Beruflich Dokumente
Kultur Dokumente
SHOP MANUAL
WB97R-5E0
BACKHOE-LOADER
SERIAL NUMBER
WB97R-5E0 F90001 and up
CONTENTS
CONTENTS
Page
10. STRUCTURE AND FUNCTION............................................................................... 10-1
WB97R-5E0 00-1
00-2 WB97R-5E0
k SAFETY
k SAFETY
GENERAL PRECAUTIONS PREPARATIONS FOR WORK
Mistakes in operation extremely dangerous. 7. Before adding or making any repairs, park the ma-
Read all the Operation and Maintenance Manual carefully chine on hard, level ground, and block the wheels to
BEFORE operating the machine. prevent the machine from moving.
1. Before carrying out any greasing or repairs, read all 8. Before starting work, lower outrigger, bucket or any
the precautions written on the decals which are suck other work equipment to the ground. If this is not pos-
on the machine. sible, use blocks to prevent the work equipment from
2. When carrying out any operation, always wear safety falling down. In addition, be sure to lock all the control
shoes and helmet. Do not wear loose work clothes, or levers and hang warning sign on them.
clothes with buttons missing. 9. When disassembling or assembling, support the ma-
• Always wear safety glasses when hitting parts chine with blocks, jacks or stands before starting
with a hammer. work.
• Always wear safety glasses when grinding parts 10. Remove all mud and oil from the steps or other places
with a grinder, etc. used to get on and off the machine. Always use the
3. If welding repairs are needed, always have a trained, handrails, ladders or steps when getting on or off the
experienced welder carry out the work. When carrying machine.
out welding work, always wear welding gloves, apron, Never jump on or off the machine.
glasses, cap and other clothes suited for welding If it is impossible to use the handrails, ladders or steps,
work. use a stand to provide safe footing.
4. When carrying out any operation with two or more
PRECAUTIONS DURING WORK
workers, always agree on the operating procedure be-
fore starting. Always inform your fellow workers be- 11. When removing the oil filler cap, drain plug or hydrau-
fore starting any step of the operation. Before starting lic pressure measuring plugs, loosen them slowly to
work, hang UNDER REPAIR signs on the controls in prevent the oil from spurting out.
the operator’s compartment. Before disconnecting or removing components of the
hydraulic circuit and engine cooling circuit, first re-
5. Keep all tools in good condition and learn the correct
move the pressure completely from the circuit.
way to use them.
6. Decide a place in the repair workshop to keep tools 12. The water and oil in the circuits are not hot when the
and removed parts. Always keep the tools and parts in engine in stopped, so be careful not to get burned.
their correct places. Always keep the work area clean Wait for the oil water to cool before carrying out any
and make sure that there is no dirt or oil on the floor. work on the cooling water circuits.
Smoke only in the areas provided for smoking. Never
13. Before starting work, turn the battery disconnect
smoke while working.
switch to OFF position, and remove the key.
WB97R-5E0 00-3
k SAFETY
14. When raising heavy components, use a hoist or 19. Be sure to assemble all parts again in their original
crane. Check that the wire rope, chains and hooks places. Replace any damage parts with new parts.
are free from damage. When installing hoses and wires, be sure that they
Always use lifting equipment which has ample ca- will not be damaged by contact with other parts
pacity. Install the lifting equipment at the correct when the machine is being operated.
places.
20. When installing high pressure hoses, make sure
Use a hoist or crane and operate slowly to prevent
that they are not twisted. Damaged tubes are dan-
the component from hitting any other part.
gerous, so be extremely careful when installing
Do not work with any part still raised by the hoist or
tubes for high pressure circuits. Also, check that
crane.
connecting parts are correctly tightened.
15. When removing covers which are under internal
21. When assembling or installing parts, always use
pressure or under pressure from a spring, always
specified tightening torques.
leave two bolts in position on opposite sides. Slowly
When installing the parts which vibrate violently or
release the pressure, then slowly loosen the bolts to
rotate at high speed, be particulary careful to check
remove.
that they are correctly installed.
16. When removing components, be careful not to
22. When aligning two holes, never insert your fingers or
break or damage the wiring.
hand.
Damage wiring may cause electrical fires.
23. When measuring hydraulic pressure, check that the
17. When removing piping, stop the fuel or oil from spill-
measuring tool is correctly assembled before taking
ing out. If any fuel or oil drips on to the floor, wipe it up
any measurement.
immediately.
Fuel or oil on the floor can cause you to slip, or can 24. Take sure when removing or installing wheels.
even start fires.
00-4 WB97R-5E0
FOREWORD
FOREWORD
This shop manual has been prepared as an aid to improve the quality of repairs by giving the operator an accurate
understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure
you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service work-
shop.
The manual is divided into chapters on each main group of components; these chapters are further divided into the
following sections.
STANDARD MAINTENANCE
This section gives the judgement standards when inspecting disassembled parts.
NOTE
The specifications contained in this shop manual are subject to change at any time and without any no-
tice.
Contact your Komatsu distributor for the latest information.
WB97R-5E0 00-5
HOW TO READ THE SHOP MANUAL
k
work. performing the work.
Safety
FILING METHOD Extra special safety precautions
are necessary when performing
1. See the page number on the bottom of the page. the work because it is under in-
File the pages in correct order. ternal pressure.
2. Following examples show you how to read the page
Special technical precautions or
number.
Example: a Caution
other precautions for preserving
standards are necessary when
10 - 3 performing the work.
3 Tightening
item Parts that require special atten-
tion for the tightening torque dur-
3. Additional pages: additional pages are indicated by torque
ing assembly.
2
a hyphen (–) and number after the page number.
Fle as in the example. Parts to be coated with adhe-
Coat
Example: sives and lubricants etc.
5
10-4 Places where oil, water or fuel
Oil, water must be added, and their quan-
10-4-1 tity.
Added pages
6
10-4-2 Places where oil or water must
10-5 Drain be drained, and quantity to be
drained.
REVISIONS
Revised pages are shown on the LIST OF REVISED
PAGES between the title page and SAFETY page.
00-6 WB97R-5E0
HOISTING INSTRUCTIONS
4
HOISTING INSTRUCTIONS
WB97R-5E0 00-7
STANDARD TIGHTENING TORQUE
3
STANDARD TIGHTENING TORQUE
The following charts give the standard tightening torques of bolts and nuts.
Exceptions are given in section of «Disassembly and Assembly».
This torque table does not apply to bolts or nuts which have to fasten nylon or other parts non-ferrous metal washer.
a Nm (newton meter): 1 Nm = 0.102 kgm
00-8 WB97R-5E0
STANDARD TIGHTENING TORQUE
3
2. TIGHTENING TORQUE FOR NUTS OF FLARED
22 27 82 78.519.6
33 41 205 196.249
Sealing surface
1” - 14 30 8.2–9.2 80–90
2” - 12 57 20.4–24.4 200–240
WB97R-5E0 00-9
COATING MATERIALS
2
COATING MATERIALS
The recommended coating materials prescribed in Komatsu Shop Manuals are listed below:
ASL800010 Used to apply rubber pads, rubber gaskets and cork plugs.
Used to apply resin, rubber, metallic and non-metallic parts when a fast, strong
ASL800020
seal is needed.
Loctite 222 Used for low resistance locking of screws, check nuts and adjustment nuts.
To prevent the loosening of bolts, nuts and plugs and the leakage of oil. Used for
Loctite 242 medium resistance locking of screws and nuts of every type, and for locking
keys and bearings.
Loctite 262 Used for high resistant of threaded parts that can be removed with normal tools.
Adhesives Used for high resistant locking and for sealing threaded parts, bolts and stud
Loctite 270
bolts.
Loctite 542 Used for sealing the union threads for hydraulic tubes.
Used for sealing rather exact plane surfaces when the option of possible future
Loctite 573
dismantling is required.
Used for high resistant locking of mechanical components that can be removed
Loctite 601
only after heating
Used to lock cylindrical couplings and for the permanent locking of threaded
Loctite 675
parts, and also to lock shafts to bearings, gears, pulleys, pins, bushings, etc.
Used by itself to seal grease fittings, tapered screw fittings and tapered screw
ASL800060
fittings in hydraulic circuits of less than 50 mm in diameter.
Antifriction compound
Applied to bearings and taper shaft to facilitate press-fitting and to prevent
(Lubricant including ASL800040
sticking, burning or rusting.
Molybdenum disulfide)
Grease Applied to bearings, sliding parts and oil seals for lubrication, rust prevention
ASL800050
(Lithium grease) and facilitation of assembling work.
00-10 WB97R-5E0
ELECTRIC
ELECTRIC
ELECTRIC
In the wiring diagrams various colour and symbols are employed to indicate the thickness of wires.
This wire code table will help you understand WIRING DIAGRAMS.
Example: R–N 1.5 indicates a cable having a nominal number 1.5 and red coating with black stripe.
CLASSIFICATION BY THICKNESS
Copper wire
Nominal Cable O.D. Current rating
number Number Ø of strands Cross section (mm) (A)
strands (mm) (mm)
0.5 16 0.20 0.35 1.55 3.5
1 14 0.30 0.99 2.80 11
1.5 21 0.30 1.48 3.35 14
2.5 35 0.30 2.47 3.80 20
4 56 0.30 3.95 4.60 28
6 84 0.30 5.93 5.20 37
10 84 0.40 10.55 7.10 53
50 399 0.40 50.11 14 160
CLASSIFICATION BY COLOUR AND CODE
Primary Auxiliary
Code A A–B A/B A–G – A–N A/N A–R A/R A–V A/V
Colour Light Blue Light Blue – White Light Blue–Yellow Light Blue–Black Light Blue–Red Light Blue–Green
Code B B–G – B–N B/N B–R B/R – B/V – –
Colour White White–Yellow White–Black White–Red White–Green –
Code C C–B C/B C–L – C–N – – – – –
Colour Orange Orange–White Orange–Blue Orange–Black – –
Code G G–N G/N G–R – G–V – – – – –
Colour Yellow Yellow–Black Yellow–Red Yellow–Green – –
Code H H–L – H–N H/N – – – – – –
Colour Grey Grey–Blue Grey–Black – – –
Code L L–B L/B L–G – – L/N – – – –
Colour Blue Blue–White Blue–Yellow Blue–Black – –
Code M M–B – M–N M/N M–V – – – – –
Colour Brown Brown–White Brown–Black Brown–Green – –
Code N – – – – – – – – – –
Colour Black – – – – –
Code R R–G – R–N R/N R–V – – – – –
Colour Red Red–Yellow Red–Black Red–Green – –
Code S S–G – S–N – – – – – – –
Colour Pink Pink–Yellow Pink–Black – – –
Code V V–B – V–N V/N – – – – – –
Colour Green Green–White Green–Black – – –
Code Z Z–B Z/B Z–N Z/N – – – – – –
Colour Violet Violet–White Violet–Black – – –
WB97R-5E0 00-11
WEIGHT TABLE
WEIGHT TABLE
k This weight table is a guide for use when transporting or handling components.
Unit: kg
Machine model WB97R-5E0
Engine assembly - Muffler - Exhaust pipe 394
Radiator - exchanger 37
Hydraulic oil tank (empty) 10
Fuel tank (empty) 68
Front counterweight 372
Engine hood 32
Cabin (without seat) 595
Seat 34
Engine-gear box-pump group 740
Piston pump 36.8
Transmission 254
Front axle 295
Rear axle 435
Front wheel 65
Rear wheel 163
00-12 WB97R-5E0
TABLE OF OIL AND COOLANT QUANTITIES
Engine oil
ACEA E5 – 30 45 SAE 5W-30
ACEAE4
Engine oil pan Engine oil.
API CH-4 CI-4
–15 50 SAE 15W-40
ACEA E5 - E3
JASO DH1
– 20 45 HO46-HM
Hydraulic system Hydraulic oil
– 25 30 SAE 5W/20
Front axle
• Differential
• Final reduction gear
Transmission oil – 20 45 UTTO FLUID
Rear axle
• Differential
• Final reduction gears
WB97R-5E0 00-13
TABLE OF OIL AND COOLANT QUANTITIES
Unit of
measure First filling quantity Oil change quantity
ment
Hydraulic transmission l 20 20
00-14 WB97R-5E0
CONVERSION TABLE
CONVERSION TABLE
METHOD OF USING THE CONVERSION TABLE
The conversion table in this section is provided to enable simple conversion of figures.
For details of the method of using the conversion table, see the example given below.
EXAMPLE
• Method of using the conversion table to convert from millimeters to inches.
1. Convert 55 mm into inches.
1 - Locate the number 50 in the vertical column at the left side, take this as A , then drow a horizontal line from
A.
2 - Locate the number 5 in the row across the top, take this as , then draw a perpendicular line down from B .
3 - Take the point where the two lines cross as C . This point C gives the value when converting from mil-
limeters to inches. Therefore, 55 mm =2.165 in.
3 - The original value (550 mm) was divided by 10, so multiply 2.165 in. by 10 (move the decimal point one place to
the right) to return to the original value. This gives 550 mm = 21.65 in.
0 1 2 3 4 5 6 7 8 9
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
C
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
A
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
WB97R-5E0 00-15
CONVERSION TABLE
From mm to in.
1 mm = 0.03937 in.
0 1 2 3 4 5 6 7 8 9
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
From kg to lb.
1 kg = 2.2046 lb.
0 1 2 3 4 5 6 7 8 9
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.24 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
00-16 WB97R-5E0
CONVERSION TABLE
0 1 2 3 4 5 6 7 8 9
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
0 1 2 3 4 5 6 7 8 9
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.969 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 12.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
WB97R-5E0 00-17
CONVERSION TABLE
From Nm to lb.ft.
1 Nm = 0.737 lb.ft.
0 1 2 3 4 5 6 7 8 9
10 7.370 8.107 8.844 9.581 10.318 11.055 11.792 12.529 13.266 14.003
20 14.740 15.477 16.214 16.951 17.688 18.425 19.162 19.899 20.636 21.373
30 22.110 22.847 23.584 24.321 25.058 25.795 26.532 27.269 28.006 28.743
40 29.480 30.217 30.954 31.691 32.428 33.165 33.902 34.639 35.376 36.113
50 36.850 37.587 38.324 39.061 39.798 40.535 41.272 42.009 42.746 43.483
60 44.220 44.957 45.694 46.431 47.168 47.905 48.642 49.379 50.116 50.853
70 51.590 52.327 53.064 53.801 54.538 55.275 56.012 56.749 57.486 58.223
80 58.960 59.697 60.434 61.171 61.908 82.645 63.382 64.119 64.856 65.593
90 66.330 67.067 67.804 68.541 69.278 70.015 70.752 71.489 72.226 72.963
100 73.700 74.437 75.174 75.911 76.648 77.385 78.122 78.859 79.596 80.333
110 81.070 81.807 82.544 83.281 84.018 84.755 85.492 86.229 86.966 87.703
120 88.440 89.177 89.914 90.651 91.388 92.125 92.862 93.599 94.336 95.073
130 95.810 96.547 97.284 98.021 98.758 99.495 100.232 100.969 101.706 102.443
140 103.180 103.917 104.654 105.391 106.128 106.865 107.602 108.339 109.076 109.813
150 110.550 111.287 112.024 112.761 113.498 114.235 114.972 115.709 116.446 117.183
160 117.920 118.657 119.394 120.131 120.868 121.605 122.342 123.079 123.816 124.553
170 125.290 126.027 126.764 127.501 128.238 128.975 129.712 130.449 131.186 131.923
180 132.660 133.397 134.134 134.871 135.608 136.345 137.082 137.819 138.556 139.293
190 140.030 140.767 141.504 142.241 142.978 143.715 144.452 145.189 145.926 146.663
00-18 WB97R-5E0
CONVERSION TABLE
From Nm to kgm
1 Nm = 0.102 kgm
0 1 2 3 4 5 6 7 8 9
10 1.020 1.222 1.224 1.326 1.428 1.530 1.632 1.734 1.836 1.938
20 2.040 2.142 2.244 2.346 2.448 2.550 2.652 2.754 2.856 2.958
30 3.060 3.162 3.264 3.366 3.468 3.570 3.672 3.774 3.876 3.978
40 4.080 4.182 4.284 4.386 4.488 4.590 4.692 4.794 4.896 4.998
50 5.100 5.202 5.304 5.406 5.508 5.610 5.712 5.814 5.916 6.018
60 6.120 6.222 6.324 6.426 6.528 6.630 6.732 6.834 6.936 7.038
70 7.140 7.242 7.344 7.446 7.548 7.650 7.752 7.854 7.956 8.058
80 8.160 8.262 8.364 8.466 8.568 8.670 8.772 8.874 8.976 9.078
90 9.180 9.282 9.384 9.486 9.588 9.690 9.792 9.894 9.996 10.098
100 10.200 10.302 10.404 10.506 10.608 10.710 10.812 10.914 11.016 11.118
110 11.220 11.322 11.424 11.526 11.628 11.730 11.832 11.934 12.036 12.138
120 12.240 12.342 12.444 12.546 12.648 12.750 12.852 12.954 13.056 13.158
130 13.260 13.362 13.464 13.566 13.668 13.770 13.872 13.974 14.076 14.178
140 14.280 14.382 14.484 14.586 14.688 14.790 14.892 14.994 15.096 15.198
150 15.300 15.402 15.504 15.606 15.708 15.810 15.912 16.014 16.116 16.218
160 16.320 16.422 16.524 16.626 16.728 16.830 16.932 17.034 17.136 17.238
170 17.340 17.442 17.544 17.646 17.748 17.850 17.952 18.054 18.156 18.258
180 18.360 18.462 18.564 18.666 18.768 18.870 18.972 19.074 19.176 19.278
190 19.380 19.482 19.584 19.686 19.788 19.890 19.992 20.094 20.196 20.298
WB97R-5E0 00-19
CONVERSION TABLE
0 1 2 3 4 5 6 7 8 9
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.2 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 876.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
00-20 WB97R-5E0
CONVERSION TABLE
0 1 2 3 4 5 6 7 8 9
10 145.0 159.5 174.0 188.5 203.0 217.5 232.0 246.5 261.0 275.6
20 290.0 304.6 319.1 333.6 348.1 362.6 377.1 391.6 406.1 420.6
30 435.1 449.6 464.1 478.6 493.1 507.6 522.1 536.6 551.1 565.6
40 580.1 594.6 609.1 623.6 638.1 652.6 667.1 681.6 696.1 710.6
50 725.1 739.6 754.1 768.6 783.2 797.7 812.2 826.7 841.2 855.7
60 870.2 884.7 899.2 913.7 928.2 942.7 957.2 971.7 986.2 1000.7
70 1015.2 1029.7 1044.2 1058.7 1073.2 1087.7 1102.2 1116.7 1131.2 1145.7
80 1160.2 1174.7 1189.2 1203.7 1218.2 1232.7 1247.2 1261.8 1276.3 1290.8
90 1305.3 1319.8 1334.3 1348.8 1363.3 1377.8 1392.3 1406.8 1421.3 1435.8
100 1450.3 1464.8 1479.3 1493.8 1508.3 1522.8 1537.3 1551.8 1566.3 1580.8
110 1595.3 1609.8 1624.3 1638.8 1653.3 1667.8 1682.3 1696.8 1711.3 1725.8
120 1740.4 1754.9 1769.4 1783.9 1798.4 1812.9 1827.4 1841.9 1856.4 1870.8
130 1885.4 1899.9 1914.4 1928.9 1943.4 1957.9 1972.4 1986.9 2001.4 2015.9
140 2030.4 2044.9 2059.4 2073.9 2088.4 2102.9 1217.4 2131.9 2146.4 2160.9
150 2175.4 2189.9 2204.4 2218.9 2233.5 2248.0 2262.5 2277.0 2291.5 2306.0
160 2320.5 2335.0 2349.5 2364.0 2378.5 2393.0 2407.5 2422.0 2436.5 2451.0
170 2465.5 2480.0 2494.5 2509.0 2523.5 2538.0 2552.5 2567.0 2581.5 2596.0
180 2610.5 2625.0 2639.5 2654.0 2668.5 2683.0 2697.7 2712.1 2726.6 2641.1
190 2755.6 2770.0 2784.6 2799.1 2813.6 2828.1 2842.6 2857.1 2871.6 2886.1
200 2900.6 2915.1 2929.6 2944.1 2958.6 2973.1 2987.6 3002.1 3016.6 3031.1
210 3045.6 3060.1 3074.6 3089.1 3103.6 3118.1 3132.6 3147.1 3161.6 3176.1
220 3190.7 3205.2 3219.7 3234.2 3248.7 3263.2 3277.7 3192.2 3306.7 3321.2
230 3335.7 3350.2 3364.7 3379.2 3393.7 3408.2 3422.7 3437.2 3451.7 3466.2
240 3480.7 3495.2 3509.7 3524.2 3538.7 3553.2 3567.7 3582.2 3596.7 3611.2
WB97R-5E0 00-21
CONVERSION TABLE
TEMPERATURE
Fahrenheit-Centigrade conversion; a simple way to convert a Fahrenheit temperature reading into a Centigrade tem-
perature reading or vice versa is to enter the accompanying table in the center or boldface column of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit tem-
peratures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of Centigrade val-
ues and read the corresponding Fahrenheit temperature on the right.
1 °C = 33.8°F
°C °F °C °F °C °F °C °F
00-22 WB97R-5E0
10 STRUCTURE AND FUNCTION
WB97R-5E0 10-1
STRUCTURE AND FUNCTION POWER TRAIN
POWER TRAIN
1 2
3 4
RKA52470
5 7 8
6
DESCRIPTION
• The driving power for the engine (1) is transmitted • The driving power is transmitted from the
through the flywheel to the converter (2). transmission (3) to the front (5) and rear (6) axles
The converter (2) uses hydraulic oil to convert the through the cardan drive shafts (7 and 8).
torque transmitted by the engine (1) into driving • The driving power transmitted to the front (5) and rear
power. The converter (2) transmits motion to the drive (6) axles is reduced by the differentials and then
shaft of the transmission (3) and to the drive shaft of transmitted to the planetary gear through the
the hydraulic pump (4). differential shafts.
• The transmission (3) is electro-hydraulic in all its
functions (power shuttle); direction and speed can be
selected manually from a dedicated control unit and is
managed by solenoid valves.
10-2 WB97R-5E0
STRUCTURE AND FUNCTION POWER TRAIN
8
4
2 7 10
RKZ09610
WB97R-5E0 10-3
STRUCTURE AND FUNCTION TRANSMISSION (4WD)
TRANSMISSION (4WD)
Hydraulic convertor-transmission circuit diagram
10-4 WB97R-5E0
STRUCTURE AND FUNCTION TRANSMISSION (4WD)
WB97R-5E0 10-5
STRUCTURE AND FUNCTION TRANSMISSION
TRANSMISSION
10-6 WB97R-5E0
STRUCTURE AND FUNCTION TRANSMISSION
Kinematics diagram
Axis D
L
L
Axis A
Axis B
Axis C
Axis E
D
Input shaft A
Output shaft C
Output shaft E
RKZ11140
WB97R-5E0 10-7
STRUCTURE AND FUNCTION CONTROL VALVE BLOCK
1 3 7 6
2 4 5
RKZ11150
ELECTRICAL COMPONENTS
1. C24 – 2nd gear solenoid valve (ED6)
2. C27 - 4WD solenoid valve(ED5)
3. C26 – 4th gear solenoid valve (ED2)
4. C21 - Reverse gears command solenoid valve (ED4)
5. C22 – Forward gear solenoid valve (ED3)
6 - C25 – 3rd gear solenoid valve (ED7)
7. C23 – 1st gear solenoid valve (ED1)
10-8 WB97R-5E0
STRUCTURE AND FUNCTION DRIVE SHAFTS
DRIVE SHAFTS
Drive shaft for forward and reverse movement
1 2
a b c
6
5
RKZ11160
4 3
Drive shaft
3
1
2
4
a
5 RKZ11170
WB97R-5E0 10-9
STRUCTURE AND FUNCTION DRIVE SHAFTS
c a b 6
7
9 8 RKZ11180
3
2
1 a
RKZ11190
5
4
a. 4WD disengagement command port 3. 4WD gear driven (Z=41)
1. Front output shaft 4. Piston (n°3).
2. 4WD disengagement piston 5. Spring
10-10 WB97R-5E0
STRUCTURE AND FUNCTION FRONT AXLE
FRONT AXLE
Differential
1 2 3 4
16
15
7
8
14
9
13
10
12 11
RKZ09700
WB97R-5E0 10-11
STRUCTURE AND FUNCTION FRONT AXLE
7
3
2
1 5 8
6 9
4
10
11
RKZ09710
13
22 12
17
14
18 16
21 15
20 19
10-12 WB97R-5E0
STRUCTURE AND FUNCTION FRONT AXLE
B 1
C 2 3
A RKZ09720
A
a b
7 7
5
4 6
Section B - B
Section A - A Detail C
WB97R-5E0 10-13
STRUCTURE AND FUNCTION REAR AXLE
REAR AXLE
Differential
3
4
2
1 5
6
7 7
14
13
12 8
RKZ09730
9
11 10
1. Bearing 8. Bearing
2. Planetary gear 9. Ring nut
3. Ring gear (Z=32) 10. Sealing ring
4. Planetary gear 11. Flange
5. Differential housing 12. Spacer
6. Ring nut 13. Bevel pinion (Z=13)
7. Half-axle 14. Planetary gear
10-14 WB97R-5E0
STRUCTURE AND FUNCTION REAR AXLE
1
3 4
2
11 8 7 6
9
10 RKA52480
WB97R-5E0 10-15
STRUCTURE AND FUNCTION REAR AXLE
Brakes
1 2
3 4
7
Particolare
Detail A A
A
RKA52850
10-16 WB97R-5E0
STRUCTURE AND FUNCTION REAR AXLE
Differential lock
a
RKZ09760
3
8 7 6 5 4
WB97R-5E0 10-17
STRUCTURE AND FUNCTION HYDRAULIC PUMP
HYDRAULIC PUMP
Pd2
Ps
View X
P1L PLS
Pd P1c
Z
X
3 2
PM Pen P1
1
RKZ09410
View Z
10-18 WB97R-5E0
STRUCTURE AND FUNCTION HYDRAULIC PUMP
1. MAIN PUMP
A
A
View X
Z X
B B
D Pd4 Pa PM2
C C
RKZ09420
D Pe Pd5
View Z
PORT FUNCTIONS
Port Pa - Delivery control group feed
Port Pe - Delivery control signal
Port Pd4 - Drain
Port Pd5 - Drain
Port PM2 - Operating mode signal
WB97R-5E0 10-19
STRUCTURE AND FUNCTION HYDRAULIC PUMP
1 1 14
Section A - A Section C - C
4 5 6 7 8
3
13
RKZ09520
Section D - D
12 11 10 9
Section B - B
10-20 WB97R-5E0
STRUCTURE AND FUNCTION HYDRAULIC PUMP
FUNCTION
The rotation and torque transmitted to the pump shaft is converted into hydraulic energy and pressurized oil is delivered
according to the load requirements.
The amount of oil delivered can be modified by changing the angle of the swash plate.
8 7 6 5 1 10
3
4
RKZ09790
9 A a
STRUCTURE
• Groove a supports and makes cylinder block (1) an integral part of shaft (2), and shaft (2) is supported by front and
rear bearings (3), (4).
• The end of piston (5) is a concave ball, and shoe (6) is caulked to it to form one unit. Piston (5) and shoe (6) form a
spherical bearing.
• Swash plate (7) is supported by pump body (8) and ball (9), and has a flat surface A.
Shoe (6) remains in contact with swash plate (7) and slides in a circular movement.
Pressurised oil is introduced between shoe (6) and swash plate (7) forming a static bearing that allows shoes (6) to
slip.
• The pistons (5) perform their relative movements in an axial direction, inside cylindrical chambers fashioned in the
cylinder block (1).
• The rotation of the cylinder block (1) pressurises the oil inside the chambers of the block; pressure is adjusted by the
valve plate (10). The surface of the swash plate (10) is so designed that the oil pressure always remains within
acceptable limits. The oil in each chamber is drawn in and discharged through holes in the valve plate (10).
WB97R-5E0 10-21
STRUCTURE AND FUNCTION HYDRAULIC PUMP
OPERATION
1. Pump operation
1 - The cylinder block (1) rotates with the shaft (2), and 7 6 1
the shoe (6) slides on the flat surface A.
When this happens, the swash plate (7) rotates on the
ball (9), and the angle a between the axis of the
cylinder block (1) and the axis X of the swash plate (3) X
changes. The angle a is known as the swash plate
angle. a
2 - When the axis X of the swash plate (7) retains the
angle a in relation to the axis of the cylinder block
(1), flat surface A acts as a cam for the shoe (6).
This is why the piston (5) slides inside the cylinder
block (1), creating a difference between volumes E
and F and therefore causing the suction and
delivery of oil in a quantity that is equivalent to the 9 A RKZ09530
3 6 E
F RKZ09550
10-22 WB97R-5E0
STRUCTURE AND FUNCTION HYDRAULIC PUMP
2. Control of Delivery
1 - When angle a of the swash plate increases, the
difference between volumes E and F increases too,
and this makes delivery Q increase accordingly. 8 9 7 E
Angle a of the swash plate is varied by the servo-
piston (11).
WB97R-5E0 10-23
STRUCTURE AND FUNCTION HYDRAULIC PUMP
Pe Pd5
Ad4 Pa PM
A A
B B
RKZ09430
PORT FUNCTIONS
T port - Drain
P1 port - Delivery control group feed
Pd4 port - Drain
PE port - Delivery control signal output
PM port - Operating mode signal input
10-24 WB97R-5E0
STRUCTURE AND FUNCTION HYDRAULIC PUMP
2.1 PC VALVE
2 3 4 5
6 7 8
1
9
RKZ09770
Pd4 PPL Pa PM Pa
Section A - A
WB97R-5E0 10-25
STRUCTURE AND FUNCTION HYDRAULIC PUMP
2.2 LS VALVE
1 2 4
3 5
6
RKZ09780
10-26 WB97R-5E0
STRUCTURE AND FUNCTION HYDRAULIC PUMP
LS VALVE FUNCTION
• The LS valve controls the pump delivery according to
the stroke of the control valve lever, i.e., in function of
the delivery demands made by the actuators.
• The LS valve detects the actuator’s delivery needs
by means of the differential pressure DPLS
existing between pressure PPLS (control valve
Pump delivery Q
input pressure) and pressure PLS (control valve
output pressure). The sensing of this differential
pressure permits control of the main pump delivery
Q. (PPLS, PLS and DPLS are, respectively, the
pump pressure, the Load Sensing pressure, and
the difference in pressure between these two
values). LS differential pressure dPLS bar
• In other words, the LS valve detects the pressure
difference DPLS generated by the passage of the
oil flow through the surface freed by the control RKZ09570
WB97R-5E0 10-27
STRUCTURE AND FUNCTION HYDRAULIC PUMP
RKZ09580
10-28 WB97R-5E0
STRUCTURE AND FUNCTION HYDRAULIC PUMP
PC VALVE OPERATION
1. Spring operation
• PC valve spring loading (3) is defined by swash plate position.
• If control piston (6) moves to the right, spring (3) is compressed by lever (2) and spring loading increases.
1 5 4 PA
Check valve
D C B
PT
Engine
C B 3
F
LS valve
Solenoid
valve
G
J
RKZ09490
• The force applied by the pressure against the spool (4) decreases, and the spool (5) shifts slightly to the right.
At the same time, a connection opens between passages C and D, and pressurised oil from valve LS is sent for relief
(PT).
• Simultaneously, passages F and G on valve LS are interconnected: pressure at passage J is sent for relief (PT), and
the control piston (2) shifts to the left.
• Pump delivery increases as a result.
• When the control piston (2) moves, the lever (3) moves to the left, and the spring (1) expands, thereby reducing its
load on the spool (5). Consequently, the spool (5) moves to the left and stops the oil flow between C and D, and a
passage opens between ports B and C.
• As a result of that, the pressure in C increases, and the control piston (2) stops.
WB97R-5E0 10-29
STRUCTURE AND FUNCTION HYDRAULIC PUMP
1 5 4 PA
Check valve
D C B
PT
Engine
C B 3
2
LS valve
Solenoid
valve
J G
RKZ09500
• The force applied by the pressure against the spool (4) increases, and the spool (5) shifts slightly to the left. At the
same time, a connection opens C and B, and the pressure of the oil sent to valve LS becomes equivalent to the
pump's delivery pressure (PA).
• Simultaneously, passages F and G in valve LS are interconnected, and pressure at port J becomes equivalent to the
pump's delivery pressure (PA), and the control piston (2) shifts to the right.
• Pump delivery decreases as a result.
• When the control piston (2) moves, the lever (3) moves to the right, and the spring (1) compresses, thereby
increasing its load on the spool (5).
Consequently, the spool (5) moves to the right and stops the oil flow C and B, and a passage opens D and C.
• As a result of that, the pressure in C decreases, and the control piston (2) stops.
10-30 WB97R-5E0
STRUCTURE AND FUNCTION HYDRAULIC PUMP
1 5 4 PA
Check valve
D C B
PT
Engine
C B 3
LS valve
Solenoid
valve
G
J
RKZ09510
• The equilibrium between the force applied by pressure PA against spool (4) and the force applied by spring (1)
against spool (5) is what determines the position at which the control piston (2) (hence pump delivery) stops.
WB97R-5E0 10-31
STRUCTURE AND FUNCTION 10-SPOOL CONTROL VALVE
Komatsu Ltd.
AC AC
PA1 B1 A1
AB AB
DLS PPPC T
AA AA
LS P D
R R A2
PA2 B2
B3 N N
PA3 A3
X M M A4
B4
PA4
L L
B5 A5
PA5
K K
B6 A6
PA6
B7 J J
PA7 A7
B8 A8
PA8
F F
E E
D
PA7 PA8 Z
B9 A9
RKZ09120
B10 A10
ViewZ
10-32 WB97R-5E0
STRUCTURE AND FUNCTION 10-SPOOL CONTROL VALVE
AE
C B A
PP
PB1
PB2
PB3
PB4
PB5
PB6
PB7
PB8
RKZ09590
PB10 C B A PB9
AE
WB97R-5E0 10-33
STRUCTURE AND FUNCTION 10-SPOOL CONTROL VALVE
10-34 WB97R-5E0
STRUCTURE AND FUNCTION 10-SPOOL CONTROL VALVE
7
22
8
6
25
9
23
24
21 5
20 4 10
3 11
19
2 12
18
1 13
17
14
16
15
B-B A-A
17
16
RKZ09130
K-K J-J
WB97R-5E0 10-35
STRUCTURE AND FUNCTION 10-SPOOL CONTROL VALVE
10-36 WB97R-5E0
STRUCTURE AND FUNCTION 10-SPOOL CONTROL VALVE
AD
20 9
8
17
21
10
22 11
7
23
6 12
24 5 13
25
4 14
3 15
26 2
1
16
AD
19 18 D-D C-C
RKZ09140
27
28
AD - AD
WB97R-5E0 10-37
STRUCTURE AND FUNCTION 10-SPOOL CONTROL VALVE
10-38 WB97R-5E0
STRUCTURE AND FUNCTION 10-SPOOL CONTROL VALVE
3 4
2 7
1
E-E M-M
5 8
F-F N-N
6 9
RKZ09101
L-L P-P
WB97R-5E0 10-39
STRUCTURE AND FUNCTION 10-SPOOL CONTROL VALVE
5 6
AC - AC
R-R
3
1
AA - AA
AB - AB
RKZ09111
AE - AE
10-40 WB97R-5E0
STRUCTURE AND FUNCTION CLSS
CLSS
1. DESCRIPTION
1.1 CHARACTERISTICS
The term CLSS means Closed Center Load Sensing System, which has the following characteristics:
a) High precision control that is independent of the load applied to the movement;
b) High precision control of digging action even during delicate manoeuvres;
c) Ability to perform complex operations, guaranteed by control of oil flow in function of the aperture surfaces of the
shuttles;
d) Energy savings guaranteed by control of pump delivery.
1.2 STRUCTURE
• The CLSS system includes the variable flow pump, the control valve and the working equipment.
• The pump includes the main pump, the TCC valve
and the LS valve.
Actuator
PLS
Control valve
TCC valve
LS valve
PP
Servo
piston
RKP00661
WB97R-5E0 10-41
STRUCTURE AND FUNCTION CLSS
2. OPERATING PRINCIPLES
2.1 CONTROL OF THE ANGLE OF THE PUMPING PLATE
• The angle of the swash plate (and hence the pump delivery) is controlled in such a way that the differential pressure
DPLS between the delivery pressure PP of the pump and the pressure PLS at the outlet of the control valve towards
the actuator is maintained at a constant value. (DPLS=Pump delivery pressure PP – pressure PLS of delivery to the
actuator.
• If the differential pressure DPLS becomes lower than the set pressure of the LS, valve, the angle of the swash plate
increases.
If the differential pressure DPLS increases, the angle of the swash plate decreases.
a For details about this movement, see the description of the "HYDRAULIC PUMP".
Actuator
Max.
Min.
PLS
Pump passage
LS passage 0 LS differential
pressure ΔPLS Set differential
pressure of LS valve
Main pump
PP RKP02931
Min. Max.
Servo piston
Δ PLS
LS valve
Differential
pressure high Differential
pressure
low
PC valve
10-42 WB97R-5E0
STRUCTURE AND FUNCTION CLSS
Load
Load
W W
Actuator Actuator
ΔP ΔP
S1 S2
Pressure Pressure
compensation compensation
valve valve
LS valve RKP02941
WB97R-5E0 10-43
STRUCTURE AND FUNCTION CLSS
A1 Arm
PB1 B1
8 PA1
4
9 D
DLS
LS
P
T
10 1
2
Ts
PPPC
5
Boom
A2
swing
PB2 B2
8 PA2
5
6
A3 Shovel
PB3 B3
8 PA3
A4 Boom
B4
PB4
7
8 PA4
4
A5
Bucket
PB5 B5
8 PA5
A6 Bucket 4 in 1
PB6 B6
8 PA6
A7
Jig arm
PB7 B7
8 PA7
A8 Shovel
raising
PB8 B8
PA8
8
11 A9 Right
outrigger
PB9 B9
PA9
A10 Left
SS outrigger
B10
PB10 PA10
RKZ09180
10-44 WB97R-5E0
STRUCTURE AND FUNCTION CLSS
1. Unloading valve:
pressure LS + 27.5 bar
2. Max. pressure valve: 218 bar
3. Safety valve: 270 bar
4. Check valve
5. Anti-shock/anticavitation valve: 215 bar
6. Anti-shock/anticavitation valve: 220 bar
7. Anti-shock/anticavitation valve: 350 bar
8. Pressure compensation valves
9. Priority valve
10. Servocontrols reducing valve
11. Backhoe plate lock valve
WB97R-5E0 10-45
STRUCTURE AND FUNCTION CLSS
Function
• When the control valve is in “NEUTRAL” position, pump delivery Q (resulting from the swash plate being at its min.
angle) is sent into the tank circuit.
When this happens, the pump's delivery pressure PP is regulated at 27.5 bar (28 kg/cm2) by means of the spring (2)
inside the valve. (LS signal with PLS pressure=0 bar (0 kg/cm2)
PP
S1 1 S2
RKZ09190
S3
T 2 PL
Functioning
• Pump pressure PP acts on spool (1) – left, on surface S1, and right, on surface S2 – whereas Load Sensing pressure
PLS acts on surface S2.
• Since no LS signal with PLS pressure is generated when the control valve is in “NEUTRAL” position, the only
pressure acting on spool (1) in this condition is the pump's delivery pressure PP as regulated by spring compression
(2).
• As the pump's delivery pressure PP increases and the resulting force equals spring loading (2), the spool (1) shifts
to the right. The pump's delivery circuit PP is then connected to the tank circuit T by means of the holes in spool (1).
• This ensures that the pump delivery pressure PP stays regulated at 27.5 bar (28 kg/cm2).
PP = Pump circuit
PLS = Load Sensing circuit
T= Tank circuit
A = To control valve spools
10-46 WB97R-5E0
STRUCTURE AND FUNCTION CLSS
Function
• When the actuators' delivery needs during fine control are within the delivery values related to the minimum angle
of the swash plate, the pump's delivery pressure PP is regulated by pressure PLS at +27.5 bar (28 kg/cm2).
Since the unloading valve opens when the differential pressure between the pump's delivery pressure PP and
pressure PLS of the LS equals spring loading (2) (27.5 bar (28 kg/cm2)), the differential pressure DPLS becomes
27.5 bar (28 kg/cm2).
PP
S1 1 A S2
B
RKZ09200
S3
T 2 PL
Functioning
• When fine controls are performed at the control valve, a PLS pressure is generated. This pressure acts on surface
S3 on the right hand side of the spool (1). Since pressure PLS of LS is low – because the control valve passage is
small – the difference with the pump's delivery pressure PP is great.
• When the differential pressure between the pump's delivery pressure PP and pressure PLS of the LS equals spring
loading (2) (27.5 bar (28 kg/cm2)), the spool (1) shifts to the right and, in turn, the pump circuit PP connects to the tank
circuit T.
• The pump's delivery pressure PP is regulated by the combination of the pressure from the spring (27.5 bar (28 kg/
cm2)) and the pressure PLS of the LS, i.e. when the differential pressure DPLS reaches a value of 27.5 bar (28 kg/
cm2).
WB97R-5E0 10-47
STRUCTURE AND FUNCTION CLSS
Function
• When the request for oil flow from the actuators exceeds the minimum delivery of the pump during use of the control
valve, the connection to the tank circuit is eliminated and the entire pump delivery Q is sent to the actuators.
PP
S1 1 S2
RKZ09210
S3
T 2 PL
Functioning
• When the control valve spool is caused to perform a longer travel, this generates a pressure PLS of the LS, which
acts on the right hand side of the spool (1).
Since the control valve passage is wide, the difference between the pressure PLS of the LS and the pump's delivery
pressure PP is small.
• For this reason, since the differential pressure between the pump's delivery pressure PP and the pressure PLS of
the LS fails to reach the spring loading pressure value of spring (2) (27.5 bar (28 kg/cm2), the spool (1) is pushed to
the left by the spring (2).
• The result is that the connection between the pump delivery circuit PP and the tank circuit T is excluded and the
entire pump delivery Q is sent to the actuators.
10-48 WB97R-5E0
STRUCTURE AND FUNCTION CLSS
Function
• LS pressure is the actuator's pressure at control valve output.
• This pressure actually reduces the pump's PP pressure – via the pressure compensation group reducing valve (3)
– to the same A pressure of the actuator circuit and then sends it into the PLS circuit of the LS.
• In the outriggers control valve, the actuator's pressure A is introduced directly into circuit PLS of the LS
A b a
SLS
PLSS
2 3
PLS
c
PP 4
SA PA RKZ09220
Functioning
• When the spool (1) is operated, pump pressure PP starts flowing into the circuit of actuator A – from the delivery
control valve (2) and from the notch a via the duct b.
• At the same time, the pressure reducing valve (3) moves to the right thereby making the pump's pressure PP drop
as it flows through the bottleneck c, and causing the pressure to flow into the circuit PLS of the LS and into the
chamber of spring PLSS.
• At this point, the PLS circuit of the LS is connected to the tank circuit T by means of the by-pass plug (4). (See the
description of the LS by-pass plug).
• The pressure acting on the left side of the reducing valve (3) is pressure PA (= A) of the actuator, whereas the
pressure acting on the right hand side is the reduced pressure PP of pump delivery.
• The reducing valve (3) therefore balances out when pressure PA of the actuators and pressure PLSS of the spring
chamber are balanced. This in turn allows the pressure PP – now reduced by the bottleneck c – to be introduced into
the PLS circuit of the LS at the same pressure A as the actuator's circuit.
WB97R-5E0 10-49
STRUCTURE AND FUNCTION CLSS
A a PP
RKZ09240
b PLS
Functioning
• When the spool (1) is operated, pump pressure PP starts flowing into the circuit of actuator A through the duct a.
• At the same time, pressurised oil is introduced into the PLS circuit of the LS through holes b.
a The outriggers circuit differs from the working equipment circuit in that the operating pressure of actuator A is
introduced directly into the PLS circuit of the LS.
10-50 WB97R-5E0
STRUCTURE AND FUNCTION CLSS
Description
• The LS by-pass plug unloads residual pressure from the Load Sensing's PLS circuit.
• This makes the increment rate of Load Sensing's PLS pressure smoother.
Moreover, by eliminating oil (through the bottleneck), a loss of pressure is generated in the flow that is controlled by
the spool, and stability is increased as a result, thereby reducing the actual differential pressure LS.
b a
T PLS
RKZ09250
T PP
Functioning
• Pressurised oil in the Load Sensing PLS circuit flows through filter a, through orifice b and into the tank circuit T.
PP = Pump circuit
PLS = Load Sensing circuit
T = Drain circuit
WB97R-5E0 10-51
STRUCTURE AND FUNCTION CLSS
Function
• Pressure compensation occurs during simultaneous operation of several movements, specifically when the
pressure of an actuator becomes lower than the pressure of the actuator on the opposite side, and pump delivery is
on the verge of being increased.
In this specific case, the RH actuator withstands a higher pressure than the LH actuator.
W A W A
aB aB
PLSS PPA PA
2 PA RKZ09260
1
PPA
PLS
PP
Functioning
• During simultaneous operation, when RH actuator pressure increases, delivery in circuit A of the LH actuator tends
to increase.
• In this case, the PLS pressure of the LS for the RH actuator acts on chamber PLS1 of the spring and pushes the
pressure reducing valve (1) and the delivery control valve (2) to the left.
• The delivery control valve (2) produces a bottleneck between the pump's delivery PP circuit and the PPA circuit
upstream of the control valve spool.
This bottleneck generates a pressure loss between circuits PP and PPA.
• The delivery control valve (2) and the pressure reducing valve (1) are balanced out at a point where the differential
pressure between PA and PLS (these two acting on both surfaces of the pressure reducing valve (1)), equals the
loss of pressure between PP and PPA (these two acting on both surfaces of the delivery control valve (1)).
• The differential pressure between the upstream pressure PPA and the downstream pressure of both spools in the
control valves concerned in the simultaneous movements are equalised, and pump delivery is distributed
proportionally to the sections a that are responsible for opening the notches of each spool.
10-52 WB97R-5E0
STRUCTURE AND FUNCTION CLSS
Function
• In order to equalize the characteristics of each actuator, the pressure compensation valve will determine the
compensation characteristics by performing a micrometer adjustment of the surface ratio S1/S2. This is the ratio of
area S1 (delivery control valve (2) end) to area S2 (pressure reducing valve (1) end).
S1 = surface of the delivery control valve (2) – Surface of piston (3).
S2 = surface of pressure reducing valve (1) – Surface of piston (3).
T
A b
S1
S2
RKZ09230
PPA 1
2 3
PP PA PLS
WB97R-5E0 10-53
STRUCTURE AND FUNCTION CLSS
Function
• The purpose of the priority valve is to feed pressurised oil to the steering unit and to the other actuators.
• Oil distribution is determined by the position of the spool (1) of the priority valve, which is in turn determined by LS
signal, pump delivery, steering circuit pressure, and hydraulic circuit pressure.
• The position of the spool (1) is determined in such a way as to ensure that the oil delivered to the steering unit
matches the delivery needs at any time.
PP DLS
D
1
RKZ09270
P LS
10-54 WB97R-5E0
STRUCTURE AND FUNCTION CLSS
Function
• This valve regulates the servocontrol feed pressure at 37.3 bar.
• When actuator pressure is low, the sequential valve closes to permit an increase in the pump's delivery pressure PP
in order to supply pressure to the servocontrols.
PPPC
4
PP 5
2
TO ACTUATORS
1 PLS
TS RKZ09280
Functioning
• The spool (1) of the unloading valve moves, and delivery pressure is regulated at 37.3 bar.
(For details, see 3.2 UNLOADING VALVE).
• The spool (2) and valve (3) reduce the pump's delivery pressure PP to 37.3 bar.
Pressure is then sent to the servocontrols via port PC.
WB97R-5E0 10-55
STRUCTURE AND FUNCTION CLSS
PPPC
4
PP 5
2
TO ACTUATORS
1 PLS
TS RKZ09290
Functioning
• The spool (1) of the unloading valve moves to the left, and the pump's delivery pressure exceeds the pressure of the
actuator circuit (5) by an amount equivalent to LS differential pressure.
(For details, see 3.2 UNLOADING VALVE).
• If the pump's delivery pressure PP exceeds 37.3 bar, valves (2) and (3) reduce pressure PP to 37.3 bar.
The reduced pressure is then sent to the servocontrols via port PC.
• When this occurs, the sequential reducing valve (4) stays open.
10-56 WB97R-5E0
STRUCTURE AND FUNCTION CLSS
PPPC
4
PP 5
2
TO ACTUATORS
1 PLS
TS RKZ09300
• When the pump's delivery pressure PP is lower than 37.3 bar, the sequential reducing valve shifts to the right,
thereby reducing the flow of the PP pressure to the actuator circuit (5).
This generates a pressure gap between PP pressure and actuator pressure.
PP pressure is incremented in excess of 37.3 bar and is then reduced to 37.3 bar by valves (2) and (3) to guarantee
pressure feed to the servocontrols.
WB97R-5E0 10-57
STRUCTURE AND FUNCTION CLSS
Function
• The purpose of this solenoid valve is to send pump delivery pressure PP to backhoe plate lock cylinders.
Lock cylinder
SS
1 4
T
PP
RKZ09310
Functioning
• When the solenoid valve is deenergized, pump delivery pressure PP flows through orifice (2) and check valve (3)
and into the SS circuit of the plate lock cylinders.
• When the entire circuit reaches pump delivery pressure PP, the check valve (3) lowers, thereby dividing the circuit,
which is therefore kept at the maximum pressure reached by the delivery circuit.
10-58 WB97R-5E0
STRUCTURE AND FUNCTION CLSS
1 4
T
PP
RKZ09320
Functioning
• When the solenoid valve is energized, pressurised oil in the SS circuit is sent to the tank circuit through spool (4).
• As a result, the SS circuit pressure decreases, and the plate is released, so it can be shifted.
WB97R-5E0 10-59
STRUCTURE AND FUNCTION STEERING UNIT
STEERING UNIT
a e b
LS
L R
T P
RKP03740
c d
OPERATION
• The steering unit is composed of a control valve and a
rotating oil dispenser, and is of the hydrostatic type.
• When the steering wheel is turned, the control valve
sends oil from the pump (by means of the rotating oil
dispenser) to one of the sides of the steering cylinder.
The rotating dispenser ensures that the volume of oil
supplied to the cylinder is proportionate to the angle of
rotation of the steering wheel.
• In the event of malfunction, the oil dispenser will
function automatically as a hand-pump, thus
guaranteeing emergency steering.
10-60 WB97R-5E0
STRUCTURE AND FUNCTION PPC VALVES
PPC VALVES
SHOVEL PPC VALVE (FLOAT + RETURN TO DIG)
P2 P4
P3 P1
D D
T P
B A
C C
A B
View Z RKZ08920
WB97R-5E0 10-61
STRUCTURE AND FUNCTION PPC VALVES
6
5 7
4 8
3
9
2
10
1
11
A-A C-C
D-D
RKZ08980
B-B
1. Spool 7. Joint
2. Adjusting screw (inner) 8. Cover
3. Adjusting screw (outer) 9. Retainer
4. Piston 10. Piston
5. Disk 11. Body
6. Disk
10-62 WB97R-5E0
STRUCTURE AND FUNCTION PPC VALVES
OPERATION
D D
f f
T T
P P
1 1
P2 P1 P3 P4
A Control B A Control B
valve valve RKZ08990
WB97R-5E0 10-63
STRUCTURE AND FUNCTION PPC VALVES
10-64 WB97R-5E0
STRUCTURE AND FUNCTION PPC VALVES
When the disk (5) pushes down on the piston (4), and
the retainer (9) pushes down on the spool (1),
calibrated hole f is put in direct connection with
chamber PP, which is in turn connected to a 5
constantly pressurised servocontrols circuit.
Oil is then allowed to flow directly into section B-P1 4
thereby pushing the stem of the main control valve to
the end of its travel. This causes the main control
valve to send the oil contained in chamber AB
towards input P2, through calibrated hole f' and into
relief chamber D.
D
p’
T
P
f
PP
P2 P1
A Control B
valve RKZ09020
WB97R-5E0 10-65
STRUCTURE AND FUNCTION PPC VALVES
A Control B
valve RKZ09021
10-66 WB97R-5E0
STRUCTURE AND FUNCTION PPC VALVES
P4
P2
P1 P3
P T
RKZ09360
P1 P3
RKZ09350
Z
P1 port - To control valve (8 spools) (PA7 port)
To control valve (10 spools) (PA9 port)
P2 port - To control valve (8 spools) (PB7 port)
To control valve (10 spools) (PB9 port)
P3 port - To control valve (8 spools) (PA8 port)
To control valve (10 spools) (PA10 port)
P4 port - To control valve (8 spools) (PB7 port)
To control valve (10 spools) (PB10 port)
P port - To EV1 solenoid valve group (P2 port)
Port T - To hydraulic tank
WB97R-5E0 10-67
STRUCTURE AND FUNCTION PPC VALVES
2
3
4 5
RKZ09370
6 7
1. knob
2. Nut
3. Lever
4. Boot
5. Plate
6. LH PPC valve body
7. RH PPC valve body
10-68 WB97R-5E0
STRUCTURE AND FUNCTION PPC VALVES
OPERATION
P2 P1
A Control B
valve RKZ09380
• Ports A and B of control valve and ports P1 and P2 of PPC valves are connected to the tank circuit.
• Hence, the spool is in neutral position.
WB97R-5E0 10-69
STRUCTURE AND FUNCTION PPC VALVES
P2 P1
A Control B
valve RKZ09390
• When the lever (1) is moved in the direction shown by the arrow, the valves (2) are rotated and a passage is opened
between delivery duct a and port P1, while port P2 remains conected to the tank circuit.
• Pressure at port P1 increases as the travel of lever (1) increases. Consequently, the spool of the control valve moves
to the left by a distance that is proportional to the travel of the lever (1).
10-70 WB97R-5E0
STRUCTURE AND FUNCTION PPC VALVES
P2 P1
A Control B
valve RKZ10610
• When lever (1) is moved fully to the left, the valves (2) are fully rotated.
• Port P1 is then connected directly to delivery duct a whereas port P2 is connected to tank circuit only, and the spool
of the control valve performs its full travel.
WB97R-5E0 10-71
STRUCTURE AND FUNCTION PPC VALVE (BACKHOE CONTROLS)
P
T
2 4
3 View A
RKZ10250
A
10-72 WB97R-5E0
STRUCTURE AND FUNCTION PPC VALVE (BACKHOE CONTROLS)
WB97R-5E0 10-73
STRUCTURE AND FUNCTION PPC VALVE (BACKHOE CONTROLS)
10-74 WB97R-5E0
STRUCTURE AND FUNCTION SOLENOID VALVE GROUP (EV1)
ACC P1
2 3 4 5
6
1
7
A2
A1
P2 P
PM T
B2 UBH UL B1
Hydraulic circuit
ACC B2 A2 UBH UL B1 A1 PM
P1
S2
S2
ORF1
CV1
P2 ø0.5mm
SV2
S1
S1 SV1 SV3 SV4 SV5
P T RKZ10300
WB97R-5E0 10-75
STRUCTURE AND FUNCTION SOLENOID VALVES
SOLENOID VALVES
HAMMER SOLENOID VALVE
10-76 WB97R-5E0
STRUCTURE AND FUNCTION SOLENOID VALVES
1. Jig arm solenoid valve (out) Port A - To control valve (Port PA7)
2. Jig arm solenoid valve (in) Port B - To control valve (Port PB7)
Port P - From servocontrol valve (Port UBM)
Port T - To hydraulic tank
WB97R-5E0 10-77
STRUCTURE AND FUNCTION SHOVEL CYLINDERS
SHOVEL CYLINDERS
RAISING CYLINDER
7 2 6 1
5 4 3
8
707-00-0Y891
DUMPING CYLINDER
7 2 6 5 4 3 1
8
707-00-0Y920
4 IN 1 BUCKET
2 3 4 5 1
6 7
8
42N-6C-12800
1. Cylinder 5. Stem
2. Nut 6. Head
3. Gasket 7. Head bushing
4. Piston
10-78 WB97R-5E0
STRUCTURE AND FUNCTION SHOVEL CYLINDERS
CHARACTERISTICS
Cylinder Lifting Dump 4 in 1 bucket
Piston rod diameter 50 45 40
Internal cylinder diameter 90 70 70
Piston stroke 570 745 230
Max. cylinder length 1740 2145 705
Min. cylinder length 1170 144 475
Key size for piston safety nut 55 40 36
WB97R-5E0 10-79
STRUCTURE AND FUNCTION BACKHOE CYLINDERS
BACKHOE CYLINDERS
BOOM CYLINDER
11 8
7 6
3 5 9
2 4
1
707-02-0Y941
10
1. Bottom bushing 6. Gasket
2. Stem 7. Guide ring
3. Head 8. Cushion plunger
4. Cylinder 9. Bottom bushing
5. Piston 10. Dowel
ARM CYLINDER
7 8
6
3 5
2 4 10
1
707-00-0Y871
10-80 WB97R-5E0
STRUCTURE AND FUNCTION BACKHOE CYLINDERS
BUCKET CYLINDER
8
7 6
5
3 2 4 9
1
707-00-0y901
OUTRIGGER CYLINDER
2 1 3 6 4 5 7
707-00-0Y830
WB97R-5E0 10-81
STRUCTURE AND FUNCTION BACKHOE CYLINDERS
12
707-02-07732
9 10
2 6 5
4
1 3
42N-6C-13301
1. Stem 4. Piston
2. Head 5. Gasket
3. Cylinder 6. Guide ring
10-82 WB97R-5E0
STRUCTURE AND FUNCTION BACKHOE CYLINDERS
CHARACTERISTICS
Cylinder Boom Arm Bucket
Piston rod diameter 60 55 55
Internal cylinder diameter 120 115 90
[ ] with 2 piece boom [125]
Piston stroke 850 700 765
Max. cylinder length 2160 1765 1850
Min. cylinder length 1310 1065 1085
Key size for piston safety nut – 55 55
CHARACTERISTICS
Cylinder Outriggers Boom swing Jig arm
Piston rod diameter 50 50 40
Internal cylinder diameter 100 100 70
Piston stroke 515 230 1140
Max. cylinder length 1365 319.5 2590
Min. cylinder length 850 89.5 1450
Key size for piston safety nut 60 -- 46
WB97R-5E0 10-83
STRUCTURE AND FUNCTION AIR-CONDITIONING UNIT
AIR-CONDITIONING UNIT
2
Low steam pressure
1a
3 1
7
5
8
CAB INTERIOR
RKA51830
10-84 WB97R-5E0
STRUCTURE AND FUNCTION OPERATION OF THE AIR CONDITIONING UNIT
WB97R-5E0 10-85
STRUCTURE AND FUNCTION
10-86 WB97R-5E0
20 TESTING AND ADJUSTMENTS
WB97R-5E0 20-1
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA
Engine oil
Entire speed range °C – –
temperature
Pumping element
mm 1.00±0.05 1.00±0.05
pre-lift
20-2 WB97R-5E0
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA
a b c a b c
Boom swing, 4 in 1 bucket
6 6 – – – –
Control valve
• See Fig. A
Arm, shovel bucket,
boom, bucket, mm 6.5 6.5 – – – –
attachment
Shovel arm command
• See Fig. B 6 5.5 2 – – –
only
Raise 95 80–110
Shovel arm control lever Neutral o
Lower 95 80–110
Dump 95 80–110
Shovel control lever Neutral o
Curl 95 80–110
Travel of levers and pedals
WB97R-5E0 20-3
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA
• Engine stopped
Accelerator pedal • Knob lever: at the center Min. o Max. mm 80 65–95
and at 90° from the lever
• Value reading at the end
of working stroke
• Attachments on the
ground
Righto Left 3.5 3.1–3.9
Steering wheel • Instrument: metre w/ rev.
millimetre divisions Left o Right 3.5 3.1–3.9
Force for lever, pedal and steering wheel operation
20-4 WB97R-5E0
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA
WB97R-5E0 20-5
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA
Shovel (Dump) – –
4 in 1 bucket (open-close) – –
Boom (lowering) – –
Bucket (curled) – –
Bucket (Dump) – –
20-6 WB97R-5E0
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA
Shovel cylinder 28 40
15 min.
(Cylinder out) [ ] This value are for machines equipped with cold
[39] [56]
climate device
Complete working
equipment Measuring posture: see Fig. E 220 350
( B u c k e t t e e t h t i p • In this position check the extension of each cylinder [310] [543]
lower) and the leakage with normal load on the bucket.
• On level ground.
• With standard arm
Boom cylinders Bucket (L= 600mm, Weight =170 kg): load in bucket: 13 20
400 kg
(Cylinder out) • With jig arm
[18] [36]
Backhoe
WB97R-5E0 20-7
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA
2.0
Boom Max. 8.0
Shovel
(each cylinder)
1.6
Shovel Max. 6.0
(each cylinder)
20-8 WB97R-5E0
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA
Lifting
Arm shovel 3.9 3.5–4.3
Measuring posture: see Fig. H
Cylinders fully out • Engine speed: max.
• Oil temperature: 45–55 °C
Lowering
• Shovel speed button: applied
Shovel at the ground 2.9 2.6–3.2
Shovel
Curl
Shovel 2.1 1.9–2.3
Measuring posture: see Fig. J
Cylinders fully out • Engine speed: max.
• Oil temperature: 45–55 °C
• Shovel speed button: applied
Dump
Cylinders fully in 2.6 2.3–2.9
Work equipment speed
Lifting q
Boom 2.7 2.4–2.9
Measuring posture: see Fig. K [2.7] [2.4–3.0]
Cylinders fully in • Engine speed: 1700 +0 50 rpm
• Oil temperature: 45–55 °C sec.
• Backhoe balanced
Lowering
• Power mode ON
Teeth bucket on level [ ] with safety valve 2.6 2.3–2.9
ground [2.8] [2.5–3.1]
Opening
3.3 3.0–3.6
Arm Measuring posture: see Fig. L [3.4] [3.1–3.7]
• Engine speed: 1700 +0 50 rpm
Backhoe
• Power mode ON
4.1 3.7–4.5
Cylinders fully out [ ] with safety valve
[4.2] [3.8–4.6]
Dump
WB97R-5E0 20-9
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA
Right q
2.7 2.4–3.0
Boom swing
Measuring posture: see Fig. N
Backhoe
0
Right end travel • Engine speed: 1700 + 50 rpm
• Oil temperature: 45–55 °C sec.
• Arm horizontal
• Power mode ON
Left end travel
Left q
2.7 2.4–3.0
Work equipment speed
Up
5.5 5.0–6.1
4.6 4.1–5.1
q Times are referred to the cylinder stroke whitout the brake phase.
NOTE.The engine speed (1700 +0 50 rpm) has to be checked with the procedure described at paragraph «MEASURING
ENGINE SPEED» in this section.
20-10 WB97R-5E0
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA
WB97R-5E0 20-11
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA
Fig. A Fig. B
a a b c
b
RKZ10840
RKA52860
Fig. C Fig. D
80mm
~10°
RKZ10680
RKZ10860
20-12 WB97R-5E0
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA
Fig. E Fig. F
1400 mm
RKA52870
RKA52880
Fig. G Fig. H
RKA52890
RKZ10720
WB97R-5E0 20-13
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA
Fig. J Fig. K
RKA52900
RKZ10730
Fig. L Fig. M
RKA52920
RKA52910
20-14 WB97R-5E0
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA
Fig. N Fig. P
RKA52871
RKZ10790
Fig. Q Fig. R
45 °
RKA52930
RKA52940
WB97R-5E0 20-15
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA
Fig. S Fig. T
RKA52950
RKA52960
20-16 WB97R-5E0
TESTING AND ADJUSTMENTS SPECIAL TOOLS
SPECIAL TOOLS
Commercially
1 Pressure gauge 2 Full scale 60 bar
available
Commercially
2 Pressure gauge 1 Full scale 250 bar
available
Commercially
3 Pressure gauge 1 Full scale 400 bar
E available
5 Servocontrol kit
Differential digital 1 0-1000 bar
6 pressure gauge
ATR800200
1 Flow-meter 1 Delivery 0–300 l/min.
F
2 Pipe fitting kit 1 –
Commercially
1 Maintenance station 1 For coolant R134a
available
Commercially
3 Leak detector 1 For coolant R134a
available
WB97R-5E0 20-17
TESTING AND ADJUSTMENTS VALVE CLEARANCE ADJUSTING
1
2
RKZC3150
20-18 WB97R-5E0
TESTING AND ADJUSTMENTS ENGINE SPEED TESTS
a Check hydraulic oil temperature with a probe a Normal speed: 600 rpm
plunged in the reservoir or with a probe applied to Minimum speed: 600 rpm
the reservoir wall.
2. With converter stalled
Temperature should be at 50±5°C.
1 -Increase speed to high idling and brake with the
2 -Place the machine on solid level ground with the working brakes.
transmission in NEUTRAL. 2 -Hold the brakes while simultaneously engaging 3rd
gear; let the engine stabilize, and read the rpm value.
3 -Stop the engine and apply a reading notch “B” to the
engine pulley (1) for the stroboscopic rev counter. a Minimum speed: 2125 rpm
Maximum speed: 2225 rpm
WB97R-5E0 20-19
TESTING AND ADJUSTMENTS TENSIONING THE AIR-CONDITIONING COMPRESSOR BELT
TENSIONING THE AIR- 5 -Once proper tension is reached, retain the position of
the adjustment bolt (3) with the nut (2).
CONDITIONING COMPRESSOR
BELT
1 -Loosen the screw (1) and the nut (2).
3 2
RKTA1205
4
RKTA1204
7
1
3 -Apply a 10 kg force halfway between compressor
pulley (5) and engine pulley (6).
4
10 kg
F
RKTA1221
5
6
RKT01261
20-20 WB97R-5E0
TESTING AND ADJUSTMENTS BLEEDING AIR FROM CIRCUITS - ELIMINATING RESIDUAL
3 -Stop the engine, check and top up the oil in the tank.
a Above operation is to be carried out every time 6 -Repeat the same steps for the opposite braking unit.
maintenance is made on braking circuit to remove or a Check frequently the oil level in the tank and
replace a component, or when air entered into the carry out filling every time level approaches to
circuit. minimum.
a Machine must be stopped with attachments on level a After air bleeding apply on screws (2) safety
ground. plugs (4).
1 -Make sure that oil in brake system tank (1) is at
maximum level.
4
2
1
RKZC3190
RKZC3170
WB97R-5E0 20-21
TESTING AND ADJUSTMENTS BLEEDING AIR FROM CIRCUITS - ELIMINATING RESIDUAL
20-22 WB97R-5E0
TESTING AND ADJUSTMENTS ADJUSTING ACCELERATOR PEDAL TRAVEL AND ACCELERATOR
2 8
1
RKZC3212
RKZC3200 2 -Remove the metal sheet (1) closing the bottom of the
cab and the upright guard (2).
2 -Unloose nut (3) of some turns and screw nut (4) untill
the play of the cable is zero, pushing the accelerator
lever (5) against the low idle adjusting screw.
1
2
RKZC3220
RKZC3200
WB97R-5E0 20-23
TESTING AND ADJUSTMENTS ADJUSTING ACCELERATOR PEDAL TRAVEL AND ACCELERATOR
RKZC3230
RKZC9590
20-24 WB97R-5E0
TESTING AND ADJUSTMENTS ADJUSTING BRAKE PEDAL SLACK/ALIGNMENT
RKZC6050
RKZC3251
5 -Loosen nuts (3) and adjust slack using stoppers (4).
• Control
1 -Remove mat.
4 3
2 -Check height “A” between floor and pedal lower
edge.
1 RKZC3460
RKZ11390
WB97R-5E0 20-25
TESTING AND ADJUSTMENTS BRAKING SYSTEM CHECKS
RKZC6051
1 4
A
E2 5
8 RKZC6081
RKZC6070
20-26 WB97R-5E0
TESTING AND ADJUSTMENTS BRAKING SYSTEM CHECKS
4 -Remove the bracket (6) and the clamp (7). a Check to ensure that the pressure tap (9) is
installed between the braking group and the cut
out valve (10).
50 200
0 250
RKZC9600 9
E2
5 -Disconnect the delivery hoses (8) from the pump that
is being tested. Connect a pressure gauge E2 (250
bar) to the pump during the inspection.
RKZ11401
6 -Apply the brake pedal corresponding to the pump level of oil in the axle, and the fact that the oil is
and pressurize the circuit to approx. 120 bar. stirred as a result. Replace all sealing rings in
the various axle sections and completely
a Do not exceed maximum permitted pressure change the lubricant.
(1505 bar).
7 -Repeat the test for the other braking group using the
7 -Hold the pressure on the pedal for at least 2 minutes same procedure as above.
and verify that pressure and pedal position remain
unchanged. 8 -Restore the braking circuit to operating condition.
a If the position of the pedal needs to be changed in k When checks and repair (if any) are complete,
order to hold the pressure, then the loss of bleed the air from the braking groups (See
pressure is to be blamed on leaks inside the "BLEEDING AIR FROM CIRCUITS -
pump, and in this case the pump needs to be ELIMINATING RESIDUAL PRESSURE").
changed. To confirm whether this is the case,
check the oil. If a leak condition exists, the oil will
be stirred.
WB97R-5E0 20-27
TESTING AND ADJUSTMENTS PARKING BRAKE ADJUSTMENT
RKZC6130
1
a Direction of rotation is from the operator’ point of
view when the operator is sitting on the driver’s
seat.
2
6 -Re-apply the parking brake and repeat the test.
RKZC6120
20-28 WB97R-5E0
TESTING AND ADJUSTMENTS CHECKING AND SETTING PRESSURE IN THE ATTACHMENTS
STEERING UNIT
SAFETY VALVE
Komatsu Ltd. LS
TRANSMISSION
HYDRAULIC PUMP
DIESEL
CONTROL VALVE
RKZ10890
NOTE
Shown in this section is the servocontrolled version
of the control valve.
• Introduction
1 -The machine is equipped with a single control valve
with hydraulically controlled spools. The control
valve is protected against overpressure by a single
upper valve (or main valve, referred to as "LS safety
valve") with adjustable pressure setting.
WB97R-5E0 20-29
TESTING AND ADJUSTMENTS CHECKING AND SETTING PRESSURE IN THE ATTACHMENTS
A1
Curl B3 270
Lowering A4 270
Boom A2
Lifting B4 345 B2
Dump A5 –
B3 A3
Backhoe bucket
Curl B5 270
B4 A4
Closes A6 270
4 in 1 bucket
Opens B6 270 B5 A5
Out A7 –
Jig arm
B6 A6
In B7 –
Lifting A8 – B7 A7
Shovel arm
Lowering B8 –
B8 A8
Down A9 – RKZ11110
Right outrigger
Up B9 –
Down A10 –
Left outrigger
Up B10 –
20-30 WB97R-5E0
TESTING AND ADJUSTMENTS CHECKING THE SETTING OF MAIN RELIEF AND SECONDARY
P1C
RKZC3270
WB97R-5E0 20-31
TESTING AND ADJUSTMENTS CHECKING THE SETTING OF MAIN RELIEF AND SECONDARY
3 -Check pressure for each movement, with the control 4 -Connect a pressure gauge E3 (600 bar) to the
lever at the end of its travel and at stabilized adapter.
pressure.
5 -Start the engine, connect a weight of approx. 1500 kg
a Move piston to the end of stroke to check the to the bucket, and fully lower the outriggers.
pressure.
Right 225–250
Boom swing
Left 225–250
1
Shovel Dump 235–260
RKA52970
RKA52980
2
E3
RKZC6170
20-32 WB97R-5E0
TESTING AND ADJUSTMENTS CHECKING THE SETTING OF MAIN RELIEF AND SECONDARY
P1C
RKZC3270
RKZC3290
WB97R-5E0 20-33
TESTING AND ADJUSTMENTS SETTING THE MAIN RELIEF VALVES AND THE REDUCING VALVES
1
1
RKZC3291 RKZC3300
2 -Adjust the pressure using the screw (2). 2 -Adjust the pressure using the nut (2).
• To INCREASE pressure turn in CLOCKWISE • To INCREASE pressure turn in CLOCKWISE
direction. direction.
• To DECREASE pressure turn in • To DECREASE pressure turn in
COUNTERCLOCKWISE direction. COUNTERCLOCKWISE direction.
1 2
2
RKZ10930
3 Nut: 29.4-39.2 Nm
RKZ10940
20-34 WB97R-5E0
TESTING AND ADJUSTMENTS SETTING THE MAIN RELIEF VALVES AND THE REDUCING VALVES
D C
Komatsu Ltd.
A B RKZ10950
2 1
RKZ10960
WB97R-5E0 20-35
TESTING AND ADJUSTMENTS CHECKING AND ADJUSTING THE LS DIFFERENTIAL PRESSURE.
1- Disconnect hose (1) from the Load Sensing line, 1 -Loosen the retaining nut (1) and turn the adjustment
Install a tee with pressure tap (2) and reconnect hose screw (2).
(1).
E4
1
RKZC3330
RKZC3310
1
P1C
2
E4
E4
RKZC3320
20-36 WB97R-5E0
TESTING AND ADJUSTMENTS CHECKING AND ADJUSTING SERVOCONTROLS SUPPLY
1 2
E1 3
RKZC3340
RKZ10980
2 -Start the engine and run the engine at low idling with 3 Nut: 22 ± 2.5 Nm
all levers in neutral position.
3 -Check the pressure.
RKZC3350
WB97R-5E0 20-37
TESTING AND ADJUSTMENTS ADJUSTING THE PC VALVE
1 -Loosen the nut (1) and turn the adjustment screw (2).
2
RKZ10990
3 Nut: 27.4-34.4 Nm
MAX 180
0°
MAX 180
RKZ11000
20-38 WB97R-5E0
TESTING AND ADJUSTMENTS TESTING AND SETTING STEERING CONTROL SYSTEM PRESSURE
1 -Connect a pressure gauge E3 (600 bar) to the 1 -Remove the plug (3).
pressure tap P1C on the backhoe control valve. 2 -Insert a wrench of 4 mm and loosen screw (4).
• To INCREASE pressure rotate in CLOCKWISE
direction.
E3 • To DECREASE pressure rotate in
COUNTERCLOCKWISE direction.
3 -Stop the engine and replace the plug (3); ensure that
the seal (5) is in its proper position.
3 Plug: 50±10 Nm
P1C
3
RKZC3270 5
WB97R-5E0 20-39
TESTING AND ADJUSTMENTS CHECKING FOR LEAKS IN THE STEERING CYLINDERS
1
2
RKZC3360
20-40 WB97R-5E0
TESTING AND ADJUSTMENTS TESTING PRESSURES IN THE POWER TRAIN GROUP
3 Plug: 30 Nm
P18 P17
RKA52990
2 -Start the engine and heat the engine and all the fluids
up to working temperature. In particular make sure
that the power train oil reaches a temperature of
805 °C.
P3 3 -Bring the engine up to MIN (idling) and check the
pressure on the pressure gauge E6.
WB97R-5E0 20-41
TESTING AND ADJUSTMENTS TESTING PRESSURES IN THE POWER TRAIN GROUP
3 Plug: 30 Nm
7 -Repeat the same test for the FORWARD gear,
reading the pressure from the orifice protected by the
plug (P17).
• If the pressures are different for the two travel
directions, there is a loss of pressure on the
clutch piston with lower pressure.
• Supply pressure
1 -Remove the plug (P21) and connect the pressure
gauge E6.
P21
RKZC6160
2 -Start the engine and heat the engine and all the fluids
up to working temperature. In particular make sure
that the power train oil reaches a temperature of 80±5
°C.
3 Plug: 30 Nm
20-42 WB97R-5E0
TESTING AND ADJUSTMENTS TESTING THE CORRECT FUNCTIONING OF THE POWER TRAIN
RKZC3251
• Control
C1
1 -Start the engine and heat the engine and all the fluids
up to working temperature. In particular make sure
that the power train oil reaches a temperature of
805 °C.
3 Dowels: 12 Nm
WB97R-5E0 20-43
TESTING AND ADJUSTMENTS JIG ARM CLEARANCE ADJUSTMENT
2
1
RKZ02391
A
RKZA8010
• Guide adjustment
1 -Connect the 2nd arm (1) to some hoisting tackle;
introduce the 2nd arm into the fixed arm (2) and push
it down to the end of back travel.
4 4
RKZD0030
1 2
RKZA8001
20-44 WB97R-5E0
TESTING AND ADJUSTMENTS JIG ARM CLEARANCE ADJUSTMENT
RKZD0060
8 -Lock the dowels (4) with the nuts (5) while holding
them in their angular positions.
3 Nuts: 200 Nm
RKZD0040
RKZD0070
4 4
RKZD0030
WB97R-5E0 20-45
TESTING AND ADJUSTMENTS ANALYSIS OF CAUSES HYDRAULIC DRIFT
RKZC3450
A
10 -Stop the engine and check the shovel position for 5
RKZC3440
minutes.
• If shovel link has a lowering movement, drift is
2 -Stop the engine and release residual hydraulic
due to gaskets of plugged cylinder.
pressures.
11 -Repeat operation from stage 8 to stage 10 to check
3- Disconnect pipes (1) and (2) from lift cylinders (3) and
the other cylinder.
plug them.
• Shovel dump check
1 -Put the machine with shovel on level ground and
2 teeth tilted of about 10°.
Put in the bucket a weight of 1500 kg.
RKZC3380
1500 kg
5 -Start the engine and curl shovel until the teeth are in
RKZ02130
tilt position by about 10°.
20-46 WB97R-5E0
TESTING AND ADJUSTMENTS ANALYSIS OF CAUSES HYDRAULIC DRIFT
2
RKZC3390
RKA53000
3 -Plug dump cylinder hole, base side, and apply a
temporary pipe on head side to catch possible oil
leakage. • Boom testing
4 -Start the engine and raise the shovel until shovel 1 -Set the machine with arm in vertical position and with
hinge pin is aligned with shovel arm hinge pin. bucket on level ground leaned on the side.
3
4
2
RKZ02630
control valve.
4 -Plug the two hoses to avoid impurity inlet.
To test the individual cylinders, proceed as follows:
5 -Plug the cylinder head side.
6 -Lower the shovel to the ground.
6 -Apply a temporary pipe on pipe (3) base side to catch
7 -Remove from one of the cylinders the plug fitted on
possible oil leakage.
the cylinder bottom side in Phase 3.
WB97R-5E0 20-47
TESTING AND ADJUSTMENTS ANALYSIS OF CAUSES HYDRAULIC DRIFT
2
1
3
RKZC3410
RKA53010
• Arm testing
1 -Set the machine with arm fully extended and with
bucket teeth on ground.
RKA53030
450 kg
RKA53040
20-48 WB97R-5E0
TESTING AND ADJUSTMENTS ANALYSIS OF CAUSES HYDRAULIC DRIFT
RKZC3420
RKA53050
WB97R-5E0 20-49
TESTING AND ADJUSTMENTS ANALYSIS OF CAUSES HYDRAULIC DRIFT
RKA53620
A
RKA53600
2
1
RKA53610
20-50 WB97R-5E0
TESTING AND ADJUSTMENTS TESTING THE AIR-CONDITIONING UNIT
6 -Close the doors and windows and let the A/C unit
operate in these conditions for 5 - 10 minutes.
Ambient
20 25 30 35
temperature (°C)
Outgoing
air temperature 6 -- 8 8 -- 10 8 -- 12 9 -- 14
(°C)
WB97R-5E0 20-51
TESTING AND ADJUSTMENTS TESTING THE AIR-CONDITIONING UNIT
20-52 WB97R-5E0
TESTING AND ADJUSTMENTS EMPTYING THE AIR-CONDITIONING UNIT
RKZC3032
WB97R-5E0 20-53
TESTING AND ADJUSTMENTS TROUBLESHOOTING
TROUBLESHOOTING
FRONT AXLE TROUBLESHOOTING
Wheel vibration; front tyre resistance; halfshaft breakage
CAUSES REMEDY
Incorrect installation Correct installation
Replace the differential in case it does not survive any one of the
Defective axle
test phases
Remove excessive weight and redistribute load, following
Bent halfshaft
instructions related to the vehicle
Replace the tyre or adjust pressure to have same radius on both
Different rotation radius of the tyres
tyre
Remove excessive weight and redistribute load, following
Bent halfshaft
instructions related to the vehicle
Excess of noise
CAUSES REMEDY
Incorrect installation Correct installation
Replace the differential in case it does not survive any one of the
Defective axle
test phases
Remove excessive weight and redistribute load, following
Bent halfshaft
instructions related to the vehicle
Replace the tyre or adjust pressure to have same radius on both
Different rotation radius of the tyres
tyre
Remove excessive weight and redistribute load, following
Overloading/ incorrect weight distribution
instructions related to the vehicle
Incorrect wheel adjustment Verify group integrity and wheel side bearings.
20-54 WB97R-5E0
TESTING AND ADJUSTMENTS TROUBLESHOOTING
Contamination in the axle box or Look for foreign particles. Check assembly of the
incorrect assemblyof parts various parts of the axle.
Friction noise
CAUSES REMEDY
Incorrect installation Correct installation
Replace the differential in case it does not survive any one of the
Defective axle
test phases
Remove excessive weight and redistribute load, following
Overloading/ incorrect weight distribution
instructions related to the vehicle
Check the condition of ring gear, pinion gear, bearings etc.
Spoiled or worn out axle parts
Replace when ever necessary.
Contamination in the axle box or Look for foreign particles. Check assembly of the
incorrect assemblyof parts various parts of the axle.
Incorrect adjustment of bevel gearset:
Parts of the transmission worn out. Replace or adjust as required.
(transmission gears, U joints, etc.)
WB97R-5E0 20-55
TESTING AND ADJUSTMENTS TROUBLESHOOTING
CAUSES REMEDY
Excessive backlash between pinion and ring gear Replace
Worn out pinion and gear ring Replace
Worn out pinion bearings Replace
Pinion bearings loosened Replace
Excessive pinion axial backlash Replace
Worn out differential bearings Replace
Differential bearings loosened Replace
Ring gear out of roundness Replace
Low lubricant level Top up
Poor or wrong lubricant Replace
Bent halfshaft Replace
Intermittent noise
CAUSES REMEDY
Ring gear damaged Replace bevel gear set
Differential box bolts loosened Tighten to torque
Constant noise
CAUSES REMEDY
Ring gear teeth or pinion damaged Replace bevel gear set
Worn out bearings Replace
Pinion spline worn out Replace
Bent halfshaft Replace
20-56 WB97R-5E0
TESTING AND ADJUSTMENTS TROUBLESHOOTING
WB97R-5E0 20-57
TESTING AND ADJUSTMENTS TROUBLESHOOTING
20-58 WB97R-5E0
TESTING AND ADJUSTMENTS TROUBLESHOOTING
Excess of noise
CAUSES REMEDY
Incorrect installation Correct installation
Replace the differential in case it does not survive any one of the
Defective axle
test phases
Remove excessive weight and redistribute load, following
Bent halfshaft
instructions related to the vehicle
Replace the tyre or adjust pressure to have same radius on both
Different rotation radius of the tyres
tyre
Remove excessive weight and redistribute load, following
Overloading/ incorrect weight distribution
instructions related to the vehicle
Incorrect wheel adjustment Verify group integrity and wheel side bearings.
Contamination in the axle box or Look for foreign particles. Check assembly of the
incorrect assemblyof parts various parts of the axle.
WB97R-5E0 20-59
TESTING AND ADJUSTMENTS TROUBLESHOOTING
• Vehicles with wide steering angle may proceed • Reduce the steering angle to minimum and decelerate
with kicks, have steering difficulty or cause when the vehicle begins to kick.
pneumatic wearing at sharp turns.
Incorrect wheel adjustment Verify group integrity and wheel side bearings.
Friction noise
CAUSES REMEDY
Incorrect installation Correct installation
Replace the differential in case it does not survive any one of the
Defective axle
test phases
Remove excessive weight and redistribute load, following
Overloading/ incorrect weight distribution
instructions related to the vehicle
Check the condition of ring gear, pinion gear, bearings etc.
Spoiled or worn out axle parts
Replace when ever necessary.
Contamination in the axle box or Look for foreign particles. Check assembly of the
incorrect assemblyof parts various parts of the axle.
Incorrect adjustment of bevel gearset:
Parts of the transmission worn out. Replace or adjust as required.
(transmission gears, U joints, etc.)
20-60 WB97R-5E0
TESTING AND ADJUSTMENTS TROUBLESHOOTING
Intermittent noise
CAUSES REMEDY
Ring gear damaged Replace bevel gear set
Differential box bolts loosened Tighten to torque
Constant noise
CAUSES REMEDY
Ring gear teeth or pinion damaged Replace bevel gear set
Worn out bearings Replace
Pinion spline worn out Replace
Bent halfshaft Replace
WB97R-5E0 20-61
TESTING AND ADJUSTMENTS TROUBLESHOOTING
20-62 WB97R-5E0
TESTING AND ADJUSTMENTS TROUBLESHOOTING
WB97R-5E0 20-63
TESTING AND ADJUSTMENTS TROUBLESHOOTING
TRANSMISSION TROUBLESHOOTING
Vehicle does not move
CAUSES REMEDY
Faulty supply to solenoid valves Check/Replace
Damaged wiring connections between
Repair/Replace
transmission and vehicle
Oxidised contacts in
Clean
electrical wiring
Break in electric cable Replace
Damaged solenoids Replace
Damaged sensors Replace
Short circuits or false contacts Check/replace fuses
Gear selector and direction of movement selector
Replace selector
malfunction
Shift electronic control malfunction Replace
Incorrect oil level Top up
Check for leaks Repair/Top up
Blocked intake filter Clean
Damaged oil pump Replace
Damaged oil pump relief valve Replace oil pump
Blocked/damaged transmission filter Replace
Damaged/jammed control valve Replace
Damaged converter Replace
Oil temperature below 0ûC Wait for oil to reach working temperature (stall test)
Damaged rotary seals Replace
Reverser locking Repair
Worn clutch unit Replace/Repair clutch unit
No drive transmission
Check/Repair/Replace
(broken gears, shafts, bearings, etc.)
20-64 WB97R-5E0
TESTING AND ADJUSTMENTS TROUBLESHOOTING
Overheating
CAUSES REMEDY
Damaged hydraulic cooling system Repair
Dirty heat exchanger Clean
Parking brake inadvertently activated Release
Excessive dirt on axle wheel hubs Clean
Seizing (broken gears, shafts, bearings, etc.) Check/Repair/Replace
Braking force outside transmission:
Check/Repair axle
irregular axle operation
Clutch plate drag Repair/Replace
Damaged converter Replace
Damaged oil thermostat Replace
Incorrect oil level Top up
Worn oil pump Replace
Noise
CAUSES REMEDY
Damaged converter Replace
Damaged oil pump Replace
Aeration/Cavitation Check oil level / Check oil specifications
Seizing (broken gears, shafts, bearings, etc.) Check/Repair/Replace
Worn clutch plates Replace
Irregular actuation
CAUSES REMEDY
Damaged control valve Replace
Electrical system fault Repair/Replace
Worn clutch plates Replace
Damaged converter Replace
Low oil temperature (high oil viscosity) Wait for oil to reach working temperature (stall test)
Overheating See "overheating"
Gear selector or direction of movement selector
Replace
malfunction
Control module malfunction Replace
Shift electronic control malfunction Replace
Damaged hydraulic system Repair/Replace
WB97R-5E0 20-65
TESTING AND ADJUSTMENTS TROUBLESHOOTING
20-66 WB97R-5E0
30 REMOVAL AND INSTALLATION
WB97R-5E0 30-1
REMOVAL AND INSTALLATION HOW TO READ THE MANUAL
(2) Information needed for installation is marked with the symbol [*1]; The same symbol is repeated at the end of
each removal procedure for the same item, to indicate to which installation item it refers.
(Example)
REMOVAL OF THE GROUP ● ● ● : ........................................ Title of operation
2. To the precautions to be taken during the removal or installation of the groups, must be added the specific
"PRECAUTIONS TO BE TAKEN WHILE WORKING".
Always make sure that these precautions are taken.
4. List of the tightening torques and weights, and the quantities oil, liquids or grease needed to fill tanks
and containers
(1) In the operating procedures, you will find the symbols 2,3 , 4, 5, 6; in the following
order, these represent the values of «TIGHTENING TORQUES», «WEIGHT OF PARTS OR GROUPS»,
«QUANTITIES OF OIL OR LIQUIDS TO BE INTRODUCED», «SCREW LOCKING MATERIAL, SEALANTS
AND LUBRICATION», «LUBRICATING GREASE».
NOTE
If no symbol is indicated, the values to be used are those given in the introductory sections of this manual.
30-2 WB97R-5E0
REMOVAL AND INSTALLATION PRECAUTIONS TO BE TAKEN WHILE WORKING
WB97R-5E0 30-3
REMOVAL AND INSTALLATION SPECIAL TOOLS
SPECIAL TOOLS
Nature of work Symbol Code Name Q.ty
1 CA715655 Plunger 1
2 CA119097 Plunger 1
3 CA715360 Plunger 1
4 CA715035 Plunger 1
5 CA715026 Plunger 1
6 CA715077 Plunger 1
7 CA715034 Plunger 1
8 CA715163 Plunger 1
9 CA119043 Plunger 1
10 CA715779 Plunger 1
Disassembly - assembly
D 11 CA715164 Plunger 1
front axle
12 CA119030 Ring nut spanner wrench 1
13 CA119230 Plunger 1
16 CA119225 Plunger 1
20 CA715179 Plunger 1
21 CA715701 Plunger 1
30-4 WB97R-5E0
REMOVAL AND INSTALLATION SPECIAL TOOLS
1 CA715550 Plunger 1
Removal/installation tool
2 CA715902 1
self adjusting kit
3 CA715167 Plunger 1
4 CA715901 Bushing 1
5 CA715026 Plunger 1
6 CA715291 Plunger 1
Removal/installation tool
7 CA715900 1
differential ring nut
15 CA716135 Plunger 1
16 T.B.A. Plunger 1
WB97R-5E0 30-5
REMOVAL AND INSTALLATION SPECIAL TOOLS
1 CA715409 Plunger 1
2 CA715004 Plunger 1
3 CA715623 Plunger 1
4 CA715494 Control 1
6 CA715497 Plunger 1
7 CA715356 Calibrator 1
8 CA715501 Plunger 1
Installation/assembly tool
9 CA715358 1
clutches
10 CA715499 Protection 1
11 CA715046 Plunger 1
14 CA715745 Calibrator 1
16 CA715149 Plunger 1
18 CA715747 Calibrator 1
19 CA715748 Plunger 1
20 CA716009 Calibrator 1
21 CA716010 Protection 1
23 CA716019 Plunger 1
24 CA716020 Calibrator 1
25 CA716021 Extractor 1
30-6 WB97R-5E0
REMOVAL AND INSTALLATION SPECIAL TOOLS
790-502-1003 Equipment 1
1
790-101-1102 Pump 1
2 790-102-3802 Key 1
790-302-1310 Key 65 mm 1
790-302-1280 Key 55 mm 1
3
790-302-1270 Key 50 mm 1
790-302-1390 Key 46 mm 1
4 790-102-4300 Expander 1
796-720-1670
Calibrator for boom cylinder 1
07281-01279
796-720-1660
Calibrator for arm and swing cylinders 1
07281-01159
5
796-720-1650 Calibrator for bucket and shovel arm
1
07281-01029 cylinders
790-101-5021 . Handle 1
01010-50816 . Screw 1
790-102-4300 Key 1
8
790-102-4310 Pin 2
WB97R-5E0 30-7
REMOVAL AND INSTALLATION ENGINE HOOD
ENGINE HOOD
Removal 4 -Attach lifting equipment to engine hood (3); pull out
3
8
1
RKZC0770
2
4 Engine hood: 32 kg
1
RKZC0740 Installation
• To install, reverse removal procedure.
2 -Fully raise the engine hood (3), remove the safety
pins (4) and disconnect the gas springs (5) from the a Check catch (9) for proper centring.
chassis.
9
4
RKZC0780
RKZC0750
8
7
RKZC0760
30-8 WB97R-5E0
REMOVAL AND INSTALLATION FRONT GUARD
FRONT GUARD
Removal 4 -Connect the guard (6) to the lifting equipment and
resting on the ground. 5 -Take out the screws (1) and remove the protection
Stop the engine and remove the ignition key. (6).
6
1
RKZC9612
1 Installation
RKZC0741
3 Screw: 300 Nm
3 4
RKA53740
5 RKZC0791
WB97R-5E0 30-9
REMOVAL AND INSTALLATION RADIATOR GROUP - INTERCOOLER
RKZC0810
RKZC0771
2 8
7
9
RKZC9611
3 -Open the cock (3) and drain the coolant liquid. [*1]
(5).
30-10 WB97R-5E0
REMOVAL AND INSTALLATION RADIATOR GROUP - INTERCOOLER
7 -Loosen and remove the four screws and the fan 12 -Loosen and remove two nuts (20), washer (21) and
guard (10). vibration dampers (22) fixing the radiator group;
move the group to the front.
10
22
21
RKZC9640 20
RKZC0883
14
11 13
RKZC9682
12
14 -Remove conveyor (24).
RKZC9650
24
9 -Remove the clamp (15) and disconnect the manifold
(16) from radiator.
19
RKZC9691
17
15
16
18
RKZC9660
WB97R-5E0 30-11
REMOVAL AND INSTALLATION RADIATOR GROUP - INTERCOOLER
a Mark the position of pipes (26) and (27) connect. 5 Coolant liquid: 14 l
a Plug pipes, hoses and holes immediately to [*2]
prevent contamination and leak of oils.
a Fill the tank with hydraulic oil up to maximum level.
5 Hydraulic oil: 40 l
27 28 29
[*3]
25 a Ensure that the level of transmission oil is at
maximum.
30
RKZ14550
RKZC9711
30-12 WB97R-5E0
REMOVAL AND INSTALLATION INTERCOOLER
INTERCOOLER
Removal 4 -Remove the screws, remove the condenser (3) and
3
1 RKZC9621
5 -Remove the clamps (4) and (5); loosen the clamp (6)
and disconnect the manifold (7) from intercooler.
RKZC0771
5
RKZC9651
6 -Remove the surge tank (8) and the right support (9).
2
7 -Disconnect the inlet pipe (10) from the intercooler.
RKZC9611
10
9
RKZC9720
WB97R-5E0 30-13
REMOVAL AND INSTALLATION INTERCOOLER
11
RKZC9681
12
13
12
RKZC9730
Installation
• To install, reverse removal procedure.
30-14 WB97R-5E0
REMOVAL AND INSTALLATION CONDENSER
CONDENSER
Removal Installation
k Fully raise the front working equipment and engage • To install, reverse removal procedure.
the safety stop.
1 -Refill the air-conditioning unit. (For details, see "20
Also place the backhoe in its secure position.
TESTING AND ADJUSTMENTS").
1 -Drain the air conditioning unit.
(For details see "20 TESTING AND
ADJUSTMENTS").
2
1
RKZC0861
3
5 5
6
4
RKA53750
WB97R-5E0 30-15
REMOVAL AND INSTALLATION EXHAUST PIPE
EXHAUST PIPE
Removal Installation
1 -Loosen the nuts (1) on the jumper pin (2) retaining the • To install, reverse removal procedure.
muffler pipe (3) to the exhaust pipe.
3
1
RKZC0920
RKZC1010
RKZC1020
30-16 WB97R-5E0
REMOVAL AND INSTALLATION MUFFLER
MUFFLER
Removal 4 -Remove the air filter cartridges (7).
hood.
1 -Loosen the nuts (1) on the jumper pin (2) retaining the
muffler pipe (3) to the exhaust pipe.
RKA53760
1
5 -Remove the tie rod (8).
3
1
RKZC0920
RKA53770
5
RKZC0930
RKZC0951
6 Installation
• To install, reverse removal procedure.
RKZC0940
WB97R-5E0 30-17
REMOVAL AND INSTALLATION AIR FILTER
AIR FILTER
Removal 5 -Remove the screw (8).
1 -Park the machine on hard, level ground, apply the 6 -Loosen and remove the screws (9) and remove the
parking brake, stop the engine and remove the filter (10) together with the filter holder and the tie rod.
ignition key.
9
RKA53771
2
1 Installation
RKZC9740 • To install, reverse removal procedure.
6 5
RKZC9750
RKA53760
30-18 WB97R-5E0
REMOVAL AND INSTALLATION ENGINE BELT
ENGINE BELT
Replacement 4 -Remove the bracket (5).
k Fully raise the front working equipment and engage 5 -Replace the belt according to the instructions
the safety stop. provided in the engine manual (manual code
Also place the backhoe in its secure position. WEBMNEF001).
RKZC9760
RKZC9631
4
3
RKZC9721
WB97R-5E0 30-19
REMOVAL AND INSTALLATION TURBOCHARGER
TURBOCHARGER
Removal 5 -Remove the screw (8).
k Fully raise the front working equipment and engage 6 -Loosen and remove the screws (9) and remove the
the safety stop. filter (10) together with the filter holder and the tie rod.
Also place the backhoe in its secure position.
3
8
9
RKA53771
1
12
RKZC9770
4
13
RKZC9781
RKA53760
30-20 WB97R-5E0
REMOVAL AND INSTALLATION AIR-CONDITIONING UNIT COMPRESSOR
1
8
3
RKZC3000
RKZC9642
3 -Disconnect fluid delivery and return pipes (5), (6)
from compressor (4). [*1] 6 -Loosen the screw (9) retaining the tensioner (10).
a Collect the O-rings. 7 -Loosen the nut (11) and turn the screw (12) to loosen
the belt.
12 11
6
4
9 10
RKZC3010
RKTA1206
WB97R-5E0 30-21
REMOVAL AND INSTALLATION AIR-CONDITIONING UNIT COMPRESSOR
15
15
13
4
14
15
RKZC3030
Installation
• To install, reverse removal procedure.
[*1]
30-22 WB97R-5E0
REMOVAL AND INSTALLATION AIR-CONDITIONING UNIT COMPRESSOR BELT
8
7
1
RKZC3031
Installation
• To install, reverse removal procedure.
[*1]
RKZC0983
6 5
3 4
RKTA1207
WB97R-5E0 30-23
REMOVAL AND INSTALLATION FAN AND HEATING GROUP
6 Coolant liquid: 14 l 6
a Drain the air conditioning unit.
(For details see "20 TESTING AND
ADJUSTMENTS"). 7
1 -Remove the floor-mat (1); disconnect the connectors RKZC6380
2 10 8
3
1
RKA53780
2 -Take out the screws (4) and remove the control unit
protection (5).
9
RKZC6530
11
RKZC6230
RKZC1070
30-24 WB97R-5E0
REMOVAL AND INSTALLATION FAN AND HEATING GROUP
8 -Disconnect the connector (13) from the instrument 13 -Loosen nuts and remove knobs (21) from outrigger
board (12). PPC valves.
9 -Disconnect connectors (14) and (15) from the lighter. 14 -Remove PPC valve mounting plate (22).
13
21
22
14 15 12
RKZC1080 RKZC1110
10 -Extract screws (16) and remove the hand accelerator 15 -Extract screws (23) and remove contact carrier plate
handle (17). (24) for rear wiper.
17
23
24
16
RKZC1120
18
16 -Extract the lower screws (25) retaining the right hand
RKZC1090
case (10).
25
25
10
19 20 RKZC6520
RKZC1100
WB97R-5E0 30-25
REMOVAL AND INSTALLATION FAN AND HEATING GROUP
17 -Extract three screw covers (26) and screws retaining 20 -Move the rear of the right hand case (10) towards the
the right hand case (10) at the rear. middle of the cab, remove pin (30), and disconnect
hand accelerator cable (31).
31
RKZC1140
32
18 -Extract two screw covers (27) and screws; extract
RKZC1170
the lower screw (28) and washer.
33
27
28
RKZC6190
RKZC2990
19 -Extract the upper screw (29) retaining the right hand
case (10) and its washer.
24 -Engage the parking brake.
25 - Raise right hand case (10) until PPC valve control
and parking brake lever are disengaged; fully
10 remove the case.
29
10
RKZC1160
RKZC6180
30-26 WB97R-5E0
REMOVAL AND INSTALLATION FAN AND HEATING GROUP
35
36
34 41
RKZC1220
44 47
36
45
43
46
RKZC1200
RKZC6200
40
39
38
37 48 48
RKZC1210
41
RKZC1231
WB97R-5E0 30-27
REMOVAL AND INSTALLATION FAN AND HEATING GROUP
Installation
1 - Refill the coolant liquid.
30-28 WB97R-5E0
REMOVAL AND INSTALLATION BATTERY
BATTERY
Removal 7 -Loosen wing nut (4) and remove tie rod (5) and
RKA53810
Installation
• To install, reverse removal procedure.
1 [*1]
RKA53790
k Connect the battery positive (+) cable first, and then
the battery negative (–) cable.
5 -Disengage battery negative (–) terminal (2) from
shield and disconnect from battery.
3
2
RKA53800
WB97R-5E0 30-29
REMOVAL AND INSTALLATION FUEL TANK
FUEL TANK
Removal 4 -Disconnect the connector (5) from the level gauge
resting on the ground. 5 -Mark and disconnect the fuel inlet and return hoses
Engage the parking brake, stop the engine and (7), (8).
remove the ignition key. a Plug all pipes/hoses to prevent contamination.
1 -Take the cap (2) off the filling inlet of the fuel tank (3)
and remove also the bottom plug in order to drain the 5 8
fuel.
6
3
1 2
RKZC1310
4 Fuel tank: 68 kg
RKZC1290
4 9
RKZC1320
Installation
RKZC1300
[*1]
3 Tank retaining screws: 120 Nm
1 -Refill the fuel tank.
30-30 WB97R-5E0
REMOVAL AND INSTALLATION STEERING WHEEL AND TRANSMISSION-REVERSE, DIRECTION
RKZC1360
1
1 5 -Loosen and remove screws (9) and (10) and release
direction indicator group (11)and transmission
reverse control group (12).
RKZC1330
12
2 -Loosen and remove the retaining nut (2) and remove 9
the steering wheel (3).
10
11
RKZC1370
RKZC1340
13
3 -Remove four screw covers (4) and loosen four 14
screws (5) retaining the instrument panel. 12
4 11
5
RKZC1380
RKZC1350
WB97R-5E0 30-31
REMOVAL AND INSTALLATION STEERING WHEEL AND TRANSMISSION-REVERSE, DIRECTION
Installation
• To install, reverse removal procedure.
[*1]
a Before attempting to tighten the screws, check the
antirotation stake (15) for proper engagement into
the steering column (16).
16
15
RKZC1390
30-32 WB97R-5E0
REMOVAL AND INSTALLATION WORKING BRAKE PUMP GROUP
8
1
10
2
RKA53781
9
4 -Loosen and remove the upper screws (4) retaining
the instrument panel holder (5).
RKZC1420
5
8
RKZC1400
RKZC1430
WB97R-5E0 30-33
REMOVAL AND INSTALLATION WORKING BRAKE PUMP GROUP
9 -Take out the lower screws (11) and remove the Installation
instrument panel holder (5).
• To install, reverse removal procedure.
[*1]
[*2]
11
RKZC6220
10 -Remove the plug and (12) and draw oil from the tank
(13).
11 -Reinstall the plug and disconnect connectors (14) 21
and pressure switch connectors (15) and (16).
12 -Remove the tank (13).
14
12
13
16
15
RKZC1450
RKZ10751
3 Union: 20 Nm
17
19
20
18 RKZC1460
30-34 WB97R-5E0
REMOVAL AND INSTALLATION STEERING UNIT
STEERING UNIT
Removal 4 -Loosen and remove the upper screws (4) retaining
RKZC1400
3 6
1
RKA53780
CONTROL GROUP").
7 -Slide the instrument panel holder (5) up to remove it.
RKZC1381
RKZC6221
WB97R-5E0 30-35
REMOVAL AND INSTALLATION STEERING UNIT
[*1]
a Start the engine and perform several complete
steering manoeuvres in both directions, to bleed the
air out of the steering system.
7
8
RKZC1480
10
10
RKZC1490
12
11
RKZC1500
30-36 WB97R-5E0
REMOVAL AND INSTALLATION CAB
CAB
Removal 6 -Disconnect pipes (8) from steering unit (7). [*2]
k Lower the working equipment completely until it a Mark the positions of the pipes to prevent
rests on the ground. exchanging positions when reconnecting.
Engage the parking brake and stop the engine. a Plug the pipes and pipe-fittings to prevent entry
k Turn the battery disconnect switch to OFF position,
of impurities.
and remove the key.
6 Coolant liquid: 14 l
a Only for machines equipped with an air-
conditioning unit.
Drain the air conditioning unit. (For details see "20 8
TESTING AND ADJUSTMENTS"). [*1] 8
1 -Remove the exhaust pipe. (For details see
RKZC1493
"EXHAUST PIPE").
2 -Remove the front mat, remove screws (1) and loosen 7 -Remove nut and disconnect strap (9) from frame.
screw (2). 8 -Mark and disconnect the tubes (10). [*3]
3 -Remove the steering unit guard (3). a Plug the pipes and pipe-fittings to prevent entry
of impurities.
1
1
3
10
2
RKZC3041 9
RKZC9800
4 -Disconnect the injection pump control fork (5) from
the pitman arm (4). 9 -Take out the screws (11) and remove the hood (12).
5 -Disengage the control cable (6).
5
12
11
6
RKZC6231
RKZC9790
WB97R-5E0 30-37
REMOVAL AND INSTALLATION CAB
14
18
14
19
20
RKZC6240
11 -Lift rear window (15) to the top and remove the rear
mat.
RKZC6540
RKZC1871
21 21
12 -Take out the screws (16) and remove the platform
(17).
16
21
21
16 RKZC1992
17
RKZC1973
30-38 WB97R-5E0
REMOVAL AND INSTALLATION CAB
15 -Disconnect servocontrol supply hoses (23) and (24) 18 -Remove nuts (28) as well as front and rear screws.
from solenoid valve group (22). [*6]
28
22 28
24 RKZC3061
25
30
29
RKZC3012
RKZC2073 20 -Take out the screws (31) and remove the protection
(32).
17 -Take out the screws (26) and remove the protection
(27).
27 31
32
26 26
31
RKZC0743
RKZC1302
WB97R-5E0 30-39
REMOVAL AND INSTALLATION CAB
21 -Disconnect hose (34) from condenser (33). [*7] 24 -Remove the screw (36) and disconnect the ground
wire (37).
a Cap the hose and hole to ward off humidity.
25 -Pull out screws (38) and remove cable guard (39).
a Release the hose and route it under the cab.
38
36
37
34
33
39
RKZC3091
RKZC3071
35
41
40
RKZC3101
A A
RKZC3081
30-40 WB97R-5E0
REMOVAL AND INSTALLATION CAB
Installation
• To install, reverse removal procedure.
[*1]
a Drain and refill the air-conditioning unit
[*2]
a Bleed the air from the steering circuit. (For details,
see "20 TESTING AND ADJUSTMENTS").
[*3]
[*4]
[*5]
a Adjust the stroke of the parking brake lever. (For
details, see "20 TESTING AND ADJUSTMENTS").
[*6]
3 Union (34): 16 Nm
1 - Refill the coolant liquid.
WB97R-5E0 30-41
REMOVAL AND INSTALLATION HYDRAULIC OIL TANK
RKZC1382
RKZC1510
8
2 -Remove the front mat (2).
3 -Disconnect the connectors (3) and remove the seat
(4).
RKZC1401
4
2
RKA53782
11
10
RKZC1411
30-42 WB97R-5E0
REMOVAL AND INSTALLATION HYDRAULIC OIL TANK
7 -Loosen and remove the lower screws (12) retaining 11 -Remove the fill plug (14) and draw the brake fluid.
the front trim cover (11).
a Replace plug to prevent contamination.
8 -Fully lower the steering column; extract the knob
12 -Disconnect oil level and pressure switch connectors
(13).
(15) and (16).
11 15
14
13
12
16
16
RKZC1421
RKZC1451
RKZC1431
19
20
RKZC6222
18
RKZC1481
WB97R-5E0 30-43
REMOVAL AND INSTALLATION HYDRAULIC OIL TANK
16 -Loosen and remove five screws (21) and remove the 22 -Disconnect connector (32) from washer pump (31).
metal sheet (22) closing off the cab floor.
21
31
22
32
21
RKZC1550
RKZC6250
23 24
33
26 RKZC1560
25
24 -Loosen and remove screws (35) and washers.
Remove the complete bulkhead (36) and move it to
the rear of the machine.
27
RKZC9791
30
36
RKZC9810
28
29
RKZC1540
30-44 WB97R-5E0
REMOVAL AND INSTALLATION HYDRAULIC OIL TANK
25 -Take out the screws (37) and remove the conveyor 28 -Disconnect the pump suction pipe (43).
(38).
a Plug the pipe to prevent contamination.
43
37
38
RKZC1580
RKZC1610
45
44
40
39
RKZC1590
RKZC1620
42
47
41
46
RKZC1600
RKZC1630
WB97R-5E0 30-45
REMOVAL AND INSTALLATION HYDRAULIC OIL TANK
[*1]
49 a Bleed the air from the braking circuit. (For details, see
"20 TESTING AND ADJUSTMENTS").
[*2]
a Check and adjust the stroke of the hand accelerator.
48
1 -Refill the hydraulic oil.
3 -Bleed the air from the cylinders. (For details, see "20
33 -Remove two screws (50) and washers to release the
TESTING AND ADJUSTMENTS").
complete tank (39).
4 -Stop the engine, check the oil level in the tank and, if
necessary, top it up.
39
50
RKZC1650
39
RKZC1660
30-46 WB97R-5E0
REMOVAL AND INSTALLATION PISTON PUMP
PISTON PUMP
Removal 3 -Disconnect the delivery hose (5) and the LS and
4 5
RKZC1680
9
RKZC1511
11
4
10
RKZC6270
WB97R-5E0 30-47
REMOVAL AND INSTALLATION PISTON PUMP
3 -Stop the engine and check the oil level in the tank.
RKZC6280
9 -Take out the upper screw (11) and remove the pump
(4).
RKZC1710
30-48 WB97R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
TRANSMISSION
Removal 3 -Disconnect rear cardan shaft (4) from transmission
1
5
RKA53820
RKZC1711
2 -Remove the front mat and remove the metal sheet (2)
closing off the cab floor.
2 6
RKZC1732
RKZC1521
WB97R-5E0 30-49
REMOVAL AND INSTALLATION TRANSMISSION
6 -Disconnect seven solenoid valve connectors (7) and 11 -Remove the screws and remove the cover (15)
shift oil temperature sensor connector (8) from giving access to the converter coupling flange.
gearshift (3).
12 -Slowly rotate the engine flywheel until the converter
7 -Take out the screws and remove the harness holder retaining screws (16) are centred in the hole; remove
(9). the four screws. [*5]
7
9 15
16
3 8
RKZC6291 RKZC1760
8 -Disconnect the connector (10) from the rev sensor 13 -Procure to support the engine (17) with a stand “C”
(11). placed under the flywheel bell.
11 17
C
10
RKZC6310 RKZC1781
9 -Disconnect delivery hose (12) to oil cooler and return 14 -Disconnect the gearbox oil load and oil level control
hose (13) from gearbox (3). pipe (18), remove the screw (19) and remove the
complete pipe (18).
10 -Remove the clamp (14).
9 18
12
18
19
13 14 RKZC6320
RKZC6300
30-50 WB97R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
15 -Remove the nuts (20) on the vibration dampers (21), 18 -Move the gearbox group (3) towards the rear of the
the screws (22) and remove the gearbox supports machine and extract the group.
4 Transmission: 254 kg
(23). [*6] [*7]
21 21
23
23
20 3
20
22
22
RKZC6330
RKZC6360
3 Screw: 120 Nm
[*4]
17 -Loosen and remove the two screws (24) retaining the 3 Screw: 64 Nm
gearbox (3) to the engine (17). [*8] [*6]
24 [*8]
WB97R-5E0 30-51
REMOVAL AND INSTALLATION TRANSMISSION
6 11
13 12
7 14
16
2
10
5 9
3
8
4
1 18
15
RKZ11200
1 -Remove the drain plug (1) and drain the oil from the 2 -Remove the two cap screws (2) which fasten the
transmission. cover for the oil screen.
2
1
RKZC3490 RKZC3500
30-52 WB97R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
3 -Remove the cover (3), the oil screen (4) and the ring 6 -Check the valve (8) condition.
(5).
a Clean with care the valve and replace the O-ring
(9) and (10) if necessary.
4
3
9
5 10
RKZC3510 8
RKZC3540
RKZC3520
11
RKZC3550
12
8
RKZC3530
RKZC3560
WB97R-5E0 30-53
REMOVAL AND INSTALLATION TRANSMISSION
9 -To check the REVERSE clutch pressure, remove 12 -Remove the thermostat (16).
the plug (13).
13
16
RKZC3600
RKZC3570
1.2 Assembly
10 -To check the lubrication pressure, remove the plug
(14). 1 -Assemble the speed sensor (15) to the prescribed
torque
3 Sensor: 50 Nm
14
RKZC3580 15
3 Thermostat: 30 Nm
15
RKZC3590
16
RKZC3600
30-54 WB97R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
3 -Assemble the plugs (12), (13) and (14) to the 6 -Assemble the oil filter protection valves (8).
prescribed torque after the pressure check. Tighten the valve (8) to the prescribed torque
3 Caps: 30 Nm 3 Valve: 23 Nm
13
12 8
RKZC3571 RKZC3530
4 -Assemble by hand the breather (11) to the 7 -Assemble the connector (7) for the oil filter (6) then
transmission housing and tighten it strongly. tighten it to the prescribed torque.
3 Union: 50 Nm
11
RKZC3550
RKZC3610
5 -Clean with care the oil filter protection valve (8).
Assemble the new O-ring (9) and (10).
8 -Assemble new oil filter (6).
9
6
10
8
RKZC3540
RKZC3521
WB97R-5E0 30-55
REMOVAL AND INSTALLATION TRANSMISSION
5
RKZC3620
3 Screw: 23 Nm
3
2
RKZC3501
3 Plug: 80 Nm
RKZC3490
30-56 WB97R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
4
3
2
5 6
1
RKZ11210
RKZC3630
RKZC3640
WB97R-5E0 30-57
REMOVAL AND INSTALLATION TRANSMISSION
3 -Extract the pump (3) by means of two levers. 6 -If replacement is necessary, remove the seal ring (5).
RKZC3650
RKZC3680
4 -Remove the oil pump (3).
F1
3
5
3
RKZC3660
4
4
RKZC3670
RKZC3670
30-58 WB97R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
3 Screw: 23 Nm
a Check that reference marks made on the oil
pump and on the bell housing coincide.
RKZC3700
1
RKZC3710
3
6 RKZC3630
RKZC3720
WB97R-5E0 30-59
REMOVAL AND INSTALLATION TRANSMISSION
1 6 4
2
5
7
3
11
10
9
8
RKZ11220
1 -Drain oil from transmission hydraulic circuit, 2 -Lift control valve (2).
disconnect all electrical connections.
Remove screws (1).
1
1 2
RKZC3740
RKZC3730
30-60 WB97R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
3 -Remove the gasket (3). 6 -Remove the valves (5) and (6).
3
5
RKZC3750 RKZC3780
4 -Place the control valve unit on a clean workbench. 7 -Check the valves (5) and (6) condition.
Remove fastening screws (4) from the valves (5) and
(6).
5
6
5
RKZC3790
4
RKZC3760 8 -Unscrew and remove the valve (7).
RKZC3800
5
RKZC3770
WB97R-5E0 30-61
REMOVAL AND INSTALLATION TRANSMISSION
RKZC3810
10
8
10 -Unscrew and remove the oil filter protection valve (8).
RKZC3540
3 Valve: 23 Nm
RKZC3530
9
6 6 6 6
10
8
RKZC3540
6 5 5
RKZ11230
30-62 WB97R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
4 -Assemble the valve mounting screws (4). 7 -Tighten the bolts (1) to the prescribed torque.
3 Screws: 23 Nm
1
1
4
RKZC3761
RKZC3830
5 -Assemble the new gasket (3).
RKZC3750
11
RKZC3820
WB97R-5E0 30-63
REMOVAL AND INSTALLATION TRANSMISSION
1
5
2
7
RKZ11240
1 -Drain oil from transmission hydraulic circuit. 2 -Remove the pipe (2) (2nd speed) unscrewing related
Uns cr e w the c onnecti ons o f pi pe (1) (s haft connections.
lubrication) and remove the pipe (1).
RKZC3850
RKZC3840
30-64 WB97R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
3 -Remove the pipes (3) (4th speed), (4) (4WD), (5) (1st 2 -Assemble the pipe (2) tightening torques the
speed) and (6) (3rd speed) unscrewing related connections to the prescribed torque.
3 Unions: 30 Nm
connections.
3 6
2
4
5
RKZC3850
RKZC3860
3 -Assemble the pipes (3), (4), (5) and (6) then tighten
4 -Remove the pipe (7) (shaft lubrication) unscrewing related connections to the prescribed torque.
3 Unions: 30 Nm
related connections.
6
3
7 4
5
RKZC3870
RKZC3860
4.1 Assembly
4 -Assemble the pipe (7) tightening torques the
1 -Assemble the pipe (1) tightening the connections to connections to the prescribed torque.
3 Unions: 30 Nm
the prescribed torque.
3 Unions: 30 Nm
RKZC3870
RKZC3840
WB97R-5E0 30-65
REMOVAL AND INSTALLATION TRANSMISSION
5. Transmission housing
5.1 Disassembly
8 6
18 11
10
19 7
20
12
14
15
13
16
17
4
3
5
2
1 RKZ11250
1 -Drain oil from transmission. 2 -If necessary use a screwdriver and two screws to
Unscrew flange (2) fastening bolt (1). stop flange rotation.
RKZC3880 RKZC3900
30-66 WB97R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
3 -Collect the washer (3). 6 -Remove the fastening screws (6) from the flange (7).
RKZC3940
RKZC3910
7
4
RKZC3950
RKZC3960
RKZC3930
WB97R-5E0 30-67
REMOVAL AND INSTALLATION TRANSMISSION
9 -If to be replaced, remove teflon seal ring (9) by cutting 12 -Unscrew flange (13) fastening bolt (12).
it. Use a screwdriver and two screws to stop flange
rotation.
a This is a destructive operation for the seal ring.
13
9 RKZC3901
RKZC3970
12 14
10
RKZC3911
RKZC3980
13
15
11
RKZC3990
RKZC4000
30-68 WB97R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
15 -Remove seal ring (16). 18 -Lift the front half housing (19) by means of two hooks.
19
16
RKZC4040
RKZC4010
19 -Remove the three O-rings (20).
20
19 20
18
17
RKZC4050
5.2 Assembly
RKZC4020
20
20
RKZC4030
RKZC4050
WB97R-5E0 30-69
REMOVAL AND INSTALLATION TRANSMISSION
2 -Assemble all the transmission internal parts. 5 -Assemble seal ring (5) on front shaft output.
Apply a thin film of prescribed sealant on the edge of Use tool F8.
the rear half-housing.
2 Loctite 510
5
RKZC4080
19
4
RKZC3920
RKZC4040
3 Screws: 50 Nm
RKZC3912
17
RKZC4070
30-70 WB97R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
8 -Tighten the bolt (1) to the prescribed torque. 11 -Assemble the washer (14) and bolt (12).
Use screwdriver and two screws to stop flange
rotation.
3 Screws: 139 Nm
12 14
RKZC3911
16
RKZC4090
RKZC4100
13
11
15
RKZC3921 RKZC4110
WB97R-5E0 30-71
REMOVAL AND INSTALLATION TRANSMISSION
14 -Assemble snap ring (10). 17 -Apply a thin film of sealant to the flange (7).
2 Loctite 510
a Verify that the two holes for oil passage (A)
match.
10
RKZC4120
3 Screw: 50 Nm
9
RKZC4130
RKZC3940
RKZC3960
30-72 WB97R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
6. Shafts A - D
6.1 Disassembly
33
37 17 18 32
11 34
16 10
8 38
6 39
40
7 27
4
3
2
1
31
21
20
19 22
23
9 24
5 25
12
26
28
15 30
14 29
13 35
36
RKZ11260
1 -Grasp with pliers the input shaft assembly A . 2 -If to be replaced, remove the teflon seal ring (1).
Remove with shaft assembly D and lift.
D
A RKZC4160
RKZC4150
WB97R-5E0 30-73
REMOVAL AND INSTALLATION TRANSMISSION
RKZC4170 RKZC4200
RKZC4210
7
RKZC4180
3 RKZC4220
RKZC4190
30-74 WB97R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
9 -Remove spacer (8). 12 -Use prybars to lift and to remove the thrust plate lock
ring (11) evenly.
8
11
RKZC4230
RKZC4260
9 17
RKZC4240
18
11 -Remove the snap ring (10). RKZC4270
10
RKZC4250
RKZC4280
WB97R-5E0 30-75
REMOVAL AND INSTALLATION TRANSMISSION
15 -Place a mark on each thrust plate lock ring (11), 18 -Loosen the handles of the threaded rods to release
clutch plate (18) and clutch drive plate (17). the tension from the spring.
These marks will be used for reference during the Remove the top piece of the F9 special tool.
reassembly procedure.
11
F9
17
18
RKZC4301
RKZC4290
13
F9
13
15
RKZC4320
RKZC4300
14
RKZC4330
RKZC4310
30-76 WB97R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
21 -Remove clutch piston (19) by blowing in compressed 24 -Remove snap ring (23).
air through the delivery hole.
19
23
RKZC4370
RKZC4340
24
21 20 RKZC4380
RKZC4350
24
23 -Turn the shaft.
If Teflon seal rings (22) are to be replaced, remove
the rings by cutting them.
25
RKZC4390
22
RKZC4360
WB97R-5E0 30-77
REMOVAL AND INSTALLATION TRANSMISSION
27 -Remove gear (26) and needle cage (12). drive plates with clean transmission oil before
assembly.
RKZC4430
RKZC4440
30-78 WB97R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
16
RKZC4470
RKZC4450
3 -Insert clutch piston (19) with special tool F10 as
protection of seal rings (21).
2 -Remove bearing (37) of shaft D by means of an
extractor.
19
F10
37
RKZC4480
RKZC4460
4 -Assemble sleeve (5).
6.2 Assembly
SHAFT A
RKZC4330
21 20
RKZC4350
WB97R-5E0 30-79
REMOVAL AND INSTALLATION TRANSMISSION
5 -Assemble spring (15) and washer (13). 8 -Loosen the handles of the threaded rods to release
the tension from the spring.
Remove the top piece of the F9 special tool.
13
F9
15
RKZC4320
6 -Lower the spring (15) lock washer (13). Use tool F9. RKZC4301
F9
13
RKZC4300
a Ensure that the snap ring (14) is well fitted. 10 -Insert thrust washer (8)
14
8
RKZC4310
RKZC4500
30-80 WB97R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
11 -Insert needle cage (7). 14 -Locate the pack assembly by means of two
screwdrivers.
RKZC4220
RKZC4530
12 -To assemble the clutch pack start with the gear (6) on
the bench. 15 -Assemble snap ring (10).
Install the thrust plate (11) so that the reference mark
on top of the plate made during disassembly is facing
towards the gear.
11 10
RKZC4540
6
16 -Assemble washer (4).
RKZC4510
18
RKZC4200
17
RKZC4520
WB97R-5E0 30-81
REMOVAL AND INSTALLATION TRANSMISSION
17 -Heat the bearing (3) to 80–100 °C. Assemble bearing 20 -Install the F5a spacer onto the input shaft with the
(3). Use tool F2. chamfered end facing in.
F2
F5a
RKZC4550 RKZC4570
18 -Install the snap ring (2). 21 -Slide the F5b expander/protector onto the input shaft
NOTA and on the spacer.
For clarity of the Teflon sealing ring installation The expander/protector will stop in the correct
procedure the following photos do not show the position to install the seal ring in the groove.
clutch pack, gear, spacer, bearing, and snap ring
installed on the input shaft.
F5b
2
RKZC4580
RKZC4590
RKZC4560
30-82 WB97R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
F6
RKZC4620
F7
17
RKZC4630
25
RKZC4640
WB97R-5E0 30-83
REMOVAL AND INSTALLATION TRANSMISSION
27 -Heat the bearing (24) to 80–100 °C. 30 -Slide the F12 expander/protector and the spacer
Use driver F11 to drive the bearing (24) onto the input onto the shaft. The expander/protector will stop in the
shaft until the bearing makes contact with the thrust correct position to install the seal ring in the groove.
washer.
F12b
24
RKZC4680
RKZC4650
23
RKZC4660
RKZC4690
F13
F12a
RKZC4670
RKZC4700
30-84 WB97R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
33 -Install the end of the F14 seal compressor with the 34 -Turn the seal compressor around and slide the end
deep chamfer onto the shaft and over the sealing with the narrow chamfer over the shaft and over the
ring. Use a back and forth twisting motion to allow the seal ring.
seal compressor to slip over the top of the sealing Leave the seal compressor in place for 15 minutes
ring and seat the sealing ring into the groove. Be until the sealing ring has cooled and is properly sized
careful not to damage the seal ring. After the sealing and seated in the groove. Once the sealing ring has
ring is seated in the groove, remove the seal cooled, remove the seal compressor from the shaft.
compressor from the shaft. To install the three Teflon rings remaining, carry out
steps 29 to 33 in this section using the other spacers
of tool F12.
F14
RKZC4710
RKZC4720
WB97R-5E0 30-85
REMOVAL AND INSTALLATION TRANSMISSION
7
4
6 5
8 1
3 2
6 5
RKZ11270
30-86 WB97R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
16
RKZC4730
RKZC4760
37
RKZC4740
RKZC4750
WB97R-5E0 30-87
REMOVAL AND INSTALLATION TRANSMISSION
7. AXIS B
7.1 Disassembly
12
10 11
9
8
B
xis
7 s e/A
6 As
4 5
3 26
22
2
1 25
B 18
xis
e/A 24
A ss
16 21 23
14
20
19
17
15
13 RKZ11280
1 -Remove screws (28) and protection (29). 2 -Lift the three shafts B-C-E, at the same time B-C-E.
Use tool F15.
F15
28
29
RKZC4770
RKZC4780
30-88 WB97R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
1
5
2
RKZC4820
RKZC4790
7 -Remove spacer (6).
RKZC4830
3
4
23
RKZC4840
RKZC4810
WB97R-5E0 30-89
REMOVAL AND INSTALLATION TRANSMISSION
9
8
RKZC4850 RKZC4890
10 -Remove roller retainers (7) and washer (13). 14 -Remove thrust plate (10) by means of two
screwdrivers.
10
7
13
RKZC4860
RKZC4900
11 -Remove spring pin (24) and spacer (14).
15 -Remove disc (11) and counterdiscs (12) pack.
24 12 11
14
RKZC4870
RKZC4910
12 -Slightly press thrust plate (10).
16 -Lower the spring (17) retaining washer (16).
Use tool F9.
F9
10
RKZC4880
RKZC4920
30-90 WB97R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
15
18
RKZC4930 RKZC4950
18 -Loosen the handles of the threaded rods to release 21 -Remove clutch piston (19) by blowing in compressed
the tension from the spring. air through the delivery hole.
Remove the top piece of the F9 special tool.
F9
19
RKZC4960
RKZC4920
16
17
21 20
RKZC4940
RKZC4350
WB97R-5E0 30-91
REMOVAL AND INSTALLATION TRANSMISSION
23 -Remove the teflon seal ring (26). - Verify that all the clutch plates do not appear burned
or that the friction material it is not damaged and that
splines are well traced.
- Verify also that all the clutch drive plates (12) are
perfectly plane and inspect for pitting or scoring.
In the case that at least one of the above problems
occurs, replace the complete clutch kit with a new
one. If using a new clutch kit soak the clutch plates in
clean transmission oil for at least an hour before
assembly. In any case lubricate the contact surfaces
26 of clutch drive plates with clean transmission oil
before assembly.
RKZC4970
Number of clutch plate 8
24 -Remove bearing (25) by means of an extractor. Number clutch steel plate 8
25 12
RKZC4980
25 -Check:
- the sealing ring grooves (large and small) for wear
and damage if necessary.
- on the output shaft for wear and damage.
- the oil passages in the output shaft to be sure that
the passages are open and free of foreign material.
- the ball bearings and the needle bearings for flat
areas, pitting, and other damage.
Use new parts as required. RKZC4431
11
RKZC4441
RKZC4420
26 -If the clutch discs are to be used again, keep the 28 -Inspect the bore of the shaft in the input shaft housing
clutch packs in the same previous assembly order for damage that will cause leakage when the clucth is
separate and record which clutch pack goes with assembled. Check the slots in the side of the input
each clutch. shaft housing for damage from the tangs on the steel
discs. Use new parts as required during assembly.
27 -At each disassembly:
- verify with a caliper that the total thickness of the
clutch kit is within the wear limit.
30-92 WB97R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
7.2 Assembly
1 -Assemble bearing (25). 4 -Apply a thin film of grease on the sealing rings just
Use tool F2. inserted.
F2
25
RKZC4990 RKZC4470
2 -Assemble a new Teflon sealing ring (26). 5 -Insert clutch piston (19) with special tool F10 as
To install the ring (26), repeat steps 29 to 34 in protection of seal rings (21).
section "6.2 Assembly" using tool F5.
19
F10
RKZC4480
RKZC5000
18
21 20
RKZC4950
RKZC4350
WB97R-5E0 30-93
REMOVAL AND INSTALLATION TRANSMISSION
7 -Assemble spring (17) and washer (16). 10 -Loosen the handles of the threaded rods to release
the tension from the spring.
Remove the top piece of the F9 special tool.
16 F9
17
RKZC4940
F9
17 22
RKZC4302
RKZC4911
24
14
15
RKZC5010
RKZC4311
30-94 WB97R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
13 -Insert washer (13) and roller bearing (7). 16 -Apply compressed air at low pressure in hole in order
to push the thrust plate (10) against the retaining ring
(9), then align the clutch plate (11) spline.
9
10
7
13 11
RKZC5020
clutch pack.
17 -Assemble gear (8) paying attention it completely fit in
its seat.
10
RKZC5030
23
RKZC5040
RKZC5070
WB97R-5E0 30-95
REMOVAL AND INSTALLATION TRANSMISSION
19 -Assemble the washer (6) and lock ring (5). 21 -Assemble gear (4) taking care to orientate the shelf
facing the clutch and bearing (3).
Use tool F16.
4 3
6
RKZC5080
assembly.
The clutch plate lock ring must be all the way up
against the lock ring.
Use a feeler gauge to measure the distance between
the clutch plate lock ring and the first clutch plate (11).
11
RKZC4631
30-96 WB97R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
4 5
3
22 -Try to rotate the 2nd speed gear. The 2nd speed gear
must turn freely on the input shaft.
Apply compressed air of approximately 6 bar to the
F15
2nd speed gear clutch passage.
Hear the 2nd speed gear piston moving to lock the
2nd speed gear clutch pack. Try to move the 2nd
speed gear. The 2nd speed gear must not turn on the
input shaft.
If the clutch does not work correctly, disassemble the
clutch to find the problem.
1 3 Screw: 50 Nm
2
RKZC5100
28
24 -Lift the three shafts B-C-E at the same time and insert 29
into the half-housing. Use tool F15. RKZC4770
WB97R-5E0 30-97
REMOVAL AND INSTALLATION TRANSMISSION
8. AXIS C
8.1 Disassembly
8 9 29 31
6 7 28
27
5 26
4 25 45
3 30 44
24
2
1 23
43
42
20 41
19 22
17 40
15
14 39
13
38 57
12
21 37 55
10
18
16 36
35 53
34 51 58
33 56
49
11 47
52 54
50
48
32 46 RKZ11300
1 -Remove screws (59) and protection (60). 2 -Lift the three shafts B-C-E, at the same time B-C-E.
Use tool F15.
F15
59
60
RKZC4771
RKZC4780
30-98 WB97R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
3 -By means of an extractor remove bearing (58). 7 -Remove snap ring (38).
38
58
RKZC5110 RKZC5150
4 -Remove the spacer (57). 8 -Remove the thrust plate (39) by means of two
screwdrivers.
57 39
RKZC5120
RKZC5160
5 -Remove the gear (54) with its inner parts.
9 -Remove clutch kit (40).
40
54
RKZC5130
RKZC5170
6 -Overturn the group. Push down the thrust plate (39).
10 -Push down the thrust washer (42) to allow lock ring
removal (41). Use the special tool F9.
39
41
RKZC5140
RKZC5180
WB97R-5E0 30-99
REMOVAL AND INSTALLATION TRANSMISSION
11 -Loosen the handles of the threaded rods to release 14 -If to be replaced, remove teflon seal ring (45) and
the tension from the spring. relevantimer O-ring from outer seat of piston (44).
Remove the top piece of the F9 special tool.
F9
45
RKZC5220
RKZC5190
17
53
RKZC5230
RKZC5800
46
50
44
37
RKZC5210 RKZC5240
30-100 WB97R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
17 -Check the condition of removed parts (46), (47), 20 -Remove gear (35).
(50), (55) and (56).
47 50
56 35
46 55 RKZC5280
RKZC5250
50
52 RKZC5290
48
RKZC5260 22 -Remove spacer (31).
51
49
RKZC5300
RKZC5270
WB97R-5E0 30-101
REMOVAL AND INSTALLATION TRANSMISSION
23 -Push down the counterdisk (33) to set free the lock 26 -Remove clutch kit (32).
ring (34).
32
33 34
RKZC5340
RKZC5310
34
22
RKZC5350
RKZC5320
33 F9
29
RKZC4303
RKZC5330
30-102 WB97R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
29 -Remove snap ring (30). 32 -Extract clutch piston (26) from its seat by blowing in
compressed air through the delivery hole.
30
RKZC4312
RKZC5370
27
F9
26
RKZC5380
RKZC4301
29
25 24
22
RKZC5360
RKZC4351
WB97R-5E0 30-103
REMOVAL AND INSTALLATION TRANSMISSION
35 -Overturn the shaft (23). Cut and remove the seal 39 -Remove roller retainers (7) and washer (8).
rings (16), (17), (18) and (19).
16
7
17
8
18
19
RKZC5430
RKZC5390
21
RKZC5440
RKZC5400
41 -Push down the thrust plate (5) to set free the lock ring
37 -Remove spacer (2). (4).
2 4 5
RKZC5410 RKZC5311
RKZC5420 RKZC5321
30-104 WB97R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
43 -Remove the thrust plate (5) by means of two 46 -Remove snap ring (9).
screwdrivers.
RKZC4313
RKZC5331
6 F9
RKZC5341
RKZC4301
45 -Lower the spring (11) lock washer (10). Use tool F9.
48 -Remove the lock ring (9), the thrust washer (10) and
spring (11).
F9
10 9
10
11
RKZC4304
RKZC5361
WB97R-5E0 30-105
REMOVAL AND INSTALLATION TRANSMISSION
49 -Extract clutch piston (13) from its seat by blowing in areas, pitting, and other damage.
compressed air through the delivery hole. Use new parts as required.
RKZC5370 RKZC4420
50 -Remove the bush (12) and clutch piston (13). 53 -If the clutch discs are to be used again, keep the
clutch packs in the same previous assembly order
separate and record which clutch pack goes with
12 each clutch.
13 A
RKZC5381
14
15
RKZC5450
52 -Check:
- the sealing ring grooves (large and small) for wear
and damage if necessary.
- on the output shaft for wear and damage.
- the oil passages in the output shaft for restrictions or
foreing matter.
- the ball bearings and the needle bearings for flat
30-106 WB97R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
54
RKZC4442
WB97R-5E0 30-107
REMOVAL AND INSTALLATION TRANSMISSION
3 -Assemble new teflon ring (45) with relative O-ring on 6 -Lower the spring (43) lock washer (42).
clutch piston (44). Use tool F9.
F9
44
42 43
45
RKZC5480 RKZC5191
4 -Apply a thin film of grease on the outer edge and in 7 -Insert snap ring (41).
the inner part of clutch piston (44) and assemble in
gear (54).
a Ensure that the snap ring (41) is well fitted.
44 41
54
RKZC5180
RKZC5490
41
42
43
F9
RKZC5500
RKZC5510
30-108 WB97R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
9 -Insert clutch kit (40) and thrust plate (39) into the gear 12 -Assemble new teflon ring (25) and relevant inner O-
(54). ring, new teflon ring (24) and relevant inner O-rings
respectively into the piston (26) outer and inner
seats.
39
26
40
54 25 24
RKZC5520
correctly seated.
13 -Apply a thin film of grease on the sealing rings just
inserted.
38
RKZC5150
assembly.
The clutch plate lock ring must be all the way up 14 -Insert clutch piston (26) with special tool F10 as
against the lock ring. protection of seal rings (24).
Use a feeler gauge to measure the distance between
the clutch plate lock ring and the first clutch plate (40).
RKZC4481
40
RKZC5530
WB97R-5E0 30-109
REMOVAL AND INSTALLATION TRANSMISSION
27
30
RKZC4951
RKZC4312
16 -Assemble spring (28) and retainer washer (29).
F9
28
RKZC5540
F9
29
22
RKZC4303
RKZC5550
30-110 WB97R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
21 -Insert the thrust washer (31) into the shaft (23). 24 -Insert the roller bearing (36) and thrust plate (33).
Apply a thin film of grease under washer (31) to avoid
its falling when overturning the shaft.
31
36
33
RKZC5600
34
31
22 RKZC5610
23
32
34
A
33
32
RKZC4912 RKZC5620
WB97R-5E0 30-111
REMOVAL AND INSTALLATION TRANSMISSION
27 -Measure the clutch discs clearance for each clutch 30 -Assemble the gear assembly (54) on main shaft (23).
assembly.
The clutch plate lock ring must be all the way up
against the lock ring. 54
Use a feeler gauge to measure the distance between
the clutch plate lock ring and the first clutch plate (32).
RKZC5640
46
32 F2
RKZC4632
RKZC5650
50
RKZC5280
52
48
37 RKZC5260
23
RKZC5630
30-112 WB97R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
33 -Install new sealing rings (49) and (51) to bushing (50) 36 -Assemble the spacer (57).
using tools F22, F23 and F24. Carry out steps 29 to
34 in section "6.2 Assembly" to install.
57
RKZC5120
RKZ11310
37 -Assemble bearing (58). Use tool F2.
50 58
RKZC5680
13
55
F2
14 15
56
RKZC4353
RKZC5670
WB97R-5E0 30-113
REMOVAL AND INSTALLATION TRANSMISSION
39 -Apply a thin film of grease on the sealing rings just 42 -Assemble spring (11) and washer (10).
inserted.
10
11
RKZC4321
RKZC4470
43 -Lower the spring (11) lock washer (10). Use tool F9.
40 -Insert the clutch piston (13) with the special tool F10
as protection of seal rings (15).
F9
10
13
F10
RKZC4304
12
RKZC4313
RKZC4331
30-114 WB97R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
45 -Loosen the handles of the threaded rods to release 48 -Assemble thrust plate (5).
the tension from the spring.
Remove the top piece of the F9 special tool.
F9
5
RKZC5570
4
21
RKZC5690
23
6
4
5
RKZC4913 RKZC5051
WB97R-5E0 30-115
REMOVAL AND INSTALLATION TRANSMISSION
51 -Measure the clutch discs clearance for each clutch 54 -Assemble the thrust washer (2).
assembly.
The clutch plate lock ring must be all the way up
against the lock ring.
Use a feeler gauge to measure the distance between
the clutch plate lock ring and the first clutch plate (6).
RKZC5710
6
F2
RKZC4633
RKZC5720
F5
RKZC5430
3 RKZC4681
RKZC5700
30-116 WB97R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
9
8
4 5 6
7
1 2 3 10
11
RKZ11330
WB97R-5E0 30-117
REMOVAL AND INSTALLATION TRANSMISSION
57 -Verify that all the gears can freely rotate on the main 58 -Hook the three shafts B-C-E using the special tool
shaft. F15. Lift the shafts B-C-E at the same time and insert
Apply compressed air of approximately 6 bar to the the unit into the half-housing. Use tool F15.
1st speed gear clutch passage.
Hear the 1st speed gear piston moving to lock the 1st
speed gear clutch pack. Try to move the 1st speed
F15
gear. The 1st speed gear must not turn on the input
shaft.
If the clutch does not work correctly, disassemble the
clutch to find the problem.
Apply compressed air of approximately 6 bar to the
3rd speed gear clutch passage.
Hear the 3rd speed gear piston moving to lock the 3rd
speed gear clutch pack. Try to move the 3rd speed
gear. The 3rd speed gear must not turn on the input
shaft. RKZC4780
3 Screw: 50 Nm
4th speed gear clutch passage.
Hear the 4th speed gear piston moving to lock the 4th
speed gear clutch pack. Try to move the 4th speed
gear. The 4th speed gear must not turn on the input
shaft.
If the clutch does not work correctly, disassemble the
clutch to find the problem.
59
60
RKZC4771
30-118 WB97R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
9. AXIS E
9.1 Disassembly
5
18
E 4 13 17
3
2 16
1
15
E
14
12 23
11 22
10 21
9 20
7 19
8
RKZ11340
1 - Remove screws (24) and protection (25). 2 - Lift the three shafts B-C-E at the same time.
Use tool F15.
F15
24
25
RKZC4772
RKZC4780
WB97R-5E0 30-119
REMOVAL AND INSTALLATION TRANSMISSION
19
23
22 RKZC5760
RKZC5730
7 -Overturn the shaft (12).
Press the Belleville washers (5) and remove
4 -By neans of an extractor, remove bearings (21) and
retaining ring (2).
(1). Remove spacer (20).
Use tool F25.
F25
20
1 21 5
12
RKZC5740
2
RKZC5770
18
3
4
RKZC5750
RKZC5780
30-120 WB97R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
9 -Remove the Belleville washers (5) and spacer (6). 12 -Remove brake counter disk (14).
5
14
RKZC5790 RKZC5820
10 -Remove snap ring (17). 13 -Extract piston (8) using pins (10) as pusher.
17
RKZC5800 RKZC5830
11 -Remove the thrust plate (16) and clutch kit (15). 14 -Remove the O-rings, inner (7) and outer (9).
RKZC5810
9
RKZC5840
WB97R-5E0 30-121
REMOVAL AND INSTALLATION TRANSMISSION
10
10
10 11
RKZC4431
11
18 -Inspect the bore of the shaft in the input shaft housing
RKZC5850
for damage that will cause leakage when the clucth is
assembled.
16 -If the clutch discs are to be used again, keep the
Check the slots in the side of the input shaft housing
clutch packs in the same previous assembly order
for damage from the tangs on the steel discs.
separate and record which clutch pack goes with
Use new parts as required during assembly.
each clutch.
30-122 WB97R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
9.2 Assembly
1 -Insert inner (7) and outer (9) O-rings on clutch piston 4 -Apply a thin film of grease on O-Rings and position
(8). the pins on clutch piston (8) in correspondence with
the holes on output shaft.
7 8
9
RKZC5840
RKZC5870
10
10
10 11
11 12
RKZC5850
14
10
RKZC5860
12
RKZC5890
WB97R-5E0 30-123
REMOVAL AND INSTALLATION TRANSMISSION
7 -Mount the clutch kit (15) starting with a drive plate (A) 11 -Assemble roller bearing (19) and spacer (20).
followed by a clutch plate (B).
B
20
19
RKZC5940
RKZC5900
F2
21
16
RKZC5950
RKZC5910
17
12
RKZC5920 RKZC5960
10 -Assemble gear (18). 14 -Preassemble spacer (6), washer (4) and lock ring (2).
18
6
RKZC5930 RKZC5970
30-124 WB97R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
15 -Using a thickness gauge measure quote X between 18 -Insert Belleville washer (5).
washer (4) and lock ring (2).
a Check the Belleville washer (5) orientation.
Subtract from quote X fixed quote S1 (S1=1.80mm).
The result S is the thickness of shims (3) which has to
be inser to between washer (4) and locking (2).
S=X-S1=X-1.80mm
5
5
2
X
6 RKZC6000
RKZC6010
F25
RKZ11360
2
4 RKZC5771
RKZC5990
WB97R-5E0 30-125
REMOVAL AND INSTALLATION TRANSMISSION
21 -Assemble bearing (1) using tool F16. 24 -In order to verify the seal of rings (7) and (9) feed the
piston chamber with oil at 10 bar and check with a dial
gauge located as shown in the photo if the real stroke
is included between 1.7 and 1.9 mm.
F16
RKZC6020
F5
RKZC4681
F4
RKZC6030
30-126 WB97R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
1
4
1.7 1.9
RKZ11370
3 Screw: 50 Nm
Listen to hear the piston moving to unlock the clutch
pack. The belleville washers compressing.
Try to move the 4WD gear.
The 4WD gear must turn freely on the 4WD shaft.
If the clutches do not work correctly, disassemble the
clutches to find the problem.
26 -Lift the three shafts B-C-E at the same time and insert
into the half-housing. Use tool F15.
F15
24
25
RKZC4772
RKZC4780
WB97R-5E0 30-127
REMOVAL AND INSTALLATION CONVERTOR
CONVERTOR
Removal Installation
k Lower the working equipment completely until it
rests on the ground.
Stop the engine and remove the ignition key.
A
k Eliminate all residual pressure from all circuits by
moving the hydraulic controls in all directions.
3 -Remove the converter (1). [*1] a To aid in mating flywheel and joint, before mating
engine and transmission, tighten a threaded shank
“A” as guide to the joint:
RKZC1840
30-128 WB97R-5E0
REMOVAL AND INSTALLATION ENGINE
ENGINE
Removal 4 -Disconnect the heating system hoses (3) and (4) and
remove the tie strap (5) retaining the gearbox oil
1 -Remove: hoses.
• ENGINE HOOD
• FRONT GUARD a Cap pipes, hoses and holes to prevent
• FRONT COUNTERWEIGHT contamination.
• RADIATOR GROUP - INTERCOOLER
• CONDENSER
• MUFFLER
• AIR FILTER
3
• PISTON PUMP
• TRANSMISSION
For details, see the individual removal procedures.
2 -Disconnect the fuel inlet and return pipes (1) and (2), 4
release them from the tie straps and position them
aside.
1
2
8
6
RKZC2860
7
3 -Remove the screws and release the straps (1) and
RKZC2890
(2) retaining the heating system hoses.
Only if equipped
11
2 RKZC2870
10
9
RKZC2900
WB97R-5E0 30-129
REMOVAL AND INSTALLATION ENGINE
17
18
9
16
12 RKZC2910
RKTA0811
14
13
20
19
21
RKZC9820
RKZC2930
15 23
22
RKZC2920
RKTA0801
30-130 WB97R-5E0
REMOVAL AND INSTALLATION ENGINE
13 -Release the entire engine harness from the tie straps 17 -Loosen and remove nuts (25), screws (26) and
and route the harness down, and use some straps on vibration dampers (27) from front engine mounts. [*1]
the inner sides of the frame to let the wiring hang
18 -Remove the engine (28).
temporarily.
4 Engine: approx. 370 kg
27
25
26
28
RKZC9830
RKZC2980
14 -Check to ensure that all hoses to the engine are
released from straps or ties.
Installation
15 -Tighten a revolving lifting eye “A” to the muffler inner
• To install, reverse removal procedure.
mounting hole.
[*1]
3 Nuts: 200 Nm
A a Check transmission oil level before starting the
engine.
RKZC2960
28 A
24
RKZC2970
WB97R-5E0 30-131
REMOVAL AND INSTALLATION CONTROL VALVE
CONTROL VALVE
Removal 6 -Loosen the clamp (4) on the control valve support
1 -Swing the boom at a full 90° to access the rear of the frame (5) (4 screws).
machine.
2 -Lower the outriggers to the ground. Curl the bucket
and allow it to rest on the ground on its back as shown
4
in the illustration.
Apply the parking brakes and stop the engine.
3 -Release all residual pressure.
(For details see "20 TESTING AND
ADJUSTMENTS").
5
RKZC1922
6
7
RKZC1980
RKA53840
5 -Take out the screws (2) and remove the platform (3).
3
RKZC1970
30-132 WB97R-5E0
REMOVAL AND INSTALLATION CONTROL VALVE
8 -Disconnect upper servocontrol hoses (8) and 11 -Support control valve (13) by means of two ropes
actuator hoses (9) from control valve. connected to a lift arm to be introduced through the
cab opening.
a Check that all the hoses are marked and note
Apply a slight tension to the ropes.
down the bends and routing patterns.
a Pay special attention to rope routing to prevent
a Cap pipes, hoses and holes to prevent
damaging the unions.
contamination.
8 8
RKZC6550
10 4
RKZC1981
11
RKA53850
12
RKZC1951
WB97R-5E0 30-133
REMOVAL AND INSTALLATION CONTROL VALVE
Installation
• To install, reverse removal procedure.
[*1]
a Install control valve from top.
1 -Start the machine to circulate the oil; check to ensure
that there are no leaks.
2 -Bleed the air from the working equipment circuits.
(For details see "20 TESTING AND
ADJUSTMENTS").
3 -Stop the engine, check the hydraulic oil level and top
up as necessary.
30-134 WB97R-5E0
REMOVAL AND INSTALLATION FRONT AXLE
FRONT AXLE
Removal 7 -If equipped, remove the front counterweight. [*1]
1- Start the engine and force the shovel downwards in 4 Counterweight: 372 kg
order to raise the machine and the front wheels.
8 -Remove the front wheels. [*2]
4 Wheel: 65 kg
2 -Place two stands “A” and some blocks beneath the
chassis.
9 -Remove front cardan shaft protection (3).
RKZC2000
RKA53821
3 -Slowly lower the machine onto the blocks, checking
that the wheels remain at least 5 cm above the 10 -Disconnect the cardan shaft (4) from the axle. [*3]
ground.
RKZC2011
RKZC0772
WB97R-5E0 30-135
REMOVAL AND INSTALLATION FRONT AXLE
13 -Position a jack “B” and some blocks “C” beneath the Installation
axle (8). Raise the jack until the blocks can be forced
under the axle arms. • To install, reverse removal procedure.
14 -Take out the nut and remove the retaining screw (9)
1 -Check the oil level in the tank and start the engine.
of the axle oscillation pin (10).
2 -Perform a few complete steering manoeuvres in both
15 -Tighten a hammer puller into the central hole of the
directions to bleed the air from the steering circuit.
axle oscillation pin (10); pull out the axle oscillation
pin. [*5]
10
RKZC2031
30-136 WB97R-5E0
REMOVAL AND INSTALLATION FRONT AXLE
21 10
9
20
8
19
18
6
17
16 7
11
15 12
13 14
5
4
3
2
1
RKZ09810
1 -Unloose the guide rod (2) locknut (1) of some turns till 2 -Loosen the nuts (4) and (9) and remove the tie rods
it is over the end of the threaded pin. (3) and (10).
Beat on the nut (1) with a hammer in order to disjoin
3 -Remove the fastening screws (6) of the cylinder, then
the guide rod (2) from the swivel housing (3).
take the cylinder (7) out of its housing using a rubber
a Don’t beat on the end of the threaded pin. hammer.
a This is a destructive operation for the nut (1). a Remove only those parts that need to be
overhauled and/or replaced.
3
4
7
6
2
1 4
3 5
5
RKZB5581
RKZ07111
4 -Detach the cylinder head (15) from the cylinder case 5 -Recover all sealing rings (16) and (18), O-rings (14)
(19). and (20), and scrapers (21) and (13) from cylinder
Remove off the cylinder head and the rod (17) from body (19) and rod (17).
the cylinder case (19).
WB97R-5E0 30-137
REMOVAL AND INSTALLATION FRONT AXLE
19 4
7
17
20 21 6
14 15 4
13 18 5
16 5
RKZ07121 RKZ07111
17 6
20 21
14 15
13 18
7
16
RKZ07121
(19).
6 -Align the swivel housing with the axle (parallel wheel
hub).
Screw the guide rod (5) so that the ball joint can be
inserted into the swivel housing arm.
19
a It is important to unscrew the locking nut (9) to
carry out this operation.
17
10
RKZB0093
11
3 -Install ball joints (5) and (8), nuts (4) and (9) and tie
rods (3) and (10) at the rod (17) ends and tighten.
RKZB1163
30-138 WB97R-5E0
REMOVAL AND INSTALLATION FRONT AXLE
7 -Insert the ball joint (8) (into its own housing on the 2- Using a measuring tape, measure the distance in
swivel housing. mm “M” from the farthest bar ends, and tighten or
Assemble and tighten the lock nut (1) with loosen the guide rods until the distance is the same
dynamometric wrench. on both sides.
2 3
1
RKZB1173
RKZB1200
9 -Screw in the lock nuts (4) and (9) of the tie rods (3)
and (10) only when the toe-in adjustment has been
carried out.
Toe-in adjustment
1 -Put two equal one-meter-long linear bars “A” on the
wheel sides and lock them with two nuts on the wheel
hub stud bolt.
50 cm 50 cm
RKZB1190
WB97R-5E0 30-139
REMOVAL AND INSTALLATION FRONT AXLE
3 -Check that the difference of the measurements 5 -Once adjustment is complete, tighten the retaining
between the wheel hubs diameters ends is within the nuts on the guide tie rods.
3 Nuts: 250 Nm
requested tolerance range.
The nominal toe-in (A) value is referred to the
external diameter of the wheel hubs flange, therefore
the measured toe-in value (M) at the bars ends must
be related to the ratio between length of the bar and
flange diameter.
nominal toe-in = A –0 2 mm
measured toe-in = M –0 5 mm
A -0 2 mm
RKZB1221
M
A
RKZ09820
RKZB1230
4- If toe-in is incorrect, operate with two wrenches on 2 -Adjust a goniometer to the angle of 65° and position it
the guide rods screwing in and out the two joint tie on the long bar.
rods equally till the toe-in is within the required Move a wheel side till it forms, with the two bars, the
tolerance. angle fixed by the goniometer.
RKZB1210 RKZB1240
30-140 WB97R-5E0
REMOVAL AND INSTALLATION FRONT AXLE
RKZB1251
WB97R-5E0 30-141
REMOVAL AND INSTALLATION FRONT AXLE
7
6
9
3
8
10
2
1
RKZ09830
k Before draining the oil, position the epicyclic 1 -Remove the fastening screws (1).
reduction gear (3) with the plug (2) on the upper part
and loosen it of some turns in order to eliminate any
possible inner pressure, then remove it completely.
Turn the hub upside-down till the hole is in the lowest
point.
Drain the oil completely.
2 1
3
RKZC0600
RKZB0102
30-142 WB97R-5E0
REMOVAL AND INSTALLATION FRONT AXLE
2.2 Assembly
8
7
RKZC0610
condition.
4 -Remove the thrust washers (8). 2 - Insert the needles (5) and (7) into the gears (6).
a With new planetary gears is advisable to a Grease well the needles (5) and (7).
assembly new roller bearings.
Insert the gears (6) with assembled needles in the
planetary carrier pins.
8
7
7 5
RKZ09840
6
RKZC0620
9
8
RKZ09850
WB97R-5E0 30-143
REMOVAL AND INSTALLATION FRONT AXLE
RKZC0600
RKZB0102
30-144 WB97R-5E0
REMOVAL AND INSTALLATION FRONT AXLE
19 27
18
14
13 26
11 23
12
22 25
10
15
7
4 21
20
16
3
9 17
1
8
6
2 5
RKZ09860
k Before disassembling the wheel hub, it is advisable 2 -Remove the lock ring (1) from the double U-Joint
to secure it with a belt or a rope on a hoist or any other shaft and collect the washers (2), (3).
supporting device, in order to avoid its accidental fall
that could damage either the operator or the wheel
hub group.
1
1 -Insert a lever between the swivel housing (14) and
the axle beam and fit it into the double U-Joint.
With the lever push the double U-Joint in the direction
of the wheel hub to allow the lock ring (1) removal.
RKZB0133
RKZC0630
WB97R-5E0 30-145
REMOVAL AND INSTALLATION FRONT AXLE
3 -Unscrew and remove the fastening screws (5) from 8 -Remove the hub (11), using levers and a hammer to
the wheel carrier (7) group. facilitate the operation.
7 5
11
RKZB0141
RKZB0172
4 -In order to remove the wheel carrier group (7) from its
housing, screw (5) at least two of the just removed
9 -Position on a flat surface the hub and take the seal
screws in the threaded extraction holes.
ring out (13) with a lever.
5 -Extract and remove the hub-lock ring gear (7)
a This is a destructive operation for the seal ring.
together with the epicyclic ring gear (4).
10 -Take the bearing cups out (9) and (12), on both sides
of the hub, using a hammer and a suitable tool to be
beaten.
7
11 -Remove the bearing cone (12) from the swivel
5 housing using a suitable, commercially available
puller.
5
5 12
RKZB0152
9
6 -Remove the stop ring (4) and disjoin the hub-lock 13
ring gear (7) from the epicyclic ring gear (3).
4
RKZC0640
30-146 WB97R-5E0
REMOVAL AND INSTALLATION FRONT AXLE
12 -Unscrew and remove the fastening screws (19) from 3.2 Assembly
the upper (18) and (17) lower (16) king pin.
19
D2 D3
22 23
18
14
16
RKZB5621 RKZB1013
14 -Remove the swivel housing (14) from the axle beam 3 -Position the lower king pin (16) on a workbench and
and from the shaft (24). assemble the cone of the spherical joint (15) with the
special tool D4 under a press. Grease well the king
pin housings with grease ASL800050.
4 -Position the Belleville washers (25) and (27) on the
king pin housings (16) and (18).
14
27
15
24
16
RKZB0212
16 -Turn the swivel housing (14) and take the bush (22)
out, using a driver and a hammer.
14
23
22
RKZB5631
WB97R-5E0 30-147
REMOVAL AND INSTALLATION FRONT AXLE
5 -Secure the swivel housing (7) group with a rope. 8 -Position the wheel hub (11) on a workbench and
Lubricate the seal ring lip and protect the splined end force both cups of the taper roller bearings (9) e (12)
of the axle shaft by winding it with thin adhesive tape in position with the special tool D5 under a press or
to avoid damage to the seal ring. After assembly, with a hammer.
remove completely the adhesive tape. Assemble the
9 -Insert the seal ring (13) into the wheel hub (11) with
swivel housing on the axle beam.
the special tool D6 and a hammer.
6 -Assemble the two king pins, the upper (16) and the
lower (18), and tighten the retaining screws (17) and
(19). 12 13
9
3 Screw: 190 Nm
a Make sure that the Belleville washers (25) and
(27) remain in their position.
D5 D6
18 D5 11
RKZB1424
A = 5.900-5.905 mm
B = 52.229-52.279 mm
C = 23.072-23.173 mm
RKZB1433
9 12
C A C
RKZ05743
30-148 WB97R-5E0
REMOVAL AND INSTALLATION FRONT AXLE
12 -Position the wheel carrier (7) on a workbench and 15 -Force all the hub dowel bushes completely with the
force the bushes (6) to the carrier surface level with special tool D1 and a hammer.
the special tool D1. Assemble the wheel carrier (7) fastening screws (5)
At least two bushes (diametrically-opposed) should and tighten.
3 Screw: 120 Nm
be set slightly higher than the carrier surface level to
be used as dowel pins.
7
5
6
7
RKZB1443
RKZB1093
16 -Install washers (2) and (3) to the axle shaft and install
13 -Preassemble the wheel carrier - (7) epicyclic ring
the stop ring (1) by pushing it from the end of the
gear group (7) and (4) with the special locking ring (8)
serrated hub to its seat while counteracting with a
shown in figure.
lever inserted between beam and swivel housing and
engaged onto the double U joint.
4
1
7
RKZ05733
RKZB0133
14 -Assemble the wheel carrier group on the wheel hub
using the two projecting bushes (6) as dowel pins.
Screw the relative screws (5) in order to put in contact
the ring bevel gear with the wheel hub.
RKZB1103
WB97R-5E0 30-149
REMOVAL AND INSTALLATION FRONT AXLE
7
8
1
2
8
7 4 5
RKZ09880
1 -Remove the U-Joint (6) from the axle beam (1). 2 -Take the seal ring (5) out of the axle (1) beam with a
lever.
4
RKZC0650
5
5
RKZC0660
30-150 WB97R-5E0
REMOVAL AND INSTALLATION FRONT AXLE
4 -Extract the upper bushings (2) and cup (3) from the 4.2 Assembly
king pin housings.
1 -Using tool D7 and a hammer, install bushing (2) and
a Examine the bushing and housing before cup (3).
removal and replace depending on wear
a To make installation easier, allow the bushings and
conditions.
cups to cool in liquid nitrogen at less than -100°C.
2
2 D7
2
1 D7
3
3
RKZ09890
3
RKZC0670
5 -Take the seal ring (7) out of the axle (1) beam with a
2 -Assemble the bush (4) on the axle beam with the
suitable tool.
special tool D9 and a hammer.
a This is a destructive operation for the seal rings.
3 -Assemble the seal ring (5) on the beam with the
Only if necessary, remove the bushings with a special tool D10 and a hammer.
standard three-gripping point extractor or a suitable Fill 3/4 of the seal ring cavity with grease ASL800050.
driver and a hammer.
4 5
7
8 1
8
RKZ09910
7
4 -Lubricate the bush (5) and the seal ring lip (6). Insert
RKZ09900
the U-Joint (7) inside the axle beam.
RKZC0650
WB97R-5E0 30-151
REMOVAL AND INSTALLATION FRONT AXLE
8 1
8
7
RKZ09900
30-152 WB97R-5E0
REMOVAL AND INSTALLATION FRONT AXLE
5. Differential support
5.1 Disassembly
6
12
5 7 11 14
10
13
4
3
1
RKZ09920
1 -Loosen and remove the screws (2) on the differential 2 -Loosen and remove the screws (6) to remove the two
support (1). Remove the differential support (1) from ring nut retainers (5).
the axle beam (14).
14
RKZ09940
2 1
RKZ09930
WB97R-5E0 30-153
REMOVAL AND INSTALLATION FRONT AXLE
4 4
RKZ09950
4 -Unscrew the adjuster ring nuts (3), (7) using tool D12
and a wrench. 1
RKZ09980
7 3 5.2 Assembly
1 -Position the complete differential box (13), with the
outer cups (4) of the tapered roller bearings already
assembled, on the differential carrier (1).
4
11 4
10
13
RKZ09990
9
RKZ09970
30-154 WB97R-5E0
REMOVAL AND INSTALLATION FRONT AXLE
10
A
9
RKZ09970
0.18 -0.28 mm
7 3
Adjust by operating the ring nuts (3), (7) by means of
tool D12.
D12 RKZ09960
RKZ09951
WB97R-5E0 30-155
REMOVAL AND INSTALLATION FRONT AXLE
6 -If the measured backlash is lesser than the given 8 -Once pinion/ring gear backlash is determined,
tolerance range, screw the ring nut (7) from the side measure total bearing preload (T) (pinion/ring gear
opposite to the ring gear and unscrew (3) the system) using a force gauge with the cable wound
opposite one of the same measure. around the splined pinion end. The reading should be
within the following values:
6a -If the measured backlash is higher than the given
tolerance range, screw the ring nut (3) from the side T= (P + 3. 7 5) – (P + 5. 7 5) da N
of the ring gear and unscrew the opposite (7) one of w here P is t h e e f f e c t iv e ly me a s u r e d p in i o n
the same measure. preloading
(For details, see "6. Differential group")
13
RKZ10100
b b
a a
RKZ10010
30-156 WB97R-5E0
REMOVAL AND INSTALLATION FRONT AXLE
10 -When all adjustments are complete, install the ring 12 -Before matching surfaces, make sure that they are
nut retainers (5) and their respective screws (6), perfectly clean, degrease and clean them with
and tighten to the specified torque. appropriate detergents.
3 Screw: 266 Nm
Spread a film of adhesive on the contact surface
between the axle beam (14) and the differential
carrier (1).
6 2 Loctite: 510
6
5 a check that two dowel pins (12), (8) are in their
5 seats.
RKZ09940
14
3 Screw: 266 Nm
12
RKZ10040
10
RKZ10030
14
2 1
RKZ09930
WB97R-5E0 30-157
REMOVAL AND INSTALLATION FRONT AXLE
RKZ10070
RKZ10050
OK Z
RKZ10060
30-158 WB97R-5E0
REMOVAL AND INSTALLATION FRONT AXLE
6. Differential group
6.1 Disassembly
7 4 1
6
3
5
9
11
13 8
10
12
RKZ10080
1 -Pry the cover (13) away from the differential 2 -Remove the seal rings (12) and (11) from the cover
support using a lever. (13).
11
13 13
RKZ10100
12
RKZ10110
WB97R-5E0 30-159
REMOVAL AND INSTALLATION FRONT AXLE
3
D14
7
10
D15 8
RKZ10180
RKZ10170
4 -Remove the ring nut (10) and collect its retaining 7 -To remove bearing inner ring (3) from bevel pinion
washer (9). (1), use a commercially available grip puller.
Recover bearing inner ring (3) and the shim (2)
under it.
9
10 2
1
RKZ10120
5 -Tap the shaft with a soft hammer to remove the bevel RKZ10190
pinion (1).
8 -Check all pinion components for wear.
a Take care not to drop the bevel pinion (1).
a The ring nut (10) and the snap spacer (5) must be
Recover washers (4) and (6), collapsible spacer (5)
replaced when reassembling the unit.
and bearing cone (8).
5
5
10
1
6
4 RKZ10200
RKZ10090
30-160 WB97R-5E0
REMOVAL AND INSTALLATION FRONT AXLE
6.2 Assembly
1 -Place differential support (7) on a work bench. 4 -Install tool D18, D19 to bearing seats in differential
Force bearing outer rings (3) and (8) into it using support (7) and retain with halfbridles.
special tool D16 and a hammer.
D18 D19
3
7
8
RKZ10220
RKZ10180
D18 D19
D19 X
D18
D17
10 RKZ10210
RKZ10230
V
8
10 3
RKZ10130
RKZ10150
WB97R-5E0 30-161
REMOVAL AND INSTALLATION FRONT AXLE
7 -Pick the (S) shim (2) from the range of shims 9 -Install the selected shim (2) to the pinion shaft (1) with
available. the chamfer facing the gear.
Force bearing (3) onto the pinion shaft (1) using a
SHIM RANGE press and driver D20, and ensure that the bearing is
Shims 2.5 2.6 2.7 2.8 2.9 3.0 3.1 3.2 3.3 3.4 fully locked into position.
Install shims (4) and (6), and a new collapsible
spacer (5).
3 6
5 4
2
1
RKZ10160
1
8 -Remove special tool D18, D19 from differential
RKZ10240
support.
Remove ring nut (10), false pinion, and bearing
10 -Install preassembled bevel pinion group (1) to the
cones (3) and (8).
differential support (7), and install bearing inner ring
(8) to pinion end as shown.
To force bearing (8), use driver D20 and a hammer.
7
a Oppose a resistance to the striking force (e.g. a
sledge hammer).
8 8
10 3
RKZ10130
1
6
4
RKZ10090
30-162 WB97R-5E0
REMOVAL AND INSTALLATION FRONT AXLE
11 -Insert a ring nut washer (9) and screw a new lock ring 13 -Measure preload P of tapered bearings (3) and (8)
nut (10) on the pinion end. using a force gauge with the string wound around the
splined end of pinion (1).
Adjustment is carried out by gradually increasing the
tightening torque of the ring nut (10), paying attention
not to overtighten.
RKZ10120
12 -Screw the ring nut in (10), using the wrench for ring
nut D14 and for pinion retainer D15.
10
D14
10
D15
RKZC0680
RKZ10170
WB97R-5E0 30-163
REMOVAL AND INSTALLATION FRONT AXLE
11
13
12
RKZ10110
13
RKZ10100
30-164 WB97R-5E0
REMOVAL AND INSTALLATION FRONT AXLE
11
1 7
2
5 9
4 10
4
8
2
7
6
3
RKZ14580
1 Lock the differential in a clamp. 4 -Disassemble the differential box in two half boxes
(3), (10) complete with the relevant components.
2 -Unscrew all the fastening screws (1) on ring bevel
gear (11). a Scribble some match marks before separating
the two half housings.
a This will make both differential half boxes (3),
(10) free, so take care not to drop the internal 5 -Recover the components from both half boxes.
components.
6 -Check the operating and wear conditions of the
3 -Remove the bevel gear crown (11). components.
11 3
10
1
RKZ14590
RKZB0571
WB97R-5E0 30-165
REMOVAL AND INSTALLATION FRONT AXLE
7 -Take the bearing (2) out of the differential half box (3) 3 -Position the ring bevel gear (3) and then fix the whole
e (10), using two levers or a three-hold extractor. by tightening the screws (4).
3 Screw: 95 Nm
10 2
RKZ14600
7.2 Assembly
RKZB1291
1 -Assemble the cones of the new taper roller bearings
(2) on the half boxes (3), (10) using the special tool
D13 and a hammer.
3
2
10 2
RKZ14600
3
10
RKZ14590
30-166 WB97R-5E0
REMOVAL AND INSTALLATION REAR AXLE
Removal
1 -Place the backhoe bucket with its back on the ground
while holding the arm in the upright position.
RKZC2050
2 -Lower the shovel to the ground as well. 7 -Disconnect cable (3) from parking brake (4). [*2]
RKZC2070
RKZC2130
3 -Lower backhoe outriggers (1) and force them 8 -Disconnect differential lock hose (5).
downwards in order to raise rear wheels (2) by a Cap the hose and hole to prevent contamination.
approximately 5 cm.
4 -Prepare a safety stand “A” approximately 65 cm
high, beneath the backhoe chassis. Pull up the
outriggers until the machine is resting on the stand
“A”.
5
RKZC2080
1
RKA53960
WB97R-5E0 30-167
REMOVAL AND INSTALLATION REAR AXLE
9 -Disconnect service brake pipes (7) from axle (6). [*3] 13 -Lower the jack until the axle (6) is disengaged from
the chassis.
a Disconnect pipes (7) from hoses (8); loosen and
remove clamp (9) and pipes (7). 14 -Extract the entire axle.
8
7
11 11
6
7 RKZC2120
RKZC2090
Installation
10 -Disconnect the cardan shaft (10) from the rear axle.
[*4] • To install, reverse removal procedure.
[*1]
[*3]
RKA53970
30-168 WB97R-5E0
REMOVAL AND INSTALLATION REAR AXLE
10
9
5 3
2
6
12
11
4
1
7
RKZ08460
1 -Loosen nut (1) (n°2). 2 -Loosen and remove the screws (2) (n°2).
2
3
1
RKZB7100
RKZB7110
4 -Remove the snap ring (4) and the input flange (5).
WB97R-5E0 30-169
REMOVAL AND INSTALLATION REAR AXLE
1.2 Assembly
1 -Introduce a new seal (10) into in the central body
5 7 using special tool E1.
11
4
10
6
RKZ08470
11
9
8
RKZ08480
2 O-ring: ASL800050
11
5 7
RKZ08490
RKZ08470
5 -Position the brake caliper (3) on the flange disc (9). a Be careful to avoid damaging the brake pads.
30-170 WB97R-5E0
REMOVAL AND INSTALLATION REAR AXLE
3 9
RKZB7120
6 -Screw in the bolts (2) and tighten the nuts (1) to the
prescribed torque.
3 Nuts: 115 Nm
3 Screw: 45 Nm
1±0.5 mm
2 2 RKZ08520
WB97R-5E0 30-171
REMOVAL AND INSTALLATION REAR AXLE
1.3 Maintenance
10
5
18 2
3 6
4
20
18
11 9 19
16
13 8
15
1
17
12
RKZ08530
1 -Insert mounting bolts through sleeves (9) and thread Ball and Cam Replacement
brake mounting locking nuts as far as possible on
1 -Remove both Adjustment Locking Nuts (12, 13),
mounting bolts. This is not required if brake assembly
Thrust, stainless steel and Hardened Washer (1, 16,
comes with the sleeve/bolt sub-assy. Position the
17), Lever (11), and Boot (3) from Adjustment Bolt
brake over disc align with mounting holes in
(2).
mounting bracket.
2 -Remove outer cam (4) and Ball Assembly (8) from
2 -Thread mounting bolts (9) into mounting bracket,
Adjustment Bolt (2).
adjusting bolts until a 0.5 – 1.5 mm exists between
the Sleeves and the Locking Nuts. Tighten the 3 -Use a screwdriver, or similar tool, to gently pry inner
Locking Nuts to 115 Nm of torque against the Cam (4) protrusions on back of cam, loose from
bracket. Torque Plate (5), and remove from Adjustment Bolt
(2). Remove Seal (15) from Adjustment Bolt (2).
3 -Refer to Adjustment Procedure to set backlash of
installed brake assembly. 4 - Install new Seal (15) on Adjusting Bolt (2), inserting
through inner Cam (4) until Seal (15) bottoms out on
Brake pad looseness adjustment procedure Torque plate.
1 -Loosen adjustment nuts (12, 13). a We recommend lubricating the cams' thrust
surfaces before installing the cams (4).
2 Cam surface: ASL800050
2 -Tighten inner Adjustment Nut (12) until firm contact is
made with the disc by the linings. Torque to 13–14
Nm. 5 -Install new Cam (4) on Adjustment Bolt (2), taking
Ensure that the control lever is in the brake apply care to orient protrusions into Holes in Torque Plates
position. (5).
3 -Back off inner Adjustment nut (12) 4 to 6 faces and
6 -Install Ball Assembly (8) onto Adjusting Bolt (2),
check that disc is free to move.
orienting balls into pockets of Inner Cam (4). Install
4 -Tighten outer Locking Nut (13) against inner outer Cam (4) onto Adjustment Bolt (2), orienting
Adjustment Nut (12) to lock Adjustment Bolt (2) in pockets onto Balls of Balls Assembly (8). Install boot
place. Tighten at 61 -74 Nm. (3) over cam assembly.
30-172 WB97R-5E0
REMOVAL AND INSTALLATION REAR AXLE
7 -Install Lever (1), using protrusions on back of outer Sleeve seal replacement
Cam (4) and holes in Lever (1) to orient lever to
proper operating position. 1 -Loosen the two locking nuts on the mounting bolts
and remove the mounting bolt/sleeve assembly (9)
8 -Install remaining washer and nuts and follow from the brake.
adjustment procedure at paragraph 1.2.
2 -Insert sleeve seals (18) between the torque (5, 7) and
a Check to ensure that the coated side of shim (11)
align with the sleeve bores.
is oriented towards the steel washer (17).
a Lubricate the mounting bolt/sleeve fit before
Lining Replacement installing
1 -Loosen two adjustment Locking Nuts (12, 13) 2 Bushings: ASL800050.
enough to remove each Torque Plate (5, 7) away
from disc far enough to provide backlash to remove 3 -Install the mounting bolt / sleeve assembly through
old carrier and lining assemblies and install new the front pad support (5), the sleeve seals (18) and
ones. (It may be necessary to remove one or both the rear pad support (7).
Nuts)
4 -Mount brake per paragraph 1.1 and adjust per
2 -Collapse the two Lining retraction Springs (10) and section 1.2.
remove them from brake Head Assembly.
Replacing the cable attachment bracket
3 -Remove Torque Plates (5, 7) away from disc, move
Carrier and Lining Assemblies (6) out of pockets, and 1 -Remove the screws (19) of the bracket (20) from pad
remove from the Brake Head Assembly from the support (5).
side. Remove the bracket (20).
4 -Before installing new pads, it is necessary to 2 -Position the bracket (20) in correspondence with the
introduce grease between bushings (9) and pad threaded holes of the pad support (5).
supports (5, 7). Fix the bracket (20) to the front torque plate (5) with
2 Bushings: ASL800050
the appropriate screws (19).
3 Screw: 63 Nm
a Once grease has been applied, slide the
supports onto the bushings so as to distribute
grease evenly.
5 -Install new Carrier and Lining Assemblies (6) in each
Torque Plate (5, 7).
WB97R-5E0 30-173
REMOVAL AND INSTALLATION REAR AXLE
11
12 8 10
9 16
13 17
14 3
15
18
19
2 4
5
6
5
6 RKZ08540
1 -Drain the oil completely from the differential. 2 -Remove all but two of the cap screws (1).
2 Differential oil: approx. 15 l
RKZB7140
RKZB7130
30-174 WB97R-5E0
REMOVAL AND INSTALLATION REAR AXLE
3 -Connect the hub (2) to a lifting device and tension the 6 -Stand the hub up, mark the reaction plat (5) that was
rope. against the axle housing (3). Remove the reaction (6)
and brake disks (5) and pins (7).
a insert two dowel rod to enable removal.
a Check friction plate and brake separator
thickness. For details, see ("40MAINTENANCE
STANDARD")
3
2 RKZB7150
RKZB7170
2
3
2 RKZB7150
5 -Slowly pull hub (2) away from axle and the half shaft
(4), make sure that brake disks (5) and plates (6) stay
with the hub.
RKZB7180
RKZB7160
10
RKZB7190
9 -Check to ensure that screws (8) and Belleville a If brake discs are being replaced, replace screws
washers (9) are not damaged. and washers with the new kit.
WB97R-5E0 30-175
REMOVAL AND INSTALLATION REAR AXLE
14
RKZB7200
10- Remove the lock ring (11) and remove the self
adjuster (12).
RKZB7230
11
10
12
RKZB7210
12 E2 10
13
E2
RKZB7220
15
RKZB7250
30-176 WB97R-5E0
REMOVAL AND INSTALLATION REAR AXLE
15 -Remove O-rings (16) and (17) from the brake piston 2.2 Assembly
(10).
1 -Install a new O-Ring (19) onto hub (2).
16
17
19
10
RKZB7260
RKZB7280
18
18
15
RKZB7270
15
RKZB7290
16
17
19
10
RKZB7260
RKZB7280
WB97R-5E0 30-177
REMOVAL AND INSTALLATION REAR AXLE
4 - Lubricate O-rings (16), (17) and (18), and install 7 -Place bushing (14) inside calibrated ring E2 with the
complete piston (15) to brake cylinder (10) chamfer facing upwards.
2 O-ring: ASL800050
Place pin E2 into brake adjuster (14).
17
14
E2
E2 14
15
16
10 RKZB7330
RKZB7300
7 13
RKZB7340
2
RKZB7310
9 -Using driverE2, push the rings (13) until solid contact
against calibrated ring E2 is obtained.
6 -Install the complete brake cylinder (10) and remove
a Repeat procedure for the remaining 2 self adjust.
pins (7).
E2 13
10 RKZB7350
RKZB7320
30-178 WB97R-5E0
REMOVAL AND INSTALLATION REAR AXLE
10 -Insert the adjuster (12) into the brake piston, make 13 - Install Belleville washers (9) to screws (8) taking care
sure that the chaffered side is up. to orient them as shown in the previous illustration.
9
14
12
RKZB7360 RKZB7380
11 -Install the snap rings (11) into the self adjuster bore. 14 -Mount the shouldered bolts (8) and spring washers
(9) and tighten to the requested torque
3 Screw: 16 Nm
a Check to ensure that spring ring teeth are facing
the self adjust kit as shown in the following
illustration.
11
RKZB7390
RKZB7211
15 -Put the half shaft (4) and brake separator plate pins
12 -Snap ring (11) orientation and Belleville washers (9). (7) into the axle housing.
9 11
7
RKZ08550
RKZB7400
WB97R-5E0 30-179
REMOVAL AND INSTALLATION REAR AXLE
16 -Using the reference mark made during disassembly, 19 -Attach lifting equipment to hub assembly (2) and
place the inner brake separator plate (5) into the axle guide onto the axle (3).
housing (3).
a Use a piece of rope and lift and rotate the half
shaft while pushing the hub onto the axle.
3
5 RKZB7410
4
17 - Place the inner brake disk (6) and the second brake
2 RKZB7430
separator (5).
20 -Install screws (1) tighten to the required torque
3 Screw: 226 Nm
each differential) in oil at least 24 hours prior to
installation.
5 RKZB7440
18 -Place the outer brake disk (6) and make sure the RKZB7140
6
RKZB7420
RKZB7130
30-180 WB97R-5E0
REMOVAL AND INSTALLATION REAR AXLE
3. Wheel hub
3.1 Disassembly
8
14
11
13
12
10
2
1
3
4
5
RKZ08560
1 -Loosen the screws (1). 2 -Mark side gears (2), retaining washer (3) and
indexed washer (4).
a Replace screw with a new set.
6 2
1
RKZB7460
RKZB7450
WB97R-5E0 30-181
REMOVAL AND INSTALLATION REAR AXLE
3 -Remove screws (1), retaining washer (3) and 6 -Locate the snap ring (6) slot and open it while raising
indexed washer (4). the planetary carrier (5).
6
1
3 5
RKZB7470 RKZB7500
4 -Mark the mounting position of retaining washer (3) 7 -Only if necessary: only if necessary, remove from the
and indexed washer (4) on the planetary carrier (5). planetary carrier (5) the side gears (2) and their
related rollers (7) (n° 66 per gear).
7
5
2
RKZB7480
5 8
E4
RKZB7490
RKZB7520
30-182 WB97R-5E0
REMOVAL AND INSTALLATION REAR AXLE
10
12
9
9
RKZB7530
9
13
11
RKZB7540
11 9 14
10
RKZB7550
RKZB7580
WB97R-5E0 30-183
REMOVAL AND INSTALLATION REAR AXLE
15 -Using an angle grinder, cut the cage and etch the 3 -Install spacer (14) on wheel flange (10
bearing ring (13).
Use a chisel to cut and remove bearing inner race
(13).
14
10
10
13
RKZB7580
9
E6
10
12
RKZB7541
10
11
13
RKZB7610
RKZB7590
30-184 WB97R-5E0
REMOVAL AND INSTALLATION REAR AXLE
6 -Using spanner E4, tighten ring nut (8) to the required 9 -Attach lifting equipment to planetary carrier (5) and
torque. lower into hub (9).
9
E4
8
RKZB7650
RKZB7620
10 -During installation the locking ears of the planetary
carrier (5) must engage the ring nut (8) as shown in
7 -Apply a light coat of Lithium based grease to the
figure and in next one.
planetary carrier (5) stud to hold the needle bearings
(7) (n° 33) in place.
5
7
RKZB7660
RKZB7630
7
2
RKZ08570
RKZB7640
WB97R-5E0 30-185
REMOVAL AND INSTALLATION REAR AXLE
12 -Open the snap ring (6) and slowly lower the planetary
carrier (5).
5
RKZB7500
3
RKZB7470
30-186 WB97R-5E0
REMOVAL AND INSTALLATION REAR AXLE
6 9
7
1 4
3 5
8
1
RKZ08460
1 -Drain the oil completely from the differential. 2 -Remove the all screws (1).
RKZB7670
RKZB7130
WB97R-5E0 30-187
REMOVAL AND INSTALLATION REAR AXLE
3 -Separate from axle (2) the differential housing (3) 6 -Use the tool E7, unscrew the adjuster ring nuts (5) e
using pry bars in slots. (6).
E7
3
2
5
RKZB7680 RKZB7710
4 -Attach lifting eyes to differential housing (3) and 7 -Remove out the differential case (7). The external
remove it. rings (8) and (9) are removed together with the
differential housing.
RKZB7690
5 -Remove the bolts (4) securing the ring nuts (5) and
(6). 7
RKZB7720
4.2 Assembly
1 -Using driver E8, install bearing outer races (8) and (9)
4 to differential housing (7).
5
E8
RKZB7700
8
RKZB7730
30-188 WB97R-5E0
REMOVAL AND INSTALLATION REAR AXLE
E7
RKZB7750
5 6
RKZ08590
RKZB7740
WB97R-5E0 30-189
REMOVAL AND INSTALLATION REAR AXLE
7 -Repeat the whole sequence of the above mentioned 9 -If the reading is not within the requested range,
operations till the indicated conditions are reached. thoroughly check the assembly of each component
and operate the adjuster ring nuts (5) and (6) of the
differential support:
a - if total preload is less than the specified value,
tighten the adjuster ring nuts (5) and (6) by the
same amount, while keeping the pinion/ring gear
backlash value unchanged;
b - if total preload is greater than the specified
value, loosen the adjuster ring nuts (5) and (6) by
the same amount, while keeping the pinion/ring
gear backlash value unchanged;
RKZB7740
E9
RKZB7760
RKZ14610
30-190 WB97R-5E0
REMOVAL AND INSTALLATION REAR AXLE
3 Screw: 10Nm
teeth surfaces will be regular.
Z - Excessive contact on the tooth tip:
Approach the pinion to the ring bevel gear and
then move the ring bevel gear away from the
pinion in order to adjust the backlash.
X - Excessive contact at the tooth base: 4
Move the pinion away from the ring bevel gear
and then approach the ring bevel gear to the
pinion in order to adjust the backlash.
Z 5
OK
RKZB7700
12 -Movements to correct:
1 - move the pinion for type X contact adjustment.
2 - move the pinion for type Z contact adjustment.
RKZB7770
3
2
RKZB7691
WB97R-5E0 30-191
REMOVAL AND INSTALLATION REAR AXLE
3 Screw: 169 Nm
17 -Refill the hydraulic oil.
RKZB7670
30-192 WB97R-5E0
REMOVAL AND INSTALLATION REAR AXLE
9
10
5
4 1
12
2
11
6
3
8
13
7
RKZ08620
1 -Loose plug (1) but do not remove it. 2 -Hold the differential lock fork (2) down to catch a
block inside of the housing, remove the plug (1).
1
RKZB7780
RKZB7790
WB97R-5E0 30-193
REMOVAL AND INSTALLATION REAR AXLE
3 -Pull the differential lock fork (2) up, place a flat piece 6 -Remove the spring (4).
of steel under the shaft (3) to keep it from moving
down.
RKZB7830
3
RKZB7800 7 -Remove the shaft (3) from differential housing.
RKZB7840
8 -Remove the fork (2), spring (7) and bushing (8) from
RKZB7810 the shaft (3).
2 8 7
3
RKZB7850
RKZB7820
30-194 WB97R-5E0
REMOVAL AND INSTALLATION REAR AXLE
9 -Remove O-Ring (9) from plug (1) and O-rings (11) 3 -Insert in the differential housing the shaft (3)
and (12) from the piston (10). complete.
10 11
12
1 3
9
RKZB7860 RKZB7840
10 11
12
1
9 RKZB7830
8 6
13
2 3 8 7
RKZB7820
RKZB7870
WB97R-5E0 30-195
REMOVAL AND INSTALLATION REAR AXLE
6 -Pull the differential lock fork (2) up, place a flat piece 9 -Tighten plug (1) to the requested torque.
3 Plug: 180 Nm
of steel under the shaft (3) to keep it from moving
down.
3 RKZB7780
RKZB7800
RKZB7810
RKZB7790
30-196 WB97R-5E0
REMOVAL AND INSTALLATION REAR AXLE
6. Differential
6.1 Disassembly
11 2
17
3
16
10
9
13
21 20 22
10 9
18
8 23 25
7 24
5 9
4 10
1 18 21
19 20
14
6 15
RKZ08630
1 -If differential bearings are to be replaced, remove 2 -Remove snap ring (4).
bearing outer rings (1) and (2).
Remove sleeve (3).
1 4
RKZB7900
RKZB7890
WB97R-5E0 30-197
REMOVAL AND INSTALLATION REAR AXLE
5 7
RKZB7910 10
11
8
12
RKZB7920
8 -Push the pin (13) towards the flat surface side (14).
9
13
14
RKZB7930
RKZB7960
30-198 WB97R-5E0
REMOVAL AND INSTALLATION REAR AXLE
15
18
18
14
20
21
RKZB7970
10 -Push the pin (13) out of the housing and remove the RKZB8000
13
16 17
22 23
RKZB7980
11 -Push the short spider pins (18) out of the spacer (19) RKZB8010
19
18 25
18
24
RKZB7990
RKZB8020
WB97R-5E0 30-199
REMOVAL AND INSTALLATION REAR AXLE
6.2 Assembly 4 -Lubricate and install planetary gear (20) and its
respective thrust washer (21) and introduce the pins
1 -Install and lubricate new O-rings (26) on the pins
(18) forward enough to support them.
(25).
26
25
18
18
20
21
RKZB8030
RKZB8000
19
24 18
18
RKZB8020
24
3 -Lubricate and install sun gear (22) and thrust washer
(23).
a Orient pin (13) with the flats on the pin facing up.
2 Gear and pin: differential oil
22 23
RKZB8010 13
16 17
RKZB7980
30-200 WB97R-5E0
REMOVAL AND INSTALLATION REAR AXLE
7 -Lubricate and install the planetary gear (14) and 10 -Install the planetary gear (8).
thrust washer (15) and introduce the pin (13). Orient
the hole so as to align with the hole on the differential
housing (24).
15
8
24
14 RKZB7920
5 7
11
RKZB7910
12
RKZB8040
3 Caps: 25 Nm
5
RKZB8050
RKZB7930
WB97R-5E0 30-201
REMOVAL AND INSTALLATION REAR AXLE
RKZB7901
22
RKZB7891
15 -Install bearing outer rings (1) and (2) using driver E8.
E8
1
RKZB8070
30-202 WB97R-5E0
REMOVAL AND INSTALLATION REAR AXLE
7. Differential group
7.1 Disassembly
8
9
10
6
7
2
1
5
RKZ08640
1 -Fit the differential carrier (1) in a vise. 2 -Remove the ring nut (1) and collect its retaining
Unscrew the lock nut (1) using special tools E9 - E10. washer (2).
E9 2 1
RKZB8080
E10
RKZB7751
WB97R-5E0 30-203
REMOVAL AND INSTALLATION REAR AXLE
3 -Tap the shaft with a soft hammer to remove the bevel 6 -Check all pinion components for wear.
pinion (3).
a The ring nut (1) and the snap spacer (6) must be
a Take care not to drop the bevel pinion (3). replaced.
3 5
1
4
6
7
RKZ08660
5 RKZ08650
7.2 Assembly
1 -Place the differential support (9) on a workbench.
4 -Remove bearing outer rings (7) and (8) from Introduce bearing outer rings (7) and (8) using
differential support (9) using a driver and a hammer. special tools E11 - E12 and a hammer.
E11
8
9
9 7
RKZB8090 RKZB8110
5 -To remove bearing inner ring (8) from bevel pinion 2 -Insert inner rings (7) and (8) in their housings.
(3), use a commercially available grip puller. Assemble the false pinion E13 and its ring nut (1).
Recover bearing inner ring (8) and the shim (10) Tighten without exceeding the ring nut, till the
under it. backlash is eliminated.
8
3
9
7
E13
8 1
10
RKZ08670
RKZB8100
30-204 WB97R-5E0
REMOVAL AND INSTALLATION REAR AXLE
3 -Install special tool E14 to the differential group 6 -In order to determine the necessary thickness value
supports (9). (S) between the pinion and the bearing, subtract the
value (V), stamped on the pinion head (V=requested
distance), from the measured value (X).
S = (X–V) mm
E14
RKZB8120
SHIM RANGE
Shims 2.5 2.6 2.7 2.8 2.9 3.0 3.1 3.2 3.3 3.4
9 RKZB8130
RKZB8150
C
X
A
B
RKZ08680
WB97R-5E0 30-205
REMOVAL AND INSTALLATION REAR AXLE
8 -Remove the special tool E14 to the differential group 11 -Install bearing outer ring (7) to pinion end.
supports (9). To install bearing (8), use special tool E3 and a
Remove the ring nut (10), the false pinion E13 and hammer.
the bearing cones (7) and (8).
8
7
9
7
E13
1
RKZB8180
RKZ08670
12 -Insert a ring nut washer (2) and screw a new lock ring
9 -Select a suitable shim (10) and install with the nut (1) on the pinion end.
chamfer facing the gear, then install bearing inner
ring (8) to pinion (3) with the help of a press and tool
E3, and check to ensure that it fits snugly in place.
2 1
10
3 RKZB8080
RKZB8160
4
6
5
RKZB8170
30-206 WB97R-5E0
REMOVAL AND INSTALLATION REAR AXLE
13 -Screw the ring nut in (1), using the wrench for ring nut 15 -Once you got the requested preloading value, caulk
E10 and for pinion retainer E9. the ring nut (1).
E9 RKZB8200
E10
RKZB7751
RKZB8190
WB97R-5E0 30-207
REMOVAL AND INSTALLATION SHOVEL PPC VALVE
5 RKZC2140
6 4
RKZC2130
6
1 -Remove four screws (1) and remove PPC valve and
parking brake casing (2).
RKZC2150
Installation
1 • To install, reverse removal procedure.
[*1]
1
contamination.
P1
2
T
T
4
P4
RKZ10761
30-208 WB97R-5E0
REMOVAL AND INSTALLATION SHOVEL LIFT CYLINDERS
on the ground; apply the parking brake, and stop the a Do not engage the piston return hose with the
engine. sling.
1 -Introduce non-slip blocks “A” between the shovel 5 -Extract pin (6) to expose piston eye and safety rod
dump tie bar (1) and the spacer (2) of the fulcrum (9).
lever (3) on removal side. 6 -Remove rod.
3
A 8
1
10
RKZC2160
B
2 -Take off the snap-ring (4) and the internal retaining RKZC2190
4 Cylinder: approx. 46 kg
RKZC2170
8
9
11
8 13
RKZC2200
7
6
RKZC2180
WB97R-5E0 30-209
REMOVAL AND INSTALLATION SHOVEL LIFT CYLINDERS
Installation
• To install, reverse removal procedure.
[*1]
30-210 WB97R-5E0
REMOVAL AND INSTALLATION SHOVEL DUMP CYLINDERS
apply the parking brake, and stop the engine. a Cap the hoses and holes to prevent
contamination.
1 -Remove the strap retaining the piston return hose
(1).
RKZC2210
RKZC2260
8 9
10 7
RKZC2240
WB97R-5E0 30-211
REMOVAL AND INSTALLATION SHOVEL DUMP CYLINDERS
[*1]
a After bleeding the air, check the oil level in the tank.
Machines equipped with return-to-dig only
30-212 WB97R-5E0
REMOVAL AND INSTALLATION SHOVEL
SHOVEL
Removal 3 -Take out the screws (4) and remove the pins (5) of the
but without forcing it downwards. 4 -Start the engine and put the machine into reverse
gear in order to disengage the boom (6).
4 Shovel: 436 kg
1 -Stop the engine and release residual pressures.
5
RKZC2130
RKZA1471
2 -Take out the screws (1) and remove the pins (2) of the
lever (3). Installation
Rest the lever (3) on the boom. [*1] [*2]
• To install, reverse removal procedure.
[*1]
3 [*2]
RKZA1461
WB97R-5E0 30-213
REMOVAL AND INSTALLATION FRONT WORKING EQUIPMENT
RKZC2270
A
RKZC2191
3 -Open the front hood and take out the screws (2) that 5
lock the axle oscillation pins (3) of the boom (4).
Close the front hood.
RKZC2300
30-214 WB97R-5E0
REMOVAL AND INSTALLATION FRONT WORKING EQUIPMENT
6 -Start the engine and put the machine into reverse Installation
gear travel until the boom is disengaged.
• To install, reverse the removal procedure, if
a If the working equipment is to be detached while
necessary using the front towing hook.
the engine or gearshift is out of order and the
machine cannot travel automatically, it can be [*1]
a After bleeding the air, check the oil level in the tank.
WB97R-5E0 30-215
REMOVAL AND INSTALLATION BACKHOE PPC VALVES
4
3
RKZC9860
RKA53860
7 RKZC9850
1
9 -Remove the PPC valve (8).
1
8
RKZC9840
a Cap pipes, hoses and holes to prevent • To install, reverse removal procedure.
contamination. a Carefully inspect the hoses for the proper
position when connecting them.
(For de ta ils, see "1 0 STRUCTURE AND
FUNCTION").
30-216 WB97R-5E0
REMOVAL AND INSTALLATION PPC VALVE SUPPORT RELEASE CABLES
5 6
4
RKZC9890
RKA53860
7 -Using a screwdriver, raise the lever (8) and
disengage the pawl (9).
2 -Remove the rear mat (1).
8 -Disengage the support (10) coating (4).
10
8 4
7
RKZC9880
9
3 -Loosen and remove the four screws (2) with their RKZC9900
11
RKZC9841
RKZC9910
5 -Loosen the nut (5) and tighten fully the tensioner (6).
[*1]
WB97R-5E0 30-217
REMOVAL AND INSTALLATION PPC VALVE SUPPORT RELEASE CABLES
Installation
• To install, reverse removal procedure.
3 Nut: 4.5 Nm
RKZC9891
30-218 WB97R-5E0
REMOVAL AND INSTALLATION PPC VALVE SUPPORT RETURN GAS SPRING
5 6
4
RKZC9890
RKA53860
7 -Using a screwdriver, raise the lever (8) and
disengage the pawl (9).
2 -Remove the rear mat (1).
8 -Disengage the support (10) coating (9).
1
10
8 4
7
9
RKZC9880
RKZC9900
2 11
11
3
2
RKZC9920
RKZC9841
5 -Loosen the nut (5) and tighten fully the tensioner (6).
[*1]
WB97R-5E0 30-219
REMOVAL AND INSTALLATION PPC VALVE SUPPORT RETURN GAS SPRING
[*1]
2 Pin: Grease GL2
12
RKZC9930
30-220 WB97R-5E0
REMOVAL AND INSTALLATION SOLENOID VALVE GROUP (servocontrol and optional attachment)
4
RKA53860
Installation
2
• To install, reverse removal procedure.
RKZC1031
RKZC9941
WB97R-5E0 30-221
REMOVAL AND INSTALLATION BACKHOE BOOM CYLINDER
1
RKZC2350
3
2 7 -Remove snap rings (8), shims (9), and levers (5).
A 8
9
RKA53870
11
6
10
5
RKZC2370
RKZC2340
30-222 WB97R-5E0
REMOVAL AND INSTALLATION BACKHOE BOOM CYLINDER
12
14
B 13
RKZC2410
4 Cylinder: 87.5 kg
a Do not engage the hoses with the band.
11 -Pull out pin (13) and recover spacers (14). [*1] [*2]
16
14
12
15
13 RKZC2420
RKZC6440
Installation
12 -Start the engine and retract the piston.
Stop the engine and release residual pressures. • To install, reverse removal procedure.
[*2]
RKZC2400
a After bleeding the air, check the oil level in the tank.
WB97R-5E0 30-223
REMOVAL AND INSTALLATION ARM CYLINDER
ARM CYLINDER
Removal
1 -Fully extend the arm (1) and fully open the bucket (2).
Manoeuvre the boom until the outer end of the boom 7 6
is in a level position. 8
2 -Place and force a jack stand “A” and a non-slip block 5
under the boom.
1 RKZC2440
RKA53870
4 11
4 -Lower the outriggers to the ground, apply the parking
brake, and stop the engine. 10
4
10 -Pull out the piston attachment pin (9). [*1] [*2]
RKZC6450
30-224 WB97R-5E0
REMOVAL AND INSTALLATION ARM CYLINDER
11 -Pull out the cylinder attachment pin (7) until the eye of Installation
cylinder (4) is exposed. [*1] [*2]
• To install, reverse removal procedure.
12 -Remove cylinder (4) and recover shims (if any).
4 Arm cylinders: 67 kg
[*1]
a After bleeding the air, check the oil level in the tank.
RKZC2470
WB97R-5E0 30-225
REMOVAL AND INSTALLATION JIG ARM CYLINDER
9 7
1 RKZA7951
4
10 -Remove cylinder (3).
2 Installation
• To install, reverse removal procedure.
[*1]
A
k When aligning the positions between the hole and
B RKZA7931
the pin, turn the engine over at low idling speed.
Do not insert fingers into the holes to check
2 -Place a sling around the cylinder (3). alignment.
3 -Take off the snap ring and remove the pin (4). [*1] [*2] [*2]
a After bleeding the air, check the oil level in the tank.
RKZA7941
9 -Remove the screws (11) and the pin (12). [*1] [*2]
30-226 WB97R-5E0
REMOVAL AND INSTALLATION OUTRIGGER CYLINDER
OUTRIGGER CYLINDER
Removal 6 -Sling the outrigger cylinder (6) and remove the
2
RKA53910
RKA53920
RKA53890
8 -Remove bolt (9) and extract pin (10)
5
4
RKA53980
RKA53900
WB97R-5E0 30-227
REMOVAL AND INSTALLATION OUTRIGGER CYLINDER
[*1]
[*2]
a After bleeding the air, check the oil level in the tank.
RKA53990
30-228 WB97R-5E0
REMOVAL AND INSTALLATION OUTRIGGER ARMS
OUTRIGGER ARMS
Removal Installation
k Before removing outrigger arms, the outrigger • To install, reverse removal procedure.
RKA54000
RKA54010
RKA54020
WB97R-5E0 30-229
REMOVAL AND INSTALLATION BACKHOE SWING CYLINDERS
RKZC2560
RKA53930
5
1
RKZC2570
6 RKZC2580
RKZC2550
30-230 WB97R-5E0
REMOVAL AND INSTALLATION BACKHOE SWING CYLINDERS
7 -Take out the screws (8) and remove the pins (9). 2 -Connect the four tubes (7) to the cylinders.
8 -Rotate the cylinders to disengage the piston heads 3 -Start the engine and swing the boom in order to
from the swing bracket (10) and remove the cylinders center one of two pins (9). Secure the 1st pin with the
(6). screw (8).
4 Cylinder: approx. 34 kg
Perform the same operation for the other pin.
9
9 8
8
10 RKZC2591
RKZC2590
[*2]
[*3]
7
6 RKZC2551
[*1]
WB97R-5E0 30-231
REMOVAL AND INSTALLATION BACKHOE BUCKET CYLINDER
1 6
3
2
RKZC2620
9
4
RKZC2630
RKZC2610
30-232 WB97R-5E0
REMOVAL AND INSTALLATION BACKHOE BUCKET CYLINDER
1 -Start the engine and bleed the air from the cylinders.
11 -Remove cylinder (4). (For details, see "20 TESTING AND
a After bleeding the air, check the oil level in the tank.
WB97R-5E0 30-233
REMOVAL AND INSTALLATION BACKHOE BOOM SAFETY CYLINDER
1 -Fully extend the arm (1) and fully open the bucket (2).
Manoeuvre the boom until the outer end of the boom
is in a level position. 8
8 7
2 -Place and force a jack stand “A” and a non-slip block
under the boom.
Lower arm (3) until bucket teeth touch the ground.
3
RKZC2640
2
6 -Disconnect feed hose (9).
RKZC2650
6 Installation
4
• To install, reverse removal procedure.
30-234 WB97R-5E0
REMOVAL AND INSTALLATION CYLINDER
CYLINDER
SHOVEL ARM, SHOVEL, BOOM, ARM, BUCKET, OUTRIGGERS
Disassembly
1 -Position cylinder to be disassembled (1) to
equipment U1.
4 3
2 -Using wrench U2 with torque amplifier, fully unscrew
the head (2).
U1
U2 2 1 U3
U1 RKZ11440
3
U1
5a
RKZ11620
WB97R-5E0 30-235
REMOVAL AND INSTALLATION CYLINDER
10
U6 U7
18 15
RKZ11600
All cylinders
18
2 -Using tool U7, install scraper ring (15) and snap ring
12
(14).
17
3 -Assemble seals (16) and (17).
17
16
13
14
15
RKZ11510
30-236 WB97R-5E0
REMOVAL AND INSTALLATION CYLINDER
1 –Using tool U4 expand seal (11) and fit it on the piston. a Arm cylinder only.
Check orientation of brake bushing (5a).
2 -Calibrate seal (11) using calibrator U5.
5a 5
U5
U4 11
11
6 RKZ11610
RKZ11530
4 6 2
RKZ11470 U1
9 8
7
RKZ11630
WB97R-5E0 30-237
REMOVAL AND INSTALLATION CYLINDER
4 -Install safety dowel (19) and tighten until snug. Final assembly
2 Dowel: Loctite 542 1 -Lubricate piston seals (5) and head gaskets (2) and
introduce piston into cylinder (1).
4 5 2
U1
RKZ11641
U3
3 -When assembly is complete, plug union fitting holes
to prevent contamination.
RKZ11442
30-238 WB97R-5E0
REMOVAL AND INSTALLATION CYLINDER
1 -Position cylinder (1) to equipment U1. a If removal is awkward, tighten screw until snug
and work thread with a tap.
2 -Using wrench U2 with torque amplifier, fully unscrew
the head (2).
4
U2 2 1
U1
4
RKZ11450
RKZ11420
6 -Using a wrench U8, remove the complete piston (6).
3 -Extract the complete piston (3). a If no U8 tool is used, drill 4 holes ( Ø 10) and
loosen the complete piston.
a Place a receptacle to collect the oil.
3 U8
U1 4
DH
RKZ11490
RKZ11430
3
5
U1
6
2
RKZ11480
RKZ11540
WB97R-5E0 30-239
REMOVAL AND INSTALLATION CYLINDER
8 -Remove guide ring (7), seal (8), O-ring (9) and their Assembly
respective anti-extrusion rings from piston.
a Lubricate surfaces to prevent damage to the
gaskets, seals, O-rings, scraper, etc.
U6 U7
19 16
RKZ11650
18
17
14
15
16
RKZ11511
30-240 WB97R-5E0
REMOVAL AND INSTALLATION CYLINDER
2 -Calibrate seal (8) using calibrator U5. 2 -Remove any existing dirt from the rod and install the
head (2).
U5
U4
8
2 5 6
8
U1
RKZ11531
RKZ11541
8 7 H
U8
5
9
6
RKZ11550
12 11 10 RKZ11500
3b -With new parts:
a - Thread the piston (6) in, ensure it contacts the
rod (5), and then tighten.
3 Piston: 297±27.4 Nm
5
RKZ11560
WB97R-5E0 30-241
REMOVAL AND INSTALLATION CYLINDER
RKZ11570
Final assembly
1 -Lubricate piston seal (6) and head gasket (2) and
introduce piston into cylinder (1).
3 Head: 785±78.5 Nm
a When assembly is complete, plug cylinder union
fittings to prevent contamination.
U2 2 1
U1
RKZ11420
30-242 WB97R-5E0
REMOVAL AND INSTALLATION BACKHOE WORKING EQUIPMENT
3
2
RKZC2411
6 6
6
RKA54030
B
RKZC2701
WB97R-5E0 30-243
REMOVAL AND INSTALLATION BACKHOE WORKING EQUIPMENT
9 -Disconnect hoses (9) from bucket cylinder. 13 -Start the engine, draw in the outriggers and move the
machine forward.
a Cap pipes, hoses and holes to prevent
contamination. a Recover the shims between boom and swing
bracket.
a Mark the pipes to avoid exchanging them during
installation. 4 Backhoe working equipment
with standard arm: 850 kg
9 Installation
9
• To install, reverse removal procedure.
1 -Start the engine and bleed the air from all circuits.
(For details, see "20 TESTING AND
ADJUSTMENTS").
RKZC2680
C
RKZC6490
10
11
RKZC2700
30-244 WB97R-5E0
REMOVAL AND INSTALLATION BACKHOE BUCKET
BACKHOE BUCKET
Removal Installation
k Place the bucket on a level surface, resting on its • To install, reverse removal procedure.
back.
[*1]
4 Bucket: 158 kg
[*2]
7
4
6
2
5
1
3
RKZA1350
WB97R-5E0 30-245
REMOVAL AND INSTALLATION BACKHOE BOOM
BACKHOE BOOM
Removal 7 -Take out the retaining screw and remove the pin (3).
[*1] [*2]
1 -Remove the arm cylinder.
(For details see "ARM CYLINDER"). a Recover the shims (4) between boom and swing
bracket.
2 -Remove the arm.
(For details see "ARM").
4 Boom: 248 kg
Installation
1 • To install, reverse removal procedure.
1 1
[*1]
RKA53940
k When aligning the positions between the hole and
the pin, turn the engine over at low idling speed.
6 -Hook the boom (2). Do not insert fingers into the holes to check
alignment.
[*2]
a After bleeding the air, check the oil level in the tank.
RKA54040
30-246 WB97R-5E0
REMOVAL AND INSTALLATION ARM
ARM
Removal
1 -Remove the bucket.
8 5
(For details see "BACKHOE BUCKET").
3 -Take out the lock nut (2), and the washer and remove
the pin (3) and the links (4). [*1] [*2]
A
4
RKZC2730
11 -Take out the screws (9) and remove the pin (10). [*1]
1 [*2]
3
a Recover the shims.
12 -Remove the arm (8).
RKZA1360
10
4 -Start the engine, bring the arm into a vertical position
and lower it to the ground. 8 9
7
RKZC2740
6 5 Installation
• To install, reverse removal procedure.
[*1]
7 -Start the engine and retract the piston completely. 2 Internal bushing: ASL800050
8 -Rest cylinder (5) on a block “A” and disconnect from a Tighten the locknut completely, then release it half a
the hoisting device. turn.
[*3]
WB97R-5E0 30-247
REMOVAL AND INSTALLATION JIG ARM
JIG ARM
Removal Installation
1 -Remove the bucket. • To install, reverse removal procedure.
(For details see "BACKHOE BUCKET").
[*1]
1
3
RKZA1360
4 -Disconnect the jig arm hoses (5) and (6), the bucket
cylinder hoses (7) and (8), and the hoses of the
auxiliary equipment (9) and (10).
11
6
7 10
9 8
5
RKZA7970
30-248 WB97R-5E0
REMOVAL AND INSTALLATION 2nd ARM
2nd ARM
Removal 5 -Connect the 2nd arm (7) to some hoisting tackle.
1 -Remove the bucket (1). a Use the bucket pin hole and the safety pin holes.
(For details see "BACKHOE BUCKET").
1 2
3
RKZA8000
3 -Remove the 2nd arm cylinder. 7 -Stop the engine and loosen by several turns the gib
(For details see "JIG ARM CYLINDER"). adjustment screws.
a For safety, tightly plug all the disconnected a Loosen the screws on both sides.
hoses.
8 -Slide out the 2nd arm (7).
4 -Take out the lock nut (4), and the washer and remove
the pin (5) and the links (6). [*1] [*2] [*3] Installation
• To install, reverse removal procedure.
6 [*1]
WB97R-5E0 30-249
REMOVAL AND INSTALLATION 2nd ARM GUIDES
6
7
RKZ02390
Installation
A
• To install, reverse removal procedure.
RKZA8010
[*1]
3 2
1
5 6
RKZA8020
a Use the bucket pin hole and the safety pin holes.
RKZA8030
30-250 WB97R-5E0
REMOVAL AND INSTALLATION BACKHOE SWING BRACKET
4 Bracket: 162.5 kg
1 -Remove the equipment.
(For details see "BACKHOE WORKING
EQUIPMENT").
2 -Take out the screws (1) and remove the pins (2) that 10
connect the swing cylinders (3). [*1] [*2]
2
1
10
3
10
RKA54060
Installation
RKZC2592 • To install, reverse removal procedure.
a After bleeding the air, check the oil level in the tank.
4 -Sling the swing bracket (5)
• To install, reverse removal procedure.
5 -Take out screws (6) and (7) and remove pins (8) and
(9) from swing bracket. [*1] [*2]
5 8 6
RKA54050
WB97R-5E0 30-251
REMOVAL AND INSTALLATION BACKHOE SWING BRACKET
30-252 WB97R-5E0
40 STANDARD MAINTENANCE
WB97R-5E0 40-1
STANDARD MAINTENANCE EXPLANATION OF TERMS FOR MAINTENANCE STANDARD
Example:
Standard size Tolerance
120 –0.022
–0.126
Example:
Tolerance
Standard size
Shaft Hole
–0.030 +0.046
60
–0.076 +0
40-2 WB97R-5E0
STANDARD MAINTENANCE EXPLANATION OF TERMS FOR MAINTENANCE STANDARD
R e p a i r l i m i t a n d a l l o w ab l e v a l u e o r
allowable dimension
• The size of a part changes because of wear and
deformation while it is used. The limit of changed size
is called the “repair limit”.
• If a part is worn to the repair limit, it must be replaced
or repaired.
• The performance and function of a product lowers
while it is used. A value which the product can be used
without causing a problem is called the “allowable
value” or “allowable dimension”.
• If a product is worn to the allowable value, it must be
checked or repaired. Since the permissible value is
estimated from various tests or experiences in most
cases, however, it must be judged after considering
the operating condition and customer's requirement.
WB97R-5E0 40-3
STANDARD MAINTENANCE TRANSMISSION
TRANSMISSION
3 23 Nm
3 30 Nm
3 30 Nm
X
3 30 Nm
A
3 30 Nm
3 30 Nm
3 30 Nm
View X
3 30 Nm
3 30 Nm
K
3 23 Nm
3 30 Nm
3 30 Nm
View Z
K-K RKZ11670
40-4 WB97R-5E0
STANDARD MAINTENANCE TRANSMISSION
2 Loctite 510
3 50 Nm
3 50 Nm
2 Loctite 510
3 50 Nm
3 50 Nm
L
L
3 139 Nm
3 139 Nm
3 50 Nm
2 Loctite 542
A-A
3 50 Nm
RKZ11410 2 Loctite 542
WB97R-5E0 40-5
STANDARD MAINTENANCE TRANSMISSION
3 23 Nm
3 30 Nm
3 50 Nm
3 23 Nm
3 50 Nm
2 Loctite 542
B-B RKZ11680
40-6 WB97R-5E0
STANDARD MAINTENANCE FRONT AXLE
FRONT AXLE
Differential
3 95 Nm
2 Loctite 270
3 13 Nm
3 60 Nm
2 Loctite 510
2
3 169 Nm 2 Loctite 638
3
4
RKZ10381
WB97R-5E0 40-7
STANDARD MAINTENANCE FRONT AXLE
RKZ10390
3 266 Nm
3 60 Nm
Unit: mm
40-8 WB97R-5E0
STANDARD MAINTENANCE FRONT AXLE
Planetary - Joint
3 190 Nm
3 8 Nm
3 120 Nm
1
RKZ10401
3 80 Nm
3 70 Nm
3 8 Nm
2 Loctite 270
Unit: mm
WB97R-5E0 40-9
STANDARD MAINTENANCE FRONT AXLE
3 350 Nm 3 120 Nm B
39,32°
50°
A
A 3 300 Nm
3 250 Nm
1920 -02
3 150 Nm
3 220 Nm
Particolare
Detail CC
A-A B-B
RKZ10411
Unit: mm
40-10 WB97R-5E0
STANDARD MAINTENANCE REAR AXLE
REAR AXLE
1
3 10 Nm 3 10 Nm
3 155 Nm
2 Loctite 270
3
4
RKA53650
Unit: mm
No. Check item Criteria Remedy
Standard
clearance Clearance limit
1 Axle clearance
---- ----
2 Backlash of crown wheel and pinion 0.21–0.29 0.29 Adjust
Pinion rotation force (without sealing ring)
3 As measured on pinion Ø 34.8 115-138 Nm
WB97R-5E0 40-11
STANDARD MAINTENANCE REAR AXLE
3 80 Nm 2 Loctite 638 3 18 Nm
3 1500 Nm
3 60 Nm
3 226 Nm 3 10 Nm
2 Loctite 270
2 Loctite 638
2 Loctite 510
3 169 Nm
2 Loctite 638 3 80 Nm
3 120 Nm 1
2
RKA53660
40-12 WB97R-5E0
STANDARD MAINTENANCE REAR AXLE
1 2
3
2 ASL800050
2 Loctite 638
3 15.3 Nm RKA53670
Unit: mm
WB97R-5E0 40-13
STANDARD MAINTENANCE REAR AXLE
3 180 Nm
RKA53680
40-14 WB97R-5E0
STANDARD MAINTENANCE REAR AXLE
RKA53700
Unit: mm
WB97R-5E0 40-15
STANDARD MAINTENANCE REAR AXLE
3 115 Nm
3 169 Nm
3 45 Nm
3 61–74 Nm
3 13–14 Nm
2 ASL800050
2 ASL800050
2 ASL800050
2 ASL800050
3 180 Nm
3 180 Nm
RKA53690
40-16 WB97R-5E0
STANDARD MAINTENANCE HYDRAULIC PUMP
HYDRAULIC PUMP
3 19.6-24.5 Nm
View X
3 157-196 Nm
A A
3 68.6-83.4 Nm
Z
X
3 27.4-34.3 Nm
3 7.8-9.8 Nm
3 68.6-83.4 Nm
3 19.6-27.4 Nm
3 11.8-14.7 Nm
RKZ10440
View Z
WB97R-5E0 40-17
STANDARD MAINTENANCE HYDRAULIC PUMP
3 27.4-34.3 Nm Z
3 27.4-34.3 Nm
X
3 27.4-34.3 Nm 3 27.4-34.3 Nm
RKZ10450
A-A
40-18 WB97R-5E0
STANDARD MAINTENANCE CONTROL VALVE
CONTROL VALVE
3 9.8-12.7 Nm
Komatsu Ltd.
AC AC
AB AB
AA AA
3 9.8-12.7 Nm
R R
N N
M M
X
L L
K K
J J
3 9.8-12.7 Nm F F
E E
3 9.8-12.7 Nm D
Z
3 29.4-34.3 Nm
RKZ09121
3 58.8-73.5 Nm
ViewZ
WB97R-5E0 40-19
STANDARD MAINTENANCE CONTROL VALVE
AE
C B A
RKZ09591
C B A
AE
ViewX
40-20 WB97R-5E0
STANDARD MAINTENANCE CONTROL VALVE
3 49-58.8 Nm
5 6
9 3
3 39.2-49 Nm
10 39.2-49 Nm
4
3
3 3
3
2 39.2-49 Nm
2
39.2-49 Nm
3
39.2-49 Nm
11
7
8
B-B A-A
RKZ09131
K-K J-J
WB97R-5E0 40-21
STANDARD MAINTENANCE CONTROL VALVE
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free Installed Installed Free Installed
installed length load installed load
x Øe
Spool return spring
1 (shovel arm raise 27.1x16.2 26.7 14.7N – 11.8N
control)
Spool return spring
2
(in arm control)
41.1x19.3 40.5 34.3N – 27.4N
40-22 WB97R-5E0
STANDARD MAINTENANCE CONTROL VALVE
AD
7 2
3 24.5-34.3 Nm
8
3
1 4
8
8 1 5
3 47-58.8 Nm
8 3
1
3 19.6-24.5 Nm
5
AD
3 24.5-34.3 Nm
6 6
D-D C-C
3 14.7-19.6 Nm
3 24.5-34.3 Nm
RKZ09141
AD - AD
WB97R-5E0 40-23
STANDARD MAINTENANCE CONTROL VALVE
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free Installed Installed Free Installed
installed length load installed load
x Øe
Pressure compensation valve
spring
1 (Shovel arm, backhoe bucket, 15.4x6 8 7.44N – 5.96N
boom, shovel, boom swing, jig
arm, 4 in 1 bucket)
Pressure compensation valve
2 spring (arm) 31.4x14.4 21.8 63.7N – 51.0N
40-24 WB97R-5E0
STANDARD MAINTENANCE CONTROL VALVE
3
3 65.7-82.3 Nm
2 2
1 1 7
1 2 E-E 2 1 K-K
F-F L-L
RKZ09102
J-J M-M
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free
installed Installed Installed Free Installed
length load installed load
x Øe
Spool return spring Replace
1 18.0x18 17.5 39.2N – 31.4N
(Outrigger control) spring
Spool return spring
2 20.2x14.2 10.4 30.4N – 24.3N
(Outrigger control
Control valve spring
3 13.0x8.8 11 3.92N – 3.1N
plate lock
WB97R-5E0 40-25
STANDARD MAINTENANCE CONTROL VALVE
3 34-44 Nm
3 34.3-44.1 Nm
AC - AC
N-N
3 65.7-82.3 Nm
AA - AA
RKZ08892
AB - AB AE - AE
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free
installed Installed Installed Free Installed Replace
x Øe length load installed load spring
Pressure compensation
1 valve spring. 31.7x9.2 27.5 43.1N – 34.5N
40-26 WB97R-5E0
STANDARD MAINTENANCE PPC VALVES
PPC VALVES
SHOVEL CONTROL
3 69–88 Nm
3 39–49 Nm
3 1–2 Nm
1 3 5 7
2 4 6 8
P2 P1 P3 P4
RKA53080
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free
Installed Installed Free Installed
installed length load installed load
x Øe
1 Return spring (outer) (P2) 31.6 39.1 N
2 Adjusting spring (inner) (P2) 24.6 5.28 N
3 Return spring (outer) (P1) 30.6 41.2 N Replace
4 Adjusting spring (inner) (P1) 23.8 5.28 N
5 Return spring (outer) (P3) 31.9 38.5 N
6 Adjusting spring (inner) (P3) 25.3 5.28 N
7 Return spring (outer) (P4) 31.6 64.9 N
8 Adjusting spring (inner) (P4) 24.9 5.28 N
WB97R-5E0 40-27
STANDARD MAINTENANCE SHOVEL CYLINDERS
SHOVEL CYLINDERS
DUMP CYLINDER
3 539±54 Nm 3 1250±130 Nm
1 3
2
707-00-0y920-1
LIFTING CYLINDER
3 677±67.5 Nm 3 1670±170 Nm
1 3
2
707-00-0y891-1
Unit: mm
Criteria
No. Check item Cylinder Standard Tolerance Standard Clearance Remedy
size Shaft Hole clearance limit
40-28 WB97R-5E0
STANDARD MAINTENANCE SHOVEL CYLINDERS
4 IN 1 BUCKET
3 690±69 Nm 3 540±54 Nm
1
42N-6C-12800-1
Unit: mm
Criteria
No. Check item Standard Tolerance Standard Clearance Remedy
size Shaft Hole clearance limit
WB97R-5E0 40-29
STANDARD MAINTENANCE BACKHOE CYLINDERS
BACKHOE CYLINDERS
BOOM
3 2740-2840 Nm
with Loctite 262
3 1010±100 Nm 3
1
2
707-02-0Y941-1
ARM
3 2450±240 Nm 3
3 984±98.1 Nm
1
2
707-00-0Y871-1
BUCKET
31670±170 Nm
1 3
2
707-00-0Y901-1
40-30 WB97R-5E0
STANDARD MAINTENANCE BACKHOE CYLINDERS
BOOM SWING
3 44.1-53.9 Nm 3 785±78.5 Nm
1 2
3 297±29.4 Nm
707-02-07730-1
Unit: mm
Criteria
Boom 60
– 0.030 + 0.151 0.035–
0.527
– 0.076 + 0.005 0.227
Arm 60
– 0.030 + 0.046 0.030–
0.432
– 0.076 0 0.132
Clearance between
1 piston rod and bushing
Bucket 55 – 0.030 + 0.151 0.036– 0.527 Replace
– 0.076 + 0.006 0.227 bushing
Boom 60
– 0.060 + 0.174 0.160–
1.000
– 0.106 + 0.100 0.280
WB97R-5E0 40-31
STANDARD MAINTENANCE BACKHOE CYLINDERS
OUTRIGGERS
3 1420±140 Nm
3 785±78.5 Nm
with Loctite 262
1
707-00-0Y0830_1
JIG ARM
3 1080±100 Nm
3 539±54 Nm
1
42N-6C-13301-1
Unit: mm
Criteria
Outriggers 50
– 0.030 + 0.162 0.025–
0.414
– 0.076 + 0.005 0.238
Clearance between
1 piston rod and head Replace
Jig arm 40
– 0.025 + 0.064 0.050–
0.414
– 0.050 + 0.025 0.114
40-32 WB97R-5E0
STANDARD MAINTENANCE FRONT WORKING EQUIPMENT
E
C E
C
D
B
B D
A
A
1 3
2
A-A B-B
C-C
5
4
D-D E-E
RKZ10480
WB97R-5E0 40-33
STANDARD MAINTENANCE FRONT WORKING EQUIPMENT
Unit: mm
Criteria
Clearance between
2 mounting pin and bushing of 45
– 0.050 + 0.240
0.130–0.329 1.000
link and bucket
– 0.089 + 0.080
Clearance between
3 mounting pin and bushing of 45 – 0.050 + 0.096 0.093–0.185 1.000 Replace
link and link
– 0.089 + 0.043
Clearance between
4 mounting pin and bushing (of 60 – 0.060 + 0.178 0.170–0.284 1.000
lift arm) and link – 0.106 + 0.110
Clearance between
5 mounting pin and bushing of 50 – 0.050 + 0.240 0.130–0.329 1.000
lift arm and frame – 0.089 + 0.080
40-34 WB97R-5E0
STANDARD MAINTENANCE SWING BRACKET
SWING BRACKET
RKA53710
WB97R-5E0 40-35
STANDARD MAINTENANCE SWING BRACKET
Unit: mm
Criteria
Clearance between
2 mounting pin and bushing of 65 – 0.060 + 0.228 0.207–0.334 1.000
swing bracket (lower) and – 0.106 + 0.147
sliding plate
Clearance between
3 mounting pin and bushing of 65 – 0.060 + 0.228 0.210–0.334 1.000
sliding plate (upper) and – 0.106 + 0.150 Replace
boom swing bracket bushing
and
Clearance between pin
4 mounting pin swing cylinder 55 –0.030 +0.097 0.068–0.173 1.000
head and bushing on swing –0.076 +0.038
bracket
40-36 WB97R-5E0
STANDARD MAINTENANCE SWING BRACKET
RKA53720
WB97R-5E0 40-37
STANDARD MAINTENANCE SWING BRACKET
Unit: mm
Criteria
Clearance between
2 mounting pin and bushing of 45
– 0.050 +0.240
0.130–0.329 1.000
arm and bucket
– 0.089 +0.080
Clearance between
3 mounting pin and bushing of 45 – 0.050 +0.240 0.130–0.329 1.000
arm and link
– 0.089 +0.080
Replace
Clearance between
4 mounting pin and bushing of 45 –0.050 +0.240 0.130–0.329 1.000
link and link – 0.089 +0.080
Clearance between
5 mounting pin and bushing of 50 – 0.050 +0.084 0.087–0.173 1.000
boom and arm – 0.089 +0.037
40-38 WB97R-5E0
90 DIAGRAMS AND DRAWINGS
WB97R-5E0 90-1
DIAGRAMS AND DRAWINGS
90-2 WB97R-5E0
DIAGRAMS AND DRAWINGS HYDRAULIC CIRCUIT DIAGRAM
RKA53730
WB97R-5E0 90-3
HYDRAULIC CIRCUIT DIAGRAM DIAGRAMS AND DRAWINGS
90-4 WB97R-5E0
DIAGRAMS AND DRAWINGS ELECTRICAL CIRCUIT DIAGRAM (1/3)
V-Z1
L-N1.5
M-B1.5
M-N1.5
A 1 2 3 4
G-L1
R-N1
G-M1
H-V1
A/B1
H1.5
C-B1
L-B1
G/R1
V/N1
G-V1.5
M1
L-R1
L-R1
C-L1
C-L1
A-G1
G-V1
A-G1
G-N1
C-L1
C-L1
L-R1
L-R1
A/R1
V-Z1
A/R1
R/N1
H-V1
R/N1
L/R1
V-N1
V-N1
C-L1
N1
N1
N1
N1
N1
4 2 8 5 7 4 1 9 10 12 8 7 2
N1
N1
N1
A1
R1
N1
N1
N1
X57 X57 X57 X57 X57 X60 X60 X60 X60 X60 X60
1
R N F Out1 Out2 56 1 L R 31b 53 15 53c X180
7 1 3 4 6 7 1 3 4 6 4 6 1 3 7 1 1 1 1
;
R
N
F I 2 Dx WASHER I
0 1 3 4 6 7 1 3 7 1 3 X140 X140 X140 X140 X140 X142 X142 X142 X142 X142 X146 X143 X136 X138
LAVACRISTALLO X89 X89 X89 X89 X89 7 7 1 3 X141 X141 X141 X141 X141
X80 X80 X80 X81 X81 X81 X82 X82 X82 7 1 3 4 6 7 1 3 4 6 4 6 1 3 7
HORN 1 3 4 6 7 0 1 E146 E143 E136 E138
7 1 3 7 1 3 7 1 3 II I 0 II I 0
CLAXON
Sx V180 1 1
H 1 0 0 1 0 0
5 2 8
+ 56b 56a 49 H
S57 S60 8 2 5 8 2 5
S141 5 2 8 4 4 4 4
9 5 3 11 6 S89 8 2 5 S80 8 2 S81 8 2
S82 8 2 S140 8 2 5 S142 8 2 5 X141 X141 X141 X146 X143 X136 X138
X60 X60 X60 X60 8 2 5 8 2 8 2 8
X140 X140 X140 X142 X142 X142
X89 X89 X89 X81 X81 2
H-R1
A-G1
V1
H1
C1
X80 X80 X82 X82
A-G1.5
A-G1.5
G-N1.5
G-N1.5
L-R1
C-L1
C-L1
A-G1
A-G1
G-V1
G-V1
1
R1
N1
N1
N1
N1
X181
L/R1
C-L1
C-L1
V-Z1
A-B1
V/N1
A/R1
A/R1
A/R1
A/R1
V-N1
A-G1
G/R1
G-M1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 9 10 11 12
L-B0.5
C-L0.5
X63 X64
V0.35
A/V1
Z-B1
B-V1
A-V1
S/N1
V-N1
A-R1
S-N1
H-V1
R-V1
M/B1
S-G1
S1
V1
M-N1
N1
H1
G-M1
G1
B-N1
B-N1
A-B1
A-N1
R/N1
A-N1
S-N1
R/N1
N1
N1
N1
N1
7 1 3 7 1 3 7 1 3
X83 X83 X83 X85 X85 X85 X84 X84 X84
7 1 3 7 1 3 7 1 3
1
1 0 1 0 0
S83 8 2
S85 8 2
S84 8 2
8 2 8 2
X83 X83 X85 X85 8 2
X84 X84
Z-N1
A-B1
A-B1
A-N1
R/N1
R/N1
S-N1
R/N1
R/N1
gnd7.2
gnd7.3
gnd8
Gnd7.2 Gnd7.3
Gnd8
G-L1
M-N1
B-G1
A-B1
A-B1
H-L1
S/N1
Z/N1
N1
L/R1
N1
G1
N1
N1
N1
N1
7 1 3 4 6 7 1 3 4 6 1 3 7
X86 X86 X86 X86 X86 X88 X88 X88
A/V1
H1.5
A/B1
L-N1
X87 X87 X87 X87 X87
N1
N1
R-N1
R-G1
7 1 3 4 6 7 1 3 4 6 1 3 7
G-V1.5
0 1
A6 II I 0 1 0
H1.5
V1.5
A-B1
G-N1
H1.5
V1.5
N1.5
2 4 3 1
G1
A1
1 X58 X58 X58 X55 5 2 8
1
X53.1
1
X54.1
S87
X59.1
UNIT S86 8 2 5
S88 8 2
5 2 8 1 1
X151.2
X147.2
S53 S54 B59 53
53a
M 53b M MULTIFUNCTION 01171127 8
X86
2
X86
5
X86 X88
8
X88
2 X87 X87 X87 - - - - - - - - X148.1 X152
31b
56a
56b
56a
56b
57
57
L
R
G1.5
Z/N1
Z/N1
H-L1
H-L1
A-B1
A-B1
M-N1
G1
31
M
M58 42N-06-15161
1 1 1 M55
31
31
X53.2 X54.2 X59.2
1 2
X58 X55 E147
B-R1
C-B1
- -
R-G1
N1
X147.1 X151.1 1 2
N1
N1
N1
N1
X148.2 X152
L-N1.5
C-L0.5
L-B0.5
gnd7.1
M/B1
V-N1
M-N1
Z-B1
B-V1
H-R1
L-B1
G/R1
S/N1
S-G1
R-N1
R-G1
A-V1
H-V1
A-G1
R-V1
C-B1
S-N1
H-R1
A-R1
A-G1.5
A-G1.5
G-N1.5
G-N1.5
M1
H1
N1
C1
S1
G-V1
V1.5
V1.5
H1.5
H1.5
A-B1
G-N1
G/R1
A-B1
A-G1
G-M1
H-V1
V-N1
A-N1
C-L1
G-L1
G1.5
M-N1
A-B1
S/N1
V/N1
Z/N1
V-N1
H-L1
A/R1
V-Z1
B-N1
R/N1
PPC CONTROL SWITCH
4WD SOLENOID VALVE
R1
R1
A1
G1
A1
N1
X10.s 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 X9.s 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
EC POWER SWITCH
PPC SEAT SWITCH
SEAT SWITCH
4WD SWITCH
OUT BUZZER
42N-06 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
X10.p X9.p X26.p 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
X25.p X25.p X25.p X25.p X25.p X25.p X25.p X25.p X25.p
CAVO1 V0.35
R1 ACC BR R2 C
42N-06
L-B0.5
L-N1.5
C-L0.5
X44.p X44.p X44.p X44.p X44.p X44.p X44.p X44.p X44.p X44.p X44.p X44.p X44.p X44.p X44.p X44.p X44.p X44.p
N1.5
N1.5
12670 OFF
A-G1.5
A-G1.5
R-N1.5
G-N1.5
G-N1.5
ACC
B-V1
A-V1
G-L1
V1.5
V1.5
V-N1
H/R1
B-R1
H-V1
V-N1
R-V1
C-B1
A-R1
R1.5
H1.5
H1.5
N2.5
M/B1
H-R1
R-G1
G1.5
Z/N1
A-B1
V1
R1
M-N1
A-B1
Z-N1
G-L1
A-B1
V/N1
A/R1
H1
C1
N1
G-M1
H-V1
V-N1
V-N1
B-N1
R/N1
H/R1
G-V1
G1
G/R1
B-G1
G-N1
M1
GND
A1
ST
N1
G1
G-M1
15720
S24 B
A1 A2 A3 A4 A5 A6 A7 A8 B1 B2 B4 B5 B6 B7 B8 C1 C2 C3 C4 C5 C6 C7 C8 A1
B-R1.5
X6
L/R1
Z-B1
H-L1
Z/N1
S/N1
A-B1
Z-N1
A-B1
X24.acc X24.b X24.br X24.c
C-B1
B-N1
B/G1
B-R1
S-N1
H/R1
H/N1
C-N1
X24.r1 S1 S2 S3 S4 S5 S6
M-V1
M-V1
S1
N1
G-M1
M1
N1.5
G-N1.5
B/N1
X24.gnd
M/N1
M/N1
L6
R6
S-N1
A-B1
R1
X158 18 M-N1
X158 19 L-B1
A-B1
Z-N1
C/B1
C-B1
A-R1
C-N1
M-B1
M-V1
M-N1
N1
N1
X158 42
X158 46 M-B1
X158 47 G/R1
R/N1
R/N1
M/B1
S-N1
H-N1
M-N1 X47 1
C-B1
M-B1
2
M1
3
B0.35
M-B1 4
B/N1
5
M/N1
H-R1
Z-N1 6
CAVO1
N1
A-B1 7
N1 8
B/G1
C-B1
A-R1 9
L/R1
A/R1
L-N1.5
C-L0.5
M-N1
M-V1 10
M-B1
R-N1
R-G1
A-V1
G-L1
A-G1 11
M1
N1
12
Z-B1
1
R1 CN-F20
1 X6.p C-B1
2
Z1 CN-F20
2 X6.p V-B1
M/B1
L-N1.5
3 3 X6.p
N1.5
C-B1
C-B1
C-B1
M/N1
CN-F20
M/B1
M-B1
4 4 X6.p
C-L1
B-N1
A-R1
CN-F20
C-L1
A-G1
S/N1
N1
V6
5
R-V1
B-G1
B/N1 5 X6.p
B-G1 1 2 3 CN-F20
B6
S40 X42 X42 6
1 1 1 2 1 1 2 Z-B1 CN-F20
6 X6.p M-N1
X17.1 B A C X48 86
Y49 X49 X555 X555 86 87
Y48 87 1 M42 B-N1 7 7 X6.p H-L1
N1
X13 X13 K56 X56 X56 X23 K61 X61 X61 K45 X45 CN-F20
H/N1
1 2 X56 2 X40 2 3 4 X61 CN-F20
R16
V23
B-N1
R6
N1
12
R-N1.5 12X6.p B1
N1
N1
R6
R-G1
CN-F20
N1
M-V1
H-L1
V-B1
X43 42N-06 R-V1
1 R-G1
15 2 G-N1
10 20
13730
RPM x 100 3 R1 1
B-N1
X7.p
5 25 4 B-N1 X7.s 1
N1.5
N1
H-R1
A-G1
G/R1
H-R1
5 H-N1 H-L1
0 30 X160.p 1
Z-N1 H/R1
L6
V6
R6
6 1 X5
7 6 5 4 3 2 1
7 C-L0.5 X5.s +15Key +30 +15 G-N1 2 1
R1
X3.p
8 C-B1 3 X3.s 1
9 A-V1 X3.s
1 UNIT
42N-06-15141 (01171166) H-G1 4
V-B1
A-V1
B-R1
P43 X4.s 1
R1 M-B1 2
10 B-V1 2 5 X5
B-R1
11 L-B0.5 B-R1.5 3 F25 F14 F13 F12 F24 F21 F7 F22 F18 F16 F17 2 R-N1.5 N1 6
B-R1 B-R1
G1.5
M/N1 10A 10A 10A 5A 7.5A 10A 7.5A 7.5A 10A 10A 10A
13 4 3 H1 CAVO3 V0.35 7
Sal2
Z-B1 Z-N1 V1
G-N1
14 5 4 8
V-B1
V-B1
V-B1
86 87a 87
X4 X4 X4
17 V1 6 5 C1 L/B1 9 K4 8687a 87
R-V1
C-B1
18 V-B1 7 6 R1.5 B/N1 10
19 8 7 R1.5 11 85 30
20 N1 9 8 A-G1.5 12 85 30 V-B1
X4 X4 Sal3
10 9 G-N1.5 V-B1
B-G1 11 Sal1
V-B1
V-B1
R-V1
R-G1
H-R1 12
K2 K1
13
F8 F11 F10 F23 15
F15 15 F2 F9 F1
M/B1
M-B1 14 7.5A 7.5A 10A 10A 31 T 10A 31 T
15A 15A 15A
X27.s A-R1
A/C
R/N1
1 15
A-N1
53M 53M
C-B2.5 R/N1 16 1
42N-07-11400 2 A-N1.5 17
X46
S46
V-B1
V-B1
V-B1
V-B1
V-B1
B-R1
B-R1
B-R1
B-R1
C-B1
C-B1
B-N1
R-V1
R-G1
M-N1
R-V1 18 2 1
X28.s X41.s
A R4 R-G1 19
HEATING 20
7
X1
8
X1
12
X1
13
X1
1
X2
2
X2
3
X2
4
X2
5
X2
6
X2
7
X2
8
X2
9
X2
11
X2
12
X2
42N-07-11300 B N4 21
S41 2 X30
B-V1
H-R1
L/R1X2.s 1 1 KOMTRAX UNIT
K11 F5 K5 K3 K4 1 2
2 F6 F3 F4 F19 F20 X30.1 X30.1
10A
R1.5
N1.5
87a 87a 87a 87a
N1
86 87 86 87 86 87 86 87
B-R1 3 15A 3A 3A 15A 15A
G1
R-N1 4 85 30 85 30 85 30 85 30
L-N1.5 5 B0.35
X1.s 1 SAL1
6 V1.5
H-R1
V0.35
H1.5
H-R1
7 2
H-N1
V-B1
Z-B1
M-N1
G1 G-M1
N4
V1
B6
8 3
A-N1.5 A-N1.5 9 4 G-N1 H-R1 X158 1
L-N1.5 10 5 H-R1 X158 2
K10 K6 K8 K9 K7 M-V1
11 D2 D3 D1 86 87a 87 86 87a 87 86 87a 87 86 87a 87 86 87a 87 6 B-L1X158 3
G1
H-G1 12 7 H-R1 X158
Z-B1
5
85 30 85 30 85 30 85 30 85 30
M1 13 8 H1.5 H-L1X158 7
14 9 G-N1 X158 8
R-G1 15 10 G-N1 A1 X158 9
A-G1 16 11 G1 H/R1 X158 10
Z-N1 S/N1 17 H1 X158 12
B/N1 X158 20
M-B1 X158 21
L/B1X158 22
CAVO3 V0.35 X158 25
R-G1.5
N1 X158 29
H-R1 X158 34
H-N1 H-N1 X158
N1
37
G-N1 G-N1 X158 38
A-B1
H-N1
N1
N1
N1
V-N1 L1 X158 41
gnd11 M-N1
A-N1.5
A1 B-V1 X158 48
V-B1
S-N1
RD gnd9
gnd1.3
gnd1.2
gnd1.1
N10
R-N1.5
C-B1
R6
R6
A-B1
C-B1
A1
G1
C-B1 C-B1
R-N1.5
A-N1.5
F27 C-B2.5 A1
Z-B1
Z-B1
B6
175A
C-B2.5
H-N1
H-L1
B-N1
G-M1
N1.5
V-N1
Z-N1
Z-B1
C-B1
C-N1
A-N1
V-N1
V/N1
M-N1
N1.5
G-N1
A-B1
B-R1
N1.5
S-N1
H-N1
A1
H1
L1
N1
G1
A1
V1
N1.5
N1.5
N1.5
H-L1
Z-B1
V-Z1
H-L1
Z-N1
C/B1
V/N1
A-B1
42N-06
H/R1
B-N1
V-N1
C-B2.5
A-N1.5
C-B1
A-N1
L1
R-N1.5
H-N1
C-N1
G-N1
G-N1
A1
B2
A1
M-N1
H1
G-M1
G1
Z-B1
V-B1
Z-N1
S-N1
H-N1
Gnd6
M-V1
42N-06
M16
V1
B6
N6
11450 11280
11161 B0.35
V0.35
B2 X207
1
X208
X207
X207
2
X208
B-R1
A-B1
B-R1
V0.35
B0.35
N1
G-N1
G-N1
G-N1
A1
1
B-L1
N1
H-L1
G1
B-V1
V-N1
H/R1
B-N1
L1
H-N1
G-N1
A1
H1
N1
G-M1
R-N1.5
A-N1.5
C-B2.5
CONNECT TO HARNESS
R25
R70
Z-B1
Z-N1
V-B1
H-N1
M-V1
S-N1
Z-B1
H-L1
V-Z1
R70
R25
R25
M16
Z-N1
V/N1
C/B1
C-B1
A-N1
C-N1
M-N1
B6
V1
N1
42N-06-15960
X101.3 X101.4 X100.1 X100.2 X100.3 X100.4 B A C
1 1 1 X101.1 X101.2 X209 X209 X209
X119.2
1 X119.1 X116 1 1 1 1 1 1 1 1 1 1 - 1 1 1 1 1 1 1 1
X118.1 1 1 A B C 1 1 X90 X91 X92 X93 X94 X95 X96 X98 X99 X97 X103.1 1 X200 X201 X202 X203 X204 X205 X206 X211
X117 X115 1 X112 X112 X112 X121 X60 M116 Y90 Y91 Y92 Y93 Y94 Y95 Y96 Y98 Y99 X210 Y200 Y201 Y202 Y203 Y204 Y205 Y206 B209
G1 R114 X114 X113 Y60 E101 E100 B210
59c
59c
B211
57
57
E103
L
G118 30
M
50
G119 30
D+
W
Y117 B115 B113 B112 B121 M
G t
12Vcc 3 p p t
31
31
U H97
31 2 t 2 2 2 2 2 2 2 2 2 2 - 2 2 2 2 2 2 2 2
X113 2 2 X90 X91 X92 X93 X94 X95 X96 X98 X99 X97 X103.2 X200 X201 X202 X203 X204 X205 X206 X211
N70
N1.5
X121 X60
N1.5
N6
N1
N1
N1
N1
N1
N1
N1
N1
N1
N1
N2
N1
N1
N1
N1
N1
N1
N1
N1
N1
N1
N1
N1
N1
Gnd5 Gnd1.1
Gnd3.1
WB97R-5E0 90-5
ELECTRICAL CIRCUIT DIAGRAM (1/3) DIAGRAMS AND DRAWINGS
ID Description ID Description
ID Description
H17 Buzzer Y92 Back-up alarm
A6 Multifunction unit
K1 Unrepeat start unit Y93 Rear PPC solenoid valve
B13 Return to dig sensor
K2 Flasher Y94 Differential lock solenoid valve
B59 Brake oil low level switch
K3 Low beam relay Y95 Unlock arm solenoid valve
B112 Thermistor switch
K4 Main beam relay Y96 Unlock plate solenoid valve
B113 Air filter
K5 Front horn relay Y98 Closing grab solenoid valve
B115 Engine oil low pressure switch
K6 Return to DIG solenoid valve relay Y99 Opening solenoid valve
B121 Horn
K7 Light stop relay Y117 Elettrostop
B209 Fuel level sender
K8 Assent start relay Y200 4th speed solenoid valve
B210 Gear oil temperature sensor
K9 Forward speed relay Y201 Forward speed solenoid valve
B211 Cardan sensor
K10 Reverse speed relay Y202 1st speed solenoid valve
CN-F20 Komtrax Interface connector
K11 Stop drive relay Y203 2nd speed solenoid valve
E100 Right rear light
K45 Preheating Relay Y204 Double traction solenoid valve
E101 Left rear light
K56 Starting relay Y205 Reverse speed solenoid valve
E136 Right rear working light
K61 Service relay Y206 3rd speed solenoid valve
E138 Left rear working light
M42 Rear Windshield-washer
E143 Right front lateral working light
M55 Motor pump
E146 Left front lateral working light
M58 Front windshield-washer
E147 Left front light
M116 Compressor
E148 Beacon lamp
R114 Preheating
E151 Right front light
S1 Kich down switch
E152 Cabin lamp
S2 Solenoid valve EC Power switch
F1 Central front working light fuse 15A
S3 Lock grab switch
F2 Central rear working light fuse 15A
S4 Declutch switch
F3 Right position light fuse 3A
S5 Open grab switch
F4 Left position light fuse 3A
S6 Differential lock switch
F5 Horn fuse 10A
S24 Starting switch
F6 Lateral rear working light fuse 15A
S40 Seat Switch
F7 Windshield wiper-washer + rear horn fuse 7,5A
S41 Rear horn switch
F8 Stop light switch fuse 7,5A
S54 Stop light switch
F9 Lateral front working light fuse 15A
S46 Parking brake switch
F10 Front windshield-motor supply fuse 10A
S53 Stop light switch
F11 Optional fuse 7,5A
S57 Gear steering column
F12 Front + lateral instrument + buzzer fuse 5A
S60 Steering column light switch
F13 Supply level grip fuse 10A
S80 Ride control switch
F14 Light switch + switch optional fuse 10A
S81 Unlock arm button
F15 Elettrostop + safety starter fuse 10A
S83 E/C power button
F16 Beacon light fuse 10A
S84 EMPI solenoid valve switch
F17 Warning switch fuse 10A
S85 Rear horn button
F18 Cabin lamp + cigarette lighter fuse 10A
S86 General light switch
F19 Low beam fuse 15A
S87 4wd switch
F20 Main beam light 15A
S88 PPC button
F21 Return to DIG sender supply fuse 10A
S89 Warning switch
F22 EC power fuse 7,5A
S140 Rear working light switch
F23 +15 Steering unit fuse 10A
S141 Beacon lamp switch
F24 Flasher fuse 7,5A
S142 Front working light switch
F25 Reverse speed buzzer + Steering column 10A
Y48 Float solenoid valve
F27 General fuse 200A
Y49 Return to dig solenoid valve
G1 Battery
Y60 Emp. solenoid valve
G118 Starter
Y90 PPC solenoid valve
G119 Generator
Y91 ECOPOWER solenoid valve
90-6 WB97R-5E0
DIAGRAMS AND DRAWINGS ELECTRICAL CIRCUIT DIAGRAM (2/3)
42N-06 42N-06
14250 P63 11832
R1 L/R1
R/N1 R1 N1
A 1 2 3 4
A1 N1 V-N1
V/N1
V/N1
A/R1
C-L1
V-Z1
A/R1
N1
A1
L-N1.5
N1
G-L1
H1.5
A/B1
C-L1
C-B1
V-N1
R-N1
G-M1
M-B1
M-N1
L-B1
G/R1
N1
A1
optional7
;
1 1 3 4 6 7 1 3 7 1 3 7 1 3
M1
N1
G-V1.5
V180 X180 X89 X89 X89 X89 X89 X80 X80 X81 X81 X81 X82 X82
L-R1
L-R1
C-L1
C-L1
A-G1
G-V1
A-G1
G-N1
C-L1
C-L1
L-R1
L-R1
N1
N1
N1
N1
4 1 9 10 12 8 7 2 1 3 4 6 7 7 1 3 7 1 3 7 1 3
4 2 8 5 7 X60 X60 X60 X60 X60 X60 X60 X60
1 1
X57 X57 X57 X57 X57 1 0 0 1 0 0
0
Dx 4 1 9 10 12 8 7 2 I
R N F Out1 Out2 WASHER
LAVACRISTALLO 7 1 3 4 6 7 1 3 4 6 4 6 1 3 7 1 1 1 1
R
N
F S89 8 2 5 S80 8 2 S81 8 2
S82 8 2 X140 X140 X140 X140 X140 X142 X142 X142 X142 X142 X146 X143 X136 X138
HORN X141 X141 X141 X141 X141
Sx CLAXON 1 8 2 5 8 2 8 2 8 2 7 1 3 4 6 7 1 3 4 6 4 6 1 3 7
S60
5 3 11 6
X181 X89 X89 X89 X80 X80 X81 X81 X82 X82 0 1 E146 E143 E136 E138
II I 0 II I 0
5 3 11 6
L/R1
G-M1
V-N1
G/R1
V-N1
C-L1
C-L1
V/N1
A/R1
A/R1
V-Z1
A/R1
A/R1
X60 X60 X60 X60
5 2 8
+
S57 8 2 5 8 2 5
4
S142 S141 5 2 8 4 4 4
9 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 9 10 11 12 S140 8 2 5 8 2 5 X141 X141 X141 X146 X143 X136 X138
X63 X64 X140 X140 X140 X142 X142 X142
L-B0.5
C-L0.5
G-N1.5
G-N1.5
A-G1.5
A-G1.5
B0.5
L-B1
A/B1
A/V1
H-L1
G-L1
B-V1
A-V1
V-N1
V-N1
A-R1
H/R1
R-V1
G/R1
R-N1
M/B1
H-N1
M-B1
G-N1
V1
S1
A1
V1
M-N1
M-N1
H1
C1
N1
H1
G-M1
G1
M1
H-R1
L-R1
C-L1
C-L1
A-G1
A-G1
G-V1
G-V1
C-L1
L-R1
L-R1
R1
N1
N1
N1
N1
A-N1
S-N1
N1
N1 S-N1
R/N1 N1
B-N1
A-B1
A-B1
N1
R/N1
A158 7 1 3 7 1 3 7 1 3
G-N1
X83 X83 X83 X85 X85 X85 X84 X84
X158 4 H-L1 optional
7 1 3 7 1 3 7 1 3
X158 16 B-R1
1
1 0 1 0 0
X158 18 M-N1
X158 19 L-B1
GEAR UNIT
X158 26 B-G1 S83 8 2
S85 8 2
S84 8 2
8 2 8 2 8 2
X158 27 Z-B1 X83 X83 X85 X85 X84 X84
28 A/G1
R/N1
S-N1
R/N1
X158
Z-N1 A-B1 A-N1 R/N1 R/N1
X158 42 A-R1
Z-N1 A-B1
46 M-B1
N1
X158
X158 47 G/R1 N1
53 Z-N1 N1
C-B1
N1
N1
N1
N1
R-G1
X158
H1.5
A/V1
L-N1
A/B1
X158 55 V-B1 R-N1 N1 Sal6
56 B-R1 N1
N1
X158
1 GND7.2
N1
1 1 2 4 3 X55
X53.1 X54.1 1 M58 X58 X58 X58 M55 H-R1 GND7.3
G1
A-B1
X59.1
B-G1 B53 B54 B59 B-G1 A-B1 GND8
G-L1
1
S-N1
S-N1
X159 53a
M
L/R1
C-L1
A/R1
A/R1
R-V1
N1
G1
G1
53 M 31b
DIAGNOSTIC
2 Z-B1
A1
V1
N1
H1
X159
Gnd7.2 Gnd7.3 Gnd8
X159 3 V-B1
UNIT
GEAR
31 7 1 3 4 7 1 3 4 6 1 3 7
X159 4 N1 1 X86 X86 X86 X86 X88 X88 X88 X87 X87 X87 X87 X87
1 1 X59.2 1
X159 5 A/G1 X53.2 X54.2 X58 2 7 1 3 4 6 7 1 3 4 6 1 3 7
B-R1
R-G1
X55 0 1
B-R1
N1.5
X159 6 II I 0 1 0
N1
N1
5 2 8
S87
S86 8 2 5
S88 8 2
5 2 8
A/R1
G-V1.5
8 2 5 8 2 X87 X87 X87
S-N1
X86 X86 X86 X88 X88
H1.5
V1.5
A-B1
G-N1
H1.5
V1.5
N1.5
N1.5
SUPPLY
UNIT
C14 C-L1
N1
A-B1
1
H/R1
H-R1
H-R1
X402
GEAR
G1
A1
G1.5
M-V1
2 C24
G1
G1
X402
1 1
- - - - - - - - X148.1 X152
56a
56b
56a
56b
57
57
L
R
MACHINE FUCTION 01171128 M
R-V1
C-L1
R-N1
N1.5
C-B1
A1
C1
N1
L/B1
31
31
L/B1
A-G1.5
A-G1.5
G-N1.5
G-N1.5
L/B1
G-V1
V1.5
V1.5
H1.5
H1.5
A-B1
G-N1
EC POWER SWITCH
2 2
R1
R1
A1
G1
X401 X400
A-V1
OUT BUZZER
X44.s 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
C-B1
C-B1
BACK PPC
V-N1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
G/R1
X44.p
R1 ACC BR R2 C
GND
OFF ACC
A-G1.5
A-G1.5
R-N1.5
G-N1.5
G-N1.5
R1
V1.5
V1.5
Z-N1
R1.5
H1.5
H1.5
N2.5
ST
G-V1
G-N1
G1
G1
C-L1
S24 B A1 A2 A3 A4 A5 A6 A7 A8 B1 B2 B3 B4 B5 B6 B7 B8 C1 C2 C3 C4 C5 C6 C7 C8
C-L1
Z-N1
V-N1
G/R1
X6
H/R1
R1
G1
B A C
B-G1
Z-B1
Z/N1
A-B1
Z-N1
C-B1
B-N1
C-N1
M-V1
X13 X13 X13
N1
X24.r1 X24.acc X24.b X24.c X24.br X24.gnd
N1
1
B-R1.5
X500
N1.5
B/N1
A1
M/N1
M/N1
C24
L6
R6
B13
A-B1
A-B1
H/N1
M1
2
X500
B0.5
A-B1
A1
CAVO4
42N-06
CAVO4 B0.5
CAVO4 SCH0.5 15720
SCH0.5
Schermo2
CAVO4
G-N1.5
S-N1 S1 S2 S3 S4 S5 S6
A-G1.5
S-N1
A-B1
Z-N1
C/B1
C-B1
C-N1
M-B1
M-V1
L-N1.5
M-N1
N1
N1
Z-N1
H-N1
M/B1
C-B1
X47
M-N1 1
C-B1 2
C/B1 3
M-B1 4
C-N1 5
Z-N1 6
C-L1
B-N1
B6
R-G1
M/N1
S/N1 B-G1 A-R1 V6 M/B1 A-B1
N1.5
7
B-G1
N1
M16
8
1 1 1 S40 1 3
X17.2 X49 1 86 87 Y48 X48 86 87 1 1 9
Y49 K61
X42 X42
K45
X555 K56 X56 X56 X61 X61 X23 X45
M-V1 10
M42
V/N1
86 87 86 87 86 87
53a 11
H17 53 M
31b
85 30 85 30 85 30 12
X15.p A-N1.5 2 85 X56.1 85 X61.1 2
1 1 2 X555 X56 2 X61 X23 31 B
N1 X17.1 X49 X48 1 2 3 4
R1 C-B1
C-B1
N1
2 X40 CN-F20 X6.p
42N-06
C-B1
C-B1
H/N1
N1
R6
N1
M-V1
1 1
Z1 V-B1
B-N1
N1
R1
N1
N1
2 CN-F20 X6.p
R6
X42 2 2
R16
13730
N1.5
M-B1
M-B1
CN-F20 X6.p
3 3
CN-F20 X6.p
4 4
B/N1 CN-F20 X6.p R-V1
5 5
B-N1 Z-B1 CN-F20 X6.p M-N1
6 6
B-N1 CN-F20 X6.p H-L1
7 7
R-G1.5 CN-F20 X6.p B1
8 8
B1 CN-F20 X6.p A-V1
9 9
CN-F20 X6.p
10 10
N1 CN-F20 X6.p B-R1
11 11
R-N1.5 CN-F20 X6.p B1
12 12
X43 1 R-G1
H-L1
V-B1
15 2 G-N1
10 20 H-R1 H-R1
RPM x 100 3 R1 R-V1
H-R1
H-L1
G-N1.5
V-N1
H-R1
G/R1
5 25 4 B-N1
H-N1 H/R1
L6
5
V6
R6
0 30 1
6 Z-N1 H/R1 H/R1 X160.p
B-N1
R1
X7.p
7 6 5 4 3 2 1 1X160.p X7.s 1
7 X5.s G-N1
OPTIONAL 4WS
C-B1 2X160.p
8
Z-N1
H-R1
M-B1
M-B1
R-N1
B-N1
1
+15Key +30 +15 X5
X3.s 3X160.p
UNIT (01171166) H-G1
N1
N1
R6
R6
9 1
X4.s M-B1 4 X160.p 1
10B-V1 R-G1.5 2 1 X3.p
L-B0.5 B-R1.5 F25 F14 F13 F12 F24 F21 F22 F18 F16 F17 R-N1.5 N1 N1 5X160.p X3.s 1
11 3 F7 2
V-B1
A-V1
B-R1
10A 10A 10A 5A 7.5A 10A 7.5A 7.5A 10A 10A 10A 6X160.p
12 Z1 4 3 2
X5
A-G1.5
7 X160.p
13M/N1 Z-N1 5 4 B1 B-R1
V/N1
N2.5
H-R1
H/R1
G-N1
S-N1
M-N1
M-N1
A-G1
V1.5
Sal7 8 X160.p
14Z-B1 B-R1 B-R1
C14
6 5
N1
B0.5
V-B1
V-B1
V-B1
10X160.p 86 87a 87
16 8 7 R1.5 B-V1 K400 X4 X4 X4
A-G1.5 11X160.p
CAVO4
17 9 8 8687a 87
R-V1
C-B1
G-N1.5 12
18 10 9
B0.5
SCH0.5
85 30
19 G-V1 B-G1 11
85 30 V-B1
20 H-R1 12 K2 K1 X4 X4 Sal3
P43 V-B1
A-R1 A-R1
CAVO5
13 F10 F23 15 15 F2 F9 F1
B0.5
F8 F11 F15
Schermo
Sal1
M-B1 10A 10A 15A 15A 15A
CAVO6
14 7.5A 10A
V-B1
V-B1
7.5A
R-V1
M/B1
R-G1
31 T 31 T
N1.5
15
V1
53M 53M
CAVO6
16
A-N1.5 A-N1.5 17 2
C14
1 X30.1
X27.s A-R1 R-V1 18 X46 1
A/C
CAVO5 SCH0.5
1 X501
CAVO5 B0.5
C-B2.5
19
Z-N1
S46 X30
V-B1
V-B1
V-B1
V-B1
V-B1
B-R1
B-R1
B-R1
B-R1
C-B1
C-B1
B-N1
R-V1
X27.s
R-G1
M-N1
2 20
42N-07-11400
21 Sal3
L/R1 X2.s 2 A1 7
X1
8
X1
12
X1
13
X1
1
X2
2
X2
3
X2
4
X2
5
X2
6
X2
7
X2
8
X2
9
X2
11
X2
12
X2
1 2 1 1 X501
X28.s
A R4 K11
HEATING A-G1.5 2 F5 K5 K3 K4 X46 X30.1 X30.2
10A
F6 F3 F4 F19 F20
B1
86 87a 87 86 87a 87 86 87a 87 86 87a 87
X28.s N4 B-R1 15A 3A 3A 15A
R1.5
B 3 15A
42N-54-11300 KOMTRAX UNIT
R/N1
S-N1
M-N1
M-N1
A-G1
V1.5
V-N1
M-B1
V1.5
H1.5
H1.5
A-B1
Z-B1
C-B1
A-B1
G1
4
N1
85 30 85 30 85 30 85 30
A158
N1
A1
L-N1.5 5
X1.s H-R1 R/N1X158 1
A-B1 6 UNIT (01171166) 1 V1.5
H-R1X158 2
7 2 H1.5
B-L1X158 3
8 3 G1
C-L1 H-R1X158 5
A-N1.5 9 4 G-N1
H-L1X158 7
L-N1.5 10 5 M-V1
K10 K6 K8 K9 K7 G1 H-R1X158 8
11 D2 D3 D1 86 87a 87 86 87a 87 86 87a 87 86 87a 87 86 87a 87 6
S1 X158 9
12 7 V1.5
H-G1 85 30 85 30 85 30 85 30 85 30 H/R1X158 10
13 8 H1.5 H1.5
M-V1 X158 11
14 9 G-N1 G-N1
H1 X158 12
15 10
CENTRALINA CAMBIO
L/B1 L/B1X158
CAVO5 SCH0.5
14
A-G1 G1
CAVO5 B0.5
16 11
B/N1X158 20
A-R1
H-R1
H-R1
G-N1
S/N1
N1
G1
17
M-B1 M-B1 X158 21
H-R1 L/R1 L/R1X158 22
M/N1 M/N1 X158
N1.5
23
C-B2.5
R-N1.5
B1
Sal1 B1 B1 X158
H-R1
25
H-N1
V-B1
Z-N1
Z-B1
H-R1
G-N1
B-N1
C-B1
N1.5
N1.5
H-L1
H-G1
R16
N1
N1
N1
N1
R4
R6
R6
R6
N1
N1
A1
29
H-R1
H-R1
Sal2 H-R1
A-R1 H-R1 H-R1X158 34
G-N1 H-N1X158 37
H-R1
CAVO4 B0.5 CAVO4 B0.5 G-N1 X158 38
G-N1 G-M1 G-M1 X158 39
A1 L1X158 41
A/N1X158 43
V/N1 V/N1 C1 C1 X158 44
V-Z1
Z-N1 S-N1 S-N1X158 45
A-N1.5
L1 B-V1X158
S-N1
N1.5
N1.5
H-L1
N1.5
B-R1
H-G1
48
R16
Z-B1
M/N1
N2.5
H-L1
M-N1
M-N1
A-G1
B-N1
H-R1
A/N1
L/R1
V-N1
N1
N1
N1
R6
R6
R6
R6
N1
R4
B6
N1
N1
A1
C-N1X158
A-N1
N1.5
N1.5
N1.5
49
N1
N1
H1
L1
C1
B/V1
N1
N1
N1
H-L1 B/V1X158 50
A-G1 A-G1 A-G1
A-B1 Z/B1X158 51
N1
N1
gnd9
gnd11
gnd10
gnd1.3
gnd1.2
gnd1.1
C-B2.5
R-N1.5
A-N1.5
X68.2 X68.3
X68.1
H-N1
V-B1
Z-N1
Z-B1
S-N1
G-N1
H-L1
M-N1
M-N1
B-N1
B-N1
H-R1
G-M1
A/N1
L/R1
B/V1
V-N1
M/N1
Z/B1
Z-N1
Z-B1
C-B1
C/B1
V-Z1
A-N1
V-N1
V/N1
H-L1
N1.5
G-N1
A-B1
B-R1
N1.5
S1
S1
H1
L1
C1
F27
N1
G1
M16
200A
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1 X11.p 1 2 3 4 5 6 7 8 9 X11.p 12 13 14 15 X12.p 1 2 3 4 5 6 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 10 11 12
X7.p X65.p X77.pX77.pX77.pX77.pX77.pX77.pX77.pX77.pX77.p X8.p
A-N1.5
R-N1.5
B-L1
L/R1
Z/B1
Z-B1
42N-06
H-L1
B/V1
V-B1
Z-N1
A/N1
N1.5
N1.5
42N-06
S-N1
H/R1
Z-B1
V-Z1
H-L1
B-N1
V-N1
H-N1
L1
H-N1
Z-N1
H-R1
C/B1
V/N1
A-B1
M-V1
C-B1
A-N1
G-N1
M/N1
V1
A1
B1
B2
C-N1
M-N1
H1
C1
G-N1
G-M1
A1
G1
M16
B6
11161 12560
11451
A-N1.5
C-B2.5
R-N1.5
Z-B1
Z-N1
V-B1
S-N1
B-L1
L/R1
Z/B1
H-N1
H-L1
B/V1
H-R1
H-R1
M-V1
A/N1
B-V1
B-V1
B6
V1
R25
R70
R70
R25
R25
V-N1
B-N1
N1
L1
H-R1
M16
G-N1
M/N1
B1
B2
M-N1
H1
C1
G-M1
Z-B1
H-L1
V-Z1
Z-N1
V/N1
C/B1
A-B1
B-R1
C-B1
A-N1
B-R1
C-N1
G-N1
G-N1
A1
G1
H-N1 N1 N1
H/R1
A1
1
1 1 1 1 2 3 X207
1 X119.1 X116 1 1 1 1 1 2 3 1 1 1 1 1 X101 X101 X101 1 1 1 1 1 1 1 1 1 2 1 3 1 3 1 1 1 1 B A C
X118.1 1 1 A B C 1 1 Y90 X90
Y91 X91
Y92 X92
Y93 X93
E100 X100 X100 X100
Y95 X95
Y96 X96
Y98 X98
Y99 X99 X97
E101
X103 X350 X351 X352 X353 X354 X355 X356 X357 X211 X211 X211 X210 X210 1 X408 X407 M207 X406 X405 X209 X209 X209
G118 G119 X119.2 X117 X115 1 X112 X112 X112 X121 X60 M116 Y350 Y351 Y352 Y353 Y354 Y355 Y356 Y357 X212
X113 Y60 M
59c
59c
G1 R114
57
57
X114
L
30 50 E103 B210
M 30
D+
W
Y117 B115 B113 B112 B121 M RPM B209 1
G t p X208
12Vcc 3 p p t B208
31
31
U H97 B211 t
N1
2
31 2 t
2 2 2 2 4 2 2 2 2 2 4 2 2 2 2 2 2 2 2 2 X212 2 2 2 2 2
X113 2 2 X90 X91 X92 X93 X100 X95 X96 X98 X99 X97 X101 X103 X350 X351 X352 X353 X354 X355 X357 2
N1.5
N1.5
N1.5
N1.5
X121 X60
H-R1
H-R1
H-R1
H-R1
X210
N1
N2
N1
N1
N1
N1
N1
N1
N1
N1
N1
L1
N1
N1
N1
N1
N1
N1
N1
N1
H1
N1
N1
N1
N1
N1
gnd1.1
S0
gnd2.2 Sal1
N6
gnd2.3 GND1
Gnd1
WB97R-5E0 90-7
ELECTRICAL CIRCUIT DIAGRAM (2/3) DIAGRAMS AND DRAWINGS
ID Description ID Description
ID Description
F19 Low beam fuse 15A S140 Rear working light switch
A1 Komtrax unit
F20 Main beam light 15A S141 Beacon lamp switch
A6 Multifunction unit
F21 Return to DIG sender supply fuse 10A S142 Front working light switch
A158 Gear unit
F22 EC power fuse 7,5A V180 Current electric limitator for warning light
B13 Return to dig sensor
F23 +15 Steering unit fuse 10A X30 Lighter
B53 Stop switch
F24 Flasher fuse 7,5A Y48 Float solenoid valve
B54 Stop light switch
F25 Reverse speed buzzer + Steering column 10A Y49 Return to dig solenoid valve
B59 Brake oil low level switch
F27 General fuse 200A Y60 Emp. solenoid valve
B112 Thermistor switch
G1 Battery Y90 PPC solenoid valve
B113 Air filter
G118 Starter Y91 ECOPOWER solenoid valve
B115 Engine oil low pressure switch
G119 Generator Y92 Back-up alarm
B121 Horn
H17 Buzzer Y93 Rear PPC solenoid valve
B208 Fuel high level sensor
H97 Horn Y95 Unlock arm solenoid valve
B209 Fuel level sender
K1 Unrepeat start unit Y96 Unlock plate solenoid valve
B210 Oil transmission temperature switch
K2 Flasher Y98 Closing grab solenoid valve
B211 Speed meter sensor
K3 Low beam relay Y99 Opening solenoid valve
B212 Transmission oil pressure switch
K4 Main beam relay Y117 Elettrostop
B405 4th gear switch
K5 Starter cut relay Y200 2WS solenoid valve
B406 3rd gear switch
K6 Return to DIG solenoid valve relay Y350 1st speed solenoid valve
B407 2nd gear switch
K7 Light stop relay Y351 2nd speed solenoid valve
B408 1st gear switch
K8 Assent start relay Y352 3rd speed solenoid valve
CN-F20 Komtrax Interface connector
K9 Forward speed relay Y353 4th speed solenoid valve
E100 Right rear light
K10 Reverse speed relay Y354 Forward speed solenoid valve
E101 Left rear light
K11 Stop drive relay Y355 Reverse speed solenoid valve
E103 Number plate light
K45 Preheating Relay Y356 Differential lock solenoid valve
E136 Right rear working light
K56 Starting relay Y357 Doble traction solenoid valve
E138 Left rear working light
K61 Service relay
E143 Right front lateral working light
M207 Motor pump
E146 Left front lateral working light
M42 Rear Windshield-washer
E147 Left front light
M55 Motor pump
E148 Beacon lamp
M58 Front windshield-washer
E151 Right front light
M116 Compressor
E152 Cabin lamp
P43 Instruments panel
F1 Central front working light fuse 15A
P63 Front instruments
F2 Central rear working light fuse 15A
R114 Preheating
F3 Right position light fuse 3A
S0 Main switch
F4 Left position light fuse 3A
S24 Starting switch
F5 Horn fuse 10A
S40 Seat Switch
F6 Lateral rear working light fuse 15A
S46 Parking brake switch
F7 Windshield wiper-washer + rear horn fuse 7,5A
S57 Gear steering column
F8 Stop light switch fuse 7,5A
S60 Light steering column
F9 Lateral front working light fuse 15A
S80 Ride control switch
F10 Front windshield-motor supply fuse 10A
S81 Unlock arm button
F11 Optional fuse 7,5A
S82 Unlock plate switch
F12 Front + lateral instrument + buzzer fuse 5A
S83 E/C power button
F13 Supply level grip fuse 10A
S84 EMPI solenoid valve switch
F14 Light switch + switch optional fuse 10A
S85 Rear horn button
F15 Elettrostop + safety starter fuse 10A
S86 General light switch
F16 Beacon light fuse 10A
S87 4wd switch
F17 Warning switch fuse 10A
S88 PPC button
F18 Cabin lamp + cigarette lighter fuse 10A
S89 Warning switch
90-8 WB97R-5E0
DIAGRAMS AND DRAWINGS ELECTRICAL CIRCUIT DIAGRAM (3/3)
A-G1
A-G1
C-B1
G-N1
L-R1
L-B1
G-V1
G-V1
N1
N1
N1
N1
N1
C-L1
C-L1
42N-06-15540
R/N1
H-V1
R/N1
V-N1
V-N1
A/R1
A/R1
V/N1
V/N1
V/N1
A/R1
A/R1
V-Z1
C-L1
C-L1
V-Z1
L/R1
R1
N1
N1
N1
N1
A1
P63 7 1 3 4 6 7 1 3 4 6 4 6 1 3 7 1 1 1 1
X140 X140 X140 X140 X140 X142 X142 X142 X142 X142 X146 X143 X136 X138
M-N1.5
M-B1.5
L-N1.5
A 1 2 3 4 1 1 3 4 6 7 7 1 3 7 1 3 7 1 3 X141 X141 X141 X141 X141
G-M1
R-N1
H-V1
C-B1
G-L1
G/R1
A/B1
H1.5
V180
L-B1
X180 X89 X89 X89 X89 X89 X80 X80 X81 X81 X81 X82 X82 7 1 3 4 6 7 1 3 4 6 4 6 1 3 7
E146 E143 E136 E138
M1
0 1
1 3 4 6 7 7 1 3 7 1 3 7 1 3 II I 0 II I 0
1 1
4 2 8 5 7 4 1 9 10 12 8 7 2 1 0 0 1 0 0
2
5 8
X57 X57 X57 X57 X57 X60 X60 X60 X60 X60 X60 S141
G-V1.5
S140 8 2 5
S142 8 2 5
G-V1
C-B1
L-R1
L-R1
C-L1
L-B1
R N F Out1 Out2 56 1 L R 31b 53 15 53c 5 2 8 4 4 4 4
N I 2 0
S89 8 2 5 S80 8 2
S81 8 2
S82 8 2
X140
8
X140
2 5
X140
8
X142
2
X142
5
X142
X141 X141 X141 X146 X143 X136 X138
R F Dx WASHER I
LAVACRISTALLO 1 8 2 5 8 2 8 2 8 2
N1
N1
N1
N1
X181 X89 X89 X89 X80 X80 X81 X81 X82 X82
R1
L-R1
G-N1
G-N1.5
N1
A-G1
G-N1.5
A-G1
A-G1
A-G1
G-V1
A-G1.5
G-V1
86
87
86
87
86
87
A-G1.5
C-L1
HORN
CLAXON
Sx
L/R1
A-B1
G-M1
A-G1
V-N1
G/R1
C-L1
C-L1
V-N1
V/N1
A/R1
A/R1
A/R1
A/R1
V-Z1
H
+ 56b 56a 49 H K340 K342 K341
S57 S60
9 5 3 11 6
X60 X60 X60 X60
G-N1.5
H-R1
H1
V1
A-G1
C1
30
30
30
85
85
85
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 9 10 11 12 X340 X342 X341
A-N1
A-N1
R/N1
R/N1
S-N1
S-N1
R/N1
R/N1
S-N1
B-N1
V-N1
A-B1
A-B1
N1
N1
X63 X64 G-N1.5
N1
N1
R1
N1
A-G1.5
A-G1.5
N1
N1
FRONT DASHBOARD HARNESS 42N-06
V0.35
V-N1
G-M1
C-L0.5
L-B0.5
M/B1
B-V1
A-V1
A/V1
A-R1
N1
S-G1
S/N1
S-N1
S1
H-V1
R-V1
M-N1
Z-B1
G1
H1
V1
7 1 3 7 1 3 7 1 3
0A008271 REV00 11520 X83 X83 X83 X85 X85 X85 X84 X84
R1
7 1 3 7 1 3 7 1 3
1
1 0 1 0 0
N1
S83 8 2
S85 8 2
S84 8 2
8 2 8 2 8 2
X83 X83 X85 X85 X84 X84
G-M1
G/R1
A-G1
S-N1
R/N1
R/N1
R/N1
R/N1
H-V1
V-N1
A-N1
Z-N1
A-B1
L/R1
A-B1
A-B1
A1
N1
N1 N1
N1 N1
G-N1.5
A-G1.5
SAL1
N1 N1
M-N1
B-G1
S-N1
R/N1
S/N1
G-L1
A-B1
A-B1
A-B1
H-L1
Z/N1
Z/N1
G1
G1
N1
N1
N1
1
X345.s
V-N1
G1
7 1 3 4 6 7 1 3 4 6 1 3 7
X86 X86 X86 X86 X86 X88 X88 X88 X87 X87 X87 X87 X87
7 1 3 4 6 7 1 3 4 6 1 3 7
WORKING
G-V1.5
0 1
G-N1.5
G-N1.5
A-G1.5
LIGHT OTIONALS
G-N1
G-N1
II I 0
H1.5
H1.5
H1.5
H1.5
1 0
G-V1
A-B1
A-B1
V1.5
V1.5
V1.5
V1.5
G1
G1
N1
R1
R1
A1
A1
R1
5 2 8
S87
S86 8 2 5
S88 8 2
N1
A/B1
L-N1
H1.5
5 2 8 1 2
8 2 5 8 2
N1
X87 X87 X87 X148.1
R-N1
R-G1
A/V1
X152
X86 X86 X86 X88 X88
X147.3 X147.2 X147.5 X147.4 X151.3 X151.2 X151.5 X151.4
M-N1
G1
2 4 3 1
56b
56b
57
57
R
L
56a
56a
H/R1
G1.5
G1
A-B1
A-B1
X58 X58 X58 X55
H-L1
H-L1
Z/N1
Z/N1
1 1 1 M
X53.1 X54.1 X59.1
31
31
S53 S54 B59 53a
M A6 42N-06-15161
53 M 53b
E147 E151
31b
UNIT 1
X148.2
E148 1
X152
E152
31 X147.1 X151.1
M55 MULTIFUNCTION 01171127
N1
1 1 1 M58
N1.5
N1.5
N1.5
N1
N1
N1
N1
N1
X53.2 X54.2 X59.2
1 2
N1
R-G1
B-R1
X58 X55
GND7.2
C-B1
Gnd7.2 Gnd7.2 Gnd7.2 Gnd7.2 Gnd7.2 Gnd7.2 Gnd7.2 Gnd7.2
M-B1.5
L-N1.5
C-L0.5
M-N1
R-G1
M/B1
H-R1
G/R1
S-G1
R-N1
A-G1
H-R1
V-N1
H-V1
R-V1
C-B1
S-N1
A-R1
B-V1
S/N1
A-V1
L-B1
G-M1
M-N1
G-N1.5
G-N1.5
M1
G/R1
A-G1
B-G1
A-G1.5
A-G1.5
H-V1
V-N1
A-N1
V-N1
B-N1
R/N1
S-N1
H1
N1
C1
A-B1
Z-N1
G-L1
A-B1
S/N1
S1
C-L1
G1.5
Z/N1
H-L1
V-Z1
L/R1
N1.5
DIFFERENTIAL LOCK SWITCH
G-N1
G-V1
A-B1
H1.5
H1.5
V1.5
V1.5
A1
G1
R1
R1
N1
Gnd8 Gnd7.3 Gnd7.2
A1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 X9.s 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
EC POWER SWITCH
X10.p
11
1
1
10
R-G 1 17
A-B 0.5 18
H 1 21
10
17
18
13
15
13
15
B-R 1 16
16
12
12
H-V 1 19
14
14
X44.p
8
G 1 20
3
5
6
6
2
2
9
9
4
4
X26.p
11
1
10
17
21
13
15
16
12
19
14
7
20
3
5
6
6
2
2
9
9
4
4
G-M 1
M/B 1
V-N 1
M-N 1
B-V 0.5
H-R 1
M1
H/R 1
L-N 1.5
G-L 1
C-L 0.5
L-B 0.5
C1
V-N 1
R-V 1
V1
C-B 1
H-N 1
11
ACC
10
17
18
13
15
16
12
R1 BR R2 C
14
SEAT SWITCH
8
3
6
2
9
4
4WD SWITCH
OUT BUZZER
OFF ACC
R1
A-G 1.5
A-G 1.5
R 1.5
R-N 1.5
V 1.5
V 1.5
H 1.5
H 1.5
G-N 1
G1
G-V 0.5
G-N 1.5
G-N 1.5
A1
A-B 1
ST
L/R 1
G/R 1
A-B 1
G-M 1
H-V 1
V-N 1
N1
Z-N 1
G-L 1
A-B 1
V/N 1
V-N 1
A/R 1
B-G 1
B-N 1
H/R 1
R/N 1
TRAX UNIT
S24 B
GND
X158 A1
18 M-N 1 S47
A-B 1 B1
L-B 1
M-V 1 A1
B-G 1 C1
B-N 1 B8
Z-N 1 B5
Z/N 1 B6
M 1 C7
C-R 1 A7
C-N 1 A8
G-M 1 B4
B-R 1 C2
H/N 1 C6
A3
A5
H/R 1 C4
H-L 1 A6
A-B 1 C8
Z-B 1 A2
S-N 1 C3
M-V 1 A4
S 1 C5
19
B/N 1
X24.r1 X24.acc X24.b X24.br X24.c X6
R6
X24.gnd
B-R 1.5
M/N 1
M/N 1
42 A-R 1
M-B 1
A-B 1
46
S-N 1
R1
C1 47 G/R 1
B1
C4
C3 Z-V 1
C-N1
A-B1
Z-N1
C/B1
M-B1
C-B1
M-V1
M-N1
N1
N1
X149
A5
R/N 1
S-N 1
X47
X149 M-N 1 1
A4
Z-V 1
2
A8
3
B8
M-B 1
A-B 0.5
4
M-B 1
R-G 1
R-N 1
M1
C8 Z-V 1 - 5
SA2
Z-N 1
Z-V 1
A-B 1
C-L 0.5
X149
M/N 1
7
B5
8
A-R 1 9
H-R 1
A/R 1
L/R 1
X149 M-V 1 10
A7
A-G 1 11
B6
12
BUZZER PRESSURE A1 42N-06 LOADER KNOB HARNESS
H101 SWITCH C7 15720
B103 00000832 REV00
Z-B 1
1
C5
1
X101.2 X101.1
C-R 1
-
M/B 1
A-G 1
M1
C-L 1
L-N 1.5
C-L 1
N1
M/N 1
M-N 1
2 2
C-B 1
N1
C-B 1
1 2
C-B 1
3 3
S/N 1
A-R 1
X6.p
86
30
CN-F20
B6
4 4
B-G 1
B/N 1
B-N 1
R-V1
2
X556 X6.p
X556 1 2 3 CN-F20
L6
K104
V6
1 2
S-L 1 1 B A C 1 2 1 S40 1 2
X42 X42 Z-B 1 CN-F20
5 5
X6.p M-N1
1
X558
7 1 3 4 6
S-L 1 X558 Y49 X49 X13 X13 X555 X555 86 87
Y48 X48 86 87 1 M42 B-N 1 6 6
H-L1
N1
1 2 X17.1
K56 K61 K45
0
1 X56 X56 X61 X45 CN-F20 X6.p
X23 X61
X15.s X15.p N1 V555 86 87 86 87 86 87 M M R-G 1.5 CN-F20
7 7
X6.p B1
N1 2 8 8
8 2 5 S100 2
B1 CN-F20 X6.p A-V1
85 30 85 30 85 30 9 9
R-N1 A-N 1.5
1
1
X105
X104 1 H17 B13 85 X56.1 85 X61.1 B
CN-F20
10
X6.p
10
B-R1
8
2
85
87a
R-L 0.5
V23
B-N 1
R 16
M16
X40 11 11
N1
R-N 1.5 B1
M-N1
H/N 1
X6.p
M-V 1
CN-F20
N1
N1
N1
R-G 1
12 12
H-L1
V-B1
R-N1
X43 R-V1
1 R-G 0.5
2 G-N 0.5
N1
15 X7.p
10 20 3 R 0.5 1
RPM x 100
B-N1
4 B-N 0.5
H-R 1
A-G 1
G/R 1
H-R 1
5 25 X7.s 1
42N-06 DRIVER SITE HARNESS 5 H-N 0.5 H-L 1
1
X2.p H/R 1
V6
16351
R6
1
L6
KIT 0 30
6 Z-N 0.5 X5
1
X5.s
7 C-L 0.5 +15Key +30 +15 1
OPTIONAL 8 C-B 0.5 X3.p
X3.s 1
X3.s
9 A-B 0.5 1 42N-06-15141 UNIT (01171166)
0A050434 REV07
B-R1
R 0.5
V-B1
A-V1
X4.s 2
10 B-V 0.5 2 1 X5
B-R1
G-N 1
11 B-R 1.5 3 F25 F14 F13 F12 F24 F21 F7 F22 F18 F16 F17 2 R-N 1.5
B-R1 B-R1
M/N 1 H1
G 1.5
13 4 10A 10A 10A 5A 7,5A 10A 7,5A 7,5A 10A 10A 10A 3
Sal2
14 Z-B 0.5 Z-N 1 5 4 V1 86 87a 87
V-B1
V-B1
V-B1
X4 X4 X4
15 R-L 0.5 6 5 C1 K4 86 87a 87
C-B1
R 1.5
R-V1
17 7 6
R-G1
R-V1
B-G 1 11 2 Sal1
42N-06-15280
V-B1
V-B1
H-R 1 12 3
OPTIONAL
K2 K1
13 F2 F9 F1 4
F8 F11 F10 F23 15
F15 15
M-N1
M/B 1
R-G1
B-R1
B-R1
B-R1
B-R1
C-B1
C-B1
B-N1
R-V1
V-B1
V-B1
V-B1
V-B1
V-B1
R-V 1 18 9
A-N 1
R/N 1
X28.s
A 19 10
HEATING R-G 0.5
20 1 11
KOMTRAX HARNESS 42N-06
X1 X1 X1 X1 X2 X2 X2 X2 X2 X2 X2 X2 X2 X2 X2
A1
H-R 1
B-V 1
X2.s 2 1
L/R 1 1
K11 F5 K5 K3 K4
X41.s
1 2
1 KOMTRAX UNIT
2
86 87a 87 10A 86 87a 87 86 87a 87 86 87a 87
F6 F3 F4 F19 F20 X30.1 X30.1
S41
R 1.5
3 15A 3A 3A 15A 15A 2
G1
B-R 1
H-N 0.5
Z-B 0.5
M-N 1
R-N 1 4 85 30 85 30 85 30 85 30
L-N 1.5 5
X1.s
6 1 V 1.5
7 2 H 1.5
8 3 G1 G-M 1
X158
A-N 1.5 A-N 1.5 9 4 G-N 0.5 SAL1 H-R 1 1
H-R 1
L-N 1.5 10 5 H-R 1 2
K10 K6 K8 K9 K7 M-V 1 A158
11 D2 D3 D1 86 87a 87 86 87a 87 86 87a 87 86 87a 87 86 87a 87 6 B-L 1 3
G1 H-R 1
H-G 1 12 7 V 1.5 5
85 30 85 30 85 30 85 30 85 30
M1 13 8 H 1.5 H-L 1 7
16 11 G1 H/R 1 10
TRAX UNIT
12871 A-G 1
0A050003 REV00 Z-N 1 S/N 1 17 H1 12
B/N 1 20
M-B 1 21
L/B 1 22
25
R-G 1.5
29
H-R 1 34
H-N 1 H-N 1 37
G-N 1
A-N 1.5
C-N 1
G-N 1 38
S-N 1
V-N 1 L1 41
gnd11 M-N 1
A1 B-V 1 48
gnd10 C-N 1 49
RD gnd9
gnd1.3
gnd1.2
N10
gnd1.1
R-N 1.5
C-B 2.5
Gnd11 Gnd10 Gnd9 Gnd1.3 Gnd1.2 Gnd1.1
R4
R6
R6
C-B 0.5
A-B 1
G1
A1
C-B 0.5 C-B 0.5
F27 A1
175A
H-N 0.5
R-N 1.5
C-B 2.5
A-N 1.5
V-B 0.5
Z-B 0.5
M16
B-N 0.5
M-N 1
S-N 1
G-M 1
A-N 1
V-N 1
V-N 1
H-N 1
Z-B 1
Z-N 1
A-B 1
V/N 1
Z-B 1
V 0.5
H-L 1
G-N 1
B-R 1
A-B 1
B6
H1
A1
L1
G1
A1
10
11
12
13
14
15