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CONTENTS
Page
10. STRUCTURE AND FUNCTION............................................................................... 10-1
WB93R-5E0 00-1
PAGE INTENTIONALLY
LEFT BLANK
REVISED PAGES
REVISED PAGES
The affected pages are indicated by the use of the fol-
lowing marks. It is requested that necessary actions be
taken to these pages according to table below. Mark Indication Action required
WB93R-5E0 00-3
(1)
REVISED PAGES
00-4 WB93R-5E0
(1)
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, remove the leads from the bat-
smoke while working.
tery. Always remove the lead from the negative ( – )
terminal first.
WB93R-5E0 00-5
k SAFETY
14. When raising heavy components, use a hoist or 19. Be sure to assemble all parts again in their original
crane. Check that the wire rope, chains and hooks places. Replace any damage parts with new parts.
are free from damage. When installing hoses and wires, be sure that they
Always use lifting equipment which has ample ca- will not be damaged by contact with other parts
pacity. Install the lifting equipment at the correct when the machine is being operated.
places.
20. When installing high pressure hoses, make sure
Use a hoist or crane and operate slowly to prevent
that they are not twisted. Damaged tubes are dan-
the component from hitting any other part.
gerous, so be extremely careful when installing
Do not work with any part still raised by the hoist or
tubes for high pressure circuits. Also, check that
crane.
connecting parts are correctly tightened.
15. When removing covers which are under internal
21. When assembling or installing parts, always use
pressure or under pressure from a spring, always
specified tightening torques.
leave two bolts in position on opposite sides. Slowly
When installing the parts which vibrate violently or
release the pressure, then slowly loosen the bolts to
rotate at high speed, be particulary careful to check
remove.
that they are correctly installed.
16. When removing components, be careful not to
22. When aligning two holes, never insert your fingers or
break or damage the wiring.
hand.
Damage wiring may cause electrical fires.
23. When measuring hydraulic pressure, check that the
17. When removing piping, stop the fuel or oil from spill-
measuring tool is correctly assembled before taking
ing out. If any fuel or oil drips on to the floor, wipe it up
any measurement.
immediately.
Fuel or oil on the floor can cause you to slip, or can 24. Take sure when removing or installing wheels.
even start fires.
00-6 WB93R-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.
WB93R-5E0 00-7
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.
other precautions for preserving
Example: a Caution
standards are necessary when
10 - 3 performing the work.
3 Tightening
item Parts that require special atten-
3. Additional pages: additional pages are indicated by torque tion for the tightening torque dur-
ing assembly.
a hyphen (–) and number after the page number.
2
Fle as in the example. Parts to be coated with adhe-
Coat
Example: sives and lubricants etc.
5
10-4 Places where oil, water or fuel
Oil, water must be added, and their quan-
10-4-1 tity.
Added pages
6
10-4-2 Places where oil or water must
10-5 Drain be drained, and quantity to be
drained.
REVISIONS
Revised pages are shown on the LIST OF REVISED
PAGES between the title page and SAFETY page.
00-8 WB93R-5E0
HOISTING INSTRUCTIONS
4
HOISTING INSTRUCTIONS
WB93R-5E0 00-9
STANDARD TIGHTENING TORQUE
3
STANDARD TIGHTENING TORQUE
The following charts give the standard tightening torques of bolts and nuts.
Exceptions are given in section of «Disassembly and Assembly».
This torque table does not apply to bolts or nuts which have to fasten nylon or other parts non-ferrous metal washer.
a Nm (newton meter): 1 Nm = 0.102 kgm
00-10 WB93R-5E0
STANDARD TIGHTENING TORQUE
3
2. TIGHTENING TORQUE FOR NUTS OF FLARED
22 27 8±2 78.5±19.6
33 41 20±5 196.2±49
Sealing surface
1” - 14 30 8.2–9.2 80–90
2” - 12 57 20.4–24.4 200–240
WB93R-5E0 00-11
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.
Vaseline ----- Used for protecting battery electrode terminals from corrosion
00-12 WB93R-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 – – –
WB93R-5E0 00-13
WEIGHT TABLE
WEIGHT TABLE
k This weight table is a guide for use when transporting or handling components.
Unit: kg
Machine model WB93R-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 232
Front axle 295
Rear axle 435
Front wheel 65
Rear wheel 163
Work equipment
• Boom 313
• Shovel 436
• Fulcrum lever 13x4
• Tilt lever 32,5x2
• Raise cylinder 46x2
• Tilt cylinder 35x2
Work equipment
• with standard arm 850
• with long arm 885
• with jig arm 1030
Boom 248
Arm 213
Long arm 245
Boom swing bracket 162,5
Backframe 246
Control valve (8-spool) 42,1
Control valve (10-spool) 47,5
Control valve (8-spool) 460
Jig arm 39x2
Outriggers 87,5
Boom cylinder 67
Arm cylinder 52,5
Bucket cylinder 27,5x2
Outriggers cylinder 34x2
Swing cylinder 158
00-14 WB93R-5E0
TABLE OF OIL AND COOLANT QUANTITIES
OIL
ACEA E5 SAE 5W-30
ACEA E4
SAE 10W
OIL
Hydraulic API CD, CF, SAE 10W-30
CF2 98 40
system
SAE 15W-40
(e) HO46-HM
Hydraulic system
with 98 40
biodegradable oil
Front axle:
7 7
Differential
Final reduction
OIL 0.75 0.75
gear (ea)
UTTO FLUID
Rear axle:
Differential and fi- 15 15
nal reduction gears
Hydraulic OIL GM
20 20
transmission DEXRON® II D
®
(DEXRON is a reg-
Braking istered trademark of
General Motors Cor- 0.8 0.8
system poration)
Fuel a
DIESEL OIL 150 –
tank ASTM D975 N. 2
Engine PERMANENT
cooling COOLANT 14 –
system (aa)
WB93R-5E0 00-15
TABLE OF OIL AND COOLANT QUANTITIES
(1) When the diesel oil sulphur content is less than 0,5%, change the engine oil according to the periodic maintenance
intervals indicated in the operation and maintenance manual.
If the diesel oil sulphur content exceeds 0.5%, change the engine oil according to the following table:
(2) Use engine oil, API CI to ensure the engine's constant and correct operation.
(3) Use Komatsu genuine products whose characteristics have been specifically formulated and approved for use in the
engine, in the work equipment hydraulic circuit, in the transmission, in the axles and in the brakes.
First filling quantity:
total quantity of oil, including the oil for the components and pipes.
Oil change quantity:
quantity of oil necessary to fill the system or unit during the normal inspection and maintenance operations.
00-16 WB93R-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.
1 - The number 550 does not appear in the table, so divide by 10 (move the decimal point one place to the left) to
convert it to 55 mm.
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
WB93R-5E0 00-17
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
00-18 WB93R-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
WB93R-5E0 00-19
CONVERSION TABLE
From Nm to lb.ft.
1 Nm = 0.737 lb.ft.
0 1 2 3 4 5 6 7 8 9
10 7.370 8.107 8.844 9.581 10.318 11.055 11.792 12.529 13.266 14.003
20 14.740 15.477 16.214 16.951 17.688 18.425 19.162 19.899 20.636 21.373
30 22.110 22.847 23.584 24.321 25.058 25.795 26.532 27.269 28.006 28.743
40 29.480 30.217 30.954 31.691 32.428 33.165 33.902 34.639 35.376 36.113
50 36.850 37.587 38.324 39.061 39.798 40.535 41.272 42.009 42.746 43.483
60 44.220 44.957 45.694 46.431 47.168 47.905 48.642 49.379 50.116 50.853
70 51.590 52.327 53.064 53.801 54.538 55.275 56.012 56.749 57.486 58.223
80 58.960 59.697 60.434 61.171 61.908 82.645 63.382 64.119 64.856 65.593
90 66.330 67.067 67.804 68.541 69.278 70.015 70.752 71.489 72.226 72.963
100 73.700 74.437 75.174 75.911 76.648 77.385 78.122 78.859 79.596 80.333
110 81.070 81.807 82.544 83.281 84.018 84.755 85.492 86.229 86.966 87.703
120 88.440 89.177 89.914 90.651 91.388 92.125 92.862 93.599 94.336 95.073
130 95.810 96.547 97.284 98.021 98.758 99.495 100.232 100.969 101.706 102.443
140 103.180 103.917 104.654 105.391 106.128 106.865 107.602 108.339 109.076 109.813
150 110.550 111.287 112.024 112.761 113.498 114.235 114.972 115.709 116.446 117.183
160 117.920 118.657 119.394 120.131 120.868 121.605 122.342 123.079 123.816 124.553
170 125.290 126.027 126.764 127.501 128.238 128.975 129.712 130.449 131.186 131.923
180 132.660 133.397 134.134 134.871 135.608 136.345 137.082 137.819 138.556 139.293
190 140.030 140.767 141.504 142.241 142.978 143.715 144.452 145.189 145.926 146.663
00-20 WB93R-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
WB93R-5E0 00-21
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
00-22 WB93R-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
WB93R-5E0 00-23
CONVERSION TABLE
TEMPERATURE
Fahrenheit-Centigrade conversion; a simple way to convert a Fahrenheit temperature reading into a Centigrade tem-
perature reading or vice versa is to enter the accompanying table in the center or boldface column of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit tem-
peratures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of Centigrade val-
ues and read the corresponding Fahrenheit temperature on the right.
1 °C = 33.8°F
°C °F °C °F °C °F °C °F
00-24 WB93R-5E0
10 STRUCTURE AND FUNCTION
WB93R-5E0 10-1
STRUCTURE AND FUNCTION POWER TRAIN
POWER TRAIN
1 2
3 4
RKZ09600
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 flanges (3) to the front (5) and rear (6)
The converter (2) uses hydraulic oil to convert the axles 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) has two hydraulically-activated
clutches that can be selected by an electrically-
controlled gear selector.
It also has manual gear selection (four forward gears
and four reverse gears).
10-2 WB93R-5E0
STRUCTURE AND FUNCTION POWER TRAIN
8
4
2 7 10
RKZ09610
WB93R-5E0 10-3
STRUCTURE AND FUNCTION TRANSMISSION (4WD)
TRANSMISSION (4WD)
Diagram of the power train
Z=45
Z=27 Z=29
Z=50
Z=36
4
8
5
Z=27
9
Z=17
RKZ09620
10-4 WB93R-5E0
STRUCTURE AND FUNCTION TRANSMISSION (4WD)
2nd gear
3rd gear
4th gear
1st gear
Ø3
Ø4
Ø4
Ø3
Bearing
Ø2
0.5–5 bar in neutral
0.5–3.5 bar with
forward
reverse
5 6
Ø 5–Ø7
Bearing
Ø2
Ø 4.5
11–13 bar
11–13 bar
t°
Air breather
Hose
opening 23 bar
Hose
Ø 1.3
7
11–13 bar
2
Opening valve
9 10
3 15 16
0.5–9.0 bar
13 8
12
3.5–5,5 bar
11
Opening
1
4WD
14
RKZ09630
WB93R-5E0 10-5
STRUCTURE AND FUNCTION TRANSMISSION
TRANSMISSION
2 3
E b
1
a 4
E
D 6
D 5 A
7 8
B B
RKZ09640
10-6 WB93R-5E0
STRUCTURE AND FUNCTION TRANSMISSION
3 4 5
18
17
16
8 7
9
14
10
15 RKZ09650
11 13 12
Section A - A
WB93R-5E0 10-7
STRUCTURE AND FUNCTION TRANSMISSION
2 3 4 5 6 7 8 9 10
9
11
10 SectionCC- -CC
Sezione
Section B-B
Sezione B - B
13 14 15 16 17
12
SectionDD- D- D
Sezione
RKZ00991
SectionEE- E- E
Sezione
10-8 WB93R-5E0
STRUCTURE AND FUNCTION DRIVE SHAFTS
DRIVE SHAFTS
Drive shaft for forward and reverse movement
1 2
a b c
RKZ09660
6
5
4 3
a. Port commanding reverse clutch 1. Reverse gear clutch (Z=29)
b. Port commanding forward clutch 2. Forward gear clutch (Z=29)
c. Lubrication port 3. Forward clutch piston
4. Reverse clutch piston
5. Shoulder ring
6. Driven shaft
Driven gear shaft
2 3
5
1
4
6
RKZ09670
8 8
1. 2nd gear driven gear (Z=44) 5. 3rd gear driven gear (Z=33)
2. 1st gear driven gear (Z=50) 6. Rear output shaft
3. 4WD drive gear (Z=45) 7. Shoulder ring
4. 4th gear driven gear (Z=23) 8. Synchronizer
WB93R-5E0 10-9
STRUCTURE AND FUNCTION DRIVE SHAFTS
a
1
5 RKZ09680
4 3
10-10 WB93R-5E0
STRUCTURE AND FUNCTION CONTROL VALVE BLOCK
3 4 5 6 7 8 9
1 10
11
RKZ09690
15 14 12 13 12
Section F - F
1. Ball 9. Valve
2. Spring 10. Piston rod
3. Piston 11. Spring
4. Spring 12. Spool return spring
5. Spring 13. Spool
6. Spring-guide pin 14. Forward gear command solenoid
7. Valve 15. Reverse gear command solenoid
8. Spring
WB93R-5E0 10-11
STRUCTURE AND FUNCTION FRONT AXLE
FRONT AXLE
Differential
1 2 3 4
16
15
7
8
14
9
13
10
12 11
RKZ09700
10-12 WB93R-5E0
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
WB93R-5E0 10-13
STRUCTURE AND FUNCTION FRONT AXLE
B 1
C 2 3
A RKZ09720
A
a b
7 7
5
4 Section B - B 6
Section A - A Detail C
10-14 WB93R-5E0
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. Gasket
4. Planetary gear 11. Flange
5. Differential housing 12. Spacer
6. Ring nut 13. Bevel pinion (Z=13)
7. Half-axle 14. Differential housing
WB93R-5E0 10-15
STRUCTURE AND FUNCTION REAR AXLE
1
3 4
11
5
RKZ09740
10 9 8 7
6
10-16 WB93R-5E0
STRUCTURE AND FUNCTION REAR AXLE
Brakes
1 2
3 4
7
Detail A
Particolare A
A
RKZ09750
WB93R-5E0 10-17
STRUCTURE AND FUNCTION REAR AXLE
Differential lock
a
RKZ09760
3
8 7 6 5 4
10-18 WB93R-5E0
2.5 bar
5 bar
WB93R-5E0
16
µ m
T
E
Ø0,5
PLS
Pen
P1L
LS
PRIORITY VALVE
qMAX
STRUCTURE AND FUNCTION
VALVOLA PRIORITARIA
P 8 bar
160 bar
80 l/min
270bar
Pp
qMIN
LS VALVE
CLOCKWISE
PC VALVE
80L/min
P1
2xØ1 A0
OUT
IN
B0
80L/min
2xØ1 160
bar
MARTELLO
HAMMER
10 140L/min
0µ
m A1
DIGGING DUMP B1
PS
Pd
PM
P1c
Pd2
140L/min
2° BRACCIO
ARM
D
Ø1.5 Ø1.3
PRIORITY DLs
VALVE Ø0,5
LS
275bar
P
T
P
SELF REDUCING 5 bar
218 bar
170 bar
VALVE
0
+5
37,3bar
Ø0.62
Ts
225 bar 0
PPPC
+20
LS
215
bar
225
*100L/min
Cilindro di sterzo
Steering cylinder
bar 0
A2
HYDRAULIC CIRCUIT (WITH MECHANICAL CONTROL)
T
+20
LEFT (BH) RIGHT (BH) ROTAZIONE 1° BRACCIO
B2
BOOM SWING
*100L/min
215
R
bar
220
bar
T
120L/min
A3 BENNA ANTERIORE
DIGGING DUMP B3 FRONT BUCKET
110L/min
LOCK
PB3 PA3
DIFFERENTIAL
P2
0,5mm
1° BRACCIO
120L/min
BOOM
P1
A1
B1
A2
B2
A4
UL
LOCK
Acc
PM
BH BOOM
RAISE LOWER
344 120L/min
bar
100L/min
A5
DIGGING DUMP B5
120L/min BENNA RETROESC.
REAR BUCKET
T
P
P1
CN-S1
100 µm
P1
90L/min
0,6mm
A6
100 µm
BENNA 4 in 1
P
OPEN CLOSED B6 4 in 1 BUCKET
P2
Ø0,6 75L/min
P2
PB6 PA6
Manipolatore pala
T
P3
Ø0,6
Loader ppc valve P1
0,6mm
P3
Stabilizer ppc valve
2° BRACCIO
P3
P4
100L/min
P4
TELESCOPICO
P4
A7
P2
Manipolatore stabilizzatori
CLOSED EXTENDED B7
TELESCOPIC ARM
CN-S4
80L/min
P3
P4
P2
P1
120L/min SOLLEVAMENTO
0,6mm
A8
PALA
FLOAT LOWER RAISE B8
Ø0,6 100L/min LIFT FRONT ARM
PB8 PA8
STABILIZZATORE
RKZ10350
50L/min DESTRO
A9 R.H. STABILIZER
RAISE LOWER B9
PB9 50L/min
PA9
Ø0.5
STABILIZZATORE
SS SINISTRO
50L/min
A10 L.H. STABILIZER
BLOCCAGGIO PIASTRA
SIDE SHIFT RAISE LOWER B10
50L/min
BLOCCAGGIO PIASTRA
CLAMP CYLINDERS
HYDRAULIC CIRCUIT (WITH MECHANICAL CONTROL)
10-19
2.5 bar
5 bar
16
µm
T
E
Ø0,5
PLS
Pen
P1L
qMAX
LS
PRIORITY VALVE
VALVOLA PRIORITARIA
qMIN
LS VALVE
CLOCKWISE
P 8 bar
160 bar
80 l/min
270bar
Pp
STRUCTURE AND FUNCTION
PC VALVE
P1
2xØ1
80L/min MARTELLO
2xØ1 A0 HAMMER
OUT
IN
B0
80L/min
160
PB0 bar
10 PA0
0µ
m
PS
Pd
PM
P1c
140L/min
Pd2
A1
DIGGING DUMP B1
PB1 2° BRACCIO
140L/min
Ø0,6 ARM
Ø0,6
PA1
D
Ø1.5 Ø1.3
PRIORITY DLs
VALVE
LS Ø0,5
P
275bar
170 bar
0
T
+5
SELF REDUCING 5 bar
225 bar
218 bar
0
VALVE
+20
37,3bar
LS
Ø0.62
PPPC Ts
225
Cilindro di sterzo
Steering cylinder
215
bar 0
T
bar
+20
*100L/min
A2
LEFT (BH) RIGHT (BH)
ROTAZIONE 1° BRACCIO
R
B2
HYDRAULIC CIRCUIT (WITH SERVOCONTROL)
T
BENNA ANTERIORE
DIGGING DUMP B3 FRONT BUCKET
110L/min
PB3 PA3
LOCK
DIFFERENTIAL
P2
1° BRACCIO
0,5mm
120L/min
10
BOOM
A4
P1
RAISE LOWER
A1
B1
A2
B2
UL
LOCK
1
Acc
PM
B4
UBH
PB4
BH BOOM
0.32L-10bar
344 120L/min
2
PA4
100L/min
3
A5
7 4 8 5 9 6
DIGGING DUMP B5
PB5 120L/min BENNA RETROESC.
11
T
REAR BUCKET
P
PA5
P1
P1
CN-S1
100 µm
100 µm
P
90L/min
0,6mm
A6 BENNA 4 in 1
P2
OPEN CLOSED B6 4 in 1 BUCKET
P2
T
Ø0,6 75L/min
PB6 PA6
Manipolatore pala
P3
P3
Ø0,6
0,6mm
RKZ10360
P4
2° BRACCIO
P3
P4
Manipolatore stabilizzatori
100L/min
P4
A7
TELESCOPICO
P2
P4
P3
CLOSED EXTENDED B7
CN-S4
PB7 80L/min
P2
P1
PA7
0,6mm
120L/min SOLLEVAMENTO
0,6mm
A8
FLOAT PALA
OPTION LOWER RAISE B8
Ø0,6 100L/min LIFT FRONT ARM
PB8 PA8
10-20
STABILIZZATORE
50L/min DESTRO
A9 R.H. STABILIZER
PB9 RAISE LOWER B9
50L/min
PA9
Ø0.5
STABILIZZATORE
SS SINISTRO
50L/min
A10 L.H. STABILIZER
BLOCCAGGIO PIASTRA
SIDE SHIFT RAISE LOWER B10
2
50L/min
3
PB10 PA10
1
3
4
T1
2
CILINDRI
P
CLAMP CYLINDERS
BLOCCAGGIO PIASTRA
4
Manipolatore sinistro
2
3
1
3
4
T1
2
P
R.H. ppc valve
4
Manipolatore destro
T
P
B2
A2
A1
WB93R-5E0
HYDRAULIC CIRCUIT (WITH SERVOCONTROL)
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
WB93R-5E0 10-21
STRUCTURE AND FUNCTION HYDRAULIC PUMP
1. MAIN PUMP
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
10-22 WB93R-5E0
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
WB93R-5E0 10-23
STRUCTURE AND FUNCTION HYDRAULIC PUMP
FUNCTION
The rotation and torque transmitted to the pump shaft is converted into hydraulic energy and pressurized oil is delivered
according to the load requirements.
The amount of oil delivered can be modified by changing the angle of the swash plate.
8 7 6 5 1 10
3
4
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).
10-24 WB93R-5E0
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 X
(3) 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 9 A RKZ09530
3 6 E
F RKZ09550
WB93R-5E0 10-25
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).
10-26 WB93R-5E0
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
WB93R-5E0 10-27
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
10-28 WB93R-5E0
STRUCTURE AND FUNCTION HYDRAULIC PUMP
2.2 LS VALVE
1 2 4
3 5
6
RKZ09780
WB93R-5E0 10-29
STRUCTURE AND FUNCTION HYDRAULIC PUMP
LS VALVE FUNCTION
• The LS valve controls the pump delivery according
to the stroke of the control valve lever, i.e., in
function of the delivery demands made by the
actuators.
• The LS valve detects the actuator’s delivery
needs by means of the differential pressure
DPLS existing between pressure PPLS (control
Pump delivery Q
valve input pressure) and pressure PLS (control
valve output pressure). The sensing of this
differential pressure permits control of the main
pump delivery Q. (PPLS, PLS and DPLS are,
respectively, the pump pressure, the Load
Sensing pressure, and the difference in pressure LS differential pressure dPLS bar
between these two values).
• In other words, the LS valve detects the pressure
difference DPLS generated by the passage of RKZ09570
10-30 WB93R-5E0
STRUCTURE AND FUNCTION HYDRAULIC PUMP
RKZ09580
WB93R-5E0 10-31
STRUCTURE AND FUNCTION HYDRAULIC PUMP
PC VALVE OPERATION
1. Spring operation
• PC valve spring loading (3) is defined by swash
plate position.
• If control piston (6) moves to the right, spring (3)
is compressed by lever (2) and spring loading
increases.
1 5 4 PA
Check valve
D C B
PT
Engine
C B 3
F
LS valve
Solenoid
valve
G
J
RKZ09490
• The force applied by the pressure against the spool • When the control piston (2) moves, the lever (3)
(4) decreases, and the spool (5) shifts slightly to the moves to the left, and the spring (1) expands,
right. thereby reducing its load on the spool (5).
At the same time, a connection opens between ports Consequently, the spool (5) moves to the left and
C and D, and pressurised oil from valve LS is sent for stops the oil flow between ports C and D, and a
discharge (PT). passage opens between ports B and C.
• Simultaneously, ports F and G on valve LS are • As a result of that, the pressure at port C increases,
interconnected, and pressure at port J is sent for and the control piston (2) stops.
relief (PT); the control piston (2) shifts to the left.
• Pump delivery increases as a result.
10-32 WB93R-5E0
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 • When the control piston (2) moves, the lever (3)
(4) increases, and the spool (5) shifts slightly to the moves to the right, and the spring (1) compresses,
left. At the same time, a connection opens between thereby increasing its load on the spool (5).
ports C and B, and the pressure of the oil sent to valve Consequently, the spool (5) moves to the right and
LS becomes equivalent to the pump's delivery stops the oil flow between ports C and B, and a
pressure (PA). passage opens between ports D and C.
• Simultaneously, ports F and G on valve LS are • As a result of that, the pressure at port C decreases,
interconnected, and pressure at port J becomes and the control piston (2) stops.
equivalent to the pump's delivery pressure (PA), and
the control piston (2) shifts to the right.
• Pump delivery decreases as a result.
WB93R-5E0 10-33
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
10-34 WB93R-5E0
PAGE INTENTIONALLY
LEFT BLANK
STRUCTURE AND FUNCTION 8-SPOOL CONTROL VALVE (WITH MECHANICAL CONTROL)
Komatsu Ltd.
AC AC
DLS B1 A1
PPPC AB AB
T
AA AA
LS P D
N N A2
B2
M M
PA3 X B3 A3
L L A4
B4
K K
B5 A5
J J
PA6 B6 A6
F F
E E
D
PA7 PA8
Z
B7 SS A7
RKZ08310
B8 View Z A8
10-36 WB93R-5E0
STRUCTURE AND FUNCTION 8-SPOOL CONTROL VALVE (WITH MECHANICAL CONTROL)
AE
C B A
PP
PB3
PB6
C B A
PB8 AE
PB7
RKZ08320
View X
A1 - To the arm cylinder (Head side) P- From hydraulic pump (P1 port)
A2 - To the boom (LH-RH) swing cylinder D- To the steering unit (P Port)
(Bottom side) DLS - From the steering unit (LS Port)
A3 - To the shovel cylinders (Bottom side) PP - To the hydraulic pump (P1L port)
A4 - To the boom cylinder (Bottom side) T- To hydraulic tank
A5 - To the backhoe bucket cylinder (Head side) TS - To hydraulic tank
A6 - To the shovel arm raise cylinder PPPC -To solenoid valve group EV1 (P Port)
(Bottom side) SS - To the backhoe plate lock cylinders
A7 - To the RH outrigger cylinder (bottom side) PA3 - From the shovel PPC valve (P2 port)
A8 - To the LH outrigger cylinder (bottom side) PA6 - From the shovel PPC valve (P3 port)
B1 - To the arm cylinder (Bottom side) PA7 - From the outriggers PPC valve
B2 - To the boom (LH-RH) swing cylinder (P1 port)
(Head side) PA8 - From the outriggers PPC valve
B3 - To the shovel cylinders (Head side) (P3 port)
B4 - To the boom cylinder (Head side) PB3 - From the shovel PPC valve (P1 port)
B5 - To the backhoe bucket cylinder (Bottom side) PB6 - From the shovel PPC valve (P4 port)
B6 - To the shovel arm raise cylinder PB7 - From the outriggers PPC valve
(Head side) (P2 port)
B7 - To the RH outrigger cylinder (Head side) PB8 - From the outriggers PPC valve
B8 - To the LH outrigger cylinder (Head side) (P4 port)
LS - To the hydraulic pump (PLS port)
WB93R-5E0 10-37
STRUCTURE AND FUNCTION 8-SPOOL CONTROL VALVE (WITH MECHANICAL CONTROL)
6
7
18
19 5
17
8
16
20 15
4
3
9
14 2 10
13 1 11
12
RKZ08330
B-B A-A
10-38 WB93R-5E0
STRUCTURE AND FUNCTION 8-SPOOL CONTROL VALVE (WITH MECHANICAL CONTROL)
AD
7
16
6 13
17
8
18 9
5
19
4
10
20 3 11
21 2
1
12
AD
15 14
D-D C-C
22
23 RKZ08340
AD - AD
WB93R-5E0 10-39
STRUCTURE AND FUNCTION 8-SPOOL CONTROL VALVE (WITH MECHANICAL CONTROL)
3 4
2 7
1
E-E K-K
5 8
F-F L-L
6 9
RKZ08880
J-J M-M
10-40 WB93R-5E0
STRUCTURE AND FUNCTION 8-SPOOL CONTROL VALVE (WITH MECHANICAL CONTROL)
5
4
AC - AC
N-N
AA - AA
RKZ08890
AB - AB AE - AE
WB93R-5E0 10-41
STRUCTURE AND FUNCTION 10-SPOOL CONTROL VALVE (WITH MECHANICAL CONTROL)
Komatsu Ltd.
AC AC
B1 A1
PPPC AB AB
T
DLS
AA AA
LS P D
R R A2
B2
P P
X B3 A3
PA3
N N A4
B4
M M
B5 A5
L L
B6 A6
K K
J J
PA8 B7 A7
F F
B8 A8
E E
PA7 PA10 D
Z
B9 SS A9
RKZ08900
B10 A10
View Z
10-42 WB93R-5E0
STRUCTURE AND FUNCTION 10-SPOOL CONTROL VALVE (WITH MECHANICAL CONTROL)
AE
C B A
PP
PB3
PB8
PB10 C B A
AE PB9 RKZ09030
View X
A1 - To the arm cylinder (Head side) B10 - To the LH outrigger cylinder (Head side)
A2 - To the boom (LH-RH) swing cylinder (Bottom side) LS - To the hydraulic pump (PLS port)
A3 - To the shovel cylinders (Bottom side) P - From hydraulic pump (P1 port)
A4 - To the boom cylinder (Bottom side) D - To the steering unit (P Port)
A5 - To the backhoe bucket cylinder (Head side) DLS - From the steering unit (LS Port)
A6 - To the 4 in 1 bucket cylinder (Bottom side) PP - To the hydraulic pump (P1L port)
A7 - To the jig arm cylinder (Bottom side) T - To hydraulic tank
A8 - To the shovel arm raise cylinder (Bottom side) TS - To hydraulic tank
A9 - To the RH outrigger cylinder (Bottom side) PPPC - To solenoid valve group EV1 (P Port)
A10 -To the LH outrigger cylinder (Bottom side) SS - To the backhoe plate lock cylinders
B1 - To the arm cylinder (Bottom side) PA3 -From the shovel PPC valve (P2 port)
B2 - To the boom (LH-RH) swing cylinder (Head side) PA6 -From solenoid valve group EV1 (A1 Port)
B3 - To the shovel cylinders (Head side) PA8 -From the shovel PPC valve (P3 port)
B4 - To the boom cylinder (Head side) PA9 -From the outriggers PPC valve (P1 port)
B5 - To the backhoe bucket cylinder (Bottom side) PA10 - From the outriggers PPC valve (P3 port)
B6 - To the 4 in 1 bucket cylinder (Head side) PB3 -From the shovel PPC valve (P1 port)
B7 - To the jig arm cylinder (Head side) PB6 -From solenoid valve group EV1 (B1 Port)
B8 - To the shovel arm raise cylinder (Head side) PB8 -From the shovel PPC valve (P4 port)
B9 - To the RH outrigger cylinder (Head side) PB9 -From the outriggers PPC valve (P2 port)
PB10 -From the outriggers PPC valve (P4 port)
WB93R-5E0 10-43
STRUCTURE AND FUNCTION 10-SPOOL CONTROL VALVE (WITH MECHANICAL CONTROL)
7
8
22
23 6
25
9
24
21 5
20 4
10
3 11
19
2 12
18
13
17 1
14
16
15
B-B A-A
17 16
10-44 WB93R-5E0
STRUCTURE AND FUNCTION 10-SPOOL CONTROL VALVE (WITH MECHANICAL CONTROL)
AD
9
20
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 C-C
D-D
27
28
AD - AD RKZ09050
WB93R-5E0 10-45
STRUCTURE AND FUNCTION 10-SPOOL CONTROL VALVE (WITH MECHANICAL CONTROL)
3 4
2 7
1
E-E M-M
5 8
F-F N-N
6 9
RKZ08881
L-L P-P
10-46 WB93R-5E0
STRUCTURE AND FUNCTION 10-SPOOL CONTROL VALVE (WITH MECHANICAL CONTROL)
5 6
AC - AC
R-R
AA - AA
RKZ08891
AD - AD AE - AE
WB93R-5E0 10-47
STRUCTURE AND FUNCTION 8-SPOOL CONTROL VALVE (WITH SERVOCONTROL)
Komatsu Ltd.
AC AC
PA1 B1 A1
AB AB
DLS T
PPPC
AA AA
LS P D
N N
PA2 B2 A2
B3 M M
PA3 A3
X L L A4
B4
PA4
K K
B5 A5
PA5
J J
B6 A6
PA6
F F
E E
D
PA7 PA8
Z
B7 SS A7
RKZ09060
B8 A8
ViewZ
10-48 WB93R-5E0
STRUCTURE AND FUNCTION 8-SPOOL CONTROL VALVE (WITH SERVOCONTROL)
AE
C B A
PP
PB1
PB2
PB3
PB4
PB5
PB6
RKZ09070
PB8 C B A PB7
AE
View X
WB93R-5E0 10-49
STRUCTURE AND FUNCTION 8-SPOOL CONTROL VALVE (WITH SERVOCONTROL)
6
7
18
17
19 8
20
16 4
3
15 9
2 10
14
1 11
13
12
RKZ09080
B-B A-A
10-50 WB93R-5E0
STRUCTURE AND FUNCTION 8-SPOOL CONTROL VALVE (WITH SERVOCONTROL)
AD
7
16
6 13
17
8
18 9
5
19
4
10
20 3 11
21 2
1
12
AD
15 14
D-D C-C
22
23 RKZ08340
AD - AD
PRESSURE REDUCING VALVE 11. Backhoe bucket
1. Shovel arm 12. Shovel arm
2. Backhoe bucket 13. Max. pressure valve
3. Boom 14. Check valve
4. Front bucket 15. Check valve
5. Boom swing 16. Check valve
6. Arm 17. Check valve
18. Check valve
DELIVERY CONTROL VALVE 19. Check valve
7. Arm 20. Check valve
8. Boom swing 21. Check valve
9. Front bucket 22. LS, DLS pressure check valve
10. Boom 23. LS by-pass plug
WB93R-5E0 10-51
STRUCTURE AND FUNCTION 8-SPOOL CONTROL VALVE (WITH SERVOCONTROL)
3 4
2 7
1
E-E K-K
5 8
F-F L-L
6 9
RKZ09100
J-J M-M
10-52 WB93R-5E0
STRUCTURE AND FUNCTION 8-SPOOL CONTROL VALVE (WITH SERVOCONTROL)
5 6
AC - AC
N-N
3
1
AA - AA
AB - AB RKZ09110
AE - AE
1. Servocontrol max. pressure valve
2. Max. pressure valve spool
3. Sequential reducing valve
4. Blow out plug
5. Unloading valve
6. LS by-pass plug
7. Spool (Arm control)
WB93R-5E0 10-53
STRUCTURE AND FUNCTION 10-SPOOL CONTROL VALVE (WITH SERVOCONTROL)
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
10-54 WB93R-5E0
STRUCTURE AND FUNCTION 10-SPOOL CONTROL VALVE (WITH SERVOCONTROL)
AE
C B A
PP
PB1
PB2
PB3
PB4
PB5
PB6
PB7
PB8
RKZ09590
PB10 C B A PB9
AE
WB93R-5E0 10-55
STRUCTURE AND FUNCTION 10-SPOOL CONTROL VALVE (WITH SERVOCONTROL)
10-56 WB93R-5E0
STRUCTURE AND FUNCTION 10-SPOOL CONTROL VALVE (WITH SERVOCONTROL)
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
1. Anticavitation valve 13. Anticavitation valve (jig arm retract)
(jig arm extend) 14. Anticavitation valve (4 in 1 bucket dump)
2. Anticavitation valve (backhoe bucket curl) 15. Spool (shovel arm control)
3. Anti-shock/anticavitation valve (boom raise) 16. Spool (Jig arm control)
4. Anticavitation valve (shovel dump) 17. Spool (4 in 1 bucket control)
5. Anti-shock/anticavitation valve (LH swing) 18. Spool (backhoe bucket control)
6. Anticavitation valve (arm out) 19. Spool (boom control)
7. Safety valve 20. Spool (front bucket control)
8. Anticavitation valve (arm in) 21. Spool (boom swing control)
9. Anti-shock/anticavitation valve (RH swing) 22. Spool (arm control)
10. Anti-shock/anticavitation valve (shovel curl) 23. Spool (priority valve)
11. Anticavitation valve (boom lower) 24. Unloading valve
12. Anticavitation valve (backhoe bucket dump) 25. LS by-pass plug
WB93R-5E0 10-57
STRUCTURE AND FUNCTION 10-SPOOL CONTROL VALVE (WITH SERVOCONTROL)
AD
20 9
8
17
21
10
22 11
7
23
6 12
24 5 13
25
4 14
3 15
26 2
1
16
AD
19 18 D-D C-C
RKZ09140
27
28
AD - AD
PRESSURE REDUCING VALVE DELIVERY CONTROL VALVE 20. Check valve
1. Shovel arm 9. Arm 21. Check valve
2. Jig arm 10. Boom swing 22. Check valve
3. 4 in 1 bucket 11. Front bucket 23. Check valve
4. Backhoe bucket 12. Boom 24. Check valve
5. Boom 13. Backhoe bucket 25. Check valve
6. Front bucket 14. 4 in 1 bucket 26. Check valve
7. Boom swing 15. Jig arm 27. LS, DLS pressure check valve
8. Arm 16. Shovel arm 28. LS by-pass plug
17. Max. pressure valve
18. Check valve
19. Check valve
10-58 WB93R-5E0
STRUCTURE AND FUNCTION 10-SPOOL CONTROL VALVE (WITH SERVOCONTROL)
3 4
2 7
1
E-E M-M
5 8
F-F N-N
6 9
RKZ09101
L-L P-P
WB93R-5E0 10-59
STRUCTURE AND FUNCTION 10-SPOOL CONTROL VALVE (WITH SERVOCONTROL)
5 6
AC - AC
R-R
3
1
AA - AA
AB - AB
RKZ09111
AE - AE
1. Servocontrol max. pressure valve
2. Max. pressure valve spool
3. Sequential reducing valve
4. Blow out plug
5. Unloading valve
6. LS by-pass plug
7. Spool (Arm control)
10-60 WB93R-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
WB93R-5E0 10-61
STRUCTURE AND FUNCTION CLSS
2. OPERATING PRINCIPLES
2.1 CONTROL OF THE ANGLE OF THE PUMPING PLATE
• The angle of the swash plate (and hence the pump delivery) is controlled in such a way that the differential pressure
DPLS between the delivery pressure PP of the pump and the pressure PLS at the outlet of the control valve towards
the actuator is maintained at a constant value. (DPLS=Pump delivery pressure PP – pressure PLS of delivery to the
actuator.
• If the differential pressure DPLS becomes lower than the set pressure of the LS, valve, the angle of the swash plate
increases.
If the differential pressure DPLS increases, the angle of the swash plate decreases.
a For details about this movement, see the description of the "HYDRAULIC PUMP".
Actuator
Max.
Swash plate angle Q
Control valve
Min.
PLS
Pump passage
LS passage 0 LS differential
pressure 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
10-62 WB93R-5E0
STRUCTURE AND FUNCTION CLSS
Load
Load
W W
Actuator Actuator
ΔP ΔP
S1 S2
Pressure Pressure
compensation compensation
valve valve
LS valve RKP02941
WB93R-5E0 10-63
STRUCTURE AND FUNCTION CLSS
B1
Arm 4. Check valve
8
5. Anti-shock/anticavitation valve: 215 bar
4
6. Anti-shock/anticavitation valve: 220 bar
9 D
7. Anti-shock/anticavitation valve: 350 bar
DLS
8. Pressure compensation valves
LS
P
T 9. Priority valve
10 1
10. Servocontrols reducing valve
2
T 11. Backhoe plate lock valve
PPPC
5
A2
Boom
B2 swing
8
5
6
A3 Shovel
PB3 B3
8 PA3
A4 Boom
B4
8 7
4
A5 Bucket
B5
8
4
A6 Shovel
raising
PB6 B6
8 PA6
1 A7 Right
outrigger
PB7 B7
PA7
A8 Left
SS
B8
outrigger
PB8 PA8
RKZ09150
10-64 WB93R-5E0
STRUCTURE AND FUNCTION CLSS
3
PP PP 1. Unloading valve:
4 pressure LS + 27.5 bar
2. Max. pressure valve: 218 bar
A1
Arm 3. Safety valve: 270 bar
8
B1
4. Check valve
4 5. Anti-shock/anticavitation valve: 215 bar
9 D 6. Anti-shock/anticavitation valve: 220 bar
DLS 7. Anti-shock/anticavitation valve: 350 bar
P
LS 8. Pressure compensation valves
T
10 1 9. Priority valve
2 10. Servocontrols reducing valve
Ts
PPPC
5 11. Backhoe plate lock valve
A2 Boom
B2 swing
8
5
6
Shovel
A3
PB3 B3
8 PA3
4
8
A4
Boom
B4
8 7
8 4
A5 Bucket
B5
8
4
A6 Bucket 4 in 1
PB6 B6
8 PA6
A7
Jig arm
PB7 B7
8 PA7
Shovel
A8
raising
PB8 B8
8 PA8
11 A9 Right
outrigger
PB9 B9
PA9
A10 Left
SS
outrigger
B10
PB10 PA10
RKZ09160
WB93R-5E0 10-65
STRUCTURE AND FUNCTION CLSS
1. Unloading valve:
3 pressure LS + 27.5 bar
PP 2. Max. pressure valve: 218 bar
4 3. Safety valve: 270 bar
4. Check valve
Arm
5. Anti-shock/anticavitation valve: 215 bar
A1
PB1 B1
8 PA1 6. Anti-shock/anticavitation valve: 220 bar
4 7. Anti-shock/anticavitation valve: 350 bar
9 D 8. Pressure compensation valves
DLS
9. Priority valve
LS
P 10. Servocontrols reducing valve
T
10 1 11. Backhoe plate lock valve
2
Ts
PPPC
5
A2 Boom
PB2 B2 swing
8 PA2
5
6
A3 Shovel
PB3 B3
8 PA3
A4
Boom
B4
7
PB4
8 PA4
4
A5 Bucket
PB5 B5
8 PA5
A6 Shovel
raising
PB6 B6
PA6
8
11 A7
Right
outrigger
PB7 B7
PA7
A8
Left
SS outrigger
B8
PB8
PA8
RKZ09170
10-66 WB93R-5E0
STRUCTURE AND FUNCTION CLSS
3 1. Unloading valve:
PP
pressure LS + 27.5 bar
4
2. Max. pressure valve: 218 bar
3. Safety valve: 270 bar
A1 Arm 4. Check valve
8
PB1 B1 5. Anti-shock/anticavitation valve: 215 bar
PA1
6. Anti-shock/anticavitation valve: 220 bar
4
7. Anti-shock/anticavitation valve: 350 bar
9 D
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
WB93R-5E0 10-67
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 PP = Pump circuit
S1, and right, on surface S2 – whereas Load Sensing PLS = Load Sensing circuit
pressure PLS acts on surface S2. T= Tank circuit
• Since no LS signal with PLS pressure is generated A = To control valve spools
when the control valve is in “NEUTRAL” position, the
only pressure acting on spool (1) in this condition is
the pump's delivery pressure PP as regulated by
spring compression (2).
• As the pump's delivery pressure PP increases and the
resulting force equals spring loading (2), the spool (1)
shifts to the right. The pump's delivery circuit PP is
then connected to the tank circuit T by means of the
holes in spool (1).
• This ensures that the pump delivery pressure PP
stays regulated at 27.5 bar (28 kg/cm2).
10-68 WB93R-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
WB93R-5E0 10-69
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
10-70 WB93R-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
WB93R-5E0 10-71
STRUCTURE AND FUNCTION CLSS
A a PP
RKZ09240
b PLS
10-72 WB93R-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
WB93R-5E0 10-73
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
10-74 WB93R-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
WB93R-5E0 10-75
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
10-76 WB93R-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.
WB93R-5E0 10-77
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.
10-78 WB93R-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.
WB93R-5E0 10-79
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.
10-80 WB93R-5E0
STRUCTURE AND FUNCTION CLSS
Lock cylinder
SS
1 4
T
PP
RKZ09320
Functioning
• When the solenoid valve is energized, pressurised oil in the SS circuit is sent to the tank circuit through spool (4).
• As a result, the SS circuit pressure decreases, and the plate is released, so it can be shifted.
WB93R-5E0 10-81
STRUCTURE AND FUNCTION STEERING UNIT
STEERING UNIT
a e b
LS
L R
T P
RKP03740
c d
10-82 WB93R-5E0
STRUCTURE AND FUNCTION PPC VALVES
PPC VALVES
SHOVEL PPC VALVE (STANDARD)
P2 P4
P3 P1
Z
E E
D D
B
T P
A C
C A
View Z RKZ09330
WB93R-5E0 10-83
STRUCTURE AND FUNCTION PPC VALVES
5 7
4
8
3
9
2
1 10
A-A B-B
D-D
C-C
E-E
RKZ09340
1. Spool 6. Nut
2. Adjusting screw (inner) 7. Joint
3. Adjusting screw (outer) 8. Cover
4. Piston 9. Retainer
5. Disk 10. Body
10-84 WB93R-5E0
STRUCTURE AND FUNCTION PPC VALVES
OPERATION
WB93R-5E0 10-85
STRUCTURE AND FUNCTION PPC VALVES
A Control B
valve RKZ09460
10-86 WB93R-5E0
STRUCTURE AND FUNCTION PPC VALVES
P2 P4
P3 P1
D D
T P
B A
C C
A B
View Z RKZ08920
WB93R-5E0 10-87
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
10-88 WB93R-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
WB93R-5E0 10-89
STRUCTURE AND FUNCTION PPC VALVES
(5).
The equilibrium position is then kept until the
position of piston (4) is changed, i.e.:
a) as long as pressures at ports B and P1 are
perfectly balanced;
10-90 WB93R-5E0
STRUCTURE AND FUNCTION PPC VALVES
A Control B
valve RKZ09010
4. During fine control
(NEUTRAL o Full stroke)
When the disk (5) pushes down on the piston (4),
and the retainer (9) pushes down on the spool (1),
calibrated hole f is put in direct connection with 5
chamber PP, which is in turn connected to a
constantly pressurised servocontrols circuit. 4
Oil is then allowed to flow directly into section B-P1
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
WB93R-5E0 10-91
STRUCTURE AND FUNCTION PPC VALVES
11
6. When control lever is moved from float back 10
to neutral position
The disk (5) can be moved back to neutral position D
by applying a force that exceeds the force applied T
by the solenoid. P
The floating state can also be cancelled, and the
lever can move back to neutral position,
denergizing the solenoid.
PP
P3 P4
A Control B
valve RKZ09021
10-92 WB93R-5E0
STRUCTURE AND FUNCTION PPC VALVES
P2 P4
P4
P2
P1 P3
P T
RKZ09360
P1 P3
RKZ09350
Z
P1 port - To control valve (8 spools) (PA7 port)
To control valve (10 spools) (PA9 port)
P2 port - To control valve (8 spools) (PB7 port)
To control valve (10 spools) (PB9 port)
P3 port - To control valve (8 spools) (PA8 port)
To control valve (10 spools) (PA10 port)
P4 port - To control valve (8 spools) (PB7 port)
To control valve (10 spools) (PB10 port)
P port - To EV1 solenoid valve group (P2 port)
Port T - To hydraulic tank
WB93R-5E0 10-93
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
10-94 WB93R-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.
WB93R-5E0 10-95
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).
10-96 WB93R-5E0
STRUCTURE AND FUNCTION PPC VALVES
P2 P1
A Control B RKZ10610
valve
• 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.
WB93R-5E0 10-97
STRUCTURE AND FUNCTION PPC VALVE (BACKHOE CONTROLS)
P
T
2 4
3 View A
RKZ10250
A
10-98 WB93R-5E0
STRUCTURE AND FUNCTION PPC VALVE (BACKHOE CONTROLS)
1 T
P
2 4
3 View A
RKZ10260
WB93R-5E0 10-99
STRUCTURE AND FUNCTION SOLENOID VALVE GROUP (EV1)
ACC P1
2 3 4
A2
VL
P2 P
PM
T
B2
Hydraulic circuit
ACC B2 A2 PM UL
P1
S2
CV1
P2
SV2
S1
SV1 SV3
P T
RKZ10270
10-100 WB93R-5E0
STRUCTURE AND FUNCTION SOLENOID VALVE GROUP (EV1)
ACC P1
4
2 3
5
1
6
A2
A1
P2 P
PM T
B2 UL B1 Hydraulic circuit
ACC B2A2 PM UL B1 A1
P1
S2
S2
ORF1
CV1
P2 ø0.5mm
SV2
S1
S1
SV1 SV3 SV4
P T RKZ10280
WB93R-5E0 10-101
PAGE INTENTIONALLY
LEFT BLANK
STRUCTURE AND FUNCTION SOLENOID VALVE GROUP (EV1)
ACC P1
2 3 4 5
6
1
7
A2
A1
P2 P
PM T
B2 UL B1
Hydraulic circuit
ACC B2 A2 PM UL B1 A1 UBH
P1
S2
S2
ORF1
CV1
P2 ø0.5mm
SV2
S1
S1 SV1 SV3 SV4 SV5
P T RKZ10300
WB93R-5E0 10-103
STRUCTURE AND FUNCTION SAFETY VALVES
SAFETY VALVES
SHOVEL RAISE
a
A
b b
2 3 4
5
Pressione Δp (bar)
Pressure Δp (bar)
50
45
40
35
30
25 a
20 b
15
10
c
1 5
0 0
RKZ0840 10 20 30 40 50 60 70 80 90 100
Portata Q (l / min)
Flow Q (l / min)
Sezione A - A RKZ08050
CHARACTERISTICS
Safety valve calibration: 220 +0 10 bar
10-104 WB93R-5E0
STRUCTURE AND FUNCTION SAFETY VALVES
SHOVEL DUMP
c b
RKZ08060
Pressione Dp (bar)
Pressure Dp (bar)
24
20
16
b
a
12
0 12 24 36 48 60
Portata Q (l / min)
Flow Q (l / min)
RKZ08070
WB93R-5E0 10-105
STRUCTURE AND FUNCTION SAFETY VALVES
BOOM
a
b
RKZ08080
Pressione Dp (bar)
Pressure Dp (bar)
35
28
21
a b
14
RKZ08090
10-106 WB93R-5E0
STRUCTURE AND FUNCTION SAFETY VALVES
ARM
b
RKZ08100
24
Pressione Dp (bar)
Pressure Dp (bar)
20
16
b
12
a
Portata Q (l / min)
Flow Q (l / min)
RKZ08110
WB93R-5E0 10-107
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
10-108 WB93R-5E0
STRUCTURE AND FUNCTION SHOVEL CYLINDERS
4 IN 1 BUCKET
2 3 4 5 1
6 7
8
42N-6C-12800
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 1400 475
Key size for piston safety nut 55 50 36
WB93R-5E0 10-109
STRUCTURE AND FUNCTION BACKHOE CYLINDERS
BACKHOE CYLINDERS
BOOM CYLINDER
11 8
7 6
3 5 9
2 4
1
707-02-0Y941
10
1. Bottom bushing 5. Piston 9. Bottom bushing
2. Stem 6. Gasket 10. Dowel
3. Head 7. Guide ring 11. Ball-bearings (no. 10)
4. Cylinder 8. Cushion plunger
ARM
7 8
6
3 5
2 4 10
1
707-00-0Y871
10-110 WB93R-5E0
STRUCTURE AND FUNCTION BACKHOE CYLINDERS
BUCKET CYLINDER
8
7 6
5
3 2 4 9
1
707-00-0y901
OUTRIGGER CYLINDER
3
2 6 4 5 7
707-00-0Y0910
WB93R-5E0 10-111
STRUCTURE AND FUNCTION BACKHOE CYLINDERS
12
707-02-07730
9 10
2 6 5
4
1 3
42N-6C-13301
10-112 WB93R-5E0
STRUCTURE AND FUNCTION BACKHOE CYLINDERS
CHARACTERISTICS
Cylinder Boom Arm Bucket
Piston rod diameter 60 60 55
Internal cylinder diameter 120 115 90
Piston stroke 850 700 765
Max. cylinder length 2160 1765 1850
Min. cylinder length 1310 1065 1085
Key size for piston safety nut – 65 55
CHARACTERISTICS
Cylinder Outriggers Boom swing Jig arm
Piston rod diameter 40 50 40
Internal cylinder diameter 70 100 70
Piston stroke 635 230 1140
Max. cylinder length 1690 319.5 2590
Min. cylinder length 1055 89.5 1450
Key size for piston safety nut 46 -- 46
WB93R-5E0 10-113
STRUCTURE AND FUNCTION AIR-CONDITIONING UNIT
AIR-CONDITIONING UNIT
2
Low pressure steam
1a
3 1
8
5
7
9 INTERIOR OF CAB
RKZ03130
10-114 WB93R-5E0
STRUCTURE AND FUNCTION HOW THE AIR-CONDITIONING UNIT FUNCTIONS
WB93R-5E0 10-115
PAGE INTENTIONALLY
LEFT BLANK
STRUCTURE AND FUNCTION FUSE AND RELAY CENTRE
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
15 15
5 120232 CONNECTOR M5 2
T 31 T 31
3
6 124004 CONNECTOR 2
7.5
7.5
7.5
10
10
10
10
10
15
15
15
15
3
5
16 163007 FUSE 10A 11
17 163010 FUSE 3A 2 21 19 5
7.5
7.5
10
10
15
15
10
10
10
10
REV.B
20 190289 WASHER 6.4x11.3x1.6 UNI1751 INOX 1
21 19 5
21 190468 NUT M5 UNI 5588-65 INOX 2
NAiS
NAiS
NAiS
NAiS
NAiS
NAiS
NAiS
NAiS
23 190534 NUT M4 BLOK UNI 7473 INOX A2 4
12V
12V
12V
12V
12V
12V
12V
12V
12V
24 191368 WASHER 3.5x13.6x2 CERTENE 4
WB93R-5E0 10-117
STRUCTURE AND FUNCTION DRIVER SEAT WIRING
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
X17.2 X17.1
X61 BUZZER BUZZER
X5.s
X48
7
SERVICE RELAY
4
TO UNIT
3
FLOATING
6
2
5
1
SOLENOID VALVE
X47 87
85
30
PPC VALVE
X49
86
X56
1 2
6
8
5
9 10 11 12
4 3 2 1
SOLENOID VALVE
87
85
1
86
2
30
2
1
11 10
21 20
19 18 17
9
X3.s
8
7
6
16 15 14
5
TO UNIT
4
2.5A
13 12
1
2
1
X55
DIODE
X44.p
TO CABIN
1
4
7
10 2
13 5
16 8
11 3
17 16
14 6
17 9
8 7
12
15
18
X43
15 14
X2.s
6
5
4
13 12
INSTRUMENTS PANEL
3
+15 TO UNIT Gnd1.1 X6
11 10
1
1
11
Gnd1.2 Gnd1.3 TO CONTROL UNIT
X42 CN-F20
8
A
7
B
6
10 5
C
4
20 8
3
2
7 1
WINSHIELD WIPER
6
KOMTRAX
5
4
3
A
2
B
1
C
4 9 10 11 12
3
2 5 6 7 8
1 1 2 3 4
11 10
X1.s
5
4
3
9
2
8
TO UNIT
1
7
X41.s
X8.p
5
REAR HORN BUTTON
9
4
X4.s
8
3
10 7
2
11 8
12 9
TO GEAR
7
1
6
4 1
5 2
2
6 3
TO UNIT
1
X11.p
15 12 9
14 11 8
13 10 7
6
5
4
TO SOLENOID VALVE
3
2
1
X40
2
1
SEAT SWITCH
3
4
X30.1 1 X23
1
2
2
2.5A
15
14
12
13
11
10
9
8
6
7
X7.p
5
3
4
2
1
TO ENGINE
X30.2
CABIN LAMP
A
X28.s X13
B
HEATING SYSTEM
X24.br RETURN TO DIG SENSOR
1 2 ELETTROSTOP
X27.s X68.1
AIR CONDIONING UNIT X24.b +30 12
15
18
21
17
20
STARTING SWITCH
9 14 19
6 11 16
3 8 13
5 10
2 7
POS. B
4
1
X24.acc +30
18 15 12
17 14 11
16 13 10
9 6 3
8 5 2
7 4 1
X10.p
+30 RELAY UNIT TO FRONT DASHBOARD
3 6
STARTING SWITCH
2 5
1 4
POS. Acc
X9.p
X24.c X12.p TO FRONT DASHBOARD
STARTING SWITCH TO REAR LINE
POS. C
X24.r1 X15.p
2
+15Key
1
STARTING SWITCH OPTIONAL SUPPLY
POS. R1 +15 KEY FUSES BOX
3
6 9
2 9 6
5 12 3 8
X45
1 8 15 5
4 11 18 2 7
4
X61.1
7
X68.2
14 21
10 17 1
13 20
16
19
86 PREHEATING
X26.p X25.p SUPPLY +30 30 SERVICES RELAY X65.p RELAY
SWITCH PANEL SWITCH PANEL +50 START
42N-06-12880
Gnd9 X24.gnd
X56.1
30 PREHEATING RELAY
10-118 WB93R-5E0
STRUCTURE AND FUNCTION SWITCH PANEL WIRING
3
X80
2
RIDE CONTROL SWITCH
1
8
7
X85
8
1
4
REAR HORN SWITCH
5
3
6
X25.s
TO DRIVER SITE
9 6 3
8 5 2
7 4 1
3
X81
2
ARM UNLOCK SWITCH
1
7
8
X86
8
7
1
5
3
6
7
8
4
1
X87
5
2
4WD SWITCH
6
3
3
5
2
X82
1
7
PLATE UNLOCK SWITCH
8
19 16
7
13
4 20 17
7
8 14
11 10 4
1
5 21 18
1
8
15 5
6 12 2
2
9
6
X88
3
3
3
X83
2
E/C POWER SWITCH
1
7
8
8
X89
1
4
2
WARNING SWITCH
3
150
OH
M1
/4 W X181
1A CURRENT LIMITER
X180
6
CURRENT LIMITER
3
5
X84
2
4
1
7
42N-06-11850
WB93R-5E0 10-119
STRUCTURE AND FUNCTION FRONT DASH WIRING
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
X59.1
BRAKE OIL LOW LEVEL
X60
STEERING COLUMN
LIGHT SWITCH
7
8
9
X59.2 6
5
4
10
11
12
3
BRAKE OIL LOW LEVEL 2
1
X10.s
TO DRIVER SITE
3
X58
6
2
9
12
FRONT WINDSHIELD-WIPER
12
4
15
11
7
10
34
18
14
21
17
13
5
20
16
X63
19
8
16
7
FRONT CONTROL PANEL
15
6
14
5
13
4
12
3
11
2
10
1
9
12
11
6
10
5
9
4
8
3
7
2
1
1
X64
2
4
3
10
8
11
9
13
_
12
14
16
I
X9.s
15
17
18
X54.2
STOP LIGHT SWITCH
6
5
4
3
2 7
1 8
9
10
11
12
X57
STEERING COLUMN
X53.1 X54.1 GEAR SHIFT
STOP SWITCH STOP LIGHT SWITCH
X53.2
STOP SWITCH
42N-06-11210
10-120 WB93R-5E0
STRUCTURE AND FUNCTION ROOF WIRING
ROOF WIRING
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
X141
BEACON LIGHT SWITCH
X140
REAR WORKING X138
LIGHT SWITCH
LATERAL REAR LEFT
WORKING LIGHT
4 1
3 2
X136
X142 LATERAL REAR RIGHT
FRONT WORKING WORKING LIGHT
4
LIGHT SWITCH
1
X147.2
2
3
2
X147.1
8 1
8
L.H. FRONT LIGHT 1
2
X147.3
6
L.H. FRONT LIGHT 3 7 5
4
4 7
5
L.H. FRONT LIGHT 6
3
X147.4
2
6
1
5
L.H. FRONT LIGHT
8
4
7
X147.5
L.H. FRONT LIGHT
X148.2 Gnd8
BEACON LAMP INTAKE
X151.1
R.H. FRONT LIGHT
X148.1
16
17
18
13
BEACON LAMP INTAKE
14
15
10
11
12
7
8
4
9
X44.s
5
6
1
2
2
TO DRIVER SITE
1
3
2
1
3
X151.2
4
3
4
X146 X143
R.H. FRONT LIGHT
LATERAL FRONT LEFT
LATERAL FRONT RIGHT X151.5 Gnd7.3
WORKING LIGHT
WORKING LIGHT R.H. FRONT LIGHT
X151.3
R.H. FRONT LIGHT
X151.4
R.H. FRONT LIGHT
Gnd7.1
X152.2
3
2
CABIN LAMP
1
X152.1
4
5
6
WB93R-5E0 10-121
STRUCTURE AND FUNCTION ENGINE WIRING
ENGINE WIRING
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
X117
ELETTROSTOP
X115
ENGINE OIL
PRESSURE SWITCH X116
COMPRESSOR ELECTRONIC
CLUTCH
X114
PREHEATER
X112
THERMISTOR
B
A
X128.s
+50 START
X113
1
87 PREHEATING RELAY
X121
HORN
1
2
Gnd6
GROUND
13
14
10
15
11
7
12
X7.s
8
4
9
5
1
6
2
3
TO CAB LINE
2
1
2
X118.1 1
+50 START
X60 B
EMPI SOLENOID VALVE 2-WAY CONNECTOR DT
2-WAY CONNECTOR DT
Gnd5
GROUND
X119.1
W ALTERNATOR
X119.2
D+ ALTERNATOR
42N-06-11161
10-122 WB93R-5E0
STRUCTURE AND FUNCTION SPEED SELECTOR WIRING
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
X106
2
4WS SOLENOID VALVE
1 X105
TRANSMISSION OIL
TEMPERATURE SENDER
A
C
B
X111
1
2
FUEL LEVEL SENDER
X104
4th SPEED SWITCH
12
10
11 8
9
7
4
6
5
X110.s
3
2
FULL LEVEL SIGNAL
X8.s
TO DRIVER SITE
1
2
X107
DECLUCH SWITCH
Gnd4
GROUND
2
1
X109.s
PUMP
2 1
X203
REVERSE SPEED
SOLENOID VALVE
2 1
42N-06-11190 X108
FORWARD SPEED
SOLENOID VALVE
WB93R-5E0 10-123
STRUCTURE AND FUNCTION BACKHOE WIRING
BACKHOE WIRING
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
X90
2
REAR PPC
1
SOLENOID VALVE
Gnd2.2
Gnd2.1
X91
2
EC POWER
1
SOLENOID VALVE Gnd2.3
X94
2
DIFFERENTIAL LOCK
1
SOLENOID VALVE
15
14
12
13
11
9
10
6
7
X11.s
3
4
2
1
X95 TO DRIVER SITE
2
ARM UNLOCK
1
SOLENOID VALVE
X99
2
SHOVEL OPEN
1
SOLENOID VALVE
X98
4
5
1
6
2
2
3
SHOVEL CLOSE
1
BACK-UP ALLARM
1
X93
2
X96
2
PLATE UNLOCK
1
SOLENOID VALVE
X100
REAR RIGHT LIGHT
1
2
X97
REAR HORN SWITCH
X101
REAR LEFT LIGHT
X103
42N-06-11450 PLATE LIGHT
10-124 WB93R-5E0
STRUCTURE AND FUNCTION JIG ARM WIRING
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
X3.2
HAMMER SWITCH
1
2
4
3
X4
R.H. PPC VALVE
X3.1
HAMMER SWITCH
X5
INPUT JIG ARM
SOLENOID VALVE
2
1
X2.p
ADDITIONAL SUPPLY
2
1
X6
OUTPUT JIG ARM
1 2
SOLENOID VALVE
2
1
X15.p
TO CABIN LINE 42N-06-12340
2
X7
1
HAMMER
SOLENOID VALVE
GND
WB93R-5E0 10-125
STRUCTURE AND FUNCTION WIRING DIAGRAM (STANDARD VERSION) (see also Group 90)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 B59
B105
Livello olio freni
Sensore temperatura olio trasmissione
BRAKE OIL LOW LEVEL SWITCH
Gearing oil temperature sensor
B111 Galleggiante livello carburante Fuel level sender
B112 Termistore Thermistor switch
B113 Filtro aria Air filter blocked switch
B115 Sensore press. olio motore Engine oil low pressure switch
B121 Avvisatore acustico Horn
E100 Fanale podteriore DX Right rear beam
E101 Fanale posteriore SX Left rear beam
E103 Luce targa Plate light
E136 Faro di lavoro posteriore DX laterale Lateral right rear working light
42-N-06 42-N-06
E138 Faro di lavoro posteriore SX laterale Lateral left rear working light
15121 11850 E143 Faro lavoro ant. DX lat. Lateral right front working light
42-N-06-15110
P63 42-N-06 E146 Faro di lavoro anteriore SX laterale Lateral left front working light
V-Z1 11831 E147 Faro anteriore SX Left front light
E148 Presa girofaro Beacon lamp
M-B1.5
M-N1.5
L-N1.5
V/N1
G-M1
A 1 2 3 4
A/B1
C-B1
G-L1
R-N1
H-V1
H1.5
G-V1.5
E151 Faro ant. DX Right front light
M1
A-G1
A-G1
G-N1
G-V1
R/N1
L-R1
L-R1
C-L1
C-L1
C-L1
C-L1
L-R1
L-R1
N1
N1
N1
N1
N1
A/R1
A/R1
H-V1
R/N1
C-L1
L/R1
V-N1
V-N1
V-Z1
E152 Plafoniera Room lamp
A1
R1
N1
N1
N1
N1
N1
N1
F1 FUSIBILE FARI LAVORO ANTERIORI CENTRALI 15A Central front working light fuse 15A
4 2 8 4 1 9 10 12 8 7 2 1 7 1 3 4 6 4 6 1 3
X57 X57 X57 X60 X60 X60 X60 X60 X60 7 1 3 4 6 7
X180 1 1 1 1 F2 FUSIBILE FARI LAVORO POSTERIORI CENTRALI 15A Central rear working light fuse 15A
X141
X141
X141
X141
X141
X140
X140
X140
X140
X140
X142
X142
X142
X142
X142
4 2 8 4 1 9 10 12 8 7 2 1 3 4 6 7 F3 FUSIBILE LUCE POSIZIONE DX 3A Right position light fuse 3A
X89 X89 X89 X89 X89 7 1 3 7 1 3 7 1 3 X146 X143 X136 X138
R N F Dx I 0 X80 X80 X80 X81 X81 X81 X82 X82 7 1 3 4 6 7 1 3 4 6 4 6 1 3 7 F4 FUSIBILE LUCE POSIZIONE SX 3A Left position light fuse 3A
3 6 7 0 1
1 4 II I 0 II I 0
E143
E136
7 1 3 7 1 3 7 1 3 F5 FUSIBILE AVVISATORE ACUSTICO 10A Horn fuse 10A
V180 1 0 1 0
0 1 0 1 5 2 8 E146 E138 F6 FUSIBILE FARI LAVORO POSTERIORI LATERALI 15A Lateral rear working light fuse 15A
Sx 8 2 8 2
H 5 5 4 4 4 4 F7 FUSIBILE TERGI POSTERIORE + AVVISATORE Winshield wiper-washer + rear horn fuse 7,5A
9 5 3 11 6 8 2 5 8 2 8 2 8 8 2 5 S141 5 2 8
S57 S60 S89 S80 S81 S82 2 S140 8
X140 X140
2 5
X140
S142 X142 X142 X142
X141 X141 X141 X146 X143 X136 X138 ACUSTICO POSTERIORE 7,5A
9 5 3 11 6 8 2 5 8 2 8 2 8 2 F8 FUSIBILE SWITCH LUCI STOP 7,5A Stop light swicth fuse 7,5A
X57 X60 X60 X60 X60 X89 X89 X89 X80 X80 X81 X81 X82 X82
A-G1.5
A-G1.5
G-N1.5
G-N1.5
A-G1
A-G1
1
G-V1
G-V1
L-R1
C-L1
C-L1
F9 FUSIBILI FARI LAVORO ANTERIORI LATERALI 15A Lateral front working light fuse 15A
R1
N1
N1
N1
N1
A-G1
H-R1
X181
H1
C1
G-M1
V1
A-B1
A-G1
G/R1
A/R1
A/R1
A/R1
A/R1
C-L1
C-L1
L/R1
V/N1
V-N1
V-Z1
F10 FUSIBILE ALIM. TERGI ANTERIORE 10A Front windhield-motor supply fuse 10A
42-N-06 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 F11 FUSIBILE OPTIONAL 7,5A Optional fuse 7,5A
F12 FUSIBILE BUZZER+STR.ANTERIORE+STR.LATERALE 5A Front + lateral instruments + buzzer fuse 5A
X63 X64
L-B0.5
C-L0.5
11210
G-M1
M/B1
M-N1
B-V1
A-V1
A/V1
H-V1
R-V1
Z-B1
V-N1
F13 FUSIBILE ALIM. MANIPOLATORE 10A Supply level grip fuse 10A
G1
N1
H1
V1
F14 FUSIBILE LAMPADE SWITCH + SWITCH OPTIONAL 10A Light switch + swicth optional fuse 10A
F15 FUSIBILE ELETTROSTOP+SICUREZZA AVVIAMENTO 10A ELETTROSTOP + SAFETY STARTER FUSE 10A
F16 FUSIBILE GIROFARO 10A Beacon light fuse 10A
A-B1
B-N1
B-N1
A-N1
A-N1
R/N1
S-N1
R/N1
N1
N1
N1
N1
F17 FUSIBILE SWITCH EMERGENZA 10A Warning swicth fuse 10A
F18 FUSIBILE PLAFONIERA+ACCENDISIGARI 10A Cabin lamp + cigarette lighter fuse 10A
7 1 3 7 1 3 7 1 3
F19 FUSIBILE ANABBAGLIANTI 15A Low beam fuse 15A
X83 X83 X83 X85 X85 X85 X84 X84 F20 FUSIBILE ABBAGLIANTI 15A Main beam light 15A
7 1 3 7 1 3 7 1 3 F21 FUSIBILE ALIM. SENSORE RETURN TO DIG 10A Return to DIG sender supply fuse 10A
0 0 0 1
1 1 F22 FUSIBILE EC POWER 7,5A EC POWER FUSE 7,5A
L/R1
F23 FUSIBILE +15 CENTRALINA STERZATURA 10A +15 STEERING UNIT FUSE 10A
8 2 8 2 8 2
S83 S85 F24 FUSIBILE ALIM. INTERMITTENZA 7,5A FLASHER FUSE 7,5A
8 2 8 2 S84 8 2 F25 FUSIBILE SIRENA RETRO + ALIM. DEVIO 10A REVERSE SPEED BUZZER + STEERING COLUMN 10A
X83 X83 X85 X85 X84 X84
F27 FUSIBILE GENERALE 200A GENERAL FUSE 200A
A-B1
A-B1
A-N1
R/N1
R/N1
S-N1
R/N1
R/N1
Z-N1
G1 BATTERIA Battery
G118 Motorino avviamento Starter motor
G119 Alternatore Generator
H17 BUZZER BUZZER
H1.5
H97 CLAXON POSTERIORE REAR HORN SWITCH
A/B1
K1 CENTRALINA ANTIRIPETIZIONE AVVIAMENTO Unrepeat start unit
M-N1
B-G1
A-B1
A-B1
C-B1
G-L1
H-L1
S/N1
Z/N1
G1
N1
N1
N1
N1
N1
R-G1
R-N1
A/V1
K2 INTERMITTENZA Flasher
K3 RELE' ANABBAGLIANTI Low beam relay
1
2 4 3 7 1 3 4 6 7 1 3 4 6 1 3 7 K4 RELE' ABBAGLIANTI Main beam relay
1 1 1 X55
X53.1 X54.1 X59.1 X58 X58 X58 X86 X86 X86 X86 X86 X88 X88 X88 X87 X87 X87 X87 X87 K5 RELE' AVVISATORE ACUSTICO ANTERIORE Front horn relay
M58 M 7 1 3 4 6 7 1 3 0 1 4 6 1 3 7 K6 RELE' ELETTROVALVOLA RETURN TO DIG Return to DIG solenoid valve relay
S53 S54 B59 II I 0 0
G-V1.5
53a 1 K7 RELE' LUCI STOP Light stop relay
53 M 53b
A-B1
G-N1
H1.5
H1.5
V1.5
V1.5
G1
A1
R1
31b 5 2 8 K8 RELE' CONSENSO AVVIAMENTO Assent start relay
M55 42-N-06-15151 8 2 5 8 2
31 1 1 K9 RELE' MARCIA AVANTI Forword speed relay
1 1 1 2 S86 8 2 5 S88 8 2 S87 5 2 8
X87 X87 X87 - - - - - - - - X148.1 X152.1 K10 RELE' MARCIA INDIETRO Reverse speed relay
X53.2 X54.2 X59.2
1
X55 A6 UNIT X86 X86 X86 X88 X88 X147.2 X151.2
K11 RELE' STACCO TRASMISSIONE Stop drive relay
G1
G1.5
56a
56b
56a
56b
57
57
R
L
N1
N1
M-N1
A-B1
A-B1
R-G1
R-G1
B-R1
H-L1
H-L1
Z/N1
Z/N1
M K45 Rele' preriscaldo Preheating Relay
N1
MULTIFUNCTION 01171128
K56 Rele' avviamento Starting relay
31
31
K61 Rele' servizi Service realy
- E147 - E151 1
E148 E152 M42 Tergi posteriore Rear Windshield-washer
N1.5
N1.5
N1.5
N1
N1
N1
N1
N1
4th GEAR POWER SUPPLY SWITCH
FUNCTION MACHINE UNIT SUPPLY
L-B0.5
L-N1.5
C-L0.5
M-N1
A-G1
B-V1
H-R1
R-N1
A-V1
Z-B1
H-V1
R-V1
R-G1
A-G1.5
A-G1.5
V-N1
G-N1.5
G-N1.5
R114 Candelette Preheating
M1
H1
N1
C1
G-M1
V1
M-N1
A-B1
A-G1
A-B1
A-N1
B-N1
G/R1
G-L1
A/R1
H-V1
C-L1
H-L1
R/N1
H/R1
S/N1
V/N1
V-N1
V-N1
G1.5
Z/N1
V-Z1
G-N1
G-V1
A-B1
LIGHTS AND SWITCH 4WD
H1.5
H1.5
V1.5
V1.5
A1
N1
Gnd7.1 S2 INTERRUTTORE ELETTROVALVOLA EC POWER SOLENOID VALVE E.C. POWER SWITCH
R1
R1
A1
G1
N1
PPC CONTROL SWITCH
4WD SOLENOID VALVE
S3 INTERRUTTORE CHIUSURA BENNA LOCK GRAB SWITCH
EC POWER SWITCH
1 2 3 4 5 6 7 8 9 X25.s X26.s 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 19 20 21
SEAT SWITCH
4WD SWITCH
OUT BUZZER
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 18 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 19 20 21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 S6 INTERRUTTORE BLOCCO DIFFERENZIALE DIFFERENTIAL LOCK SWITCH
X10.p X9.p X25.p X26.p X44.p
R1
OFF
ACC R1 ACC BR R2 C S24 Quadro avviamento Starting switch
R1
M-N1.5
A-G1.5
A-G1.5
G-N1.5
G-N1.5
N2.5
R1.5
R-N1.5
A1
L-B0.5
L-N1.5
C-L0.5
A-B1
H1.5
H1.5
G-N1
G1
V1.5
V1.5
ST
GND
G-M1
G-M1
M/B1
M-N1
A-B1
M-V1
B-R1
R-G1
C-B1
B/G1
B-N1
B-V1
H-R1
R-N1
G/R1
A-V1
G-L1
G-L1
A/R1
G-V1
H-L1
H-V1
R-V1
H-V1
R/N1
H/R1
S/N1
V/N1
V-N1
V-N1
V-N1
V-N1
G1.5
Z/N1
N1.5
N1.5
V-Z1
S40 Micro sedile Seating switch
M1
G1
H1
C1
N1
V1
G-M1
A-B1
A-B1
M-V1
M-V1
C-B1
B-N1
B/G1
B-R1
C-N1
H-N1
Z-B1
H-L1
H/R1
H/R1
H/N1
S/N1
Z-N1
L/R1
Z/N1
B-R1.5
M1
N1
X24.gnd
M/N1
M/N1
M/N1
H-N1
S-N1
C-B1
M-V1
M-N1
V/N1
Z-N1
S85 PULSANTE AVV. ACUSTICO POSTERIORE Rear horn switch
A-B1
M-B1
C/B1
Z-N1
N1
S86 INTERRUTTORE GENERALE LUCI General light switch
S87 INTERRUTTORE 4WD 4WD Switch
S88 PULSANTE PPC PPC switch
X47
M-B1.5
1
S89 INTERRUTTORE WARNING WARNING switch
2
S104 Sw 4° marcia 4TH SPEED SWITCH
3
S107 Stacco trasmissione DECLUCH SWITCH
4
S140 Interruttore fari lavoro posteriori Rear working light switch
5
S141 Interruttore girofaro Beacon light switch
6
Interruttore fari lavoro anteriori
OF OPT. HARNESS
L-N1.5
15710
42N-06-15840
42N-06-15940
C-B1
C-B1
C-B1
N1.5
1 X15.p A-N1.5 Y93 Ev. PPC PPC solenoid valve
B-G1
S/N1
B-N1
A-R1
M/N1
C-L1
C-L1
M16
2 X15.p N1 Y94 Ev blocco differenziale Lock Differential gear solenoid valve
B6
N1
V6
1 2 3
A-G1
N1
N1
H/N1
R-G1
B-N1
M-V1
N1
X17.2
R16
Y203 Ev. marcia indietro Reverse solenoid valve
G/R1
A-G1
N1
R6
Z-B1 CN-F20 6 6 X6.p M-N1
R6
P43 B-N1 X12.s CONNETTORE A linea posto guida TO DRIVER SITE HARNESS CONNECTOR
N1
B-N1 CN-F20 7 7 X6.p H-L1 X8.s CONNETTORE A linea posto guida TO DRIVER SITE HARNESS CONNECTOR
X43 R-G1.5CN-F20 8 8 X6.p B1
1 R-G1 X128.s CONNETTORE A linea posto guida TO DRIVER SITE HARNESS CONNECTOR
B1 CN-F20 9 9 X6.p A-V1 X7.s
15 2 G-N1 CONNETTORE A linea posto guida TO DRIVER SITE HARNESS CONNECTOR
10 20 CN-F20 10 10 X6.p
RPM x 100 3 R1 X1.s CONNETTORE A LINEA CENTRALINA 01171062 TO UNIT 01171062 CONNECTOR
CN-F20 11 11 X6.p B-R1 X10.p
5 25 4 B-N1 CONNETTORE A LINEA CRUSCOTTO ANTERIORE TO FRONT DASHBOARD HARNESS CONNECTOR
R-G1.5 CN-F20 12 12 X6.p B1
H-R1
N1.5
R6
L6
V6
0 30
H-L1
H-L1
V-B1
A-N1
7 C-L0.5 7 6 5 4 3 2 1 X15.p CONNETTORE A LINEE OPTIONAL TO OPTIONAL HARNESS CONNECTOR
+15Key +30 +15 R-V1
8 C-B1 X2.s CONNETTORE A LINEA CENTRALINA 01171062 TO UNIT 01171062 CONNECTOR
X3.s 1
9 A-V1 42-N-06-15141 UNIT(01171166) X4.s R1
1 X25.p CONNETTORE A LINEA PANNELLO INTERRUTTORI TO SWITCHES PANEL HARNESS CONNECTOR
X7.p
10 B-V1 2 1 X26.p CONNETTORE A LINEA PANNELLO INTERRUTTORI TO SWITCHES PANEL HARNESS CONNECTOR
B-N1
11 L-B0.5 B-R1.5 3 F25 F14 F13 F12 F24 F21 F7 F22 F18 F16 F17 2 R-N1.5 X28.s CONNETTORE RISCALDAMENTO HEATING CONNECTOR
X7.s
1
M/N1 Z1 4 10A 10A 10A 5A 7,5A 10A 7,5A 7,5A 10A 10A 10A H1 X3.s CONNETTORE A LINEA CENTRALINA 01171062 TO UNIT 01171062 CONNECTOR
13 3
1
14 Z-B1 Z-N1 5 4 V1 X5
X4.s CONNETTORE A LINEA CENTRALINA 01171062 TO UNIT 01171062 CONNECTOR
17 V1 B1 6 5 C1 1 X44.p CONNETTORE A linea cabina TO CABIN HARNESS CONNECTOR
X3.p
18 V-B1 7 6 R1.5 X3.s 1 X5.s CONNETTORE A LINEA CENTRALINA 01171062 TO UNIT 01171062 CONNECTOR
19 G-V1 8 7 R1.5 X65.p CONNETTORE A linea motore TO MOTOR HARNESS CONNECTOR
B-R1
A-V1
V-B1
2
20 N1 9 8 A-G1.5 X5
X7.p CONNETTORE A linea motore TO MOTOR HARNESS CONNECTOR
B-R1
H-R1 10 9 G-N1.5 X8.p CONNETTORE A linea cambio TO GEAR HARNESS CONNECTOR
B-R1 B-R1
B-G1 11 86 87a 87 X9.p CONNETTORE A linea cruscotto anteriore TO FRONT DASHBOARD HARNESS CONNECTOR
Sal2
H-R1 12
K2 K1 X25.s CONNETTORE A L. POSTO GUIDA TO DRIVER SITE HARNESS CONNECTOR
V-B1
V-B1
V-B1
X4 X4 X4
13 86 87a 87 X26.s CONNETTORE A L. POSTO GUIDA TO DRIVER SITE HARNESS CONNECTOR
H-N1 F8 F11 F10 F23 15 F15 15 K4
C-B1
R-V1
M-B1.5 14 F2 F9 F1 X10.s CONNETTORE A linea posto guida TO DRIVER SITE HARNESS CONNECTOR
10A 31 T 31 T
7,5A 7,5A 10A
G1.5 15 53S 53M 53S 53M 15A 15A 15A 85 30
X9.s CONNETTORE A linea posto guida TO DRIVER SITE HARNESS CONNECTOR
10A
A-N1
X30
R/N1
R/N1 16 1 85 30 V-B1 X44.s CONNETTORE A linea posto guida TO DRIVER SITE HARNESS CONNECTOR
A-N1.5 17 X46 X4 X4 V-B1 Sal3 X11.s CONNETTORE A linea posto guida TO DRIVER SITE HARNESS CONNECTOR
S46
1 X27.s A-R1 R-V1 18 2 1 X27s CONNETTORE A linea condizionata A/C HARNESS CONNECTOR
Sal1
A/C
R-G1
R-V1
V-B1
V-B1
R-G1 19 X41.s X41.s P43 PANNELLO STRUMENTI INSTRUMENTS PANEL
2 X27.s C-B2.5
20 P63 PANNELLO DI CONTROLLO ANTERIORE FRONT CONTROL PANEL
42N-07-11500 2
M-N1.5 21 S41 A4 CENTRALINA KOMTRAX KOMTRAX UNIT
X2.s 1 X1 CONNETTORE komtrax unit Komtrax unit Connector
A L/R1 1
F5 K5 1 2 Komtrax unit Connector
HEATING X28.s R4
A-G1.5 2
K11 K3 K4 X30.1 X30.1
X2 CONNETTORE komtrax Unit
86 87a 87 86 87a 87 86 87a 87 86 87a 87 F6 F3 F4 F19 F20 X3.p Connettere a X3.s X3.s Connector
10A
M-N1
B-R1
B-R1
B-R1
B-R1
C-B1
C-B1
R-G1
B-N1
R-V1
V-B1
V-B1
V-B1
V-B1
V-B1
R1.5
N1.5
B-R1 3
G1
N1
42-N-06
11810
Gnd1
Gnd10
N1
R-N1.5
B1
Z-B1
GND9
GND1.3
GND1.2
GND1.1
42-N-06
R4
R6
R6
R6
Gnd1.1
1
Gnd1.3
Gnd1.2
Gnd10
Gnd9
12310
Gnd1
X107
X68.1 X68.3 S107
X68.2
A-N1.5
M1
Z-B1
Z-B1
S-N1
C-B2.5
B-N1
F27
G-M1
M-N1
A-B1
C-B1
A-N1
G-N1
B-R1
B-N1
H-N1
H-N1
H-R1
C/B1
C-N1
H/R1
Z-B1
H-L1
V-B1
Z-N1
V/N1
V-N1
V-N1
N1.5
N1.5
N1.5
B6
G1
A1
N1
200A
V1
2
X107
X7.p 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 X65.p 1 X11.p 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 X12.p 1 2 3 4 5 6 X8.p 1 2 3 4 5 6 7 8 9 10 11 12
A-B1
G-N1
C-B1
A-N1
B-N1
C/B1
C-N1
H-N1
H-R1
Z-B1
H-L1
Z-B1
H/R1
H-L1
Z-N1
V/N1
V-N1
N1.5
N1.5
N1.5
V-Z1
42-N-06
CONNECTTO HARNESS
G1
A1
B2
V1
M-V1
A-N1.5
H-N1
R-N1.5
Z-B1
S-N1
C-B2.5
V-B1
Z-N1
M1
Gnd6 42-N-06
M16
B6
N6
11450
11161 X109 1
42N-06-15960
X109 2
X110.s 1
B-N1
B-V1
N1
H-N1
H-R1
Z-B1
H-L1
V-N1
X100.3 B-R1
A1
X100.4 N1
X100.1 G1
X101.2 A-B1
X101.1 G-N1
G-N1
X101.3B-R1
G-N1
A B C
X101.4 N1
A-N1.5
C-B2.5
R-N1.5
M-V1
H-N1
Z-B1
S-N1
V-B1
Z-N1
R70
R25
R25
B6
N1
V1
X100.2
1
M-N1
C-B1
A-N1
C-N1
C/B1
Z-B1
H-L1
Z-N1
V/N1
N1.5
V-Z1
1 1 1
N1
X105
N1
1
1 1 1
- X104 B105 Y106 X106 Y108 X108 Y203 X203
X119.2
1 1 1 1 1 1 1 1 1 1
1 X119.1 1 1 A B C 1 1 X116
X90 X91 X92 X93 X94 X95 X96 X98 X99 X97
S104
G118 X118.1 X117 X115 1 X112 X112 X112 X121 Y60 X60 M116 Y90 Y91 Y92 Y93 Y94 Y95 Y96 Y98 Y99 X103.1
G1
59c
59c
E101 B111
57
57
X114 X113
L
30
M
50 G119 D+
30 G W
B115 B113 B121 M
t
12Vcc 3
R114 Y117 p p B112 t 2 2 2 2
E103
31
H97
31
31 t 2 2
N70
X113
X121 X60
X90 X91 X92 X93 X94 X95 X96 X98 X99 X97
X103.2 E100
N1.5
N6
N1
N1
N1
N1
N1
N1
N1
N1
N1
N1
N1
N1
N1
N1
N1
N1.5
N1
N1
N1
N1
N2
Gnd3.1 42-N-06
Gnd5 GND2.2 GND2.1
Gnd4
11190
E34000-076
10-126 WB93R-5E0
20 TESTING AND ADJUSTMENTS
WB93R-5E0 20-1
(1)
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA
Compression
Oil temperature: 69–72°C bar
pressure
(Engine speed) rpm
(SAE30 oil)
Engine oil
With blow-by
pressure mm H2O
Free exhaust
(SAE30 oil)
Engine oil
Entire speed range °C
temperature
Fuel
B.T.D.C. mm
injectiontiming
WB93R-5E0 20-3
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA
l a b c l a b c
Boom swing, 4 in 1
Control valve
45 6 6 -- -- -- -- --
bucket, jig arm, outriggers
• See Fig. A
Arm, shovel, boom, mm
45 6,5 6,5 -- -- -- -- --
bucket
Shovel arm
• See Fig. B – 6 5,5 2 -- -- -- --
command only
Shovel arm Raise 95 80–110
Neutral o
control lever Lower 95 80–110
Shovel control Dump 95 80–110
Neutral o
lever Curl 95 80–110
Boom backhoe Raise 100 85–115
Neutral o
controllever Lower 100 85–115
• Engine stopped Opening 100 85–115
Arm backhoe control lever • Knob lever: at the center Neutral o
Travel of levers and pedals
20-4 WB93R-5E0
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA
• Engine stopped
Travel of levers and pedals
Control lever
1,5 1,0–2,0
Boom
• Engine speed: min.
Arm control • Oil temperature: 45–55 °C
• Tool connection at the centre of knob and 1,5 1,0–2,0
lever
at 90° from the lever.
Bucket control • Tool connection on edge
1,3 0,8–1,8
lever (for pedals) kg
• Value reading at the 10 mm before end of working
Boom swing stroke. 1,3 0,8–1,8
control lever • Instrument force gauge.
• Ambient temperature: 15–35 °C
Outriggers control
1,5 1,0–2,0
lever
Fuel control
6,0 5,0–7,0
lever
Input 3,5 2,5–4,5
Jig arm control pedal
Out 5,0 4,0–6,0
Hammer control pedal 3,5 2,5–4,5
Accelerator pedal 4,0 2,5–5,5
• Force measured on steering wheel knob at min.
Steering wheel RPM for approx. half a revolution under steady – –
motion at a speed of 2.5” per rev.
WB93R-5E0 20-5
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA
4 in 1 bucket
270 260–280
(opens-closes)
Boom
345 320–360
(raising)
Pressures of secondary valves circuits
Bucket (Dump) – –
Jig arm
– –
(out - in)
20-6 WB93R-5E0
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA
WB93R-5E0 20-7
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA
★ The technical data of follow table are referred to a machine with max. 500 kg shovel, 600 mm (max. 160 kg) backhoe
bucket and standard arm (or jig arm) closed.
Complete
working equipment Measuring posture: see Fig. D
150 300
(Shovel teeth tip • In this position check in feedback of each cylinder
lower) and the leakage with applied load on the tip of
shovel teeth.
• On level ground.
Shovel
Complete
working equipment
200 350
(Bucket teeth tip
lower) Measuring posture: see Fig. E
• In this position check the extension of each
cylinder and the leakage with normal load on the
Boom cylinders bucket.
10 20
(Cylinder out) • On level ground.
• Bucket: load with standard arm: 340 kg
Backhoe
20-8 WB93R-5E0
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA
★ The technical data of follow table are referred to a machine with max. 500 kg shovel, 600 mm (max. 160 kg) backhoe
bucket and standard arm (or jig arm) closed.
2,0
Boom Max. 8,0
(each cylinder)
Shovel
1,6
Shovel Max. 6,0
(each cylinder)
WB93R-5E0 20-9
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA
★ The technical data of follow table are referred to a machine with max. 500 kg shovel, 600 mm (max. 160 kg) backhoe
bucket and standard arm (or jig arm) closed.
Arm shovel
Lifting
3,6 3,1–4,1
Cylinders Measuring posture: see Fig. H
fully • Engine speed: max.
out • Oil temperature: 45–55 °C
Lowering
• Shovel speed button: applied
2,6 2,2–3,0
Shovel at the ground
Shovel
Shovel
Curl
2,3 2,0–2,6
Cylinders Measuring posture: see Fig. J
fully out • Engine speed: max.
• Oil temperature: 45–55 °C
• Shovel speed button: applied
Dump
Boom
Lifting q
2,7 2,3–3,1
Measuring posture: see Fig. K
Cylinders
fully in • Engine speed: 1700 +0 50 rpm
• Oil temperature: 45–55 °C sec.
• Backhoe balanced
Lowering
• Power mode ON
Teeth bucket on level 2,0 1,7–2,3
ground
Opening
Arm
3,8 3,2–4,3
Measuring posture: see Fig. L
Cylinders
Backhoe
• Power mode ON
Cylinders 4,4 3,7–5,1
fully out
Bucket
Dump
2,4 2,0–2,8
Measuring posture: see Fig. M
Cylinders
• Engine speed: 1700 +0 50 rpm
fully in
• Oil temperature: 45–55 °C
• Backhoe balanced
• Power mode ON
Curl
20-10 WB93R-5E0
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA
★ The technical data of follow table are referred to a machine with max. 500 kg shovel, 600 mm (max. 160 kg) backhoe
bucket and standard arm (or jig arm) closed.
Right q
3,2 2,7–3,7
Work equipment speed
Boom swing
Measuring posture: see Fig. N
Backhoe
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.
WB93R-5E0 20-11
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA
★ The technical data of follow table are referred to a machine with max. 500 kg shovel, 600 mm (max. 160 kg) backhoe
bucket and standard arm (or jig arm) closed.
20-12 WB93R-5E0
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA
l a b c l a b c
Boom swing, 4 in 1
Control valve
45 6 6 -- -- -- -- --
bucket, jig arm, outriggers
• See Fig. A
Arm, shovel, boom, mm
45 6,5 6,5 -- -- -- -- --
bucket
Shovel arm
• See Fig. B – 6 5,5 2 -- -- -- --
command only
Shovel arm Raise 95 80–110
Neutral o
control lever Lower 95 80–110
Shovel control Dump 95 80–110
Neutral o
lever Curl 95 80–110
Boom backhoe • Engine stopped Raise 50 40–60
Neutral o
Travel of levers and pedals
WB93R-5E0 20-13
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA
• Engine stopped
Travel of levers and pedals
Shovel arm
1,5 1,0–2,0
control lever
Shovel control lever 1,5 1,0–2,0
Force for lever, pedal and steering wheel operation
Control lever
• Engine speed: min. 1,8 1,3–2,3
Boom • Oil temperature: 45–55 °C
Arm control • Tool connection at centre of knob and 80 mm
away from handle base (see Fig. C) 1,8 1,3–2,3
lever
• Value reading at the 10 mm before end of working
Bucket control stroke.
• Instrument force gauge. 1,3 0,8–1,8
lever kg
• Ambient temperature: 15–35 °C
Boom swing
1,3 0,8–1,8
control lever
Outriggers control
1,5 1,0–2,0
lever
Fuel control
6,0 5,0–7,0
lever
Accelerator
4,0 2,5–5,5
pedal
• Force measured on steering wheel knob at min.
Steering wheel RPM for approx. half a revolution under steady – –
motion at a speed of 2.5” per rev.
20-14 WB93R-5E0
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA
Shovel
270 260–280
(curled)
Shovel
240 230–255
(Dump)
4 in 1 bucket
270 260–280
(opens-closes)
Boom
345 320–360
(raising)
Pressures of secondary valves circuits
Bucket (Dump) – –
Jig arm
– –
(out - in)
WB93R-5E0 20-15
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA
20-16 WB93R-5E0
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA
★ The technical data of follow table are referred to a machine with max. 500 kg shovel, 600 mm (max. 160 kg) backhoe
bucket and standard arm (or jig arm) closed.
Complete
working equipment Measuring posture: see Fig. D
150 300
(Shovel teeth tip • In this position check in feedback of each cylinder
lower) and the leakage with applied load on the tip of
shovel teeth.
• On level ground.
Shovel
Complete
working equipment
200 350
(Bucket teeth tip
lower) Measuring posture: see Fig. E
• In this position check the extension of each
cylinder and the leakage with normal load on the
Boom cylinders bucket.
10 20
(Cylinder out) • On level ground.
• Bucket: load with standard arm: 340 kg
Backhoe
WB93R-5E0 20-17
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA
★ The technical data of follow table are referred to a machine with max. 500 kg shovel, 600 mm (max. 160 kg) backhoe
bucket and standard arm (or jig arm) closed.
2,0
Boom Max. 8,0
(each cylinder)
Shovel
1,6
Shovel Max. 6,0
(each cylinder)
20-18 WB93R-5E0
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA
★ The technical data of follow table are referred to a machine with max. 500 kg shovel, 600 mm (max. 160 kg) backhoe
bucket and standard arm (or jig arm) closed.
Lifting
Arm shovel
3,6 3,1–4,1
Measuring posture: see Fig. H
Cylinders
• Engine speed: max.
fully out
• Oil temperature: 45–55 °C
Lowering
• Shovel speed button: applied
2,6 2,2–3,0
Shovel at the ground
Shovel
shovel
Curl 2,3 2,0–2,6
Cylinders Measuring posture: see Fig. J
fully out • Engine speed: max.
• Oil temperature: 45–55 °C
• Shovel speed button: applied
Dump
Boom
Lifting q
2,7 2,3–3,1
Measuring posture: see Fig. K
Cylinders
fully in • Engine speed: 1700 +0 50 rpm
• Oil temperature: 45–55 °C sec.
• Backhoe balanced
Lowering
• Power mode ON
Teeth bucket on level 2,0 1,7–2,3
ground
Opening
Arm
3,8 3,2–4,3
Measuring posture: see Fig. L
Cylinders
Backhoe
• Power mode ON
Cylinders 4,4 3,7–5,1
fully out
Bucket
Dump
2,4 2,0–2,8
Measuring posture: see Fig. M
Cylinders
• Engine speed: 1700 +0 50 rpm
fully in
• Oil temperature: 45–55 °C
• Backhoe balanced
• Power mode ON
Curl
WB93R-5E0 20-19
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA
★ The technical data of follow table are referred to a machine with max. 500 kg shovel, 600 mm (max. 160 kg) backhoe
bucket and standard arm (or jig arm) closed.
Right q
3,2 2,7–3,7
Work equipment speed
Boom swing
Measuring posture: see Fig. N
Backhoe
3,2 2,7–3,7
q Times are referred to the cylinder stroke whitout the brake phase.
NOTE. The engine speed (1700 +0 50 rpm) has to be checked with the procedure described at paragraph
«MEASURING ENGINE SPEED» in this section.
20-20 WB93R-5E0
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA
★ The technical data of follow table are referred to a machine with max. 500 kg shovel, 600 mm (max. 160 kg) backhoe
bucket and standard arm (or jig arm) closed.
WB93R-5E0 20-21
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA
Fig. A Fig. B
, a b c
a b
RKZ10850 RKZ10840
Fig. C Fig. D
80mm
~10°
RKZ10680
RKZ10860
20-22 WB93R-5E0
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA
Fig. E Fig. F
1m 1m
RKZ10690
RKZ10700
Fig. G Fig. H
RKZ10830 RKZ10720
WB93R-5E0 20-23
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA
Fig. J Fig. K
RKZ10730 RKZ10740
Fig. L Fig. M
RKZ10780
RKZ10750
20-24 WB93R-5E0
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA
Fig. N Fig. P
RKZ10760
RKZ10790
Fig. Q Fig. R
45°
RKZ10800
RKZ10810
WB93R-5E0 20-25
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA
Fig. S Fig. T
RKZ10820
RKZ10830
20-26 WB93R-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
WB93R-5E0 20-27
PAGE INTENTIONALLY
LEFT BLANK
TESTING AND ADJUSTMENTS VALVE CLEARANCE ADJUSTING
RKZC3150
WB93R-5E0 20-29
TESTING AND ADJUSTMENTS ENGINE SPEED TESTS
a If low and high idling speed with engine without load are
not within permissible value, before going on with other
operations, check accelerator pedal stoppers and
wiring sheathings. (See "ADJUSTING
ACCELERATOR PEDAL TRAVEL AND
ACCELERATOR LEVER").
20-30 WB93R-5E0
TESTING AND ADJUSTMENTS ENGINE SPEED TESTS
• ANALYSIS
1 -If readings are not within the required interval, check the
engine according to the instructions provided in manual
code WEBMNEF001.
2 -If the engine has no conditions, adjust the pump's power
absorption (PC valve).
WB93R-5E0 20-31
TESTING AND ADJUSTMENTS TENSIONING THE AIR-CONDITIONING COMPRESSOR BELT
3 2
1
4
RKTA1204
3 2
RKTA1205
7
1
RKTA1221
20-32 WB93R-5E0
TESTING AND ADJUSTMENTS BLEEDING AIR FROM CIRCUITS - ELIMINATING RESIDUAL
1 -Start the engine and run the engine at high speed for
about 5 minutes to heat the oil.
3 -Stop the engine, check and top up the oil in the tank.
RKZC3180
WB93R-5E0 20-33
TESTING AND ADJUSTMENTS BLEEDING AIR FROM CIRCUITS - ELIMINATING RESIDUAL
RKZC3190
20-34 WB93R-5E0
TESTING AND ADJUSTMENTS ADJUSTING ACCELERATOR PEDAL TRAVEL AND ACCELERATOR
RKZC3200
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.
7 5 6 RKZC9580
RKZC3212
WB93R-5E0 20-35
TESTING AND ADJUSTMENTS ADJUSTING ACCELERATOR PEDAL TRAVEL AND ACCELERATOR
RKZC3220
RKZC3230
20-36 WB93R-5E0
TESTING AND ADJUSTMENTS ADJUSTING BRAKE PEDAL SLACK/ALIGNMENT
RKZC3251
• Control
1 -Remove mat. 1
RKZ11390
• Adjustment
4 -Remove the front cover (2). 2
(For details see "30 REMOVAL AND INSTALLATION").
RKZC6050
RKZC3460
WB93R-5E0 20-37
TESTING AND ADJUSTMENTS BRAKING SYSTEM CHECKS
RKZC2072
20-38 WB93R-5E0
TESTING AND ADJUSTMENTS BRAKING SYSTEM CHECKS
RKZC6051
5
8 RKZC6081
6 7
RKZC9600
RKZC6101
WB93R-5E0 20-39
TESTING AND ADJUSTMENTS BRAKING SYSTEM CHECKS
50 200
0 250
7 -Repeat the test for the other braking group using the
same procedure as above.
20-40 WB93R-5E0
TESTING AND ADJUSTMENTS PARKING BRAKE ADJUSTMENT
RKZC6110
RKZC6120
WB93R-5E0 20-41
TESTING AND ADJUSTMENTS CHECKING AND SETTING PRESSURE IN THE ATTACHMENTS
STEERING UNIT
SAFETY VALVE
Komatsu Ltd. LS
TRANSMISSION
HYDRAULIC PUMP
DIESEL
CONTROL VALVE
RKZ10890
• Introduction
1 -The machine is equipped with a single control valve
with mechanically and/or 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.
2 -The full pump delivery supplies the control valve.
20-42 WB93R-5E0
TESTING AND ADJUSTMENTS CHECKING AND SETTING PRESSURE IN THE ATTACHMENTS
RKZ11100
A1
Dump A5 –
Backhoe bucket
Curl B5 270 A2
B2
Closes A6 270
4 in 1 bucket B3 A3
Opens B6 270
Out A7 – B4 A4
Jig arm
In B7 – A5
B5
Lifting A8 –
Shovel arm
Lowering B8 – B6 A6
Down A9 – A7
Right outrigger B7
Up B9 –
Down A10 – B8 A8
Left outrigger RKZ11110
Up B10 –
WB93R-5E0 20-43
TESTING AND ADJUSTMENTS CHECKING THE SETTING OF MAIN RELIEF AND SECONDARY
2 -Start the engine and run the engine at low idling with all
levers in neutral position.
P1C
RKZC3260
RKZC3270
20-44 WB93R-5E0
TESTING AND ADJUSTMENTS CHECKING THE SETTING OF MAIN RELIEF AND SECONDARY
Set
Cylinder and movement
(bar)
Hammer 180–210
Right 225–250
Boom swing
Left 225–250
Shovel Dump 235–260
WB93R-5E0 20-45
TESTING AND ADJUSTMENTS CHECKING THE SETTING OF MAIN RELIEF AND SECONDARY
3 -Disconnect the hose (1) and connect a tee fitting (2) with
adapter.
2
4 -Connect a pressure gauge E3 (600 bar) to the adapter. E3
RKZC3280
RKZ10910
6 -Slowly extend the arm and boom and take the pressure
when the boom lowers.
RKZ10920
20-46 WB93R-5E0
TESTING AND ADJUSTMENTS CHECKING THE SETTING OF MAIN RELIEF AND SECONDARY
3 -Set the main relief valve to a value 30 bar higher than the
maximum pressure to be tested.
(For details, see "Setting the main relief valve").
Set
Cylinder and movement
(bar)
Arm Closing 260–280
Shovel Curl 260–280
Boom Lowering 260–280
Backhoe bucket Curl 260–280
Closes 260–280
4 in 1 bucket
Opens 260–280
WB93R-5E0 20-47
TESTING AND ADJUSTMENTS SETTING THE MAIN RELIEF VALVES AND THE REDUCING VALVES
RKZC3291
3 Nut: 29.4-39.2 Nm
a When adjustment is complete, check the setting of 2
the main relief valve using the procedures used for
measurements. RKZ10930
20-48 WB93R-5E0
TESTING AND ADJUSTMENTS SETTING THE MAIN RELIEF VALVES AND THE REDUCING VALVES
RKZC3300
RKZ10940
A B RKZ10950
RKZ10960
WB93R-5E0 20-49
TESTING AND ADJUSTMENTS CHECKING AND ADJUSTING THE LS DIFFERENTIAL PRESSURE -
RKZC3310
20-50 WB93R-5E0
TESTING AND ADJUSTMENTS CHECKING AND ADJUSTING THE LS DIFFERENTIAL PRESSURE -
3 Nut: 27.4-34.3 Nm 1
2
3 -When adjustment is complete, check the setting of the
LS valve (1) using the procedures used for checking.
RKZ10970
WB93R-5E0 20-51
TESTING AND ADJUSTMENTS CHECKING AND ADJUSTING SERVOCONTROLS SUPPLY
2 -Start the engine and run the engine at low idling with all
levers in neutral position.
a Each turn of the screw (3) will change the pressure RKZC3350
by _____ bar.
3 Nut: 22 ± 2.5 Nm
2
3
RKZ10980
20-52 WB93R-5E0
TESTING AND ADJUSTMENTS ADJUSTING THE PC VALVE
1 -Loosen the nut (1) and turn the adjustment screw (2).
3 Nut: 27.4-34.4 Nm
MAX 180
0°
MAX 180
RKZ11000
WB93R-5E0 20-53
TESTING AND ADJUSTMENTS TESTING AND SETTING STEERING CONTROL SYSTEM PRESSURE
• Control
1 -Connect a pressure gauge E3 (600 bar) to the pressure E3
tap P1C on the backhoe control valve.
• Setting
3
a If pressure is not within permissible value, carry out
setting acting on upper valve (1) of the steering unit (2). 5
1 -Remove the plug (3).
4
2 -Insert a wrench of 4 mm and loosen screw (4).
• To INCREASE pressure rotate in CLOCKWISE
direction. 1
• To DECREASE pressure rotate in
COUNTERCLOCKWISE direction.
2
3 -Stop the engine and replace the plug (3); ensure that the RKPB1360
3 Plug: 50±10 Nm
20-54 WB93R-5E0
TESTING AND ADJUSTMENTS CHECKING FOR LEAKS IN THE STEERING CYLINDERS
3 -Disconnect the supply hose (2) from the cylinder (1) on RKZC3360
the side where the rod is fully out (3); plug the hose
tightly.
WB93R-5E0 20-55
TESTING AND ADJUSTMENTS TESTING PRESSURES IN THE POWER TRAIN GROUP
a Test condition:
• Engine: stopped.
• Brake pedals: connected by a cotter pin. RKZ11010
• Machine: on solid and level ground with the
equipment raised and safety devices engaged.
2 -Start the engine and heat the engine and all the fluids up
to working temperature. In particular make sure that the
power train oil reaches a temperature of 80±5 °C.
3 -With the engine at MIN, check the pressure on the
pressure gauge E6.
20-56 WB93R-5E0
TESTING AND ADJUSTMENTS TESTING PRESSURES IN THE POWER TRAIN GROUP
2 -Remove the plug (P19) and connect the pressure gauge P19
P18
E6.
3 -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: 23 Nm
8 -Repeat the same test for the FORWARD gear, reading
the pressure from the orifice protected by the plug (P18).
• If the pressures are different for the two travel
directions, there is a loss of pressure on the clutch
piston with lower pressure.
WB93R-5E0 20-57
TESTING AND ADJUSTMENTS TESTING THE CORRECT FUNCTIONING OF THE POWER
• Control
1 -Start the engine and heat the engine and all the fluids up
to working temperature. In particular make sure that the
power train oil reaches a temperature of 80±5 °C.
20-58 WB93R-5E0
TESTING AND ADJUSTMENTS JIG ARM CLEARANCE ADJUSTMENT
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.
1 2
RKZA8001
2 -Raise the arm (1) until it contacts the upper guide shoes
(3).
RKZ02391
4 4
RKZD0030
WB93R-5E0 20-58-1
(1)
TESTING AND ADJUSTMENTS JIG ARM CLEARANCE ADJUSTMENT
RKZD0040
RKZD0050
4 4
RKZD0030
3 Dowels: 12 Nm
4
RKZD0060
20-58-2 WB93R-5E0
(1)
TESTING AND ADJUSTMENTS JIG ARM CLEARANCE ADJUSTMENT
8 -Lock the dowels (4) with the nuts (5) while holding them
in their angular positions.
5
3 Nuts: 200 Nm
RKZD0070
WB93R-5E0 20-58-3
(1)
PAGE INTENTIONALLY
LEFT BLANK
TESTING AND ADJUSTMENTS ANALYSIS OF CAUSES HYDRAULIC DRIFT
FRONT EQUIPMENT
• Testing of front bucket lifting
1 -Put the machine with bucket teeth on blocks A of about
10 cm and in vertical position compared to ground.
3- Disconnect pipes (1) and (2) from lift cylinders (3) and
plug them.
A
4 -Plug cylinders, base side, and apply a temporary pipe, RKZC3440
5 -Start the engine and retract the bucket until to bring the
teeth in tilt position of about 10°.
8 -Remove from one of the cylinders the plug fitted on the RKZC3380
9 -Start the engine and retract the bucket until to bring the
teeth in tilt position of about 10° towards upper.
RKZC3450
WB93R-5E0 20-59
TESTING AND ADJUSTMENTS ANALYSIS OF CAUSES HYDRAULIC DRIFT
1500 kg
RKZ02130
2
RKZC3390
20-60 WB93R-5E0
TESTING AND ADJUSTMENTS ANALYSIS OF CAUSES HYDRAULIC DRIFT
BACKHOE
a Test condition:
• Backhoe aligned
• Lifted outriggers
• Boom testing
1 -Set the machine with arm in vertical position and with
bucket on level ground leaned on the side.
1
RKZC3400
RKZ11030
• Arm testing
1 -Set the machine with arm fully extended and with bucket
teeth on ground.
RKZ11040
WB93R-5E0 20-61
TESTING AND ADJUSTMENTS ANALYSIS OF CAUSES HYDRAULIC DRIFT
3 -Disconnect pipes (1) and (2) pipes from arm cylinder (3)
and plug them to avoid impurity inlet.
2
a If safety valve is fitted, provide to removal.
1
3
4 -Plug arm cylinder hole on head side and fit a temporary
pipe on base side to catch possible oil leakage.
RKZC3410
RKZ11050
• Bucket testing
1 -Set the machine with vertical arm and horizontal bucket
leaned at level ground on the side.
Put in the bucket a weight of 450 kg or fill it with earth.
450 kg
RKZ11060
RKZC3420
20-62 WB93R-5E0
TESTING AND ADJUSTMENTS ANALYSIS OF CAUSES HYDRAULIC DRIFT
RKZ11070
• Outriggers testing
1 -Set the machine with arm in vertical position and with
bucket on level ground leaned on the side.
RKZ11080
RKZC3430
RKZ11090
WB93R-5E0 20-63
TESTING AND ADJUSTMENTS TESTING THE AIR-CONDITIONING UNIT
Ambient
20 25 30 35
temperature (°C)
Outgoing
air temperature 6 -- 8 8 -- 10 8 -- 12 9 -- 14
(°C)
20-64 WB93R-5E0
TESTING AND ADJUSTMENTS TESTING THE AIR-CONDITIONING UNIT
WB93R-5E0 20-65
TESTING AND ADJUSTMENTS EMPTYING THE AIR-CONDITIONING UNIT
20-66 WB93R-5E0
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.
WB93R-5E0 20-67
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.
Uneven wear of tyre
CAUSES REMEDY
Incorrect installation Correct installation
Replace the differential in case it does not survive any one of the
Defective axle
test phases
Remove excessive weight and redistribute load, following
Bent halfshaft
instructions related to the vehicle
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
Blocked halfshaft:
Blocked halfshaft:
• Abnormal functioning of the differential or
• Verify assembly and all components
breakage/blockage of command device.
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.)
20-68 WB93R-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
WB93R-5E0 20-69
TESTING AND ADJUSTMENTS TROUBLESHOOTING
20-70 WB93R-5E0
TESTING AND ADJUSTMENTS TROUBLESHOOTING
WB93R-5E0 20-71
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.
20-72 WB93R-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.
Uneven wear of tyre
CAUSES REMEDY
Incorrect installation Correct installation
Replace the differential in case it does not survive any one of the
Defective axle
test phases
Remove excessive weight and redistribute load, following
Bent halfshaft
instructions related to the vehicle
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
Blocked halfshaft:
• 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.)
WB93R-5E0 20-73
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
20-74 WB93R-5E0
TESTING AND ADJUSTMENTS TROUBLESHOOTING
WB93R-5E0 20-75
TESTING AND ADJUSTMENTS TROUBLESHOOTING
20-76 WB93R-5E0
TESTING AND ADJUSTMENTS TROUBLESHOOTING
TRANSMISSION TROUBLESHOOTING
WB93R-5E0 20-77
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
Worn synchronizer clutch Replace
Worn 4WD clutch 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"
Damaged hydraulic system Repair/Replace
20-78 WB93R-5E0
TESTING AND ADJUSTMENTS TROUBLESHOOTING
WB93R-5E0 20-79
30 REMOVAL AND INSTALLATION
WB93R-5E0 30-1
FRONT AXLE............................................................. 186 OUTRIGGER CYLINDER...........................................298
• Removal................................................................ 186 • Removal ................................................................298
• Installation............................................................. 188 • Installation .............................................................299
FRONT AXLE............................................................. 189 BACKHOE SWING CYLINDERS...............................300
• Disassembly and assembly .................................. 189 • Removal ................................................................300
REAR AXLE............................................................... 222 • Installation .............................................................302
• Removal................................................................ 222 BACKHOE BUCKET CYLINDER ..............................303
• Installation............................................................. 224 • Removal ................................................................303
• Disassembly and assembly .................................. 225 • Installation .............................................................304
SHOVEL PPC VALVE ............................................... 275 BACKHOE BOOM SAFETY CYLINDER ...................305
• Removal................................................................ 275 • Removal ................................................................305
• Installation............................................................. 276 • Installation .............................................................306
SHOVEL LIFT CYLINDERS ...................................... 277 BACKHOE WORKING EQUIPMENT.........................307
• Removal................................................................ 277 • Removal ................................................................307
• Installation............................................................. 278 • Installation .............................................................308
SHOVEL DUMP CYLINDERS ................................... 279 BACKHOE BUCKET..................................................309
• Removal................................................................ 279 • Removal ................................................................309
• Installation............................................................. 280 • Installation .............................................................309
SHOVEL..................................................................... 281 BACKHOE BOOM CYLINDER ..................................310
• Removal................................................................ 281 • Removal ................................................................310
• Installation............................................................. 281 • Installation .............................................................310
FRONT WORKING EQUIPMENT .............................. 282 ARM............................................................................311
• Removal................................................................ 282 • Removal ................................................................311
• Installation............................................................. 283 • Installation .............................................................311
BACKHOE PPC VALVES (Optional)........................ 284 JIG ARM .....................................................................312
• Removal................................................................ 284 • Removal ................................................................312
• Installation............................................................. 285 • Installation .............................................................312
PPC VALVE SUPPORT RELEASE CABLES ........... 286 2nd ARM ....................................................................313
• Removal................................................................ 286 • Removal ................................................................313
• Installation............................................................. 287 • Installation .............................................................313
PPC VALVE SUPPORT RETURN GAS SPRING ..... 288 2nd ARM GUIDES......................................................314
• Removal................................................................ 288 • Removal ................................................................314
• Installation............................................................. 289 • Installation .............................................................314
SOLENOID VALVE GROUP BACKHOE SWING BRACKET ..................................315
(servocontrol and optional attachment) ................. 290 • Removal ................................................................315
• Removal................................................................ 290 • Installation .............................................................315
• Installation............................................................. 291 COMPLETE BACKHOE BACKFRAME.....................316
BACKHOE BOOM CYLINDER.................................. 292 • Removal ................................................................316
• Removal................................................................ 292 • Installation .............................................................317
• Installation............................................................. 294 BACKFRAME LOCK PISTONS.................................318
ARM CYLINDER ........................................................ 295 • Removal ................................................................318
• Removal................................................................ 295 • Installation .............................................................319
• Installation............................................................. 296
JIG ARM CYLINDER ................................................. 297
• Removal................................................................ 297
• Installation............................................................. 297
30-2 WB93R-5E0
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.
WB93R-5E0 30-3
REMOVAL AND INSTALLATION PRECAUTIONS TO BE TAKEN WHILE WORKING
30-4 WB93R-5E0
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
WB93R-5E0 30-5
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 CA715477 Plunger 1
Removal/installation tool
7 CA715900 1
Disassembly - assembly differential ring nut
E
rear axle 8 CA715391 Plunger 1
30-6 WB93R-5E0
REMOVAL AND INSTALLATION SPECIAL TOOLS
1 CA715409 Plunger 1
2 CA715004 Plunger 1
3 CA715623 Plunger 1
4 CA715354 Plunger 1
6 CA715497 Plunger 1
7 CA715356 Calibrator 1
8 CA715501 Plunger 1
Installation/assembly tool
9 CA715358 1
clutches
Disassembly - assembly
F 10 CA715499 Protection 1
transmission
11 CA715046 Plunger 1
13 CA715746 Plunger 1
14 CA715745 Calibrator 1
16 CA715149 Plunger 1
Removal/installation tool
17 CA715493 1
stop ring
18 CA715257 Protection 1
19 CA715263 Protection 1
WB93R-5E0 30-7
PAGE INTENTIONALLY
LEFT BLANK
REMOVAL AND INSTALLATION ENGINE HOOD
ENGINE HOOD
Removal
k Lower the working equipment completely until it is
3
1
RKZC0740
2 -Fully raise the engine hood (3), remove the safety pins
(4) and disconnect the gas springs (5) from the chassis.
RKZC0750
8
7
RKZC0760
4 Engine hood: 32 kg
3
RKZC0770
WB93R-5E0 30-9
REMOVAL AND INSTALLATION ENGINE HOOD
Installation
• To install, reverse removal procedure.
RKZC0780
30-10 WB93R-5E0
REMOVAL AND INSTALLATION FRONT GUARD
FRONT GUARD
Removal
k Lower the working equipment completely until it is
resting on the ground.
Stop the engine and remove the ignition key.
1
1 -Loosen and remove the screws (1) and washers and
remove the front grille (2). 2
1
RKZC0741
3
RKZC0790
4 -Take out the screws (1) and remove the protection (4).
RKZC9610
Installation
• To install, reverse removal procedure.
[*1]
WB93R-5E0 30-11
REMOVAL AND INSTALLATION RADIATOR GROUP - INTERCOOLER
RKZC0771
RKZC9611
3 -Open the cock (3) and drain the coolant liquid. [*1]
RKZC0810
6
RKZC9620
30-12 WB93R-5E0
REMOVAL AND INSTALLATION RADIATOR GROUP - INTERCOOLER
RKZC9630
7 -Loosen and remove the four screws and the fan guard
(10).
10
RKZC9640
8 -Remove tha clamps (11) and (12); loosen the clamp (13)
and disconnect the manifold (14) from intercooler.
11 13
12
RKZC9650
18
RKZC9660
WB93R-5E0 30-13
REMOVAL AND INSTALLATION RADIATOR GROUP - INTERCOOLER
20
21
RKZC9670
24
23
22
RKZC0882
25
RKZC9680
RKZC9690
30-14 WB93R-5E0
REMOVAL AND INSTALLATION RADIATOR GROUP - INTERCOOLER
RKZC9700
32
RKZC9710
WB93R-5E0 30-15
REMOVAL AND INSTALLATION RADIATOR GROUP - INTERCOOLER
Installation
• To install, reverse removal procedure.
[*1]
5 Coolant liquid: 14 l
[*2]
5 Hydraulic oil: 40 l
[*3]
[*4]
a Align radiator (6) with fan, making sure the fan protrudes
from fan shroud. 6
RKZ14550
30-16 WB93R-5E0
REMOVAL AND INSTALLATION INTERCOOLER
INTERCOOLER
Removal
k Fully raise the front working equipment and engage the
safety stop.
Also place the backhoe in its secure position. 1
RKZC0771
RKZC9611
3
RKZC9621
5 -Remove tha clamps (4) and (5); loosen the clamp (6)
and disconnect the manifold (7) from intercooler.
4 6
5
RKZC9651
WB93R-5E0 30-17
REMOVAL AND INSTALLATION INTERCOOLER
6 -Remove the surge tank (8) and the right support (9).
8
7 -Disconnect the inlet pipe (10) from the intercooler.
10
9
RKZC9720
11
RKZC9681
12
13
12
RKZC9730
Installation
• To install, reverse removal procedure.
30-18 WB93R-5E0
REMOVAL AND INSTALLATION CONDENSER
CONDENSER
(For machines equipped with an air-conditioning unit)
Removal
k Fully raise the front working equipment and engage the
safety stop.
Also place the backhoe in its secure position.
RKZC0861
4
RKZC0910
Installation
• To install, reverse removal procedure.
WB93R-5E0 30-19
REMOVAL AND INSTALLATION EXHAUST PIPE
EXHAUST PIPE
Removal
1 -Loosen the nuts (1) on the jumper pin (2) retaining the
muffler pipe (3) to the exhaust pipe. 1
3
1
RKZC0920
RKZC1010
RKZC1020
Installation
• To install, reverse removal procedure.
30-20 WB93R-5E0
REMOVAL AND INSTALLATION MUFFLER
MUFFLER
Removal
k Fully raise the front working equipment and engage the
safety stop. 1
Also place the backhoe in its secure position.
2 -Loosen the jumper pin (4), disconnect the pipe (3) from
the muffler (5) and remove pipe.
5
RKZC0930
3 -Loosen the tie strap (6) retaining the muffler pipe to the
turbocharger.
RKZC0940
Installation 7
5 7
• To install, reverse removal procedure.
RKZC0950
WB93R-5E0 30-21
REMOVAL AND INSTALLATION AIR FILTER
AIR FILTER
Removal
1
1 -Park the machine on hard, level ground, apply the
parking brake, stop the engine and remove the ignition
key.
2
1
RKZC9740
6 5
RKZC9750
4 -Loosen and remove the screws (7) and remove the filter
(8) together with the filter holder.
7
8
RKZC0980
Installation
• To install, reverse removal procedure.
30-22 WB93R-5E0
REMOVAL AND INSTALLATION ENGINE BELT
ENGINE BELT
Replacement
k Fully raise the front working equipment and engage the
1
safety stop. 2
Also place the backhoe in its secure position.
RKZC9631
4
3
RKZC9721
RKZC9760
WB93R-5E0 30-23
REMOVAL AND INSTALLATION TURBOCHARGER
TURBOCHARGER
Removal
k Fully raise the front working equipment and engage the
3
safety stop.
Also place the backhoe in its secure position.
RKZC9751
3 -Loosen and remove the screws (5) and the air filter (6).
5
6
RKZC0981
4 -Loosen and remove screw (7) and nut (8), and remove
heat guard (9).
8
9
RKZC9780
30-24 WB93R-5E0
REMOVAL AND INSTALLATION TURBOCHARGER
10
RKZC1000
Installation
• To install, reverse removal procedure.
WB93R-5E0 30-25
REMOVAL AND INSTALLATION AIR-CONDITIONING UNIT COMPRESSOR
RKZC3000
RKZC3010
RKZC0984
30-26 WB93R-5E0
REMOVAL AND INSTALLATION AIR-CONDITIONING UNIT COMPRESSOR
RKZC9642
7 -Loosen the nut (11) and turn the screw (12) to loosen the
belt.
12 11
9 10
RKTA1206
4
14
15
Installation RKZC3030
[*1]
WB93R-5E0 30-27
REMOVAL AND INSTALLATION AIR-CONDITIONING UNIT COMPRESSOR BELT
RKZC9641
RKZC0983
6 5
3 4
RKTA1207
7
7
9
8
7
RKZC3031
30-28 WB93R-5E0
REMOVAL AND INSTALLATION AIR-CONDITIONING UNIT COMPRESSOR BELT
Installation
• To install, reverse removal procedure.
[*1]
WB93R-5E0 30-29
REMOVAL AND INSTALLATION FAN AND HEATING GROUP
2 -Take out the screws (4) and remove the control unit 5
protection (5). 4
RKZC1040
7
RKZC1050
9
RKZC1060
30-30 WB93R-5E0
REMOVAL AND INSTALLATION FAN AND HEATING GROUP
11
RKZC1070
13
14 15 12
RKZC1080
16
18
RKZC1090
19 20
RKZC1100
WB93R-5E0 30-31
REMOVAL AND INSTALLATION FAN AND HEATING GROUP
21
22
RKZC1110
23
24
RKZC1120
25
10
RKZC1130
RKZC1140
30-32 WB93R-5E0
REMOVAL AND INSTALLATION FAN AND HEATING GROUP
27
28
RKZC1150
29
RKZC1160
20 -Move the rear of the right hand case (10) towards the
middle of the cab, remove pin (30), and disconnect hand
30
accelerator cable (31).
32
RKZC1170
33
RKZC2990
WB93R-5E0 30-33
REMOVAL AND INSTALLATION FAN AND HEATING GROUP
25 - Raise right hand case (10) until PPC valve control and 10
parking brake lever are disengaged; fully remove the
case.
RKZC1180
FAN
35
26 -Disconnect the connector (34).
36
27 - Remove screw (35), then rotate fan group (36)
counterclockwise.
34
RKZC1190
36
RKZC1200
39
38
37
RKZC1210
30-34 WB93R-5E0
REMOVAL AND INSTALLATION FAN AND HEATING GROUP
41
RKZC1220
43 43
41
RKZC1230
Installation
1 - Refill the coolant liquid.
WB93R-5E0 30-35
REMOVAL AND INSTALLATION BATTERY
BATTERY
Removal
k Lower the working equipment completely until it is
resting on the ground.
Engage the parking brake, stop the engine and remove
the ignition key.
1
1 -Lift the door (1) and disconnect the catch (2).
2
RKZC1240
4
RKZC1250
4 -Take out the screws and remove the platform (5) and
door.
RKZC1260
7
RKZC1270
30-36 WB93R-5E0
REMOVAL AND INSTALLATION BATTERY
7 -Loosen wing nut (9) and remove tie rod (10) and bracket
(11). 11
8 -Remove the battery (8).
8 9
10
RKZC1280
Installation
• To install, reverse removal procedure.
[*1]
k Connect the battery positive (+) cable first, and then the
battery negative (–) cable.
WB93R-5E0 30-37
REMOVAL AND INSTALLATION FUEL TANK
FUEL TANK
Removal
k Lower the working equipment completely until it is
resting on the ground.
Engage the parking brake, stop the engine and remove
the ignition key.
1 -Take the cap (2) off the filling inlet of the fuel tank (3) and
remove also the bottom plug in order to drain the fuel.
RKZC1290
RKZC1300
RKZC1310
30-38 WB93R-5E0
REMOVAL AND INSTALLATION FUEL TANK
4 Fuel tank: 68 kg
9
RKZC1320
Installation
• To install, reverse removal procedure.
[*1]
WB93R-5E0 30-39
REMOVAL AND INSTALLATION STEERING WHEEL AND TRANSMISSION-REVERSE, DIRECTION
RKZC1330
2 -Loosen and remove the retaining nut (2) and remove the
steering wheel (3). 3
RKZC1340
4
5
RKZC1350
RKZC1360
30-40 WB93R-5E0
REMOVAL AND INSTALLATION STEERING WHEEL AND TRANSMISSION-REVERSE, DIRECTION
10
11
RKZC1370
11
RKZC1380
Installation
• To install, reverse removal procedure. 16
[*1]
15
RKZC1390
WB93R-5E0 30-41
REMOVAL AND INSTALLATION WORKING BRAKE PUMP GROUP
RKZC1031
RKZC1400
5 -Remove the guards (6) and extract the upper screws (7)
retaining the front trim cover (8).
RKZC1410
30-42 WB93R-5E0
REMOVAL AND INSTALLATION WORKING BRAKE PUMP GROUP
RKZC1420
RKZC1430
11
RKZC1440
10 -Remove the plug and (12) and draw oil from the tank
(13). 14
12
11 -Reinstall the plug and disconnect connectors (14) and
pressure switch connectors (15) and (16).
16
15
RKZC1450
WB93R-5E0 30-43
REMOVAL AND INSTALLATION WORKING BRAKE PUMP GROUP
18 RKZC1460
Installation
• To install, reverse removal procedure.
[*1]
[*2]
21
a Make sure that the push-rods (21) center the seating of
the pistons.
[*3]
3 Union: 20 Nm
RKZ10751
30-44 WB93R-5E0
REMOVAL AND INSTALLATION STEERING UNIT
STEERING UNIT
Removal
k Lower the working equipment completely until it rests
on the ground.
Engage the parking brake, stop the engine and remove
the ignition key. 3
2 -Disconnect the connector (2) and remove the seat (3). 1 RKZC1030
RKZC1381
RKZC1400
RKZC1470
WB93R-5E0 30-45
REMOVAL AND INSTALLATION STEERING UNIT
RKZC1441
7
8
RKZC1480
10
10
RKZC1490
Installation
• To install, reverse removal procedure.
[*1]
11
a Start the engine and perform several complete steering
manoeuvres in both directions, to bleed the air out of the
steering system.
RKZC1500
30-46 WB93R-5E0
REMOVAL AND INSTALLATION CAB
CAB
Removal
k Lower the working equipment completely until it rests
on the ground.
Engage the parking brake and stop the engine.
6 Coolant liquid: 14 l
a Only for machines equipped with an air-
conditioning unit.
Drain the air conditioning unit.
(For details see "20 TESTING AND ADJUSTMENTS").
[*1]
2
RKZC3041
RKZC9790
WB93R-5E0 30-47
REMOVAL AND INSTALLATION CAB
8
8
RKZC1493
9
RKZC9800
9 -Take out the screws (11) and remove the hood (12).
12
11
RKZC1041
14
14
RKZC3050
30-48 WB93R-5E0
REMOVAL AND INSTALLATION CAB
11 -Lift rear window (15) to the top and remove the rear mat.
15
RKZC1871
16
RKZC1881
18
RKZC1891
14 -Take out the screws (no. 4) and remove the hood (20).
20
RKZC1902
WB93R-5E0 30-49
REMOVAL AND INSTALLATION CAB
15 -Take out four screws and remove the metal sheet (21)
closing off the floor.
21
RKZC1911
22
22
23
RKZC1972
a Check that all the hoses are marked and note down
the bends and routing patterns.
26
RKZC2321
30-50 WB93R-5E0
REMOVAL AND INSTALLATION CAB
RKZC2071
31
30
RKZC3110
32 32
RKZC1301
34
34
RKZC3060
WB93R-5E0 30-51
REMOVAL AND INSTALLATION CAB
36
35
RKZC3011
39
40
39
RKZC0742
38
37
RKZC3070
30-52 WB93R-5E0
REMOVAL AND INSTALLATION CAB
26 -Remove the hole plugs and tighten two lifting eyes into
the lifting holes provided.
Connect the cab (41) to the lifting equipment and apply
light tension. 41
27 -Lift the cab by about 30 cm and place some safety blocks
“A” under it.
A A
RKZC3080
45
RKZC3090
46
RKZC3100
WB93R-5E0 30-53
REMOVAL AND INSTALLATION CAB
Installation
• To install, reverse removal procedure.
[*1]
[*2]
a Bleed the air from the steering circuit. (For details, see
"20 TESTING AND ADJUSTMENTS").
[*3]
[*4]
[*5]
[*6]
3 Union (38): 16 Nm
30-54 WB93R-5E0
REMOVAL AND INSTALLATION HYDRAULIC OIL TANK
RKZC1510
2 RKZC1032
RKZC1382
WB93R-5E0 30-55
REMOVAL AND INSTALLATION HYDRAULIC OIL TANK
RKZC1401
11
10
RKZC1411
12
RKZC1421
RKZC1431
30-56 WB93R-5E0
REMOVAL AND INSTALLATION HYDRAULIC OIL TANK
RKZC1442
11 -Remove the fill plug (14) and draw the brake fluid.
15
a Replace plug to prevent contamination. 14
12 -Disconnect oil level and pressure switch connectors
(15) and (16).
16
16
RKZC1451
17 RKZC1461
15 -Pull out the screws (19) and remove the protection (20).
19
20
18
RKZC1481
WB93R-5E0 30-57
REMOVAL AND INSTALLATION HYDRAULIC OIL TANK
22
21
RKZC1520
27
RKZC9791
28
29
RKZC1540
31
32
RKZC1550
30-58 WB93R-5E0
REMOVAL AND INSTALLATION HYDRAULIC OIL TANK
34
33
RKZC1560
35 35
36
RKZC9810
25 -Take out the screws (37) and remove the conveyor (38).
37
38
RKZC1580
40
39
RKZC1590
WB93R-5E0 30-59
REMOVAL AND INSTALLATION HYDRAULIC OIL TANK
41
RKZC1600
43
RKZC1610
RKZC1620
47
46
RKZC1630
30-60 WB93R-5E0
REMOVAL AND INSTALLATION HYDRAULIC OIL TANK
48
RKZC1640
50
RKZC1650
39
Installation
• To install, reverse removal procedure.
[*1]
a Bleed the air from the braking circuit. (For details, see
"20 TESTING AND ADJUSTMENTS").
RKZC1660
[*2]
3 -Bleed the air from the cylinders. (For details, see "20
TESTING AND ADJUSTMENTS").
4 -Stop the engine, check the oil level in the tank and, if
necessary, top it up.
WB93R-5E0 30-61
REMOVAL AND INSTALLATION PISTON PUMP
PISTON PUMP
Removal
k Lower the working equipment completely until it rests
on the ground.
Stop the engine and remove the ignition key.
RKZC1670
4 5
RKZC1680
4 -Disconnect the suction pipe (8) and the draining hose (9)
from the pump.
9
RKZC1511
30-62 WB93R-5E0
REMOVAL AND INSTALLATION PISTON PUMP
10
RKZC1690
8 -Place tool “B1” under the pump until the pump fully
supported.
B1
RKZC1700
9 -Take out the upper screw (11) and remove the pump (4).
Installation
• To install, reverse removal procedure.
RKZC1710
[*1]
3 Screw: 38±1 Nm
[*2]
3 -Stop the engine and check the oil level in the tank.
WB93R-5E0 30-63
REMOVAL AND INSTALLATION TRANSMISSION
TRANSMISSION
Removal
k Lower the working equipment completely until it rests
on the ground.
Stop the engine and remove the ignition key.
RKZC1711
2 -Remove the front mat and remove the metal sheet (2)
closing off the cab floor.
RKZC1521
5
4
RKZC1720
30-64 WB93R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
RKZC1671
RKZC1730
11
10
RKZC1740
13
14
RKZC1750
WB93R-5E0 30-65
REMOVAL AND INSTALLATION TRANSMISSION
16
RKZC1760
18
17 19
RKZC1770
20
RKZC1780
13 -Disconnect the gearbox oil load and oil level control pipe
(21), remove the screw (22) and remove the complete
pipe (21). 21
21
22
RKZC6322
30-66 WB93R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
23 23
25 25
RKZC1800
B2
RKZC1810
20
6
RKZC1830
4 Transmission: 232 kg
RKZC1820
WB93R-5E0 30-67
REMOVAL AND INSTALLATION TRANSMISSION
Installation
• To install, reverse removal procedure.
[*1]
[*2]
[*3]
3 Screw: 120 Nm
[*4]
1 -Start the engine to circulate the oil. Check that there are
no leaks.
30-68 WB93R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
TRANSMISSION
7 6
16
11
6
15 14
14
8
13
9
10
12
5
4
1
RKZ10520
1 -Remove the drain plug (1) and drain the oil from the
transmission.
RKZB8210
2 -Remove the two cap screws (2) which fasten the cover
for the oil screen.
RKZB8220
WB93R-5E0 30-69
REMOVAL AND INSTALLATION TRANSMISSION
4 5
RKZB8230
5 -Remove the connector for the oil filter (7) and its
elements: plugs (6) and cover (9).
6 9
6
RKZB8240
RKZB8250
10
RKZB8260
30-70 WB93R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
10
RKZB8270
12
RKZB8280
13
RKZB8290
14
15
14
RKZB8300
WB93R-5E0 30-71
REMOVAL AND INSTALLATION TRANSMISSION
1.2 Assembly
1 -Assemble the port plugs (14), the breather (15) and the 16
oil temperature sensor (16).
3 Sensor: 30 Nm
14
15
14
RKZB8300
13
RKZB8290
12
RKZB8280
10
RKZB8270
30-72 WB93R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
10
RKZB8260
RKZB8250
3 Union: 50 Nm
6 9
6
RKZB8240
4 5
RKZB8230
WB93R-5E0 30-73
REMOVAL AND INSTALLATION TRANSMISSION
3 Screw: 23 Nm
2
RKZB8220
RKZB8210
30-74 WB93R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
2. OIL PUMP
2.1 Disassembly
4
3
4
RKZ10530
1 -Remove the drain plug (1) and drain the oil from the
transmission.
RKZB8310
RKZB8320
WB93R-5E0 30-75
REMOVAL AND INSTALLATION TRANSMISSION
RKZB8330
RKZB8340
RKZB8350
30-76 WB93R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
2.2 Assembly
1 -Use the tool F1,Assemble the seal ring (2) on the oil
pump (2).
F1
4
2
RKZB8360
RKZB8370
RKZB8380
RKZB8390
WB93R-5E0 30-77
REMOVAL AND INSTALLATION TRANSMISSION
5 -Apply a thin coat of grease to the seat of the oil pump (2)
and install.
RKZB8400
3 Screw: 23 Nm
RKZB8410
30-78 WB93R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
4
3
4
RKZ10540
1 -Remove the drain plug (1) and drain the oil from the
transmission.
2 -Remove the fittings (1) and (2) and remove the pipe (3)
4
4
RKZB8420
3.2 Assembly
1 -Mount the clutch pipe (3) and the fittings (1) and (2).
3 Screw: 40 Nm
1
2 3
4
4
RKZB8420
WB93R-5E0 30-79
REMOVAL AND INSTALLATION TRANSMISSION
30 32
20 29
18 28
19 31
27 33
17
16 26 34
13 14 15
11 35
24 25 36
12
53 23 38 37
9 10 22
7 21 39
6 40
41
46
4 42
43
3 44
45
1 47 48
8
5 49
2 50
51 52
RKZ10550
1 -Remove the drain plug (1) and drain the oil from the
transmission.
13
2 -Take out the screws (13) and remove the distributor (53)
RKZB8430
RKZB8440
30-80 WB93R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
3 -Take out the screws (48) and remove the plate (50).
50
48
RKZB8450
51
RKZB8460
53
RKZB8470
7 -Push down the piston (4) then remove the snap ring (3).
4
RKZB8480
WB93R-5E0 30-81
REMOVAL AND INSTALLATION TRANSMISSION
8 -Remove the piston (4), the spring (5) and the bush (6)
and check the wear conditions of the components.
6
4
RKZB8490
RKZB8510
RKZB8520
10
RKZB8530
30-82 WB93R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
11 -Turn the control valve (53) and remove the screws (33).
33
53
RKZB8540
34
RKZB8550
35
RKZB8560
36
RKZB8570
WB93R-5E0 30-83
REMOVAL AND INSTALLATION TRANSMISSION
43
RKZB8580
42 41 40 39
RKZB8590
37
RKZB8600
26
RKZB8610
30-84 WB93R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
25
RKZB8620
32
RKZB8630
30
29
RKZB8640
28
27
RKZB8650
WB93R-5E0 30-85
REMOVAL AND INSTALLATION TRANSMISSION
24
RKZB8660
24
21
RKZB8670
23
22
21
RKZB8680
RKZB8690
30-86 WB93R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
20
RKZB8700
28 -Remove the O-ring (19), the solenoid valve (18) and the
O-ring (17); 19
18
17
RKZB8710
18
RKZB8720
17
RKZB8730
WB93R-5E0 30-87
REMOVAL AND INSTALLATION TRANSMISSION
RKZB8790
30-88 WB93R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
4.2 Assembly
1 -Assemble the O-Rings (17);
17
RKZB8730
3 Cartridge: 25-30 Nm
18
RKZB8720
18
17
RKZB8710
3 Nut: 5-7 Nm
20
RKZB8700
WB93R-5E0 30-89
REMOVAL AND INSTALLATION TRANSMISSION
23
22
21
RKZB8680
24
21
RKZB8670
3 Cartridge: 21.5-24.5 Nm
24
RKZB8660
28
27
RKZB8650
30-90 WB93R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
30
29
RKZB8640
3 Nut: 7-10 Nm
32
RKZB8630
25
RKZB8620
26
RKZB8610
WB93R-5E0 30-91
REMOVAL AND INSTALLATION TRANSMISSION
37
RKZB8600
42 41 40 39
RKZB8590
43
RKZB8580
36
RKZB8570
30-92 WB93R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
35
RKZB8560
34
RKZB8550
3 Screw: 9.8-11.8 Nm
33
53
RKZB8540
10
RKZB8530
WB93R-5E0 30-93
REMOVAL AND INSTALLATION TRANSMISSION
RKZB8520
RKZB8510
26 -Assemble the piston (4), the spring (5) and the bush (6).
4
RKZB8490
27 -Push down the piston (4) then assemble the snap ring
(3) in its seat.
3
4
RKZB8480
30-94 WB93R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
53
RKZB8470
51
RKZB8460
3 Screw: 23Nm
50
48
RKZB8450
RKZB8440
WB93R-5E0 30-95
REMOVAL AND INSTALLATION TRANSMISSION
3 Screw: 23Nm 13
RKZB8430
30-96 WB93R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
1
8
7
6
2
5
3
43
RKZ10560
1 -Remove the drain plug (1) and drain the oil from the
transmission.
1
2 -Remove the screws (1) and remove the solenoid valve
housing (2). 2
RKZB8750
RKZB8760
WB93R-5E0 30-97
REMOVAL AND INSTALLATION TRANSMISSION
RKZB8770
RKZB8780
RKZB8790
30-98 WB93R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
5.2 Assembly
1 -Assemble valve (3) to the housing.
RKZB8790
3 Cartridge: 22 Nm
5
RKZB8770
3 -Assemble the 4WD solenoid valve (7) and the nut (8).
3 Nut: 5-8 Nm 7
RKZB8760
RKZB8780
WB93R-5E0 30-99
REMOVAL AND INSTALLATION TRANSMISSION
3 Screw: 23Nm 1
2
RKZB8750
30-100 WB93R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
6. Transmission housing
6.1 Disassembly
15 20 43
14 42 22
23
16 21
41
25 26 27 30
10
28 33
11
39 13
C 24 12
36 19
37
31 17
32 18
1 29
34
A
35 38
6 40
4
3
8 9
2
7
E 5 RKZ10570
RKZB8800
2
RKZB8810
WB93R-5E0 30-101
REMOVAL AND INSTALLATION TRANSMISSION
RKZB8820
4
3
RKZB8830
RKZB8840
RKZB8850
30-102 WB93R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
8
RKZB8860
9
7
RKZB8870
RKZB8880
11
RKZB8890
WB93R-5E0 30-103
REMOVAL AND INSTALLATION TRANSMISSION
12
13
RKZB8900
14 14
RKZB8910
16
RKZB8920
18 -Remove the six cap screws (17) and the two capscrews
(42) which fasten the rear cover (18) to the rear half 43 42
housing.
17
18 RKZB8930
30-104 WB93R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
RKZB8940
19
RKZB8950
20
RKZB8960
21
RKZB8970
WB93R-5E0 30-105
REMOVAL AND INSTALLATION TRANSMISSION
22
RKZB8980
23
RKZB8990
24
RKZB9000
26 25
RKZB9010
30-106 WB93R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
27
RKZB9020
28
RKZB9030
29
RKZB9040
30
RKZB9050
WB93R-5E0 30-107
REMOVAL AND INSTALLATION TRANSMISSION
31
RKZB9060
32
RKZB9070
F2
33
RKZB9080
RKZB9090
30-108 WB93R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
35
RKZB9100
RKZB9110
38 37
RKZB9120
40
RKZB9130
WB93R-5E0 30-109
REMOVAL AND INSTALLATION TRANSMISSION
39
39
RKZB9140
30-110 WB93R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
6.2 Assembly
1 - Push the secondary shaft toward the rear of the rear
housing so that there is clearance between the snap ring
groove and the rear housing. 29
Install the snap ring (29).
RKZB9040
39
39
RKZB9140
RKZB9150
38 37
RKZB9160
WB93R-5E0 30-111
REMOVAL AND INSTALLATION TRANSMISSION
RKZB9170
3 Screw: 50 Nm 34
RKZB9180
3 Screw: 50 Nm
35
RKZB9190
RKZB9200
30-112 WB93R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
7 F4
RKZB9210
8
RKZB8860
RKZB8850
14 -Install the three cap screws (6) which fasten the cover to
the front housing.
3 Screw: 23 Nm
6
RKZB8840
WB93R-5E0 30-113
REMOVAL AND INSTALLATION TRANSMISSION
RKZB8830
RKZB9220
RKZB8820
3 Screw: 139 Nm
2
RKZB8810
30-114 WB93R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
RKZB9230
28
RKZB9030
27
RKZB9020
3 Screw: 80 Nm
26 25
RKZB9010
WB93R-5E0 30-115
REMOVAL AND INSTALLATION TRANSMISSION
25 26
RKZB9240
30
33
RKZB9250
32
RKZB9260
RKZB9270
30-116 WB93R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
30
RKZB9050
24
RKZB9000
23
RKZB8990
RKZB8980
WB93R-5E0 30-117
REMOVAL AND INSTALLATION TRANSMISSION
21
RKZB8970
32 -Install the pins (20) to fasten the shift collars to the shift
rods. 41
Mount the centering pins (41).
20
RKZB9280
19
F8
RKZB9290
3 Screw: 50 Nm
17
35 -Mount the O-ring (43).
18 RKZB8930
30-118 WB93R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
16
RKZB8920
3 Screw: 23 Nm
14 14
RKZB8910
13
RKZB8900
11
RKZB8890
WB93R-5E0 30-119
REMOVAL AND INSTALLATION TRANSMISSION
3 Screw: 139 Nm
10
RKZB8880
30-120 WB93R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
7. SHAFTS A - D
7.1 Disassembly
37 18 32 33
D 17 34
11
16 27
10
8
6
7
4 A
3
38
2
1 39
40
31 22
A 23
9
24
21 25
12
20
26
19 28
5 30
15 29
13 35
14 36
RKZ10580
A
RKZB9300
Shaft A
RKZB9310
WB93R-5E0 30-121
REMOVAL AND INSTALLATION TRANSMISSION
RKZB9320
RKZB9330
RKZB9340
RKZB9350
30-122 WB93R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
RKZB9360
RKZB9370
RKZB9380
RKZB9390
WB93R-5E0 30-123
REMOVAL AND INSTALLATION TRANSMISSION
10
RKZB9400
11
RKZB9410
18
RKZB9420
RKZB9430
30-124 WB93R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
RKZB9440
F9
13
RKZB9450
14
RKZB9460
13
RKZB9450
WB93R-5E0 30-125
REMOVAL AND INSTALLATION TRANSMISSION
13
15
RKZB9470
RKZB9480
RKZB9490
21
RKZB9500
30-126 WB93R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
22
RKZB9510
23
RKZB9520
24
RKZB9530
24
25
RKZB9540
WB93R-5E0 30-127
REMOVAL AND INSTALLATION TRANSMISSION
26
12
RKZB9550
RKZB9560
Shaft D
16
RKZB9600
37
RKZB9610
30-128 WB93R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
4 -If the clutch discs are to be used again, keep the clutch RKZB9570
RKZB9590
WB93R-5E0 30-129
REMOVAL AND INSTALLATION TRANSMISSION
7.2 Assembly
Shaft A
21
RKZB9500
RKZB9620
19
F10
RKZB9630
RKZB9480
30-130 WB93R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
13
15
RKZB9470
6 -Lower the lock spring cover (13). Insert lock ring (14).
Use tool F9.
F9
14
RKZB9640
RKZB9650
RKZB9660
WB93R-5E0 30-131
REMOVAL AND INSTALLATION TRANSMISSION
RKZB9370
10 -To assemble the clutch pack start with the gear (6) on
the bench. Install the clutch plate lock ring (11) so that
the reference mark on top of the plate made during 11
disassembly is facing towards the gear.
6
RKZB9670
17
11
RKZB9680
RKZB9690
30-132 WB93R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
10
RKZB9700
RKZB9350
F2
RKZB9710
RKZB9320
WB93R-5E0 30-133
REMOVAL AND INSTALLATION TRANSMISSION
RKZB9720
F5
RKZB9730
F5
RKZB9740
F5
RKZB9750
30-134 WB93R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
RKZB9560
F7
RKZB9760
23 -Turn the seal compressor around and slide the end with
the narrow chamfer over the shaft and over the seal ring.
Leave the seal compressor in place for 15 minutes until
the sealing ring has cooled and is properly sized and
seated in the groove.
After the seal ring has cooled, remove the seal
compressor from the shaft.
RKZB9780
24 -Turn the shaft around and carry out steps 1 - 10 for the
other clutch.
Lubricate the ring (25) with transmission oil. Install the
ring (25) so the notch on the inside rim goes onto the pin. 25
Make sure that the side with the oil grooves is down.
RKZB9790
WB93R-5E0 30-135
REMOVAL AND INSTALLATION TRANSMISSION
F11
24
RKZB9800
23
RKZB9810
F12a F12b
RKZB9820
F12b
RKZB9830
30-136 WB93R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
22
RKZB9840
F13
RKZB9850
31 -Install the end of the F14 seal compressor with the deep
chamfer onto the shaft and over the sealing ring.
Use a back and forth twisting motion to allow the seal
compressor to slip over the top of the sealing ring and
seat the sealing ring into the groove.
Be careful not to damage the seal ring.
After the sealing ring is seated in the groove, remove the
seal compressor from the shaft.
F14
RKZB9860
32 -Turn the seal compressor around and slide the end with
the narrow chamfer over the shaft and over the seal ring.
Leave the seal compressor in place for 15 minutes until
the sealing ring has cooled and is properly sized and
seated in the groove. After the seal ring has cooled,
remove the seal compressor from the shaft.
For the introduction of the other three teflon rings, repeat
the operations from sequence 27 to sequence 31, using
the following spacer rings:
CA715743/2 for the 2nd teflon ring,
CA715743/3 for the 3rd teflon ring,
CA715743/4 for the 4th teflon ring.
F14
RKZB9870
WB93R-5E0 30-137
REMOVAL AND INSTALLATION TRANSMISSION
Shaft D
F3 16
1 -Assemble D shaft bearing (16).
Use tool F3
RKZB9880
RKZB9890
RKZB9900
RKZB9910
30-138 WB93R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
7 6 5 4
3 23 13
8
6 5
WB93R-5E0 30-139
REMOVAL AND INSTALLATION TRANSMISSION
8. SHAFTS B - C
8.1 Disassembly
17
20 37
16 38 13
15 36
27 14
29
30 1
C
18 33 28 2
31 C
32 34 5
35 6
25 8 7
26
24 9 3
22 10
21
23 11
6 B
5
4
12 40
42 41
B
19 39 RKZ10600
F15
B
RKZB9920
RKZB9930
30-140 WB93R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
Shaft C
1 -Remove bearing (1) by means of an extractor.
RKZB9940
RKZB9950
RKZB9960
RKZB9970
WB93R-5E0 30-141
REMOVAL AND INSTALLATION TRANSMISSION
RKZB9980
RKZB9990
10 10
9
9
8 8 RKZC0010
30-142 WB93R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
12
RKZC0020
15
RKZC0030
15
16
RKZC0040
16
RKZC0050
WB93R-5E0 30-143
REMOVAL AND INSTALLATION TRANSMISSION
20
17
RKZC0060
19
RKZC0070
RKZC0080
RKZC0090
30-144 WB93R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
22
23
RKZC0100
18 -Remove the steel ring (24) and the sintered ring (25).
24
25
RKZC0110
26
RKZC0120
27
23
RKZC0130
WB93R-5E0 30-145
REMOVAL AND INSTALLATION TRANSMISSION
21 -Remove the steel ring (28) and the sintered ring (29).
28
29
RKZC0111
30
RKZC0121
31
RKZC0140
36
RKZC0160
30-146 WB93R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
37
RKZC0170
38
RKZC0180
14
RKZC0190
13
RKZC0200
WB93R-5E0 30-147
REMOVAL AND INSTALLATION TRANSMISSION
Shaft B
1 -Remove bearing inner race (39) by means of a puller.
39
RKZC0210
40
41
RKZC0220
8.2 Assembly
Shaft C
13
RKZC0200
RKZC0190
30-148 WB93R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
38
RKZC0180
37
RKZC0170
36
RKZC0160
34
33
32 31
RKZC0230
WB93R-5E0 30-149
REMOVAL AND INSTALLATION TRANSMISSION
32
RKZC0240
30
RKZC0121
29
RKZC0111
27
23
RKZC0130
30-150 WB93R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
26
RKZC0120
25
RKZC0110
23
RKZC0100
RKZC0090
WB93R-5E0 30-151
REMOVAL AND INSTALLATION TRANSMISSION
16 -Ensure the spacer (21) and gear (18) make solid contact 18
with the synchronizer (23).
RKZC0080
19
RKZC0070
17
20
RKZC0250
16
17
RKZC0270
30-152 WB93R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
RKZC0260
17
RKZC0061
F16
15
RKZC0280
15
RKZC0030
WB93R-5E0 30-153
REMOVAL AND INSTALLATION TRANSMISSION
12
RKZC0020
11
10
8
9 7
RKZC0231
26 -Install springs (10), blocks (8), balls (9) and sleeve (7) to
hub (11).
Using a punch or screwdriver, push in the balls (9) to
complete assembly of hub (11).
11
8 9 10
7
RKZC0241
RKZC0290
30-154 WB93R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
RKZB9970
RKZB9960
RKZC0300
F2
RKZC0310
WB93R-5E0 30-155
REMOVAL AND INSTALLATION TRANSMISSION
Shaft B
1 -Heat the inner race of the bearing (39) to 80÷100°C
(176°÷212°F) and use the tools F16 mount the ring
inside the bearing (39).
F16
39
RKZC0320
40
41
RKZC0330
RKZB9931
9. SHAFT E
9.1 Disassembly
RKZB9921
30-156 WB93R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
16
14
7 13
11
9
12
15
8
12
10
4
2
1
6
E 5
3 RKZ10640
RKZC0340
15
RKZC0350
WB93R-5E0 30-157
REMOVAL AND INSTALLATION TRANSMISSION
16
RKZC0360
4 -Using tool F17, push down on the spring cover until stop
ring is exposed (1).
Remove stop ring (1) from its seat and remove tool F17,
1
then remove washer (2). F17
RKZC0380
RKZC0370
RKZC0390
30-158 WB93R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
RKZC0400
8 -Remove the two O-rings (6) and (9) from the shaft.
RKZC0410
RKZC0420
14
RKZC0430
WB93R-5E0 30-159
REMOVAL AND INSTALLATION TRANSMISSION
13
RKZC0440
13
12 12
RKZC0450
13 11 10
RKZC0460
14 -Do not remove 4WD clutch pipe (7) from front housing
unless absolutely necessary.
7
RKZC0470
30-160 WB93R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
9.2 Assembly
1 -Install spring (11) and valve (10) in cylinder (13).
13 11 10
RKZC0460
13
12 12
RKZC0450
13
RKZC0440
14
RKZC0430
WB93R-5E0 30-161
REMOVAL AND INSTALLATION TRANSMISSION
RKZC0410
RKZC0400
RKZC0390
RKZC0370
30-162 WB93R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
RKZC0480
10 -Using tool F17, push down on spring cover until the stop
ring seat (1) is exposed and complete the assembly of
the stop ring (1).
Release tension and remove the tool.
Ensure that the stop ring (1) is correctly positioned in the F17
recess of the spring cover.
2 1
RKZC0490
8 F18
RKZC0500
RKZC0510
WB93R-5E0 30-163
REMOVAL AND INSTALLATION TRANSMISSION
RKZC0520
14 -Turn the seal compressor around and slide the end with
the narrow chamfer over the shaft and over the seal ring.
Leave the seal compressor in place for 15 minutes until
the sealing ring has cooled and is properly sized and F7
seated in the groove.
After the seal ring has cooled, remove the seal
compressor from the shaft.
RKZC0520
F19
RKZC0530
30-164 WB93R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
10 11 9 13 12 14
4
8 8
3 6 5 16
15
RKZ10660
16
RKZC0360
WB93R-5E0 30-165
REMOVAL AND INSTALLATION TRANSMISSION
15
RKZC0350
E B
RKZC0341
RKZC0470
30-166 WB93R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
6 7
7
5
4
1
3
2
93
10
11
14
11
13
RKZ10670
RKZC0540
2 -Remove the shift tower assembly (2) and the O-ring (3).
3
RKZC0710
WB93R-5E0 30-167
REMOVAL AND INSTALLATION TRANSMISSION
RKZC0550
RKZC0560
RKZC0570
8
RKZC0580
30-168 WB93R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
9
RKZC0590
10
RKZC0690
RKZC0700
10 -Do not remove pins (11) and do not separate forks from
shifters unless it is necessary. 11
Mark the forks and the shifters to prevent mixing them
during installation.
11
RKZC0720
WB93R-5E0 30-169
REMOVAL AND INSTALLATION TRANSMISSION
10.2Assembly
1 -Apply grease to the ball of the shift lever.
Install the shift lever (6) in the cover (2).
RKZC0700
C
D
RKZC0730
10
RKZC0690
9
RKZC0590
30-170 WB93R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
8
RKZC0580
RKZC0570
7 -Install the boot (5) so that the edge is seated on the pin
ends.
Pay attention not to drop the pins.
5
RKZC0560
RKZC0550
WB93R-5E0 30-171
REMOVAL AND INSTALLATION TRANSMISSION
3
RKZC0711
3 Screws (1): 23 Nm
RKZC0540
11 -Fit the two pins (11) to lock gear control fork 3rd and 4th
speed (13) and gear control 1st and 2nd speed (14). 11
13
14
11
RKZC0721
30-172 WB93R-5E0
REMOVAL AND INSTALLATION CONVERTOR
CONVERTOR
Removal
k Lower the working equipment completely until it rests
on the ground.
Stop the engine and remove the ignition key.
RKZC1840
Installation
• To install, reverse removal procedure.
[*1]
WB93R-5E0 30-173
REMOVAL AND INSTALLATION ENGINE
ENGINE
Removal
1 -Remove:
• ENGINE HOOD
• FRONT GUARD
• FRONT COUNTERWEIGHT
• RADIATOR GROUP - INTERCOOLER
• INTERCOOLER
• MUFFLER
• ENGINE BELT
• PISTON PUMP
• TRANSMISSION
For details, see the individual removal procedures.
2 -Disconnect the fuel inlet and return pipes (1) and (2),
release them from the tie straps and position them
aside.
1
2
RKZC2860
3 -Remove the screws and release the straps (1) and (2)
retaining the heating system hoses.
1 2
2 RKZC2870
RKZC2880
30-174 WB93R-5E0
REMOVAL AND INSTALLATION ENGINE
8
6
7
RKZC2890
Only if equipped
6 -Disconnect suction and delivery hoses (10) and (11) 11
from air-conditioning group compressor (9).
10
9
RKZC2900
Only if equipped
7 -Release the wiring harness (12) to the compressor (9)
from the tie straps and disconnect.
12 RKZC2910
RKZC2930
WB93R-5E0 30-175
REMOVAL AND INSTALLATION ENGINE
15
RKZC2920
16
RKTA0811
20
19
21
RKZC9820
23
22
RKTA0801
30-176 WB93R-5E0
REMOVAL AND INSTALLATION ENGINE
RKZC9830
RKZC2960
RKZC2970
26
28
RKZC2980
WB93R-5E0 30-177
REMOVAL AND INSTALLATION ENGINE
Installation
• To install, reverse removal procedure.
[*1]
3 Nuts: 200 Nm
a Check transmission oil level before starting the
engine.
30-178 WB93R-5E0
REMOVAL AND INSTALLATION CONTROL VALVE (Standard version)
4 -Lift rear window (1) to the top and remove the rear mat.
1
RKZC1870
Only if equipped
5- Remove screws (2) and remove control pedals (3) for jig
arm and hammer. 3
RKZC1880
RKZC1890
WB93R-5E0 30-179
REMOVAL AND INSTALLATION CONTROL VALVE (Standard version)
7 -Take out the screws (n°4) and remove the hood (6).
RKZC1900
8 -Take out four screws and remove the metal sheet (7)
closing off the floor.
RKZC1910
RKZC1920
10 -Make sure that all the hoses are marked; disconnect the
lower hoses (10), together with all accessible side hoses
(11), from the control valve. 11
a Cap pipes, hoses and holes to prevent 10
contamination.
11
10 RKZC1930
30-180 WB93R-5E0
REMOVAL AND INSTALLATION CONTROL VALVE (Standard version)
11 -Make sure that all the hoses are marked; disconnect the
upper hoses (12), together with all accessible side
hoses (13), from the control valve.
12
RKZC1940
9
14
RKZC1921
15
16
RKZC1950
17
RKZC1941
WB93R-5E0 30-181
REMOVAL AND INSTALLATION CONTROL VALVE (Standard version)
RKZC3120
16 -Loosen and remove the four screws (19) (n° 3) and the
relative washers.
19
19
RKZC1960
Installation
• To install, reverse removal procedure. RKZC3130
[*1]
a Install control valve from top.
1 -Start the machine to circulate the oil; check to ensure
that there are no leaks.
3 -Stop the engine, check the hydraulic oil level and top up
as necessary.
30-182 WB93R-5E0
REMOVAL AND INSTALLATION CONTROL VALVE (version with servocontrol)
4 -Lift rear window (1) to the top and remove the rear mat.
1
RKZC1870
5 -Take out the screws (2) and remove the platform (3).
3
RKZC1970
RKZC1922
WB93R-5E0 30-183
REMOVAL AND INSTALLATION CONTROL VALVE (version with servocontrol)
a Check that all the hoses are marked and note down
the bends and routing patterns.
6
a Cap pipes, hoses and holes to prevent
contamination. 7
RKZC1980
9 9
RKZC1990
5
10
RKZC1923
11
12
RKZC1951
30-184 WB93R-5E0
REMOVAL AND INSTALLATION CONTROL VALVE (version with servocontrol)
RKZC3140
12 -Loosen and remove the four screws (14) (n° 3) and the
relative washers.
14 14
RKZC1981
Installation
• To install, reverse removal procedure. RKZC3131
[*1]
a Install control valve from top.
1 -Start the machine to circulate the oil; check to ensure
that there are no leaks.
3 -Stop the engine, check the hydraulic oil level and top up
as necessary.
WB93R-5E0 30-185
REMOVAL AND INSTALLATION FRONT AXLE
FRONT AXLE
Removal
1- Start the engine and force the shovel downwards in
order to raise the machine and the front wheels.
6 -Remove the engine hood (1) and the front guard (2).
(For details, see "ENGINE HOOD" and "FRONT
GUARD").
2
7 -If equipped, remove the front counterweight. [*1]
4 Wheel: 65 kg
RKZC2010
30-186 WB93R-5E0
REMOVAL AND INSTALLATION FRONT AXLE
C
B
RKZC2020
13 -Take out the nut and remove the retaining screw (8) of
the axle oscillation pin (7). 7
14 -Tighten a hammer puller into the central hole of the axle
oscillation pin (7); pull out the axle oscillation pin. [*5]
RKZC2030
WB93R-5E0 30-187
REMOVAL AND INSTALLATION FRONT AXLE
Installation
• To install, reverse removal procedure.
[*1]
[*2]
[*3]
[*4]
[*5]
30-188 WB93R-5E0
REMOVAL AND INSTALLATION FRONT AXLE
FRONT AXLE
Disassembly and assembly
1. CYLINDER GROUP DISASSEMBLY
1.1 Disassembly
21 10
9
20
8
19
18
6
17
16 7
11
15 12
13 14
5
4
3
2
1
RKZ09810
1 -Unloose the guide rod (2) locknut (1) of some turns till it
is over the end of the threaded pin. 3
Beat on the nut (1) with a hammer in order to disjoin the
guide rod (2) from the swivel housing (3).
RKZB5581
2 -Loosen the nuts (4) and (9) and remove the tie rods (3)
and (10). 4
a 4
Remove only those parts that need to be 5
overhauled and/or replaced.
5
RKZ07111
WB93R-5E0 30-189
REMOVAL AND INSTALLATION FRONT AXLE
16
RKZ07121
1.2 Assembly
19
1 -Install new sealing rings (16) and (18), O-rings (14) and
(20), and scrapers (21) and (13) to cylinder head (15), to 17
rod piston (17) and into cylinder body (19). 20 21
14 15
13 18
16
RKZ07121
19
17
RKZB0093
3 -Install ball joints (5) and (8), nuts (4) and (9) and tie rods
(3) and (10) at the rod (17) ends and tighten. 4
4
5
5
RKZ07111
30-190 WB93R-5E0
REMOVAL AND INSTALLATION FRONT AXLE
3 Screw: 120 Nm
7
RKZB5461
RKZB1163
7 -Insert the ball joint (8) (into its own housing on the swivel
housing.
Assemble and tighten the lock nut (1) with
2 3
dynamometric wrench.
3 Nut: 220 Nm
8 -Repeat the operation for the opposite side.
1
RKZB1173
9 -Screw in the lock nuts (4) and (9) of the tie rods (3) and
(10) only when the toe-in adjustment has been carried
out.
WB93R-5E0 30-191
REMOVAL AND INSTALLATION FRONT AXLE
Toe-in adjustment
1 -Put two equal one-meter-long linear bars “A” on the
A
wheel sides and lock them with two nuts on the wheel
hub stud bolt.
RKZB1200
M -0 5 mm
RKZ09820
30-192 WB93R-5E0
REMOVAL AND INSTALLATION FRONT AXLE
RKZB1210
3 Nuts: 250 Nm
RKZB1221
RKZB1230
RKZB1240
WB93R-5E0 30-193
REMOVAL AND INSTALLATION FRONT AXLE
RKZB1251
30-194 WB93R-5E0
REMOVAL AND INSTALLATION FRONT AXLE
7
6
9
3
8
10
2
1
RKZ09830
RKZB0102
RKZC0600
WB93R-5E0 30-195
REMOVAL AND INSTALLATION FRONT AXLE
10
RKZC0610
2.2 Assembly
8
1 -Recover all epicyclic reduction gear components: the
planetary gears carrier (3), the gears (6), the needle 7
bearings (5) and (7), washer (8) and the snap rings (9) of
every pin (4).
7 5
a With new gears, it is advisable to install new needle
rollers.
6
RKZ09840
2 - Insert the needles (5) and (7) into the gears (6).
a Grease well the needles (5) and (7).
Insert the gears (6) with assembled needles in the
planetary carrier pins.
6
RKZC0620
30-196 WB93R-5E0
REMOVAL AND INSTALLATION FRONT AXLE
RKZ09850
RKZC0600
RKZB0102
WB93R-5E0 30-197
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
2 -Remove the lock ring (1) from the double U-Joint shaft
and collect the washers (2), (3).
1
RKZB0133
30-198 WB93R-5E0
REMOVAL AND INSTALLATION FRONT AXLE
RKZB0141
4 -In order to remove the wheel carrier group (7) from its
housing, screw (5) at least two of the just removed
screws in the threaded extraction holes. 7
5
5
RKZB0152
6 -Remove the stop ring (4) and disjoin the hub-lock ring
gear (7) from the epicyclic ring gear (3).
Only if necessary
7 -Remove the centering bushes (6) of the hub lock ring
7
gear with a hammer and the special tool D1.
4
RKZC0640
RKZB0172
WB93R-5E0 30-199
REMOVAL AND INSTALLATION FRONT AXLE
9 -Position on a flat surface the hub and take the seal ring
out (13) with a lever. 12
RKZB5621
14 -Remove the swivel housing (14) from the axle beam and
from the shaft (24).
14
24
RKZB0212
RKZB5631
30-200 WB93R-5E0
REMOVAL AND INSTALLATION FRONT AXLE
3.2 Assembly
1 -Force the bush (22) into the swivel housing (14) with the
special tool D2. and a hammer or a press.
D2 D3
2 -Assemble the seal ring (23) on the swivel housing (14) 22 23
with the special tool D3.
and a hammer. Lubricate the ring with grease
ASL800050. 14
RKZB1013
25 RKZB5661
3 Screw: 190 Nm 16 14
a Make sure that the Belleville washers (25) and (27)
remain in their position. RKZB1412
A = 5.900 – 5.905 mm
B = 52.229 – 52.279 mm 9 12
C = 23.072 – 23.173 mm C A C
RKZ05743
WB93R-5E0 30-201
REMOVAL AND INSTALLATION FRONT AXLE
9 -Insert the seal ring (13) into the wheel hub (11) with the
special tool D6 and a hammer.
D5 D6
D5 11
RKZB1424
RKZB1433
7
RKZB1093
RKZ05733
30-202 WB93R-5E0
REMOVAL AND INSTALLATION FRONT AXLE
RKZB1103
3 Screw: 120 Nm
RKZB1443
16 -Install washers (2) and (3) to the axle shaft and install the
stop ring (1) by pushing it from the end of the serrated
hub to its seat while counteracting with a lever inserted
1
between beam and swivel housing and engaged onto
the double U joint.
RKZB0133
WB93R-5E0 30-203
REMOVAL AND INSTALLATION FRONT AXLE
7
8
1
2
8
7 4 5
RKZ09880
RKZC0650
2 -Take the seal ring (5) out of the axle (1) beam with a
lever.
30-204 WB93R-5E0
REMOVAL AND INSTALLATION FRONT AXLE
4 -Extract the upper bushings (2) and cup (3) from the king
pin housings. 2
a Examine the bushing and housing before removal
and replace depending on wear conditions.
1
3
RKZ09890
5 -Take the seal ring (7) out of the axle (1) beam with a
suitable tool.
7
a This is a destructive operation for the seal rings.
Only if necessary, remove the bushings with a standard 8 1
three-gripping point extractor or a suitable driver and a
hammer.
4.2 Assembly
1 -Using tool D7 and a hammer, install bushing (2) and cup 2 D7
(3). 2
3
3
RKZC0670
2 -Assemble the bush (4) on the axle beam with the special
tool D9 and a hammer.
3 -Assemble the seal ring (5) on the beam with the special
tool D10 and a hammer. 4 5
Fill 3/4 of the seal ring cavity with grease ASL800050.
RKZ09910
WB93R-5E0 30-205
REMOVAL AND INSTALLATION FRONT AXLE
4 -Lubricate the bush (5) and the seal ring lip (6). Insert the
U-Joint (7) inside the axle beam.
RKZC0650
8 1
8
7
RKZ09900
30-206 WB93R-5E0
REMOVAL AND INSTALLATION FRONT AXLE
5. DIFFERENTIAL SUPPORT
5.1 Disassembly
6
12
5 7 11 14
10
13
4
3
1
RKZ09920
2 1
RKZ09930
RKZ09940
WB93R-5E0 30-207
REMOVAL AND INSTALLATION FRONT AXLE
RKZ09950
4 -Unscrew the adjuster ring nuts (3), (7) using tool D12
and a wrench.
7 3
D12 RKZ09960
RKZ09970
a Take care not to loose the cups bearing (13) that are
removed together with the differential case (1).
4 4
a Do not mismatch the cups of the bearings (4) if
bearings are not to be replaced.
RKZ09980
30-208 WB93R-5E0
REMOVAL AND INSTALLATION FRONT AXLE
5.2 Assembly
1 -Position the complete differential box (13), with the outer
cups (4) of the tapered roller bearings already
assembled, on the differential carrier (1).
13
RKZ09990
RKZ09970
D12 RKZ09960
RKZ10000
WB93R-5E0 30-209
REMOVAL AND INSTALLATION FRONT AXLE
0.18 -0.28 mm
RKZ10100
RKZ10000
30-210 WB93R-5E0
REMOVAL AND INSTALLATION FRONT AXLE
RKZ09940
3 Screw: 266 Nm
11
10
RKZ10030
2 Loctite: 510
14
a check that two dowel pins (12), (8) are in their seats.
12
RKZ10040
WB93R-5E0 30-211
REMOVAL AND INSTALLATION FRONT AXLE
2 1
RKZ09930
1 -To test the marks of the bevel gear teeth, paint the ring
gear with red lead paint.
The marking test should be always carried out on the
ring bevel gear teeth and on both sides.
RKZ10050
3 -Movements to correct:
1 - move the pinion for type X contact adjustment X.
2 - move the pinion for type Z contact adjustment.
RKZ10070
30-212 WB93R-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
13
RKZ10100
2 -Remove the seal rings (12) and (11) from the cover (13).
11
a This is a destructive operation for the seal rings.
13
12
RKZ10110
WB93R-5E0 30-213
REMOVAL AND INSTALLATION FRONT AXLE
10
D15
RKZ10170
4 -Remove the ring nut (10) and collect its retaining washer
(9).
9
10
RKZ10120
6
4
RKZ10090
RKZ10180
30-214 WB93R-5E0
REMOVAL AND INSTALLATION FRONT AXLE
7 -To remove bearing inner ring (3) from bevel pinion (1),
use a commercially available grip puller.
Recover bearing inner ring (3) and the shim (2) under 3
it.
RKZ10190
a The ring nut (10) and the snap spacer (5) must be
replaced when reassembling the unit.
5
10
RKZ10200
6.2 Assembly
1 -Place differential support (7) on a work bench. 3
Force bearing outer rings (3) and (8) into it using
special tool D16 and a hammer.
RKZ10180
D19
D18
D17
10 RKZ10210
WB93R-5E0 30-215
REMOVAL AND INSTALLATION FRONT AXLE
8
10 3
RKZ10130
RKZ10220
RKZ10230
S=X-V mm
RKZ10150
30-216 WB93R-5E0
REMOVAL AND INSTALLATION FRONT AXLE
7 -Pick the (S) shim (2) from the range of shims available.
SHIM RANGE
Shims 2.5 2.6 2.7 2.8 2.9 3.0 3.1 3.2 3.3 3.4
RKZ10160
8
10 3
RKZ10130
9 -Install the selected shim (2) to the pinion shaft (1) with
the chamfer facing the gear.
3 6
Force bearing (3) onto the pinion shaft (1) using a press
and driver D20, and ensure that the bearing is fully
locked into position.
5 4
Install shims (4) and (6), and a new collapsible spacer
(5). 2
1
a Use only one new spacer at any time.
RKZ10240
6
4
RKZ10090
WB93R-5E0 30-217
REMOVAL AND INSTALLATION FRONT AXLE
11 -Insert a ring nut washer (9) and screw a new lock ring nut
(10) on the pinion end.
9
10
RKZ10120
12 -Screw the ring nut in (10), using the wrench for ring nut
D14 and for pinion retainer D15.
P=9.2-13.7 daN
RKZ10140
10
RKZC0680
30-218 WB93R-5E0
REMOVAL AND INSTALLATION FRONT AXLE
12
RKZ10110
13
RKZ10100
WB93R-5E0 30-219
REMOVAL AND INSTALLATION FRONT AXLE
7. DIFFERENTIAL GROUP
7.1 Disassembly
11
1 7
2
5 9
4 10
4
8
2
7
6
3
RKZ10250
RKZB0571
RKZ10260
30-220 WB93R-5E0
REMOVAL AND INSTALLATION FRONT AXLE
7 -Take the bearing (2) out of the differential half box (3) e
(10), using two levers or a three-hold extractor.
3
2
10 2
RKZ10270
7.2 Assembly
1 -Assemble the cones of the new taper roller bearings (2) 3
on the half boxes (3), (10) using the special tool D13 and 2
a hammer.
10 2
RKZ10270
RKZ10260
3 -Position the ring bevel gear (3) and then fix the whole by
tightening the screws (4). 11
3 Screw: 95 Nm
2 Screw: Loctite 270 1
RKZB1291
WB93R-5E0 30-221
REMOVAL AND INSTALLATION REAR AXLE
REAR AXLE
Removal
1 -Lower the backhoe outriggers (1) and force them
downwards in order to raise the rear wheels.
4 -For added safety, place the backhoe bucket with its back
on the ground while holding the arm in its upright
position.
Lower shovel to the ground as well.
RKZC2060
RKZC2050
RKZC2070
30-222 WB93R-5E0
REMOVAL AND INSTALLATION REAR AXLE
5
RKZC2080
7
RKZC2090
10
RKZC2100
RKZC2110
WB93R-5E0 30-223
REMOVAL AND INSTALLATION REAR AXLE
13 -Lower the jack until the axle (6) is disengaged from the
chassis.
11 11
6
RKZC2120
Installation
• To install, reverse removal procedure.
[*1]
[*3]
[*4]
30-224 WB93R-5E0
REMOVAL AND INSTALLATION REAR AXLE
10
9
5 3
2
6
12
11
4
1
7
RKZ08460
1
RKZB7100
RKZB7110
WB93R-5E0 30-225
REMOVAL AND INSTALLATION REAR AXLE
4 -Remove the snap ring (4) and the input flange (5).
RKZ08470
RKZ08480
7 -Remove the seal ring (10) from the central housing (11)
with a puller. 11
a This is a destructive operation for the seal ring.
10
RKZ08490
1.2 Assembly
11
1 -Introduce a new seal (10) into in the central body using
special tool E1.
10
RKZ08490
30-226 WB93R-5E0
REMOVAL AND INSTALLATION REAR AXLE
2 -Insert the dowel pin (10) and the brake caliper support
(7) on the central body (9).
Screw in and tighten the fastening screws (8). 11
3 Support screws: 80 Nm 9
12
RKZ08500
2 O-ring: ASL800050 5 7
4 -Insert the thickness (6) on the splined pinion end, a new
O-Ring (7), the input flange (5) and the lock ring (4).
4
RKZ08470
3 9
RKZB7120
6 -Screw in the bolts (2) and tighten the nuts (1) to the
prescribed torque.
1±0.5 mm
3 Nuts: 115 Nm
3 Screw: 45 Nm
1
2 2 RKZ08520
WB93R-5E0 30-227
REMOVAL AND INSTALLATION REAR AXLE
1.3 Maintenance
10
5
18 2
3 6
4
20
18
11 9 19
16
13 8
15
1
17
12
RKZ08530
1 -Insert mounting bolts through sleeves (9) and thread 4 -Tighten outer Locking Nut (13) against inner
brake mounting locking nuts as far as possible on Adjustment Nut (12) to lock Adjustment Bolt (2) in
mounting bolts. This is not required if brake assembly place. Tighten at 61 -74 Nm.
comes with the sleeve/bolt sub-assy. Position the
brake over disc align with mounting holes in
mounting bracket. Ball and Cam Replacement
2 -Thread mounting bolts (9) into mounting bracket, 1 -Remove both Adjustment Locking Nuts (12, 13),
adjusting bolts until a 0,5 – 1,5 mm exists between Thrust, stainless steel and Hardened Washer (1, 16,
the Sleeves and the Locking Nuts. Tighten the 17), Lever (11), and Boot (3) from Adjustment Bolt
Locking Nuts to 115 Nm of torque against the (2).
bracket. 2 -Remove outer cam (4) and Ball Assembly (8) from
Adjustment Bolt (2).
3 -Refer to Adjustment Procedure to set backlash of
installed brake assembly. 3 -Use a screwdriver, or similar tool, to gently pry inner
Cam (4) protrusions on back of cam, loose from
Brake pad looseness adjustment procedure Torque Plate (5), and remove from Adjustment Bolt
1 -Loosen adjustment nuts (12, 13). (2). Remove Seal (15) from Adjustment Bolt (2).
2 -Tighten inner Adjustment Nut (12) until firm contact is 4 - Install new Seal (15) on Adjusting Bolt (2), inserting
made with the disc by the linings. Torque to 13–14 through inner Cam (4) until Seal (15) bottoms out on
Nm. Torque plate.
Ensure that the control lever is in the brake apply a We recommend lubricating the cams' thrust
position. surfaces before installing the cams (4).
3 -Back off inner Adjustment nut (12) 4 to 6 faces and 2 Cam surface: ASL800050
check that disc is free to move.
5 -Install new Cam (4) on Adjustment Bolt (2), taking
care to orient protrusions into Holes in Torque Plates
(5).
30-228 WB93R-5E0
REMOVAL AND INSTALLATION REAR AXLE
6 -Install Ball Assembly (8) onto Adjusting Bolt (2), Sleeve seal replacement
orienting balls into pockets of Inner Cam (4). Install
outer Cam (4) onto Adjustment Bolt (2), orienting 1 -Loosen the two locking nuts on the mounting bolts
pockets onto Balls of Balls Assembly (8). Install boot and remove the mounting bolt/sleeve assembly (9)
(3) over cam assembly. from the brake.
7 -Install Lever (1), using protrusions on back of outer 2 -Insert sleeve seals (18) between the torque (5, 7) and
Cam (4) and holes in Lever (1) to orient lever to align with the sleeve bores.
proper operating position.
a Lubricate the mounting bolt/sleeve fit before
8 -Install remaining washer and nuts and follow installing
2 Bushings: ASL800050.
adjustment procedure at paragraph 1.2.
a Check to ensure that the coated side of shim (11)
is oriented towards the steel washer (17). 3 -Install the mounting bolt / sleeve assembly through
the front pad support (5), the sleeve seals (18) and
Lining Replacement the rear pad support (7).
1 -Loosen two adjustment Locking Nuts (12, 13) 4 -Mount brake per paragraph 1.1 and adjust per
enough to remove each Torque Plate (5, 7) away section 1.2.
from disc far enough to provide backlash to remove
old carrier and lining assemblies and install new Replacing the cable attachment bracket
ones. (It may be necessary to remove one or both
1 -Remove the screws (19) of the bracket (20) from pad
Nuts)
support (5).
2 -Collapse the two Lining retraction Springs (10) and Remove the bracket (20).
remove them from brake Head Assembly.
2 -Position the bracket (20) in correspondence with the
3 -Remove Torque Plates (5, 7) away from disc, move threaded holes of the pad support (5).
Carrier and Lining Assemblies (6) out of pockets, and Fix the bracket (20) to the front torque plate (5) with
remove from the Brake Head Assembly from the the appropriate screws (19).
3 Screw: 63 Nm
side.
2 Bushings: ASL800050
a Once grease has been applied, slide the
supports onto the bushings so as to distribute
grease evenly.
WB93R-5E0 30-229
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
RKZB7130
RKZB7140
30-230 WB93R-5E0
REMOVAL AND INSTALLATION REAR AXLE
3
2 RKZB7150
4 -Remove last two cap screws (1) and separate the hub
(2) from the axle (3).
3
2 RKZB7150
5 -Slowly pull hub (2) away from axle and the half shaft (4),
make sure that brake disks (5) and plates (6) stay with
the hub. 5
6
4
RKZB7160
6 -Stand the hub up, mark the reaction plat (5) that was
against the axle housing (3). Remove the reaction (6)
and brake disks (5) and pins (7). 5
RKZB7170
WB93R-5E0 30-231
REMOVAL AND INSTALLATION REAR AXLE
RKZB7180
10
RKZB7190
RKZB7200
10- Remove the lock ring (11) and remove the self adjuster
(12).
11
12
RKZB7210
30-232 WB93R-5E0
REMOVAL AND INSTALLATION REAR AXLE
12 E2
13
E2
RKZB7220
RKZB7230
13 -Use an acceptable flat bars and pry the brake piston (10)
up from the hub.
10
RKZB7240
10
15
RKZB7250
WB93R-5E0 30-233
REMOVAL AND INSTALLATION REAR AXLE
16
17
10
RKZB7260
18
15
RKZB7270
19
RKZB7280
2.2 Assembly
1 -Install a new O-Ring (19) onto hub (2).
19
RKZB7280
30-234 WB93R-5E0
REMOVAL AND INSTALLATION REAR AXLE
18
15
RKZB7290
16
17
10
RKZB7260
2 O-ring: ASL800050 17
15
16
10
RKZB7300
2
RKZB7310
WB93R-5E0 30-235
REMOVAL AND INSTALLATION REAR AXLE
10
RKZB7320
14
E2
E2 14
RKZB7330
13
RKZB7340
E2 13
RKZB7350
30-236 WB93R-5E0
REMOVAL AND INSTALLATION REAR AXLE
10 -Insert the adjuster (12) into the brake piston, make sure
that the chaffered side is up.
14
12
RKZB7360
11 -Install the snap rings (11) into the self adjuster bore.
RKZB7211
9 11
RKZ08550
RKZB7380
WB93R-5E0 30-237
REMOVAL AND INSTALLATION REAR AXLE
3 Screw: 16 Nm
8
RKZB7390
15 -Put the half shaft (4) and brake separator plate pins (7)
into the axle housing.
7
RKZB7400
3
5 RKZB7410
17 - Place the inner brake disk (6) and the second brake
separator (5).
6
a If brake discs (6) are replaced, soak discs (for each
differential) in oil at least 24 hours prior to
installation.
5 RKZB7440
30-238 WB93R-5E0
REMOVAL AND INSTALLATION REAR AXLE
18 -Place the outer brake disk (6) and make sure the slots of
the inner and outer brake disks are aligned with each
other.
6
RKZB7420
a Use a piece of rope and lift and rotate the half shaft 3
while pushing the hub onto the axle.
4
2 RKZB7430
RKZB7140
RKZB7130
WB93R-5E0 30-239
REMOVAL AND INSTALLATION REAR AXLE
3. WHEEL HUB
3.1 Disassembly
8
14
11
13
12
10
2
1
3
4
5
RKZ08560
1
RKZB7450
RKZB7460
30-240 WB93R-5E0
REMOVAL AND INSTALLATION REAR AXLE
3
RKZB7470
RKZB7480
RKZB7490
6 -Locate the snap ring (6) slot and open it while raising the
planetary carrier (5).
5
RKZB7500
WB93R-5E0 30-241
REMOVAL AND INSTALLATION REAR AXLE
5 RKZB7510
8 -Using spanner E4, loosen and remove the ring nut (8).
8
E4
RKZB7520
10
9
RKZB7530
11
RKZB7540
30-242 WB93R-5E0
REMOVAL AND INSTALLATION REAR AXLE
11 9
RKZB7550
RKZB7560
13
RKZB7570
14
10
RKZB7580
WB93R-5E0 30-243
REMOVAL AND INSTALLATION REAR AXLE
13
RKZB7590
3.2 Assembly
1 -Install bearing outer races (13) and (11) to hub (9) using
special tool E5 and a press. Using special tool E6 install
the hub seal (12). E6
12
RKZB7600
10
13
RKZB7590
14
10
RKZB7580
30-244 WB93R-5E0
REMOVAL AND INSTALLATION REAR AXLE
10
RKZB7541
11
RKZB7610
RKZB7620
RKZB7630
WB93R-5E0 30-245
REMOVAL AND INSTALLATION REAR AXLE
8 -Install the side gear (2) and the remaining needle rollers
(7) (N° 33) into the side gear.
7
2
RKZB7640
RKZB7650
RKZB7660
RKZ08570
30-246 WB93R-5E0
REMOVAL AND INSTALLATION REAR AXLE
12 -Open the snap ring (6) and slowly lower the planetary
carrier (5).
5
RKZB7500
13 -Install washers (3) and (4) and tighten screws (1); apply
the specified sealant and tighten to the required torque.
3
RKZB7470
WB93R-5E0 30-247
REMOVAL AND INSTALLATION REAR AXLE
6 9
7
1 4
3 5
8
1
RKZ08460
RKZB7130
RKZB7670
30-248 WB93R-5E0
REMOVAL AND INSTALLATION REAR AXLE
3
2
RKZB7680
RKZB7690
5 -Remove the bolts (4) securing the ring nuts (5) and (6).
RKZB7700
6 -Use the tool E7, unscrew the adjuster ring nuts (5) e (6).
E7
5
RKZB7710
WB93R-5E0 30-249
REMOVAL AND INSTALLATION REAR AXLE
7
RKZB7720
4.2 Assembly
1 -Using driver E8, install bearing outer races (8) and (9) to
E8
differential housing (7).
8
a Try not to mismatch bearings if bearings are not to
be replaced.
RKZB7730
7
RKZB7721
3 -Insert and tighten adjustment ring nuts (5) and (6) in the
differential support with tool E7, so as to pre-load the
E7
differential bearings slightly.
5
RKZB7710
30-250 WB93R-5E0
REMOVAL AND INSTALLATION REAR AXLE
RKZB7740
RKZ08590
RKZB7740
WB93R-5E0 30-251
REMOVAL AND INSTALLATION REAR AXLE
RKZB7760
10 -To test the marks of the bevel gear teeth, paint the ring
gear with red lead paint.
The marking test should be always carried out on the
ring bevel gear teeth and on both sides.
RKZ08340
11 -Contact:
OK-Correct contact: Z
If the bevel gear is well adjusted, the mark on the OK
teeth surfaces will be regular.
Z - Excessive contact on the tooth tip:
Approach the pinion to the ring bevel gear and then
move the ring bevel gear away from the pinion in
order to adjust the backlash. X
X - Excessive contact at the tooth base:
Move the pinion away from the ring bevel gear and
then approach the ring bevel gear to the pinion in
order to adjust the backlash. RKZ08350
30-252 WB93R-5E0
REMOVAL AND INSTALLATION REAR AXLE
12 -Movements to correct:
1 - move the pinion for type X contact adjustment.
2 - move the pinion for type Z contact adjustment.
RKZ08360
3 Screw: 10Nm
4
RKZB7700
RKZB7770
3
2
RKZB7691
WB93R-5E0 30-253
REMOVAL AND INSTALLATION REAR AXLE
3 Screw: 169 Nm
1
RKZB7670
30-254 WB93R-5E0
REMOVAL AND INSTALLATION REAR AXLE
9
10
5
4 1
12
2
11
6
3
8
13
7
RKZ08620
RKZB7780
RKZB7790
WB93R-5E0 30-255
REMOVAL AND INSTALLATION REAR AXLE
3 -Pull the differential lock fork (2) up, place a flat piece of
steel under the shaft (3) to keep it from moving down.
3
RKZB7800
RKZB7810
RKZB7820
RKZB7830
30-256 WB93R-5E0
REMOVAL AND INSTALLATION REAR AXLE
RKZB7840
8 -Remove the fork (2), spring (7) and bushing (8) from the
shaft (3).
2 8 7
3
RKZB7850
9 -Remove O-Ring (9) from plug (1) and O-rings (11) and
(12) from the piston (10).
10 11
12
1
9
RKZB7860
5.2 Assembly
1 -Install new O-rings (11) and (12) on the piston (10) and
O-Ring (9) on plug (1). Lubricate the O-rings. 10 11
12
1
9
RKZB7860
WB93R-5E0 30-257
REMOVAL AND INSTALLATION REAR AXLE
RKZB7870
RKZB7840
RKZB7830
RKZB7820
30-258 WB93R-5E0
REMOVAL AND INSTALLATION REAR AXLE
6 -Pull the differential lock fork (2) up, place a flat piece of
steel under the shaft (3) to keep it from moving down.
3
RKZB7800
RKZB7810
RKZB7790
3 Plug: 180 Nm
1
RKZB7780
WB93R-5E0 30-259
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
RKZB7890
RKZB7900
30-260 WB93R-5E0
REMOVAL AND INSTALLATION REAR AXLE
5 7
RKZB7910
RKZB7920
RKZB7930
10
RKZB7940
WB93R-5E0 30-261
REMOVAL AND INSTALLATION REAR AXLE
7 -Remove the ring gear cap screws (11), remove the ring
gear (12).
11
12
RKZB7950
8 -Push the pin (13) towards the flat surface side (14).
13
14
RKZB7960
15
14
RKZB7970
10 -Push the pin (13) out of the housing and remove the
planetary gear (16) and thrust washer (17).
13
16 17
RKZB7980
30-262 WB93R-5E0
REMOVAL AND INSTALLATION REAR AXLE
11 -Push the short spider pins (18) out of the spacer (19) by
pushing them through the hole in the spacer (19).
19
18
18
RKZB7990
18
18
20
21
RKZB8000
13 -Remove side gear (22) and thrust washer (23) from the
housing.
22 23
RKZB8010
24
RKZB8020
WB93R-5E0 30-263
REMOVAL AND INSTALLATION REAR AXLE
6.2 Assembly
1 -Install and lubricate new O-rings (26) on the pins (25).
RKZB8030
25
24
RKZB8020
22 23
RKZB8010
20
21
RKZB8000
30-264 WB93R-5E0
REMOVAL AND INSTALLATION REAR AXLE
18
18
24
RKZB7991
6 -Lubricate and install the sun gear (16) and thrust washer
(17).
Introduce the pin (13) as far as it will go.
a Orient pin (13) with the flats on the pin facing up.
2 Gear and pin: differential oil
13
16 17
RKZB7980
24
14
RKZB7971
3 Screw: 155 Nm
12
RKZB8040
WB93R-5E0 30-265
REMOVAL AND INSTALLATION REAR AXLE
3 Caps: 25 Nm
RKZB7930
RKZB7920
11 -Apply a thin coat of grease to the cover (5) and install the
shoulder ring (7).
2 Cover: ASL800050
5 7
RKZB7910
RKZB8050
30-266 WB93R-5E0
REMOVAL AND INSTALLATION REAR AXLE
RKZB7901
14 -Install sleeve (3) and make sure that sleeve fits snugly
into position.
22
a To make installation easier, rotate the side gear
(22).
3
RKZB7891
15 -Install bearing outer rings (1) and (2) using driver E8.
RKZB8070
WB93R-5E0 30-267
REMOVAL AND INSTALLATION REAR AXLE
7. DIFFERENTIAL GROUP
7.1 Disassembly
8
9
10
6
7
2
1
5
RKZ08640
E10
RKZB7751
2 -Remove the ring nut (1) and collect its retaining washer
(2).
2 1
RKZB8080
30-268 WB93R-5E0
REMOVAL AND INSTALLATION REAR AXLE
5 RKZ08650
RKZB8090
5 -To remove bearing inner ring (8) from bevel pinion (3),
use a commercially available grip puller.
Recover bearing inner ring (8) and the shim (10) under it. 3
10
RKZB8100
a The ring nut (1) and the snap spacer (6) must be
replaced.
5
RKZ08660
WB93R-5E0 30-269
REMOVAL AND INSTALLATION REAR AXLE
7.2 Assembly
1 -Place the differential support (9) on a workbench. E11
Introduce bearing outer rings (7) and (8) using special
tools E11 - E12 and a hammer.
9
7
RKZB8110
7
E13
1
RKZ08670
E14
RKZB8120
9 RKZB8130
30-270 WB93R-5E0
REMOVAL AND INSTALLATION REAR AXLE
A
B
RKZ08680
RKZB8140
7 -Select the shim with the thickness value (S) among the
range of available shims (10), and fit to shaft under the
pinion head.
Shims 2.5 2.6 2.7 2.8 2.9 3.0 3.1 3.2 3.3 3.4 3
RKZB8150
7
E13
1
RKZ08670
WB93R-5E0 30-271
REMOVAL AND INSTALLATION REAR AXLE
10
RKZB8160
4
6
5
RKZB8170
RKZB8180
12 -Insert a ring nut washer (2) and screw a new lock ring nut
(1) on the pinion end.
2 1
RKZB8080
30-272 WB93R-5E0
REMOVAL AND INSTALLATION REAR AXLE
13 -Screw the ring nut in (1), using the wrench for ring nut
E10 and for pinion retainer E9. E9
a The torque setting is given by the preloading
measurement on bearings (7) and (8); Tighten the
ring nut (1) step by step.
1
a If it is tightened too much, the elastic spacer (6)
should be replaced and the procedure repeated.
When you check the preloading, it is advisable to
beat slightly both pinion (3) ends with a soft
E10
hammer, so as to help setting the bearings (7) and
(8). RKZB7751
RKZB8190
RKZB8200
WB93R-5E0 30-273
PAGE INTENTIONALLY
LEFT BLANK
REMOVAL AND INSTALLATION SHOVEL PPC VALVE
RKZC2130
2
RKZC1051
5 RKZC2140
RKZC2150
WB93R-5E0 30-275
REMOVAL AND INSTALLATION SHOVEL PPC VALVE
Installation
P3 P
• To install, reverse removal procedure.
Front
[*1] 3
P
1
when connecting them.
(For details, see "10 STRUCTURE AND P1
2
FUNCTION").
T
T
4
P4
RKZ10761
30-276 WB93R-5E0
REMOVAL AND INSTALLATION SHOVEL LIFT CYLINDERS
RKZC2160
6
5
RKZC2170
3 -Remove the tie strap (7) retaining the piston return hose
(8).
5 -Extract pin (6) to expose piston eye and safety rod (9).
6 -Remove rod.
7
6
RKZC2180
B
RKZC2190
WB93R-5E0 30-277
REMOVAL AND INSTALLATION SHOVEL LIFT CYLINDERS
11
8 13
RKZC2200
Installation
• To install, reverse removal procedure.
[*1]
[*2]
a After bleeding the air, check the oil level in the tank.
30-278 WB93R-5E0
REMOVAL AND INSTALLATION SHOVEL DUMP CYLINDERS
3 -Place a sling round the cylinder (3) and insert a block “A”
RKZC2210
between the spacer (4) of the piston fulcrum lever (5)
and the link (6).
12
11
RKZC2250
15
13
14
RKZC2260
WB93R-5E0 30-279
REMOVAL AND INSTALLATION SHOVEL DUMP CYLINDERS
Installation
• To install, reverse removal procedure.
[*1]
[*2]
a After bleeding the air, check the oil level in the tank.
Machines equipped with return-to-dig only
2 -Check sensor position and adjust as necessary.
(For details, see "20 TESTING AND ADJUSTMENTS").
30-280 WB93R-5E0
REMOVAL AND INSTALLATION SHOVEL
SHOVEL
Removal
k Lower the shovel to the ground, resting on its back, but
without forcing it downwards.
RKZC2130
2 -Take out the screws (1) and remove the pins (2) of the
lever (3).
Rest the lever (3) on the boom. [*1] [*2]
1
RKZA1461
3 -Take out the screws (4) and remove the pins (5) of the
shovel fulcrum. [*1] [*2]
4 -Start the engine and put the machine into reverse gear in 4
order to disengage the boom (6).
4 Shovel: 436 kg
6
5
RKZA1471
Installation
• To install, reverse removal procedure.
[*1]
[*2]
WB93R-5E0 30-281
REMOVAL AND INSTALLATION FRONT WORKING EQUIPMENT
A
RKZC2191
3 -Open the front hood and take out the screws (2) that lock
the axle oscillation pins (3) of the boom (4).
Close the front hood.
4 3
RKZC2290
4
RKZC2280
30-282 WB93R-5E0
REMOVAL AND INSTALLATION FRONT WORKING EQUIPMENT
Installation
• To install, reverse the removal procedure, if necessary
using the front towing hook.
[*1]
[*2]
a After bleeding the air, check the oil level in the tank.
WB93R-5E0 30-283
REMOVAL AND INSTALLATION BACKHOE PPC VALVES (Optional)
RKZC9840
RKZC9860
7 RKZC9850
30-284 WB93R-5E0
REMOVAL AND INSTALLATION BACKHOE PPC VALVES (Optional)
RKZC9870
Installation
• To install, reverse removal procedure.
WB93R-5E0 30-285
REMOVAL AND INSTALLATION PPC VALVE SUPPORT RELEASE CABLES
RKZC2060
RKZC9880
RKZC9841
5 -Loosen the nut (5) and tighten fully the tensioner (6).
[*1]
5 6
4
RKZC9890
30-286 WB93R-5E0
REMOVAL AND INSTALLATION PPC VALVE SUPPORT RELEASE CABLES
7
9
RKZC9900
11
RKZC9910
Installation
• To install, reverse removal procedure.
2 -Keeping the position, lock the tensioner (5) with the nut 5
(6).
3 Nut: 4.5 Nm
6
RKZC9891
WB93R-5E0 30-287
REMOVAL AND INSTALLATION PPC VALVE SUPPORT RETURN GAS SPRING
RKZC2060
RKZC9880
RKZC9841
5 -Loosen the nut (5) and tighten fully the tensioner (6).
[*1]
5 6
4
RKZC9890
30-288 WB93R-5E0
REMOVAL AND INSTALLATION PPC VALVE SUPPORT RETURN GAS SPRING
8 4
7
9
RKZC9900
11
11
RKZC9920
12
RKZC9930
Installation
• To install, reverse removal procedure.
[*1]
WB93R-5E0 30-289
REMOVAL AND INSTALLATION SOLENOID VALVE GROUP (servocontrol and optional attachment)
RKZC2060
RKZC1031
Standard version
3 -Remove rear mat, optional device control pedals (if
4
any), hood (3), and the metal sheet closing off the floor
(4).
RKZC1901
RKZC9940
30-290 WB93R-5E0
REMOVAL AND INSTALLATION SOLENOID VALVE GROUP (servocontrol and optional attachment)
Installation
• To install, reverse removal procedure.
WB93R-5E0 30-291
REMOVAL AND INSTALLATION BACKHOE BOOM CYLINDER
3 -Lower the arm until the bucket teeth touch the ground.
A
RKZC2330
5
RKZC2340
RKZC2350
8
9
RKZC2360
30-292 WB93R-5E0
REMOVAL AND INSTALLATION BACKHOE BOOM CYLINDER
10
RKZC2370
RKZC2380
13
RKZC2390
RKZC2400
WB93R-5E0 30-293
REMOVAL AND INSTALLATION BACKHOE BOOM CYLINDER
14
13
RKZC2410
4 Cylinder: 87,5 kg
RKZC2420
Installation
• To install, reverse removal procedure.
[*1]
[*2]
a After bleeding the air, check the oil level in the tank.
30-294 WB93R-5E0
REMOVAL AND INSTALLATION ARM CYLINDER
ARM CYLINDER
Removal
1 -Fully extend the arm (1) and fully open the bucket (2). 3 1
Manoeuvre the boom until the outer end of the boom is in
a level position.
2
2 -Place and force a jack stand “A” and a non-slip block
under the boom.
RKZC2430
RKZC2440
4 11
10
RKZC2450
WB93R-5E0 30-295
REMOVAL AND INSTALLATION ARM CYLINDER
RKZC2460
11 -Pull out the cylinder attachment pin (7) until the eye of
cylinder (4) is exposed. [*1] [*2]
7
4
12 -Remove cylinder (4) and recover shims (if any).
4 Arm cylinders: 67 kg
RKZC2470
Installation
• To install, reverse removal procedure.
[*1]
[*2]
a After bleeding the air, check the oil level in the tank.
30-296 WB93R-5E0
REMOVAL AND INSTALLATION JIG ARM CYLINDER
9 -Remove the screws (11) and the pin (12). [*1] [*2] RKZA7941
5
11 10
6
Installation
8
• To install, reverse removal procedure. 12
[*1]
[*2]
a After bleeding the air, check the oil level in the tank.
WB93R-5E0 30-297
REMOVAL AND INSTALLATION OUTRIGGER CYLINDER
OUTRIGGER CYLINDER
Removal
k Set the backhoe with the centered attachments with the
arm in vertical position and the bucket leaned on the
back at level ground.
1 RKZC2480
RKZC2490
4 -Disconnect from cylinder (5) the pipes (4) and plug them
to avoid impurity entry. 3 4
a Plug also the union to avoid the movement of piston.
RKZC2500
5 -Take off snap ring (6) and slide pin (7) out until cylinder
(5) is disengaged. [*1] [*2]
7 6
RKZC2510
30-298 WB93R-5E0
REMOVAL AND INSTALLATION OUTRIGGER CYLINDER
RKZC2520
RKZC2530
Installation
• To install, reverse removal procedure.
[*1]
a After bleeding the air, check the oil level in the tank.
WB93R-5E0 30-299
REMOVAL AND INSTALLATION BACKHOE SWING CYLINDERS
RKZC2060
RKZC2540
RKZC2550
RKZC2560
30-300 WB93R-5E0
REMOVAL AND INSTALLATION BACKHOE SWING CYLINDERS
RKZC2570
6 RKZC2580
7 -Take out the screws (8) and remove the pins (9).
9
8 -Rotate the cylinders to disengage the piston heads from 8
the swing bracket (10) and remove the cylinders (6).
4 Cylinder: approx. 34 kg
10
RKZC2590
WB93R-5E0 30-301
REMOVAL AND INSTALLATION BACKHOE SWING CYLINDERS
Installation
1 -Mount the cylinders (6) and the upper cylinder fulcrum
support (2). Secure the support with the four screws (3). 5 3
[*1]
[*2]
a After bleeding the air, check the oil level in the tank. RKZC2591
30-302 WB93R-5E0
REMOVAL AND INSTALLATION BACKHOE BUCKET CYLINDER
RKZC2600
RKZC2610
5 -Take out the lock-nut (5) and the washer and remove the
pin (6). [*1] [*2] [*3]
RKZC2620
8 -Take off the snap ring (9) and remove the pin (10).
[*1] [*2] 10
RKZC2630
WB93R-5E0 30-303
REMOVAL AND INSTALLATION BACKHOE BUCKET CYLINDER
14
13
4
RKZA9951
Installation
• To install, reverse removal procedure.
[*1]
[*2]
1 -Start the engine and bleed the air from the cylinders.
(For details, see "20 TESTING AND ADJUSTMENTS").
a After bleeding the air, check the oil level in the tank.
30-304 WB93R-5E0
REMOVAL AND INSTALLATION BACKHOE BOOM SAFETY CYLINDER
RKZC2600
6
4
5
RKZC2341
5 -Loosen and remove nut (7) and remove tie rod (8).
8
8 7
RKZC2640
10
RKZC2650
WB93R-5E0 30-305
REMOVAL AND INSTALLATION BACKHOE BOOM SAFETY CYLINDER
Installation
• To install, reverse removal procedure.
30-306 WB93R-5E0
REMOVAL AND INSTALLATION BACKHOE WORKING EQUIPMENT
3 -Lower the arm until the bucket teeth touch the ground.
A
4 -Lower the outriggers to the ground, apply the parking
brake, and stop the engine.
A B
RKZC2660
RKZC2411
WB93R-5E0 30-307
REMOVAL AND INSTALLATION BACKHOE WORKING EQUIPMENT
RKZC2680
C
RKZC2690
RKZC2700
Installation
• To install, reverse removal procedure.
1 -Start the engine and bleed the air from all circuits.
(For details, see "20 TESTING AND ADJUSTMENTS").
30-308 WB93R-5E0
REMOVAL AND INSTALLATION BACKHOE BUCKET
BACKHOE BUCKET
Removal
7
k Place the bucket on a level surface, resting on its back. 4
1 -Take out the safety pin (1) and remove the connecting 6
pin (2) between bucket (3) and tie-rods (4). [*1] [*2] 2
2 -Take out the safety pin (5) and remove the pin (6) that 5
attaches the bucket to the arm (7).
[*1] [*2] 1
3
4 Bucket: 158 kg
RKZA1350
Installation
• To install, reverse removal procedure.
[*1]
[*2]
WB93R-5E0 30-309
REMOVAL AND INSTALLATION BACKHOE BOOM CYLINDER
4 Boom: 248 kg
RKZC2710
Installation
• To install, reverse removal procedure.
[*1]
[*2]
a After bleeding the air, check the oil level in the tank.
30-310 WB93R-5E0
REMOVAL AND INSTALLATION ARM
ARM
Removal 4
1 -Remove the bucket.
(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]
2
4 -Start the engine, bring the arm into a vertical position
and lower it to the ground.
RKZA1360
11 -Take out the screws (9) and remove the pin (10). RKZC2441
[*1] [*2]
a Recover the shims.
12 -Remove the arm (8). 8 5
4 Standrd arm: 213 kg
Installation
• To install, reverse removal procedure.
[*1]
[*2]
RKZC2740
WB93R-5E0 30-311
REMOVAL AND INSTALLATION JIG ARM
JIG ARM
Removal 4
1 -Remove the bucket.
(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]
2
RKZA1360
4 -Disconnect the jig arm hoses (5) and (6), the bucket
cylinder hoses (7) and (8), and the hoses of the auxiliary
equipment (9) and (10).
Installation
• To install, reverse removal procedure.
[*1]
[*2]
30-312 WB93R-5E0
REMOVAL AND INSTALLATION 2nd ARM
2nd ARM
Removal
1 -Remove the bucket (1).
(For details see "BACKHOE BUCKET").
4 -Take out the lock nut (4), and the washer and remove the
pin (5) and the links (6). [*1] [*2] [*3] 6
5 -Connect the 2nd arm (7) to some hoisting tackle.
a Use the bucket pin hole and the safety pin holes.
5
6 -Start the engine and, maintaining constant tension on 3
the section of cable or chain connected to the bucket
coupling, slowly raise the boom until both sections of 4
cable or chain are under slight tension.
RKZA7990
Installation
• To install, reverse removal procedure.
RKZA8000
[*1]
[*2]
WB93R-5E0 30-313
REMOVAL AND INSTALLATION 2nd ARM GUIDES
A
RKZA8010
5 6
RKZA8020
6
7
RKZ02390
Installation
2
• To install, reverse removal procedure.
1
[*1]
RKZA8030
30-314 WB93R-5E0
REMOVAL AND INSTALLATION BACKHOE SWING BRACKET
2 -Take out the screws (1) and remove the pins (2) that
connect the swing cylinders (3). [*1] [*2] 3
3 -Remove boom safety cylinder (4).
(For details see "BACKHOE BOOM SAFETY
CYLINDER").
RKZC2592
5 -Take out screws (6) and (7) and remove pins (8) and (9)
4
from swing bracket. [*1] [*2]
6 -Remove swing bracket (5) and shims (10) and slide the
hoses off. [*3]
4 Bracket: 162,5 kg
RKZC2351
Installation
8
• To install, reverse removal procedure. 5
[*1]
[*2]
13
13
RKZ01330
WB93R-5E0 30-315
REMOVAL AND INSTALLATION COMPLETE BACKHOE BACKFRAME
RKZC2770
7
RKZC2780
RKZC2790
30-316 WB93R-5E0
REMOVAL AND INSTALLATION COMPLETE BACKHOE BACKFRAME
RKZC2800
Installation
• To install, reverse removal procedure.
[*1]
a After bleeding the air, check the oil level in the tank.
WB93R-5E0 30-317
REMOVAL AND INSTALLATION BACKFRAME LOCK PISTONS
RKZC2801
UPPER PISTON
1 -Remove two pipes (2) and (3).
RKZC2810
LOWER PISTON
1 -Remove pipe (3).
RKZC2820
REPLACING SEALS
8 9 10
1 -Remove seal (8), guide ring (9), and seal (10).
10
RKZC2830
30-318 WB93R-5E0
REMOVAL AND INSTALLATION BACKFRAME LOCK PISTONS
2 -Thoroughly clean the seats and install new seals and the
guide ring.
6
RKZC2840
RKZC2850
Installation
• To install, reverse removal procedure.
WB93R-5E0 30-319
40 STANDARD MAINTENANCE
WB93R-5E0 40-1
STANDARD MAINTENANCE TRANSMISSION
TRANSMISSION
3 30 Nm
G
F
A
3 23 Nm
3 23 Nm 3 23 Nm
C C
H H
B B E E
3 23 Nm 3 23 Nm RKZ10310
40-2 WB93R-5E0
STANDARD MAINTENANCE TRANSMISSION
3 50 Nm
3 50 Nm
3 23 Nm
3 40 Nm
3 139 Nm
2 Loctite 518
3 23 Nm RKZ10320
A-A
WB93R-5E0 40-3
STANDARD MAINTENANCE TRANSMISSION
3 23 Nm 3 80 Nm 3 25 Nm
3 50 Nm
2 Loctite 542
3 23 Nm
D D
RKZ10330
3 30 Nm 3 26-30 Nm
40-4 WB93R-5E0
STANDARD MAINTENANCE TRANSMISSION
3 9-11 Nm
3 7-10 Nm
3 21.5-24.5 Nm
D-D
3 22 Nm 3 23 Nm
3 5-8 Nm
RKZ10340
E-E
WB93R-5E0 40-5
STANDARD MAINTENANCE TRANSMISSION
3 30 Nm
I I
3 100 Nm 3 23 Nm 3 50 Nm
2 Loctite 270
F-F G-G
3 40 Nm
2 Loctite 542
2 Loctite 638
RKZ10370
H-H I-I
40-6 WB93R-5E0
STANDARD MAINTENANCE FRONT AXLE
FRONT AXLE
Differential
3 95 Nm
2 Loctite 270
3 13 Nm
3 169 Nm
2 Loctite 510
2 Loctite 638
2
3
4
RKZ10380
WB93R-5E0 40-7
STANDARD MAINTENANCE FRONT AXLE
RKZ10390
3 266 Nm
3 60 Nm
Unit: mm
40-8 WB93R-5E0
STANDARD MAINTENANCE FRONT AXLE
Planetary - Joint
3 190 Nm
3 8 Nm
3 120 Nm
1
RKZ10400
3 70 Nm
3 8 Nm
2 Loctite 270
Unit: mm
WB93R-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
RKZ10410
A-A B-B
Deatil C
Unit: mm
40-10 WB93R-5E0
STANDARD MAINTENANCE REAR AXLE
REAR AXLE
Differential
3 10 Nm
3 155 Nm
2 Loctite 270
3 169 Nm
A
2 3 80 Nm
3 80 Nm 2 Loctite 638
3 25 Nm
2 Loctite 270
3
4
A-A
Unit: mm
No. Check item Criteria Remedy
Standard
Clearance limit
1 Axle clearance clearance
---- ----
2 Backlash of crown wheel and pinion 0.21–0.29 0.29 Adjust
Pinion rotation force (without sealing ring)
3 115-138 Nm
As measured on pinion Ø 34.8
Pinion-crown rotation force (without sealing ring)
4 148-188 Nm
As measured on pinion Ø 34.8
WB93R-5E0 40-11
STANDARD MAINTENANCE REAR AXLE
Planetary
3 70 Nm 3 8-12 Nm
3 500 Nm 2 Loctite 270
3 1000 Nm
3 79 Nm
2 Loctite 270
3 226 Nm 3 60 Nm
RKZ09741
2 Loctite 270
Unit: mm
40-12 WB93R-5E0
STANDARD MAINTENANCE REAR AXLE
Brakes
3 16 Nm
Detail A
RKZ10430
Unit: mm
WB93R-5E0 40-13
STANDARD MAINTENANCE REAR AXLE
Differential lock
3 180 Nm
RKZ09761
40-14 WB93R-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
WB93R-5E0 40-15
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
40-16 WB93R-5E0
PAGE INTENTIONALLY
LEFT BLANK
STANDARD MAINTENANCE CONTROL VALVE
CONTROL VALVE
8-SPOOL VERSION (WITH MECHANICAL CONTROL)
D
3 9.8-12.7 Nm
Komatsu Ltd.
AC AC
AB AB
AA AA
3 9.8-12.7 Nm
N N
M M
X
L L
K K
J J
3 9.8-12.7 Nm F F
3 9.8-12.7 Nm
E E
Z
3 29.4-34.3 Nm
RKZ08311
View Z 3 58.8-73.5 Nm
40-18 WB93R-5E0
STANDARD MAINTENANCE CONTROL VALVE
AE
C B A
C B A RKZ08321
AE
View X
WB93R-5E0 40-19
STANDARD MAINTENANCE CONTROL VALVE
3 49-58.8 Nm
3 39.2-49 Nm
3 39.2-49 Nm
3 39.2-49 Nm
3 39.2-49 Nm
5 3 39.2-49 Nm
3 137-157 Nm A-A
3 117.6-161.8 Nm
3
117.6-161.8 Nm
4 9
1
6
7 RKZ08331
B-B
40-20 WB93R-5E0
STANDARD MAINTENANCE CONTROL VALVE
Unit: mm
Criteria Remedy
Standard size Repair limit
No. Check item
Free
Installed Installed Free Installed
installed x
length load installed load
Øe
Spool return spring
1 (shovel arm raise 27.1x16.2 26.7 14.4N – 11.8N
control)
Spool return spring
2 (backhoe bucket 66.5x21.1 25.4 73.5N – 58.8N
boom control)
Spool return spring
3 (shovel control) 27.2x16.6 26.7 30.38N – 34.3N
Replace
Spool return spring spring
4
(boom swing control)
42x20 25.4 75.5N – 59.6N
WB93R-5E0 40-21
STANDARD MAINTENANCE CONTROL VALVE
AD
2
7
3 117.6-161.8 Nm
8
3
1 4
8
8
1
8 5
3 19.6-24.5 Nm
1 3
3 14.7-19.6 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
RKZ08341
AD - AD
40-22 WB93R-5E0
STANDARD MAINTENANCE CONTROL VALVE
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free
Installed Installed Free Installed
installed
length load installed load
x Øe
Pressure compensation valve
spring
1
(Shovel arm, backhoe bucket,
15.4x6 8 7.44N – 5.96N
boom, shovel, boom swing)
Pressure compensation valve
2 spring 31.4x14.4 21.8 63.7N – 51.0N
(arm)
Pressure compensation valve
3 spring. 18.9x8.4 15 15.7N – 12.5N Replace
(Boom swing, backhoe bucket) spring
Pressure compensation valve
4 spring. 37.1x8.6 24 34.3N – 27.4N
(Front bucket)
Pressure compensation valve
5 spring. 20x8.4 15 4.32N – 3.45N
(boom, shovel arm)
6 Check valve spring 27.2x6.9 21 4.70N – 3.76N
7 Check valve spring 27.2x6.9 22 3.92N – 3.14N
8 Check valve spring 21.9x5 15.8 1.96N – 1.57N
9 Check valve spring 11.3x4.3 7.5 1.72N – 1.38N
WB93R-5E0 40-23
STANDARD MAINTENANCE CONTROL VALVE
3 65.7-82.3 Nm
3
2 2
1 1
1 2 E-E 2 1 K-K
F-F L-L
RKZ03882
L-L M-M
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free
Installed Installed Free Installed
installed
length load installed load
x Øe
Spool return spring Replace
1 18.0x18 17.5 39.2N – 31.4N
(Outrigger control) spring
Spool return spring
2 20.2x14.2 10.4 30.4N – 24.3N
(Outrigger control
Control valve spring
3 plate lock 13.0x8.8 11 3.92N – 3.1N
40-24 WB93R-5E0
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
length Replace
x Øe load installed load
spring
Pressure compensation
1 31.7x9.2 27.5 43.1N – 34.5N
valve spring.
WB93R-5E0 40-25
STANDARD MAINTENANCE CONTROL VALVE
D
3 9.8-12.7 Nm
Komatsu Ltd.
AC AC
AB AB
AA AA
R R
X P P
N N
3 9.8-12.7 Nm
M M
L L
K K
J J
3 9.8-12.7 Nm F F
3 9.8-12.7 Nm
E E
3 29.4-34.3 Nm Z
RKZ08901
View Z 3 58.8-73.5 Nm
40-26 WB93R-5E0
STANDARD MAINTENANCE CONTROL VALVE
AE
C B A
C B A RKZ09031
AE
View X
WB93R-5E0 40-27
STANDARD MAINTENANCE CONTROL VALVE
3 49-58.8 Nm
3 3
39.2-49 Nm
3 3
137-157 Nm
117.6-161.8 Nm 117.6-161.8 Nm
3
4
39.2-49 Nm 3
3 39.2-49 Nm
2
3
3
1 39.2-49 Nm
3
39.2-49 Nm
10
39.2-49 Nm
11
6
7
B-B A-A
RKZ09041
K-K J-J
40-28 WB93R-5E0
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 14.4N – 11.8N
control)
Spool return spring
2 (backhoe bucket 66.5x21.1 25.4 73.5N – 58.8N
boom control)
Spool return spring
3 (shovel control) 27.2x16.6 26.7 30.38N – 34.3N
10 Spool
return spring
29x17.5 28.5 22.5N – 18.0N
(Jig arm control)
11 Spool
return spring
(4 in 1 bucket control)
42.2x20 25.4 98.0N – 78.4N
WB93R-5E0 40-29
STANDARD MAINTENANCE CONTROL VALVE
AD
7 2
3 24.5-34.3 Nm
8
3
1 4
8
1
8 5
8 3
1
3 19.6-24.5 Nm
5
AD
6 6 C-C
3 24.5-34.3 Nm
D-D
3 17.4-19.6 Nm
3 24.5-34.3 Nm
AD - AD RKZ09051
40-30 WB93R-5E0
STANDARD MAINTENANCE CONTROL VALVE
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free
Installed Installed Free Installed
installed
length load installed load
x Øe
Pressure compensation valve
spring
1
(Shovel arm, backhoe bucket,
15.4x6 8 7.44N – 5.96N
boom, shovel, boom swing)
Pressure compensation valve
2 spring 31.4x14.4 21.8 63.7N – 51.0N
(arm)
Pressure compensation valve
3 spring. 18.9x8.4 15 15.7N – 12.5N Replace
(Boom swing, backhoe bucket) spring
Pressure compensation valve
4 spring. 37.1x8.6 24 34.3N – 27.4N
(Front bucket)
Pressure compensation valve
5 spring. 20x8.4 15 4.32N – 3.45N
(boom, shovel arm)
6 Check valve spring 27.2x6.9 21 4.70N – 3.76N
7 Check valve spring 27.2x6.9 22 3.92N – 3.14N
8 Check valve spring 21.9x5 15.8 1.96N – 1.57N
9 Check valve spring 11.3x4.3 7.5 1.72N – 1.38N
WB93R-5E0 40-31
STANDARD MAINTENANCE CONTROL VALVE
3 65.7-82.3 Nm
3
2 2
1 1
1 2 E-E 2 1 K-K
F-F L-L
RKZ03882
L-L M-M
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free
Installed Installed Free Installed
installed
length load installed load
x Øe
Spool return spring Replace
1 18.0x18 17.5 39.2N – 31.4N
(Outrigger control) spring
Spool return spring
2 20.2x14.2 10.4 30.4N – 24.3N
(Outrigger control
Control valve spring
3 plate lock 13.0x8.8 11 3.92N – 3.1N
40-32 WB93R-5E0
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 Free Installed
installed Replace
length load installed load
x Øe spring
Pressure compensation
1 31.7x9.2 27.5 43.1N – 34.5N
valve spring.
WB93R-5E0 40-33
STANDARD MAINTENANCE CONTROL VALVE
3 9.8-12.7 Nm
Komatsu Ltd.
AC AC
AB AB
AA AA
3 9.8-12.7 Nm N N
M M
X L L
K K
J J
3 9.8-12.7 Nm
F F
E E
3 9.8-12.7 Nm
D
3 58.8-73.5 Nm
3 29.4-34.3 Nm
RKZ09062
40-34 WB93R-5E0
STANDARD MAINTENANCE CONTROL VALVE
AE
C B A
RKZ09071
C B A
AE
View X
WB93R-5E0 40-35
STANDARD MAINTENANCE CONTROL VALVE
3 49-58.8 Nm
3
3 39.2-49 Nm
39.2-49 Nm
3 39.2-49 Nm
3
39.2-49 Nm
5 6 3 39.2-49 Nm
A-A
10
3
4
3 2
2 2
1
7
8
RKZ09080
B-B
40-36 WB93R-5E0
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
WB93R-5E0 40-37
STANDARD MAINTENANCE CONTROL VALVE
AD
2
7
3 117.6-161.8 Nm
8
3
1 4
8
8
1
8 5
3 19.6-24.5 Nm
1 3
3 14.7-19.6 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
RKZ08341
AD - AD
40-38 WB93R-5E0
STANDARD MAINTENANCE CONTROL VALVE
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free
Installed Installed Free Installed
installed
length load installed load
x Øe
Pressure compensation valve
spring
1
(Shovel arm, backhoe bucket,
15.4x6 8 7.44N – 5.96N
boom, shovel, boom swing)
Pressure compensation valve
2 spring 31.4x14.4 21.8 63.7N – 51.0N
(arm)
Pressure compensation valve
3 spring. 18.9x8.4 15 15.7N – 12.5N Replace
(Boom swing, backhoe bucket) spring
Pressure compensation valve
4 spring. 37.1x8.6 24 34.3N – 27.4N
(Front bucket)
Pressure compensation valve
5 spring. 20x8.4 15 4.32N – 3.45N
(boom, shovel arm)
6 Check valve spring 27.2x6.9 21 4.70N – 3.76N
7 Check valve spring 27.2x6.9 22 3.92N – 3.14N
8 Check valve spring 21.9x5 15.8 1.96N – 1.57N
9 Check valve spring 11.3x4.3 7.5 1.72N – 1.38N
WB93R-5E0 40-39
STANDARD MAINTENANCE CONTROL VALVE
3 65.7-82.3 Nm
3
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 Free Installed
installed
length load installed load
x Øe
Spool return spring Replace
1 18.0x18 17.5 39.2N – 31.4N
(Outrigger control) spring
Spool return spring
2 20.2x14.2 10.4 30.4N – 24.3N
(Outrigger control
Control valve spring
3 plate lock 13.0x8.8 11 3.92N – 3.1N
40-40 WB93R-5E0
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 Free Installed
installed Replace
x Øe length load installed load
spring
Pressure compensation
1 31.7x9.2 27.5 43.1N – 34.5N
valve spring.
WB93R-5E0 40-41
STANDARD MAINTENANCE 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
40-42 WB93R-5E0
STANDARD MAINTENANCE CONTROL VALVE
AE
C B A
RKZ09591
C B A
AE
ViewX
WB93R-5E0 40-43
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
40-44 WB93R-5E0
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
WB93R-5E0 40-45
STANDARD MAINTENANCE CONTROL VALVE
AD
7 2
3 24.5-34.3 Nm
8
3
1 4
8
8 1 5
3 47-58.8 Nm
8 3
1
3 19.6-24.5 Nm
5
AD
6 6
3 24.5-34.3 Nm
D-D C-C
3 14.7-19.6 Nm
3 24.5-34.3 Nm
RKZ09141
AD - AD
40-46 WB93R-5E0
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 31.4x14.4 21.8 63.7N – 51.0N
(arm)
Pressure compensation valve
3 spring. 18.9x8.4 15 15.7N – 12.5N Replace
(Boom swing, backhoe bucket) spring
Pressure compensation valve
4 spring. 37.1x8.6 24 34.3N – 27.4N
(Front bucket)
Pressure compensation valve
spring.
5
(boom, shovel arm
20x8.4 15 4.32N – 3.45N
jig arm, 4 in 1 bucket)
6 Check valve spring 27.2x6.9 21 4.70N – 3.76N
7 Check valve spring 27.2x6.9 22 3.92N – 3.14N
8 Check valve spring 21.9x5 15.8 1.96N – 1.57N
9 Check valve spring 11.3x4.3 7.5 1.72N – 1.38N
WB93R-5E0 40-47
STANDARD MAINTENANCE CONTROL VALVE
3 65.7-82.3 Nm
3
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 Free Installed
installed
length load installed load
x Øe
Spool return spring Replace
1 18.0x18 17.5 39.2N – 31.4N
(Outrigger control) spring
Spool return spring
2 20.2x14.2 10.4 30.4N – 24.3N
(Outrigger control
Control valve spring
3 plate lock 13.0x8.8 11 3.92N – 3.1N
40-48 WB93R-5E0
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 Free Installed
installed Replace
length load installed load
x Øe spring
Pressure compensation
1 31.7x9.2 27.5 43.1N – 34.5N
valve spring.
WB93R-5E0 40-49
STANDARD MAINTENANCE PPC VALVES
PPC VALVES
SHOVEL CONTROL
1 2
3 3
RKZ10460
A-A C-C
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free
Installed Installed Free Installed
installed
length load installed load
x Øe
Return spring (outer) Replace
1
(for ports P1 and P2)
Return spring (outer)
2
(for ports P3 and P4)
3 Adjusting screw (inner)
40-50 WB93R-5E0
STANDARD MAINTENANCE PPC VALVES
1 2
3 3
RKZ10470
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free
Installed Installed Free Installed
installed
length load installed load
x Øe
Return spring (outer) Replace
1
(for ports P1 and P2)
Return spring (outer)
2
(for ports P3 and P4)
3 Adjusting screw (inner)
WB93R-5E0 40-51
STANDARD MAINTENANCE SHOVEL CYLINDERS
SHOVEL CYLINDERS
DUMP CYLINDER
3 539±54 Nm 3 1250±130 Nm
1 3
2
707-00-0y920-1
RAISE 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
Lifting 50
-- 0.030 + 0.162
0.035 0.238
Tolerance between -- 0.076 + 0.005
1 Replace
piston rod and head -- 0.025 + 0.141
Dump 45 -- 0.064 + 0.004
0.029 0.205
Lifting 60
-- 0.060 + 0.174
0.160 0.280
Tolerance between -- 0.106 + 0.100
2 bushing and piston
head mounting pin Dump 45
-- 0.050 + 0.142
0.130 0.231
-- 0.089 + 0.080 Replace
pin and
T ole ra nc e be twe en Lifting 60
-- 0.060 + 0.174
0.160 0.280 bushing
bushing -- 0.106 + 0.100
3
and cylinder mounting -- 0.050 + 0.142
pin Dump 50 0.130 0.231
-- 0.089 + 0.080
40-52 WB93R-5E0
STANDARD MAINTENANCE SHOVEL CYLINDERS
4 IN 1 BUCKET
3 690±69 Nm 3 540±54 Nm
1
42N-6C-12800-1
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free
Installed Installed Free Installed
installed
length load installed load
x Øe
Tolerance between -- 0.025 + 0.064 Replace
1 40 0.05 0.114
piston rod and head -- 0.050 + 0.025
Tolerance between
2 bushing and piston head 40 -- 0.150
0
mounting pin
WB93R-5E0 40-53
STANDARD MAINTENANCE BACKHOE CYLINDERS
BACKHOE CYLINDERS
BOOM
3 2740-2840 Nm
with Loctite 262
3 981±98 Nm 3
1
2
707-02-0Y941-1
ARM
3 2450±240 Nm 3
3 961±96.1 Nm
1
2
707-00-0Y871-1
BUCKET
31670±170 Nm
1 3
2
707-00-0Y901-1
40-54 WB93R-5E0
STANDARD MAINTENANCE BACKHOE CYLINDERS
BOOM SWING
3 44.1-53.9 Nm 3 785±78.5 Nm
1 2
3 735±49 Nm
707-02-07730-1
Unit: mm
Criteria
Boom 60
-- 0.030 + 0.151
0.036 0.227
-- 0.076 + 0.006
Boom swing 50
- 0.030 + 0.164
0.037 0.240
-- 0.076 + 0.007
Boom 60
-- 0.060 + 0.174
0.160 0.280
-- 0.106 + 0.100
Arm 50
-- 0.050 + 0.142
0.130 0.231
Tolerance between -- 0.089 + 0.080
2 bushing and piston
head mounting pin -- 0.050 + 0.142
Bucket 45 -- 0.089 + 0.080
0.130 0.231
Boom swing 55
-- 0.060 + 0.174
0.160 0.280
-- 0.106 + 0.100 Replace
pin and
-- 0.060 + 0.174 bushing
Boom 60 0.160 0.280
-- 0.106 + 0.100
T ol e r an c e b et w e en
bushing -- 0.060 + 0.174
3 Arm 60 0.160 0.280
and cylinder mounting -- 0.106 + 0.100
pin
Bucket 45
-- 0.050 + 0.142
0.130 0.231
-- 0.089 + 0.080
WB93R-5E0 40-55
STANDARD MAINTENANCE BACKHOE CYLINDERS
OUTRIGGERS
3 911±91.1 Nm
3 539±54 Nm with Loctite 262
1
707-00-0Y0910-1
JIG ARM
3 1080±100 Nm
3 539±54 Nm
1
42N-6C-13301-1
Unit: mm
Criteria
40-56 WB93R-5E0
PAGE INTENTIONALLY
LEFT BLANK
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
40-58 WB93R-5E0
STANDARD MAINTENANCE FRONT WORKING EQUIPMENT
Unit: mm
Criteria
Clearance between
1 bushings and bucket 45 -- 0.050 + 0.080
0.130–0.329
mounting pin -- 0.089 + 0.240
WB93R-5E0 40-59
STANDARD MAINTENANCE SWING BRACKET
SWING BRACKET
B
A
C
A C
1
3 4
B-B
2
1
A-A 5
RKZ10490
C-C
40-60 WB93R-5E0
STANDARD MAINTENANCE SWING BRACKET
Unit: mm
Criteria
Clearance between
1 rotating bushing and boom 60 -- 0.010 + 0.090
0.070–0.175
swing cylinder bushing -- 0.085 + 0.060
Clearance between
2 bushing and (lower) swing 65 -- 0.060 + 0.190
0.250–0.370
bracketrotating pin -- 0.106 + 0.264
WB93R-5E0 40-61
STANDARD MAINTENANCE BACKHOE WORKING EQUIPMENT
C
C
D B
A
A
D
3
2
1
4
A-A
B-B
5
6 6
RKZ10500
D-D
C-C
40-62 WB93R-5E0
STANDARD MAINTENANCE BACKHOE WORKING EQUIPMENT
Unit: mm
Criteria
WB93R-5E0 40-63
90 OTHER
WB93R-5E0 90-1
OTHER ELECTRICAL DIAGRAM (STANDARD VERSION)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 B59
B105
Livello olio freni
Sensore temperatura olio trasmissione
BRAKE OIL LOW LEVEL SWITCH
Gearing oil temperature sensor
B111 Galleggiante livello carburante Fuel level sender
B112 Termistore Thermistor switch
B113 Filtro aria Air filter blocked switch
B115 Sensore press. olio motore Engine oil low pressure switch
B121 Avvisatore acustico Horn
E100 Fanale podteriore DX Right rear beam
E101 Fanale posteriore SX Left rear beam
E103 Luce targa Plate light
E136 Faro di lavoro posteriore DX laterale Lateral right rear working light
42-N-06 42-N-06
E138 Faro di lavoro posteriore SX laterale Lateral left rear working light
15121 11850 E143 Faro lavoro ant. DX lat. Lateral right front working light
42-N-06-15110
P63 42-N-06 E146 Faro di lavoro anteriore SX laterale Lateral left front working light
V-Z1 11831 E147 Faro anteriore SX Left front light
E148 Presa girofaro Beacon lamp
M-B1.5
M-N1.5
L-N1.5
V/N1
G-M1
A 1 2 3 4
A/B1
C-B1
G-L1
R-N1
H-V1
H1.5
G-V1.5
E151 Faro ant. DX Right front light
M1
A-G1
A-G1
G-N1
G-V1
R/N1
L-R1
L-R1
C-L1
C-L1
C-L1
C-L1
L-R1
L-R1
N1
N1
N1
N1
N1
A/R1
A/R1
H-V1
R/N1
C-L1
L/R1
V-N1
V-N1
V-Z1
E152 Plafoniera Room lamp
A1
R1
N1
N1
N1
N1
N1
N1
F1 FUSIBILE FARI LAVORO ANTERIORI CENTRALI 15A Central front working light fuse 15A
4 2 8 4 1 9 10 12 8 7 2 1 7 1 3 4 6 4 6 1 3
X57 X57 X57 X60 X60 X60 X60 X60 X60 7 1 3 4 6 7
X180 1 1 1 1 F2 FUSIBILE FARI LAVORO POSTERIORI CENTRALI 15A Central rear working light fuse 15A
X141
X141
X141
X141
X141
X140
X140
X140
X140
X140
X142
X142
X142
X142
X142
4 2 8 4 1 9 10 12 8 7 2 1 3 4 6 7 F3 FUSIBILE LUCE POSIZIONE DX 3A Right position light fuse 3A
X89 X89 X89 X89 X89 7 1 3 7 1 3 7 1 3 X146 X143 X136 X138
R N F Dx I 0 X80 X80 X80 X81 X81 X81 X82 X82 7 1 3 4 6 7 1 3 4 6 4 6 1 3 7 F4 FUSIBILE LUCE POSIZIONE SX 3A Left position light fuse 3A
3 6 7 0 1
1 4 II I 0 II I 0
E143
E136
7 1 3 7 1 3 7 1 3 F5 FUSIBILE AVVISATORE ACUSTICO 10A Horn fuse 10A
V180 1 0 1 0
0 1 0 1 5 2 8 E146 E138 F6 FUSIBILE FARI LAVORO POSTERIORI LATERALI 15A Lateral rear working light fuse 15A
Sx 8 2 8 2
H 5 5 4 4 4 4 F7 FUSIBILE TERGI POSTERIORE + AVVISATORE Winshield wiper-washer + rear horn fuse 7,5A
9 5 3 11 6 8 2 5 8 2 8 2 8 8 2 5 S141 5 2 8
S57 S60 S89 S80 S81 S82 2 S140 8
X140 X140
2 5
X140
S142 X142 X142 X142
X141 X141 X141 X146 X143 X136 X138 ACUSTICO POSTERIORE 7,5A
9 5 3 11 6 8 2 5 8 2 8 2 8 2 F8 FUSIBILE SWITCH LUCI STOP 7,5A Stop light swicth fuse 7,5A
X57 X60 X60 X60 X60 X89 X89 X89 X80 X80 X81 X81 X82 X82
A-G1.5
A-G1.5
G-N1.5
G-N1.5
A-G1
A-G1
G-V1
G-V1
1
L-R1
C-L1
C-L1
F9 FUSIBILI FARI LAVORO ANTERIORI LATERALI 15A Lateral front working light fuse 15A
R1
N1
N1
N1
N1
A-G1
H-R1
X181
H1
C1
G-M1
V1
A-G1
A-B1
G/R1
A/R1
A/R1
A/R1
A/R1
C-L1
C-L1
V/N1
L/R1
V-N1
V-Z1
F10 FUSIBILE ALIM. TERGI ANTERIORE 10A Front windhield-motor supply fuse 10A
42-N-06 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 F11 FUSIBILE OPTIONAL 7,5A Optional fuse 7,5A
F12 FUSIBILE BUZZER+STR.ANTERIORE+STR.LATERALE 5A Front + lateral instruments + buzzer fuse 5A
X63 X64
L-B0.5
C-L0.5
11210
G-M1
M-N1
M/B1
B-V1
A-V1
H-V1
R-V1
A/V1
Z-B1
V-N1
F13 FUSIBILE ALIM. MANIPOLATORE 10A Supply level grip fuse 10A
G1
N1
H1
V1
F14 FUSIBILE LAMPADE SWITCH + SWITCH OPTIONAL 10A Light switch + swicth optional fuse 10A
F15 FUSIBILE ELETTROSTOP+SICUREZZA AVVIAMENTO 10A ELETTROSTOP + SAFETY STARTER FUSE 10A
F16 FUSIBILE GIROFARO 10A Beacon light fuse 10A
A-B1
B-N1
B-N1
A-N1
A-N1
R/N1
S-N1
R/N1
N1
N1
N1
N1
F17 FUSIBILE SWITCH EMERGENZA 10A Warning swicth fuse 10A
F18 FUSIBILE PLAFONIERA+ACCENDISIGARI 10A Cabin lamp + cigarette lighter fuse 10A
7 1 3 7 1 3 7 1 3
F19 FUSIBILE ANABBAGLIANTI 15A Low beam fuse 15A
X83 X83 X83 X85 X85 X85 X84 X84 F20 FUSIBILE ABBAGLIANTI 15A Main beam light 15A
7 1 3 7 1 3 7 1 3 F21 FUSIBILE ALIM. SENSORE RETURN TO DIG 10A Return to DIG sender supply fuse 10A
0 0 0 1
1 1 F22 FUSIBILE EC POWER 7,5A EC POWER FUSE 7,5A
L/R1
F23 FUSIBILE +15 CENTRALINA STERZATURA 10A +15 STEERING UNIT FUSE 10A
8 2 8 2 8 2
S83 S85 F24 FUSIBILE ALIM. INTERMITTENZA 7,5A FLASHER FUSE 7,5A
8 2 8 2 S84 8 2 F25 FUSIBILE SIRENA RETRO + ALIM. DEVIO 10A REVERSE SPEED BUZZER + STEERING COLUMN 10A
X83 X83 X85 X85 X84 X84
F27 FUSIBILE GENERALE 200A GENERAL FUSE 200A
A-B1
A-B1
A-N1
R/N1
R/N1
S-N1
R/N1
R/N1
Z-N1
G1 BATTERIA Battery
G118 Motorino avviamento Starter motor
G119 Alternatore Generator
H17 BUZZER BUZZER
H1.5
H97 CLAXON POSTERIORE REAR HORN SWITCH
A/B1
K1 CENTRALINA ANTIRIPETIZIONE AVVIAMENTO Unrepeat start unit
M-N1
B-G1
A-B1
A-B1
C-B1
G-L1
H-L1
S/N1
Z/N1
G1
N1
N1
N1
N1
N1
R-G1
R-N1
A/V1
K2 INTERMITTENZA Flasher
K3 RELE' ANABBAGLIANTI Low beam relay
1
2 4 3 7 1 3 4 6 7 1 3 4 6 1 3 7 K4 RELE' ABBAGLIANTI Main beam relay
1 1 1 X55
X53.1 X54.1 X59.1 X58 X58 X58 X86 X86 X86 X86 X86 X88 X88 X88 X87 X87 X87 X87 X87 K5 RELE' AVVISATORE ACUSTICO ANTERIORE Front horn relay
M58 M 7 1 3 4 6 7 1 3 0 1 4 6 1 3 7 K6 RELE' ELETTROVALVOLA RETURN TO DIG Return to DIG solenoid valve relay
S53 S54 B59 II I 0 0
G-V1.5
53a 1 K7 RELE' LUCI STOP Light stop relay
53 M 53b
A-B1
G-N1
H1.5
H1.5
V1.5
V1.5
G1
A1
R1
31b 5 2 8 K8 RELE' CONSENSO AVVIAMENTO Assent start relay
M55 42-N-06-15151 8 2 5 8 2
31 1 1 K9 RELE' MARCIA AVANTI Forword speed relay
1 1 1 2 S86 8 2 5 S88 8 2 S87 5 2 8
X87 X87 X87 - - - - - - - - X148.1 X152.1 K10 RELE' MARCIA INDIETRO Reverse speed relay
X53.2 X54.2 X59.2
1
X55 A6 UNIT X86 X86 X86 X88 X88 X147.2 X151.2
K11 RELE' STACCO TRASMISSIONE Stop drive relay
G1
G1.5
56a
56b
56a
56b
57
57
R
L
N1
N1
M-N1
A-B1
A-B1
R-G1
R-G1
B-R1
H-L1
H-L1
Z/N1
Z/N1
M K45 Rele' preriscaldo Preheating Relay
N1
MULTIFUNCTION 01171128
K56 Rele' avviamento Starting relay
31
31
K61 Rele' servizi Service realy
- E147 - E151 1
E148 E152 M42 Tergi posteriore Rear Windshield-washer
N1.5
N1.5
N1.5
N1
N1
N1
N1
N1
4th GEAR POWER SUPPLY SWITCH
FUNCTION MACHINE UNIT SUPPLY
L-B0.5
L-N1.5
C-L0.5
M-N1
A-G1
H-R1
R-N1
B-V1
A-V1
H-V1
R-V1
Z-B1
R-G1
A-G1.5
A-G1.5
V-N1
G-N1.5
G-N1.5
R114 Candelette Preheating
M1
H1
N1
C1
G-M1
V1
M-N1
A-G1
A-B1
A-B1
A-N1
B-N1
G/R1
G-L1
A/R1
H-V1
R/N1
H/R1
C-L1
H-L1
S/N1
V/N1
V-N1
V-N1
G1.5
Z/N1
V-Z1
G-N1
G-V1
A-B1
LIGHTS AND SWITCH 4WD
H1.5
H1.5
V1.5
V1.5
A1
N1
Gnd7.1 S2 INTERRUTTORE ELETTROVALVOLA EC POWER SOLENOID VALVE E.C. POWER SWITCH
R1
R1
A1
G1
N1
PPC CONTROL SWITCH
4WD SOLENOID VALVE
S3 INTERRUTTORE CHIUSURA BENNA LOCK GRAB SWITCH
EC POWER SWITCH
1 2 3 4 5 6 7 8 9 X25.s X26.s 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 19 20 21
SEAT SWITCH
4WD SWITCH
OUT BUZZER
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 18 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 19 20 21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 S6 INTERRUTTORE BLOCCO DIFFERENZIALE DIFFERENTIAL LOCK SWITCH
X10.p X9.p X25.p X26.p X44.p
R1
OFF
ACC R1 ACC BR R2 C S24 Quadro avviamento Starting switch
R1
M-N1.5
A-G1.5
A-G1.5
G-N1.5
G-N1.5
N2.5
R1.5
R-N1.5
A1
L-B0.5
L-N1.5
C-L0.5
A-B1
H1.5
H1.5
G-N1
G1
V1.5
V1.5
ST
GND
G-M1
G-M1
M-N1
M/B1
A-B1
R-G1
M-V1
B-R1
C-B1
B/G1
B-N1
H-R1
G/R1
B-V1
R-N1
A-V1
G-L1
G-L1
A/R1
G-V1
H-V1
R-V1
H-V1
R/N1
H/R1
H-L1
S/N1
V/N1
V-N1
V-N1
V-N1
V-N1
G1.5
Z/N1
N1.5
N1.5
V-Z1
S40 Micro sedile Seating switch
M1
G1
H1
C1
N1
V1
G-M1
A-B1
A-B1
M-V1
M-V1
C-B1
B-N1
B/G1
B-R1
C-N1
H-N1
H/R1
H/R1
H/N1
Z-B1
H-L1
S/N1
Z-N1
L/R1
Z/N1
B-R1.5
M1
N1
X24.gnd
M/N1
M/N1
N1.5
S54 MICRO 4WD STOP Stop 4WD Switch
B1
R6
L6
M/N1 S57 Devio cambio Steering column gear switch
A1 S60 Devio luci Steering column light switch
S2 S3 S4 S5 S6 S80 INTERRUTTORE RIDE CONTROL Ride control switch
S81 PULSANTE SBLOCCO BRACCIO Arm unlock switch
M1 S82 INTERRUTTORE SBLOCCO PIASTRA Plate unlock switch
S83 PULSANTE E/C POWER E/C Power Switch
S84 INTERRUTTORE VALVOLE EMPI EMPI solenoid valve switch
M/N1
H-N1
S-N1
C-B1
M-N1
M-V1
V/N1
Z-N1
S85 PULSANTE AVV. ACUSTICO POSTERIORE Rear horn switch
A-B1
M-B1
C/B1
Z-N1
N1
S86 INTERRUTTORE GENERALE LUCI General light switch
S87 INTERRUTTORE 4WD 4WD Switch
S88 PULSANTE PPC PPC switch
X47
M-B1.5
1
S89 INTERRUTTORE WARNING WARNING switch
2
S104 Sw 4° marcia 4TH SPEED SWITCH
3
S107 Stacco trasmissione DECLUCH SWITCH
4
S140 Interruttore fari lavoro posteriori Rear working light switch
5
S141 Interruttore girofaro Beacon light switch
6
Interruttore fari lavoro anteriori
OF OPT. HARNESS
L-N1.5
15710
42N-06-15840
42N-06-15940
C-B1
C-B1
C-B1
N1.5
1 X15.p A-N1.5 Y93 Ev. PPC PPC solenoid valve
B-G1
S/N1
M/N1
B-N1
A-R1
C-L1
C-L1
M16
2 X15.p N1 Y94 Ev blocco differenziale Lock Differential gear solenoid valve
B6
N1
V6
1 2 3
A-G1
CN-F20
N1
N1
H/N1
R-G1
B-N1
M-V1
N1
X17.2
R16
Y203 Ev. marcia indietro Reverse solenoid valve
G/R1
A-G1
N1
R6
Z-B1 CN-F20 6 6 X6.p M-N1
R6
P43 B-N1 X12.s CONNETTORE A linea posto guida TO DRIVER SITE HARNESS CONNECTOR
N1
B-N1 CN-F20 7 7 X6.p H-L1 X8.s CONNETTORE A linea posto guida TO DRIVER SITE HARNESS CONNECTOR
X43 R-G1.5CN-F20 8 8 X6.p B1
1 R-G1 X128.s CONNETTORE A linea posto guida TO DRIVER SITE HARNESS CONNECTOR
B1 CN-F20 9 9 X6.p A-V1 X7.s CONNETTORE A linea posto guida
15 2 G-N1 TO DRIVER SITE HARNESS CONNECTOR
10 20 CN-F20 10 10 X6.p
RPM x 100 3 R1 X1.s CONNETTORE A LINEA CENTRALINA 01171062 TO UNIT 01171062 CONNECTOR
CN-F20 11 11 X6.p B-R1 X10.p
5 25 4 B-N1 CONNETTORE A LINEA CRUSCOTTO ANTERIORE TO FRONT DASHBOARD HARNESS CONNECTOR
R-G1.5 CN-F20 12 12 X6.p B1
H-R1
N1.5
R6
V6
L6
0 30
H-L1
H-L1
V-B1
A-N1
7 C-L0.5 7 6 5 4 3 2 1 X15.p CONNETTORE A LINEE OPTIONAL TO OPTIONAL HARNESS CONNECTOR
+15Key +30 +15 R-V1
8 C-B1 X2.s CONNETTORE A LINEA CENTRALINA 01171062 TO UNIT 01171062 CONNECTOR
X3.s 1
9 A-V1 42-N-06-15141 UNIT(01171166) X4.s R1
1 X25.p CONNETTORE A LINEA PANNELLO INTERRUTTORI TO SWITCHES PANEL HARNESS CONNECTOR
X7.p
10 B-V1 2 1 X26.p CONNETTORE A LINEA PANNELLO INTERRUTTORI TO SWITCHES PANEL HARNESS CONNECTOR
B-N1
11 L-B0.5 B-R1.5 3 F25 F14 F13 F12 F24 F21 F7 F22 F18 F16 F17 2 R-N1.5 X28.s CONNETTORE RISCALDAMENTO HEATING CONNECTOR
X7.s
1
M/N1 Z1 4 10A 10A 10A 5A 7,5A 10A 7,5A 7,5A 10A 10A 10A H1 X3.s CONNETTORE A LINEA CENTRALINA 01171062 TO UNIT 01171062 CONNECTOR
13 3
1
14 Z-B1 Z-N1 5 4 V1 X4.s CONNETTORE A LINEA CENTRALINA 01171062 TO UNIT 01171062 CONNECTOR
X5
17 V1 B1 6 5 C1 1 X44.p CONNETTORE A linea cabina TO CABIN HARNESS CONNECTOR
X3.p X5.s
18 V-B1 7 6 R1.5 X3.s 1 CONNETTORE A LINEA CENTRALINA 01171062 TO UNIT 01171062 CONNECTOR
19 G-V1 8 7 R1.5 X65.p CONNETTORE A linea motore TO MOTOR HARNESS CONNECTOR
B-R1
A-V1
V-B1
2
20 N1 9 8 A-G1.5 X5
X7.p CONNETTORE A linea motore TO MOTOR HARNESS CONNECTOR
B-R1
H-R1 10 9 G-N1.5 X8.p CONNETTORE A linea cambio TO GEAR HARNESS CONNECTOR
B-R1 B-R1
B-G1 11 86 87a 87 X9.p CONNETTORE A linea cruscotto anteriore TO FRONT DASHBOARD HARNESS CONNECTOR
Sal2
H-R1 12
K2 K1 X25.s CONNETTORE A L. POSTO GUIDA TO DRIVER SITE HARNESS CONNECTOR
V-B1
V-B1
V-B1
X4 X4 X4
13 86 87a 87 X26.s CONNETTORE A L. POSTO GUIDA TO DRIVER SITE HARNESS CONNECTOR
H-N1 F8 F11 F10 F23 15 F15 15 K4
C-B1
R-V1
M-B1.5 14 F2 F9 F1 X10.s CONNETTORE A linea posto guida TO DRIVER SITE HARNESS CONNECTOR
10A 31 T 31 T
7,5A 7,5A 10A
G1.5 15 53S 53M 53S 53M 15A 15A 15A 85 30
X9.s CONNETTORE A linea posto guida TO DRIVER SITE HARNESS CONNECTOR
10A
A-N1
X30
R/N1
R/N1 16 1 85 30 V-B1 X44.s CONNETTORE A linea posto guida TO DRIVER SITE HARNESS CONNECTOR
A-N1.5 17 X46 X4 X4 V-B1 Sal3 X11.s CONNETTORE A linea posto guida TO DRIVER SITE HARNESS CONNECTOR
S46
1 X27.s A-R1 R-V1 18 2 1 X27s CONNETTORE A linea condizionata A/C HARNESS CONNECTOR
Sal1
A/C
R-G1
R-V1
V-B1
V-B1
R-G1 19 X41.s X41.s P43 PANNELLO STRUMENTI INSTRUMENTS PANEL
2 X27.s C-B2.5
20 P63 PANNELLO DI CONTROLLO ANTERIORE FRONT CONTROL PANEL
42N-07-11500 2
M-N1.5 21 S41 A4 CENTRALINA KOMTRAX KOMTRAX UNIT
X2.s 1 X1 CONNETTORE komtrax unit Komtrax unit Connector
A L/R1 1
F5 K5 1 2 Komtrax unit Connector
HEATING X28.s R4
A-G1.5 2
K11 K3 K4 X30.1 X30.1
X2 CONNETTORE komtrax Unit
86 87a 87 86 87a 87 86 87a 87 86 87a 87 F6 F3 F4 F19 F20 X3.p Connettere a X3.s X3.s Connector
10A
M-N1
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
R1.5
N1.5
B-R1 3
G1
N1
42N-07-11300 B X3.s Connettere a X3.p X3.p Connector
X28.s 15A 3A 3A 15A 15A
R-N1 4 85 30 85 30 85 30 85 30 X4 Connettore Rele for starter cut Starter cut Relay connector
L-N1.5 5
N4
42-N-06
11810
Gnd1
Gnd10
N1
R-N1.5
B1
Z-B1
GND9
GND1.3
GND1.2
GND1.1
42-N-06
R4
R6
R6
R6
Gnd1.1
1
Gnd1.3
Gnd1.2
Gnd10
Gnd9
12310
Gnd1
X107
X68.1 X68.3 S107
X68.2
A-N1.5
M1
Z-B1
Z-B1
S-N1
C-B2.5
B-N1
F27
G-M1
M-N1
A-B1
C-B1
A-N1
G-N1
B-R1
B-N1
H-N1
C-N1
H-N1
H-R1
C/B1
H/R1
Z-B1
H-L1
V-B1
Z-N1
V/N1
V-N1
V-N1
N1.5
N1.5
N1.5
B6
G1
A1
N1
200A
V1
2
X107
X7.p 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 X65.p 1 X11.p 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 X12.p 1 2 3 4 5 6 X8.p 1 2 3 4 5 6 7 8 9 10 11 12
A-B1
G-N1
C-B1
A-N1
B-N1
C-N1
H-N1
H-R1
C/B1
H/R1
Z-B1
H-L1
Z-B1
H-L1
Z-N1
V/N1
V-N1
N1.5
N1.5
N1.5
V-Z1
42-N-06
CONNECTTO HARNESS
G1
A1
B2
V1
M-V1
A-N1.5
R-N1.5
H-N1
S-N1
C-B2.5
Z-B1
V-B1
Z-N1
M1
Gnd6 42-N-06
M16
B6
N6
11450
11161 X109 1
42N-06-15960
X109 2
X110.s 1
B-N1
B-V1
N1
H-N1
H-R1
Z-B1
H-L1
V-N1
X100.3 B-R1
A1
X100.4 N1
X100.1 G1
X101.2 A-B1
X101.1 G-N1
G-N1
G-N1
X101.3B-R1
A B C
X101.4 N1
A-N1.5
C-B2.5
R-N1.5
M-V1
H-N1
S-N1
Z-B1
V-B1
Z-N1
R70
R25
R25
B6
N1
V1
X100.2
1
M-N1
C-B1
A-N1
C-N1
C/B1
Z-B1
H-L1
Z-N1
V/N1
N1.5
V-Z1
1 1 1
N1
X105
N1
1
1 1 1
- X104 B105 Y106 X106 Y108 X108 Y203 X203
X119.2
1 1 1 1 1 1 1 1 1 1
1 X119.1 1 1 A B C 1 1 X116
X90 X91 X92 X93 X94 X95 X96 X98 X99 X97
S104
G118 X118.1 X117 X115 1 X112 X112 X112 X121 Y60 X60 M116 Y90 Y91 Y92 Y93 Y94 Y95 Y96 Y98 Y99 X103.1
G1
59c
59c
E101 B111
57
57
X114 X113
L
30
M
50 G119 D+
30 G W
B115 B113 B121 M
t
12Vcc 3
R114 Y117 p p B112 t 2 2 2 2
E103
31
H97
31
31 t 2 2
N70
X113
X121 X60
X90 X91 X92 X93 X94 X95 X96 X98 X99 X97
X103.2 E100
N1.5
N6
N1
N1
N1
N1
N1
N1
N1
N1
N1
N1
N1
N1
N1
N1
N1
N1.5
N1
N1
N1
N1
N2
Gnd3.1 42-N-06
Gnd5 GND2.2 GND2.1
Gnd4
11190
WB93R-5E0 E34000-076
90-3