKING EQUIP-

MENT»).

3 - Take off the engine hood. (For details, see «REMO-

VAL OF THE ENGINE HOOD»).

4 - Take out the screws (1) and remove the front counter-

weight (2). (For details, see «REMOVAL OF THE

FRONT COUNTERWEIGHT»).

5 - Remove the radiator-oil cooler group. (For details,

see «REMOVAL OF THE RADIATOR-OIL COOLER

GROUP»).

6 - Raise the protective sleeve (3), disconnect the con-

nector (4).

7 - Disconnect the rear cardan shaft (6) from the gearbox

(5).

8 - Remove the front cardan shaft (7).

30-45

REMOVAL AND INSTALLATION ENGINE-GEARBOX-PUMP GROUP

WB97S-2

RKZA9140

21

1

RKZA8850

4

3

RKZA9311

5

6

RKZA9320

7



9 - Disconnect the suction hose (10) and the drainage pi-

pe (11) from the pump (9).

Disconnect also the power increment solenoid con-nector.


10 - Disconnect the Load Sensing signal pipe (12) and the

delivery pipe (13) from valve (14).


11 - Disconnect from the transmission (15) the connectors

(16) and the oil cooling circuit pipes and the control

lines (17).


12 - Disconnect the connectors from sensors (18), from

thermostat (19) and from speed sensor (20).

30-46


WB97S-2

RKZA8872

10

11

9

RKZA8862

13

14

12

RKZA8880

15

16 16

17

RKZO4370

18

20

18

19

18



13 - Disconnect the coolant liquid temperature sensors

(21) and (22) from the engine.

14 - Disconnect the cab heating pipes (23) from the coo-

lant pump.

15 - Disconnect the connector (24) of the oil pressure sen-

sor and the connector (25) of the solenoid that stops

the engine.

16 - Disconnect the cable (26) of the cold-start equipment,

the cab heating-pipe support clip (27), and the fuel

tank flow-back hose (28).

17 - Disconnect the cables (29) of the pedal and hand ac-

celerators. Disengage the support sheathing (30).

30-47


WB97S-2

RKZA7890

2122

23

RKZA0660

24

25

RKZA1762

26

28

27

RKZA0092

29

30



18 - Disconnect the fuel lines (32) from the separator (31)

and plug them.

19 - Remove the separator.

20 - Disconnect the cables (33) from the starting motor

(34) and the cables (35) from the alternator (36).


ning unit.

Save the coolant R134a and disconnect the delivery

tubes (38) and suction tubes (39) from the compres-

sor (37).

H Immediately plug the tubes and orifices tightly toprevent moisture from entering into the air-condi-tioning circuit.

H Disconnect the air-conditioning unit connectors(40) and (41).

22 - Remove the plate (42) and push it towards the back of

the machine.

30-48


WB97S-2

RKZA0670

31

32

RKZA0680

36

33

34

35

RKZA8575

4139

38

40

37

RKZA0383

42



23 - Disconnect the flexible return hose (44) from the muf-

fler (43).

24 - Attach the entire group to some hoisting tackle using

the engine bracket (45) and the muffler support (46).Apply a slight tension to the hoisting chains.

H The chains should have a total length of about 800mm and a difference between the arms of 53 mm.

H The shortest length should be attached to the bracket(45).

H When under tension the cables should be about 200mm apart at the height of the muffler.

25 - Loosen and remove the nuts (47) of the anti-vibration

supports (48) of the engine and gearbox, and take out

the screws (49).

26 - Raise the entire group until the chassis supports are

disengaged, and than accompany the group in order

to slide it away from the front part of the chassis.

Engine-gearbox-pump group: 740 kg

30-49


WB97S-2

RKZA0691

43

44

RKZA0702

45 46

RKZA1640

200 mm

-- 53 mm

RKZA0712

47

49

49

47

4848



INSTALLATION OF THE ENGINE GEARBOX-PUMP GROUP


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

Hydraulic oil: 92 ,

2 - Fill the gearbox up to its maximum level.

Gearbox oil: 16 ,

3 - Refill the coolant liquid.


4 - Drain and refill the air-conditioning unit.

Quantity of fluid (R134a): 970w15 g

Quantity of oil: See the amount recovered.

Screws for front counterweight: 300w30 Nm

Screws on gearbox side: 70 Nm

Screws on gearbox side: Loctite 262

Nut on axle side 70 Nm

H Fill up the pump casing and the pump, to bring thetank up to pressure.For the method see «20. TESTING AND ADJUST-MENTS».

H Bleed the air from the fuel lines.

Nuts from the anti-vibration supports:196w19,6 Nm

4 - Start the engine to circulate the oil and coolant liquid.

Check that there are no leaks.

5 - Use a leak detector to check the leaktightness of the

delivery and return pipes of the air-conditioning unit

compressor.

6 - Bleed the air from the working equipment circuits.


MENTS»).

7 - Stop the engine, check the levels and, if necessary,

top them up.

30-50


WB97S-2



REMOVAL OF THE PISTON PUMP



Release all residual pressure in all circuits.(For details, see «20. TESTING AND ADJUST-MENTS»).


Quantity of oil: 92 ,

1 - Disconnect the suction hose (2) and the drainage pi-

pe (3) from piston pump (1).

2 - Disconnect the delivery pipe (4) and the Load Sen-

sing signal line (5).


3 - Disconnect the solenoid connector (6).

4 - Take out the rear cardan shaft (7).

5 - Attach the pump (1) to the tool B1 mounted on a pit

jack.

H For attachment purposes, use the pump body fil-ling pipe (8).

30-51

REMOVAL AND INSTALLATION PISTON PUMP

WB97S-2

RKZA8873

3

1

2

RKZA8863

45

6

RKZA2040

9

7

RKZA2050

1

B1



6 - Take out the two screws (9) and remove the pump (1)

complete with its O-ring (10).

Pump: 40 kg

INSTALLATION OF THEPISTON PUMP. To install, reverse the removal procedure.

1 - Fill the tank with hydraulic oil up to maximum level.

Hydraulic oil: 92 ,

H Fill the pump body and the pump, bringing thetank up to pressure.For the method, see «20. TESTING AND ADJUST-MENTS».

Screws for suction flange: 100 Nm

Screws for delivery flange: 60 Nm



Nut on axle side: 70 Nm

Pump retaining screws: Loctite 262

Pump retaining screws: 220 Nm

2 - Start the engine to circulate the oil in all hydraulic cir-

cuits.

3 - Stop the engine, check the oil level in the tank and, if

necessary, top it up.

30-52

REMOVAL AND INSTALLATION PISTON PUMP

WB97S-2

RKZA0741

1

8

10

B1



REMOVAL OF THE TRANSMISSION

Lower the working equipment completely until itrests on the ground, and stop the engine.Make the backhoe safe.




Hydraulic oil: 92 ,


Gearbox oil: 16 ,

1 - Remove the piston pump. (For details, see «REMO-

VAL OF THE PISTON PUMP»).

2 - Raise the protective sleeve (1), disconnect the con-

nector (2) of the transmission disengagement.

3 - Disconnect the pipe (3) that fills the gearbox with oil.

4 - Take out the front cardan shaft (4).

5 - Take off the cover (5) of the flywheel oil-sump and ta-

ke out the six retaining screws (6) of the converter

coupling flange (7).

30-53

REMOVAL AND INSTALLATION TRANSMISSION

WB97S-2

RKZA8851

2

1

RKZA2071

34

RKZA0761

5

67



6 - Disconnect the connectors (9) of the solenoids and

the tubes (10) for oil circulation and controls from

transmission (8).H Plug the pipes to prevent entry of impurities.

7 - Disconnect the connectors from sensors (11), from

thermostat (12) and from speed sensor (13).

8 - Remove the plate (14) and push it towards the back of

the machine.

9 - Attach the engine-gearbox group to the hoisting tack-

le using the engine bracket (15) and the muffler sup-

port (16). Apply tension to the hoisting chains.

30-54


WB97S-2

RKZA8881

10

99

8

RKZO4371

11

13

11

12

11

RKZA1914

14

RKZA2081

15 16



10 - Loosen and remove the nuts (17), and screws (18)

and the anti-vibration nuts (19).

11 - Remove the gearbox supports (20).

12 - Attach in the place of the supports (20), the tool C1

mounted on a pit jack «A» which can be lowered by

approx. 60 cm.

H Secure the tool C1 and screws «B» M12x40.

13 - Loosen and remove the twelve screws (21) that hold

the engine and gearbox together.

14 - Remove the entire gearbox, by shifting it towards the

back of the machine in order to disengage the conver-

tor. Lower it slowly and turn the group in a clockwise

direction to disengage it from the chassis in order to

extract it.

30-55


WB97S-2

RKZA9310

17 1820

19

17 18

RKZA9200

A

B

C1

22

RKZA8770

21



INSTALLATION OF THE TRANSMISSION


Hydraulic oil: 92 ,

Gearbox oil: 16 ,

H Fill the pump body and the pump in order to pressuri-se the tank.For the method, see «20. TESTING AND ADJUST-MENTS».

Screws for securing lever: 120 Nm

Screws: Loctite 262



Nuts on axle side: 70 Nm

Flange screws: Loctite 262

Flange screws: 70 Nm

Anti-vibration nuts: 196w19.6 Nm

Support screws: Loctite 262

Support screws: 90 Nm

Engine-gearbox screws: Loctite 262

Engine-gearbox screws: 90 Nm

1 - Start the engine to circulate the oil. Check that there

are no leaks.



MENTS»).


top them up.

30-56


WB97S-2



REMOVAL OF THE CONVERTOR





Hydraulic oil: 92 ,


Gearbox oil: 16 ,

1 - Remove the piston pump. (For details, see «REMO-

VAL OF THE PISTON PUMP»).

2 - Remove the gearbox (For details, see «REMOVAL OFTHE GEARBOX»).

3 - Slide the convertor (1) away from the gearbox shafts

(2), (primary and secondary).

H If necessary, use two levers applied in opposedpositions.

H Take great care not to damage the centering hubof the gearbox.

INSTALLATION OF THE

CONVERTOR. To install, reverse the removal procedure.

H Engage the two shafts (primary and secondary) byslowly rotating the body of the convertor.

1 - Refill the tank with hydraulic oil up to maximum level.

Hydraulic oil: 92 ,

H Fill the pump body and the pump, bringing thetank up to pressure.For the method, see «20. TESTING AND AD-

JUSTMENTS».

2 - Refill the gearbox.

Gearbox oil: 16 ,

3 - Start the engine to circulate the oil in all circuits.

Check that there are no leaks.



MENTS»).


top them up.

30-57

REMOVAL AND INSTALLATION CONVERTOR

WB97S-2

RKZA8730

12



REMOVAL OF THE TRANSMISSION-REVERSE, DIRECTIONINDICATOR AND HEADLIGHT DIPPER BEAM CONTROL GROUP



1 - Remove four nut (1) and divide the transmission-re-

verse (2) from direction and headlight dipper beam

control group (3).

2 - Remove four screw (4) and guard (5).

3 - Raise the protective sleeve (6) and disconnect the

connector (7); remove the direction and headlight dip-

per beam control group.

4 - Rotate in counterclockwise direction the ring (8) and

disconnect the control group (2).

INSTALLATION OF THETRANSMISSION-REVERSE,DIRECTION INDICATOR ANDHEADLIGHT DIPPER BEAM

CONTROL GROUP. To install, reverse the removal procedure.

30-58

REMOVAL AND INSTALLATIONTRANSMISSION-REVERSE, DIRECTION INDICATOR AND

HEADLIGHT DIPPER BEAM CONTROL GROUP

WB97S-2

RKZA8660

2

1

RKZA8670

34

5

RKZA8680

7

6

RKZA8690

8

2



REMOVAL OF THE STEERING UNIT

Lower the working equipment completely until itrests on the ground and stop the engine and removethe ignition wrench.



1 - Disconnect the five pipes (2) from the steering unit (1)

and plug them to prevent entry of impurities.

H Mark the positions to prevent exchanges duringre-connection.

2 - Remove the central guard (3) beneath the steering

wheel.

3 - Remove the guard (4) raise the protective sleeve (5)

and disconnect the connectors (6) and (7).

4 - Disconnect the connector (8) and the relay (9).

5 - Loosen the steering column (11) retaining screws (10)

and the steering unit (1).

6 - Take out the screws (12) and remove the plate (13)

that supports the steering column and the steering

unit.

7 - Take out the screws (10) and remove the steering unit

(1).

INSTALLATION OF THESTEERING UNIT. To install, reverse the removal procedure.

H Bleed the air from the Load Sensing circuit. (For de-tails, see «20. TESTING AND ADJUSTMENTS»).

H Start the engine and perform several complete stee-

ring manoeuvres in both directions, to bleed the airout of the steering system.

30-59

REMOVAL AND INSTALLATION STEERING UNIT

WB97S-2

RKZA0870

21

RKZA8700

5

4

3

RKZA8890

6

7

RKZA0891

89

11

1312

10



REMOVAL OF THE WORKING BRAKE PUMP GROUP



1 - Remove the cap (1) of the oil tank (2) and draw out the

oil contained inside it.

2 - Remove the oil tank (2).

3 - Remove the clip (3) that holds the delivery lines (4).

4 - Remove the delivery lines (4) from the pumps (5).

5 - Take out the four screws (6) and remove the pump

group (5).

H If only one pump is to be removed, also discon-nect the pressure- equalizing pipe (7).

INSTALLATION OF THEWORKING BRAKE PUMP GROUP. To install, reverse the removal procedure.

H Bleed the air from the braking circuit. (For details, see«20. TESTING AND ADJUSTMENTS»).

H Make sure that the push-rods (8) center the seating ofthe pistons.

H After installation, check the idle stroke and parallelismof the brake pedals and, if necessary, adjust the cou-pling microswitches for 4-wheel brake control. (For de-tails, see «20. TESTING AND ADJUSTMENTS»).

Pipe fitting: 20 Nm

30-60

REMOVAL AND INSTALLATION WORKING BRAKE PUMP GROUP

WB97S-2

RKZA0900

5

4

1

2

6

6

3

7

RKZA0910

8 9



REMOVAL OF THE FRONT WORKING EQUIPMENTCONTROL VALVE

Lower the working equipment completely until itrests on the ground and stop the engine and removethe ignition wrench.


1 - Remove the grip (1) of the hand accelerator and di-

sengage the protective sleeves (2) and (3).

2 - Take out the screws (4) and remove the guard (5).

3 - Disconnect the spool control tie-rods (7) from the con-

trol valve (6).

4 - Disconnect from the control valve all pipes and lines

for the actuators (8), pump delivery (9), drainage

(10), Load Sensing (11) and plug them.

H Mark the pipes to avoid exchanging positions du-ring reconnection.

5 - Take out the four control valve retaining screws.

6 - Remove the control valve (6).

INSTALLATION OF THE FRONTWORKING EQUIPMENT CONTROLVALVE. To install, reverse the removal procedure.

1 - Start the engine to circulate the oil, and check that

there are no leaks.

2 - Bleed the air from all circuits. (For details, see «20.

TESTING AND ADJUSTMENTS»).

3 - Stop the engine and check the oil level in the tank.

30-61

REMOVA L AND INSTALLATION FRONT WORKIN G EQUIPMENT CONTROL VALVE

WB97S-2

RKZA8753

1

2

3

45

RKZA8780

6

7

RKZA2101

6

8

10

11

9



REMOVAL OF THE FRONT AXLE

1 - Start the engine and force the front bucket down-

wards in order to raise the machine and the front

wheels.

2 - Place two stands «A» beneath the chassis.

3 - Slowly lower the machine onto the blocks, checking

that the wheels remain at least 5 cm above the

ground.


4 - Engage the parking brake.

5 - Stop the engine and eliminate residual pressure from

all circuits. (See «20. TESTING AND ADJUST-

MENTS»).

Raise the engine hood and disconnect the cablefrom accumulator negative terminal (±).

6 - Take off the front wheels (1).

Wheel: 163 kg

7 - Remove the front guard (2). (For details, see «REMO-

VAL OF FRONT GUARD»).

8 - Remove the front wheel cover.

9 - Disconnect the cardan shaft (4) from the axle (3).

10 - Disconnect the lines (5) from the steering cylinder


11 - Disconnect the tubes (6) for lubrication support (7).

12 - Disconnect cable (8).

30-62

REMOVAL AND INSTALLATION FRONT AXLE

WB97S-2

RKZA9150

A

RKZA9160

21

3

RKZA9270

3

4

RKZA9280

3

5

5

7

8

6

6



13 - Position a jack «B» and some blocks «C» beneath the

axle. Raise the jack until the blocks can be forced un-

der the axle arms (3).H It should be possible to lower the jack 10 cm in or-

der to disengage the axle from the fulcrum sup-ports.

14 - Loosen and remove the fixed support screw (8).

15 - Lower the jack until the axle is disengaged.

16 - Extract the entire axle (3).

Front axle: 530 kg

INSTALLATION OF THEFRONT AXLE. To install, reverse the removal procedure.

Nuts for front wheels: 800 Nm

Front closing screws: 300w30 Nm

Screws: 73,5 Nm

H Bleed the air from the Load Sensing circuit. (For de-tails, see «20. TESTING AND ADJUSTMENTS».

Screws: 568 Nm

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.

30-63

REMOVAL AND INSTALLATION FRONT AXLE

WB97S-2

RKZA9280

3

5

5

7

86

6

RKZA9250

8

8



REMOVAL OF THE REAR AXLE

1 - Lower the backhoe outriggers (1) and force them

downwards in order to raise the rear wheels (2) by ap-

prox. 5 cm.

2 - Prepare a safety stand «A», approx. 65 cm high, be-

neath the backhoe chassis. Pull up the outriggers un-

til the machine is resting on the stand «A».

3 - For safety's sake, rest the backhoe bucket with its

back on the ground, keeping the arm vertical. Also

rest the front bucket on the ground.

4 - Stop the engine and completely release residual

pressures from all the circuits. (For details, see

«20.TESTING AND ADJUSTMENTS»).


5 - Remove rear wheel.

Wheel: 163 kg

6 - Mark the pipe (3) and disconnect them from steering

cylinder.

H Plug the pipes and holes to prevent entry of impu-rities.

7 - Disconnect the working brake hoses (4) from the axle.

H Plug the pipes and holes to prevent entry of impu-rities.

8 - Disconnect the parking brake command cable (5) and

free collar.

9 - Disconnect the cardan shaft (6) from the rear axle.

10 - Disconnect the steering cylinder sensor connector.

30-64

REMOVAL AND INSTALLATION REAR AXLE

WB97S-2

RKZA0960

1

2

A

1

RKZA0970

RKZA9230

A

RKZA9290

6

5

4

3



11 - Partially loosen the screws (7) in order to eliminate

the tightening torque and thus facilitate subsequent

dismantling.H Loosen the screws in criss-cross sequence.

12 - Place a jack «C» and some blocks beneath the axle

(8). Raise the jack until the blocks can be forced un-

der the arms of the axle.

H Leave free the screws (7) and plates (9) that se-cure the axle.

H It should be possible to lower the jack by approx.20 cm.

13 - Remove the screws (7) and the plates (9).

14 - Lower the jack until the axle (8) is disengaged fromthe chassis.

15 - Extract the entire axle (8).

Entire rear axle: 540 kg

INSTALLATION OF THEREAR AXLE. To install, reverse the removal procedure.

Wheel nuts: 800 Nm

H Bleed the air from the braking circuits.(See «20. TESTING AND ADJUSTMENTS»).

H Adjust the stroke of the parking brake lever.

(See «20. TESTING AND ADJUSTMENTS»).

Screws: 73,5 Nm

Screws: 980 Nm

Screws: Loctite 243

H Tighten in two stages, using the criss-cross me-thod.

1 - Check the 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.

30-65

REMOVAL AND INSTALLATION REAR AXLE

WB97S-2

RKZA9240

7

RKZA9120

8

C

7

9



REMOVAL OF STEERING SOLENOID VALVE GROUP

Lower all working equipment and stop engine.

Disconnect the cable from accumulator negative ter-

minal (±).

1 - Disconnect the solenoids (Y1), (Y2), (Y3), (Y4) from

the valve body (1).

H Ensure that the wiring harness is clearly labelled,if in doubt mark the corresponding position of thesolenoids.

2 - Disconnect the pipes (2) - (3) - (4) - (5) from the valve

body (1).

H Mark the pipes for correct re-assembly.

H Cap the pipe ends to prevent impurities entering.

3 - Remove the screws (6) that fasten the valve body (1)to the support bracket (7).

INSTALLATION OF THESTEERING SOLENOIDVALVE GROUP. Installation is the reverse of the removal procedure.

H Check the mounting position carefully.1 - Start engine.

2 - Steer the vehicle in both directions to remove any air

in the steering system.

3 - Stop the engine and check the oil level in the tank.

30-66

REMOVAL AND INSTALLATION STEERING SOLENOID VALVE GROUP

WB97S-2

RKZA9300

5

1

2 3 4

Y1

Y2

Y3

Y4

6

RKZ04550

Y3

Y4

Y1

Y2

Direction of travel

c

d

Steering unit

Rear cylinder

Front cylinder



REMOVAL OF THE FRONT BUCKET BOOM-RAISING CYLINDER

Lower completely the working equipment until itrests on the ground and stop the engine.

1 - Put a sling round the cylinder (1) and insert someblocks «A» between the boom (2) and the fulcrum le-

ver spacer (3).

2 - Take off the snap-ring and the internal retaining spa-

cer for the piston attachment pin (4).

3 - Take out the pin (4) in order to free the piston head

(5), but leave the fulcrum lever engaged (3).

4 - Start the engine to retract the piston (1).

H Bind the piston head with wire to secure the fully re-tracted position and stop the engine.



5 - Disconnect the tubes (6) and (7) and plug them to pre-

vent entry of impurities.

6 - Remove the snap-ring (8) and the spacer (9).

7 - Remove the cylinder (1).

Cylinder: 40 kg

INSTALLATION OF FRONTBUCKET BOOM-RAISINGCYLINDER. To install, reverse the removal procedure.

When aligning the positions between the hole andthe pin, turn the engine over at low idling speed.Do not insert fingers into the holes to check align-ment.

Internal bushing: ASL800050

1 - Start the engine and bleed the air from the cylinders.


MENTS»).

H After bleeding the air, check the oil level in the tank.

30-67

REMOVAL AND INSTALLATION FRONT BUCKET BOOM-RAISING CYLINDER

WB97S-2

RKZA2160

5

4

32

A

1

RKZA1951

6

7

1

RKZA2170

19

8



REMOVAL OF THE FRONT BUCKET TILT CYLINDERS


1 - Loosen the clips (1) and remove the tube protection(2).

H For the right-hand cylinder onlyDisconnect the sensor (3) and remove the bucket po-sition indicator (4).

2 - Place a sling round the cylinder (5) and insert a block

«A» between the spacer (7) of the piston fulcrum lever

and the lever (8).

3 - Take off the snap-ring and the internal retaining spa-

cer for the piston attachment pin (9).

4 - Take out the pin (9).

5 - Start the engine to retract the piston (10).

H Bind the piston head with wire to secure the fully re-tracted position and stop the engine.



6 - Take out the screw (11) and remove the clamp (12).

7 - Disconnect the tubes (13) and (14) and plug them to

prevent entry of impurities.

8 - Remove the snap-ring (15) and the spacer (16).


Cylinder: 40 kg

INSTALLATION OF THE FRONTBUCKET TILT CYLINDERS.

To install, reverse the removal procedure.





MENTS»).H After bleeding the air, check the oil level in the tank.

30-68

REMOVAL AND INSTALLATION FRONT BUCKET TILT CYLINDERS

WB97S-2

RKZA2180

3 4

1

12

RKZA2190

A5

6

7

8

RKZA2200

10

11

12

13

149

RKZA2210

11

12

15

16



REMOVAL OF THE FRONT BUCKET

Lower the bucket to the ground, resting on its back,but without forcing it downwards.

1 - Stop the engine and release residual pressures.

2 - Take out the screws (1) and remove the pins (2) of the

lever (3).

Rest the lever (3) on the boom.

3 - Take out the screws (4) and remove the pins (5) of the

bucket fulcrum.

4 - Start the engine and put the machine into reverse

gear in order to disengage the boom (6).

INSTALLATION OF THEFRONT BUCKET. To install, reverse the removal procedure.



30-69

REMOVAL AND INSTALLATION FRONT BUCKET

WB97S-2

RKZA9080

RKZA1460

3

1

2

RKZA1470

4

5

6



REMOVAL OF THE FRONT WORKING EQUIPMENT

Lower the working equipment completely until itrests on the ground stop the engine and removethe ignition wrench.


1 - Remove the tilt cylinders. (See «REMOVAL OF FRONT

BUCKET TILT CYLINDERS»).

2 - Disconnect the cylinders (2) from the boom and rest

them on wooden blocks «A» placed on the front axle.

3 - Put a sling round the boom (1) as shown in the figure,

and attach it to the hoisting tackle. Apply a slight ten-

sion to the cables.

4 - Open the front hood (3) and take out the screws (4)

that lock the axle oscillation pins of the boom (1).

Close the front hood.

30-70

REMOVAL AND INSTALLATION FRONT WORKING EQUIPMENT

WB97S-2

RKZA9080

RKZA2220

A2

1

RKZA1090

44

RKZA9210

1



5 - Using a puller, take out the axle oscillation pins (5) of

the boom (1).

6 - Start the engine and put the machine into reverse

gear travel until the boom is disengaged.

H If the working equipment is to be detached to aidthe removal of the engine-gearbox-pump group,and the machine cannot travel automatically, itcan be towed using the towing hooks of the bac-khoe.

7 - Place two stands in position and lower the boom until

it is resting on them.

Work equipment: 960 kg

INSTALLATION OF THE FRONT WORKING EQUIPMENT

. To install, reverse the removal procedure, if necessa-ry using the front towing hook.



. Start the engine and bleed the air from the cylinders.(For details, see «20. TESTING AND ADJUST-MENTS»).


30-71

REMOVAL AND INSTALLATION FRONT WORKING EQUIPMENT

WB97S-2

RKZA7920

1

5



REMOVAL OF THE BACKHOE CONTROL VALVE

1 - Swing the backhoe completely to the right of the ma-

chine, and rotate the boom to approx. 45ë to the right.

2 - Lower the outriggers to the ground, open the bucket

and rest the arm on a block «A», keeping it perpendi-

cular to the ground.

3 - Rest the bucket teeth on the ground, release the bac-

khoe plate and stop the engine.


4 - Take out the lower window (1) of the cab and comple-

tely raise the upper window.

5 - Remove the grips (2) of the control levers of the ou-

triggers and the grip (3) of the lever-locking device.

6 - Raise the protective sleeves (4) of the control levers,

take out the screws (5) and remove the cover (6).

H If any optional devices have been fitted, unhookthe spool command tie-rods (7) and remove thepedals (8) and the supports (9).

30-72

REMOVAL AND INSTALLATION BACKHOE CONTROL VALVE

WB97S-2

RKZA1680

RKZA1100

1

RKZA1110

4

4

3

5

6

2

RKZA1120

7

8 9



7 - Disconnect the connector (10) of the solenoid (11) of

the control valve (12).

8 - Disconnect the lever command tie-rods from the con-

trol valve.

9 - Disconnect from the control valve the pipes (14) (de-

livery, return, Load Sensing and actuators). Plug

them to prevent entry of impurities.

H Mark the pipes to prevent exchanging positionsduring re-connection.

10 - Attach the control valve (12) to some hoisting tackle

and apply a slight tension to the cables.

11 - Remove the four screws (15) and then the entire con-

trol valve.

Control valve: 6-spool 47 kg7-spool 53 kg8-spool 59 kg

INSTALLATION OF THEBACKHOE CONTROL VALVE. To install, reverse the removal procedure.

H Bleed the air from Load Sensing circuits and from thehydraulic circuits of all the actuators. (For details, see«20. TESTING AND ADJUSTMENTS).

30-73

REMOVAL AND INSTALLATION BACKHOE CONTROL VALVE

WB97S-2

RKZA2251

14

13

11

10

12

RKZA2260

15 15



REMOVAL OF BACKHOE BOOM CYLINDER

1 - Remove the lubrication nipple and the extension (1).

Extend the arm (2) completely and fully open the

bucket (3).Manoeuvre the front equipment until the bucket teethare resting on the ground, the arm on a block «A»about 10 cm high, and the joint between the armand the boom on a stand «B», about 70 cm high.

2 - Stop the engine and release residual pressures.

3 - Place a sling around the cylinder (4).

4 - Take out the screws (5) and remove the pin (6).

5 - Start the engine and retract the piston.

H Secure the position of total retraction by bindingthe piston head rod with wire.

6 - Stop the engine and release any residual hydraulic

pressures. (For details, see «20. TESTING AND AD-

JUSTMENTS»).

7 - Disconnect the pipes (7) and (8) and plug them to pre-


8 - Take out the screw (9) and remove the pin (10).


Cylinder: 78 kg

INSTALLATION OF THEBACKHOE BOOM CYLINDER. To install, reverse the removal procedure.





MENTS»).

H After bleeding the air, check the oil level in thetank.

30-74

REMOVAL AND INSTALLATION BACKHOE BOOM CYLINDER

WB97S-2

RKZA1150

1

6

5

RKZA0140

3

2

BA

10

9

RKZA1170

5

6

RKZA1180

8

4

7



REMOVAL OF THE BACKHOE ARM CYLINDER

Extend the arm (1) completely and fully open thebucket (2). Lower the arm (3) until the joint betweenthe arm and the boom is resting on a stand «A» about

90 cm high, and tip of the arm on a block « B» about10 cm high. Rest the bucket teeth on the ground.

1 - Stop the engine and release the pressures in the cy-

linder by moving the control lever several times.


3 - Take out the screws (5) and remove the pin (6).

4 - Start the engine and retract the piston (7).

H Secure the position of total retraction of the piston

(7) by binding the piston head rod with wire.

5 - Stop the engine and release the residual hydraulic


JUSTMENTS»).

6 - Disconnect the pipes (8) and (9) and plug them to pre-


7 - Take out the snap-ring (10) and remove the pin (11).


Cylinder: 69 kg

INSTALLATION OF THEBACKHOE ARM CYLINDER






MENTS»).


30-75

REMOVAL AND INSTALLATION BACKHOE ARM CYLINDER

WB97S-2

RKZA1160

2

13

B

A

RKZA1190

5

64

RKZA1200

78

4 9

RKZA1210

11 4

10



REMOVAL OF THE JIG ARM CYLINDER

Open the arm (1) completely and lower it until it restson a trestle "A" that is roughly 40 cm high.Extend the jig 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) pressu-

res, by moving the command pedal several times.

2 - Put a sling around the cylinder (3).

3 - Take off the snap ring and remove the pin (4).

4 - Start the engine to retract the piston.

H Secure the fully retracted position of the piston bybinding it with wire.


pressures.

(For details see «20. TESTS AND ADJUSTMENTS»).

6 - Take out the safety pin (5).

7 - Disconnect the hoses (6), (7), (8) and (9), and plugthem to prevent entry of impurities.

8 - Remove the clamp (10).

9 - Remove the screws (11) and the pin (12).


INSTALLATION OF THEJIG ARM CYLINDER. To install, reverse the removal procedure.

When aligning positions between hole and pin, letthe engine turn over at low idling.Do not insert fingers into the holes to check on align-ment.

Internal bushings: ASL800050


(For details, see «20. TESTS AND ADJUSTMENTS»).


30-76

REMOVAL AND INSTALLATION JIG ARM CYLINDER

WB97S-2

RKZA7930

1

2

4

A

B

RKZA7940

5

3

RKZA7950

9 7

8

6

12

11 10



REMOVAL OF THE BACKHOE BUCKET CYLINDER

Extend the arm (1) completely and fully open thebucket (2). Lower the boom (3) until the arm is restingon a stand «A» about 90 cm high, and tip of the arm

on a block «B» about 10 cm high. Rest the bucketteeth on the ground.

1 - Stop the engine and release the pressures in the cy-

linder (4) by moving the control lever several times.


3 - Take out the lock-nut (5) and the washer and remove

the pin (6).

4 - Start the engine and retract the piston (7).

H Secure the position of total retraction of the pistonby binding the piston head rod with wire.



JUSTMENTS»).

6 - Disconnect the bracket (8) and the pipes (9) and (10),


H For the jig arm, take out the screw (14) and remo-ve the pin (15).

7 - Take out the snap-ring (11) and remove the pin (12).

H For the jig arm, take out the screw (14) and remo-

ve the pin (15).8 - Remove the cylinder (4).

Cylinder: 49 kg

INSTALLATION OF THEBACKHOE BUCKET CYLINDER

. To install, reverse removal procedure.



H Tighten the locknut completely, then release ithalf a turn.



MENTS»).H After bleeding the air, check the oil level in the tank.

30-77

REMOVAL AND INSTALLATION BACKHOE BUCKET CYLINDER

WB97S-2

RKZA2291

2

31

AB

4

RKZA2300

7

4

5

6

RKZA2310

4

910

11

128

RKZA7960

12

13

14

15

For jig arm



REMOVAL OF THE OUTRIGGER CYLINDERS

Position the backhoe with the equipment centered,the arm vertical and the back of the bucket restingon the ground.

1 - Extend the outriggers (1) of about 15 cm, stop the en-

gine and release the cylinders pressures.

2 - Place a lifting platform "A" beneath outrigger (2).

Raise this until it is forced up against the outrigger.


4 - Disconnect from cylinder (5) the pipe (4) and plug

them to avoid impurity entry.

Plug also the union to avoid the movement of piston.

5 - Remove screw (6) and extract the pin (7) until the cy-

linder (5) is free.

6 - Raise the lifting platform "A" to disengage the cylin-

der head (5) from frame.

Place a sling round the cylinder (5) and apply slight

tension to the cables.

30-78

REMOVAL AND INSTALLATION OUTRIGGER CYLINDERS

WB97S-2

RKZA0971

1

RKZA1240

A

1

2

RKZA1250

45

6

7

3

4

RKZA1260

7

5



7 - Take out the screw (9) and remove the pin (10).


Cylinder: 42 kg

INSTALLATION OF THEOUTRIGGER CYLINDERS. To install, reverse the removal procedure.

Do not insert fingers into the holes to check align-ment.




MENTS»).


30-79

REMOVAL AND INSTALLATION OUTRIGGER CYLINDERS

WB97S-2

RKZA1270

9

8



REMOVAL OF THE BACKHOE SWING CYLINDERS

Position the backhoe with the equipment centered,the arm vertical and the back of the bucket restingon the ground.

1 - Stop the engine and release cylinder pressures by

moving the control levers several times.

2 - Take out the screws (1) and remove vertically the upper

support (2) of the cylinder fulcrum.

3 - Disconnect the four tubes (4) from the cylinders (3)


4 - Take out the screws (5) and remove the pins (6).

5 - Rotate the cylinders to disengage the piston headsfrom the swing bracket (7) and remove the cylinders

(3).

Cylinder: 30 kg

INSTALLATION OF THEBACKHOE SWING CYLINDERS

1 - Mount the cylinders (3) and the upper cylinder ful-

crum support (6). Secure the support with the fourscrews (1).

Support screw: Loctite 262

Support screw: 100w10 kgm

2 - Connect the four tubes (4) to the cylinders.

3 - Start the engine and swing the boom in order to cen-

ter one of two pins (8). Secure the 1st pin with the

screw (7).

Perform the same operation for the other pin.





MENTS»).


30-80

REMOVAL AND INSTALLATION BACKHOE SWING CYLINDERS

WB97S-2

RKZA0970

RKZA1280

3

2

1

1

RKZA1290

6

4

5

3

7



REMOVAL OF BACKHOE BACKFRAME LOCK CYLINDER

H Set the backhoe with the centered attachments withthe arm in vertical position and the bucket leaned

on the back at level ground.1 - Unlock the backframe (1).



JUSTMENT»).

3 - Disconnect from cylinder (2) the pipes (3) and (4) and

plug them to avoid impurity entry.

4 - Remove screws (5) and cylinders (2).

INSTALLATION OF BACKHOEBACKFRAME LOCK CYLINDER. To install, reverse the removal procedure.

Locking screw: Loctite 262

Locking screw: 41w4 kgm

Cylinder seat: ASL800050

1 - Start the engine, lock and unlock the backframe seve-

ral times to make the circuit feeling.

30-81

REMOVAL AND INSTALLATION BACKHOE BACKFRAME LOCK CYLINDER

WB97S-2

RKZA0970

RKZA1300

3 2

51

4



DISASSEMBLY OF CYLINDERS(Front bucket raise and tilt, boom, arm, bucket, outriggers and jig arm)

1 - Place the cylinder (1) on the tool A1. Engage the cy-

linder head in the tools A2 appropriate to the diame-

ter of the hole.

For the arm cylinder with side-digging boom first ex-tract the snap-rings (2) and the ball-and-socket joint(3).

2 - Using the specially-made wrench A4, A5, A6 un-

screw the cylinder head (4) and extract it from the cy-

linder (1).

For the side-digging boom cylinder, first removethe lock-nut (5) that secures the piston-rod seal.

3 - Raise the cylinder (1) and attach the piston head to

the mobile group of the tool.

4 - Extract the piston-rod group (6) from the cylinder (1).

5 - Remove the cylinder (1) and the piston-rod group (6).

30-82

REMOVAL AND INSTALLATION CYLINDERS

WB97S-2

RKZA1540

1

A2

A2

A1

RKZA1530

1 4

3 2

5

RKZA1560

1

6

4

A1



6 - Secure the piston-rod group (6) on the tool A1.

7 - For the side digging boom cylinder: remove the

snap-spin (10).

8 - For the piston rod of the boom cylinder: remove the

screw (7).

9 - Use the appropriate socket wrench A7 on the piston

hexagon (11) and unscrew the piston.

H Measurement of the socket wrench:For raising the front bucket: 55 mmFor tilting the front bucket: 55 mmBoom: 65 mmArm: 55 mmBucket: 55 mm

Outriggers: 46 mmJig arm: 46 mmSide digging boom: 46 mm

10 - For the piston rod of the boom cylinder: Take out

the ball bearings (8) and the cushion plunger (9).

11 - Dismantle all the groups by removing all the seals,

the dust-seals, the guide rings, and the fulcrum bus-

hings.

The seals, the dust seals and the guide ringscannot be used again.

Carefully check the pistons (11). If both safety-

caulked areas show wear, the pistons must bereplaced.

30-83


WB97S-2

7

9

8

1° BRACCIO

RKZ00020

BOOM

10

116

PISTONEDEPORTABILE

116

116

2° BRACCIO

SOLLEVAMENTOROVESCIAMENTO

RKZ00010

SIDE DIGGINGBOOM PISTON

ARM

RAISINGTILTING



ASSEMBLY OF CYLINDERS(Front bucket raise and tilt, boom, arm, bucket, outriggers and jig arm)

H Take great care not to damage the seals and the sli-ding surfaces.

H Prepare each individual component before the finalassembly.

1. ASSEMBLY OF THE CYLINDER HEAD

1.1 Only for the cylinders for front bucket raise

and tilt, boom, arm, bucket, outriggers, jig arm

1 - Mount the gasket (12) in the cylinder head.

2 - Mount the gasket (13) in the cylinder head.

H Make sure that the lips are turned towards the in-side of the cylinder.

3 - Mount the guard ring (14) using the tool A8.

4 - Mount the O-ring (15) and the anti-extrusion ring (16)

on the outside of the cylinder head.

1.2 Cylinder for side digging boom

1 - Insert the gasket (17) in the cylinder head, and let it

beat on seat bottom, then insert the anti-extrusion

ring (18).

H Check carefully the assembly orientation.

2 - Mount the guard ring (19) in the lock-nut (5).

3 - Tighten the lock nut (5) until leaning lightly on anti-ex-

trusion ring (18).

4 - Assemble on head the O-ring (20), the anti-extrusion

(21), the O-ring (22) and the ring (23).

2. RE-ASSEMBLING THE PISTON

2.1 Only for the cylinders for front bucket raise

and tilt, boom, arm, bucket, outriggers, jig arm

1 - Use the tool A9 with the appropriate diameter, mount

the ring (24) the external ring (25) and the anti-extru-

sion rings (26) onto the piston (11).

2 - Prepare the guide ring (27).H There are two guide rings (27) for the boom pi-

ston.

3 - For the boom piston only: insert the O-ring (28) into

the internal seating.

30-84


WB97S-2

16 15

14 13 12

RKZ00040

21 20

19 18 17

22

23

5

RKZ00050

24

26

25 26 27

11

RKZ00090

RKZA1580

28

27

A9



2.1 Side digging boom cylinder

H This mounting should be performed directly on piston.

1 - Mount central ring (29), rubber ring (30) and anti-ex-trusion ring (31).

2 - Mount on piston first washer (32), guide ring (33), cen-

tral ring assembly (29), second guide ring (34) and se-

cond washer (35).

3 - Tighten nut (36) and lock the piston group after loc-

king rod head under the press. (See «3. RE-ASSEM-

BLING THE PISTON-ROD GROUP»).

4 - Insert the snap ring (10).

3. RE-ASSEMBLING THE PISTON-ROD GROUP

1 - Only for the cylinders for front bucket raise and

tilt, boom, arm, bucket and side digging boom:

using a press and tools A2 with the appropriate dia-

meter, insert the bushing (37) into the piston head (6).

2 - Mount the bushing A10 of the correct diameter onto

the tip of the piston rod (6).

3 - Slightly lubricate the cylinder head seals (4) and slide

the group onto the piston rod (6).

Seals: ASL800050

4 - For the cylinders of the outriggers only: mount the

spacer (38) with the O-ring (39).

H Check carefully the assembly orientation.

For the arm cylinder only: insert the spacer (40).

30-85


WB97S-2

3431303133

32 35

36

10

29RKZ00060

RKZA1500

6

37

A1A2

RKZA1510

46

6A10

638

STABILIZZATORI

2° BRACCIO

40

39

RKZ00070

A10

OUTRIGGERS

ARM



5 - Remove from the tip of the piston rod (6) the bushing

A10 and mount the piston (11) and the nut (36).

H Grease the piston threading.

Piston locking nut: Loctite 262

Piston locking nut:Front bucket raise: 290w29 kgmFront bucket tilt: 290w29 kgmArm: 290w29 kgmBucket: 290w29 kgmOutriggers: 155w15 kgmJig arm: 155w15 kgm

6 - For the boom cylinder: mount the cushion plunger

(9), slide the eleven ball-bearings (8) into the hole,

and mount the dowel bolt (7).

Dowel bolt: Loctite 262

Dowel bolt: 23w2 Nm

7 - Screw the complete piston (11) onto the piston rod,

and secure it with the dynamometric wrench.

Piston: 120 ± 125 kgm

8 - Caulk the piston (11) to correspond to the slot in the

piston rod (6) not previously used.

4. RE-ASSEMBLING THE CYLINDERS

1 - Mount onto the apparatus A1 the tools A2 with the

appropriate diameter.

2 - For the boom, arm, bucket and side digging boom

cylinders only:

Position the bushing (41) and mount it in the cylinder

head (1).

H There are two bushings for the arm cylinder, witha spacer between them.

H Leave the cylinder in position for subsequent as-

sembly.

3 - Lubricate the threading and the first part of the cylin-

der (1).

Cylinder: ASL800050

4 - Mount the two halves of the tool A11 with the appro-

priate diameter at the mouth of the cylinder (1).

30-86


WB97S-2

6

11

7

9

8

RKZ00021

RKZA1551

116

RKZA1541

1

41

A1

A2

A2

RKZA1520

1 A11



5 - Mount the piston rod group (6) on the apparatus A1

and raise the mobile part to the end of its stroke.

6 - Place the cylinder (1) in a vertical position and guide

the piston into the tool A11.

7 - Lower the apparatus that supports the piston rod (6)

in order to center the piston in the tool A11.

8 - Mount the first guide ring (27) onto the piston and in-

sert part of the piston into the tool A11.

For the boom cylinder only: mount the second gui-

de ring (27) and fully insert the piston.

Insert the piston slowly in order to calibrate the guiderings (27) without overheating them.

9 - Take the cylinder out of the tool A11 and then lowerthe apparatus A1 further in order to bring the cylinder

head (4) and the piston rod head closer to the cylin-

der.

10 - Bring the cylinder (1) into position for screwing in the

cylinder head (4).

11 - Insert the cylinder head into the cylinder and screw it

in by hand for several turns.

12 - Use the right special wrench A4, A5, A6 to screw the

cylinder head (4) home.

Cylinder head: 95 ± 100 kgm

13 - For the side digging boom cylinders only: tighten

the lock-nut (5).

Lock-nut: 50 kgm

30-87


WB97S-2

RKZA1561

1

6

4

A1

A11

RKZ00080

5



DISASSEMBLY OF BOOM SWING CYLINDER

1 - Place the cylinder (1) on the apparatus A1. Engage

the axle oscillation pins in the tools A3.

2 - Using the specially-designed wrench A6, unscrew the

cylinder head (2) and extract it completely from the

cylinder (1).3 - Remove the safety dowel bolt (10).

4 - Raise the cylinder (1) and attach the piston head to

the mobile group of the apparatus A1.

5 - Extract the piston rod group (4) from the cylinder.

6 - Remove the cylinder and the piston rod group.

7 - Secure the complete piston rod (4) to the apparatus

A1.

8 - Raise the part caulked for safety purposes and un-

screw the piston using the tool A7.

Check the piston (5) carefully. If both safety-caulkedareas have been used, the piston must be replaced.

9 - Remove the snap-ring (6) from the piston and extract

the ring (7) and the spacer ring (8).

H Make a note of the order of assembly of the ring(7).

10 - Using a puller remove the swing bushings (9) from

the cylinder axle oscillation pins.

11 - Dismantle the groups by removing all the seals, the

guard rings, the guide rings and the piston fulcrum

bushing.

The seals, guard rings and guide rings must notbe used again.

30-88

REMOVAL AND INSTALLATION BOOM SWING CYLINDER

WB97S-2

RKZ00362

4

138

2

9

7

3

6

5



ASSEMBLY OF BOOM SWING CYLINDER

H Take great care not to damage the seals and the sli-ding surfaces.

H Prepare each individual component before the finalassembly.

1. Assembly of the cylinder head

1 - Mount the gasket (10) and the gasket (11) in the cylin-

der head.


2 - Mount the scraper ring (12).

3 - Mount the O-ring (13), the anti-extrusion ring (14) and

lastly the O-ring (15) of the front seal.

2. Re-assembling the piston

1 - Use the tool A9 with the appropriate diameter, mount

the rubber ring (16) and the seal ring (17) onto the pi-

ston. Remove the tool A9 and mount the anti-extru-

sion rings (18).

2 - Prepare the guide rings (19).

3 - Mount the O-ring (20) in the internal seating of the pi-

ston.

3. Re-assembling the piston-rod group

1 - Using a press and tools A2 with the appropriate dia-

meter, insert the bushing (21) into the piston head (4).

2 - Insert the ring (8) into the piston rod (4).

H Check carefully the direction of assembly of thering (8).

3 - Insert the spacer ring (7) and secure the group with

the snap-ring (6).

4 - Mount the bushing A10 of appropriate diameter on

the tip of the piston rod (4).

5 - Lightly lubricate the cylinder head gaskets (2) and sli-

de the group onto the piston rod (4).

Gaskets: ASL800050

6 - Lubricate the O-ring seals (22) and screw the piston

(5) onto the piston rod (4) by hand for several turns.

O-ring seal: ASL800050

7 - Position the group on the tool A1 and tighten the pi-

ston with the round prong wrench A7.

Piston: 95 ± 100 kgm

30-89


WB97S-2

RKZ00110

13 15214

11 1210

RKZA1600

A9

171819 18 19

16

20

RKZA1590

21

3

A2

A10

RKZ00120

45

8

22

6

7



4. Re-assembling cylinders

1 - Mount on the apparatus A1 the tool A3 and engage

the cylinder axle oscillation pins (1).

2 - Lubricate the threading and the first part of the cylin-

der (1).

Cylinder: ASL800050

3 - Mount the two halves of the tool A11 with the appro-

priate diameter at the mouth of the cylinder (1).

4 - Mount the piston rod group on the apparatus A1 and

raise the mobile part up to the end of its stroke.

5 - Place the cylinder (1) in a vertical position.

6 - Lower the mobile part of the apparatus in order to

center the piston (5) in the tool A11.

7 - Wind the first guide ring (19) round the piston and in-

sert part of the piston into the tool A11. Wind the se-

cond guide ring (19) and fully insert the piston.

Insert the piston slowly in order to calibrate the guiderings (19) without overheating them.

8 - Insert the cylinder head (2) and screw it in by hand for

several turns.

9 - Use the special wrench A6 to screw the cylinder head

(4) home.

Cylinder head: 95 ± 100 kgm

10 - Screw the brake cylinder (3) into the cylinder (1).

Brake cylinder: Loctite 270

Brake cylinder: 8 2 kgm

11 - Remove the cylinder from the equipment.

12 - Using and press and the appropriate tool A3 mount

the swing bushings (9).

30-90


WB97S-2



DISASSEMBLY OF BACKHOE BACKFRAME LOCK CYLINDER

1 - Plug one of the two cylinder (1) ports.

2 - Connect to the other port compressed air (max. 3

bar).

3 - Slowly insert pressure up to piston (2) comes out.

H Retain piston and protect from oil using glovesand a protection.

4 - Remove gasket (3).

The gasket has be replaced.

ASSEMBLY OF BACKHOE

BACKFRAME LOCK CYLINDER1 - Use the tool with the appropriate diameter, mount the

seal ring (3) onto the piston (2).


2 - Put the piston (2) onto cylinder (1).

Cylinder: ASL800050

3 - Apply an elastic band for piston ring and using a

press insert the piston.

30-91

REMOVAL AND INSTALLATION BACKHOE BACKFRAME LOCK CYLINDER

WB97S-2

RKZ00190

1

3 2



REMOVAL OF THE BOOM SAFETY CYLINDER

Center the backhoe with the arm vertical and theback of the bucket on the ground.

1 - Make sure that the safety stop (1) is raised.


pressures.

3 - Disconnect the tube (2) that feeds the cylinder (3).

Plug the tube to prevent entry of impurities.

4 - Take out the cotter pins, remove the pins (4) and (5)

and the cylinder (3).

INSTALLATION OF THE BOOMSAFETY CYLINDER


Pin seatings: ASL800050

H Install new cotter pins.

1 - Start the engine and perform several lock and release

manoeuvres to fill up and bleed air from the unit.

30-92

REMOVAL AND INSTALLATION BOOM SAFETY CYLINDER

WB97S-2

RKZA0970

RKZA1310

31

5

4

2



REMOVAL OF THE BACKHOE WORKING EQUIPMENT

Fully extend the arm and open the bucket complete-ly. Lower the equipment until it is resting on theground.



JUSTMENTS»).

2 - Remove the boom cylinder. (For details, see «REMO-

VAL OF BOOM CYLINDER»).

3 - Take out the bracket (1) mounted inside the boom. Di-

sconnect the tubes (2) from the arm cylinders and the

bucket. Plug all tubes to prevent entry of impurities.

H Mark the tubes to prevent exchanging positionsduring re-connection.

4 - Put a sling round the equipment (3) and apply slight


5 - Take out the snap-rings and remove the pin (4).

6 - Remove the working equipment (3).

Standard working equipment: 850 kg

INSTALLATION OF THE BACKHOEWORKING EQUIPMENT




H Pass the tubes of the cylinders inside the brackets (5).



MENTS»).


30-93

REMOVAL AND INSTALLATION BACKHOE WORKING EQUIPMENT

WB97S-2

RKZA1320

2

1

RKZA1330

3

4

RKZA1340

5



REMOVAL OF THE BACKHOE BUCKET

Place the bucket on a level surface, resting on itsback.

1 - Take out the safety pin (1) and remove the connectingpin (2) between bucket (3) and tie-rods (4).

2 - Take out the safety pin (5) and remove the pin (6) that

attaches the bucket to the arm.

INSTALLATION OF THEBACKHOE BUCKET




30-94

REMOVAL AND INSTALLATION BACKHOE BUCKET

WB97S-2

RKZA1350

4

7

6

5

3

2

1



REMOVAL OF THE ARM

1 - Remove the bucket. (For details, see «REMOVAL OF

BUCKET»).

2 - Remove the bucket cylinder and the lever (1). (For de-

tails, see «REMOVAL OF THE BUCKET CYLINDER»).

3 - Take off the lock-nut (2), and the washers, and remo-

ve the pin (3) and the lever (4).

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 cylinder.

6 - Put a sling around the arm cylinder (5), remove the

screws (6) and remove the pin (7).

7 - Start the engine and retract the piston completely (8).

H Secure the fully retracted position by binding thepiston head with wire.

8 - Rest the cylinder (5) on a block «A».

9 - Stop the engine.

10 - Attach the arm (9) to the hoisting tackle and apply a

slight tension to the cable.

11 - Take out the screws and remove the pin (10).

12 - Remove the arm (9).

Arm: 213 kg

INSTALLATION OF THE ARM


When aligning the positions between the hole andthe pin, do not insert fingers into the holes to check

alignment.




30-95

REMOVAL AND INSTALLATION ARM

WB97S-2

RKZA1360

13

4

2

RKZA1201

8 5

RKZA1370

76

RKZA1380

10

A

9



REMOVAL OF COMPLETE JIG ARM

1 - Remove the bucket. (For details, see «REMOVAL OF

BUCKET»).

2 - Remove the bucket cylinder and the link (1). (For de-

tails, see REMOVAL OF BUCKET CYLINDER«).

3 - Take out the lock nut (2) and the washer, and remove

the pin (3) and the cylinder link (4).

4 - Disconnect the jig arm hoses (5) and (6), the bucket

cylinder hoses (7) and (8), and the hoses of the auxi-

liary equipment (9) and (10).

H Mark the hoses to avoid exchanging them duringINSTALLATION.


6 - Proceed with the removal as for the arm.

(See «REMOVAL OF THE ARM»).

Jig arm cylinder: 392 kg

INSTALLATION OF THECOMPLETE JIG ARM. To install reverse the removal procedure.

When aligning positions between hole and pin, donot insert fingers into the holes to check on align-ment.



When aligning positions between hole and pin let theengine turn over at low idling.Do not insert fingers into the holes to check on align-ment.

30-96

REMOVAL AND INSTALLATION JIG ARM

WB97S-2

RKZA1360

13

4

2

RKZA7970

11

5

6

7

89

10



REMOVAL OF 2nd ARM

1 - Remove the bucket (1). (For details, see «REMOVAL

OF BUCKET»).

2 - Remove the bucket cylinder (2) and the link (3).

(For details, see «REMOVAL OF THE BUCKET CY-

LINDER»).

3 - Remove the 2nd arm cylinder.

(For details, see «REMOVAL OF THE 2nd ARM CY-

LINDER»).For safety, tightly plug all the disconnected ho-ses.

4 - Take out the lock nut (4), and the washers and remo-

ve the pins (5) and the links (6).

5 - Connect the 2nd arm (7) to some hoisting tackle.

H Use the bucket pin hole and the safety pin holes.

6 - Start the engine and, maintaining constant tension on

the section of cable or chain connected to the bucket

coupling, slowly raise the boom until both sections of

cable or chain are under slight tension.

7 - Stop the engine and loosen by several turns the gib

adjustment screws.

HLoosen the screws on both sides.

8 - Slide out the 2nd arm (7).

2nd arm: 160 kg

INSTALLATION OF 2nd ARM.

To install, reverse the removal procedure.

When aligning the positions between hole and pin,do not insert fingers into the holes to check on align-ment.


H Tighten the locknut completely, then release it

half a turn.

30-97

REMOVAL AND INSTALLATION 2nd ARM

WB97S-2

RKZA7980

7

1

3

2

RKZA7990

3

4

5

6

RKZA8000

7



REMOVAL OF 2nd ARM GUIDES

1 - Remove the bucket (1). (For details, see «REMOVAL

OF BUCKET»).

2 - Partially extend the 2nd arm (1).

3 - Rest the arm (2) on a trestle "A" about 80 cm (3.5 ft.)

high.

4 - Loosen and remove the screws (3), the spring wash-

ers and remove the upper guides (4).

5 - Connect the 2nd arm (1) to some hoisting tackle.

H Use the bucket pin hole and the safety pin holes.

6 - Slowly raise the 2nd arm (1) until it rests on the sup-

porting surfaces of the upper guides.

7 - Loosen the nuts (5) and remove the adjustment dowel

bolts (6).

8 - Raise the lower guides (7) and slide them out.

INSTALLATION OF2nd ARM GUIDES. To install, reverse the removal procedure.

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.

TESTS AND ADJUSTMENTS»).

30-98

REMOVAL AND INSTALLATION 2nd ARM GUIDES

WB97S-2

RKZA8010

12

A

RKZA8020

3

5 6

RKZA8030

1

2

RKZ0239

3

4

5

6

7



REMOVAL OF THE BACKHOE BOOM

1 - Remove the arm. (For details, see «REMOVAL OF

THE ARM»).

2 - Remove the arm cylinder. (For details, see «REMO-

VAL OF THE ARM CYLINDER»).

3 - Start the engine and rest the boom on the ground.

4 - Remove the boom cylinder. (For details, see «REMO-

VAL OF THE BOOM CYLINDER»).

5 - Take out the bracket (1) and disconnect the tubes (2)

from the arm cylinders and the bucket. Plug all tubes

to prevent entry of impurities.

H Mark the tubes to prevent exchanging positionsduring re-connection.

6 - Put a sling round the boom (3).

7 - Take out the snap-rings and remove the pin (4).

8 - Remove the boom (3).

Boom: 323 kg

INSTALLATION OF THEBACKHOE BOOM




H Pass the cylinder tubes inside the brackets (5).



MENTS»).


30-99

REMOVAL AND INSTALLATION BACKHOE BOOM

WB97S-2

RKZA1320

2

1

RKZA1390

3

4

RKZA1340

5



REMOVAL OF THE BACKHOE SWING BRACKET

1 - Remove the working equipment. (For details, see

«REMOVAL OF THE WORKING EQUIPMENT»).

2 - Take out the screws (1) and remove the pins (2) that

connect the swing cylinders (3).

3 - Disconnect the tube (4) of the boom safety cylinder (5)

and remove the retaining clip (6). Plug the tube to pre-


4 - Take out the four screws (7) and remove the boom sa-

fety group (8).

5 - Put a sling round the swing bracket (9).

6 - Take out the screws (10) and (11) and remove the

swing bracket axle oscillation pins (12) and (13).

7 - Remove the swing bracket (9) and the relative shim

adjustments to given clearance.

Bracket: 133 kg

INSTALLATION OF THEBACKHOE SWING BRACKET




Safety group screws: 27w3 kgm

H Insert the shims.



MENTS»).


30-100

REMOVAL AND INSTALLATION BACKHOE SWING BRACKET

WB97S-2

RKZA7760

2

1

3

RKZA1400

4

7

6

8 5

RKZA1410

9

11

13

1210

RKZA1420

9



REMOVAL OF BACKHOE BACKFRAME

1 - Remove the equipment. (For detail see «REMOVAL

OF BACKHOE WORKING EQUIPMENT»).

2 - Remove the swing cylinders. (For detail see «REMO-

VAL OF SWING CYLINDER»).

3 - Remove the swing bracket. (For detail see «REMO-

VAL OF SWING BRACKET»).

4 - Disconnect from union (1) the feeding pipes (2) of

backhoe backframe and plug them to avoid impurity

entry.

5 - Loose nuts (4) and remove washers (5) and four

screw (6).

Loose partially lateral nuts (4) to remove backframe

(3) from frame (8).6 - Put a sling round the backframe (3) and apply slight


7 - Remove external nuts (4), washers (5) and screws (6).

8 - Remove the sliding piece (7) and then lower the back-

frame and remove it.

Backframe: 237 kg

INSTALLATION OFBACKHOE BACKFRAME


Nut: Loctite 262

Nut: 100w10 kgm



MENTS»).


30-101

REMOVAL AND INSTALLATION BACKHOE BACKFRAME

WB97S-2

RKZA1430

65

21

RKZA1440

4 57

3

8

RKZA1660

3



30-102

REMOVAL AND INSTALLATION

WB97S-2



40-1WB97S-2

STANDARD MAINTENANCE

Transmission . ..... ..... ..... ..... ..... ..... ..... ..... .. 3

Front axle............................................... 6

Rear axle ............................................... 9

Hydraulic pump ....................................... 14

2-Spool control valve ... ... ... ... ... ... ... ... ... ... ... 163-Spool control valve ... ... ... ... ... ... ... ... ... ... ... 18

6-Spool control valve ... ... ... ... ... ... ... ... ... ... ... 22

7-Spool control valve ... ... ... ... ... ... ... ... ... ... ... 25

8-Spool control valve... ... ... ... ... ... ... ... ... ... ... .27

Brake pump............................................29

Shovel cylinder ........................................30

Backhoe cylinder......................................32

Front working equipment .............................36Swing bracket ..... ..... .... ..... ..... ..... ..... ..... ..38

Backhoe working equipment .... .. .. .. .. .. .. .. .. .. .. . 40



40-2 WB97S-2




TRANSMISSION

40-3WB97S-2

RKZ04251

A

A

HH

FF

G

G

C

C

E

E

B

B

DD

L

. . . . . . . Nm

23w1 Nm



40-4 WB97S-2

RKZ04271

Sezione A - A

50w2.5 Nm

50w2.5 Nm

50w2.5 Nm

Loctite 510

139w7 Nm

50w2.5 Nm

Loctite 510

Loctite 510

139w7 Nm

23w1 Nm

23w1 Nm

Section A ± A



40-5WB97S-2

RZ03110

Sezione B - B

Sezione C - C

Sezione D - D

Sezione E - E

50w2.5 Nm 25w1 Nm

23w1 Nm

25w1 Nm

25w1 Nm

80w4 Nm

Section B ± B

Section C ± C

Section D ± D

Section E ± E

RZ03120

Particolare L

Sezione H - H

Sezione F - F

Sezione G - G

80w4 Nm

23w1 Nm

26±30 Nm

50w2.5 Nm

26±30 Nm

40w2 Nm

25w1 Nm

Section F ± FSection G ± G

Section H ± H

Detail L



Unit: mm

Në Check item Criteria Remedy

1 Axle clearanceStandard clearance Clearance limit

Adjust

Ð Ð

2Backlash of crown wheeland pinion

0.20 ± 0.30 Ð

3Pinion preload "P"(without seal ring)

92±137 N

4Pinion-crown wheel preload(without seal ring)

(P+34)± (P+51) N

FRONT AXLE

Differential

40-6 WB97S-2

RKZ04261

1

23

4

155 Nmwith Loctite 270

13 Nm

413 Nm

Loctite 510

169 Nm

60 Nm



Unit: mm


1 Hub rotation torque Ð Adjust

2 Drive shaft axle clearance Ð Replace

Planetary - Joint

40-7WB97S-2

RKZ04301

1

2

79 Nm

300 Nm

8 Nm

8 Nm

25 Nm200 Nm


60 Nm



Unit: mm


1Clearance betweenbushing and pin

Standardsize

Tolerance Standardclearan-

ce

Clearancelimit Replace bus-

hingShaft Hole

Ð Ð Ð Ð Ð

Steering cylinder

40-8 WB97S-2

RKZ04381

A

1

A

A B

B

Sezione A - A Particolare A

2145 +-02

Sezione B - B

x

y

250 Nm

300 Nm 460 Nm

Y= 50 mm (standard wheel)56 mm (optional wheel)

X= 62 mm (standard wheel)56 mm (optional wheel)

800 Nm

260 Nm

200 Nm

150 Nm

Section A ± A Section B ± B Detail A



Unit: mm


1 Axle clearanceStandard clearance Clearance limit

Adjust

Ð Ð

2Backlash of crown wheeland pinion

0.20 ± 0.30 Ð

3Pinion preload "P"(without seal ring)

92±138 N

4 Pinion-crown wheel preload(without seal ring) (P+25.9) ± (P+38.8) N

REAR AXLE

Differential

40-9WB97S-2

RKZ04401

Sezione Z - Z

1

Z

Z

2

3

4

155 Nm

with Loctite 270


320 Nm


80 Nm

60 Nm

190 Nm 120 Nm

Section Z ± Z



Unit: mm


1 Hub rotation torque Ð Adjust

2 Drive shaft axle clearance Ð

Planetary - Joint

40-10 WB97S-2

RKZ04411

1

2

79 Nm

70 Nmwith Loctite 270 3 Nm

23 Nm

60 Nm

25 Nm

230 Nm

8 Nm300 Nm



Unit: mm


1 Brake disc return spring

Standard size Repair limit

Replace ifdamaged ordeformed

Freeinstalled

Installedlength

Installedload

Freeinstalled

Installedload

Ð Ð Ð Ð Ð

2 Disc thickness

Standard thickness Min. thickness

Replace4.83w0.13 Ð

Brakes

40-11WB97S-2

RKZ04421

Particolare A

300mm (Min.)

310mm (Max.)

50 N

1

2

A

10 Nm

35 Nm


190 Nm

Detail A



Steering cylinder

40-12 WB97S-2

RKZ04441

A

A

A

Sezione A - A Particolare A

x

y

2145 +-02

250 Nm

300 Nm

Y= 50 mm (standard wheel)56 mm (optional wheel)

X= 62 mm (standard wheel)56 mm (optional wheel)

800 Nm

260 Nm150 Nmwith Loctite 270

Section A ± A Detail A



40-13WB97S-2




Unit: mm


1 Ball-bearing loading 0 ± 0.05 Adjust

2Backlash between pistonand cylinder

Standardsize

ToleranceStandardclearance

Clearancelimit

Shaft Hole

3Backlash between pistonand shoe

4 Drive shaft diameterStandard value Max. value

5 Spring

Standardsize


Clearancelimit

Shaft Hole

HYDRAULIC PUMP

40-14 WB97S-2

A

Particolare A

4

51

3

2

RKZ01290Detail A



Unit: mm


1 Spring


Free

installedx ée

Installedlength Installedload Freeinstalled Installedload

2Power regulation spring(external)

3Power regulation spring(internal)

4 PC valve spring (external)

5 PC valve spring (internal)

6 LS valve spring (external)

7 LS valve spring (internal)

40-15WB97S-2

RKZ00641

Sezione C - C

Sezione D - D

1 2 3

76

54

Section C ± C

Section D ± D

. . . . . . . . . Nm . . . . . . . . . Nm . . . . . . . . . Nm

. . . . . . . . . Nm . . . . . . . . . Nm . . . . . . . . . Nm

. . . . . . . . . Nm. . . . . . . . . Nm. . . . . . . . . Nm



Unit: mm


1 Check valve spring


Freeinstalled

x ée

Installedlength

Installedload

Freeinstalled

Installedload

2 Priority valve spring


40-16 WB97S-2

A

A

C

C

D

D

B

B

RKZ01081Sezione A - A Sezione B - B

2

1

. . . . . . . . . Nm. . . . . . . . . Nm

. . . . . . . . . Nm

25 Nm 20 Nm20 Nmwith Loctite 542



25 Nm




Unit: mm


1 Spool return spring


Freeinstalled

x ée

Installedlength

Installedload

Freeinstalled

Installedload


40-17WB97S-2

RKZ00661

Sezione C - C

Sezione D - D

E

E

Sezione E - E

E

E

1

2

2

1

70w7 Nm

10w1 Nm10w1 Nm

70w7 Nm

10w1 Nm

10w1 Nm

. . . . . . . . . Nm

10w1 Nm

. . . . . . . . . Nm

30w3 Nm

Section C ± C

Section D ± D

Section E ± E



Unit: mm




Freeinstalled

x ée

Installedlength

Installedload

Freeinstalled

Installedload



40-18 WB97S-2

A

A

B

C

C

D

D

B

E

E

RKZ01071Sezione A - A Sezione B - B

2

1

. . . . . . . . . Nm . . . . . . . . . Nm

. . . . . . . . . Nm

25 Nm20 Nm 20 Nm

with Loctite 542



100 Nm

Section A ± ASection B ± B



Unit: mm




Freeinstalled

x ée

Installedlength

Installedload

Freeinstalled

Installedload

2 Spool locking spring



40-19WB97S-2

4

4

F

RKZ01300

Sezione C - C

Sezione D - D

F

F

Sezione F - F

F

3

1

2

Sezione E - E

F

F

Section C ± C

70w7 Nm 10w1 Nm

70w7 Nm10w1 Nm

10w1 Nm

70w7 Nm

10w1 Nm

. . . . . . . N m

70w7 Nm

. . . . . N m

. . . . . . . . . Nm

70w7 Nm

. . . . . . . . . Nm

70w7 Nm

30w3 Nm

Section D ± D

Section E ± E

Section F ± F



Unit: mm




Freeinstalled

x ée

Installedlength

Installedload

Freeinstalled

Installedload





With Return to Dig

40-20 WB97S-2

B

B

A

A

C

C

D

D

E

E

RKZ01091Sezione A - A

Sezione B - B

2

1

. . . . . . . . . Nm

. . . . . . . . . Nm

. . . . . . . . . Nm


100 Nm


20 Nm25 Nm

Section A ± ASection B ± B



Unit: mm




Freeinstalled

x ée

Installedlength

Installedload

Freeinstalled

Installedload





40-21WB97S-2

FF

RKZ00941

Sezione C - C

Sezione D - D

Sezione F - F

Sezione E - E

F

F

F

1

2

3

F

4

4

Section C ± C

Section D ± D

Section E ± E

Section F ± F

10w1 Nm

70w7 Nm

10w1 Nm

70w7 Nm

10w1 Nm

. . . . . . . . . Nm

. . . . . Nm

70w7 Nm70w7 Nm

. . . . . . . . . Nm

. . . . . . . . . Nm

. . . . . . . . . Nm

70w7 Nm

. . . . . . . . . Nm

70w7 Nm

30w3 Nm



Unit: mm




Freeinstalled

x ée

Installedlength

Installedload

Freeinstalled

Installedload


40-22 WB97S-2

RKZ00231

Sezione A - A

Sezione B - B

1

A

A

B

B

C

C

D

D

D

D

B

B

E

E

H

G

G

H

G

G

. . . . . . . . . Nm

10w1 Nm

70w7 Nm45 Nm70 Nm

20 Nmcon Loctite 542

70 Nm

. . . . . . . . . Nm

70w7 Nm

10w1 NmSection A ± A

Section B ± B



Unit: mm




Freeinstalled

x ée

Installedlength

Installedload

Freeinstalled

Installedload


40-23WB97S-2

RKZ01310

Sezione C - CSezione D - D

Sezione E - E

Sezione F - F

F

F

F

F

F

F

1

1

2

2

1

70w7 Nm

. . . . . . . . . Nm

10w1 Nm 10w1 Nm

70w7 Nm

10w1 Nm

70w7 Nm

10w1 Nm

70w7 Nm

10w1 Nm

70w7 Nm

10w1 Nm

30w3 Nm

10w1 Nm

70w7 Nm


Section E ± E

Section F ± F



Unit: mm


1 Unloading valve spring


Freeinstalled

x ée

Installedlength

Installedload

Freeinstalled

Installedload

40-24 WB97S-2

RKZ00791

Sezione G - G

Sezione H - H

1

10 Nm

25 Nm

20 Nm20 NmSection G± G

Section H ± H



For jig arm

For side digging boom

For hammer


40-25WB97S-2

RKZ00241

A

A

RKZ00251

B

B

RKZ00261

C

C



Unit: mm




Freeinstalled

x ée

Installedlength

Installedload

Freeinstalled

Installedload

40-26 WB97S-2

RKZ00961

Sezione B - B

Sezione C - C

Sezione A - A

1

11

70w7 Nm

10w1 Nm

70w7 Nm

10w1 Nm

10w1 Nm70w7 Nm

. . . . . . . . . Nm

10w1 Nm10w1 Nm

70w7 Nm

. . . . . . . . . Nm

10w1 Nm

70w7 Nm

. . . . . . . . . Nm

. . . . . . . . . Nm

70w7 Nm 10w1 Nm


Section C ± C



For hammer and jig arm

For side digging boom and jig arm


40-27WB97S-2

RKZ00271

a

d

bC

C

A

A

RKZ00281

e

f

b

c

B

B

A

A



Unit: mm




Freeinstalled

x ée

Installedlength

Installedload

Freeinstalled

Installedload

40-28 WB97S-2

RKZ00961

Sezione B - B

Sezione C - C

Sezione A - A

1

11

70w7 Nm

10w1 Nm

70w7 Nm

10w1 Nm

10w1 Nm70w7 Nm

. . . . . . . . . Nm

10w1 Nm

10w1 Nm

70w7 Nm

. . . . . . . . . Nm

10w1 Nm

70w7 Nm

. . . . . . . . . Nm

. . . . . . . . . Nm

70w7 Nm 10w

1 Nm


Section C ± C



Unit: mm


1 Ball valve spring


Replace ifdamaged ordeformed

Freeinstalled

Installedlength

Installedload

Freeinstalled

Toleranceload

w8 N

2 Spring

3 Pump spring

4 Spring

BRAKE PUMP

40-29WB97S-2

RKZ00931

4

1 2 3



DUMP CYLINDER

RAISE CYLINDER

Unit: mm


1Tolerance betweenpiston rod andcylinder head

CylinderStandard

size

ToleranceMinimumclearance

Clearancelimit

Shaft Hole

Raise 50± 0.025± 0.050

+ 0.064+ 0.025

0.05 0.114

Dump 50 ± 0.025± 0.050 + 0.064+ 0.025 0.05 0.114

2Tolerance betweenbushing and pistonrod mounting pin

Raise 45± 0.050± 0.089

+ 0.24+ 0.08

0.13 0.329

Dump 45± 0.050± 0.089

+ 0.24+ 0.08

0.13 0.329

3

Tolerancebetween bushingand cylindermounting pin

Raise 50± 0.038± 0.083

+ 0.24+ 0.08

0.118 0.323

Dump 50± 0.038± 0.083

+ 0.24+ 0.08

0.118 0.323

SHOVEL CYLINDER

40-30 WB97S-2

RKZ00780

3 1 2

290w29 kgm 95 kgm

RKZ00770

3 1 2

290w29 kgm 98 kgm



40-31WB97S-2




BOOM

ARM

BUCKET

BACKHOE CYLINDER

40-32 WB97S-2

RKZ00750

2

1 3

95± 100 kgm

RKZ00740

21 3

95 ± 100 kgm 290w29 kgm

RKZ00730

2 1 3

95±100 kgm 290w29 kgm



Unit: mm


1Clearance betweenpiston head andcylinder head

CylinderStandard

size

ToleranceMinimumclearance

Clearancelimit

Replace

Shaft Hole

Boom 60± 0.030± 0.060

+ 0.076+ 0.030

0.06 0.136

Arm 60± 0.030± 0.060

+ 0.076+ 0.030

0.06 0.136

Bucket 60± 0.030± 0.060

+ 0.076+ 0.030

0.06 0.136

Boom swing 50± 0.025± 0.050

+ 0.064+ 0.025

0.05 0.114

2Tolerance betweenbushing and pistonhead mounting pin

Boom 50± 0.050± 0.089

+ 0.24+ 0.08

0.13 0.329

Replacepin andspring

Arm 45± 0.050± 0.089

+ 0.24+ 0.08

0.13 0.329

Bucket 50± 0.050± 0.089

+ 0.24+ 0.08

0.13 0.329

Boom swing 50± 0.050± 0.089

+ 0.119+ 0.080

0.13 0.208

3


Boom 50± 0.050± 0.089

+ 0.24+ 0.08

0.13 0.329

Arm 45± 0.050± 0.089

+ 0.24+ 0.08

0.13 0.329

Bucket 45± 0.050± 0.089

+ 0.24+ 0.08

0.13 0.329

BOOM SWING

40-33WB97S-2

RKZ00363

21

95±100 kgm

35±100 kgm

8 ± 10 kgmwith Loctite 270



OUTRIGGERS

JIG ARM

SIDE DIGGING BOOM

40-34 WB97S-2

RKZ00710

1

155w15 kgm95± 100 kgm

1

RKZ04581

95± 100 kgm95 ± 100 kgm

RKZ00680

3 42

95 ± 100 kgm 80 kgm



ARM (for side digging boom)

Unit: mm


1Clearance betweenpiston rod andcylinder head

Cylinder

Standard

size

ToleranceStandard

clearance

Clearance

limit

Replace

Shaft Hole

Outriggers 40± 0.025± 0.050

+ 0.064+ 0.025

0.050 0.114

Arm for sidedigging boom

60± 0.030± 0.060

+ 0.076+ 0.030

0.060 0.136

Jig arm 40 Ð Ð Ð Ð

2Clearance betweenpiston rod andbushing

Side diggingboom

45± 0.009± 0.025

+ 0.380+ 0.040

0.049 0.405

3Tolerance betweenbushing and pistonrod mounting pin

Side diggingboom

40± 0.050± 0.089

+ 0.119+ 0.080

0.130 0.208


45± 0.050± 0.089

+ 0.119+ 0.080

0.130 0.208

4


Side diggingboom

40± 0.050± 0.089

+ 0.119+ 0.080

0.130 0.208

5Clearance betweenbearing and bearingseat


750

± 0.0130

± 0.035Ð 0.013

40-35WB97S-2

RKZ00671

3 51

95± 100 kgm 155w16 kgm




40-36 WB97S-2

RKZ04390

Sezione A - A

4

5

1 32

Sezione B - B

Sezione C - C

Sezione D - D

Sezione E - E

A

A

B

BD

D

C

C

E

E


Section C ± C

Section D ± D Section E ± E



Unit: mm


1Clearance between bushing

and bucket mounting pin

Standardsize


Clearancelimit

Replace

Shaft Hole

45±0.050±0.089

+0.080+0.240

0.130 ± 0.329

2Clearance between bushingand link mounting pin

45±0.050±0.089

+0.080+0.240

0.130 ± 0.329

3Clearance between bushingand tilt lever mounting pin

45±0.050±0.089

+0.080+0.119

0.130 ± 0.208

4Clearance between bushingand link mounting pin

45±0.050±0.089

+0.080+0.119

0.130 ± 0.208

5Clearance between bushingand boom mounting pin

50±0.038±0.093

+0.080+0.240

0.118 ± 0.323

40-37WB97S-2



SWING BRACKET

40-38 WB97S-2

RKZ02720

5

B

B

A

C

A C

Sezione A - A

1

1

Sezione B - B

2

Sezione C - C

6

3

4

Section A ± A

Section B ± B

Section C ± C



Unit: mm


1Clearance between rotatingbushing and boom swingcylinder bushing

Standardsize


Clearancelimit

Replace

bushingand pin

Shaft Hole

55± 0.060± 0.106

+ 0.090+ 0.060

0.120 ± 0.196

2Clearance between bushingand (lower) swing bracketrotating pin

65± 0.060± 0.106

+ 0.190+ 0.264

0.250 ± 0.370

3Clearance between bushingand (upper) swing bracketrotating pin

65± 0.060± 0.106

+ 0.190+ 0.264

0.250 ± 0.370

4Clearance between bushingand mounting pin

Standard size Limit size

4.75 0.1 Ð

5 Central shim thickness 4.75 0.1 Ð

6 Lower shim thickness 4.75 0.1 Ð

40-39WB97S-2



BACKHOE WORKING EQUIPMENT

40-40 WB97S-2

RKZ02900

D

D

CC

B

B

A

A

2

1

3

4

56 6

Sezione A - A

Sezione B - B

Sezione C - C Sezione D - D

Section A ± A

Section B ± B




Unit: mm


1Clearance between linkbushings and bucketmounting pin

Standardsize


Clearancelimit

Replacespring andpin

Shaft Hole

40± 0.050± 0.089

± 0.080± 0.240

0.130 ± 0.329 Ð

2Clearance between armbushings and bucketmounting pin

40± 0.050± 0.089

± 0.080± 0.240

0.130 ± 0.329 Ð

3Clearance between armbushings and levermounting pin

45± 0.050± 0.089

± 0.080± 0.240

0.130 ± 0.329 Ð

4Clearance between bushingsand tilt lever mounting pin

45± 0.050± 0.089

± 0.080± 0.240

0.130 ± 0.329 Ð

5Clearance between bushingsand arm mounting pin

50± 0.050± 0.089

± 0.080± 0.119

0.130 ± 0.208 Ð

6Clearance betweenbushings and boommounting pin

50± 0.038± 0.083

± 0.080± 0.119

0.118 ± 0.202 Ð

40-41WB97S-2



40-42 WB97S-2

komatsu WB97 S-2 _SF10001_WEBM002400_U0512

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