Komatsu PC95 - 1

WEBMPC9500
SHOP
MANUAL
PC95 -1
HYDRAULIC EXCAVATOR
SERIAL NUMBER
5000007 and up
SHOP
WEBMPC9500
MANUAL
PC95- 1
HYDRAULIC EXCAVATOR
SERIAL NUMBER
5000007 and up
This shop manual may contain attachments and optional equipment that are not
avaiable in your area.
Please consult your local FKI distributor for those items you may require.
Materials and specifications are subject to change without notice.
TEMAS - GALLARATE (VA) ITALY (6916GB-07/96)
PC95-1 mount the 1004-4 engine.

For detail of the engine, see the 1000 Series Engine Shop Manual.
FKI FAI KOMATSU INDUSTRIES S.p.A.

SEDE LEGALE: 36025 NOVENTA VICENTINA (VI) ITALY • tel. 0444/760033 • tlx. 480264 • fax 0444/861569
UFFICI E STABILIMENTO: 35042 ESTE (PD) ITALY • tel. 0429/600601 • tlx. 431396 • fax 0429/601000
CONTENTS
No. of page
10 STRUCTURE AND FUNCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
20 TESTING AND ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1
30 DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-1
40 MAINTENANCE STANDARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1
00-2
The affected pages are indicated by the use of the
following marks. It is requested that necessary ac- Mark Indication Action required
tions be taken to these pages according to table
below.
C Page to be newly Add
c Page to be replaced Replace
( ) Page to be delete Discard
Pages having no marks are those previously revised

or made additions
LIST OF REVISED PAGES
Time of Time of Time of Time of Time of

Mark Page Mark Page Mark Page Mark Page Mark Page
revision revision revision revision revision
10-26 20-23 20-65 30-19

00-1
10-27 20-24 20-66 30-20
00-2
10-28 20-25 20-67 30-21
00-2-1
10-29 20-26 20-69 30-22
00-2-2
10-30 20-27 20-70 30-23
00-3
10-31 20-28 20-71 30-24
00-4
10-32 20-29 20-72 30-25
00-5
10-33 20-30 20-73 30-26
00-6
10-34 20-31 20-74 30-27
00-7
10-35 20-32 20-75 30-28
00-8
10-36 20-33 20-76 30-29
00-9
10-37 20-34 20-77 30-40
00-10
10-38 20-35 20-78 30-41
00-11
10-39 20-36 20-79 30-42
00-12
10-40 20-37 20-80 30-43
10-41 20-38 20-81 30-44
10-1
10-42 20-39 20-82 30-45
10-2
10-43 20-40 20-83 30-46
10-3
10-45 20-41 20-84 30-47
10-4
10-47 20-42 20-85 30-48
10-5
20-43 20-86 30-49
10-6
20-1 20-44 20-87 30-50
10-7
20-2 20-45 30-51
10-8
20-3 20-46 30-1 30-52
10-9
20-4 20-47 30-2 30-53
10-10
20-5 20-48 30-3 30-54
10-11
20-6 20-49 30-4 30-55
10-12
20-7 20-50 30-5 30-56
10-13
20-8 20-51 30-6 30-57
10-14
20-9 20-52 30-7 30-58
10-15
20-10 20-53 30-8 30-59
10-16
20-11 20-54 30-9 30-60
10-17
20-12 20-55 30-10 30-61
10-18
20-13 20-56 30-11 30-62
10-19
20-14 20-57 30-12 30-63
10-20
20-15 20-58 30-13 30-64
10-21
20-16 20-59 30-14 30-65
10-22
20-17 20-60 30-15 30-66
10-23
20-19 20-61 30-16 30-67
10-24
20-21 20-62 30-17 30-68
10-25
20-22 20-63 30-18 30-69
00-2-1
Time of Time of Time of Time of Mark Page Time of
Mark Page Mark Page Mark Page Mark Page
revision revision revision revision revision
30-70 30-127
30-71 30-128
30-72 30-129
30-73 30-130
30-74 30-131
30-75 30-132
30-76 30-133
30-77 30-134
30-78 30-135
30-79 30-136
30-80
30-81 40-1
30-82 40-2
30-83 40-3
30-84 40-4
30-85 40-5
30-86 40-6
30-87 40-7
30-88 40-8
30-89 40-9
30-90 40-10
30-91 40-11
30-92 40-12
30-93 40-13
30-94 40-14
30-95 40-15
30-96 40-16
30-97 40-17
30-98 40-18
30-99 40-19
30-100 40-20
30-101 40-21
30-102 40-22
30-103 40-23
30-104 40-24
30-105 40-25
30-106 40-26
30-107 40-27
30-108 40-28
30-109 40-29
30-110
30-111
30-112
30-113
30-114
30-115
30-116
30-117
30-118
30-119
30-120
30-121
30-122
30-123
30-124
30-125
30-126
00-2-2
IMPORTANT SAFETY NOTICE
Proper service and repair is extremely important for the safe operation of your machine.
The service and repair techniques recommended by FKI and describe in this manual are both effective
and safe methods of operation. Some of these operations require the use of tools specially designed by
FKI for the purpose.
To prevent injury to workers, the symbols and are used to mark safety precautions in this man-
ual. The cautions accompanying these symbols should always be carefully followed. If any danger arises
or may possibly arise, first consider safety, and take necessary steps to face.
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 care- chine on hard, level ground, and block the tracks
fully BEFORE operating the machine. to prevent the machine from moving.
1. Before carrying out any greasing or repairs, read 8. Before starting work, lower blade, bucket or any
all the precautions written on the decals which other work equipment to the ground. If this is
are suck on the machine. not possible, use blocks to prevent the work
equipment from falling down. In addition, be sure
2. When carrying out any operation, always wear to lock all the control levers and hang warning
safety shoes and helmet. Do not wear loose work sign on them.
clothes, or clothes with buttons missing.
9. When disassembling or assembling, support the
. Always wear safety glasses when hitting parts
machine with blocks, jacks or stands before start-
with a hammer.
ing work.
. Always wear safety glasses when grinding
parts with a grinder, etc. 10. Remove all mud and oil from the steps or other
places used to get on and off the machine. Always
3. If welding repairs are needed, always have a use the handrails, ladders or steps when getting
trained, experienced welder carry out the work. on or off the machine.
When carrying out welding work, always wear Never jump on or off the machine.
welding gloves, apron, glasses, cap and other If it is impossible to use the handrails, ladders or
clothes suited for welding work. steps, use a stand to provide safe footing.
4. When carrying out any operation with two or more
workers, always agree on the operating procedure
before starting. Always inform your fellow workers PRECAUTIONS DURING WORK
before starting any step of the operation. Before
11. When removing the oil filler cap, drain plug or hy-
starting work, hang UNDER REPAIR signs on
draulic pressure measuring plugs, loosen them
the controls in the operator's compartment.
slowly to prevent the oil from spurting out.
5. Keep all tools in good condition and learn the cor- Before disconnecting or removing components of
rect way to use them. the hydraulic circuit and engine cooling circuit,
first remove the pressure completely from the cir-
6. Decide a place in the repair workshop to keep
cuit.
tools and removed parts. Always keep the tools
and parts in their correct places. Always keep 12. The water and oil in the circuits are not hot when
the work area clean and make sure that there is the engine in stopped, so be careful not to get
no dirt or oil on the floor. burned.
Smoke only in the areas provided for smoking. Wait for the oil water to cool before carrying out
Never smoke while working. any work on the cooling water circuits.
00-3
13. Before starting work, remove the leads from the 24. Take sure when removing or installing tracks.
battery. Always remove the lead from the negative When removing the track, the track separates
( ± ) terminal first. suddenly, so never let anyone stand at either
end of the track.
14. When raising heavy components, use a hoist or
crane. Check that the wire rope, chains and hooks
are free from damage.
Always use lifting equipment which has ample ca-
pacity. Install the lifting equipment at the correct
places.
Use a hoist or crane and operate slowly to prevent
the component from hitting any other part.
Do not work with any part still raised by the hoist
or crane.
15. When removing covers which are under internal
pressure or under pressure from a spring, always
leave two bolts in position on opposite sides.
Slowly release the pressure, then slowly loosen
the bolts to remove.
16. When removing components, be careful not to
break or damage the wiring.
Damage wiring may cause electrical fires.
17. When removing piping, stop the fuel or oil from
spilling out. If any fuel or oil drips on to the floor,
wipe it up immediately.
Fuel or oil on the floor can cause you to slip, or
can even start fires.
18. As a general rule, do not use gasoline to wash
parts. In particular, use only the minimum of gaso-
line when washing electrical parts.
19. Be sure to assemble all parts again in their origi-
nal places. Replace any damage parts with new
parts.
When installing hoses and wires, be sure that
they will not be damaged by conctat with other
parts when the machine is being operated.
20. When installing high pressure hoses, make sure
that they are not twisted. Damaged tubes are dan-
gerous, so be extremely careful when installing
tubes for high pressure circuits. Also, check that
connecting parts are correctly tightened.
21. When assembling or installing parts, always use
specified tightening torques.
When installing the parts which vibrate violently or
rotate at high speed, be particulary careful to
check that they are correctly installed.
22. When aligning two holes, never insert your fingers
or hand.
23. When measuring hydraulic pressure, check that
the measuring tool is correctly assembled before
taking any measurement.
00-4
FOREWORD
This shop manual has been prepared as an aid to improve the quality of repairs by giving the operator an ac-
curate understanding of the product and by showing him the correct way to perform repairs and make judgements.
Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service
workshop.
The manual is divided into chapters on each main group of components; these chapters are further divided into
the following sections.
STRUCTURE AND FUNCTION

This section explains the structure and function of each component. It serves not only to give an under-
standing of the structure, but also serves as reference material for troubleshooting.
TESTING AND ADJUSTING

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

This section explains the order to be followed when removing, installing, dissassembling or assembling
each component, as well as precautions to be taken for these operations.
MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.
NOTICE
The specifications contained in this shop manual are subject to change at any time without any notice.
Contact your FKI distributor for the latest information.
00-5
HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL
VOLUMES SYMBOLS
Shop manual are issued as a guide to carry out re- In order to make the shop manual greatly chelpful,
pairs. These various volumes are designed to avoid important points about safety and quality are marked
duplicating the same information. with the following symbols.
DISTRIBUTION AND UPDATING Symbol Item Remarks
Any additions, amendments or other changes will Special safety precautions are ne-
be sent to FKI distributors. cessary when performing the
Get the most up-to-date information before you start work.
any work.
Safety
Extra special safety precautions
are necessary when performing
FILING METHOD the work because it is under inter-
nal pressure.
1. See the page number on the bottom of the page.
File the pages in correct order. Special technical precautions or
other precautions for preserving
2. Following examples show you how to read the Caution standards are necessary when
page number. performing the work.
Example
Weight of parts or systems.
10 - 3 Caution necessary when selecting
Weight hoisting wire, or when working
posture is important, etc.
Item number (10. Structure and
Function) Parts that require special attention
Tightening for the tightening torque during as-
Consecutive page number for each torque sembly.
item.
Parts to be coated with adhesives
Coat and lubricants etc.
3. Additional pages: additional pages are indicated
by a hyphen (-) and number after the page num- Places where oil, water or fuel
ber. Oil, water must be added, and their quantity.
Fle as in the example.
Example: Places where oil or water must be
Drain drained, and quantity to be
10-4
drained.
10-4-1
10-4-2
] Added pages
10-5
REVISED EDITION MARK

(1 2 3 ....)
When a manual is revised, an edition mark is re-
corded on the bottom outside corner of the pages.
REVISIONS
Revised pages are shown on the LIST OF RE-
VISED PAGES between the title page and SAFETY
page.
00-6
HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
ing, and a serious accident can result.

Heavy parts (25 kg or more) must be lifted Hooks have maximum strenght at the middle
with a hoist etc. portion.
In the Disassembly and Assembly, section,
every part weighing 25 kg or more is clearly in-
dicated with the symbol
1. If a part cannot be smoothly removed from the

machine by hoisting, the following checks should
be made:
. Check for removal of all bolts fastening the part
to the relative parts.
. Check for any part causing interference with 3) Do not sling a heavy load with one rope alone,
the part to be removed. but sling with two or more ropes symmetrically
wound on to the load.
Slinging with one rope may cause turning of
2. Wire ropes the load during hoisting, untwisting of the
1) Use adequate ropes depending on the weight rope, or slipping of the rope from its original
of parts to be hoisted, referring to the table be- winding position on the load, which can
low: cause dangerous accidents.
WIRE ROPES 4) Do not sling a heavy load with ropes forming a

(Standard «S» or «Z» twist ropes wide hanging angle from the hook.
without galvanizing) When hoisting a load with two or more ropes,
the force subjected to each rope will increase
Rope diameter (mm) Allowable load (tons) with the hanging angles.
The table below shows the variation of allow-
10 1.0 able load (kg) when hoisting is made with two
ropes, each of which is allowed to sling up to
11.2 1.4 1000 kg vertically, at various handing angles.
When two ropes sling a load vertically, up to
12.5 1.6 2000 kg of total weight can be suspended.
14 2.2 This weight becomes 1000 kg when two ropes
make a 120ë hanging angle.
16 2.8 On the other hand, two ropes are subjected to
an excessive force as large as 4000 kg if they
18 3.6 sling a 2000 kg load at a lifting angle of 150ë.
20 4.4
22.4 5.6
30 10.0
40 18.0
50 28.0
60 40.0
The allowable load value is estimated to be

one-sixth or one-seventh of the breaking
strength of the rope used.
2) Sling wire ropes from the middle portion of the

hook.Slinging near the edge of the hook may
cause the rope to slip off the hook during hoist-
00-7
STANDARD TIGHTENING TORQUE
The following charts give the stardard tightening torques of bolts and nuts. Exceptions are given in sections of «Dis-
assembly and Assembly».
1. STANDARD TIGHTENING TORQUE OF BOLTS AND NUT
Width across flat

Thread diameter Pitch of (mm)
of bolts bolts
(mm) (mm)
kgm Nm kgm Nm
6 1 10 5 0.96w0.1 9.5w1 1.3w0.15 13.5w1.5
8 1.25 13 6 2.3w0.2 23w2 3.2w0.3 32.2w3.5
10 1.5 17 8 4.6w0.5 45w4.9 6.5w0.6 63w6.5
12 1.75 19 10 7.8w0.8 77w8 11w1 108w11
14 2 22 12 12.5w1 122w13 17.5w2 172w18
16 2 24 14 19.5w2 191w21 27w3 268w29
18 2.5 27 14 27w3 262w28 37w4 366w36
20 2.5 30 17 38w4 372w40 53w6 524w57
22 2.5 32 17 52w6 511w57 73w8 719w80
24 3 36 19 66w7 644w70 92w10 905w98
27 3 41 19 96w10 945w100 135w15 1329w140
30 3.5 46 22 131w14 1287w140 184w20 1810w190
33 3.5 50 24 177w20 1740w200 250w27 2455w270
36 4 55 27 230w25 2250w250 320w35 3150w350
39 4 60 ÐÐ 295w33 2900w330 410w45 4050w450
This torque table does not apply to bolts or nuts which have to fasten nylon or other parts non-ferrous metal washer.
. Nm (Newton meter): 1 Nm = 0.102 kgm
00-8
2. TIGHTENING TORQUE FOR NUTS OF FLARED

Use these torques for nut part of flared.
Thread diameter Width across flats TIGHTENING TORQUE

of nut part of nut part
(mm) (mm) kgm Nm
1/2" - 20 17 2.6w0.5 25.5w4.9

9/16" - 18 17 4w0.5 39.2w4.9
3/4" - 16 22 6.7w2 65.7w19.6
7/8" - 14 27 8w2 78.5w19.6
1.1/16" - 12 32 9.7w3 95.15w29.4
5 "
1. /16 - 12 38 17w3 166.7w29.4
5 "
1. /8 - 12 50 20w5 196.2w49
22 27 8w2 78.5w19.6
33 41 20w5 196.2w49
COATING MATERIALS
The recommended coating materials prescribed in FKI Shop Manuals are listed below:
Nomenclature Code Applications

ASL800010 Used to apply rubber pads, rubber gaskets and cork plugs.
Used to apply resin, rubber, metallic and non-mettalic 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.
Adhesives LOCTITE 262 Used for high resistant of threaded parts that can be removed with normal tools.
Used for high resistant locking and for sealing threaded parts, bolts and stud
LOCTITE 270 bolts that normaly must to be not removed.
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 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.
Gasket sealant
Used by itself on mounting suface on the final drive and transmission cases.
ASL800070 (Thickness after tightening :0,07-0,08 mm).
Antifriction compound
Applied to bearings and taper shaft to facilitate press-fitting and to prevent stick-
(Lubricant inclunding ASL800040 ing, burning or rusting.
Molybdenum disulfide)
Grease Applied to bearings, sliding parts and oil seals for lubrication, rust prevention and
(Lithium grease)
ASL800050 facilitation of assembling work.
Vaseline ± Used for protecting battery electrode terminals from corrosion.
00-9
ELECTRIC WIRE CODE
ELECTRIC ELECTRIC WIRE CODE
In the wiring diagrams, various colors 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 ù of strands Cross section Applcable circuit
number (mm) (A)
strands (mm) (mm2)
0.5 16 0.20 0.50 2.40 6 Instrument
1 14 0.30 0.99 2.80 11 lighting - signal etc.
1.5 21 0.30 1.48 3.35 14 Working light - solenoid valve etc.
2.5 35 0.30 2.47 3.80 20 Control panel - Ignition switch etc.
4 56 0.30 3.95 4.60 28 Alternator - preheating etc.
6 84 0.30 5.93 5.20 37 Starter motor fuses
50 399 0.40 50.11 14 160 Ground - starter motor
CLASSIFICATION BY COLOUR AND CODE

Primary Auxiliary
Code A A-N A/N A-R A/R A-V A/V
Colour Light blue Light blue-Black Light blue-Red Light blue-Green
Code B B-G B/G B-N B/N B-R B/R
Colour White White-Yellow White-Black White-Red
Code C C-V C/V ÐÐ ÐÐ ÐÐ ÐÐ
Colour Orange Orange-Green ÐÐ ÐÐ
Code G G-N G/N G-R G/R G-V G/V
Colour Yellow Yellow-Black Yellow-Red Yellow-Green
Code H H-G H/G H-N H/N H-R H/R
Colour Gray Gray-Yellow Gray-Black Gray-Red
Code L L-G L/G L-N L/N L-R L/R
Colour Blue Blue-Yellow Blue-Black Blue-Red
Code M M-B M/B M-N M/N ÐÐ ÐÐ
Colour Brown Brown-White Brown-Black ÐÐ
Code N ÐÐ ÐÐ ÐÐ ÐÐ ÐÐ ÐÐ
Colour Black ÐÐ ÐÐ ÐÐ
Code R R-N R/N R-V R/V ÐÐ ÐÐ
Colour Red Red-Black Red-Green ÐÐ
Code S S-G S/G S-N S/N ÐÐ ÐÐ
Colour Pink Pink-Yellow Pink-Black ÐÐ
Code V V-B V/B V-N V/N ÐÐ ÐÐ
Colour Green Green-White Green-Black ÐÐ
Code Z Z-B Z/B Z-G Z/G Z-N Z/N
Colour Violet Violet-White Violet-Yellow Violet-Black
COMPOSITION OF THE COLOURS

The coloration of two-colour wires is indicated by the composition of the symbols listed.
Example: G-V = Yellow-Green with longitudinal colouring.
G/V = Yellow-Green with transversal colouring.
00-10
WEIGHT TABLE
This weight table is a guide for use when transporting or handling components.
Unit: kg
Machine model PC95-1
From serial no. 5000007
Engine assembly 492
Radiator - exchanger 41
Hydraulic tank (without hydraulic oil) 76
Fuel tank (without fuel) 104
Revolving frame 1092
Counter weight 1150
Swing circle 130
Swing machinery assembly 65
Main hydraulic pump 60
Auxiliary pump 8
Operator's cab 250
Operator's seat 32
Operator's seat support 9
Platform 55
Control valve 60
Track frame assembly 1021

. Idler assembly 75
. Sprocket 23
. Final drive 67
. Track roller 16
. Carrier roller 11
Track-shoe assembly (standard) 976
Engine hood (movable) 60
Engine hood (fixed) 83
Control valve hood 16
Center swivel joint 36
Swing bracket 230
Boom 358
1st boom 272
2nd boom 195
Arm (L=1850) 156
Arm (L=1600) 134
Blade 250
00-11
TABLE OF OIL AND COOLANT QUANTITIES
KIND OF AMBIENT TEMPERATURE CAPACITY ( < )
RESERVOIR
FLUID ±20 ±10 0 10 20 30ëC Specified Refill
SAE 10W
Lubricating oil
SAE 20W-20 11.5 11.5
sump
SAE 30 1 1
Engine oil filter
SAE 40
OIL
. API CD-SG
Hydraulic system SAE 10W 145 82
. MIL-L-2104 E
. CCMC D4-G4
Idler 0.600 ÐÐ
Carrier
SAE 30W 0.120 ÐÐ
roller
Track
0.250 ÐÐ
roller
Final
OIL 1 1
drive (each)
. API GL5 SAE 80W/90
Swing . MIL-L-2105 D 4 4
machinery
Fuel tank DIESEL FUEL * ASTM D975 N. 2

140 ÐÐ
WATER+
20 ÐÐ
ANTI-FREEZE
Cooling system WATER 20 ÐÐ
PERMANENT
20 ÐÐ
LIQUID
ASTM: America Society of Testing and Materials * ASTM D975 N. 1
SAE: Society of Automotive Engineers

API: American Petroleum Institute
MIL: USA Military Specification
CCMC: Common Market Constructors Committe
Specified capacity: Total amount of oil including oil for components and oil in piping.
Refill capacity: Amount of oil needed to refill system during normal inspection and maintenance.
NOTE:
(1) When fuel sulphur content is less than 0.5%, (2) When starting the engine is weathers temperature
change oil in the oil pan ebery periodic mainte- below 0ëC, be sure to use engine oil SAE 10W,
nance hours described in operation and mainte- SAE 20W-20, even if weather temperature goes
nance manual. up to 10ëC day time.
Change oil according to the following table if fuel (3) Use classification CD as engine oil, if use classifi-
sulphur content is above 0.5%. cation CC, reduce the engine oil change interval to
half.
Fuel sulphur content Oil change interval in engine oil pan
(4) Use original products, which have characteristics
0.5 to 1.0% 1/2 of regular interval specifically formulated and approved for the en-
gine, the hydraulic circuit of equipment and for re-
Above 1.0% 1/4 of regular interval ductions.
00-12
STRUCTURE AND FUNCTION
P.T.O. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . 10- 2 Swing motor . . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . . 10-25

Power train . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . 10- 3 Swing motor relief valve . . . .. . . . .. . . . . .. . . . . .. . . . . 10-26
Final drive - sprocket . . . .. . . . .. . . . . .. . . . .. . . . . .. . . 10- 4 Center swivel joint. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . . 10-27
Track frame. . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . 10- 5 Travel motor . . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . . 10-28
Idler and recoil spring . . .. . . . .. . . . . .. . . . .. . . . . .. . . 10- 6 Travel acceleration valve . . .. . . . .. . . . . .. . . . . .. . . . . 10-29
Carrier roller . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . 10- 7 Servocontrol feed unit . . . . . .. . . . .. . . . . .. . . . . .. . . . . 10-30
Track roller. . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . 10- 7 Swing motor braking circuit selector valve.. . . . . 10-32
Track shoe. . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . 10- 8 Accumulator . . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . . 10-33
Swing circle. . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . 10- 9 R.H. PPC valve . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . . 10-34
Swing machinery . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . 10-10 L.H. PPC valve . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . . 10-35
Check valve and oil cooler safety by-pass. . .. . . 10-11 Travel PPC valve .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . . 10-36
Hydraulic circuit diagram . . . . .. . . . . .. . . . .. . . . . .. . . 10-12 2nd boom PPC valve . .. . . . . .. . . . .. . . . . .. . . . . .. . . . . 10-37
Main hydraulic pump . . . .. . . . .. . . . . .. . . . .. . . . . .. . . 10-13 Boom swing PPC valve . . . . .. . . . .. . . . . .. . . . . .. . . . . 10-38
Pump drive . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . 10-14 Blade PPC valve .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . . 10-39
Summation horsepower control. . . .. . . . .. . . . . .. . . 10-15 Blade safety valve. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . . 10-40
3 circuit control valve . . . .. . . . .. . . . . .. . . . .. . . . . .. . . 10-18 Solenoid valves. . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . . 10-41
Mode-system . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . 10-20 Electrical circuit diagram (1 - Engine line) . . .. . . . . 10-43
Auxiliary pump . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . 10-21 Electrical circuit diagram (2 - Solenoid valve line) 10-45
Control valve (ports) . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . 10-22 Electrical circuit diagram (3 - Light line) . . . . .. . . . . 10-47
Control valve (valve) . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . 10-24
10-1
P.T.O.
2 1 3 4
A
5
6
15
14 7
13 8
12
11
9
10
A Section A - A
D0400002
1. Connecting plate 9. Pump plate

2. Crown wheel 10. Screw
3. Flywheel housing 11. Flywheel
4. Centering ring 12. Washer
5. Screw 13. Screw
6. Screw 14. Nut
7. Screw 15. Rubber
8. Hub
10-2
POWER TRAIN
1 4
9
D0400106
13 12 11 10
1. Swing motor 8. Travel motor

2. Swing machinery 9. Final drive and sprocket
3. Swing circle 10. Servocontrol feed unit
4. Control valve 11. Travel acceleration solenoid valve
5. Auxiliary pump 12. Center swivel joint
6. Main hydraulic pump 13. Idler
7. Engine
10-3
FINAL DRIVE - SPROCKET
a 20 21
1
2
3 4 5
9
10
11
12
17 16 15 14 13
19 18
D0400107
1. Sprocket 18. Floating seal

2. Screw 19. Screw
3. No. 2 planetary carrier 20. Coupling
4. No. 2 planetary gear (31 teeth) 21. Retainer
5. Ring gear (80 teeth)
6. Cover
7. No. 1 planetary gear (34 teeth)
8. Friction pad a. X4 Port - From swivel joint (1a Port)
9. No. 1 sun gear (10 teeth)
10. No. 1 planetary carrier
11. Level and refilling plug SPECIFICATIONS
12. Retainer Reduction ratio: 1 : 53
14. Disk brake Nominal torque: 600 daNm
15. Piston return spring Amount of oil: 1 ,
16. Piston
17. Disc pushing
10-4
TRACK FRAME
1 2 3 4
7 6 5
D0400108
1. Idler
2. Track frame
3. Carrier roller
4. Final drive
5. Track roller (No. 6)
6 Track shoe
7. Guard
10-5
IDLER AND RECOIL SPRING
1 A 3 4
2
10 5
9 6
8 7
D0400109
1. Idler SPECIFICATIONS
2. Recoil spring Amount of oil: 600 cc
3. Packing
4. Lubricator
5. Support
6. Pin
7. Bushing
8. Idler shaft
9. Floating seal
10. Lubricating plug
10-6
CARRIER ROLLER
2 3 4 5 6
8 1. Cover
2. Bearing
3. Roller
4. Seal
5. Collar
6. Shaft
7 7. Retainer
8. Lubricating plug
SPECIFICATIONS
Amount of oil: 120 cc
D0400110
TRACK ROLLER
3 4 5 6 7
1. Shaft
2. Pin
3. Support
4. Seal
5. Bushing
6. Lubricating plug
7. Roller
SPECIFICATIONS
Amount of oil: 250 cc
D0400111
2 1
10-7
TRACK SHOE
8 9 7 6
5 4
D0400112
1. Master bushing Standard shoe:

2. Master pin Widt: 450 mm
3. Master washer Link pitch: 140 mm
4. Regular pin
5. Regular bushing
6. Link
7. Shoe
8. Shoe bolt
9. Shoe nut
10-8
SWING CIRCLE
1 6
2 Section A - A
3 5
5
Detail A
B
A
8
A
Detail B
A
B D0400135
1. Swing circle outer race SPECIFICATIONS

2. Swing circle inner race Reduction ratio: 81
Ð = 7.36
3. Ball bearing 11
4. Pin Amount of grease: 18 kg
5. Screw
6. Screw
7. Nut
8. Grease nipple
10-9
SWING MACHINERY
11 12
10
13
9
a
8
14
7
15
6
16
5
17
4
18
3
19
2
1 D0400022
18
1. Swing pinion (11 teeth) 15. No. 1 planetary gear (31 teeth)
2. Case 16. No. 2 sun gear (18 teeth)
3. No. 2 planetary carrier 17. No. 2 planetary gear (29 teeth)
4. Drive gear (78 teeth) 18. Bearing
5. No. 1 planetary carrier 19. Drain plug
6. Brake disks a. C Port - From shuttle valve (B Port)
7. Piston guide
8. Piston
SPECIFICATIONS
9. Refilling and level plug
Reduction ratio: 1 : 33
10. Spring
11. Coupling Nominal torque:: 300 daNm
12. Support Amount of oil: 4 ,
13. Breather
10-10
CHECK VALVE AND OIL COOLER SAFETY BY-PASS
8 A
a
2
7
3
1
b
A B
B
6
Oil cooler
Hydraulic tank
4
5 Control valve
c
C T
D0400023
1. Valve body SPECIFICATIONS

2. Spring centering By-pass valve (3): 3 bar
3. By-pass valve Check valve (4): 2 bar
4. Check valve
5. Check valve seat
6. Check valve spring
7. By-pass valve spring
a. A Port - To tank
b. B Port - To oil cooler (A Port)
c. C Port - From control valve (T Port) and
swing motor (S Port)
10-11
HYDRAULIC CIRCUIT DIAGRAM
L.H. final drive with hydraulic motor R.H. final drive with hydraulic motor
Min. desplacement: min 26 cc/rev Min. desplacement: min 26 cc/rev
max 45 cc/rev max 45 cc/rev
Swing machinery with hydraulic motor
Theoretical displacement: 33 cc/rev B A
L.H.outrigger R.H..outrigger Boom Bucket Arm cylinder Boom swing

cylinder cylinder cylinder cylinder cylinder
C T
Blade
190/160 bar
190/160 bar
cylinder
A 8a 6a 7a 9a B
B X X1 A T X4 X5 X5 X4 T
4a 4a
8A 6A 7A 9A
C1 V1 4A 4A
C2 V2
5a 3a
2A 2a
EV3
1A 1a
5A 3A A P
B9
B T
M3 a10 A10 B10 a9 A9 C M2 a8 A8 B8 a7 A7 B7 a6 A6 B6 C6 a5 A5 B5 C a4 B3 A3 a3 C7 B2 A2 a2 B1 A1 a1 M1
P3
350 bar
350 bar
220 bar
320 bar
320 bar
300 bar
300 bar
300 bar
300 bar
320 bar
320 bar
320 bar
320 bar
280 bar
320 bar
280 bar
200 bar
b10 b9 P2 b8 b7 b6 b5 T b4 b3 b2 b1 P1
Servocontrol feed unit
0
Relief valve: 45 -4,5 bar
0
Reducing valve: 35 -3,5 bar
P3 T BV
EV4
EV5
P1 P2 PV PR
V=0.35 l
a1 b1 a8 b8 a7 b7 a6 b6 a5 b5 a3 b3 a2 a4 b2 a10 X X1 b10 a9 b9
P3 T P
A1
A3
Engine EV1
Perkins 1004.4 Brake
M3 X2 X3 R1
S1 A2 A2
C
DIESEL EV2
1 2 2 1 3 1 4 2 2 1 1 2 1 3 4 2 1 2
2 bar
P2 Travel 3 bar
acceleration
A B A Boom Bucket Arm Swing
P T P T P T P T P T P T P T
B
P1
A1
S Boom swing 2nd boom R.H. PPC valve L.H. travel R.H. travel L.H. PPC valve Blade PPC valve
PPC valve PPC valve PPC valve PPC valve
G R2
Main hydraulic pump
Max. discharge: 2x74 l/1'
Max. unitary displacement: 28 cc/rev
10-12
MAIN HYDRAULIC PUMP
b
b c
4
a d
e 5
D0400024
1. Drive SPECIFICATIONS
2. Pump case Max. unitary displacement: 28 cc/rev.
3. Power control Max. power at 2000 rpm: 44 kW
4. 3 circuit control valve Max. pressure: 350 bar
5. Mode-system Max. delivery: 2x74 ,/1'
a. S Port - To tank
b. A2 Port - To control valve (P2 Port) and to ser-
vocontrol feed unit (P1 Port)
c. A1 Port - To control valve (P1 Port) and to ser-
vocontrol feed unit (P3 Port)
d. X3 Port - From P3 pump (A3 Port)
e. X2 Port - From servocontrol feed unit (PR Port)
10-13
PUMP DRIVE
11
5
6
4
2
A
1
12
10
Transmission diagram
14 View A 13
8 7 D0400025
1. Drive shaft Pump gear ratio: 1 : 1.354

2. Seal ring
3. Snap ring
4. O-Ring
5. Bearing
6. Auxiliary drive
7. Bearing
8. Bearing
9 Ring nut
10. Snap ring
11. P3 - P4 pump gear (48 teeth)
12. Inlet gear (65 teeth)
13. P1 pump gear (48 teeth)
14. P2 pump gear (48 teeth)
10-14
SUMMATION HORSEPOWER CONTROL
4
5
2
3
6
7
8
1 2
15 9
14 10
13 11
12
P1 P2
Section A - A
D0400026
1. Pressure overanging valve FUNCTION

2. Control piston . The automatic governor at power addition is a reg-
3. Lever fulcrum ulatory device that comes into action in function of
4. Calibration spring the working pressure that continuously positions
5. Min. displacement stop the two mechanically coupled pumps P1 and P2,
in order to vary displacement between a minimum
6. Piston return spring and a maximum value.
7. Lever Delivery varies in function of the system pressures
8. Bearing to ensure that a constant torque is obtained from
9. Control piston the main engine.
10. Swivel fork
P (bar)
11. Positioning piston
350
12. Max. displacement stop
13. Mode-system group 300
14. 3 circuit control valve 250

15. Push rod 200
150
100
50
25 50 75 100 Q (l/min)
D0400027
10-15
OPERATION
1 - Operation when an increase of pressure is required.
A
R1 R2 2
4 h 5 A2 A3
2 A1 c
3
c
6
7
Z
15 10 a P1 b P2
Section A - A
e d 9
14 11
g
13
12
Detail Z D0400028
. The delivery pressures of pumps P1 and P2 are . If the pressure value in chamber c is less than Pm,
transmitted to two separate chambers, a and b, the control rod (2) moves and the check valve R1 of
and act on a floating control piston (2) with two chamber a which has a higher pressure, opens to
equal surfaces A1 and A2 and a third, A3, that cor- pressurize the control circuit until this pressure
responds to the sum of the first two, according to equals the circuit pressure at a value Pm; once
the relation: A1 + A2=A3 . pressure has been stabilized the check valve R1
Pressure differences between the two pumps, and closes in order to allow passage of the amount of
therefore in the two chambers a and b which are oil drained through the clearance h existing be-
in direct communication with surfaces A1 and A2, tween the positioning piston (11) and its slideway
creates a pressure signal corresponding to the ar- and guide.
ithmetic mean of the two pressures according to . The oil passing through the check valve R1 into
the relation: chamber c, also pressurizes line d within which is
P1+P2 housed the control piston (9) that presses down
ÐÐÐÐ = Pm on the lever (7).
2
Pressure generates a force on the surface of the
NOTE - The following example considers an in- control piston (9) causing it to move and push
crease in pressure in pump P1; the same example against the calibration spring (4).
remains valid for a pressure increase for pump P2
(check valve R2).
10-16
. The movement of the control piston (9) opens pas- generated by the force of the spring (4) and the
sage e thus pressurizing the lower chamber g of force generated by the pressure on the control pis-
the positioning piston (11) and forcing it to rise. This ton (9).
reduces the angle of the pump cylinder blocks and . Once equilibrium between the moments has been
therefore also reduces the delivery. reached the control piston (9) closes the passage
The movement of the positioning piston (11) also that communicates with the lower chamber of the
moves the control piston (9) so that its position positioning cylinder.
changes with respect to the fulcrum of the lever (7).
. Equilibrium is maintained until a positive or nega-
. The positioning piston ends its stroke when parity tive variation occurs in the pressure required from
has been re-established between the moments one or both pumps.
2 - Operation when pressure is reduced
A
h R1 R2 2
4 A2 A3
5
2 A1 c
3
c
d
7
6
X
15 a P1 b P2
Section A - A
10
8 9
e
14
11
g
13
12 e
D0400029
Detail X
NOTE - The example considers a reduction in pres- ment opens the line e thus releasing pressure and,
sure in pump P1 and assumes a condition of equi- due to the thrust exerted by the spring (6), also
librium throughout the control system. withdrawal of the oil present in the lower chamber
g of the positioning piston (11).
. When the pump is asked to provide lower pressure
and pressure drops in chamber a, the measuring . The descent of the piston and the resulting in-
piston (2) moves to the left, pushed by the action crease in pump displacement continues until the
of the mean pressure Pm on surface A3. equilibrium between the pressures acting on the
control rod (2) has been fully recovered, i.e. until
. Delivery to chamber c and line d is reduced and
re-establishment of the mean pressure Pm and
pressure therefore decreases due to a steady leak-
the equilibrium of the moments acting on the lever
age of oil through clearance h between the posi-
(7).
tioning piston (11) and its guide.
. The control piston (9) is moved by the thrust ex-
erted by the spring (4) on the lever (7). This move-
10-17
3 CIRCUIT CONTROL VALVE
2 6
4
1
D0400030
1 3 circuit control valve piston FUNCTION

2. Push rod
. The 3 circuit valve limits the pre-established maxi-
3. Calibration spring mum torque of the endothermic motor when, in ad-
4. Positioning piston dition to the torque required from pumps P1 and
5. Lever P2, a pressure increase is also demanded of the
6. Control piston auxiliary pump P3 which provides for cabin rota-
tion, the servocontrol powering group and the
blade.
a. X3 Port - From P3 pump (A3 Port)
. The pressure signal that causes a reduction in the
displacement of pumps P1 and P2 in function of
the pressure needed by the devices powered by
pump P3, is taken directly from the circuit.
10-18
OPERATION
5 d
6
2
e
h 4
g
1
P (bar)
350
300
D0400032
250
200
150
100
50
25 50 75 100 Q (l/min)
D0400031
NOTE - This example describes the influence ex- moves the control piston (6). This movement frees
erted by cabin rotation because it is the most sig- passage e and oil flows into the lower chamber g
nificant, but the concept is also valid for the other of the positioning piston (4), giving rise to a se-
circuits coupled to pump P3. quence of reduced delivery from pumps P1 and
. Activation of the command for cabin rotation de- P2 and therefore also a reduction of their absorbed
mands maximum pressure from the auxiliary pump power. Once cabin inertia has been overcome, the
P3 because the hydraulic rotation motor needs the pressure required for rotation diminishes, the load-
maximum torque to overcome inertia. ing on the calibration spring (3) lessens, and a new
The pressure signal is transmitted to chamber h constant modulation of the delivery of pumps P1
and acts on the piston (1) through the push rod and P2 commences, until the system has returned
(2), acting directly on the lever (5) which is subject to a state of equilibrium.
to counterpressure from the calibration spring. (3). . The return to rest of the control piston (6) and the
Rotation of the lever (5) interrupts the equilibrium of push rod (2) corresponds to the termination of ca-
the moments and the pressure present in line d bin rotation.
10-19
MODE-SYSTEM
P (bar)
350
300
4
250
200
j 150
100
50
3
25 50 75 100 Q (l/min)
D0400034 D0400033
8 1 2
1. Mode-system piston SPECIFICATIONS

2. Limit stop Calibration power: 70% engine nominal
3. Spring horsepower (30.8 kW)
4. 3 circuit control valve piston
OPERATION
5. Push rod
When the operator selects this mode of operation he
6. Calibration spring
activates the EV5 with a switch (S9); the oil (at the
7. Lever same pressure as the servocontrols) enters chamber
8 Locking nut j and pushes the control piston (1) down to its limit
stop (2).
a. X2 Port - From servocontrol feed unit (EV5) This movement compresses the spring (3) which in
(PR Port). turn pushes up the piston (4) containing the seating
of the push rod (5) that compresses the calibration
FUNCTION spring (6) of the control system for the power absorbed
by pumps P1 and P2.
. This group reduces the absorbed power of pumps Compression of the calibration spring (6) causes the
P1 and P2, in a set manner, independently of the lever (7) to rotate and this torque gives rise to the se-
required working pressure. quence of movements that coordinate the power lim-
. The pressure signal needed to reduce power is in- itation.
terpreted by a switch-activated solenoid valve EV5 The mode-system group can be regulated to reach the
belonging to the servocontrol power group. percentage of power absorbed by pumps P1 and P2 by
acting on a lock-nut (8) that calibrates the spring (3).
10-20
AUXILIARY PUMP
1 2
D0400113
1. Drive shaft SPECIFICATIONS

2. P3 pump body Theoretic displacement: 22.9 cm3/rev.
3. Cover Discharge at 2000 rpm: 58 ,/1'
Nominal pressure: 200 bar
a. A3 Port - To control valve (P3 Port), Max. pressure: 245 bar
to circuit valve (X3 Port) and
servocontrol (P2 Port)
b. S1 Port - From tank
10-21
CONTROL VALVE (Ports)
a b c d
j i h g f e
k l m n o p q r s
dd cc bb aa z y x w v t
ee ff gg hh ii jj
nn mm ll kk
oo pp tt qq rr ss
D0400114
10-22
a. b4 Port - From R.H. PPC valve (1 Port)
b. b3 Port - From R.H. travel PPC valve (2 Port)
c. b2 Port - From L.H. PPC valve (3 Port)
d. b1 Port - From swing boom PPC valve (2 Port)
e. b5 Port - From R.H. travel PPC valve (1 Port)
f. b6 Port - From R.H. PPC valve (2 Port)
g. b7 Port - From R.H. PPC valve (1 Port)
h. b8 Port - From 2nd boom PPC valve (1 Port)
i. b9 Port - From blade PPC valve (2 Port)
j. b10 Port - From L.H. PPC valve (2 Port)
k. A10 Port - To swing motor (B Port)
l. A9 Port - To center swivel joint (5A Port)
m. A8 Port - To 2nd boom cylinder bottom side
n. A7 Port - To boom cylinder side and control valve (C Port)
o. A6 Port - To bucket cylinder bottom side
p. A5 Port - To center swivel joint (8A Port)
q. A3 Port - To center swivel joint (9A Port)
r. A2 Port - To arm cylinder head side
s. A1 Port - To boom swing cylinder head side
t. B1 Port - To boom swing cylinder bottom side
v. B2 Port - To arm cylinder bottom side
w. B3 Port - To center swivel joint (7A Port)
x. C Port - To boom cylinder bottom side and control valve (A7 Port)
y. B5 Port - To center swivel joint (6A Port)
z. B6 Port - To bucket head side
aa. B7 Port - To boom cylinder head side
bb. B8 Port - To 2nd boom cylinder head side
cc. B9 Port - To center swivel joint (3A Port)
dd. B10 Port - To swing motor (A Port)
ee. a10 Port - From L.H. PPC valve (4 Port)
ff. a9 Port - From blade PPC valve (1 Port)
gg. a8 Port - From 2nd boom PPC valve (2 Port)
hh. a7 Port - From R.H. PPC valve (3 Port)
ii. a6 Port - From R.H. PPC valve (4 Port)
jj. a5 Port - From L.H. travel PPC valve (2 Port)
kk. a1 Port - From swing boom PPC valve (1 Port)
ll. a2 Port - From L.H. PPC valve (1 Port)
mm. a3 Port - From R.H. travel PPC valve (1 Port)
nn. a4 Port - From L.H. PPC valve (3 Port)
oo. P3 Port - From auxiliary pump (A3 Port)
pp. P2 Port - From main pump (A2 Port)
qq. T Port - To by-pass valve (C Port)
rr. C7 Port - To EV3 (P Port)
ss. P1 Port - From main pump (A1 Port)
tt. C6 Port - From EV3 (A Port)
10-23
CONTROL VALVE (Valve)
9 5 3 2 6
8 10 3 2 6 1
6
8 10 9 7
4 1 5 2 3
D0400115
2 3
1. Relief/anti-cavitation valve (280 bar) 6. Anticavitation valve

2. Relief/anti-cavitation valve (300 bar) 7. Check valve
3. Relief/anti-cavitation valve (320 bar) 8. Anticavitation valve
4. Relief/anti-cavitation valve (200 bar) 9. Check valve
5 Anticavitation valve 10. Plug
10-24
SWING MOTOR
e 1
c d X f
2 2 b
a
D0400039
1. Motor SPECIFICATIONS
2. Relief valve Theoretic displacement: 32 cc/rev.
Swing motor relief valve
a. A Port - From control valve (B10 Port)
Rated pressure: 160-190 bar at 50 ,/1'
b. B Port - From control valve (A10 Port)
c. X Port - From L.H. PPC valve (4 Port)
d. X1 Port - From L.H. PPC valve (2 Port)
e. T Port - To tank
f. S Port - To check valve (C Port)
10-25
SWING MOTOR RELIEF VALVE
1. Piston
1 2. Plunger
3. Spring
4. Pilot valve
2 5. Main valve
6. Orifice
7. Spring
3 a. Pilot system port (From control valve

a10 - b10 port)
4 Measured at V=41 mm2/s and t=50°C

10
Pressure difference (Dp bar)
7 8
5
6
6 4
0
D0400040 0 20 40 60 80 100
Flow Q (l / min)
FUNCTION AND OPERATION D0400152
The function of these valves is to protect the engine

from pressure peaks and extreme pressure drops
due to sudden interruptions in cabin rotation. Protec-
tion consists of transferring amongst the various lines
either the amount of oil that has caused a pressure
peak, or the amount of oil required to prevent the ca- 1
vitation phenomenon.
Function of the safety valve

. In normal conditions valves (4) and (5) are closed.
When the pressure of line b (higher than the cali-
brated value) is transferred to chamber a through
a nozzle (6), the pilot valve (4) opens to allow the 3
pressurized oil to flow through a hole c. The pres-
sure in line b acts on the main valve (5) which
opens to allow passage of the oil-flow in line b to c
line d.
4
Function of the anti-cavitation valve
a
. When there is pressure in line d and a vacuum in
line b the pressure in line d acts on the main valve 5
(5) which is opened to allow communication be-
tween lines b and d. d 6
. The pilot system pressure that acts on the control
valve shuttling that governs cabin rotation is also
transmitted to the piston (1). When the piston
moves it increases the load on the spring (3) of
b
D0400041
the pilot valve in proportion to the pressure needed
for rotation.
10-26
CENTER SWIVEL JOINT
Front of machine
Inlet axis
2 1 2A-4A
3
2a 6a
8a
4
9A
5 3a
7A 1a
8A
5A
6A Inlet axis
4A 6A-8A
Inlet axis
6 7A-9A
3A 9a
7 4a
7a
2A 5a
8
1A Inlet axis
1A-3A-5A
10 D0400116
View X
9
1. Screw
2. Grease nipple
3. Cover
X 4. Guard ring
5. O-Ring seal
6. Seal
7. Rotor
8. O-ring seal
9. Body
10. Guard ring
1A. From EV1 (A1 Port) 1a. To travel motor (X4 Port)
2A. From EV2 (A2 Port) 2a. To travel motor (X5 Port)
3A. From control valve (B9 Port) 3a. To blade cylinder relief valve (V1 Port)
4A. To tank 4a. From travel motor (T Port)
5A. From control valve (A9 Port) 5a. To blade cylinder safety valve (V2 Port)
6A. From control valve (B5 Port) 6a. To L.H. travel motor (B Port)
7A. From control valve (B3 Port) 7a. To R.H. travel motor (B Port)
8A. From control valve (A5 Port) 8a. To L.H. travel motor (A Port)
9A. From control valve (A3 Port) 9a. To R.H. travel motor (A Port)
10-27
TRAVEL MOTOR
d 2
a 1 D0400117
1. Motor SPECIFICATIONS
2. Travel acceleration valve
Max. displacement: 45 cc/rev.
Min. displacement: 26 cc/rev.
L.H. TRAVEL MOTOR R.H. TRAVEL MOTOR

a. T Port - To center swivel joint (4a Port) a. T Port - To center swivel joint (4a Port)
b. A Port - To center swivel joint (8a Port) b. A Port - To center swivel joint (9a Port)
c. B Port - To center swivel joint (6a Port) c. B Port - To center swivel joint (7a Port)
d. X5 Port - To center swivel joint (2a Port) d. X1 Port - To center swivel joint (2a Port)
10-28
TRAVEL ACCELERATION VALVE
3 7
4
2 8 a D0400118
OPERATION In this condition the same pressure that moves the ra-
dial pistons (3) of the motor, causes the piston (4) to
NOTE
move and thus, through the push-rod (5) moves the
1 - The valve (1) selects the circuit under pressure floating plate (6) to the end of the stroke against the
that will rotate the motor to the right or to the stop (7) that determines the minimum displacement.
left. The condition of minimum displacement (correspond-
2 - The example takes into consideration passing ing to the maximum travel speed) is maintained
from lowspeed travel (max. displacement and throughout the time that EV2 remain energized; when
torque) to high-speed travel (min. displacement this valve is no longer energized the spring (8) return
and torque) with a constant pump delivery. the piston rod (2) to its end or stroke positions and
When EV2 is energized, the pressure of the servocon- puts lines b and d into communication to relieve the
trols acts on the head of the piston rod (2) of the travel pressure that maintained the condition of minimum
acceleration valve which causes it to move, thus creat- displacement.
ing a communication between lines a and b.
10-29
SERVOCONTROL FEED UNIT
1
C
b
a
A A
d c
2
3 4 C
D0400047
e f
1. Relief servocontrol solenoid valve (EV4)

2. Mode-system solenoid valve (EV5) B B
3. Relief valve
4. Reducing valve
5. Accumulator
g
a. P2 Port - From P3 pump (A3 Port) SPECIFICATIONS

b. PR Port - To mode-system (X2 Port) Relief valve (3):
0
45 ± 4.5 bar
c. BV Port - To PPC valves (P1 Port) Reducing valve (4):
0
35 ± 3.5 bar
d. T Port - To tank
e. PV Port - To EV1-EV2 solenoid valve (P Port)
f. P1 Port - From P2 pump (A2 Port)
g. P3 Port - From P1 pump (A1 Port)
10-30
10 7
11
Section C - C
8 9 12 D0400048
1
Section B - B
Section A - A
6. Selector valve (P1 e P3) OPERATION

7. Selector valve (P2) The pressurized oil coming from pumps P1, P2 and
8. Relief valve P3 to the ports P1, P2 and P3 feeds the servocontrols
and the auxiliary services through the circuit selection
9. Relief valve spring
valve (6-7).
10. Check valve The high pump pressure is reduced to the operating
11. Reducing valve pressures of the servocontrols by the fixed calibration
12. Reducing valve spring reducing valve (4) that charges the accumulator (5)
through check valve (10) and supplies the solenoid
valves EV4 and EV5 with the oil delivery required to
allow the servocontrols and the auxiliary circuits to
function.
The circuits supplied by this group are protected by
the overpressures of the safety valve (3).
10-31
SWING MOTOR BRAKING CIRCUIT SELECTOR VALVE
2 3 1 2
A
c a
A
b D0400050
Section A - A
1. Body
2. Valve seat
3. Ball
a. A Port - From L.H. PPC valve (4 Port)

b. B Port - To swing machinery brake (C Port)
c. C Port - From L.H. PPC valve (2 Port)
10-32
ACCUMULATOR
D0400051
TECHNICAL DATA FUNCTION

. A rubber bag (1) containing nitrogen gas is used in
Servocontrol feed group:
the accumulator. Its function is to maintain oil pres-
Nominal volume: 0.35 , sure in the circuit to which the accumulator is con-
Pre-set pressure:
0
12 +1 bar nected.
Working pressure: 35345 bar
OPERATION
. When the engine is running, the chamber A of the

rubber bag (1) (containing nitrogen) is compressed
by the pressurized oil from line B.
. If the oil pressure in line B falls below the maximum
calibration pressure (even after intensive use), the
rubber bag (1) will expand due to the pressure of
the nitrogen inside it.
10-33
R.H. PPC VALVE
4
Front of machine
a c b
1
f e d
View Z
Operating curve c port

3
bar
P.C.
+3
19,5 0
+0
5,8 -0,7
0
0,9 6,4 7,5560,3 PLUNGER
Z MOUVEMENT (mm)
D0400052 D0400140
Operating curve e port Operating curve d - f ports
bar bar
P.C. P.C.
+3 +2,5
25 0 25 0
0
7 -1
0
6 -0,7
0 0
0,975 6,475 7,5560,3 PLUNGER 0,975 6,475 7,5560,3 PLUNGER
MOUVEMENT (mm) MOUVEMENT (mm)
D0400148 D0400149
1. Control lever
2. Rubber gaiter
3. Body
4. Electrical conctat
a. P Port - From servocontrol feed unit (BV Port) d. 4 Port - To bucket control valve (a6 Port)
b. T Port - To tank e. 3 Port - To boom control valve (a7 Port)
c. 1 Port - To boom control valve (b4 - b7 Port) f. 2 Port - To bucket control valve (b6 Port)
10-34
L.H. PPC VALVE
1
Front of machine
a c b
3 f e d
View Z
Z
D0400139
Operating curve c - e ports Operating curve d - f ports

bar bar
P.C.
+3
24 0
+2,5
25 0
0 +0,3
6 -0,7 5,5 -0,3
0 0
0,975 6,475 7,5560,3 PLUNGER 0,975 6,475 PLUNGER
MOUVEMENT (mm) MOUVEMENT (mm)
D0400149 D0400150
1. Control lever
2. Rubber gaiter
3. Body
a. P Port - From servocontrol feed unit (BV Port) d. 2 Port - To swing motor control valve (b10 Port)
b. T Port - To tank e. 3 Port - To arm control valve (a4 - b2 Port)
c. 1 Port - To arm control valve (a2 Port) f. 4 Port - To swing motor control valve (a10 Port)
10-35
TRAVEL PPC VALVE
c d
1
°
12
L.H. version R.H. version

2
12°
5 4
b
3
D0400119
Operating curve
bar
P.C.
1. Pedal 19
+3
0
2. Support
3. Control unit
4. Adjustable stop
+0
5. Rubber jacket 5,8 -0,7
0
0,9560,22 4,9560,32 5,860,25 PLUNGER
MOUVEMENT (mm)
0
2° 10° 12° PEDAL
DEFLECTION (degree)
D0400141
R.H. PPC VALVE L.H. PPC VALVE
a. P Port - From EV4 (BV Port) a. P Port - From EV4 (BV Port)
b. T Port - To tank b. T Port - To tank
c. 1 Port - To control valve (a3 Port) c. 1 Port - To control valve (b5 Port)
d. 2 Port - To control valve (b3 Port) d. 2 Port - To control valve (a5 Port)
10-36
2nd BOOM PPC VALVE
°
c d
12
1
12°
4
5
b 2
a 3
D0400055
1. Pedal Operating curve

2. Support bar
3. Control unit
P.C.
4. Adjustable stop +3
19
5. Rubber jacket
0
a. P Port - From EV4 (BV Port)

b. T Port - To tank +0
5,8 -0,7
c. 1 Port - To control valve (b8 Port) 0

d. 2 Port - To control valve (a8 Port) 0,9560,22 4,9560,32 5,860,25 PLUNGER
MOUVEMENT (mm)
0
2° 10° 12° PEDAL
DEFLECTION (degree)
D0400141
10-37
BOOM SWING PPC VALVE
c d
4
12° 12°
b 2
a 3
D0400057
1. Pedal Operating curve

2. Support bar
3. Control unit
P.C.
4. Adjustable stop +3
19
5. Rubber jacket
0

b. T Port - To tank +0
5,8 -0,7
c. 1 Port - To boom swing control valve (a1 Port) 0

d. 2 Port - To boom swing control valve (b1 Port) 0,9560,22 4,9560,32 5,860,25 PLUNGER
MOUVEMENT (mm)
0
2° 10° 12° PEDAL
DEFLECTION (degree)
D0400141
10-38
BLADE PPC VALVE
a b
c
20°
d
20°
2 1
D0400058
Operating curve
1. Operating bar
2. Control unit P.C.

b. T Port - To tank 19
+3
0
c. 1 Port - To control valve (a9 Port)

d. 2 Port - To control valve (b9 Port)
+0
5,8 -0,7
0
0,9 5,1 6 PLUNGER
MOUVEMENT (mm)
0
3°15' 21°24' 25° ROCKER LEVER
DEFLECTION (degree)
D0400142
10-39
BLADE SAFETY VALVE
a b
c d
D0400060
a. V2 Port - From center swivel joint (5a Port) SPECIFICATIONS

b. V1 Port - From center swivel joint (3a Port) Start opening: 8 bar
c. C2 Port - To blade cylinder bottom side
d. C1 Port - To blade cylinder head side
16
14
12
10
2
8 ➔C
V2
6 V2
C2➔
4
2
0
0 6 12 18 24 30
Flow Q (l / min)
D0400143
10-40
SOLENOID VALVES
FOR TRAVEL MECHANICAL BRAKE - TRAVEL ACCELERATION
2 3
1
a
D0400120
c d
1. Block 20
2
2. EV1 brake
3. EV2 travel acceleration

3
a. P Port - From feed unit (PV Port) 10

b. T Port - To tank
c. A1 Port - To center swivel joint (1A Port)
d. A2 Port - To center swivel joint (2A Port)
0
0 10 20 30 40
Flow Q (l / min)
D0400153
10-41
FOR STRAIGHT TRAVEL (EV3)
a b
d c
D0400068
Measured at V=41 mm2/s and t=50°C

a. P Port - From control valve (C7 Port) 3
b. A Port - To control valve (C6 Port) 10
c. T Port - Plug 8
d. B Port - Plug
6
0
0 20 40 60 80
Flow Q (l / min)
D0400151
10-42
ELECTRICAL CIRCUIT DIAGRAM
1 - ENGINE LINE
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
3 4
X6 B-N 1 See solenoid valves line
K1 D
P2-1
G 1 See light line
G-R 1
B/N 1
K2
R 2.5
A 2.5
V-N 1
A 2.5
P3-1
OFF ACC
15 ACC. BR R2 C F 1S F 3S F 6I F 8S F 11S
R1 ST
S1 1 2 3 4 5 6 7 8 9 10 11 12 13 1 2 3 4 8
O V
1 2 B
7.5A 3A
X8 X9 15A 3A 3A
X22
X6
G/R 1
G/R 1
G-R 1
B/N 1
Z/B 1
Z-B 1
G/N1
A1 +-
N 1
R 1
G 4
S 1
V 1
V 4
H 1
L 4
R 2.5
R 2.5
X3
G 4
R 4
R 4
V 4
9
H-N 1
V-B 1
G/N1
V-N 1
Z-B 1
Z/B1
H 1
V 1
S 1
V 1
S 1
15 9
11
15
G 1 2 3 4 5 6 7
A-V1 6
A-V0.5 7
G 1 2 3 1 3 4 13
X1 X2 X11 X7 X3 9
G 0.5 13
G 1 2
G 0.5 16
B-N 1 B-N0.5
R 4
V 4
G-R 1
G/N 1
H-N 1
V-B 1
V-N 1
Z/B 1
Z/B 1
Z-B 1
G 4
R 4
H 1
V 1
S 1
10 12
Z 1
V 1
S 1
N 1 1
N 0.5 14
-
+
0000000h
G-V 1 4
L-G0.5 4
+ Z-B 1 3
Z-B0.5 8
V-N 1 M 0.5
B1 12Vcc Fu V V 1
5
7
V 0.5
3
2
5
50 A R 1 R 0.5
- X3
8 6
H-N 1 11
H 0.5 10
V-B 1 12
L 0.5 5
R 50
S 1
L6
13 1
X4 X5
OFF
LO
N 50
Z/B 1
G 4
OFF
Fu V HI 1
G-R 1
H-N 1
V-B 1
N 1
N 1
V 4
V 1
S 1
Z 1
H1
B 4 B 4 2
80A
D+
R1 S2 S3 S4 S5 EV 1 2
M1
30
M 50
G1 3
B+
G W
X 10
U
N 1
N 1
N 1
COMPONENTS CONNECTORS FUSE S: F1 - Stop engine solenoid valve
B1 - Battery X1 - 2-ways connector engine-main box line F3 - Buzzer (under operator's seat)
G1 - Alternator X2 - 2-ways connector engine-dashboard line F8 - Control panel
FuV - Fuse X3 - 17-ways connector starter switch-dashboard line F11 - Pre-heater box
M1 - Starter motor X4 - 13-ways connector R.H. dashboard-control panel line
R1 - Pre-heater X5 - 16-ways connector control panel FUSE I: F6 - Pre-heater
K1 - Diode box X6 - 4-ways connector R.H. dashboard-main box line
K2 - Pre-heater box X7 - 7-ways connector engine-dashboard line
A1 - Buzzer X8 - 13-ways connector diode box
EV - Stop engine solenoid valve X9 - 8-ways connector preheater box
S1 - Starter switch X11 - 3-ways connector engine-main box line
S2 - Air filter clogging sensor
S3 - Engine oil low pressure sensor
S4 - Coolant high temperature sensor
S5 - Coolant temperature sensor
10-43
2 - SOLENOID VALVE 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
X6 3 4
B-N 1 1
A-N1.5
See engine line 3A
P1-19 X24
R 2.5
A 2.5
A 2.5
15 30 L 15 30 L
F2S 15 ACC. BR R2 C
F10S F 6S F 2I F 9S 1 0
F 1I 1 0 2
F 4I
OFF
OFF
OFF ACC
S13 S10
ON
ON
R1 ST
7.5A 7.5A 10A 7.5A 7.5A 10 A 10 A

1 2 B
49 30b R
S17
49 30b R
S8
S11
X6
L-N1.5
S1
S-G1.5
R-V 1
R-V 1
H/R 1
R/N 1
A/R 1
L-R 1
S9
H 1.5
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 O V 1 2 3
R 2.5 A F E B
X16 X25
A-N1.5
10
L-N1.5
R/N 1
A/R 1
Z-B 1
L/G 1
Z-B 1
N 1
N 1
R 2.5 1 2
X3 3A
4 3
X13
X13
1
16 14 7
L/R 1 X26
X3 6
X3
A-N1.5
L-N1.5
B-N 1
S-G1.5
A-N1.5
M/B 1
B-N 1
L/G 1
H-G1.5
L/R 1
H 1.5
M/B1
A-V1.5
H 1.5
R 4
R 4
M-N1.5
M-B1.5
Z-N1.5
V-N1.5
L-R 1
86 87 87b
G 1
G 5 9 6 3 4 5 6 11 12 13 1 2 3 4
X1 X2 X17 X12 K3 85 30 X17 X18
H-G1.5
S-G1.5
A-N1.5
A-V1.5
R 4
M/B 1
B-N 1
H/R 1
L/G 1
L-R 1
H 1.5
L/R 1
M-N1.5
M-B1.5
Z-N1.5
V-N1.5
R 4
N 1
H 1.5
+
B1 12Vcc Fu V
M-B1.5
M-N 1
50 A
-
S12
R 50
L6
S6
H 1.5
L/R 1
B-N 1
H-G1.5
A-V1.5
N 1
N 50
3 4 B A B A 1 2 3
X28 X14 X15 X23
M-N1.5
S-N1.5
Z-N1.5
V-N1.5
A-N1.5
M/B 1
L/G 1
L-R 1
S18
A2 EV1 EV2 EV3 EV4 S7 EV5 EV6 EV8 EV7
M1
30
M 50
1A 1A 1A 1A 1A
I1 1A 1A 1A
S-G1.5
N 1.5
N 1.5
N 1.5
N 1.5
N 1
N 1
N 1
N 1
N 1
COMPONENTS CONNECTORS
B1 - Battery S6 - Travel acceleration switch X1 - 2-ways connector engine-main box line X26 - 1-way connector diode
FuV - Fuse S7 - Relief servocontrol switch X2 - 2-ways connector engine-dashboard line X27 - 2-ways connector dashboard-main box line
M1 - Starter motor S8 - Travel brake switch X3 - 17-ways connector starter switch-dashboard line X28 - 4-ways connector working lamp
K3 - 2nd speed relay S9 - Mode-system switch X6 - 4-ways connector R.H. dashboard-main box line
I1 - Fuel level sensor S10 - Horn switch X12 - 13-ways connector solenoid valves-main box line
A2 - Horn S11 - Rotary and cutting shovel X13 - 7-ways connector main box- dashboard line FUSE S: F2 - Servocontrol
EV1 - Travel brake solenoid valve switch X14 - 2-ways connector relief servocontrol F6 - Straight travel and travel acceleration
EV2 - Travel acceleration solenoid valve S12 - Hammer switch X15 - 2-ways connector Mode-system F9 - Mode system
EV3 - Straight travel solenoid valve S13 - Straight travel switch X16 - 2-ways connector horn F10 - Travel brake
EV4 - Relief servocontrol solenoid valve S17 - Overload switch (optional) X17 - 7-ways connector solenoid valve-R.H. dashoboard line
EV5 - Mode-system solenoid valve S18 - Overload sensor (optional) X18 - 1-way connector solenoid valves line
EV6 - Bucket R.H. rotation solenoid valve X23 - 3-ways connector fuel level sensor FUSE I: F1 - Horn
EV7 - Bucket L.H. rotation solenoid valve X24 - 1-way connector overload sensor F2 - Travel acceleration
EV8 - Hammer solenoid valve X25 - 3-ways connector hammer and rotating and cutting F4 - Hammer and rotating and cutting shovel
S1 - Starter switch shovel switch
10-45
3 - LIGHT LINE 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
3 4
X6
B 2.5
B 2.5
R 2.5
R 2.5
A 2.5
A 2.5
15 30 L
F 9I F 10I F 4S F 8I F 7I F 5I F 11I
OFF
F 7S
ON
15 ACC. BR R2 C 2 1 0 2 1 0
OFF ACC
R1 ST F 3I
S1 S15 49 30b R
7.5A 15A 10A 15A 10A 7.5A 10A 7.5A
1 2 B
10A
X6 S14 S16
G-N1.5
Z-G1.5
B-R1.5
1 1 2 3 4 5 6 7 8
A F E B C A F E B C
R 2.5
X29
G-R1.5
G-R1.5
R-N1.5
B-R1.5
C-V1.5
L-R1.5
17
M 1.5
R 1.5
B 1.5
G 1
N 1
N 1
R-N 1
B-G 1
B 1.5
R 2.5
X3
7
5 X13 12
X3
X13 X13
6
G-R1.5
1
See engine line
B-G1.5
B-G1.5
B-R1.5
R 4
R 4
B-G 1
M 1.5
M 1.5
M 1.5
M 2.5
G 1
B 1.5
B 1.5
B 1.5
B 2.5
M 1
B 1
P1-19 2
K5
G 2 8 11 86 87 87b 86 87 87b 86 87 87b
G 1 2 7 8 9 10
X1 X2 X12 X3 85 30 85 30 K6 85 30
K4
B-G1.5
B-R1.5
Z-G1.5
R 4
B-G 1
M 1.5
M 1.5
R 2.5
R 2.5
B 1.5
B 1.5
R 4
N 1
N 1
N 1
M1
B1
R-N1.5
B-G1.5
B-G1.5
B-R1.5
R-N 1
N 1.5
+ 1 2 3 6 4 7
B1 12Vcc Fu V
50 A X20
-
R 50
L6
C-V1.5
L-R1.5
N 1.5
B-G1.5
N 50
B-R1.5
M 1.5
M 1.5
B 1.5
B 1.5
1 2 1 2 3 4
X28 X21
L1 L2 P1
L3
M1
30
M 50
M2 M
N 1.5
N 1.5
N 1.5
N 1.5
N 1.5
N 1
COMPONENTS CONNECTORS FUSE S: F4 - Beam
B1 - Battery X1 - 2-ways connector engine-main box line F7 - 15 Cabin
FuV - Fuse X2 - 2-ways connector engine-dashboard line
P1 - Electric socket X3 - 17-ways connector main box-dashboard line FUSE I: F3 - Heating
M1 - Starter motor X6 - 4-ways connector R.H. dashboard-main box line F4 - Hammer and rotating and cutting
M2 - Heating fan motor X12 - 13-ways connector solenoid valves-main box line shovel
K4 - Optional working beam relay X13 - 7-ways connector main box-dashboard line F5 - 30 Cabin
K5 - Driving beam relay X20 - 7-ways connector operator's cab F7 - Lower beam
K6 - Lower beam relay X21 - 4-ways connector heating F8 - Driving beam
L1 - L.H. beam X28 - 4-ways connector working beam F9 - Working beam
L2 - R.H. beam X29 - 1-way connector beam diodes F10 - Electric socket
L3 - Working beam
S1 - Starter switch
S14 - Beam switch
S15 - Rotary beam switch
S16 - Heating fan
10-47
TESTING AND ADJUSTMENTS
Normal or standard technical data . . . . .. . . . . .. . . . .. . . 2 Adjusting the maximum speed

Equipment for testing, adjusting and of the travel motors . . . . . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 45
identifying faults. . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 19 Checking that the travel speed increment
Measuring the engine speed.. . . . . .. . . . .. . . . . .. . . . .. . 21 is functioning correctly . . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 47
Valve clearance adjustment. . . . . . . .. . . . .. . . . . .. . . . .. . 22 Testing for internal oil leakage
Measurement of compression pressure. . . . . .. . . . .. . 23 in the travel motors . . . . . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 48
Checking and tightening the fan-belt. . .. . . . . .. . . . .. . 24 Adjusting boom and arm safety valves. . . . .. . . . .. . . . 49
Adjusting the stroke of the accelerator lever . . . . .. . 25 Adjusting 2nd boom safety valves. . . . .. . . . . .. . . . .. . . . 50
Adjusting PPC valve clearance . . . .. . . . .. . . . . .. . . . .. . 26 Measuring the initial intervention point of the
pressure switch that signals overloading. . .. . . . .. . . . 51
Adjusting the safety microswitches. . . . .. . . . . .. . . . .. . 28
Adjusting the valve that regulates
Centring the stroke of the blade control lever . . . .. . 28 the closing speed of the 2nd boom . . .. . . . . .. . . . .. . . . 52
Measuring the swing circle axial clearance. .. . . . .. . 29 Measurement of internal oil leakages
Testing and adjusting track-shoe tension . . . .. . . . .. . 30 in the swing motor.. . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 53
Bleeding air from the main pumps (P1 and P2). .. . 31 Checking for leakages inside the swivel joint. . .. . . . 54
Bleeding air from the PPC valves circuits . . .. . . . .. . 31 Analysis of the causes of hydraulic drifts . .. . . . .. . . . 56
Bleeding air from the cylinders . . . .. . . . .. . . . . .. . . . .. . 32 1. Boom test . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 56
Releasing residual pressure from the circuits . . . .. . 32 2. Arm test . . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 56
Checking and regulating pressure 3. Testing the functionality of the boom
in the hydraulic circuits . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 33 and the arm safety valve. . . .. . . . . .. . . . . .. . . . .. . . . 57
Checking the intervention point 4. 2nd boom test . . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 58
of the flow regulator . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 39 5. Testing the functionality of the
Checking the intervention point for 2nd boom safety valves.. . . . .. . . . . .. . . . . .. . . . .. . . . 59
horsepower control of the 3-circuit valve. . . . .. . . . .. . 40 6. Bucket test . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 59
Checking and adjusting pressures in the 7. Boom swing test . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 60
servocontrol supply units . . . . .. . . . . .. . . . .. . . . . .. . . . .. . 41 8. Blade test. . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 60
Adjusting the main safety valve of pump P4 . . . . .. . 42 9. Swing motor test. .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 61
Measuring pump delivery . . . .. . . . . .. . . . .. . . . . .. . . . .. . 43 10. Travel motor test .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 62
Measuring travel deviation . . . . . . . . .. . . . .. . . . . .. . . . .. . 44 Troubleshooting . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 65
When carrying out controls, adjustments or analyses for troubleshooting, park the machine on firm, level
ground. Apply all the machine safety devices and use blocks to prevent any machine movement.
When more than one person is engaged in the work, use the prescribed notices that indicate that the machine
is undergoing maintenance. Do not allow any unauthorised persons to remain in the vicinity.
When checking the level of the cooling liquid, wait until this liquid has cooled. If the radiator cap is removed
while the liquid is still hot and under pressure, it may cause severe burns.
Take great care not to get entangled in moving parts (fan, alternator belt or any of the rotating elements).
20-1
NORMAL OR STANDARD TECHNICAL DATA
. FOR ENGINE
Engine 1004-4
Standard Permissible
Check item Test Conditions Unit value value
High idling rpm 2160w50 Ð

Engine speed Low idling rpm 1000 50
(no-load) Ð
Set speed rpm 2050 50 Ð
Sudden acceleration Index Ð Ð

Exhaust gas colour
At high idling speed Bosch Ð Ð
Intake valve (20ëC) 0.20

Valve clearance mm Ð
Exhaust valve (20ëC) 0.45
Water temperature in operating range

Blow-by pressure ,/min Ð 60
At high idling speed SAE 30 oil
Min. engine oil Water temperature in operating range

kg/cm2 3.4v4 2.1
pressure At high idling speed
Oil temperature Entire speed range ëC 85ëC Max. 120
Fuel injection timing B.T.D.C. degrees 16.5 Ð
Slack when pushed with finger

Fan-belt tension force of 4.5 kg
mm 10 Ð
20-2
. FOR MACHINE
All tests, if not otherwise specified, should be performed with WORKING MODE in position P
Classifi- Check item Test conditions Unit Standard Permissible

cation value value
Engine speed with pump P1 2100w50 Min. 2000

at max. pressure
. Hydraulic oil temp.: 45v55ëC
. Engine oil pressure: in correct range
Engine speed with pumps 2100w50 Min. 2000
P1 and P2 at max. pressure . Cooling water temp.: in correct range
Engine
. Swing lock pin inserted

. Max. pressure P1: with arm rpm
Engine speed with . Max. pressure P1-P2: with arm and
pumps P1-P2-P3 bucket
2050w50 Min. 1950
at max. pressure
. Max. pressure P1-P2-P3 with arm,
Engine speed when pumps bucket and swing
P1-P2 are at max. pressure 2150w50 Min. 2050
and the WORKING MODE
selector is in pos. E
Boom control valve a b a b
Arm control valve 9w0.5 9w0.5 8.7w0.5 9.3w0.5
Bucket control valve 9w0.5 9w0.5 8.7w0.5 9.3w0.5

a b
Swing control valve 9w0.5 9w0.5 8.7w0.5 9.3w0.5
Spool travel
Blade control valve 9w0.5 9w0.5 8.7w0.5 9.3w0.5

mm
Boom swing control valve 9w0.5 9w0.5 8.7w0.5 9.3w0.5
2nd boom control valve 9w0.5 9w0.5 8.7w0.5 9.3w0.5

D0400173
Right travel control valve 8w0.5 8w0.5 7.7w0.5 8.3w0.5
Left travel control valve 8w0.5 8w0.5 7.7w0.5 8.3w0.5

Boom and arm speed
8w0.5 8w0.5 7.7w0.5 8.3w0.5
redoubling control valve
Raise
Boom control lever . At centre of Neutral Lower 80w8 72v88
lever knob
. Reading at end Extended
Arm control lever of travel Neutral Retracted 80w8 72v88
. Engine
stopped Open
Bucket control lever . Equipment on Neutral Curled 80w8 72v88
the ground
Travel of lecers and pedals
Swing right
Swing control lever Neutral Swing left 80w8 72v88
Raise
Blade control lever Neutral Lower 50w5 45v55
mm
Swing right
Boom swing pedal Neutral Swing left 20w2 18v22
Open
2nd boom pedal Neutral Closed 30w3 27v33
Travel control pedal Neutral

Forward
120w12 108v132
(right-left) Backward
Travel accelerator . At centre of pedal 5w0.5 4.5v5.5

control pedal
Fuel control lever Min. Max. 150w15 135v165
20-3
. FOR MACHINE

cation value value
Raise boom . Engine speed: high idling 2.6w0.3 Max. 3.1

. Oil temperature: 45v55ëC
Lower boom . Instrument coupling at centre 2.6w0.3 Max. 3.1
Operating force for control of levers and pedals
of control lever knob

Bucket curled-open . Instrument coupling on outside 2.0w0.3 Max. 2.7
edge of pedal control
Arm open-close 2.6w0.3 Max. 3.1
Swing (R.H.-L.H.) 2.0w0.3 Max. 2.7
Blade 2.0w0.3 Max. 2.7

kg
Boom swing pedal 9.0w2 Max. 12
2nd boom pedal 8.0w2 Max. 12
Lever (centre) 3.0w0.3 2.7v3.3

Travel control lever
(R.H.-L.H.)
Pedal 9.0w1 8.0v10.0
Travel accelerator 9.0w1 8.0v10.0

control pedal
Fuel control levers 3.0w0.3 Max. 4.0
1st Section 280w5 280w15

. Engine speed: max.
Main valve
pressure
2nd Section . Oil temperature: 45v55ëC 280w5 280w15

. Check one circuit at a time bar
3rd Section 200w5 200w15
Servocontrols (Safety) Ð Ð
Raise 320w5 320w15

Boom
Lower 220w5 220w15
Hydraulic pressure (Reducing valve.)
Arm 320w5 320w15

. Engine speed: max.
Bucket 320w5 320w15
. Check one circuit at a time
Swing 190/160w5 190/160w5
bar
Blade 200w5 200w15
Boom swing 320w5 320w15
2nd boom 350w5 350w15
Travel 300w5 300w15
+ 0
Servocontrols 35 ±3.5 35 5
20-4
. FOR MACHINE

cation value value
Work equipment at max. reach
Braking angle
D0400155
Degrees Max. 50 Max. 80
(mm) (330) (540)
. Load in the bucket: 540 kg
. Engine speed: high idling.
. Make centring marks on the outer swing
circle rings. Rotate the upper turret 360ë
and stop. Measure the difference between
the marks after stopping.
Working equipment at max. reach
90ë Ð Ð
Time taken to start swing sec

D0400155
. Engine speed: high idling 180ë 4.3w0.4 Max. 5.1

. Time taken also from starting posi-
Swing
tion to swing 90ë and 180ë.
Working equipment at max. reach
Time taken to swing sec 35w1.5 Max. 38

D0400155
. Engine speed: high idling

. Make one turn to settle machine.
. Measure the time taken to make 5 full
swings
15°
D0400207
Hydraulic drift of swing . Load in the bucket: 500 kg Degrees 0 Ð

. Engine switched off (mm)
. Brake disengaged (with specific tool)
. Park the machine on a 15ë slope and set
the boom at 90ë with respect to the ground
surface
. On the outer swing circle, mark the posi-
tion between turret and track frame.
. After 15 minutes measure the drift.
20-5
. FOR MACHINE

cation value value

Swing
Internal leakage from swing . Oil temperature: 45v55ëC

motor . Swing block: engaged
,/min Max. 0.608 Max. 1.3
. Measure the leakage
20-6
. FOR MACHINE

cation value value
Measuring posture
Low speed
30 1 Min. 27
D0400157
Travel motor swing rpm
speed (1) (no-load)
High speed
. Rest the bucket on the ground, 58 2 Min. 54
raise one track-shoe and mark a
position on the reduction unit.
Measure the rotating speed of the
sprocket wheel. Repeat for the
2nd track-shoe
Measuring posture
Low speed
45° Max. 28.3
Ð
Min. 19.0
Travel speed (2) sec

D0400156
Travel
High speed
. Engine speed: high idling Max. 17.3

. Oil temperature: 45v55ëC Ð
Min. 11.0
. On flat ground
. Travel for at least 10 metres and
then check on the time needed to
cover 20 metres
45°
D0400156

Travel deviation . Oil temperature: 45v55ëC mm Max. 200 Max. 220
. Travel 20 metres on flat ground and mea-
sure the deviation.
H The surface must be hard and horizontal.
20m
10m
D0400158
H Measure dimension «X»
20-7
. FOR MACHINE

cation value value
. Measuring posture
15°
Hydraulic drift of travel mm Max. 0 Ð
motors D0400208
. Engine: switched off

. Oil temperature: 45v55ëC.
. Machine stationary on sloping ground.
. Measure the drift after 5 minutes
Travel
. Engine speed: high idling.
Leakage from travel

motors ,/min Max. 12.8 Max. 25

. Travel brakes engaged
. Measure the leakages
H Measure one motor at a time.
20-8
. FOR MACHINE

cation value value
Measuring posture
Boom
A Max. 700 Max. 1050
Total work equipment

(Standard boom) Boom
(Downward movement B Max. 700 Max. 1100
bucket teeth tips) A
B
C Boom
C Max. 700 Max. 1200
D0400159
Boom
A Max. 8 Max. 12
Boom cylinder Boom

(Retraction) . In this position, measure exten- Max. 10 Max. 15
sion or retraction of each cylinder, B
mm
and any leakages occurring when
a load is applied to the tips of the Boom
bucket teeth. C Max. 13 Max. 20
. Horizontal levelled ground
. Bucket: rated load (540 kg) Boom
. Levers: neutral A Max. 56 Max. 84
Arm cylinder Boom
Hydraulic drift of working equipment
(Extension) . Safety valve disengaged Max. 60 Max. 90

B
. Take measurements as soon as
the engine stops
. Measure the variations every 5 Boom
C Max. 65 Max. 98
minutes and check the total varia-
tion after 15 mins.
Bucket cylinder Max. 18 Max. 30
(Retraction)
Measuring posture Boom
A Max. 700 Max. 1150
Total work equipment
(Downward movement Boom
of tips of bucket teeth) B Max. 700 Max. 1200
(2-piece boom)
Boom
C Max. 700 Max. 1300
A
B Boom
C
A Max. 10 Max. 15
Boom cylinder D0400200 Boom

(Retraction) B Max. 13 Max. 20
Boom
C Max. 18 Max. 27
. In this position, measure extension
and retraction of each cylinder, and Boom
mm Max. 46 Max. 69
any leakages when a load is ap- A
2nd boom cylinders plied to the tips of the bucket teeth. Boom
(Retraction) . Horizontal levelled ground B Max. 50 Max. 75
. Bucket: rated load (540 kg)
Boom
. Levers: neutral Max. 55 Max. 83
C
. Oil temperature: 45v55ëC Boom
Max. 56 Max. 84
. Safety valve disengaged A
Arm cylinder . Take measurements as soon as Boom
(Extension) the engine stops B Max. 60 Max. 90
. Measure the variations every 5
minutes and check the total varia- Boom
C Max. 65 Max. 93
tion after 15 mins.
Bucket cylinder Max. 45 Max. 63
(Retraction)
20-9
. FOR MACHINE

cation value value
Boom
A Max. 16 Max. 30
Boom swing Boom

(Standard boom) B Max. 18 Max. 35
15° Boom
C Max. 22 Max. 40
D0400272 mm
Boom
. Engine: switched off A Max. 19 Max. 35
Hydraulic drift of working equipment

Boom swing . In the same position as above, Boom
(boom and 2-piece boom) park the machine on a 15ë slope B Max. 21 Max. 40
and bring the turret round to 90ë.
Measure the extension and retrac- Boom
tion of the cylinder after 15 mins. C Max. 25 Max. 48
Blade
(measure the downward
movement of the edge of D0400160
mm Max. 5 Max. 8
the blade)
. Safety valve disengaged
. Raise the blade and measure the height of
the edge from the ground.
Measure the downward after 15 mins.
Boom Max. 3.3 Max. 13.5
2nd boom Max. 2.0

Internal cylinder leankage
Max. 8.0
(2 cylinders) (each cylinder)
Arm Max. 2.4 Max. 9.6
. Check leakages: on the cylinder on the
cc/
side oppsite to the one under pressure
min
Bucket H Check one cylinder at a time Max. 2.0 Max. 8.0
H For the 2-piece boom check the two cylin-
ders individually but simultaneously.
Boom swing Max. 2.4 Max. 9.6
Blade Max. 3.3 Max. 13.5
20-10
. FOR MACHINE

cation value value
. Measuring posture
Boom
Raise
2w0.1 Max. 2.4
Bucket teeth on the ground
Lower
D0400161
2.3w0.1 Max. 2.8
Cylinder completely . Engine speed: high idling
extended
2nd boom . Measuring posture
Closed
Cylinders completely 5.0w0.3 Max. 6.0
retracted
Inout
D0400166 5.4w0.3 Max. 6.5
Cylinders completely . Engine speed: high idling
extended . Oil temperature: 45v55ëC.
Arm . Measuring posture
Cylinder completely Closed 3.1w0.2 Max. 3.7

retracted
Inout
Work equipment
D0400162
3.8w0.2 Max. 4.5
Cilindro completamente . Engine speed: high idling
esteso .
Speed
Oil temperature: 45v55ëC

sec
Bucket . Measuring posture
Curled
Cylinder completely 4.1w0.2 Max. 5.0

retracted
Dump
D0400163 2.5w0.1 Max. 3.0

extended . Oil temperature: 45v55ëC
Boom swing . Measuring posture

L.H.
Cylinder completely 5.9w0.3 Max. 7.0

retracted
R.H.
D0400165
5.9w0.3 Max. 7.0
extended . Oil temperature: 45v55ëC
. Measuring posture
Blade
Raise
1.2w0.1 Max. 1.4

Blade on the ground
Lower
D0400164
Blade raised to max. 1.4w0.1 Max. 1.7
height
20-11
. FOR MACHINE

cation value value
Measuring posture
Boom
(Standard) Max. 2 Max. 3
D0400167
. Engine speed: low idling

. Retract fully the cylinders of the arm and
bucket.
Lower bucket to ground and measure time
taken for chassis to rise from ground.
Measuring posture
Work equipment
Time lags
Boom
(2-piece boom) Max. 2 Max. 3
sec
D0400171

bucket.
Extend the 2nd boom fully.
Lower bucket to ground and measure time
taken for chassis to rise from ground.
Measuring posture
2nd boom D0400172 Max. 2 Max. 3

0
. Chock valve: 60+ 5
bucket.
Extend the 2nd boom fully. Bring the boom
into a vertical position.
Close completely the 2nd boom and mea-
sure the time taken increase the pressure.
20-12
. FOR MACHINE

cation value value
Measuring posture
D0400168
Arm Max. 2 Max. 3

. Bring the boom into a horizontal position.
Retract the cylinder of the arm completely
and then extend it.
Amount of time when arm stops for a mo-
ment.
Measuring posture
Work equipment
Time lags
D0400169
Bucket Max. 2 Max. 3
sec

. Oil temperature 45v55ëC
. Bring the boom into a horizontal position.
Retract the bucket cylinder completely,
then extend it.
Measure the time that elapses between the
bucket stopping at dead centre and then
starting to move again.
Measuring posture
D0400170
Blade Max. 1 Max. 2

. Raise the blade to its max. height, then
lower it.
Measure the time it takes for the rear of the
machine to be lifted off the ground, starting
from the time the blade contacts the
ground.
20-13
. FOR MACHINE

cation value value
. Engine: 2000 rpm

50 bar 58.4 52.5
Gear pump P3 . Oil temperature: 45v55ëC
100 bar 58.2 52.4
(22.9 cc/rev) . Measure the delivery at
50-100-200 bar
200 bar 58.0 52.2
. Engine: 2000 rpm 50 bar 32.2 29.0

Gear pump P4
(12.7 cc/rev) . Valve calibration to MAX: 200 bar 100 bar 32.1 28.9
Pumps
. Measure the delivery at

50-100-200 bar 200 bar ,/min 32.0 28.8
. Engine: 2000 rpm
. Measure (for each pump) the delivery at
50-100-200-300 e 350 bar
Piston pumps (P1 and P2) . Measure the deliveries for See following pages
WORKING MODE in position P
and in position E
. Measure the deliveries for
WORKING MODE in position P
and with the 3-circuit valve functioning
20-14
Classifi- . Delivery of individual piston pumps, P1 and P2

cation . WORKING MODE selector: position P.
. Pump speed: 2000 rpm.
P(bar)
350
300
250
STANDARD PUMP
RANGE POMPE
DELIVERY
STANDARD RANGE
200
Pump characteristics
PUMP
LIMITEDELIVERY
DI PORTATA
LOWER
MINIMALIMIT
AMMESSA
150
100
50
0
10 25 50 75 Q (l / min)
D0400177
H When measuring the deliveries with the pumps mounted on the machine, it becomes difficult to use
the accelerator to set the number of engine rpm corresponding to the test speed prescribed for the
pump.
Measure the delivery with the engine set to 2000 rpm, and perform a proportional calculation to find
the delivery value required for the test.
H Engine/pump gear ratio: 1:1.354
20-15

cation . WORKING MODE selector: position E (Mode System).
P(bar)
350
300
250
200
STANDARD PUMP
RANGE POMPE
DELIVERY
STANDARD RANGE
150
PUMP
LIMITEDELIVERY
DI PORTATA
LOWER
MINIMA LIMIT
AMMESSA
100
50
0
10 25 50 75 Q (l /min)
D0400178
pump.
20-16

cation . WORKING MODE selector: position P (3-circuit valve operation)
P(bar)
350
300
250
200
STANDARD PUMP
RANGE POMPE
DELIVERY
STANDARD RANGE
150
PUMP
LIMITEDELIVERY
DI PORTATA
LOWER
MINIMA LIMIT
AMMESSA
100
50
0
10 25 50 75 Q (l / min)
D0400179
pump.
20-17
20-18
EQUIPMENT FOR TESTING, ADJUSTING, AND IDENTIFYING FAULTS
Measurement check points Symbol Code Name Q.ty Remarks
Valve clearance A 1 Commercially Feeler gauge 1 Ð

available
1 ATR800090 Compression gauge 1 0-70 kg/cm2

Compression pressure B
2 ATR800130 Adapter 1 Ð
1 ATR800070 Multi-scale tachometer 1 20 - 4000 rpm

Engine and track shoe C
rotation speed
2 ATR800060 Stroboscopic tachometer 1 6 - 30000 rpm
Commercially Digital temperature

Water and oil temperature D 1 available gauge 1 ± 50 - 1200 ëC
1 ATR800010 Pressure gauge 2 Scale 600 bar
E 3 ATR800150 Pressure gauge 1 Scale 250 bar

Hydraulic pressure
1 Flowmeter 1
F ATR800120 Ð
2 Tube union kit 1
Extension for travel

G 1 ATR200370 motors
1 Ð
Instrument for sectioning

Drift Test H 1 ATR200380 circuits 1 Ð
Included in the
Track shoe tension L 1 21D-98-11650 Grease nipple 1 machine tool kit
20-19
20-20
TESTING AND ADJUSTMENTS MEASURING THE ENGINE SPEED
MEASURING THE ENGINE SPEED
When measuring the speed (rpm) of the engine, do

not touch heated parts and take care not to become
entangled in rotating elements.
C1
H Do not start to measure engine speed until the follow-
ing conditions have been met:
. Engine cooling water temperature: 68v80ëC
. Hydraulic system oil temperature: 45v55ëC
1 - Install and connect the tachometer C1.

H If a stroboscopic tachometer C2 is used, make a
distinct mark on the motor pulley to facilitate the
reading. F0400001
2 - Start the engine and check:

. Low idling without load (accelerator lever in «mini- MIN MAX
mum» position).
. High idling without load (accelerator lever in
«maximum» position).
H Low idling 1000 50 rpm
H High idling 2160w50 rpm
H If the minimum and maximum engine speeds

without load do not fall within the correct range,
check the position stops of the accelerator lever
and the accelerator cable sheathing (See «AC-
CELERATOR LEVER ADJUSTMENT») before F0400002
performing the stress tests.
. Engine rpm with the pumps working.

H Max. speed when working: 2050 50 rpm
H If the efficiency is not within the permissible limits,

call the Authorised Repair Shop to come and give
the engine a diagnostic check.
20-21
TESTING AND ADJUSTMENTS VALVE CLEARANCE ADJUSTMENT
VALVE CLEARANCE ADJUSTMENT
H Adjust the clearance between the valves and the rock-

er arms to the following values: 6
Unit: mm 1
Intake valves Exhaust valves
Engine cold
0.20 0.45
H Adjust (following the ignition order) cylinders 1-3-4-2.

H Normal direction of rotation: COUNTERCLOCKWISE,
as seen from the flywheel.
F0400003
. Locating the cylinders

1 - Remove the valve cover (1).
2 - Rotate the crankshaft in the normal direction until
the intake valve of cylinder no. 4 is about to open
and the exhaust valve of the same cylinder is IN EX EX IN IN EX EX IN
about to close.
Check the clearance of the valves of cylinder no. 1
and adjust them.
3 - With the valves of cylinder number 2 prepared as Cylinder
Cilindro 1 2 3 4
described for cylinder no. 4, check/adjust the
clearance between the valves of cylinder no. 3. D0400215
4 - Having prepared the valves of cylinder no. 1

check/adjust the clearance of the valves of cylin-
der no. 4.
5 - Having prepared the valves of cylinder no. 3,
check/adjust the clearance of the valves of cylin- 3
der no. 2. 2
. Adjustment method
Adjust the clearance by inserting the feeler gauge (2)
between the valve and the rocker arm (3) to be ad-
justed. Turn the valve tappet (4) until it touches the
feeler gauge (2). Block the tappet (4) with the nut (5).
D0400216
H Lock the nut and then check the clearance once
again.
. Replacing the valve cover

Clearance
Gioco 4 5
1 - Check the condition of the valve cover seal and
the retaining washers. Clean the sealing surface
of the cylinder head.
2 - Position the valve cover (1) and the lateral protec-
tion. Mount the seals and the flanged nuts (6).
Flanged nuts on the valve cover: (20 Nm)
2.1 kgm
D0400217
20-22
TESTING AND ADJUSTMENTS MEASUREMENT OF COMPRESSION PRESSURE
MEASUREMENT OF COMPRESSION PRESSURE
When measuring the compression, be careful not to

get caught up in the cooling fan, the alternator belt or 1
any other rotating parts.
2
H Test conditions:
. Engine: at running temperature
. Hydraulic oil: 45v55ëC.
. Battery: fully charged
. Valve clearance: adjusted (See «VALVE CLEAR-
ANCE ADJUSTMENT»)
1 - Disconnect the high pressure tubes (1).
2 - Remove the nozzle holder (2) of the cylinder to be
F0400004
checked.
3 - Install the adapter B2 and connect the pressure
gauge B1.
B1
B2
F0400005
4 - Disconnect the cables (3) from the solenoid valve (4)

that stops the engine.
5 - Turn the engine using the starting motor and mea- 3
sure the compression.
H Compression value: 4
normal 24v26 kg/cm2
minimum permissible 20 kg/cm2
H Measure the compression value once the pres-
sure gauge has stabilised.
F0400006
6 - After measuring the pressure, replace the nozzle

holder and reconnect the high pressure and flow-
back tube.
Nozzle holder retaining screws:
12 Nm (1.2 kgm)
High pressure connector: 19 Nm (1.9 kgm)
H Check all the cylinders.
20-23
TESTING AND ADJUSTMENTS CHECKING AND TIGHTENING THE FAN-BELT
CHECKING AND TIGHTENING THE FAN-BELT

1. Measuring the tension
1 - Press the belt (1) at the mid-point of the longest
free length and measure the sag.
At a pressure of 4.5 kg, the sag should be 10 mm.
If this value is not found, adjust the tension of the 1
belt. 10 mm
4,5 kg
F0400007
2. Adjusting belt tension

2 1
1 - Unscrew the screws (2) of the alternator (3) and 3
thescrews (4) of the fan-belt stretcher stop.
2 - Turn the alternator (3) to obtain the correct belt
tension (1) and tighten the screws (2) and (4).
3 - Measure the belt tension (1) again.
H If a new belt has been fitted, measure the tension 4
once again after about 20 hours of operation.
F0400008
20-24
TESTING AND ADJUSTMENTS ADJUSTING THE STROKE OF THE ACCELERATOR LEVER
ADJUSTING THE STROKE OF THE ACCELERATOR LEVER
H Test conditions:
. Engine: Switched off, but at working temperature.
. Low idling: within correct range.
. Hydraulic oil: 45v55ëC
. Accelerator lever (8) at the mid-point of its stroke.
1 - Use the stretcher (2) to eliminate clearance in the

jacket (1). 2
2 - Raise the right-hand cover in order to reach the 1
screws (3) and (4).
3 - Unscrew the nuts (5) and (6) and tighten the screws F0400009
(3) and (4) in the support (7).
4 - Move the accelerator lever (8) slowly towards low id-

8 3 8
ling position. Stop this movement when the lever (9)
on the cover of the injection pump comes into contact 6
with the low idling adjustment screw (10). 7
5 - Adjust the screw (3) until it is 0.1 mm from the lever 7
(8) and lock it in this position with the nut (5).
5
6 - Move the lever (8) towards the high idling position. 4
Stop this movement when the lever (9) on the cover
of the injection pump rests against the lead-sealed
high idling adjustment screw (11).
D0400227
7 - Adjust the screw (4) to 0.1 mm from the lever (8) and
lock it in this position with the nut (6).
H After adjustment, replace the right-hand cover
and check that the aperture does not impede
the movement of the lever (8) towards its extreme 10 9
positions.
11
F0400056
20-25
TESTING AND ADJUSTMENTS ADJUSTING PPC VALVES CLEARANCE
ADJUSTING PPC VALVES CLEARANCE
Adjust PPC valve levers clearance as follows.
Rest the work equipment on the ground and stop the

engine.
Turn the ignition key to position «I» and move the
control levers in all directions to relieve all pressure
in the hydraulic circuits.
Turn the ignition key to position «O» (OFF) and re-
move it.
Put the safety device lever in its «ENGAGED» posi-
tion.
Slowly unscrew the filling-cap of the oil-tank to re- 1
lease any residual pressure.
2
1. Front equipment and swing PPC valves 3
3
1 - Unscrew the retaining nut (1) of the disk (2).
2 - Screw the disk (2) down until it comes into light
contact with the four plungers (3). Tighten it for an-
other 1/8th of a turn (45ë).
H During this adjustment, take care not to acti-
vate the plungers (3).
3 - Secure the position with the retaining nut, tigh-
tened to the specific torque.
Retaining nut: 30w3 Nm
D0400197
2. Blade PPC valve

1 - Remove the command PPC valve coupling from
the PPC valve.
1 2
2 - Unscrew the nuts (1) that block the adjustment
3
screws (2).
3 - Tighten the adjustment screws (2) until any clear-
ance has been eliminated. Tighten for a further
quarter of a turn (90ë).
H During this adjustment, take care not to acti-
4 - Secure the retaining nuts with the specific torque.
Retaining nut: 8w1 Nm.
D0400198
20-26
TESTING AND ADJUSTMENTS ADJUSTING PPC VALVES CLEARANCE
3. Travel, 2nd boom and boom swing PPC valves

H For travel PPC valves remove the control levers.
1 - Unscrew the nuts (1) that block the adjustment
screws (2).
2 - Tighten the adjustment screws (2) until all clear-
ance is eliminated. Tighten for a further quarter 1
of a turn (90ë).
H During this adjustment, take care not to acti- 2
3 - Secure the adjustment screws with the retaining
3
nuts, tightened to the specific torque.
Retaining nuts: 8w1 Nm.
D0400199
20-27
ADJUSTING THE SAFETY MICROSWITCH
TESTING AND ADJUSTMENTS CENTRING THE STROKE OF THE BLADE CONTROL LEVER
ADJUSTING THE SAFETY MICROSWITCH
H Test conditions:
. Engine: switched off but at working temperature.
. Hydraulic oil: 45v50ëC. 2
1 - Unscrew the nut (1) that secures the microswitch (2).
2 - Tighten or unscrew the microswitch (2) to the extent
indicated.
H Projection of microswitch: 16 1 mm
3 - Secure it in position with the nut (1). 1
F0400010
2
1
16 0+1
D0400218
CENTRING THE STROKE OF THE BLADE CONTROL LEVER
H Test conditions:
. Engine: switched off but at working temperature.
1 - Check that the lever returns to the NEUTRAL posi-

tion.
2 - Check the state of the springs (1).
3 - Unscrew the nuts (2).
4 - Unscrew the tie-rod (3) in order to move the lever for-
wards, or tighten it in order to move the lever towards
the rear of the machine.
1
5 - Lock the nuts (2).
2
3
F0400011
20-28
TESTING AND ADJUSTMENTS MEASURING THE SWING CIRCLE AXIAL CLEARANCE
MEASURING THE SWING CIRCLE AXIAL CLEARANCE

1. Test procedure
1 - Park the machine on firm, flat ground, revolving
frame aligned with the track shoe.
2 - Extend the boom, the arm and the bucket, in such
a way that they cover the maximum radius of ac-
tion when the teeth of the bucket are at the same
height as the lower platform of the revolving
frame.
D0400174
3 - Attach a comparator with a magnetic base (1) to

the rear of the track frame (2), and so that the tra-
cer rests below the outside ring of the swing circle
3
(3).
4 - Preload the comparator by about 1 mm and set
this measurement to zero.
2 F0400012
5 - Close the bucket, position the arm perpendicular

to the ground and rest the back of the bucket on
the ground.
6 - Push down with the boom until the front of the ma-
chine rises, transferring the weight of the track
frame onto the sprocket.
150 ÷ 200 mm
7 - Check the movement of the comparator (1) in
these conditions. The value read corresponds to
the value of the swing circle axial clearance.
D0400175
H For the standard value of the clearance, see
«STANDARD MAINTENANCE».
While the machine is off the ground, take
care not to put hands or feet beneath the
track shoes.
8 - Return the machine to phase 2 conditions and

check that the comparator returns to «zero». If it
does not, repeat the test, starting at phase 4.
20-29
TESTING AND ADJUSTMENTS TESTING AND ADJUSTING TRACK-SHOE TENSION
TESTING AND ADJUSTING TRACK-SHOE TENSION

1. Test
H Test conditions:
. Firm, flat ground.
. Work equipment resting on the ground.
1 - Swing the turret 90ë to the side of the track to be

tested. 100 ÷ 150 mm
2 - Close the bucket, position the arm perpendicular

to the ground and rest the bucket on the ground.
D0400176
3 - Push down with the boom until the track-shoe to
be tested has been raised completely from the
ground.
4 - Measure the distance between the track-shoe

race and the central track rollers.
H Distance between track roller and track-shoe:
20v25 mm
20425 mm
F0400013
2. Adjustment
If track-shoe tension is not within permissible limits,
adjust them as follows. 1
H Before introducing the grease-pump (2), and on

completion of the adjustment, thoroughly clean
the grease nipple and the surrounding area.
1 - If the tension is too slack.
Inject grease through the grease nipple (1), using
the grease nipple L1.
H If the grease proves difficult to inject, slowly
move the machine backwards and forwards F0400014
over a short stretch.

2 - If the tension is too tight.
Loosen the grease nipple (1) slowly to allow
grease to flow out of the valve.
The grease contained in the stretching cylin-

der is under pressure and could injure the op-
erator. For this reason the valve should not
be loosened by more than one turn.
H If the grease does not flow easily, move
the machine backwards and forwards
L1
slowly over a short stretch.
2
F0400015
20-30
TESTING AND ADJUSTMENTS BLEEDING AIR - RELEASING RESIDUAL PRESSURE
BLEEDING AIR - RELEASING RESIDUAL PRESSURE
Bleeding air from pumps P1 and P2

H When the hydraulic oil tank is drained, or when the
main pumps are removed for revision or replacement, 2 1
air must be bled from the intake circuit as follows:
1 - Remove the plug (1) of the pump body (2).
2 - Fill the tank with oil up to the level of the hole in
the plug (1).
3 - Replace the plug (1).
Cap: 30 Nm.
4 - Continue to fill the tank until the maximum level is F0400016
reached.
5 - Start the engine and bring it up to low idling speed
for a few minutes before starting to bleed the air
from the servocontrol circuit and, if necessary,
from the cylinders. (See «BLEEDING AIR FROM
THE SERVOCONTROL CIRCUIT» and «BLEED-
ING AIR FROM THE CYLINDERS»).
Bleeding air from the PPC valves circuit

H When tubing or PPC valves circuit components are
moved, air must be bled, as follows:
1 - With the engine set to minimum, operate the PPC
valves to bring the upper chamber of each spool 1
to maximum pressure.
2 - While maintaining this situation, slowly loosen the
bleeder plug (1) to let all the air out of the control
circuit of the control valve spool.
3 - When oil leaks from the bleeder vent without a
trace of air, tighten the plug once more (1).
Plug: 9 Nm.
F0400017
H Repeat this bleeding process for each control.
H To bleed the speed-redoubling spool for
boom-raising and arm-closing, loosen the
plug of the redoubling spool while raising
the boom or closing the arm.
20-31
TESTING AND ADJUSTMENTS BLEEDING AIR - RELEASING RESIDUAL PRESSURE
Bleeding air from the cylinders

H Once the hydraulic cylinders or the tubes connected
to them have been removed, the air must be bled as
follows:
1 - Start the engine and let it run at high idling speed
for about 5 minutes.
2 - Reduce engine speed to low idling, and raise and
lower the boom 4-5 times.
H Lower and raise the boom piston to about 100
mm from the ends-of-stroke.
3 - Increase engine speed to high idling and repeat
the operations described at point 2. Reduce en-
gine speed to low idling and take the piston
through its entire stroke until the hydraulic pump
has reached maximum pressure.
4 - Repeat the operations (starting from point 2) for
the cylinders of the 2nd boom, the arm and the
bucket.
Releasing residual pressure from the circuits

1 - Rest the work equipment on the ground and stop the
engine.
2 - Put the ignition key at position «I» and move the con-
trol lever in all directions to relieve all pressure in the
main hydraulic circuits and the PPC valves.
3 - Turn the ignition key to position «O» (OFF) and re-
move it.
4 - Put the lever of the safety device into the «LOCKED»
position.
5 - Slowly loosen the oil-tank filler-cap to release any re-
sidual pressure. D0400184
20-32
CHECKING AND REGULATING PRESSURE
TESTING AND ADJUSTMENTS IN THE HYDRAULIC CIRCUITS

IN THE HYDRAULIC CIRCUITS
INTRODUCTION
. The control valve is divided into three normally inde-
pendent sections, supplied by pumps P1-P2-P3 re-
spectively.
. Each section is protected against overpressures by a
main (or primary) relief valve with a fixed setting,
which must be lead-sealed on completion of each ad-
justment.
CONTROL VALVE
DISTRIBUTORE
SEZ. 3 SEZ. 2 SEZ.1

M2
M3 M1
MAIN RELIEF
VALVOLA VALVE
GENERALE
SECTION
SEZIONE 33
MAIN RELIEF VALVE MAIN RELIEF
VALVOLA VALVE
GENERALE
VALVOLA
SECTION
GENERALE
2 SECTION
SEZIONE 11
SEZIONE 2
A3 P3
A2
DIESEL
P2
P1 A1
D0400180
. The sections consist of the spools that govern:
Sec- Control Ports

tion
10 9 8 7 6 5 3 2 1
Boom swing (Left-Right) A1-B1
Arm (Open-Close) A2-B2 PORTS
UTILIZZI
1
R.H. travel motor (Backward-Forward) A3-B3
A
Boom speed increment C
L.H. travel motor (Forward-Backward) A5-B5 B

Bucket (Curl-Dump) A6-B6
2
Boom (Raise-Lower) A7-B7
2nd boom (Raise-Lower) A8-B8
10 9 8 7 6 5 C 3 2 1
Blade (Down-Up) A9-B9 D0400181
3
Swing (Left-Right) A10-B10
20-33
. The movements of the work equipment (boom, 2nd 1 1

boom, arm, bucket and boom swing) and the travel, 2
are all protected by independently adjusted safety
and anticavitation valves (1), mounted on sections 1
and 2 of the control valve.
. Blade movements are protected by anticavitation
valves (2) mounted on section 3 of the control valve.
2
1 F0400018
. Revolving frame swing movements are protected by

safety and anticavitation valves (3) that can be re-ad-
justed with a hydraulic pilot system, mounted directly 3
on the swing motor (4).
3
4
F0400019
CHECKING VALVE ADJUSTMENT
1. General, or main safety valves

H Test conditions:
. Engine: at working temperature
. MIN. and MAX. motor speeds: within permis-
sible limits.
. WORKING MODE selector: position P
. Travel brake: engaged.
1 - Connect the pressure gauge E1 (600 bar) to the

adapters M1-M2 and pressure gauge E2 (400 E1 M1
bar) to adapter M3.
2 - Start the engine and put the accelerator into the
high idling position.
3 - Check the general pressure for each of the three
sections by means of the following operations:
Section 1 - Move the arm to its open or closed
end-of-stroke and check that the pres- M2
sure gauge connected to the adapter
M1 shows a pressure of 280w5 bar. F0400020
20-34
Section 2 - Bring the bucket to its open or closed

end-of-stroke and check that the pres-
sure gauge connected to the adapter E2
M2 shows a pressure of 280w5 bar.
Section 3 - Raise the blade to the end of its stroke
and check that the pressure gauge
connected to the adapter M3 shows
a pressure of 200w5 bar.
If the values read on the pressure gauge do not fall M3
within the indicated range, adjust all the main safety
valves.
(See «SETTING OF PRIMARY AND SECONDARY
F0400021
VALVES»).
2. Secondary valves: Boom - 2nd boom - Arm -
Bucket - Boom swing
H Test conditions:
. MIN. and MAX. engine speed: within correct
range
. Travel brake: engaged.
1 - Connect two pressure gauges E1 (600 bar) to the

adapters M1-M2.
2 - Start the engine and put the accelerator into the
MAX position.
3 - Adjust the main safety valves of sections 1 and 2
to a pressure of 370 w 5 bar.
4 - Executing one movement at a time, bring the pis- M2 9 7 5
ton to the end of its stroke in both directions. Use
the pressure gauge to check the maximum pres-
sure of the secondary valve corresponding to the
movement executed.
H The settings of the secondary valves are:
Cylinder Setting of the secondary valves

Left (1) 320w5 bar
Boom swing
Right (2) 320w5 bar
Open (3) 320w5 bar 10 8 6 4 2 M1
Arm
Closed (4) 320w5 bar
Closed (5) 320w5 bar 3 1
Bucket
Open (6) 320w5 bar
Raise (7) 320w5 bar
Boom
Lower (8) 220w5 bar
Open (9) 350w5 bar
2nd boom
Closed (10) 350w5 bar
H If the opening pressures of the valves do not

correspond to the values indicated, they must
be adjusted. (See «SETTING OF PRIMARY
ANDSECONDARY VALVES»). D0400182
20-35
3. Secondary valves for travel motors

H Make sure that the travel brake is engaged.
1 - Push the right-hand travel lever forwards as far as M2 13
it will go and read the maximum pressure on the
1st section pressure gauge.
2 - Repeat this operation by pulling the lever back-
wards and repeat the measurement reading.
3 - Perform the same procedure with the left-hand le-
ver, reading the maximum pressures on the pres-
sure gauge of the 2nd section.
H The setting of the secondary valves for the tra-
vel motors should be 300w5 bar.
H If the valves do not open at the indicated pres- 14 12 M1
sure, adjust the setting.
After the final check, adjust the main safety
11
valves of the 1st and 2nd sections to their normal
pressure value. (See «REGULATION OF MAIN
SAFETY VALVES»).
VALVE SETTINGS
1. Primary and secondary valves
H This setting is valid for:
. Main safety valves of all sections of the control
D0400183
valve
. Secondary valves of the boom cylinder
. Secondary valves of the 2nd boom cylinder
. Secondary valves of the arm cylinder
. Secondary valves of the bucket cylinder 3
. Secondary valves of the boom swing cylinder
2
. Secondary valves of the travel motors
1
For these settings the machine should be pre-

pared in the same way as for the pressure tests.
1 - Unscrew the locknut (1).

2 - Adjust pressure with the adjusting screw (2).
. To INCREASE pressure, turn in a CLOCK-
WISE direction.
. To DECREASE pressure, turn in a COUN-
TERCLOCKWISE direction.
3 - Block the position with the nut (1).
Locknut: 10w1 Nm
On completion of the adjustment, attach seals

(3) to protect against any unauthorised tamper-
ing.
D0400204
20-36
2. Safety valves for the swing motor

H Test conditions:
. Main safety valve of the 3rd section: set to the
permissible values.
. Revolving frame: swing lock pin inserted. 1
3
F0400022
Preparation
1 - Disconnect the servocontrol hoses (1) and (2) of 6
4 5
element (3) of the swing, and plug them to prevent
entry of impurities.
2 - Disconnect the tubes (4) and (5) from the selection
valve (6) and cap the inputs a and c.
3 - Connect two extension tubes (7) and (8) of the
same section to tubes (4) and (5).
H Length of the extensions: approx. 700 mm.
4 - Connect the ends of the extension tubes to the el-
bow on the swing element. F0400023
H Connect: tube 7 to elbow a10

tube 8 to elbow b10
5 - Disconnect the tubes (2-9) and (1-10) from the tee
(11) and (12) in order to adjust the safety valves. 7
H Cap the tubes and elbows to prevent entry of
impurities.
H Mark the tubes to facilitate subsequent reas- 8
sembly of the hydraulic circuit.
4
a
a10 6
7 5
c
11
1
3
10
8 9
12
2 b10 D0400219
20-37
Setting
H First set the maximum pressure and then the working
pressure.
E2
H Check one valve at a time.
1 - Connect the pressure gauge E2 (400 bar) to the adap-
ter M3 of the 3rd section of the control valve.
2 - Unscrew the nut (1) of the valve to be tested and tight-
en the cartridge (2) of the adjustment piston as much
as possible. Secure the position with the nut (1). M3
3 - Start the motor and bring it up to low idling speed.
F0400021
4 - Unscrew the locknut (3).

5 - Swing the revolving frame to the side of the valve
being adjusted. 2
10 6 1 Nm
6 - With the swing control lever at the end of its stroke,
turn the cartridge (4) to regulate the maximum pres- 1
sure.
. To INCREASE pressure, turn in a CLOCKWISE 4
direction. 10 6 1 Nm
. To DECREASE pressure, turn in a COUNTER- 3
CLOCKWISE direction.
H Adjustment pressure: 190w5 bar.
7 - Secure the position of the cartridge (4) with the nut
(3).
Locknut: 10w1 Nm
8 - Unscrew the nut (1) and, with the swing control lever
still at the end of its stroke, unscrew the cartridge (2)
until the working pressure can be read on the pres-
sure gauge.
H Working pressure: 160w5 bar.
. To DECREASE pressure, turn in an COUNTER-
. To INCREASE pressure, turn in a clockwise direc-
tion.
9 - Secure the position of the cartridge (2) with the nut
(1).
Locknut: 10w1 Nm. D0400185
10 - Repeat the same operations on the other valve.

11 - Switch off the motor and release any residual pres-
sures as indicated at the beginning of the paragraph.
12 - Re-assemble the hydraulic circuit.
20-38
CHECKING THE INTERVENTION POINT OF THE
TESTING AND ADJUSTMENTS SUMMATION HORSEPOWER CONTROL
CHECKING THE INTERVENTION POINT OF THE SUMMATION

HORSEPOWER CONTROL
H Test conditions:
E1 M1
. Engine: at working temperature.
. WORKING MODE selector: position P.
Relieve the residual pressures from the circuits (See

«RELEASING RESIDUAL PRESSURES FROM THE
CIRCUITS»).
1 - Disconnect the hoses (1) and (2) from the ports X2 M2

and X3 and cap them.
F0400020
2 - Connect the two pressure gauges E1 (600 bar) to the
adapters M1 and M2 of the control valve (1st and 2nd
section).
3 - Connect the pressure gauge E3 (250 bar) to the port
G of the pump.
4 - Start the engine and bring it up to high idling speed.
5 - Raise the boom completely and close the arm com-
pletely. G
6 - Operate the control levers of the boom and arm simul-
taneously to pressurise the pumps.
H The pumps should be pressurised slowly and si- 2
multaneously. 1 F0400024
7 - Check at which point the pressure gauge E3 (250 bar)

starts to indicate pressure (intervention point).
H Intervention point: 155w5 bar
H If the intervention is early or delayed, adjust it with
the screw (3) after having loosened the nut (4).
. To BRING FORWARD the intervention point, 3
turn in a COUNTERCLOCKWISE direction.
. To DELAY the intervention point, turn in a 4
On completion of the adjustment, apply the seal-
ing cap to protect against tampering.
8 - Stop the engine, release any residual pressures and

re-assemble the hydraulic circuit. F0400025
20-39
CHECKING THE INITIAL HORSEPOWER CONTROL
TESTING AND ADJUSTMENTS POINT FOR THE 3-CIRCUIT VALVE
CHECKING THE INITIAL HORSEPOWER CONTROL POINT

FOR THE 3-CIRCUIT CONTROL VALVE
H Test conditions: E3 G
. WORKING MODE selector: position E
. Revolving frame:swing lock pin inserted
Release any residual pressure from the circuits (See

«RELEASING RESIDUAL PRESSURES FROM THE
CIRCUITS»).
1
1 - Disconnect the hose (1) from the port X2 and cap it. F0400026
2 - Connect the two pressure gauges E1 (600 bar) to the

adapters M1 and M2 of the control valve (1st and 2nd
section). E1 M1
3 - Connect the pressure gauge E3 (250 bar) to the port

G of the pump.
5 - Raise the boom completely and close the arm com-
pletely.
6 - Move the swing control lever to the end of its stroke in M2
one direction or another. At the same time, slowly
move the arm-closing lever and activate the boom- F0400020
raising lever in order to pressurise the pumps.

H The pumps should come up to pressure slowly
and simultaneously.
G
7 - Check at which point the pressure gauge E3 (250 bar)
starts the pressure-indicating movement (intervention
point).
H If the intervention is early or delayed, adjust it with 2

the cartridge (1) after having loosened the nut (2).
. To BRING FORWARD the intervention point,
turn in a CLOCKWISE direction.
. To DELAY the intervention point, turn in an 1
COUNTERCLOCKWISE direction.
H Intervention point: 110w5 bar. F0400027
8 - Stop the engine, release any residual pressures, and

re-assemble the hydraulic circuit.
20-40
CHECKING AND ADJUSTING PRESSURES
TESTING AND ADJUSTMENTS IN THE SERVOCONTROL SUPPLY UNITS
CHECKING AND ADJUSTING PRESSURES IN THE

SERVOCONTROL SUPPLY UNITS
H Test conditions:
. Engine: at working temperature 1
Release any residual pressures from the circuits

(See «RELEASING RESIDUAL PRESSURES FROM
THE CIRCUITS»).
1. Reduction valve
1 - Connect the pressure gauge E4 (100 bar) to the
adapter (1). F0400028
2 - Start the engine and move the accelerator into its

minimum position.
E4
3 - Put the lever of the safety device in its working po-
sition, (UNLOCKED). 1
4 - Bring a servocontrol circuit up to pressure by op-
erating the work equipment. Check the working
pressure on the pressure gauge E4.
H Working pressure: 35 3.5 bar.
H If the working pressure is lower that the per-
missible value, insert a shim (2) underneath
the spring (3) of the reduction valve.
H The 1 mm shim changes the pressure by 1.8 F0400029
bar.
2. Safety valve
1 - Remove the reduction valve and place a 7 mm
shim (2) underneath the spring (3), to increase
the working pressure for the purpose of checking
the safety valve.
2 - Replace the reduction valve.
3 - Start up the engine and move the accelerator into
its minimum position.
4 - Move the lever of the safety device into its working
position (UNLOCKED).
5 - Bring a servocontrol circuit up to pressure by op-
erating the work equipment. Check the working
pressure on the pressure gauge. This value will
correspond to the pressure at which the safety
valve intervenes.
H Working pressure: 45 4.5 bar. 5
H If the working pressure is lower that the per-
missible value, insert a shim (4) underneath
the spring (5). 4
H The 1 mm shim changes the pressure by 7.1
bar. Valvola 3
Safety di
6 - Release any residual pressures and remove the valve
sicurezza
shim (2) in order to return the reduction valve to 2
its working pressure. Reducing
Valvola
valve
riduttrice
7 - Seal the valve against tampering. D0400225
20-41
TESTING AND ADJUSTMENTS ADJUSTING THE MAIN SAFETY VALVE OF PUMP P4
ADJUSTING THE MAIN SAFETY VALVE OF PUMP P4
H Test conditions:
. MIN. and MAX. swing speed: within the correct
range
E2
. Hydraulic oil 45v55ëC
. Machine: with safety devices engaged on all work
equipment.
Test
1 - Set the main safety valve of section 3 of the control
F0400030
valve to a value of 220w5 bar (See «REGULATION

OF MAIN SAFETY VALVES»).
2 - Release any residual pressures from the circuits (See
E2
«RELEASING RESIDUAL PRESSURES FROM THE M4
CIRCUITS»).
3 - Disconnect the supplementary equipment from the
hydraulic system. Cap the equipment tubes to pre-
vent entry of impurities.
4 - Cap the tubes of the hydraulic system of the machine.
ter M4 of the supplementary equipment circuit.
F0400031
6 - Start the engine and put the accelerator into its high
idling position.
7 - Operate the pedal control of the hammer, or the dual-
A
control push-button mounted on the right-hand lever.
Check the pressure reading on the gauge.
H Normal pressure: 200w5 bar.
Adjustment
1 - If the pressure is not within the normal range, set the
valve (1) by turning the adjusting screw (2).
. To INCREASE the pressure, turn in a CLOCK-
WISE direction. F0400032
. To DECREASE the pressure, turn in an COUN-

TER-CLOCKWISE direction.
2 - Secure this position with the nut (3).
A
3 - Bring the adjustment of the main valve of section 3 of 1 2
the control valve back to a normal value of 200w5
bar.
4 - Stop the engine and release any residual pressures
in the equipment circuits by repeatedly operating
the concrete breaker pedal button or the dual-control
button on the right-hand lever.
3
D0400201
20-42
TESTING AND ADJUSTMENTS MEASURING PUMP DELIVERY
MEASURING PUMP DELIVERY
H Test conditions:
. Work equipment on the ground and made safety.
1. Connecting the flowmeter

1 - Disconnect the delivery tube of the pump to be
To utilization
All'utilizzo
checked.
2 - Connect the delivery outlet of the pump to the inlet
port of the flowmeter F1. 1
3 - Connect the discharge port of the flowmeter to the Frompompa
Dalla pump
tube disconnected in phase 1.
4 - Mount a rev. counter to measure that the delivery
from the tested pump is within the tolerances al- F1
lowed for the rated engine rpm.
H If an electronic pressure-transducer type rev. D0400220
counter is installed on a diesel supply tube

to the nozzle, make sure that it is mounted
at a distance from the hose-clamps.
2. Measurement for pumps P1 - P2

1 - Start the engine and bring it up to a speed of 2000
rpm.
2 - Adjust the delivery pressure with the flowmeter
knob (1) and measure the effective delivery of
the pump.
H Perform this test several times, varying the
pressure to cover the entire duty range
(max. 350 bar).
3 - Stop the engine, release any residual pressures
and repeat the same operations for pump P2.
4 - Check the delivery/pressure values against the
values in the diagram given in the «TECHNICAL F1
1
DATA». If the measured values differ by more than
7% from the nominal values, the pumps need an F0400033
overhaul.
3. Measurement for pumps P3 and P4

1 - Start the engine and bring it up to a speed of 2000
rpm. F1
2 - Check on the no-load delivery, and then on deliv- 1
ery at pressures of 50, 100 and 200 bar.
3 - Stop the engine and release any residual pres-
sures.
If the measured values differ from the minimum

permissible values, overhaul the pumps. F0400034
20-43
TESTING AND ADJUSTMENTS MEASURING TRAVEL DEVIATION
MEASURING TRAVEL DEVIATION
H Test conditions:
. Engine: at working temperature. 45°
. Track-shoe tension: within the correct range
H Let the machine travel over a firm, flat surface.
1. Measuring the deviation

1 - For this measurement the boom, arm and bucket
must be folded into the appropriate travelling posi-
tions. D0400186
H Fully extend the cylinder of the arm and buck-

et, and position the boom at 45ë.
2 - Bring the engine up to high idling speed.
3 - Push the travel lever forwards to the end of its
stroke.
4 - Travel for 10 metres and then measure the devia-
tion accomplished by the machine over the next
20 metres.
5 - Check whether or not the deviation occurs in the
same direction when travelling in reverse.
Travel straight
Traslarethrough
senzawithout
fermarsistopping
per 20mfor 20 m Travel for
Traslare per1010m
m
Makeun
Fare a mark
segno Makeun
Fare a mark
segno
Linea teorica
Theoretical linedi
20m of traslazione
travel 10m 0
Mark
Segno Mark
Segno
Measure
Misurarethe
la a Mark
dimension
dimensionea a della Segno
ofdeviazione
the deviation
D0400188
20-44
ADJUSTING THE MAXIMUM SPEED
TESTING AND ADJUSTMENTS OF THE TRAVEL MOTORS
ADJUSTING THE MAXIMUM SPEED OF THE TRAVEL MOTORS
H Test conditions:
. Track shoe tension: within the correct range
Test
1 - Swing the revolving frame 90ë towards the track-shoe
to be checked, and position the arm perpendicular to
the ground.
2 - Rest the back of the bucket on the ground and, push- D0400187
ing down with the boom and the arm, raise the ma-
chine until the track-shoe is at least 10 cm above
the ground.
C2
3 - Make a distinct mark for the test.
4 - Bring the engine up to high idling speed.
5 - Move forwards the travel lever of the travel motor to
be tested and press the speed increment pedal.
6 - Measure the rotation speed of the driving wheel with
the tachometer C2.
H Normal speed: 58 2 rpm
7 - Make this measurement in both directions of rotation F0400035
and for both track shoes.

The rotation speed should be the same for both
motors.
Adjustment
Release any residual pressures (See «RELEASING

RESIDUAL PRESSURES FROM THE CIRCUITS»).
1 - Remove the crankcase (1) of the motor to be regu-
lated.
1
F0400036
2 - Detach the hose (2) from the braking system and re-
move the extension (3).
3 - Attach the special extension G1.
G1
4 - Connect the braking system hose (2) to the special
extension G1.
3
5 - With the track-shoe associated with this motor still
raised, remove the locknut (4) of the speed governor (5).
5
6 - Start the engine and bring it up to high idling speed. 2
7 - Move forwards the travel lever of the travel motor to
be tested and press the speed increment pedal. F0400037
20-45
ADJUSTING THE MAXIMUM SPEED
TESTING AND ADJUSTMENTS OF THE TRAVEL MOTORS
8 - In test phase, vary the speed of the travel motor by 9 - While the travel motor is running, engage the brak-
acting on the speed governor (5) ing system. With the motor blocked, mount and
tighten the locknut (4).
. To INCREASE the speed turn in an COUN-
TERCLOCKWISE direction. Locknut: 10w1 Nm.
. To DECREASE the speed, turn in a CLOCK- The rotation speed of the two motors should
WISE direction. be perfectly equal. If necessary, repeat the
same adjustment for the other motor.
H Normal speed: 58 2 rpm
10 - Stop the engine, release any residual pressures
H Each turn of the adjusting screw changes the and re-assemble the hydraulic braking circuit.
speed by 5 rpm.
4 5
Speed
Velocità
A
+ -
View A
Vista A
D0400205
20-46
CHECKING THE CORRECT FUNCTIONING
TESTING AND ADJUSTMENTS OF THE TRAVEL ACCELERATION VALVE
CHECKING THE CORRECT FUNCTIONING

OF THE TRAVEL ACCELERATION VALVE
H Test conditions: 5 - Repeat this test while operating the travel accel-
. Engine: at working temperature. eration valve.
. Hydraulic oil: 45v55ëC. H During the test, do not use the button that gov-
. WORKING MODE selector: position P. erns straight-line travel because that automati-
cally excludes the travel acceleration.
1 - Park the machine on flat ground. H If the travel acceleration does not function
2 - Start the engine and bring it up to high idling equally for both motors, a deviation will occur.
Check the valve (1) and the cleanliness of the
speed.
nozzles (2) of the slower of the two motors.
3 - Push the travel levers forwards to the end of their H If one of the motors is not influenced by the
strokes. speed increment, check the state of the push-
rod (3), which makes the hanger (4) tilt.
4 - After travelling 10 metres, start measuring the time
taken to cover the next 20 metres.
2 2
P 1
Detail P P
Particolare
D0400206
20-47
TESTING FOR INTERNAL OIL LEAKAGE
TESTING AND ADJUSTMENTS IN THE TRAVEL MOTORS
TESTING FOR INTERNAL OIL LEAKAGE IN THE TRAVEL MOTORS
Before taking this measurement, check the efficiency

of the parking brakes.
H Test conditions.
1 - Remove the protective casings (1).

1
F0400036
2 - Disconnect the drainage tube (2) from the motor to be

tested, and cap it.
3 - Attach a temporary tube to collect any draining oil.
5 - Use the button (S8) to engage the parking brakes.
6 - Push the travel lever of the motor to be tested for-
wards to the end of its stroke. 2
7 - Hold this position for 30 seconds, then measure the

leakage for the next minute.
H Repeat the same test several times, after having F0400038
moved the machine a few centimetres to change

the position of the cylinder block of the motor.
8 - Stop the engine and, following the same procedure,
check the other travel motor.
9 - Re-assemble the hydraulic drainage circuit and re-
place the casings.
20-48
TESTING AND ADJUSTMENTS ADJUSTING BOOM AND ARM SAFETY VALVES
ADJUSTING BOOM AND ARM SAFETY VALVES
H Test conditions Boom

. Main safety valves: set to 370w5 bar V2
. Secondary valves: set to normal values.
VALVES»).
1 - Rest the work equipment on the ground, stop the en-
C2
gine and release any residual pressures (See «RE-
2
LEASING RESIDUAL PRESSURES FROM THE CIR- F0400039
CUITS»).
2 - Disconnect the pipe (1) from the coupling V2 and the
pipe (2) from coupling C2. Arm
1
H Disconnect the safety valve from the arm cylinder.
3 - Cap the pipe (2) to prevent entry of impurities. V2
H For the arm, cap the cylinder.
4 - Connect the tube (1) to the coupling C2, using a tube
with equal section.
H For the arm, connect the flange V2 to the coupling
C2.
5 - Unscrew the nut (6) and remove the threaded rod (5) C2
and the nut (4). F0400040

7 - Bring the boom cylinder bottom side or the arm cylin-
der head side slowly up to maximum pressure (320
5
bar), checking that no oil leaks out of the valve. 6 10
8 - Maintaining pressure, adjust the valve with the screw 70 Nm 4

3
(3), until a slight leakage of oil (just a few drops every 140 Nm
minute) is seen coming from the flange V2. 7
. To INCREASE pressure, turn in a CLOCKWISE
direction.
. To DECREASE pressure, turn in an COUNTER- V2
H Every turn of the screw (3) changes the pressure
by 110 bar.
9 - Block the screw (3) in position with the nut (4).
Locknut: 70 Nm. C2
10 - Screw the rod in (5) until it comes into contact with the
retaining element (7) and then turn it back for 5-6
turns. Secure it in position with the nut (6). T
11 - Rest the equipment on the ground, stop the engine,
and release any residual pressures.
12 - Re-assemble the valve connections. P
13 - Readjust the setting of the main safety valves.
VALVES»).
D0400202
20-49
TESTING AND ADJUSTMENTS ADJUSTING 2nd BOOM SAFETY VALVES
ADJUSTING 2nd BOOM SAFETY VALVES
H Test conditions:
. Hydraulic oil: 45v55ëC. 6
. WORKING MODE selector: position P 5
. Main safety valve of the 2nd section of the control 2
valve: set to 370w5 bar 3
. Secondary valves: set to normal values. 8
VALVES»). 1
1 - Rest the work equipment on the ground, stop the en- 7

F0400046
gine and release any residual pressures (See «RE-
LEASING RESIDUAL PRESSURES FROM THE CIR-
CUITS»).
H Adjust the valves of one cylinder at a time.
2 - Disconnect the pipes (1), (2), (3) and (4). 10 9
3 - Use hoses of equal section to connect up the pipes in
the following manner:
pipe (1) port (5).
pipe (2) port (6)
4 - Cap pipes (3) and (4) to prevent entry of any impuri-
ties. 13
7
5 - Remove the access caps (9) to the adjustment screws
(10-11).
5
7 - Move the 2nd boom pedal to the end of its opening
stroke.
8 - Adjust the valve (12) until a slight leakage of oil can
be seen from the flange (8).
. To INCREASE pressure, turn in a CLOCKWISE
direction.
. To DECREASE pressure, turn in an COUNTER-
H Every turn of the screw changes the pressure by
165 bar.
9 - Move the 2nd boom pedal to the end of its closing
6
stroke.
10 - Using the procedure indicated in point 8 adjust the
valve (13) until a slight leakage of oil is visible from 8 12
the port (7).
11 - Stop the engine and release any residual pressures.
12 - Replace the caps (9) and re-assemble the hydraulic
circuits.
Locknut 20 Nm.
13 - Repeat the same regulation operations for the valves 11 9
of the other cylinder.
D0400203
20-50
MEASURING THE INITIAL INTERVENTION POINT
TESTING AND ADJUSTMENTS OF THE OVERLOAD SENSOR
MEASURING THE INITIAL INTERVENTION POINT

OF THE OVERLOAD SENSOR
E2
H Test conditions:
. Boom safety valve: set to normal values
Test
ter M2 of the 2nd section of the control valve. M2
2 - Start the engine and bring it up to 2000 rpm.
F0400044
3 - Set the overload alarm to «ON» (illuminated switch

S17).
4 - Raise the boom to the end of its raising stroke. 5 3
4
5 - Bring the boom-raising cylinder slowly up to pressure,
checking at which pressure-value the overload signal
is triggered.
H Normal intervention pressure: 155w10 bar.
Adjustment
If the intervention pressure point is not within normal lim-
its, adjust the pressure switch as follows: P
1 - Unscrew and remove the protective cap (1). F0400042
2 - Pressurise the boom-raising cylinder up to a normal

intervention pressure.
3 - Turn the adjustment screw (2) until the acoustic over- P
load signal is triggered.
. To INCREASE pressure, turn in an COUNTER-
. To DECREASE pressure, turn in a CLOCKWISE
direction.
H Every turn of the screw (2) changes the pressure
by about 80 bar.
4 - Relieve pressure and repeat the test several times to 1 2
check that the interventions occur within normal lim-
its. D0400221
5 - Replace the protective cap (1).
If the setting is found to be unstable or impossible, 5 4

install a new overload sensor.
6
When a setting is made in these conditions, the inter-
vention points with the boom and arm extended are
automatically set by the cam profile (3). 3
Before removing the overload sensor (4) or the cam

(3), rotate and use a screw (6) to secure the activat-
ing lever (5) in its safety position.
F0400043
20-51
ADJUSTING THE VALVE THAT CONTROLS
TESTING AND ADJUSTMENTS THE CLOSING SPEED OF THE 2nd BOOM
ADJUSTING THE VALVE THAT CONTROLS THE CLOSING SPEED

OF THE 2nd BOOM
E2
H Test conditions:
. Olio idaulico: 45v55ëC

ter M2 of the 2nd section of the control valve.
2 - Start the engine and completely extend the arm and M2
bucket.
F0400044
3 - Raise the boom and open the 2nd boom as far as it

will go.
4 - Use the control pedal of the 2nd boom to close it to the
end of its downward stroke, and check the pressure
on the pressure gauge E2. +
H Closing pressure: 60 5 bar --
. To INCREASE pressure (i.e. to slow down the
descent) turn the knob in a CLOCKWISE direc-
tion.
. To DECREASE pressure, turn the knob in an
COUNTERCLOCKWISE direction.
F0400045
20-52
MEASUREMENT OF INTERNAL OIL
TESTING AND ADJUSTMENTS LEAKAGES IN THE SWING MOTOR
MEASUREMENT OF INTERNAL OIL LEAKAGES

IN THE SWING MOTOR
H Test conditions: 2
. WORKING MODE selector: position P 1
. Revolving frame: secured by the rotation-blocking
pin.
1 - Disconnect the drainage hose (1) of the motor (2).
2 - Attach a provisional hose to collect the drainage oil.
3 - Start the engine and bring it up to high idling speed. F0400047
4 - Push the swing control lever as far as it will go.

5 - Hold it in this position for 30 seconds and then mea-
sure the oil leakage for the next minute.
6 - Reduce motor speed to low idling, swing the revol-
ving frame 180ë and repeat the measurement.
7 - Check that the average between the two measure-
ments falls within the normal range. (See «TECHNI-
CAL DATA»).
8 - Re-assemble the hydraulic drainage circuit.
20-53
TESTING AND ADJUSTMENTS CHECKING FOR LEAKAGES INSIDE THE SWIVEL JOINT
CHECKING FOR LEAKAGES INSIDE THE SWIVEL JOINT
H Test conditions:
9 RH travel motor - Forwards
8 LH travel motor - Forwards
7 RH travel motor - Backwards
1. Functionality test 6 LH travel motor - Backwards
1 - When one of the lower-level tools (blade, travel 5 Blade cylinder bottom edge (descent)
motors, speed increment, brakes) is found to be 4 Drainage travel motor
defective, one of the causes of the failure may
3 Blade cylinder top edge (rise)
be the swivel joint.
2 Travel speed increment
2 - To confirm the defect it is sufficient to by-pass the
joint by connecting (using an additional length of 1 Travel reduction brake
tubing) the input and output hoses of the joint of
the branch to be checked.
If the defect disappears, it is certainly due to the
swivel joint.
If the defect remains, it can be due to other
causes, but not to the swivel joint.
2. Identification of defective seal
These tests should be performed on those
branches subjected to working pressures. Tests
on unstressed or unused branches are therefore
excluded.
The test method consists in pressurising the branch
under examination and measuring any leakage from
adjacent branches, as set out in the following table:
Në Branch to be tested (under pressure) Adjacent parts (Leakages) Në

External leakage (visible) ±
9 RH travel motor - Forwards
LH travel motor - Forwards 8
RH travel motor - Forwards 9
8 LH travel motor - Forwards
RH travel motor - Backwards 7
LH travel motor - Forwards 8
7 RH travel motor - Backwards
LH travel motor - Backwards 6
RH travel motor - Backwards 7
6 LH travel motor - Backwards
Blade cylinder bottom edge (descent) 5
LH travel motor - Backwards 6
5 Blade cylinder bottom side (descent)
Drainage travel motor 4
Drainage travel motor 4
3 Blade cylinder head side (rise)
Travel speed increment 2
Blade cylinder top edge (rise) 3
2 Travel speed increment
Travel brake 1
Travel speed increment 2
1 Working brakes
External leakage (visible) ±
The numbers correspond to the numbers stamped on the input and output ports of the swivel joint.
20-54
TESTING AND ADJUSTMENTS CHECKING FOR LEAKAGES INSIDE THE SWIVEL JOINT
Preparation for testing:

1
. travel motors
. travel brakes 2
. speed increment
1 - Relieve all residual hydraulic pressures (See «RE-
CUITS»). 3
2 - Identify the branch involved in the test (1).
3 - Disconnect the hoses (2) from the branches adjacent
to the part to be tested and cap them tightly.
Make sure that the detached tubes are securely
sealed, to prevent jets of high-pressure oil es- D0400222
caping if circuits that are not undergoing tests
should accidentally become pressurised.
H The tubes of the adjacent branches must be dis-
connected from the upper parts of the swivel
joint.
4 - Provisional hoses (3) for collecting any oil leakages
should be connected to the inlets of the branches ad-
jacent to the one being tested.
Preparation for testing the blade
3
1 - Relieve all residual hydraulic pressures (See «RE-
CUITS»).
2 - Identify the branch involved in the test.
3 - Disconnect the tube corresponding to the branch to
be tested from the safety valve input and cap it.
1
Make sure that the detached tubes are securely
sealed, to prevent the escape of jets of oil at high
pressure.
4 - Cap the valve to prevent entry of impurities.
5 - Disconnect from the swivel joint the hoses (2) of the
branches adjacent to the branch to be tested, and
cap them tightly.
Make sure that the detached hoses are securely 3
sealed, to prevent jets of high-pressure oil es-
caping if the circuits that are not undergoing
tests should accidentally become pressurised.
H The tubes of adjacent branches must be discon- D0400229
nected from the upper parts of the swivel joint.
6 - Provisional hoses (3) to collect any leaking oil should
be connected to the inlets of the branches adjacent to
the one being tested.
Test
1 - Start the engine and bring it up to the test speed de-
scribed for each group or component.
2 - Pressurise the branch to be tested.
3 - After 30 seconds, watch for another minute if there
are any leakages.
H If oil leaks out of one of the two provisional hoses,
it means that there is a leakage in the intermedi-
ate gasket between the branch connected to the
provisional hose and the pressurised branch.
20-55
TESTING AND ADJUSTMENTS ANALYSIS OF THE CAUSES OF HYDRAULIC DRIFTS
ANALYSIS OF THE CAUSES OF HYDRAULIC DRIFTS
H If hydraulic drift occurs in the work equipment, a

check must be carried out to see if the cause is due
to a cylinder gasket or to the control valve.
H Conditions for all checks:
. Removal and connection of tubes only after relief
of residual pressures. (See «RELEASING RESI-
DUAL PRESSURES FROM THE CIRCUITS»).
1. Boom test D0400190
1 - Position the machine with the arm vertical and the

bucket on the ground, resting on its back.
2 - Stop the engine and release any residual hydrau-
lic pressure.
2
3 - Disconnect the hose (1) that feeds the cylinder on
the head side.
4 - Remove the pipe (2) that connects the safety valve
(port C2) to the cylinder on the bottom side.
5 - Cap the two tubes to prevent entry of impurities.
6 - Cap the cylinder hole (3) on the bottom side. 3
F0400048
7 - Start up the motor and extend the arm completely.

8 - Stop the engine and check the position of the
boom for 5 minutes.
. If the boom drops, the drift is due to the cylin-
der gasket.
. If the boom does not drop, the drift is due to
the control valve.
1
F0400049
2. Arm test
1 - Position the machine with the arm completely ex-
tended and the bucket teeth on the ground.
lic pressure.
D0400191
20-56
3 - Disconnect the pipes (1) and (2) from the arm cy-
linder and cap them to prevent entry of impurities. 2
H If a safety valve has been installed, remove it.
4 - Cap the arm cylinder hole on the head side and at- 1
tach a provisional hose on the bottom side to col-
lect any leaking oil.
F0400057
5 - Start the engine and raise the boom.

6 - Stop the engine and check the position of the arm
for 5 minutes.
. If the arm drops, the drift is due to the cylinder
gasket.
. If the arm does not drop, the drift is due to the
control valve.
D0400465
3. Testing the functionality of the boom and arm

safety valve.
H This test should be carried out after having

checked that the drift is not due to the cylinder
gaskets (See «BOOM TEST» and «ARM TEST»),
and after having checked the valve settings
(See «ADJUSTING BOOM AND ARM SAFETY
VALVES»).
1 - Depending upon which valve is to be checked, po- 1
sition the machine as for the «Boom test» or for the
«Arm test».
F0400050
2 - Disconnect the hose (1) that supplies the valve
(port V2).
3 - Disconnect:
For the boom, the head side pipe. 1
For the arm, the bottom side pipe.
4 - Start the engine and extend the arm completely
for the «Boom test», or raise the boom for the
«Arm test».
5 - Stop the engine and check for leakages from the
valve for 5 minutes.
. If there is any leakage, the valve is defective.
F0400051
20-57
4. 2nd boom test

1 - Position the machine with the arm and the 2nd
boom completely extended. Rest the bucket teeth
on the ground.
lic pressures.
D0400192
3 - Disconnect the two pipes (1) and (2) and cap them
to prevent entry of impurities.
H If a safety valve has been installed, remove it.
4 - Cap the cylinder couplings on the bottom side and 1
attach provisional hoses on the head side to col-
lect any leaking oil.
2
F0400058

6 - Stop the engine and check the position of the 2nd
boom for 5 minutes.
. If the 2nd boom closes, the drift is due to the
cylinder gasket.
. If the 2nd boom does not close, the drift is due 50 cm
to the control valve.
To check one cylinder at a time, proceed as follows:
7 - Rest the bucket on the ground and release any re-
sidual hydraulic pressures.
8 - From one cylinder remove the cap mounted on the D0400193
bottom side during phase 4.

9 - Start the engine, raise the boom and then stop the
engine.
10 - Check the position of the 2nd boom for 5 minutes.
. If the 2nd boom closes, the drift is due to the
gaskets of the cylinder that has been capped.
11 - Repeat the operation from phase 8 to phase 10 to
test the other cylinder.
20-58
5. Testing the functionality of the 2nd boom safety

valves
H This test should be performed after having ascer- V2

tained that the drift is not due to the cylinders.
(See «2nd BOOM TEST») and after having checked
the adjustment of the safety valves (See «AD- V1
JUSTING 2nd BOOM SAFETY VALVES»).
1 - Position the machine with the arm and 2nd boom
fully extended. Rest the bucket teeth on the
ground.
2 - Stop the engine and relieve any residual hydraulic F0400052
pressures.
3 - Disconnect the connecting tubes of the safety
valves (two pipes of ports V1 and V2 for each
valve).
5 - Stop the engine and check the position of the 2nd
boom for 5 minutes. 50 cm
. If the 2nd boom tends to close, both safety

valves are defective.
D0400193
6. Bucket test
bucket horizontal and resting on the ground. Put a
weight in the bucket, or fill it with earth.
lic pressure.
3 - Disconnect the pipes (1 and 2) of the bucket cylin-
der and cap them to prevent entry of impurities.
4 - Cap the hole in the bucket cylinder on the bottom
side and attach a provisional hose on the head
side to collect any oil leakages. D0400194
F0400053
20-59

bucket for 5 minutes.
. If the bucket tends to open, the drift is due to
the cylinder gasket.
. If the bucket does not tend to open, the drift is
due to the control valve. 50 cm
D0400195
7. Boom swing test

1 - Position the machine with the boom, arm and
bucket raised and with the revolving frame turned
90ë to the right.
lic pressure.
3 - Disconnect the pipes (1 and 2) of the boom swing
cylinder and cap them. 15°
4 - Cap the hole in the boom swing cylinder on the

bottom side and attach a provisional hose to the
D0400211
head side to collect any oil leakages.
5 - Start the engine and move the machine onto a 15ë
slope.
boom for 5 minutes.
. If the boom tends to swing, the drift is due to
the cylinder gasket.
. If the boom does not tend to swing, the drift is
due to the control valve. 1 2
F0400054
8. Blade test
1 - Position the machine with the arm vertical and
resting on the ground, and with the bucket resting
on its back.
2 - Bring the blade to roughly half its potential stroke
and rest it on a centrally placed block.
27 cm
lic pressure.
D0400196
20-60
4 - Disconnect the pipe (1) and the safety valve (2)

from the blade cylinder and cap them to prevent
entry of dust or foreign bodies.
5 - Cap the hole in the blade cylinder on the head
side and attach a provisional hose to the bottom
side of the cylinder to collect any oil leakages. 1
6 - Start the engine, push down with the boom to

raise the machine in order to remove the block
2
on which the blade is resting.
7 - Lower the machine and stop the engine.
F0400059
8 - Check the position of the blade for 5 minutes.

. If the blade tends to sink, the drift is due to the
cylinder.
. If the blade does not tend to sink, the drift is
due to the safety valve group.
H To discover whether or not the drift is due to
the swivel joint, see «CHECKING FOR LEA-
KAGES INSIDE THE SWIVEL JOINT - BLADE
CIRCUITS».
D0400226
9. Swing motor test

1 - Position the machine with boom, arm and bucket
raised as in the figure, and with the revolving
frame turned 90ë.
lic pressure.
D0400228
3 - Disconnect the hoses (1 and 2) from the motor

and cap them to prevent entry of impurities. At-
tach some provisional hoses to the motor to col-
lect any oil leakages.
1
F0400055
20-61
4 - Disconnect the hose of the swing brake from the

selector valve and install the test equipment H1 E5
between the choke valve (3) and the hose (4). At-
tach the pressure gauge E5 (60 bar) to the adapter
of the apparatus H1 to measure the brake release
pressure for the entire duration of the test.
5 - Keeping the test equipment cock open, start the 3
engine and swing the revolving frame round sev-
eral times. 4
H1
6 - With the braking circuit pressurised (35 3.5 bar),
close the test equipment cock to maintain pres- D0400223
sure and thus cancel out the braking action.
7 - Let the machine travel onto a 15ë slope, and stop
the engine.
8 - Mark the position between revolving frame and
track frame on the swing circle. Check on any
swinging movement of the revolving frame for 5
minutes.
. If the revolving frame tends to swing, the drift
is due to the swing motor.
. If the revolving frame does not tend to swing, 15°
the drift is due to the control valve
H During this test, the pressure indicated on the
pressure gauge E5 should not drop below the D0400230
limit value of 10 bar.
10. Testing the travel motors

bucket on the ground resting on its back. Stop the
engine.
D0400274
20-62
2 - Disconnect the brake release hose (1) and insert

the test equipment H1 between the solenoid valve
block and the hose (1). Connect the pressure
gauge E5 (60 bar).
H Attach the pressure gauge firmly.
H1
E5
D0400224
3 - Start the motor, raise the front equipment and let

the machine travel onto a 15ë slope.
H The sprocket should be towards the top of the
slope.
4 - Close the cock of the test equipment H1 to main-
tain pressure (35 3.5 bar) and thus cancel the
braking action. Stop the engine.
5 - After 5 minutes, mark the position of the machine. 15°
6 - Check both track shoes for machine movement

every 5 minutes, for a total of 15 minutes.
D0400212
H During this test, the pressure indicated by the
pressure gauge E5 should not drop below the
limit value of 10 bar.
20-63
20-64
TROUBLESHOOTING
Procedures to follow while troubleshooting. .. . . . .. . 66 Difficulties with raising or lowering the boom. . .. . . . 79
Rules to be observed when working on Excessive response time for the boom, arm
hydraulic circuits or equipment . . . .. . . . .. . . . . .. . . . .. . 67 and bucket . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 80
Checks to be carried out before troubleshooting . . 69 Boom slow to rise
Excessive travel deviation. . . .. . . . . .. . . . .. . . . . .. . . . .. . 70 Arm slow to close . . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 82
The machine deviates excessively at The servocontrol supply group does not
commencement of travel . . . . .. . . . . .. . . . .. . . . . .. . . . .. . 74 function or the pressure is unstable . .. . . . . .. . . . .. . . . 83
Work equipment, revolving frame swing The control levers move, but the movements
and travel slow or without power . .. . . . .. . . . . .. . . . .. . 75 are incomplete or have no effect . . . . .. . . . . .. . . . .. . . . 84
Work equipment, revolving frame swing and The speeds do not change if the working mode
travel function intermittently. .. . . . . .. . . . .. . . . . .. . . . .. . 76 selector is positioned on E .. . . . .. . . . . .. . . . . .. . . . .. . . . 86
Revolving frame swing is slow in both directions . . 77 Abnormal pump noise . . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 86
Revolving frame swing is slow in one direction, Engine loses power or stalls during work . .. . . . .. . . . 87
and does not brake properly on that side. . . .. . . . .. . 78
20-65
TROUBLESHOOTING PROCEDURES TO FOLLOW WHILE TROUBLESHOOTING
PROCEDURES TO FOLLOW WHILE TROUBLESHOOTING
Park the machine on firm, flat ground. Always make sure that the swing-blocking safety pin is in place, that the
boom swing control pedal lock is engaged, and that the safety devices of the work equipment are in their
locked position.
. When more than one person is involved in the operation, keep scrupulously to agreed signals and phrases. Do
not allow any unauthorised person into the working area.
. Take care not to touch heated parts, or to become entangled in rotating elements.
If electrical wiring is to be disconnected, first disconnect the negative clamp (-) from the battery.
Always release residual pressures before removing caps, or loosening hydraulic or coolant circuit tubes. When
mounting measurement instruments or other special testing equipment, make sure that they are connected
correctly.
The purpose of troubleshooting is to diagnose the original cause of the fault, to carry out repairs quickly, and to
prevent repetition of the damage.
Before one can do this, however, one must be familiar with the machine, its component parts and how they
function.
One method that may shorten the time needed for trouble-shooting is to ask the operator a few questions. His
replies may help to direct the search to possible causes that have given rise to the fault.
1. When trouble-shooting, do not immediately take 3 - Check that the levers for each individual com-
components to pieces. If components are re- mand pass through their entire stroke.
moved and taken apart immediately after a defect 4 - Check all other components that are subject to
has been noticed, and without any preliminary regular maintenance. If deemed useful, carry
analysis, there is a risk of: out normal maintenance.
. dismantling parts that are only apparently in- 4. Confirmation of the defect.
volved in the fault; . Personally check out the nature of the trouble
. unnecessarily dismantling parts not required to make sure that it is a true fault, or whether
for achieving a repair; or not it may have been caused by the way in
. frequently making it impossible to find the ori- which the machine was used, or by other
ginal cause of the defect. causes.
This behaviour causes loss of time and unneces- H When the machine is started up to identify
sary use of tools and products (oil, grease, etc.) any symptoms which might determine or
but, worse still, it leads to loss of faith on the part direct attention to the identification of a
of the user or the operator. fault, avoid taking measurements or hand-
For these reasons, when trouble-shooting, one ling the machine in such a way as to wor-
sen the problem.
must first obtain information, and then follow es-
tablished procedures while searching for the fault. 5. Fault-diagnosis
. Use the results obtained from points 2 and 4
2. Questions to put to the operator: to approach the cause of the fault or failure
1 - Are there any other problems, in addition to and then use the search table to identify the
the one notified? defective part more precisely.
2 - Did you notice anything unusual before the H The basic procedure for troubleshooting is
fault occurred? as follows:
3 - Did this fault occur unexpectedly, or has the 1 - Start with the simpler faults.
machine been suffering from other problems 2 - Start from the most likely points.
previously 3 - Look for other related components and
4 - Under what precise conditions did the fault oc- pertinent information.
cur? 6. Methods for the removal of the cause that gave
5 - Have other repairs been carried out before the rise to the fault.
fault occurred? . If the fault is repaired, but the cause that gave
6 - Have similar faults ever occurred previously? rise to it is not dealt with, the same fault may
occur again. To avoid such repetition, look for
3. Tests to be performed before starting any trouble- the cause of the problem and deal with that as
shooting operations. well.
1 - Check the oil level in the tank.
2 - Check that there are no external oil leakages
from hoses, pipes, or hydraulic equipment.
20-66
RULES TO BE OBSERVED WHEN WORKING
TROUBLESHOOTING ON HYDRAULIC CIRCUITS OR EQUIPMENT
RULES TO BE OBSERVED WHEN WORKING ON HYDRAULIC

CIRCUITS OR EQUIPMENT
1 - Do not add hydraulic oil, change filters or carry out in- 6 - Do not let the oil drain out onto the ground, but
ternal inspections of the hydraulic equipment in con- collect it in containers that can be disposed of
ditions of dust, rain or wind. as industrial waste.
2 - During inspection or dismantling of hydraulic equip- 7 - When changing oil and/or filters, make sure that
ment, observe scrupulous cleanliness in order to pre- the fillers and the surrounding area are clean.
vent entry of foreign bodies or dust.
8 - Drain the hydraulic oil and engine oil while they
3 - If an emergency intervention is unavoidable in the are still hot, but not hot enough to cause burns
area where work is in progress, take all possible pre- (max. 50ëC).
cautions to prevent penetration of dust or foreign This method ensures removal of suspended
bodies into the tubes or components. particles of metal and sludge. Drain only
If necessary remove the defective hydraulic equip- through the proper drainage outlets.
ment to the workshop where repairs are normally car-
9 - When refilling the hydraulic oil, use only clean
ried out.
containers and decanting pumps. If possible
4 - Before reinstalling hydraulic equipment that has been start the engine, perform a few movements with
repaired or substituted because of failure, test its per- all the equipment and then filter the oil through
formance using the appropriate test equipment. appropriate apparatus for filtering out ultra-fine
particles (about 3 m).
5 - After removing pipes, cap the holes or pipes with
caps, adhesive cocke or plastic covers. 10 - If hydraulic hoses are to be substituted, flush
Never seal them with rags because if there is even a them all out at high pressure in order to remove
minimal leakage of oil, impermeability to dust cannot all impurities before installation.
be guaranteed. Furthermore, the area around the
plug may become impregnated with dirt that could
prove difficult to remove.
20-67
20-68
TABLE OF FAILURE MODES AND CAUSES TESTS TO
TROUBLESHOOTING BE CARRIED OUT BEFORE TROUBLESHOOTING
TABLE OF FAILURE MODES AND CAUSES TESTS

TO BE CARRIED OUT BEFORE TROUBLESHOOTING
Standard
Operations values Remedy
1 - Check the fuel level Ð Fill up
2 - Check for dirt or water

in the fuel tank Ð Clean or drain
Lubricants, cooling, fuel
3 - Check the level of the hydraulic oil Ð Fill up
4 - Check the hydraulic oil filter Ð Substitute
5 - Check the oil level in the final drive Ð Fill up
6 - Check the oil level in the swing machinery Ð Fill up
7 - Check the engine oil level Ð Fill up
8 - Check the cooling liquid level of the engine Ð Fill up
9 - Check the engine air filter Ð Clean or substitute
1 - Check the tightening and condition of Ð Tighten or substitute

Electrical circuit
the accumulator clamps
2 - Check the tightening and condition of

the alternator clamps Ð Tighten or substitute
3 - Check the tightening and condition of

the starting motor clamps Ð Tighten or substitute
Hydraulic circuit
1 - Check any unusual noises or smells Ð Repair
2 - Check any oil leakages Ð Repair
3 - Bleed air from the circuits Ð Bleed
1 - Check the accumulator voltage

(engine stopped) Substitute
10-14 V
2 - Check the electrolyte level Fill up

Ð
3 - Check the electrical wiring
(burnt through or damaged insulation) Substitute
Ð
Electrical components
4 - Check terminal blocks and cable attachments Repair

Ð
5 - Check the cable attachment in the connectors Disconnect and
and look for any presence of water Ð dry
6 - Check that the fuses are in good condition and

Ð Substitute
not corroded
7 - Check the alternator voltage 14 V

(engine at about 1500 rpm) Substitute
8 - Check that there is no noise when the ignition Ð Substitute the

key is turned to position I noisy part
20-69
TROUBLESHOOTING
EXCESSIVE TRAVEL DEVIATION

(at low and high speed)
H For details on testing the deviation, see «TESTING AND ADJUSTMENTS»
4
YES Check whether
or not the devia-
tion is inverted if
the hoses of the
3 travel motors are
inverted on the
Check that the control valve.
YES deviation occurs
in both forward 5
and reverse
movement Check whether
or not the devia-
tion can be
eliminated by
connecting the
hoses to exclude
NO the swivel joint.
YES
2
Check that the
rotation speeds 8
YES of the travel Check whether
motors, without there are any
1 load, are nor- YES metal particles
mal. suspended in
Check that the
speed of the the reduction
boom and arm . First adjust the unit oil
track-shoe tension.
are normal
rpm
. If the machine Standard
deviates speed
to the right, check
the arm With NO
sec. increment 7
. Engine: high idling
Opening speed Check that the
YES oil leakages in
Closing [ If the speed with in- the motor are
crement is abnor- normal.
mal, see point 11
. If the machine
deviates . Max.............l/min
to the left, check
the boom . Engine: high idling
sec. speed
6 . Brake engaged
Opening
Check that the
Closing pedal controls
NO pass through
their full stroke.
Stroke: w12ë
NO
NO
20-70
TROUBLESHOOTING
Cause Remedy
Defective control valve Repair or

substitute
Defective travel motor Repair o

substitute
Leakages inside Repair

the swivel joint
Defective motor Repair o

substitute
Repair o
Defective final drive substitute
YES Leakage of the

secondary valves Substitute
YES Repair o
9 Defective travel motor substitute
11
Check if the de-
viation can be Check whether
inverted by ex- YES or not the de- YES Clogged nozzle of travel
changing the viation also oc- acceleration valve Clear or
12 substitute
secondary curs at high or broken push-rod
valves on the speed. Check whether
control valve. or not the speed
10 increment valve
NO is being pres-
Check that the surised.
oil leakages of
NO the swivel joint
are normal. Pressures: 35 3.5 bar Defective push-button,
electrical connections Substitute
NO or EV2 solenoid
Max. leakage: ..........
cc/min.
Defective swivel joint Repair

NO
Loss of travel motor Repair o

efficiency substitute
Defective PPC valve Substitute
20-71
TROUBLESHOOTING
EXCESSIVE TRAVEL DEVIATION

(at low and high speed)
H For details on testing the deviation, see «TESTING AND ADJUSTMENTS»
15 YES
Check whether
or not the de-
viation can be
YES inverted by ex-
changing the
14 delivery hoses
of the pumps P1
Check that ad- and P2.
YES justment of the
main safety NO
13 valves is normal
Check that the Main safety valves:
servocontrol 280w5 bar
NO pressures are NO
normal.
Pressures: 35 3.5 bar
NO
20-72
TROUBLESHOOTING
Cause Remedy
Loss of efficiency in Repair o

pump P1 or P2 Substitute
Secondary valves Regulate or

substitute
Main safety valves Regulate
Reducing valve Regulate
20-73
TROUBLESHOOTING
The machine deviates excessively at the commencement of travel

(Shifting the levers from a neutral to MAX position)
Cause Remedy
3
Check that the
YES plays in the PPC
2 valves have
Defective PPC valve Adjust
Check whether been adjusted

or not the trouble
YES remains after
having inverted
the tubes of the 4
1 slow motor on
Check that the the control valve Check whether
or not the noz-
pressure of the zles of the con- Clogged spool nozzles Clean
servocontrols is NO trol valve spools
normal are clogged.
Pressures: 35 3.5 bar
Reduction valve Regulate
NO
Cause Remedy
The machine deviates when other movements are exe-
cuted, even with the parallelism engaged
Solenoid EV3 or Substitute EV
relative electrical or repair
Cause Remedy
The machine does not move when commanded to travel

Solenoid valve EV1 or
relative electrical Substitute EV
circuit defective or repair
(the negative brake
is not released)
20-74
TROUBLESHOOTING
Work equipment, revolving frame swing and travel are slow or

without power
Cause Remedy
YES Defective secondary Regulate or

valve substitute
3
YES Check that
2 pump deliveries
are normal
Check that the
setting of the
YES main safety Repair or
valves remains Pump defective substitute
constant with NO
the motor at MIN
and MAX
Defective main safety Substitute
Dp MAX: 10 bar NO valve
1
Check that the
pressure of the Not function- Check the
YES ing or func- Adjust or
servocontrols is servocontrol safety substitute
tioning alter- microswitch
normal and nately
constant. 5
Check that the
Pressures: 35 3.5 bar YES solenoid valve
EV4 is function-
4 ing normally
Check that the
regulation of the Not function- EV4 solenoid valve Substitute
NO reduction valve NO ing defective
is normal
Reducing valve Regulate

NO
20-75
TROUBLESHOOTING
Work equipment, revolving frame swing and travel mechanisms

function intermittently
Cause Remedy
YES Defective control valve Substitute

spools
2
Check whether
or not the con-
YES trol valve spools
of the individual
movements
have seized up
Air in the servocontrol Bleed air

NO circuits
1
Check that the Not function- Check the
pressure of the YES ing or func- servocontrol Adjust
servocontrols is tioning alter- safety or substitute
constant 4 nately microswitch
Pressures: 35 3.5 bar Check that the
YES solenoid EV4 is
functioning cor-
3 rectly
Check that the EV4 solenoid valve

accumulator is Not function- Substitute
NO NO ing defective
fully charged
Pre-set pressures
12 1 bar Recharge or
Accumulator substitute
NO
20-76
TROUBLESHOOTING
The revolving frame swing speed is slow in both directions
Cause Remedy
YES Swing machinery Substitute

brake defective
4
Check that the
YES adjustments of
the secondary
3 valves are nor-
Check that the mal
servocontrol
YES Adjustment: Secondary valves
pressure 190/160w5 bar Regulate
reaches the NO incorrectly regulated
2 swing machin-
Check whether ery brake
YES the oil leakages Choke valves or selection Clean or
in the swing valves defective substitute
motor are nor- NO
mal
1
MAX. ........ cc/min.
Check that the Swing motor defective Substitute
main safety NO
valve of the 3rd
section of the
control valve is
regulated to YES Main safety valve Regulate
normal values wrongly adjusted
5
Main safety valve:
200w5 bar Check whether
or not it is pos- YES Main safety valve
sible to set the Substitute
NO 6 defective
main safety
valve Check whether
or not the trou-
ble can be 7 YES
eliminated by Pump P3 defective Substitute
NO changing the Check whether
main safety or not the trou-
valve. ble can be
eliminated by
inverting the
NO deliveries of
pumps P2 and
P3 on the con-
trol valve.
Control valve defective Substitute
NO
20-77
TROUBLESHOOTING
The revolving frame swing speed is slow in one direction, and does
not brake properly on that side
Cause Remedy
YES Repair or
2 Control valve defective substitute
Check whether
or not the defect
YES remains when
the anticavita-
tion valves are
inverted on the
control valve.
Anticavitation valves Substitute
1 NO defective
Check whether
or not the defect Repair or
can be inverted YES
Swing motor defective substitute
by inverting the
tubes on the 4
control valve. Check that the
YES setting of the
secondary
valves on the
3 motor is normal
Check that the
Adjustment:
swing motor Valves incorrectly
drainage is nor-
190/160w5 bar Regulate
NO NO regulated
mal
Max. ........ cc/min. Repair or

Swing motor defective substitute
NO
20-78
TROUBLESHOOTING
Difficulties with raising or lowering the boom
Cause Remedy
YES Repair or
Control valve defective substitute
3
Check that the
YES pressure of the
servocontrols is
2 normal
Check that the Pressure: 35 3.5 bar
YES setting of the Repair or
Cylinder defective substitute
secondary valve NO
is normal
Adjustment:
320 w 5 bar
Adjust
NO
Raising
YES
Defect of cylinder gasket Sostituire
4
Check that the
intermediate cy-
NO linder leakages YES Repair or
are normal 5 Pumps P1 - P2 defective substitute
Check that the
1 regulation of the
Check that the NO main safety
other equipment valve is normal.
is working at Valves incorrectly
regulated Adjust
normal speed NO
YES Dismantle
7 Defective valve and check
Check that the
YES pilot pressure is
reaching the
6 boom safety
valve.
Check that the Check the supply line
YES control valve NO
spool passes
through its en-
tire stroke
Repair or
Control valve defective substitute
Lowering NO
Servocontrol pressure Adjust

NO
20-79
TROUBLESHOOTING
Excessive response time for the boom, arm and bucket

H When travel and boom swing are normal
. Engine: low idling speed
YES
3
YES Check that the YES
working speeds
are normal
5
Check that the
YES deliveries of
pumps P1 and
2 P2 are normal
4
Check that the
YES pressure of the Check that the
servocontrols is engine is run-
normal and NO ning normally NO
stable
Pressure: 35 3.5 bar
1
NO
Check whether
or not this phe-
nomenon is oc-
curring with all
the equipment NO
(boom, arm and
bucket)
6 YES
Check whether
or not the defect
can be elimi-
nated by invert- YES
NO ing the second-
ary valves of the 7
faulty equip- Check that the
ment. pressure of the
servocontrols is
NO normal and
stable
NO
20-80
TROUBLESHOOTING
Cause Remedy
Anticavitation valves Substitute

defective
Spool defective Substitute
Repair or
Pumps defective substitute
Engine See
engine
manual
Supply to the
servocontrols Regulate
defective
Secondary valves
defective Substitute
Incomplete spool stroke Substitute

spool
Supply to the
servocontrols Regulate
defective
20-81
TROUBLESHOOTING
Boom slow to rise

Arm slow to close
Cause Remedy
YES Choke nozzle clogged Clean

2
Check that the
YES rest of the
1 equipment is
working at nor-
Check that the mal speed
servocontrol
pressure is
reaching the Servocontrol pressure Adjust
choke valve of NO
the speed re-
doubling spool.
Supply line interrupted Check
NO
20-82
TROUBLESHOOTING
The servocontrol supply group does not function or the pressure is

unstable
Cause Remedy
4
YES The pressure
value at the PV Reduction valve Regulate
port is low.
3
Check whether
YES the pressure at
2 the PV port is
Check whether low.
the pressure re-
mains stable Reduction valve Repair or
while the work defective substitute
equipment exe- NO
YES cutes several
movements, or
whether it tends YES
to drop below Filtering element Substitute
the minimum
permissible va- 5
lues.
1 Check whether
Check whether Pressure: 35 3.5 bar or not the filter is
NO clogged
or not there is
pressure at the
output of the
group Recharge or
Accumulator flat substitute
NO
6 YES P3 pump entrainment Repair

Check that the defective
EV4 solenoid
NO valve is ener-
gised. EV4 solenoid valve or Repair or
NO relative circuit defective substitute
20-83
TROUBLESHOOTING
The control levers move, but equipment movements are incomplete

or have no effect
H WORKING MODE selector: position P
YES
4
Check the sta-
YES bility of the ser- YES
vocontrol sys-
tem pressure 5
Pressure: 35 3.5 bar Check that the
3 safety micro-
Check that the NO switch is func-
YES deliveries of tioning normally
pumps P1-P2-
P3 are normal
NO
2
Check that the
YES diesel engine is
functioning nor- NO
1 mally
Check that the
level of hydrau-
lic oil in the tank
is within correct NO
limits
NO
20-84
TROUBLESHOOTING
Cause Remedy
Air in the circuit Bleed the

spools
EV4 solenoid defective Repair or

substitute
Switch defective Adjust or

substitute
Pumps defective Repair or

substitute
See
Engine engine
manual
Hydraulic oil level Top up
20-85
TROUBLESHOOTING
Speeds do not change if the working mode selector is positioned

on E
Cause Remedy
YES Mode System piston Overhaul

defective the group
2
Check that
YES pressure is
reaching the
Mode System
1 device
Check that
pressure to the EV5 solenoid valve or Substitute or
servocontrols is relative command
NO
circuit defective repair
normal

Servocontrols feed unit Adjust
NO
Abnormal noises in the pumps
Cause Remedy
YES Pumps defective Substitute

3
Check that there
YES are no metallic
particles in the
filter of the hy-
2 draulic system
Check that the Move the equipment
YES suction hose is a few times and check Repeat the
completely air- NO whether or not the noise inspections
tight persists or changes
1
Check that the
hydraulic oil le- Air infiltrations Eliminate
vel is within NO
normal limits
Oil level Top up

NO
20-86
TROUBLESHOOTING
Engine loses power or stalls during work
Cause Remedy
YES
Summation horsepower Repair or
2 control defective substitute
Check whether
or not the defect
YES occurs only YES 3-circuit valve Repair or
when the work 3 defective substitute
equipment is in
use. Check whether
or not the defect
1 occurs in com-
NO bination with a
Check whether swing opera-
or not the pump tion.
goes into self- 3-circuit valve and
regulation. Repair or
summation horsepower substitute
(Summation NO control defective
horsepower
control function-
ing)
Pump defective Overhaul or

NO substitute
20-87
DISASSEMBLY AND ASSEMBLY
HOW TO READ THE MANUAL. . . .. . . . .. . . . . .. . . . .. . . 3 PUMP GROUP

PRECAUTIONS TO BE TAKEN WHILE Removal and Installation. . . . .. . . . . .. . . . . .. . . . .. . . . 28
WORKING . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 4 HYDRAULIC PUMP
SPECIAL TOOLS . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 5 Disassembly . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 29
STARTING MOTOR Assembly . . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 36
Removal and Installation .. . . . . .. . . . .. . . . . .. . . . .. . . 7 GEAR-PUMP
ALTERNATOR Removal and Installation. . . . .. . . . . .. . . . . .. . . . .. . . . 42
Removal and Installation .. . . . . .. . . . .. . . . . .. . . . .. . . 8 Disassembly . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 43
NOZZLE HOLDER Assembly . . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 46
Removal and Installation .. . . . . .. . . . .. . . . . .. . . . .. . . 9 ENGINE-PUMP COUPLING JOINT
AIR FILTER GROUP Removal and Installation. . . . .. . . . . .. . . . . .. . . . .. . . . 51
Removal and Installation .. . . . . .. . . . .. . . . . .. . . . .. . 10 SWIVEL JOINT
MUFFLER Removal and Installation. . . . .. . . . . .. . . . . .. . . . .. . . . 52
Removal. . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 11 SWING MOTOR
Installation .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 12 Removal and Installation. . . . .. . . . . .. . . . . .. . . . .. . . . 53
ENGINE HOOD SWING MACHINERY
Removal and Installation .. . . . . .. . . . .. . . . . .. . . . .. . 13 Removal and Installation. . . . .. . . . . .. . . . . .. . . . .. . . . 54
FIXED HOOD Disassembly . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 55
Removal. . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 14 Assembly . . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 63
Installation .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 15 REVOLVING FRAME
SEAT Removal .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 74
Removal and Installation .. . . . . .. . . . .. . . . . .. . . . .. . 16 Installation. . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 75
CABIN SWING CIRCLE
COUNTERWEIGHT TRAVEL MOTOR
RADIATOR TRACK-SHOES
HYDRAULIC OIL COOLER SPROCKET
HEATING FAN FINAL DRIVE
Removal. . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 21 Removal and Installation. . . . .. . . . . .. . . . . .. . . . .. . . . 80
Installation .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 22 Disassembly . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 81
FUEL TANK Assembly . . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 87
Removal and Installation .. . . . . .. . . . .. . . . . .. . . . .. . 23 IDLER AND RECOIL SPRING
HYDRAULIC OIL TANK Removal and Installation. . . . .. . . . . .. . . . . .. . . . .. . . . 97
Removal and Installation .. . . . . .. . . . .. . . . . .. . . . .. . 24 IDLER
ENGINE-PUMP GROUP Disassembly and assembly. .. . . . . .. . . . . .. . . . .. . . . 98
Removal. . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 25 RECOIL SPRING AND CYLINDER
Installation .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 27 Disassembly and assembly. .. . . . . .. . . . . .. . . . .. . . . 99
30-1
TRACK ROLLER BLADE CYLINDER
Removal and Installation. . . . .. . . . .. . . . . .. . . . .. . . 100 Removal and Installation . .. . . . . .. . . . .. . . . . .. . . . . 116
CARRIER ROLLER WORK EQUIPMENT CYLINDERS
Removal and Installation. . . . .. . . . .. . . . . .. . . . .. . . 101 Disassembly . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . 117
RI.H. PPC VALVE Assembly . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . 118
(Boom-Bucket) OVERLOAD SENSOR
Removal and Installation. . . . .. . . . .. . . . . .. . . . .. . . 102 Removal and installation . .. . . . . .. . . . .. . . . . .. . . . . 122
L.H. PPC VALVE WORK EQUIPMENT
(Arm - Swing) (For boom version)
Removal and Installation. . . . .. . . . .. . . . . .. . . . .. . . 103 Removal and installation . .. . . . . .. . . . .. . . . . .. . . . . 123
BLADE PPC VALVE WORK EQUIPMENT
Removal and Installation. . . . .. . . . .. . . . . .. . . . .. . . 104 (For the 2-piece boom version)
PPC VALVE Removal . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . 124
(For travel, boom swing, 2-piece boom) Installation . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . 125
Removal and Installation. . . . .. . . . .. . . . . .. . . . .. . . 105 BUCKET
SERVOCONTROL FEED UNIT Removal and Installation . .. . . . . .. . . . .. . . . . .. . . . . 126
Removal and Installation. . . . .. . . . .. . . . . .. . . . .. . . 106 ARM
CONTROL VALVE Removal . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . 127
Removal and Installation. . . . .. . . . .. . . . . .. . . . .. . . 107 Installation . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . 129
BOOM CYLINDER 2-PIECE BOOM
Removal and Installation. . . . .. . . . .. . . . . .. . . . .. . . 108 Removal . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . 130
BOOM CYLINDER Installation . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . 131
(2-piece boom version) BOOM
Removal . . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 109 Removal and Installation . .. . . . . .. . . . .. . . . . .. . . . . 132
Installation. . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 110 BOOM (2-piece boom version)
2-PIECE BOOM CYLINDER Removal . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . 133
Removal . . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 111 Installation . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . 134
Installation. . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 112 SWING BRACKET
ARM CYLINDER Removal and Installation . .. . . . . .. . . . .. . . . . .. . . . . 135
Removal and Installation. . . . .. . . . .. . . . . .. . . . .. . . 113 BLADE
BUCKET CYLINDER Removal and Installation . .. . . . . .. . . . .. . . . . .. . . . . 136
Removal and Installation. . . . .. . . . .. . . . . .. . . . .. . 114
BOOM SWING CYLINDER
Removal and Installation. . . . .. . . . .. . . . . .. . . . .. . . 115
30-2
DISASSEMBLY AND ASSEMBLY HOW TO READ THE MANUAL
HOW TO READ THE MANUAL

1. Removal and Installation of the groups
(1) The procedures and information needed to carry out the work of removing or Installing units or groups are
given in the removal procedure. The sequence of operations is not repeated in the installation procedure.
(2) Information needed for installation is marked with the symbol . The same symbol is repeated at the
end of each removal procedure for the same item, to indicate to which installation item it refers.
(Example)
REMOVAL GROUP : *** : . . . . . . . . . . . . . . . . . . . . . . . . Title of operation
:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety precautions to be followed when carrying

out the operation.
1 - Remove XXXX (1):. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Step in removal procedure.
H : . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Technique or important point to remember when re-
moving XXXX (1)
2 - ~ ~ ~ (2): . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . This sign means that information is given for
the installation procedure
3 - Remove &&&& (3):
........... ,: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Recovery of oil or water, and the quantity to be re-
covered.
INSTALLATION GROUP *** : . . . . . . . . . . . . . . . . . . . . . Title of operation.

. To install, reverse removal procedure.
: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Technique to be used for installation.
H : . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Technique or important point to remember when re-
moving ~ ~ ~ (2).
. Addition of water or oil: . . . . . . . . . . . . . . . . . . . . . . Step in removal procedure.
H : . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Point to remember when adding water or oil.
2. To the precautions to be taken during the removal or installation of the groups, must be added the specific
«PRECAUTIONS TO BE TAKEN DURING THE OPERATIONS».
Always make sure that these precautions are taken.
3. List of special tools.

(1) For details of the descriptions, codes and quantities of each tool (A1; A2 etc.) mentioned in the operational
procedures, see the list «SPECIAL TOOLS» supplied in this section.
4. List of the tightening torques and weights, and the quantities oil, liquids or grease needed to fill
tanks and containers
(1) In the operating procedures, you will find the symbols , , , . In the following order, these
represent the values of «TIGHTENING TORQUES», «WEIGHT OF PARTS OR GROUPS», «QUANTITIES
OF OIL OR LIQUIDS TO BE INTRODUCED», «SCREW LOCKING MATERIAL, SEALANTS AND LUBRICA-
TION», «LUBRICATING GREASE».
NOTE
If no symbol is indicated, the values to be used are those given in the introductory sections of this manual.
30-3
DISASSEMBLY AND ASSEMBLY PRECAUTIONS TO BE TAKEN WHEN WORKING
PRECAUTIONS TO BE TAKEN WHEN WORKING
H When dismantling or installing a part, always take the following general precautions.
1. Precautions for removal operations

. If not otherwise indicated, lower the work equipment until it rests on the ground.
. If the coolant liquid contains an anti-freeze substance, follow the instructions given for drainage.
. After having removed flanges and tubes, insert plugs to prevent impurities from entering.
. Before removing a cylinder, fully retract the piston and tie it with wire.
. Use a sufficiently large container to collect the oil.
. Before removing a part from the machine, check the alignment reference marks which show the correct in-
stallation position. If necessary add further marks to avoid incorrect installation.
. While dismantling the connectors, always grasp them firmly to avoid undue strain on the wiring.
. If necessary, attach markers to the wires and tubes to avoid muddling them up during installation.
. Check the number and height of the adjustments to a given clearance and store them in a safe place.
. When raising the machine or some parts of it, use adequate equipment for the weight of the part concerned.
. When using screws or eyebolts to remove items of the machinery, screw them alternately, and as deeply as
they will go.
. Before removing a piece, clean the surrounding area and, after removal, cover the area to prevent dirt or
dust from gaining entrance.
2. Precautions to be taken during installation
. Tighten nuts and screws with the specified tightening torques.
. Install the flexible hoses, taking care not to entangle or twist them.
. Bend the cotter pins and stops in such a way as to secure them.
. When coating the threads with adhesives, clean the piece to remove oil and grease, then apply just enough
adhesive to cover the threading in a uniform manner.
. When applying a liquid sealant, clean the surface involved, remove residual oil and grease, check that there
are no dents or dirt, then apply the liquid sealant in a uniform manner.
. Clean all the parts, remove dirt, rust, burrs, or dents.
. Apply a film of engine oil over all the moving parts.
. Apply a film of anti-friction grease (ASL800040) over all surfaces assembled with pressure, to avoid sticking.
. After having mounted the snap-rings, check that they are firmly positioned in their seatings.
. When installing electrical system jacks, remove any oil, dust or water that may have penetrated into them,
then connect them firmly.
. If using eyebolts, check that they are not distorted, screw them in fully, and then align the eye with the hoist-
ing hook.
. Mount the flanges in a uniform manner, and tighten the screws in criss-cross sequence, to avoid excessive
pull on one side only.
3. Precautions to be taken on completion of removal and installation operations.
. If the coolant liquid has been drained away, close the drainage plug and add new liquid up to normal level.
Start the engine to circulate the liquid throughout the cooling system and then top up the level once more.
. When the hydraulic equipment has been dismantled, add engine oil to the indicated level. Start up the en-
gine to circulate the oil in the hydraulic circuits, and then top up to the indicated level.
. If hoses or hydraulic equipment, such as hydraulic cylinders, pumps, motors, solenoid valves and valves,
are removed for repairs or substitution, bleed air from the hydraulic circuits after having re-assembled the
machine.
H For details, see «20. TESTING AND ADJUSTMENTS».
. After having re-assembled cylinder joints or cylinders, or work equipment articulations, lubricate thoroughly.
30-4
DISASSEMBLY AND ASSEMBLY SPECIAL TOOLS
SPECIAL TOOLS
Nature of work Symbol Code Description Q.ty Notes
1 ATR200390 Coupling for brake 1 Ð

Installation of swing release
machinery for revolving frame
A 2 ATR200400 Rear raising equipment 1 Ð
Removal/Installation
revolving frame
3 ATR200410 Front raising equipment 1 Ð
Removal/Installation of B 1 ATR200420 Swing circle raising 1 Ð

swing circle equipment
Disassembly/Assembly C 1 ATR200430 Press equipment 1 Ð

the recoil spring group
Removal/Installation of D 1 ATR200440 Raising equipment 1 Ð

control valve
For track-shoe joint pin

1 ATR200460 Pin removing tool 1 - idler
Removal/Installation of E
track-shoes
2 ATR200450 Raising equipment 1 For idlers
Pliers for mounting

1 ATR200470 gaskets All cylinders
ATR200480 é 50 calibrator 1
To calibrate piston rod
2 ATR200490 é 60 calibrator 1
gaskets
ATR200500 é 70 calibrator 1
ATR200510 é 90 plunger 1
To assemble piston
3 ATR200520 é 100 plunger 1
gaskets
ATR200530 é 120 plunger 1
ATR200540 é 90 calibrator ring 1

To calibrate piston
4 ATR200550 é 100 calibrator ring 1
gaskets
Disassembly/Assembly F
the cylinders ATR200560 é 120 calibrator ring 1
ATR200570 é 50 insertion bushing 1

for piston rod
ATR200580 é 60 insertion bushing 1 To mount flange

5 for piston rod and head
ATR200590 é 70 insertion bushing 1

for piston rod
6 ATR200600 Pliers for mounting 1 All cylinders

snap-ring
Socket wrench For arm cylinder

7 ATR800180 (6-point 75) 1 Removal-installation of
piston-retaining nut
Tool for disassembly and

8 ATR200610 assembly cylinders 1 All cylinders
Removal/Installation of
counterweight Dynamometric wrench
G 1 ATR800190 with multiplier
1 Max. 400 kgm (400 dNm)
Disassembly/Assembly of
arm cylinder nut
30-5
DISASSEMBLY AND ASSEMBLY SPECIAL TOOLS
SPECIAL TOOLS
Type of job Symbol Code Description Q.ty Notes
1 ATR500900 Puller 1 To extract bushings
Disassembly/Assembly H 2 ATR500910 Plunger 1 To mount bushings

of gear-pump
To mount driving
3 ATR500920 Centering apparatus 1
gear
1 ATR500820 Puller 1 To remove 2nd reduction

and pin shaft
2 ATR500840 Puller 1 To remove pins
To disassembly final
3 ATR500780 Tool 1 drive
A Plunger 1
To mount pins
4 ATR500810 B Pad 1
and bearings
Disassembly/Assembly L B Pad 1
of final drive
To disassembly and
5 ATR500830 Pad 1 assembly
final drive bearings
To check pre-
6 ATR500850 Tool 1
loading of bearings
7 ATR500800 Ring 1 To mount front seal on

flanged hub
To mount front seal on

8 ATR500790 Ring 1 transmission body
To remove and
1 ATR500860 Wrench 1 mount lock-nut
To remove inside ring

2 ATR500870 Pusher 1 from pinion bearing
To assemble inside
3 ATR500880 Pusher 1
Disassembly/Assembly of bearing ring
M
swing machinery
To mount outside
4 ATR500590 Pusher 1 bearing ring
5 ATR200380 Circuit sectioning tool 1 To test brake release

seal
6 ATR800140 Pressure gauge 1 Full scale 400 bar
30-6
DISASSEMBLY AND ASSEMBLY STARTER MOTOR
REMOVAL OF STARTER MOTOR

Disconnect the lead from the negative (±) battery
terminal.
1 - Remove the lower central grid (1) of the revolving

frame.
2 - Remove the selector valve (2) from the fixed hood to
free access to the starter motor. 1
3 - Disconnect the three screws (3) from the hatch (4) of
the fixed hood.
H Loosen but leave in position the screw (5) that al-
lows the hatch (4) to be turned.
D0400466
4 - Remove the top two nuts (6).
5 - Remove the bottom nut (7) through the space below
the revolving frame.
3 2
6 - Pull the starter motor (8) out a little way and discon-
nect the electric wiring (9) and the earth cable (10). 5
7 - Extract the starter motor (8).
3
4
INSTALLATION OF STARTER
MOTOR F0400089
. To install, reverse the removal procedure.

9
6
8
7 10
F0400090
30-7
DISASSEMBLY AND ASSEMBLY ALTERNATOR
REMOVAL OF ALTERNATOR
terminal.
1 - Remove the hatch (1) in the engine casing (2).

2 1
2 - Disconnect the cable (3) and the plug (4).
3 - Loosen the bolts (5-6-7) sufficiently to allow the alter-
nator (8) to be rotated.
4 - Free the pulley from the fan-belt (9) and draw out the
alternator (8).
F0400091
INSTALLATION OF ALTERNATOR 5 6
8
H Adjust the tension of the fan-belt. (For details, see 4

«20. TESTING AND ADJUSTMENTS - Tightening
the fan-belt).
7
3
9
F0400092
30-8
DISASSEMBLY AND ASSEMBLY NOZZLE HOLDER
REMOVAL OF NOZZLE HOLDER
1 - Remove the flow-back tubing (1).

1
2 - Unscrew the high-pressure fittings (2) from the nozzle
holder and from the injection pump. 2
H Do not bend the tubes and, if necessary remove
the clamps (3).
3
F0400093
3 - Remove the screws (4) that hold the collar (5) in place
and remove the nozzle holder (6) and copper washer 5
(7). Remove the dust-seal (8) and the spacer (9).
6
7
9
D0400393
INSTALLATION OF
NOZZLE HOLDER
H Use new dust-seals (8), spacers (9) and copper
washers (7).
High-pressure fittings: 18 Nm
Collar screws: 12 Nm
H Use new seals for the flow-back tubing.
30-9
DISASSEMBLY AND ASSEMBLY AIR FILTER GROUP
REMOVAL OF AIR FILTER GROUP

terminal.
1 - Loosen the clamp (1) that attaches the sleeve (2) to 1

2 3
the engine induction manifold.
2 - Loosen the clamp (3) that attaches the sleeve (4) to
the induction pipe (5). 5
4
F0400094
3 - Remove the fuses (7) from the filter support (6).
F0400095
4 - Disconnect the connectors (8) from the clogged-filter

indicator. 8
5 - Remove the screws (9) that attach the filter support (6).
6 - Remove the filter group (10).

10
F0400096
INSTALLATION OF AIR FILTER

GROUP
Filter support screws: Loctite 242.
30-10
DISASSEMBLY AND ASSEMBLY MUFFLER
REMOVAL OF MUFFLER
terminal.
1 - Remove the air filter. (For details, see «REMOVAL OF

AIR FILTER GROUP»). 1
3
2 - Loosen the tail-pipe clamp (1).
3 - Remove the screws (2) and the tail-pipe (3).
2
F0400097
4 - Remove the top hatch (4) of the engine-hood (5).
5 4
F0400230
5 - Remove the two screws (6) of the suction tube (7) and
loosen the screw (8). 8 7 6
F0400098
6 - Raise the suction tube (7) and secure it in position,

supported by a provisionally mounted M10x50 screw 7
(9).
12
7 - Remove the pipe (10) that supplies fuel to the cold
start equipment.
8 - Remove the fuel-lift pump control-rod support (11)
and the lifting support (12) for raising the engine. 9
10
11
F0400099
30-11
DISASSEMBLY AND ASSEMBLY MUFFLER
9 - Remove the screws (13) of the muffler (14) and en-

gine bracket (15). 13
10 - Remove the three nuts (16) that attach the muffler to 16

15
the exhaust manifold (17).
17
14
F0400100
11 - Lift out the muffler (14).
14
F0400101
INSTALLATION OF MUFFLER
Engine bracket screws: Loctite 242.
30-12
DISASSEMBLY AND ASSEMBLY ENGINE HOOD
REMOVAL OF ENGINE HOOD

Lower the work equipment until it is resting on the
2
ground and switch off the engine.
1 - Detach the gas cylinder (1) from the engine hood. 1

2 - While holding up the engine hood (2) remove the
screws (3) that attach the hood to the hinges (4).
H Mark the position of any shims.

Engine hood: 60 kg
1
F0400102
INSTALLATION OF ENGINE HOOD

3
H Check the centering and adjustment of the clos-

ing hook (5).
H Position any shims.
4
Replace the cotter pins (6).
F0400103
6
5
F0400104
30-13
DISASSEMBLY AND ASSEMBLY FIXED HOOD
REMOVAL OF FIXED HOOD

Release residual pressures from all circuits. (For de-

tails, see «20. TESTING AND ADJUSTMENTS»). 1
2
terminal.
. Drain the hydraulic oil.

Quantity of oil: approx. 82 ,
F0400231
1 - Remove the cabin and the engine hood.

(For details, see «REMOVAL OF CABIN» and «RE-
MOVAL OF ENGINE HOOD»).
4 3
2 - Remove the clamp (1) and the tail-piece (2).
3 - Remove the alternator inspection hatch (3).
4 - Disconnect the selector valve (4) from the fixed hood.
F0400105
5 - Disconnect the by-pass valve (5) and the tube (6) of

the servocontrol feed unit (7) from the tank. Also re-
move the tank unions. 6
10
6 - Disconnect the servocontrol feed unit tubes (8) from
the pumps.
5
7 - Inside the engine compartment, disconnect all the hy- 7
draulic tubes and all electrical cables that pass
through the wall (9) of the fixed hood towards the front 11
9
equipment.
8 - Remove the sleeve (10) that connects the air filter to 8
the suction pipe attached to the fixed hood (11). F0400106
9 - Disconnect the support (12) of the vibration damper of

the radiator. 12
F0400107
30-14
DISASSEMBLY AND ASSEMBLY FIXED HOOD
10 - Remove the eight screws (13) that attach the hood to

the revolving frame.
H Mark the position of any shims.
13
F0400108
11 - Screw the hoisting eyebolts into the engine hood.

12 - Attach the hood (14) to the hoisting tackle and re-
move it. 14
Engine hood: 83 kg
F0400109
INSTALLATION OF FIXED HOOD

1 - Fill the hydraulic oil tank up to its maximum level.
While filling, bleed air from the main pumps.

(For details, see «20. TESTING AND ADJUST-
MENTS»).
Hydraulic oil needed: approx. 82 ,
2 - Start the engine to circulate the oil and check that

there are no leakages.
3 - Switch off the engine, check the levels and, if neces-
sary, top up.
30-15
DISASSEMBLY AND ASSEMBLY SEAT
REMOVAL OF SEAT
ground, switch off the engine and remove the ignition
key.
1
1 - Raise the front window (1) completely.

2 - Remove the lower window (2) and place it in the sup-
ports provided at the back of the cabin.
3 - Remove the four screws (3) that secure the seat.
H Slide the seat forwards and backwards in order to
reach the screws.
4 - Remove the seat. 2
Seat: 32 kg
INSTALLATION OF SEAT
F0400110
F0400111
30-16
DISASSEMBLY AND ASSEMBLY CABIN
REMOVAL OF CABIN
ground and switch off the engine. 2
1 - Remove the seat. (For details, see «REMOVAL OF

SEAT»). 1
2 - Temporarily remove the windshield-washer tray (1)
from its support (2).
3 - Remove the (6+1) attachment screws (3). 4
4 - Disconnect the connector (4).

5 - Replace the windshield-washer tray (1) on its support F0400112
(2).
6 - Disconnect the heating hose (5) from the diffuser (6).
7 - Remove the upper protective caps and mount the
hoisting eyebolts (7).
8 - Attach the eyebolts (7) to the hoisting tackle and 3
move the cabin.
Cabin: 250 kg
INSTALLATION OF CABIN F0400113

H Make sure that the short screw (8) is placed on the
LH side.
7 7
F0400115
F0400114
30-17
DISASSEMBLY AND ASSEMBLY COUNTERWEIGHT
REMOVAL OF COUNTERWEIGHT
1 - Remove the engine-hood.

(For details, see «REMOVAL OF ENGINE HOOD»).
1
2 - Remove the engine-hood hook support (1).
3 - Remove the protective caps and firmly tighten the
hoisting eyebolts (2).
4 - Attach the hoisting tackle and apply slight tension to
the cables. F0400116
5 - Using the tool G1, loosen the screws (3) and their
safety washers.
6 - Remove the counterweight (4).
2 2
INSTALLATION OF
COUNTERWEIGHT
4
F0400117
Counterweight screws: Loctite 242
Counterweight screws: 981 Nm
H Carefully check that the vertical positioning mea-

surement «A» is 95w1 mm with respect to the re- A
volving frame. 4
F0400118
30-18
DISASSEMBLY AND ASSEMBLY RADIATOR
REMOVAL OF RADIATOR
. Drain the engine coolant liquid.

Coolant liquid: 24 ,
1 - Remove the engine hood.

(For details, see «REMOVAL OF ENGINE HOOD»). 1
2 - Remove the lower left hatch (1) of the revolving
frame.
D0400402
3 - Remove the fan guard.
4 - Remove the conveyor (3) and push it towards the en-
gine.
4
5 - Disconnect the tubes (4-5) between radiator and en-
gine.
6 - Remove the container (6) together with the relative
tubing and support (7). 2
3
7 - Remove the elastic support (8).
8 - Remove the four screws (9) and the upper frame (10).
9 - Lift out the radiator (11) from above.
5
F0400119
INSTALLATION OF RADIATOR
8 10
1 - Fill up the coolant liquid circuit.
Coolant liquid: approx. 24 ,
2 - Start the engine to circulate the coolant liquid and 9

check that there are no leakages.
3 - Switch off the engine, check the level of the liquid in
11
the container and, if necessary, top it up. 7 6
F0400232
30-19
DISASSEMBLY AND ASSEMBLY HYDRAULIC OIL COOLER
REMOVAL OF HYDRAULIC OIL COOLER


1 - Remove the radiator. (For details, see «REMOVAL

OF RADIATOR»).
2 - Slowly unscrew the bottom tube (1) to drain the oil 1
contained in the oil cooler.
Oil cooler: approx. 9 , F0400120
3 - Disconnect the tubes (1) and (2) and plug them to pre-
4 - Raise the hydraulic oil cooler (3) and move it towards
the back of the machine.
5 - Lift out the hydraulic oil cooler (3).
INSTALLATION OF HYDRAULIC
OIL COOLER
H Add oil to the hydraulic tank up to max. level.

1 - Start the engine to fill up the oil cooler and check that
2 - Switch off the engine, check the oil level of the hy-
draulic oil tank and, if necessary, top it up.
30-20
DISASSEMBLY AND ASSEMBLY HEATING FAN
REMOVAL OF HEATING FAN


terminal.
1
Drain the coolant liquid to a level below that of the
connecting tubes (1-2) between the engine and the
heating fan.
Quantity of cooling liquid: approx. 6 ,. 2
1 - Disconnect the tubes (1-2) from the engine and lower F0400121
their extremities to drain the radiator completely.

Quantity of cooling liquid: approx. 1.5 ,.
3
2 - Remove the seat. (For details, see «REMOVAL OF
SEAT»).
4
3 - Remove the swing locking pin knob (3).
4 - Remove the glove-compartment (4) (6 screws).
F0400122
5 - Move the sliding plate (5) forwards as far as it will go.

6 - Remove the screws (6) of the seat support group (7). 5
11
F0400123
7 - Remove the lower diffuser (8), complete with the tube

attaching it to the fan group.
6
8
7
F0400124
30-21
DISASSEMBLY AND ASSEMBLY HEATING FAN
8 - Raise the seat support group (7) from the rear.

H Wedge the group securely in this position with an
approx. 50 mm thick block.
9 - Disconnect the air delivery hose (9) from the cabin dif-
fuser (10), and release it from its clamps.
10 - Remove the fan two screws (11) and draw the fan (12)
towards the back of the machine.
11 - Disconnect the connector (13). 50 mm
12 - Disconnect the delivery and return tubes (14). 7

F0400125
13 - Disconnect the air delivery hose (15).
10
F0400233
11
13
12
14
15
F0400126
INSTALLATION OF HEATING FAN

1 - Make sure that the heating cock is fully open.

2 - Fill up with coolant liquid.
Quantity of coolant liquid: approx. 7.5 ,.
3 - Start the engine to circulate the coolant liquid.

4 - Switch off the engine and top up the level.
30-22
DISASSEMBLY AND ASSEMBLY FUEL TANK
REMOVAL OF FUEL TANK

1 - Remove the top engine hood and the lower RH hatch

of the revolving frame.
2 - Disconnect the clamps from both battery terminals.
First disconnect the negative (±) terminal

clamps.
3 - Remove the battery (1). 1

F0400127
4 - Remove the grommet (2) and draw out the cables

connecting the battery (3), the horn and the fuel level
indicator (4).
5 - Remove the cap of the fuel tank, open the tank drai-
nage cock (5), and drain the fuel.
4
Fuel: max. 140 ,
2
6 - Close the delivery cock (6) and disconnect the fuel
delivery and flow-back tubes (7-8). Plug them to pre- 3
7 - Remove the six screws.
Check the number of shims needed for each F0400128
screw.
8 - Attach the tank (9) to the hoisting tackle and lift it out. 5
Fuel tank: 105 kg
7
8
INSTALLATION OF FUEL TANK
1 - Fill the fuel tank and check that it does not leak. 6
F0400129
H Before starting the engine, bleed air from the

lines.
9
F0400130
30-23
DISASSEMBLY AND ASSEMBLY HYDRAULIC OIL TANK
REMOVAL OF HYDRAULIC OIL TANK

1 2
tails, see «20. TESTING AND ADJUSTMENTS»).
terminal.

1 - Remove the fuel tank. (For details, see «REMOVAL

OF FUEL TANK»).
F0400234
2 - Disconnect the by-pass valve (1).

3 - Disconnect the return tube (2) of the servocontrol
feed unit from the tank.
4 - Disconnect the suction tubes (3-4) from the main
pumps (P1 and P2) and from the gear pump. 3
5 - Disconnect all the return tubes (5) from the tank.
6 - Remove the tank attachment screws.
Check the quantity of shims necessary for each
screw.
4
7 - Attach the tank (6), complete with pump suction tubes F0400298
(7-8), to the hoisting tackle and lift it out.

Tank oil: 76 kg
INSTALLATION OF HYDRAULIC 5
OIL TANK

1 - Fill the oil tank up to max. level.
During the filling operation, bleed the air from
the pumps P1-P2. (For details, see «20. TEST-
F0400131
ING AND ADJUSTMENTS»).
Hydraulic oil required: approx. 82 ,

6
3 - Bleed the air from the servocontrol circuit. (For de- 7
4 - Switch off the engine, check the level and, if neces-
sary, top it up.
8
F0400132
30-24
DISASSEMBLY AND ASSEMBLY ENGINE-PUMP GROUP
REMOVAL OF ENGINE-PUMP GROUP



terminal.
2
F0400133
. Drain the engine coolant liquid.

Quantity of coolant liquid: 24 ,
. Turn off the diesel-fuel supply cock.

1
1 - Remove the cabin.
(For details, see «REMOVAL OF CABIN»).
2 - Remove the engine-hood.
(For details, see «REMOVAL OF ENGINE-HOOD»).
F0400134
3 - Disconnect from the pumps the servocontrol feed unit

tubes (1), the suction tube flanges (2), the delivery
tubes (3), and the pump horse-power control (4), (3- 3
circuit valve and Mode system). 4 3
1 4
2
F0400135
4 - Remove the lower casings (5-6) of the RH engine

compartment (7) of the revolving frame.
5 - Remove the fixed hood.
(For details, see «REMOVAL OF FIXED HOOD»).
5 6
7
D0400399
30-25
6 - Disconnect the radiator tubes (8-9) and the heating

system tubes (10-11).
7 - Remove the fan guard (12). 14
8 - Remove the fastening screws (13) of the conveyor 10

8
(14). Push the conveyor towards the engine in order 12
to disengage it from the radiator supports.
13 11
F0400136
9 - Disconnect the lead from the positive (+) battery

terminal (15). Remove the two hose-clamps (16) and
the earth cable (±) (17) of the frame.
10 - Remove the knob of the swing-locking pin (18) and 15
the glove compartment (19). ---
21
17 16 20
11 - Disconnect the engine wiring connectors (20) from D0400392
the diode box. Remove the clamp (21).
18
19
F0400235
12 - Disconnect the earth cable (22) from the starting mo-

tor and free the cables from the clamps (23) that se-
cure them to the frame.
23
22
23
F0400236
30-26
13 - Disconnect the accelerator control cable (24).

14 - Using the lifting support supplied, slowly raise the en-
gine-pump group (25).
24
15 - Remove the nuts (26) from the screws (27).
16 - Slowly raise the engine-pump group.

H When moving the group, accompany the electric
cables and take care not to damage them.
H Check that the engine and the pump have been
completely released from all connections.
F0400137
Engine group and pump: 570 kg.
INSTALLATION OF ENGINE-PUMP 27
27
GROUP
26
F0400138
H Before re-connecting the tubes, check that no

seals have been damaged.
Engine fastening screws: 157w9.8 Nm. 25
1 - Fill the hydraulic tank up to its maximum level.
While filling the tank, bleed air from pumps P1-

P2 (For details, see «20. TESTING AND AD-
JUSTMENTS»).
2 - Fill the cooling circuit up to its maximum level. F0400139
Coolant liquid needed: approx. 24 ,
3 - Start the engine to circulate oil and coolant liquid, and

check that there are no leakages.
4 - Switch off the engine, check the levels and, if neces-
sary, top them up.
5 - Bleed air from the servocontrol circuit. (For details,
see «20. TESTING AND ADJUSTMENTS»).
30-27
DISASSEMBLY AND ASSEMBLY PUMP GROUP
REMOVAL OF PUMP GROUP

4
3 5
terminal.
7
6
1
1 - Remove the engine hood. (For details, see «RE-
MOVAL OF ENGINE HOOD»).
F0400237
2 - Disconnect the suction (1) and delivery (2-3) hoses of

the main pump.
3 - Disconnect the tube (4) of the MODE SYSTEM device
and the 3-circuit valve (5) and the supply tubes (6-7-8)
of the servocontrol supply group.
4 - Disconnect the suction (9) and delivery (10-11) tubes
of the gear-pump.
5 - Remove the air filter together with its support. (For de-
tails, see «REMOVAL OF AIR FILTER»).
6 - Attach the group (12) to the hoisting tackle.
Pump group: 68 kg
7 - Take out the screws and remove the pump group.
INSTALLATION OF PUMP GROUP 11

8
9
H Before connecting the tubes, check the seals for

damage.
10
Pump group screws: Loctite 242
Pump group screws: 68 Nm.
1 - Fill the hydraulic oil tank to maximum level. F0400238
While filling tank, bleed air from pumps P1 and
P2 (For details, see «20. TESTING AND AD-
JUSTMENTS»).
sary, top it up.
4 - Bleed air from the servocontrol circuit. (For details, 12
see «20. TESTING AND ADJUSTMENTS»).a
F0400140
30-28
DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP
DISASSEMBLY OF HYDRAULIC PUMP
1 - Remove the Mode System group (1) complete with

the 3-circuit valve (2).
If the seating (3) of the push-rod is removed dur-
ing removal of the complete Mode System, the
displacement regulation group (4) must also be 3
dismantled.
4
2
1
D0400312
2 - Remove the pressure regulation group (5) and the

spring (6).
5
6
D0400313
3 - Take away the calibration group (7) and the screw (8).
H Before proceeding with the removal, take mea-
7 8
A
surements «A» and «B» very accurately. Write B
them down and keep them somewhere safe, be-
cause they will be needed during the installation 9
phase in order to preserve the original pump cali-
bration.
H Take care that the calibration spring (9) does not
fall inside the pump body.
D0400314
4 - Loosen the twelve screws (10).

10
D0400315
30-29
5 - Remove the complete control body (4).

H If necessary, use a soft-headed mallet.
4
D0400316
6 - Loosen the screw (11) and take away the complete

rocker-arm support (12).
12
11
D0400317
7 - Remove the control piston (13).
13
D0400318
8 - Loosen the screws (14) and take away the complete

lower cover.
H Do not change the position of the screw (15).
15
14 D0400319
30-30
9 - Remove the pilot system bushing (16).
16
D0400320
10 - Remove the positioning piston (17) and the cylinder

block connecting fork (18).
16 18
17
D0400321
11 - Remove the cylinder blocks (19) and the distribution

plates (20). 20 19
H Be careful with the Belleville washers (21) (four for
each cylinder block) and the spring guide collars
(22), (one for each cylinder block).
21 22
D0400322
12 - Remove the transmission crankcase (23), using le-

vers and a soft-headed mallet. 23
H Take care not to damage the machined surfaces.
D0400323
30-31
13 - Remove the gear of the auxiliary pump (24), complete

with its bearing.
24
D0400324
14 - Use a puller to remove the bearing (25).
25
D0400325
15 - Use specially-shaped levers to remove the rotating

groups (26).
H Take care not to damage the machined surfaces. 26 26
D0400326
16 - Clamp the rotating group (26) in a vice.

H Use a soft-jawed vice to avoid damaging the gear- 26
teeth.
D0400327
30-32
17 - Remove the seven screws (27) that secure the retain-

ing plate (28).
28
To facilitate removal, heat the rotating group up
to 120v130ëC.
H Repeat this operation for the other rotating group. 27
D0400328
18 - Remove the snap ring (29) from the transmission

crankcase. 30
29
D0400329
19 - Use levers to remove the front cover (31).

H Protect the toothing of the drive shaft (30) with ad-
hesive tape to prevent damage. 31
D0400330
20 - Take the front cover (31) to pieces, removing the re-

taining ring (32) and the O-ring (33).
Remove the spacer (34). 34
33
31 32
D0400331
30-33
21 - Remove the snap ring (35).

35
D0400332
22 - Clamp the gear of the drive shaft (30) in a vice.

H Use a vice fitted with jaws to prevent damage to 30
the gear teeth.
D0400333
23 - Loosen the locknut (36).
36
D0400334
24 - With a soft-headed mallet, extract the drive shaft (30)

from the transmission crankcase (37).
37
30
D0400335
30-34
25 - Remove the bearing ring (38), the bearing and the

bearing ring (39).
38
39
D0400336
26 - Remove the snap ring (40) and the spacers (41).
40
41
D0400337
30-35
ASSEMBLY OF THE HYDRAULIC PUMP
1 - Remove the retaining washer and clean all the ma-

chined surfaces.
D0400338
2 - Assemble the drive shaft (30) with the bearings (38-

39), the spacer (41), the retaining ring (40) and the 39 40 41 38
locknut (36). 30
H Tighten the locknut to a measurement of 51 0.05
mm.
Ring nut: Loctite 242
51--00,05 36
D0400339
3 - Mount the pistons (42) complete with the ring, king-

bolt (43), retaining plate (28) and screws (27). 43
Screws: Loctite 242 42
Screws: 2.9 Nm
28
27
D0400340
4 - Assemble the spring-guide collars (22) and the spring

(21).
H Make sure that the springs are the right way up. 21
22
D0400341
30-36
5 - Insert the rotating group complete with pistons (26) in

the cylinder block (19).
26
H Support the cylinder block on a surface of some
soft material, to prevent damage to the sliding sur-
face.
H Repeat operations 3,4 and 5 for the second rotat-
ing group. 19
D0400342
6 - Heat the transmission crankcase (37) to 80ëC and in-

sert the pre-assembled drive shaft (44). 37 44
H Make sure that the retaining ring (40) fits into the
crankcase seating.
40
80°C
D0400343
7 - Insert the rotating groups (45 and 46).

H Make sure that the reference notches between
45 46 44
the rotating groups (45 and 46) and between the
rotating group (46) and the drive shaft (44), are 44
aligned.
45 46
D0400344
8 - Mount the bearing (25), the neutral gear (24) and the
bearing (47).
47
24
25
D0400345
30-37
9 - Mount the washer (48) and the crankcase of the rotat- 80°C
ing group (23). 23
H To facilitate the installation of the crankcase, heat
the bearing seating area (47) to a temperature of 48
roughly 80ëC.
D0400346
10 - Insert the cylinder connection fork (18) with the ma-

chined surface facing upwards. 18
D0400347
11 - Mount the positioning piston (17).

Suction
Lato side
aspirazione Foro
Hole
H Make sure that the hole in the bottom of the posi-
tioning piston (17) is facing the right way.
Cylinder side
Lato cilindri View
VistaAA
17
A D0400348
12 - Mount the pilot system bushing (16).
16
D0400349
30-38
13 - Mount the pilot system piston (13).
13
D0400350
14 - Mount the complete rocker-arm support (12).

Centring pin (49) and seating (3):
Loctite 262 12
Screws: 10 Nm. 49
3
D0400351
15 - Mount the spring (6) and the lower cover (14) com-
plete with the seal (50).
Screw: 25 Nm 6
50
14 D0400352
16 - Mount the pressure regulation group (5) complete

with seals.
Pressure regulation group screw: 69 Nm
5
D0400353
30-39
17 - Mount the distribution plate (20).

H Make sure that the distribution plates are correctly
20 20
mounted and that they slide freely.
H To hold the distribution plates in place, spread
some ASL800050 on the surface.
D0400354
18 - Mount the control body (4) with the washer (51) and
the screws (10). 4
Screws: 25 Nm.
10 51
D0400355
19 - Mount the Mode System group (1) complete with the

3-circuit valve (2).
H To facilitate installation, immobilise the push-rod
with ASL 800050 grease injected into the seating.
Mode System group: 60 Nm.
D0400356
20 - Mount the calibration group (7) and the screw (8).

H Regulate the group and the screw until the pre- 7 52 53 8
cise measurements «A» and «B» have been ob-
tained (measured during phase 3 of the disman-
tling operations). A B
Nut (52): 10 Nm
Nut (53): 22 Nm
Group attachment screws (7): 69 Nm
D0400357
30-40
21 - Mount the retaining ring (32) and the O-ring (33) in the
front cover (31). 33
31
If the shaft looks worn in the area of contact with
the retaining ring (32), insert a spacer (54) be- 32
tween the cover and the retaining ring to vary
the contact area.
54
D0400358
22 - Mount in the transmission crankcase (23):

- the snap ring (35);
- the spacer (34); 34 35
- the complete front cover (31); 23
- the snap ring (29).
Retaining ring and front cover: ASL800050 29
H Check carefully that the snap rings (34) and (15)
are correctly positioned. 31
D0400359
30-41
DISASSEMBLY AND ASSEMBLY GEAR-PUMP
REMOVAL OF GEAR-PUMP
3


terminal.
2
. Drain the hydraulic oil. 1

1 - Disconnect the suction (1), delivery (2), and servocon-
F0400239
trol supply (3) tubes.
2 - Remove the screws (4) and lift out the pump (5) to-
gether with its O-ring seal.
5
INSTALLATION OF GEAR-PUMP F0400141
H Before connecting the tubes, check the seals for

damage.
H Before mounting the sealing ring, make sure that

the seal is undamaged.
1 - Fill the hydraulic oil tank to maximum level.
While filling, bleed air from the main pumps (P1-
P2). (For details, see «20. TESTING AND AD-
JUSTMENTS»).

sary, top it up.
4 - If necessary, bleed air from the servocontrol circuit.
(For details, see «20. TESTING AND ADJUSTMENTS»).
30-42
DISASSEMBLY OF GEAR-PUMP
H We shall describe here the dismantling of a double

pump. In the case of a single pump, ignore the opera-
tions regarding the body of pump P4.
H If it becomes necessary to use a lever while disman- P4
tling the pump, take care not to damage the machined P3
surfaces.
P3
F0400441
1 - Clamp the pump (1) in a vice with the drive shaft fa-
cing downwards, and mark all the sections.
H Do not tighten the vice near or on machined sur-
faces.
F0400060
2 - Remove the nuts (2), the washers (3) and, if the pump
is double, also the stud-bolts (4).
H If a main valve has been installed, remove it first.
2 4
F0400061
3 - Remove the rear cover (5).

The centring bushings (6) may remain either in
the pump body (11) or in the cover (5): do not re-
move them! 5
11
6
F0400062
30-43
4 - Remove the thrust bearing (7).
8
7
F0400063
5 - Remove the driven gear (8), the driving gear (9) and
the internal thrust bearing (10).
H Take care that the two gears do not receive any
blows which could dent them.
9
10
F0400064
6 - Remove the pump body (11) from the bushing sup-

port (12).
H Take care not to damage the machined surfaces. 11
12
F0400065
7 - Remove the bushing support (12).

The centring bushings (14) may remain either in
the bushing support (12) or in the pump body.
Do not remove them !
12
14
F0400066
30-44
8 - Remove the connecting shaft (15), the thrust bearing

(16), the driven gear (17), the driving gear (18) and the 15
thrust bearing (19). 19
H Take care that the two gears do not receive any 18
blows which could dent them.
16
17
F0400067
9 - Remove the first pump body (20).

20
F0400068
10 - Extract the bushings (22), using the tool H1.
H1
22
F0400069
11 - Remove the retaining ring (21).
21
19
D0400401
30-45
ASSEMBLY OF THE GEAR-PUMP
H If difficulties are encountered when installing the

pump body and the bushing support, use only soft-
headed mallets.
1 - Remove all dents or burrs from the machined sur-

faces, using a medium-grain pumice stone.
F0400070
2 - If bushings have been removed, smooth the holes

with emery paper.
H Before commencing installation operations, wash
the pieces carefully with solvent and dry with com-
pressed air.
F0400071
3 - Clamp the front cover (23) in a vice with the flange fa-
cing downwards.
H Check that the caps (24) are not damaged or loo-
sened. If they are damaged, fit new ones.
24
23
F0400072
30-46
4 - Screw the caps (24) down as tightly as possible.

Cap: Loctite 542
H Chamfer the caps both round the edge and at the
end of the screwdriver slot.
H Chamfer the holes with a 1" 1/2 steel ball.
F0400073
5 - Remove all dents or burrs from the machined sur-

faces, using a medium-grain pumice-stone. Smooth
the edges of the bushings with emery paper.
H Before starting installation, wash the piece thor-
oughly with solvent and dry it with compressed
air.
F0400076
6 - Insert the bushings (22).

H Insert the bushings (22) in the holes of the driving Slit
Taglio
gear with the slit facing upwards.
H Insert the bushings (22) in the holes of the driven
gear with the slit facing downwards.
22
H The bushings should be inserted in the holes in Holes of the
Foro ingranaggio
one single operation, using the tool H2 and a driving gear
conduttore Hole of the
Foro ingranaggio
driven
condottogear
press.
Slit
Taglio
F0400074
H2
22
F0400075
30-47
7 - Insert the centring bushings (14) with a soft-headed

mallet.
H Check that the holes are free of burrs and impuri-
ties.
14
F0400077
8 - Mount the retaining ring (21) in the front cover (23).

External retaining ring and internal cover:
ASL800070.
21
H After installation, carefully remove all excess li-
quid sealant ASL800070
F0400078
9 - Mount the O-rings (25) in the pump body (20) and

mount the pump body (20) on the front cover (23).
H Make sure that no damage is done to the O-ring in
contact with the front cover.
20
H Mount the pump body, positioning the largest
hole on the suction side.
25
F0400079
10 - Mount the seals (26) on the thrust bearings (16 and

8
19).
H Make sure that the concave side of the seal is
turned towards the thrust bearing.
26
19
F0400080
30-48
11 - Mount the first thrust bearing (19) and the driven gear
(17).
H Make sure that the seal of the thrust bearing is
turned towards the front cover.
19
F0400081
12 - Insert the driving gear (18), slightly greased, into the

tool H3, also previously greased, and slide it gently,
with alternating rotatory movements, into the retain- 18
ing ring, until the driving gear makes contact with
thrust bearing.
H3
H Lubricate the gears with oil.
17
F0400082
13 - Mount the thrust bearing (16) with the seal facing up-
wards.
16
F0400083
14 - Mount the bushing support (12).

H Make sure that the centring bushings (14) are
aligned with the holes. Drive them home in the
pump body using a soft-headed mallet.
H Make sure that no damage is done to the O-ring
(25) mounted on the pump body.
14
12
25
F0400084
30-49
15 - Mount the connecting shaft (15) and repeat opera-

tions 9 and 10 for the second pump body.
15
F0400085
16 - Mount the driven (8) and driving (9) gears.

H Make sure that both the gears are in contact with
the thrust bearing. 8
25
F0400086
17 - Repeat operations 3, 4 and 5 for the rear cover (5)

and then mount it.
H Make sure that the centring bushings (14) are 15
aligned with the holes. Drive them home in the
pump body using a soft-headed mallet.
H Make sure that no damage is done to the O-ring
(25) mounted on the pump body.
9 8
14
F0400087
18 - Mount the stud-bolts (27), the washers (28) and tight-

en the nuts (29).
H Tighten the nuts in criss-cross sequence and in
two phases.
Final nut torque: 190 Nm.
27
28
29
F0400088
30-50
DISASSEMBLY AND ASSEMBLY ENGINE-PUMP COUPLING JOINT
REMOVAL OF ENGINE-PUMP COUPLING JOINT

3
Release residual pressures from all circuits. (For de- 1

terminal.
1 - Remove the pump group. (For details, see «RE- 2

MOVAL OF PUMP GROUP»). 4
F0400142
2 - Unscrew the retaining screw (1) of the coupling half

(2) on the pump side.
3 - Unscrew the screws (3) and remove the coupling half
(4) on the flywheel side.
INSTALLATION OF ENGINE-PUMP
COUPLING JOINT
H Before coupling the engine to the pump, check the

condition of the rubber loose-pieces and make sure
that they are firmly attached to the coupling half on
the pump side.
Coupling half screws on pump side: Loctite 242

Coupling half screws on pump side: 88 Nm
Coupling half screws on flywheel side:

Loctite 242
Coupling half screws on flywheel side: 34 Nm
30-51
DISASSEMBLY AND ASSEMBLY SWIVEL JOINT
REMOVAL OF SWIVEL JOINT

1

terminal. 1
1 - Remove the distributor hood.

F0400143
2 - Disconnect the tubes (1) on the lower side of the joint

(2) and plug them.
H Mark the tubes before disconnecting them, to
avoid errors when re-assembling.
3 - Disconnect the tubes (3) on the top of the joint (2) and
plug them.
3 4
H Mark the tubes before disconnecting them, to
avoid errors when re-assembling.
4 - Disconnect the supply and drainage tubes (4) from
the swing motor, in order to raise the joint.
H Plug the tubes and fittings of the swing motor to
prevent entry of impurities. 3
5 - Unscrew and remove the screws (5) of the swivel F0400144
joint.
6 - Screw an eyebolt into the central hole (6) and lift out
the swivel joint (2). 6
2
Swivel joint: 36 kg
INSTALLATION OF SWIVEL JOINT

1 - Start the engine, move the machine in both directions 5
and move the blade several times to bleed all air from
the circuits.
F0400145
2 - Switch off the engine and top up the oil in the hydrau-
lic tank.
30-52
DISASSEMBLY AND ASSEMBLY SWING MOTOR
REMOVAL OF SWING MOTOR

6
4
3 1
1 - Disconnect the supply (1), return (2), and drainage 2
tubes (3), and the safety valve pilot system tubes (4) 7
and plug them.
2 - Remove the screws (5) that attach the motor (6) to the 5
reduction unit (7). F0400240
3 - Remove the motor (6).

Motor: 11 kg
INSTALLATION OF
SWING MOTOR
30-53
DISASSEMBLY AND ASSEMBLY SWING MACHINERY
REMOVAL OF SWING MACHINERY

1
Release residual pressures from all circuits. (For de- 5 2

3
1 - Remove the fixed hood.
2 - Disconnect the tubes for delivery (1), return (2), drai-
nage (3), and braking (4), and the safety valve pilot
system (5) from the swing group and plug them all. 4
7
3 - Disconnect from the control valve (6) all tubes that F0400147
might obstruct the raising of the reduction unit, and

plug them.
4 - Remove the screws (7) from the swing machinery (8).
5 - Attach the hoisting tackle and remove the swing ma-

8
chinery (8-9).
Swing machinery: 84 kg
7 6
F0400241
INSTALLATION OF
SWING MACHINERY
. To install, reverse the removal procedure. 8 9
In order to centre the screw holes:

a - Connect the tool A1 to the brake release fit-
ting and connect a 5v6 bar compressed air
supply.
b - Raise the front work equipment by a few cen-
timetres and turn the revolving frame manu- F0400148
ally until the swing machinery is in the cor-
rect position for attachment.
1 - Start the engine, turn the frame in both directions,
and move the equipment from which the tubes have
been detached. Check the seals.
8 9
2 - Switch off the engine and check the level of hydraulic
oil in the tank.
A1
F0400149
30-54
DISASSEMBLY OF SWING MACHINERY
H Before dismantling the swing machinery, mark the po- 40

sitions between the hydraulic motor (40) and the mo-
tor flange (39), between the brake unit (30) and the 39
toothed ring (12), and between the toothed ring (12)
and the gearbox housing (17).
30
12
17
D0400467
1 - Take out the screws (42) and detach the hydraulic

motor (40).
42
40
F0400309
2 - Detach the O-ring (41) from the motor (40).

40
41
F0400310
3 - Take out the fifteen screws (9) and the nut (31) on the
stud-bolt corresponding to the position of the oil level
check rod.
31
F0400311
30-55
4 - Detach the brake-flange group (30-39) from the gear-

box housing. 39
30
F0400312
5 - Detach the O-ring (10) from the brake unit (30). 10

30
F0400313
6 - Take out the screws (2) and remove the motor flange
(39) from the brake unit (30).
39
30
F0400314
7 - Detach the O-ring (3) from the motor flange seating

3
(39).
39
F0400315
30-56
8 - Using a press and a pad, press on the spring retainer

(1) and remove the snap-ring (38).
38
F0400316
9 - Remove the spring retainer (1).

1
F0400317
10 - Remove the springs (36) from the piston seatings

(37). 37
36
F0400318
11 - Turn the brake unit (30) upside down and remove the
snap-ring (29).
29
30
F0400319
30-57
12 - In one movement remove the stack of brake disks

(32-33) and the spring retainer (28).
28
32 33
F0400320
13 - Using a punch of some soft material and in one move-

ment, remove the spacer (8) and the piston (37) from 30
the brake unit.
37
F0400321
14 - Detach the O-ring (35) and the ring wear (34) from the
spacer (8).
35
34
F0400322
15 - Detach the O-rings (5-6) and the rings wear (4-7) from
the brake unit (30). 4 5
6
30
F0400323
30-58
16 - Extract the brake shaft (17) from the gearbox hous-

ing. 17
F0400324
17 - Remove the pinion (13) from the 1st sun gear.
13
F0400325
18 - Remove the 1st sun gear group (11).

11
F0400326
19 - Remove the pinion (15) of the 2nd sun gear.
15
F0400327
30-59
20 - Take out the ring gear (12).

12
F0400328
21 - Remove the 2nd sun gear group (14).

14
F0400329
22 - Remove the O-ring (16) from the gearbox housing

(17). 16
17
F0400330
23 - Lift the safety riveting of the lock-nut (18) that secures

the swing pinion (23).
23
18
F0400331
30-60
24 - Using the tool M1 remove the lock-nut (18).
M1
F0400332
25 - Lift off the spacer (19).
19
F0400333
26 - Using an extractor, lift the swing pinion out (23) of the

gearbox housing (17).
17 23
F0400334
27 - Remove the stud-bolt (26) from the gearbox housing

(17).
17
26
F0400335
30-61
28 - Using an extractor, remove the external bearing ring

(20) from the gearbox housing (17).
20
17
F0400336
29 - Turn the gearbox housing (17) upside down and re-

move the swing pinion sealing ring (21).
17
21
F0400337
30 - Using an internal extractor, remove the external bear-

ing ring (22) from the reduction unit.
22
F0400338
31 - Using the tool M2 and a press, remove the internal

bearing ring (22), the sealing ring (24) and the spacer
(25) from the swing pinion (23). M2
23
24
25
F0400339
30-62
ASSEMBLY OF SWING MACHINERY

1. IMPORTANT REMARKS
When installing the swing machinery, some fundamental
rules must be followed:
a - In the case of a damaged sun gear, the entire reduc-
tion unit must be substituted, not just the single sun
gear.
b - Always fit a new O-ring with the part to be replaced,
after thoroughly cleaning the installation seating and
after having spread a film of grease (ASL800050) over
the seatings and the seals to facilitate installation.
2. INSTALLATION
1 - Mount the spacer (25) on the swing pinion shaft (23).
H Check that the chamfered part rests on the pinion.
25
23
F0400340
2 - Mount the metal sealing ring (24).
24
F0400341
3 - Fill the metal sealing ring (24) with grease:

(ASL800050).
24
F0400342
30-63
4 - Apply a layer of grease over the inside bearing ring

(22).
Bearing: ASL800050
22
F0400343
5 - Using the tool M3 and a press, drive the inside bear-

ing ring (22) down over the spacer (25).
M3
22
F0400344
6 - Using the tool M4 and a press, drive the outside bear-

ing ring (22) down over the gearbox housing (17).
M4
17
F0400345
7 - Using the same method as above, mount the outside

ring of the other bearing (20) in the gearbox housing.
20
F0400346
30-64
8 - Mount the sealing ring (21) in the gearbox housing

(17).
21
17
F0400347
9 - Position the gearbox housing (17) over the swing pi-

nion (23).
17
23
F0400348
10 - Mount the inside bearing ring (20) on the swing pinion

(23).
20
23
F0400349
11 - Using the tool M3 and a press, assemble the pinion

(23) - gearbox housing (17) group.
17
M3
F0400350
30-65
12 - Mount the spacer (19) over the swing pinion shaft

(23).
19
23
F0400351
13 - Tighten the lock-nut (18).

H Use a new lock-nut.
Lock-nut: Loctite 242.
18
F0400352
14 - Use the special wrench M1 and a dynamometric

wrench to tighten the lock-nut (18).
Lock-nut: 1000w50 Nm
H If new bearings (20-22), pinion (23), or gearbox
17
housing (17) have been fitted, check the rotating
torque of the pinion (23).
Pinion rotation: 50v60 Nm M1
H If the torque is higher, increase the thickness of
the spacer (19).
H If the torque is lower, reduce the thickness of the
spacer (19).
F0400353
15 - Block the position of the lock-nut (18) with 3 safety

caulkings, corresponding to the grooves in the pinion
shaft (23).
23
18
F0400354
30-66
16 - Lubricate the O-ring seating of the gearbox housing

(17) and mount the seal (16). 16
Seating: ASL800050.
17
F0400363
17 - Mount the stud-bolt (26) in the hole in the gearbox

housing (17) and tighten it.
Stud-bolt: 45w5 Nm
17
26
F0400364
18 - Install the 2nd sun gear groups (14).

14
F0400365
19 - Mount the toothed ring (12).

H Check the position against the marks made be- 12
fore dismantling.
F0400366
30-67
20 - Mount the pinion (15) of the 2nd sun gear.
15
F0400367
21 - Mount the 1st sun gear (11).

11
F0400355
22 - Mount the pinion (13) of the 1st sun gear.
13
F0400368
23 - Mount the brake shaft (17).
17
F0400369
30-68
24 - Mount the O-ring (35) and the anti-extrusion ring (34)

in the spacer (8).
O-ring: ASL800050 34
35
F0400370
25 - Mount the O-rings (5-6) and the anti-extrusion rings

(4-7) in the brake body (30). 5
O-ring: ASL800050
6
7
4 5
F0400356
26 - Mount the brake piston (37) in the spacer (8) and

mount this complete group in the brake body (30).
H Take care not to damage the O-ring seals (5-6). 37
30
F0400357
27 - Insert the springs (36) into the seatings of the brake

piston (37). 36
37
F0400371
30-69
28 - Mount the springs retainer (1).

1
F0400372
29 - Using a press and a plunger, press down on the

springs retainer (1) and mount the snap-ring (38) in
the seating of the brake body (30).
38
30
F0400373
30 - Mount a new stack of brake disks, starting with a

bronze disk (33) (external toothing) and continuing
with a steel disk (32) (internal toothing). 33
H Mount 6 bronze and 5 steel disks.
F0400358
31 - Mount the springs retainer (28).

28
F0400359
30-70
32 - Mount the snap-ring (29) in the housing body (30).
29
30
F0400374
33 - Mount the O-ring (3) in the seating of the motor flange

(39).
3
O-ring: ASL800050.
39
F0400375
34 - Join the motor flange (39) to the brake body (30)

(8 screws).
Screws: 50w5 Nm
H Check the position against the marks made be-
fore dismantling.
39
30
F0400360
35 - Mount the O-ring (10) in the brake body (30).

10
30
F0400376
30-71
36 - Position the motor flange/brake housing group (39-

30) over the toothed ring (12).
H Position the group (39-30) so that the oil filling and 39
control level cap is aligned with the stud-bolt (26).
30
F0400377
37 - Mount the nut (31) and the fifteen screws (9).

Screws and nut: 85 Nm
31
12 9
F0400361
38 - Mount the O-ring (41) in the seating of the hydraulic

motor (40).
41 40
F0400378
39 - Check that the axial height between the surface of the

motor flange (39) and the brake shaft (17) is within tol-
39
erance limits.
H Axial height: 90.5w0.5 mm.
17
90,5 ± 0,5
D0400468
30-72
40 - Mount the hydraulic motor (40) over the gearbox and

40
fasten the screws (42).
H Check the position against the marks made be-
fore dismantling.
Screws: 86 Nm
42
F0400362
41 - Check the leaktightness of the seals of the brake-re-

lease group.
For this job, use the tool M5 and the 400 bar pressure
gauge, M6.
H Testing pressure: 150 bar
H Testing time: 3 min.
H Max. pressure drop: 0 bar.
100
200
300
M5
0 400
bar
M6
D0400469
30-73
DISASSEMBLY AND ASSEMBLY REVOLVING FRAME
REMOVAL OF REVOLVING FRAME
1 - Remove the upper work equipment (For details, see 1

«REMOVING UPPER WORK EQUIPMENT»).
2
2 - Remove the engine hood and the top hood-panel.
(For details, see «REMOVAL OF ENGINE HOOD»).
3 - Remove the cabin, leaving the seat in place. (For de-
tails, see «REMOVAL OF CABIN»).
2
4 - Remove the boom cylinder. (For details, see «RE-
MOVAL OF BOOM CYLINDER»).
5 - Disconnect all the lower tubes (2) from the swivel joint
(1) and plug them. Also plug the fittings left on the F0400242
joint.
6 - Remove the lower left-hand protective casing (3) of
the revolving frame (4) to gain access to the retaining
nuts of the LH area.
7 - Start the engine and swing the revolving frame (3) un-
til a screw (5) in the rear extraction compartment of
the track frame (6) has been centred.
8 - Remove the screw (5).
4
9 - Repeat the same operations for the other thirty-four 3
screws.
Leave two screws in position for reasons of
safety, one at the front and one at the rear. D0400400
10 - Using the equipment A2 and A3 attach the revolving

frame to a hoisting tackle and apply slight tension to
the chains.
11 - Loosen and disengage the two screws, leaving them 7

inserted in the bearing ring (7).
5
12 - Raise the revolving frame (4) slowly.
H While raising the revolving frame, take great care

not to damage the swivel joint. 6
Revolving frame: 3500 kg
F0400150
A2
A3
F0400151
30-74
DISASSEMBLY AND ASSEMBLY REVOLVING FRAME
INSTALLATION OF REVOLVING FRAME

8
Revolving frame attachment screws

(with nut): 314 Nm
(without nut): 314 Nm
8
(without nut): Loctite 242
H Align the two positions corresponding to the cen-
tering pins (9), then assemble.
F0400152
Sealant and swing circle platform gaskets:
ASL800050
Internal swing circle grease:
approx. 25 kg
H After connecting up all the hydraulic tubes, start

the engine and move all parts of the equipment
several times to bleed air from the circuits, while
checking for leakages.
H Switch off the engine and check level of the hy- 7
draulic oil.
8
F0400153
Installation Procedure
In order to swing the revolving frame for centering
the reference pins (8), the pinion-swing circle cou- 9
pling and for centering the swing circle perforations
in the lower frame compartment:
A1
1 -Disconnect the delivery tubes (9) from the swing
motor (10).
2 -Disconnect the brake release tube (11) and apply 10
the tool A1. 11
3 -Connect the tool A1 to 5v6 bar compressed air F0400243
supply.
4 -Rotate the revolving frame by hand until it is in the
correct position.
5 -Insert the two screws (5) left in the swing circle (7)
and secure them.
7
6 -Insert all the other screws (5). 5
7 -After having secured all the screws that join the
swing circle to the revolving frame, reconnect
the delivery tubes (9) of the swing motor (10),
and the brake release tube (11). 6
8 - Detach the hoisting tackle.
F0400150
30-75
DISASSEMBLY AND ASSEMBLY SWING CIRCLE
REMOVAL OF SWING CIRCLE
1 - Remove the upper revolving frame. (For details, see

3
«REMOVAL OF UPPER REVOLVING FRAME»). 1
2 - Completely remove all contaminated grease.
3 - Remove the screws (1) that secure the swing circle
(2).
4 - Remove the swing circle (2) using the tool B1. S
Swing circle: 130 kg.

2
F0400244
INSTALLATION OF
SWING CIRCLE
B1
2
H Before installing the swing circle, check the condition
of the central gasket (3).
For reasons of safety, when installing the swing cir-
cle, insert two screws into the front and back holes S
in the frame.

F0400154
Before attaching the swing circle, check that the area

marked with an «S» is positioned on the right-hand
side of the chassis.
Attachment screws: Loctite 242
Attachment screws: 314 Nm
Lubricating grease: approx. 25 kg
30-76
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR
REMOVAL OF TRAVEL MOTOR


1 - Remove the protective cover (1).

2 - Disconnect from the motor the hydraulic tubes (2), the
drainage tubes (3), the speed increment tubes (4), 1
and the brake tubes (5) and plug them.
3 - Remove from the motor (7) the two attachment F0400036
screws (6).
4 - Remove the motor (7). 7

4 6
2
INSTALLATION OF 5
TRAVEL MOTOR
3
6
Motor attachment screws: Loctite 242 F0400156
Motor attachment screws: 85 Nm
1 - Start the motor and move the machine in both direc-

tions to circulate the oil and check that there are no
leakages.
2 - Stop the motor and check the level of oil in the tank. If
necessary, top it up.
30-77
DISASSEMBLY AND ASSEMBLY TRACK SHOES
REMOVAL OF TRACK SHOES
1 - Move the machine until the master pin (1) on the track
shoe idler (2) is in its highest position.
2 - Slowly loosen the lubricator (3) to let out the grease
and relieve track shoe tension.
The grease contained in the track shoe stretch-

ing cylinder is under pressure and could cause
serious injury to the operator. For this reason 1
the valve should not be loosened by more than
one turn.
2
H If the grease does not flow out easily, move
the machine backwards and forwards F0400157
slowly.
3 - Remove the master pin (1) using the tool E1.
4 - Raise the end-piece of the track-shoe (4) with a crane.
3
5 - Reverse the machine to remove the track shoe (4),
then lay it out on the ground.
6 - Force the boom down to raise the lower chassis and
lift the track shoe away.
INSTALLATION OF
TRACK SHOES F0400158
H Adjust the track shoe tension. (For details see «20.

TESTING AND ADJUSTMENTS»). 4
1 - Rotate the revolving frame 90ë towards the side on

which the track shoe is to be mounted. Force the
boom down to raise the lower frame.
2 - Lay the track shoe out on the ground beneath the low-
er rollers. Let down the lower frame.
F0400227
3 - Attach the first joint to the sprocket assembly and

move the machine forwards until the articulation is
above the sprocket.
4 - Attach a crane to the end-piece of the track shoe in
order to keep it raised.
5 - Insert the master pin (1) using the tool E1.
30-78
DISASSEMBLY AND ASSEMBLY SPROCKET
REMOVAL OF SPROCKET ASSEMBLY
1 - Remove the track shoe assembly. (For details, see

«REMOVAL OF TRACK SHOE ASSEMBLY»).
2 - Turn the revolving frame 90ë towards the sprocket as-
sembly to be removed.
3 - Force the boom down perpendicular to the ground BLOCK
BLOCCO
and raise the lower chassis.
Insert safety blocks beneath the chassis.
4 - Remove the screws (1) and their washers.

5 - Remove the sprocket assembly (2). D0400403
Sprocket assembly: 23 kg
1
INSTALLATION OF SPROCKET
ASSEMBLY

Attachment screws: 300 Nm 2
F0400159
30-79
DISASSEMBLY AND ASSEMBLY FINAL DRIVE
REMOVAL OF FINAL DRIVE
1 - Remove the sprocket assembly (For details, see «RE-

MOVAL OF SPROCKET ASSEMBLY»).
2 - Remove the travel motor (For details, see «REMOVAL
OF TRAVEL MOTOR»). 1
3 - Remove the screws (1).
4 - Put a sling round the travel reduction unit (2) and lift it
out.
Final drive: 67 kg
F0400162
INSTALLATION OF FINAL DRIVE


Attachment screws: 300 Nm
1 - Before moving the machine, fill the final drive unit

with oil. 2
Oil: 1 ,
F0400160
30-80
DISASSEMBLY OF FINAL DRIVE
1 - Remove the snap-ring (1) that secures the cover (4).

4
F0400381
2 - Insert a 6-point wrench into the cap cavity (2). Exert

leverage and lift off the cover (4). 4
F0400382
3 - Lift the O-ring (6) off the gearbox housing (12).

6
12
F0400383
4 - Remove the 1st sun gear pinion (7) (sun gear type).
F0400384
30-81
5 - Lift off the planetary carrier (9) of the 1st sun gear.
F0400385
6 - Take out the four screws (8) that hold the planetary
carrier (10) of the 2nd sun gear to the flanged hub (18).
10
F0400386
7 - Mount tool L1 and lift out the 2nd sun gear (10) and
the brake shaft (19) in one block.
L1
19
10
D0400530
8 - Lift out the brake disks (20-21).
20 21
F0400387
30-82
9 - Using a press, slide the flanged hub (18) off the gear-
box housing (12).
12
18
F0400388
10 - Using the tool L2, extract the four pins (11) from the
flanged hub (18).
L2
18
11
F0400389
11 - Mount the tool L3 on the inside bearing ring (13B).
13B
L3
F0400390
12 - Using a puller, extract the inside bearing ring (13B)

from the flanged hub (18).
18
13B
F0400391
30-83
13 - Remove the 1st half-seal (16) from the flanged hub

(18). 16
18
F0400392
14 - Mount the complete tool L4 and, by screwing in the

screw L4C, compress the springs (30) until the L4C
snap-ring (27) is released.
L4
27
30
D0400529
15 - Remove the snap-ring (27) from its seating in the

flanged hub (18).
L4
18
F0400393
16 - Lift off the tool L4 and slide out the snap-ring (27).
27
F0400394
30-84
17 - Remove the spring retainer (28).

28
F0400395
18 - Take the eleven springs (30) out of their seatings in

the piston (29).
30
F0400396
19 - Use pliers to lift off the brake piston (29).

H To facilitate this operation, introduce compressed
air into the hole in the brake command.
29
F0400397
20 - Remove the O-rings (23-24) and the rings wear (22-

25) from the flanged hub (18). 23 24
18
F0400398
30-85
21 - Turn the gearbox housing (12) upside down and, with

a copper punch, slide off the outside bearing ring
(13B). 13B
12
F0400399
22 - Lift the snap-ring (15) out of the gearbox housing (12).
15 12
F0400400
23 - Lift the spacer (14) out of the gearbox housing (12).

15
12
F0400401
24 - Position the gearbox housing (12) on two spacers

and, using the tool L5 and a press, extract the bear-
ing (13A).
L5
F0400402
30-86
ASSEMBLING OF FINAL DRIVE

1. Important notes
When installing the final drive, some fundamental
rules must be followed:
a) In the case of a damaged gear, the entire reduc-
tion unit must be substituted, not just the single
gear.
b) Always fit a new O-ring with the part to be re-
placed, after thoroughly cleaning the assembly
seating and after having spread a film or grease
(ASL800050) over the seatings and the seals to fa-
cilitate assembly.
2. Method for Installing the front half-seal

In order to achieve perfect leaktightness, the rings
must be assembled in the following manner:
a) Thoroughly clean the housings «1» and «2», if ne-
A
cessary using metal brushes or solvents (the sur-
faces in contact with the «3» rubber rings must be
perfectly clean and dry).
b) Make sure that the sealing surfaces «4» of the
rings «5» are free of any scratches, dents or foreign
bodies and that the surfaces «6» of the rings are
perfectly clean and dry).
D0400471
c) Remove from the lapped surfaces «4» of rings «5»
every trace of dust or finger-prints, and them dam-
pen them with a fine layer of oil, taking care not to
oil the remaining parts.
3. Preloading check on the bearings

If new bearings (13A-13B) are to be fitted, perform the 1 2
following calibration on the new bearings before
mounting them:
1 - Measure the height «A» of the bearing housing in 6
the motor-hub (18).
3
5 5
4 4
D0400478
30-87
2 - Mount the bearings (13A-13B), the spacer (14), 1300 daN

and the snap-ring (15) in the apparatus L6.
3 - Apply a load of 1300 daN (1275 Kg) to the inside
bearing ring (13A).
+0,4
B = A +0
4 - Read off the test height «B» (fig. 2).
5 - Compare the heights «A» and «B» («B»=A+0.04).
H If the height «B» is lower, exchange the spacer
(14) for a thicker one.
H If the height «B» is higher, reduce the thickness of
the spacer (14) by grinding the faces. D0400472
When the gearbox housing (12) is joined to the
flanged hub (18) (with a dynamometric wrench),
carry out a test to check the rotation torque of
the gearbox housing (12).
H Rotation torque: 20v28 Nm.
4. Assembly
25
1 - Mount the rings wear (22-25) and the O-rings (23-24) 24
in the flanged hub.
23
22
F0400403 D0400470
2 - Insert the brake piston (29) in the flanged hub (18)

H Take care not to damage the O-rings (23-24).
29
18
F0400404
30-88
3 - Insert the eleven springs (30) in their seatings in the

brake piston (29).
30
F0400405
4 - Mount the spring retainer (28).
28
F0400406
5 - Using the tool L4, press on the spring retainer (28)

until it is possible to position the snap-ring (27).
L4
28
F0400407
6 - Mount the snap-ring (27) in the flanged hub (18).
18 27
F0400408
30-89
7 - Mount the first half-seal (16) on the tool L7.

16
L7
F0400409
8 - Mount the first half-seal (16) on the flanged hub (18).
18
F0400410
9 - Position the pins (11) in their seatings in the flanged

hub (18).
Using a pad and a press, drive them into their seat-
ings.
11
18
F0400411
10 - Insert the inside bearing ring (13A) into the gearbox

housing (12). 13A
12
D0400475
F0400412
30-90
11 - Position the outside bearing ring (13B) in the gearbox

housing (12). 13B
12
D0400476
F0400413
12 - Using the tool L5 and a press, push the outside bear-

ing ring (13B) about 10 mm beyond the seating of the
snap ring (15).
L5
F0400414
13 - Insert the spacer (14) into the gearbox housing (12).

14
12
F0400415
14 - Mount the snap-ring (15) in the gearbox housing (12).

H Take great care to place it in the correct position.
15 12
D0400473
F0400416
30-91
15 - Mount the outside bearing ring (13B) in the gearbox

housing (12). 13B
12
D0400474
F0400417
16 - Using the tool L6 and a press, drive home the outside

bearing ring (13B) over the snap-ring (15).
L6
F0400418
17 - Mount the inside bearing ring (13A) in the gearbox

housing (12).
13A
D0400477
12
F0400419
18 - Mount the 2nd half-seal (16) on the tool L8.

16
L8
F0400420
30-92
19 - Mount the 2nd half-seal (16) on the gearbox housing

(12).
12
F0400421
20 - Thoroughly clean the surfaces of the front seal and lu-

bricate them with a fine layer of oil.
F0400422
21 - Position the gearbox housing (12) on the flanged hub

(18), taking care that the inside bearing ring (13A)
makes perfect contact. L5
Using a press and the tool L5, complete the as-
sembly.
H When turning over the gearbox housing (12), en- 12
sure that the inside bearing ring (13A) does not
fall out of the gearbox housing (12).
18
F0400423
22 - Mount the brake shaft (19).
19
F0400424
30-93
23 - Mount a new stack of brake disks, starting with a

bronze disk (21) (external toothing) and continuing
with a steel disk (20) (internal toothing). 21
H Mount 8 bronze disks and 7 steel disks.
F0400425
24 - Position the 2nd sun gear group (10) on the pins (11)
of the flanged hub (18).
10
F0400426
25 - Using a press, drive home the 2nd sun gear group (10)
onto the flanged hub (18).
10
F0400427
26 - Mount the four screws (8) that secure the 2nd sun
gear (10).
Screws: Loctite 242 8
10
F0400428
30-94
27 - Tighten the screws (8).

Screws: 220 Nm
F0400429
28 - Mount the 1st sun gear group (9).
F0400430
29 - Mount the 1st sun gear pinion (7).
F0400431
30 - Mount the O-ring seal (6) in the gearbox housing (12).
6
12
F0400432
30-95
31 - Mount the outer cover (4).

4
F0400433
32 - Mount the snap-ring (1) that secures the cover (4).
F0400434
33 - Fill up with oil.

Oil: 1,3 ,
30-96
DISASSEMBLY AND ASSEMBLY IDLER AND RECOIL SPRING ASSEMBLY
REMOVAL OF IDLER AND RECOIL SPRING ASSEMBLY
1 - Position the connecting pin (1) of the track shoe

above the idler (2).
2 - Slowly loosen the grease nipple (3) to let the grease
out and release the track-shoe tension.
The grease contained in the track-shoe idler is
under pressure and could cause serious injury
to the operator. For this reason the valve should
not be loosened for more than one turn. 1
H If the grease does not run out easily, slowly
move the machine backwards and forwards. 2
F0400157
Rest the work equipment on the ground and
switch off the engine.
3 - Remove the connecting pin (1) using the tool E1.

H While taking the track shoe to pieces, support the 3
part of the shoe that encircles the idler by placing 7
a block beneath the shoe ribbing.
4 - Lay the track shoe out on the ground.
5 - Using the tool E2, put a sling around the group (4)
and draw it out of the track-frame guides (5).
Complete group: 75 kg 6
6 - Unscrew and take out the screws (6) and remove the
cylinder (7). F0400163
H Take care not to damage the grease nipple (3).

7 - Set the group down firmly on a flat surface, support
the track shoe idler (2) and remove the screws (8) that E2
join the track shoe idler group (4) to the recoil spring
group (9).
H Before removing the screws (8) mark the connect-
ing bracket (10) and the spacers. 4
INSTALLATION OF IDLER AND

RECOIL SPRING ASSEMBLY 5
F0400164
H Adjust the tension of the track shoe. (For details 10

see «20. TESTING AND ADJUSTMENTS»). 8
9
F0400165
30-97
DISASSEMBLY AND ASSEMBLY IDLER
DISASSEMBLY OF IDLER
H When dismantling the idlers, fit all new seals. 1

4 5
H Remove the cap (10) and drain the oil. 3
Track shoe idler: approx. 0.600 ,
1 - Detach the recoil spring assembly (2) from the sup-

ports (1) of the idler.
H Before removing the screws (3), mark the joint
support (4) and the spacers (5).
2 - Take away the pins (6). 5
2
3 - Using a press, extract the pin (7) and remove the sup- F0400245
ports (1) and the lateral seals (8).
4 - Remove the bushings (9).
ASSEMBLY OF IDLER
10
. To install, reverse the removal procedure. 1 1
H Use a press for the final assembly. 6 6

H Line up the holes and the supports before inserting
the pins.
1 - Fill up with oil and replace the cap (10).
7
Track shoe idler: 0.6 ,
Oil cap: 55w5 Nm

8 8
9 9
D0400404
30-98
DISASSEMBLY AND ASSEMBLY THE RECOIL SPRING GROUP AND CYLINDER
DISMANTLING AND RE-ASSEMBLING THE RECOIL SPRING GROUP

AND CYLINDER
1. Recoil spring
F
Disassembly
C1
1 - Remove the welded base (1).
2 - Position the group (2) beneath the press and cen- 2
tre the tool C1.
The spring is mounted under a high installed

load, so make sure that the group is well-
centred.
3 - Apply pressure and, once the spring (3) is fully
compressed, remove the safety pin (4) and the D0400409
ring nut (5).
4 - Slowly reduce pressure to free the spring.
A
H Free spring length: 233 mm.
5 - Dismantle the internal tie-rod (6), the spring (3)
and the flange (7).
Assembly
H Check the total length of the group.

. Total length «A»: 245w1 mm
D0400408
. Spring pre-loading: 4000 kg
. Length of spring when pre-loaded: 203 mm
H Check that the base (1) is tightly welded.
4
3
5
6
1 7
D0400406
2. Cylinder
Disassembly
4
1 - Remove the lubricator (1) and the washer (2). 6
2 - Draw the piston (3) out of the cylinder (4). 5
3 - Remove the ring (5).
3 1
2
4 - Remove the seal (6) from the piston (3).
Assembly
. To re-assemble, reverse the removal procedure.
Piston and sealants: ASL800050. D0400407
30-99
DISASSEMBLY AND ASSEMBLY TRACK ROLLER
REMOVAL OF TRACK ROLLER
1 - Slowly unscrew the lubricator (1) to let out the grease

and relieve tension on the track shoe.
1
The grease contained in the track shoe cylinder
is pressurised and could cause serious injury to
the operator. For this reason the valve should
not be loosened by more than one turn.
slowly.
2 - Loosen the screws (2) that hold the idlers (4).
3 - Rotate the revolving frame 90ë towards the removal F0400246
side. Force the boom down to raise the lower chassis

(3).
4 - Remove the track roller (4).
INSTALLATION OF
TRACK ROLLER
H With the lower chassis (3) raised, install the idlers 2

(4) and lightly fasten the attachment screws (2). F0400161
Idler attachment screws: Loctite 242

H Slowly let down the lower frame (3) until the idlers
(4) rest completely on the track shoe and then
tighten the screws (2) firmly.
Idler attachment screws: 118 Nm.
H Adjust track-shoe tension. (For details, see «20.

TESTING AND ADJUSTMENTS»).
4 3
F0400166
30-100
DISASSEMBLY AND ASSEMBLY CARRIER ROLLER
REMOVAL OF CARRIER ROLLER
1 - Slowly unscrew the lubricator (1) to let out the grease

and relieve tension on the track shoe.
1
The grease contained in the track shoe stretch-
ing cylinder is under pressure and could cause
serious injury to the operator. For this reason
the valve should not be loosened by more than
one turn.
slowly.
Lower the work equipment to the ground and
switch off the engine. F0400246
2 - Raise the track shoe (2) to a height that leaves the id-
ler (3) free. For reasons of safety, position some
2
blocks (4).
3 - Loosen the retaining screw (5) and remove the carrier
roller. 4
3
INSTALLATION OF
CARRIER ROLLER
. To install, reverse the removal procedure. F0400167
H Adjust track shoe tension (For details, see «20.

5
H Before finally securing the retaining screws, lower
the track shoe (2) and check that the idler (3) is
perfectly centred.
F0400168
30-101
DISASSEMBLY AND ASSEMBLY R.H. PPC VALVE (BOOM - BUCKET)
REMOVAL OF R.H. PPC VALVE (BOOM - BUCKET)

1
Disconnect the lead from the negative (±) battery 3

terminal.
1 - Remove the five retaining screws (1-2) of the RH

2 1
dashboard
H To remove the inside screw (2), lower the seat and F0400169
push it right back.

2 - Remove the dashboard (3).
3 - Disconnect the connector (4). 3
H If a connector (5) has been fitted for the rotating
and cutting shovel, disconnect that also. 5
4 - Disconnect the six tubes (6) from the PPC valve and
plug them to prevent entry of impurities. 4
H Mark the positions to avoid errors during assem-
bly.
5 - Lift the rubber protection (7) and remove the PPC
valve (8).
F0400170
INSTALLATION OF 8
R.H. PPC VALVE
6
F0400171
H Check the positions carefully when reconnecting

the tubes
P - Pressure
T - Unload
1 - Boom descent 1
2 - Bucket opening
3 - Boom rising P T
4 - Bucket closing
If necessary, bleed air from the servocontrol circuit.

(For details, see «20. TESTING AND ADJUST- 2 4
MENTS»).
3
F0400172
30-102
DISASSEMBLY AND ASSEMBLY L.H. PPC VALVE (ARM-SWING)
REMOVAL OF L.H. PPC VALVE (ARM-SWING)

2
Release residual pressures from all circuits. (For de- 3

terminal. 1
2
1 - Remove the seven LH - dashboard retaining screws
(1-2). 1
H To remove the inside screws (2), lower the seat F0400173
and move both platform and seat back as far as

they will go.
2 - Remove the dashboard (3).
3 - Disconnect the connector (4). 3
4 - Disconnect the six tubes (5) from the PPC valve and
plug them to prevent entry of impurities.
bly.
5 - Lift the rubber protection (6) and remove the PPC
valve (7).
4
F0400174
INSTALLATION OF
7
L.H. PPC VALVE
5
F0400175
H Check the positions carefully when reconnecting

the tubes.
P - Pressure
T - Unload
1 - Arm opening 1
2 - RH swing
3 - Arm closing P T
4 - LH swing
If necessary, bleed air from the servocontrol circuit.

2 4
MENTS»).
3
F0400172
30-103
DISASSEMBLY AND ASSEMBLY BLADE PPC VALVE
REMOVAL OF BLADE PPC VALVE

1
Disconnect the lead from the negative (±) battery 3

terminal.
1 - Remove the cabin (For details, see «REMOVAL OF

2 1
CABIN»).
F0400169
2 - Remove the five screws (1-2) from the RH dashboard.

H To remove the inside screw, lower the seat and
move it back as far as it will go.
3 - Remove the dashboard (3). 3
4 - Draw out the cotter pin (4) that connects the PPC
valve rocker arm (5) to the fork (6).
5 - Disconnect the four tubes (7) and plug them to pre-
vent impurities from entering.
6 - Remove the screws, nuts and washers (8).
7 - Remove the PPC valve (9).
F0400299
INSTALLATION OF BLADE
PPC VALVE
9 8
7 4
8 5
F0400176
30-104
DISASSEMBLY AND ASSEMBLY PPC VALVE (For travel, boom swing, 2-piece boom)
REMOVAL OF PPC VALVE

(For travel, boom swing, 2-piece boom)
1 1

2 3
1 - Disconnect the tubes (1-2) (four for each PPC valve)
and plug them to prevent impurities from entering.
bly.
2
2 - Remove the supply and return fittings (3) (P and T). F0400177
3 - Remove the screws (4) that attach the PPC valve to

the platform (four for each PPC valve).
1
4 - Lift out the PPC valve concerned (5).
3
INSTALLATION OF PPC VALVE

Fittings: 35 Nm. 2
F0400178
5 4
5
F0400179
30-105
DISASSEMBLY AND ASSEMBLY SERVOCONTROL FEED UNIT
REMOVAL OF SERVOCONTROL FEED UNIT

8
1
terminal.
2
1 - Disconnect the connectors (1) and (2) from the speed
increment and travel brake solenoids.
2 - Disconnect the connectors (3) and (4) from the supply 12
group solenoids. 6
3 - Disconnect the tubes (5-6-7) from the pumps and plug 7

them.
4 - Disconnect the tubes (8-9) from the feed unit and plug
them.
H Secure the tube fitting (8) in a raised position to
avoid oil leakage. 4
5 - Unscrew the screws (10) and lift out the entire group 10
(11).
5
3
F0400180
INSTALLATION OF
8
Keep the tube fitting (8) in its raised position to avoid 11

oil leakage.
9
Attach the core hitch (12) beneath the upper left-hand
screw.
1 - Start the engine to circulate the oil and check that F0400181

2 - Bleed air from the servocontrol circuits. (For details,
see «20. TESTING AND ADJUSTMENTS»).
30-106
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
REMOVAL OF CONTROL VALVE

ground and switch off the engine. 3 D1

1 - Disconnect from the control valve all three delivery

tubes (1), all eighteen service tubes (2), all twenty ser-
vocontrol tubes (3), and the exhaust pipe (4). Plug all
the tubes and fittings.
H Mark the tubes to avoid errors when reconnect- 3
ing. F0400182
2 - Disconnect the two travel parallelism tubes (6) from

the plate (5) and plug them. Also plug the fittings on
the plate. 4
1 1
3 - Attach the hoisting equipment D1 to the control valve.
4 - Hook up the tackle and apply a slight tension.
5 - Remove the three screws (7) and lift out the control 7
valve.
Control valve: 60 kg 6
5
INSTALLATION OF F0400183
CONTROL VALVE
2 - Bleed air from the circuits. (For details, see «20.
3 - Switch off the engine and check the level in the oil
tank.
30-107
DISASSEMBLY AND ASSEMBLY BOOM CYLINDER
REMOVAL OF BOOM CYLINDER

Extend the arm fully and open the bucket comple-
tely. Lower the work equipment until it is resting on 2
the ground
1 - Put a sling around the cylinder (1).

2 - Switch off the engine, release pressure in the cylinder
by moving the RH PPC valve lever several times.
3
3 - Remove the screw (2) and draw out the pin (3).
4
4 - Start the engine to retract the piston (4). 1
5 - Lower the cylinder (1) until it rests on a stand «A». F0400184
H To hold the piston rod in its fully retracted position

tie it with wire.
6 - Switch off the engine and release any residual hy-
draulic pressures. (For details, see «20. TESTING
AND ADJUSTMENTS»).
1
7 - Disconnect the tubes (5-6) and plug them. Also plug
the holes in the safety valve to avoid entry of impuri-
ties.
8 - Remove the screw (7) and take out the valve.
9 - Remove the screw (8) and draw out the pin. A
F0400185
10 - Lift out the cylinder (1).
INSTALLATION OF BOOM
CYLINDER
9
H Insert the adjustments to a given clearance (dis-

tributed on both sides of the cylinder rod) until a
clearance of 1v2 mm is obtained.
10
When aligning the positions between hole and
pin, let the engine run at minimum idling.
Do not insert fingers into the hole to check the F0400186
alignment.
Inside bushings : ASL800050 7 8

tributed on both sides of the piston rod) until a
clearance of 0.5v1 mm is obtained.
. Start the engine and bleed air from the cylinder. (For 5
details, see «20. TESTING AND ADJUSTMENTS»).
6
H After bleeding the air, check the oil level in the
tank.
F0400187
30-108
REMOVAL OF BOOM CYLINDER (For 2-piece boom)
1 - Fully extend the front work equipment, raise the

boom and 2-piece boom and position a supporting
stand (A) between them.
H The stand should be 1.60 m high.
2 - Manoeuvre the arm until the bucket is resting on the
ground. Switch off the engine.
A
F0400647
3 - Put a sling round the RH cylinder (1) of the 2-piece

boom and remove the self-locking nut (2), the screw 1 1
(3) and the adjustment to a given clearance (4).
4
4
2
5
5 3
F0400492
4 - Slide off the pin (5) that connects the RH cylinder (1)
to the 2-piece boom, until the piston rod is completely
disconnected.
5 - Start the motor and retract the RH cylinder piston. 6
H To secure the piston rod in this position, tie it with

wire and switch off the engine.
1
6 - Disconnect the tubes (6) from the RH cylinder (1) and
plug them.
7 - Slide out the pin (7) until the cylinder (1) is free and 7
remove it. F0400493
8 - Put the boom cylinder in a sling.

9 - Slide the pin (7) out until the boom cylinder piston rod
(8) is disconnected.
H To hold the piston rod it its fully retracted position,
tie it with wire and switch off the engine.
8
10 - Start the engine and retract the piston.
11 - Lower the cylinder (8) and rest it on a stand (B). 7
B
F0400649
30-109
12 - Disconnect the tubes (9) and (10) and plug them. Also 11
plug hole in the safety valve (11) to prevent impurities
from entering.
10
13 - Remove the screws (12) and take out the safety valve
(11).
12
9
F0400490
14 - Remove the screws (13) and take out the pin (14).
15 - Remove the cylinder.
8 13
14
INSTALLATION OF THE BOOM

F0400495
CYLINDER (For 2-piece boom)

Self-locking nut: 118 Nm.
Inside bushings: ASL800050.

pin, run the engine at minimum idling.
Do not insert fingers in the holes to check the
alignment.


tributed on both sides of the cylinder) until a clear-
ance of 0.5v1 mm is obtained.
. Start the engine and bleed the air from the cylinders
MENTS»).
H After bleeding the air, check the level of the oil
tank.
30-110
DISASSEMBLY AND ASSEMBLY 2-PIECE BOOM CYLINDER
REMOVAL OF 2-PIECE BOOM CYLINDER
1 - Fully extend the front work equipment, raise the

boom and 2-piece boom and position a supporting
stand (A) between them.
H The stand should be 1.60 m high.
2 - Manoeuvre the arm until the bucket is resting on the
ground. Switch off the engine.
A
F0400647

boom and remove the self-locking nut (2), the screw 1 1
(3) and the adjustment to a given clearance (4).
4
4
2
5
5 3
F0400492
4 - Slide off the pin (5) that connects the RH cylinder (1)
to the 2-piece boom, until the piston rod is completely
disconnected.
5 - Start the motor and retract the RH cylinder piston. 6
H To hold the rod in its fully retracted position, tie it
with wire and switch off the engine.
6 - Disconnect the tubes (6) from the RH cylinder (1) and 1
plug them.
7 - Slide out the pin (7) to free the cylinder (1) and re-
move it. 7
F0400493
8 - Put the boom cylinder in a sling.

9 - Slide the pin (7) out to disconnect the boom cylinder
piston rod (8).
10 - Start the engine and retract the piston.
H To hold the rod in its fully retracted position, tie it 8
with wire and switch off the engine.
11 - Lower the cylinder and rest it on a stand (B). 7
B
F0400649
30-111
DISASSEMBLY AND ASSEMBLY 2-PIECE BOOM CYLINDER
12 - Repeat the procedure from points 3-7 to remove the

LH cylinder of the 2-piece boom.
6
7
9
F0400499
INSTALLATION OF 2-PIECE
BOOM CYLINDER
When aligning the positions between hole and pin,

run the engine at minimum idling.
Do not insert fingers in the holes to check the align-
ment.

tributed on both sides) until a clearance of
0.5v1 mm is obtained for each cylinder.

. Start the engine and bleed the air from the cylinders
MENTS»).
H After bleeding the air, check the level of the oil
tank.
30-112
DISASSEMBLY AND ASSEMBLY ARM CYLINDER
REMOVAL OF ARM CYLINDER

Open the front work equipment completely, then
raise it and place a supporting stand between the
boom and the 2-piece boom. Manoeuvre the bucket
until its teeth are resting on the ground, together with
the arm.

by moving the LH PPC valve lever several times.
F0400500
4 - Start the engine to retract the piston (4).

H To hold the piston in its fully retracted position, tie
the rod with wire.
5
1
AND ADJUSTMENTS»).
6 - Disconnect the tubes (5) and plug them. 4
3
If a safety valve has been installed, disconnect
the tubes (6-7) from the valve.
2
F0400501
INSTALLATION OF
ARM CYLINDER
H IInsert the adjustments to a given clearance (dis-

tributed on both sides of the piston rod) until a 6
7
pin, let the engine run at minimum idling. F0400247
Do not insert fingers into the hole to check the

alignment.
Inside bushings: ASL800050

9 8
1
. Start the engine and bleed air from the cylinder. (For
tank.
F0400189
30-113
DISASSEMBLY AND ASSEMBLY BUCKET CYLINDER
REMOVAL OF BUCKET CYLINDER

the ground
1 - Switch off the engine and release pressure in the cy-

2
linder by moving the RH PPC valve lever several
times.
2 - Remove the ring nut (2) and draw out the pin (3).
3 - Switch off the engine and retract the piston rod (4).
H To hold the piston rod in its fully retracted posi- 3
tion, tie it with wire. F0400642

AND ADJUSTMENTS»).
6
5 - Disconnect the hoses (5) and plug them. Also plug
7
the holes of the rigid tubes to avoid entry of impuri-
ties. 1


5
F0400155
INSTALLATION OF BUCKET
5
CYLINDER
6
7

pin, do not insert fingers into the hole to check
the alignment. F0400190

tank.
30-114
DISASSEMBLY AND ASSEMBLY BOOM SWING CYLINDER
REMOVAL OF BOOM SWING CYLINDER
1 - Swing the boom to the right to extend the cylinder

fully.
2 - Swing the revolving frame 45ë and rest the work
equipment on the ground.
3 - Switch off the engine and move the PPC valve sev-
eral times to release all residual pressures.
2
4 - Remove the RH front guard (1) from the revolving 1
frame (2).
5 - Disconnect the tubes (3) from the cylinder and plug
them. Also plug the flanges (4) of the cylinder (5). D0400405
6 - Disconnect the lubricator tube (6).

7 - Place a block beneath the cylinder head to prevent
the edge of the frame making dents in the piston
rod. Also place a support beneath the cylinder.
8 - Remove the screw (7), draw out the pin (8) and detach
the piston rod from its support (9).
9 - Remove the screws (10) and draw out the stop (11) 4 3 3
and the pin (12). 4
5
10 - Slide the cylinder out partially from the front and, as
soon as possible, put it in a sling and lift it off.
H During this operation take great care not to dent F0400192
the piston rod.
INSTALLATION OF BOOM SWING 12 10

CYLINDER
6
11
tributed on both sides of the piston) until a clear-
ance of 1v2 mm is obtained.


alignment.

7
8
9
tank. F0400194
30-115
DISASSEMBLY AND ASSEMBLY BLADE CYLINDER
REMOVAL OF BLADE CYLINDER

Swing the upper revolving frame 90ë to the right and
lower the blade and the work equipment to the 6 10
2
ground in their safe positions.
8 9
1 - Remove the protection (1).
1
2 - Put the blade cylinder (2) in a sling and put the cable
under slight tension. 7
3 - Switch off the engine and release pressures in the cy-

linder by moving the lever of the blade PPC valves 5
several times in both directions. 4
4 - Take out the screw (3) and remove the pin (4). 3
F0400195
5 - Start the engine and retract the piston (5).

H To hold the piston in its completely retracted posi-
tion, tie it with wire.
6 - Stop the motor and release any residual hydraulic
pressures. (For details, see 20. TESTING AND AD-
JUSTMENTS).
7 - Disconnect the tubes (6-7) from the safety valve (8).
Plug the tubes and the safety valves to prevent entry
of impurities.
8 - Take away the screw (9) and remove the pin (10).
9 - Remove the blade cylinder (2).
INSTALLATION OF BLADE
CYLINDER
H Insert the adjustments to a given clearance on

both sides of the piston.
When aligning the hole and pin, let the engine

run at minimum idling.
alignment.
H Insert the adjustments to a given clearance on

both sides of the piston.
H After bleeding the air, check the level of oil in the
tank.
30-116
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT CYLINDERS
DISASSEMBLY OF WORK EQUIPMENT CYLINDERS
1 - Place the cylinder on the tool F8 and partially extract

the piston. 3
2 - Loosen the retaining screws of the flange (1) that se- F8 5
cures the head (2) and take it away. Move the flange
(1) towards the piston rod.
3 - Push the head (2) into the cylinder (3) and remove the
snap ring (4).
H Take great care not to damage the inside of the
cylinder.
4 - Slide the piston rod (5) out of the cylinder (3), com-
plete with the flange (1), the snap ring (4), the head
F0400196
(2) and the piston (6).

5 - Remove the screws (7) and remove the two half-
flanges (8). 1 2
5 6
8
7
4
F0400197
For the arm cylinder only:

1 - Heat the safety valve (9) and the end nut (10)
to a temperature of 140v150 ëC
2 - Loosen and remove the safety screw (9).
10
9
3 - Loosen and remove the nut (10).
H Use the key F7 and the dynamometric key
G1.
H Before continuing with the dismantling op-
erations, allow the piston rod to cool down.
F0400198
6 - Take the group to pieces.

For the arm cylinder, first take away the thirteen
brake pin (12) retaining balls (11).
7 - Remove the seals from the piston rod, the piston, the
12
head and the flange.
11
F0400199
30-117
ASSEMBLY OF THE WORK EQUIPMENT CYLINDERS
H Take care not to damage the seals or the sliding sur-

faces.
H Prepare each individual component before final as-
3
2
sembly.
1 2
1. Assembly of the head-retaining flange.

1
1 - Mount the scraper (1) in the external seating of the
flange (2), making sure that it is positioned correctly.
Drive home the scraper using the press.
2 - Mount the O-ring seal (3). D0400398 F0400200
H Use grease to hold the washer in place.

Sealant: ASL800050
6 5
7 1
2. Head assembly
1 - Mount the internal central retaining ring, positioning 4 2
first the O-ring (1) and then the sealing ring (2).
H Make sure that the lowering of the retaining ring is
turned towards the inside of the cylinder.
3 4
2 - Use the tool F1, mount the lip seal (3).
H Check that the lips are facing towards the inside D0400395
of the cylinder.
3 - Mount the guide rings (4).
6 5 1 6 5 6
4 - Mount the O-rings (5) and relative anti-extrusion rings 7
(6) on the outside of the head (7).
H Check the position of the anti-extrusion rings (6).
4
3 2 4 D0400394
1 2 F1
7 2
F0400201 F0400202
30-118
5 - Gauge the diameter of the internal seals, mounting

the group underneath the press and using the speci-
fic gauging knuckle pin F2 for the diameter of the pis-
ton rod.
F2
F0400203
3. Piston assembly
1 - Using the tool F3, mount the piston seal. Mount in the
correct sequence the rubber ring (1), the external seal
(2), and the rings wear (3).
2 - Mount the guide rings (4).
1 2 F3
3 - For the arm piston only: Mount the O-ring (5) and
the rings wear (6) for the sealing between piston rod
and piston.
F0400204
4 3 2 3 4
6 5 6
D0400397
4 - Gauge the diameter of the seal (2) of the piston (7),

mounting the group under the press and using the
specific gauging ring F4 for the piston diameter.
7
F4
F0400205
30-119
4. Piston rod group assembly

1 - Mount on the end of the piston rod (1) the bushing F5
of the correct diameter. 2
1 4
2 - Slide the head-retaining flange (2), the snap ring (3)
and the head (4) onto the piston rod.
H Check carefully the positioning of the head-retain-
ing flange.
3 - Remove the bushing F5 from the end of the piston.
F5 3
F0400228
4 - Mount the O-ring (5) and the rings wear (6) in the end-
seating, for the sealing between the piston ring and 5
piston.
H For the arm piston ring, the seal is housed in the
piston itself. 7 8
6
5 - Mount in the correct sequence the brake bushing (7)
(for the boom and arm cylinders only) and the piston
(8).
F0400229
6 - For the arm piston only: mount the brake pin (9) and
slide the thirteen retaining balls (11) into the hole (10).
7 - Mount the half-flanges (12) that hold the piston (8) in 8 12
place, and secure them with the screws (1). 10
Flange retaining screws: 5w0.5 kgm
13
11 9
F0400248
For the arm piston only:

1 - Mount the nut (14) that holds the piston (8) in
place, and tighten with the socket wrench F7 8
14
and the dynamometric tool with multiplier G1.
Piston retaining nut: Loctite 262 15
Piston retaining nut: 300w20 kgm
(294w19.5 dNm)
2 - Mount the safety screw (15).
Safety screws: Loctite 262
Safety screws: 10w1 kgm (98w9.8 Nm)
F0400249
30-120
5. Cylinder assembly
1 - Place the cylinder (1) and the piston rod group (2) on 1 3
the equipment F8 and align their axes. 4
2
2 - Lubricate the external seals and insert the piston (3)
in the cylinder (1).
Piston sealants: Grease ASL800050
H Before inserting the piston, check that the seals
are not damaged and that they fit perfectly in their
seatings.
3 - Lubricate the external seals of the head (4) and insert 5
it completely into the cylinder (1). F8 F0400250
Head sealants: Grease ASL800050

H Before inserting the head, check that the seals
are not damaged and that they fit perfectly in their
seatings.
4 - Using the tool F6, position the snap ring (5) that holds
8
the head (4) in the cylinder seating. 6
H Check that the snap ring is completely inserted in
the seating.
5 - Position the flange (6) that holds the head in place,
and secure it with the screws (7). F6
H Before positioning the flange, check that the O-
ring flange seal (8) is in its seating.
Flange blocking screws: 5w0.5 kgm
F0400211
(49w5 Nm)
7
F0400226
30-121
DISASSEMBLY AND ASSEMBLY OVERLOAD SENSOR
REMOVAL OF OVERLOAD SENSOR

6
1 - Disconnect the plug (1) of the pressure switch (2). 8
2 - Unscrew the screw (3) and remove the core hitch
clamp (4).
1 4
3 - Disconnect the tube (5) from the pressure switch (2) 3
and plug it. Also plug the hole in the pressure switch.
4 - Bring the activating lever (6) into its stop position and
secure it with a screw (7) (M6x12). F0400212
5 - Take out the screws (8) and draw out the group.
5
2
INSTALLATION OF OVERLOAD
SENSOR 6
. To install, reverse the removal procedure. 7

H When removing the screw (7), accompany the le-
ver in order to let the roller come down gently onto 9
the cam (9).
F0400213
30-122
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT (For the boom)
REMOVAL OF WORK EQUIPMENT

(For the boom)
the ground
1 - Put a sling around the cylinder (1) of the boom. 7
by moving the PPC valve lever several times.
3 - Remove the screw (2) and draw out the pin (3). 3
6
4 - Start the engine to retract the piston (4). 4
H To hold the piston in its fully retracted position, tie 1
it with wire.
F0400251
5 - Lower the cylinder (1) until it comes to rest on blocks

(A).
AND ADJUSTMENTS»).
7 - Remove the overload sensor (For details, see «RE-
MOVAL OF OVERLOAD SENSOR»). 1
8 - Disconnect the hoses (5) and plug them. Also plug
the rigid tubes.
9 - Put the equipment in a sling and apply slight tension
to the cables.
10 - Remove the screw (6) and the pin (7). Lift off the work
equipment (8). A
Work equipment: 980 kg F0400185
INSTALLATION OF WORK
EQUIPMENT (For the boom)

tributed on both sides of the piston) until a clear- 5 5
When aligning the positions between holes and


alignment.

tributed on both sides of the arm) until a clearance
of 0.5v1 mm is obtained.
. Start the engine to circulate the oil, and bleed air from
the cylinder.
H After bleeding the air, switch off the engine and
check oil level in the tank.
8
F0400215
30-123
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT (2-piece boom version)
REMOVAL OF WORK EQUIPMENT (2-piece boom version)

Fully extend the arm and the 2-piece boom and com-
pletely curl up the bucket. Position a stand (A)
(height 1.60 m.) between the boom and the 2-piece
boom, and rest the back of the bucket on the ground.
Stabilise the machine by resting the blade and/or the
stabilisers on the ground.
Completely eliminate residual pressures from all the A
circuits. (For details, see «20. TESTING AND AD-
JUSTMENTS»).
F0400653
1 - Disconnect the boom cylinder (1) from the 2-piece

boom and rest it on a stand (B).
H In order to disconnect the boom cylinder, it is ne-
cessary to remove the RH cylinder of the 2-piece
boom. (See «REMOVAL OF 2-PIECE BOOM CY- 2
LINDERS up to point 11). 1
A
After having disconnected the boom cylinder, re-
assemble the RH cylinder of the 2-piece boom
with the pin (2) and fasten it with its own screws.
B
F0400650
2 - Disconnect the eight hoses (3) that control the front

work equipment cylinders, and plug them. Also plug
the union fittings of the hoses (4).
3
3 - Remove the overload sensor (See «REMOVAL OF
OVERLOAD SENSOR»).
F0400505
4 - Put the boom (5) in a sling and apply slight tension to

the cables.
H Pass the cables through the rigid tubes to avoid 5
distortion.
7
5 - Remove the screws (6) and take out the pin (7).
6 - Raise the boom (5) until it is disengaged from the swi- 6

vel support (8) and take away the stand (A).
A 8
F0400651
30-124
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT (2-piece boom version)
7 - Swing the group to the side of the machine and rest

the boom on a stand (C).
5
D0400479
INSTALLATION OF THE
WORK EQUIPMENT
(2-piece boom version)
H Insert the shims (distributed on both sides of the

top of the cylinder) until a clearance of 1v2 mm
is obtained.

alignment.
H Insert the shims (distributed on both sides of the

top of the piston rod) until a clearance of 1v2
mm is obtained.
the cylinder. (For details, see «20. TESTING AND AD-
JUSTMENTS»).
H After bleeding the air, switch off engine and check
oil level in the tank.
30-125
DISASSEMBLY AND ASSEMBLY BUCKET
REMOVAL OF BUCKET
Lower the bucket to the ground, resting with its back
on a flat surface. 7
4
1 - Take out the safety pin (1) and the connecting pin (2)
between bucket (3) and tie-rod (4).
6
2
5
2 - Take out the safety pin (5) and the pin (6) that con-
nects the bucket to the arm (7).
1 3
INSTALLATION OF BUCKET F0400216
H Insert the adjustments to a given clearance be-

tween bucket (3) and tie-rod (4).
When lining up the hole and the pin, let the en-
gine turn at low idling speed.
Do not insert fingers into the holes to check
alignment.
H Insert the adjustments to a given clearance (on

both sides) between the bucket (3) and the arm
(7), until a play of 0.5v1 mm is obtained.
30-126
DISASSEMBLY AND ASSEMBLY ARM
REMOVAL OF ARM
1 - Remove the bucket (For details, see «REMOVAL OF

BUCKET»).
2 - Remove the bucket cylinder. (For details, see «RE- 1
MOVAL OF BUCKET CYLINDER»).
3 - If the machine is designed for the application of op-
tional front equipment, disconnect the boom (or the 2-
piece boom), the tubes (1) and remove the supports (2).
2
F0400507
4 - Loosen the ring nut (3) and pin (4) and remove the
thrust lever (5).
3
4
F0400146
5 - Raise the boom and bring the arm (6) into a vertical
position and then lower it to the ground.
D0400480
6 - Switch off the engine and release residual pressures.

10 7
7 - Put the arm cylinder (7) in a sling, remove the screw 9
(8) and take out the pin (9).
8 - Start the engine and fully retract the piston (10).
H To hold the piston rod in its fully retracted posi-

8
F0400508
30-127
9 - Rest the cylinder (7) on a block (A).

10 - Switch off the engine. 7
A
F0400509
11 - Connect the arm (7) to the hoisting tackle and apply

slight tension to the cable.
12 - Remove the cotter-pin (11) and the nut (12).
12
11
F0400510
13 - Take out the screw (13) and pull out the pin (14).
14 - Lift off the arm (6). 6
Arm: 156 kg.
14
13
F0400511
15 - Start the engine and, for reasons of safety, lower the

boom or 2-piece boom until it rests on the ground.
F0400646
30-128
INSTALLATION OF ARM

H Insert shim

pin, do not insert fingers into the hole to check
the alignment.

tributed on both sides of the piston) until a clear-
Do not insert fingers into the holes to check the
alignment.

tributed on both sides) until a clearance of
0.5v1 mm is obtained.
pin, do not insert fingers into the holes to check
the alignment.
30-129
DISASSEMBLY AND ASSEMBLY 2-PIECE BOOM
REMOVAL OF 2-PIECE BOOM
1 - Remove the bucket, the bucket cylinder, the arm cy-

linder and the arm. For details see:
. REMOVAL OF BUCKET
1
. REMOVAL OF BUCKET CYLINDER
. REMOVAL OF ARM CYLINDER
. REMOVAL OF ARM
2 - Start the engine and bring the 2-piece boom (1) into a
vertical position. Lower it until it rests on the ground
and switch off the engine.
F0400652

boom and remove the nut (3), the screw (4) and the 2 2
shim (5).
4 - Slide out the pin (6) that connects the RH cylinder (2)
to the 2-piece boom (1) until the piston rod is comple- 5
tely disconnected. 5
3
6 4
F0400531
5 - Start the engine and completely retract the piston rod

of the RH cylinder.
H To hold the piston rod in a fully retracted position,
tie it with wire and switch off the engine.
6 - Lower the cylinder until it is in a vertical position, leav-
ing the boom tied up.
7 - Repeat these operations from point 3 to point 6 in or-
der to disconnect the LH cylinder (7).
F0400532
8 - Hook the 2-piece boom to the hoisting tackle.

9 - Remove the screws and take out the pin (8).
10 - Take off the 2-piece boom. 8

2-piece boom: 195 kg
7
F0400513
30-130
DISASSEMBLY AND ASSEMBLY 2-PIECE BOOM
INSTALLATION OF 2-PIECE BOOM

alignment.
. Insert the shims (distributed on both sides of the

boom) until a clearance of 0.5v1 mm is obtained.
the cylinder. (For details, see «20. TESTING AND AD-
JUSTMENTS»).
check the oil level in the tank.
30-131
DISASSEMBLY AND ASSEMBLY BOOM
REMOVAL OF BOOM
1 - Remove the arm (For details, see «REMOVAL OF 2

ARM»).
2 - Remove the arm cylinder. (For details, see «RE-
MOVAL OF ARM CYLINDER»).
3 - Start the engine and lower the boom to the ground.
4 - Switch off the engine and move the PPC valve sev-
eral times to release pressures in the cylinder. 3
5 - Put the boom cylinder in a sling (1).
6 - Take out the screw (2) and pull out the pin (3). 4
1
7 - Start the engine and fully retract the piston (4). F0400184
H To hold the piston rod in its fully retracted posi-

8 - Switch off the engine and release all pressures. (For 9
9 - Lower the piston until it is resting on blocks (A).
10 - Remove the overload sensor. (For details, see «RE- 1
MOVAL OF OVERLOAD SENSOR»).
8
11 - Put the boom (5) in a sling, using the attachment hole
in the arm cylinder. Apply slight tension to the cable.
12 - Disconnect the front equipment hoses (6) and plug
them. Also plug the rigid tubes (7).
13 - Take out the screw (8) and pull out the pin (9). A
14 - Lift off the boom (5).
F0400300
Boom: 358 kg
INSTALLATION OF BOOM 5


alignment. F0400220

7 7

tributed on both sides of the boom) until a clear-
. Start the engine to circulate the oil and bleed air from
the cylinders.
6 6
check the oil level in the tank.
F0400301
30-132
REMOVAL OF BOOM (2-piece boom version)
1 - Remove the bucket, the bucket cylinder, the arm cy-

linder, the arm, and the 2-piece boom. For details
see:
. REMOVAL OF BUCKET
. REMOVAL OF BUCKET CYLINDER
. REMOVAL OF ARM CYLINDER
. REMOVAL OF ARM
. REMOVAL OF 2-PIECE BOOM
2 - Replace the fulcrum pin (1) of the 2-piece boom and

secure it with the proper screws.
2 1
3 - Manoeuvre the boom (2) until the fulcrum pin is rest-
ing on a stand (A), 1.60 m high.
A
4 - Switch off the engine and release any residual pres-
sures in the boom cylinder.
5 - Remove the 2-piece boom cylinders (3) and let the
3
boom cylinder (4) rest on a stand. (For details, see
«REMOVAL OF 2-PIECE BOOM CYLINDER»).
4
F0400645
6 - Remove the overload sensor. (For details, see «RE-

MOVAL OF OVERLOAD SENSOR»).
7
7 - Disconnect the six connecting hoses of the front work 6
5
equipment cylinders (5) and the two tubes (6) of the
optional equipment.
H Plug the hoses and rigid tubes to prevent entry of im-
purities.
F0400515
8 - Take out the four screws (7) and lift away the com-
plete rack of tubes. 7
F0400516
30-133
9 - Screw four M10 UNI 2947 eyebolts (8) as far as they

will go into the holes of the rack of tubes.
8 10
10 - Attach the hoisting tackle to the eyebolts and apply
slight tension to the cables.
11 - Take out the screws (9) and remove the pin (10).
12 - Lift away the entire boom (2).
Boom: 272 kg.
2
9
F0400648
INSTALLATION OF BOOM
(2-piece boom version)
Do not insert fingers in the holes in order to

check the alignment.
H Insert shims on both sides of the boom, until a

. Start the engine to let the oil circulate and bleed air
from the cylinders.
check the level in the oil tank.
30-134
DISASSEMBLY AND ASSEMBLY SWING BRACKET
REMOVAL OF SWING BRACKET

Extend the work equipment fully and rest it on the
ground.
1 - Remove the front work equipment. (For details see

«REMOVAL OF WORK EQUIPMENT»).
1
2 - Remove the boom cylinder (For details, see «RE-
MOVAL OF BOOM CYLINDER»).
3 - Attach the swing bracket to the hoisting tackle (1) and
apply slight tension to the cable.
4 - Place a jack (3) beneath the lower pin (2).
5 - Take out the retaining screws and pull out the pin (2). F0400221
6 - Take out the retaining screws and, with the help of a

lever, pull out the upper pin (4).
7 - Lift out the swing bracket (1).
Swing bracket: 36 kg
2
INSTALLATION OF SWING 3
SUPPORT
. To install, reverse the removal procedure. F0400222
Lower pin: ASL800050
Upper pin: ASL800050
F0400223
H Insert the adjustments to a given clearance be-

tween the chassis and the support.
1
Unit: mm
Pos. Code No. Thick- Quantity

ness
1 390617004 5 1
2 390617003 1 2 3
3 390617004 5 1
2
Supporting surfaces and adjustments to a gi-
ven clearance: ASL800050
D0400396
30-135
DISASSEMBLY AND ASSEMBLY BLADE
REMOVAL OF BLADE
1 - Remove the blade cylinder (For details, see «RE- 1

MOVAL OF BLADE CYLINDER»).
2 - Attach the hoisting tackle to the blade, using the 2
holes provided on the sides (1) and the piston cou-
1
pling (2).
H Adjust the length of the chains to keep the group
in equilibrium.
3 - Loosen the screws (3) and remove the pin (4).
5
4 - Remove the blade (5).
F0400224
INSTALLATION OF BLADE 3

4
pin, run the engine at minimum idling.
Do not insert fingers in the holes to check the
alignment.
F0400225

tributed on both sides of the fulcrum bushings).
30-136
MAINTENANCE STANDARD
P.T.O. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . 40- 2 Auxiliary pump . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . . 40-15

Travel machinery. . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . 40- 3 Control valve . . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . . 40-16
Sprocket .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . 40- 4 Swing motor relief valve . . . .. . . . .. . . . . .. . . . . .. . . . . 40-17
Track frame and recoil spring. . . . . .. . . . .. . . . . .. . . 40- 5 Travel motor.. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . . 40-18
Idler . . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . 40- 6 Servocontrol feed unit .. . . . . .. . . . .. . . . . .. . . . . .. . . . . 40-19
Carrier roller . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . 40- 7 L.H. and R.H. PPC valve . . .. . . . .. . . . . .. . . . . .. . . . . 40-20
Track roller. . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . 40- 8 2 nd boom, R.H. travel, L.H. travel and
Track shoe. . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . 40- 9 boom swing PPC valve . . . . .. . . . .. . . . . .. . . . . .. . . . . 40-21
Swing circle. . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . 40-10 Blade PPC valve. .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . . 40-22
Swing machinery . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . 40-11 Blade safety valve . . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . . 40-23
Check valve and oil cooler safety by-pass. . .. . . 40-12 Cylinders . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . . 40-24
Pump drive . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . 40-13 Work equipment (1 - piece boom). . . . .. . . . . .. . . . . 40-26
Summation horsepower control - Work equipment (2 - piece boom). . . . .. . . . . .. . . . . 40-28
Mode system . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . 40-14
40-1
P.T.O.
A
50 Nm
50 Nm
35 Nm
50 Nm
80 Nm
Section A - A
D0400072
40-2
TRAVEL MACHINERY
300 Nm
220 Nm
55 6 5 Nm
1
85 Nm
D0400121
Unit: mm
Në Check item Criteria Remedy
Standard value Limit value

1 Preload bearing
1200 daN 1500 daN
40-3
SPROCKET
300 Nm
2 1
4 D0400122
Unit: mm
Standard size Tolerance Repair limit

1 Wear of roots of sprocket teeth
+1
433 420
± 3.5
0
2 Wear of tips of sprocket teeth 495 ±3 482
Face width of sprocket teeth

3 (teeth crest) 36 ÐÐ 33
Face width of sprocket teeth

4 (bottom land) 46 w1 42
40-4
TRACK FRAME AND RECOIL SPRING
1
D0400123
Unit: mm
Item Repair limit
Curvature 5 (for 1000 mm)

1 Deformation of frame Rebuild
Torsion 5 (for 300 mm)
Opening of idler
5
portion
Item Standard size Limit size

Build up
welding
Track frame 61 66
2 Vertical width of idler guide
Build up
Idler support 60 57 welding or
replace
Build up
Track frame 161 166 welding
3 Horizontal width of idler guide
Idler support 160 155
Standard size
Installed Installed
4 Recoil spring Free length Replace
length load
233 203 4000 kg
40-5
IDLER
4
5 3
55 6 5 Nm
2 1
7 6
D0400124
Unit: mm
Standard size Repair limit

1 Outer diameter of protrusion
408 398
2 Outer diameter of tread 380 370 Build up

welding or
3 Width of protrusion 49 40 replace
4 Total width 105 96
5 Width of tread 28 32.5
Tolerance
Standard Standard Clearance
size clearance limit
Clearance between shaft and bushing Shaft Hole
6
+0 + 0.133 0.133 ±
42 1.5 Replace
± 0.025 + 0.237 0.262

7 End play of idler
0.65 v 1.2 2
40-6
CARRIER ROLLER
6 585 Nm
1 2
5 3
4 7
D0400125
Unit: mm

1 Outer diameter of tread
145 136
2 Outer diameter of protrusion 120 111
3 Width of protrusion 53 45
4 Total width 110 102
5 Width of tread 28.5 32.5
Tolerance
Standard Standard Interference
size interference limit
Interference between shaft and collar Shaft Hole
6
+ 0.085 + 0.039 0.085 ± 0.015
36
± 0.060 ±0 0.021 0.01

7 End play of roller
0.1 v 0.6 1.2
40-7
TRACK ROLLER
60 Nm
3 4
2 1
5 6
D0400126
Unit: mm

1 Flange (outside) outer diameter
160 150
2 Tread outside diameter 135 125
3 Tread width 28 32
4 Flange width 14 10
Tolerance
Clearance between shaft and bushing Shaft Hole
5
0 + 0.189 0.075 ±
40 ± 0.025 1.5
+ 0.075 0.214
Tolerance
Standard Standard Interference
size interference limit
Interference between roller and Shaft Hole
6 bushing
+ 0.07 0 0.095 ±
48 + 0.039 0.015
+ 0.095 0.031
Standard tolerance Clearance limit

7 End play of idler
0.2 v 1.2 2
40-8
TRACK SHOE
3 4
1
160 6 10 Nm
6 7
8 2 D0400127
Unit: mm

Link pitch Turn or
1 replace
140 143.6
Bushing outside diameter Turn or

2 42 36.8 replace
Lud welding
3 Grouser height 27 15 rebuild
or replace
Rebuild or
4 Link height 78 73.4 replace
Tolerance
Standard Standard Interfer.
size interf. limit
Interference between bushing Shaft Hole
5 and link
± 0.2 0.35 ±
42 w 0.05 0.07
± 0.3 0.15 Replace
Interference between regular pin and 0 ± 0.25 0.35 ±
6 link 27 ± 0.084 0.08
± 0.35 0.166
Interference between master pin and ± 0.14 ± 0.25 ± 0.21

7 link 27 ÐÐ
± 0.2 ± 0.35 ± 0.05
Standard tolerance Clearance limit

8 Clearance between link joint surface Replace
1.6 v 2.2 3
40-9
SWING CIRCLE
314 6 10 Nm
314 6 10 Nm
Section A - A
1
D0400136
Unit: mm
Standard clearance Clearance limit

1 Axial bearing clearance
0.3 v 1.2 3 Replace
Backlash between pinion and swing
2 circle teeth 0.06v0.76 2.0
40-10
SWING MACHINERY
85 Nm
50 Nm
85 Nm
120 Nm
1 950 4 1050 Nm
D0400079
Unit: mm
Standard value Limit value

1 Preload bearing
6634765 kg
663 v 765 kg
(650047500 N)
40-11
CHECK VALVE AND OIL COOLER SAFETY BY-PASS
A Section A - A
D0400080
Unit: mm
By-pass valve spring Installed Installed Installed Replace

1 Free length Free length
length load load if
damaged
38 25 15w1 35 13 or deformed
2 Check valve spring 38 25 7w0.5 35 5
40-12
PUMP DRIVE
A 20 Nm
3
Section A - A
A D0400081
Unit: mm

Backlash between inlet gear and Replace
1 auxliary pump gear
ÐÐ ÐÐ
Backlash between inlet gear and Replace

2 No. 1 pump gear ÐÐ ÐÐ
Backlash between No. 1 pump gear

3 and No. 2 pump gear ÐÐ ÐÐ Replace
40-13
SUMMATION HORSEPOWER CONTROL - MODE SYSTEM
40 Nm
A
22 Nm
10 Nm
20 Nm
2 2
20 Nm
3
Section A - A
4
60 Nm
40 Nm
40 Nm
D0400082
Unit: mm
Calibration spring Installed Installed Installed Replace

length load load
42 33 366 N 41.1 339 N
2 Check valve spring 8 5 15.6 N 7.5 13.9 N Replace
3 Piston return spring 103.5 80 200 N 101 186 N Replace
4 Mode-system spring 23 18 151 N 22.1 183.3 N Replace
40-14
AUXILIARY PUMP
3 190 Nm
1
D0400128
2
Unit: mm

1 Clearance between side plate and gear
ÐÐ ÐÐ Replace
2 Clearance between shaft and bushing ÐÐ ÐÐ
3 Clearance between gears and casing ÐÐ ÐÐ Replace
Pump Delivery Standard Repair limit

speed pressure delivery delivery
4 Delivery rpm bar (,/min.) (,/min.) Check
P3 Pump ÐÐ ÐÐ ÐÐ ÐÐ
40-15
CONTROL VALVE
90 Nm 90 Nm
90 Nm
35 Nm
9 Nm 90 Nm 90 Nm
100 Nm
200 Nm 200 Nm 100 Nm
30 Nm 30 Nm 37 Nm
160 Nm 200 Nm 30 Nm
35 Nm 90 Nm
9 Nm 90 Nm
90 Nm 90 Nm
87 Nm 9 Nm
100 Nm
90 Nm 140 Nm 90 Nm
140 Nm 37 Nm D0400129
40-16
SWING MOTOR RELIEF VALVE
10 6 1 Nm
10 6 1 Nm
40 6 4 Nm
90 6 10 Nm
1
D0400085
Unit: mm
Pilot valve spring Installed Installed Installed Replace

length load load
ÐÐ ÐÐ ÐÐ ÐÐ ÐÐ
2 Anticavitation valve spring ÐÐ ÐÐ ÐÐ ÐÐ ÐÐ Replace
40-17
TRAVEL MOTOR
A A
B
10 Nm
Section B - B
Section A - A
D0400130
Unit: mm
Preload cylinder spring Installed Installed Installed Replace

length load load
59.0 35.5 598.2 57.5 559
2 Spool return shaft ÐÐ 17 30.8 ÐÐ 26.9 Replace
40-18
100 6 10 Nm 2 17,5 6 1,75 Nm
17,5 6 1,75 Nm
1
3
100 6 10 Nm
150 6 15 Nm
12 6 1,2 Nm 12 6 1,2 Nm
D0400088
Unit: mm
Relief valve spring Installed Installed Installed Replace

length load load
ÐÐ ÐÐ ÐÐ ÐÐ ÐÐ
2 Check valve spring ÐÐ ÐÐ ÐÐ ÐÐ ÐÐ Replace
3 Reducing valve spring ÐÐ ÐÐ ÐÐ ÐÐ ÐÐ Replace
40-19
L.H. AND R.H. PPC VALVE
A 1
T
A
P
2
4
1-2-3
4-5
D0400090
Section A - A
Në Item Pilot system
1 Metering spring 1
2 Metering spring 3
3 Metering spring 2-4
4 Centering spring 1-3
5 Centering spring 2-4
Unit: mm
Metering spring Installed Installed Installed Replace

length load load
31.4 29.4 15.44 N ÐÐ 14.28 N
2 Metering spring 31.1 29.3 18.72 N ÐÐ 17.30 N Replace
3 Metering spring 30.5 29.0 15.9 N ÐÐ 14.75 N Replace
4 Centering spring 43.6 32.65 39.42 N ÐÐ 36.65 N Replace
40-20
2nd BOOM, R.H. TRAVEL, L.H. TRAVEL AND BOOM SWING PPC
VALVE
5 Nm
with Loctite 242
A
8 Nm
1
1
30 Nm
2 2 with Loctite 242
A Section A - A
D0400092
Unit: mm
Installed Installed Installed

Free length Free length
length load load
1 Metering spring 2nd boom 30.4 29.0 14.84 N ÐÐ 13.76 N Replace
R.H. Travel
L.H. Travel 29.6 28.7 18.09 N ÐÐ 16.83 N
Boom swing 30.4 29.0 14.84 N ÐÐ 13.80 N
2nd boom 46.8 35.3 178.25 N ÐÐ 165.25 N
Centering spring R.H. Travel Replace

2 L.H. Travel 47.9 35.2 284.48 N ÐÐ 264.55 N
Boom swing 44.8 35.2 56.25 N ÐÐ 52.32 N
40-21
BLADE PPC VALVE
2 2
1 1
D0400093
Unit: mm
Metering spring Installed Installed Installed Replace

length load load
25.0 23.5 15.15 N ÐÐ 14.04 N
40-22
BLADE SAFETY VALVE
83 Nm
33 Nm
D0400094
Unit: mm
Installed Installed Installed

1 Check valve spring Free length Free length
length load load
16.5 11.12 2.464 kg 13.5 1.1 kg
40-23
CYLINDERS
BUCKET
ARM (2 PIECES)
BOOM SWING
BLADE
2 50 Nm 1 50 Nm D0400096
BOOM
2 50 Nm 1 50 Nm D0400097
ARM
2 50 Nm 1 50 Nm D0400098
40-24
Unit: mm
Tolerance
Cylinder
Shaft Hole
± 0.030 0 0.030
Bucket 60 + 0.166 0.326
± 0.060 0.226
2nd boom ± 0.05 0 0.025

(2 pieces) 50 + 0.166 0.316
± 0.025 0.216
Clearance between
1 piston rod and ± 0.030 0 0.030
bushing Boom swing 60 + 0.166 0.326
± 0.060 0.226
± 0.030 0 0.030
Blade 60 + 0.166 0.326
± 0.060 0.226
± 0.030 0 0.030
Boom 70 + 0.166 0.326
± 0.060 0.226
± 0.030 0 0.030
Arm 60 + 0.166 0.326
± 0.060 0.226
± 0.05 + 0.119 + 0.13

Bucket 50 1.0
± 0.089 + 0.08 + 0.208
2nd boom ± 0.05 + 0.119 + 0.13

(2 pieces) 50 1.0
± 0.089 + 0.08 + 0.208
± 0.05 + 0.119 + 0.13

Boom swing 50 1.0
± 0.089 + 0.08 + 0.208
Clearance between
2 cylinder head
bushing and pin ± 0.05 + 0.119 + 0.13
Blade 50 1.0
± 0.089 + 0.08 + 0.208
± 0.06 + 0.146 + 0.16

Boom 60 1.0
± 0.106 + 0.1 + 0.252
± 0.05 + 0.119 + 0.13

Arm 50 1.0
± 0.089 + 0.08 + 0.208
± 0.05 + 0.119 + 0.13

Bucket 50 1.0
± 0.089 + 0.08 + 0.208
2nd boom ± 0.06 + 0.146 + 0.16

(2 pieces) 60 1.0
± 0.106 + 0.1 + 0.252
± 0.05 + 0.119 + 0.13

Boom swing 50 1.0
Clearance between ± 0.089 + 0.8 + 0.208
3 cylinder bottom
bushing and pin ± 0.05 + 0.119 + 0.13
Blade 50 1.0
± 0.089 + 0.08 + 0.208
± 0.06 + 0.146 + 0.16

Boom 60 1.0
± 0.106 + 0.1 + 0.252
± 0.05 + 0.119 + 0.13

Arm 50 1.0
± 0.089 + 0.08 + 0.208
40-25
WORK EQUIPMENT
(1 - piece boom)
A B
7 6 4 5 3
Section A - A Section B - B Section C - C
2 8
Section D - D Section E - E Section F - F
D0400131
40-26
Unit: mm
Tolerance
Standard Standard Tolerance
Clearance between swing size clearance limit
bracket-to-revolving Shaft Hole
1
frame mounting and pin bushing
± 0.072 + 0.145 0.271
100 0.8
± 0.0126 + 0.044 0.116
Clearance between boom-to-swing ± 0.060 + 0.047 + 0.107

2 bracket mounting pin and bushing 60 0.8
± 0.106 + 0.127 + 0.233
Clearance between boom-to-arm ± 0.060 + 0.047 + 0.107

3 mounting pin and bushing 60 0.8
± 0.106 + 0.127 + 0.233
Clearance between bucket cylinder- ± 0.050 + 0.095 + 0.184 Replace

4 to-link mounting pin and link bushing 50 1
± 0.089 + 0.016 + 0.066
Clearance between arm-to-link ± 0.050 + 0.095 + 0.184

5 mounting pin and bushing 50 1
± 0.089 + 0.016 + 0.066
Clearance between bucket-to-arm ± 0.050 + 0.095 + 0.184

± 0.089 + 0.016 + 0.066
Clearance between bucket-to-link ± 0.050 + 0.095 + 0.184

± 0.089 + 0.016 + 0.066
Clearance between blade mounting ± 0.050 + 0.095 + 0.184

8 pin and bushing 50 1.5
± 0.089 + 0.016 + 0.066
40-27
WORK EQUIPMENT
(2 - piece boom)
B
A
7 6 4 5 3
Section A - A Section B - B Section C - C
9 2
Section D - D Section E - E Section F - F

D0400132
40-28
8
Section G - G
D0400133
Unit: mm
Tolerance
Standard Standard Tolerance
Clearance between swing size clearance limit
bracket-to-revolving Shaft Hole
1
frame mounting and pin bushing
± 0.072 + 0.145 0.271
100 0.8
± 0.0126 + 0.044 0.116
Clearance between boom-to-swing ± 0.060 + 0.047 + 0.107

2 bracket mounting pin and bushing 60 0.8
± 0.106 + 0.127 + 0.233
Clearance between boom-to-arm ± 0.060 + 0.047 + 0.107

3 mounting pin and bushing 60 0.8
± 0.106 + 0.127 + 0.233
Clearance between bucket cylinder- ± 0.050 + 0.095 + 0.184

4 to-link mounting pin and link bushing 50 1
± 0.089 + 0.016 + 0.066
Replace
Clearance between arm-to-link ± 0.050 + 0.095 + 0.184
± 0.089 + 0.016 + 0.066
Clearance between bucket-to-arm ± 0.050 + 0.095 + 0.184

± 0.089 + 0.016 + 0.066
Clearance between bucket-to-link ± 0.050 + 0.095 + 0.184

± 0.089 + 0.016 + 0.066
Clearance between blade fulcrum pin ± 0.050 + 0.095 + 0.184

8 and bushing 50 1.5
± 0.089 + 0.016 + 0.066
Clearance between bushing and ± 0.060 + 0.047 + 0.107

9 mounting pin of 2nd boom 60 0.8
± 0.106 + 0.127 + 0.233
40-29

Komatsu PC95 - 1

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Komatsu PC95 - 1

Uploaded by

Copyright:

Available Formats

WEBMPC9500

PC95-1 mount the 1004-4 engine.

FKI FAI KOMATSU INDUSTRIES S.p.A.

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

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

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

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

c Page to be replaced Replace

( ) Page to be delete Discard

Pages having no marks are those previously revised

LIST OF REVISED PAGES

Time of Time of Time of Time of Time of

10-26 20-23 20-65 30-19

STRUCTURE AND FUNCTION

TESTING AND ADJUSTING

DISASSEMBLY AND ASSEMBLY

HOW TO READ THE SHOP MANUAL

DISTRIBUTION AND UPDATING Symbol Item Remarks

REVISED EDITION MARK

ing, and a serious accident can result.

1. If a part cannot be smoothly removed from the

WIRE ROPES 4) Do not sling a heavy load with ropes forming a

The allowable load value is estimated to be

2) Sling wire ropes from the middle portion of the

STANDARD TIGHTENING TORQUE

1. STANDARD TIGHTENING TORQUE OF BOLTS AND NUT

Width across flat

6 1 10 5 0.96w0.1 9.5w1 1.3w0.15 13.5w1.5

8 1.25 13 6 2.3w0.2 23w2 3.2w0.3 32.2w3.5

10 1.5 17 8 4.6w0.5 45w4.9 6.5w0.6 63w6.5

12 1.75 19 10 7.8w0.8 77w8 11w1 108w11

14 2 22 12 12.5w1 122w13 17.5w2 172w18

16 2 24 14 19.5w2 191w21 27w3 268w29

18 2.5 27 14 27w3 262w28 37w4 366w36

20 2.5 30 17 38w4 372w40 53w6 524w57

22 2.5 32 17 52w6 511w57 73w8 719w80

24 3 36 19 66w7 644w70 92w10 905w98

27 3 41 19 96w10 945w100 135w15 1329w140

30 3.5 46 22 131w14 1287w140 184w20 1810w190

33 3.5 50 24 177w20 1740w200 250w27 2455w270

36 4 55 27 230w25 2250w250 320w35 3150w350

39 4 60 ÐÐ 295w33 2900w330 410w45 4050w450

2. TIGHTENING TORQUE FOR NUTS OF FLARED

Thread diameter Width across flats TIGHTENING TORQUE

1/2" - 20 17 2.6w0.5 25.5w4.9

Nomenclature Code Applications

ELECTRIC ELECTRIC WIRE CODE

CLASSIFICATION BY COLOUR AND CODE

COMPOSITION OF THE COLOURS

Machine model PC95-1

From serial no. 5000007

Engine assembly 492

Hydraulic tank (without hydraulic oil) 76

Fuel tank (without fuel) 104

Revolving frame 1092

Counter weight 1150

Swing circle 130

Swing machinery assembly 65

Main hydraulic pump 60

Operator's cab 250

Operator's seat support 9

Track frame assembly 1021

Track-shoe assembly (standard) 976