Excavator

WX90

Service Manual

Cre 9-35990
 NOTE: CASE Company reserves the right to make changes in the specification and design of the machine
without prior notice and without incurring any obligation to modify units previously sold.

The description of the models shown in this manual has been made in accordance with the technical spec-
ifications known as of the date of design of this document.

Copyright  2001 Case France

Printed in France
Cre 9-35990 October 2001
 IN-3

INTRODUCTION WX90

TO THE READER

• This manual has been written for a skilled you notice a mistake in this manual
technician, in order to give him the content, please contact:
information necessary to repair this
machine. CASE FRANCE S.A.
18, place des Nymphéas
- Read this manual carefully for correct ZI Paris Nord II - 93420 Villepinte
information about repair procedures. FRANCE

- For any question or comment, or in case

ADDITIONAL REFERENCE MANUALS

• In addition to this Workshop Manual, refer also

to the following:

- Operation and maintenance instruction

manual
- Spare parts catalog

DESCRIPTION OF THE COMPLETE

WORKSHOP MANUAL

• The complete repair manual consists of one and install procedures, disassembly and
volume: assembly procedures.

WX90 - Workshop Manual "Excavator" • The complete Workshop Manual for the
excavator model 9-35990 consists of the
• “Excavator" Workshop Manual contains the following volume identified by print number as
technical information necessary for machine/ shown herebelow:
engine service and repair, service equipment,
information on maintenance standards, remove
15501 9-35990

VOLUME MACHINE TYPE PRINT No.

Workshop Manual - "Excavator" WX90 9-35990
 IN-4

INTRODUCTION WX90

AVOID ACCIDENTS

Most accidents, whether they occur in industry, on the farm, at home or

on the highway, are caused by the failure of some individuals to follow
simple and fundamental safety rules or precautions. For this reason
MOST ACCIDENTS CAN BE PREVENTED by recognising the real
cause and doing something about it before the accident occurs.
Regardless of the care used in the design and construction of any type
of equipment there are conditions that cannot be completely safeguarded
against without interfering with reasonable accessibility and efficient
operation.
Carefully read indications, cautions and safety warning quoted in the
“SAFETY RULES” section.
A careful operator is the best insurance against an accident.
The complete observance of one simple rule would prevent many
thousand serious injuries each year.
That rule is:
Never attempt to clean, oil or adjust a machine while it is in motion.

ATTENTION

On machines having hydraulically, mechanically and/or cable

controlled equipment (such as showels, loaders, dozers, scrapers
etc.) be certain the equipment is lowered to the ground before
servicing, adjusting and/or repairing. If it is necessary to have the
equipment partially or fully raised to gain access to certain items,
be sure the equipment is suitably supported by means other than
the hydraulic lift cylinders, cable and/or mechanical device used
for controlling the equipment.

COPYRIGHT BY CASE FRANCE SA

18, place des Nymphéas ZI Paris Nord II - 93420 Villepinte France
15501 9-35990

All rights reserved. Reproduction of text and illustrations in whole or in part,

is strictly prohibited.
 INDEX WX90 - 1 - 1

WX90

SECTION 1 HOW TO USE

INDEX

Group 1 - SECTIONS AND GROUPS INDEXES ........................................................... HU1-1-1

Group 2 - INTRODUCTION ............................................................................................ HU1-2-1

2.1 Introduction
2.2 Manual handling
2.3 Symbols and indications

Group 3 - FEATURES OF THE MANUAL ...................................................................... HU1-3-1

3.1 Manual composition

3.2 Brief information for manual consultation
15501 9-35990
15501 9-35990
 HU1-1-1

SECTIONS AND GROUPS INDEXES WX90

1. SECTIONS AND GROUPS INDEXES PAGE

SECTION 1 - HOW TO USE

Group 1 - SECTIONS AND GROUPS INDEXES ........................................................... HU1-1
Group 2 - INTRODUCTION ............................................................................................ HU1-2
Group 3 - FEATURES OF THE MANUAL ...................................................................... HU1-3

SECTION 2 - SAFETY RULES

Group 1 - GENERAL INFORMATION ............................................................................ SR2-1
Group 2 - SAFETY RULES ............................................................................................ SR2-2
Group 3 - SAFETY DECALS .......................................................................................... SR2-3

SECTION 3 - SPECIFICATION
Group 1 - GENERALITY .................................................................................................. SP3-1
Group 2 - TECHNICAL SPECIFICATIONS ..................................................................... SP3-2
Group 3 - LUBRICANTS AND SPECIFICATIONS .......................................................... SP3-3

SECTION 4 - SUPERSTRUCTURE
Group 1 - SUPERSTRUCTURE ...................................................................................... SS4-1
Group 1A - FLEXIBLE HOSES AND CONNECTIONS ................................................ SS4-1A
Group 2 - HYDRAULIC PUMPS ................................................................................... HYP4-2
Group 3 - CONTROL VALVE ......................................................................................... CV4-3
Group 4 - SWING DEVICE ........................................................................................... SRD4-4
Group 5 - PILOT VALVES ............................................................................................... PV4-5
Group 6 - CENTER JOINT .............................................................................................. CJ4-6
Group 7 - STEERING VALVE ......................................................................................... SV4-7
Group 8 - BRAKE PEDAL VALVE ................................................................................ BRV4-8
Group 9 - ACCUMULATORS ....................................................................................... ACC4-9
Group 10 - SOLENOID VALVES ................................................................................ SOV4-10

SECTION 5 - UNDERCARRIAGE
Group 1 - UNDERCARRIAGE ........................................................................................ UC5-1
Group 2 - TRAVEL HYDRAULIC MOTOR ................................................................... HYP4-2
Group 3 - TRANSMISSION ............................................................................................ CV4-3
Group 4 - AXLES ............................................................................................................. AX5-4
Group 5 - TRANSMISSION SHAFT ................................................................................ TS5-5

SECTION 6 - FRONT-END ATTACHMENT

Group 1 - FRONT-END ATTACHMENT .......................................................................... FA6-1
Group 2 - HYDRAULIC CYLINDERS ............................................................................. CY6-2
Group 3 - PINS AND BUSHINGS .................................................................................... FA6-3

SECTION 7 - HYDRAULIC SYSTEM

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Group 1 - GENERALITIES ............................................................................................. HS7-1

Group 2 - MAIN HYDRAULIC SYSTEM ......................................................................... HS7-2
Group 3 - PILOT/BRAKES SYSTEM .............................................................................. HS7-3
Group 4 - STEERING SYSTEM ..................................................................................... HS7-4
Group 5 - BRAKES SYSTEM ......................................................................................... HS7-5
Group 6 - OPERATION OF CIRCUITS .......................................................................... HS7-6
Group 7 - TRAVEL CIRCUIT .......................................................................................... HS7-7
Group 8 - HYDRAULIC SYSTEM DIAGRAM ................................................................. HS7-8
 HU1-1-2

SECTIONS AND GROUPS INDEXES WX90

SECTION 8 - ELECTRICAL SYSTEM

Group 1 - SAFETY RULES ......................................................................................... ES8-1-1
Group 2 - SPECIFICATIONS AND DATA ................................................................... ES8-2-1
Group 3 - LOCATION AND FUNCTIONS OF COMPONENTS ................................... ES8-3-1
Group 4 - ARRANGEMENTS AND OPERATION ....................................................... ES8-4-1
Group 5 - ELECTRICAL SYSTEM GENERALITIES ................................................... ES8-5-1
Group 6 - ELECTRIC COMPONENTS ........................................................................ ES8-6-1

SECTION 9 - TROUBLESHOOTING
Group 1 - INTRODUCTION .......................................................................................... TS9-1-1
Group 2 - HYDRAULIC SYSTEM TROUBLESHOOTING ............................................ TS9-2-1
Group 3 - ELECTRICAL SYSTEM TROUBLESHOOTING .......................................... TS9-3-1

SECTION 10 - OPERATIONAL PERFORMANCE TEST

Group 1 - INTRODUCTION ........................................................................................... PT10-1
Group 2 - PERFORMANCE STANDARD ...................................................................... PT10-2
Group 3 - PREPARATION FOR PERFORMANCE TEST ............................................. PT10-3
Group 4 - EXCAVATOR PEFORMANCE TEST ............................................................ PT10-4
Group 5 - COMPONENTS PERFORMANCE TEST ..................................................... PT10-5

SECTION 11 - ENGINE
Group 10 - GENERAL INFORMATION ...................................................................... EM11-10
Group 11 - SPECIFICATION ...................................................................................... EM11-11
Group 12 - CYLINDER HEAD ASSEMBLY ................................................................ EM11-12
Group 13 - PISTON AND CONNECTION ROD ......................................................... EM11-13
Group 14 - CRANKSHAFT ......................................................................................... EM11-14
Group 15 - TIMING CASE COVER AND DRIVE ........................................................ EM11-15
Group 16 - GENERAL DESCRIPTION ....................................................................... EM11-16
Group 17 - ENGINE TIMING ...................................................................................... EM11-17
Group 19 - LUBRICATION SYSTEM ......................................................................... EM11-19
Group 20 - FUEL SYSTEM ........................................................................................ EM11-20
Group 21 - COOLING SYSTEM ................................................................................. EM11-21
Group 22 - FLYWHELL AND HOUSING .................................................................... EM11-22
Group 23A - ELECTRICAL EQUIPMENT ................................................................ EM11-23A
Group 23B - ELECTRICAL EQUIPMENT ................................................................ EM11-23B
Group 23C - ELECTRICAL EQUIPMENT ............................................................... EM11-23C
Group 25 - AUXILIARY EQUIPMENT ........................................................................ EM11-25
15501 9-35990
 HU1-2-1

INTRODUCTION WX90

2. INTRODUCTION

2.1 INTRODUCTION

This service manual has been prepared in order to increase repair quality, providing to the technicians the
elements for a good knowledge of the product and showing the proper procedures to carry out the
maintenance operations. We recommend to thoroughly read the content and follow it when necessary.

It is a concise guide for a specific machine. It covers construction features, operation principle, troubleshooting,
disassembly and assembly of components and repair action.

Using this manual in systematic and rational way it is possible to reduce the repairing errors and delay that
could cause machine stop with a detriment of cost management.

The information quoted in this service manual are supplied also to be used for training aids. Therefore it is
advisable to be used in the training of new personnel that will be employed in the machine maintenance.

All the information, illustrations and specifications contained in this service manual are based on the latest
product information available at the time of publication.
CASE reserves the right to makes changes at any time without notice to this service manual for technical or
trading reasons.

2.2 MANUAL HANDLING

15501 9-35990

2.2.1 CHANGES AND SUPPLEMENTS

This service manual is carried out in loose-leaf and therefore can be easily kept up-to-date.
The personnel in charge is responsible for updating the manual and will insert the changes or supplements
that CASE will issue to its service organisation.
 HU1-2-2

INTRODUCTION WX90

2.3 SYMBOLS AND INDICATIONS

In this service manual, symbols and indications are used to draw the attention on important points for safety
and quality.

2.3.1 SAFETY

This safety symbol is used for important safety message. When you see this symbol, be alert to the
potential for personal injury. Strictly follow the recommended precautions.

2.3.2 INDICATIONS

Reading this service manual you can find indications as “IMPORTANT” or “NOTE” that have the following
meaning:

• IMPORTANT
Indicates a situation which, if not avoided, could caused damages to the machine.

• NOTE
Indicates supplementary technical information or know-how.
15501 9-35990
 HU1-3-1

FEATURES OF THE MANUAL WX90

3. FEATURES OF THE MANUAL

3.1 MANUAL COMPOSITION

This service manual is divided into eleven Sections. The Section names and its contents are as below. To
fully use this service manual it is essential to understand how it is organised. Therefore, in order to speed up
the searching of wished subject, it is advisable to carefully read this chapter.

SECTION 1 - HOW TO USE

Begin to read first this Section to know the manual composition. This will help you for subject
searching.

SECTION 2 - SAFETY RULES

Indication on how to avoid dangerous situation during the use and maintenance are given in this
Section. Furthermore safety decals and relate indications used on the machine are listed on this
Section.

SECTION 3 - SPECIFICATION
This Section quotes the specification and data of the machine.

SECTION 4 - SUPERSTRUCTURE
This Section contains the information relate to operation principle of the systems, of the
assemblies and their components located on the machine upper frame. Furthermore the
assembly/disassembly procedures of main devices are quoted.
15501 9-35990

SECTION 5 - UNDERCARRIAGE
This Section contains the information relate to operation principle of the systems, of the
assemblies and their components located on the machine lower frame. Furthermore the
assembly/disassembly procedures of main devices are quoted.(axles, transmission, travels
motor, etc..).
 HU1-3-2

FEATURES OF THE MANUAL WX90

SECTION 6 - FRONT-END ATTACHMENT

This Section describes the front-end attachment and its components and maintenance rules with
related disassembly/assembly.

SECTION 7 - HYDRAULIC SYSTEM

This Section describes the operation of the machine from hydraulic point of view.

SECTION 8 - ELECTRICAL SYSTEM

This Section describes the electric system of the machine, the main electrical component and
the connection with the electrical users.

SECTION 9 - TROUBLESHOOTING
IIn this Section information is provided for troubleshooting to the hydraulic and electric systems
and the necessary instruction to use the support equipment (test harnesses and test device).

SECTION 10 - OPERATIONAL PERFORMANCE TEST

Performance data and the procedures to detect data are provided in this Section.
15501 9-35990

SECTION 11 - ENGINE
This Section contains the necessary information for engine overhaul and repair.
 HU1-3-3

FEATURES OF THE MANUAL WX90

3.2 BRIEF INFORMATION FOR MANUAL CONSULTATION

The manual is divided into section, each of them quotes a specific portion of the machine or specific related
subject.

Some section (those related to main mechanical assembly) are divided into:
• Operation principle O/P (Operation Principle)
• Disassembly and assembly D/A (Disassembly/Assembly)

In the Operation Principle, the assemblies and their components are described with technical data.

In the disassembly and assembly the procedures are described to perform repair or overhaul, with special tool
required and technical data.

Each section is divided into group, and the group, in turn, in pages. Each page has a number, located in the
upper right corner. Each number contains the following information;

• example:

SR 3 - 2 - 1

Consecutive page number for each group.

▼

Group number.
▼ ▼ ▼

Section number.
Section or Group abbreviation.
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 HU1-3-4

FEATURES OF THE MANUAL WX90

NOTES:

15501 9-35990
 INDEX WX90 - 2 - 1

WX90

SECTION 2 SAFETY RULES

INDEX

Group 1 - INFORMATION SECTION ............................................................................. SR2-1-1

Generalities
Starting
Operating
Stopping

Group 1 - Maintenance ................................................................................................. SR2-1-5

Generalities
Transfers and transportation
Engine
Electrical system
Hydraulic system
Tools
Removing twin wheels

Group 2 - SAFETY RULES ............................................................................................ SR2-2-1

Group 3 - SAFETY DECALS ......................................................................................... SR2-3-1

15501 9-35990
15501 9-35990

SAFETY PRECAUTIONS
GENERALITIES
Read the Operator's Manual carefully before starting,
operating, maintaining, fuelling or servicing the machine.
Carefully read the explanation to each and all safety
signs in the special section of this Manual before
starting, operating, maintaining, fuelling or servicing
the machine.
Machine-mounted safety plates are colour coded
yellow with black borders when they refer to points
where special ATTENTION must be paid and failure
to observe them may cause a serious DANGER to the
integrity of machine operators. They are white with
red borders and black lettering when they refer to a
FORBIDDEN practice.
It is fundamental that all machine operators know very
well the meaning of each safety plate as this
considerably decreases operating hazards and
accidents.
Do not allow unauthorised personnel to operate or
service this machine.
Do not wear rings, wrist watches, jewellery, loose or
hanging garments, such as ties, torn clothing,
scarves, unbuttoned or unzipped jackets that can get
caught in moving parts. Wear certified safety clothes
such as: hard hat, no-slip footwear, heavy gloves, ear
protection, safety glasses , reflector vests, respirators
every time the job requires it. Ask your employer
about safety regulations in force and protective
equipment.
Always keep the operator’s compartment, step plates,
grab-rails and handles clean and clear of foreign
objects, oil, grease, mud or snow to minimise the
danger of slipping or stumbling. Remove mud or
grease from your shoes before operating the
machine.
Do not jump on or off the machine. Always keep both
hands and one foot, or both feet and one hand in
contact with steps and/or grab rails.
Do not use controls or hoses as hand holds. Hoses
and controls are movable parts and do not provide
solid support. Besides, controls may be inadvertently
moved and cause unexpected movement of the
machine or its attachments.
Never operate the machine or its attachments from
any position other than sitting in the driver’s seat.
Keep head, body, limbs, hands and feet inside the
operator’s compartment at all times to reduce
exposure to external hazards.
Be careful of possible slippery conditions of the steps
and hand rails as well as of the ground around the
machine. Wear protective boots or shoes with the
15501 9-35990
soles made of highly no-slip rubber.
Do not leave the machine until it has come to a
complete stop.
Always check height, width and weight limitations
which may be encountered in the working site and
ensure the machine does not exceed them.
SR2-1-1
Assess exact paths of gas ducts, water mains,
telephone lines, sewers, overhead and underground
electric lines and all other possible obstacles.
Such paths should be opportunely defined by
competent Authorities. If necessary, require that the
service is interrupted or said installations are moved
prior to starting the work.
You must know the working capacity of the machine.
Define the rear upperstructure swing area and provide
for opportune barriers to prevent access into it.
Never exceed machine lifting capacity.
Remain within the limits shown in the loading capacity
chart located on the machine.
STARTING
Never start or operate a failed machine. Walk all
around the machine before mounting.
Before operating the machine, make sure that any
possible dangerous condition has been properly
removed. Before starting machine, check that steering
and attachment controls are in the neutral position
and the safety lever is in the LOCK position.
Immediately report any malfunction of parts or
systems to the maintenance managers for proper
action.
Prior to starting the engine, check, adjust and lock the
driver’s seat for maximum riding comfort and control
accessibility. Prior to operating the machine and/or its
attachments, check that bystanders are outside the
machine operating range. Sound the horn.
Obey all hand signals, safety indications and signs.
Due to the presence of flammable fluids, never check
fuel level, refuel, charge the batteries or use the
starting fluid in the presence of smoking materials,
open flames or sparks.
Ensure that nobody is within the excavator operating
area before starting the machine, swinging the upper
structure or moving in any direction.
Adjust all rear-view mirrors for maximum visibility of
the area behind the machine.
Ensure that engine speed is appropriate to the job to
be carried out.
If any hydraulic control or system exhibits erratic
performance or responds abnormally, have the
machine checked for air in the system.
Air in these circuits may cause incorrect movements
with consequent accident hazard. Refer to the
Operator's Manual about corrective action to be taken.
OPERATING
Do not run the engine of this machine in closed
buildings without proper ventilation capable to remove

SAFETY PRECAUTIONS
harmful exhaust gases which concentrate in the air.
Keep the operator’s compartment free of foreign
objects, especially if not firmly secured. Never use the
machine to transport objects, unless proper securing
points are provided.
Do not carry riders on the machine.
Study and familiarise with escape routes alternative to
normal exit routes.
For your personal safety, do not climb on or off the
machine while it is in motion.
Make sure that bystanders are clear of the machine
operating range before starting the engine and
operating the attachment. Sound the horn.
Obey all hand signals, safety indications and signs.
When backing, always look to where the machine is
to be moved. Be alert of the position of bystanders.
Should someone enter the work area, stop the
machine.
Maintain a safe distance from other machines or
obstacles to ensure required visibility conditions.
Always give way to loaded machines.
Maintain a clear vision of the surroundings of the
travel or work area at all times.
Keep cab windows clean and repaired.
When pulling loads or towing through a cable or
chain, do not start suddenly at full throttle. Take-up
slack carefully.
Avoid kinking or twisting chains or cables.
Carefully inspect cables or chains for flaws or
problems before proceeding.
Do not pull through a kinked chain or cable as the
high anomalous stresses existing in this condition
may induce failures in the kinked portion.
Always wear heavy gloves when handling chains or
cables.
Chains and cables should be securely anchored using
suitable hooks. Anchor points should be strong
enough to withstand the expected load.
Keep everyone clear of anchor points and cables or
chains. Do not pull or tow unless the operator’s
compartments of the machines involved are
properly protected against possible backlash in
case of cable or chain failure or detachment.
Be alert of soft ground conditions close to newly
constructed walls. The fill material and machine
weight may cause the wall to collapse under the
machine.
In darkness, check area of operation carefully before
moving in with the machine. Use all lights provided.
Do not move into low visibility areas.
If the engine tends to slow down and stall for
whatever reason under load or at idle, immediately
report this problem to the maintenance managers for
proper action. Do not operate the machine until this
condition is corrected.
Regularly check all exhaust system components, as
exhaust fumes are toxic for the operator.
Operators must know the performance of the
SR2-1-2
machine they are driving.
When working on slopes or near sudden level drops
in the terrain, pay attention not to lose adherence and
avoid loose soft ground since overturn or loss of
machine control could result.
If noise level is high and exceeds 90 dB(A) over 8
hours at the operator’s ear, wear approved ear
protection in compliance with local regulations.
Do not operate the machine if you are extremely tired
or feel ill.
Be especially careful towards the end of the working
shift.
Where removable counterweights are provided, do
not operate the machine if they have been removed.
When operating the machine, keep in mind height
limits of overhead doors, arches, overhead cables
and lines as well as width limits of corridors, roads
and narrow passages. Also, get to know load limits of
the ground and paving type of the ramps you are to
work on.
Beware of fog, smoke or dust that obscure visibility.
Always inspect the working area to identify potential
risks such as: inclines, overhangs, trees, demolition
rubble, fires, ravines, steep slopes, rough terrain,
ditches, crowns, ridge trenches, diggings in traffic
areas, crowded parking lots, crowded service areas,
fenced zones. In such conditions, proceed with
extreme care.
Whenever possible, avoid crossing over obstacles
such as very rough terrain, rocks, logs, steps, ditches,
railroad tracks. When obstructions must be crossed,
do so with extreme care and at a square angle, if
possible. Slow down. Ease up to the break-over point,
pass the balance point slowly and ease down the
other side also using the attachment, if necessary.
To overcome deep trenches or sinking ground, place
the machine perpendicular to the obstacle, drastically
reduce ground speed and start crossing using also
the attachment if necessary, only after assessing that
ground conditions allow the traverse safely and
without risks.
The gradient you may attempt to overcome is limited
by factors such as ground conditions, load being
handled, machine type and speed, and visibility.
There is no substitute for good judgement and
experience when working on slopes.
Avoid operating the attachment too close to an
overhang or high wall, either above or below the
machine. Beware of caving edges, falling objects and
landslides. Remember that such hazards are likely to
be concealed by bushes, undergrowth and such.
Avoid faggots, bushes, logs and rocks. Never drive
15501 9-35990
over them, nor over any other surface irregularities
that discontinue adherence or traction with the
ground, especially near slopes or drop-offs.
Be alert to avoid changes in adherence conditions
that could cause loss of control. Work with extreme
care on ice or frozen ground and on stepped slopes

SAFETY PRECAUTIONS
or near drop-offs.
The word “bulldozing” generally refers to work in
virgin rough terrain, characterised by the presence of
all the perils and risks listed above. We emphasise
the danger represented in these conditions by large
tree limbs (possibly falling on the machine) and large
roots (which may act as a leverage under the
machine when up-rooted and cause the unit to
overturn).
Position the machine dependent upon the loading
and unloading areas in order to swing leftwards to
load to obtain best visibility.
Never use the bucket or attachment as a man lift
or carry riders.
Never use the machine as a work platform or
scaffolding. The machine must not be improperly
used for works not consistent with its features (such
as pushing railway cars, trucks or other machines).
Always pay attention to people within the machine
operating range.
Never move or stop the bucket, other loads or the
attachment above ground personnel or truck cabs.
Ensure the truck driver is in a safe place before
loading the truck.
Load trucks from side or rear.
Use only the type of bucket recommended
considering machine type, materials to be handled,
material piling up and loading characteristics, ground
type and other typical conditions of the work to be
performed.
When travelling with a loaded bucket, keep it as
rolled-back as possible. Keep boom and dipper as
low as possible.
Ground speed should be adequate to the load and
ground conditions.
The load must always be properly arranged in the
bucket; move with extreme care when transporting
oversize loads.
Do not lift and move the bucket overhead where
persons are standing or working, nor downhill when
working on a slope as this would decrease machine
stability. Load the bucket from the uphill side.
Loads to be raised using the machine should be
exclusively hooked to the hitch specially provided.
The excavator is no lifting and transportation means,
therefore it should not be used to position loads
accurately. Should it be exceptionally used to lift and
lay building components, special caution must be
taken as follows:
– The machine should necessarily be equipped with
the special option supplied by CASE. Follow also
safety rules for the excavator used as lifting means.
15501 9-35990
– Secure the loads to be raised using cables or
chains fastened with appropriate hooking
mechanisms.
– Nobody should be allowed to remain under the
raised load or within the excavator operating range
for any reason whatever.
SR2-1-3
Never exceed specified loading capacity. Incorrect
fastening of slings or chains may cause boom/dipper
failure or failure of the lifting means with consequent
bodily injuries and even death.
Always ensure that slings and chains used for lifting
are adequate to the load and in good condition.
All loading capacities are referred to the machine
on a level surface and should be disregarded
when working on a slope.
Avoid travelling across slopes. Proceed from uphill
downhill and vice-versa. If machine starts slipping
sideways when on a slope, lower the bucket and
thrust bucket teeth into the ground.
Working on slopes is dangerous. Grade the working
area if possible. Reduce work cycle time if it is not
possible to grade the working area.
Do not move full bucket or a load from uphill downhill
as this would reduce machine stability. Do not work
with the bucket turned to the uphill side.
Do not work with the bucket turned uphill as
counterweights protruding downhill would reduce
machine stability on the slope and increase risk of
overturning.
We recommend to work on slopes with the bucket
downhill, after checking machine stability with the
bucket empty and attachment retracted, by slowly
swinging the upperstructure by 360°.
Position the carriage at a right angle relative to
slopes, hanging walls, etc. to exit the working area
easily.
Be aware when the upperstructure is turned by 180°,
steering and travel controls are reversed.
Properly judge ground conditions with particular
attention to consistency of the area you are going to
work on.
Keep the machine sufficiently far from the ditch edge.
Never dig under the machine.
Should it be necessary to dig under the machine,
always ensure that digging walls are opportunely
propped up against landslide to prevent the machine
from falling into the trench.
Do not swing the upperstructure, raise the load or
brake abruptly if not required. This may cause
accidents.
Prior to beginning the work near gas distribution
mains or other public utilities:
- Contact the company owner of the gas mains or its
nearest branch before starting the work. Look up
the number in the telephone directory.
- Define together which precautions should be taken
to guarantee work safety.
- Decrease work speed. Reaction time could be too
slow and distance evaluation wrong.
- When working near gas mains or other public
utilities installations, appoint a person in charge of
signalling duties. This person will have the
responsibility of observing the machine, any part of
it and/or the load approaching the gas mains from a

SAFETY PRECAUTIONS
standpoint more favourable than the Operator’s.
This signal man (flag-man) must be in direct
communication with the Operator and the Operator
must pay undivided attention to the signals
supplied.
- The gas distributing Company, if previously advised
and involved in the work, as well as machine
Operator, Owner and/or any natural person or legal
entity having rent or leased the machine or being
responsible at the time by contract or by law, are
liable for the adoption of the necessary
precautions.
Working near electric lines can be very dangerous,
therefore some special precautions must be
observed.
Within this Manual, “work near electric lines” means
when the attachment or load raised by the excavator
(in any position) may reach the minimum safety
distance established by local or international Safety
Regulations.
To work without risks, keep maximum possible
distance from electric lines and never trespass
minimum safety distance. Ensure that local or
national safety regulations concerning work near
electric lines are observed.
Prior to beginning the work near electric lines:
- Contact the Company owner of the electric lines or
its nearest branch before starting the work.
Look up the in the telephone directory.
- Define together with the Company representative
which precautions should be taken to guarantee
work safety.
- All electric lines should be considered as operative
live lines even though it might be well known that
the line in question is out of work and visibly
connected to the ground.
- The Electric Power Company, if previously advised
and involved in the work, as well as machine
Operator, Owner and/or any natural person or legal
entity having rent or leased the machine or being
responsible at the time by contract or by law, are
liable for the adoption of the necessary
precautions.
- Decrease work speed. Reaction time could be too
slow and distance evaluation wrong.
- Warn all ground personnel to keep clear of the
machine and/or load at all times. If the load has to
be guided down for laying, consult the Electric
Power Company to know which precautions should
be taken.
- Appoint a person in charge of signalling duties.
This person will have the responsibility of observing
the machine, any part of it and/or the load
approaching the electric lines from a standpoint
more favourable than the Operator’s. This signal
man (flag-man) must be in direct communication
with the Operator and the Operator must pay
undivided attention to the signals supplied.
SR2-1-4
When working in or near pits, in ditches or very high
walls, check that the walls are sufficiently propped up
to avoid cave-in hazards.
Pay the utmost attention when working near overhang
walls or where landslides may take place. Make sure
that the support surface is strong enough to prevent
landslides.
When digging, there is the risk of cave-ins and
landslides.
Always check ground conditions and conditions of the
material to be removed. Support everywhere it is
required to prevent possible cave-ins or landslides
when:
- digging near previous trenches filled with material,
- digging in bad ground conditions,
- digging trenches subject to vibration from railroads,
working machines or highway traffic.
STOPPING
When the machine is to be stopped for whatever
reason, always check that all controls are in the
neutral position and that the safety lever is on the lock
position to guarantee risk-free start-up.
Never leave the machine unattended with the engine
running.
Prior to leaving the driver’s seat, and after making
sure that all people are clear of the machine, slowly
lower the attachment until resting it safely to the
ground. Retract possible auxiliary tools to the closed
safety position.
Check that all controls are in the neutral position.
Move engine controls to the shut-down position.
Switch off the starter switch key. Consult the
Operator's Manual.
Park the machine in a non-operating and no-traffic
area. Park on firm level ground. If this is not possible,
position the machine at a right angle to the slope,
making sure there is no danger of uncontrolled
sliding.
If parking in traffic lanes cannot be avoided, provide
appropriate flags, barriers, flares and other signals as
required to adequately warn the oncoming drivers.
Always switch off the starter switch key before
cleaning, repairing or servicing, or parking the
machine to prevent accidental unauthorised start-up.
Never lower the attachment or auxiliary tools other
than from sitting in the operator’s seat. Sound the
horn. Make sure that nobody is within the machine
operating range. Lower the attachment slowly.
Securely block and lock the machine every time you
15501 9-35990
leave it unattended. Return keys to the safe place
previously agreed upon. Perform all necessary
operations for stopping as detailed in the Operation
and Maintenance Instruction Manual.
Drive the machine far from pits, trenches, rocky
hanging walls, areas with overhead electric lines, and

SAFETY PRECAUTIONS
slopes before stopping it at the end of the working
day.
Align the upperstructure to the tracks in order to allow
to easily get on and off the driver’s compartment.
Move all controls to the position specified for machine
stopping. Refer to the Operator's Manual.
Never park on an incline without accurately blocking
the machine to prevent unexpected movement.
Follow stopping instructions contained in the
Operator's Manual.
MAINTENANCE
GENERALITIES
Carefully read the Operator's Manual before starting,
operating, maintaining, fuelling or servicing the
machine in any manner.
Read all safety plates mounted on the machine and
observe instructions they contain before starting,
operating, repairing, fuelling or servicing the machine.
Do not allow unauthorised personnel to repair or
service the machine.
Follow all recommended maintenance and service
procedures.
Do not wear rings, wrist watches, jewellery, loose or
hanging garments, such as ties, torn clothing,
scarves, unbuttoned or unzipped jackets that can get
caught in moving parts. Wear certified safety clothes
such as: hard hat, no-slip footwear, heavy gloves, ear
protection, safety glasses, reflector vests, respirators
when required. Ask your employer about safety
regulations in force and protective equipment.
Do not use controls or hoses as hand holds. Hoses
and controls are movable parts and do not provide
solid support. Besides, controls may be inadvertently
moved and cause unexpected movement of the
machine or its attachments.
Do not jump on or off the machine. Always keep both
hands and one foot, or both feet and one hand in
contact with steps and/or grab rails.
Never service the machine with someone sitting in the
driver’s seat, unless this person is an authorised
operator assisting in the maintenance being carried
out.
Keep the operator’s compartment, step plates, grab
rails and handles clear of foreign objects, oil, grease,
mud or snow to minimise the danger of slipping or
stumbling.
Clean mud or grease from your shoes before climbing
on the machine or driving it.
15501 9-35990
Never attempt to operate the machine or its
attachments from any position other than sitting in the
operator’s seat.
Keep the driver’s seat free from foreign objects,
especially if these are not secured.
Should it be necessary to move the attachment for
SR2-1-5
maintenance purposes, do not raise or lower the
attachment from any other position than sitting in the
operator’s seat. Before starting the machine or
moving its attachment, sound the horn and require
that nobody remains near the machine.
Raise the attachment slowly.
Always lock all moving components or parts of the
machine that must be lifted for maintenance purposes
using adequate external means as required by local
and national regulations. Do not allow anyone to
pass or stay near or below a raised attachment. If you
are not absolutely sure about your safety, do not stay
or walk under a raised attachment.
Do not place head, body, limbs, hands, feet or fingers
near articulated cutting edges deprived of the
necessary guards, unless they are suitably and safely
locked.
Never lubricate, repair or adjust the machine with the
engine running, except when this is specifically
required by the Operator's Manual.
Do not wear loose clothing, jewellery near rotating
parts.
When service or maintenance require access to areas
that cannot be reached from the ground, use a ladder
or step platform conforming to local or national
regulations to reach the working area. If such means
are not available, use machine grab rails and steps.
Always perform all service or maintenance work with
the greatest care and attention.
Shop and/or field service platforms or ladders should
be manufactured and maintained in accordance with
local or national safety regulations in force.
Disconnect batteries and label all controls to warn
that service work is in progress, according to local
and national safety regulation requirements.
Block the machine and all attachments to be raised
according to local and national safety regulation
requirements.
Do not check or fill fuel tanks or install batteries near
burning or smoking materials and open flames due to
the presence of flammable vapours.
The fuel filler pipe nozzle must be constantly kept in
contact with the filler neck and this even before fuel
starts flowing in. Keep this contact from the beginning
to the end of the fuelling operation to avoid possible
generation of sparks due to static electricity.
Use a truck or trailer to haul a failed machine. Should
it be necessary to tow it, provide for suitable danger
signals as required by the local norms and regulations
and observe recommendations given in the
Operator's Manual. Load/unload the machine on firm
level ground providing safe support to the wheels of
the truck or trailer. Use strong access ramps, with
adequate height and angle. Keep the trailer flatbed
free of mud, oil or slippery materials. Tie the machine
securely to the trailer and block carriages and
upperstructure.
Never align holes or slots using your fingers; always

SAFETY PRECAUTIONS
use appropriate aligning tools.
Remove all sharp edges and burrs from re-worked
parts.
Use only approved and effectively grounded auxiliary
power sources for heaters, battery chargers, pumps
and similar equipment to reduce electrical shock
hazard.
Lift and handle heavy components using hoisting
devices of appropriate capacity. Ensure the parts are
supported by appropriate straps and hooks.
Use lifting eyes provided to this aim.
Pay attention to bystanders near the lifting area.
Never pour gasoline or diesel fuel into open
containers. Never use gasoline, solvents or other
flammable fluids to clean parts. Use proprietary
certified non-flammable, non-toxic solvents only.
When using compressed air to clean parts, wear
safety glasses with side shields. Limit pressure to
max. 2 bar, in accordance with local and national
safety regulations in force.
Do not run the engine of this machine in closed
buildings without proper forced ventilation capable to
remove toxic exhaust gases concentrating in the air.
Do not smoke, nor allow open flames or sparks
nearby while refuelling the unit or handling highly
flammable materials.
Do not use open flames as light sources to look for
leaks or inspect anywhere on the machine.
Make sure that all mechanical tools provided are in
good condition at all times. Never use tools with
mushroomed or damaged heads. Always wear eye
protections with side shields.
Move with extreme care when working under, on or
near the machine or its attachments.
In case of attachment tests during which the engine
should be kept running, a qualified operator must sit
in the driver’s seat at all times while the mechanic is
at work.
Keep hands and clothes far OFF moving parts.
Stop the engine and move the safey lever to the lock
position before starting adjusting or repairing an
assembly.
Do not carry out any work on the attachment without
prior authorisation. Observe recommended
maintenance and repair procedures.
In case of field service, move the machine to level
ground and block it. If work on an incline cannot be
avoided, securely block the machine and its
attachments. Move the machine to level ground as
soon as possible. Do not twist chains and cables.
Never use a twisted chain or cable for lifting or
pulling. Always wear safety gloves to handle chains or
cables.
Be sure chains and cables are firmly fastened and
that the anchor point is strong enough to withstand
the expected load. Keep all bystanders clear of the
anchor point, cables or chains. Do not pull or tow
unless the operator’s compartments of the
SR2-1-6
machines involved are fitted with proper guards
against cable or chain backlash.
Keep the maintenance area clean and dry at all times.
Clean immediately all water and oil spillage.
Do not pile up oily or greasy rags as they represent a
major fire hazard. Always store them in closed metal
containers.
Before starting the machine or its attachment, check,
adjust and lock the operator’s seat. Also ensure that
nobody is within the machine or attachment operating
range before starting or operating the machine and/or
its attachments. Sound the horn.
Rust inhibitors are volatile and flammable. Prepare
parts in well ventilated areas. Keep open flames
away. Do not smoke. Store containers in a cool well
ventilated place where they could not be reached by
unauthorised people.
Do not carry loose objects in your pockets that might
fall unnoticed into open compartments.
Wear appropriate safety clothing such as hard hat,
safety shoes and gloves, safety glasses when
splinters or other particles may be ejected.
Wear the appropriate welder’s equipment such as
dark safety glasses or mask, hard hat, protective
clothing, safety gloves and footwear always while
welding or arc-cutting. Wear dark safety glasses when
you are near a welding in progress. Do not look the
welding arc without proper eye protection.
Become acquainted with all your jacking equipment
and their capacity. Ensure that the jacking point on
the machine is appropriate for the load applied. Also,
be sure the supports under the jack and between the
jack and the machine are appropriate and stable.
Any equipment supported by a jack represents a
possible hazard. Always support the load onto
appropriate blocking means as a safety measure
before proceeding with service or maintenance work,
in compliance with local or national safety regulations.
Metal cables produce steel splinters. Always wear
certified protection clothes such as safety gloves and
glasses while handling them.
Handle all parts carefully. Keep hands and fingers
away from gaps, gears, and similar. Always use and
wear certified safety clothes such as safety glasses,
gloves and footwear.
The attachment is kept constantly in position by an oil
column trapped into the high pressure circuit. Lower
the attachment to the ground and relieve pressure
from all circuits prior to carrying out any type of
maintenance or repair work.
Do not service or repair the machine if it is parked
downhill. Consult the Operator's Manual for correct
15501 9-35990
maintenance procedure.
Areas near articulated cutting edges where
mechanical parts are in motion are where personal
injuries are most likely to occur. Pay attention to
prevent possible part movements by means of blocks
or by keeping clear of such zones when motion may

SAFETY PRECAUTIONS
take place during maintenance or repair.
Move the hydraulic system lock safety lever to the lock
position when stopping the machine for whatever reason.
Always install the safety stays for the hood and other
hinged covers before performing any maintenance or
repair work in the engine compartment.
TRANSFERS AND TRANSPORTATION
Before moving or transporting the machine, block
upperstructure swing to prevent accidental
movement.
Pay particular attention during transfer on inclines,
both uphill and downhill. Keep the bucket in a position
to provide a possible anchor point into the ground in
case of slipping.
During transfers on inclines, both uphill and downhill,
keep the upperstructure aligned with the carriages.
Do not travel across the slope.
Never transfer the machine in the working site, in a
crowded area, or near people without having at least
one person charged with hand-signals who could
guide the Operator.
Sound the horn to inform that you are about to move off.
It is necessary to know load limits of bridges and
dimensional limits of tunnels. Such limits must never
be exceeded. You should also know machine height,
width, and weight. Have a signal-man help you when
clearances are limited.
Check distance between boom/dipper and
dimensional limits during transfer or transportation.
Rough terrain may cause the machine to sway and
roll to such an extent that boom/dipper could get to
contact electric lines or other obstacles. Cross
obstacles at a right angle at low speed. Pay attention
to machine shaking when the centre of gravity
overcomes the obstacle.
Keep the bucket down at all times during transfers.
Drive with the lights on and use appropriate signals
and flags.
Get to know and respect local and national
regulations.
Consider boom/dipper and upperstructure dimensions
while turning.
Use a ramp to load the machine on a trailer. If a ramp
is not available, fabricate one using blocks. The ramp
should be sufficiently strong to support machine
weight. Always load and unload on level surface.
Tow the machine following the instructions contained
in the Operator's Manual.
15501 9-35990
ENGINE
Do not run the engine in closed buildings without proper
ventilation capable to remove harmful exhaust fumes.
Do not place head, body, limbs, feet, hands or fingers
SR2-1-7
near rotating fans or belts. Be especially careful near
blower fans.
Loosen the radiator cap very slowly to relieve system
pressure before removing it. Always top-up coolant
level with the engine off or idling if hot. See the
Operator's Manual.
Keep the exhaust manifold and tube free from
combustible matters. Fit the machine with shields and
guards when working in the presence of combustible
matter free in the air.
Do not refuel with the engine running, especially if hot, as
this increases fire hazard in case of fuel spillage.
Never attempt to check or adjust fan belt tensions
when the engine is running.
Do not adjust the fuel injection pump when the
machine is operating.
Do not lubricate the machine with the engine running.
Do not run the engine with the air intakes open and
not protected. If this cannot be avoided for service
reasons, place protection meshes on all intakes
before servicing the engine.
ELECTRICAL SYSTEM
Pay attention to connect connecting cables to correct
poles (+ to +) and (- to -) at both ends. Do not short-
circuit terminals. Thoroughly follow instructions given
in the Operator's Manual.
Always move the starter switch key into the lock
position before servicing or repairing the machine.
Batteries contain SULPHURIC ACID. Protect the eyes
when working near the batteries against possible
sprays of the acid solution. Should acid contact skin,
eyes, or clothes, RINSE IMMEDIATELY IN WATER
FOR AT LEAST 15 MINUTES. Immediately seek
medical attention.
Battery released gas is highly flammable. Leave the
battery compartment cover open during recharging to
improve ventilation. Never check battery charge by placing
metal objects across the posts. Keep sparks or open
flames away from batteries. Do not smoke near the
battery to prevent explosion hazard.
Before any maintenance or repair, make sure that
there are no fuel or electrolyte leaks from the
batteries. If any, correct prior to proceeding with
further work. Do not recharge batteries in confined
spaces. Ensure proper ventilation is provided to avoid
accidental explosions due to build-up of explosive gas
released during charging.
Disconnect batteries before working on the electrical
system or carrying out any other type of work.
HYDRAULIC SYSTEM
Pressure fluid escaping from a very small hole can be
almost invisible and still have sufficient force to
 SR2-1-8
SAFETY PRECAUTIONS

penetrate the skin. Always check any suspected
pressure leaks using a piece of cardboard or wood.
Do not use hands. If injured by escaping fluid, obtain
medical attention immediately or serious infection or
reaction may develop.
Stop the engine and ensure pressure is relieved from
all systems before removing side panels, housings,
guards and covers. See the Operator's Manual.
Always use gauges of adequate capacity for pressure
testing. Refer to the Operator's Manual or Repair Manual.
Before removing objects from the tyre tread, deflate it.
Do not inflate tyres with flammable gas: they may
cause explosions and serious personal injuries.
After each shift check for loose screws and/or rim
mounting brackets. If necessary, tight them according
to the instructions herein contained.

TOOLS

Always keep head, body, limbs, feet, hands, and

fingers away from the bucket and attachments, when
in the raised position.
Prior to any maintenance or repair work, install all
supports necessary to this aim according to local and
national safety regulations.
In case the attachment is to be operated for
maintenance or repair purposes, do so exclusively
while sitting in the driver’s seat. Sound the horn
before starting the machine or moving the attachment.
Require that nobody remain near the machine. Raise
the attachment slowly.
Do not use the machine to transport loose objects,
unless proper securing devices are provided.

TYRES AND WHEELS

Make sure that the inflation pressure of the tyres is

according to the specifications issued by the
Manufacturer and check it periodically.

Should the pressure be changed, stand on the side of

the tyre at a safe distance.

Pressure check operations must be performed with

unloaded machine and cold tyres.
Never use reconditioned tyre rims, since eventual
weldings, heat-treatments or repairs not performed
correctly can weaken the wheel, thus causing
subsequent damages or dangers.

Do not perform torch cutting or welding operations on

rims with tyres installed.
Spare tyres must be inflated only as far it is necessary
to keep the rim components assembled; remember that
when not installed on the disc, a tyre inflated to
maximum pressure can explode.
15501 9-35990

Before operating on tyres, block all wheels, front and

rear. After lifting the machine with the cylinders, block it
with stands according to current safety rules and
regulations.

Deflate the tyres before removing them.

 SR2-2-1
SAFETY PRECAUTIONS

RECOGNISE SAFETY INFORMATION

• This is your SAFETY ALERT SYMBOL.

- When you see this symbol on your machine or in

this Manual, be alert of the potential for personal
injury.
- Follow recommended precautions and safe
operating practices.

F3264

UNDERSTAND SIGNAL WORDS

• In this Manual you will find the following words:

DANGER
- DANGER;
-
-
WARNING;
CAUTION. WARNING
referring to different hazard risks.
These words are always accompanied by the safety CAUTION
alert symbol.

DANGER: indicates an imminent hazardous situation

IMPORTANT
which, if not avoided, will result in death or serious injury.

WARNING: indicated a potential hazardous situation NOTE

which, if not avoided, could result in death or serious
injury.

CAUTION: indicates a potential hazardous situation

which, if not avoided, may result in minor or moderate
injury.

IMPORTANT: indicates a situation which, if not avoided,

may cause damage to the machine.

NOTE: indicates an additional explanation for

information purposes.

ENVIRONMENTAL PROTECTION

• This Manual also contains this symbol

15501 9-35990

accompanying instructions for correct behaviour as

regards environmental protection.

F5041
 SR2-2-2
SAFETY PRECAUTIONS

FOLLOW SAFETY PRECAUTIONS

• Carefully read and observe all safety signs on the

machine and read all safety precautions in this
Manual.

• Safety signs should be installed, maintained, and

replaced when necessary.

- If a safety sign or this Manual are damaged or mis-

sing, obtain a replacement from your Dealer CASE
in the same way you order a spare part (be sure to
detail machine model and serial number upon
ordering).

• Learn how to operate the machine and its controls

F1437
correctly and safely.

• Allow only trained, qualified, authorised personnel

to operate the machine.

• Keep the machine in proper working conditions.

- Unauthorised changes to the machine may impair

function and/or safety and affect machine life.

• Safety messages in this Chapter “SAFETY

PRECAUTIONS”, are intended to illustrate basic
safety procedures of the machine. However, it is
impossible for these safety messages to cover every
hazardous situation you may encounter. If you have
any doubts, consult your direct supervisor prior to
operating or servicing the machine.

PREPARE FOR EMERGENCIES

• Be prepared if a fire starts or an accident occurs.

- Keep the first-aid kit and fire extinguisher on hand.

- Thoroughly read and understand the label attached
to the fire extinguisher to use it properly.
- Establish emergency priority procedures to cope
with fires and accidents.
15501 9-35990

- Keep emergency numbers for doctors, ambulance

service, hospitals and fire department posted near
the telephone.
F1440
 SR2-2-3
SAFETY PRECAUTIONS

WEAR PROTECTIVE CLOTHING

• Wear close-fitting clothing and safety equipment

appropriate to the job.
You need:
- A hard hat;
- Safety shoes;
- Safety glasses or face shield;
- Heavy gloves;
- Ear protection;
- Reflective clothing;
- Waterproof clothing;
- Respirator or filter mask;
Be sure to correctly wear equipment and clothing
for the job.
F1438
- Do not take any chances.
- Avoid wearing loose clothing, jewellery, or other
items that can catch on control levers or other parts
of the machine.
• Operating equipment safely requires the full attention
of the operator. Do not wear radio or music
headphones while operating the machine.

PROTECT AGAINST NOISE

• Prolonged exposure to loud noise can cause impairment

or loss of hearing.

- Wear a suitable hearing protection such as earmuffs

or earplugs to protect objectionable or uncomfortably
loud noise.
F1439

INSPECT THE MACHINE

• Inspect the machine carefully every day or work-shift

by an attentive visual inspection of machine outside
prior to starting it to prevent damages and personal
injuries.

- In the walk-around inspection, be sure to cover all

points detailed in the Chapter “MAINTENANCE”,
15501 9-35990

paragraph “EXTERNAL VISUAL INSPECTION”.

F1441
 SR2-2-4
SAFETY PRECAUTIONS

USE HAND HOLDS AND STEPS

• Falling is one of the major causes of personal injury.

- When you get on and off the machine, always face

the machine and maintain a three-point contact
with the steps and handrails.

- Do not use any control as a handhold.

- Never jump off the machine.

- Never get on and off a moving machine. F1442

- Be careful of slippery conditions of platforms,

steps, and handrails when leaving the machine.

ADJUST THE OPERATOR'S SEAT

• A seat poorly adjusted for operator or work

requirements may quickly fatigue the operator
leading to improper operations.

- The seat should be adjusted whenever machine

operator changes.

- The operator should be able to fully press the

pedals and correctly move the control levers with
his back resting against the seat back.

- If not, move the seat fore and aft, and check again.
F1443
15501 9-35990
 SR2-2-5
SAFETY PRECAUTIONS

FASTEN SEAT BELT

• Should the machine overturn, the operator may

become injured and/or thrown from the cab. Not only,
the operator may be crushed by the overturning
machine resulting in serious injury or even death.

- Prior to operating the machine, thoroughly examine

belt webbing, buckle, and attaching hardware. If
any item is damaged or worn, replace the seat belt
or component before operating the machine.
F3261
- Be sure to remain seated with the seat belt securely
fastened at all times when the machine is in
operation to minimise injury hazard in case of
accident.

- After a significant accident, replace the seat belts

even though they do not look damaged.

MOVE AND OPERATE MACHINE SAFELY

• Bystanders can be run over.

- Confirm the location of bystanders before moving,

swinging, or operating the machine.

- Always keep the travel alarm in good working

condition (if equipped).

F2447
- It warns people when the machine starts to move.

- Use a signal person when moving, swinging, or

operating the machine in congested areas.

- Coordinate hand signals before starting the

machine.
15501 9-35990
 SR2-2-6
SAFETY PRECAUTIONS

OPERATE ONLY FROM THE DRIVER'S SEAT

• Avoid possible injury or machine damage.

- DO NOT start the engine by shorting across starter

terminals.

- NEVER start the engine while standing on the track

or on the ground.

- Do not start the engine by shorting across starter

motor terminals.
F4041

- Before starting the engine, ensure that all control

levers are in the neutral position.

STARTING THE ENGINE WITH BOOSTER

BATTERIES

• Battery gas may explode causing serious damages

and injuries.
- If the engine is to be started using booster
batteries, ensure to comply with all procedures
detailed in the chapter “OPERATING
INSTRUCTIONS”.
- The operator should be sitting in the driver’s seat
to keep the machine under control when the
engine starts. Starting the engine with booster F1464

batteries is a two man operation.

- Do not use batteries that have been stored in the
cold for a long time.
- Mistakes in following procedures detailed for
starting the engine with slave batteries may cause
the batteries to explode or machine to move
unexpectedly.

DO NOT CARRY RIDERS ON THE MACHINE

• Riders on the machine are subject to injuries such

as being struck by foreign objects and being thrown
off the machine.

- Only machine operator is allowed on the machine.

Keep riders off.
15501 9-35990

- Riders also obstruct the operator’s visibility,

resulting in the machine being operated unsafely. F2444
 SR2-2-7
SAFETY PRECAUTIONS

INVESTIGATE JOB SITE BEFORE HAND

• When working at the edge of an excavation or on a

road shoulder, the machine could overturn, possibly
resulting in serious injury or death.

- Investigate the configuration and ground conditions

of the job site beforehand to prevent the machine
from overturning and prevent the ground,
stockpiles, or banks from collapsing.
- Make a work plan. Use machines appropriate to
the work and job site.
- Reinforce ground, edges, and road shoulders as
necessary. Keep the machine well back from the
edges of excavations and road shoulders.
- When working on an incline or road shoulder, F2448

employ a signal person as required.

Confirm that your machine is equipped with a
F.O.P.S. (Falling Object Protective Structure) cab
before working in areas where there is the
possibility of falling stones or landslides.
- When footing is weak, reinforce the ground before
starting the work.
- When working on frozen ground, be extremely
alert. As ambient temperature rises, footing
becomes loose and slippery.

PROTECTION OF CAB

• In case of operation of the excavator under

conditions where land slides with falling rocks or
any conditions where there is a potential falling of
objects of different nature that could endanger the
operator, it is necessary to install a F.O.P.S. (Falling
Object Protective Structure) to protect the cab.
15501 9-35990

F2450
 SR2-2-8
SAFETY PRECAUTIONS

PROVIDE SIGNALS FOR JOBS INVOLVING

A NUMBER OF MACHINES

• For jobs involving several machines, provide signals

commonly known by all personnel involved.
Also, appoint a signal person to co-ordinate the job
site.
Make sure that all personnel obey the signal person’s
directions.

F3614

CONFIRM DIRECTION WHERE THE

MACHINE IS TO BE DRIVEN

• Instinctive travel pedal operation may result in

serious injury and even death.

- Before driving the machine, be aware of the

undercarriage position relative to the operator’s
seat.

- If swinging/steering axle is located behind towards

F5044
the counterweight, the machine will move reverse
when control pedal is moved forwards.
15501 9-35990
 SR2-2-9
SAFETY PRECAUTIONS

DRIVE MACHINE SAFELY

• Before starting the machine, carefully read this

manual (refer to the chapter OPERATING IN-
STRUCTIONS).

- Before moving the machine, confirm which way to

move travel pedals/levers for the corresponding
direction you wish to go.

- When traveling up or down a grade, keep the F7731

bucket in the direction of travel, approximately 20
to 30 cm (A) above the ground.

- If the machine starts skidding or is unstable, lower

the bucket immediately.

- Cross-travelling on a slope can cause the machine

skidding or overturning. When travelling up or down
a slope, make sure the tyres are oriented in the
slope direction.

- Turning on an incline may cause the machine to

tip over. If turning on an incline is absolutely una-
voidable, do so at a place where the slope is gen-
tle and the surface is firm.
F7730

- Never go down on slopes with travel pedal in neu-

tral. You might loose control and cause serious in-
juries or death.

- When going down on slopes, use a low gear. In CORRECT

this way the travel motor is used as brake and holds
the machine without overloading brakes.

- When working on a slope and the warning light

for fuel insufficient level lights up, fill the tank im- F5632

mediately.

WRONG
15501 9-35990

F5633
 SR2-2-10
SAFETY PRECAUTIONS

AVOID INJURY FROM UNEXPECTED

MACHINE MOVEMENT

• Death or serious injury may result if you attempt to

get on or off a moving machine.

• To avoid roll-aways:

- Select level ground when possible to park the

machine.

- Do not park the machine on a grade.

- Park at a reasonable distance from other

machines.

- Lower the bucket and/or other work tools to the

ground.

- Lower blade and stabilizers to the ground.

F2452

- Run the engine at slow idle speed without load for

5 minutes to cool down the engine.

- Stop the engine and remove the starter switch

key.

- Pull the safety lever (pilot control shut-off lever) to

LOCK position.

- Lock both wheels with the supplied wedges.

15501 9-35990
 SR2-2-11
SAFETY PRECAUTIONS

AVOID INJURY FROM BACK-OVER AND

SWING ACCIDENTS

• If any person is present near the machine when

backing or swinging the upperstructure, the machine
may hit or run over that person, resulting in serious
injury or death.

• To avoid back-over and swing accidents:

- Always look around BEFORE YOU BACK UP
AND SWING THE MACHINE. BE SURE THAT
ALL BYSTANDERS ARE CLEAR.
- Keep the travel alarm in working condition (if
equipped).
- ALWAYS BE ALERT FOR BYSTANDERS F1447
MOVING INTO THE WORK AREA. USE THE
HORN OR OTHER SIGNAL TO WARN
BYSTANDERS BEFORE MOVING MACHINE.
- A person could stand behind the machine, in a
dead area, not visible from rearview mirrors.
Before backing up, make sure nobody is standing
in that area.
- USE A SIGNAL PERSON WHEN BACKING UP
IF YOUR VIEW IS OBSTRUCTED. ALWAYS
KEEP THE SIGNAL PERSON IN VIEW.
- Use hand signals, which conform to your local
regulations, when work conditions require a signal
person.
- No excavator or backhoe motions shall be made
unless signals are clearly understood by both
signalman and operator.
- Learn the meaning of all flags, signs, and markings
used on the job and confirm who has the
responsibility for signaling.
- When operating in potential dangerous areas, or
in areas with low visibility, use a person for machine F3625
shifts.
- Before starting machine shifting, warn people near
the working area by means of the horn.
F7820
- Keep windows, mirrors, and lights clean and in
good condition.
- Dust, heavy rain, fog, etc., can reduce visibility.
As visibility decreases, reduce speed and use
proper lighting.
- Read and understand all operating instructions in
this Operator’s manual.
15501 9-35990
 SR2-2-12
SAFETY PRECAUTIONS

KEEP PERSONNEL CLEAR FROM WORKING

AREA

• A person may be hit severely by the swinging front

attachment or counterweight and/or may be crushed
against an other object, resulting in serious injury or
death.

- Keep all persons clear from the area of operation

and machine movement.

- Before operating the machine, set up barriers to

F5045
the sides and rear area of the bucket swing radius
to prevent anyone from entering the work area.

NEVER MOVE THE BUCKET OVER ANY ONE

• Never lift, move, or swing bucket above anyone or

a truck cab.
Serious injury or machine damage may result due
to bucket load spill or due to collision with the bucket.

F5046

AVOID UNDERCUTTING

• Never undercut or the footing might collapse.

- Before starting to work, make sure of the excavator

control direction.

- If the footing starts to collapse and if sufficient

retreat is not possible, do not panic.
15501 9-35990

- Often, the machine can be secured by lowering F5047

the front attachment.

 SR2-2-13
SAFETY PRECAUTIONS

AVOID OVERTURNING

• The danger of tipping is always present when

operating on a grade, possibly resulting in serious
injury or death.

• To avoid tipping:
- Be extra careful before operating on a grade.
- Prepare machine operating area flat by grading.
- Keep the bucket low to the ground and close to
the machine.
- Reduce machine operating speed to avoid
tipping or slipping.
- Avoid changing direction when travelling on
grades. F5826
- NEVER attempt to travel across a grade steeper
than 15 degrees.
- Reduce swing speed as necessary when
swinging loads.

• Be careful when working on frozen ground.

- Temperature increases will cause the ground to
become soft and make ground travel unstable.

F8128

NEVER UNDERCUT A HIGH BANK

• The edges could collapse or a land slide could occur

causing serious injury or death.
15501 9-35990

F5043
 SR2-2-14
SAFETY PRECAUTIONS

DIG WITH CAUTION

• Accidental severing of underground cables or gas

lines may cause an explosion and/or fire, possibly
resulting in serious injury or death.
- Before digging, check the location of cables, gas
lines, and water lines.
- Keep the minimum distance required by law from
cables, gas lines, and water lines. If a fiber optic
cable should be accidentally severed, do not look
into the end. Doing so may result in serious eye
injury.
- Contact local authorities and/or the utility
companies directly (electric power, gas, telephone,
water, sewers, telecommunications, etc.) to obtain F2446

information about underground utility lines.

OPERATE WITH CAUTION

• If the front attachment or any other part of the

machine hits against an overhead obstacle, such
as a bridge, both the machine and the overhead
obstacle will be damaged, and personal injury may
results as well.

- Take care to avoid hitting overhead obstacles with

the boom or dipper.

F2451

AVOID POWER LINES

• Serious injury or death can result from contact with

electric lines.

- In case of works near air electrical lines respect

the necessary safety distances:

Operation Voltage Safety distance

up to 1000 V 1.0 m
15501 9-35990

from 1 kV to 110 kV 3.0 m

from 110 kV to 220 kV 4.0 m
from 220 kV to 380 kV 5.0 m F2445

unknown 5.0 m
 SR2-2-15
SAFETY PRECAUTIONS

PROTECT AGAINST FLYING DEBRIS

• If flying debris hit eyes or any other part of the

body, serious injury may result.

- Guard against injury from flying pieces of metal

or debris; wear goggles or safety glasses.

- Keep bystanders away from the working area

before striking any object, to avoid personal
injury.
F1466

PARK MACHINE SAFELY

• Before working on the machine:

- Park the machine on a level surface.

- Lower the bucket to the ground.
- Turn the auto-idle (A/I) switch off.
- Move the upperstructure swing lever to lock
position.
- Run the engine at slow idle speed without load
for 5 minutes.
F5042
- Turn the starter switch key to OFF to stop the
engine. Remove the key from the switch.
- Pull the pilot control shut-off lever to LOCK
position. LOCK
- Close the windows, the roof window, and the cab
door.
- Lock all the access doors and the
compartments.
15501 9-35990

F2440
 SR2-2-16
SAFETY PRECAUTIONS

RULES FOR ROAD TRANSFER

• The machine is equipped with safety locks to be

used for road transfer.

• When transferring the machine:

- Locate upper carriage towards swinging front

axle. Insert upperstructure anti-swing lock.

- Locate cylinders as shown in the homologation

configuration.

- Lock cylinders (cocks, reference marks).

- Lift stabilizers and/or blade as shown in the

homologation configuration.

- Fit lighting devices as shown in the homologation

configuration, if required by the rules in force in F12620

the country where the machine is being used.

- Set control disconnection switch to OFF position.

- On the road follow the rules regulating traffic.

- DURING ROAD TRANSFERS ALWAYS

DISCONNECT FRONT AXLE LOCK.

15501 9-35990
 SR2-2-17
SAFETY PRECAUTIONS

SAFETY TRANSPORTING

• The danger of tipping is present when loading/

unloading the machine onto/from a truck or trailer
bed.

- Be sure to observe local regulations when

transporting the machine on public roads.

- Provide an appropriate truck or trailer for

F5048
transporting the machine.

• Take the following precautions when loading/

unloading the machine:

1. Select firm level ground.

2. Be sure to use a loading dock or ramp.

3. Be sure to have a signal person when loading/

unloading the machine.

4. Always turn the auto-idle (A/I) switch off when

loading or unloading the machine, to avoid
unexpected speed increase due to
unintentional operation of a control lever.

5. Always select the slow speed mode with the

travel speed selector. In the high speed mode, WEDGES
travel speed may automatically increase. BLOCKS
RAMPS
6. Avoid steering while driving up or down the F5827

ramp as it is extremely dangerous. If steering

is unavoidable, first move back to the ground
or flatbed, modify travelling direction, and
begin to drive again.

7. Operate the safety lever but do not operate

any other control except travel control when
driving up or down the ramp.

8. The top end of the ramp where it meets the

flatbed is a sudden bump. Take care when
traveling over it.
15501 9-35990
 SR2-2-18
SAFETY PRECAUTIONS

9. Prevent possible injury from machine

tipping while the upperstructure is rotating.

10. Keep the dipper tucked under and rotate

the upperstructure slowly for best stability.

11. Securely fasten machine frame using

chains or cables.
Refer to the chapter “SAFETY SIGNS” in
this manual.
F12624

F12621

F12622
F12625
15501 9-35990

F12626
F12623
 SR2-2-19
SAFETY PRECAUTIONS

SAFE MAINTENANCE

• To avoid accidents:
- Understand maintenance procedure before start-
ing the work.
- Keep the working area clean and dry.
- Do not spray water or steam inside the cab.
- Do not lubricate or service the machine when it is
in motion.
- Keep hands, feet and clothes far from moving parts.
• Prior to service in the machine, safely park the ma-
chine on a level surface.
- Apply the "Maintenance in progress" tag (see
SAFETY PLATES in this Chapter). This tag can
be applied to the left-hand control lever, safety le-
ver or cab door.
- Do not leave the machine unattended if servicing
F1458
requires the engine running.
- If the machine is to be raised, place boom and
dipper at an angle of 90° to 110°. Lock machine
components which should be raised for
maintenance or repair using suitable supporting
means.
- Never work under a machine kept raised by the
boom.
- Inspect certain component regularly, repair or re-
place as necessary. Refer to the Chapter MAIN-
TENANCE in this Manual.
- Keep all components in good condition and prop-
erly install. Immediately repair any fault.
- Immediately repair any damage. Replace worn or
failed components. Remove grease, oil, debris
build-ups.
- Disconnect the ground cable (-) from the battery
before carrying out any work on the electrical
system or arc-welding on the machine.
F5832
15501 9-35990

F2453
 SR2-2-20
SAFETY PRECAUTIONS

WARN OTHERS OF SERVICE WORK

• Unexpected machine movement can cause serious

injury.

- Before performing any work on the machine, at-

tach a maintenance in progress tag (see also
SAFETY PLATES in this Chapter). This tag can
be applied to the left-hand control lever, safety le-
ver or cab door.

F2431

SUPPORT MACHINE PROPERLY

• Never attempt to work on the machine without se-

curing the machine first.

- Always lower the attachment or tool to the ground

before working on the machine.
- If you must work on a lifted machine or attach-
ment, securely support the machine or attachment.
- Do not support the machine on breeze blocks,
scrap timber, or props that may crumble under con-
tinuous load.
- Do not work under a machine that is supported
solely by a jack.

F3634

STAY CLEAR OF MOVING PARTS

• Entanglements in moving parts can cause serious

injury.

• To prevent accidents, care should be taken to en-

sure that hands, feet, clothing, jewelry and hair do
15501 9-35990

not become entangled when working near rotating

parts.

F1467
 SR2-2-21
SAFETY PRECAUTIONS

PREVENT PARTS FROM FLYING OFF

• Tyres are charged with pressure.

- Tyre and/or rim parts burst may result in serious

injury or death.
- Only skilled staff can replace tyres.
- Always keep the correct tyre pressure.
- Never exceed the recommended pressure when
inflating tyres.
- Slow down or stop and let tyres get cool.
- When adjusting tyre pressure, keep at a certain F3635

distance and protect yourself. Use an extension

equipped with a quick connection for the valve
handling.
- Always stay behind the tyre when adjusting
pressure.

STORE ATTACHMENTS SAFELY

• Stored attachments such as buckets, hydraulic

breakers, and blades can fall and cause serious
injury or death.

- Securely store attachments and implements to

prevent falling. Keep children and bystanders
away from storage areas.

F1463
15501 9-35990
 SR2-2-22
SAFETY PRECAUTIONS

PREVENT BURNS

Hot spraying fluids:

• After operation, engine coolant is hot and under
pressure. Hot water or steam is contained in the
engine, radiator and heater lines.
Skin contact with escaping hot water or steam can
cause severe burns.
- To prevent possible injury from hot spraying water.
- Be sure to stop the engine, and let engine and
radiator cool.
Slowly loosen the cap to release pressure after
the system has cooled, then remove it.
F1477
- The hydraulic oil tank is pressurized. Again, be
sure to release all pressure before removing the
cap.

Hot fluids and surfaces:

• Engine oil, reduction gear oil and hydraulic oil also
become hot during operation.
The engine, hoses, lines and other parts become
hot as well.
- Wait for the oil and components to cool down
before starting any maintenance or inspection
work.
F1469

AVOID HIGH PRESSURE FLUIDS

• Escaping fluid under pressure can penetrate the skin

causing serious injury.
- Avoid this hazard by relieving pressure before
disconnecting hydraulic or other lines.
- Relieve the pressure by moving the control levers
several times. Tighten all connections before
applying pressure.
- Search for leaks with a piece of cardboard; take
care to protect hands and body from high-pressure
fluids. Wear a shield or protection glasses to F3636
protect your eyes.

• If an accident occurs, see a doctor familiar with this

type of injury immediately.
15501 9-35990

• Any fluid injected into the skin must be surgically

removed within a few hours or gangrene may result.

F1471
 SR2-2-23
SAFETY PRECAUTIONS

PREVENT FIRES
• Check for oil leaks:
- Fuel, hydraulic oil and lubricant leaks can lead to
fires that may result in serious injury.
- Check for missing or loose clamps, kinked hoses,
lines or hoses that rub against each other,
damaged oil-cooler, and loose oil-cooler flange
bolts, for oil leaks.
- Search for leaks with a piece of cardboard.
Escaping fluid under pressure can penetrate the
skin causing serious injury. Do not use your bare
hand to check for oil leaks.
- Tighten, repair or replace any missing, loose or F3638
damaged clamps, lines, hoses, oil-cooler and oil
cooler flange bolts.
- Do not bend or strike high-pressure lines.
- Never install bent or damaged lines, pipes or
hoses.
• Check for shorts:
- Short circuits can cause fires that may result in
serious injury.
- Clean and tighten all electrical connections.
- Check before each shift or after eight hours of
operation for loose, kinked, hardened or frayed
electrical cables and wires.
- DO NOT OPERATE MACHINE if cable or wires
are loose, kinked, etc.
Tighten, repair or replace any loose or damaged
electrical cables, wires, and terminal caps before
operating the machine.
• Clean flammables:
- Spilled fuel and oils, and accumulated coal dust
and other flammables may cause fires and serious
personal injury.
- Prevent fires by keeping machine clean every day.
• Check starter switch key.
- If a fire breaks out, failure to stop the engine will
escalate the fire, hampering fire fighting.
- Always check starter switch key function before
operating the machine every day:
1. start the engine and run it at slow idle;
2. turn the starter switch key to the OFF position
to confirm that the engine stops.
- If any abnormalities are found, be sure to repair
them before operating the machine.
• Check heat shields:
- Damaged or missing heat shields may lead to fires.
- Damaged or missing heat shields must be repaired
F1464
or replaced before operating the machine.
15501 9-35990
 SR2-2-24
SAFETY PRECAUTIONS

EVACUATING IN CASE OF FIRE

• If a fire breaks out, evacuate the machine in the

following way:

- Stop the engine by turning the starter switch key

to the OFF position if there is time;
- Use a fire extinguisher, if there is time;
- Exit the machine.

F3638

BEWARE OF EXHAUST FUMES

• Prevent asphyxiation. Engine exhaust fumes can

cause sickness or death.

- If you must operate in a building, be sure there is

adequate ventilation.
Either use an exhaust pipe extension to remove
the exhaust fumes or open doors and windows to
bring enough outside air into the area.

F1446
15501 9-35990
 SR2-2-25
SAFETY PRECAUTIONS

AVOID HEATING NEAR PRESSURIZED

FLUID LINES

• Flammable spray can be generated by applying heat

near pressurized fluid lines, resulting in severe burns
to yourself and bystanders.
- Do not heat by welding, soldering, or using a torch
near pressurized fluid lined or other flammable
materials.

• Pressurized lines can be accidentally cut when heat

goes beyond the immediate flame area.
- Install temporary fire resistant guards to protect
hoses or other materials when engaging in
welding, soldering, etc. F1470

AVOID APPLYING HEAT TO LINES

CONTAINING FLAMMABLE FLUIDS

- Do not weld or flame cut pipes or tubes that contain

flammable fluids.
- Clean them thoroughly with non-flammable solvent
before welding or flame cutting them. F5840

AVOID HIGH PRESSURE FLUIDS

• Avoid this hazard by relieving pressure before

disconnecting hydraulic or other lines. If inhaled,
these fumes may cause sickness.

- Avoid breathing potentially toxic fumes and dust.

- Do all such work outside or in a well-ventilated
area.
- Dispose of paint and solvents properly.
- Remove paint before welding or heating:
1. If you sand or grind paint, avoid breathing the
dust. Wear an approved respirator.
2. If you use solvent or paint stripper, remove
stripper with soap and water before welding.
F1446
Remove solvent or paint stripper containers
and other flammable material from area. Allow
fumes to disperse at least 15 minutes before
welding or heating.
15501 9-35990
 SR2-2-26
SAFETY PRECAUTIONS

PREVENT ACID BURNS

• Sulfuric acid in battery electrolyte is poisonous. It is

strong enough to burn skin, eat holes in clothing,
and cause blindness if splashed into eyes.
- Avoid the hazard by:
Filling batteries in a well-ventilated area.
Wearing eye protection and rubber gloves.
Avoiding breathing fumes when electrolyte is
added.
Avoiding spilling or dripping electrolyte.
Use proper jump start procedure.
- If you spill acid on yourself:
Flush your skin with water.
Apply baking soda or lime to help neutralize the
acid.
Flush your eyes with water for 10-15 minutes. F1474

Get medical attention immediately.

- If acid is swallowed:
Drink large amounts of water of milk. Then drink
milk of magnesia, beaten eggs, or vegetable oil.
Get medical attention immediately.

HANDLE FLUIDS - AVOID FIRES

• Handle fuel with care: it is highly flammable.

- Do not refuel the machine while smoking or near
open flame or sparks.
- Always stop engine before refueling machine.
- Fill fuel tank outdoors.

• All fuels, most lubrificants, and some antifreeze fluids

are flammable.
- Store flammable fluids away from fire hazards.
- Do not incinerate or puncture pressurized F1475

containers.
- Make sure machine is clean of trash, grease, and
debris.
- Do not store oily rags; they can ignite and burn
spontaneously.
15501 9-35990

F1457
 SR2-2-27
SAFETY PRECAUTIONS

PREVENT BATTERY EXPLOSIONS

• Battery gas can explode.

- Keep sparks, lighted matches, and flames away

from the top of battery.
- Never check battery charge by placing a metal
object across the posts.
Use a voltmeter or hydrometer.
- Do not charge a frozen battery; it may explode.
Warm battery to 16°C.

• Battery electrolyte is poisonous. If the battery should

explode, battery electrolyte may be splashed into
eyes, possibly resulting in blindness.
F1464
- Be sure to wear eye protection when checking
electrolyte specific gravity.

DISPOSE OF WASTE IN THE APPROPRIATE

MANNER

• Waste improperly disposed of represents a danger

for the envinronment. Potentially dangerous waste
used on the CASE excavators includes lubricants,
fuel, coolant, brake fluid, filters and batteries.

- Used sealed containers when discharging fluids.

Do not use containers for food or beverages which
may induce drinking.

- Do not spill waste over the ground, into drains, or

water beds. F1473

- Obtain information about the correct methods to

recycle or dispose of waste from local Authorities,
collection centres or your Dealer.
15501 9-35990
 SR2-2-28
SAFETY PRECAUTIONS

WORK IN A CLEAN AREA

• Before starting a job, clean the work area.

Remove objects that may be a safety hazard to the
mechanic or bystanders.

F5835

ILLUMINATE WORK AREA SAFELY

• Illuminate your work area adequately but safely.

- Use a portable safety light for working inside or

under the machine.

- Make sure the bulb is enclosed by a wire cage.

The hot filament of an accidentally broken bulb
can ignite spilled fuel or oil.

F1480

USE TOOLS PROPERLY

• Use tools appropriate to the work. Makeshift tools,
parts, and procedures can create safety hazards.
- Use power tools only to loosen threaded tools and
fasteners.
- For loosening and tighening hardware, use the
correct size tools.
- Do not use U.S. measurement tools on metric
fasteners.
- Avoid bodily injury caused by slipping wrenches.
15501 9-35990

• Use only recommended replacement parts. (See

F1479
PARTS CATALOG).
 SR2-3-1
SAFETY SIGNS

MONOBLOC BOOM VERSION

1. Decal, equipment safe area of operation.

2. Decal, upperstructure safe area of operation.
8. Transport hooking points.
12. Decal, lifting points.

12
12

2
1

F12617

8 8
15501 9-35990

F12916
 SR2-3-2
SAFETY SIGNS

ARTICULATED BOOM VERSION

1. Decal, equipment safe area of operation.

2. Decal, upperstructure safe area of operation.
8. Transport hooking points.
12. Decal, lifting points.

12
1

12 2

F12618

8 8
15501 9-35990

F12916
 SR2-3-3
SAFETY SIGNS

OFFSET BOOM VERSION

1. Decal, equipment safe area of operation.

2. Decal, upperstructure safe area of operation.
8. Transport hooking points.
12. Decal, lifting points.

12
12

F12619

8 8
15501 9-35990

F12916
 SR2-3-4
SAFETY SIGNS

ALL VERSIONS
13

3. Decal, no walking. 5
4. Decal, window lock.
5. Decal, reference to manuals.
6. Decal, warning to keep to a safety distance from
electrical lines.
7. Card, maintenance in progress.
9. Decal, control lock/unlock (safety lever).
6
10. Decal, warning of moving parts.
11. Decal, hydraulic oil system bleed. F6078

13. Biodegradable hydraulic oil level check plate Cab right side, inner
(optional)
LOCK 9

LOCK

F6079

F9542

Card, maintenance in progress

11 3 10

4
15501 9-35990

F7823
F6080
Rear glass cab, inner
 SR2-3-5
SAFETY SIGNS

1 - Decal, equipment safe area of operation

Make sure that exposed personnel in the area of

operation are clear of the machine before moving the
machine or its attachments. Sound horn.
Background: yellow
Stripe and lettering: black

F2455

2 - Decal, upperstructure safe area of

operation

Make sure that exposed personnel in the area of

operation are clear of the machine before moving the
machine or its attachments. Sound horn.
Background: yellow
Stripe and lettering: black

F2438

3 - Decal, no walking

Prohibition of walking on engine cowling.

Ignoring this prohibition could cause damages to
the engine cowling, as well as endangering the
safety of persons not obeying this rule.
Background: transparent
Edging and lettering: black

F2436
15501 9-35990
 SR2-3-6
SAFETY SIGNS

4 - Decal for window lock

It indicates the danger of injury deriving from incorrect

locking of front windshield in open position.
Background: yellow
Edge and graphics: black

F2437

5 - Decal, reference to manuals

It is positioned inside the cab to recommend the

careful reading of this manual prior to proceeding
with the starting, operation, maintenance, refuelling
or other interventions on the machine.
Background: yellow
Stripe and lettering: black

F2456

6 - Decal, warning to keep to a safe

distance from electrical lines

Always keep to a safe distance from electrical lines.

Also in case of work near overhead electrical lines,
keep to a safe distance.
Background: white and red
Edge and lettering: black

F6081
15501 9-35990
 SR2-3-7
SAFETY SIGNS

7 - Card, maintenance in progress

It is compulsory, for maintenance operators, to apply

a card warning about the immobilization of the
machine and the presence of personnel performing
maintenance in unseen positions. This card must be
located on the left pilot control or the cab door.
Background: yellow
Lettering: black
Edges: red

F2431

8 - Decal, transport hooking points

Indication of the four hooking points (two on front axle

and two on rear axle) to be used for machine
immobilization on the transport vehicle.
Background: white
Edging and lettering: black

F7732

9 - Decal, control lock/unlock

It indicates the control locking/unlocking positions of

safety lever.
It is imperative that should the operator leave the
cab with engine running, even for a very short time, LOCK
the safety lever must be moved to LOCK position.
Controls are disconnected and any accidental
equipment movement is impossible.
Background: white
Stripe and lettering: black
15501 9-35990

F2440
 SR2-3-8
SAFETY SIGNS

10 - Decal for engine hood warning

It indicates you have to stop the engine before

opening the hood.
Danger of serious injury due to rotating parts such
as fans, pulleys and belts.
Background: transparent
Stripe and graphics: black

F2435

11 - Decal, hydraulic oil system bleed

It indicates you have to bleed air from pumps after

replacing hydraulic oil.
Danger of pump seizure.
Background: yellow
Stripe and lettering: black

F3536

12 - Decal, lifting points

Indication of the four hooking points for machine

lifting.
Background: transparent
Stripe and graphics: black
15501 9-35990

F7733
 INDEX WX90 - 3 - 1

WX90

SECTION 3 CARATTERISTICAS AND DATA

INDEX

Group 1 - GENERALITY .................................................................................................SP3-1-1

1.1 Introduction
1.2 Basic components of the wheeled excavator with monobloc
1.3 Basic components of the wheeled excavator with triple articulation
1.4 Basic components of the wheeled excavator with offset digging arm
1.5 Dentification data

Group 2 - TECHNICAL SPECIFICATION ...................................................................... SP3-2-1

2.1 General specification

2.2 Dimension - monobloc version
2.3 Digging performances - monobloc version
2.4 Dimension - triple articulation version
2.5 Dimension - triple articulation version
2.6 Dimension - offset digging arm version
2.7 Digging performances - offset digging arm version
2.8 Digging performances - monobloc version with clamshell bucket
2.9 Digging performances - triple articulation version with clamshell bucket
2.10 Bucket usefulness depending on arm
2.11 Lifting capacities

Group 3 - FILLING CHART ............................................................................................ SP3-3-1

15501 9-35990
15501 9-35990
 SP3-1-1
GENERALITY WX90

1. GENERALITY

1.1 INTRODUCTION

The hydraulic excavator is essentially made of three main components: TURRET, WHEEL BASE and FRONT
EQUIPMENT.

This machine is entirely controlled by an hydraulic system.

The mechanical energy of the engine is transformed into hydraulic energy, actuating cylinders and hydraulic
motors, where it is reconverted into mechanical energy to perform an operation. In other words, travelling,
swinging the turret, digging and all other operations are performed using hydraulic power.

TURRET

FRONT
EQUIPMENT

F13249
15501 9-35990

WHEEL FRAME
 SP3-1-2
GENERALITY WX90

1.2 BASIC COMPONENTS OF THE WHEELED EXCAVATOR WITH MONOBLOC

6 7 9 8 18 10 17

F12628

3 2 1 15 11 16 14 13 12

1. Bucket 10. Counterweight

2. Link rod 11. Arm rotation cylinder (swing)
15501 9-35990

3. Linkage 12. Wheel assembly

4. Bucket cylinder 13. Rear axle
5. Arm 14. Cab and operator’s compartment
6. Arm cylinder 15. Carriage
7. Monobloc 16. Front axle
8. Fuel / hydraulic oil tank 17. Blade
9. Lifting cylinder 18. Hydraulic pump
 SP3-1-3
GENERALITY WX90

1.3 BASIC COMPONENTS OF THE WHEELED EXCAVATOR WITH TRIPLE ARTICULATION

6 7 10 9 19 8 20 11 18

F12629

3 2 1 16 12 17 15 14 13

1. Bucket 11. Counterweight

2. Link rod 12. Arm rotation cylinder (swing)
15501 9-35990

3. Linkage 13. Wheel assembly

4. Bucket cylinder 14. Rear axle
5. Arm 15. Cab and operator’s compartment
6. Arm cylinder 16. Carriage
7. Positioning arm 17. Front axle
8. Fuel / hydraulic oil tank 18. Blade
9. Lifting cylinder 19. Arm one
10. Positioning cylinder 20. Hydraulic pump
 SP3-1-4
GENERALITY WX90

1.4 BASIC COMPONENTS OF THE WHEELED EXCAVATOR WITH OFFSET DIGGING ARM

6 7 21 20 9 19 10 8 22 11 18

F12630

3 2 1 16 12 17 15 14 13

1. Bucket 12. Arm rotation cylinder (swing)

2. Link rod 13. Wheel assembly
15501 9-35990

3. Linkage 14. Rear axle

4. Bucket cylinder 15. Cab and operator’s compartment
5. Arm 16. Carriage
6. Arm cylinder 17. Front axle
7. Third element 18. Blade
8. Fuel / hydraulic oil tank 19. First element
9. Lifting cylinder 20. Second element
10. Arm angle cylinder 21. Link rod
11. Counterweight 22. Hydraulic pump
 SP3-1-5
GENERALITY WX90

I
1.5 DENTIFICATION DATA

15

3 14

13 12 11 10 F12605

1.5.1 WHEELED EXCAVATOR MARKING DECAL

15501 9-35990

1. Machine technical type. 9. Not applicable.

2. Homologation number. 10. Not applicable.
3. Identification number. 11. Machine manufacturing year.
4. Machine total mass allowable. 12. Engine power in kW.
5. Max. load on front axle. 13. Absorption coefficient.
6. Max. load on rear axle. 14. Frame identification number.
7. Not applicable. 15. Identification decal: diesel engine type and serial
8. Not applicable. number.
 SP3-1-6
GENERALITY WX90

NOTES:

15501 9-35990
 SP3-2-1
TECHNICAL SPECIFICATIONS WX90

2. TECHNICAL SPECIFICATIONS
2.1 GENERAL SPECIFICATIONS

2.1.1 ENGINE

Setting power (ISO/TR14396) ......................... 57 kW

Setting power (80/1269 CEE) ......................... 53 kW
Make and model .......................... PERKINS 1004.42
Type ................ diesel, 4 strokes, naturally-aspirated,
Rated speed .......................................... 2000 rev/min
Free speed during work ........................ 1800 rev/min
Number of cylinders .................................................4
Displacement .............................................. 4233 cm3
Bore and stroke ..................................... 103x127 mm
«Auto/Idling» device with engine automatic reset to
minimum speed with controls in neutral. The device
can be disconnected by hand with a suitable knob in
cab.
Electronic engine speed control through selector
knob.
Button E (Economy) to reduce fuel consumption.
Automatic cold start device for easy start-up down F0110A

to -18°C outside temperature.

2.1.2 HYDRAULIC SYSTEM

“Load Sensing” closed centre hydraulic system for

equipment control with CSS (Cross Sensing System)
type swing upperstructure circuit for perfectly
simultaneous movements.
SPC (Swing pressure Control) device for perfect
controllability and high operation comfort in
upperstructure acceleration/stop.
Main pumps: two variable displacement pumps:
equipment/travel control pump
- maximum output at 2000 rev/min ............. 150 I/min
- maximum operating pressure ..................... 350 bar
upperstructure swing control pump
- maximum output at 1800 rev/min ............... 50 I/min
- maximum operating pressure ..................... 310 bar
Cylinders:
- lifting ......................................................................1
bore x stroke ....................................... 100x750 mm
- penetration .............................................................1
bore x stroke ....................................... 100x750 mm
- positioner (triple articulation only) ..........................2
bore x stroke ......................................... 70x610 mm
15501 9-35990

- bucket ....................................................................1
bore x stroke ......................................... 70x750 mm
- swing ......................................................................1
bore x stroke ....................................... 100x550 mm
- blade ......................................................................2
bore x stroke ......................................... 80x200 mm
Cylinders with hydraulic end-of-stroke. Less equipment F8462

stress and higher operation comfort.

 SP3-2-2
TECHNICAL SPECIFICATIONS WX90

2.1.3 DRIVE LINE

With variable displacement hydraulic motor and two-

speed (work and transfer) transmission flanged to rear
axle. Work or transfer speed can be selected by means
of a selector in the cab only with the machine stopped.

Max. slope to
a a a
Hydraulic speeds 1 2 3 be overcome
Work speed Km/h: 0÷4 0÷7 0÷11 60 %
Transfer speed km/h: 0÷10 0÷20 0÷30 16 %

F0112A

2.1.4 CONTROLS

Controls operated by two crossed-direction levers that

operate all equipment shifts and upperstructure rotation.
A pedal controls forward and reverse travel. A safety
lever disconnects fully the equipment.

F8463
15501 9-35990
 SP3-2-3
TECHNICAL SPECIFICATIONS WX90

2.1.5 AXLES

Axles with oil bath disc brakes.

Rear axle steering fitted rigid.
Front axle steering and swinging:
total swing ............................................................ 15°
max. height ...................................................290 mm
The front axle can be hydraulically locked in any
position.

F8464

2.1.6 UPPERSTRUCTURE SWING

Swing motor ................................... with axial pistons

Swing brake ............................. automatic, with discs
Final reduction .......................... planetary, in oil bath
Slewing ring ....................................... in grease bath
Swing speed ............................................... 9 rev/min

F0735F
15501 9-35990
 SP3-2-4
TECHNICAL SPECIFICATIONS WX90

2.1.7 BRAKING SYSTEM

Service brakes: disc-type in oil bath, acting on the 4

wheels, with double independent circuit.
Parking brake: multiple disc type in oil bath.
Mechanically-operated by means of springs.
Disconnection by means of a hydraulic control.
Emergency brake: the two independent circuits allow
the emergency braking in case of failure of one circuit.
Working brake: acting on service brakes.

F10579

2.1.8 STEERING SYSTEM

Choice of three steering types:

2 steering wheels, 4 steering wheels, crab.
Choose a steering type by means of a special knob in
the cab. Wheel alignment signalled in the cab by a
warning light, steering mode signalled in the cab by
means of warning lights with ideograms.
Steering type ............... ORBITROL with safety valves
Pumps ........................................................ gear-type
Double rod and double effect cylinder. Possibility of
steering with engine off and excavator travelling.
Tyre outer steering radius:
Front axle steered .......................................6000 mm
Front and rear axle steered ......................... 3600 mm

F0120A

2.1.9 ELECTRICAL SYSTEM

15501 9-35990

Operating voltage ................................................ 24V

Maintenance-free series-mounted batteries ............2
- capacity .......................................................... 75 Ah
Alternator ........................................................... 55 A
Starter motor ..................................................... 4 kW
 SP3-2-5
TECHNICAL SPECIFICATIONS WX90

2.1.10 TYRES

Installation Inflation
Type Brand
dual pressure

8.25-20
BARUM coupled 6 bar
PR 14

500/45-20
ALLIANCE single 6 bar
PR 18
F6106gb

F2497

2.1.11OPERATING WEIGHTS (APPROX.)

Weight in working configuration: machine with 1850

mm dipstick, 0,145 m3 bucket, twin tyres, full tank and
operator.

Monobloc version:
Rear blade ................................................... 8850 kg.
Rear stabilizers ............................................ 8700 kg.
Rear stabilizers and front blade ................... 9200 kg.

Triple articulation version: F13250

Rear blade ................................................... 9030 kg.

Rear stabilizers ............................................ 8880 kg.
Rear stabilizers and front blade ................... 9380 kg.

Offset digging version:

Rear blade ................................................... 9100 kg.
Rear stabilizers ............................................ 8950 kg.
Rear stabilizers and front blade ................... 9450 kg.
15501 9-35990
 SP3-2-6
TECHNICAL SPECIFICATIONS WX90

2.2 DIMENSIONS (mm) - (MONOBLOC VERSION)

1165 1000 1025 1190 1000 1025

F12631
4290 4415

4 stabilizer version Front blade and rear stabilizer version

H F
B
L
C

G M A N
O Q F12632

Rear blade version

H F
E
L C

G M A P
I R F12633

Rear stabilizer version

15501 9-35990

ARM A B C D E F G H I L M N O P Q R

1850 2200 615 1120 1490 465 2410 1680 2950 2200 320 3650 1045 2200 1025 6905 6880

2200 2200 615 1120 1490 465 2290 1680 2950 2200 320 3635 1045 2200 1025 6895 6870
F5997gb
 SP3-2-7
TECHNICAL SPECIFICATIONS WX90

2.3 DIGGING PERFORMANCES (mm) - (MONOBLOC VERSION)

8 7 6 5 4 3 2 1 0

4
E

3 C

D
2
60°

0
60°

-1
F
B'
B
-2

-3

-4 2440

8 7 6 5 4 3 2 1 0
F12634
A'
A

ARM mm 1850 2200

A mm 7035 7367
A' mm 6814 7159
B mm 3635 3985
B' mm 3280 3669
C mm 6109 6303
15501 9-35990

D mm 4346 4540
E mm 3088 3114
F mm 2335 2640
BUCKET BREAKOUT FORCE kg 5400 5400
ARM
kg 4400 3900
BREAKOUT FORCE
F5998gb
 SP3-2-8
TECHNICAL SPECIFICATIONS WX90

2.4 DIMENSIONS (mm) - (TRIPLE ARTICULATION VERSION)

1165 1000 1025 1190 1000 1025

F12631
4290 4415

4 stabilizer version Front blade and rear stabilizer version

H
F
B
L C

G M A N
O Q F12635

Rear blade version

H
F
E
L C

G M A P
F12636
I R

Rear stabilizer version

15501 9-35990

ARM A B C D E F G H I L M N O P Q R

1850 2200 614 1120 1490 465 1925 1680 2950 2200 320 4333 1045 2200 1025 7038 7018

2200 2200 614 1120 1490 465 2500 1680 2950 2200 320 4332 1045 2200 1025 7037 7018
F6000gb
 SP3-2-9
TECHNICAL SPECIFICATIONS WX90

2.5 DIMENSIONS (mm) - (TRIPLE ARTICULATION VERSION)

8 7 6 5 4 3 2 1 0
8

6
E

4 C

3 D

2 60°

0 60°

-1
F
B' B
-2

-3

-4
2440
8 7 6 5 4 3 2 1 0 F12637
A'
A

ARM mm 1850 2200

A mm 7837 8183
A' mm 7645 8000
B mm 3746 4096
B' mm 3585 3946
C mm 7894 8222
15501 9-35990

D mm 6027 6355
E mm 3238 3464
F mm 3238 3464
BUCKET BREAKOUT FORCE kg 5400 5400
ARM
kg 4400 3900
BREAKOUT FORCE
F6001gb
 SP3-2-10
TECHNICAL SPECIFICATIONS WX90

2.6 DIMENSIONS (mm) - (OFFSET DIGGING ARM VERSION)

1165 1000 1025 1190 1000 1025

F12631
4290 4415

4 stabilizer version Front blade and rear stabilizer version

H F

B
L C

G M A N
F12638
O Q

Rear blade version

H F

E
L C

G M A P
F12639
I R

Rear stabilizer version

15501 9-35990

ARM A B C D E F G H I L M N O P Q R

1850 2200 614 1120 1490 465 2613 1680 2950 2200 320 3646 1045 2200 1025 6891 6871

2200 2200 614 1120 1490 465 2613 1680 2950 2200 320 3680 1045 2200 1025 6925 6905
F6003gb
 SP3-2-11
TECHNICAL SPECIFICATIONS WX90

2.7 DIGGING PERFORMANCES - (OFFSET DIGGING ARM VERSION)

7 6 5 4 3 2 1 0
7

3
C

2 D 60°

0 60°

F
-1
B'
B
-2
2120

-3

-4
2440
7 6 5 4 3 2 1 0
A'
F12640
A

ARM mm 1850 2200

A mm 6875 6976

A' mm 6648 6845

B mm 3625 3973

B' mm 3497 3572

15501 9-35990

C mm 5601 5728

D mm 3977 4102

F mm 1730 2060

BUCKET BREAKOUT FORCE kg 5400 5400

ARM
kg 4400 3900
BREAKOUT FORCE
F6004gb
 SP3-2-12
TECHNICAL SPECIFICATIONS WX90

2.8 DIGGING PERFORMANCES - (MONOBLOC VERSION WITH CLAMSHELL BUCKET)

9 8 7 6 5 4 3 2 1 0

7
E
6

2 C

-1

-2 B' B

-3

-4

-5
9 8 7 6 5 4 3 2 1 0 F12641

NOTE: Digging performances depend on the features of the clamshell bucket used, chosen according to the
machine lifting capacity and version.

ARM mm 1850 2200

A mm 6770 7100
15501 9-35990

B mm 4570 4920

B' mm 4140 4488

C mm 3731 4024

E mm 3538 3566
F6002gb
 SP3-2-13
TECHNICAL SPECIFICATIONS WX90

2.9 DIGGING PERFORMANCES - (TRIPLE ARTICULATION VERSION WITH CLAMSHELL

BUCKET)

9 8 7 6 5 4 3 2 1 0
9

E
7

3
C
2

-1

-2 B' B

-3

-4

-5
9 8 7 6 5 4 3 2 1 0
F12642
A

NOTE: Digging performances depend on the features of the clamshell bucket used, chosen according to the
machine lifting capacity and version.

ARM mm 1850 2200

A mm 7469 7802
15501 9-35990

B mm 4647 4988

B' mm 4216 4557

C mm 5323 5616

E mm 3634 3860
F7763gb
 SP3-2-14
TECHNICAL SPECIFICATIONS WX90

BACKHOE BUCKETS

Capacity SAE (m3) 0.100 0.120 0.140 0.160 0.240 0.310 0.360

Width (mm) 300 350 400 450 600 750 850

Weight (kg) 117 125 138 145 170 200 220

Number of teeth 2 2 3 3 4 4 5

Radius at the teeth points (mm) R = 1050

Type of teeth ESCO SUPER V19

15501 9-35990
 SP3-2-15
TECHNICAL SPECIFICATIONS WX90

2.11 LIFTING CAPACITY

2.11.1 READING KEY FOR THE LIFTABLE LOAD CHART LOCATED IN THE CAB

F12607

1. Boom length.

2. 2nd boom length “LD”, alternatively.

3. Load distance from pivot point.

4. Maximum liftable load in tons to roll-over limit as

per ISO 10567 Standards.

5. Maximum liftable load in tons at maximum distance

from pivot point.

6. Maximum working distance from pivot point

7. Counterweight weight.

8. Main relief valve/hydraulic safety valves pressure

setting.
15501 9-35990
 SP3-2-16
TECHNICAL SPECIFICATIONS WX90

2.11.2LIFTABLE WITH BUCKET LOAD CHART

NOTE: Lift loads as per ISO 10567 Standards (75%
stability, 87% hydraulic system). On 360° with
oscillating axle locked and blade/stabilizers lifted
from the ground.
NOTE: If is necessary to lift of a load with the machine
equipped with some or all the above mentioned parts
(bucket, hooks, etc.), subtract their weight from the
weights shown on the chart. This is done to calculate
the lifting working capacity.

max lift max

WX90M (Monobloc boom) 3m 4,5 m 6m
load distance

Dipper Z2 0.81* t 1.11 t — 0.78 t 5.69 m

1850 mm Z1 0.99 t 0.94 t — 0.76 t 5.71 m
Boom (bucket 145 dm3)
Z3 1.93 t — — 1.38 t 3.82 m

3000 mm Dipper Z2 1,22* t 1.12 t — 0.72 t 5.95 m

2200 mm Z1 0.95 t 0.88 t — 0.70 t 5.97 m
(bucket 145 dm3)
Z3 2.09 t — — 1.58 t 3.49 m
F12612gb

* Value limited by the hydraulic system.

max lift max

WX90T (Ar ticulation boom) 3m 4,5 m 6m
load distance

Dipper Z2 1.97 t 1.01 t 0.64 t 0.49 t 6.97 m

1850 mm Z1 1.65 t 0.89 t 0.59 t 0.48 t 6.99 m
Boom Positioner (bucket 145 dm3)
Z3 1.73 t 0.91 t 0.60 t 0.59 t 6.08 m
1895 1900 Z2 20.9 t 1.03 t 0.64 t 0.44 t 7.32 m
mm mm Dipper
2200 mm Z1 1.61 t 0.87 t 0.57 t 0.43 t 7.34 m
(bucket 145 dm3)
Z3 1.67 t 0.89 t 0.59 t 0.57 t 6.15 m
F12611gb

max lift max

WX90EX (Offset boom) 3m 4,5 m 6m
load distance

Dipper Z2 2.06 t 1.08 t — 0.70 t 5.75 m

1850 mm Z1 1.63 t 0.40 t — 0.66 t 5.73 m
15501 9-35990

Boom (bucket 145 dm3)

Z3 1.69 t — — 1.12 t 3.93 m

2880 mm Dipper Z2 — 1.11 t 0.65 t 0.63 t 6.08 m

2200 mm Z1 1.61 t 0.88 t 0.61 t 0.60 t 6.06 m
(bucket 145 dm3)
Z3 1.64 t — — 0.90 t 4.46 m
F12613gb
 SP3-2-17
TECHNICAL SPECIFICATIONS WX90

LIFTABLE TO BUCKET HOOKING PIN LOAD CHART

NOTE: Lift loads as per ISO 10567 Standards (75%
stability, 87% hydraulic system). Load at the hook
(hook, reverse cylinder, bucket, rod, idler gear, etc.
excluded) on 360° with oscillating axle locked and
blade/stabilizers lifted from the ground.
NOTE: If is necessary to lift of a load with the machine
equipped with some or all the above mentioned parts
(bucket, hooks, etc.), subtract their weight from the
weights shown on the chart. This is done to calculate
the lifting working capacity.

max lift max

WX90M (Monobloc boom) 3m 4,5 m 6m
load distance

Z2 — 1.26 t — 0.90 t 5.73 m

Dipper
1850 mm Z1 1.08 t 1.04 t — 0.89 t 5.76 m
Boom Z3 — — — — —

3000 mm Z2 — 1.37 t — 0.84 t 5.99 m

Dipper
2200 mm Z1 1.01 t 0.98 t — 0.83 t 6.01 m
Z3 1.67 t — — 1.29 t 4.33 m
F12614gb

max lift max

WX90T (Ar ticulation boom) 3m 4,5 m 6m
load distance

Z2 — 1.15 t 0.78 t 0.63 t 6.88 m

Dipper
1850 mm Z1 1.87 t 1.05 t 0.73 t 0.62 t 6.90 m
Boom Positioner
Z3 1.96 t — — 1.24 t 4.19 m
1895 1900 Z2 — 1.17 t 0.78 t 0.58 t 7.23 m
mm mm Arm
2200 mm Z1 1.82 t 1.04 t 0.72 t 0.57 t 7.25 m
Z3 — 1.05 t — 0.63 t 5.29 m
F12615gb

max lift max

WX90EX (Offset boom) 3m 4,5 m 6m
load distance

Z2 2.16 t 1.21 t — 0.82 t 5.78 m

Dipper
Z1 1.81 t 1.05 t — 0.79 t 5.76 m
15501 9-35990

1850 mm
Boom Z3 1.88 t — — 1.27 t 3.98 m

2880 mm Z2 2.27 t 1.23 t 0.78 t 0.76 t 6.09 m

Dipper
2200 mm Z1 1.79 t 1.04 t 0.75 t 0.73 t 5.99 m
Z3 1.83 t — — 1.06 t 4.48 m
F12616gb
 SP3-2-18
TECHNICAL SPECIFICATIONS WX90

NOTES:

15501 9-35990
 SP3-3-1
FILLING CHART WX90

3. FILLING CHART
QUANTITY RECOMMENDED FLUIDS AND LUBRICANTS

COMPONENT TO BE FILLED MANUFACTURER'S INTERNATIONAL

Litres Ambra SPECIFICATIONS SPECIFICATIONS NOTES

Protective fluid to be mixed

with water at 50%. This mix
has anticorrosive,
18.5 AGRIFLU NH 900 A _ antiscaling, and anti-foaming
Engine cooling system
properties; does not freeze
down to -35° C.

147 _ _ Diesel ASTM _

Fuel tank
N. 2-D tipo TT
SUPER GOLD Multigrade oil for aspirated
15W-40 NH 330 G or turbochargerd diesel
8.5 API CF-4/SG
Engine engine of every types and
CCMC D4
SUPER GOLD powers.
NH 324 G MIL-L-2104 E
10W-30

1.2 HYPOIDE QFH 520 B API GL 5

Gearbox MIL-L-2105 D _
90/LS

Gear oil with Estreme

Swing reduction unit 3 HYPOIDE 90 NH 520 A API GL 5 Pressure (E.P.) perfor-
MIL-L-2105 D mance.

Front axle differential 7 API GL 5

HYPOIDE QFH 520 B
Rear axle differential 7 MIL-L-2105 D _
90/LS
Axle reduction gears (each) 0.9

HI-TECH 46 _ High viscosity lubricant

Attachment hydraulic system (**)
Pressure grease fittings
Swing joint teeth
QFH 583/HD
for excavators and
120
earthmoving machine
_ hydraulic controls.
Lithium-based grease
_ containing molybdenum
MG2 QFH 585/GR _ disulphide, resists to
5 kg (*) water, low temperature
and high loads; NLGI 2
consistency.

Oil quantities shown are necessary for periodical changes following discharging and filling procedures detailed for each assembly.
(*) First filling only.

LUBRICANT TYPE OPERATING RANGE (AMBIENT TEMPERATURE °C)

TO BE FILLED Ambra VISCOSITY -30 -20 -10 0 10 20 30 40 50

Engine SUPER GOLD SAE 15W - 40

15W-40

SUPER GOLD SAE 10W - 30

10W-30

Gearbox HYPOIDE 90/LS SAE 80W - 90

Swing reduction unit HYPOIDE 90 SAE 80W - 90

15501 9-35990

Front/rear axle differential HYPOIDE 90/LS SAE 80W - 90

Axle reduction gears (each)

Hydraulic system HI-TECH 46 ISO VG 46

(**) IMPORTANT: if the machine has been filled with biodegradable hydraulic oil PANOLIN AG.-HLP SYNTH 46 (opt), be informed that this
oil cannot be mixed with mineral hydraulic oil. Carefully follow the use indications detailed in the section VARIANTS of this manual. In case
of doubts, refer to the dealer.
 SP3-3-2
FILLING CHART WX90

NOTES:

15501 9-35990
 INDEX WX90 - 4 - 1

WX90

SECTION 4 SUPERSTRUCTURE

INDEX

Group 1 - SUPERSTRUCTURE ................................................................................... S-S4-1-1

1.1 Main frame and counterweight

1.2 Engine group
1.3 Hydraulic oil reservoir
1.4 Fluel reservoir
1.5 Cover and protections
1.6 Cab group
1.7 Cab heater
1.8 Cab electric components
1.9 Chassis elecric components
1.10 Superstructure maintenance
1.11 Superstructure hydraulic system piping

Group 1A - FLEXIBLE HOSES AND CONNECTIONS ................................................ S-S4-1A-1

1A.1 Flexible hoses and connections

Group 2 - HYDRAULIC PUMP - O/P - D/A ................................................................ HYP4-2-1

2.1 Hydraulic pump - O/P

2.2 Main pump - O/P
2.3 Secondary pump - O/P
2.4 Gear double pump - O/P
2.1 Main pump - D/A
2.2 Secondary pump - D/A
2.3 Gear double pump - D/A

(to be continued)
15501 9-35990

O/P = OPERATION PRINCIPLE

D/A = DISASSEMBLY AND ASSEMBLY
 INDEX WX90 - 4 - 2
INDEX ( continues)

Group 3 - CONTROL VALVES - O/P - D/A ................................................................... CV4-3-1

3.1 Main control valve - O/P

3.2 Rotation control valve - O/P
3.1 Main control valve - D/A
3.2 Rotation control valve - D/A

Group 4 - SWING DEVICE - O/P - D/A ....................................................................... SRD4-4-1

4.1 Swing device - O/P

4.2 Swing hydraulic motor - O/P
4.3 Swing reduction device - O/P
4.1 Swing hydraulic motor - D/A
4.2 Disassembly and assembly of swing reduction device - D/A

Group 5 - PILOT VALVES - O/P .................................................................................... PV4-5-1

5.1 Hand pilot valve - O/P

5.2 Pedal - O/P

Group 6 - CENTER JOINT - O/P - D/A .......................................................................... CJ4-6-1

6.1 Center joint - O/P

6.1 Disassembly and assembly of center joint - D/A

Group 7 - STERING VALVE - O/P - D/A ...................................................................... SV4-7-1

7.1 Stering valve - O/P

7.1 Stering unit disassembly and assembly - D/A

Group 8 - BRAKE PEDAL VALVE - O/P - D/A ............................................................ BRV4-8-1

8.1 Brake pedal valve - O/P

8.1 Maintenance - D/A
8.2 Brake pump disassembly - assembly - D/A

Group 9 - ACCUMULATORS - O/P - D/A ................................................................... ACC4-9-1

9.1 Accumulators - O/P

9.1 Disassmbly and assembly of accumulator - D/A

Group 10 - SOLENOID VALVES - O/P ....................................................................... SOV4-10-1

15501 9-35990

10.1 Selector solenoid valves - O/P

10.2 Service solenoid valve group - O/P
10.3 Stering type control solenoid valve - O/P
10.4 Power control disconnection solenoid valve (with flow divider) - O/P
10.5 Solenoid valve for clamshell bucket rotation control - O/P

O/P = OPERATION PRINCIPLE

D/A = DISASSEMBLY AND ASSEMBLY0
 SS4-1-1

SUPERSTRUCTURE WX90

1. SUPERSTRUCTURE

1.1 MAIN FRAME AND COUNTERWEIGHT

1.1.1 CONSTRUCTION

Main frame consists of center frame, bed (right, left) and tail frame.
They are welded together.
Swing device and control valve are installed to the center frame. Operator's cab and hydraulic oil tank are
mounted on the left bed.
Fuel tank is mounted on the right bed.
Engine, pumps and counter weight are mounted on the tail frame.

1.1.2 SPECIFICATIONS AND DATA

Main frame .......................................... 800 kg

Counterweight ........................... 1650 ± 30 kg

1 - Counterweight
2 - Main frame

2 1
15501 9-35990

F8461
 SS4-1-2

SUPERSTRUCTURE WX90

1.2 ENGINE GROUP

1.2.1 CONSTRUCTION AND FUNCTION

Engine

The PERKINS 1004.42 type engine is used in this excavator.

This engine is a 4-cylinder of 4233 cm3, direct injection, water-cooled and naturally aspirated.
The engine is mounted on the main frame through for elastic supports (two front and two rear) of a silent-block
type.

15501 9-35990

F8481
 SS4-1-3

SUPERSTRUCTURE WX90

Radiator

The coolant radiator is located in front of the engine, together with the oil heat exchanger and it is cooled by
the engine fan.
A temperature sensor of the coolant, inserted into the coolant radiator body, informs the operator, through a
specific indicator on the monitor located in the cab, that an excessive temperature has been reached.

1 - Oil radiator
2 - Coolant radiator
3 - Level tank
4 - Filling plug

3
15501 9-35990

F8482
 SS4-1-4

SUPERSTRUCTURE WX90

Air cleaner

The air cleaner consists of a plate outer case (C), a main cleaning element (A), a relief filter element (B), an
outlet for an air clogging switch.
This machine is provided with an air cleaner warning lamp which lights up the monitor panel when the air
cleaner’s element becomes clogged.

Clogging switch

C
15501 9-35990

F8483
 SS4-1-5

SUPERSTRUCTURE WX90

Exhaust gases silencer

The gases generated during the combustion are sent, through the turbocharger, to the exhaust silencer (1)
and from the latter, they are discharged through duct (2) away from the machine.

1
15501 9-35990

F8484
 SS4-1-6

SUPERSTRUCTURE WX90

1.2.2 SPECIFICATIONS

Engine

Mark and Model PERKINS 1004.42

Type diesel, 4 cycle, vertical on-line, overhead valves, direct
injection, naturally aspirated and water-cooled.

Numbers of cylinder - Bore x stroke 4 (on line) - 103 x 127 mm

Displacement 4233 cm3

Release sequence 1-4-2-3

Rotation direction Clockwise (viewed from fan side)

- Cooling system Water circulated by centrifugal pump

Maximum operating temperature control: 103° C

- Starting motor Pinion shift system

Voltage/Output 24V 4kw

- Generator AC generator belt drive

Voltage/Output 24V 40A

- Super charging system

Injection pump LUCAS

Radiator

- Radiator area 18.5 dm2

Oil cooler

- Radiator area 14.6 dm2

Air Filter

- Elements Two: main cleaning element and relief filter element

- Air flow rate 280 m3/h

15501 9-35990
 SS4-1-7

SUPERSTRUCTURE WX90

1.3 HYDRAULIC OIL RESERVOIR

1.3.1 LAY-OUT AND OPERATION

Oil reservoir

Hydraulic oil reservoir is separated inside by a panel which divides it into two parts: the part where the pump
sucts and the part where the oil returns.
Inside the reservoir, the full flow oil filter is located in the return part.
Remove cover (2) to gain access to oil filter.
Plug (10) is used for oil filling.
Valve (12) self-pressurizes the reservoir (0,35 bar) and allows air flow inside of it when necessary (0,01÷0,03
bar).
Plug (15) is used to empty the reservoir.
The two glass holes (9) show oil level, which should never be lower then the lower mark but should touch the
upper mark during check.
For oil level correction or check, refer to what specified in the use and maintenance manual.

Oil reservoir is self-pressurized.

Each time a pipe, a fitting or a plug should be removed, depressurize by untightening valve (12).

Pressurization valve
- Inlet valve opening pressure: 0,010÷0,03 bar
- Pressurization valve opening pressure: 0,35 bar

8 10

12

1 - Tank
2 - Filter cover
8 - Hydraulic oil filter
9 - Level
10 - Filling plug
15501 9-35990

12 - Pressure valve
15 - Drain plug

15

F8485
 SS4-1-8

SUPERSTRUCTURE WX90

1.3.2 HYDRAULIC OIL FILTER

Description

The filter is located in a compartment within the hydraulic tank so that all of return oil passes through the filter
to reach the tank. The filter is secured to the tank with three brackets (2) tightened with screws(3).

4 1
2
5 3

11
7 10
9
8
001/63

1 - Bridge 7 - Shell
2 - Bracket 8 - Central stud bolt
3 - Screw 9 - Nut
4 - Rod 10 - Spring holder
5 - Magnetic disc 11 - Bypass spring
6 - Filter cartridge
15501 9-35990
 SS4-1-9

SUPERSTRUCTURE WX90

1.3.3 SPECIFICATIONS AND DATA

Oil tank

- Oil capacity 80 l
- Weight 74 kg
- Filtering cartridge 10 µm
- Filter average delivery 390 l/min.
- Filter bypass opening pressure 1,5 bar

Structure and function

On bridge (1) four rods (4) are fitted on which magnetic discs (5) are installed with the interposition of non
magnetic rings.
These rods (4) are contained on the filter element through which the fluid flows to the tank. When the fluid flows
to rods (4), magneti particles are splitted.
In this way some solid particles are held before the fluid reaches filter cartridge (6), enabling the filter to operate
efficiently for longer periods.
Through filter cartridge (6) and holes on shell (7) bottom, fluid reaches the tank.
Should the build-up of impurities cause a back pressure in the return line greater than maximum allowable
limit, the filter element can be axially moved along central stud bolt (8), enabling its bypass.
During bypass magnetic disc (5) continues to operate and its special design allows any filtered impurity to
remain in the filter body and not to reach the tank.

Disassembly - assembly of oil filter

Remove external tank cap by untightening fixing screws.

Loosen screws (3) fixing bridge (1) by brackets (2). Turn brackets to allow filter removal.
Lift filter element assembly leaving shell (7) inside the tank.
Remove filter element untightening nut (9) to free spring holder (10) and spring (11). Remove filter cartridge (6).
Clean magnetic disc (5) and rod (4) with a brush.

Reassembly

Assembly a new filter cartridge (7), make sure that all of seals are in good condition and reassemble by
reversing the disassembly procedure.

Maintenance

Replace filter cartridge (6) every 500 hours.

CAUTION Hydraulic oil filling and topping up should be made through the filter only.
For this purpose a cap (1) is provided on tank cover (2), thus ensuring that all of oil is correctly filtered.
No other filling method Is allowed.
15501 9-35990
 SS4-1-10

SUPERSTRUCTURE WX90

1.4 FUEL RESERVOIR

1.4.1 CONSTRUCTION AND FUNCTION

The fuel reservoir is equipped with a strainer in the filler neck and a level indicator, and is also equipped with
a fuel level sensor connected to the relevant indicator, a reserve indicator, located on the monitor in the cab.
For the sensor and indicator, refer to Section 9.

1.4.2 SPECIFICATIONS AND DATA

Fuel capacity ........................................... 147 l

Tank body weight ................................. 119 kg

1 - Fuel reservoir
2 - Strainer
3 - Filler cap
4 - Fuel level indicator
5 - Fuel level sensor
6 - Draining valve
7 - Fuel filter 3

5 4

F8656

6
15501 9-35990

7
 SS4-1-11

SUPERSTRUCTURE WX90

1.5 COVERS AND PROTECTIONS

1.5.1 VARIOUS COVERS ON THE SUPERSTRUCTURE

The various cowlings on the superstructure have the purpose of protecting the hydraulic components from
rain, dust and the danger of possible damages caused by external obstructions.

7 2

F13251
15501 9-35990

1 - Right-hand door
2 - Battery case door
3 - Left-hand door
5 - Central protection
6 - Gas filled jack
7 - Central door
8 - Central hood
 SS4-1-12

SUPERSTRUCTURE WX90

1.5.2 ENGINE COVER

The engine cover is installed to protect the engine from damages from external obstructions.

1 - Engine cover
2 - Lock
3 - Gas filled jack

15501 9-35990

F13317
 SS4-1-13

SUPERSTRUCTURE WX90

1.5.3 LOWER PROTECTION

The lower protections have the purpose of protecting the hydraulic components from dust and the danger of
possible damages caused by external obstructions.

1 - Lower protection, cab (front)

4 - Lower protection, pumps
5 - Lower protection, fuel reservoir
6 - Protection, water tank
7 - Protection, engine oil pump

1 6 F8668
15501 9-35990
 SS4-1-14

SUPERSTRUCTURE WX90

1.6 CAB GROUP

1.6.1 CONSTRUCTION

The cab group includes: cab, seat, steering and controls column, floor plate and carpet. The entire group is
mounted on anti-vibration elastic blocks.

Cab

The cab is totally designed to suit the operator’s comfort, in accordance with ISO standards, with an optimized
sound proofing level. The dimensions of the glassed surfaces offer an excellent visibility in all directions.

1 3

F8653
15501 9-35990

1 - Outer door opening handle

2 - Inner door opening handle
3 - Door locking mechanism in "open" position
4 - Door unlocking mechanism from "open" position
5 - Windshield locking latch in "closed" position
6 - Windshield locking latch in "open" position
7 - Windshield unlocking from "open" position
 SS4-1-15

SUPERSTRUCTURE WX90

Operator’s seat

The operator’s seat has been designed to offer maximum comfort. It incorporates adjustable armrests, an
adjustable backrest angle, back support adjustment, longitudinal adjustment (forward and backward),
longitudinal shock absorbing adjustment. Also, it is equipped with a seat shock absorber system operating
in accordance with the weight of the operator.

1 - Graduated scale for shock absorption -

weight adjustment
2 - Fore-and-aft adjustment lever
4 - Lever for seat shock absorption 7
5 - Back adjustment lever
6 - Armrest adjustment control lever
7 - Headrest adjustment control lever

5 6
2
4
1 F8658

Steering and control column

The controls for the operation of the machine are

grouped around the operator’s seat, inside the
cab.
1 - Monitor panel. 10 18 6 23 11 12
2 - Switch panel.
3 - Control pedals for travel/articulated arm.
1
4 - Lifting and bucket control lever.
5 - Control lever for dipstick and
2
upperstructure swing.
17
6 - Steering wheel.
7 - Brake pedal. 7 24
8 - Upperstructure swing lock. 3
9 - Seat 5 4
10 - Windshield wiper and washer control. 8
21
11 - Control for direction indicator and lights. 9 20 22 19 14
12 - Gear selection control.
14 - Start-up key.
15 - Mode E (economy) switch. 15
16 - Manual accelerator.
15501 9-35990

17 - Horn. 16
18 - Emergency lights switch.
19 - Rotating beacon. F13252

20 - Tipping device switch.

21 - Manoeuvre lock switch.
22 - Optional.
23 - Commutator: brakes and axle lock.
24 - Immobiliser (antitheft device).
 SS4-1-16

SUPERSTRUCTURE WX90

Floor plate

The control devices, the seat group as well as the heater are secured to the floor plate.

1 - Floor plate
2 - Floor mat
3 - Elastic supports
4 - Soundproof panel

4
F8654
15501 9-35990

Elastic supports

Four elastic supports ensure a solid mounting of the cab on the frame of the machine and, at the same time,
minimize the vibrations generated during the operation of the excavator.
 SS4-1-17

SUPERSTRUCTURE WX90

1.7 CAB HEATER

1.7.1 Construction

The machine is provided with a cab heater which consist of hoses connected to engine and of a control
located on the right rear side of the cab.
Before the heater is switched on, open the water cocks on engine. When heating system is not in use, keep
the water cocks on engine block shut.

1 - Electric fan
3 - Cover
4 - Heater
5 - Condensation container

F8669
15501 9-35990

1.7.2 Specifications and data

Heating power ................................................................................................................ 4640 ± 10% Kcal/h

Air flow ................................................................................................................................ 510 ± 10% m3/h
 SS4-1-18

SUPERSTRUCTURE WX90

1.8 CAB ELECTRIC COMPONENTS

(A) Cab electric components location.

(For further informations about electric components see section 8).

4 7

F8661

1
15501 9-35990

1 - Radio set
2 - Antenna
3 - Speaker
4 - Windshield washer with electric motor
5 - Wiper motor
6 - Lighter
7 - Ceiling light
 SS4-1-19

SUPERSTRUCTURE WX90

(B) Cab electric control location.

1 - Left pilot valve switches

2 - Right pilot valve switches
3 - Control panel
4 - Left-hand panel
5 - Starting key switch
6 - Right-hand panel
7 - Central panel
8 - Wiper switch
9 - Speed change control
10 - Light switch
11 - Immobiliser (antitheft device).

10

5
3
11
8

4
15501 9-35990

F13609
 SS4-1-20

SUPERSTRUCTURE WX90

1.9 CHASSIS ELECTRIC COMPONENTS

1.9.1 POWER SUPPLY AND STARTER

F8662

1 - Battery
15501 9-35990

2 - Ground cable
3 - Battery disconnection
4 - Main fuse (40A)
5 - Battery cable/Starter cable
6 - Start relay fuse (80A)
7 - Starter ground
8 - Starter motor
 SS4-1-21

SUPERSTRUCTURE WX90

1.9.2 THROTTLE CONTROL AND ALTERNATOR

1 - SMC control unit

2 - EC motor
4 - Alternator

F13253
15501 9-35990
 SS4-1-22

SUPERSTRUCTURE WX90

1.9.3 SWITCHES AND SENSORS LOCATION

(A) Engine and radiator.

3 - Engine oil pressure switch

4 - Engine oil level sensor
5 - Cooling temperature sensor

F8663

B) Fuel tank and hydraulic tank.

2
15501 9-35990

F8665 1 - Fuel level sensor

2 - Hydraulic oil level sensor
 SS4-1-23

SUPERSTRUCTURE WX90

(C) Brake valve

2 - Brake light control pressure switch

F10580

D) Hydraulic system

1 - Pressure switch 2
2 - Pressure switches
2
2

F8671

((E) Air cleaner

1 - Air cleaner clogging switch

15501 9-35990

F8672
 SS4-1-24

SUPERSTRUCTURE WX90

1.9.4 ROAD AND WORK LIGHTS LOCATION

1 - Direction light
2 - Head-light
4 - Tail light
5 - Reflector
6 - Horn
7 - Work light
8 - Stop/parking lights
6

7
2
1

4
15501 9-35990

8 8

4
F13254
 SS4-1-25

SUPERSTRUCTURE WX90

1.9.5 SPECIFICATIONS AND DATA

• BATTERY
- Voltage 12V
- Rating 75 Ah
- Discharge current 420A
- Weight with electrolyte 23 kg

• BOOM HEAD-LIGHT
-Voltage and watt Halogen 24 V, 70 W

• ROAD HEAD-LIGHT
- Voltage and watt 24 V, 4 W - 24 V, 70 W

• ROAD TAIL LIGHT

- Voltage and watt 24 V, 21 W

• DIRECTION LIGHT
- Voltage and watt 24 V, 4 W

• CEILING LIGHT
- Voltage and watt 24 V, 5 W

• RADIO
- Voltage 24 V

• SPEAKER
- Allowable input (rated) 10 W
(max.) 20 W
- Rated impedance 4 ohm

• WIPER MOTOR
- Rated voltage and current 24 V, 2 A

• IMMOBILISER (antitheft device)

- Rated voltage 24 V
- Operation temperature -25° ÷ +80°C
15501 9-35990
 SS4-1-26

SUPERSTRUCTURE WX90

NOTES:

15501 9-35990
 SS4-1-27

SUPERSTRUCTURE WX90

1.10 SUPERSTRUCTURE MAINTENANCE

1.10.1 CAB REASSEMBLY/ASSEMBLY

Reassembly

1 Position the machine with the bucket resting on the

ground.
Stop the engine.

F8882

2 Move away steering wheel (1) from the seat

1
operating lever (2), to change steering wheel
inclination.

20
10
30

F8488

3 Remove air duct pipe (3) from the cab.

3
15501 9-35990

F8494
 SS4-1-28

SUPERSTRUCTURE WX90

4 Disconnect cable connectors (11, relay), (12, an-

tenna, ceiling light, windshield wiper) and (13,
loudspeakers) in the cab rear part and ground cable 12 13
(14) inside the cab.

14 14 F7420

5 Remove plugs (21) from air duct cover (16).

Untighten screws (17) to remove air duct cover (16). 21 17 16

F7413

6 Push air duct (18) towards the cab rear part until it
comes out of the coupling and remove it.

18
15501 9-35990

Duct coupling F8883

 SS4-1-29

SUPERSTRUCTURE WX90

7 Attach the cab to the hoist by using lifting belts.

WARNING
Cab approx. weight: 250 kg.

F7415

8 Remove screws (19) and nuts (22).

22
19
22

F8884

9 Carefully remove the cab.

15501 9-35990

F7417
 SS4-1-30

SUPERSTRUCTURE WX90

NOTES:

15501 9-35990
 SS4-1-31

SUPERSTRUCTURE WX90

Cab assembly

WARNING
Cab approx. weight: 250 kg.

1 Attach the cab to the hoist by using lifting belts.

Lift the cab and place it on the main frame.

F7417

2 Tighten screws (19) and nuts (22).

22
19
22

F8884

3 Connect cable connectors (11, relay), (12, anten-

na, ceiling light, windshield wiper) and (13,
loudspeakers) in the cab rear part and ground 12 13
cable (14) inside the cab.
15501 9-35990

14 14 F7420
 SS4-1-32

SUPERSTRUCTURE WX90

4 Push air duct (18) towards the cab front part and fit
it into the coupling duct.

18

Duct coupling F8883

5 Install air duct cover (16) and secure it with screws

(17). Plug (21) access holes to screws (17). 21 17 16

F7413

15501 9-35990
 SS4-1-33

SUPERSTRUCTURE WX90

1.10.2 COUNTERWEIGHT REASSEMBLY/ASSEMBLY

Reassembly

1 Swing the turret 90° with respect to the undercarriage

and position the equipment with the bucket on the
ground.
Stop the engine.

F13255

1
2 Remove the engine cowling removing the four
screws (1) and the two jacks (2) inside the engine
1
compartment.
Disconnect the lights electric connections.
2

F13256

3 Remove water-oil cooler protection (3).

3
15501 9-35990

F13257
 SS4-1-34

SUPERSTRUCTURE WX90

5 Prepare hooking devices.

Apply lifting cables to eye bolts (4) and support the
counterweight.
Eye bolts (M27)

WARNING
Counterweight approx. counterweight: 1670 kg.

F13258

6 Remove the screws (5), (6) securing the

counterweight to the frame.
6

F8498

7 Lift the counterweight, move it away and lower it to

the ground.
15501 9-35990

F8499
 SS4-1-35

SUPERSTRUCTURE WX90

Assembly

1 Lift the counterweight and position it on the frame in

correspondence with the securing holes.

F13259

2 Tighten temporarily the four securing screws fra-

me/counterweight. 6
Torque tighten the screws (5) (6).
(5) tightening torque: 60 daNm
5
(6) tightening torque: 40 daNm

F8498

3 Remove the lifting eyes and reinstall plugs (7).

15501 9-35990

F13260
 SS4-1-36

SUPERSTRUCTURE WX90

4 Assembly of water-oil cooler protection (3).

F13257

5 Assembly of engine hood by tightening the four

screws (1) and the two rams (2) inside engine case. 1
Connect light electrical connections.
Tightening torque 9 da Nm. 1

F13256

15501 9-35990
 SS4-1-37

SUPERSTRUCTURE WX90

1.10.3 SUPERSTRUCTURE REASSEMBLY/ASSEMBLY

Reassembly

- Remove the front equipment assembly as shown on section 6 of this manual.

- Remove rear hood as shown on paragraph 1.10.2 of this chapter.

4
1 Remove ladder (3) and toolbox (4).

3
F13261

2 Fit hooking devices, chains and cables.

(1) Eyebolts M27 1

2
(2) Front hooking on arm pivot pin

F13262

3 Before lifting, make sure of stability.

Front side
1 2
15501 9-35990

Rear side

F8737
 SS4-1-38

SUPERSTRUCTURE WX90

4 Hook the lifting device (bridge crane, hoist).

Lift slightly and set the cables under load, than
check that they do not interfere with the engine.

WARNING
Counterweight approx. superstructure: 5000 kg.

F8734

5 Drain oil from hydraulic oil reservoir.

F8733

6 Remove (5) swing hydraulic motor delivery pipes.

Remove brake disconnection pipe (6).
Disconnect swing brake as follows: 5
fit a pressure intake (7) p/n 154205073 on non-
return valve (8) and inject a 30÷50 bar pressure.
15501 9-35990

F8732
 SS4-1-39

SUPERSTRUCTURE WX90

7 Disconnect hydraulic pipes from rotating control

valve rotor.

F8735

8 Plug in the electrical connection of the central joint,

rotor side.

F8736

9 Untighten two left side screws (7),(8) and two right 7 8

side screws (9),(10).
15501 9-35990

F8507
 SS4-1-40

SUPERSTRUCTURE WX90

10 Turn the superstructure by hand until 2 screws

can be seen.

F8509

11 Untighten the two screws.

Repeat 7 times until all the screws are removed.

F8510

12 Lift the superstructure with care to avoid damage

the hoses connected with the joint, when crossing
the central hole of lower frame carriage.

WARNING
Counterweight approx. superstructure: 5000 kg.
15501 9-35990

F8739
 SS4-1-41

SUPERSTRUCTURE WX90

Assembly

1 Lower the superstructure with care to avoid damage

the hoses connected with the joint, until crossing
the central hole of lower frame carriage.

F8739

2 Position the platform so that the slewing ring holes 9 10

coincide with the carriage holes. Lower the platform
until reaching the slewing ring centering.
Tighten two left side screws (7),(8) and two right
side screws (9),(10).

Tightening torque: 29 ± 3 daNm

Repeat 7 times for all the other screws.

F8511

3 Connect the hydraulic pipes to the central joint.

For the connection of the pipes, refer to the number

on the control valve corresponding to the single
ports, see Chapter 6 Center joint.
15501 9-35990

F8735
 SS4-1-42

SUPERSTRUCTURE WX90

4 Plug in the electrical connection of the central joint

F8736

5 Fit ladder (3) and tool box (4). 4

3
F13261

6 Remove hooking devices, chains and cables.

2 1
(1) Eyebolts M27
(2) Front hooking on arm pivot pin

F13262
15501 9-35990

- Fit front equipment assembly as shown on section 6 of this manual.

- Fit rear hood as shown on paragraph 1.10.2 of this chapter.
 SS4-1-43

SUPERSTRUCTURE WX90

7 Reset swing reductor:

Remove pressure intake (7).
Fit swing hydraulic motor delivery pipes (5). 5
Fit swing brake disconnection pipe (6).

F8880

8 Fill the hydraulic oil reservoir.

- Refer to the Use and Maintenance manual code
6-29950 gb.

F8881
15501 9-35990
 SS4-1-44

SUPERSTRUCTURE WX90

1.11 SUPERSTRUCTURE HYDRAULIC SYSTEM PIPING

1.11.1 GENERALITIES

The pipes of the hydraulic systems can be identified as: main pipes, pilot pipes, brakes pipes and steering
pipes.

1.11.2 MAIN PIPES

The pumps group (main pump + swing pump), driven by the engine, sucts oil from the reservoir and pumps
it under pressure to the control valve, and in turn, reaches the actuators. All the operations relative to: travel,
turret swing, equipment operations are hydraulically controlled by a corresponding motor or hydraulic cylinder.
The connections between hydraulic reservoir, pumps group, control valve, motors and/or hydraulic cylinders
are obtained by a piping system defined as main pipes.

SUCTION AND DELIVERY PIPES

5 3

F8687
15501 9-35990

1 2

1 - Main pump 4 - Hydraulic oil reservoir

2 - Swing pumps 5 - Accumulator
3 - Control valve 6 - Swing control valve
 SS4-1-45

SUPERSTRUCTURE WX90

Return pipes 1 - Control valve

2 - Oil/Diesel fuel reservoir
3 - Hydraulic oil heat exchanger
4 - Main pump
5 - Clamshell bucket valve

3
15501 9-35990

F8686
 SS4-1-46

SUPERSTRUCTURE WX90

Travel and swing control pipes

1 - Distributore principale
2 - Swing motor/reduction unit
3 - Central joint
4 - Swing control valve

F8508

Front equipment cylinders control pipes

1 - Control valve
2 - Boom control pipes
3 - Arm control pipes
3 5 3 4 - Positioner control pipes
5 - Bucket control pipes
2 6 - Clamshell bucket swing hoses

2
15501 9-35990

6 1
F8690
 SS4-1-47

SUPERSTRUCTURE WX90

1.11.3 PILOT SYSTEM PIPES

The pilot system pipes include the suction and delivery pilot pump and the connection system between pilot
valves and control valve.

A) Hoses for servocontrols intake and delivery

1 - Left control lever 7 - Diesel engine

2 - Right control lever 8 - Power control pump
3 - Accumulator 9 - Brake pedal
4 - Clamshell bucket valve 10 - Oil filter
5 - Hydraulic reservoir 11 - Splitting valve
6 - Rotating distributor

1 2 4 5

11

3 6

9
15501 9-35990

10

F10583
 SS4-1-48

SUPERSTRUCTURE WX90

(B) Boom and bucket control.

1 - Main control valve

2 - Right control lever (1st arm/bucket)
3 - Pilot block
4 - Left control lever

3
15501 9-35990

F8689
 SS4-1-49

SUPERSTRUCTURE WX90

(C) Arm and swing control

1 - Main control valve

2 - Right control lever
3 - Left control lever
4 - Swing reductor
5 - Pilot block
6 - Selection solenoid valve
7 - User solenoid valve

5 6
15501 9-35990

7
F8746
 SS4-1-50

SUPERSTRUCTURE WX90

1.11.4 TRAVEL AND POSITIONER CONTROL HOSES

1 - Main control valve

2 - Travel control pedal
3 - User solenoid valve
4 - Pilot block
5 - Selection solenoid valve

4
15501 9-35990

F8747
 SS4-1-51

SUPERSTRUCTURE WX90

1.11.5 SWING MOTOR CONTROL HOSES

1 - Main control valve

2 - Oil reservoir
3 - Swing reductor
4 - Pilot block
5 - Rotating hydraulic joint
6 - Splitting valve
7 - Selection solenoid valve

6
15501 9-35990

4
F8748
 SS4-1-52

SUPERSTRUCTURE WX90

1.11.6 ANGLE HOSES CONTROL HOSES

BLADE/STABILIZER CYLINDER CONTROL HOSES

1 - Main control valve

2 - Rotating distributor
3 - Arm angle cylinder

3
15501 9-35990

F8749
 SS4-1-53

SUPERSTRUCTURE WX90

1.11.7 STEERING PIPES

Construction

The steering pipes include the suction and delivery control and return.

- Suction pipes
The circuit between reservoir and pump is defined intake hoses. The steering pump sucts oil from the
reservoir. The intake hose of steering pump is in common with brake/power control pump.

- Delivery pipes
The circuit between the steering pump and the power steering is defined as delivery pipe.

- Control pipes
The circuit between power steering valve, steering mode selection valve and central joint is defined control
hoses.
When the steering wheel is turned to the right or to the left, oil delivered by the steering pump is distributed
by the power steering valve, in relation with the angle movement of the steering wheel supplying the steering
cylinder through the central joint.
The oil pressure is set at 140 bar by the pressure relief valve of the power steering valve.

- Return pipes
The circuit between power steering valve and hydraulic system is defined as return pipes.

1 - Power steering valve

2 - Steering pump
3 - Central joint
4 - Hydraulic oil reservoir
5 - Diesel engine
6 - Steering solenoid valve

1 3
15501 9-35990

6
F8750
 SS4-1-54

SUPERSTRUCTURE WX90

1.11.8 BRAKES PIPES

Construction

The brakes pipes include the suction, delivery and discharge pipes. In this system, the hydraulic oil is taken
from the reservoir by gear pump (1) and through filter (4) reaches the brake pedal valve (2).

From the brake pedal valve itself, the oil is sent to central joint (5).

1 - Pilot/Brake pump
2 - Brake pedal valve
3 - Accumulators
4 - Pilot filter
5 - Rotary joint
6 - User block
9 - Accumulator
10 - Splitting valve

10

3
15501 9-35990

F10584
 SS4-1A-1

SUPERSTRUCTURE WX90

1A. FLEXIBLE HOSES AND CONNECTIONS

1A.1 FLEXIBLE HOSES AND CONNECTIONS

1A.1.1 FLEXIBLE HOSES

Description
The flexible hoses for pressurized oil include three fundamental parts (fig. 1):
- A sub-layer of extruded and vulcanized elastomer.
- One or more layers of reinforcing metal insertions.
- An outer covering layer of vulcanized elastomer.

Reinforcing insertions
Covering layer Sub layer

Fig. 1
Standards
In fig. 2 the arrangement of the forces acting on the hoses subject to an internal pressure is shown. The action
of these forces is entirely contained by the metalic insertions ensuring an adequate safety margin for the
explosion of the hose.
The safety margin for each hose is expessed as a ratio between the bursting pressure (ps) and the operating
pressure (pe): its entity depends upon the characteristics of the inner pressure, that could be:
- static practically constant
- dynamic, with cyclic variations in time.
Normally, the following safety metric are considered:
with static pressure with dynamic pressure

ps ps
pe = pe =
2,5 ÷ 3 4

Cyclic variations of the inner pressure during

time with a trapezium wave are adopted for the
test of hoses in accordance with the current
standards.
ISO 3862 - 1980 and others (international)
15501 9-35990

UNI 6451 - 69 (Italy)

SAE j343 (USA)
DIN 20024 (Germany)
The values of operating pressures are indicated
in the specific sections, in correspondence
with the technical specifications of the single
versions, together with the values of the bursting
pressure.
Fig. 2
 SS4-1A-2

SUPERSTRUCTURE WX90

Identification

The identification codes of hoses are stamped on the connecting sleeve.

Each hose has an identification code stamped on the sleeve.
If a hose is without marking and this cannot be traced on the spare parts catalog, describe the specifications
when ordering a replacement.
The specifications of a hose is identified by the inner diameter, length of the hose including the connections,
the type of connection (straight, 90°, 45°) the type of thread JIC - ORS or SAE flange.

Total length Total length

ORS - ORS JIC - JIC

Total length Total length

ORS - ORS JIC - JIC

The direction angle is measured

anticlockwise, starting from the
Total length
nearest connection directed
downward.
ORS - ORS
direction angle

Angle in degrees

Total length
Anticlockwise
SAE - ORS rotation direction

F8506.

Fig. 3
15501 9-35990

The operating safety of hoses depends, at a great extent, from their correct mounting on the components
of hydraulic systems, as well, allowing eventual position movements linear and angular or both, if required.
The installation must, in fact, be made in such a manner that the hoses are not subject - in any position - to
twisting , traction or excessive flexion effort. The latter data such to determine a reduction of the bending
radius beyond admissible limits.
In case of frequent movements, it is recommended to increase the minimum bending radius to avoid reducing
operating life.
 SS4-1A-3

SUPERSTRUCTURE WX90

1A.1.2 TERMINAL CONNECTIONS OF HOSES

Description

The connections represent the sealing coupling system between the hose and the seat on the mechanical
group or component to which they are connected.
All the types fall under the principle that the bursting pressure of the hose can be reached, prior to the
beginning of leakages of fluid from the connections or the withdrawal of the hose from them.
In order to perform this principle it is necessary to ensure a permanent sealing between the sub layer of the
hose and the connection as well an efficient mounting of the connection on the hose.
The connections for hoses are of a pressed type when mounted on zinc and passivated carbon steel pipes.

Pressed connections are made of a ring nut and sleeve, properly dimensioned for the mounting on the hose
(fig. 4).
After the mounting on the end of the hose, the sleeve is radially deformed, until a permanent mounting
between the various elements is obtained.
The great technical advantage of such a solution consists in a guaranteed optimized coupling between
connection and hose, particularly reliable also when pulsating pressures are involved.

Hoses are equipped with SAE, ORS, JIC 37° connection.

Identification code stamped on each hose.

xxxxxxxx

F8513

SAE HOSES ORS HOSES JIC 37° HOSES

15501 9-35990

Fig. 4
 SS4-1A-4

SUPERSTRUCTURE WX90

SAE standard heavy and light type counter flanges

SAE 6000 counter flanges

for pressures up to 420 bar - 6000 psi

Description X Q T D E
SAE 6000 mm mm mm mm mm
1
/2 9.1 40.5 8.5 32.5 15.7
3
/4 11.9 50.8 10.5 42.0 19

1" 14 57.2 13 48.5 22.5

1"1/4 15.7 66.7 15 54.7 23.8

1"1/2 18.3 79.4 17 64.5 27

2" 22.3 96.8 21 80.0 36.5

SAE 3000 counter flanges

for pressures up to 210 bar - 3000 psi

Description X Q T D E
SAE 3000 mm mm mm mm mm
1
/2 8.6 38.1 8.5 31 12.7
3
/4 11.1 47.6 10.5 39 14.2

1" 13.2 52.4 10.5 45.3 14.2

1"1/4 15 58.7 12 51.5 14.2

1"1/2 17.8 69.8 13.5 61 15.7

2" 21.3 77.7 13.5 72 15.7

O-Rings for SAE 3000 & SAE 6000

counter flanges
Description I S
SAE 3000 and 6000 mm mm
1
/2 18.6 3.5
15501 9-35990

3
/4 25 3.5

1" 32.9 3.5

1"1/4 37.7 3.5

1"1/2 47.2 3.5

2" 56.7 3.5

 SS4-1A-5

SUPERSTRUCTURE WX90

1A.1.3 ADAPTOR CONNECTIONS

The connections of hoses to hydraulic components are made of adaptors.

The threaded seats of the adaptors used are listed herebelow.

Dimensions of GAS-BSPP threaded seats

L
F F
F F D D
D D D3
K°
R. 0,25
D1
D6
D2
90° 3.2
E A
D7 A X

45° B 1 B
B1 B

F8878 F8879

Seats for flat seal Seats for JIS B2351 in slot seal

Dimensions in mm

DIMENSION 1/4-19 3/8-19 1/2-14 3/4-14 1"-11 DIMENSION 1/4-19 3/8-19 1/2-14 3/4-14 1"-11

F 13.16 16.66 20.96 26.44 33.25 F 13.16 16.66 20.96 26.44 33.25

A 1.5 2 2.5 2.5 2.5 A 1.5 2 2.5 2.5 2.5

B 12 12 14 16 18 B 13 13 17.5 18.5 22

B1 18.5 18,5 22 24 27 B1 18 18 24 25 30
15501 9-35990

D 19.5 24 28.5 35 43 D 23 27 33 44 50

D6 21 24.5 30 37 46 D6 24 28 34 45 51

D7 13.2 16.7 21 26.5 33.3 D7 15.6 18.6 22.6 29.8 35.8

L 9 9.5 11.5 13.5 15.5 L 2.5 2.5 2.5 3.5 3.5

 SS4-1A-6

SUPERSTRUCTURE WX90

Dimensions of UNF threaded seats

L
F F
F F D D
D D D3
K°
R. 0,25
D1
D6
D2
90° 3.2
E A
D7 A X

45° B 1 B
B1 B

F8878 F8879

Seats for flat seal Seats for SAE J475 in slot seal

Dimensions in mm
DIMENSION 9/16-18 3/4-16 7/8-14 1"1/16-12 1"3/16-12 DIMENSION 9/16-18 3/4-16 7/8-14 1"1/16-12 1"3/16-12

F 14.29 19.05 22.23 26.99 30.16 F 14.29 19.05 22.23 26.99 30.16

A 1.5 1.5 2.5 2.5 2.5 A 1.5 1.5 2.5 2.5 2.5

B 13 15 17 20 20 B 13 15 17 20 20

B1 16 18 20 24 24 B1 16 18 20 24 24

D D 20.5 26 29.5 36.5 40.5

D6 25 30 34 41 45 D1 25 30 34 41 45

D7 D2 18 22 26 32 35

L 10.5 12 13.5 15.5 15.5 D3 15.70 20.65 24 29.20 32.40

15501 9-35990

E 2.7 2.7 2.7 3.5 3.5

K 12° 15° 15° 15° 15°

 SS4-1A-7

SUPERSTRUCTURE WX90

Dimensions of METRIC threaded seats

L
F F
F F D D
D D D3
K°
R. 0,25
D1
D6
D2
90° 3.2
E A
D7 A X

45° B 1 B
B1 B

F8878 F8879

Seats for flat seal Seats for ISO 6149 in slot seal

Dimensions in mm
DIMENSION 14x1.5 16x1.5 18x1.5 20x1.5 22x1.5 DIMENSION 14x1.5 16x1.5 18x1.5 20x1.5 22x1.5

F 14 16 18 20 22 F 14 16 18 20 22

A 1.5 1.5 2 2 2.5 A 1.5 1.5 2 2 2

B 12 12 12 14 14 B 11.5 13 14.5 14.5 15.5

B1 18.5 18.5 18.5 20.5 20.5 B1 14 15.5 17 17 18

D 20 23 26 28 29 C 7.5 9 11 12 14

D6 21.5 24.5 27.5 30 31.5 D 19.5 22.5 24.5 27.5 27.5

D7 14 16 18 20 22 D1 21 24 26 27 29

L 9 10.5 12 12 12.5 D2 19.5 22.5 24.5 25.5 27.5

15501 9-35990

D3 15.8 17.8 19.8 21.8 23.8

E 2.4 2.4 2.4 2.4 2.4

K 15° 15° 15° 15° 15°

L 10.5 12 13.5 13.5 14

 SS4-1A-8

SUPERSTRUCTURE WX90

Fitting of banjo unions, adjustable with lock nuts, with retaining washer and O-ring, in seats for GAS BSPP,
METRIC, UNF flat seal.

Lock nut
Protection washer
Retaining washer
O-Ring

F8456

Lubricate the O-Ring smearing it
with a light film of oil, tighten the
securing nut completely to free
entirely the relief of the thread and
visually check that the protection
washer can reach the position
indicated in the figure.
Mount the connection in the
appropriate seat without forcing it,
until the protection washer and the
retaining washer, depending upon
the type of fitting being performed,
touch the machined surface.
Correct the position rotating
anticlockwise the connection up to
one turn max., to reach the desired
position, than, holding the position
with a wrench, tighten the nut.
15501 9-35990
 SS4-1A-9

SUPERSTRUCTURE WX90

Fitting of banjo unions, adjustable with lock nuts, with retaining washer and O-ring, in seats for JIS B2351,
SAE J475, ISO 6149 seal with slot

Lock nut
Protection washer

O-Ring

F8454

Lubricate the O-Ring smearing it
with a light film of oil, tighten the
securing nut completely to free
entirely the relief of the thread and
visually check that the protection
washer can reach the position
indicated in the figure.
15501 9-35990
Fit the union into the suitable seat
without forcing, until the protection
washer touches the machined
surface.
Correct the position rotating
anticlockwise the connection up to
one turn max., to reach the desired
position, than, holding the position
with a wrench, tighten the nut.
 SS4-1A-10

SUPERSTRUCTURE WX90

1A.1.4 TIGHTENING TORQUES FOR CONNECTIONS AND HOSES

Tightening torques of screws for SAE J518 flanges

DIMENSION Wrench mm Tightening torques Nm

M8 30 ± 3

M10 65 ± 3

M12 110 ± 11

M14 140 ± 14

M16 230 ± 23

All tightening the torques listed above refer to screws mounted, previously lubricated by dipping into engine
oil.

SPECIFICATIONS 1) Hand tighten Q.ty 2 opposite screws with an air wrench at min. power.
2) Tighten manually with a wrench or an air wrench up to the nominal tightening
prescribed for the 2 screws diametrically opposite to the previous ones.
3) Tighten the two screws previously approached in the same manner.

15501 9-35990
 SS4-1A-11

SUPERSTRUCTURE WX90

Tightening torque of threaded connections

The tightening torques listed must be reduced by 25% in case the connection is mounted with the use of
Teflon.
GAS BSPP

DIMENSION Wrench mm Tightening torques Nm

1/4" 19 45 ± 4,5

19 45 ± 4,5

3/8" 22 105 ± 10,5

24 105 ± 10,5

27 150 ± 15

1/2" 30 200 ± 20

36 200 ± 20

36 200 ± 20

3/4" 38 230 ± 23

41 230 ± 23

41 230 ± 23

1" 46 360 ± 36

50 360 ± 36

1"1/4 50 360 ± 36

METRIC

DIMENSION Wrench mm Tightening torques Nm

M12 x 1.5

M14 x 1.5

M16 x 1.5

M18 x 1.5

M20 x 1.5
15501 9-35990

M22 x 1.5

M26 x 1.5

M27 x 2

M33 x 2
 SS4-1A-12

SUPERSTRUCTURE WX90

Tightening torque of ORS hose and pipe nuts

WARNING: before mounting check the following points:

- Check that the securing bushes of the connections to the hose show clear signs of the pressing. Otherwise
discard the hose.
- O-ring presence and efficiency on hose union.
- Remove the sealing plugs and ensure that the connections are clean.
- Lubricate the thread of the connection and the O-Ring with engine oil.

DIMENSION Wrench mm Tightening torques Nm

9/16-18 UNF 19 30 ± 3

11/16-16 UN 22 70 ± 7

13/16-16 UN 27 95 ± 9

1"-14 UNS 30 140 ± 14

1"3/16-12 UN 36 180 ± 18

1"7/16-12 UN 41 210 ± 21

1"11/16-12 UN 50 330 ± 33

Tightening torque of JIC 37° hose and pipe nuts

WARNING: before mounting check the following points:

- Check that the bushes of the connections to the hose show clear signs of the pressing. Otherwise discard
the hose.
- Remove the sealing plugs and ensure that the connections are clean.
- Lubricate the thread of the connection and the O-Ring with engine oil.

DIMENSION Wrench mm Tightening torques Nm

7/16-20 UNF 13/14 30 ± 3

15501 9-35990

1/2-20 UNF 16 30 ± 3

9/16-18 UNF 22/17 40 ± 4

3/4-16 UNF 27/22 80 ± 8

 OPERATION PRINCIPLE HYP4-2-1
(O/P)
HYDRAULIC PUMP WX90

2. HYDRAULIC PUMPS

2.1 HYDRAULIC PUMPS

The machine is equipped with a group of pumps providing the main hydraulic power to all the systems and
with a gear double pump feeding the power system/brakes and steering.

2.1.1 PUMPS GROUP

The pumps group is mounted on the flywheel side of the engine and includes two pumps:
- main pump and secondary pump.
The two pumps, of a variable displacement swashplate axial piston type are tandem mounted.
The main pump is driven by the engine through an elastic joint; the secondary pump is driven by the through
shaft of the main pump.

1 - Secondary pump
4
2 - Main pump
3 - Flange
4 - Elastic joint
3

1
15501 9-35990

F8457
OPERATION PRINCIPLE HYP4-2-2
(O/P)
HYDRAULIC PUMP WX90

2.1.2 GEAR DOUBLE PUMP

The gear double pump is mounted on secondary pump and includes two gear pumps mounted axially.

1 - Power system/brakes pump

2 - Steering pump

F8683
15501 9-35990
 OPERATION PRINCIPLE HYP4-2-3
(O/P)
HYDRAULIC PUMP WX90

2.2 MAIN PUMP

2.2.1 CONSTRUCTION AND FUNCTION

The main pump (A11VO75 LRCS) is of a variable displacement swashplate axial piston type. The
displacement is proportionate to the revolution speed and the displacement. The position of the swashplate
allows a continuous variation of the displacement. The pump includes, essentially: a rotating group, included
inside the pump body; a valve plate; a regulator.

2.2.2 OPERATION OF THE MAIN PUMP

When the drive shaft rotates, oil is sucked by the movement of the pistons sliding along swashplate (5) through
the inlet ports of the valve plate.
When the pistons reach the bottom dead center (cylinder chamber totally filled with oil) the relevant cylinders
where they slide are communicating with the delivery port of the valve plate. While the shaft rotates, the oil
sucked by the retracting movement of the piston during the inlet phase, is pushed-out during the pushing
movement of the piston itself, in the compression phase. The alternating movement of the pistons, occurring
in a sequence for all 9 pistons due to the rotation of the shaft, causes the pressurised hydraulic oil to exit into
the feeding delivery piping. The delivery of the pump is proportionate to the r.p.m. and the inclination angle
of the swashplate where the pistons slide and it can be changed from a maximum to a minimum.
The speed of the pump depends upon the r.p.m of the engine to which it is mechanically connected.

2 1 5 4

1 - Rotor group
2 - Pump body
3 - Valve plate
4 - Regulator
5 - Swashplate
15501 9-35990

3
OPERATION PRINCIPLE HYP4-2-4
(O/P)
HYDRAULIC PUMP WX90

2.2.3 ROTOR GROUP

The rotor group includes 9 pistons sliding over the swashplate and kept in position by the retaining plate and
the cup springs (see detail X).
During the rotation of the drive shaft, the cylinder block, driven in a rotation, ensures that the pistons, sliding
over the swashplate, are alternatively moved, with a stroking travel inside the relevant cylinders.
The plate is at an angle with respect to the rotation shaft and its position can change as a function of the request
made by the operator and the power absorbed by the load. By changing the angle of the plate, the stroke of
the pistons with respect to the cylinders is changed, thus the displacement of the pump and the relevant
delivery is changed.
The valve plate is fixed and contacts the end of the cylinder block.

Rotor group

19 18 20 15 17 11 12 2 1

Detail X
5 6 7 10 4 13 16 14 21

1 - Cylinder 12 - Retaining ball

2 - Piston 13 - Washer, bearing
3 - Cup spring 14 - Locking segment
15501 9-35990

4 - Swashplate 15 - Bearing
5 - Shaft 16 - Bearing
6 - Cover 17 - Retaining ring
7 - Retainer 18 - Retaining ring
8 - Washer 19 - Seal
9 - Spacer 20 - O-ring
10 - Retaining pin 21 - Screw
11 - Retaining plate 22 - Valve plate
 OPERATION PRINCIPLE HYP4-2-5
(O/P)
HYDRAULIC PUMP WX90

2.2.4 VALVE PLATE

The valve plate is mounted on the pump body and supports the regulator.

9 10 5 4 2 1 6

11

5 11

5
4
3 12
7
5 13

6 8

5 5 1 - Bush 8 - Orifice
2 - Valve plate 9 - Plug
3 - Bearing 10 - Plug
4 - Centering dowel 11 - Orifice
5 - Dowel 12 - O-ring
6 - Plug 13 - Bonded seal
7 - Plug

Inside, the seats for the swashplate control piston are made.
15501 9-35990
OPERATION PRINCIPLE HYP4-2-6
(O/P)
HYDRAULIC PUMP WX90

2.2.5 REGULATOR

The regulator of the main pump includes:

1 - a constant power regulation circuit;
2 - a power control circuit related to the load requirement of the “cross sensing” swing pump;
3 - a control circuit monitoring the load applied to the “load sensing” pump.

3
X

1 - Power control valve

2 - Power control valve related to the load of the swing pump (cross sensing)
3 - Load sensing regulation valve
X - Input of the load sensing line

15501 9-35990

Section B-B Section C-C

 OPERATION PRINCIPLE HYP4-2-7
(O/P)
HYDRAULIC PUMP WX90

Constant power regulation circuit

The constant power regulation circuit controls the volume of oil delivered by the pump related to the operating
pressure of the circuit and the power output, so that, for a given speed of the pump, the driving
power required from the engine is not exceeded, and the relation N = P . Q = constant (where N = Diesel
Engine Power, P = Oil pressure, Q = delivery and K = coefficient). K

11

The pressure of the hydraulic oil of the feeding circuit, acting on a plunger inside counter-piston (3), actuates
a swinging arm (4).
On the other side of the swinging arm, a spring, adjustable from outside, is acting through a push-rod. When
turning screw (11) the power regulation is changed.
If the operating pressure of the feeding circuit exceeds the load setting of the spring, the power regulation valve
is commanded to open by the movement of the swinging arm. Thus, the feeding circuit line is connected with
the swashplate control piston (2) that, when moving, changes the position of the swashplate toward smaller
inclination angles. Consequently, the pump output decreases.

By reducing the oil flow, the new equilibrium value is re-established, so that P Q = constant is satisfied.
.

1 - Main pump 9
2 - Swashplate control piston
3 - Counter piston 7
4 - Swinging arm
5 - Power regulation valve 4
6 - Load sensing regulation valve 11
7 - Power regulation valve related to swing 10
pump load (cross sensing) 5
9 - Operation pressure reference line 1
10 - Plunger 3
11 - Adjusting screw
15501 9-35990

F8931
OPERATION PRINCIPLE HYP4-2-8
(O/P)
HYDRAULIC PUMP WX90

Power regulation circuit related to secondary pump load (cross sensing)

The power regulation circuit related to the secondary pump load is a system designed to maintain constant
the addition of all the powers absorbed by the main and secondary pump driven by the same shaft. The cross
sensing power regulation is actuated by the operating pressure of the secondary pump.
If the main pump is operating, and there is a load demand on the secondary pump, the cross sensing circuit
monitors the pressure variation coming from the circuit supplied by the secondary pump, altering the setting
of the power absorbed by the main pump in a proportional manner.

The intervention of the signal coming from the secondary pump applied to the cross sensing valve (7) acts
in contrast with the power regulation valve setting spring (11), changing the equilibrium point of the swinging
arm at a lower point.
In practice, each power demand on the secondary pump is compensated by deducting power from the main
pump.

Load sensing regulation circuit

The circuit includes the load sensing valve (6) located in the regulator and has the function of regulating the
output delivered by the main pump as a function of the variation required by the actuators, so that the
displacement of the main pump is best adapted in all the various operating conditions.
15501 9-35990
 OPERATION PRINCIPLE HYP4-2-9
(O/P)
HYDRAULIC PUMP WX90

The load sensing valve compares the pressure before and after restriction (8) generated by the position of
the spool in the control valve body and acts on the pump regulator so that the pressure drop (∆p) through the
restriction is maintained constant and the delivery of the pump is kept steady. (∆p = pump pressure - Actuator
pressure).
The pressure difference before and after the restriction is set at ∆p = 18 +1 - 0 bar.
If the pressure difference ∆p tends to increase, the load sensing valve intervenes and allows the passage of
oil to the swashplate angle control piston to move it toward minimum displacement.
If the pressure difference ∆p, on the contrary, tends to diminish, the load sensing valve intervenes to command
the pump toward maximum displacement, until the position of the load sensing valve is balanced, so that the
pressure drop before and after the restriction generated by the spool is maintained at 18 bar.
When the main pump works on the power curve, the load sensing circuit is by-passed.

2.2.6 SPECIFICATIONS AND DATA

PUMP TYPE A11VO75 LRCS

Displacement Vmax = 74 cm3

Max. delivery Qmax = 143 liter/min

at 2000 rpm Qmin = 15 cc/rew

Max. power Nmax = 43 kW

at 2000 rpm T≤ 205 Nm

Weight (without fluid) P = 45 kg

15501 9-35990
OPERATION PRINCIPLE HYP4-2-10
(O/P)
HYDRAULIC PUMP WX90

2.3 SECONDARY PUMP

2.3.1 CONSTRUCTION AND FUNCTION

The secondary pump (A10VO28 DFLR) is of a variable displacement swashplate axial piston type. The
displacement is proportionate to the revolution speed and the displacement. The position of the swashplate
allows a continuous variation of the displacement. The pump includes, essentially: a rotating group, included
inside the pump body; a valve plate; two regulators.

2.3.2 OPERATION OF THE SECONDARY PUMP

When the drive shaft rotates, oil is sucked by the movement of the pistons sliding along swashplate (3) through
the inlet ports of the valve plate.
When the pistons reach the bottom dead center (cylinder chamber totally filled with oil) the relevant cylinders
where they slide are communicating with the delivery port of the valve plate. While the shaft rotates, the oil
sucked by the retracting movement of the piston during the inlet phase, is pushed-out during the pushing
movement of the piston itself, in the compression phase. The alternating movement of the pistons, occurring
in a sequence for all 9 pistons due to the rotation of the shaft, causes the pressurised hydraulic oil to exit into
the feeding delivery piping. The delivery of the pump is proportionate to the r.p.m. and the inclination angle
of the swashplate where the pistons slide and it can be changed from a maximum to a minimum.
The speed of the pump depend upon the r.p.m. of the engine, to which it is mechanically connected, through
the main pump.

6
3 11

8 9

7
10 5

1 - Drive shaft
2 - Cylinder block
3 - Swashplate
4 - Valve plate
15501 9-35990

5 - Angle control piston

6 - Counter piston
7 - Delivery regulator
8 - Power regulator
9 - Cut-off valve
10 - Pump body
11 - Valve plate
 OPERATION PRINCIPLE HYP4-2-11
(O/P)
HYDRAULIC PUMP WX90

2.3.3 ROTOR GROUP

The rotor group includes 9 pistons sliding over a swashplate kept in position by the retaining plate and pre-
load springs.
During the rotation of the drive shaft, the cylinder block, driven in a rotation, ensures that the pistons, sliding
over the swashplate, are alternatively moved, with a stroking travel inside the relevant cylinders.
The plate is at an angle with respect to the rotation shaft and its position can change as a function of the power
absorbed, through the regulator. By changing the angle of the plate, the stroke of the pistons with respect to
the cylinders is changed, thus the displacement of the pump and the relevant delivery is changed.
The valve plate is fixed and contacts the end of the cylinder block.

1 3 4 6 7 8

11

2 5 9 10
1 - Safety ring
2 - Seal
3 - Front roller bearing
4 - Pistons
5 - Swashplate
15501 9-35990

6 - Spacer
7 - Rear roller bearing
8 - Ring
9 - Reference dowel
10 - Plug
11 - Inlet plate
OPERATION PRINCIPLE HYP4-2-12
(O/P)
HYDRAULIC PUMP WX90

2.3.4 REGULATORS

The regulators of the secondary pump include: 2

- a constant power regulation circuit; 1
- a cut-off intervention circuit.

4 A

15501 9-35990

1 - Displacement regulation valve

2 - Cut-off valve
3 - Power regulation valve
4 - Piston
 OPERATION PRINCIPLE HYP4-2-13
(O/P)
HYDRAULIC PUMP WX90

Constant power regulation circuit

The constant power regulation circuit controls the volume of oil delivered by the pump related to the operating
pressure of the circuit and the power output, so that, for a given speed of the pump, the driving
.
power required from the engine is not exceeded, and the relation N = P Q = constant (where N = Diesel
Engine Power, P = Oil pressure, Q = delivery and K = coefficient). K
The power regulation circuit includes a displacement regulation valve (1) and power regulation valve (3).
The combined operation between these two valves, allows the variation of the displacement of the pump as
a function of the load: in essence, the regulation of power.
Plunger (4) of the displacement regulator is connected to the pilot line and it is subject to pressure on both
sides (A and B).
Side (B) is pre-loaded by a regulation spring. As far as the pressure in (A) is equal to the pressure in (B) the
plunger is kept in rest position. Under these conditions, the secondary pump provides maximum delivery.
When the operating pressure exceeds the value for the beginning of the intervention of the power regulator,
the power regulation valve (3) opens, discharging side (B) of the plunger, thus creating a pressure differential
between (A and B).
This differential modifies the position of the plunger and the signal in the line is sent to the swashplate angle
control piston, thus modifying the displacement, until a new equilibrium point is found.

P2

B
X

Ø 0.8

(1)
(8)
CUT-OFF: 310 bar

(2)

(4) (3)

1 - Flow adjustment
valve
15501 9-35990

2 - Cut-off valve
(5) 3 - Swash control piston
4 - Power check valve
Q max Q min. 5 - Lock piston
S L1 L 6 - To main pump
CROSS SENSING 7 - Cross sensing line
(6)
(7) 8 - Pilot line
OPERATION PRINCIPLE HYP4-2-14
(O/P)
HYDRAULIC PUMP WX90

Cut-off intervention circuit

Once a value of 310 bar is reached on the operation line, the plunger of the cut-off valve (2) overcomes the
load of the spring, connecting the pilot line (8) with the angle control piston. Under these conditions, the pump
provides a displacement capable of ensuring a steady pressure and compensating eventual leakages in the
system.
The cut-off valve inhibits every other function of the regulators.

2.3.5 SPECIFICATIONS AND DATA

PUMP TYPE A10VO28 DFLR

Displacement Vgmax = 28 cm3

Max. delivery Qgmax = 56 liter/min

at 2000 rpm

Max. power Pomax = 14 kW

at 2000 rpm

Weight (without fluid) P = 15 kg

15501 9-35990
 OPERATION PRINCIPLE HYP4-2-15
(O/P)
HYDRAULIC PUMP WX90

2.4 GEAR DOUBLE PUMP

2.4.1 GENERALITIES

The gear double pump, of a fixed displacement type, includes the power system/brakes pump (1) and steering
pump (2), and is mounted on the front left side of the engine.
The power system /brakes pump (1) sucks the oil through a suction filter from the hydraulic reservoir and sends
it, after going through the power system filter, to the brake valve and then, after charging the brake system
accumulators, sends it to the priority valve feeding the controls.
Steering pump (2) sucks the oil through the suction filter from the hydraulic reservoir and sends it directly to
the inlet of the power steering valve.

Operation

A gear is driven by the engine through the transmission and drives a second gear.
As a consequence of the rotation in an opposite direction of the gears, the vanes between the teeth become
free. The depression created and the pressure acting on the surface of the fluid in the reservoir, push the oil
from the reservoir to the pump.

2.4.2 SPECIFICATIONS AND DATA

(1) Power system/brakes pump:

q = 11 cu cm/turn
Q = 22 l/min (at 2000 rpm) 1

(2) Steering pump:

q = 19 cu cm/turn
Q = 38 l/min (at 2000 rpm) 2

SUCTION
15501 9-35990

1 - Power system/brakes pump F8512

2 - Steering pump

DELIVERY
OPERATION PRINCIPLE HYP4-2-16
(O/P)
HYDRAULIC PUMP WX90

NOTES:

15501 9-35990
 DISASSEMBLY AND ASSEMBLY HYP4-2-1
(D/A)
HYDRAULIC PUMPS WX90

2.1 MAIN PUMP

2.1.1 GENERAL REPAIR INSTRUCTION

NOTE - Observe the following notices when

carrying out repair work on hydraulic
components.

• Close all ports of the hydraulic components.

F8649

• Replace all removed seals.

F8650

• Check all seals and sliding surfaces for wear.

ATTENTION - Rework of sealing area f. ex.

with abrasive paper, can damage surface.

F8651

• Fill up main pump with hydraulic oil before

start-up.
15501 9-35990

F8652
DISASSEMBLY AND ASSEMBLY HYP4-2-2
(D/A)
HYDRAULIC PUMPS WX90

2.1.2 SUB ASSEMBLES

Seal kit for drive shaft.

F8578

External seal kit.

F8579

Housing.

F8580

Complete rotary group.

15501 9-35990

F8581
 DISASSEMBLY AND ASSEMBLY HYP4-2-3
(D/A)
HYDRAULIC PUMPS WX90

(1) Hydraulic control small size.

(2) Hydraulic control big size.

F8582

Valve plate.

F8583

Complete regulator.

F8584
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DISASSEMBLY AND ASSEMBLY HYP4-2-4
(D/A)
HYDRAULIC PUMPS WX90

2.1.3 SEALING OF THE DRIVE SHAFT

F8585

Protect the drive shaft.

F8586

Loosen retaining ring and remove it, press away

front cover.
15501 9-35990

F8587
 DISASSEMBLY AND ASSEMBLY HYP4-2-5
(D/A)
HYDRAULIC PUMPS WX90

1. Fit a new shaft seal ring with a suitable

bushing.

2. Fit a new disc before shaft seal ring.

F8588

2.1.4 SEALING OF THE REGULATOR HOUSING

Remove screws and press off regulator, thereby

make sure that sealing surface is not damaged.
15501 9-35990

F8589
DISASSEMBLY AND ASSEMBLY HYP4-2-6
(D/A)
HYDRAULIC PUMPS WX90

(1) Power control.

(2) Pressure control.
(3) Load-Sensing valve.

NOTE: Do not change position of adjustment

screws. Remove complete set of threaded bush
with adjustment screws.

3
2
1

F8590

F8591
15501 9-35990
 DISASSEMBLY AND ASSEMBLY HYP4-2-7
(D/A)
HYDRAULIC PUMPS WX90

Remove protection cover. Measure and note

adjustment heigth "H".

F8592

2.1.5 REMOVE PORT PLATE, REGULATOR

Remove regulator housing.

F8593

Remove O-rings, measuring piston with bush

and spring.
15501 9-35990

F8594
DISASSEMBLY AND ASSEMBLY HYP4-2-8
(D/A)
HYDRAULIC PUMPS WX90

Mark position of the connection plate.

Loosen connection plate fixation.

F8595

Remove port plate with control plate.

Disassemble regulator.
(1) Hydraulic small.
(2) Hydraulic large.

2 1

F8596

Hydraulic control rod - small size (1)

Hydraulic control rod - big size (2)

2
15501 9-35990

F8597
 DISASSEMBLY AND ASSEMBLY HYP4-2-9
(D/A)
HYDRAULIC PUMPS WX90

Remove control plate.

Mark position.

F8598

Disassemble regulator.
* Do not change setting.
15501 9-35990

F8599
DISASSEMBLY AND ASSEMBLY HYP4-2-10
(D/A)
HYDRAULIC PUMPS WX90

2.1.6 REMOVE ROTARY GROUP

F8600

Loosen fixing of the retaining segments.

F8601

Remove retaining segments with screws.

15501 9-35990

F8602
 DISASSEMBLY AND ASSEMBLY HYP4-2-11
(D/A)
HYDRAULIC PUMPS WX90

Remove O-ring.

F8603

Remove cylinder with pistons.

F8604

Remove Q-min and Q-max screws after noting

down adjustment dimension.

F8605

Remove joint pin for swivel cradle.

15501 9-35990

F8606
DISASSEMBLY AND ASSEMBLY HYP4-2-12
(D/A)
HYDRAULIC PUMPS WX90

Remove completely cover ring.

F8607

Press out drive shaft.

F8608

Remove swivel cradle with bearing as well as

bearing case.

15501 9-35990

F8609
 DISASSEMBLY AND ASSEMBLY HYP4-2-13
(D/A)
HYDRAULIC PUMPS WX90

2.1.7 INSPECTION NOTES

1 2 3 4
Check!
Gears (1), contact area shaft seal (2), gears (3),
bearing seat (4).

F8610

Check!
Cage set (1).
Bearing cup set (2).
Bearing Bearing cup

F8611

Check!
Contact area (*).

F8612

Check!
Socket for regulator (*).
15501 9-35990

F8613
DISASSEMBLY AND ASSEMBLY HYP4-2-14
(D/A)
HYDRAULIC PUMPS WX90

Check!
Contact area of bearing (1).
1 1

F8614

Inspection!
Retaining ball (1).
Retaining plate (2).
1

F8615

Inspection!
Fixing segments.

F8616

Inspection!
Slipper pads (1).
Axial backlash (2). 2 1
15501 9-35990

F8617
 DISASSEMBLY AND ASSEMBLY HYP4-2-15
(D/A)
HYDRAULIC PUMPS WX90

Inspection!
Cylinder boring (1).
Gears (2). 2 1

F8618

Inspection!
1
Cylinder contact area (1).
Contact area control plate (2).

2
F8619

Check!
Fixing segments (*).

F8620

Check!
Pistons (*).
15501 9-35990

F8621
DISASSEMBLY AND ASSEMBLY HYP4-2-16
(D/A)
HYDRAULIC PUMPS WX90

Check!
Positioning piston (1).
1 2 1
Boring - control bush (2).

F8622

Check! 1
Boring (*).
Contact area control plate (1).

F8623

2.1.8 PUMP ASSEMBLY

Insert bearing bell.

F8624

Clean threaded borings.

15501 9-35990

F8625
 DISASSEMBLY AND ASSEMBLY HYP4-2-17
(D/A)
HYDRAULIC PUMPS WX90

Install bearings with wire guide on swivel cradle.

Fixing with auxiliary device.

F8626

Auxiliary devices e.g.

Clamp.
Rubber rings.
Grease.

F8627

Place swivel cradle with bearing into bearing

shell.

ATTENTION! Installation position.

F8628

Remove auxiliary devices.

ATTENTION! Check bearing seals.

15501 9-35990

F8629
DISASSEMBLY AND ASSEMBLY HYP4-2-18
(D/A)
HYDRAULIC PUMPS WX90

Adjust guide wire. Install joint pins. Install locking

screws. 1
1. Auxiliary device (threaded rod).

1
F8630

Fit swivel cradle with threaded pin in zero position.

1. Auxiliary device (threaded pins 2x).

F8631

Install drive shaft.

F8632

Mount cover ring.

15501 9-35990

F8633
 DISASSEMBLY AND ASSEMBLY HYP4-2-19
(D/A)
HYDRAULIC PUMPS WX90

Mount shims, springs and retaining ball.

NOTE: Observe correct mounting position *.

F8634

Place retaining plate with piston into cylinder.

F8635

Assembly hint:
Fix pistons with the aid of an O-ring.

F8636

Insert fixing segments.

15501 9-35990

F8637
DISASSEMBLY AND ASSEMBLY HYP4-2-20
(D/A)
HYDRAULIC PUMPS WX90

Install screws with Loctite.

ATTENTION! Pay attention with hardening time

- important.
Tight screws with torque value.

F8638

Hydraulic control rod-big size.

F8639

F8640

Hydraulic control rod-small size.

15501 9-35990

F8641
 DISASSEMBLY AND ASSEMBLY HYP4-2-21
(D/A)
HYDRAULIC PUMPS WX90

F8642

Install control plate.

Direction of rotation Direction of rotation
ATTENTION! Installation (Direction of rotation). clockwise counter-clockwise

F8643

F8644

Fix port plate, assembly with screws.

ATTENTION! Torque - screws.

15501 9-35990

F8645
DISASSEMBLY AND ASSEMBLY HYP4-2-22
(D/A)
HYDRAULIC PUMPS WX90

Remove threaded pins.

Install Q-min, Q-max - screws.
Adjustment measure.

F8646

Install measuring piston with O-rings.

F8647

Place regulator.

F8648
15501 9-35990
 DISASSEMBLY AND ASSEMBLY HYP4-2-23
(D/A)
HYDRAULIC PUMPS WX90

Tightening torques for shaft bolts THREAD STRENGTH CLASSES

(metric ISO standard)
8.8 10.9 12.9
SIZE TIGHTENING TORQUE (lb.ft.)
The values for tightening torques shown in the M3 1.1 1.6 1.9
table are valid only for shaft bolts with metric M4 2.9 4.1 4.9
ISO-standard threads and head support surface M5 6 8.5 10
dimensions in accordance with DIN 912, DIN M6 10 14 17
931 and DIN 933. M8 25 96 41
These values are also valid only for light or M10 49 69 83
unoiled, untreated surface as well as for use M12 86 120 145
only with torque-indicating wrenches and force M14 135 190 230
limiting tools. M16 210 295 355
M18 290 405 485
M20 410 580 690
M22 550 780 930
M24 710 1000 1200
M27 1050 1500 1800
M30 1450 2000 2400

Tightening torques for locking screws VSTI THREAD SIZE DESIGNATION TIGHTENING
(metric ISO fine thread) TORQUES (lb.ft)
M8x1 VSTI 8 x 1 -ED/SA 5
M10 x 1 VSTI 10 x 1 -ED 10
M12 x 1.5 VSTI 12 x 1.5 -ED 20
M14 x 1.5 VSTI 14 x 1.5 -ED 30
M16 x 1.5 VSTI 16 x 1.5 -ED/SA 30
M18 x 1.5 VSTI 18 x 1.5 -ED/SA 40
M20 x 1.5 VSTI 20 x 1.5 -ED/SA 50
M22 x 1.5 VSTI 22 x 1.5 -ED 60
M26 x 1.5 VSTI 16 x 1.5 -ED/SA 70
M27 x 2 VSTI 27 x 2 -ED 90
M30 x 1.5 VSTI 30 x 1.5 -ED/SA 100
M33 x 2 VSTI 33 x 2 -ED/SA 120
M42 x 2 VSTI 42 x 2 -ED/SA 200
M48 x 2 VSTI 48 x 2 -ED 300

Tightening torques for seal-lock nuts THREAD STRENGTH CLASSES

(metric ISO-standard thread)
8.8 10.9 12.9
The values for tightening torques shown in the SIZE TIGHTENING TORQUE (lb.ft.)
table are valid only for seal-lock nuts of the M6 10
strengthclass 8.8 and with metric ISO-standard M8 22
thread. M10 40
M12 69
M14 110
M16 170

Tightening torques for cross-slotted lens head THREAD STRENGTH CLASSES

15501 9-35990

screws DIN 7985

(metric ISO-standard thread) 8.8 10.9 12.9
SIZE TIGHTENING TORQUE (lb.ft.)
The values for tightening torques shown in the M3 1.1
table are valid only for cross-slotted lens head M4 2.9
screws DIN 7985 of the strength class 8.8 and M5 6
with metric ISO-standard thread. M6 10
M8 25
M10 49
DISASSEMBLY AND ASSEMBLY HYP4-2-24
(D/A)
HYDRAULIC PUMPS WX90

NOTES:

15501 9-35990
 DISASSEMBLY AND ASSEMBLY HYP4-2-25
(D/A)
HYDRAULIC PUMPS WX90

2.2 SECONDARY PUMP

2.2.1 GENERAL REPAIR INSTRUCTION

NOTE - Observe the following notices when carrying

out repair work at hydraulic components.

Components of spare part lists

K1 Sealing set complelely (sealing sets are based on

the type of the pump, picture shows for example A
10 VO 28 DFLR, without pilot valve seals). Sealing
material: drive shaft sealing ring FPM, others
NBR.

F6895

K2 Same like previous picture. Only difference: all

material FKM.

F6896

K3 Drive shaft: spare part supply offers you the

following drive shaft types: ISO - key design, SAE
- key design, SAE - splined design.

F6897

K4 Contents of kit "bearing set / miscellaneous parts":

2 tapered roller bearings, 2 bearings shells,
adjustment shim, spacer shim, plugs cylindric pin
to fix the valve plate.
15501 9-35990

F6898
DISASSEMBLY AND ASSEMBLY HYP4-2-26
(D/A)
HYDRAULIC PUMPS WX90

K5 The rotary group is complete with its cylinder with

mounted pressure - pins for cw or ccw rotating
units (pls order your direction of rotation).

F6899

K6 Swash plates are available for cw or ccw rotating

units in the serial design or for horse power
controlled pumps by our spare part service. (Order
your direction of rotation).

F6900

K7 Pcture right shows the control device parts without

the stopper parts. Order with stopper parts if
necessary (see RE 90 124).

F6901

K8 Order a checked and preadjusted pilot valve to

control the pump for pressure compensator ad
flow control. Easy handling is possible to convert
the design of the pilot valve.

F6902

K9 Pilot valve design 18 to 100:

Adapter without orifice of the DFR - pilot valve.
15501 9-35990

F6903
 DISASSEMBLY AND ASSEMBLY HYP4-2-27
(D/A)
HYDRAULIC PUMPS WX90

Pump unit - engine drive shaft seals

1-2 This discription shows how to change the drive

shaft sealing ring but it isn't the way of serial
assembly. The sealing ring is assembled together
with the taper roller bearing from inside the pump
housing normally to get a secure sealing condition.
If you decide to repair the pump in the shown way
be very careful while handling so that the drive
shaft wouldn't be damaged during disassembly of
the shaft sealing ring.

3 Disassemble of the key.

F6905

4 Remove the retaining ring.

F2541

5 Grind screwdriver to disassemble the shaft sealing

ring carefully. Pay attention: Damages of the drive
shaft indicate leakage.
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DISASSEMBLY AND ASSEMBLY HYP4-2-28
(D/A)
HYDRAULIC PUMPS WX90

6 Change the shaft seal and check the contact

surfaces (drive shaft and housing), grease sealing
ring before mounting.

F2539

7 ISO standard drive shaft

Use installation tool for the sealing ring.

F6906

8 Use a suitable pipe or use the control piston of a

bigger pump size to mount the shaft seal ring via
the installation tool, bout don't push it too deap. If
the shaft seal ring touches the bearing ring you will
damage the seal ring.

F2540

9 Assemble the retaining ring.

F2541

10 Assemble the rataining ring. Assemble the key

next by using a plastic hammer. This handling isn't
shown in pictures.
15501 9-35990

F6907
 DISASSEMBLY AND ASSEMBLY HYP4-2-29
(D/A)
HYDRAULIC PUMPS WX90

Disassembly and reassembly of the complete unit

11 Loosen the fixing screws and disassembly the

regulator.

F2542

12 Mark the position of the port plate to pump housing

and loosen the socket screws of the port plate.

F2543

13 Remove the port plate together with the valve

plate and control device parts.
NOTE - Hold the valve plate so that the plate can
not fall down.

F2544

14 Disassemble the taper roller bearing and

adjustment shim.

F2545

15 Disassemble the rotary group.

15501 9-35990

F2546
DISASSEMBLY AND ASSEMBLY HYP4-2-30
(D/A)
HYDRAULIC PUMPS WX90

16 Rimuovere l’anello O-ring.

F2547

17 Recuperare le semiralle cuscinetti.

F2548

18 Mediante estrattore per interni, sfilare la pista

esterna del cuscinetto anteriore.

F2549

19 Rimuovere la piastra di distribuzione.

F2550

20 Mediante estrattore per interni, sfilare la pista

esterna del cuscinetto posteriore.
15501 9-35990

F2551
 DISASSEMBLY AND ASSEMBLY HYP4-2-31
(D/A)
HYDRAULIC PUMPS WX90

21 Remove the O-rings.

F2552

22 Disassemble the head nut of threaded pin.

F2553

23 Disassemble the hexagon fixing nut and the

threaded pin.

F2554

24 Disassemble the swash control piston.

F2555

25 Disassemble the feedback piston.

15501 9-35990

F2556
DISASSEMBLY AND ASSEMBLY HYP4-2-32
(D/A)
HYDRAULIC PUMPS WX90

26 Pull out the drive shaft.

F2557

27 Remove the pistons and the retaining plate.

F2558

28 Remove the retaining ball.

F2559

29 Compress the center spring withthe help of a bolt

complete with washer.

F2560

30 Disassemble the retaining ring.

15501 9-35990

F2561
 DISASSEMBLY AND ASSEMBLY HYP4-2-33
(D/A)
HYDRAULIC PUMPS WX90

31 Remaining parts of the cylinder: pins, cylinder,

shim, spring and reaining ring.

F6908

32 Assemble the pump in reverse order and note the

following steps. (Steps 33-42).

33 Taper roller bearing in the cast iron pump housing

must have a initial tension with 0 ÷ 0,05 mm.
(See adjustment step of taper roller bearing unit
on page 40).

F6909

34-35 Port plate (direction of rotation clockwise): Both

piston guides are glued with Loctite.

- Correct position of the valve plate (clockwise 4°).

- Grease O-rings prior assembly.

F6910
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DISASSEMBLY AND ASSEMBLY HYP4-2-34
(D/A)
HYDRAULIC PUMPS WX90

36-37Port plate (direction of rotation anti-clockwise):

Both piston guides are glued with Loctite.

- Correct position of the valve plate (clockwise 4°).

- Grease O-rings prior assembly.

F6911
38 Correct position of cradle (lubrication bore relief
on the high pressure side), use cradle for clockwise
rotation, if counter clockwise use cradle for counter
clockwise rotation (two different sub-assemblies).

F6912
39 If it possible to lap the cradle (sliding area of the
piston shoes) it can be possible to use the cradle
again. Notice: It isn't allowed to press out the
piston connection parts out of the cradle (scorings
while fitting!).

F6913
40 Connection surfaces between valve plate and
cylinder: if lapping is possible use parts again, but
after lapping procedure use a lapping paper No.
1000 to plan the cylinder and valve plate.

F6914
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 DISASSEMBLY AND ASSEMBLY HYP4-2-35
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HYDRAULIC PUMPS WX90

41 Check running conditions of the control piston.

F6916

42 Check running conditions of the opposite piston.

F6915

43/44 List of A10 control valve DFR parts

4
(1) Body
(2) O-Ring 5 X
(3) Screw M6X30 DIN 912
Tightening torque 1,2 Nm
(4) Plug 7/16 UNF
Tightening torque 2,0 Nm
(5) Screw M4X4 DIN 913
Tightening torque 2,3 Nm

2
F8547

45 Opening X is plugged by plug (4).

Decompression opening X-T is closed by screw (5). 1 5 X 4
15501 9-35990

P
1 2
1 A T 3 F8548
DISASSEMBLY AND ASSEMBLY HYP4-2-36
(D/A)
HYDRAULIC PUMPS WX90

Disassembling and cleaning the control valve

46 Loosen socket screws. Remove the regulator

and place it on work bench.

F2563

47 Remove the O-ring.

F2564

48 Close the port (T), blow out with dry air pressure
at port (A) to clean the regulator.
ATTENTION - Be care that there is no skin
connection during blowing. Look how the orifice
comes out before blowing.

F2565

49 Remove the hexagon nut, disassemble first the

power control, afterwards the flow control.

F2566

50 Loosen the lock nut and unscrew threaded pin.

15501 9-35990

F2567
 DISASSEMBLY AND ASSEMBLY HYP4-2-37
(D/A)
HYDRAULIC PUMPS WX90

51 Disassemble the plug.

F2568

52 Remove the spring collar.

F2569

53 Remove the spring.

F2570

54 Remove the spring cup.

F2571

55 Disassembly the plug.

15501 9-35990

F2572
DISASSEMBLY AND ASSEMBLY HYP4-2-38
(D/A)
HYDRAULIC PUMPS WX90

56 Be careful while disassembling the piston.

F6917

57 Disassemble the plug or orifice (spring area of flow

control).

F6918

58 Clean housing and parts with clean fluid and dry

with are carefully.

F6919

59 Assemble pilot valve in reverse order and note the

following (60 to 63).

60 Check the opening of the orifice.

15501 9-35990

F6920
 DISASSEMBLY AND ASSEMBLY HYP4-2-39
(D/A)
HYDRAULIC PUMPS WX90

61 Be careful when loctiting the orifice.

62 Check the movement of the pilot valve spols, and

drillings should not be damaged.

F6922

63 Adjustments of the bypass orifice:

• open position of the orifice: like shown on the
picture.
• turn the orifice 90° to close it.

F6923

64 For adjustment of the pilot valve see set up

instructions (pag. 41).

F6924
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DISASSEMBLY AND ASSEMBLY HYP4-2-40
(D/A)
HYDRAULIC PUMPS WX90

Mechanical flow limiter (both stopper maximum

and minimum flow).

Size 28

1,58

Differential volume (cm3) if you are rotating the

threaded pin - each rotation.

mechanical stopper min. flow adjustable

Taper roller bearing initial tension

Note for size 18 and 28:

The small pump sizes have to be measured by using

a special shim (Pos. 12) with its tolerance of 1,5 ± 0,01
see detail X. This shim will be disassembled after the
measurement. Measurement, thickness of the special
shim and necessary pretention all together makes the
thickness of the adjustment shim (Pos. 12).

Cast iron housing must have initial tension of the

bearings: 0 ÷ 0,05 mm, grind Pos. 12 if necessary.

15501 9-35990
 DISASSEMBLY AND ASSEMBLY HYP4-2-41
(D/A)
HYDRAULIC PUMPS WX90

Testing and set up instuctions

DR: When pressure line is closed adjust the pressure

of the controller (if it's DFR design then open the
adjustable orifice and increase force of the FR -
spring).

F6927

FR: If swivel angle is in the mid position adjust differential

pressure 14 bar (adjustable orifice in the system
pressure line is partly closed).

F6928

Mechanical flow limiter: While screwing in the threaded

pin you will be able to reduce the flow from Vg max to
35% reduction of Vgmax dependent on the size of the
pump (If you need more reduction of the flow, don't
mount the fixing hexagon nut. Note: to adjust the
threaded pin without the fixing hexagon nut do it by the
existence of the working pressure).

F6929
15501 9-35990
DISASSEMBLY AND ASSEMBLY HYP4-2-42
(D/A)
HYDRAULIC PUMPS WX90

Tools, auxiliary tools, tightening torques

Loctite used:
break - off plugs N. 601
other applications N. 242

Maximum tightening torques (Ma Nm)

(screws lubricated µ = 0,125)

Screw Thread sizes

strength
class M4 M5 M6 M8 M10 M12 M14 M16 M18 M20 M24 M30

8.8 2,3 5,0 8,5 21 41 72 115 176 240 350 600 1220

10.9 3,2 7,2 12 29 58 100 165 250 350 490 840 1670

12.9 4,1 8,5 14,5 35 70 121 195 300 410 590 990 2000

F8549

15501 9-35990
 DISASSEMBLY AND ASSEMBLY HYP4-2-43
(D/A)
HYDRAULIC PUMPS WX90

2.3 GEAR DOUBLE PUMP

CAUTION - The weight of the gear double pump is about 5.2 kg.

2.3.1 DISASSEMBLY

NOTE - Prior to proceeding with the disassembly operation:

• clean accurately the outer surfaces of the gear double pump;
• each reference marks on the contact faces, on cover (1), bodies (2 and 7), flange (10) and suction and
delivery ports.
See fig. 3.

1 Block flange (10) of the pump in a vice, with cover (1) upward.

2 Loosen and remove screws (24).

3 Remove cover (1) and the relevant O-ring (16).

4 Remove the body of power system/brakes pump (2) complete with gears (13 and 14) and bushes (3 and
4).

5 Pull-out gears (13 and 14) then recover bushes (3 and 4) from power system/brakes valve (2).

6 Remove the two back-up rings (19) and seals (18) from bushes (3 and 4).

7 Remove the two intermediate plates (5 and 6) then separate them and pull-out joint (15) and O-rings (16).

8 Remove the body of steering pump (7) complete with gears (11 and 12) and bushes (8 and 9).

9 Pull-out gears (11 and 12) then recover bushes (8 and 9) from the power steering body (7).

10 Remove back-up rings (19) and seals (18) from bushes (8 and 9).

11 Remove O-ring (16) from flange (10).

12 Using the appropriate pliers, remove snap ring (21), then remove the two seals (17) together with
reinforcement ring (20).
15501 9-35990
DISASSEMBLY AND ASSEMBLY HYP4-2-44
(D/A)
HYDRAULIC PUMPS WX90

2.3.2 INSPECTION

Check that the components removed are free from fouling and do not show signs of discoloration, then clean
them with diesel fuel.

NOTE - Do not clean rubber made components with diesel fuel.

Pump body

In order to work in an efficient manner, the pump is designed so that the relevant gears turn with the tip of the
teeth very near the body. Thus, a used pump shows a contact trace near the suction port. The nominal length
of the contact trace is about 1/3 of the inner circumference of the body.
In case the trace is longer than half the circumference, this could be an indication of the wear of one bush or
one gear shaft.

ACCEPTABLE TRACE

Fig. 1
NON ACCEPTABLE TRACE

Bush

A bush can be considered in good conditions, when the inner contact face is not rough and the contact faces
of the gears are shining without signs of important scoring.

Replace the bush when the following conditions are found:

• when the roughness of the inner surface is such to be felt by a finger nail;
• when the contact results extended to the entire sliding surface;
• when the roughness of the side face is such to be felt by a finger nail;
• when it is evident that foreign materials have entered the bushing mating faces, the gears and the pump
body.

HUB FACE
CONTACT SURFACE
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SUCTION SIDE DELIVERY SIDE

Fig. 2
 DISASSEMBLY AND ASSEMBLY HYP4-2-45
(D/A)
HYDRAULIC PUMPS WX90

Gear

Replace the gear when the following conditions are found:

when the sides of the gears are chipped;
when the surface of the gears is cracked or abnormally worn on one side only.

NOTE - If the surface is rough or discoloured, also the bush and the pump body could result in bad conditions,
thus it is necessary to check them.
15501 9-35990
DISASSEMBLY AND ASSEMBLY HYP4-2-46
(D/A)
HYDRAULIC PUMPS WX90

2.3.3 ASSEMBLY (see figure 3)

NOTE - Prior to proceeding with the assembly operations:

• clean all components, then lubricate the inner ones with hydraulic fluid;
• install the O-rings only after greasing appropriately the relevant seats.

1 Install bush (8) in the steering pump body (7), ensuring that the direction of the suction and delivery are
correct.

2 Insert gears (11 and 12) and close the gear group by mounting bush (9).

3 Insert flange (10) paying special attention to seals (17).

4 Install intermediate plate (6), then insert joint (15) in the relevant seat, ensuring that it engages perfectly
with gear (12).

5 Install intermediate plate (5) after positioning dowels (22).

6 Install bush (4) in the power system/brakes valve body (2), ensuring that the directions of the suction and
delivery are correct.

7 Mount the power system/brakes pump body (2) on intermediate plate (5).

8 Insert gears (13 and 14) and close the gear group by mounting bush (3).

9 Insert dowels (22), then install cover (1).

10 Mount the four screws (24) and the relevant washers (23) tightening them to the prescribed torque.
Tightening torque: 4 daNm.

NOTE - Prior to the installation on the machine, check, by rotating manually, that the pump is not seized.
15501 9-35990
 DISASSEMBLY AND ASSEMBLY HYP4-2-47
(D/A)
HYDRAULIC PUMPS WX90

10 16 11 6 5 4 2 3 1

18

14

19

17 13

24

23

22 9 7 8 12 15 F8959

Fig. 3

1 - Cover 9 - Bush 17 - Seal ring

2 - Pump body 10 - Flange 18 - Seal
3 - Bush 11 - Gear 19 - Back -up ring
4 - Bush 12 - Gear 22 - Centering ping
5 - Intermediate plate 13 - Gear 23 - Nut
6 - Intermediate plate 14 - Gear 24 - Screw
7 - Pump body 15 - Joint
8 - Bush 16 - O-ring
15501 9-35990
DISASSEMBLY AND ASSEMBLY HYP4-2-48
(D/A)
HYDRAULIC PUMPS WX90

NOTES:

15501 9-35990
 OPERATION PRINCIPLE CV4-3-1
(O/P)
CONTROL VALVE WX90

3. CONTROL VALVES

3.1 MAIN CONTROL VALVE

3.1.1 GENERAL INFORMATION

The main control valve is a compensated Load Sensing type, controlling the motion of arm, of travel, of blade
stabilizers.
It includes:
• Inlet section.
• Nine distribution elements.
• One closing section.
• One coupling tie rod kit.

Inlet section

The inlet section includes:

• delivery connection
• drain connection
• max relief valve (load Sensing)
• safety valve
• drain valve
• adjusted opening (regulator)
• two-way throttle valve with different throttle for the two directions.

Control valve elements

The distribution sections are 9, each one containing:

• one spool
• one return mechanism (caps and springs)
• one compensator
• one non return valve
• antichoc and anticavitation valve (according to the use).

WARNING
As each distribution element has been designed according to the use, the relevant rods are not
interchangeable.

Each distribution element should transfer hydraulic oil flow requirement to the users according to the needs
of the operator who operates control levers/pedals.

Closing section
15501 9-35990

The closing section completes the control valve. It has no valve and no cavitation.

Tie rod kit

It includes three tie rods secured to the inlet section and relevant lock nuts.
OPERATION PRINCIPLE CV4-3-2
(O/P)
CONTROL VALVE WX90

Fig. 1 - Main control valve

1
F8487

1 - Inlet section
2 - Control valve section (nine sections)
3 - Closing section
15501 9-35990
 OPERATION PRINCIPLE CV4-3-3
(O/P)
CONTROL VALVE WX90

Fig. 2 - Control valve hydraulic diagram (main distribution)

Closing section

Section n. Hammer
9

Section n. Blade/stabilizer cylinder

8

Arm angle
Section n. (swing)
7

Section n. Travel motor

6

Section n. Travel motor

5

Section n. Positioner
control valve
4

Section n. Penetration
3

Section n. Lifting
2

Section n. Bucket
1
15501 9-35990

Inlet section

To oil cooler
From main
F8678
pump
OPERATION PRINCIPLE CV4-3-4
(O/P)
CONTROL VALVE WX90

3.1.2 OPERATION OF LS MAIN CONTROL VALVE

• Load Sensing circuit

The right body of control valve, together with the main pump, operates so as to guarantee an hydraulic supply
distribution in an independent way of load applied, if it remain out of power controlling.
The circuit, called Load Sensing, works so that only the required flow oil is generated by the main pump.

As long as no pilot control valves are operated and no flow is required from user (all control spools are in neutral
position), the Load Sensing line, and therefore X port of pump governor, has no pressure (see Fig. 2A).
The spool of Load Sensing valve of main pump governor is maintained in rest position by the setting spring
action.

In these conditions the main pump supplies only as much oil, as it is required to compensate the system
leakage; the pressure of pump supply line (stand-by pressure) is about 26 bar (this value can be measured
at M port of main pump).

When a spool control valve (2) is operated by a pilot valve device, an hydraulic oil route from the pump to the
user is opened.
The opening cross section, that occurs with the movement of directional control valve spool, operates
practically like a gauging orifice.
Any oil flow change (movement speed of user) controlled by the operator, has an effect on the pump flow
through the Load Sensing signal.

When only one spool of directional control valve (2) is operated, the pump pressure is provide to the user, and
by means of the Load Sensing line, is applied to the spring side spool of Load Sensing valve (1.1) of pump
governor.
The position of pump swivel plate will change to increase the flow in according to the demand.
When the pump supply pressure exceeds the load pressure, the user begins to move and the incoming flow
generates a pressure drop (∆p2) through the orifice of control spool.
When this pressure drop (∆p2) corresponds to the spring setting load of Load Sensing valve of governor, a
balance is established (∆p = 19 bar).
The pump reacts to each control spool movement because its governor has the function to maintain a pressure
drop constant (∆p2) to any change of gauging orifice (control spool).

Fig. 2A - Schematic diagram of Load Sensing Circuit

1
15501 9-35990

F8518

3 2 7 5 6 1.1 1.2

1 Main pump - 1.1 Load Sensing controller - 1.2 Constant Power control valve - 2 Control valves spool axis for
direction and speed control equivalent to a gauging orifice - 3 Pressure compensator with integrated Load Sensing
pressure comparison - 4 Load holding check valves - 5 Flow limiter valve - 6 Pressure cut off valve - 7 Load Sensing
line.
 OPERATION PRINCIPLE CV4-3-5
(O/P)
CONTROL VALVE WX90

Fig. 3 - Main pump exploded view

7
2

7
2

7
2

7
6
2
4
1
2
2 6
7
2
2
6
7
9
2
6
7
9
2
3
7 6

8
5
7 2
6
8 9

6
9

6
8

6
8 20
F8680
15501 9-35990

1 - Drain valve 6 - Anticavitation and non-return valve

2 - Safety valve 7 - Plug and compensator
3 - Relief valve LS 8 - Anticavitation and safety valve
4 - Two-way throttle valve 9 - Plug
5 - Adjusted opening (governor LS) 20 - Tie rod kit
OPERATION PRINCIPLE CV4-3-6
(O/P)
CONTROL VALVE WX90

10
2
11
2
6
10
9
12
9
6
10
9
13
9
6
10 8
14
8
6
10
8
15
8
6
2
10
2
16
6
10
2
17
2
6
10
2
18
2
6
10
2
19
2
6

3
5

2
Fig. 3A - Main pump

F8679

1 - Drain valve 11 - Hammer control rod

15501 9-35990

2 - Safety valve 4 1 12 - Stabilizer/blade cylinder control rod

3 - Relief valve LS 13 - Arm angle control rod
4 - Two-way throttle valve 14 - Travel control rod 1st spool
5 - Adjusted opening (governor LS) 15 - Travel control rod 2nd spool
6 - Anticavitation and non-return valve 16 - Positioner control rod
7 - 17 - Penetration control rod
8 - Anticavitation and safety valve 18 - Lifting control rod
9 - Plug 19 - Bucket control rod
10 - Pressure compensator
 OPERATION PRINCIPLE CV4-3-7
(O/P)
CONTROL VALVE WX90

• Load compensation circuit

In case several users are operated at the same time, the pressure of highest load always is directed into the
Load Sensing line and forwarded to the pump Load Sensing governor (see Fig. 4).
All the pressure compensators (3) are connected among them by means of Load Sensing line.
The pressure compensator related to the highest load user is fully opened.
The flow to the other lower load users is controlled by the pressure compensator on which this highest load
pressure works, with the result to equalise the difference between the own user pressure and pressure of
highest load.
By that the same conditions on all the gauging orifice of operated users are obtained, that is:
a) the pump pressure before the gauging orifices.
b) a pressure behind the gauging orifices which will assume a value equal to the pressure before the gauging
orifice minus the pressure drop set on Load Sensing controller of pump (1.1).
In this way the movement is guaranteed at the same time to all the users, apart from the applied load to each
user.

• Unsaturated circuit

If now the required oil flow of operated users becomes higher than the maximum pump flow, the pressure drop
on the gauging orifice of spool axis decreases under the value of pressure drop of Load Sensing controller
(1.1).
In these conditions the Load Sensing controller is out of function and the pump is thereby swivelled to the
maximum and follows the constant power controller only.
The distribution of the oil flow to the users is therefore proportional and corresponds only to the opening of
gauging orifice and is further on load independent (always if it remains out of power controlling).
The pressure drop over the gauging orifice is equal to:

∆p 2.1 = ∆p 2.2 = ∆p 2.3 < ∆p 1.1

In these conditions all the users are operating. The pump flow is distributed to the users proportionally to the
cross opening section of control spools, assuring the movement at the same time. This property remains
established until a pressure drop of ∆p 2 = 3 bar.

Fig. 4 - Schematic diagram of Load Sensing Circuit

All spools operating 1

15501 9-35990

F8518

3 2 7 5 6 1.1 1.2

1 Main pump - 1.1 Load Sensing controller - 1.2 Constant Power control valve - 2 Control valves spool axis for
direction and speed control equivalent to a gauging orifice - 3 Pressure compensator with integrated Load Sensing
pressure comparison - 4 Load holding check valves - 5 Flow limiter valve - 6 Pressure cut off valve - 7 Load Sensing
line.
OPERATION PRINCIPLE CV4-3-8
(O/P)
CONTROL VALVE WX90

Directional control valve description

• Construction

Each directional control valve (see Fig. 5) consists of housing (3), the control spool (10) with pressure
compensator (5) and the load holding check valves (11). The directional control valve can be arranged with
pressure relief valve and anticavitation valves (2) or only anticavitation valves, or only plugs.
The control spool (10) is spring centered by the spring seat and spring (8) from each side and is closed both
sides by the cover (7).
The throttle valves one way (1) are located in the covers.

Fig. 5 - Directional control valve (section - distribution element diagram)

2 3 4 5 13 11 2

9
9
8
8
12
14 12

15
7
7

15 4

10

11
13

3 F8522

14 2 2
15501 9-35990

1 Throttle valve one way - 2 Pressure relief and anticavitation valve - 3 Housing - 4 User port A - 5 Pressure
compensator - 6 User port B - 7 Cover - 8 Spring - 9 Spring seat - 10 Control spool - 11 Load holding check valve
- 12 Spool stroke limits - 13 Spring compensator spool - 14 Pilot pressure port a - 15 Pilot pressure port b.

NOTE - The figure shows the directional control valve relate to arm section with control spool in neutral position.
 OPERATION PRINCIPLE CV4-3-9
(O/P)
CONTROL VALVE WX90

• Function of the directional control valve, one user operated

With all spools in the neutral position, so all user ports are closed (see Fig. 5). The Load Sensing line is free
of pressure.
The spools of pressure compensators (5) are at the lowest stroke end by the force of the spring (13).When
one pilot device operates, the pilot oil goes, for example, to a port (14) over the throttle valve with the free flow
check (1) to the spring chamber (8). By this pilot pressure the control spool (10) is shifted in proportional way
to the pressure signal.
The oil out of the channel P goes to the chamber P' below the pressure compensator (5). The spool of the
pressure compensator moves against the weak spring (13) upward. A pressure is signalled into the Load
Sensing line.
The pump begins to supply oil at a pressure equal to the load plus the ∆p (21 bar).
The connection P' to P" is opened now. When the pressure increases above the load pressure, the load holding
check valve opens the path P" and the oil flow comes to the user port A or B depending on the side selected.
The user starts moving with the control speed given by the pilot valve.
The pressure P' is equal to P" (spring unconsidered) and the Load Sensing pressure corresponds the user
pressure in A. The pressure compensator must not do any load compensation (therefore is completely
opened).
The main pump generates the flow according to the requirement as selected by the pilot maintaining constant
the ∆p pressure before and behind the spool control. The ∆p value is set on the Load Sensing controller of
pump (1.1).
This flow will remain constant if the control spool opening will not change.
Subsequently, the preselected speed of the user, remains constant apart from the load of user, if it remains
out of pump power controlling area.

• Function of directional control valve, several users operated

If during the operation previously described, several users are operated, a signal coming from user with highest
load is supplied to the pump through the Load Sensing channel.
The pump modifies its condition, supplying a flow equal to the sum of the flows required from the several users
to the pressure value determined by the user that works with highest load (see Fig. 6).

This signal has an influence also on the pressure compensators that are working with lower load in the following
way:

A) The pressure compensator of user with highest load is completely opened.

B) All control valve compensators receive the signal from the rear side (spring side) closing them; in this way
the pressure after control spools will be equal for all users, because it is no more dependent on user but
on the load generated by the same compensators.

C) The compensators of the users that work at lower load of the compensator of the above point A), assume
a position so as to maintain constant the pressure after the control spools, and to compensate the pressure
difference between the load required and that supplied from pump.

Higher is the pressure difference between pump load and user load, and smaller is the clearance of the opening
passage from compensator toward the user.
15501 9-35990
OPERATION PRINCIPLE CV4-3-10
(O/P)
CONTROL VALVE WX90

Fig. 5A - Pressure compensator

1 - Plug
2 - Plug seal
3 - Compensator
1

F8523

Fig. 6 - Schematic diagram of function with several users

50 bar 100 bar 150 bar

50 l/min. 50 l/min. 50 l/min.

User
compensator
15501 9-35990

Main pump
 OPERATION PRINCIPLE CV4-3-11
(O/P)
CONTROL VALVE WX90

NOTE: Control spool axis in neutral position. The user not operates.

Fig. 7

F8519

NOTE: Control spool in position for user operation of A side.

Pilot control valve at the stroke end.
Side B: return from the user.

Fig. 8

A P' P" B

a b

F8520
Pa P P Pb T

NOTE: Pressure compensator in the control function of a lower loaded user while an another control spool is
operating with an high load.

Fig. 9
A P' P" B

a b
15501 9-35990

F8521
Pa P P Pb T
OPERATION PRINCIPLE CV4-3-12
(O/P)
CONTROL VALVE WX90

Pressure relief and anticavitation valve description

• Construction

The pressure relief and anticavitation valve (see fig. 10) is screwed on directional control valve and consists
of housing with main and pilot valve.
The main valve consists of spool (3) with needle spool (9) and is maintained closed by the pressure action in
chamber B (4).
The spring (5) press against the valve seat (19) as return spring.
The pilot valve consists of poppet valve (14), which is closed by the spring action (15) onto the valve seat (13).
The spring force (15) on the poppet valve (14) can be adjusted by the screw (7) allowing the relief pressure
setting.

• Pressure relief valve function

When the pressure from chamber A (1) via the channel (8, 12) in the chamber B (4) reaches the value set at
poppet valve (14), this opens it.
The oil behind the poppet valve (14) in chamber C (6) escapes over the channels (17, 18) to the chamber D
(10). By this the pressure drop in chamber B (4) takes place. The needle spool (9) moves to the right and sits
with its hollow cavity at the head on to the tip of the poppet (14). A throttled flow takes place from chamber A
(1) to the chamber B (4) now. By these two measures the valve is stabilized.
The pressure in chamber B (4) is reduced now to a ratio A : B = 1 : 1.4. The user pressure in chamber A (1)
opens the spool (3) and allows oil to flow to the chamber D (10).

As long as the hydraulic force which acts at the front area of the needle spool (9) equalises the mechanical
force of the adjustment spring (15) and the pilot poppet valve (14) remains open, the load pressure in the
chamber A or B can be limited.

If the pressure in the user chamber A or B drops now so far, the spring force (15) of the poppet valve (14)
presses against the seat (13) and prevents an oil flow from the chamber C (6) to the chamber D (10).
By the throttled oil flow over the clearance (12) to the chamber B (4), its pressure reaches and equalises to
the pressure of chamber A (1).
The spool (3) closes and the needle spool reaches its rest position by the force of the spring (5).
The pressure relief valve, used in pairs, are installed on directional control valve related to arm, boom and
bucket.
The pressure relief valve, used as main pressure relief of the main pump circuit is installed directly on right
body (M7) of control valve. The setting values of each pressure relief valve are shown on hydraulic diagram
of Fig. 2.

• Anticavitation valve function

If in the chamber A (1) an underpressure occurs, so that a differential pressure related to chamber D (10) is
generated, the spool (3) is shifted and opens the connection between chamber A (1) and chamber D (10).
15501 9-35990
 OPERATION PRINCIPLE CV4-3-13
(O/P)
CONTROL VALVE WX90

Fig. 10 - Pressure relief and anticavitation valve

3
2 4 (B)
5 6 (C)
19
16 7
1 (A)
9
8
12
20
10 (D)

17
20 20

13 14 18 15

re
su
es
/Pr
ne
7 Pr
e ss
io

15

14

Attention to spool seal

assembly position.
For installation a tool is
20 necessary.

F8524

1 - Chamber A 12 - Clearance
2 - Lock effective area 13 - Valve seat
15501 9-35990

3 - Lock 14 - Poppet valve

4 - Chamber B 15 - Spring
5 - Spring 16 - Spool effective area
6 - Chamber C 17 - Channel
7 - Adjusting screw 18 - Channel
8 - Channel 19 - Valve seat
9 - Needle spool 20 - Anticavitation and safety valve
10 - Chamber D
OPERATION PRINCIPLE CV4-3-14
(O/P)
CONTROL VALVE WX90

Cut off valve

The pressure related to maximum load is limited by the direct acting of the cut off valve (see fig. 11).
The valve operates on the Load Sensing line and prevents the increase of pressure above the setting value
of 330 ± 5 bar.

• Construction and function

The valve essentially consists of the housing, the poppet (1), spring (3) and adjusting screw (4). The spring
(3) acts upon the poppet (1) on its seat. The channel P is connected to the Load Sensing line. The pressure
in the Load Sensing line acts upon the poppet surface.
If the existing pressure in the channel P exceeds the spring (3) setting, the poppet (1) opens against the spring
(3). The fluid flows from channel P to channel T.
The pressure adjustment is performed by the adjusting screw (4).
Reaching the spring setting value, the poppet (1) opens and puts to drain the Load Sensing signal, so that the
pressure on main line is limited.

Fig. 11 - Cut off valve

5 1

3 2

T
P

P
T
6
4
6
6
4
15501 9-35990

F8539

1 Piston - 2 Control line - 3 Spring - 4 Adjustingscrew - 5 Valve seat - 6 Cut of pressure valve.
 OPERATION PRINCIPLE CV4-3-15
(O/P)
CONTROL VALVE WX90

Anticavitation valve

• Construction

The anticavitation valves (Fig. 12) are screwed on the directional control valve related to travel and positioning
sections, and consist of a housing (9), with valve seat (5) within the spool (8) can shift against a spring (4).

• Function as check valve

The user pressure in the channel B is applied via the channel (7) in the chamber (3), spring (4) side. Because
of the effective area, the spool is held in the seat and the connection to tank port is prevented.

• Function as anticavitation valve

If in the channel B (1) an underpressure occurs so that a differential pressure relate to channel T (6) is
generated, the spool (8) is shifted and opens the connection between channel B (1) and channel T (6).

Fig. 12 - Anticavitation valve

5 2 3 9

B
1

T
7 6 4 9 10

10 10 10 10 10
15501 9-35990

F8540

1 - Channel B 6 - Channel T
2 - Effective spool area 7 - Channel
3 - Spring chamber 8 - Spool
4 - Spring 9 - Housing
5 - Valve seat 10 - Anticavitation valve
OPERATION PRINCIPLE CV4-3-16
(O/P)
CONTROL VALVE WX90

Unloading valve

• Construction

It includes a block fastened to control valve (M7) right body, a spool and a cursor which keeps oil at disposal
for control user.

• Function

Main pump never stops sending oil to control valve. Unloading valve discharges oil directly when no control
is used and guarantees a minimum quantity of oil for the control if used; this allows a prompt response at control
operation.

Fig. 13 - Unloading valve 1 - Plug

2 - Spool
3 - Seal
4 - Outer spring
5 - Inner spring
6 - Valve assembly

2 6 15501 9-35990

F8541
 OPERATION PRINCIPLE CV4-3-17
(O/P)
CONTROL VALVE WX90

Flow limiter valve

The flow limiter valve (Fig. 14) is installed on the Load Sensing line in parallel to the cut off valve in the central
body of control valve.
The valve has two functions:
• When no user is operated (all control spool axis are in neutral position) the flow limiter valve releases the
Load Sensing line to the tank.
• If a user runs against the maximum pressure (i.e. to the cylinder stroke end) and another user is operated,
the pressure drop generated before and after control spool axis is used to control the pump flow through the
moving of swivel cylinder plate.

The flow of Load Sensing line that pass through the flow limiter valve while another user is operating, is used
to check the position of the pump swivel plate from stroke end of minimum flow.

• Construction and function

The flow limiter valve consists of a gauging orifice and a pressure compensator with a control spool.
The pressure compensator holds the pressure drop over the gauging orifice in the flow condition, to a constant
value.
By that the flow is maintained constant to the predesigned value.
The gauging orifice controls the flow going out to the value of 1 liter/minute.
In the initial position the port P is opened to tank, while in flow condition the pressure in the spring chamber
is lesser than the amount of pressure drop caused by the gauging orifice.
The nominal ∆p is determined by the spring. If the flow going to the port T is higher than 1 liter/minute, the
pressure drop increases, the control spool moves and reduces the outgoing flow so far as the difference of
pressure in P and in the spring chamber corresponds to the nominal ∆p value.

Fig. 14 - Flow limiter valve

P
15501 9-35990

Flow limiter valve

F8542
OPERATION PRINCIPLE CV4-3-18
(O/P)
CONTROL VALVE WX90

3.2 ROTATION CONTROL VALVE

3.2.1 GENERAL INFORMATION

The rotation control valve is an open-centre type, controlling superstructure rotation.

It includes:
• Inlet section.
• One distribution elements.
• One drain section.
• One coupling tie rod kit.

Inlet section

The inlet section includes the primary valve (relief valve), delivery connection.

Control valve element (section)

The distribution section is one only and includes:

• one spool
• one return mechanism (caps and springs)
• one non return valve
• anticavitation valve.

Drain section

The drain section completes the control valve including drain connection.

Tie rod kit

It includes four tie rods secured to the inlet section and relevant lock nuts.

WARNING
As each distribution element has been designed according to the use, the relevant rods are not
interchangeable.

Each distribution element should transfer hydraulic oil flow requirement to the users according to the needs
of the operator who operates control levers/pedals.
15501 9-35990
 OPERATION PRINCIPLE CV4-3-19
(O/P)
CONTROL VALVE WX90

Fig. 15 - Rotation control valve (assembly)

F8458

1 - Relief valve 5 - Closing section

2 - Rotation control rod 6 - Non return valve
3 - Anticavitation and safety valve 7 - Inlet section
4 - Tie rod kit 8 - Rotation section

Fig. 16 - Rotation control valve (exploded view)

6 1
4 5

3
15501 9-35990

F8682
OPERATION PRINCIPLE CV4-3-20
(O/P)
CONTROL VALVE WX90

Fig. 17 - Rotation control valve (hydraulic diagram)

From secondary pump

1 6
7 Inlet section

Rotation control valve element

8
3
3

5 Closing section

F8681
To reservoir

1 - Relief valve 5 - Closing section

2 - Rotation control rod 6 - Non return valve
3 - Anticavitation and safety valve 7 - Inlet section
4 - Tie rod kit 8 - Rotation section

Fig. 18 - Rotation control valve (section)

6 1

15501 9-35990

2
F8459
 OPERATION PRINCIPLE CV4-3-21
(O/P)
CONTROL VALVE WX90

Fig. 19 - Relief valve

1 - Plug
2 - Valve

F3350

Fig. 20 - Anticavitation valve

6
15501 9-35990

7
1 - Cover
2 - Nut
3 - Adjusting screw
4 - Spring F3353
5 - Poppet valve
6 - Lock
7 - Valve
OPERATION PRINCIPLE CV4-3-22
(O/P)
CONTROL VALVE WX90

NOTES:

15501 9-35990
 DISASSEMBLY AND ASSEMBLY CV4-3-1
(D/A)
CONTROL VALVE WX90

3.1 MAIN CONTROL VALVE

3.1.1 MAINTENANCE

Control valve maintenance essentially consists of:

- cleaning and check of the following parts:

• bucket control rod (section 1);

• lifting control rod (section 2);
• digging control rod (section 3);
• positioner control rod (section 4);
• travel control rod (section 5);
• travel control rod (section 6);
• arm angle control rod (section 7);
• side stabilizer/blade control rod (section 8);
• hydraulic hammer control rod (section 9);

- cleaning, check and replacement, if necessary, of the following valves:

• relief valve (inlet section);

• safety valves (inlet section);
• unloading valves (inlet section);
• two-way throttle valve, adjusted opening (inlet section);
• two-way throttle valve different for the two flow ways (inlet section);
• non return valves (on all sections);
• anticavitation and non return valves (on sections 5,6);
• anticavitation and antichoc valves (on sections 1,2,3,4);

CAUTION - The control valve weight is about 85 kg.

3.1.2 DISASSEMBLY AND ASSEMBLY OF MAIN CONTROL VALVE PARTS

NOTE - Before disassembly:

• clean main control valve outer surface;
• replace seals and O-rings, each time control valve bodies are to be splitted.

1 For control valve splitting; inlet section, 9 user sections, closing section, untighten the three fastening
screws.

2 Replace seals and relative O-rings.

4 Assembly follows the above steps in reverse order.

5 Tighten the fastening screws at the correct tightening torque, see chart on paragraph 3.1.5.
15501 9-35990
DISASSEMBLY AND ASSEMBLY CV4-3-2
(D/A)
CONTROL VALVE WX90

3.1.3 REMOVAL AND FITTING OF DISTRIBUTION ELEMENT RODS

Main control valve rods

NOTE - The rods involved in this removal are:

• bucket control rod.
• lifting control rod;
• digging control rod;
• positioner control rod;
• travel control rod (sect.5);
• travel control rod (sect.6);
• arm angle control rod;
• stabilizer/blade control rod;
• hydraulic hammer control rod;

WARNING
• As each distribution element has been designed according to the use, the relevant rods are not
interchangeable and cannot be overturned.
• Spring cover caps should not be exchanged.
• Do not change the position of adjusting screws for distribution rod end-of-stroke adjustment. If
adjusting screw removal is necessary, measure their length before removal, between the screw
head and lock nut. In this way you can easily replace them in their original position.

1 Untighten the fastening screws of spring cover caps.

2 Remove the screws, without changing the position of the adjusting screws.

3 Remove the rods and mark their position for an easy refitting.

4 Assembly follows the above steps in reverse order.

5 Tighten the fastening screws at the correct tightening torque, see chart on paragraph 3.1.5.

3.1.4 VALVE REMOVAL AND FITTING OF MAIN CONTROL VALVE

NOTE - The valves involved in this removal are:

• relief valve (inlet section);
• safety valves (inlet section);
• unloading valves (inlet section);
• two-way throttle valve, adjusted opening (inlet section);
• two-way throttle valve different for the two flow ways (inlet section);
• non return valves (on all sections);
• anticavitation and non return valves (on sections 5,6);
• anticavitation and antichoc valves (on sections 1,2,3,4);

NOTE - Before removal:

• clean control valve r.h. body outer surface;
• replace seals and O-rings, each time a valve has to be removed.
15501 9-35990

1 For valve removal, untighten directly the relative valve body.

2 Fit or replace, making sure to tighten the valve body at the correct tightening torque shown on chart on
paragraph 3.1.5.
 DISASSEMBLY AND ASSEMBLY CV4-3-3
(D/A)
CONTROL VALVE WX90

Instructions for fitting and removal of securing covers.

Manual fitting of securing covers Removal of securing

on relief valve. covers.

3.1.5 MAIN CONTROL VALVE TIGHTENING TORQUES (See fig. 3)

ITEM DESCRIPTION TIGHTENING TORQUE

Nm
1 Unloading valve 100
2 Safety valve 70
3 Relief valve LS 70
4 Two-way throttle valve 20
5 Adjusted opening (governor LS) 20
6 Anticavitation and non return valve 25
7 Plug 70
8 Anticavitation and safety valve 70
9 Plug 30
20 Tie rods 60
15501 9-35990
DISASSEMBLY AND ASSEMBLY CV4-3-4
(D/A)
CONTROL VALVE WX90

3.2 ROTATION CONTROL VALVE

3.2.1 MAINTENANCE

Control valve maintenance essentially consists of:

- cleaning and check of the following parts:
• rotation control rod;

- cleaning, check and replacement, if necessary, of the following valves:

• primary valve;
• anticavitation and safety valve;

CAUTION - The control valve weight is about 15 kg.

3.2.2 DISASSEMBLY AND ASSEMBLY OF ROTATION CONTROL VALVE

NOTE - Before disassembly:

• clean control valve outer surface;
• replace seals and O-rings, each time control valve parts are to be splitted.

1 For inlet section splitting from from the rotation control valve element, untighten the four fastening
screws.
2 Replace seals and relative O-rings.
3 Assembly follows the above steps in reverse order.
4 Tighten the fastening screws at the correct tightening torque, see chart on paragraph 3.2.5.

3.2.3 REMOVAL AND FITTING OF DISTRIBUTION ELEMENT ROD

Rotation control valve rod

• rotation control valve rod;

1 Untighten the fastening screws of spring cover caps.

2 Remove the screws, without changing the position of the adjusting screws.
3 Remove the rod.
4 Assembly follows the above steps in reverse order.
5 Tighten the four fastening screws at the correct tightening torque, see chart on paragraph 3.2.5.

3.2.4 VALVE REMOVAL AND FITTING OF ROTATION CONTROL VALVE

NOTE - The valves involved in this removal are:

• anticavitation and non return valves (section);
• relief valve (inlet section).

NOTE - Before removal:

• clean control valve outer surface;
• replace seals and O-rings, each time a valve has to be removed.
15501 9-35990

1 For valve removal, untighten directly the relative valve body.

2 Fit or replace, making sure to tighten the valve body at the correct tightening torque shown on chart on
paragraph 3.2.5.
 DISASSEMBLY AND ASSEMBLY CV4-3-5
(D/A)
CONTROL VALVE WX90

3.2.5 ROTATION CONTROL VALVE TIGHTENING TORQUES (See fig.16)

ITEM DESCRIPTION TIGHTENING TORQUE

Nm
1 Relief valve 70
3 Anticavitation and non return valve 25
6 Non return valve 25
4 Tie rods 18
15501 9-35990
DISASSEMBLY AND ASSEMBLY CV4-3-6
(D/A)
CONTROL VALVE WX90

NOTES:

15501 9-35990
 OPERATION PRINCIPLE SRD4-4-1
(O/P)
SWING DEVICE WX90

4. SWING DEVICE

4.1 SWING DEVICE

4.1.1 OUTLINE

The swing device consists of an hydraulic motor and a swing reduction device.
The hydraulic motor is an axial piston type.
The swing reduction carries out the upperstructure swing movement by means of motor pinion matching to
the inner race of swing bearing.
The swing device is located on main frame of upperstructure.

Hydraulic diagram

Swing hydraulic motor

Swing reduction device

Swing hydraulic motor

F8543
15501 9-35990
4.1.2 SPECIFICATIONS AND DATA

Swing reduction device technical data

Type ................................................................................................................................................ planetary

Ratios .............................................................................................................................................. 1 : 22,67:
Oil quantity ............................................................................................................................... 3 litres± 10 %
Weight (*) ..................................................................................................................................70 kg ± 10 %
Brake opening min. pressure ............................................................................................................. 5,5 bar
Brake disconnection control max. pressure ........................................................................................ 50 bar

(*) Without oil and with swing hydraulic motor.

Swing motor technical data (theorethical values)

Type ........................................................................................................................................... axial pistons
Displacement ........................................................................................................................................ 32 cc
Weight ................................................................................................................................................ 10,5 kg

1 - Fill plug - oil level and exhaust M22x1,5

2 - Drain oil plug M18x1,5
3 - Brake control connection M14x1,5

F10578
 OPERATION PRINCIPLE SRD4-4-3
(O/P)
SWING DEVICE WX90

4.2 SWING HYDRAULIC MOTOR

4.2.1 DESCRIPTION

The swing hydraulic motor consists of an axial pistons motor. The motor receives oil coming from the control
valve, that operates on pistons, and causes the drive shaft rotation.
The direction of rotation of swing hydraulic motor is depending on which input port the oil is fed.
The axial pistons motor consists of a cylinder block (3) containing seven pistons (4), that can slide into their
seats. The cylinder block (3) turns together the output shaft (1) when the pistons shift with alternative motion.
The seven pistons (4) are installed on spherical couplings.
The cylinder block (3) is tilted respect to the output drive shaft (1): The control plate (5) is in contact with the
cylinder block end(3): The tilt angle of cylinder block(3) is 40°.

F6960

7
5 1
2
3
6

1 - Output drive shaft

2 - Retaining disc
3 - Cylinder block
4 - Piston
5 - Control plate
15501 9-35990

6 - Center pin
7 - Port plate
8 - Swing relief valves
OPERATION PRINCIPLE SRD4-4-4
(O/P)
SWING DEVICE WX90

4.2.2 OPERATION PRINCIPLE

The drive shaft (1) complete with the retaining disc is supported by bearings in such way to allow the retaining
plate to turn freely.
If a force (F) is diagonally applied to the retaining disc, this force is decomposable in its two components (F1
- perpendicular to the disc) and (F2 tangential to the circumference of the disc). The force (F1) pushes the disc
in the axial direction, meanwhile the force (F2) operates to turn clockwise the disc.
If a force (F') is applied to the disc, this similarly can be decomposed in the components (F'1) and (F'2), where
(F'2) causes to turn counterclockwise the disc.

When the oil enters in the left ports of control plate (5) and goes out through right ports, the oil pressure is
applied to the rear faces of the pistons (4) connected to the left ports and the output drive shaft (1) turns
clockwise.
In this case, the pistons (4) turn clockwise together the cylinder block (3) to the same speed of the output shaft
(1), shifting into the inner of the cylinder block (3).
Subsequently, when the piston (4) reaches the top dead point, the cylinder of the same piston is put to
connection with the output drain ports of control plate (5).
When the pistons (4) reach the output drain ports, the pressure on the rear faces of pistons leaves off,
cancelling in this way the applied force to the output drive shaft (1).
Subsequently, the pistons (4) are put in rotation by output drive shaft (1) and they move in alternative direction
in the cylinder block (3).
The existing oil on the rear faces of pistons is drained to the tank.
The movements described above, are common for all the seven pistons (4) and the output drive shaft (1) turn
clockwise. If the suction and drain ports are used in reverse direction, the movements previously described
are performed in reverse order and the output drive shaft (1) turns counterclockwise.
15501 9-35990
 OPERATION PRINCIPLE SRD4-4-5
(O/P)
SWING DEVICE WX90

4.2.3 SWING RELIEF VALVES

Description

Two swing relief valves are installed on ports plate of swing motor. The valves are double stage type with two
different setting adjustment hydraulically controlled by external piloting.
The purpose of these valves is to protect the hydraulic circuit from pressure peak that can take place during
the swing starting phase of upperstructure and to limit the pressure in the swing circuit during the
upperstructure braking phase. Furthermore, these valves operate also as anticavitation valves.
By operation of the pilot valve, the hydraulic pilot pressure, (other than to the control valve) is fed to the brake
disengagement circuit on the swing reduction device through the throttle valve -one way, and the swing relief
valve relevant to swing direction set up.
With pilot pressure applied, the relief valve release to the drain at 320 bar.
When the pilot valve is taken back to neutral position (upperstructure braking phase), the pilot pressure is shut
off and the swing relief valve release the pressure at 190 bar.
Shutting off the pilot pressure, a throttle valve-one way allows the brake engagement with a certain delay
respect to swing stopping of upperstructure.

2 2

6
15501 9-35990

1 Swingrelief valves. F8551

2 Throttle valve-one way.
4 Brake swing.
5 Rotating control valve.
6 Block.
OPERATION PRINCIPLE SRD4-4-6
(O/P)
SWING DEVICE WX90

Operation principle

When the pressure in the chamber (C), connected through the duct (8) with the chamber (A), reaches the
setting value adjusted by means of spring (M), the poppet valve (F) rises and connects the chamber (C) with
chamber (B) in low pressure.
In this way the spool (O) is pushed toward the high by the pressure in (A).
The oil is therefore released in the channel (B) limiting, in this way, the overpressure on the line (A).
As shown in the figure, the channel (B) is common for both valves, this because the oil that is released through
the channel (B), is not sent to drain, as usual, but is used to supply again the swing motor avoiding in this way,
the anticavitation effect on hydraulic motor.
Therefore, the swing relief valve also carries out the anticavitation function when the pressure on side (B) is
bigger than the pressure in the channel (A). In this situation the oil pressure working against the section (S),
overcomes load spring (M1) which holds the spool in position, allowing the oil transfer between chamber (B)
and chamber (A).

M M

F F
8 8
M1 C C
M1
S S
O O

A
15501 9-35990

F3410
 OPERATION PRINCIPLE SRD4-4-7
(O/P)
SWING DEVICE WX90

4.3 SWING REDUCTION DEVICE

4.3.1 DESCRIPTION

The swing reduction device is used to transfer the swing movement to the upperstructure.
The swing reduction device has an epicycloid final reduction from which the force is transfer, by means of
drive shaft with built pinion (1) to the inner gear race bearing.
All gears, including the pinion shaft, are obtained from highly alloy steel.
The gears of planet carriers groups and the pinion are case-hardened and tempered.
The reduction housing (2) is built in spheroidal cast-iron.
The forged pinion is built in only one piece with the drive shaft, is cemented, tempered, and rectified, and it
allows to obtain, with reduced number of teeth, high reduction ratios between pinion and race bearing.
The pinion shaft is sustained by a couple of bearings (3) and (4). The swing reduction components are lubricate
by oil immersion.
The swing reduction is equipped with multiple discs brake (5) spring loaded (6) that, with machine at standstill
are locked from integrated spring action.
Only when the pilot pressure is applied, the springs force are overcome, open the discs, and unlock the brake,
allowing the swing movement.
The brake group, together with the swing reduction, makes only one assembly.
The swing reduction device is completed with a flange to allow the fixing on the machine.

4
2
3 1
15501 9-35990

5
5

F7007
OPERATION PRINCIPLE SRD4-4-8
(O/P)
SWING DEVICE WX90

NOTES:

15501 9-35990
 DISASSEMBLY AND ASSEMBLY SRD4-4-1
(D/A)
SWING DEVICE WX90

4.1 SWING HYDRAULIC MOTOR

NOTE - Before starting the disassembly, clean accurately the outside of swing hydraulic motor, then loose
fixing screws, drain the oil, disconnect the related hydraulic hoses and lift the swing device by means of an
hoist.
Whenever swing motor disassembly is performed, it is advisable to replace the O-rings, seals and bearings,
because it is difficult to determine visually the remaining useful life.

CAUTION - The approximate weight of swing hydraulic motor is = 10.5 Kg.

4.1.1 SHAFT SEALS

1 Free circlip and remove.

2 Prise off front cover.

3 Visual check:
• Shaft seal (1).
• Cover (2).
15501 9-35990

• Drive shaft (3).

• Housing (4).
• O-ring (5).
DISASSEMBLY AND ASSEMBLY SRD4-4-2
(D/A)
SWING DEVICE WX90

4 Remove shaft seal.

5 Press in the shaft seal ring to the correct position

with a suitable sleeve.

6 Fit new O-ring, ensure it is a snug fit. Grease O-

ring and lips of shaft seal.

7 Fit circlip using a punch. Check that circlip is well

seated.
15501 9-35990
 DISASSEMBLY AND ASSEMBLY SRD4-4-3
(D/A)
SWING DEVICE WX90

4.1.2 COVER PLATE

1 Mark position of cover plate (arrow). Remove

screws.

2 Swing port plate on locating pin and lift off.

3 Note position of locating pin (arrow).

4 Visual check:
• O-ring (1).
• Groove (2).
• Plate (3).
15501 9-35990
DISASSEMBLY AND ASSEMBLY SRD4-4-4
(D/A)
SWING DEVICE WX90

5 Lightly grease and fit O-ring.

6 Install the port plate to the correct position, noting

to align it to the marks, previously signed.

7 Tighten screws using torque wrench. For torque

tightening setting, make reference to the table at
the end of paragraph.

8 Motor, bi-directional. (Viewd on spherical

surface).
15501 9-35990

F7008
 DISASSEMBLY AND ASSEMBLY SRD4-4-5
(D/A)
SWING DEVICE WX90

4.1.3 ROTARY GROUP

1 Mark position of cover plate (arrow). Remove

screws.

2 Swing port plate on locating pin and lift off.

3 Free circlip and remove.

4 Prise off the front cover.

15501 9-35990
DISASSEMBLY AND ASSEMBLY SRD4-4-6
(D/A)
SWING DEVICE WX90

5 Remove the shim(s).

6 Remove rotary group with extractor.

7 Loosen the screw, then remove retaining plate.

NOTE - The screws are held by Loctite.

8 Before proceeding to the assembly of rotary

group, it needs to perform the following check: 3

• Drive shaft
1. Should be free of corrosion or erosion. no 3
damage to spline.
2. No trace of wear, free of scratches.
3. Cups free of scratches and no pitting.
1 2

9 Remove front cover.

15501 9-35990

F7009
 DISASSEMBLY AND ASSEMBLY SRD4-4-7
(D/A)
SWING DEVICE WX90

• Piston
1. Axial play of piston. 2 2
2. Should be free of scratches.

• Centre pin
1. Should be free of scratches, no pitting. 2
2. Should be free of scratches. 1

• Retaining plate
1. Free of scratches, no wear.

• Cylinder block and control plate

1. Bore unscratched, and not worn.
2. Faces, smooth and even, no cracks or
scratches. 2 2
15501 9-35990

1
DISASSEMBLY AND ASSEMBLY SRD4-4-8
(D/A)
SWING DEVICE WX90

• Bearings housings
1. No damage or wear.

9A Insert centre pin with retaining ring.

Correctly fit retaining plate.

10 Apply Loctite sparingly to the fixing screws only.

11 Heavily grease then fit spring pad and Belleville

washers.
15501 9-35990
 DISASSEMBLY AND ASSEMBLY SRD4-4-9
(D/A)
SWING DEVICE WX90

12 Make sure all parts are fitted in correctly.

13 Fit pistons in the relate bores.

14 Press pistons in the relate cups with cylinder

block held in central position.

15 Swivel cylinder block to maximum.

15501 9-35990
DISASSEMBLY AND ASSEMBLY SRD4-4-10
(D/A)
SWING DEVICE WX90

16 Heat housing at 80°C.

80°C

17 Install preheated housing to stroke, then

reposition the unit.

18 Install shims, if necessary.

19 Lay rotating unit to closing plate. Check if plate

position is correct.
15501 9-35990
 DISASSEMBLY AND ASSEMBLY SRD4-4-11
(D/A)
SWING DEVICE WX90

20 After assembling the shaft seal, install the circlip

using a punch. Check for correct position of circlip
into its seat.

21 Install seal ring after applying a film of grease.

22 Install the port plate to the correct position, noting

to align it to the mark previously signed.

23 Tighten screws using torque wrench for setting.

For tightening torque, make reference to the table
at the end of the paragraph.
15501 9-35990
DISASSEMBLY AND ASSEMBLY SRD4-4-12
(D/A)
SWING DEVICE WX90

4.1.4 TIGHTENING TORQUE

THREAD BOLT HARDNESS GRADE

8.8 10.9 12.9

Nm/ftlb
M3 1.08/0.78 1.6/1.15 1.9/1.37
M4 2.84/2.05 4.0/2.89 4.8/3.47
M5 5.90/4.26 8.3/6.00 9.8/7.09
M6 9.80/7.09 14/10.1 17/12.2
M8 24/17.3 34/24.5 40/28.9
M10 48/34.6 68/49.1 81/58.5
M12 84/60.6 118/85.2 142/102.5
M14 132/95.3 186/134.3 226/163.2
M16 206/148.7 289/208.6 348/251.3
M18 284/205.0 397/286.6 476/343.7
M20 402/290.2 569/410.8 677/488.8

THREAD Nm ftlb

M12 x 1.5 20 14.5

M22 x 1.5 60 43.3
M26 x 1.5 70 50.6
M33 x 2 120 86.8

THREAD Nm ftlb

M12 x 1.5 30 21.7

M14 x 1.5 40 28.9

15501 9-35990
 DISASSEMBLY AND ASSEMBLY SRD4-4-13
(D/A)
SWING DEVICE WX90

4.2 DISASSEMBLY AND ASSEMBLY OF SWING REDUCTION DEVICE

4.2.1 DISASSEMBLY

NOTE - Before starting the disassembly, clean accurately the outside of swing motor and reduction device,
then loose fixing screws, drain the oil, disconnect the related hydraulic hoses and lift the swing device by
means of an hoist.
Whenever a swing device disassembly is performed, it is advisable to replace the O-rings, seals and bearings,
because it is difficult to determine visually the remaining useful life.
In case of damaged gears, never replace a gear alone, but the complete reduction group with relate sun gear.

CAUTION - The approximate weight of swing reduction device is = 70 Kg.

Motor and brake

1 Loose the screws (25), then withdraw the hydraulic

swing motor by means of an hoist.

2 Loose the screws (38), mating the brake housing

(33) to the reduction device, then withdraw the brake
housing.
15501 9-35990
DISASSEMBLY AND ASSEMBLY SRD4-4-14
(D/A)
SWING DEVICE WX90

4 By means of a press, work on spring pusher disc

(22) to slacken the spring action (21).

5 Remove, by means of proper pliers, the circlip

(31).

6 Remove the spring pusher disc (22) and extract

the springs (21) from the relating piston (32).

7 Turn upside down the group, then remove the

circlip (14).
15501 9-35990
 DISASSEMBLY AND ASSEMBLY SRD4-4-15
(D/A)
HYDRAULIC PUMPS WX90

8 Remove the spacer ring (15) then extract the

brake disc package (36) and (37).

9 Using a copper hammer, work to extract the

piston (32) from brake housing (33).

10/11 Remove the seal rings (16 - 17 - 19 and 20)

then perform the relevant check.
15501 9-35990
DISASSEMBLY AND ASSEMBLY SRD4-4-16
(D/A)
HYDRAULIC PUMPS WX90

Gears

12 Extract the brake shaft (34) keyed on the 1st

reduction sun gear (12).

13 Remove the 1st reduction sun gear (12).

14 Extract the 1st reduction complete (11).

15501 9-35990
 DISASSEMBLY AND ASSEMBLY SRD4-4-17
(D/A)
HYDRAULIC PUMPS WX90

15 Remove the 1st reduction gear crown (39).

16 Loosen screws (40) and remove the connecting

flange (9) between first and second reduction
gear crown.

17 Take off the second reduction sun gear (8).

15501 9-35990
DISASSEMBLY AND ASSEMBLY SRD4-4-18
(D/A)
HYDRAULIC PUMPS WX90

18 Remove the second reduction gear crown (41).

19 Take off the second reduction planet carriers

group (5).

Pinion and housing

20 Loosen the locking ring nut (43) from the shaft

pinion (1) after removed the caulking. on the edge
carry out during the assembly to avoid loosening.
15501 9-35990
 DISASSEMBLY AND ASSEMBLY SRD4-4-19
(D/A)
HYDRAULIC PUMPS WX90

21 Turn upside down and loosen the fixing screws

(47) of front cover (48) of reduction housing (42).

22 By means of press remove the pinion shaft (1)

from reduction housing (42).

23 By means of an inner puller, extract the bearing

(44) from reduction housing (42), then by means
of outer puller, extract the bearing (46) from
pinion shaft (1).

NOTE - The swing reduction device is now

completely disassembled: therefore proceed to
the check and inspection of all the items.
15501 9-35990
DISASSEMBLY AND ASSEMBLY SRD4-4-20
(D/A)
HYDRAULIC PUMPS WX90

4.2.2 ASSEMBLY

Pinion and housing

1 Install the lamellar ring (3) on the front cover (48).

2 Install on the pinion shaft (1), the spacer ring (2)

previously heated to the temperature of 150°C,
then insert the front cover (48) complete with
lamellar ring (3).

3 By means of a press, install the bearing (46)

previously filled with Lithium grease type AGIP
MU/EP2 on the pinion shaft (1).

15501 9-35990
 DISASSEMBLY AND ASSEMBLY SRD4-4-21
(D/A)
HYDRAULIC PUMPS WX90

4 To take the reduction housing (42) and there

install the seal rings (45), then by means of a
press install the pinion shaft (1) complete with
bearing (46) and front cover (48) on the reduction
housing (42).

5 By means of setting torque wrench, tighten the

screws (47), fixing front cover (48) to the proper
torque.
Tightening torque: 2.5 daNm.

6 Turn upside down the reduction housing (42), and

by means of a press install the bearing (44) then
screw the ring nut (43). Tighten to the proper
torque.
Tightening torque: 110÷120 daNm.
15501 9-35990
DISASSEMBLY AND ASSEMBLY SRD4-4-22
(D/A)
HYDRAULIC PUMPS WX90

7 Caulk the ring nut edge (43), by means of a

punch, in three hollows on the shaft pinion (1) to
avoid loosening.

Gears

8 Install the 2nd reduction (5) on the pinion shaft

(1), then the O-ring (6) on its related groove on the
reduction housing (42).

9 Install the second reduction gear crown (41), then

the relate O-ring.
15501 9-35990
 DISASSEMBLY AND ASSEMBLY SRD4-4-23
(D/A)
HYDRAULIC PUMPS WX90

10 Install the connecting flange (9), tighten the screws

(40) to the proper torque:
Tightening torque: 14.5 daNm.

11 Install the second reduction sun gear (8).

12 Install the first reduction planet carriers group

(11) complete.
15501 9-35990
DISASSEMBLY AND ASSEMBLY SRD4-4-24
(D/A)
HYDRAULIC PUMPS WX90

13 Install O-ring in the relate groove on the connecting

flange (9), then install the first reduction gear
crown (39).

14 Install the first reduction sun gear (12).

15501 9-35990
 DISASSEMBLY AND ASSEMBLY SRD4-4-25
(D/A)
HYDRAULIC PUMPS WX90

16 Install O-rings (19) and (20) on brake housing

(33).

NOTE - For correct installation of O-rings and

back-up rings, proceed according to the following
diagram.

A
The back-up ring must always be fitted behind the
O-ring from side of the oil pressure input port.
A - Pressure oil input.
B - Back-up ring.
C - O-ring.

B C B B

17 Install in the brake housing (33), piston (32).

18 Insert the springs (21) in the piston (32).

15501 9-35990
DISASSEMBLY AND ASSEMBLY SRD4-4-26
(D/A)
HYDRAULIC PUMPS WX90

19 By means of a press, install the spring pusher

disc (22) then the circlip (31).

20 Turn upside the group and install the discs brake.

Starting with a sintered disc (36), following install
alternatively a steel disc (37) and with another
sintered disk till to completion.

Sintered discs .......................................... q.ty 6

Steel discs ............................................... q.ty 5

21 By means of a hand pump, connected to the port

of oil supply on brake using (33) carry out the seal
check, then align the teeth of brake disc (36) and
(37) using the brake shaft (34).

22 Holding hydraulic pressure, install the spacer

(15) and circlip (14).

NOTE - Position the circlip (14) in such a way the

15501 9-35990

two holes for mounting should be centred related

to the melting drain get on housing brake.
 DISASSEMBLY AND ASSEMBLY SRD4-4-27
(D/A)
HYDRAULIC PUMPS WX90

24 Fit the O-ring (13), then install the brake group

and motor flange on swing reduction, tightening
the screws (38) to the proper torque.
Tightening torque: 5 daNm.

25 Install the hydraulic motor on swing device,

checking the correct mating between the spline
drive shaft of motor and the brake shaft (34).
Tighten the screws (25) to the proper torque.
Tightening torque: 8.6 daNm.

26 Reconnect the hydraulic connection previously

disconnect and perform the correct refill of oil.
15501 9-35990
DISASSEMBLY AND ASSEMBLY SRD4-4-28
(D/A)
HYDRAULIC PUMPS WX90

18

25
23
22
21
17
16

32
34
15 36
14 37
13 33
38
31
39
40
41
12
11
9
8
7
6
5 42
43
44

47
46
3 48
2
1
F10574
15501 9-35990

1 Pinion - 2 Spacer ring - 3 Seal ring - 4 Oil drain plug - 5 Second reduction planet carriers - 6 O-ring - 7 Screw - 8
Second reduction sun gear - 9 Connecting flange - 10 Plug - 11 First reduction planet carriers - 12 First reduction
sun gear - 13 O-ring - 14 Circlip - 15 Spacer - 16 Seal ring - 17 Seal ring - 18 Filling and level oil plug - 21 Spring
- 22 Spring pusher disc - 23 O-ring - 25 Screw - 31 Circlip - 32 Piston - 33 Brake housing - 34 Brake shaft - 36 Sintered
disc - 37 Steel disc - 38 Screw - 39 First reduction gear crown - 40 Screw - 41 Second reduction gear crown - 42
Reduction housing - 43 Locking ring nut - 44 Bearing 46 Bearing - 47 Screw - 48 Front cover.
 OPERATION PRINCIPLE PV4-5-1
(O/P)
PILOT VALVES WX90

5. TRAVEL PILOT VALVE

5.1 HAND PILOT VALVE

5.1.1 OUTLINE

The pilot valve hydraulic device is an hand controlled type and operates as direct-operated pressure reducing
valve.
Pilot valve basically consists of the control lever (13), four pressure reducing valves and the housing (10).
Each pressure reducing valve consists of a control spool (6), a control spring (7), a return spring (8) and a
plunger (9).
When is in non-operative connection the control lever (13) is kept in zero position by the return spring (8).
The ports (1, 2, 3, 4 and 5) are connected to the tank port (T) via the boring (11).
With deflection of the control lever (13) the plunger (9) pushes at the same time against the return spring (8)
and control spring (7).
The control spring (7) first moves the control spool (6) downwards and closes the connection between the
appropriate port and the tank port (T). At the same time the appropriate port is connected to the port (P) via
the bore (11).
The control phase begins as soon as the control spool (6) has found its balance between the force of the control
spring (7) and the force which results from the hydraulic pressure.
Through the co-operation of control spool (6) and control spring (7) the pressure in the appropriate ports
(1,2,3,4, and 5) is proportional to the stroke of the plunger (9) and thus the position of the control lever (13).
The rubber sleeve (12) is used to protect the mechanical components of device from dust or foreign objects
entrance.

13

12

4 3 7
T 10
5
1 2
15501 9-35990

11
P 6
T P
F3784

1, 2, 3, 4, 5 Ports - 6 Control spool - 7 Control spring - 8 Return spring - 9 Plunger - 10 Housing -

11 Boring - 12 Rubber sleeve - 13 Lever.
 OPERATION PRINCIPLE PV4-5-2
(O/P)
PILOT VALVES WX90

20° 20
0' '
28° 2
B C
Pilot valve harness
A

A G A
B C G

Yellow

Brown
Green

White
Black

Grey

Blue
Red
Connector
White-Yellow

Pilot valve hydraulic diagram

Green

Blue
Red
Brown
Black

Control curve

Pressure output (bar)

4 3
T 5
30,5 ±2,5
30,5 + 2,5
- 1 2

P F8553

NOTE - Maximum allowable

torque on control lever: 8
15501 9-35990

6,5 +- 0,5 daNm.

Thrust rod stroke

0,98 7,55 (mm)
0
Lever angle
1°40' 19°30'
0°
3°50' 21°10'
F8552
 OPERATION PRINCIPLE PV4-5-3
(O/P)
PILOT VALVES WX90

BUTTON FUNCTION TABLE

Left hand pilot valve

Solenoid Solenoid Solenoid Solenoid Solenoid Solenoid Penetrating Superstructure

Button valve B1 valve B2 valve B5 valve B6 valve A6 arm rotation

A – – ON ON – – OFF
Swing

B
Outrigger ON ON – – ON OFF –
left

C
Outrigger ON ON – – – OFF –
right/blade

G
Horn – – – – – – –

Right hand pilot valve

Solenoid Solenoid Solenoid Solenoid Solenoid Solenoid Solenoid Travel

Button valve B3 valve B4 valve C1 valve C2 valve A5 valve A4

D
Positioning ON ON – – – – OFF
cylinder

E
Clamshell bucket – – ON – – – –
left-hand rotation

F
Clamshell bucket – – – ON – – –
right-hand rotation

K
Hammer – – – – ON ON –
Grass-cutter

B C E F
A D
G K
15501 9-35990

Left Right
OPERATION PRINCIPLE PV4-5-4
(O/P)
PILOT VALVES WX90

13 1
16 9

19
14 3
15 4

17
22
20

23 2
18 5

6
28 7
10 8

25
26

24
11
12

F8743
15501 9-35990

1 Control lever - 2 Rubber sleeve - 3 Inner control lever - 4 Nut - 5 Threaded spacer - 6 Control plate - 7 Cardan joint
- 8 Plate - 9 Spring dowel - 10 O-ring -11 O-ring - 12 Screw - 13 Plunger guide - 14 Seal ring - 15 O-ring -
16 Plunger - 17 Needle - 18 Plate - 19 Control spring - 20 Return spring - 21 Shims - 22 Control spool - 23 Upper
housing - 24 O-ring - 25 Cylindrical pin - 26 Lower housing - 27 O-ring - 28 Screw.
 OPERATION PRINCIPLE PV4-5-5
(O/P)
PILOT VALVES WX90

5.2 PEDAL

5.2.1 OUTLINE

The travel pilot valve hydraulic device is a pedal controlled type and operates as direct - operated pressure
reducing valve.
Travel pilot valve basically consists of one operation pedal (4), a valve unit (two valves) and a housing (31).
Each pressure reducing valve consists of a control spool (29), a spring (27), and a plunger (25).
When is in non-operative condition, the pedal lever is kept in zero position by the spring (27).
Actuating the pedal lever (4), the plunger (25) at the same time pushed against the spring (27).

3
4
17
5

8
8
7 6
9 12

25 25
29 29
27
T
27 P
31 1
2
F7012
15501 9-35990

1, 2 Ports - 3 Cover - 4 Pedal - 5 Pin - 6 Nut - 7 Screw - 8 Protection - 9 Support - 12 Screw - 17 Grub screw - 25
Plunger - 27 Control spring - 29 Control spool - 31 Upper housing.
OPERATION PRINCIPLE PV4-5-6
(O/P)
PILOT VALVES WX90

Travel pilot valve hydraulic diagram

NOTE - Maximum allowable

torque on pedal control lever:
20 daNm.

F8555

Control curve

30,7 +- 2,5

6,5 +- 0,5

0,85 5,8
0
Plunger stroke
1°15' 11°30'
0°
2°15' 12°30'
F8554
15501 9-35990
 OPERATION PRINCIPLE CJ4-6-1
(O/P)
CENTER JOINT WX90

6. CENTER JOINT

6.1 CENTER JOINT

6.1.1 GENERALITIES

The center joint is used to connect hydraulically and electrically the rotating portion of the turret to the
undercarriage (fixed portion).
The hydraulic fluid coming from the control valve or from the solenoid valves, enters the horizontal duct on
the outer sleeve (2), follows the circumference ducts, enters the vertical duct of the inner spindle (1) and
reaches the various actuators in the undercarriage.
Between one circumference duct and the next, Rotoglyd seals (7) are installed, to avoid leakages of oil from
one duct to the other.
The electrical part installed on rotary control valve consists of a ring electrical manifold controlling the electrical
functions.
The functions involved with the electrical manifold is:
• speed sensor;
• axle alignment sensor.

16 15
17
7
6
8

4 5
3 1
2

13
14

F7460
15501 9-35990

1 Inner spindle - 2 Outer sleeve - 3 Sealing flange - 4 Electrical collector support - 5 V seal - 6 O-ring - 7 Rotoglyd
seal - 8 Anti seizing ring - 13 Wire harness with four contact connectors - 14 Male connector - 15 Female connector
- 16 Nut - 17 Cover.
OPERATION PRINCIPLE CJ4-6-2
(O/P)
CENTER JOINT WX90

16
8
4
7
15
5
14
10
11
9
6

13

12

002/51

15

Fig. 1

1 - Inner rod 9- Antiseizure ring

2 - Outer liner 10 - O-ring
3 - Lock flange 11 - O-ring
4 - Brushes support flange 12 - O-ring
5 - Carter support flange 13 - Roto glyd ring
15501 9-35990

6 - Screw T. Sv 14 - Electric connections set

7 - Screw Tc 15 - Cables set
8 - Screw Tc 16 - Nut
 OPERATION PRINCIPLE CJ4-6-1
(D/A)
CENTER JOINT WX90

6.1 DISASSEMBLY AND ASSEMBLY OF CENTER JOINT

6.1.1 DISASSEMBLY

Clean rotating control valve and accessories from soil, dust or other.
Depressurize the system or all the ducts which cross the rotating control valve and cut off tension from the
electrical equiment connected with the rotating control valve.
Make sure that nobody can accidentally turn tension on or pressurize the system.
Eliminate as much fluid as possible inside the rotating control valve and avoid oil or other fluid harmful for the
environment to be dispersed on the ground by placing a suitable container under the rotating control valve.
Disconnect all hoses or connections which can hinder disassembly or be damaged during it.
Remove nut (16 fig. 1), remove electrical manifold cover.
Remove screws (7-8 fig. 1) to reach flange (3 fig. 1).
Remove screws (6 fig. 1) to remove flange (3) and ring (9) in order to free cylinder liner from rod. By means
of a universal puller remove rod (1) from cylinder liner (2).
Connect the outer part to be removed with a strong rope or chain making sure that the power resulting from
disassembly is as aligned as possible with the detail.
Remove the body with the strength necessary but without pulls by continuous clockwise/anticlockwise rotation
of the body to be removed.
It is not necessary to remove bearings before this operation.
Remove seals from their seats with a suitable sharpened tool.
After removal, seals cannot be reused.

After seal removal, clean perfectly the body removed making sure it has no faults.
Fit the new seal kit, by assembling O-rings first and then ROTO GLYD seal. Do not confuse seal seats
with ducts for oil flow. The assembling system for ROTO GLYD seal in water + Glycol or oil at 70/80°C for 10/
15 min.
Check again for the perfect location of seals in their seats and lubricate sliding surfaces with oil or, better Teflon
grease.
Check that the inner pin is not scratched or seized on the surfaces to oil and/or grease the involved part.
Fit outer body with care using the precautions mentioned above.
15501 9-35990

Fig. 2 Fig. 3 Fig. 4

OPERATION PRINCIPLE CJ4-6-2
(D/A)
CENTER JOINT WX90

6.1.2 ASSEMBLY

For assembly repeat the operations described earlier in reverse.

Before assembly, clean all the parts and make sure they are not damaged. Lubricate them with engine oil or
grease.

Assembly seals pos. 13 fig. 2 with the utmost care.

Fit O-ring into its seat and fit inner ring deforming it as shown in the pictures.

To avoid seal damage, we recommend it does not come into contact with sharpened edges and threaded walls
during assembly.
A slight lubrication makes the assembly of the components easier.

Before installation, if painting is planned, eliminate protection oil from the control valve with suitable
solvents. During this operation, do not remove thread protection plugs as aggressive products should
not touch inner seals. We remind to protect rubber parts, coupling centerings and all the areas close to
threaded connections.

Definitely avoid welding on the part or near it. This inobservance could seriously rotating control valve
structure as grounded element.

Never punch or mechanically process the rotating control valve, except for what mentioned above.
Exceptions require our approval.

Connect ducts to their connection point. Do not exchange ducts with different working pressures or
different type of fluid. These parameters should never contrast what indicated on our graphs.
Finally, it is absolutely forbidden to use fluids having unsure chemical compatibility with respect to seal
material special on our drawings.

6.1.3 HYDRAULIC PIPE POSITIONS ON CENTER JOINT

Inlet System pipes

1-2 Travel

3 Draining

5-6 Rear axle steering

7-8 Front axle steering

12 Draining
15501 9-35990

4-14 Blade / stabilizers

10 Front axle brake

11 Rear axle brake

9 Axle lock
13 Parking brake
 OPERATION PRINCIPLE SV4-7-1
(O/P)
STEERING VALVE WX90

7. STEERING VALVE

7.1 STEERING VALVE

7.1.1 DESCRIPTION

The steering unit consists of (see fig. 3):

- Metering and emergency hand pump that includes a gear wheel assembly with fixed stator (with inner teeth)
and a rotor (with outer teeth) (15).
- A 4 ways rotary distributor consisting of an outer sleeve (A) and an inner selection rotor (B).
The selection rotor is connected to the steering wheel, through column.
- A cardan shaft (11), mechanically tied to gear wheel assembly and to outer sleeve, allows the movement
transmission.
- Set of centering springs between outer sleeve and inner rotor.
- A relief valve (24-25) between the pump input and tank output ports.

Fig. 1 - Steering unit 103

83
2,8 A B

,3

46
±0
82
O
L R
Ø 25,4
Ø 44,4

91
44

83
T P

min 7,1
7 29 44 L2 45
°
L1 57

Dimensions

A = 3/4 - 16 UNF
B = 3/8 - 16 UNC
L1 = 159 mm
L2 = 20.8 mm
Weight = 5.6 kg
15501 9-35990

Hydraulic connections

L - Left control port

R - Right control port
P - Inlet to steering pump
T - Outlet to hydraulic tank
OPERATION PRINCIPLE SV4-7-2
(O/P)
STEERING VALVE WX90

7.1.2 OPERATION

When the steering wheel is at standstill, (distributor is at neutral position), there is free flow through neutral
openings.
The oil passages to the control shaft are closed so that the shocks are not transmitted to the steering wheel.
Turning the steering wheel, the rotation of rotor (B) occurs. The ducts to the cylinder passages, gradually open
to the rotation of about 1.5°. These ducts will completely opened at about 6°.
After about 4° of rotation, the neutral openings are closing.
The flow through the metering device takes place if the following conditions occur:
rotor rotation, oil volume supply directly proportional between steering wheel angular movement and control
cylinder displacement that produces the angular movement of the leading wheels. The inside supply group
from shaft to the outside sleeve of rotary distributor is in position so that the openings are closing when the
angular movement coincides with the steering wheel movement. The supply group therefore, replaces the
conventional mechanical linkage.

Fig. 2 - Steering unit hydraulic diagram

1
R

5 T To hydraulic
tank
To steering 200 +20 bar
-0 2
140 +5 bar
cylinder at 1 l/min. -0
at 5 l/min.
6 From
5 P
steering
L 3 pump
4

1 - Steering unit
2 - Relief valve (set at 140 bar)
3 - Check valve
4 - Distributor
5 - Suction valve
6 - Shock valve (set at 200 bar)
15501 9-35990
 OPERATION PRINCIPLE SV4-7-3
(O/P)
STEERING VALVE WX90

Fig. 3 3 4 20 16

13
16

12 22

18
1

7 9 (B) 2 (A) 11 14 15 15 17 21

26 2

26

1
27
29

25
24 2 5
7

3 8
4
9
11

2
13
14
12

15
21
16 22
17
18
15501 9-35990

20

1 Dust seal ring - 2 Housing consisting of distributor with spool (B) and sleeve (A). Including check valve, seats for
dual shock valves and relief valve - 3 Ball - 4 Thread bushing - 5 Lip seal - 7 Bearing assembly - 8 Ring - 9 Cross
pin - 11 Cardan shaft - 12 Set of springs - 13 O-ring - 14 Distributor plate - 15 Gearwheel set - 16 O-ring -
17 End cover - 18 Washer - 20 Screw with pin - 21 Screw (Q.ty 6) - 22 Name plate - 24 Complete relief valve -
25 Spring wire - 26 Complete shock valve - 27 Ball - 29 Bushing with pin.
OPERATION PRINCIPLE SV4-7-4
(O/P)
STEERING VALVE WX90

7.1.3 POWER STEERING TIMING

For correct keying and alignment of steering control valve, check parallelism of reference lines (A), (B), (C)
and (D).

Fig. 4 - Power steering timing

Inner gear case

C
Splined shaft

Pin Opening surface

F8473
15501 9-35990
 DISASSEMBLY AND ASSEMBLY SV4-7-1
(D/A)
STEERING VALVE WX90

7.1 STEERING UNIT DISASSEMBLY AND ASSEMBLY

7.1.1 DISASSEMBLY

1 Dismantle steering column from steering unit and place

the steering unit in the holding tool. Screw out the screws
in the end cover (6-off plus one special screw).

2 Remove the end cover, sideways.

3 Lift the gearwheel set (with spacer if fitted) off the unit.
Take out the two O-rings.

4 Remove cardan shaft.

15501 9-35990
DISASSEMBLY AND ASSEMBLY SV4-7-2
(D/A)
STEERING VALVE WX90

5 Remove distributor plate.

6 Screw out the threaded bush over the check val-

ve.

7 Remove O-ring.

8 Shake out the check valve ball and suction valve

pins and balls.
15501 9-35990
 DISASSEMBLY AND ASSEMBLY SV4-7-3
(D/A)
STEERING VALVE WX90

9 Take care to keep the cross pin in the sleeve

and spool horizontal. The pin can be seen
through the open end of the spool. Press the
spool inwards and the sleeve, ring, bearing races
and needle bearing will be pushed out of the
housing together.

10 Take ring, bearing races and needle bearing from

sleeve and spool. The outer (thin) bearing race
can sometimes "stick" in the housing, therefore
check that it has come out.

11 Press out the cross pin. Use the special screw

from the end cover.

12 Carefully press the spool out of the sleeve.

15501 9-35990
DISASSEMBLY AND ASSEMBLY SV4-7-4
(D/A)
STEERING VALVE WX90

13 Press the neutral position springs out of their slots

in the spool.

14 Remove dust seal and O-ring/kin-ring.

Dismantling the dual shock valves

15 Remove plugs from shock valves using a 6 mm

hexagon socket spaner.

16 Remove seal washers (2-off).

15501 9-35990
 DISASSEMBLY AND ASSEMBLY SV4-7-5
(D/A)
STEERING VALVE WX90

17 Unscrew the setting screws using a 6 mm

hexagon socket spanner.

18 Shake out the two springs and two valve balls

into your hand. The valve seats are bonded into
the housing and cannot be removed.

19 The dual shock valves are now dismantled.

Dismantling the pressure relief valve

20 Screw out the plug using an 8 mm hexagon

15501 9-35990

socket spanner. Remove seal washers.

DISASSEMBLY AND ASSEMBLY SV4-7-6
(D/A)
STEERING VALVE WX90

21 Unscrew the setting screw using an 6 mm

hexagon socket spanner.

22 Shake out spring and piston. The valve seat is

bonded into the housing and cannot be removed.

23 The pressure relief valve is now dismantled.

24 The steering unit is now completely dismantled.

15501 9-35990
 DISASSEMBLY AND ASSEMBLY SV4-7-7
(D/A)
STEERING VALVE WX90

7.1.2 INSPECTION

Cleaning

Clean all parts carefully.

Inspection and replacement

Replace all seals and washers. Check all parts carefully and make any replacements necessary.

Lubrication

Before assembly, lubricate all parts with hydraulic oil.

7.1.3 ASSEMBLY

1 Place the two flat neutral position springs in the slot.

Place the curved springs between the flat ones and
press them into place.

2 Line up the spring set.

3 Guide the spool into the sleeve. Make sure that spool
and sleeve are placed correctly in relation to each other.
15501 9-35990
DISASSEMBLY AND ASSEMBLY SV4-7-8
(D/A)
STEERING VALVE WX90

4 Press the springs together and push the neutral

position springs into place in the sleeve.

5 Line up the springs and centre them.

6 Guide the ring down over the sleeve.

NOTE: The ring should be able to rotate free of

the springs.

7 Fit the cross pin into the spool/sleeve.

15501 9-35990
 DISASSEMBLY AND ASSEMBLY SV4-7-9
(D/A)
STEERING VALVE WX90

8 Fit bearing races and needle bearing as shown

on below drawing.

Assembly pattern for roll bearing

1 - Outer bearing race

2 - Needle bearing
3 - Inner bearing race
4 - Spool
5 - Sleeve

*The inside chamfer on the inner bearing race must

face the inner spool.

Installation instructions for O-ring/kin-ring

9 Turn the steering unit until the bore is horizontal.

Guide the outer part of the assembly tool
75301400 into the bore for the spool/sleeve.

10 Grease O-ring and kin-ring with hydraulic oil and

place them on the tool 75301400. Ø 28.36
O-ring and kin-ring Ø 25.4
position on special
15501 9-35990

tool 75301400.
1.6

O-ring
Kin-ring
DISASSEMBLY AND ASSEMBLY SV4-7-10
(D/A)
STEERING VALVE WX90

11 Hold the outer part of the assembly tool in the

bottom of the steering unit housing and guide
the inner part of the tool right to the bottom.

12 Press and turn the O-ring/kin-ring into position in

the housing.

13 Draw the inner and outer parts of the assembly

tool out of the steering unit bore, leaving the gui-
de from the inner part in the bore.

14 With a light turning movement, guide the spool

and sleeve into the bore.

NOTE: Fit the spool set holding the cross pin

horizontal.
15501 9-35990
 DISASSEMBLY AND ASSEMBLY SV4-7-11
(D/A)
STEERING VALVE WX90

15 The spool set will push out the assembly tool

guide. The O-ring and kin-ring are now in position.

Installation instructions for O-ring/Rotoglyd-ring

9a Turn the steering unit until the bore is horizontal.

Guide the outer part of the assembly tool
75301401 into the bore for the spool/sleeve.

10a Grease O-ring and Rotoglyd-ring with hydraulic

oil and place them on the tool 75301401.

Ø 30.8

O-ring e Rotoglyd- Ø 25.4

ring position on
special tool
Rotoglyd-ring
75301401.
3.75

O-ring
15501 9-35990
DISASSEMBLY AND ASSEMBLY SV4-7-12
(D/A)
STEERING VALVE WX90

11a Hold the outer part of the assembly tool in the

bottom of the steering unit housing and guide
the inner part of the tool right to the bottom.

12a Press and turn the O-ring and Rotoglyd-ring into

position in the housing.

13a Draw the inner and outer parts of the assembly

tool out of the steering unit bore, leaving the gui-
de from the inner part in the bore.

14a With a light turning movement, guide the spool

and sleeve into the bore.

NOTE: Fit the spool set holding the cross pin

horizontal.
15501 9-35990
 DISASSEMBLY AND ASSEMBLY SV4-7-13
(D/A)
STEERING VALVE WX90

15a The spool set will push out the assembly tool
guide. The O-ring and Rotoglyd-ring are now in
position.

Assembly of check valve

16 Turn the steering unit until the bore is vertical

again. Put the check valve ball into the hole
identicated by the arrow.

17 Screw the threaded bush lightly into the check

valve bore. The top of the bush must lie just below
the surface of the housing.

Assembly of the two suction valves

18 Place a ball in the two holes indicated by the

15501 9-35990

arrows.
DISASSEMBLY AND ASSEMBLY SV4-7-14
(D/A)
STEERING VALVE WX90

19 Place a pin in the same two holes.

20 Grease the O-ring with hydraulic oil.

21 Place the distributor plate so that the channel

holes match the holes in the housing.

22 Guide the cardan shaft down into the bore so

that the slot is parallel with the connection flange.
15501 9-35990
 DISASSEMBLY AND ASSEMBLY SV4-7-15
(D/A)
STEERING VALVE WX90

23 Grease the two O-rings with hydraulic oil, and

place them in the two grooves in the gear rim.
Fit the gearwheel and rim on the cardan shaft.

24 Place the end cover in position.

25 Fit the special screw with washer and place it in

the hole where is located the Ø 8 mm ball.

26 Fit the six screws with washers and insert them.

Cross-tighten all the screws and the rolled pin
with a torque of 3.0 ± 0.6 daNm.
15501 9-35990
DISASSEMBLY AND ASSEMBLY SV4-7-16
(D/A)
STEERING VALVE WX90

Assembly of the pressure relief valve

27 Fit the piston.

28 Fit the spring.

29 Screw in the setting screw with a 6 mm hexagon

socket spanner. Make the pressure setting at ±
5 bar 140 .

30 Screw plug with seal into the housing using an 8

mm hexagon socket spanner.
Tightening torque: 5 ± 1 daNm.
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 DISASSEMBLY AND ASSEMBLY SV4-7-17
(D/A)
STEERING VALVE WX90

31 Fit the dust seal ring in the housing using special

tool 75301402 and plastic hammer.

32 Press the plastic plugs into the connection ports.

Do not use a hammer.

Assembly of the dual shock valves

33 Put a ball in the two holes indicated by the arrows.

34 Place springs and valve cones over the two balls.

15501 9-35990
DISASSEMBLY AND ASSEMBLY SV4-7-18
(D/A)
STEERING VALVE WX90

35 Screw in the two setting screws using a 6 mm

hexagon socket spanner.
Make the pressure setting at 200 +20 bar.

36 Screw plug with seal ring into the two shock

valves and tighten them with a torque of 3 daNm
using a 6 mm hexagon socket spanner.

Steering unit is now assembled.

7.1.4 SPECIAL TOOLS

NUMBER TOOL NAME Q.TY USE

75301400 O-ring + kin-ring assembly tool 1 To install the O-ring + kin-ring

75301401 O-ring + Rotoglyd-ring assembly 1 To install the O-ring + Rotoglyd-ring

tool

75301402 Dust seal ring assembly tool 1 To install the dust seal ring
15501 9-35990
 OPERATION PRINCIPLE BRV4-8-1
(O/P)
BRAKE PEDAL VALVE WX90

8. BRAKE PEDAL VALVE

8.1 BRAKE PEDAL VALVE

8.1.1 DESCRIPTION

The brake pedal valve includes a single assembly, of small dimensions and easily adjusted, with a compact
and modular configuration.
The elements making the valve are assembled into a single device capable of ensuring full reliability under
all circumstances.
This braking system provides the possibility of using, with a limited amount of external connections, a small
portion of the energy of the hydraulic system of the machine, thus leaving the entire delivery of the system
available to other functions. This function is obtained through the charge valve, that gets automatically the oil
to charge the accumulators.
Its technical characteristics result in an increased braking power and a reduced effort on the pedal. The braking
pressure is regulated by modules connected to the braking circuits.

3 4 5

8 7

9
F10585

1 Service brake cylinder - 2 Pedal/support group - 3 First braking module - 4 Second braking module -
5 Accumulators charge valve - 6 Service brake control solenoid valve - 7 Adjustment screw - 8 Accumulator
pressure check and adjustment.
15501 9-35990

The brake pedal valve is made of elements assembled in a modular mode.

These elements are:
• Pedal/support group.
• First braking module.
• Second braking module.
• Accumulators charge valve.
• Service brake cylinder.
• Service brake control solenoid valve.
OPERATION PRINCIPLE BRV4-8-2
(O/P)
BRAKE PEDAL VALVE WX90

Support/pedal group

The whole brake system is secured through the pedal/support group, to the floor plate of the machine.
This group regulates:
• the maximum braking pressure obtained through the rod stopping the stroke of the drive linkage;
• the angle of the pedal.

Braking modules

The braking modules are the elements controlling the braking pressure. Each braking module is connected
to a valve and an accumulator. The accumulators are high pressure type containers with a special membrane
subject, on one side, to the gas pressure, and to the oil pressure on the other. Three threaded outlets connect
the module to the brakes, the accumulator and the pressure switch controlling the stop lights.
The modules have longitudinal ducts allowing an hydraulic connection with the discharge and the charging
circuit of the accumulators.

Accumulators charge valve

The valve maintains the value of the pressure of the accumulators in a determined range (110 ÷ 140 bar). This
pressure is set by turning the screw located on the cylindrical end and is protected by a cap nut.

Service brake cylinder

The service brake cylinder controls hydraulically the braking modules. They actuate the service brakes
mounted on the front and rear axles at a pressure equal to the charge pressure of the brake accumulators.

Service brake control solenoid valve

The solenoid valve, of a cartridge type, is mounted on the cover of the accumulators charge valve. The service
brake control solenoid valve is actuated by the service brake actuating button located in the cab. When
energised, it allows the passage of oil from the service accumulators to the service brake cylinder.

15501 9-35990
 OPERATION PRINCIPLE BRV4-8-3
(O/P)
BRAKE PEDAL VALVE WX90

8.1.2. OPERATION PRINCIPLE

The brake pedal valve controls the charge of the accumulators that are fed by the hydraulic power control
system, with a priority over other functions, through the accumulators charge valve. During the charge phase,
the charge valve acts as a distributor of differential delivery, ensuring the hydraulic supply to other functions
of the power control systems.
Once the charge pressure of the accumulator is reached, the charge valve directs the entire flow from the
pump to the subsequent functions.
The pressure in the accumulator circuit is maintained steady within the tolerance range of the charge valve.
The two service braking circuits are mutually protected through the check valves so that, in case of failures
of one the two circuits, the other operates perfectly.
The charge condition of the accumulator is monitored by the pressure switch so that the operator has a visual
signal in case of insufficient hydraulic pressure (i.e engine stoppage). Moreover, it signals, once the machine
is started, the efficient operation of the braking system.

Operation of the service braking system

When the service brake pedal is actuated, the two circuit braking valve regulates the pressure in the brake
cylinders according to the actuating force. The machine is slowed down by the action of the wheel brakes both
on the front and rear axles.
At the end of the braking phase, the oil returns into the reservoir.
In case of failure of one brake circuit, the second one remains in operating conditions through the mechanical
contact of the two braking valve plungers, ensuring the perfect functionality of the two accumulators. The
actuating force remains unchanged.
Every time the service brake is actuated, a pressure switch (set at 5 bar) monitors the pressure on the rear
axle brake circuit and energises the stop lights.

Operation of the service brake control solenoid valve

When the service brake button is actuated, the service brake control solenoid valve is energised and the
movement of the spool connects the accumulator charge pressure with the service brake actuating cylinder.
The stroke of the service brake control piston actuates the two brake modules that connect the accumulators
to the front and rear axle brake circuits.
When the service brake button is actuated, the axle lock is automatically actuated. The axle unlocking is
possible by actuating directly the axle locking button.

14 2 13 16 15 10 11 12

17
4
9
5

7
15501 9-35990

3 1 8
F8556

1 Feeding to the systems - 2 Connection for service brake - 3 Discharge to the reservoir - 4 Connection for pressure
switch - 5 Stop lights pressure switch - 6 Delivery to front axle - 7 Delivery to rear axle - 8 Feeding to the pump - 9
Brakes system low pressure indicator pressure switch - 10 Service accumulator - 11 Charge accumulator -
12 Accumulators charge valve - 13 Brakes modules - 14 Service brake actuating solenoid valve - 15 Service brake
actuating cylinder - 16 Brake pedal - 17 Transducer
OPERATION PRINCIPLE BRV4-8-4
(O/P)
BRAKE PEDAL VALVE WX90

8.1.3 SPECIFICATIONS AND DATA

Braking system ................................................................................................................................. type S6

Installation ...................................................................................................................................... horizontal
Diameter of brake valve modules ....................................................................................................... 14 mm
Braking circuits ............................................................................................................................................. 2
Diameter of service brake ................................................................................................................... 12 mm
Braking pressure ................................................................................................................................. 35 bar
Maximum pressure ........................................................................................................................... 140 bar
Nominal control voltage of solenoid valve ........................................................................................... 27 Vcc

15501 9-35990
 DISASSEMBLY AND ASSEMBLY BRV4-8-1
(D/A)
BRAKE PEDAL VALVE WX90

8.1 MAINTENANCE

8.1.1 MAINTENANCE STANDARD

The precautions to be strictly observed during the assembly operations are listed here below.

• Connect all connections when the engine is inoperative and the system is not activated. For any operation
while the engine is running, check that the connections of discharge (N) and secondary supply (B) are open,
since severe damages to elements of the system and to persons could result if these connections are closed.

• Ensure that connections and lines are clean; foreign materials and dust into the system cause malfunctions
and wear.

• To bleed the air from the system, when the accumulators are charged and the engine is running, push the
brake pedal and open the bleeders for a few seconds.

• Insert the group from the bottom, after removing the side screw securing the pedal to the linkage.

• Help the filling of the feeding pump, bleeding the air from feeding connection (P) or an accumulator.

8.1.2 SETTING

Adjustment and check of accumulators pressure

When the accumulators are discharged, connect a manometer (scale 250 bar) to the special plug.
Start the engine and press the pedal some times to cause the automatic charge; read the pressure. The max./
min. pressure stage is not adjustable. The max. pressure is adjustable through the adjusting screw
(8)(protected by the blind nut) on the body of the accumulators charge valve.
The pressure of max. charge of the accumulators is 150 bar.

Adjustment of service brakes pressure

Connect a manometer (scale 250 bar) with a

brake circuit and brake.
The pressure depends on the pedal's stroke.
The braking pressure is adjustable by the
adjusting screw (7) under the pedal. The max.
pressure for the brakes pistons is 35 bar.
15501 9-35990

F0215A
DISASSEMBLY AND ASSEMBLY BRV4-8-2
(D/A)
BRAKE PEDAL VALVE WX90

Adjustment screw for brake pressure

F10575

15501 9-35990
 DISASSEMBLY AND ASSEMBLY BRV4-8-3
(D/A)
BRAKE PEDAL VALVE WX90

8.2 BRAKE PUMP DISASSEMBLY - ASSEMBLY

47 46 43 44 45 44 43 42

48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
15
63
1
60
64 2
65 41 3
66
40 4
67
39 5
15
38 6
68
37 7
8
36 9
35 10
004/64
34 11
33 12
32 13
31 14
15501 9-35990

SECTION A - A 30 15
29 16
28 17
27 18
2-004/64
26 21 25 24 23 22 21 20 19
DISASSEMBLY AND ASSEMBLY BRV4-8-4
(D/A)
BRAKE PEDAL VALVE WX90

Description of brake pump disassembly - assembly

1 - Blind nut M10 35 - Spring for priority valve

2 - Nut M4 36 - Charge valve cover
3 - Flat washer 37 - Pin for single direction valve opening
4 - Adjustment nut 38 - Spring for single direction valve opening
5 - Dowel M4x50 39 - Brake control spring
6 - Spring seat 40 - Screw for double adjustment
7 - Screw for spring compression 41 - Flexible washer
8 - Needle valve seat 42 - Brake pedal
9 - O-ring 43 - Nut M8x1,25
10 - Piston for single direction valve holder 44 - Dowel M8x40
11 - Seal needle 45 - Protection
12 - O-ring 46 - Support
13 - O-ring 47 - Work brake sleeve
14 - Valve spring 48 - Seeger
15 - O-ring 49 - Cylinder-shaped pin Ø 12x40
16 - Bushing for single direction valve holder 50 - O-ring
17 - O-ring 51 - Link rod
18 - O-ring 52 - Piston for brake control
19 - O-ring 53 - Upper spring guide
20 - Pressure switch plug 54 - Approach spring
21 - O-ring 55 - Pressure spring
22 - Plug for single direction valve 56 - Seal
23 - Spring for single direction valve 57 - Return spring
24 - Head-shaped valve body 58 - Lower spring guide
25 - Head-shaped seat for single direction 59 - Seeger
valve 60 - Control valve piston
26 - Accumulator charge valve body 61 - O-ring
27 - Seeger 62 - Control valve body
28 - Seeger 63 - O-ring
29 - Adjusting washer 64 - Control valve body
30 - Piston for priority valve 65 - Centering bushing
31 - Cone-shaped filter 66 - Solenoid valve assy
32 - Spring for filter retaining 67 - Spring for control valve piston
33 - O-ring 68 - Screw TC M8x1,25x150
34 - O-ring

15501 9-35990
 DISASSEMBLY AND ASSEMBLY BRV4-8-5
(D/A)
BRAKE PEDAL VALVE WX90

8.2.1 ASSEMBLY

Turn the operation machine off.

Drain pressure from brake accumulators

operating repeatedly on brake pedal and
on parking brake lever when the engine is off.

Remove all unions, pressure gauges and

electrical connections.

F0183A

Remove connection pipe of working brake

cylinder piloting.
During assembly tighten drilled screw M14 x 1,5
(wrench 19) with a tightening torque of 44 Nm
and drilled screw M10 x 1 (wrench 14) with a
tightening torque of 25 Nm.

F0184A

Remove screws fixing control valve section

assy from the bottom of pressure check section.
Tighten assy fixing screws with a tightening
torque of 30 Nm.

F0185A
15501 9-35990

F0186A
DISASSEMBLY AND ASSEMBLY BRV4-8-6
(D/A)
BRAKE PEDAL VALVE WX90

Separate the 4 sections making sure the inner

details do not come out.

The two braking modules are not the same;

the module in contact with pedal support is
the one with Ø 6 holes, supply and drain, not
passing.
Braking modules are coupled with the relative
pistons. Do not reverse them.

F0187A

F0188A

Braking module no. 1

15501 9-35990

F0223A
 DISASSEMBLY AND ASSEMBLY BRV4-8-7
(D/A)
BRAKE PEDAL VALVE WX90

Remove control valve piston located into braking

module.
Remove seals on the pictured surface.

F0189A

Remove the retaining ring of retaining valve

case assy for accumulator.

F0190A

Remove retaining valve case assy.

F0191A

Remove retaining valve and spring from the

case.

If fitting plug M10 x 1 in the connection for

pressure gauge use a tightening torque of 25
Nm for assembly.
15501 9-35990

F0192A
DISASSEMBLY AND ASSEMBLY BRV4-8-8
(D/A)
BRAKE PEDAL VALVE WX90

Braking module no. 2

15501 9-35990

F0224A
 DISASSEMBLY AND ASSEMBLY BRV4-8-9
(D/A)
BRAKE PEDAL VALVE WX90

Remove distribution piston in the braking module.

Remove seals located on the pictured surface.
Remove the retaining ring of retaining valve case assy for accumulator.
Remove retaining valve case assy.
Remove retaining valve and spring from the case.
If fitting plug M10 x 1 in the connection for pressure gauge use a tightening torque of 25 Nm for assembly.

Support for pedal and working brake sleeve

15501 9-35990

F10577
DISASSEMBLY AND ASSEMBLY BRV4-8-10
(D/A)
BRAKE PEDAL VALVE WX90

F0226A

Unscrew sleeve for working brake from pedal

support. During assembly use a tightening torque
of 45 Nm.

F0193A

Remove piloting piston and seal located inside

the sleeve from the sleeve.

F0194A

Remove retaining ring from central cavity.

15501 9-35990

F0195A
 DISASSEMBLY AND ASSEMBLY BRV4-8-11
(D/A)
BRAKE PEDAL VALVE WX90

Remove the different components located inside

the support (seal " BALSELE" should be
disassembled with a rod having a "L"-shaped
edge).

F0196A

Remove spring holders and springs located into

pedal support.

F0197A

F0198A
15501 9-35990
DISASSEMBLY AND ASSEMBLY BRV4-8-12
(D/A)
BRAKE PEDAL VALVE WX90

Loading valve

F0179A

Unscrew lock ring nut of solenoid located on the

3-way valve.
During assembly use a 10 Nm tightening torque.

F0199A

Remove solenoid and unscrew the 3-way valve

from accumulator valve body.
During assembly use a 50 Nm tightening torque.
15501 9-35990

F0200A
 DISASSEMBLY AND ASSEMBLY BRV4-8-13
(D/A)
BRAKE PEDAL VALVE WX90

Unscrew the 6 M8 x 1,25 screws fixing valve cap

to valve body.
During assembly use a 30 Nm tightening torque.

F0202A
15501 9-35990

F0201A
DISASSEMBLY AND ASSEMBLY BRV4-8-14
(D/A)
BRAKE PEDAL VALVE WX90

Untighten blind plug (dull yellow or black).

During assembly use a 30 Nm tightening torque.

Remove retaining snap ring on adjustment screw.

F0203A

Untighten adjustment nut (dull yellow or black).

Remove spring having an outer diameter of
19,5 and O-ring located inside hole +20 and
spring supporting the main piston.
Unscrew adjustment screw.
Use a 30 Nm tightening torque.

F0204A

F0216A
15501 9-35990
 DISASSEMBLY AND ASSEMBLY BRV4-8-15
(D/A)
BRAKE PEDAL VALVE WX90

Unscrew brass compression screw and

remove the components located inside the
body of the adjustment screw.
Use a 10 Nm tightening torque.

F0205A

F0206A

Untighten with a CH6 wrench the plug of the

single direction valve and the plug for pressure
gauge.
When assembling use a 45 Nm tightening
torque.

F0207A
15501 9-35990

F0208A
DISASSEMBLY AND ASSEMBLY BRV4-8-16
(D/A)
BRAKE PEDAL VALVE WX90

Remove plugs, the single direction valve with

tabs, its seat, spring and seal.

F0209A

F0217A

F0218A
15501 9-35990
 DISASSEMBLY AND ASSEMBLY BRV4-8-17
(D/A)
BRAKE PEDAL VALVE WX90

Remove main piston and the bushing holding the

single direction valve.

F0210A

Remove seals between valve cap and accumulator

valve body.

F0211A

Remove retaining ring inside main piston and remove

the details located inside.

F0212A
15501 9-35990

F0219A
DISASSEMBLY AND ASSEMBLY BRV4-8-18
(D/A)
BRAKE PEDAL VALVE WX90

Remove the piston holding the single direction

valve from the bushing and unscrew the seat for
pin valve. Remove the details located inside.
Remove all seals fitted to these details.

F0213A

F0222A

For locking pin valve seat use a torque of 6 Nm

(max) applying on thread edge thread-locking
LOCTITE quality MEDIUM code 242 or use a
thread-locking with similar features.

Carefully remove grease from the thread

before applying LOCTITE.

F0221A
15501 9-35990

F0220A
 DISASSEMBLY AND ASSEMBLY BRV4-8-19
(D/A)
BRAKE PEDAL VALVE WX90

F0179A

Clean all the components.

During assembly, oil all the inner components paying attention to all outer agents harmful for the correct
operation of brake pedal.

Never use gasoline, solvents or other flammable liquids when cleaning details.
Use homologated solvents on the market non flammable and non toxic.
Remove servovalve seat.

Pressure adjustment of accumulator charge start

The accumulator charge valve with two coaxial adjustments allows to adjust the recharge point and the max.
pressure of the accumulator in a range varying from +10% to +35% with respect to recharge pressure.

Adjustment (A) adjusts accumulator recharge pressure (minimum pressure) and adjustment B adjusts the
accumulator end-of-charge pressure.
Adjust after locating a manometer at outlet (R) or (F).
With valve supply operating (engine on), operate brake pedal to reduce oil pressure in the accumulator and
located recharge point on pressure gauge; set adjusting screw (A) to the position corresponding to the value
desired. Lock screw with nut. Adjust max. pressure with adjustment (B).
Start with screw fully closed and unscrew until is necessary for pressure to increase to the value wanted. For
a better valve operation it is important that max. pressure is at least 5÷8 bar higher than pressure noted with
screw (A)closed.
It is important that lock (C) is fitted on the adjustment screw to avoid the extreme tightening of screw (A) and
cause the pump closing.
15501 9-35990
DISASSEMBLY AND ASSEMBLY BRV4-8-20
(D/A)
BRAKE PEDAL VALVE WX90

F0214A

The value of pressure for accumulator charge

start is indicated on the plate fitted to accumulator
valve body (4).

The value of braking pressure is indicated on the

plate fitted to accumulator valve body.

Each module of braking unit is equipped with an 1 Rif 2

identification plate including:
3 P1 4
(1) - Product no. of reference Pf
(2) - Week and year of manufacture
FO434A
(3) - Accumulator pressure recharge
(4) - Braking pressure

COCK

MANOMETER B

F
N

ACCUMULATOR
R A
GEAR PUMP
15501 9-35990

C
B
P

F0433A
 DISASSEMBLY AND ASSEMBLY BRV4-8-21
(D/A)
BRAKE PEDAL VALVE WX90

8.2.2 INCONVENIENTS, CAUSES AND REMEDIES

Inconvenients Cause Remedies

Sudden braking Wrong pressure adjustment. Verify pressure operating the register under the
pedal, checking pressure with a manometer.

Insufficient braking Wrong pressure adjustment. Verify pressure operating the register under the
pedal, checking pressure with a manometer.
Pay attention not to exceed the 35 bar pressures.

Delayed braking and Feeding speed and brakes Check that the brakes plant tubes are not clogged.
pedal's return discharge insufficient. High viscosity of the hydraulic fluid.

Braking pressure non Pressure in accumulators is badly Check the correct adjustment of accumulators
constant adjusted. pressure; if necessary, operate the adjuster on the
cylindrical head of the accumulator charge valve.

Continuous recharge Accumulators with too low or too
of the accumulators high nitrogen precharge.
Check nitrogen pressure in accumulators, after
emptying them from oil with a special tool and recharge
it.
Nitrogen pressure can be checked reading the
pressure of the last part of oil which has come out.

Feeding pump always Worn pump. Check the valve.

under pressure
Dirt in the valve. Careful check of the valve (correct sliding of the parts;
perfect entireness of the sealing seats and couplings
checks).

Accumulators can't Foreign matters prevent the priority Check the sliding of all parts, mainly of the inlet valve.
be charged valve from sliding.
Check the hydraulic connection.

After revising the charge valve of the accumulator,

check the correct position of the piston stop ring
opposite to the feeding connection.

Brakes remain braked Uncorrected discharge. The system does not discharge free and pressure
influences the brakes.

Non return of the pedal. Check that the pedal stop adjuster allows a light
backlash between return and operating piston.

Eliminate possible cloggings inside the chamber under

the pedal, operating from the front plug.
15501 9-35990

Dashboard indicator The pressure switch fails to Adjust the pressure switch to 90 bar if necessary,
can't be turned on or operate. replace.
always on

Strokes on the pedal Sudden pressure changes on the Check that there are no obstructions along the
discharge. discharge duct.
DISASSEMBLY AND ASSEMBLY BRV4-8-22
(D/A)
BRAKE PEDAL VALVE WX90

8.2.3 PRESSURE SWITCHES

General information

They are made up of a sensitive element with with an oil screen membrane, silver electrical contacts, seals
commectors.
The electrical connection and the inner elements are protected against humidity and dust infiltrations by
means of a protection cap.

1 2 3
F8558

Features and data

Pressure switch setting (1) .................................................................................................................. 90 bar

Pressure switch setting (2) .................................................................................................................... 5 bar
Transducer (3) signalling the correct braking pressure to the pressure gauge
located on the steering column ................................................................................................... 90÷140 bar

3 1 2

15501 9-35990

F10565

1 - Pressure switch for brake system low pressure (90 bar)

2 - Stop light pressure switch (5 bar)
3 - Transducer
 OPERATION PRINCIPLE ACC4-9-1
(O/P)
ACCUMULATORS WX90

9. ACCUMULATORS

9.1 ACCUMULATORS

9.1.1 GENERALITIES

Four accumulators (three for the brake system and one for the power controls) are mounted on the turret.
Functionally, the accumulators are identical, of a membrane type, and ensure a certain number of actutions
of the systems they are connected with, in case of lack of hydraulic pressure.
The membrane type accumulator includes a pressure resistant steel container, mounting inside, as a
separation element, a membrane made of elastic material. The membrane is secured by a ring nut between
the lower and upper portion of the body.
In the central lower part of the membrane, a metal disc is incorporated, preventing its exit from the fluid inlet
port.

1 - Gas valve
2 - Container
3 3 - Membrane
4 - Valve head
4 5 - Oil side mounting

When no hydraulic pressure is present, the membrane, loaded on the gas side by the pre-load pressure (P0)
leans against the inner surface of the accumulator and the head closes the fluid flow. When hydraulic pressure
is applied, the pre-load pressure is overcome compressing the nitrogen, and the head is lifted, thus the fluid
enters the accumulator.
The quantity of useful oil results from the difference between the volume of gas and the minimum and
maximum operating pressure.

P0 P1 P2
V0 V1 V2
∆V
15501 9-35990
OPERATION PRINCIPLE ACC4-9-2
(O/P)
ACCUMULATORS WX90

9.1.2 MAINTENANCE

Testing or reduction of pressure

To perform this operation it is necessary to provide a hose. Discharge the pressure in the pump circuit, remove
or isolate the accumulator, remove the protection cap of the pre-charge valve on the shockless device, install
the pre-charge device tightening ring nut (1) on the accumulator valve.
Screw, without tightening it, handle (4) and read the charge pressure on pressure gauge (3); if it is too high,
open slightly discharge valve (2).
Unscrew handle (4), remove the re-charge device, re-install the protection cap on the accumulator valve.

Increasing the charge pressure

To pre-charge or to increase the pre-charge pressure, remove the protection cap of the valve on the shockless
device, install the pre-charge device, turning ring nut (1), leaving handle (4) unscrewed and tighten completely
discharge valve (2).
Remove cap (5) and connect hose (6) to a bottle of nitrogen. Tighten, without forcing, handle (4) and open
slowly the nitrogen bottle.
While reading pressure gauge (3) increase the pre-charge pressure until a value slightly over the desired value
is obtained.
Loosen handle (4), close the bottle valve, empty hose (6) opening and closing valve (2) and wait for a few
minutes.
Tighten handle (4) and read the pressure; if it is correct, unscrew handle (4) and remove hose (6), unscrewing
ring nut (1). If it is not correct, increase or reduce the pressure, as indicated above.

NOTE - For the pre-charge, nitrogen only must be used.

2 3 4 5 6 7

1
15501 9-35990

Accumulator Nitrogen bottle

 OPERATION PRINCIPLE ACC4-9-3
(O/P)
ACCUMULATORS WX90

9.1.3 SPECIFICATIONS AND DATA

Power system accumulator

Nominal capacity ................................................................................................................................ 0.35 ltr
Pre-charge pressure .......................................................................................................................... 13 bar
Weight .................................................................................................................................................... 2 kg

Brake system accumulators

Nominal capacity ................................................................................................................................ 0.35 ltr
Pre-charge pressure .......................................................................................................................... 50 bar
Weight .................................................................................................................................................... 2 kg
15501 9-35990
OPERATION PRINCIPLE ACC4-9-4
(O/P)
ACCUMULATORS WX90

NOTES:

15501 9-35990
 DISASSEMBLY AND ASSEMBLY ACC4-9-1
(D/A)
ACCUMULATORS WX90

9.1 DISASSEMBLY AND ASSEMBLY OF ACCUMULATOR

1 Discharge the pressure from the system.

2 Ensure that the accumulator is totally empty of gas using the testing/inflating device. If the latter is not
available, push the sealing valve with a screwdriver until no more gas is flowing out.

3 Loosen and remove the re-charge valve assembly.

4 Loosen the upper cap with a filter type wrench.

5 Pull-out the membrane.

6 Clean thoroughly the inside of the accumulator.

7 Smear the seat for the new membrane with grease.

8 Install a new membrane.

9 Replace the O-ring with a new one.

10 Tighten strongly the upper cap.

11 Install a new charge valve.

12 Bring the accumulator to the pressure desired, using the pre-charge device.

ATTENTION
Do not use any gas besides NITROGEN Danger of explosion.

WARNING
Before testing the pre-charge or changing the pressure, ensure that the accumulator is totally discharged on
the fluid side.
In case of replacement of the membrane, wet the walls with the fluid pumped or with a compatible one to
facilitate the adherence of the new membrane.
Before installing the accumulator, ensure that:
• the data etched on the body are compatible with the specifications of the system;
• the pre-charge pressure corresponds to the required value.
• An incorrect pre-charge pressure, besides causing a bad operation of the system, can impair the life of the
membrane or bag. The value of the pre-charge is related to a 20°C temperature.

NOTE: these instructions are supplied for knowledge. sono fornite per conoscenza. For accumulator
maintenance, refer to your CASE dealer.
15501 9-35990
DISASSEMBLY AND ASSEMBLY ACC4-9-2
(D/A)
ACCUMULATORS WX90

NOTES:

15501 9-35990
 OPERATION PRINCIPLE SOV4-10-1
(O/P)
SOLENOID VALVES WX90

10. SOLENOID VALVES

10.1 SELECTOR SOLENOID VALVES

10.1.1 GENERALITIES

The solenoid valves are located in the superstructure lower part, reservoir side. Their function is to divert oil
flow coming from control lever and control pedal towards user control lines: digging control line and blade/
stabilizer line; travel control line and positioning arm line, superstructure rotation control line and arm angle
line.

10.1.2 CONSTRUCTION

The six selector solenoid valves are fitted on a body.

Selector solenoid valve

F8559

Solenoid No. Solenoid valve Disenergized Energized

B1 1 Solenoid valve Penetrator Blade - stabilizers
B2 2 Solenoid valve Penetrator Blade - stabilizers
15501 9-35990

B3 3 Solenoid valve Travel TB positioner

B4 4 Solenoid valve Travel TB positioner
B5 5 Solenoid valve Rotation Swing
B6 6 Solenoid valve Rotation Swing
7 Body
OPERATION PRINCIPLE SOV4-10-2
(O/P)
SOLENOID VALVES WX90

Please find, herebelow, the inner hydraulic diagram of the selector solenoid valves assembly, the
connections with the general hydraulic system and the functions of the relevant solenoid valves.

Selector solenoid valves assembly and hydraulic diagram

1 2 5 6 3 4 7 F8560

Solenoid No. Solenoid valve Disenergized Energized

B1 1 Solenoid valve Penetrator Blade - stabilizers
B2 2 Solenoid valve Penetrator Blade - stabilizers
B3 3 Solenoid valve Travel TB positioner
B4 4 Solenoid valve Travel TB positioner
B5 5 Solenoid valve Rotation Swing
B6 6 Solenoid valve Rotation Swing
7 Body

Functions of solenoid valves

- Solenoid valves B1-B2

Penetration/blade-stabilizers
Four-way and two-position solenoid valve, normally open. If activated, it sends l.h. control lever oil to the
spool controlling blade/stabilizer cylinders. In rest position, it sends the oil to the spool controlling
penetration cylinder.

- Solenoid valves B3-B4

Travel/positioner
Four-way and two-position solenoid valve, normally open. If activated, it sends pedal power control oil to
15501 9-35990

the spool controlling positioner cylinders. In rest position, it sends the oil to the spool controlling travel
hydraulic motor.

- Solenoid valves B5-B6

Rotation/swing
Four-way and two-position solenoid valve, normally open. If activated, it sends l.h. control lever oil to the
spool controlling arm angle cylinder. In rest position, it sends the oil to the spool controlling superstructure
rotation hydraulic motor.
 OPERATION PRINCIPLE SOV4-10-3
(O/P)
SOLENOID VALVES WX90

10.2 SERVICE SOLENOID VALVE GROUP

10.2.1 GENERALITIES

The service solenoid valve group is located in the turret in the air cleaner and hydraulic pumps compartment.
Its function is to allow, through solenoid valves, the delivery of piloting oil to the relevant actuators mounted
on the machine.

10.2.2 CONSTRUCTION

The service solenoid valve group is made up of a body and six solenoid valves.

Service solenoid valve group

2 6

1 8

9
7

4
5

F8561

1 - Parking brake
2 - Stabilizers/1st travel speed
15501 9-35990

3 - Solenoid valves and axle lock

4 - Grass-cutter solenoid valve
5 - Hydraulic hammer/grass-cutter control
6- (Tortoise)
7- (Hare)
rd
8 - 3 travel speed
9 - Body
OPERATION PRINCIPLE SOV4-10-4
(O/P)
SOLENOID VALVES WX90

Herebelow, please find the internal hydraulic diagram of the services solenoid valve group, the connections
with the main hydraulic system, the functions of the pressure relief valve and the relevant solenoid valves.

Service solenoid valve assembly and hydraulic diagram

7 5

F8562

8 6 4 3 2 1

1 - Parking brake 6- (Tortoise)

2 - Stabilizers/1st travel speed
7- (Hare)
3 - Solenoid valves and axle lock
4 - Grass-cutter solenoid valve 8 - 3rd travel speed
5 - Hydraulic hammer/grass-cutter control 9 - Body

Functions of solenoid valves

- Parking brake solenoid valve A1.

Two-way and two-position solenoid valve, normally open. It feeds the double pedal for travel control or
positioning arm depending if the solenoid valve is in rest position or energized. This solenoid valve is
excited by parking brake button and intercepts the possibility of travel control.
- 1st travel speed/stabilizer solenoid valve A2.
Three-way and two-position solenoid valve, normally closed. If activated, it sends power control oil to travel
hydraulic motor governor to keep it to the max. displacement (hydraulic motor free to change displacement).
With the solenoid valve in rest position, the governor is connected with the reservoir. The solenoid valve
allows also blade/side stabilizer operation.
- Solenoid valve and axle lock solenoid valve A3.
Three-way and two-position solenoid valve, normally closed. If energized, it opens and allows power
control oil to operate front axle lock valve. In rest position, the hydraulic circuit is cut off and consequently,
axle lock valve, normally closed, intercepts the hydraulic connection between the two lock cylinders.
- Hydraulic hammer/grass-cutter control solenoid valve A4/A5.
Six-way and three-position solenoid valve, normally closed. Se attivata invia l'olio servocomandi alla
15501 9-35990

valvola martello.

- (Tortoise - Hare) solenoid valve A6/A7.

Six-way and three-position solenoid valve, normally closed. If energized, it sends power control oil to
transmission control cylinder.
- 3rd travel speed solenoid valve A8.
Four-way and two-position solenoid valve, normally closed. If energized, it sends power control oil to travel
2nd spool of main control valve.
 OPERATION PRINCIPLE SOV4-10-5
(O/P)
SOLENOID VALVES WX90

10.3 STEERING TYPE CONTROL SOLENOID VALVE

10.3.1 GENERALITIES

- Steering type control solenoid valve.

Six-way, three-position solenoid valve, normally closed. If activated, it sends oil to rear axle or to front axle
and steering valve.

Solenoid valve parts

Each solenoid valve includes a body (3), three solenoid valves, coils and relative cables.

Steering type control solenoid valve group

F8565

1 - Double steering type solenoid valve

2 - Solenoid valve for rear wheel alignment lock
3 - Crab steering type solenoid valve
4 - Body

Hydraulic diagramof steering type control solenoid valve

2
3
15501 9-35990

1 4
F8566
OPERATION PRINCIPLE SOV4-10-6
(O/P)
SOLENOID VALVES WX90

10.4 POWER CONTROL DISCONNECTION SOLENOID VALVE (WITH FLOW DIVIDER)

10.4.1 GENERALITIES

Description
The block with power control valve includes a body (1) with flow divider (4) which constantly keeps power
control capacity at 9 lt./min. and sends the exceeding capacity to the solenoid valve controlling clamshell
bucket rotation, a relief valve (3) which keeps pressure constantly at 45 bar, a non return valve (2) preventing
oil return from the accumulator, a solenoid valve (5) cutting off oil flow to power controls.

Power control disconnection solenoid valve

3
1
2
F8567

1 - Blcok body
2 - Non return valve
3 - Relief valve
4 - Flow divider
5 - Solenoid valve
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6 - Solenoid
7 - Accumulator
 OPERATION PRINCIPLE SOV4-10-7
(O/P)
SOLENOID VALVES WX90

Assembly and hydraulic diagramof power control disconnection solenoid valve

4 3 6

1
5

4
3

1 - Blcok body F8568

15501 9-35990

2 - Non return valve

3 - Relief valve
4 - Flow divider
5 - Solenoid valve
6 - Solenoid
7 - Accumulator
OPERATION PRINCIPLE SOV4-10-8
(O/P)
SOLENOID VALVES WX90

10.4. 2 PILOT SYSTEM PRESSURE RELIEF VALVE

Description
The valve has the function of maintaining the pressure value of the oil inside the solenoid valves group at
45 ± 3 bar. In case the pressure exceeds its value, the valve operates discharging the excess into the return
line to the reservoir.

Operation
The valve inner operation is as follows:
- The pressure existing in duct (P) acts on needle (2), through seat opening (1) on seat spring-loaded side.
If pressure in duct (P) exceeds spring adjustment value (6), needle (2) moves and oil flow out from drainage
(T). With this movement pressure drops on needle (2) and it moves due to hydraulic pressure action in duct
(P) as it is no longer contrasted.
Needle motion (2) connects duct (P) and duct (T) until adjustment pressure is restablished.

Sectional view of pilot system pressure relief valve - Hydraulic diagram

9 8 7 3 11 10 1

4 6 2 5

1 - Seat
2 - Needle
3 - Cartridge P
4 - Piston F8569

5 - Spring guide
6 - Spring
15501 9-35990

7 - O-ring
8 - Nut
9 - Screw
10 - Ring
11 - Ring
 OPERATION PRINCIPLE SOV4-10-9
(O/P)
SOLENOID VALVES WX90

10.5 SOLENOID VALVE FOR CLAMSHELL BUCKET ROTATION CONTROL

10.5.1 GENERALITIES

Description
Four-way, three-position solenoid valve. If activated in a position, power control flow divider exceeding
oil feeds clamshell bucket rotation in one direction.
If activated in the other position, it feeds clamshell bucket rotation in the opposite direction. In central
position, it connects the circuit with the reservoir with rotation connections cut off. The block of this
solenoid valve includes also the relief valve, adjusted at 90 bar with 19 l/min.

Solenoid valve for clamshell bucket rotation control

1 3

F8571

1 - Block body
2 - Relief valve
3 - Solenoid valve
15501 9-35990
OPERATION PRINCIPLE SOV4-10-10
(O/P)
SOLENOID VALVES WX90

Assembly and hydraulic diagram of clamshell bucket rotation control

1
1 - Block body
2 - Pressure relief valve
3 - Solenoid valve

3 2

Solenoid electrical diagram F8572

Solenoid features
Nominal voltage: ............................................................................................................................... 27 V
Coil inside diode: .................................................................................................................. type IN 5406

+ positive
Coil circuit

- negative
15501 9-35990

Diode IN 5406

F8570
Solenoid valve connector diode

The electrical energizing of the solenoid valves causes current peaks that could damage electrical and
electronic components installed on the machine. A diode is included to avoid the inconvenient, located inside
the solenoid, between the positive and negative line of each valve solenoid.
 INDEX WX90 - 5 - 1

WX90

SECTION 5 UNDERCARRIAGE

INDEX

Group 1 - UNDERCARRIAGE ....................................................................................... UC5-1-1

1.1 Outlines
1.2 Lower frame
1.3 Swing bearing
1.4 Travel unit
1.5 Wheels
1.6 Blade assembly
1.7 Lateral stabilizers
1.8 Hydraulic hoses and undercarriage components

Group 2 - TRAVEL HYDRAULIC MOTOR - O/P - D/A ............................................... HYM5-2-1

2.1 Travel hydraulic motor - O/P

2.1 Disassembly and assembly - D/A

Group 3 - TRASMISSION - O/P - D/A ........................................................................... TM5-3-1

3.1 Trasmission - O/P

3.1 Transmission assembly and disassembly - D/A
15501 9-35990

O/P - OPERATION PRINCIPLE (to be continued)

D/A - DISASSEMBLY AND ASSEMBLY
 INDEX WX90 - 5 - 2
INDEX (continues)

Group 4 - AXLES - O/P - D/A ........................................................................................ AX5-4-1

4.1 Rear axle - O/P

4.2 Front axle - O/P
4.3 Braking unit - O/P
4.1 Rear axle - D/A
4.2 Front axle - D/A

Group 5 - TRANSMISSION SHAFT - O/P - D/A ............................................................. TS5-5-1

5.1 Transmission shaft - O/P

5.1 Disassembly and assembly - D/A

O/P - OPERATION PRINCIPLE

D/A - DISASSEMBLY AND ASSEMBLY

15501 9-35990
 UC5-1-1

UNDERCARRIAGE WX90

1. UNDERCARRIAGE

1.1 OUTLINES

The undercarriage is composed of the following parts:

1 - Swing bearing
2 - Lower frame
3 - Travel assembly (front axle, cardan joint, rear axle, transmission housing)
4 - Twin tyre assembly

The undercarriage can be fitted with:

- Blade / Lateral stabilizers

3
4

4
15501 9-35990

F8545
 UC5-1-2

UNDERCARRIAGE WX90

1.2 LOWER FRAME

1.2.1 DESCRIPTION

The lower frame assembly consists of a single welded element. The joint between the lower frame and the
upperstructure is carried out by means of a swing bearing that, moreover, allows the swing of upperstructure.
Ladders and tools box are fixed on the sides of lower frame.

5 1 2

F13264
15501 9-35990

1 - Lower frame
2 - Swing bearing
3 - Tool box
4 - Parking wedges
5 - Towing hook
 UC5-1-3

UNDERCARRIAGE WX90

1.3 SWING BEARING

1.3.1 DESCRIPTION

The swing bearing consists of an outer race (3) bolted to the upperstructure, an inner race (2) bolted to the
lower frame and a double rows of balls (4).
The swing reduction pinion (8), controlled by swing motor through the swing reduction gears, rotates on its
own axis and it also revolves round the centre of inner race of swing bearing, allowing the upperstructure to
swing independently of the lower frame.

7 9

5
10
2
8
3

6 1

F8563

1 - Lower frame 7 - Platform

2 - Inner race 8 - Swing reduction pinion
3 - Outer race 9 - Outer race screw
4 - Bearing ball 10 - Inner race screw
5 - Inner seal
6 - Outer seal
15501 9-35990
 UC5-1-4

UNDERCARRIAGE WX90

1.3.2 DATA

Dimensions

Hole center No. 36 equidistant holes

Hole center No. 36 equidistant holes

F8564

Maximum trust clearance . ................................................................................................... 0.05 - 0.25 mm

Maximum radial clearance .................................................................................................... 0.01 - 0.10 mm

Teeth

Module ......................................................................................................................................................... 8
Number of teeth ......................................................................................................................................... 81
Pressure angle ......................................................................................................................................... 20°
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 UC5-1-5

UNDERCARRIAGE WX90

1.3.3 MAINTENANCE

(1) Preliminary operations:

- Remove the counterweight (see section 4 - Upperstructure).

- Remove the front attachment (see section 6 - Front attachment).
- Remove the upperstructure (see section 4 - Upperstructure).

(2) Removal operations:

- Remove the inner race fixing screws.

- Install three eyebolts placing them to 120° on the swing bearing circle.
- Uplift the swing bearing by means of hoist.
Slewing ring weight 129 kg.

(3) Installation operations:

- Place the complete swing bearing assembly on lower frame.

- Tighten the screws on the inner race.
Tightening torque 29 ± 3 daNm.
- Position the upperstructure platform aligning the holes.
- Install and tighten the screws (see section 4 Upperstructure).
Tightening torque 29 ± 3 daNm.
- Complete the assembly by fixing the upperstructure, and installing the front attachment and
counterweight (see section 6 - Front attachment and section 4 - Upperstructure).

(4) Note for installation:

- The races on which the steel balls run, are induction hardened.
On the inner race (inside gear side) the soft zone is marked with “S”.
To minimize the load on this zone, the side marked “S” must be positioned on the right side of the
frame, as illustrated here below. Also the outer race has a soft zone near to the ball filler port, that
must be positioned toward the right side, as illustrated.
- Every time the swing bearing is installed, do not re-use the old screws but replace them with new
screws.

3 BALL
FILLER PORT
15501 9-35990

1 SOFT ZONE 2 SOFT ZONE

OUTER RACE INNER RACE

1 - Soft zone of outer race

2 - Soft zone of inner race
3 - Ball filler port
 UC5-1-6

UNDERCARRIAGE WX90

1.4 TRAVEL UNIT

1.4.1 DESCRIPTION

The travel unit includes: an hydraulic motor (1), a transmission unit (2), drive shaft (3), rear axle (4), front axle (5).

1
3
2
4
5

F8573
15501 9-35990
 UC5-1-7

UNDERCARRIAGE WX90

1.5 WHEELS

1.5.1 DESCRIPTION

The wheels adopted can be both in twin and in individual assembly.

- For twin assembly, conventional tyres are used (1).
- For individual assembly, radial tyres are used (2).

The adoption of these tyres assures the best performance for each application. None of these choices is
absolutely the best but each of them offers particular advantages to be considered when choosing the suitable
tyre for a special kind of work.

1 2

F13591

1 - CONVENTIONAL TYRE
Twin assembly (twin type)
type 8,25 - 20 EM NB-38 14 PR MITAS ....................................................... Inflation pressure 6,75 bar
15501 9-35990

2 - RADIAL TYRE
Individual assembly
type 500/45-20 ALLIANCE ............................................................................. Inflation pressure 6,0 bar
 UC5-1-8

UNDERCARRIAGE WX90

- Each wheel, used for INDIVIDUAL TYRE ASSEMBLY, is composed of: tyre, rim, inflation valve.
The tyre is radial type and the rim is drop centre type.
The four wheels use the same rims and tyres but the tread pattern is oriented according to the travel direction.
Therefore there are two kind of wheel assemblies, two for left side and two for right side installation.

Tyre bead base

Inflation valve seat

Disc

F13592

RIM FOR INDIVIDUAL TYRE ASSEMBLY

15501 9-35990

F13593

COVERING FOR INDIVIDUAL ASSEMBLY

 UC5-1-9

UNDERCARRIAGE WX90

- Each wheel, used for twin assembly (twin type), is composed of: tyre, rim , inner tube and inflation valve.
The tyre is conventional type and the rim is flat, demountable rings (three piece): side ring with conical base,
retainer ring (or tightening ring), with locking system.
The rims are different in relation with their installation position on the machine. The rim for outer wheels
installation has an offset of the disc bigger than the disc offset of the inner wheel rim.
The tyres are the same but the tread pattern are oriented according to the travel direction.
Therefore there are two inner wheels and two outer wheels assemblies for left side and two inner wheels and
two outer wheels assemblies for right side installation.
In the cavity between outer and inner wheel a rubber ring (1) is installed to avoid the soil and stones keeping.

Side ring with conical base (or counter-rim)

Flat rim
Retainer ring (or tightening ring)

Disc

Offset

F13594

RIM FOR TWIN ASSEMBLY

Inner tyre
15501 9-35990

Spacer rubber ring

F13595
Outer tyre

COVERING FOR TWIN ASSEMBLY

 UC5-1-10

UNDERCARRIAGE WX90

Valve
Each rim is equipped with an inflation valve.

Valve seat

Sealing ring

Rim

Valve cover

Nut

Sealing ring valve

Tightening elbow valve

F13596

On above is shown a rim section of a wheel. This rim installs an elbow valve screwed to feasible the tyre
inflation.

15501 9-35990
 UC5-1-11

UNDERCARRIAGE WX90

1.5.2 CONVENTIONAL TYRES

Conventional tyres are used in most applications due to the continuous improvements in the resistance
characteristics of synthetic yarns, used in housing manufacture. Each string of every ply, with an angle of
about 60°, runs from a bead to the other. The subsequent plies cross opposed angles among the string.
The higher the number of piles, the higher the load that the tyre can stand.
The max. load a conventional tyres can stand, is given by PR (ply rating) number, a theoretical number which
must not be confused with the real number of plies, usually lower. PR is considered the index of tyre load
capacity.
Conventional tyres, being manufactured with different kinds of compounds, can stand higher temperatures
(110° C) than radial tyres but they hold the heat longer, due to the high tickness of housing plies.

Advantages of conventional tyres

- Max. side protection of housing on side.

- Easy repair and remanufacture.
- Low costs per hour.
- Excellent resistance to sudden changes of temperature.
- High side stability.
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 UC5-1-12

UNDERCARRIAGE WX90

1.5.3 RADIAL TYRES

The housing of radial tyres has two main parts both manufactured with steel strings. In the radial tyre a strings
ply goes from a bead to the other forming the side strength element. The steel strings form a right angle with
the tyre middle plane; in conventional tyres this angle was acute.
The difference in the strings and individual ply manufacture guarantee to the radial type a higher vertical
flexibility. This is an advantage for the sides but not for the tread. Therefore, the second main component of
the radial tyre is the belt wrapping the housing below the tread. The belt, formed by overlapped plies in steel
string, increase the contact area and the tread resistance. The radial tyre is better for traction and floatage.
Due to the special adhesive substances used to adhere rubber to steel, the limit temperature these tyres can
reach is lower than the one of conventional tyres (about 93°C). However radial tyres, due to the lighter
structure and the better thermal conductivity of steel, eliminate heat more easily and can operate at higher
speeds.

Advantages of radial tyres

- Higher works speeds.

- Higher floating.
- Higher traction.
- Higher penetration-resistance.
- Lower roller resistance.
15501 9-35990
 UC5-1-13

UNDERCARRIAGE WX90

1.5.4 PRECAUTIONS TYRES INFLATION

- During inflation, tyres can undergo an explosive disjunction, possible to generate serious injuries.
- Before tyres inflation, always check rims conditions and tyres outer conditions for the presence of dents,
cuts, reinforcement plies tearing and other faults.
- It is recommended that checks and maintenance are carried out by a specialized technician.
- Inflate by using a protection cage and a tyre inflation gun with extension complete with checking pressure
gauge.
- Before start the inflation, make sure no people is nearby and stay on the track side or outer belt.
- Never exceed the prescribed pressures for the single types of tyres and always check for equal pressures
between right hand tyre and the correspondent left hand tyre.

Inflation standard pressure:

Conventional tyre twin 8.25 - 20 EM NB-38 14 PR MITAS = 6.75 bar
Radial tyre individual 500/45-20 ALLIANCE = 6 bar
Elements which may give a correction of the standard pressures:
- Overload.
- Run shape.
- Need for “floating”, that is improvement of rolling attitude on insubstantial bottoms.
- Room temperature.
The prescribed pressure is related to cold tyres.
If it could not feasible to detect the pressure in those conditions, it will be necessary to use a suitable correction
factor.

a) Temperature higher than 25°C

(pressure taken outside, in the yard)
- from 25 to 29°C ................................................................................................... increase pressure by 4%
- from 30 to 34°C ................................................................................................... increase pressure by 6%
- from 35 to 39°C ................................................................................................... increase pressure by 8%
- from 40 to 45°C ................................................................................................. increase pressure by 10%
15501 9-35990

b) Room temperature lower to 0°C

The use of low temperature tyres ( < 0°C) implies an increase of the base pressures depending on the
room temperature in yards and, in case of uses at rather low temperatures, it may need special precautions.
 UC5-1-14

UNDERCARRIAGE WX90

1.5.5 TYRES UTILIZATION RULES

Pressure

The use of tyres at the right pressure and its continuous check are one of the best and more efficient rules
to obtain the best performances and the longest life of tyres.
On the contrary, the use of non suitable pressures is a great contribution to the early breakages. A great
amount of damages - both to the structure and to the tyres lugs - may be avoided with a continuous check of
inflating. A too low a pressure may damage the textile structure of the tyre; the continuous and abnormal flexion
of flanks can cause cuttings and separation in the manufacture.
An extreme inflation must be avoided as well because it may lead to anomalous wears and even the structure
breakage. We remind you that the pressure must be determined considering the total load on the machine,
included possible accessory equipment.
Anyway, the tyre pressure must never exceed the max. values indicated for the dimension in subject. It is good
to check inflation monthly with a reliable tool. Fit the caps on the valves to prevent air losses.

Use on the road

The tyres have been designed to work on the fields where the transverse rods penetrate the soil and every
part of the track gets in contact with it. The running on hard or asphalted surface causes the tyre distortion
and the rods bend extremely when getting in contact with the ground and are loaded by the weight.
On hard soils, the result of all this is that the tyre is “grated” away by this movement and an early and irregular
wear is created.
For the road running it is recommended to increase tyres inflation, within the max. limits for the dimension in
subject; this allows to reduce the rods movement, the reason of the anomalous wear.
In these conditions, however, the wear in the centre of the tread is greater.

Repairs

Check the condition of your tyres periodically, mainly during wet seasons.
Humidity is not good for tyres. Cuts on the tread or flanks reaching the strings are a way of access for humidity
and foreign materials which make the tyre structure unserviceable.
A tyre with the above damages must be carefully and immediately repaired by competent staff.
If only the rubber part is concerned in the damage, without touching the structure, it is important to avoid that
stones and foreign materials can get inside.

15501 9-35990
 UC5-1-15

UNDERCARRIAGE WX90

1.5.6 TWIN WHEELS DISASSEMBLY AND

ASSEMBLY

Disassembly

1 Raise the machine from the side where you

need to remove the wheels.
Raise the wheel about 10 cm (4 in) with
the help of the front attachment and hold
machine with proper device.

WARNING
Before operating, deflate outer tyre (inner
ring kept tight by the pressure of the two twin
tyres is now free).

2 Remove the two inflating valves from

the special fork.

3 Untighten the nuts of the stud bolts.

4 Be care to the coming out of the

inflating valve extension.
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 UC5-1-16

UNDERCARRIAGE WX90

5 Remove the outer wheel.

6 Remove the space rubber ring.

7 Remove the inner wheel.

NOTE: Check the stud bolts.

If, one or more stud bolts should be
replaced, for safety reason all the stud
bolts set of the wheel must be replaced,
because even the remaining bolts will be
surely damaged.

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 UC5-1-17

UNDERCARRIAGE WX90

Assembly

CAUTION
Before installing the wheel check that tyre
tread is oriented according to the travel
direction of the machine.

NOTE: For an easy assembly it is advisable to

fit the wheel with tyres partially inflated.

1 Install the inner wheel.

Match the rim surface with the axle hub
centering base.
Lock the inner rim to avoid its movement.

NOTE : The inner rim has the shorter disc

offset.

2 Insert the rubber spacer ring.

NOTE: For a good working and a longer

tyre life, centre the spacer on the tyre.

3 Fit outer wheel checking that the inflating

valve of the inner tyre comes out of the
outer rim holes.

WARNING
Two hub studs are longer. They are used to
15501 9-35990

center the spacer.

NOTE: The outer rim has the greater disc

offset.
 UC5-1-18

UNDERCARRIAGE WX90

4 Tighten the rim fixing nuts on the wheel hub.

Tightening torque: 50 to 60 daNm

5 Insert the two inflating valves into the

suitable fork.

6 Inflate the tyres to the foreseen values.

Inflation pressure:
Conventional tyre
twin 8.25 - 20 EM NB-38 14 PR MITAS type
= 6.75 bar
Radial tyre
individual 500/45 -20 ALLIANCE type = 6 bar

7 Lowering the machine to the ground having

it supported on the tyres.
15501 9-35990

NOTE: About 2 hours of travelling after a

wheel reinstallation, check again the nuts
tightening torque.
 UC5-1-19

UNDERCARRIAGE WX90

1.5.7 REMOVING AND ASSEMBLY TYRES

Removing

NOTE: Use suitable grips and levers to remove

the tyre.

a. Remove the retaining ring (1) locking

system as shown in the figure.

b. Insert the levers at the end under the

retaining ring (1) and, keeping the levers
close together, work progressively round
the circumference of the ring (1) until it is
completely freed. F13653

IMPORTANT: Do not distort the retaining ring

(1) by forcing it.

c. Remove the shoulder (2) and the tyre (3). 3

2
Assembly and inflating a tyre

NOTE: Use suitable grips and levers to install 1

the tyre.

a. Clean the shoulder (2) and the rim (4) with

a hard brush. Remove any rust, if
necessary. F13655

IMPORTANT: Particular attention should be

paid to ensuring that the retaining ring groove in
the rim is clean and smooth. 3

b. Check the condition of the rim (4) and the

shoulder (2) making sure there are no signs 2
of cracks, distortion or serious damage due
to rust. 1

c. Check the condition of the safety-type

retaining ring and its locking system.
4 5

F13654
CAUTION
Discard any items which are defective or in
questionable condition and replace them
with genuine.

d. Inspect the tyre carefully. If necessary,

15501 9-35990

order a new tyre to the same specifications

or see your Dealer for variants.

e. Inflate the inner tube slightly for it to take

shape, dust it with talcum powder and install
it inside the tyre.

F13656
 UC5-1-20

UNDERCARRIAGE WX90

f. Install the rubber flap (5) protecting the inner

tube (3).
g. Grease the beads (8) of the tyre.

9
IMPORTANT: Make sure the tread of the tyre is
facing the same way as when removed.

h. Install the tyre (3), inner tube (9) and flap

(5) assembly on the rim (4), making sure
the valve (6) is correctly positioned as per
the indications given below.
8 4 5 8
- Inner wheel: the valve should be poin-ting
F13669
towards the wheel disc.
- Outer wheel: the valve should be pointing
away from the wheel disc.

3
IMPORTANT: Never unscrew a valve to ensure
correct orientation (risk of leakage).
7

i. Install the shoulder (2) correctly on the rim 2

(4).
l. Install the safety-type retaining ring, fitting
it progressively in its groove with a lever
and seating it well in the bottom of the 9 6
groove. F13657

IMPORTANT: It is essential for the retaining

ring to be firmly seated in its groove on the outer
side of the wheel. 11

m. Press the shoulder (2) into place hard up

against the retaining ring, after making sure
that if is in the correct position.
m. Before inflating the tyres, make sure the tyre
fitting lines (7) are centred in relation to the
rim (4) and the shoulder (2).
o. Install the wheel in an inflating cage (9) and
inflate the tyre to a pressure of 2 bar. F13658

p. Install the plate (10) over the 2 lugs, taking

care to mount it correctly (position of holes,
curving the right way).

IMPORTANT: The plate must go on easily,

leaving just a little play.
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 UC5-1-21

UNDERCARRIAGE WX90

q. Now check that all parts are in place and

correctly installed.
Condition a: The plate goes on easily,
leaving just a little play.
Condition b: The retaining ring is correctly
seated in its groove, on the outer side of
the wheel.
Condition c: The fitting lines (7) are centred
and concentric with the rim and shoulder.
If any one of the above conditions a, b or c
is not fulfilled, then the assembly has not
been carried out correctly.
Make the following operations. 11
Remove the plate (10).
Deflate the tyre. F13660

Remove the safety-type retaining ring (1)

and the shoulder (2).
Repeat Steps (i) to (q).
If any one of the above conditions a or b is
still not fulfilled, then the rim is not to
specifications. Replace the rim with a new
one.
r. Lock the safety-type retaining ring firmly into
place with the safety pin (11).
s. Inflate the tyre to the pressure specified.
t. Check that the retaining ring is correctly
mounted in its groove (it is imperative that
the ring be fully seated in the groove, all
the way round the wheel). Any gaps
appearing between the ring and the edge
of the groove or the shoulder are totally
unacceptable. If gaps are detected, leave
the wheel in the inflating cage, deflate the
tyre completely and repeat Steps (i) to (t).
If no gaps are detected, remove the wheel
from the inflating cage.
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 UC5-1-22

UNDERCARRIAGE WX90

1.6 BLADE ASSEMBLY

The machine can be equipped with a blade for small levelling works.
The blade assembly essentially consists of a blade, two upper levers connecting the installation plate with the
blade, and a lower lever that, beside connecting blade and installation plate, receives the motion by means
of retraction or extension of the cylinders.

5
2 2

5 4 5

F8753
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1 - Blade
2 - Link rod
3 - Right hand small arm
4 - Left hand small arm
5 - Pivot
6 - Hydraulic cylinder
 UC5-1-23

UNDERCARRIAGE WX90

1.7 LATERAL STABILIZERS

The machine can be equipped with one or two couple of stabilizers (outriggers) that assure, together with
locking axle system, the machine stability during the working operation.

3 6

6 5

1 4 1 5

F8752

1 - Stabilizer
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3 - Right hand small arm

4 - Left hand small arm
5 - Pivot
6 - Hydraulic cylinder
 UC5-1-24

UNDERCARRIAGE WX90

1.8 HYDRAULIC HOSES AND UNDERCARRIAGE COMPONENTS

1.8.1 HYDRAULIC TRAVEL MOTOR HOSES

All hoses connect the rotary joint to the hydraulic travel motor.

2 1

F8754
15501 9-35990

1 - Central joint
2 - Hydraulic travel motor
 UC5-1-25

UNDERCARRIAGE WX90

1.8.2 TRANSMISSION UNIT HOSES

The hoses connect the rotary joint to the transmission unit through the transmission control solenoid valves.

F8755
15501 9-35990

1 - Central joint
2 - Transmission unit
3 - Travel hydraulic motor
4 - Gearbox control hose
 UC5-1-26

UNDERCARRIAGE WX90

1.8.3 WORK AND PARKING BRAKE HOSES

The brake hoses connect the rotary joint to the front and rear axles braking devices.
On the front axle operates also a negative brake, or parking brake.

2 3

1 4

F8802
15501 9-35990

1 - Front axle work brake hose

2 - Central joint
3 - Rear axle work brake hose
4 - Front axle parking brake hose
 UC5-1-27

UNDERCARRIAGE WX90

1.8.4 STEERING HOSES

The steering hoses connect the rotary joint to the steering cylinder; this, operating on the swivel joint boxes,
performs the steering movement on front and rear wheels.

3 1 4

3 2

F8803

1 - Front axle hoses

15501 9-35990

2 - Rear axle hoses

3 - Steering cylinder
4 - Central joint
 UC5-1-28

UNDERCARRIAGE WX90

1.8.5 FRONT AXLE LOCKING AXLE CYLINDERS HOSES

These hoses connect the rotary joint to the two cylinders operating on front axle.
The axle locking valve, controlled by a solenoid valve located in the solenoid valves assembly, allows the
following operations:
- axle locking, when the two cylinders are not in communication each with other caused by the insertion of
the axle locking valve. The hydraulic oil remains then trapped in the related cylinders avoiding the axle rock;
- axle unlocking with controlled damping when the two cylinder are in communication each other (axle locking
valve not inserted).
The hydraulic oil can flow from one cylinder to the other allowing the damped rocking of the front axle.

3
4

15501 9-35990

F8804
1 - Axle locking cylinders
2 - Pressure reducing valve
3 - Central joint
4 - Axle locking valve
 UC5-1-29

UNDERCARRIAGE WX90

Axle locking valve

Weight: kg 1,400

F6974

Pressure reducing valve

Weight: kg 1,650
15501 9-35990

F6975
 UC5-1-30

UNDERCARRIAGE WX90

Hydraulic diagram of axle lock cylinders

1 - Hydraulic cylinder.
2 - Axle locking valve.
3 - Reduction valve.

F8807

Axle locking hydraulic cylinder

- Technical data
N. 2 hydraulic cylinder at simple effect.
Stroke: 100 mm
Rod diameter: 70 mm
Weight: 20 kg each

5
3

2
15501 9-35990

1
1 - Housing
2 - Rod
F8808
3 - Scraper ring
4 - Seal
5 - Guiding rings
 UC5-1-31

UNDERCARRIAGE WX90

1.8.6 BLADE/REAR STABILIZER HOSES

The drive hose contains a selection valve sending oil to the two blade cylinders at the same time, or separately
to each stabilizer cylinder. The selection valve is locked in central position if the machine is equipped with blade
and is driven by a piloting if the machine is equipped with stabilizers.

3
4

F8809
15501 9-35990

1 - Rotary joint
2 - Selector valve
3 - Check valve
4 - Blade/stabilizer cylinders
5 - To the piloting
 UC5-1-32

UNDERCARRIAGE WX90

Blade/stabilizer selection valve

A selection valve is fitted in the duct connecting the rotary joint with the blade/stabilizer cylinders. It allows them
to operate independently, though with one single control device in the control valve.
This selection valve is a 6-way and 3-position control valve. The central position obtained only by mechanical
fitting allows the feeding of the two cylinders at the same time (dozing blade control).
If the mechanical fitting is eliminated, the valve reaches an end and allows the feeding of one single cylinder.
The valve has a hydraulic piloting which allows positioning to the opposite end without stopping in the central
one.
The hydraulic piloting is reached by a solenoid valve operated by a switch in the cab's control panel. It sends
servocontrol oil pressure to the valve.

010/64

1 - Body
2 - Spool
3 - Mechanical control
4 - Piloting 4
15501 9-35990

011/64
 UC5-1-33

UNDERCARRIAGE WX90

Valve for blade/stabilizer cylinder locking

On blade/stabilizer and arm angle cylinders a double locking valve is fitted. It enables cylinders to keep their
position without drawings both in operation and in transfer conditions.
Hydraulic oil from control valve enters from (V1) moves and reach the cylinder through retain (10) and through
(C1). The cylinder remains still until pressure increases and moves pilot piston (2). It moves retain (10) opposite
to the previous one and enables the connection with the control valve of the opposite part of the cylinder. Block
(10) is self-cleaning and not sensitive to impurities, thus allowing a perfect seal.

9 11 4 3 1 10 2 10 4 3 11 9

F8811

Blade/stabilizer cylinder

- Technical data
- Rod diameter: 56 mm
- Inner body diameter: 80 mm
- Outer body diameter: 96 mm
- Maximum stroke: 200 mm
- Supply and return port connections: 3/8-19 BSPP CAVA JIS
15501 9-35990

F8984
 UC5-1-34

UNDERCARRIAGE WX90

NOTES:

15501 9-35990
 OPERATION PRINCIPLE HYM5-2-1
(O/P)
TRAVEL HYDRAULIC MOTOR WX90

2. TRAVEL HYDRAULIC MOTOR

2.1 TRAVEL HYDRAULIC MOTOR

2.1.1 DESCRIPTION

The travel hydraulic motor has the purpose of transmitting the motion, through the transmission, to the front
and rear axles.
The travel hydraulic motor is of a bent axis (bent body), variable displacement type with a group of tapered
axial pistons.
The displacement regulator is mounted in the travel motor head.
The displacement can be changed in a continuous mode within the maximum displacement (Vgmax.) and
minimum displacement (Vgmin.) ratio
Vgmax : Vgmin = 4,85.
When at travel break away or during up-hill travels, the displacement of the motor increases, thus the travel
force increases.
To obtain maximum travel speed, the displacement of the motor must result at minimum value.

The travel hydraulic motor is composed, essentially, of the following parts:

1 - Rotor group
2 - Regulator group
3 - Brake valve
4 - Positioning piston
5 - Housing

1 5 4 2

3
15501 9-35990

F8814
OPERATION PRINCIPLE HYM5-2-2
(O/P)
TRAVEL HYDRAULIC MOTOR WX90

2.1.2 ROTOR GROUP

The rotor group is composed of: valve plate (1), seven pistons (2), drive shaft (3), cylinder block (4), spring
(5), center shaft (6), bearings (7), seal (8).
The pressure of the hydraulic oil is applied through valve plate (1) to the piston and the latter, under the action
of the oil, makes an extending stroke and being connected to the drive shaft, their movement is changed into
a rotary motion of the drive shaft itself.
The cylinder block rotates with the pistons, that, in a sequence of extending strokes, generate a torque output
on the drive shaft.
The oil, after moving the pistons, is discharged in the return line by the pistons themselves during the retracting
phase.
The cylinder block can change its angle with respect to the axis of the shaft 5° through 25°. By changing the
angle, the stroke of the piston is changed, thus the torque generated.
The output torque of the drive shaft is a function of the hydraulic pressure and the angle of the cylinder block,
whereas the rotation speed is a function of the oil displacement and the angle of the cylinder block; in practice,
by reducing the angle of the cylinder block, the speed increases and the traction force decreases, by
increasing the angle, the speed is reduced and the traction force increases.

2
1

3
8

6
7 2 F7017
7 5
15501 9-35990

1 - Valve plate
2 - Piston
3 - Drive shaft
4 - Cylinder block
5 - Spring
6 - Center shaft
7 - Bearings
8 - Seal
 OPERATION PRINCIPLE HYM5-2-3
(O/P)
TRAVEL HYDRAULIC MOTOR WX90

2.1.3 REGULATOR GROUP

The travel hydraulic motor is equipped with an automatic displacement regulator related to the operating
pressure.
Beginning of regulation at Vgmin (minimum torque, maximum speed)
End of regulation at Vgmax (maximum torque, minimum speed)
This regulator measures internally the operating pressure in A or B and arranges the angle of the rotor group,
when the operating pressure set on the regulator itself is reached, from Vgmin toward Vgmax, through the
positioning piston.

Reduced speeds control

The regulator is also equipped with an additional piloting connection on X that allows the positioning of the
motor in Vgmax, not withstanding the operating pressure.
This function is used to obtain the first hydraulic speed (hydraulic motor in max. displacement supplied by
control valve spool).

Brake valve

Overpressure valve

Regulator

F8985
15501 9-35990
OPERATION PRINCIPLE HYM5-2-4
(O/P)
TRAVEL HYDRAULIC MOTOR WX90

2.1.4 BRAKE VALVE

The braking action is actuated by spool (1) depending upon the pressures at inlet A and outlet B (forward
speed condition) or inlet B and outlet A (reverse speed condition). The braking effect is showing-up when the
differential between the inlet and outlet pressures is such that spool (1) is tending toward neutral condition.
The neutral condition will occur only when the pedal pilot valve is completely released.
To protect the circuit, two pressure relief valves have been mounted. They operate when: the pedal pilot valve
is completely released (braking phase); the hydraulic motor is subject to the action of the front equipment.
These valves have the function of avoiding that the oil pressure trapped inside the circuit by spool (1) of the
brake valve and by check valves (2) exceeds 400 bar.

1
3
5
A B

6
7
8
9
4
10
13
12
11

F8815
15501 9-35990

A - Delivery in forward speed 7 - Spring guide plug

B - Discharge in forward speed 8 - Spring
1 - Brake valve spool 9 - Mushroom
2 - Check valve 10 - Spring
3 - Body 11 - Spring guide
4 - Seal 12 - Mushroom
5 - Spring guide sleeve 13 - Plug
6 - Spring
 DISASSEMBLY AND ASSEMBLY HYM5-2-1
(D/A)
TRAVEL HYDRAULIC MOTOR WX90

2.1 DISASSEMBLY AND ASSEMBLY

2.1.1 GENERAL INSTRUCTIONS FOR THE REPAIR

WARNING: The weight of the travel motor is about

34 kg.

• ATTENTION!
Observe the following notices when carryng out
repair work at hydraulic aggregates!

• Close all ports of the hydraulic aggregates.

• Replace all selas.

Use only original Hydromatic spare parts.

• Check all seal and sliding surfaces for wear.

15501 9-35990

ATTENTION: Rework of sealing areas for

example with abrasive paper can damage surface.
DISASSEMBLY AND ASSEMBLY HYM5-2-2
(D/A)
TRAVEL HYDRAULIC MOTOR WX90

• Fill up hydraulic aggregates with medium before

start-up.

1 Seal kit for drive shaft.

2 External seal kit.

3 Housing
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 DISASSEMBLY AND ASSEMBLY HYM5-2-3
(D/A)
TRAVEL HYDRAULIC MOTOR WX90

4 Contro valve with symmetric piston.

F7019

5 Port plate with control piston

For port plate with symmetric piston.

F7020

6/8 Cover with throttle pin*

* throttle pin as to order requiriment.

9 Cover with flushing and boots pressure valve and

throttle pin*
* throttle pin as order requiriment.
15501 9-35990
DISASSEMBLY AND ASSEMBLY HYM5-2-4
(D/A)
TRAVEL HYDRAULIC MOTOR WX90

• Control element.

F7022

10 Replace seal nut:

first measure and record setting height.

11 When tightening, counterhold setting screw, then

check setting height.

15501 9-35990
 DISASSEMBLY AND ASSEMBLY HYM5-2-5
(D/A)
TRAVEL HYDRAULIC MOTOR WX90

F7023

13 Protecting the drive shaft.

Remove retaining and shim.

14 Screw in sheet metal screw into the holes fitted

with rubber. Pull out seal with pliers.

15 Press in shaft seal ring and shim with bush to stop.

Take note of press-in depth*.
15501 9-35990

Install mark for press-in depth of safety ring.

DISASSEMBLY AND ASSEMBLY HYM5-2-6
(D/A)
TRAVEL HYDRAULIC MOTOR WX90

16 Attention: spring load.

17 Inspect:
drilling in housing, O-ring, groove.

18 Do not remove adjustment screw.

Inspect: O-ring, O-ring groove, housing.

19 Assembly aid:
15501 9-35990

insert pin with grease.

 DISASSEMBLY AND ASSEMBLY HYM5-2-7
(D/A)
TRAVEL HYDRAULIC MOTOR WX90

F7024

21 Example: A6VM ... HD control disassembly

position:
remove cover pos. 1

Pos. 1

22 (1) O-ring
(2) Imput flow of oil control
(3) Throttle pin.

Installation position differs according to the

control components.

23 (1) input flow of oil control

15501 9-35990

(2) high/low pressure

(3) high/low pressure
(4) leckage oil
(5) cotrol piston.
DISASSEMBLY AND ASSEMBLY HYM5-2-8
(D/A)
TRAVEL HYDRAULIC MOTOR WX90

F7024

25 Example: A6VM ....control - differential piston

Disassambly position: Remove cover pos. 2.
Attention! Spring load.
Dimension x: Note dimension (begin of regulation).

26 (1) Check of O-ring.

27 (1) hight pressure: small control piston side

(2) control pressure
(3) hight pressure: check valve
(4) hight pressure: check valve
15501 9-35990
 DISASSEMBLY AND ASSEMBLY HYM5-2-9
(D/A)
TRAVEL HYDRAULIC MOTOR WX90

• Symmetric piston:
note dimension x.

• For disassembly of the port plate, swivel always

rotari group to zero position.

• Remove Qmin -screw and plug.

• Swivel rotary group to zero position with screw

Qmin.
15501 9-35990
DISASSEMBLY AND ASSEMBLY HYM5-2-10
(D/A)
TRAVEL HYDRAULIC MOTOR WX90

28 Port plate.
Mark position.
Loosen screws.
Removal.

29 Replace O-ring.
Stick new O-ring with some grease.
Do not swivel rotary group.
Piston rings to hang out from the cylinder boring.

30 Stick control lens in sliding surface with

grease. Assembly in reversal order. Mount port
plate.

Rotary group vertical.

15501 9-35990
 DISASSEMBLY AND ASSEMBLY HYM5-2-11
(D/A)
TRAVEL HYDRAULIC MOTOR WX90

31 Symmetric piston

F7025

32 Loosen fixing screw.

Use only socket wrench.

33 Remove piston with piston ring.

15501 9-35990
DISASSEMBLY AND ASSEMBLY HYM5-2-12
(D/A)
TRAVEL HYDRAULIC MOTOR WX90

34 Symmetric piston
Remove screw.
Remove piston.

Not installation position.

37 Screw in threaded pin into center pin.

Fix the cylinder with disc and locknut.
Remove Qmax-stop screw.

Size: 80 : M6 x 82mm
15501 9-35990
 DISASSEMBLY AND ASSEMBLY HYM5-2-13
(D/A)
TRAVEL HYDRAULIC MOTOR WX90

38 Press out rotary group.

If the bearings are used again, do not hit on

the drive shaft.

39 Press-out the rotary group with extraction device.

40 Complete rotary group keyed

Setting of hydraulic part necessary.

F7026
15501 9-35990
DISASSEMBLY AND ASSEMBLY HYM5-2-14
(D/A)
TRAVEL HYDRAULIC MOTOR WX90

41 Rotary group
1. mechanical part: adjust drive shaft with bearing
2. hydraulic part: adjustment necessary*

42 Rotary group: all parts

* setting
setting value, torque see service information.

15501 9-35990
 DISASSEMBLY AND ASSEMBLY HYM5-2-15
(D/A)
TRAVEL HYDRAULIC MOTOR WX90

43 Remove fixing screw (cylinder).

Remove cylinder.

44 Disassemble retaining plate.

Screws are glued.
Use Torx-tools.

45 Free of corrosion, erosion or fretting, no damage

to splines or keyways.
15501 9-35990
DISASSEMBLY AND ASSEMBLY HYM5-2-16
(D/A)
TRAVEL HYDRAULIC MOTOR WX90

46 Pistons: no scoring and no pittings.

47 Center pin: no scoring and no pittings.

48 Retaining plate: no scoring and no evidence of

wear.

49 Cylinder block / control lens:

1. bores free of scoring, no evidence of wear 1
2. faces smooth and even, free of cracks and
scoring.
1
2
2
F6852

50 Control housing: sliding surface and side guides

free of scoring and no wear.
15501 9-35990
 DISASSEMBLY AND ASSEMBLY HYM5-2-17
(D/A)
TRAVEL HYDRAULIC MOTOR WX90

51 Visual check: bearing areas free of scoring and

no evidence of wear.

• Rotary group: machanical part

Adjustment dimension* and bearing torque: see
service information.

Press on bearing.
Do not exeed bearing torque during press-on.

Preload bearing with assembly sleeve and steady

control of the torque.
15501 9-35990
DISASSEMBLY AND ASSEMBLY HYM5-2-18
(D/A)
TRAVEL HYDRAULIC MOTOR WX90

• Rotary group: mechanical part

Assemble safety ring.

Detrmine dimension* for adjustment disc with final
dimensions (crossover).

• Insall adjustment disc.

Assemble safety ring.
Drive shaft ready for assembly.
15501 9-35990
 DISASSEMBLY AND ASSEMBLY HYM5-2-19
(D/A)
TRAVEL HYDRAULIC MOTOR WX90

F7068

53 Insert retaining plate with piston and center pin.

Pin screw with Precote-coating.

54 Make sure all pars are fitted in correctly.

55 Swivel cylinder block to max. and fix the cylinder.

15501 9-35990
DISASSEMBLY AND ASSEMBLY HYM5-2-20
(D/A)
TRAVEL HYDRAULIC MOTOR WX90

• Rotary group completely assembled ready for

assembly.

• Place assembly sleeve.

• Warm up housing to 80°C.

15501 9-35990
 DISASSEMBLY AND ASSEMBLY HYM5-2-21
(D/A)
TRAVEL HYDRAULIC MOTOR WX90

• Insert rotary group into housing to seat position.

• Fix zero position of cylinder with Qmax "screw".

1. disassemble cylinder fixing screw.
2. insert O-ring.
15501 9-35990
DISASSEMBLY AND ASSEMBLY HYM5-2-22
(D/A)
TRAVEL HYDRAULIC MOTOR WX90

56 Determine cylinder swivel range to max. angle

screw.

57 *Disc

58 Place centering disc.

59 Mount measuring device.

60 Check dimension x.
15501 9-35990
 DISASSEMBLY AND ASSEMBLY HYM5-2-23
(D/A)
TRAVEL HYDRAULIC MOTOR WX90

64 1. Assemble port plate with symmetric piston.

Take care of assembly design!

Tighten fixing screws wit torque.

2. Swivel rotary group to starting position.

3. Set Qmin screw to dimension*.
4. Assemble plug.

65 Assemble shaft seal, disc and safety ring.

Press-in with assembly sleeve.

Take care of press-in depth.

15501 9-35990
DISASSEMBLY AND ASSEMBLY HYM5-2-24
(D/A)
TRAVEL HYDRAULIC MOTOR WX90

Tightening torques for shaft bolts THREAD STRENGTH CLASSES

(metric ISO standard)
8.8 10.9 12.9
The values for tightening torques shown in the TIGHTENING TORQUE (lb.ft.)
table are valid only for shaft bolts with metric M3 1,1 1,6 1,9
ISO-standard threads and head support surface M4 2,9 4,1 4,9
dimensions in accordance with DIN 912, DIN M5 6 8,5 10
931 e DIN 933. M6 10 14 17
These values are also valid only for light or M8 25 96 41
unoiled, untreated surface as well as for use M10 49 69 83
only with torque-indicating wrenches and force M12 86 120 145
limiting tools. M14 135 190 230
M16 210 295 355
M18 290 405 485
M20 410 580 690
M22 550 780 930
M24 710 1000 1200
M27 1050 1500 1800
M30 1450 2000 2400

Tightening torques for locking screws VSTI THREAD DESIGNATION TIGHTENING

(metric ISO fine thread) TORQUES (lb.ft)
M8x1 VSTI 8 x 1 -ED/SA 5
M10 x 1 VSTI 10 x 1 -ED 10
M12 x 1,5 VSTI 12 x 1,5 -ED 20
M14 x 1,5 VSTI 14 x 1,5 -ED 30
M16 x 1,5 VSTI 16 x 1,5 -ED/SA 30
M18 x 1,5 VSTI 18 x 1,5 -ED/SA 40
M20 x 1,5 VSTI 20 x 1,5 -ED/SA 50
M22 x 1,5 VSTI 22 x 1,5 -ED 60
M26 x 1,5 VSTI 16 x 1,5 -ED/SA 70
M27 x 2 VSTI 27 x 2 -ED 90
M30 x 1,5 VSTI 30 x 1,5 -ED/SA 100
M33 x 2 VSTI 33 x 2 -ED/SA 120
M42 x 2 VSTI 42 x 2 -ED/SA 200
M48 x 2 VSTI 48 x 2 -ED 300

Tightening torques for seal-lock nuts THREAD STRENGTH CLASSES

(metric ISO-standard thread)
8.8 10.9 12.9
The values for tightening torques shown in the TIGHTENING TORQUE (lb.ft.)
table are valid only for seal-lock nuts of the M6 10
strenght class 8.8 and with metric ISO-standard M8 22
thread. M10 40
M12 69
M14 110
M16 170

Tightening torques for cross-slotted lens head THREAD STRENGTH CLASSES

screws DIN 7985
15501 9-35990

(metric ISO-standard thread) 8.8 10.9 12.9

TIGHTENING TORQUE (lb.ft.)
The values for tightening torques shown in the M3 1,1
table are valid only for cross-slotted lens head M4 2,9
screws DIN 7985 of the strenght class 8.8 and M5 6
with metric ISO-standard thread. M6 10
M8 25
M10 49
 OPERATION PRINCIPLE TM5-3-1
((O/P)
TRASMISSION WX90

3. TRANSMISSION

3.1 TRANSMISSION

3.1.1 OPERATION

The motion produced by hydraulic travel motor is applied to the front and rear axles by means of the
transmission.
The transmission has two gears and is flanged to the rear axle. Speed selection is hydraulically obtained
controlling transmission control cylinder piston in and speed.

F8986

2
15501 9-35990

F8455
1
2

1 - Gear control cylinder fittings

2 - Speed sensor
OPERATION PRINCIPLE TM5-3-2
((O/P)
TRASMISSION WX90

3.1.2 SPEED GEAR RATIOS

The two speed gear ratios are inside the gearbox with straight toothed wheel couplings.

Transmission ratio 1 : 3.29.

Motion inlet

F8503

A - Input gear
B - Speed keying sleeve
15501 9-35990

C - Output gear
D - Output shaft
 OPERATION PRINCIPLE TM5-3-3
((O/P)
TRASMISSION WX90

Transmission ratio 1 : 1.14.

E B

Motion inlet

D F

F8504

E - Input gear
B - Speed keying sleeve
15501 9-35990

F - Output gear
D - Output shaft
OPERATION PRINCIPLE TM5-3-4
((O/P)
TRASMISSION WX90

3.1.3 HAND OPERATED TRANSMISSION CONTROL (MACHINE STANDING STILL) WITH PARKING
BRAKE CONNECTED

With gear selector 1 on hare, 2nd speed is connected. At the same time, the warning light relative to the
selected gear 8 lights up.

CHECK

2
1 2 1
OFF

A/I
8 4

OFF
15 20
10 25 P
P

5 Km/h 30
F8501
0
F8502

An electrical signal is sent to gear selector ( / ) (1), to control unit (2) which receives a signal from
selector (4), enabling the machine to remain stopped.
From control unit, the electrical signal reaches user solenoid valve group coil (3).
The transmission control solenoid valve fitted into solenoid valve group (3), activated, send oil under pressure
of power control circuit to gear selector cylinder (7). The selected gear is connected. 15501 9-35990
 OPERATION PRINCIPLE TM5-3-5
((O/P)
TRASMISSION WX90

4
1

3
9 5
F8505

1 - Gear selector
2 - Control unit
3 - User solenoid valve group
4 - Braking type selector
5 - Power control circuit
6 - Transmission
7 - Gear selector cylinder
8 - Gear connection warning lights
9 - Rear axle
15501 9-35990
OPERATION PRINCIPLE TM5-3-6
((O/P)
TRASMISSION WX90

NOTES:

15501 9-35990
 DISASSEMBLY AND ASSEMBLY TM5-3-1
((D/A)
TRANSMISSION WX90

3.1 TRANSMISSION ASSEMBLY AND DISASSEMBLY

Fig. 1 - Descriptional Transmission unit assembly:

02
74 04
01 76-77-78-79-80
03 06 183
59 33 09
63 56
60

58 07
13 26
61 184
31 22
30 22
54 29
37 32
20
55 64 28 19
36 34 27 22 11
73 57 22 13
38
35 72
52 44
53 39
24
52 50
65
41
51
23 185
40
21 18
62 17
47 16
49
45
42
75 45 12
48
15501 9-35990

11 46 70 F8829
43
DISASSEMBLY AND ASSEMBLY TM5-3-2
((D/A)
TRANSMISSION WX90

Descriptional Transmission unit assembly:

01 - O-Ring 43 - Plate
02 - Plug 44 - O-Ring
04 - Cover 45 - Shoe
05 - Seal ring 46 - Fork
06 - Bearing 47 - Rod
07 - Cover 48 - O-Ring
09 - Bearing 49 - O-Ring
11 - Pin 50 - Piston
12 - Box 51 - Ring - Safety
13 - Screw 52 - Plug
16 - Washer 53 - Screw
17 - Screw 54 - Rod - tansmission
18 - Spacer 55 - Ring
19 - Screw 56 - Plug
20 - Spring washer 57 - O-Ring
21 - Plate 58 - Cover
22 - Cage 59 - Flange
23 - Shaft 60 - Nut
24 - Sleeve 61 - Seal ring
26 - Plate 62 - Seal ring
27 - Magnetic plug 63 - O-Ring
28 - Spacer 64 - Seal washer
29 - Switch 65 - Washer
30 - Protection 70 - Ring
31 - Screw 72 - Spring pin
32 - Spring 73 - Screw
33 - Bearing 74 - Screw
34 - Ball 75 - O-Ring
35 - Ring - Safety 76 - Shim
36 - Ring 77 - Shim
37 - Seal ring 78 - Shim
38 - Cylinder 79 - Shim
39 - Piston 80 - Shim
40 - O-Ring 183 - Shaft
41 - O-Ring 184 - Flange
42 - Piston 185 - Gear

15501 9-35990
 DISASSEMBLY AND ASSEMBLY TM5-3-3
((D/A)
TRANSMISSION WX90

3.1.1 INTRODUCTION

- Before starting disassembling operations, important thing is to clean the transmission and the work
bench.

- It is advisable to mark all the shims for the assembling operations.

- Place the transmission on a work bench and be sure that the oil has already been drained from unit.

- Verify the identification plate recording the transmission type and unit.

- Remove the delicate parts (e.g. speed sensor, lock gear switch, etc.).

WARNING: the weight of the transmission is about 70 kg.

Disassembly of assembly
Renew at each reassemble
groups

Reassemble to assembly group

Unlock-lock

Remove obstruction parts Lock - adhere (liquid sealant)

Reinstall-remount parts which had Guard against material damage, damage

obstructed disassembly to parts

Mark before disassembly, observe marks

Attention, important notice when reassemble

Check - adjust e.g. torque, dimensions, Filling - topping up - refilling e.g. oil,
pressure, etc. cooling water. Etc.

T = Special tool
Drain off oil, lubricant
P = Page

Note direction of installation Tighten

15501 9-35990

Visual inspection Apply pressure into hydraulic circuit

Possibly still serviceable, renew if Clean

necessary
DISASSEMBLY AND ASSEMBLY TM5-3-4
((D/A)
TRANSMISSION WX90

3.1.2 REMOVAL OF HYDRAULIC GEAR

CONTROL

1 Remove the gear control rod.

F1240072

2 Pull out the control rod.

F1240073

3 Remove screws on the gear control

cylinder.

F1240074

4 Remove the gear control cylinder.

15501 9-35990

F1240075
 DISASSEMBLY AND ASSEMBLY TM5-3-5
((D/A)
TRANSMISSION WX90

5 Pull out the gear control cylinder.

Pay attention to the position of the O-
rings. Remove the protection plate.

F1240076

6 Re-assembly arrangement of gear

control cylinder parts.

F1240077

Disassembly of directly flanged reduction gear

357

7 Remove fastening screws from the

reduction unit.

F1240078

8 Disjoin the entire reduction unit from the

axle and place it on a bench.
15501 9-35990

F1240079
DISASSEMBLY AND ASSEMBLY TM5-3-6
((D/A)
TRANSMISSION WX90

9/10 Remove the sealing cover with the re-

lative washer or the revolution indicator.

F1240080

11/12 Remove screw, spring and neutral

position ball (hydraulic version).

F1240083

15501 9-35990
 DISASSEMBLY AND ASSEMBLY TM5-3-7
((D/A)
TRANSMISSION WX90

13 Remove screws from the motion input

cover.

F1240084

14 Disjoin the motion entrance cover.

F1240085

15 Remove the nut from the flange.

F1240086

16 Remove the O-ring and pull out the

flange.
15501 9-35990

F1240087
DISASSEMBLY AND ASSEMBLY TM5-3-8
((D/A)
TRANSMISSION WX90

17 Remove screws from the cover.

F1240088

18 Disjoin the cover.

F1240089

19 Remove the cover by fixing the distance

washers onto the cover itself.

CAUTION: the niche must be facing

upwards.

F1240090

20 Remove screws.
15501 9-35990

F1240091
 DISASSEMBLY AND ASSEMBLY TM5-3-9
((D/A)
TRANSMISSION WX90

21 Remove the cover.

Take care not to damage planes.

F1240092

22 Take away the cover.

Pay attention to the position of the pins.

F1240093

23 Pull out gear, needle bearings and

distance piece form the box.

F1240094

24 Remove the bearing if it needs replacing.

15501 9-35990

F1240095
DISASSEMBLY AND ASSEMBLY TM5-3-10
((D/A)
TRANSMISSION WX90

25 Re-introduce the bearing into the box.

F1240096

26 Remove the oil shield plate only if

necessary.

CAUTION: the oil inlet must face

upwards.

F1240097

27 Re-introduce the oil shield plate with oil

inlet facing upwards.
Apply LOCTITE 510 on the outside.

F1240098

28 Fit the oil shield plate into position 5-5.5

mm from box plane.
15501 9-35990

F1240099
 DISASSEMBLY AND ASSEMBLY TM5-3-11
((D/A)
TRANSMISSION WX90

29 Remove the check screws from the flow

regulator plate.

F1240100

30 Remove the plate and pull out coupling

and fork at the same time.

F1240101

31 Check: sliding blocks, pin, and sliding

coupling.
Replace if worn.

F1240102

32 Remove the lower shaft.

15501 9-35990

F1240103
DISASSEMBLY AND ASSEMBLY TM5-3-12
((D/A)
TRANSMISSION WX90

33 Remove the entire shaft and the flow

regulator plate.

F1240104

34 Disassembly of the entire lower shaft.

F1240105

35 Progressive arrangement of parts fitted

onto the lower shaft.

F1240106

36 AAssembly of lower shaft.

15501 9-35990

F1240107
 DISASSEMBLY AND ASSEMBLY TM5-3-13
((D/A)
TRANSMISSION WX90

37 Removal of upper shaft.

(In case of replacement, the shaft is
supplied already assembled).

F1240108

38 Pull out the sealing ring.

F1240109

39 Re-insert a new sealing ring.

F1240110

40 Pull out the sealing ring of the cover..

15501 9-35990

F1240111
DISASSEMBLY AND ASSEMBLY TM5-3-14
((D/A)
TRANSMISSION WX90

41 Re-insert a new sealing ring.

F1240112

42 Pull out the sealing ring from the motion

input cover.

F1240113

43 Remove the bearing from the cover of

the reduction unit.

F1240114

Assembly of directly flanged reduction gear

357

44 Re-fit the bearing in the cover of the

reduction unit using ordinary tools.
15501 9-35990

F1240115
 DISASSEMBLY AND ASSEMBLY TM5-3-15
((D/A)
TRANSMISSION WX90

45 Re-insert the new sealing ring in the

motion input cover.

F1240116

46 Re-assemble the cover, spreading

LOCTITE 510 on planes and screws.

F1240117

47 Tighten screws using a torque wrench

setting of 49±51 Nm.

F1240118

48 Lubricate the lip of the sealing ring with

grease.
15501 9-35990

F1240119
DISASSEMBLY AND ASSEMBLY TM5-3-16
((D/A)
TRANSMISSION WX90

49 Re-assemble the motion upper shaft.

F1240120

50 Re-assemble the full lower shaft and the

flow regulator plate.

F1240104

51 Position the shaft so that the bearing juts

out approximately 5 mm from the cover
of the reduction unit.

F1240121

52 Temporarily re-assemble the cover with

screws.
(Be sure that the niche faces upwards).
15501 9-35990

F1240122
 DISASSEMBLY AND ASSEMBLY TM5-3-17
((D/A)
TRANSMISSION WX90

53 Simultaneously insert: fork and sliding

blocks, coupling and flow regulator plate.

F1240101

54 Re-insert screws and tighten.

F1240100

55 Tighten screws using a torque wrench

setting of 25-26 Nm.

F1240123

56 Re-assemble needle bearings, gear and

distance piece.
15501 9-35990

F1240124
DISASSEMBLY AND ASSEMBLY TM5-3-18
((D/A)
TRANSMISSION WX90

57 Check the insertion of pins.

F1240125

58 Spread LOCTITE 510 on the surface and

assemble the cover.

F1240126

59 Fasten the cover.

F1240127

60 Tighten screws using a torque wrench

setting of 49551 Nm.

CAUTION: tighten using the crossed

method.
15501 9-35990

F1240128
 DISASSEMBLY AND ASSEMBLY TM5-3-19
((D/A)
TRANSMISSION WX90

61/62 Grease components and re-introduce

ball, spring and screw (hydraulic
version).
Tighten using a max. torque wrench
setting of 80-100 Nm.

F1240083

63/64 Assemble the sealing cover with

washer and revolution indicator.
Tighten using a torque wrench setting
of max. 25 Nm.

F1240080
15501 9-35990
DISASSEMBLY AND ASSEMBLY TM5-3-20
((D/A)
TRANSMISSION WX90

65 Re-fit the reduction unit onto the axle by

spreading LOCTITE 510 on the planes.

F1240129

66 Fasten the support planes (turn flange

to assist assembly).

F1240130

67 Insert screws by applying LOCTITE 510.

F1240131

68 Screw down by placing the reduction unit

in a vertical position in relation to the axis.
15501 9-35990

F1240132
 DISASSEMBLY AND ASSEMBLY TM5-3-21
((D/A)
TRANSMISSION WX90

69 Tighten screws using a torque wrench

setting of 49-51 Nm.

F1240133

70 Extract screws and remove the

temporarily assembled cover.

F1240134

71 Fasten the bearing by using a standard

tool.

F1240135

72 Measure dimension “A” between the

bearing and the box plane using an
ordinary depth gauge (if parts are not
replaced, use disassembled distance
washers).
15501 9-35990

F1240136
DISASSEMBLY AND ASSEMBLY TM5-3-22
((D/A)
TRANSMISSION WX90

73 Measure dimension “B” on the cover,

between the bearing plane and bearing
support. Calculate the dimension of the
distance washers required:
S=Dimension B - Dimension A
Es: B=5.2-A=4.6 mm - Backlash 0.2-
0.3=Distance washer required=0.4-0.3.
B

F1240137

74 Apply LOCTITE 510 on the surface,

lubricate the sealing ring, insert the
distance washers and re-assemble the
cover with niche facing upwards.

S
F1240138

75 Fit screws after applying LOCTITE 510.

F1240139

76 Tighten screws using a torque wrench

setting of 49-51 Nm.
15501 9-35990

F1240140
 DISASSEMBLY AND ASSEMBLY TM5-3-23
((D/A)
TRANSMISSION WX90

77 Montare la flangia, l’anello OR e il dado

con LOCTITE 242.

F1240141

78 Screw down the nut of the flange.

F1240142

79 Tighten the nut using a torque wrench

setting of 260-280 Nm.

F1240143

80 Re-fix the protection plate after applying

LOCTITE 510.
15501 9-35990

F1240144
DISASSEMBLY AND ASSEMBLY TM5-3-24
((D/A)
TRANSMISSION WX90

81 Complete flanged reduction gear with

mechanical gear control.

F1240069

82 Re-assemble all the parts of the gear

control cylinder, according to their
arrangement.

F1240145

83 Re-fix the protection plate after applying

LOCTITE 510 on it.

F1240144

84 Re-fit the gear control cylinder into place

with its O-ring. .
15501 9-35990

F1240146
 DISASSEMBLY AND ASSEMBLY TM5-3-25
((D/A)
TRANSMISSION WX90

85 Re-fit screws and screw down.

F1240147

86 Re-introduce the gear control rod after

applying LOCTITE 242 on it.

F1240148

Installation of hydraulic gear control

87 Tighten the gear control rod using a

torque wrench setting of 25-26 Nm.

F1240149

88 Tighten gear control cylinder screws

using a torque wrench setting of 49-51
Nm.
15501 9-35990

F1240150
DISASSEMBLY AND ASSEMBLY TM5-3-26
((D/A)
TRANSMISSION WX90

NOTES:

15501 9-35990
 DISASSEMBLY AND ASSEMBLY AX5-4-1
(O/P)
AXLES WX90

4. AXLES

4.1 REAR AXLE

The rear axle is composed of: axle housing, differential and final drives. The transmission is flanged to the
rear axle.
15501 9-35990

F7265

K - Steering supply
F - Brakes bleeding screw
E - Brake hydraulic control
DISASSEMBLY AND ASSEMBLY AX5-4-2
(O/P)
AXLES WX90

4.1.1 AXLE HOUSING

The rear axle is composed of: a central housing (1), two intermediate covers (2) and two side arms (3).
Inside the intermediate covers (2) the seats for the cylinders of the braking system and the parking negative
brake are mounted.
The two side arms (3) are of a non steering type, and include the seat for the disc brakes and the side shafts
(4).

2 1

4
2

3
2

15501 9-35990

F8837
 DISASSEMBLY AND ASSEMBLY AX5-4-3
(O/P)
AXLES WX90

4.1.2 STEERING CONTROL CYLINDER

The front axle is equipped with a steering system controlled by an hydraulic cylinder inserted into the central
housing. Appropriate adjustable drag links (1) are screwed, on one side, directly onto the cylinder rod (2) and
on the other side are connected to the swivel knuckles.

F8838
15501 9-35990
DISASSEMBLY AND ASSEMBLY AX5-4-4
(O/P)
AXLES WX90

4.1.3 DIFFERENTIAL

The differential has the purpose of changing the relative rotation speed of the two wheels (right and left) when
travelling in an non straight direction. The differential provides, also, a reduction of the r.p.m. input through
a bevel gear unit.

Fig. 1 - Differential
(Refer to the description on the next page)

12
09 15
02 14 16
08 16 14
13 17 15
05 31
10
11 17
31
05 32
13 18
31 09
17 10
15
16
14
14
16
15
17
31
30
29
03
07 12
06 08

07
15501 9-35990

19-20-21-22
23
24-25-26-27-28 F9359
 DISASSEMBLY AND ASSEMBLY AX5-4-5
(O/P)
AXLES WX90

Differential description - Fig. 1

02 - Screw 18 - Box
03 - Seal ring 19 - Shim S=0,20
05 - Planetary 20 - Shim S=0,30
06 - Ring nut 21 - Shim
07 - Bearing 22 - Shim
08 - Bevel gear set 23 - Spacer
09 - Bearing 24 - Shim
10 - Ring nut 25 - Shim
11 - Screw 26 - Shim
12 - Screw 27 - Shim
13 - Washer 28 - Shim
14 - Seal ring 29 - Nut
15 - Ring 30 - Stud
16 - Pin 31 - Planetary
17 - Washer 32 - Sensor
15501 9-35990
DISASSEMBLY AND ASSEMBLY AX5-4-6
(O/P)
AXLES WX90

4.1.4 FINAL DRIVE

The final drive is of a planetary type and its function is to reduce appropriately the r.p.m. of the wheels with
respect to the output r.p.m. from the differential. The reduction unit is composed of a toothed drum, three
planetary gears and a solar gear mounted on the splined end of the axle shaft.

Fig. 2 - Final drive

(Refer to the description on the next page)

09
06
44 11
07
43 10 08
01 12
WITH DOWEL BUSH 16 25
03 15 17 24
04 18 13
19
52-53-54
21
14 29
30
26
32
05 33
30 30
23-28
45
22
47 21
50-31
46
20
48 15 18
36 17
37
38 42
39
10 08
34 49 11
35 01
43 36 09
44 37 WITH BUSH SOLUTION
15501 9-35990

51 38 27
40
41
F8840
 DISASSEMBLY AND ASSEMBLY AX5-4-7
(O/P)
AXLES WX90

Final drive description - Fig. 2

01 - Bearing 29 - Seal ring

03 - Nut 30 - Bearing
04 - Screw 31 - Stud
05 - Arm 32 - Hub
06 - Screw 33 - O-ring
07 - Washer 34 - Ring gear
08 - Bushing 35 - Support
09 - Seal ring 36 - Lockring
10 - Lockring 37 - Planetary
11 - O-ring 38 - Bearing
12 - Coupling 39 - Nut
13 - Bearing 40 - Washer-gasket
14 - Ring 41 - Screw
15 - Screw 42 - Support
16 - Cover 43 - Stud
17 - Plug 44 - Nut
18 - Grease fitting 45 - Lockring
19 - Pivot pin 46 - Screw
20 - Pivot pin 47 - Nut
21 - Seal ring 48 - Steel plate
22 - Articulation 49 - Lockring
23 - Scatola snodo 50 - Stud
24 - Seal ring 51 - Spacer
25 - Anello 52 - Shim
26 - Magnetic plug 53 - Shim
27 - Plug 54 - Shim
28 - Pivot case
15501 9-35990
DISASSEMBLY AND ASSEMBLY AX5-4-8
(O/P)
AXLES WX90

4.2. FRONT AXLE

The front axle is of a steering and swinging type.

The steering effect is obtained by an hydraulic cylinder acting on the two swivel knuckles (right and left) rotating
them depending upon the actuation direction of the steering wheel (front axle positioned in front of the
operator’s seat).
The swinging effect is obtained by two supports complete with bushings (2) mounted on the central housing
of the axle in turn secured to the lower frame of the machine.
The front axle is essentially composed of: an axle housing (A), containing the differential and the braking
system, a steering control cylinder (B), two final drives (C) mounted on the swivel knuckles.

15501 9-35990

A - Hydraulic brake control

B - Brakes bleeding screw
C - Parking brake hydraulic control
D - Hydraulic brake release
 DISASSEMBLY AND ASSEMBLY AX5-4-9
(O/P)
AXLES WX90

4.2.1 AXLE HOUSING

The axle body includes: two side arms (1), a central body (2) and two intermediate covers (3).
Between parts (1) and (2) the two intermediate covers (3) are overlapped. Inside the two side arms (1) is
located the braking system.
The motion is transmitted from the differential contained inside central housing (2) to the final drives, through
two joints (4).

2
3 2

4
2

1
2
15501 9-35990

F8841
DISASSEMBLY AND ASSEMBLY AX5-4-10
(O/P)
AXLES WX90

4.2.2 STEERING CONTROL CYLINDER

The front axle is equipped with a steering system controlled by an hydraulic cylinder inserted into the central
housing. Appropriate adjustable drag links (1) are screwed, on one side, directly onto the cylinder rod (2) and
on the other side are connected to the swivel knuckles.

1 2

F8842
15501 9-35990
 DISASSEMBLY AND ASSEMBLY AX5-4-11
(O/P)
AXLES WX90

4.2.3 DIFFERENTIAL

The differential has the purpose of changing the relative rotation speed of the two wheels (right and left) when
travelling in an non straight direction. The differential provides, also, a reduction of the r.p.m. input through
a bevel gear unit.

Fig. 3 - Differential
(Refer to the description on the next page)

06
07
05
04 12
08 11 13
13 11
14 12
21
14
21
03 10
15
17
09 09
04
18
10 21
05
14
12 13
11 11
13 12
14
21
02 07
17 03
18
22
19
02
01
23-24-25-26
20
16
27-28-29-30-31
15501 9-35990

F8843
DISASSEMBLY AND ASSEMBLY AX5-4-12
(O/P)
AXLES WX90

Differential description - Fig. 3

01 - Ring 17 - Ring nut

02 - Taper roller bearing 18 - Spacer
03 - Bevel gear set 19 - Flange
04 - Taper roller bearing 20 - Nut
05 - Ring nut 21 - Satellite
06 - Screw 22 - Screw
07 - Screw 23 - Shim S=0.20
08 - Screw 24 - Shim S=0.30
09 - Washer 25 - Shim
10 - Planetary gear 26 - Shim
11 - Lockring 27 - Shim
12 - Lockring 28 - Shim
13 - Pin 29 - Shim
14 - Washer 30 - Shim
15 - Differential case 31 - Shim
16 - Spacer

15501 9-35990
 DISASSEMBLY AND ASSEMBLY AX5-4-13
(O/P)
AXLES WX90

4.2.4 FINAL DRIVE

The final drive is of a planetary type and its function is to reduce in an appropriate manner, the r.p.m. of the
drive wheels with respect to the r.p.m. output of the differential. The reduction unit is composed of a toothed
hub, three planetary gears and a solar gear splined on the end of the axle shaft.

Fig. 4 - Final drive

(Refer to the description on the next page)

09
06
44 11
07
43 10 08
01 12
WITH DOWEL BUSH 16 25
03 15 17 24
04 19 18 13

52-53-54
21
14 29
30
26
32
05 33
27 30
23-28
45
22
47 21
50-31
46
20
4815 18
36 17
37
38 42
39
10 08
34 49 11
35 01
43 36 09
44 37 WITH BUSH SOLUTION
51 38 27
15501 9-35990

40
41 F8844
DISASSEMBLY AND ASSEMBLY AX5-4-14
(O/P)
AXLES WX90

Final drive - Fig. 4

01 - Bearing 29 - Seal ring

03 - Nut 30 - Bearing
04 - Screw 31 - Stud
05 - Arm 32 - Hub
06 - Arm 33 - O-ring
07 - Washer 34 - Ring gear
08 - Flange 35 - Support
09 - Seal ring 36 - Lockring
10 - Lockring 37 - Planetary gear
11 - O-ring 38 - Bearing
12 - Joint 39 - Nut
13 - Bearing 40 - Washer-gasket
14 - Bearing 41 - Screw
15 - Screw 42 - Support
16 - Cover 43 - Stud
17 - Plug 44 - Nut
18 - Grease fitting 45 - Lockring
19 - Pivot pin 46 - Screw
20 - Pivot pin 47 - Nut
21 - Seal ring 48 - Safety flange
22 - Bearing 49 - Lockring
23 - Articulation box 50 - Stud
24 - Seal ring 51 - Spacer
25 - Ring 52 - Shim
26 - Magnetic plug 53 - Shim
27 - Plug 54 - Shim
28 - Pivot case

15501 9-35990
 DISASSEMBLY AND ASSEMBLY AX5-4-15
(O/P)
AXLES WX90

4.3 BRAKING UNIT

4.3.1 SERVICE BRAKES

The braking action is hydraulically actuated in both axles through wet discs.
The service brake circuit is actuated by the action exercised on the brake valve. The latter sends pressurised
hydraulic oil (35 bar) to the piston of the front and rear axle. These pistons, after overcoming the reaction of
the springs, keeping the drive plate in rest condition, ensure that the discs are pressed one against the other,
thus providing the braking action.
The service brake circuit can be applied, while the machine is standing, by pressing a selector located on the
steering column, that controls electrically, the brake valve; the braking action occurs, under these conditions,
in a non modulated manner and allows an optimised stability during digging operations. The application of the
work brake is signalled by an indicator.

Front-rear axle braking group

4
3
3
4

5
2

F7677
15501 9-35990

2 - Brake piston
3 - Seal
4 - Ring
5 - Brake discs
DISASSEMBLY AND ASSEMBLY AX5-4-16
(O/P)
AXLES WX90

4.3.2 PARKING BRAKE

The braking action is mechanically activated at front axle inlet by means of discs in oil bath. The parking brake
is always mechanically activated by means of springs. The parking brake release circuit is driven by the
"braking type" selector. The selector electrical signal reaches the special solenoid valve in user solenoid valve
grop; the activated solenoid valve sends the oil under pressure from the power controls to the piston which
holds up the spring strength, releasing parking brake. Parking brake connection is signalled by a warning light.

18 39
17
19
14 20
13 21
12 22

11
10
9
40 16
8 38 15

3 4

7
6
24

26
26
26
42
25 23 41
27 2

F8988
25

25

2 - Hose 13 - Seal ring 24 - O-Ring

3 - Nut 14 - Antiextrusion 25 - Clutch discs
4 - O-Ring 15 - Seal ring 26 - Clutch discs
15501 9-35990

5 - Flange 16 - Antiextrusion 27 - Hub

6 - Screw 17 - Screw 38 - Seal ring
7 - Washer 18 - Cylinder 39 - Spacer
8 - Cover 19 - Pin 40 - O-Ring
9 - Shim 20 - Washer 41 - Fitting
10 - Ring 21 - Dowel 42 - Fitting
11 - Spring 22 - Nut
12 - Piston 23 - Spacer
 DISASSEMBLY AND ASSEMBLY AX5-4-1
(D/A)
AXLES WX90

4. AXLE

Disassembly and assembly of axles

In describing the operations below, it is supposed that, in some cases, the axle has already been removed
from the machine. Moreover, each one of them is finalised toward the maintenance or the replacement of the
parts more subject to wear, such the brake discs, differential, final drives etc..
During all operations, it is recommended that the appropriate special tools are used, facilitating the operation,
and ensuring, at the same time, that all machined surfaces are protected and the safety of workers is provided.
Prior to starting the disassembly of components it is recommended that a thorough cleaning of the axle is
provided, removing deposits and accumulation of grease, then draining the lubricants. All the mechanical
components removed, must be thoroughly cleaned with appropriate cleaners, then repaired or replaced, in
case they show signs of damage, excessive wear, cracks, seizing etc..
In particular, check the integrity of all moving (bearings, gears, bevel gear set, shafts) and sealing components
(O-Rings, seals) subject to higher stress and wear.
It is recommended, however, that the sealing components are replaced every time an overhaul or repair of
components is performed.
When assembled, rings and seal must be lubricated in the sealing contact area.
In the case of the bevel gear set, the replacement of one of the its gears requires the replacement of the other
one, as well.
During the assembly, all the prescribed clearances and pre-loads must be implemented.

WARNING - The weight of the front axle: .......................................................................................... 320 kg

The weight of the rear axle without transmission: ......................................................... 340 kg

Front and rear axle are equal and both steering.

They are different in the following features:

rigid (rear axle)

a - Fixing
oscillating (front axle)

flanged transmission (rear axle)

b - Inlet
parking brake (front axle)

magnetic band (rear axle)

c - Steering cylinder

d - Bevel gear set - Fitted with opposite rotation direction

15501 9-35990
DISASSEMBLY AND ASSEMBLY AX5-4-2
(D/A)
AXLES WX90

Symbols

To complete the information relative to the operations for the disassembly and/or intervention on the axle, the
use of the symbols listed below is applied. They will aid, depending upon the intervention to be performed,
and will accompany each illustration.

Disassembly of sub-groups Remove - place is safe condition

Assembly of sub-groups Place safety, glue

(liquid compound)

Avoid damages to materials and

Disassembly of bulky components parts

Assembly of bulky components Mark prior to disassembly

(for re-assembly)

Warning, important information

Charge - fill (oil - lubricant)

Check appropriate values, i.e.

Drain oil, lubricant
torques, dimensions, pressures etc.

Stretch
T = special tools

Apply pressure into hydraulic

Follow installation direction
system

Check, visual inspection

Clean

Eventually re-usable
(replace if required) Lubricate

Replace every time assembly is

performed
15501 9-35990
 DISASSEMBLY AND ASSEMBLY AX5-4-3
(D/A)
AXLES WX90

4.1 REAR AXLE/FRONT AXLE

4.1.1 CHEKING WEAR AND REPLACING THE

BRAKING DISKS
1
1 CAUTION! Perform all operations on
both arms.
Remove the oil-level plug (1).

F1240382

2 Apply the brakes and, keeping them

under pressure, check the linings “S“
between the disks using tool 75301741 .
Minimum “S“: 4.5 mm.

CAUTION! Replace the braking disks

and the intermediate disks on both sides
if necessary.

S
F13496

3 Remove rhe swinging support (2) on the

side opposite the drive.

NOTA. If the bushing (17) is worm and

needs replacing, note down the assembly 2
17
side of the connection notch “A”.
This step is valid for front axle only.

F1240384

4 Disconnect the pins of the steering bars

from the steering case (See "HOW TO
REMOVE THE STEERING
CYLINDER").
Sling the arm (3) to be removed and put 3
15501 9-35990

the rod under slight tension.

F1240385
DISASSEMBLY AND ASSEMBLY AX5-4-4
(D/A)
AXLES WX90

5 Unloose and remove the screws (4) and

the washers (5) that fix the arm (3) to the 4 5 6
central body (6).

3 F1240386

6 Remove the arm (3) together with the

pack of the braking disks (7).
Place the arm on a bench.
7

3
F1240387

7 Remove the braking disks (7) and note

down their order of assembly.

NOTE 1 - If the disks do not need

replacing, avoid switching their position.
2 - Extract the axle shaft (18).

18
7
F1240388

8 Remove the reversal springs (8) from the

piston (9). 8
9
NOTE. If the springs (8) are weak or
deformed they must be replaced.
15501 9-35990

8
F1240389
 DISASSEMBLY AND ASSEMBLY AX5-4-5
(D/A)
AXLES WX90

9 Remove the pin screws (10) guiding the

piston (8).
9
CAUTION! If the screws are to be
replaced, note down the different colours
for the different brake gap.
(See "HOW TO ASSEMBLE THE
BRAKING UNITS")

10
F1240390

10 Slowly introduce compressed air through

the connection of the braking circuit in
order to extract the entire piston.

CAUTION! Hold on to the piston as it may

be suddenly ejected and damaged.

9
F1240391

10
15
17
9
17 8
11
14 MAX 10°
16
2
1
3

13
12
6 18
15501 9-35990

7
5
4
D1240037
DISASSEMBLY AND ASSEMBLY AX5-4-6
(D/A)
AXLES WX90

4.1.2 HOW TO ASSEMBLE THE BRAKING

UNITS 14
12
1 Accurately clean the piston (9) and the
11
seats of slide and seal.
Replace the O-rings (11) and (12) and 13
the anti-extrusion rings (13) and (14);
make sure that the assembly side is
correct.

CAUTION! Accurately check the 3

positioning of the anti-extrusion rings (13) 9
F1240392
and (14).

2 Insert the stroke automatic regulation

springs (9); place them in line with the
piston (15).

15

15 9
F1240393

3 Lubricate the seals (11) and (12) and fit

the piston (9) into the arm (3).
A
CAUTION! Make sure that the piston
seat fits into the stop pin (A) inside the
arm.

F1240394

4 Assist the insertion of the piston (9) by

lightly hammering around the edge with
a plastic hammer.
15501 9-35990

F1240395
 DISASSEMBLY AND ASSEMBLY AX5-4-7
(D/A)
AXLES WX90

5 Fit the pin screws (10) making sure that

they are all of the same colour. White: 1
10
mm gap
Yellow: 0.75 mm gap
Blue: 0.5 mm gap
Apply Loctite 270 to the thread.
Torque wrench setting: 5÷7 Nm.

F7632

6 Fit the reversal springs (8) on the piston

(9). 8
9
CAUTION! Pay due attention not to
deform the connections of the springs.

8
F1240389

7 Slightly lubricate the braking disks (7) and

fit them in the arm following the correct
sequence; orient them so that the oil
circulation holes and the marks “B” are B
perfectly lined up.

NOTA. When installing the steel discs,

the slot corresponding to the oil level cap
should be kept free.
7
F1240398

8 Check that the positioning of the sealing

ring (16) on the arm is intact; install the
complete arm.
Lock it into position using two facing
screws (4) and washers (5).
15501 9-35990

16
F7633
DISASSEMBLY AND ASSEMBLY AX5-4-8
(D/A)
AXLES WX90

9 Check the flatness of the arms using

special tool 75301742 and finally lock the
arms with the screws (4) and the washer
(5) using the cross-tightening method.
Torque wrench setting: 298 Nm

F13497

4.1.3 HOW REMOVE THE COMPLETE

STEERING CASE 1

1 Remove the guard (1) and disconnect the

articulation pin (2) (See "HOW TO
REMOVE THE STEERING
CYLINDER").

F1240425

2 Sling the entire unit (7) and connect it to

the hoist, putting the rod under light
tension. 7

F1240426

3 Unloose and remove the fittin screws (3)

from the bottom articulation pin (4).

NOTE. Screws cannot be re-used.

15501 9-35990

3
F1240427
 DISASSEMBLY AND ASSEMBLY AX5-4-9
(D/A)
AXLES WX90

4 Remove the bottom articulation pin (4)

5
complete with front sealing ring (5).

4
F1240428

5 AUnloose and remove the fittin screws

(3) from the top articulation pin (6).

F1240429

6 Using two levers, remove the top

articulation pin (6) complete with front
seal (5).
Pay attention not to damage the surfaces.
6
5

F1240430

7 Remove the complete steering case (7).

7
15501 9-35990

F1240431
DISASSEMBLY AND ASSEMBLY AX5-4-10
(D/A)
AXLES WX90

8 Using a puller for inner parts, remove the

top bush (8) and the bottom ball-bush (9).

F1240432

9 Remove the articulation pins (4) and (6)

and the front sealing rings (5).
5
NOTE. Note down the side for assembly.

4 6

F1240569

10 If the ball cover (11) needs replacing,

remove it from the bottom articulation pin
(4).

11

F1240570

1
3
6
10
2 5
8
15501 9-35990

9
5
3
4 D1240038
 DISASSEMBLY AND ASSEMBLY AX5-4-11
(D/A)
AXLES WX90

4.1.4 HOW TO ASSEMBLE THE COMPLETE

STEERING CASE

1 If the bottom articulation pin (4) has been

extracted, position the pin under a press 11
and fit the ball cover (11).

F1240571

2 Fit the front sealing rings (5) onto the

articulation pins (4) and (6).
5
NOTE. Carefully check that the rings are
properly oriented (5).
4 6

F1240569

3 Lubricate the top bush (8) or the bottom

ball bush (9) and fit them into the fulcrum
holes of the arm.
Use special tools
75301743 for upper bushing
75301744 for lower bushing 9

F13498

4 Lubricate the terminal of the u-joint (10)

and install the steering case (7).
Pay due attention not to damage the dust
cover rings and the sealing rings.
7
15501 9-35990

10
F7634
DISASSEMBLY AND ASSEMBLY AX5-4-12
(D/A)
AXLES WX90

5 Fit a new seal (5) onto the top articulation

pin (6). Lubricate and install the unit in
the steering case. Position the screws (3)
and lightly tighten.
Check the correct assembly side of the 6
seal (5). 5

F1240430

6 Fit a new seal (5) onto the bottom 5

articulation pin (4). Lubricate and fit the
unit in the sterring case. Position the
screws (3) and lightly tighten.
Check for the correct assembly side of
the seal (5).

4
F1240428

7 ighten the new fittin screws (3) of top and

bottom articulation pins in sequence
using the cross tightening method. 3
Torque wrench setting: 128±142 Nm

ITA
ITA 3
F1240436

8 Connect the articulation pin (2) (See

"HOW TO INSTALL THE STEERING 1
CYLINDER").
Lubricate articulations with Molikote and
fit the dust cover (1).
15501 9-35990

F1240425
 DISASSEMBLY AND ASSEMBLY AX5-4-13
(D/A)
AXLES WX90

4.1.5 HOW TO REMOVE THE U-JOINT

NOTE. The u-joint can only be removed after

extraction of the steering case has been
performed (See: "REMOVING THE
STEERING CASE"). Different procedures
need to be followed depending on the kind of
repair operation needed and the type of axle:
1 - Axle without parking brakes: compressed
air (7 bar approx.) should be introduced
in the braking circuit in order to hold the
braking disks in position.
2 - Axle with negative brake: does not
require any preparation as the disks are
mechanically locked in position.
3 - Axle with mechanical brake: requires that
the external control levers are put under
tension in relation to each other.
4 - Disassembly to be carried out with the
arm resting on the bench.
The explanations reported herewith refer to
removal operations carried out on the bench;
the different stages of u-joint removal alsoapply
to all other solutions or versions.

1 Unloose and remove the top and bottom

check nuts (2) from the dowels (3).

3
2

F1240365

4 Remove top and bottom check dowels

(3) from the flange (5) or bush (13).
15501 9-35990

F1240366
DISASSEMBLY AND ASSEMBLY AX5-4-14
(D/A)
AXLES WX90

Flanged version

3 Remove the u-joint (4).

NOTE. To remove the u-joint use, if

necessary, a plastic hammer or a lever.

F1240576

4 Remove the snap ring (9) from the

bearing as well as the packing ring (5).

9
F1240368

5 Position the entire u-joint (4) under a

press and remove the bearing (8) and the
ring (5) simultaneously. 4

F1240369

6 Extract the sealing ring of the shaft from

the flange (5).

NOTE. Note down the assembly side of

the ring.
15501 9-35990

7
5

F1240370
 DISASSEMBLY AND ASSEMBLY AX5-4-15
(D/A)
AXLES WX90

Coupling version

7 Remove the entire u-joint (4).

NOTE. To remove the u-joint use, if

necessary, a plastic hammer or a lever.

F1240367

8 Remove the snap ring (9) from the

bushing unit (13).

13

F1240371

9 Position the entire u-joint (4) under a

press and remove the complete bush
(13). 4

13

F1240375

10 Remove the snap ring (10) from the

bearing (11). Use a puller to remove the
bearing (11), the sealing ring (12) and the
O-ring (14).
15501 9-35990

NOTE. Note down the assembly side of

the ring (12). 10
11 11 12

F1240372
DISASSEMBLY AND ASSEMBLY AX5-4-16
(D/A)
AXLES WX90

1 3

FLANGED VERSION
9
8
7
6
5

4
2

3 9
10
11
12
13
14
COUPLING VERSION
D1240039

15501 9-35990
 DISASSEMBLY AND ASSEMBLY AX5-4-17
(D/A)
AXLES WX90

4.1.6 INSTALLATION OF U-JOINT

6 5
Flanged version

1 Insert the sealing ring (7) of the shaft in

the flange (5), using tool 75301745.
NOTE. Carefully check the assembly
side. Also replace the outer O-ring (6).
7

F13499

2 Fit the flange (5) onto the u-joint (4).

Heat the bearing (8) at an approx. tem-
perature of 100° C, fit it on the u-joint and
fasten.
4

5
8
F1240374

3 Fit the snap ring (9) on the bearing (8).

9
F1240368

Coupling version

54 Using tools 75301745 and 75301746,

insert the sealing ring (12) and the
bearing (11) in the bush (13).
15501 9-35990

NOTE. Carefully check the assembly side

of the seal (12).
12 11

13 13
F13500
DISASSEMBLY AND ASSEMBLY AX5-4-18
(D/A)
AXLES WX90

5 Fit the snap ring (10) on the bearing (11).

10
11

F1240377

6 Heat the bearing in oil at an approx. tem-

perature of 100° C and fit the entire bush
(13) on the u-joint (4).

13

F1240378

7 Fit the check ring (9) on the bushing unit

(13); also put the O-ring (14) into position.

14 13

F7635

8 Insert the u-joint and tighten the top and

bottom dowels (2).
Torque wrench setting: Max. 15 Nm.
2
NOTE. For u-joint coming with a bush,
15501 9-35990

centre the point of the check dowels in

the slot.

F1240379
 DISASSEMBLY AND ASSEMBLY AX5-4-19
(D/A)
AXLES WX90

9 Apply Loctite 242 to the jutting parts of

the dowels (2).
2

F1240380

10 Screw the check nuts (3) of the dowels

(2) and lock them using a dynamometric
wrench.
Torque wrench setting: 122 Nm 3

F1240381

3 2 3 2

D1240082
15501 9-35990
DISASSEMBLY AND ASSEMBLY AX5-4-20
(D/A)
AXLES WX90

4.1.7 HOW TO DISASSEMBLEE THE

PLANETARY REDUCTION 1

1 Disconnect the steering bars from the

steering case (3).
For details, see "HOW TO REMOVE THE
COMPLETE STEERING CASE".
Remove the securing screws (1) from the 2
planetary carrier cover (2).

1
F9364

2 Disjoint the planetary carrier cover (2)

from the steering case (3) by alternatively 3
forcing a screwdriver into the appropriate
slots.

F9365

3 Remove the complete planetary carrier

cover (2). 2

F1240439

4 Unloose and remove the tightening nuts

(4) from the crown flange (5).
5
15501 9-35990

4
F1240440
 DISASSEMBLY AND ASSEMBLY AX5-4-21
(D/A)
AXLES WX90

5 Remove the safety flange (6).

F1240441
ITA

6 Using a puller, remove the complete

crown flange (5) by acting on the stud
5
bolts.

F1240442

7 Partially extract the hub (7) using a plastic

hammer.

NOTE. Alternately hammer on several 7

equidistant points.

F1240443

8 Remove the external bearing (8).

8
15501 9-35990

F1240444
DISASSEMBLY AND ASSEMBLY AX5-4-22
(D/A)
AXLES WX90

9 By hand remove the complete hub (7).

7

F1240445

10 Remove the pins and remove the

steering case (3).
For details, see "HOW TO REMOVE THE
3
COMPLETE STEERING CASE".

F1240446

11 Remove the snap rings (9).

F1240447

12 With the help of a puller, remove the

planet wheel gears (10).
10
NOTE. Note down the assembly side of
15501 9-35990

planet wheels.

F1240448
 DISASSEMBLY AND ASSEMBLY AX5-4-23
(D/A)
AXLES WX90

13 Remove the snap ring (12) from the

crown (13).

12
13

F1240450

14 Remove the crown flange (5).

F1240451

15 Remove the sealing ring from the hub

(14).

14

F1240452

16 Remove the internal bearing (15).

15501 9-35990

15

F1240453
DISASSEMBLY AND ASSEMBLY AX5-4-24
(D/A)
AXLES WX90

17 Remove the external thrust blocks from

the bearings (8) and (15) forcing a pin-
driver into the appropriate slots on the
hub (7).

NOTE. Hammer in an alternate way so

as to avoid crawling or deformation of the ITA
thrust blocks. ITA 7

F1240454

18 Use a puller to remove the centring ring

16
(16), the sealing ring (17) and the bearing
(18) from the steering case (3).
17
NOTE. Note down the orientation of both
centring ring (16) and sealing ring (17). 16 17 18
18

F1240455

19
16
18
3

17

14 12
15 5
9
10
8
20
15501 9-35990

13 11
6
4
9
10
1
2 D1240040
 DISASSEMBLY AND ASSEMBLY AX5-4-25
(D/A)
AXLES WX90

4.1.8 ASSEMBLING THE PLANETARY

REDUCTION 3
1 Lubricate the bushing (18) and the seat
of the steering case (3).
Install the bushing (18), using tool
75301747.

18
F13501

2 Lubricate the outer surface of the sealing

ring (17) and centring ring (16); fit them
into their seat using special tool
75301748.

16 17

F13502

3 Position the lower part of tool 75301749

and the thrust block of the external
bearing (8) under the press.

F13503

4 Lubricate the seats of the bearings and

position the hub (7) on tool 75301749;
position the thrust block of the internal
bearing (15).
15501 9-35990

15
NOTE. Check that the thrust block is
correctly oriented.

F13546
DISASSEMBLY AND ASSEMBLY AX5-4-26
(D/A)
AXLES WX90

5 Position the upper part of tool 75301749

and press the thrust blocks into the hub
(7) all the way down.

F13504

6 Fit the bearing (15) into the internal thrust

block.
15

F1240461

7 Apply a repositionable jointing compound

for seals to the outer surface of the
sealing ring (14). Position the sealing ring
(14) in the hub (7). 14

NOTE. Check that the ring (14) is 7

correctly oriented.

F1240462

8 Position special tool 75301750 and press

the sealing ring (14) into its seat.
15501 9-35990

14

F13505
 DISASSEMBLY AND ASSEMBLY AX5-4-27
(D/A)
AXLES WX90

9 Insert the flange (5) in the crown (13).

13

F7636

10 Insert the snap ring (12) in order to fix

the flange (5) in the crown (13).

NOTE. Carefully check that ring (12) is

properly inserted in the slot of the crown 12
13
(13).

F1240465

11 With the help of special tool 75301751,

insert the planet wheel gears (10) into the
cover (2).
Accurately check the orientation.

10
F13506

12 Lock the gears (10) into position by fitting

the snap rings (9).

9
15501 9-35990

10
F7637
DISASSEMBLY AND ASSEMBLY AX5-4-28
(D/A)
AXLES WX90

13 Fit the steering case (3) onto the U-joint

(19) and install the articulation pins. For
pin assembly details, see "HOW TO
ASSEMBLE THE COMPLETE 3
STEERING CASE".

19
F7638

14 Connect the steering bars.

For details, see "HOW TO INSTALL THE
COMPLETE STEERING CASE".

F7639

15 Install the hub (7).

7

F1240445

16 Install the external bearing (8).

8
NOTE. Using a plastic hammer, drive the
bearing to the limit stop by lightly
hammering around the edge.
15501 9-35990

F1240444
 DISASSEMBLY AND ASSEMBLY AX5-4-29
(D/A)
AXLES WX90

17 Fit the complete crown flange (5).

NOTE. In order to fasten the flange (5), 5

use a plastic hammer and alternately
hammer on several equidistant points.

F1240470

18 Apply Tecnolube Seal 101 grease to the

surface of the safety flange (6) which
touches the crown flange (5). 6
Fit the safety flange (6). 5

F7640

Apply Loctite 242 to the studs and fit in

the nuts (4).

F1240472

20 Cross tighten the nuts (4) in two stages.

Initial torque wrench setting: 120 Nm 4
Final torque wrench setting: 255±285 Nm
15501 9-35990

F1240473
DISASSEMBLY AND ASSEMBLY AX5-4-30
(D/A)
AXLES WX90

21 Fit the planetary carrier cover (2) onto the

hub (3). 20
3
CAUTION! Check that the O-ring (20) is
in good condition and in position.

2
F7641

22 Lock the planetary carrier cover (2) by

tightening the screws (1). 1
Torque wrench setting for screws: 40÷50
Nm

2
F9363

15501 9-35990
 DISASSEMBLY AND ASSEMBLY AX5-4-31
(D/A)
AXLES WX90

4.1.9 HOW TO REMOVE THE STEERING

CYLINDER
1
1 Remove the centring sensor (1) of the 2
steering piston (2), if supplied.

F1240401

2 Remove the safety cotter pins (3) from

the articulation pins (4) of the steering
bars (5).

CAUTION! Dispose of used cotter pins.

5

6
3

F1240402

3 Remove the castellated nuts (6) that lock

the articulation pins (4).
4

F1240403

4 Disconnect the tapered pins of the

articulation (4) from the steering case (7)
by means of a puller.

4 5
7
15501 9-35990

F1240404
DISASSEMBLY AND ASSEMBLY AX5-4-32
(D/A)
AXLES WX90

5 If the connection of the steering bars

includes a safety collar (13), raise the
border. 13

F1240405

6 Disconnect left and right steering bars (5)

from the piston (2).
2

F1240406

7 Remove the securing screws (8) from the

9
steering cylinder (9).

F1240407

8 Extract the cylinder (9) using a plastic

hammer.

NOTE. For cylinder disassembly, refer to

"HOW TO DISASSEMBLE THE 9
15501 9-35990

STEERING CYLINDER".

F1240408
 DISASSEMBLY AND ASSEMBLY AX5-4-33
(D/A)
AXLES WX90

7 15

5 9
11

1 10 2
15
4

6 8
3

14 7
12

4
12
14
6 13
3

13
6
3

6
3 D1240041
15501 9-35990
DISASSEMBLY AND ASSEMBLY AX5-4-34
(D/A)
AXLES WX90

4.1.10 HOW TO INSTALL THE STEERING

CYLINDER
9
1 Check that the O-rings (15) of the axle
unit are in good condition; lubricate the
seats of the seals (15) and fit the steering
cylinder (9) into its seat.

F1240409

2 Lock the cylinder by cross- tightening the

screws (8). 9 8
Torque wrench setting: 116÷128 Nm

F1240410

3 Apply Loctite 242 to the thread and

connect the steering bars by screwing the 13
terminals onto the piston stem.
Torque wrench setting: 240÷270 Nm

NOTE. Versions with coupling require

that the rim of the articulation (13) is
riveted onto the surfaces of the piston
stem.

F1240411

4 Insert the pins (4) in the steering case

(7) and lock into position using a torque
wrench setting of 260÷290 Nm. 7
Find the position of the notching in
relation to the hole of the cotter pins and
15501 9-35990

tighten the nut (6) further.

A
CAUTION! Check that rubber guards (A)
are intact.

F1240412
 DISASSEMBLY AND ASSEMBLY AX5-4-35
(D/A)
AXLES WX90

5 Insert the cotter pins (3) and bend the

safety stems.

CAUTION! Use new cotter pins.

6 3

F1240413

6 For rear axle, the proximity switch (1) for

piston centering check and screw
tightening (10) is to be fitted. 10
Torque wrench setting: 5÷6 Nm

F7642

7 CAUTION! Eliminate the action of the ne-

gative brake, if fitted.
Apply special tools 75301752 to the hubs
and lock them.
Using a level “B”, check that tools are
perfectly flat and parallel to each other.
B

F13507

8 Connect the sensor (1) to the inspection

device. 1
15501 9-35990

F1240416
DISASSEMBLY AND ASSEMBLY AX5-4-36
(D/A)
AXLES WX90

9/10 Sensor connection card. I max=0,80 A

NERO
BLACK

CONNETTORE
CONNECTOR

2 BLU
1 3
BLUE
--
4

BATTERIA
BATTERY

MARRONE
BROWN
+
2A
D1240029

11 Centre the piston by slowly moving it first

in one direction then in the other and = =
position it half way on the stroke, which
is determined by the switching on and off
of the signal lamp of the inspection device
in the reversal stage.

F1240550

12 Inspect jut “C” on one side of the piston

and note down the size for checking later
adjustments. C

NOTE. If cylinders come without a

sensor, the centring of the piston must
be carried out on the basis of the
maximum stroke.

F1240418
15501 9-35990
 DISASSEMBLY AND ASSEMBLY AX5-4-37
(D/A)
AXLES WX90

13 Without moving the piston, check front

and rear size at the edge of tools
75301752.
Max. difference: 0.6÷0.7 mm

NOTE. In order to check the rear size,

rotate the bevel pinion and check that
tools 75301752 are flat.

F13508

14 If necessary, adjust convergency without

moving the centring of the piston and
adjust the length of the steering bars (5) 5 14
or (14).

NOTE. With a half turn of screw, the front

size is reduced by about 3 mm, whereas
the rear one is increased by about 3 mm.

F1240420

15 CONVERGENCY ADJUSTMENT ON
UNITS WITH COLLAR
Unloose the nuts on the collars (12). 12

F1240421

16 Rotate the ball-and-socket joints (16) until

convergency has been obtained.
Check that articulations move easily and 16
lock the collars (12).
Torque wrench setting for nuts: 42÷ 52
15501 9-35990

Nm

F1240422
DISASSEMBLY AND ASSEMBLY AX5-4-38
(D/A)
AXLES WX90

17 CONVERGENCY ADJUSTMENT ON
ALTERNATIVE VERSIONS
Unloose the nuts (11) and screw them
15
onto the ball-and-socket joints (15). 11

F1240423

18 Hold the articulations still and rotate the

ball-and-socket joints (15). 15
Once the convergency has been 11
adjusted, lock the nuts (11).
Torque wrench setting for nuts: 298÷328
Nm

F1240424

15501 9-35990
 DISASSEMBLY AND ASSEMBLY AX5-4-39
(D/A)
AXLES WX90

4.1.11 HOW TO DISASSEMBLE THE STEERING

CYLINDER 2

1 Remove the snap ring (1) from the

cylinder head (2).

F1240354

2 With the help of a plastic hammer, push

the head (2) inside the cylinder (3).
3
NOTE. The head should line up with the
edge of the cylinder.

F1240355

3 With the help of a drift, apply pressure to

the stop ring (4) that is placed inside the
cylinder (3) and extract the ring using a 3
screwdriver.

F1240356

4 Hammer the piston (5) on the rear of the

head (2) using a plastic hammer.
Continue hammering until the head (2)
is ejected from the cylinder (3).
15501 9-35990

5
3
2
F1240357
DISASSEMBLY AND ASSEMBLY AX5-4-40
(D/A)
AXLES WX90

5 Disassemble the cylinder unit (3) by

extracting first the head (2), then the
piston (5). 5

CAUTION! Note down the assembly side 2

of the piston (5). The bevelled part “A” of
the piston is oriented towards the head
(2).
3

A F1240358

6 Remove all seals, anti-extrusion rings

and scraper rings from head (2), cylinder
(3) and piston (5).

NOTE.
1 - All seals must be replaced every time
the unit is disassembled.
2 - Particular attention must be paid not
to damage the seats of both seals
and piston slide

9
2
10
6
11 7
8
4
1

8
7
6
12
13
3
15501 9-35990

D1240035
 DISASSEMBLY AND ASSEMBLY AX5-4-41
(D/A)
AXLES WX90

4.1.12 HOW TO ASSEMBLE THE STEERING

CYLINDER
6 7 8
1 After applying grease, install the sealing
ring (6) of the shaft, the anti-extrusion ring
(7) and the scraper ring (8) inside the
cylinder (3).

CAUTION! Thoroughly check that

positioning of the anti-extrusion ring (7)
is correct.
D1240031

2 After applying grease, install the sealing

ring (6) of the shaft, the anti-extrusion ring
(7) and the scraper ring (8) in the head 8 7 6
(2).

CAUTION! Thoroughly check that

positioning of the anti-extrusion (7) ring
is correct.

D1240032

3 Fit the seal (9) onto the outside of the

head (2). 9
CAUTION!
1 - In order to facilitate assembly, apply
grease to the outer surface of the
piston.
2 - Do not roll the seal (9) up.

D1240033

4 Prepare the piston (5) by fitting it with the

guide ring (10), the magnetic ring (11),
the O-ring (12) and the seal (13). 11
13 10
CAUTION!
15501 9-35990

1 - In order to facilitate assembly, apply

grease. 12 5
2 - If a centring sensor is not fitted, then
the magnetic ring (11) should be
replaced by another guide ring (10).

D1240034
DISASSEMBLY AND ASSEMBLY AX5-4-42
(D/A)
AXLES WX90

5 Apply special tool 75301758 to the shaft

on the opposite side of the head (2) and
centre it on the cylinder (3) so that it fits
into the piston (5). 5
NOTE. Apply a little grease to seals and
cylinder.

F13509

6 Push the piston (5) into the cylinder for

100 mm using a plastic hammer.
5

3
F1240360

7 RRemove tool 75301758 and apply it to

the opposite side of the piston (5).

5
2
F13510

8 Apply grease to head (2) seals, fit the

head onto the piston and push it into the
cylinder (3) using a plastic hammer.
2
NOTE. Insert the head as to line it up with
15501 9-35990

the edge of the cylinder.

5
F13511
 DISASSEMBLY AND ASSEMBLY AX5-4-43
(D/A)
AXLES WX90

9 Insert the stop ring (4) ensuring that it

fits into the seat of the cylinder (3). 4

3
F1240363

10 Apply pressure to the head using two

screwdrivers or levers until the head is
fastened onto the stop ring (4).

F1240364

11 Fit the snap ring (1) on the head (2).

2
CAUTION! Make sure that the snap ring
(1) is securely fastened in its seat.
If necessary, force it into its seat using a
drift and a hammer.

F1240354
15501 9-35990
DISASSEMBLY AND ASSEMBLY AX5-4-44
(D/A)
AXLES WX90

4.1.13 HOW TO REMOVE AND DISASSEMBLE

THE DIFFERENTIAL UNIT

Removing

1 Remove the complete arms.

For details, see "CHECKING WEAR
AND REPLACING THE BRAKING
DISKS".

F7643

2 Mark the position of the ring nuts (1).

Remove the fittin screws (3) from the ring
nuts (1).
3

1
F1240478

3 Uniformly heat the ring nuts (1) up to a

temperature of 80° C.
1

F1240479

4 Use special tool 75301753 and remove

the ring nuts.

NOTE. Accurately clean the threaded

portions on ring nuts of body and cover.
15501 9-35990

F13512
 DISASSEMBLY AND ASSEMBLY AX5-4-45
(D/A)
AXLES WX90

5 Remove the fittin screws (4) from the

middle cover (5). 4 5

4
F1240481

6 Insert a screw-driver in the opposing slots

then force and remove the middle cover 6
5
(5) and the complete differential unit (6).

NOTE. Support the pieces using a rod.

F1240482

7 If the bearings need replacing, extract the

2 8
external thrust blocks of the bearings (7)
and (8) from middle cover (5) and central
body (2).

NOTE. Accurately check the O-ring (9). 7

5 9

F1240483

8 Remove the top plug (10).

10
15501 9-35990

F1240484
DISASSEMBLY AND ASSEMBLY AX5-4-46
(D/A)
AXLES WX90

9 Remove the fittin screws (11) from the

crown (12).

11

12

F1240485

10 If the bearing need replacing, extract the

bearing (7) and remove the crown (12). 7

12

F1240486

11 Remove the shim washer (13) and the

planetary gear (14). 13

14

F1240487

12 If the bearing need replacing, extract the

bearing (8) from the differential carrier
(15).
15501 9-35990

15

F1240488
 DISASSEMBLY AND ASSEMBLY AX5-4-47
(D/A)
AXLES WX90

13 Remove the snap rings (16) from the two

pins (17) of the planet wheel gears (18).

16 17

F1240489

14 Insert special tool 75301754 between the

planet wheel gears (18).

18 18

F13513

15 Force special tool 75301754 in-between

the planet wheel gears (18) using two pin-
drivers.

CAUTION! Make sure that special tool

75301754 is perfectly lined up with the
pins (17) when locked.

15
17
F7644

16 Place the differential carrier (15) under a

press, position bush 75301755 and insert
gudgeon 75301756. Press 75301756 pin
to limit position.
15501 9-35990

17

15

F13514
DISASSEMBLY AND ASSEMBLY AX5-4-48
(D/A)
AXLES WX90

17 Remove gudgeon 75301756 and bush

75301755.

NOTE. In this condition the tool 75301754

contains pin (17).

F13515

18 Remove tool 75301754 together with the

pin (17) of the planet wheel.

15
17
F7644

19 Leave the released planetary gear in

position and again lock tool 75301754.
Repeat the operations for the extraction
of the pin of the 2nd planet wheel (17).
Repeat the operations for all other pins.

18 18

F13513

20 Remove tool 75301754 and remove the

last two planet wheel gears (18), the 2nd
differential unit gear (14) and the relative
14
shim washer (13) from the differential
carrier.
15501 9-35990

13

15

F1240494
 DISASSEMBLY AND ASSEMBLY AX5-4-49
(D/A)
AXLES WX90

4
3 5 16
1
20
9 11
17
19
20
17 16
19
18
13

14
7 13
15 10

12 18 8
2

19
17
20 19
16
17
20
6
16

3
1
D1240036
15501 9-35990
DISASSEMBLY AND ASSEMBLY AX5-4-50
(D/A)
AXLES WX90

4.1.14 HOW TO ASSEMBLE AND INSTALL THE

DIFFERENTIAL UNIT
14
Assembling

1 Insert the shim washer (13) and the 13

planetary gear (14) in the differential
carrier (15). 15

F1240494

2 Position the shim washer (19) and the

18
first planet wheel gear (18).
Hold them in position using special tool
75301756.
19

F13516

3 With the help of gudgeon 75301756,

position the second planet wheel gear 18
(18) and the relative shim washer (19).

19 15

F13517

4 Insert tool 75301754 between the two

planetary gears (18).
Line up the entire unit using tool
75301756.
15501 9-35990

F13519
 DISASSEMBLY AND ASSEMBLY AX5-4-51
(D/A)
AXLES WX90

5 Lock tool 75301754 behind the planet

wheel gears (18).
After locking, remove tool 75301756.

18 18

F13513

6 Fit the snap rings (20) onto the pins (17).

20 17

F1240498

7 Place the differential carrier (15) under

the press, position bush 75301755 and
insert the planet wheel pin (17). 17

F13520

8 Put special tool 75301756 on top of the

planet wheel pin (17). 17
15501 9-35990

17

F13521
DISASSEMBLY AND ASSEMBLY AX5-4-52
(D/A)
AXLES WX90

9 Press 75301756 tool all the way down.

17

15

F13514

10 Remove tool 75301756, bush 75301755

and fit the snap ring (16) on the pin (17).

CAUTION! Make sure that the snap ring

centres the seat and that it rests on the 16
surface of the differential carrier.
Repeat the operations on the other planet
wheel pin or planet wheel axle. 17

F1240502

11 Position the second planetary gear (14)

in the differential carrier (15). 14

15

F7811

12 Position the shim washer (13) on the

crown (12).
13
NOTE. In order to hold the shim washer
(13) in position, apply grease to it.
15501 9-35990

12

F1240504
 DISASSEMBLY AND ASSEMBLY AX5-4-53
(D/A)
AXLES WX90

13 Position the crown (12) on the differential

carrier (15) and lock it with screws (11)
applied with Loctite 242.
Torque wrench setting for screws:
128÷142 Nm 11 12

NOTE. Secure the screws using the

cross-tightening method.

15

F1240505

14 Install the bearings (7) and (8) using tool

75301757.

8
7

F13520

15 If the bearings are replaced, insert the

2
external thrust blocks in the middle cover
(5) and in the central body (2).

F1240507

Installing
1 9
5 2
16 Position the differential unit (6) in the
central body (2) with the help of a bar
and fit the middle cover (5).
15501 9-35990

NOTE. Thoroughly check the state of the

O-ring (9) and make sure that the cover
is fitted with the oil discharge in the lower
position.

F7645
DISASSEMBLY AND ASSEMBLY AX5-4-54
(D/A)
AXLES WX90

17 Lock the middle cover (5) with screws (4).

Torque wrench setting for screw: 4
23.8÷26.2 Nm
5

4
4

F1240852

18 NOTE. If the ring nuts (1) are removed,

spread them with Loctite 242.

Tighten ring nuts on the crown side until

clearance between pinion and crown is
zero, then lock the crown; go back 1/4÷1/
2 turn.
Use special tool 75301753.

F13523

19 Pre-set the bearings by means of the ring

nut situated on the opposite side of the
crown, so as to increase pinion torque
up to 140÷210 Ncm.
Use special tool 75301759.

CAUTION! If bearings are not new, check

the static torque; if bearings are new,
check the continuous torque.

F13524

20 Introduce a comparator with rotary key

“A” through the top plug hole (10).
Position the comparator on the centre of 12 A
one of the teeth of the crown (12), pre-
set it to 1 mm and reset it.
15501 9-35990

F1240511
 DISASSEMBLY AND ASSEMBLY AX5-4-55
(D/A)
AXLES WX90

21 Manually move the crown (12) in both

directions in order to check the existing
backlash between the pinion and the A
crown.

F1240512

22 Adjust the backlash between the pinion

and the crown by unloosing one of the
ring nuts (1) and tightening the opposite
to compensate.
Normal backlash: see table.
Use special tool 75301753.

F13523

23 Difference between MIN and MAX

clearance for whole circumference
should not exceed 0.09 mm.

24 Apply Loctite 242 to the screws (3), fit

them into one of the two holes and 10
tighten.
Torque wrench setting: 23.8÷26.2 Nm
3
Fit the top plug (10) after applying
15501 9-35990

repositionable jointing compound for

seals to the rims.

F1240513
DISASSEMBLY AND ASSEMBLY AX5-4-56
(D/A)
AXLES WX90

25 Re-install the complete arms.

For details, see "CHECKING WEAR
AND REPLACING THE BRAKING
DISKS".
3

F1240385

4.1.15 HOW TO REMOVE THE BEVEL RINION

1 Remove the complete arms and the

differential unit.
For details, see "CHECKING WEAR
AND REPLACING THE BRAKING
DISKS" and "REMOVING THE
DIFFERENTIAL UNIT".

F7646

2 If disassembly is awkward, heat the

check nut (1) of the flange (2) at 80°C. 2

NOTE. Heating is meant to unloose the 1

setting of Loctite on the nut (1).

F1240514

3 Position special tool 75301760, so as to

avoid pinion rotation.
Unloose and remove the nut (1); also
remove the O-ring (3).
15501 9-35990

F13525
 DISASSEMBLY AND ASSEMBLY AX5-4-57
(D/A)
AXLES WX90

4 Remove the flange (2) complete with

guard (4) by means of a puller.

F1240516

5 Remove the swinging support (5).

5

F1240517

6 Remove the sealing ring (6).

F1240518

7 IPosition wrench 75301762 onto the ring

nut (7) and apply bar hold 75301761 to
the pinion (8).
Stop wrench 75301762 and rotate the
pinion so as to release and remove the 7
15501 9-35990

ring nut (7).

NOTE. If disassembly proves awkward,
weld the ring nut at approx. 80°C.

F13526
DISASSEMBLY AND ASSEMBLY AX5-4-58
(D/A)
AXLES WX90

8 Apply blocks 75301763 and, with the help

of a puller, extract the pinion (8) comple- 12
te with the internal bearing (9), the
distance piece (10) and shims (11).

NOTE. The thrust blocks of the bearings 8

remain in the central body (12).

F13527

9 Remove the pinion (8), shims (11) and

distance piece (10).
10
8

11

F7647

10 Using a puller and a press, remove the

inner bearing (9) from the pinion (8).

F1240578

11 Remove the thrust block of the external

bearing (13).
15501 9-35990

13

F1240521
 DISASSEMBLY AND ASSEMBLY AX5-4-59
(D/A)
AXLES WX90

12 Insert a drift in the appropriate holes and

remove the thrust block of the internal
bearing (9) as well as the shim washers
(14).

14

9
F1240522

14

12

10
13

6
5

11

7
3
1 4
15501 9-35990

2 D1240042
DISASSEMBLY AND ASSEMBLY AX5-4-60
(D/A)
AXLES WX90

4.1.16 INSTALLATION AND SETTING OF

BEVEL PINION

1 Using a surface plate, reset a centesimal DG

comparator “DG” and place it on the
measurement ring 75301764 (with a
thickness of 30.2 mm).
Preset the comparator to approx. 2 mm.

F13528

2 Bring the internal bearing (9), complete

with its thrust block, under the comparator
“DG”.
Determine overall thickness “D” of the DG
bearing checking the discrepancy
between this size and the size of the
measurement ring.
9
CAUTION! Press the thrust block in the
centre and take several measurements
while rotating the thrust block.
F1240524

3 Partially insert the thrust block of the

external bearing (13).
Use special tool 75301765.

13

F13529

4 Use special tools 75301764 and

75301765 as thrust block guide of the
external bearing (13).
15501 9-35990

13
F13530
 DISASSEMBLY AND ASSEMBLY AX5-4-61
(D/A)
AXLES WX90

5 Connect the tension rod to the press and

move the thrust block of the external
bearing (13) into its seat.
Disconnect the press and remove the
tension rod.

NOTE. Before starting the next stage,

make sure that the thrust block has been
completely inserted into its seat.

F1240527

6 Insert special tool 75301766 complete

with external bearing (13), measurement
ring 75301764.
Manually tighten.

13

F13531

7 Fit a centesimal comparator “DG1” with

long stem into tool 75301766; when the
bar rests on two size- blocks “GB” of 57 DG1
mm, reset the comparator.
Preset the comparator to approx. 2 mm
and reset.

GB

GB
F13532

8 Use tool 75301766 and take the size “A”

at about 57 mm corresponding to the
maximum diameter of arms centring.
15501 9-35990

A
F13533
DISASSEMBLY AND ASSEMBLY AX5-4-62
(D/A)
AXLES WX90

9 Calculate size “B” which will be the first

useful value for calculating the size of the T26C
shims (14) that are to be inserted under
the thrust block of the internal bearing (9).
Use tools 75301764 and 75301766.

R115
A
30.2 61

(61-A)+115+30.2=B B F13534

10 Check the nominal size (X) marked on

the pinion and add or subtract the 8
indicated variation (Y) so as to obtain size
“Z”. X
e.g.: Z= 118 + 0.1 = 118.1
Z= 118 - 0.2 = 117.8

F1240531

11 Calculate size “C” which represents the

second value for calculating the size of
the shims “S” that are to be placed under
the thrust block of the internal bearing (9).

(14) S
D Z
C=Z+D C
D1240069

12 Calculate the difference between sizes

“B” and “C” so as to obtain the size “S” of B-C=S
the shim (14) that will go under the thrust 14
block of the internal bearing (9).
15501 9-35990

F7812
 DISASSEMBLY AND ASSEMBLY AX5-4-63
(D/A)
AXLES WX90

13 IInsert shim “S” (14) and the thrust block

of the internal bearing (9) in the central
body.

NOTE. To hold shim “S” (14) in position,

apply grease.

14

9
F1240533

14 Connect the tension rod to the press,

fasten the thrust block and then remove
the tools.
Use special tool 75301765.

NOTE. Before going on to the next stage,

make sure that the thrust block has been
completely inserted.

F13535

15 Position special tool 75301766 comple-

te with tapered bearings (9) and (13);
manually tighten until a rolling torque has
been obtained. 9 13

F13536

16 IInsert the stem of a depth comparator

“DDG” in either side hole of tool
75301766; reset the comparator with a DDG
presetting of approx. 3 mm.
15501 9-35990

F1240536
DISASSEMBLY AND ASSEMBLY AX5-4-64
(D/A)
AXLES WX90

17 Remove the comparator and release

tools and bearings from the central body.
Re-install all and insert the distance piece
(10) between bearings (9) and (13); 9
manually tighten the whole pack. 10
13
Use special tool 75301766.

F13537

18 Insert depth comparator “DDG” into tool

75301766 and measure variation “H” in H
DDG
relation to the zero setting performed
back at point d.
9

13

F13538

19 The variation is to be added to a set value H+0,12÷ 0,13=S1

of 0.12÷0.13 mm., so as to obtain the size
11 S1
of shim “S1” (11) which will be inserted
between the external bearing (13) and
the distance piece (10) and
subsequently, to determine the preload
for the bearings.

F1240541

20 Position the internal bearing (9) and the

pinion (8) under a press; force the bearing
onto the pinion.
15501 9-35990

F1240542
 DISASSEMBLY AND ASSEMBLY AX5-4-65
(D/A)
AXLES WX90

21 Fit the pinion (8), shim “S1” (11) and

distance piece (10) in the main body (12). 12
10
NOTE. The finer shims must be placed 8
in- between the thicker ones.

11

F1240543

22 Insert the external bearing (13) in the

central body in order to complete the pack
arranged as in the figure. 9 11 10
13

F1240538

23 Connect the pinion (8) to the tool

75301768; connect the tool 75301768 to
the press and block.
8

F1240575

24 Apply Loctite 242 to the thread of the ring

nut (7) and screw the nut onto the pinion
(8).
8
7
15501 9-35990

F1240539
DISASSEMBLY AND ASSEMBLY AX5-4-66
(D/A)
AXLES WX90

25 Apply special wrench 75301762 to the

ring nut (7) and bar-hold 75301761 to the
pinion (8).
Lock the wrench 75301762 and rotate the
pinion using a dynamometric wrench, up
to a minimum required torque setting of
500 Nm.

F13539

26 Apply onto the pinion (8) the bar-hold

75301759 and with the help of a torque
metre, check the torque of the pinion (8).
Torque: 120÷170 Ncm

CAUTION! If torque exceeds the

maximum value, then the size of shim
“S1” (11) between the bearing (13) and
the distance piece (10) needs to be
increased.
If torque does not reach the set value,
increase the torque setting of the ring nut F13524

(7) in different stages to obtain a

maximum value of 570 Nm.

CAUTION! If torque does not reach the

minimum value, then the size of shim “S1”
(11) needs to be reduced.

CAUTION! When calculating the

increase or decrease in size of shim “S1”,
bear in mind that a variation of shim (11)
of 0.01 mm corresponds to a variation of
60 Ncm in the torque of the pinion (8).

27 Lubricate the outer surface of the new

sealing ring (6) and fit it onto the central 6
body (12) using tool 75301767.
15501 9-35990

12
F13540
 DISASSEMBLY AND ASSEMBLY AX5-4-67
(D/A)
AXLES WX90

28 Install the swinging support (5).

5
NOTE. Check that it is properly oriented.

F1240517

29 Fit the flange (2) complete with the guard

(4) and fasten it.
For keying the flange (2), use a plastic
hammer if necessary.

NOTE. Make sure that the guard (4) is

securely fastened onto the flange and
that it is not deformed.

2 4
F1240546

30 Apply Loctite 242 to the threaded part of

the pinion (8).
Position tool 75301760 and fasten it in
order to avoid rotation.
Insert O-ring (3) the nut (1) and tighten it
using a dynamometric wrench.
Torque wrench setting: 280÷310 Nm

F13541

31 Remove blocks 75301763 (used for

extracting the pinion) and re-install the
arms.
For details, see "CHECKING WEAR AND
REPLACING THE BRAKING DISKS".
15501 9-35990

F13542
DISASSEMBLY AND ASSEMBLY AX5-4-68
(D/A)
AXLES WX90

4.1.17 PARKING BRAKE

2
Disassembly

1/2 Loosen the two nuts and remove

lubrication tube (2).

F1240764

3 Remove nut (3), O-ring (4) and flange (5).

NOTE. If disassembly is awkward, heat

nut (3) at about 80°C.

3
F1240765

4 Loosen screws (6) in an alternate and

criss-cross manner until the action of
Belleville washers (11) becomes null.
Remove screws (6) and spring washers 8
of cover (8).

7 6
F1240766

5 Pull out cover (8), shims (9) separating

ring (10) and Belleville washers (11). 11
8
NOTE. Take note of the assembly
direction of: shims (9) andBelleville
washers (11).
15501 9-35990

9 10
F1240767
 DISASSEMBLY AND ASSEMBLY AX5-4-69
(D/A)
AXLES WX90

6 Slowly introduce compressed air through

the negative brakeconnection point in
order to extract the piston (12).

CAUTION! Hold piston (12) as it may be 12

rapidly ejected and damaged..

F1240768

7 Remove check screws (17) from cylinder

(18).

17

17
18
F1240769

8 Remove cylinder (18) complete with gui-

de pin (19) of piston (12). 18

NOTE. Take note of direction of

assembly.

19

F1240770

9 With the help of a lever, prize off the

distance piece (23) complete with O-ring 23
(24).
15501 9-35990

NOTE. Thoroughly clean the face of

bevel pinion support where the hub rests,
check the O-ring (24) and replace it if
24
necessary.

F1240771
DISASSEMBLY AND ASSEMBLY AX5-4-70
(D/A)
AXLES WX90

10/14 Remove friction discs (25), (26) and hub

(27).
25 26

27

F1240772

15 Remove the distance piece (39).

39

F1240777

16 Remove sealing ring (38) from cover (8).

NOTE. Take note of direction of

assembly of ring (38) and replace ring
every time the unit is disassembled. 38

F1240778

17/18 Remove sealing rings (13) and (15) and 14 13

anti-extrusion rings (14) and (16) from the
13 14
piston (12).
15 16
15501 9-35990

NOTE. Sealing rings (13) and (15) and

anti-extrusion rings (14) and (16) must
be replaced each time the unit is
disassembled.

15 16 12
F1240942
 DISASSEMBLY AND ASSEMBLY AX5-4-71
(D/A)
AXLES WX90

19 CAUTION! Always check the thickness

of braking discs (26), even if the braking
26 A 25
unit is being disassembled for other
reasons than this.
If thickness “A” of one of the discs (26) is
close to the minimum admissible size of
1.36 mm, replace the whole pack.
ITA

A minimo =1,36 mm
D1240083

20 BRAKING DISCS PACK CONTENTS

The braking discs pack is comprised of:
11 braking discs and 12 steel
counterdiscs.

D1240095

21 CAUTION! If the braking discs unit is

replaced, shims (9) - which determine the
9 10 11
preloading of Belleville washers (11) -
must to be restored.
ITA

D1240084

22 ONLY WHEN REPLACEMENT IS

NECESSARY
Remove the union pieces (41) and (42)
connecting the lubrication tube (2).
42
NOTE. During the assembly stage, union
15501 9-35990

pieces (41) and (42) must be coated with

Loctite 577 and tightened to a torque 41
wrench setting of 35 ± 50 Nm.

D1240085
DISASSEMBLY AND ASSEMBLY AX5-4-72
(D/A)
AXLES WX90

18 39
17
19
14 20
13 21
12 22

11
10
9
40 16
8 38 15

3 4

7
6
24

26
26
26
42
25 23 41
27 2

F8988
25

25

2 - Hose 17 - Screw
3 - Nut 18 - Cylinder
4 - O-Ring 19 - Pin
5 - Flange 20 - Washer
6 - Screw 21 - Dowel
7 - Washer 22 - Nut
8 - Cover 23 - Spacer
9 - Shim 24 - O-Ring
15501 9-35990

10 - Ring 25 - Clutch discs

11 - Spring 26 - Clutch discs
12 - Piston 27 - Hub
13 - Seal ring 38 - Seal ring
14 - Antiextrusion 39 - Spacer
15 - Seal ring 40 - O-Ring
16 - Antiextrusion 41 - Fitting
42 - Fitting
 DISASSEMBLY AND ASSEMBLY AX5-4-73
(D/A)
AXLES WX90

Assembly
14 13
13 14
23/24 Fit the sealing rings (13), (15) and the anti- 15 16
extrusion rings (14), (16) onto the piston
(12) of the negative brake.

NOTE. Carefully check the assembly

position of the anti-extrusion rings.

15 16 12
F1240942

25/26 Lubricate sealing ring (38) and, using tool

75301771, fit it into the cover (8).

NOTE. Carefully check the direction of

ring (38).

38
8

F13248

27/32 3-FUNCTION VERSION ONLY 10

Fit the separating ring (10) of Belleville B1
washers (11) onto the cover (8), measure
size “B” and note it down.

8
F1240783

33 Lubricate seals (13), (15) and fit the

piston (12) into the cylinder (18). Engage
12
piston on the pin (19). 18
For the assembly, use a plastic hammer
and push the piston (12) to the end of
stroke.
15501 9-35990

F1240786
DISASSEMBLY AND ASSEMBLY AX5-4-74
(D/A)
AXLES WX90

34 Lightly lubricate the braking discs (25),

(26) and fit them onto the hub (27).
Align discs (25) and fit the distance piece 23
(23).

NOTE. The braking disc pack starts and

ends with steel discs (25). 25 26
27

F1240787

35 Apply Loctite 510 on the face of the

distance piece (23). 23
Fit the discs-hub-distance piece
assembly prepared in the previous
stages onto the pinion and engage it.

F1240788

36 Lubricate the O-ring (24) and fit cylinder

(18) complete with piston (12).
18

12 24
F1240789

37 Introduce screws (17) and tighten in a

criss-cross manner: use a torque wrench
setting of 9.5÷10.5 Nm. 17

NOTE. Before giving the final tightening,

align the external surfaces of the
15501 9-35990

17
components.

F1240790
 DISASSEMBLY AND ASSEMBLY AX5-4-75
(D/A)
AXLES WX90

38 2-FUNCTION VERSION ONLY

Using a plastic hammer, push the piston
(12) to the end of stroke.
12

F1240791

39 2-FUNCTION VERSION ONLY 10

Fit the separating ring (10) of Belleville
washers onto the cover (8), measure size B
"B" and note it down. A
Measure size “A” which you will need for
calculating the shims (9) according to the
following:
S=A-(B+18.4) where: S = Shim thickness
- 18.4 mm = fixed measure of Belleville
washers.

F1241069

40 Lightly lubricate the shims (9) required

according to calculations and the
separating ring (10) of the Belleville
10
washers. Fit shims and ring on the cover
(8). 9

NOTE. Position the larger shim so that it

leans against the cover.
8

F1240793

41 Check the state of the O-ring (40).

Lubricate sealing ring (38) and fit flange
38
(5) into the cover (8).
8
15501 9-35990

40
5

F1240794
DISASSEMBLY AND ASSEMBLY AX5-4-76
(D/A)
AXLES WX90

42 Fit the Belleville washers (11) onto the

cover (8), thoroughly checking washers 11
orientation. 11
10

9
8

F1240795

43 Lubricate the O-ring (40) and install the

cover assembly (8). 8

40
F1240796

44 Fit screws (6) and washers (7); lock the

cover with a torque wrench setting of 116
± 128 Nm.

NOTE. Tighten in an alternate and criss-

cross manner.

8
6 7
F1240797

45 Apply Loctite 242 to the threaded portion

of the pinion, fit O-ring (4) and nut (3);
tighten the nut with a dynamometric
wrench set to 280 ± 310 Nm.

NOTE. Use tools 75301761 and

15501 9-35990

75301762.

F1240798
 DISASSEMBLY AND ASSEMBLY AX5-4-77
(D/A)
AXLES WX90

46/48 Install the lubrication tube (2).

F1240764

49 Check negative brake release by

introducing a pressure of 16v35 bar and
by manually rotating the flange (5).
Release pressure.

F1240801

50 CAUTION! To release the negative brake

during an emergency, (lack of pressure
due to vehicle breakdown), loosen nuts 21 22
(22) and screw dowels (21) in an alterna-
te and gradual manner until you notice
some preloading; continue by giving
another 1.5 turns.

F1240802

51 When the emergency is over, loosen the

dowels in an alternate manner until a 17
mm projection is obtained; lock into
position with the nuts (22) tightened to15
17 mm

Nm.
15501 9-35990

D1240098
DISASSEMBLY AND ASSEMBLY AX5-4-78
(D/A)
AXLES WX90

4.2 SPECIAL TOOLS

P/N DESCRIPTION USE PAGE

75301741 Curdling Check of wear and replacement of brake disks 3

75301742 Blister Check of axle arms levelness 8

75301743 Tool Assembly of upper bushing into the hole of 11

arm pivot

75301744 Tool Assembly of lower bushing into the hole of 11

arm pivot

75301745 Tool Assembly of shaft seal ring in the flange 17

75301746 Tool Assembly of seal ring and bearing in the flange 17

75301747 Tool Assembly of bearing bruss in the joint box 25

75301748 Tool Assembly of seal and centering rings 25

75301749 Tool Assembly of fifth wheel in the wheel hub 25

75301750 Tool Assembly of seal ring in the hub 26

75301751 Tool Assembly of planetary gear in the cover 27

75301752 Tool Installation of steering cylinder 35

75301753 Puller Removal of ring nuts from differential unit 44

75301754 Puller Removal of pivots and planetaries from 47

differential unit

75301755 Bushing Removal of pivots and planetaries from 47

differential unit

75301756 Pin Removal of pivots and planetaries from 47

differential unit

75301757 Tool Assembly of bearings in the differential unit 53

75301758 Centering tool Assembly of steering cylinder 42

75301759 Bush Preloading of bearings to increase the pinion 54

rotation torque
15501 9-35990

75301760 Tool used to avoid pinion Removal of cone-shaped pinion 56

rotation

75301761 Block Removal of cone-shaped pinion 57

75301762 Key Removal of cone-shaped pinion 57

 DISASSEMBLY AND ASSEMBLY AX5-4-79
(D/A)
AXLES WX90

P/N DESCRIPTION USE PAGE

75301763 Block Removal of cone-shaped pinion 58

75301764 Measuring ring Setting of cone-shaped pinion 60

75301765 Centering tool Setting of cone-shaped pinion 60

75301766 Centering tool Setting of cone-shaped pinion 61

75301767 block Setting of cone-shaped pinion 66

75301768 Tie rod Installation and setting of cone-shaped pinion 65

75301771 block Assembly of parking brake 72

15501 9-35990
DISASSEMBLY AND ASSEMBLY
AXLES WX90
TROUBLESHOOTING
Problem Cause
Overheatingbraking 1. Brake discs worn out
2. Incorrect brake fluid
3. Loss of brake fluid
4. Overheated axle causing brake
fluid to vaporize.
(Brake return when axle cools)
5. Air in brake circuit
Soft brake pedal 6. Incorrect adjustment
Ineffective safety 7. Brake disc worn out
brake
8. Oil level wrong
Overheating 9. Too small of a brake gap
10. Park brake dragging
11. Incorrect brake fluid in system
12. No free-pedal at master cylinder
13. Restriction in brake lines
14. Restriction in return line of brake
Servo system
15. Incorrect lubricant
AX5-4-80
(D/A)
Correction
Inspect disc thickness and replace if necessary.
Replace all seals in axle and master cylinder that
have made contact with the incorrect fluid and all
brake hoses.
If incorrect fluid leaked into axle oil, seals and o-
rings in axle must be replaced.
Inspect for and repair any leaks in outside circuit
or master cylinder.
If caused by incorrect brake fluid see correction
N. 3.
If leak is to the outside replace the o-rings between
the center and intermediate housings.
If leak is to the inside replace above o-rings and
brake piston o-rings.
See "overheating" problem.
Bleed brakes as described in the vehicle’s service
manual.
See correction N. 1.
See correction N. 2.
Drain, flush and refill oil to proper level.
Readjust brakes to the specifications in the
vehicle’s service manual.
Unlock the brake and adjust the correct gap.
See correction N. 3.
Readjust brake pedal as described in the vehicle’s
service manual.
Inspect for and replace damage lines.
15501 9-35990
Inspect for and replace damaged return line.
Inspect for and replace all filters and fittings on
circuit or any other obstacle on return line.
Change the retaining rings of the brake circuit and
brake pump.
 DISASSEMBLY AND ASSEMBLY AX5-4-81
(D/A)
AXLES WX90

Problem Cause Correction

Diff-lock 16. If manual control, loose or Inspect and correct linkage and readjust as
inoperative misadjusted linkage indicated in vehicle’s service manual.

17. If hydraulic control, problems in Refer to the service manual for the vehicle.
the hydraulic or electrical circuits
of the vehicle

18. If hydraulic control: problems in Rebuilt cylinder.

actuating cylinder (noteable
through loss of hydraulic oil or
increase of the oillevel in axle)

19. If with lim. slip differential, worn Replace discs.

Oil coming out of 20. Leak in internal brake system See correction N. 2 and 3.
breather

21. Leak in diff-lock actuating cylinder See correction N. 19.

NoSpin indexing 22. Unequal tire pressure left anal Inflate tires to the recommended pressure in the
noise when driving right service manual, or until the rolling radius is equal.
straight.
CAUTION! With
NoSpin, fatigue 23. Different style, size or brand of Change tires to make the rolling radius equal.
damage can occur tires between left and right hand Vary the tire pressure within the specifications until
on the side with the side the rolling radius is equal.
larger tire.

Noise during coast 24. Wheel bearings damaged Replace and adjust.
and under power the
same

Noise under power 25. Low oil level Refill oil to proper level.
greater than during
coast 26. Incorrect lubricant See correction N. 16.

27. Ring and pinion worn Inspect through top cover. Replace and adjust.

28. Worn ring and pinion bearings Replace and adjust.

29. Worn planetary gears or bearings Replace.

15501 9-35990

Noise during coast 30. Loose pinion nut Inspect ring, pinion and pinion bearings. If unda-
greater than under maged, retighten nut.
power

31. Only pinion bearing damaged See correction N. 29.

DISASSEMBLY AND ASSEMBLY AX5-4-82
(D/A)
AXLES WX90

Problem Cause Correction

Noise during turn 32. Worn spider and/or side gears Replace.
(without NoSpin)

A "Stick slip" noise 33. Worn or damaged cardanshaft Inspect and replace as described in vehicle’s
when going from service manual.
forward to reverse

34. Loose wheel Inspect for wheel and wheel stud damage.
Replace if needed and retorque lugnuts.

35. Articulation box joint and achsel Inspect and replace.

shaft damaged

36. Spider pins loose in diff-carrier Inspect through top cover. Replace.

37. Damaged or missing spider and/ See correction N. 33.

or side gear washers

15501 9-35990
 OPERATION PRINCIPLE TS5-5-1
(O/P)
TRANSMISSION SHAFT WX90

5. TRANSMISSION SHAFT

5. 1 TRANSMISSION SHAFT

The transmission shaft is a sliding cardanic joint fitted between the two axles. It is flange-mounted with one
end to the transmission output shaft and the other end to the front axle; and its function is to obtain the front
and rear wheel drive.
The transmission shaft is composed of a sliding joint shaft (1), two cardanic spider (2) and two flange forks
(3).

The transmission shaft is equipped with grease nipples (4) to allow the correct lubrication.

4
4

1 3
15501 9-35990
OPERATION PRINCIPLE TS5-5-2
(O/P)
TRANSMISSION SHAFT WX90

NOTES:

15501 9-35990
 DISASSEMBLY AND ASSEMBLY TS5-5-1
(D/A)
TRANSMISSION SHAFT WX90

5.1 DISASSEMBLY AND ASSEMBLY

5.1.1 DISASSEMBLY

1 After removing the transmission shaft, carry out

a thoroughly cleaning of all parts of the
assembly.

Note: As the shaft being a sliding joint, it is

advisable to mark with a piece of chalk the
position on the fork and on the shaft on both
sides.
F8289

2 Remove the greasing nipple from the spider

and lay the flange fork (1) on the jaws of a wise
in order to allow withdrawing of the spider from
the shaft (2).

3 Remove the safety spring rings and beat with

a mallet on the upper surface of the shaft. 2
Withdraw the bearing (3) and remove the shaft.

F8290

3
1

4 Lay spider pins on the jaws and beat on the

flange forks to withdraw the bearing.
15501 9-35990

5 Repeat the procedure for the joint of opposite

F8930
side.
DISASSEMBLY AND ASSEMBLY TS5-5-2
(D/A)
TRANSMISSION SHAFT WX90

5.1.2 ASSEMBLY

1 Fix firmly the flange fork. Insert the spider on

the flange fork respecting the orientation of
the greasing nipple hole.

greasing
nipple hole

2 To insert correctly the bearing it is advisable

the use of a centring guide. In this way the
bearing can be driven correctly in the spider
pin.

3 Remove the centring guide and insert the

second bearing from opposite side. Install the pusher
safety spring rings.
bearing

4 Repeat the operation procedure 2 and 3 to

fix the spider to the shaft.

centring
guide

5 Reinstall the greasing nipple.

6 Repeat the above operation procedure for the

opposite side of the cardanic joint.
15501 9-35990

7 Carry out the greasing. Apply the grease to

the nipples until is appears in each bearing
seal.
 INDEX WX90 - 6 - 1

WX90

SECTION 6 FRONT-END ATTACHMENT

INDEX

Group 1 - FRONT-END ATTACHMENT .......................................................................... FA6-1-1

1.1 Monoboom assembly
1.2 Triple articulation assembly
1.3 Offset digging assembly
1.4 Penetration arm assembly
1.5 Bucket assembly
1.6 Front pipings
1.7 Maintenance standard

Group 2 - HYDRAULIC CYLINDERS - O/P - D/A .......................................................... CY6-2-1

2.1 Construction and function
2.1 Cylinder disassembly-assembly

Group 3 - PINS AND BUSHINGS ................................................................................... FA6-3-1

3.1 Specifications

O/P = OPERATIONAL PRINCIPLE

D/A = DISASSEMBLY and ASSEMBLY
15501 9-35990
15501 9-35990
 FA6-1-1

FRONT-END ATTACHMENTS WX90

1. FRONT-END ATTACHMENT

1.1 MONOBOOM ASSEMBLY

1.1.1 CONSTRUCTION

The assembly consists of monoboom, articulation joint with bushings, hinge pins and cylinders.
At the end is fitted a penetration arm unit, with different arm lengths.
(1850, 2200 mm)

18
11

12
13
06
07
05
14
17
06
09 10
07
10 16
05
06 15
14
07
Monoboom version 05 02
01 - Articulation 14 01
04
02 - Bushing 08
03 - Spacer 05
04 - Pin 16
07
05 - Washer
06 - Screw 06
07 - Spring washer 08
08 - Grease fitting 16
09 - Monoboom
02
15501 9-35990

10 - Bushing 06
11 - Pin
07
12 - Washer
13 - Nut 05
14 - Pin 04
15 - Grease fitting
17 - Lifting cylinder 03
16 - Plug F8506

18 - Penetration cylinder
 FA6-1-2

FRONT-END ATTACHMENTS WX90

SPECIFICATIONS AND DATA

- Articulation weight: ....................................... 120 kg

- Dimensions:

500

F8698

- Monoboom weight with bushings: ................ 340 kg

- Dimensions:

3000
15501 9-35990
240

F8691
 FA6-1-3

FRONT-END ATTACHMENTS WX90

1.2 TRIPLE ARTICULATION ASSEMBLY

1.2.1 CONSTRUCTION

The triple articulation assembly consists of articulation joint, boom, positioning arm with bushings, hinge pins
and cylinders.
At the end is fitted a penetration arm unit, with different arm lengths.
(1850, 2200 mm)
11
12
13
16

06
07
09
05
10
14
08
10
15
04
02
05
01
07
08
06
05 15

07
06 08
15
02
03
04
F8847

Triple articulation version - Boom

15501 9-35990

01 - Articulation 09 - Boom
02 - Bushing 10 - Bushing
03 - Spacer 11 - Pin
04 - Pin 12 - Washer
05 - Washer 13 - Nut
06 - Screw 14 - Pin
07 - Spring washer 15 - Plug
08 - Grease fitting 16 - Lifting cylinder
 FA6-1-4

FRONT-END ATTACHMENTS WX90

30
24
28

29
33
34
18
23
19
22
17
21
25
29
27
32
28
24
20
31 24

18 31

19 26
24
17
25
F8846

Triple articulation version - Arm

17 - Spring washer
18 - Screw
19 - Washer
20 - Grease fitting
21 - Washer
22 - Nut
23 - Arm
24 - Bushg
25 - Pin
26 - Grease fitting
15501 9-35990

27 - Pin
28 - Spacer
29 - Ring
30 - Pin
31 - Plug
32 - Left hand positioning cylinder
33 - Right hand positioning cylinder
34 - Penetration cylinder
 FA6-1-5

FRONT-END ATTACHMENTS WX90

SPECIFICATIONS AND DATA

- Articulation weight: ............................. 120 kg

- Dimensions:
500

F8698

- Boom weight: .................................... 215 kg

- Dimensions:
550

1895
15501 9-35990

F8692
 FA6-1-6

FRONT-END ATTACHMENTS WX90

POSITIONING ARM

- Positioning arm weight: ............................ 345 kg

- Dimensions:

1900
328

F8693

15501 9-35990
 FA6-1-7

FRONT-END ATTACHMENTS WX90

1.3 OFFSET DIGGING ASSEMBLY

1.3.1 CONSTRUCTION

The offset digging assembly consists of articulation joint, boom, second element, third element and a link rod
with bushings, hinge pins and cylinders.
At the end is fitted a penetration arm unit, with different arm lengths.
(1850, 2200 mm)

13
12
11 14
10

09
11
12
13
09
10
04

07
06
05
15
16
17

18

Offset digging version 09

01 - Articulation 10
02 - Bushing 08
03 - Spacer 02
04 - Pin 05
01
05 - Washer
06 - Spring washer 06
09
07 - Screw
07
08 - Pin 07 10
09 - Grease fitting
06
10 - Plug 08 02
15501 9-35990

11 - Dust seal 05
12 - Shim 05 09
13 - Shim
14 - Pin 06 04 10
15 - Washer 03
07
16 - Nut
17 - Lifting cylinder F8848

18 - Arm
 FA6-1-8

FRONT-END ATTACHMENTS WX90

28
30 32
29 22 20
21 35
38 20
19
31
18
34
36 37
22
37 24
38 21
25 24

23
25
27
26 21
25 22
25
24
26
27
21
25
22
29
24
30
34
33 25
35

20
39

34

35

20

F8850

Fig. 2 Offset digging version

19 - Washer 30 - Nut
20 - Screw 31 - Articulation body
21 - Grese fitting 32 - Bushing
15501 9-35990

22 - Plug 33 - Rod
23 - Arm 34 - Pin
24 - Bushing 35 - Washer
25 - Dust seal 36 - Pin
26 - Shim 37 - Seal
27 - Shim 38 - Plug
28 - Pin 39 - Offset digging cylinder
29 - Washer
 FA6-1-9

FRONT-END ATTACHMENTS WX90

SPECIFICATIONS AND DATA

- Articulation weight: ............................. 120 kg

- Dimensions:

500

F8698

- Boom weight with bushings: .............. 264 kg

- Dimensions:

1054
1508
15501 9-35990

F8798
 FA6-1-10

FRONT-END ATTACHMENTS WX90

- Second element weight: .................... 155 kg

- Dimensions:

1050

F8799

- Third element weight: ........................ 148 kg

- Dimensions:

481
F8801

- Link rod weight: .................................... 28 kg

- Dimensions:

1050
15501 9-35990

F8800
 FA6-1-11

FRONT-END ATTACHMENTS WX90

1.4 PENETRATION ARM ASSEMBLY

1.4.1 CONSTRUCTION

The penetration arm assembly consists of arm with bushings, tied rods and pins and two lengths: 1850 mm
and 2200 mm.
It is applied to each version: monoboom, triple articulation, offset digging.

02
04
06
05
02 03
04 07
06 01
05
10
09

08

03
13
03
02 07
07
07
07
14
03
11
07
12
03
02
04
06
15501 9-35990

05
F8849

01 - Arm 05 - Screw 09 - Washer 13 - Bucket cylinder

02 - Pin 06 - Spring washer 10 - Nut 14 - Bucket
03 - Bushing 07 - Grease fitting 11 - Link rod
04 - Washer 08 - Lever 12 - Spacer
 FA6-1-12

FRONT-END ATTACHMENTS WX90

1.4.2 SPECIFICATIONS AND DATA

- Penetration arm weight: 1850 mm ................ 150 kg

- Dimensions:

1850
150

F8694

- Penetration arm weight: 2200 mm ................ 185 kg

- Dimensions:

2200
150

15501 9-35990

F8695
 FA6-1-13

FRONT-END ATTACHMENTS WX90

Tie rod unit

- Linkage assembly weight: ............................... 13 kg

- Dimensions:

410

F8696

- Link rod weight: ............................................... 17 kg

- Dimensions:

410
150

F8697
15501 9-35990
 FA6-1-14

FRONT-END ATTACHMENTS WX90

1.5 BUCKET ASSEMBLY

1.5.1 CONSTRUCTION

The bucket is of all-welded high-strength steel structure and provided with teeth.

F12973

1 - Tooth
2 - Pin
3 - Bucket assembly
15501 9-35990

1.5.2 APPLICABILITY

For the dimensions of bucket applicability depending on arm, refer to Section 3 paragraph 2.10.
 FA6-1-15

FRONT-END ATTACHMENTS WX90

1.3.3 REPLACING A TOOTH TIP ON A

BACKHOE BUCKET

Removal

Place the bucket a few centimetres above the

ground. F13661

Stop the engine and remove the starter switch

key.

Remove the locking pin from its housing by

striking it with a hammer until it is ejected.

F13663

Remove the worn tooth tip.

F13662

Installation

Clean the mating surface on the adaptor.

15501 9-35990

F13668
 FA6-1-16

FRONT-END ATTACHMENTS WX90

Install a new tooth tip up to the stop and hold it

in this position.

F13662

Place the locking pin in position and strike it until

it is flush with the tooth tip.

IMPORTANT: Make sure the locking pin is not

installed back to front.

NOTA: When replacing a tooth tip, it is advisable

to replace the locking pin at the same time.

F13664

15501 9-35990
 FA6-1-17

FRONT-END ATTACHMENTS WX90

1.6 FRONT PIPINGS

1.6.1 CONSTRUCTION

CONTROL PIPINGS

Front control pipings are the pipes and hoses operating lifting cylinder, positioning cylinders, penetration
cylinder and bucket cylinder.

B
G
E
I

F F8701

Line description

Lifting cylinder
- control: line A - B
Positioning cylinder
- control: line C - D
Penetration cylinder
15501 9-35990

- control: line E - F
Bucket cylinder
- control: line G - H
Preparation for bucket swing
- control: line I - L
 FA6-1-18

FRONT-END ATTACHMENTS WX90

(1) MONOBOOM PIPINGS

Front control pipings are the pipes and hoses operating lifting cylinder, penetration cylinder and bucket
cylinder. They also include the preparation for clamshell bucket.

BUCKET
CYLINDER

PENETRATION
CYLINDER

LIFTING
CYLINDER

J DD
T
W S

CC BUCKET SWING
PIPINGS

N B
15501 9-35990

F8700
M E

H
A L
F G J
 FA6-1-19

FRONT-END ATTACHMENTS WX90

(2) PIPINGS ON THE TRIPLE ARM

DD
T

W
S

CC

P N
D
M C

B
E
H
L
F9166
A I
F G
15501 9-35990
 FA6-1-20

FRONT-END ATTACHMENTS WX90

(3) PIPINGS ON OFFSET DIGGING ARM

DD
W
T

CC
S

R
Q

N D C
M

B
A
H
15501 9-35990

G E
F
I L
 FA6-1-21

FRONT-END ATTACHMENTS WX90

LIFTING CYLINDER
- Lifting cylinder control: line A-B, M-N.

N N

M B

M F8702

P
P
R
O
Q

R
15501 9-35990

F8703

C
POSITIONING CYLINDERS
Triple articulation version (02) D
- Positioning cylinder control: line C-D, O-P, R-Q.
 FA6-1-22

FRONT-END ATTACHMENTS WX90

Offset digging version (03)

- Positioning cylinder control: line C-D, R-Q.

R
Q

F9168

FRONT ATTACHMENT CYLINDERS LOCKING

COCKS

Cocks are installed in lifting, penetration and bucket

cylinders in order to lock the front attachment for the
on-road travelling position.
15501 9-35990
 FA6-1-23

FRONT-END ATTACHMENTS WX90

PENETRATION CYLINDER
Triple articulation version (02)
- Penetration cylinder control: line E-F, EE-FF and S-T.

EE
S

FF
E

F F8704

S
15501 9-35990

F8705
 FA6-1-24

FRONT-END ATTACHMENTS WX90

Monobloc version (01)

- Penetration cylinder control: line E-F and S-T.

T
S T S T

E
GG
F
HH F9170

GG

HH

EE

Offset digging version (03)

- Penetration cylinder control: line E-F, EE-FF,
GG-HH and S-T.

EE

FF
FF

15501 9-35990

F9169
E

F
 FA6-1-25

FRONT-END ATTACHMENTS WX90

BUCKET CYLINDER
Triple articulation version (02)
- Bucket cylinder control: line G-H, U-V, X-Y, W-J.

H F8706

V
F8707

W
J

J X
15501 9-35990

Y
F8708
 FA6-1-26

FRONT-END ATTACHMENTS WX90

Monoboom version (01)

- Bucket cylinder control: line G-H, X-Y, J-W.

Y X

F9171

H G

W
J

J X
15501 9-35990

Y
F8708
 FA6-1-27

FRONT-END ATTACHMENTS WX90

Offset digging version (03)

- Bucket cylinder control: line G-H, U-V, II-LL, X-Y, J-W.

U V

Y II

LL

II
LL

V
F9172 G
H
U

F9173

W
J

J X
15501 9-35990

Y
F8708
 FA6-1-28

FRONT-END ATTACHMENTS WX90

BUCKET SWING PIPINGS

Triple articulation version (02)
- Bucket cylinder control: line I-L, AA-BB, CC-DD.

BB

AA

L
F8709

DD

CC

BB

AA F8710

DD
15501 9-35990

F8711

CC
 FA6-1-29

FRONT-END ATTACHMENTS WX90

Monoboom version (01)

- Clamshell bucket preparation control: line I-L and CC-DD.

CC DD

I
F9174

DD
15501 9-35990

F8711

CC
 FA6-1-30

FRONT-END ATTACHMENTS WX90

Offset digging version (03)

- Clamshell bucket preparation control: line I-L, AA-BB, MM-NN, OO-PP and CC-DD.

BB
AA

CC DD

NN

MM

NN MM

F9175

L I

BB
AA

F9176

DD
15501 9-35990

F8711

CC
 FA6-1-31

FRONT-END ATTACHMENTS WX90

1.7 MAINTENANCE STANDARD

1.7.1 REMOVAL AND INSTALLATION OF THE

CYLINDERS

Remove bucket cylinder

(valid for the versions herebelow)

(01) Monoboom version

(02) Triple articulation version
(03) Offset digging version

1 Place the unit on level ground and stop the

F8859
engine.

2 Put wooden block under the bucket

cylinder.

F8712

3 Remove nut and push out washer.

F8713

4 Push out pin.

15501 9-35990

F8714
 FA6-1-32

FRONT-END ATTACHMENTS WX90

5 Fasten a wire to bucket cylinder to hold

cylinder rod.

F8715

6 Remove bucket cylinder hoses.

Install plugs to all side of pipings and hoses.

F8716

7 Hoist bucket cylinder.

F8717

8 Untighten fixing screw and push out pin.

Then remove cylinder.
15501 9-35990

F8718
 FA6-1-33

FRONT-END ATTACHMENTS WX90

Install bucket cylinder

Versions (01) (02) (03)

1 Install bucket cylinder to the dipstick.

Align bucket cylinder with dipstick.

F8719

2 Install pin and tighten screw.

F8720

3 Remove piping plugs. Install bucket cylinder

hoses to the cylinder.

F8756

4 Hoist bucket cylinder and links, then, align

bucket cylinder rod with links.
15501 9-35990

F8757
 FA6-1-34

FRONT-END ATTACHMENTS WX90

5 Install pin, washer and tighten nut.

F8758

15501 9-35990
 FA6-1-35

FRONT-END ATTACHMENTS WX90

Remove penetration cylinder

Versions (01) (02)

1 Place the unit on level ground and stop the

engine.
Support arm as shown in the picture.

F8860

2 Put wooden block under the penetration

cylinder.

F8759

3 Untighten fixing screw.

F8760

4 Push out pin.

15501 9-35990

F8761
 FA6-1-36

FRONT-END ATTACHMENTS WX90

5 Fasten a wire to penetration cylinder to hold

cylinder rod.

F8715

6 Remove penetration cylinder hoses.

Install plugs to all side of pipings and hoses.

F8762

7 Hoist penetration cylinder.

F8763

8 Untighten fixing screw and push out pin.

15501 9-35990

F8764
 FA6-1-37

FRONT-END ATTACHMENTS WX90

Offset digging version (03)

1 Place the unit on level ground and stop the

engine.
Support the third element as shown in the
picture.

F9121

2 Hoist cylinder.

3 Untighten locking nut and push out pin.

F9152

4 Remove bucket cylinder hoses.

Install plugs to all side of pipings and hoses.
15501 9-35990

F9153
 FA6-1-38

FRONT-END ATTACHMENTS WX90

5 Untighten cover fixing screws and lift

cylinder.

F9154

15501 9-35990
 FA6-1-39

FRONT-END ATTACHMENTS WX90

Install penetration cylinder

Versions (01) (02)

1 Align penetration cylinder with articulated

arm.

F8765

2 Install pin and tighten screw.

F8766

3 Remove piping plugs. Install penetration

cylinder hoses to the cylinder.

F8767

4 Hoist penetration cylinder. Then align

penetration cylinder rod with dipstick.
15501 9-35990

F8768
 FA6-1-40

FRONT-END ATTACHMENTS WX90

5 Install pin and tighten fixing screw.

F8769

Offset digging version (03)

1 Locate the cylinder in its seat.

F9155

2 Secure covers with screws.

F9154
15501 9-35990
 FA6-1-41

FRONT-END ATTACHMENTS WX90

3 Remove piping plugs. Install cylinder hoses

to the cylinder.

F9156

4 Install pin and tighten screw.

F9152
15501 9-35990
 FA6-1-42

FRONT-END ATTACHMENTS WX90

Remove lifting cylinder

Versions (01) (02) (03)

1 Place the unit on level ground and stop the

engine.
Support boom as shown in the picture.

F8861

2 Support lifting cylinder with a hoist.

F8770

3 Monoboom (01) and offset digging

versions (03)
Untighten fixing screw and push out pin.

F8772

4 Triple articulation version (02)

Support right positioner cylinder with a hoist.
Untighten fixing screw and push out pin to
lift cylinder.
15501 9-35990

WARNING
Be careful not to completely withdraw the
pin, in order to avoid the disconnection of left
positioning cylinder.
F8774
 FA6-1-43

FRONT-END ATTACHMENTS WX90

5 Lay cylinder on a support.

F8776

6 Fasten a wire to lifting cylinder to hold

cylinder rod.

F9127

7 Remove lifting cylinder hoses.

Install plugs to all side of pipings and hoses.

F8777

8 Untighten fixing screw and push out pin.

15501 9-35990

F8778
 FA6-1-44

FRONT-END ATTACHMENTS WX90

9 Remove cylinder.

F8779

15501 9-35990
 FA6-1-45

FRONT-END ATTACHMENTS WX90

Install lifting cylinder

Versions (01) (02) (03)

1 Hoist lifting cylinder, then, align lifting

cylinder bottom side with angle articulation.

F8780

2 Install pin and tighten screw.

F8781

3 Remove piping plugs. Install hoses to the

lifting cylinder.

F8782

4 Hoist lifting cylinder. Then align rod with

boom.
Start the engine.
Align the hole of lifting cylinder rod end with
the hole of boom center by operating to
extend or to retract the rod.
15501 9-35990

F8783
 FA6-1-46

FRONT-END ATTACHMENTS WX90

5 Monoboom (01) and offset digging (03)

versions
Install pin and tighten screw.

F8784

6 Offset digging version (02)

Install pin and tighten screw.

F8785

15501 9-35990
 FA6-1-47

FRONT-END ATTACHMENTS WX90

Removal of positioning cylinder

Triple articulation version (02)

1 Place the unit on level ground.

Support arm as shown in the picture.

F8860A

2 Hoist positioning cylinder.

Support lifting cylinder.
Support lifting arm.

F8787

F9122

3 Remove snap rings and push out pin.

15501 9-35990

F8788
 FA6-1-48

FRONT-END ATTACHMENTS WX90

4 Fasten a wire to positioning cylinder to hold

cylinder rod.

F8715

5 Remove positioning cylinder hoses.

Install plugs to all side of pipings and hoses.

F8789

6 Untighten fixing screw and push out pin.

F8790
15501 9-35990
 FA6-1-49

FRONT-END ATTACHMENTS WX90

Arm angle cylinder removal

Offset digging version (03)

1 Place the unit on level ground.

Support the third element as shown in the
picture.

F8860B

2 Hoist positioning cylinder.

F9157

3 Untighten fixing screw and push out pin.

F9158

4 Fasten a wire to positioning cylinder to hold

cylinder rod.
15501 9-35990

F8715
 FA6-1-50

FRONT-END ATTACHMENTS WX90

5 Remove positioning cylinder hoses.

Install plugs to all side of pipings and hoses.

F9159

6 Untighten fixing screws and remove

cylinder.

F9160

15501 9-35990
 FA6-1-51

FRONT-END ATTACHMENTS WX90

Install positioning cylinder

Triple articulation version (02)

1 Align cylinder rear end with lifting arm.

F8791

2 Mount the cylinders from the back side in

correspondence with the hinge point on lif-
ting boom. Install pin to secure lifting
cylinder.

F8792

3 Remove all plugs and connect control

pipings with the cylinder.

F8789

4 Hoist cylinder, then align cylinder rod with

the positioning arm.
15501 9-35990

F8793
 FA6-1-52

FRONT-END ATTACHMENTS WX90

5 Install pin and safety snap rings.

F8794

Offset digging version (03)

1 Aligncylinder rear end with lifting arm.

F9161

2 Install pin and tighten screw.

F9162

3 Remove plugs and connect cylinder control

pipings.
15501 9-35990

F9163
 FA6-1-53

FRONT-END ATTACHMENTS WX90

4 Install pin.

F9164

5 Install locks and tighten fixing screws.

F9165
15501 9-35990
 FA6-1-54

FRONT-END ATTACHMENTS WX90

SPECIFICATIONS

HYDRAULIC CYLINDER DIMENSIONS

Lifting cylinder
Bore x Rod diameter x stroke 100 x 65 x 749 mm

Minimum retracted length 1160 mm

Penetration cylinder
Bore x Rod diameter x stroke 100 x 65 x 749 mm

Minimum retracted length 1160 mm

Bucket cylinder
Bore x Rod diameter x stroke 70 x 50 x 750 mm

Minimum retracted length 1100 mm

Positioner cylinder (triple articulation version)

Bore x Rod diameter x stroke 70 x 40 x 610 mm

Minimum retracted length 925 mm

15501 9-35990
 FA6-1-55

FRONT-END ATTACHMENTS WX90

1.7.2 ASSEMBLY REMOVAL AND INSTALL

Bucket and tie rod removal

1 Set the machine on a level surface.

Lay the bucket to the ground.
Stop the engine.

F8869

2 Untighten fixing screw and push out pin

from penetration arm.
Remove linkage from bucket in the same
way.

F9177

3 Hoist bucket cylinder.

Untighten fixing screw and push out pin
from cylinder rod and penetration arm for
link rod disconnection.

F9178

Bucket cylinder removal

15501 9-35990

- See "Bucket cylinder removal" paragraph

1.7.1.
 FA6-1-56

FRONT-END ATTACHMENTS WX90

Penetration arm removal

1 Hoist penetration cylinder.

F9181

2 Hoist penetration arm.

F9182

3 Untighten fixing screw and push out pin.

F9179

4 Untighten lock nut and push out pin.

15501 9-35990

F9180
 FA6-1-57

FRONT-END ATTACHMENTS WX90

Penetration cylinder removal

- See "Penetration cylinder removal"

paragraph 1.7.1.

Lifting cylinder removal

1 Hoist arm.

- See "Lifting cylinder removal" paragraph

1.7.1.

F9204

Lifting arm removal

Versions (01) (02) (03)

1 Hoist arm.
Disconnect cylinder control hoses.
Note: Eight hoses for monoboom version
(control of lifting, penetration, bucket
cylinders and bucket swing preparation) and
ten for triple articulation and offset digging
versions (control of lifting, positioning,
penetration, bucket cylinders and bucket
swing preparation).
Plug both disconnected hoses sides to let
dirt out. F9183

2 Lay arm on a support.

15501 9-35990

F9184
 FA6-1-58

FRONT-END ATTACHMENTS WX90

3 Untighten fixing screw and push out pin.

F9184

Triple articulation version (02)

1 Hoist arm.

Positioning cylinder removal

- See "Positioning cylinder removal"

paragraph 1.7.1.

F9123

Positioning arm removal

1 Disconnect cylinder control hoses.

Plug both disconnected hoses sides to let
dirt out.

F9185

2 Untighten lock nut and push out pin.

15501 9-35990

F9186
 FA6-1-59

FRONT-END ATTACHMENTS WX90

Lifting cylinder removal

- See "Lifting cylinder removal" paragraph

1.7.1.

Offset digging version (03)

Penetration cylinder removal

- See "Penetration cylinder removal"

paragraph 1.7.1.

Link rod removal

1 Hoist link rod.

F9187

2 Untighten fixing screws and push out pins.

15501 9-35990

F9188
 FA6-1-60

FRONT-END ATTACHMENTS WX90

Articulation removal

1 Hoist articulation.

F9189

2 Disconnect cylinder control hoses.

Plug both disconnected hoses sides to let
dirt out.

F9190

3 Untighten lock nut and push out pin.

F9191

Positioning cylinder removal

- See "Positioning cylinder removal"

paragraph 1.7.1.
15501 9-35990
 FA6-1-61

FRONT-END ATTACHMENTS WX90

Second element removal

1 Hoist the second element.

F9192

2 Disconnect cylinder control hoses.

Plug both disconnected hoses sides to let
dirt out.

F9193

3 Untighten lock nut and push out pin.

F9194

Lifting cylinder removal

- See "Lifting cylinder removal" paragraph

1.7.1.
15501 9-35990
 FA6-1-62

FRONT-END ATTACHMENTS WX90

NOTES:

15501 9-35990
 OPERATIONAL PRINCIPLE CY6-2-1
(O/P)
HYDRAULIC CYLINDERS WX90

2. HYDRAULIC CYLINDERS

2.1 CONSTRUCTION AND FUNCTION

The cylinders have linear motion and transfer forces.

The maximum force developped by the cylinder depends on the useful surface and on the maximum
operating pressure:

F=pxA Force = pressure x surface

This is constant from the start to the end of stroke.

The speed depends on oil capacity and surface.
The rams can operate in push or traction.
They can transfer force in both directions.
When supplying the cylinder from A side, the rod comes out, when supplying from B side, the rod comes in.
The maximum forces depend on the relative useful surfaces and on the maximum operating pressure. They
are bigger when the piston comes out than when it returns.
Return and roll-out speeds are different with respect to the surfaces.
The rams have welded bottom and bolted or screwed head.
They have been designed for 350 bar operating pressures.
The cylinder is essentially made up of a bottom (1), a head (2), a piston (3) a rod (4). The head is secured
to the cylinder by means of screws (9) or screwed according to the version. The piston is tightenen and
fastened to the rod. A seal (6) is located between piston and cylinder. Outer seal is obtained by means of road
seals (7) and head seal (8). The ram fixing system is obtained by connections with tempered steel bushings.
An operation without "stick-slip" is possible with minimal speeds and low pressure thanks to the seals used
and the surface quality of the cylindrical body, rod and relative guide.
This has been taken into account in the design of these rams.

N° 1 For boom lifting

N° 1 For dispstick operation
N° 1 For bucket operation
N° 1 Form arm angle operation
N° 2 For dozing blade operation
N° 2 Axle lock
N° 1 Steering
N° 2 For arm articulation operation
15501 9-35990
OPERATIONAL PRINCIPLE CY6-2-2
(O/P)
HYDRAULIC CYLINDERS WX90

Features

Cylinder dimensions

Penetration Blade/ Articulated Axle Steering

Description Lifting * Bucket Angle
arm Stabilizers arm lock ** **

Fully
mm 1160 1160 1100 1120 500 925 100 -
closed

Stroke mm 750 750 750 550 200 610 - 120

Fully
mm 1910 1910 1850 1670 700 1910 - -
open
Inner
mm 100 100 70 100 80 70 74 90
diameter
Rod
mm 65 65 50 65 56 40 70 45
diameter
Bottom GAS
1/2 1/2 1/2 1/2 3/8 1/2 3/8 -
connection BSPP
Head
' 1/2 1/2 1/2 1/2 3/8 1/2 - -
connection

Weight Kg - - - - - - 20 -

TF0028Agb

Tightening torques

Penetration Blade/ Articulated Axle Steering

Description Lifting * Bucket Angle
arm Stabilizers arm lock ** **
HEAD
SCREW
Nm 219÷242 219÷242 219÷242 219÷242 219÷242 219÷242 219÷242 -
tightening
torque
HEAD
tightening Nm - - - - 200÷240 - - 140÷180
torque
PISTON
tightening Nm 710÷830 710÷830 710÷830 710÷830 1250 710÷830 - -
torque
PISTON
DOWEL
Nm 35÷45 35÷45 35÷45 35÷45 - 35÷45 - -
tightening
torque
TF0029Agb
15501 9-35990

* Lifting ram and penetration arm ram are equal.

** Axle lock ram and steering ram do not follow the construction of the illustrations.

TIGHTENING TORQUE VALUES ARE APPLIED WITH GREASE:

TUTELA MR2 SPECIFICATION NLFI2.
 OPERATIONAL PRINCIPLE CY6-2-3
(O/P)
HYDRAULIC CYLINDERS WX90

7 9 2 8 4 1 5 3 6
A

CYLINDER WITH BRAKE AND BOLTED HEAD

7 2 8 4 1 5 3 6
A

CYLINDER WITH BRAKE AND SCREWED HEAD

7 2 8 4 1 3 6
A

F0835F

CYLINDER WITH SCREWED HEAD

15501 9-35990

Fig. 1

1- Cylinder with bottom 6 - Piston seals

2- Head 7 - Rod seals
3 - Piston 8 - Head seals
4 - Rod 9 - Fixing screws
5 - Brake plate
OPERATIONAL PRINCIPLE CY6-2-4
(O/P)
HYDRAULIC CYLINDERS WX90

NOTES:

15501 9-35990
 DISASSEMBLY AND ASSEMBLY CY6-2-1
(D/A)
HYDRAULIC CYLINDERS WX90

2.1 CYLINDER DISASSEMBLY - ASSEMBLY

2.1.1 DISASSEMBLY

NOTE: Before disassembly, throughly clean the

outside of the cylinder.

1 Fasten the cylinder assembly on the

workbench.
002/67

2 Fully extend rod (02) and support the weight

of the rod with a hoist. Remove eight socket 02 04 03
bolts (04) from head (03).

003-67

3 Tap the head out of the cylinder using a soft

hammer.

004/67

4 Pull the rod assembly out of the cylinder (01).

02 01
15501 9-35990

005-67
DISASSEMBLY AND ASSEMBLY CY6-2-2
(D/A)
HYDRAULIC CYLINDERS WX90

5 Remove corn (21) from the piston nut (20).

21

20

006-67

6 Fasten the rod assembly on the workbench.

007/67

7 Loosen piston (20).

68 Foto 8/37

8 Pull piston (18) out of the rod.

18
15501 9-35990

009-67
 DISASSEMBLY AND ASSEMBLY CY6-2-3
(D/A)
HYDRAULIC CYLINDERS WX90

9 Remove guide rings (15, 16) and seal from

piston.
16 15

010-67

10 Remove head from (03) rpd.

03

11 Remove seals (09).

09

012-67

2.1.2 INSPECTION

1 Check the surfaces of piston and head for

damage or score. If repared leaks occur, care
particularly attention to score or wear on the
seal lips.
15501 9-35990

When assembling cylinder, change wearing

parts such as: wiper, oil seals, slide ring, O-
rings and backup rings.
100/67
DISASSEMBLY AND ASSEMBLY CY6-2-4
(D/A)
HYDRAULIC CYLINDERS WX90

2 Check the grooves and lands on piston and

head are clear and free from nicks or burrs.

Examine the sliding surface of bushing. If

there is any damage: change bushing.

101/67

3 Check the threads of rod and nut for damage

or fault. Light damage may be repaired using
a file or a lathe.
If damaged excessively the part should be
renewed.

102/67

4 Examine bent of the rod.

Place the rod on the V-blocks and set a
gauge, rotate rod to measure bent of rod. If
bent is excessive the rod should be renewed.

Bent limit: 0.5 mm per 1.0 m length.

103/67

5 Check the surfaces of rod and cylinder boar

for scores, scratches and wear. If score or
wear is excessive, the part should be
renewed.

Max. score depth: 0,1 mm

15501 9-35990

Wear limit: 0,2 mm

104/67
 DISASSEMBLY AND ASSEMBLY CY6-2-5
(D/A)
HYDRAULIC CYLINDERS WX90

2.1.3 ASSEMBLY

Note: Before assembly, clean all the inner

parts with hydraulic oil and dry them with
compressed air. No foreign matter should
remain in the cylinder.

14
1 Install gasket (14) on piston (18) with the 18
shown tools.
105-67

2 Install slide rings (15) and slide rings (16).

Stagger ring gaps on the piston as shown in

the figure. 16
15
15
16

106-67

3 Put hydraulic oil on outside of piston. Press

the piston into "correction guide" to shrink
the seals to the original size.

107/67

4 Press bushing (10) in hole of head (03) with

tool and install retaining ring.
10 03
15501 9-35990

108-67
DISASSEMBLY AND ASSEMBLY CY6-2-6
(D/A)
HYDRAULIC CYLINDERS WX90

5 Install gaskets (09) with the lip toward

cylinder inside.

9 109-67

6 Install wiper with the lip toward the cylinder

outside.
Use press and tool.

110/67

7 Install backup ring (12) and O-ring (13).

Put hydraulic oil on the O-ring and the seals 13
in head.

12
111-67

8 Place the rod (02) on the workbench.

Install head (03) onto the rod.
03

02
15501 9-35990

112-67
 DISASSEMBLY AND ASSEMBLY CY6-2-7
(D/A)
HYDRAULIC CYLINDERS WX90

9 Insert piston (18) onto the rod. 18

113-67

10 Tighten piston (see chart).

21

11 Tighten the nut with the screw (21) (see chart).

114-67

12 Lock the threaded hole on two points with a

hammer and a punch.

115/67

13 Hoist rod assembly (02) and keep it

horizontally.
02 20
Put hydraulic oil on piston (20) and bore of
cylinder.
15501 9-35990

116-67
DISASSEMBLY AND ASSEMBLY CY6-2-8
(D/A)
HYDRAULIC CYLINDERS WX90

14 Enter the piston (20) into cylinder (01)

aligning rod center with bore center. 20 01
Be carefull not to damage the piston seals.

117-67

15 Install head (03) with eight socket bolts (04).

03
Tightening torque (see chart). 04

118-67

15501 9-35990
 FRONT-END ATTACHMENTS FA6-3-1
PINS AND BUSHINGS WX90

3. PINS AND BUSHINGS

3.1 SPECIFICATIONS

3.1.1 PINS AND BUSHINGS

D R V B

L N M

E
F
G
S

C
H I
J J
K

F13265
Fig. 2

Mark Measuring part Clearance between pin and bushing

Nominal clearance mm Maximal clearance x 10mm
A Boom articulation 0.294 ÷ 0.100 1.30

B Ram rod connection 0.294 ÷ 0.100 1.30

C Ram connection 0.294 ÷ 0.100 1.30

D Dipstick articulation 0.294 ÷ 0.100 1.30

E Ram rod connection 0.294 ÷ 0.100 1.30

F Ram connection 0.294 ÷ 0.100 1.30

G Ram connection 0.242 ÷ 0.080 1.2

H Ram rod connection 0.242 ÷ 0.080 1.2

I Linkage articulation 0.242 ÷ 0.080 1.2

J Link rod articulation 0.242 ÷ 0.080 1.2
15501 9-35990

K Bucket articulation 0.242 ÷ 0.080 1.2

L Swing articulation 0.294 ÷ 0.100 1.4

M Ram connection 0.294 ÷ 0.100 1.30

N Ram rod connection 0.294 ÷ 0.100 1.30

WARNING: When using a hammer, some chips can be thrown away. Protect yourself.
WARNING: When disconnecting circuits, oil can flow out. As it is polluting, do not disperse them.
FRONT-END ATTACHMENTS FA6-3-2
PINS AND BUSHINGS WX90

NOTES:

15501 9-35990
 INDEX WX90 - 7 - 1

WX90

SECTION 7 HYDRAULIC SYSTEM

INDEX

Group 1 - GENERALITIES ......................................................................................... HS7-1-1

Group 2 - MAIN HYDRAULIC SYSTEM ..................................................................... HS7-2-1

2.1 Generalities
2.2 Suction circuit and delivery circuit
2.3 Return circuit
2.4 Drainage circuit

Group 3 - PILOT/BRAKES SYSTEM ......................................................................... HS7-3-1

3.1 Generalities
3.2 Suction cylinder

Group 4 - STEERING SYSTEM.................................................................................. HS7-4-1

4.1 Generalities
4.2 Steering circuit

Group 5 - BRAKES SYSTEM ..................................................................................... HS7-5-1

5.1 Generalities
5.2 Description of brakes system
5.3 Operation of brake pedal valve

Group 6 - OPERATION OF CIRCUITS ....................................................................... HS7-6-1

6.1 Generalities
6.2 Circuit with controls in neutral
6.3 Boom circuit
6.4 Dipper stick circuit
6.5 Bucket circuit
15501 9-35990

6.6 Positioner arm circuit

6.7 Travel circuit
6.8 Arm angle circuit
6.9 Stabilizer/blade control circuit
6.10 Hydraulic hammer/shrub cutter circuit
6.11 Turret swing circuit

(to be continued)
 INDEX WX90 - 7 - 2
INDEX (continued)

Group 7 - TRAVEL CIRCUIT ...................................................................................... HS7-7-1

7.1 Description
7.2 Travel hydraulic motor control circuit
7.3 Parking brake control circuit

Group 8 - HYDRAULIC SYSTEM DIAGRAM ......................................................... HS7-8- 1/2

15501 9-35990
 HS7-1-1

HYDRAULIC SYSTEM WX90

1. GENERALITIES

The hydraulic system includes the MAIN HYDRAULIC CIRCUIT, the PILOT AND BRAKES CIRCUIT and the
HYDRAULIC STEERING CIRCUIT.

The main hydraulic circuit is used to send hydraulic power to the actuators and the motors.

The pilot and brakes circuit is used to control all the functions of the control valve, thus driving the actuators
and the motors.
Moreover, the pilot and brakes hydraulic circuit actuates the brake pistons on the front and rear axle, through
the brake pedal control.

The steering hydraulic circuit is used to control the steering system through the power steering valve actuated
by the steering column.

The hydraulic system includes a main pump and a secondary pump, both of a variable displacement type,
engine driven through an elastic coupling, and a gear double fixed displacement pump for the pilot, brakes
and steering system driven by diesel engine timing control.
The hydraulic oil delivered by the main pump flows through the body of main control valve to the dipper stick
cylinder, the boom cylinders, the bucket cylinder, the positioning cylinder, the angle cylinder, the blade/
stabilizer cylinders and the travel motor.
The hydraulic oil delivered by the secondary pump flows, through the body of rotation control valve to the turret
swing motor.
The hydraulic oil delivered by the pilot and brakes pump, after going through an oil filter, feeds the brakes
system valve, then, through the priority valve, feeds, with a constant flow priority line, the service solenoid
valves group, the user solenoid valves, the control levers, the pedals and then the control valve.
The secondary pilot line feeds the rotation circuit of the clam bucket.
The hydraulic oil delivered by the steering pump feeds the power steering valve, that through the movement
of the steering column, drives the steering cylinder.
15501 9-35990
 HS7-1-2

HYDRAULIC SYSTEM WX90

NOTES:

15501 9-35990
 HS7-2-1

MAIN HYDRAULIC SYSTEM WX90

2. MAIN HYDRAULIC SYSTEM

2.1 GENERALITIES

The main hydraulic system includes a suction circuit, a delivery circuit, a return circuit and a drainage circuit.

The main system includes a main pump and a secondary pump.

The main pump feeds the main control valve, the travel hydraulic motor, the dipper stick cylinder, the boom
cylinder, the positioner cylinders and the bucket cylinder, the angle cylinder, the blade/stabilizer cylinders.
The secondary pump feeds, through the left body of the control valve the turret swing motor and the blade/
side stabiliser control.

The main and secondary pumps are of a variable displacement, axial pistons type and are tandem mounted
and connected to the engine by an elastic coupling.
The hydraulic oil delivered by the main and secondary pumps flows to the control valve controlling the various
hydraulic functions, regulating the delivery to the various actuators (cylinders and motors); the hydraulic oil
returning from the actuators, through the control valve, is sent to the oil radiator, where it is cooled and then
returned to the hydraulic reservoir through a total flow filter.
15501 9-35990
 HS7-2-2

MAIN HYDRAULIC SYSTEM WX90

2.2 SUCTION CIRCUIT AND DELIVERY CIRCUIT

The main pump sucks the hydraulic oil from the reservoir.
The delivery of the main pump reaches the main control valve whereas the delivery of the secondary pump
reaches the rotation control valve.

1 - Reservoir
3 - Secondary pump
4 - Main pump
5 - To engine
6 - Main control valve
8 - Rotation control valve 6
9 - To oil radiator T

3 4

5
15501 9-35990

F8831
 HS7-2-3

MAIN HYDRAULIC SYSTEM WX90

F8832

1 - Reservoir
15501 9-35990

3 - Secondary pump
4 - Main pump
6 - Main control valve
8 - Rotation control valve
9 - Oil radiator
 HS7-2-4

MAIN HYDRAULIC SYSTEM WX90

2.2.1 DELIVERY PRESSURE CONTROL

The control of the maximum pressure of the hydraulic circuit of the main pump is provided by two valves
mounted on the main control valve inlet section.
a) The max. pressure relief valve set at 330 bar, limits the line pressure by working on the pilot signal of
pump (LS). The pump provides only the quantity of oil required by the actuators.
b) The safety valve set at 370 bar, limits the line pressure discharging the oil flow delivered by the pump.
This valve works only in case the max. pressure relief valve (a) fails to operate.

The max. pressure regulation of the hydraulic circuit of the secondary pump is provided by a max. pressure
relief valve set at 330 bar mounted on the rotation control valve, operating in case the pressure regulator (cut-
off valve) mounted on the pump, set at 310 bar, fails to work.

2.2.2 SECONDARY PUMP DELIVERY REGULATION

When rotationcontrol valve has the spool in neutral position, and the motor is rotating (see fig. 2), the pump
works in max. displacement condition and the oil reaches the open center rotation control valve (M8), goes
through it and, passed the 3.5 bar single direction valve, reaches the oil radiator, is cooled and returns to the
reservoir.
Under low temperature conditions (high oil viscosity) or clogging of the oil cooler, the return oil exceeds the
pressure of 5 bar, actuating the by-pass valve allowing the hydraulic oil to flow directly toward the reservoir,
thus avoiding the radiator.
Under these conditions, the spring on the counter piston prevails over the swash control piston, keeping the
pump in max. displacement.

The chamber of the pump swashplate control cylinder is connected to the reservoir through pipe L. Under
working conditions (control valve spool moved from neutral position) on actuators requiring a pressure below
the beginning of regulation (a, fig. 1), the regulation occurs by a choking of the pilot valve. The control of the
delivery is only obtained by the movement of the control valve spool regulating the flow, thus changing the
speed of the movement.
If the load of the actuator requires a pressure higher than Pa, (fig. 1) the power regulation valve (4) intervenes,
with the consequent reduction of the speed of the actuator.
Beyond point (a), the power regulation valve (4) presses the setting valve; the pilot line generates a pressure
drop on the ø 0.8 mm restriction and the displacement regulation valve (1), in absence of the piloting pressure
in addition to the pre-load of the spring, moves to the right (see fig. 3) opening the duct to the swashplate control
piston (3) that with its movement reduces the displacement of the pump and changes the setting of power
regulation valve (4) until a new equilibrium point is found.
If the load of the actuator continues to change, the displacement regulation valve (1) continues to modulate
searching for a point of equilibrium.
When a 310 bar pressure is reached on the operating line, the cut-off valve intervenes (see fig.4).

When the spool of the cut-off valve moves, the displacement regulation valve (1) is intercepted and any further
load increase has no effect on the regulation, but the secondary pump will take an angle ensuring that the
pressure in the line is maintained compensating also eventual leakages in the circuit. Thus, the intervention
of the cut-off circuit limits the max. delivery pressure at 310 bar.
The secondary pump sends, during its operation, a Cross Sensing signal proportional with the load applied
to the secondary pump.
This signal generated by the secondary pump is sent to inlet Z of the main pump and allows the regulation
of the displacement of the main pump as a function of the load on the secondary pump, giving priority to the
15501 9-35990

latter in case of combined operation.

This Cross Sensing device has the purpose of avoiding, in case of combined operations, that the addition of
the powers required by the actuators does not exceed the power that can be provided by the engine.
 HS7-2-5

MAIN HYDRAULIC SYSTEM WX90

CROSS P2
P
SENSING

MB B 1
X
Ø 0.8
b
Pressione
Pressure

(1)

CUT-OFF: 310 bar

Pa a
(2)

Q
0 Portata
Delivery (4) (3)

Fig. 1 Secondary pump P - Q curve

a) beginning of regulation intervention
b) cut-off intervention
(5)
Q max Q min.
S L1 L

F9341

(1) Delivery regulation valve

(2) CUT-OFF valve (DR) Fig. 2 Operation of secondary pump
(3) Swashplate control piston under minimum load condition
(4) Power controlling valve
(5) Counter piston

CROSS P2 P2
CROSS
SENSING
SENSING
MB B 1 MB B 1
X X
Ø 0.8 Ø 0.8

(1) (1)

CUT-OFF: 310 bar CUT-OFF: 310 bar

(2) (2)

(4)

(4) (3) (3)

15501 9-35990

(5) (5)
Q max Q min. Q max Q min.

S L1 L S L1 L

F9342 F9343

Fig. 3 Operation of secondary pump with Fig. 4 Operation of secondary pump

intervention of regulator with CUT-OFF intervention
 HS7-2-6

MAIN HYDRAULIC SYSTEM WX90

2.2.3 REGULATION OF MAIN PUMP DISPLACEMENT

With the spools of the main control valve (operation at closed center) in neutral position (see fig.6), without
a load demand, the pump is positioned with the swashplate on minimum displacement. This occurs when the
pilot pressure derived from the delivery line, is sent to Load Sensing valve (1), that, overcoming the load of
the spring, moves the plunger of valve LS (1), connecting the pilot line with the swashplate control piston (5).
Under these conditions, the pump is positioned at minimum displacement.

If by intervening on a pilot valve the operator moves a spool, the main line opens and a pressure drop occurs,
operating the Load Sensing valve (1) moved by the spring.
This intercepts the swashplate control piston operating line and the pump will tend to move toward max.
displacement.
The equilibrium point is reached when between line P1 and line LS a pressure differential DP of 18 bar is
established.
With reference to figure 5, the pump displacement regulation between point 0 and point a, is controlled by the
operator (in practice, the whole delivery of the pump reaches the actuators) and the equilibrium position of
the pump swashplate is obtained when the pressure differential DP between line P1 and LS generated when
the hydraulic oil flow passes through the control valve spools equals 18 bar. The operating speed of the
actuators between point 0 and point a is controlled by the operator and is proportional to the movement of the
pilot valve.
If point a is exceeded, the operating speed of the actuators will depend on the load power required only and
not on the position of the pilot valve.
From point a to point b of the curve, the pump displacement will be reduced according to the power required
by the load through the operation of the power regulation valve (2).

Under regulating conditions, if the rotation hydraulic motor fed by the secondary pump is actuated at the same
time, the pump, as soon as the regulator intervenes, sends a Cross Sensing signal (monitoring the load
applied) to the main pump (inlet Z) in addition to the movement of the displacement regulation valve.
The intervention of the Cross Sensing valve on the main pump applied to the swashplate control piston (5)
changes the angle of the pump swashplate toward maximum displacement (see fig. 8).

Consequently, the effect of a load applied to the secondary pump is reflected also on the main pump.
In practice, to each load increase on the secondary pump, the displacement of the main pump is reduced
accordingly, so that the load on the engine stays even.

15501 9-35990
 HS7-2-7

MAIN HYDRAULIC SYSTEM WX90

LS
M B G P R T1 T2 X

b
(6)
(1)
Pressione

x
Pressure

P=18 bar

c
a
(2)

0 (3)
Q

<
Delivery
Portata DIESEL
MOTORE (4)

<
ENGINE
DIESEL Q max Q min.

Fig . 5 Main pump P - Q curve

(5)
a) beginning of regulation intervention
b) beginning of pressure cut relief valve (on
control valve)
F9344
c) reduction of displacement of main pump S M1
caused by Cross Sensing
Fig. 6 Operation of main pump under
no load conditions

(1) Load Sensing valve

(2) Power regulation valve
(3) Cross Sensing valve
(4) Counter piston
(5) Swashplate control piston
(6) Piloting pressure
CROSS SENSING LS
M B G P R T1 T2 X
LS
M B G P R T1 T2 X (6)
(1)
(6)
(1)
x
x P=18 bar

P=18 bar

(2)
(2)
(3)
(3)
<

MOTORE (4)
<

DIESEL DIESEL
<

MOTORE (4) DIESEL

<

ENGINE ENGINE Q max Q min.

DIESEL Q max Q min.

(5)
(5)
15501 9-35990

F9346 F9345
S M1 S M1

Fig. 7 Operation of main pump under condition Fig. 8 Operation of main pump under load
of power regulation intervention condition and intervention of cross
sensing
 HS7-2-8

MAIN HYDRAULIC SYSTEM WX90

2.3 RETURN CIRCUIT

The oil of the actuators operated by the main pump through the control valve and the oil of the rotation
operated by the secondary pump through the control valve, reach the hydraulic reservoir through a return
circuit equipped with two pressure relief valves with different settings.

The pressure setting of the pressurisation and check valve (9) is 3.5 bar, whereas the safety and by-pass
valve (thermostat function) is set at 5 bar.

The oil returns to the hydraulic reservoir, through the pressurisation and check valve (9) and the oil radiator,
where it is adequately cooled.

When the oil temperature is low, the relative viscosity increases, with a subsequent higher resistance to the
flow through the radiator. If the oil pressure exceeds 5 bar, both for high oil viscosity (thermostatic valve
function) and the eventual clogging of the radiator, the oil returns directly to the reservoir, by-passing the
radiator.

The hydraulic reservoir contains a total flow oil filter, capturing eventual dirt in the return oil coming from the
actuators.

10 10

9
3.5 bar

7
8

5 bar
5

2
1 - Hydraulic reservoir
2 - Oil radiator
3 - Total flow filter 1
4 - By-pass valve
5 - Radiator safety and by-pass
valve
7 - Main control valve
8 - Rotation control valve 4
9 - Pressurisation and check
valve
15501 9-35990

1.5 bar
10 - Actuators

3
F8834
 HS7-2-9

MAIN HYDRAULIC SYSTEM WX90

1
5
8

F8835

1 - Hydraulic reservoir
15501 9-35990

2 - Oil radiator
5 - Radiator safety and by-pass
valve
7 - Main control valve
8 - Rotation control valve
9 - Pressurisation and check
valve
 HS7-2-10

MAIN HYDRAULIC SYSTEM WX90

2.4 DRAINAGE CIRCUIT

Since internal leakages occur in the hydraulic motors, an oil drainage circuit is mounted sending the leaking
hydraulic oil to the reservoir.

Travel motor drainage circuit

The oil leaking from the travel motor flows out the drainage and, through a pipe crosses the center joint, and
returns to the drainage oil of swing hydraulic motor.

Swing motor drainage circuit

The drainage oil of the swing motor, returns to the hydraulic reservoir through a hose.

Pumps drainage circuit

Both main pump and the secondary pump have a drainage hose connected directly with the hydraulic
reservoir.

4 1
T1

6
L
3
5

F8729
15501 9-35990

1 - Travel motor
2 - Hydraulic reservoir
3 - Swing motor
4 - Main pump
5 - Secondary pump
6 - Center joint
 HS7-2-11

MAIN HYDRAULIC SYSTEM WX90

F8836

5 4
15501 9-35990

1 - Travel motor
2 - Hydraulic reservoir
3 - Swing motor
4 - Main pump
5 - Secondary pump
6 - Center joint
 HS7-2-12

MAIN HYDRAULIC SYSTEM WX90

NOTES:

15501 9-35990
 HS7-3-1

PILOT/BRAKES SYSTEM WX90

3. PILOT/BRAKES SYSTEM

3.1 GENERALITIES

The pilot/brakes hydraulic circuit includes a gear pump, a priority valve, a pressure relief valve set at 45 bar,
a service solenoid valve group allowing the feeding to the pilot valves, pedal pilot valves and various circuits.

The hydraulic oil feeds the following circuits:

a) The front and rear axle brakes system through a brakes valve.

b) The manual and pedal pilot valves actuating the various control valve spools.

c) The functions of the service solenoid valve group.

d) The rotary bucket control.

e) The functions of the selection solenoid valve group.

3.2 SUCTION CYLINDER

The pilot hydraulic pump (2), tandem mounted with the power steering pump, is fitted into the special diesel
engine power take-off.
The pump sucks the oil directly from the reservoir (1) and sends it to the braking system (2), after passing
through the delivery filter (3).
The priority valve at braking system inlet charges the braking system accumulator and then sends the hydraulic
oil to the power control valve. This valve included a block containing a priority flow divider (supplied by
clamshell bucket rotation), a pressure relief valve (45 bar), an accumulator keeping the pressure even if the
diesel engine is stopped, a solenoid valve cutting pressure line off.
From the power control valve, the oil reaches the pilot valves and service/selection solenoid valves.
The exceeding oil of the priority valve supplies the clamshell bucket rotation valve.
15501 9-35990
 HS7-3-2

PILOT/BRAKES SYSTEM WX90

3.2.1 PILOT/BRAKES HYDRAULIC SYSTEM BLOCK TYPE DIAGRAM

1 Hydraulic reservoir
2 Pilot system and brakes pump
3 Filter
4 Brake valve
5 Brake system accumulators
6 Brake circuit to front axle
7 Brake circuit to rear axle
8 Power control/diverter valve
9 Power control accumulator
10 Clamshell bucket rotation circuit
11 Service solenoid valve group
12 Selection solenoid valve group
13 Pedal power control
14 Right hand pilot valve
15 Left hand pilot valve
16 Main control valve
17 Rotation control valve
18 Service circuits

15501 9-35990
 HS7-3-3

PILOT/BRAKES
PILOT SYSTEM/BRAKES HYDRAULICSYSTEM
SYSTEMWX90
BLOCK DIAGRAM WX90

F8730
15

17
12
14
13

16
7
6

10
5

11
5
5

8
3

18
2
15501 9-35990

1
 HS7-3-4

PILOT/BRAKES SYSTEM WX90

3.2.2 SERVICES SOLENOID VALVES GROUP

The services solenoid valves group, mounted on a single block, feed the following systems:

- Solenoid valve A1 Two way, two position solenoid valve, normally closed. It
parking brake feeds the pedal controlling the travel or positioning arm
depending upon the rest or energised condition of solenoid
valve. This solenoid valve is energised by the braking mode
switch. In these conditions the parking brake intercepts the
possibility of controlling the travel function.

- Solenoid valve A2
stabilizer 1a travel speed
Three way, two position solenoid valve, normally closed.
When energised, it sends the piloting oil to the regulator of
the travel hydraulic motor, to keep it in max. displacement.
When the solenoid valve is in rest position, the regulator is
connected to the reservoir (hydraulic motor free to change
its displacement).
The same solenoid valve allows the operation of the blade/
side stabilisers.

- Solenoid valve A3 Three way, two position solenoid valve, normally closed.
axle lock When energised, it moves to open position and allows the
oil of the system to pilot the front axle lock valve. In rest
conditions, it cuts the hydraulic circuit and, consequently,
the axle lock valve, normally closed, intercepts the hydraulic
connection between the two lock cylinders.

- Solenoid valve A4-A5 Six way, three position solenoid valve, normally closed.
hyraulic hammer/grass-cutter When actuated, it sends pilot oil to the hammer/grass-cutter
valve.

- Solenoid valve A6-A7 Six way, three position solenoid valve, normally closed.
mechanical tranmission When actuated, it sends pilot oil to the transmission control
cylinder (tortoise), (hare).

- Solenoid valve A8 Four way, thwo position solenoid valve, normally closed.
3 rd hydraulic speeds When actuated, it sends pilot oil also to the second travel
spool of the main control valve, 3 rd speed.
15501 9-35990
 HS7-3-5

PILOT/BRAKES SYSTEM WX90

3.2.3 SELECTION SOLENOID VALVES GROUP

The selection solenoid valves group, mounted on a single block, feed the following systems:

- Solenoid valve B1-B2 Four way, two position solenoid valve, normally open.
penetration/blade-stabilizers When actuated, it sends left hand pilot oil to the spool
controlling the blade/stabilizer cylinders. In rest conditions it
sends oil to the spool controlling the penetration cylinder.

- Solenoid valve B5-B6 Four way, two position solenoid valve, normally open.
rotation/angle When actuated, it sends left hand pilot oil to the spool
controlling the arm angle cylinder. In rest conditions it sends
oil to the spool controlling the superstructure swing hydraulic
motor.

- Solenoid valve B3-B4 Four way, two position solenoid valve, normally open.
travel/positioner When actuated, it sends pedal pilot oil to the spool controlling
the positioner cylinder. In rest conditions it sends oil to the
spool controlling the travel hydraulic motor.
15501 9-35990
 HS7-3-6

PILOT/BRAKES SYSTEM WX90

3.2.4 PILOT SYSTEM ACCUMULATOR

The membrane type accumulator for the pilot system has the purpose of allowing a certain quantity of
actuations with engine inoperative. The membrane accumulator is made of a pressure resistant steel
container, having, inside, a membrane made of elastic material as separation element. The membrane is
locked by a ring nut between the lower and higher side of the body. In the central lower part of the membrane,
a metallic disc is incorporated, to prevent its exit through the fluid inlet port.
The accumulator is filled, from its upper part, by a nitrogen pre-load at 13 bar, whereas the lower part is
connected to the pilot hydraulic system, after a check valve.
Without hydraulic pressure, the membrane, loaded on the gas side at the pre-load pressure, is leaning against
the inner surface of the accumulator and the mushroom closing the fluid passage.
When piloting hydraulic pressure is applied, once it exceeds the pre-load pressure, the mushroom is lifted
and hydraulic oil enters the accumulator, pressurising the nitrogen.
The useful quantity of oil results from the difference between the gas volume and the minimum and maximum
operating pressure.

1 - Gas valve
2 - Container
3 - Membrane
4 - Valve mushroom
5 - Oil side connection
15501 9-35990
 HS7-3-7

PILOT/BRAKES SYSTEM WX90

3.2.5 PILOT SYSTEM

A To front axle brake

B To rear axle brake
1 Diesel engine
3 Pumps
10 Pilot valve oil filter
16 Single lever hand pilot valve
17 Travel control pedal
18 Brake system accumulators
21 Solenoid valve lock
22 Stop lights pressure switch
23 Service solenoid valves
24 Brake system valve
44 Priority valve for control supply
47 Delivery and drain block
15501 9-35990
 23

20 43

47
18
24

44
B
22
A
10

21 3
1
PILOT/BRAKES SYSTEM WX90

16 16 17

F8862
HS7-3-8

15501 9-35990
 HS7-4-1

STEERING SYSTEM WX90

4. STEERING SYSTEM

4.1 GENERALITIES

The steering hydraulic system includes a gear type pump, a power steering valve and two steering cylinders.

The hydraulic oil flows from the steering pump to the power steering valve. It selects the steering type solenoid
valve and, through the center joint, operates the steering control cylinders.
The oil will actuate on the right or left side of the piston, depending upon the rotation direction given to the
steering wheel.

STEERING SYSTEM BLOCK TYPE DIAGRAM

3 12

13

6
11

1 4 7 8 9 10

11
15501 9-35990

F8863

1 - Oil reservoir 9 - Power steering control valve

4 - Steering pump 10 - Anticavitation valve
5 - Rotary joint 11 - Shockless valve
7 - Check valve 13 - Steering wheel
8 - Safety and pressure relief valve
 HS7-4-2

STEERING SYSTEM WX90

4.2 STEERING CIRCUIT

The steering pump sucks the oil from the hydraulic reservoir and sends it directly to inlet (P) of the power
steering valve. It crosses the single direction valve (14).
The pressure of the hydraulic oil, at the inlet of the power steering valve, is regulated by a pressure relief valve
set at 140 +5-0 bar, then, through a check valve, reaches the power steering control valve, driven by the steering
wheel.
With the steering wheel standing still, the power steering control valve is in neutral position and the piloting
oil can flow to the return (passage from inlet P through T). Under these conditions, in case of shocks on the
wheels, the latter are absorbed by the shockless valves (set at 200 +20 -0 bar) and are not transferred to the
steering wheel. Moreover, two anticavitation valves avoid that cavitation phenomena are created in the
steering cylinder chambers.
When turning the steering wheel, the movement is transferred to the control valve, that opens gradually the
ducts to the cylinder lines, while the neutral ducts are closed.
As a consequence of the turning of the steering wheel and the rotation of the control valve, the passage of
a volume of oil occurs, directly proportionate to the angle movement of the steering wheel and producing the
angular movement of the direction wheels.
A follow-up system ensures that the ducts are closed when the movement of the control valve coincides with
that of the steering wheel.
On the machine are fitted two steering axles with the consequent steering cylinders which allow three different
steering points according to the solenoid valve position (see diagram).
If the solenoid valve (2) is not activated, the front axle is steering and the oil present in the non pressurised
chamber of the steering cylinder is controlled by the same control valve that is connected with discharge (T)
thus, with the reservoir and, at the same time, with the pressurised oil.

If the solenoid valve (2) is activated in one direction or the other, the two steering cylinders are connected
in series and the delivery oil enters the chamber of one cylinder and returns to the power steering and to the
reservoir of the chamber of the other cylinder.

15501 9-35990
 HS7-4-3

STEERING SYSTEM WX90

P
T
6 7
8

140 +5 bar

at 5 l/min.
-0
12

10 10

3
11 11
200 +20 bar

at 1 l/min.
-0

1 - Oil reservoir
5 2 - Steering type solenoid valve
3 - Rear steering cylinder
R 4 - Steering pump
L
5 - Central joint
6 - Power steering valve assembly
7 - Check valve
15501 9-35990

8 - Safety and pressure relief valve

2 9 - Power steering control valve
10 - Anticavitation valves
11 - Shockless valves
12 - Front steering cylinder
F8864
 HS7-4-4

STEERING SYSTEM WX90

NOTES:

15501 9-35990
 HS7-5-1

BRAKES SYSTEM WX90

5. BRAKES SYSTEM

5.1 GENERALITIES

The brakes system (please refer to the figure of page 2) is made of a pedal brake group (9), three
accumulators (11) two pressure switches (10) (12), a pressure transducer (14), brakes on the front (1) and
rear (2) axles.

5.2 DESCRIPTION OF BRAKES SYSTEM

The pilot system and brakes pump (5) driven by the diesel engine, sends the hydraulic oil through the pilot
system filter (8) to brake pedal group (9) integrated by 3 accumulators (11).
By pushing the pedal in the cab, that is an integral part of the brake group, the oil trapped by the accumulators
is gradually sent to the pistons of the brakes on the front and rear axles.
The travel of the oil from the brake group to the service brake pistons on the axles occurs through separate
circuits for the rear and front axles; each circuit is divided to actuate the brake pistons located in the differential
outlet.
The service brake control solenoid valve incorporated in the brake pedal allows, when actuated by the
appropriate selector located in the cab on the steering wheel, the permanent actuation of the service brakes
taking oil from an accumulator and sending it to a control plunger actuating the pedal.
The brake discs are an oil bath multiple disc type.
Two pressure switches, connected to the brake group, are used to operate the stop light (setting 5 bar) and
to operate the brake failure indicator (pressure switch setting 90 bar). A pressure transducer signals the
braking system pressure on the pressure gauge on the dashboard.
15501 9-35990
 HS7-5-2

BRAKES SYSTEM WX90

14

12 8 5

11

1 - Front axle
2 - Rear axle
5 - Brake pilot control pump
8 - Pilot control filter 10
9 - Brake pedal assembly
10 - Pressure switch for stop light control
11 - Accumulators
12 - Control pressure switch for low brake system
pressure warning light
14 - Pressure transducer

15501 9-35990

F8871
 HS7-5-3

BRAKES SYSTEM WX90

5.3 OPERATION OF BRAKE PEDAL VALVE

The hydraulic power coming from the brake pilot system pump and the pilot system filter, reaches inlet port
P of the brake pedal valve.
The brake pedal valve is of a modular type and incorporates the accumulators charge valve A (12) brake
modules (13), service brake control solenoid valve (14), brake pedal, service brake control cylinder and uses
a small portion of energy from the hydraulic system of the machine, letting the oil delivery available for the
actuators of the pilot system.
This function is obtained by charge valve (A) taking automatically the oil to charge the hydraulic accumulators.
Its technical characteristics have as a result an increase in the braking power and a reduction of the effort
on the pedal.
The braking pressure is regulated by modules connected to the braking circuits.
The system is already perfectly adjusted and set, thus no regulations are required.

16 10 11
2

14 15 12
D1
17
13
6 9
4 8
5 13 1
7

F8868

1 - Feeding to the actuators

2 - Connection for service braking
3 - Discharge to reservoir
4 - Connection to pressure switch
5 - Stop lights pressure switch
6 - Delivery to front axle
7 - Delivery to rear axle
8 - Feeding from pump
9 - Brakes system low pressure indicator pressure switch
10 - Accumulator
11 - Service accumulator
15501 9-35990

12 - Accumulator charge valve (A)

13 - Brake modules
14 - Service brake control solenoid valve (X)
15 - Service brake control cylinder
16 - Brake pedal
17 - Pressure sensor
 HS7-5-4

BRAKES SYSTEM WX90

5.3.1 OPERATION OF ACCUMULATORS CHARGE CIRCUIT

The accumulators are fed with a priority over the other actuators, by the accumulator charge valve mounted
after the pump.
During the charging phase, the charge valve operates as a differential delivery divider ensuring the feeding
of the actuators of the pilot system.
Once the accumulator charge pressure is reached, the charge valve directs the entire delivery of the pump
to the actuators of the pilot system.
The pressure in the accumulators circuit is kept constant within the tolerance range of the charge valve.
The two service braking circuits are protected from each other by check valves, so that, in case of failure of
one of them, the other is perfectly operational.
The charge condition of the accumulator is monitored by the brake low pressure switch, so that the operator
receives a visual indication in case there is a lack of energy, such as the engine is inoperative and signals,
also, after the starting of the vehicle, the efficiency of the brakes system.

5.3.2 OPERATION OF THE SERVICE BRAKING CIRCUIT

When the service brake is actuated, the valve made of the two brake modules controlling the two brake
circuits, regulates the pressure in the brake circuits proportionally with the actuating force, both on the front
and rear axles.
At the end of the braking phase, the oil returns to the reservoir.
In case of failure of one braking circuit, the other circuit, through the mechanical contact of the two pistons
of the brake module, continues to brake, ensuring the perfect functionality of the two accumulators.
The actuating force remains unchanged.
At each actuation of the service brake, a pressure switch (set at 5 bar) monitors the pressure in the rear axle
brake circuit and switches ON the stop lights.

5.3.3 OPERATION OF THE SERVICE BRAKE CONTROL SOLENOID VALVE

When the switch is actuated to working brake position, the working brake control solenoid valve is energised,
thus, by moving the spool, the accumulator charging pressure is connected to the working brake control
cylinder.
The movement of the service brake control piston controls the two brake modules that connect the
accumulators to the front and rear axle brakes circuits.
When the service brake button is actuated, the axle lock is automatically actuated.
The unlocking of the axle is possible by actuating directly the axle locking button.
15501 9-35990
 HS7-5-5

BRAKES SYSTEM WX90

5.3.4 DESCRIPTION AND OPERATION OF THE BRAKE SYSTEM ACCUMULATORS

The accumulators, of a membrane type, ensure a certain quantity of actuations of the brakes with engine
inoperative.
The membrane accumulator is made of a pressure resistant steel container, having, inside, a membrane
made of elastic material as separation element. The membrane is locked by a ring nut between the lower and
higher side of the body.
In the central lower part of the membrane, a metallic disc is incorporated, to prevent its exit through the fluid
inlet port.
The accumulators are filled, from the upper part, by a nitrogen pre-load at 50 bar, whereas the lower part is
connected to port R of the brake pedal group.

1 - Gas valve
2 - Container
3 - Membrane
4 - Valve mushroom
5 - Oil side connection

Without hydraulic pressure, the membrane, loaded on the gas side at the pre-load pressure P0, is leaning
against the inner surface of the accumulator and the mushroom closing the fluid passage.
When hydraulic pressure is applied to the brake pedal group, once it exceeds the pre-load pressure by
pressing the nitrogen, the mushroom is lifted and hydraulic oil enters the accumulator. The useful quantity
of oil results from the difference between the gas volume and the minimum and maximum operating pressure.
15501 9-35990
 HS7-5-6

BRAKES SYSTEM WX90

5.3.5 PRESSURE SWITCHES - BRAKES SYSTEM

The pressure switches on the brakes system are used to monitor failures of the brakes system and cause
the switches ON of the stop lights.
The pressure switches are made of an oil resistant membrane element, silver plated electrical contacts, body
with faston terminals, balance and pressure setting springs.
The brakes system failure monitoring pressure switch (1) is set at 90 bar, whereas the stop light pressure
switch (2) is set at 5 bar.
Transducer (3) signalling correct braking pressure 90÷140 bar to the pressure gauge located on the steering
column.

1 2 3
F8558

15501 9-35990
 HS7-6-1

OPERATION OF CIRCUITS WX90

6. OPERATION OF CIRCUITS

6.1 GENERALITIES

The main pump feeds the main control valve.

The secondary pump feeds the rotation control valve.
The 9 section main control valve is of a closed center type, whereas the 1 section rotation control valve is of
an open center type.

The paragraphs below describe the operation of the hydraulic circuits divided in accordance with the controls
of the hand and pedal pilot valves.
In the diagrams of these paragraphs, the flow of the main hydraulic feeding from the pumps to the service
involved is shown in continuous bold lines, whereas the return of the main hydraulic feeding to the reservoir
is indicated in dashed bold lines.
15501 9-35990
 HS7-6-2

OPERATION OF CIRCUITS WX90

6.2 CIRCUIT WITH CONTROLS IN NEUTRAL

Under the conditions with hand and pedal pilot valves in neutral position, the hydraulic oil coming from the
main pump reaches the main control valve, where it is intercepted by the position of the nine spools.
The hydraulic oil coming from the secondary pump, reaches the spool of the rotation control valve, it passes
it in the neutral position, and, through the check valve set at 3.5 bar, returns to the reservoir through the oil
cooler.

15501 9-35990
 HS7-7-1

TRAVEL SYSTEM WX90

7. TRAVEL CIRCUIT

7.1 DESCRIPTION

The travel system includes the travel hydraulic motor control circuit, the transmission control circuit and the
parking brake control circuit (see fig. page 7-3).

7.2 TRAVEL HYDRAULIC MOTOR CONTROL CIRCUIT

- The travel circuit is used to control the rotation of the travel hydraulic motor.
Actuating the pedal pilot valve (dual pedal) the position of the spool relative to the travel function on the
right body of the control valve is defined.
This control occurs under the condition that:

- Solenoid valve A1 located in the services solenoid valves group is energised in travel position. If this
solenoid valve is disenergised, it does not allow the control of the travel when the parking brake operated
by the braking type selector is engaged.

- Solenoid valves B3, B4 located in the selection solenoid valves group are not energised. If these solenoid
valves are energised, the piloting hydraulic oil will be directed to the spool of the control valve for the
positioner arm control instead of travel.

- The hydraulic oil of the main pump with the opening of the travel spools on the control valve is directed,
through the central joint, to port A of the travel motor (or inlet port B). The two directions are obtained by
sending the oil with the travel pedale from one of the two inlets.

- The hydraulic oil will rotate the motor at a speed proportionate to the position of the pedal pilot valve, to
the position of the speed lever and the load to which the motor is subject.

- In fact, the motor is equipped with a displacement automatic regulator, as a function of the operating
pressure. The regulator monitors the operating pressure at inlet port A or B and controls the position of
the bent axis, thus the displacement of the motor from a minimum position (minimum torque - maximum
speed) to a maximum displacement (maximum torque - minimum speed).
This occurs in second and third speed.
With the first speed the motor has the max. displacement.

- In detail, the delivery pressure is connected to the spool of the regulator in contrast with the setting
spring.
When the pressure exceeds the setting of the spring, it moves the spool and connects the inlet pressure
with the positioning cylinder. This, with its movement, will change the displacement of the motor from
minimum to maximum.
Changing the displacement, the pressure decreases, thus re-establishing the equilibrium.

- The regulator is equipped with an additional piloting for the control of the plate to maximum displacement,
through the sending of a piloting pressure to inlet “X”.
This external piloting occurs by energising solenoid valve A2 controlling the travel speed variation, located
in the services solenoid valves group.
If the 2nd speed is selected with the transmission lever, the solenoid valve A2 is not energized and pilot
control oil does not reach travel hydraulic motor governor.
If the 1st speed is connected, the solenoid valve A2 is energized and pilot control oil can reach the motor
15501 9-35990

"X" inlet.
To this piloting is applied the governor check valve in addition the service pressure signal. This shifts the
motor to the max. displacement.

In these conditions, with the additional piloting connected, the motor rotation speed will be lower than the
motor speed in normal conditions.
 HS7-7-2

TRAVEL SYSTEM WX90

- Travel valve

The travel valve (flanged directly on hydraulic motor) provides a means to protect the hydraulic motor
from pressure increase and peaks which occur during reversals of rotation. It also checks motor charge
eliminating cavitation which can occur during decrease or when motor swing speed is higher than the
one determined by hydraulic oil capacity.
The valve protecting the motor from pressure peaks includes two piloted antishock valves (400 bar) with
built-in non-return valve.
The valve checking decrease hydraulic motor charge includes four non-return valves monitoring the
circuit inside valve body and one spool piloted by delivery line pressure which should adjust discharge
line opening.
The valve includes also piloting for motor adjustment and the valve for engine cooling oil flow.

15501 9-35990
 HS7-7-3

TRAVEL SYSTEM WX90

Travel block diagram

19 18

21

22
9 3 2 1 5 4

20 17 7

P1

A5 A6
B5
6 B6

12
8

16
15

F8918

1 - Diesel engine 12 - Transmission control line

2 - Main hydraulic pump 15 - Rear bridge
3 - Secondary hydraulic pump 16 - Transmission group
4 - Brakes pilot system pump 17 - To parking brake
5 - Steering pump 18 - Service brake valve
6 - Main control valve 19 - Valve
7 - Front axle 20 - Service power control solenoid valve group
8 - Travel hydraulic motor 21 - Travel control pedale
9 - To positioner cylinder control spool 22 - Selection solenoid valve group
15501 9-35990

NOTE: The center joint has been omitted to simplify the diagram.
 HS7-7-4

TRAVEL SYSTEM WX90

7.3 PARKING BRAKE CONTROL CIRCUIT

The machine is equipped, on the rear axle, of a parking brake.

Multiple disc service brakes in oil bath.
Mechanically operated by means of springs, hydraulic release.

F7238

01 - Hydraulic oil reservoir 08 - Center joint

15501 9-35990

02 - Pilot system and brakes pump 09 - Front axle service brake

03 - Service brake valve 10 - Parking brake
04 - Service solenoid valves 11 - Pilot control accumulator
05 - Pilot control valve 12 - Brake mode selector
06 - Brake system accumulator 13 - Travel pedal
07 - Parking brake pressure switch
 HS7-8-1

HYDRAULIC SYSTEM DIAGRAM WX90

NOTES:
15501 9-35990
 HS7-8-2

HYDRAULIC SYSTEM DIAGRAM WX90

8. HYDRAULIC SYSTEM DIAGRAM

HYDRAULIC SYSTEM PARTS

1. Diesel engine 37.Travel motor

2. Main pump and swing unit 38. Slewing motor
3. Brakes pump and power steering unit 39. Bucket cylinder
4. Oil reservoir 40. Digging cylinder
5. Return oil filter 41. Lifting cylinders
6. Radiator 42. Positioner cylinder
7. Valve 43. Control valve
8. Solenoid valve for clamshell bucket swing 44. Priority valve for controls feeding
9. Hydraulic steering unit 45. Swing brake
10. Delivery oil filter 47. Inlet block and discharges
11. Pressure switch for insufficient brake charge 48. Antidrop valve (optional)
pressure
50. Hammer (optional)
12. Steering valve
51. Clamshell bucket (optional)
13. One-way throttling valves
54. Pressure intakes
14. Parking brake
15. Lock valve
16. One-lever joystick
17. Positioner/travel pedal
18. Braking system accumulators
19. Transmission
20. Main control valve
21. Solenoid valves
22. Stop lights pressure switch
23. Service solenoid valves
24. Braking system valve
25. Slewing valve
26. Travel valve
27. Selection valve for dozing blade/stabilizers
28. Axle lock-out valve
29. Rear steering cylinder
30. Front steering cylinder
31. Front axle with brake
32. Rear axle with brake and gearbox
15501 9-35990

33. Lock-out valves (optional)

34. Axle lock-out cylinder
35. Swing cylinder
36. Cylinders for dozing blade/stabilizers
 INDEX WX90 - 8 - 1

WX90

SECTION 8 ELECTRICAL SYSTEM

INDEX

Group 1 - SAFETY RULES ........................................................................................ ES8-1-1

1.1 Safety rules

Group 2 - SPECIFICATIONS AND DATA ................................................................... ES8-2-1

2.1 Specifications and data

Group 3 - LOCATION AND FUNCTIONS OF COMPONENTS .................................. ES8-3-1

3.1 Construction
3.2 Location of electrical components
3.3 Instruments and control

Group 4 - ARRANGEMENT AND OPERATION ......................................................... ES8-4-1

4.1 Electrical system

Group 5 - ELECTRICAL SYSTEM GENERALITIES .................................................. ES8-5-1

5.1 Connections with diodes

5.2 Connections with fuse box
5.3 Connections with mini relay
5.4 Controller
5.5 Monitor connections on switches-indicators panel
15501 9-35990

5.6 Connections with rotating joint

5.7 Connections with operator's right side
5.8 Connections with operator's left side
5.9 Throttle piston control electronic unit (SMC)
5.10 Connections with cab
5.11 Connections with test connector
5.12 Connections with steering column
5.13 Anti-start device connections

(to be continued)
 INDEX WX90 - 8 - 2
INDEX (continues)

Group 6 - ELECTRICAL COMPONENTS .................................................................. ES8-6-1

6.1 Throttle control

6.2 Center joint
6.3 Batteries
6.4 Alternator
6.5 Starter

15501 9-35990
 ES8-1-1

SAFETY RULES WX90

1. SAFETY RULES

1.1 SAFETY RULES

WARNING

When working on the electrical system, always wear

protective glasses and remove all rings, wrist watches
and every other metal jewellery.

WARNING DISCONNECT

Prior to any inspection or repair of electrical

components, DISCONNECT GROUND WIRE “A” from
the negative terminal “B” of the battery.
Disconnect wire “C” from the positive terminal “D”.

EARTH LINE

WARNING

NEVER PLACE METALLIC OBJECTS on the battery,

to prevent short circuits.

WARNING

GASES GENERATED BY THE BATTERY ELECTROLYTE ARE FLAMMABLE. Avoid sparks and free flames
near the batteries. During recharging, the emission of gas is intensified.
15501 9-35990

WARNING

GASES GENERATED BY THE BATTERIES ARE DANGEROUS if they contact the skin or any material.
 ES8-1-2

SAFETY RULES WX90

NOTES:

15501 9-35990
 ES8-2-1

SPECIFICATIONS AND DATA WX90

2. SPECIFICATIONS AND DATA

2.1 SPECIFICATIONS AND DATA

This machine is equipped with a 24 Volt electrical system with negative ground. Here below, the electrical
specifications of the components equipping the machine are listed:

• BATTERY
Two batteries, connected in series, equip this machine. Each single battery has the following specifications:
- Voltage .............................................................................................................................................. 12 V
- Nominal capacity of battery ............................................................................................................ 75 Ah
- Discharge current ........................................................................................................................... 440 A
- Weight with electrolyte ..................................................................................................................... 23 kg

• STARTER MOTOR (with safety relay)

- Voltage .............................................................................................................................................. 24 V

• ALTERNATOR (with built-in regulator)

- Nominal voltage ................................................................................................................................ 24 V
- Nominal current ................................................................................................................................ 55 A

• BOOM MOUNTED LIGHT (halogen light)

- Voltage and power ............................................................................................................. 24 V, 70/75 W

• FRONT ROAD LIGHT (halogen light)

- Voltage and power .......................................................................................... 24 V, 5 W - 24 V, 70/75 W

• REAR ROAD LIGHT

- Voltage and power .................................................................................................................. 24 V, 10 W

• FRONT/REAR TURNING LIGHTS

- Voltage and power .................................................................................................................. 24 V, 21 W

• SIDE TURNING LIGHTS

- Voltage and power .................................................................................................................... 24 V, 5 W

• WINDSHIELD WIPER MOTOR

- Nominal voltage and current ................................................................................................. 24 V, 2 Amp

• CAB LIGHT
- Voltage and power .................................................................................................................... 24 V, 5 W

• RADIO
- Voltage .............................................................................................................................................. 24 V

• LOUD SPEAKER
- Input power (nominal) ...................................................................................................................... 10 W
- Input power (max.) ........................................................................................................................... 20 W
- Nominal impedance ........................................................................................................................ 4 ohm
15501 9-35990

• ANTI-START (anti-theft device)

- Nominal voltage ................................................................................................................................... 24 V
- Loss ................................................................................................................................................. 2.8 mA
- Operation temperature ............................................................................................................ -25° ÷ +80°C
 ES8-2-2

SPECIFICATIONS AND DATA WX90

NOTES:

15501 9-35990
 ES8-3-3

LOCATION AND FUNCTIONS OF COMPONENTS WX90

3.2.2 ELECTRICAL COMPONENTS ON TRANSMISSION

Fig. 2

F8870

2 - Electrical/hydraulic joint
3 - Wheel alignment sensor
4 - Speed sensor
15501 9-35990
 ES8-3-4

LOCATION AND FUNCTIONS OF COMPONENTS WX90

3.2.3 ELECTRICAL SYSTEM (RELAYS - DIODES - CONTROL UNITS)

Fig. 3

1
1 9

1
7

4
5
3
6 6

F9246
Connection for frame cable

See description on page 6

15501 9-35990
 ES8-3-5

LOCATION AND FUNCTIONS OF COMPONENTS WX90

Fig. 4 - Diode location

Control check

Cold start device

Air filter clogging

Axle lock

Travel speed

Engine stop
15501 9-35990

See description on page 6

 ES8-3-6

LOCATION AND FUNCTIONS OF COMPONENTS WX90

1. Alternator relay RY1

Safety relay RY2
Anti load dump relay RY3
Working brake relay RY4
Windshield washer tank relay RY5
Lights-arm relay RY6
Horn relay RY7
Rotating beacon relay RY8
Optional RY9
Relay for control valve 1 spool / 2 spools RY10
Windshield wiper relay RY11
Relay SW B-C RY12
Switch relay B RY13
Rotating bucket relay E RY14
Rotating bucket relay F RY15
Switch relay K RY16
Engine stop relay RY17
Relay for left direction indicator RY18
Relay for right direction indicator RY19
Safe start-up relay RY20
Upper beam relay RY21
Lower beam relay RY22
Parking lights RY23
Optional RY24
Switch relay C RY25
Switch relay A RY26
Travel auto idle relay RY27
Power control relay RY28
2. Diode 1 - Start-up switch
Diode 4 - Control check
Diode 5 - Engine stop
Diode 6 - Cold start device
Diode 7 - Air filter clogging
Diode 8 - Axle lock
Diode 9 - Travel speed
Diode box 1
Diode box 2
Diode box 3
Diode box 4
3. Transmission control unit
4. SMC control unit
15501 9-35990

5. Controller box
6. Fuse boxes
7. Programmation switch
8. Additional power intake 24 volt
9. Diode box 1-2-3-4

See pictures 3-4.

 ES8-3-7

LOCATION AND FUNCTIONS OF COMPONENTS WX90

3.2.4 ROAD LIGHTS AND WORK LIGHTS

Fig. 5
6

7
2
1

8 8

5
15501 9-35990

1 - Direction indicator 4
F13276
2 - Front light
4 - Rear light
5 - Reflector
6 - Horn
7 - Work light
8 - Stop/parking lights
 ES8-3-8

LOCATION AND FUNCTIONS OF COMPONENTS WX90

3.3 INSTRUMENTS AND CONTROLS

3.3.1 GENERALITIES

To operate the machine under totally safe conditions, the operator must be perfectly aware both of the
efficiency conditions and the operational capabilities of the unit. To alert promptly the operator, in case of a
problem, several instruments and control devices have been placed on the central dashboard (Fig. 1).
Electrical control devices are also mounted on the pilot valves.
In order to make the descriptions relative to the subjects involved in this chapter, as clear and immediate as
possible, references are made to the electrical system diagram.

Fig. 1 - Central dashboard

5
2
6 TB
EX
1 2

1
3
10
Km/h
30 4
0

15 20
10 25
P
5 Km/h
30
0 F9226

1 - Hydraulic speed control lever

2 - Direction indicator and light switch
3 - Horn control
15501 9-35990

4 - Brake switch, axle lock

5 - Emergency light switch
6 - Windshield wiper switch
7 - Steering column control panel
 ES8-3-9

LOCATION AND FUNCTIONS OF COMPONENTS WX90

Fig. 2 - Side dashboard

4
15501 9-35990

F13277
1 - Control module
2 - Switches and indicators panel
3 - Engine starter switch
4 - Hand throttle control
 ES8-3-10

LOCATION AND FUNCTIONS OF COMPONENTS WX90

Fig. 3 - Pilot valves

TB 1 2
EX

10 30
Km/h

1 2

F13263

1 - Button switches on left pilot valve

2 - Button switches on right pilot valve.
15501 9-35990
 ES8-3-11

LOCATION AND FUNCTIONS OF COMPONENTS WX90

On brake switch (1) four positions can be selected: Fig. 4 - Switch and indicator panel

- travel with axle unlocked

- travel with axle locked
- parking
- working

The warning lights on panel (2), (3), (4), of the

TB

steering column show the selected function.

1 2
EX

10 30
Km/h

• For Diesel engine start, the switch should be in .

In any other position start-up is not possible.
• The switch should be in or in or in to
control the equipment. 4 3 2 1

15 20
10 25
P
5 Km/h
30
0 F9228

FUNCTION CONNECTION DEPENDING ON SWITCH POSITION

Functions Working Parking Equipment Travel Engine
Axle lock
Positions brakes brake control control start-up

Disconnected Disconnected Disconnected Free Free Disconnected

Disconnected Disconnected Connected Free Free Disconnected

Disconnected Connected Connected Disconnected Disconnected Free

15501 9-35990

Connected Disconnected Connected Free Disconnected Disconnected

F8352gb
 ES8-3-12

LOCATION AND FUNCTIONS OF COMPONENTS WX90

Fig. 5 - Switches and indicators

5 1

8 8

6 2

15 20
10 TB 1 2
EX
25
5 Km/h P
30
0

10 30
Km/h

3
7

15 20
10 25
P
5 Km/h
30
0 F9230

1 - 1st speed indicator

The actuation of this indicator shows that the slow tortoise speed has been selected.

2 - 2nd speed indicator

The actuation of this indicator shows that the fast hare speed has been selected.

3 - Rotary beacon switch

When this switch is actuated, the rotary beacon is ON.

4 - Brake failure indicator

The actuation of this indicator shows that the braking system is malfunctioning.

5 - Positioner arm indicator

The actuation of this indicator shows that the positioner arm control is actuated.

6 - Emergency flashing lights switch

When this switch is actuated, all front and rear direction lights are flashing at the same time, to signal
an emergency situation.

7 - Parking lights
15501 9-35990

The actuation of this indicator shows that the side/tail lights-low beams are actuated.

8 - Direction lights indicator

The actuation of this indicator shows that the direction indicator or the emergency flashing signal is
actuated.

9 - Upper beam indicator

The actuation of this indicator shows that the upper beam lights are ON.
 ES8-3-13

LOCATION AND FUNCTIONS OF COMPONENTS WX90

Fig. 6 - Switches on levers mounted on the steering wheel

2
TB 1 2

1
EX

4
3
10 30
Km/h

15 20
10 25
P
5 Km/h
30
0
F9231

1 - Direction lights control, lights switch

When moving or rotating this lever, the relevant circuits are actuated, thus providing the powering of
the following equipment:
- right and left direction lights;
- side and tail lights;
- low beam lights;
- high beam lights.

2 - Windshield wiper control lever

When moving this lever or pressing its end, the relevant electrical circuits are actuated, thus providing
the powering of the following equipment:
- windshield wiper;
- windshield washer motor.

3 - Travel speed selection lever

This lever allows to select three hydraulic speeds; third speed (III), second speed (II) and first speed
(I).

WORK TRAVEL MODE ROAD TRAVEL MODE

Set the switch on (tortoise) Set the switch on (hare)
15501 9-35990

Speed in Km/h Speed in Km/h

I: I÷2 I: I÷6
II: I÷6 II: I ÷ 17
III: I ÷ 10 III: I ÷ 30

4 - Horn
 ES8-3-14

LOCATION AND FUNCTIONS OF COMPONENTS WX90

Fig. 7 - Steering column panel

18 23
1 - Hydraulic speed control lever. 27 7
8 25
2 - Direction indicator and light switch.
24
3 - Horn control. 5

4 - Switch:
axle lock brakes.
2
TB 1 2
EX

6
5 - Hazard lights switch. 3 1
10 30

6 - Windshield wiper switch. 0

Km/h

7 - Warning light for right turn signal.

4
8 - Warning light for left turn signal. 16
10
9 - Speed indicator (tachometer). 13
20
10
15
11
10 - Warning light for parking lights. 25
P
5 Km/h
30
14
11 - Warning light for upper beams. 0 15
17 F6983 12
12 - Warning light for low brake pressure 9
(buzzer).

13 - Warning light for axle lock.

14 - Parking brake warning light.

15 - Warning light for working brake.

16 - Warning light for hazard lights.

17 - Pressure gauge for braking pressure.

18 - Warning light for rotating beacons.

15 20
10
25
5 Km/h P

19 - Power control lock switch. 0

30

20 - Switch for hammer/grass-cutter. 19

21 22
21 - Tipping device switch. 20
26
22 - Rotating beacon switch.

23 - Warning light for tipping device (yellow).

24 - Warning light for equipment lock.

15501 9-35990

25 - Travel mode warning lights (1), (2).

26 - Lever for steering adjustment.

27 - TB/EX warning light. F7124

 ES8-3-15

LOCATION AND FUNCTIONS OF COMPONENTS WX90

3.3.3 FUNCTIONS OF SIDE DASHBOARD

Fig. 8 - Control module 13

11
H
10
7 C F
E 8
6
E 12
A/I
1
3
4
5
CHECK
00 0014 E
1/10
H

2
2
1
OFF

14
9
A/I

F13610

1 - Alternator indicator
The actuation of this indicator shows that a failure in the battery recharging system has occurred.

2 - Engine oil pressure indicator

The red indicator comes ON in case of low engine oil pressure.

3 - Air cleaner clogging indicator

The actuation of this indicator shows that the air cleaner is clogged.

4 - Engine coolant temperature indicator

The actuation of this indicator shows that the temperature of the coolant is above the prescribed
value.

5 - Fuel indicator
The actuation of this indicator shows that the fuel level is in reserve conditions.

6 - Engine oil level indicator

15501 9-35990

This indicator comes ON when, pressing the check button (1 - Fig. 9) the level is inadequate.

7 - Coolant level indicator

This indicator comes ON when, pressing the check button (1 - Fig. 9) the level is inadequate.

8 - Hydraulic oil level indicator

This indicator comes ON when, pressing the check button (1 - Fig. 9) the level is inadequate.
 ES8-3-16

LOCATION AND FUNCTIONS OF COMPONENTS WX90

9- Hourmeter
This instrument recording the total hours worked, operates when the engine runs (a LED flashes),
must be used as a guide for the maintenance operations and checks scheduled in the “Operation
and Maintenance Manual 2905991.00en”.

10 - Fuel level gauge

This instruments shows the level of the fuel contained in the reservoir.

11 - Engine coolant temperature gauge

This instrument shows the temperature of the engine coolant.

12 - Glow plug indicator

This indicator comes ON when start-up switch is turned to HEAT.

13 - Preheating indicator

14 - Anti-start device (anti-theft device)

This tool obstructs the normal current flux . It is fit into the three essential points of electric circuit and
it stops the main part of machine functions:
- elettrostop
- battery disconnection relay
- travel
- servo controls
- stabilizers
- blade
- arm
- bucket swing
- positioner
- parcking brake

Fig. 9 - Switches and indicators panel Fig. 10 - Starter switch

CHECK

2
1
OFF

3 6
A/I

4 5

F9233
15501 9-35990

F9234
 ES8-3-17

LOCATION AND FUNCTIONS OF COMPONENTS WX90

1 - Check button
When pushing this button, it is possible to test, through the actuation of the indicators the following
levels:
- engine oil;
- coolant;
- hydraulic motor oil.

2 - Alarm buzzer cut-off switch

When this switch is actuated, the engine coolant excessive temperature and low engine oil pressure
sound alarm is neutralised (actuation of indicators). In this case, it is required that the alarm is
disactivated, bring the engine to idle speed and keep it running for a few minutes at this speed. To test
the operation of the alarm, push this switch when the engine is running.

3 - Work light switch

When this switch is actuated, the work light comes ON.

4 - Button A/1 (Auto idle)

If pressing button, indicator (yellow) on control panel comes ON. Press the button again to disconnect
auto-idle function. At the same time the corresponding indicator comes OFF.

5 - Travel mode switch

With the switch, two travel modes can be selected "Use and maintenance manual 2905991.00en":
- work travel mode
- road travel mode

6 - Starter switch
The starter switch has five positions, each actuating the electrical system in the following manner:
- position HEAT, glow plug feeding with signal to indicator (unstable position)
- position OFF, no power to the system;
- position ACC, all equipment powered, except starter circuit;
- position ON, all equipment powered after the starting of the engine;
- position START, engine starting circuit is powered (unstable position).

NOTE: When moving the starter key into position “ON”, all the indicators on the control module come
ON (test of bulbs) for about 3 seconds, except for the following indicators:
• insufficient battery charging;
• insufficient engine oil pressure;
that will remain ON until the engine is started.
If one of the indicators is not ON during the test function, the relevant bulb could be burnt out.
15501 9-35990
 ES8-3-18

LOCATION AND FUNCTIONS OF COMPONENTS WX90

Fig. 11 - Left manual pilot valve

TB 1 2
EX

10 30
Km/h

F13278

A - Button
When this button is actuated, solenoid valves B5-B6 are energised, allowing the hydraulic system to
feed pressurised oil to the swing control cylinder.

B - Button
When this button is actuated, solenoid valves B1-B2-A2 are energised, allowing the hydraulic system
to feed pressurised oil to the stabiliser line.
15501 9-35990

C - Button
When this button is actuated, solenoid valves B1-B2 are energised, allowing the hydraulic system to
feed pressurised oil to the stabiliser/blade line.

G - Horn control button

When this button is actuated, the horn is activated.
 ES8-3-19

LOCATION AND FUNCTIONS OF COMPONENTS WX90

Fig. 12 - Right manual pilot valve

TB 1 2
EX

10 30
Km/h

K
20

F13279

D - Button
When this button is actuated, solenoid valves B3-B4 are energised, allowing the hydraulic system to
feed pressurised oil to the positioner line.

E - Button
When this button is actuated, solenoid valve C1 is energised, allowing the hydraulic system to feed
pressurised oil to the clam bucket to rotate it leftward.

F - Button
When this button is actuated, solenoid valve C2 is energised, allowing the hydraulic system to feed
15501 9-35990

pressurised oil to the clam bucket to rotate it rightward.

K - Button, optional control

When this button is actuated, solenoid valve A5 is energised, allowing the hydraulic system to feed
pressurised oil to the hammer or grass-cutter, by means of switch 20 and solenoid valve A4.
 ES8-3-20

LOCATION AND FUNCTIONS OF COMPONENTS WX90

ELECTRICAL SYSTEM

Fig. 13 - Monitor and switch panels 18 19 20

17
32
16
H

15 C F
E 22
1 4 14
23
E
12 A/I
25
2 5
24

26
8
13 CHECK

10
2
1

11 OFF
21
3
21

CHECK

9 6 2
1
27 OFF

31

A/I

30

29

28
F13280

1 - Monitor panel 17 - Available indicator

2 - Switch and indicator panel 18 - Coolant temperature gauge
3 - Hand throttle control 19 - Preheat indicator
4 - Cigar lighter 20 - Fuel level indicator
5 - Ashtray 21 - Available indicators
6 - Ceiling light 22 - Led for button E (economy) on
7 - Steering type selection control 23 - Led for button A/I (auto/idle) on
8 - Button E (economy) 24 - Thermostarter indicator
15501 9-35990

9 - Heater or conditioner controls (optional) 25 - Hydraulic oil level indicator

10 - Air filter restriction indicator 26 - Level check indicator
11 - Work light indicator 27 - Level check button (CHECK)
12 - Coolant temperature gauge 28 - Control unit cut-off button
13 - Engine oil pressure indicator 29 - Travel mode switch
14 - Low battery charge indicator 30 - A/I (auto/idle) button
15 - Engine oil level indicator 31 - Work light switch
16 - Coolant level indicator 32 - Anti-start device (anti-theft device)
 ES8-3-21

LOCATION AND FUNCTIONS OF COMPONENTS WX90

Fuse Rating
PROTECTED CIRCUIT
No. (A)
FUSES IN THE BOX
1 Function memory 5
2 Engine control 10
3 Step-by-step motor 10
4 Power supply 5
5 Solenoid 5
6 Switch panel 5
7 OPT
8 OPT F5989

9 Bucket rot. & overturn sensor 5

10 OPT
11 Upper lights (opt) 20
12 Windshield wiper 10
13 Heater 15
14 OPT
15 Horn 5
16 Radio 5
17 Cigarette-lighter 5
18 Cab light 5
19 OPT
20 OPT
21 R.H. parking light 5
22 L.H. parking light + ceiling light 5
23 Dipped beams 10

24 Main beams 10
(unused for homologation)

25 Case (1) 20
26 Stop lights 5
27 OPT
28 Steering column panel 5
29 Attachment lights 5
15501 9-35990

30 Rotating beacon 5
31 Transmission card 10
32 L.H. lever 10
33 Case (2) 5
34 Socket 10
F7818gb
 ES8-3-22

LOCATION AND FUNCTIONS OF COMPONENTS WX90

Fuse Rating
PROTECTED CIRCUIT
No. (AMP)
FUSES IN THE BOX
35 Compressor (opt) 5
36 OPT
37 OPT
38 OPT
39 OPT
40 OPT
CENTRAL UNIT FUSES
FUSE FUSE FUSE

F6174
1
BOX A

Main power supply with key 40

3 2 (OPT)

Glow plug preheating 40

Engine start-up line

80
BOX B

protection
FUSE
4

OPT
1 3
F7819gb

FUSE 2
FUSE 1
40 A
40 A

BOX BOX
A B

FUSE 4
FUSE 3
OPT
80 A

2 4

F5993

15501 9-35990
 ES8-4-1

ARRANGEMENT AND OPERATION WX90

4. ARRANGEMENT AND OPERATION

4.1 ELECTRICAL SYSTEM

4.1.1 DESCRIPTION

This chapter will deal with the Switching Control Unit and the 15 Lines that make the electrical system, as
previously described. The information will be provided always referring to the electrical system. Thus, it will
be imperative, prior to reading this chapter, unfold the electrical system diagram and keep it handy, so that
it can be easily accessible.

4.1.2 OUTLINE

The electrical system is classified into the main circuit, control circuit and monitor circuit.
• Main circuit operates the engine and accessories.
• Control circuit functions to control operations of the engine and valves (including actuators, solenoid valves,
Main Controller), switch box, sensors and pressure switches).
• Monitor circuit operates the monitor devices consisting of the monitors, sensors and switches.
In this group the functions and constructions of the main circuit are introduced.
• Electric power circuit:
Supplies electric power to all electric system on this machine. (Key switch, batteries, fuses (fuse box and
fuses 40A and 80A), battery relay).
• Circuit in position (ON). It operates key switch, battery relay, fuses and monitor.
• Starting circuit: starts the engine. (Key switch, starter, starter relay).
• Charging circuit: recharges battery and supplies consumption electricity. (Alternator, regulator).
• Surge voltage prevention circuit: prevents surge voltage from occurring when the engine is stopped. (Anti
load dump relay).
• Bulb check accessory circuit: works with the key switch placed in the ACC position (key switch, battery,
fuses).
• Engine stop circuit: when the key switch is placed in OFF position, stops the engine with the engine stop
device.
• Engine control circuit.

4.1.3 ELECTRIC POWER CIRCUIT (Key switch: OFF)

The battery negative terminal is grounded to the vehicle. Current from the positive terminal flows as follows
with the key switch OFF.
Battery
Fuse 40A

Key switch B

Anti load dump relay (RY3)

Safety relay (RY2)

Fuse box

Preheating relay

Terminal 1 - Backup power source/digital clock

Terminals D1-D2-A13 - SMC power source

Terminal 5 - Controller box control unit

Emergency lights

NOTE: To consult the general electrical system, refer to the diagram enclosed at the end of this Manual.
15501 9-35990
 ES8-4-2

ARRANGEMENT AND OPERATION WX90

4.1.4 PREHEATING CONTROL CIRCUIT

The input line reaches key switch from Link fuse A1 (40 AMP.) on point B.

From Link A2 fuse (40 AMP.) it reaches point G of solenoid relay.

Turning key switch to position H during start-up, solenoid relay is fed from point G1 and warning light on
monitor point C3.

Solenoid relay energization allows the passage of input signal from resistance R1 to plug heater.

NOTE: It is normal that also work light alternator indicator and engine oil pressure indicator light up when
turning start-up key to position HEAT.

15501 9-35990
 ES8-4-3

ARRANGEMENT AND OPERATION WX90

PREHEATING CONTROL CIRCUIT

Starter SW

B G 1 G 2 ACC. M ST

Fuse LINK A H
OFF
ACC
40A
40A

1 2 ON
START
M8 M8 1 2 3 4 5 6

+ 24 VOLT

K
G e

Diode 7
A

Plug heater B g
A C
Solenoid relay

R1
A K Monitor C3

F9089

Diode 5
15501 9-35990
 ES8-4-4

ARRANGEMENT AND OPERATION WX90

4.1.5 STARTING CIRCUIT (Key switch: START)

When the key switch is turned to the START position, terminal B on the key switch is connected to terminals
G2, M and ST in the switch. The current from terminal M magnetizes the battery relay, leading the battery
current to terminal B on the starter and starter relay via the 80A fuse.

Terminal ST of the key switch is connected to terminal “e” on the starter relay coil.

With braking switch in position P a positive signal is sent to relay R20. This relay, energized, allows the
passage of a negative reaching terminal G of start-up relay, through relay R2 contacts. When it closes,
battery supply reaches starter terminal C and relay inside motor is energized. The motor starts running.

When the key switch is turned both ON and START positions, from terminal M, the power supply is applied,
via POWER ON fuse, to main controller MC and to engine stop relay R17. This power on signal instructs the
main controller the key switch is in ON position. The main controller, when receives the power on signal,
operates the EC motor in order to move the governor lever.

Relay R17, in de-energized condition, sends a positive signal to the electrostop and the fuel flow is opened
to injection pump.

With engine running and alternator generating voltage, the terminal B6 of monitor operates the safety relay
R2 that removes the ground to starter relay, shutting-off the power supply to the starter.

Moreover the safety relay R2 avoids a further starting sequence with engine running.

WARNING: BEFORE STARTING THE ENGINE, MAKE SURE BRAKE MODE SWITCH IS IN POSITION
P.

15501 9-35990
 15501 9-35990

Starter SW

17
16
18
15
+24 VOLT
SOLENOID RELAY

28
Fuse
LINK A

+24 VOLT

Battery relay
Monitor B 6

Starter
4

Fuse
5A

LINK B
Diode 6 R3

Diode box 1
STARTING CIRCUIT

R17
(key switch in START position)
ARRANGEMENT AND OPERATION WX90

Starter R2 R20 Elettrostop

Diode 4
B7
A 17

Starter relay SW
SMC

F9090
ES8-4-5
 ES8-4-6

ARRANGEMENT AND OPERATION WX90

4.1.6 CONTROL FOR HARE OR TORTOISE CHOICE

Operate tortoise/hare switch only with the following conditions:

Engine running

Set brake switch to W (working brake) position. Select the desired speed (hare/tortoise)

4.1.6.1 Slow travel control (tortoise) (engine running)

The input line from fuse N° 32 reaches relay R13 and relay 25.

The input line from fuse N° 31 reaches relay R10 and terminal 10 of mechanical gear controller.

When turning switch (2nd travel speed SW) to tortoise position the negative signal on mechanical gear
controller terminal 5 is interrupted.

From fuse n. 28 BRAKE MODE switch is fed.

In working brake position (NN) solenoid D 1 (located in brake valve) is fed and relay R4, in energized
condition, allows the positive signal coming from fuse N. 26 to reach terminal 87 of relay R4 via pressure
gauge P2 (stop lights).

From terminal 87 the signal reaches warning light L3 (working brake) and terminal 11 of mechanical gear
controller for the enable signal (tortoise).

The controller allows to send a positive signal from terminal 8 to solenoid A6 (tortoise) warning light L15, as
it does not receive a negative signal at terminal S and a positive signal at terminal 11.

NOTE: the tortoise/hare choice can be carried out only with braking mode switch in position W (working
brake).

15501 9-35990
 15501 9-35990

+24volt
2nd travel speed
+24volt
monitor 28

5A
32 31 1 2 3 4 5
1 SPEED

10A
15

10A
25 LOW

SW

W P
10 FIRST GEAR 8
POSITION
86 30 T A/L
SELCTION GEAR
5
R25 SW INPUTT

SECOND GEAR
1
POSITION
Diode 85 87 87a +24volt
5A

WORKING BRAKE 11 26
box 3 SW INPUTT

Wheel controller P2
3 4
Crab steering
Rod iron Normal
86 30 steering steering R4
86 30
L13
R13 R10 L14

85 87 87a 85 87 87a Diode box 4

Diode Stop
87a
box 1 30 87b light Steering
L3
(engine running)

86 30 column
87d 87c
R27

85 87 87a D7 D8 D9
2
Controller 6 FRONT TRAVEL
PRESS SW
ARRANGEMENT AND OPERATION WX90

PRESS SW
SMC
SLOW TRAVEL CONTROL CIRCUIT (TORTOISE)

SCM - GND SCM - GND

A 7 D2 D3 D4 D5

P4 P5
A 6

2 2
A 2 A 8
ES8-4-7
 ES8-4-8

ARRANGEMENT AND OPERATION WX90

4.1.6.2 Fast travel control (hare) (engine running)

The input line from fuse N° 32 reaches relay R13 and relay 25.

The input line from fuse N° 31 reaches relay R10 and terminal 10 of mechanical gear controller.

When turning switch (2nd travel speed SW) to hare position a negative signal is sent to mechanical gear
controller terminal S.

From fuse n. 28 BRAKE MODE switch is fed.

In working brake position (W) solenoid D 1 (located in brake valve) and relay R4 are fed. The relay, in
energized condition, allows the positive signal coming from fuse N. 26 to reach terminal 87 of relay R4 via
pressure gauge P2 (stop lights).

From terminal 87 the signal reaches warning light L3 (working brake) and terminal 11 of mechanical gear
controller for the enable signal (hare).

The controller allows to send a positive signal from terminal 1 to solenoid A7 (hare) and warning light L14,
as it receives a negative signal at terminal 5 and a positive signal at terminal 11.

NOTE: the tortoise/hare choice can be carried out only with braking mode switch in position W (working
brake).

15501 9-35990
 15501 9-35990

+24volt
2nd travel speed
+24volt
monitor
28

5A
32 31 1 2 3 4 5
3 SPEED

10A
2

10A
1 LOW

SW

W P
FIRST GEAR
10 POSITION 8
86 30 T A/L
SELCTION GEAR 5
R25 SW INPUTT
SECOND GEAR 1
85 87 87a POSITION
Diode +24volt
5A

WORKING BRAKE 11 26
box 3 SW INPUTT

Wheel controller P2
3 4 86 30

86 30 86 30 R4
L13
R13 R10 85 87a L14
85 87 87a 85 87 87a Diode box 4 87
Diode Stop
87a
box 1 30 87b
light
L3 Steering
(engine running)

86 30 87d 87c
column
DIODE BOX 4
R27
85 87 87a
D7 D8 D9
2
Controller FRONT TRAVEL
ARRANGEMENT AND OPERATION WX90

6
FAST TRAVEL CONTROL CIRCUIT (HARE)

PRESS SW PRESS SW
SMC
SCM - GND SCM - GND

A 7 D2 D3 D4 D5

P4 P5
A 6

2 2
A 2 A 8

F9112
ES8-4-9
 ES8-4-10

ARRANGEMENT AND OPERATION WX90

4.1.6.3 1st speed transmission control (hare) (engine running)

The input line from fuse N° 32 reaches relay R13 and relay 25.

The input line from fuse N° 31 reaches relay R10 and terminal 10 of mechanical gear controller.

When turning switch (2nd travel speed SW) to hare position a negative signal is sent to mechanical gear
controller terminal 5.

Travel speed switch in 1st speed position sends a negative signal to relay R13 that, in energized conditions,
sends a positive signal coming from fuse N° 32, to solenoid A2.

From fuse n. 28 BRAKE MODE switch is fed.

In working brake position (W) solenoid D 1 (located in brake valve) and relay R4 are fed. The relay, in
energized condition, allows the positive signal coming from fuse N. 26 to reach terminal 87 of relay R4 via
pressure gauge P2 (stop lights).

From terminal 87 the signal reaches warning light L3 (working brake) and terminal 11 of mechanical gear
controller for the enable signal (hare).

The controller allows to send a positive signal from terminal 1 to solenoid A7 (hare) and warning light L14,
as it receives a negative signal at terminal 5 and a positive signal at terminal 11.

NOTE: the tortoise/hare choice can be carried out only with braking mode switch in position W (working
brake).

15501 9-35990
 15501 9-35990

+24volt
2nd travel speed
+24volt
monitor
28

5A
32 31 1 2 3 4 5
3 SPEED
2

10A
10A
1 LOW

SW

W P
10 FIRST GEAR 8
30 POSITION
86 T A/L
SELCTION GEAR
5
R25 SW INPUTT

SECOND GEAR
1
POSITION
Diode 85 87 87a +24volt
5A

WORKING BRAKE 11 26
box 3 SW INPUTT

Wheel controller P2
3 4 86 30
Crab steering
Rod iron Normal
30 86 30 steering steering
R4
86
L13
R13 R10 85 87a L14
87
85 87 87a 85 87 87a Diode box 4 Stop
Diode 87a
box 1 30 87b
light Steering
L3
(engine running)

86 87d column
30
87c
R27 DIODE BOX 4

85 87 87a
D7 D8 D9
2
Controller
ARRANGEMENT AND OPERATION WX90

6 FRONT TRAVEL
PRESS SW PRESS SW
SMC
SCM - GND SCM - GND
1st SPEED (LOW) TRANSMISSION CONTROL CIRCUIT

A 7 D2 D3 D4 D5

P4 P5
A 6

2 2
A 2 A 8

F9113
ES8-4-11
 ES8-4-12

ARRANGEMENT AND OPERATION WX90

4.1.6.4 2nd speed transmission control (hare) (engine running)

The input line from fuse N° 32 reaches relay R13 and relay 25.

The input line from fuse N° 31 reaches relay R10 and terminal 10 of mechanical gear controller.

When turning switch (2nd travel speed SW) to hare position a negative signal is sent to mechanical gear
controller terminal 5.

From fuse n. 28 BRAKE MODE switch is fed.

In working brake position (W) solenoid D 1 (located in brake valve) and relay R4 are fed. The relay, in
energized condition, allows the positive signal coming from fuse N. 26 to reach terminal 87 of relay R4 via
pressure gauge P2 (stop lights).

From terminal 87 the signal reaches warning light L3 (working brake) and terminal 11 of mechanical gear
controller for the enable signal (hare).

The controller allows to send a positive signal from terminal 1 to solenoid A7 (hare) and warning light L14,
as it receives a negative signal at terminal S and a positive signal at terminal 11.

Travel speed switch, in 2nd speed position, sends no signal.

NOTE: the tortoise/hare choice can be carried out only with braking mode switch in position W (working
brake).

15501 9-35990
 15501 9-35990

+24volt
2nd travel speed
+24volt
monitor 28

5A
32 31 1 2 3 4 5
1 SPEED
2

10A
10A
3 LOW

SW

W P
10 FIRST GEAR 8
POSITION
86 30 T A/L
SELCTION GEAR
5
R25 SW INPUTT

SECOND GEAR
1
POSITION
Diode 85 87 87a +24volt
5A

WORKING BRAKE 11 26
box 3 SW INPUTT

Wheel controller P2
3 4 86 30
Crab steering
Rod iron Normal
86 30 steering steering
R4
L13
R13 R10 87a L14
85 87
85 87 87a Diode box 4 Stop
Diode
light
box 1 Steering
L3
(engine running)

86 30 column
R27
85 87 87a
D7 D8 D9
2
Controller FRONT TRAVEL
ARRANGEMENT AND OPERATION WX90

6
PRESS SW PRESS SW
SMC
SCM - GND SCM - GND

A 7 D2 D3 D4 D5
2ND SPEED (INTERMEDIATE) TRANSMISSION CONTROL CIRCUIT

P4 P5
A 6

2 2
A 2 A 8

F9114
ES8-4-13
 ES8-4-14

ARRANGEMENT AND OPERATION WX90

4.1.6.5 3rd speed transmission control (hare) (engine running)

The input line from fuse N° 32 reaches relay R13 and relay 25.

The input line from fuse N° 31 reaches relay R10 and terminal 10 of mechanical gear controller.

When turning switch (2nd travel speed SW) to hare position a negative signal is sent to mechanical gear
controller terminal 5.

Travel speed switch in 3rd speed position sends a negative signal to relay R10 that, in energized conditions,
sends a positive signal coming from steering mode switch controller, to solenoid A8.

From fuse n. 28 BRAKE MODE switch is fed.

In working brake position (W) solenoid D 1 (located in brake valve) and relay R4 are fed. The relay, in
energized condition, allows the positive signal coming from fuse N. 26 to reach terminal 87 of relay R4 via
pressure gauge P2 (stop lights).

From terminal 87 the signal reaches warning light L3 (working brake) and terminal 11 of mechanical gear
controller for the enable signal (hare).

The controller allows to send a positive signal from terminal 1 to solenoid A7 (hare) and warning light L14,
as it receives a negative signal at terminal 5 and a positive signal at terminal 11.

NOTE: the tortoise/hare choice can be carried out only with braking mode switch in position W (working
brake).

15501 9-35990
 15501 9-35990

2nd travel speed +24volt

+24volt monitor
28

5A
32 31 1 2 3 4 5
3 SPEED
2

10A
10A
1 LOW

SW

W P
10 FIRST GEAR 8
86 30 POSITION
T A/L
SELCTION GEAR 5
R25 SW INPUTT

SECOND GEAR
1
POSITION
Diode 85 87 87a +24volt
5A

WORKING BRAKE 11 26
box 3 SW INPUTT

Wheel controller P2
3 4 30 87a
Crab steering
Rod iron Normal
86 30 86 30 steering steering R4
DIODE BOX 4 L13
R13 R10 87c L14
87d
85 87 87a 85 87 87a 87b Stop
Diode Dode box 4
87a light
box 1 30 87b Steering
(engine running)

L3
86 30 87d columnn
87c
DIODE BOX 4
R27
85 87 87a
D7 D8 D9
2
Controller FRONT TRAVEL
ARRANGEMENT AND OPERATION WX90

6
PRESS SW PRESS SW
3rd SPEED TRANSMISSION CONTROL CIRCUIT

SMC
SCM - GND SCM - GND

A 7 D2 D3 D4 D5

P4 P5
A 6

2 2
A 2 A 8

F9115
ES8-4-15
 ES8-4-16

ARRANGEMENT AND OPERATION WX90

4.1.7 STANDARD STEERING CONTROL CIRCUIT (key switch in position ON)

From fuse No. 31 the input reaches wheel controller, terminal 10 of mechanical gear controller, terminal 86
of relay R10 and terminal M of rear wheel alignment sensor.

With STEERING MODE switch in standard position, the input reaches warning light L2 and terminal 30 of
relay R10.

With travel speed switch in high speed position (3rd) a negative signal is sent to relay R 10 which, in energized
condition, allows to feed solenoid A8.

The 3rd speed in standard condition can selected both in hare and in tortoise speed.

15501 9-35990
 15501 9-35990

+ 24 VOLT
31

10A
Mechanical gear controller
FIRST GEAR
10 POSITION 8

SELCTION GEAR 5
Wheel controller SW INPUTT 2nd travel speed
SECOND GEAR
POSITION 1
Crab steering

Rod iron
steering Normal steering WORKING BRAKE
SW INPUTT 11
R4
L1 L2 L3 L4
Terminal 87
A A A GXD GXD FILTERS
3 4
K K K

86 30

R10 L15
85 87 87a L14

Travel speed switch

ARRANGEMENT AND OPERATION WX90

1 23 4 5
3
2
1
2 1 2 1 2 1 M L N 2 1 2 1 2 1
STANDARD STEERING CONTROL CIRCUIT (key switch in position ON)

F F F A A A R25 Terminal 30
3 1 2 8 6 7

Alignment sensor

F9091
ES8-4-17
 ES8-4-18

ARRANGEMENT AND OPERATION WX90

4.1.8 DOUBLE STEERING CONTROL CIRCUIT (key switch in position ON)

From fuse No. 31 the input reaches wheel controller, terminal 10 of mechanical gear controller, terminal 86
of relay R 10 and terminal M of rear wheel alignment sensor.

With STEERING MODE switch in double position, the solenoids F3 and F1 and also warning light L1 are fed.

From mechanical gear controller terminal 8, an output positive signal feeds solenoid A6 (tortoise) and relay
R10 terminal 30 passing through wheel controller.

With travel speed switch in high speed position (3rd) a negative signal is sent to relay R 10 which, in energized
condition, allows to feed solenoid A8.

The 3rd speed in double condition can selectedonly in tortoise speed.

15501 9-35990
 15501 9-35990

+24 VOLT
31

10A
Mechanical gear controller

FIRST GEAR
10 POSITION 8

SELCTION GEAR
Wheel controller SW INPUTT 5 2nd travel speed
SECOND GEAR
POSITION 1
Crab steering

Rod iron
steering Normal steering WORKING BRAKE
SW INPUTT 11
R4

L1 L2 L3 L4 Terminal 87
A A A GXD GXD FILTERS
3 4
K K K

86 30

R10 L15
85 87 87a L14
(key switch in position ON)

Travel speed switch

DOUBLE STEERING CONTROL CIRCUIT

1 2 3 4 5
ARRANGEMENT AND OPERATION WX90

3
2
1

2 1 2 1 2 1 M L N 2 1 2 1 2 1

F F F A A A Terminal 30
3 1 2 8 6 7

F9092
Alignment sensor
ES8-4-19
 ES8-4-20

ARRANGEMENT AND OPERATION WX90

4.1.9 CRAB STEERING CONTROL CIRCUIT (key switch in position ON)

From fuse No. 31 the input reaches wheel controller, terminal 10 of mechanical gear controller, terminal 86
of relay R 10 and terminal M of rear wheel alignment sensor.

With STEERING MODE switch in crab position, the solenoids F2 and F1 and also warning light L3 are fed.

From mechanical gear controller terminal 8, an output positive signal feeds solenoid A6 (tortoise) and relay
R10 terminal 30 passing through wheel controller.

With travel speed switch in high speed position (3rd) a negative signal is sent to relay R 10 which, in energized
condition, allows to feed solenoid A8.

The 3rd speed in crab condition can selectedonly in tortoise speed.

15501 9-35990
 15501 9-35990

+24 VOLT
31
Mechanical gear controller

10A
FIRST GEAR
10 POSITION 8

SELCTION GEAR 5
Wheel controller SW INPUTT

SECOND GEAR
POSITION 1
Crab steering

Rod iron
steering Normal steering WORKING BRAKE 2nd travel speed
SW INPUTT 11

L1 L2 L3 L4
Terminal 87
A A A GXD GXD FILTERS
3 4
K K K

86 30

R10 L15
85 87 87a L14

Travel speed switch

1 23 4 5
ARRANGEMENT AND OPERATION WX90

3
2
1
2 1 2 1 2 1 M L N 2 1 2 1 2 1
CRAB STEERING CONTROL CIRCUIT (key switch in position ON).

F F F A A A Terminal 30
3 1 2 8 6 7

F9093
Alignment sensor
ES8-4-21
 ES8-4-22

ARRANGEMENT AND OPERATION WX90

4.1.10 PARKING BRAKE CONTROL CIRCUIT

From fuse No. 28 the input reaches brake mode switch and the two logic box relays.

In position P of brake mode switch the two logic box relays are energized and also relay R28 cutting off the
solenoid feed E 1 (excluding equipment power control piloting).

At the same time relay R20 is energized. It closes the contact and sends the negative signal to the starter
relay passing through relay R2 contacts. Under these conditions the thermal engine can be started.

With the engine running, when selecting positions W / AL / T, through logic box relays previously energized
by position P, a positive signal is sent to solenoid A 1 which enables parking brake disconnection and L2
warning light turn off. Also travel pedal can be hydraulically fed.

15501 9-35990
 15501 9-35990

Starter 24V Starter swtich

+24 VOLT
28

5A
G e

Starter relay D10

Steering column console
B g
Logic BOX relay STEERING COLUMN CONSOL

Fuse LINK A SW
L1

W P L2

L3
T A/L
L4

L5

86 30 30
86 L6

L7
R2 R20
Fuse LINK B 85 87 87a 85 87 87a
PARKING BRAKE CONTROL CIRCUIT

SW 2 P9
ARRANGEMENT AND OPERATION WX90

1 2

86 30 Parking brake
pressure 1
Monitor R28
2 A 1
85 87 87a

1
2 E 1

F9094
ES8-4-23
 ES8-4-24

ARRANGEMENT AND OPERATION WX90

4.1.11 BRAKE SYSTEM FAILURE CONTROL

Pressure switch P 1 normally closed, cuts off the supply line to buzzer and warning light L7 when brake
system pressure exceeds 90 bar.

15501 9-35990
 ES8-4-25

ARRANGEMENT AND OPERATION WX90

BRAKE SYSTEM FAILURE CONTROL

+24 VOLT

28 L7
5A

P1

Logic BOX relay

L1

L2

L3

L4

L5

L6

L7

P1
15501 9-35990

BZ

F10570
P1
PRESSURE
(Brake light) 90 bar NC.
 ES8-4-26

ARRANGEMENT AND OPERATION WX90

4.1.12 BRAKE SYSTEM PRESSURE INDICATOR LINE

Brake pressure sensor is supplied by SMC with 5 Volt voltage.

The output signal S reaches the instrument located on the central dashboard supplied by 12 Volt voltage.

15501 9-35990
 ES8-4-27

ARRANGEMENT AND OPERATION WX90

BRAKE SYSTEM PRESSURE INDICATOR LINE

+ 24 VOLT

2 3 28
10A
10A

5A
P/M

24 V DC / 12V DC

S/M P/M

MONITOR

10 3 2 1 3 2 1

D1 D2 A13 D6 BN D10 B10 B2 D20

SMC FN NO 714

NEG 2 NEG 1
D15 D18 D22 C19 B9 D4

- -
15501 9-35990

S + S +

Angle Pressure Pressure

sensor sensor sensor

F9106
 ES8-4-28

ARRANGEMENT AND OPERATION WX90

4.1.13 WORKING BRAKE CONTROL (SWITCH SW1 IN POSITION W)

Brake mode switch in position W (working brake):

1) Feeds solenoid DI and warning light L3 (ON), diode box 4 (terminal 87B) and mechanical gear controller
terminal 11.

2) Relay R4 cuts off feeding line to STOP lights.

15501 9-35990
 ES8-4-29

ARRANGEMENT AND OPERATION WX90

WORKING BRAKE CONTROL (SWITCH SW1 IN POSITION W)

P2

+24 VOLT SW1

28 26 L3
5A
5A

86 30
P2

R4 1
2 D I
85 87 87A

Logic BOX relay

L1

SW1 L2
W P
L3
T A/L
L4

L5

L6

L7

DIODE BOX 4
15501 9-35990

TERMINAL 87 B
B D C A A C D E

Mechanical
gear controller
TERMINALS 11
Stop light Stop light

F10571
 ES8-4-30

ARRANGEMENT AND OPERATION WX90

4.1.14 TRANSMISSION CONTROL WITH WORKING BRAKE CONNECTED (W)

From fuse No. 28 BRAKE MODE switch is fed.

In working brake (W) position solenoid D 1 (located in brake valve) and relay R4 are fed. The relay energizes
and enable the positive signal from fuse No. 26 to reach terminal 87 of relay R4 via pressure switch P2 (stop
lights).

From terminal 87 the signal reaches warning light L3 (working brake connected) and, at the same time, the
line reaches diode box 4 terminal 87B and mechanical gear controller terminal 11, to enable the selection
of the desired speed (tortoise or hare).

The selection is obtained by means of 2nd travel speed switch which, in hare position, sends a negative signal
to terminal 5 of mechanical gear controlling thus enabling the positive signal from fuse No. 31 to reach
solenoid A7 and warning light L14.

15501 9-35990
 15501 9-35990

2nd travel speed +24volt

+24volt monitor
28

5A
32 31 1 2 3 4 5
1 SPEED
2

10A
10A
3 LOW

SW

W P
10 FIRST GEAR 8
POSITION
86 30 T A/L
SELCTION GEAR
5
R25 SW INPUTT

SECOND GEAR
1
Diode POSITION
85 87 87a +24volt
5A

box 3 WORKING BRAKE 11 26

SW INPUTT

Wheel controller P2
3 4 86 30
Crab steering
Rod iron Normal
86 30 steering steering R4
L13
R13 R10 87a L14
85 87
85 87 87a Diode box 4
Diode Stop
box 1 light Steering
L3
86 30 colulmn
R27
85 87 87a
D7 D8 D9
2
Controller
6 FRONT TRAVEL
PRESS SW PRESS SW
ARRANGEMENT AND OPERATION WX90

SMC
SCM - GND SCM - GND

A 7 D2 D3 D4 D5

P4 P5
A 6
TRANSMISSION CONTROL WITH WORKING BRAKE CONNECTED (W).

2 2
A 2 A 8

F9110
ES8-4-31
 ES8-4-32

ARRANGEMENT AND OPERATION WX90

4.1.15 EQUIPMENT PILOTING CUT-OFF CONTROL

“Operation piloting control”

Solenoid E1 for piloting cut-off is fed by switch SW2 warning light L12 (OFF), safety lever lowered enabling
to send pilot oil to pilot controls.

With piloting inactive

1) switch SW2 disconnected (warning light L12 ON)

2) safety lever lifted

3) brake mode switch in position P by means of relay R28.

15501 9-35990
 ES8-4-33

ARRANGEMENT AND OPERATION WX90

EQUIPMENT PILOTING CUT-OFF CONTROL

L12

+ 24 VOLT Control cut-off

STEERING COLUMN
SW
CONTROL
5A

28

L8

L12
L10
SW2 L11
L13
L9

L14
L15
L16

L17

SW

W P

T A/L

86 30

R 28

85 87 87a
R 20

SAFETY RELAY B A

terminal 86

1
15501 9-35990

2 E 1

F9095
 ES8-4-34

ARRANGEMENT AND OPERATION WX90

4.1.16 POSITIONER CONTROL (TB)

With button D located on right pilot control a negative signal is sent to controller box.

The voltage signal coming out of fuse No. 37 supplies solenoids B3/B4, warning light L 16 on central
dashboard and relay R 27 which, in energized conditions, cuts off the line from terminal D 9 of SMC to
pressure switches P4-P5. In this way thermal engine speed increase is not possible during T.B. (Positioner)
operation.

Positioner operation is obtained by travel pedal.

15501 9-35990
 15501 9-35990

+24 VOLT

L16

L14
CONTROLLER
BOX
L15
VKEY 8 VBAT 5 10
D CB2
11 L16
D CB3
21
2 D L17
HAZARD
3 E FLASAER 3

4 F 6
GEAR
POSITION 17 A 87a
5 K I
POSITIONING 5A 30 B 87b
VALVE 2 37
87d C 87c

SWD FORWARD 86 30 DIODE BOX 4

18 PRESS SW 7
FORWARD \ REVERS R27
PRESS SW 6
POSITIONER CONTROL CIRCUIT (TP)

SOLENOID 85 87 87a
VALVE 1
ARRANGEMENT AND OPERATION WX90

D7 D8 D9
K A FRONT TRAVEL
A K
PRESS SW PRESS SW
DIODE 9 SMC
1 1 1 1 DIODE 8 1
SCM - GND SCM - GND
1

F9340
D2 D3 D4 D5
B 3 2 2 2 2 2 2
P4 P5 P7 P8 P6
1
B 4 2

B3 B4
ES8-4-35
 ES8-4-36

ARRANGEMENT AND OPERATION WX90

4.1.17 BLADE CIRCUIT

Blade operation is possible regardless speed switch position (hare/tortoise).

Button C on left pilot control enables the feeding of solenoids B1/B2 through relay R12.

15501 9-35990
 15501 9-35990

C
Travel speed
+ 24 volt 10 A switch
32
86 30 86 30 86 30 86 30
R12

85 87 87a 85 87 87a 85 87 87a 85 87

R13 R26 R25
Diode box

30 87d

87c

A 2
87a
C
3 30 87b
B
6 4 87d 87c
BLADE CIRCUIT

G
1 5 Diode box 3
R7 horn

LEFT PILOT CONTROL

ARRANGEMENT AND OPERATION WX90

1
B 1 2

1
B 2 2

F9097
A 2 2
ES8-4-37
 ES8-4-38

ARRANGEMENT AND OPERATION WX90

4.1.18 RIGHT STABILIZER CONTROL

Stabilizer operation is possible regardless speed switch position (hare/tortoise).

Button C on left pilot control enables the feeding of solenoids B1/B2 through relay R12.

NOTE: stabilizer control is possible only with service brake activated or working brake (W) connected.

15501 9-35990
 15501 9-35990

C
Travel speed
+ 24 volt 10 A switch
32
86 30 86 30 86 30 86 30
R12

85 87 87a 85 87 87a 85 87 87a 85 87

R13 R26 R25
Diode box 1

30 87d

87c

A 2
87a
C
3 30 87b
B
6 4 87d 87c
G
1 5 Diode box 3
R7 horn
RIGHT STABILIZER CONTROL

LEFT PILOT CONTROL

1
ARRANGEMENT AND OPERATION WX90

B 1 2

1
B 2 2

F9098
A 2 2
ES8-4-39
 ES8-4-40

ARRANGEMENT AND OPERATION WX90

4.1.19 LEFT STABILIZER CONTROL

Stabilizer operation is possible regardless speed switch position (hare/tortoise).

Button B on left pilot control enables the feeding solenoid A2 through relay R13.

Voltage to solenoids B1/B2 through relay R12.

NOTE: stabilizer control is possible only with service brake activated or working brake (W) connected.

15501 9-35990
 15501 9-35990

B Travel speed
+ 24 volt 10 A switch

32
86 30 86 30 86 30 86 30
R12

85 87 87a 85 87 85 87 85 87 87a
87a 87a
R13 R26 R25
Diode box

30 87d

87c

A 2
87a
C
3 30 87b
B 4
6 87d 87c
G
1 5 Diode box 3
R7 horn
LEFT STABILIZER CONTROL

LEFT PILOT CONTROL

ARRANGEMENT AND OPERATION WX90

1
B 1 2

1
B 2 2

F9099
A 2 2
ES8-4-41
 ES8-4-42

ARRANGEMENT AND OPERATION WX90

4.1.20 HYDRAULIC HAMMER

Hammer control is obtained by pressing button K located on right pilot control which sends a negative signal
to relay R16 enabling solenoid A4 feeding passing through SW4 located on steering column.

4.1.21 GRASS-CUTTER

Grass-cutter control is obtained by pressing button K to feed switch SW4 by means of relay R16.

By means of switch SW4 solenoids A4 or A5 for swing direction are fed.

15501 9-35990
 15501 9-35990

+ 24 VOLT 20
10
30

5A
K SW4

86 30

RIGHT PILOT CONTROL R16

85 87 87a

2 D

3 E
SW4
HYDRAULIC HAMMER, GRASS-CUTTER
ARRANGEMENT AND OPERATION WX90

4 F 6

5 K 1

2 A 5
1

F9100
1
2 A 4
ES8-4-43
 ES8-4-44

ARRANGEMENT AND OPERATION WX90

4.1.22 ARM OSCILLATION CONTROL

By means of button A located on left pilot control, relay R26 is energized and solenoids B5 and B6 are fed.

15501 9-35990
 15501 9-35990

A
+ 24 volt 10 A Travel speed
32
switch
86 30 86 30 86 30 86 30
Diode box 1 R12

85 87 87a 85 87 87a 85 87 85 87 87a

87a
R13 R26 R25

30 87d

87c

A
2
87a
C
3 30 87b

B
6 4 87d 87c
G
1 5 Diode box 3
R7 horn
ARM OSCILLATION CONTROL

LEFT PILOT CONTROL

1
ARRANGEMENT AND OPERATION WX90

1
2 B 5
B 1 2
1
1
2 B 6
B 2 2

F9101
1

A 2 2
ES8-4-45
 ES8-4-46

ARRANGEMENT AND OPERATION WX90

4.1.23 CLAMSHELL BUCKET ROTATION CONTROL CIRCUIT

To operate clamshell bucket circuit, press buttons E or F located on right pilot control. By means of relays
R14 or R15 solenoids C1 or C2 are fed.

15501 9-35990
 ES8-4-47

ARRANGEMENT AND OPERATION WX90

CLAMSHELL BUCKET ROTATION CONTROL CIRCUIT

E F

+ 24 VOLT

Right pilot
5A

control

86 30 86 30

R 15 R 14

85 87 87a 85 87 87a

2 D
1
3 E
C1 2
1 4 F 6
C2 2
5 K

F9102

C2
15501 9-35990

C1
 ES8-4-48

ARRANGEMENT AND OPERATION WX90

4.1.24 AXLE LOCK CONTROL (DISCONNECTED) WITH SW1 IN POSITION T

Solenoid A3 is fed only with brake mode switch in position T (OFF).

Warning light L 1 (OFF).

15501 9-35990
 ES8-4-49

ARRANGEMENT AND OPERATION WX90

AXLE LOCK CONTROL (DISCONNECTED) WITH SW1 IN POSITION T

L1

+24 VOLT

SW
28
5A

Logic relayRELAY
LOGIC BOX box

L1

SW1
L2
W P
L3
T A/L
L4

L5

L6

L7

1
15501 9-35990

2 A 3

F9105
 ES8-4-50

ARRANGEMENT AND OPERATION WX90

4.1.25 WINDSHIELD WIPER CIRCUIT

Windshield wiper switch located on the left side of central dashboard sends some signals to relay R11 for
the operation of windhshield wiper motor and to relay R5 for windshield washer pump.

15501 9-35990
 15501 9-35990

+24 VOLT

12

10 A
1 2 3 4
86 30 86 30 OFF
INT.
R5 R 11 ON
START
85 87a 85 87 87a
87 Windshield wiper switch

L E
WINDSHIELD WIPER CIRCUIT

B
ARRANGEMENT AND OPERATION WX90

Dioide box 2
A

B Windshield wiper motor

Windshield washer pump

F9116
ES8-4-51
 ES8-4-52

ARRANGEMENT AND OPERATION WX90

4.1.25 ROTATING BEACON CIRCUIT

Warning light L13 and relay R8 are fed (ON) by switch SW1, thus enabling the feeding from fuse 30 to rotating
beacon.

15501 9-35990
 ES8-4-53

ARRANGEMENT AND OPERATION WX90

ROTATING BEACON CIRCUIT

L13

20
10
30

SW1

+24 VOLT +24 VOLT

28 30
L8

5A
5A

L12

L10

L11

ROT LAMP SW1

L13

PILOT CUT L9

TBG SW3

L14
OUT GRASS
L15

L16

L17

Steering column panel

86 30
15501 9-35990

R8

85 87 87A

Rotating beacon F9117

 ES8-4-54

ARRANGEMENT AND OPERATION WX90

4.1.26 HORN CIRCUIT

Horn is controlled by means of two different buttons:

- with button G located on left pilot control.

- with button SW2 located on the left side of the steering column.

Both buttons act on relay R7 fed by fuse 15.

15501 9-35990
 15501 9-35990

+ 24 VOLT

15
5A
G

86 30

R7
Horn

85 87 87A
HORN CIRCUIT

A 2

C 3

6 B 4
ARRANGEMENT AND OPERATION WX90

1 G 5
Horn
HORNSW
SW22
Left pilot control
SW2

F9118
ES8-4-55
 ES8-4-56

ARRANGEMENT AND OPERATION WX90

4.1.27 TIPPING CIRCUIT (OPTIONAL)

Warning light L10 is fed (ON) by switch SW3.

The pressure adjustable by SW TBG (OPT) allows a sound when reaching the adjusted pressure.

15501 9-35990
 ES8-4-57

ARRANGEMENT AND OPERATION WX90

TIPPING CIRCUIT

LI0

20
10
30

SW3
+24 VOLT

9 Steering column console

5A

L8
Rotating
beacon L12

Control
L10
disconnection
TBG L11
SW3

L13

L9

L14

L15

L16

L17
Horn TBG (opt.)
15501 9-35990

+ -

Pressure switch TBG (opt.)

F9119
+ 24 VOLT
SOL
B3/B4
33 25

5A
20 A
A 87a

30 B
87b

87d C 87c
V key 8 V Bat 5
86 30
11
21 R27
HAZARD
FLASHER
3 85 87 87a
GEAR
POSITION
17
POSITIONING 5A 37
VALVE
2

FORWARD
PRESS SW 7
FORWARD /REVERSE
PRESS SW
6

SOLENOID
VALVE D7 D8 D9
1
FRONT TRAVEL S
PRESS SW PRESS SW
4

SMC
PRESSURE SWITCH LINE CIRCUIT

SCM-GND STEP/M-GND SOLENOID

ARRANGEMENT AND OPERATION WX90

A K K A D12 D13 A11 A14

DIODE 9 1
1 1 1 1 DIODE 8

2 2 2 2 2

F9103
P4 P5 P7 P8 P6
ES8-4-58

15501 9-35990
 F9104
5A
6
+ 24 VOLT
1

5A
15501 9-35990

239
241

237 C-9
238 C-10
248 C-20
240 C-12
C-13

1
C-3 R1A

M4
230 C-2 BVCC
C-11 BVCC

R1A
C-19 TEMP METER
l/M
L
LAMPS

GAUGE
+20 V
L

MAIN

FUEL METER
ILLUMINATION

C18
F/M
BATTERY
BACKUP

BATTERY

C
+9 V

MOMENTALY
1Kx3

C-7 E MODE IN MOMENTALY

MOMENTALY

C6 HP MODE IN
MOMENTALY
ALTO IDLE SW
MONITOR

MODE SW

A12 BACK-UP EN-INPUT

MODE

HP MODE LED
LED

E MODE LED
SID M1 M2 M3

AUTO IDLE LED

ENG. OIL
LEVEL SW

B-3 E-MODE OUTPUT TRAVEL2

REALLY HIGH
SPEED SW B-5
B-9 MODE OUTPUT 1
TRAVEL

B-10 MODE OUTPUT 2

2 SPEED SW

LOW
B-1 AUTO IDLE OUTPUT
??? SPEED OFF
B-11 HP MODE OUTPUT
RAD.

A-11 WIPER RY OUTPUT A OFF

RE
A-6 WIPER RY OUTPUT A WIPER SW AL
LY
WASHER SW
LEVEL SW

WIPER SELECTOR

CAAB WIRE D2
96 K

ENG.OIL LEVEL 5
WIPER OFF SW D3

L1
WIPER ON SW D4
COOLING WATER LEVEL

6
WIPER VOL SW D4
HYD

L2
WASHER SW D5
WASHER SW

7
HY OIL LEVEL
LEVEL SW

L3
8
CHARGE

L4
LIGHT 1A LIGHT 2 LIGHT RY OUTPUT 2 B-8

9
ENG.OIL PRESSURE
1

L5
REALLY LIGHT LIGHT RY OUTPUT 1 B-7
ENG. OIL

LIGHT SW
PRESS SW

10
OVER HEAT
OFF

L6
12
FUEL ALARM

L7
5,6KX7
SW1 A-7
18 19

A-8

13
AIR CLEANER SW2
OVER

L8
C15 AIR HEATER RY SW3 A-9
HEAT SW

20 21

SW5 A-10

14

L9
22
SW6 A-11
C16 WORKING LIGHT SW

15
25
SW7 A-2
AIR

L10
C17 SPARE

16
26

5,6KX3
SW8 A-3

L11
CLEAN. SW

OPEN A-4
WIPER RY OUTPUT A
B14 OPEN

27 28
A-5

3
B15 WIPER RY OUTPUT B

4
ALTERNATOR C-14
B16 WIPER RY OUTPUT C

11
BZ
B12 WIPER RY OUTPUT BN
A LOAD DUMP B-6

34
B12 WASHER RY OUTPUT HOUR METER C-1

S/M
SMC
TOB3
CONTROL CIRCUIT FOR TEMPERATURE AND PRESSURE LEVELS
ARRANGEMENT AND OPERATION WX90
ES8-4-59
 ES8-4-60

ARRANGEMENT AND OPERATION WX90

4.1.28 BRAKE SIGNAL CONTROL (STOP LIGHTS)

P2

+24 VOLT

28 26 P2

Pressure switch normally

5A
5A

open 5±0.5 BAR

86 30
P2

R4 1
2 D I
85 87 87A

Logic relé box

L1

SW1 L2
W P
L3
T A/L
L4

L5

L6

L7

DIODE BOX 4
TERMINAL 87 B
15501 9-35990

B D C A A C D E

Mechanical
gear controller
TERMINALS 11
Stop light Stop light
F10572
 ES8-5-1

ELECTRONIC UNITS WX90

5. ELECTRICAL SYSTEM GENERALITIES

5.1 CONNECTIONS WITH DIODES

The systems of this group identify the connections coming and leaving the groups for an esier troubleshooting.
They also identify all the wire as numbered on the machines.
15501 9-35990

F9295
 ES8-5-2

ELECTRONIC UNITS WX90

5.2 CONNECTIONS WITH FUSE BOX

15501 9-35990

F9297
 ES8-5-3

ELECTRONIC UNITS WX90

5.3 CONNECTIONS WITH MINI RELAYS

F9296
15501 9-35990
 ES8-5-4

ELECTRONIC UNITS WX90

5.4 CONTROLLER

5.4.1 GENERALITIES

The electronic controlled, located under heater control, checks minirelay operation (with start-up key in first
position.

CONTROLLER BOX

F9300

15501 9-35990
 ES8-5-5

ELECTRONIC UNITS WX90

5.5 MONITOR CONNECTIONS ON SWITCHES-INDICATORS PANEL

F8934
15501 9-35990
 ES8-5-6

ELECTRONIC UNITS WX90

5.6 CONNECTIONS BETWEEN OPERATOR'S SEAT AND FRAME

Frame wire

F8935 15501 9-35990

 ES8-5-7

ELECTRONIC UNITS WX90

5.7 CONNECTIONS WITH OPERATOR'S RIGHT SIDE

F8936
15501 9-35990
 ES8-5-8

ELECTRONIC UNITS WX90

5.8 CONNECTIONS WITH OPERATOR'S LEFT SIDE

F9305

15501 9-35990
 ES8-5-9

ELECTRONIC UNITS WX90

5.9 THROTTLE PISTON CONTROL ELECTRONIC UNIT (SMC)

5.9.1 GENERALITIES

The electronic unit, located into radiator compartment, is providing the control of the throttle control piston.
The variation of the engine speed, can occur in a pre-arranged mode or manually. In both cases, the unit
controls the electrical motor, that will position the lever located on the injection pump, at an angle
corresponding to the desired engine speed.

F9306
15501 9-35990
 ES8-5-10

ELECTRONIC UNITS WX90

5.10 CONNECTIONS BETWEEN OPERATOR'S SEAT WIRE AND FRAME WIRE

Operator's seat wire

F9308
15501 9-35990
 ES8-5-11

ELECTRONIC UNITS WX90

5.11 CONNECTIONS WITH TEST CONNECTOR

DOCTOR EX PROGRAMMATION SWITCH

F9307
15501 9-35990
 ES8-5-12

ELECTRONIC UNITS WX90

5.12 CONNECTIONS WITH STEERING COLUMN

F7130

15501 9-35990
 ES8-5-13

ELECTRONIC UNITS WX90

5.13 ANTI-START DEVICE CONNECTIONS

F13607
15501 9-35990

1 - Anti-start device wrench

2 - Anti-start device gearcase
 ES8-5-14

ELECTRONIC UNITS WX90

Principal electric cable

B
B

A
A

F13608
15501 9-35990
 ES8-6-1

ELECTRIC COMPONENTS WX90

6. ELECTRIC COMPONENTS

6.1 THROTTLE CONTROL

The throttle control is operated by an EC motor and swing is controlled by the sensore located on the metal
housing next to EC motor rotor. EC motor (1) has no possibility of being disassembled, since its components
(housing, electric motor, mobile rod, cap) cannot be maintained.

F7462

EC MOTOR

The EC motor is used to adjust engine speed.

It includes a worm screw coupled to a helical wheel to avoid synchronism loss.
On the outlet gear is fitted an angle sensor measuring EC motor swing degrees to calculate the position of
injection pump control.

Outlet shaft Worm screw

Outlet gear
15501 9-35990

Sensor gear
Motor

Angle sensor F7497

Helical wheel
 ES8-6-2

ELECTRIC COMPONENTS WX90

6.2 CENTER JOINT

6.2.1 GENERALITIES

The center joint, allows the passage of hydraulic oil and the electrical wiring between the turret (swinging part)
and the undercarriage (fixed part).
The description here below analyses the electrical collector only.
This collector is made of a ten ring pack (1), separated by insulating diaphragms and brushes (2) equipped
with connectors for the input and output wires.
The ring pack is secured to the inner part of the support, whereas the brush holder groups are connected to
the structure of the collector itself, that in turn, is secured to the outer part of the center joint.
The particular structure of protection cover (3), opening upward, allows the wiring, inspection and maintenance
operations.

6.2.2 MAINTENANCE

In order to obtain a correct wiring, it is necessary to follow the follow cautions:

• check that, internally, there are no eventual deposits of graphite powder; in such a case, remove them using
a dry rag;
Warning - Never use water or other liquids. The rings must always be dry and clean.
• ensure that the contact between wire and brush holder is perfect;
• check that the input and output wires are correctly secured, so that any interference of the wires with moving
parts is avoided;
• check that all brushes are perfectly placed in their seat and aligned in the groove of the corresponding ring;
• check the correct tightening of all electrical and hydraulic connections.

WARNING - Always disconnect the electric power prior to the removal of the protecting cover and ensure that
it cannot be returned during the maintenance operations.

3
2

F9299
15501 9-35990

1 - Rings pack
2 - Brush holder group
3 - Protecting cover
 ES8-6-3

ELECTRIC COMPONENTS WX90

6.3 BATTERIES

6.3.1 DESCRIPTION

The machine includes two free-maintenance and series-mounted batteries (1). For battery disconnection, set
the relative switch (2) to position OFF.

6.3.2 ELECTRICAL FEATURES

Nominal voltage 12V

Nominal capacity (20 h) 75 Ah

Discharge current (-18°C) 440 A

6.3.3 MAINTENANCE PRECAUTIONS

• Make sure the two batteries are correctly connected.

• Batteries contain SULPHURIC ACID:
Always protect your eyes when working near batteries, to avoid accidental contact with the acid solution.
In case the solution comes in contact with your skin or eyes, rinse immediately and call a doctor.
• The gas released by the batteries is highly inflammable:
in case of battery recharge, leave battery compartment open to improve ventilation. Avoid to recharge in
closed rooms. Do not keep sparks or open flames close to batteries.
• Disconnect batteries before any maintenance operation on main machine electrical system.

6.3.4 PROTECTION FUSE

The electrical system includes two fuses Link 40A and one fuse Link 80A for battery protection located in the
same compartment.
15501 9-35990

F7004
 ES8-6-4

ELECTRIC COMPONENTS WX90

6.4 ALTERNATOR

6.4.1 DESCRIPTION

The alternator pulley receives motion by drive shaft pulley by means of transmission belt. Tension adjuster
is mounted on the rear part of the alternator itself.
This adjuster is sealed, therefore maintenance is not possible.

6.4.2 OPERATION

The electrical operation of group alternator-rectifier-tension adjuster is the following. By rotating the alternator
pulley, an alternate tension is produced in the stator windings due to rotor remaining magnetism.
Diodes in rectifier bridge transform stator alternate tension into direct tension between terminal (B+)
connected with the batteries and ground.
Alternator rotation speed increases and electrical current is supplied for battery charge and user feeding.
A part of the generated output is sent to inductor winding and controlled by the tension adjuster to allow
alternator output feeding in the different charge conditions.

6.4.3 FEATURES

Output 24V 55A

Rotation clockwise

F7006
15501 9-35990
 ES8-6-5

ELECTRIC COMPONENTS WX90

6.4.4 MAINTENANCE PRECAUTIONS

Follow the indications herebelow to avoid diode or transistor damage:

• Do not disconnect batteries with the engine running. This would cause a sudden tension change in alternator
charge system, producing serious damage.
• Do not disconnect any electrical wire before the engine stops and before all switches are in OFF position.
• Do not short-circuit by connecting electrical wires to wrong terminals. Always identify the correct terminal
before the connection. A short-circuit or a wrong connection generating a reverse polarity causes serious
damages.
• Do not search for tension by means of sparkle contacts.

6.4.5 PROTECTION FUSE

The electrical system includes a fuse Link 80A for alternator protection, mounted on the alternator itself.
15501 9-35990
 ES8-6-6

ELECTRIC COMPONENTS WX90

6.5 STARTER

6.5.1 DESCRIPTION

The starter essentially includes:

• an electromagnetic switch for pinion connection on crown teeth and electrical contacts closing;
• a real electrical motor including fixed windings (inductors) and mobile windings on rotor (induced);
• a return device for pinion connection.

6.5.2 ELECTRICAL FEATURES

Voltage 24 V

Rotation clockwise

Control electromagnetic

Power 4 kW

6.5.3 PROTECTION FUSE

The electrical system includes a fuse Link 40A for start-up spool protection.

15501 9-35990

F7005
 ES8-6-9

ELECTRIC COMPONENTS WX90

NOTES:
15501 9-35990
 ES8-6-10

ELECTRIC COMPONENTS WX90

ELECTRICAL SYSTEM DESCRIPTION

1. Batteries 84. Programming switch connector
2. Battery isolator relay 85. Level check button (CHECK)
3. Stater motor 86. Buzzer stop button
4. Starter relay 87. Windscreen washer control button
5. Fuse 4 (BOX B) (opt) 88. Windscreen wiper control button
6. Key-start switch 89. Lights control button
7. Diode 1 90. Blade/stabilizer solenoid valve B1
8. Diode 6 91. Blade/stabilizer solenoid valve B2
9. Cold start aid 92. Solenoid valve for left bucket swingC1
10. Engine stop solenoid 93. Solenoid valve for right bucket swing C2
11. Horn button 94. Grass-cutter/hammer solenoid valve A5
12. Horn relay R7 95. Grass-cutter solenoid valve A4
13. Windscreen washer electrical pump relay R5 96. Swing solenoid valve B3
14. Horn 97. Swing solenoid valve B4
15. Fuse 1 (BOX A) 40 Amp 98. Controller box
16. Step-by-step motor 99. Air conditioner control panel
17. Left-hand control lever 100. Air conditioning system (opt)
18. Alternator relay R1 101. Auto/idle control button
19. Right-hand control lever 102. Steering mode switch
20. Windscreen wiper 103. Relay R25
21. Windscreen washer electrical pump 104. Hydraulic transmission solenoid valve A8
22. Cab light 105. Rod steering solenoid valve F3
23. Fuse box 106. Rear steering lock solenoid valve F1
24. Compressor relay (opt) 107. Crab steering solenoid valve F2
25. Radio 108. Sensor for rear axle aligned wheels
26. Cigar lighter 109. 2nd speed solenoid valve A7
27. Safety relay R20 110. 1st speed solenoid valveA6
28. Conditioned air thermostat 111. Unused warning light
29. Boom light 112. Pressure switches
30. Preheating 113. Parking brake pressure switch
31. Light relay on arm R6 114. Air conditioning compressor engage control (opt)
32. Alternator 115. Mechanical transmission control
33. Swing solenoid valve B5 116. 3rd speed relay R10
34. Fuse 3 (BOX B) 80A 117. Brake oil pressure sensor
35. Swing solenoid valve B6 118. Relay R11
36. Engine stop coil relay R17 119. Preheating relay
37. Diode 5 120. Control check relay R28
38. Diode 7 121. Diode 4
39. Air filter restriction sensor 122. Relay R18
40. High engine coolant temperature sensor 123. Work lamp warning light
41. Hydraulic oil level sensor 124. Relay R19
42. Engine coolant level sensor 125. Fuse 2 (BOX A) 40A
43. Engine oil level sensor 126. Relay R8
44. Fuel level sensor 127. TBG horn (opt)
45. Engine coolant temperature sender 128. Relay R21 (opt)
46. Low engine oil pressure sensor P7 129. TBG pressure switch (opt)
47. Relay R12 130. Safety switch
48. Relay R13 131. Relay R23
49. Relay R26 132. Auto/Idle relay R27
50. Relay R15 133. Relay R22
51. Diagnostic tool connection (Dr. EX) 134. Relay R4
52. Engine speed hand control 135. Steering column
53. (SMC) main controller unit 136. Brake failure pressure switch
54. E button (Economy) 137. Low pressure brake pressure switch
55. Relay R14 138. Work brake solenoid valve D1
56. Engine speed control unit 139. Front floodlight
57. Anti-load dump relay R3 140. Front side direction indicators
58. Safety relay R2 141. Rear lights
59. Relay R16 142. Number plate light
60. Electrical fuel lift pump 143. Loud-speakers
61. Engine speed control unit panel light 144. Aerial
62. Optional equipment connector 145. Diode box 1
63. Engine speed pedal enabling connector 146. Diode box 2
64. Air conditioner pressure switch 147. Diode box 3
65. Hour-counter 148. Diode box 4
66. Engine coolant temperature gauge 149. Complete control module
67. Fuel level gauge 150. Travel speed selector
68. Instrument panel lighting 151. Diode 9
69. Engine oil level warning light 152. Connector (normally open) (opt)
15501 9-35990

70. Engine coolant level warning light 153. Rotating beacon

71. Hydraulic oil level warning light 154. Parking brake solenoid valve A1
72. Battery charge malfunction warning light 155. Control check solenoid valve E1
73. Low engine oil pressure warning light 156. Axle lock solenoid valve A3
74. High engine coolant temperature warning light 157. Diode 8
75. Buzzer 158. Check panel diode
76. Travel speed sensor 159. Working light switch
77. Air filter restriction warning light 160. Emergency lights switch
78. Low fuel level warning light 161. Direction indicator control
80. Angle (EC) sensor 162. 1st, 2nd, 3rd speed switch
81. Auto/idle indicator (led) connected 163. Preheating warning light
82. E mode engaged light (led) 164. Resistance
83. Stabilizer solenoid valve A2 - 1st travel speed
 ES8-6-11

ELECTRIC COMPONENTS WX90

See Poster
Electrical Circuit
9-40340
15501 9-35990
CAB ELECTRICAL CABLE
 INDEX WX90 - 9 - 1

WX90

SECTION 9 TROUBLESHOOTING

INDEX

Group 1 - INTRODUCTION ......................................................................................... TS9-1-1

1.1 General information

Group 2 - HYDRAULIC SYSTEM TROUBLESHOOTING .............................................. TS9-2-2

2.1 Generalities
2.2 Front attachment
2.3 Swing
2.4 Travel
2.5 Brake system
2.6 Steering system
2.7 Drive axles
2.8 Transmission

Group 3 - ELECTRICAL SYSTEM TROUBLESHOOTING ............................................. TS9-3-1

3.1 Electrical system components

3.2 Relays and fuses
3.3 Checks on electrical components
3.4 Pilot electronical circuit checks
3.5 Brake system electrical circuit checks
3.6 Travel control electrical circuits checks
3.7 Stabilizers control electrical circuits checks
3.8 Blade control electrical circuit checks
3.9 Positioning control electrical circuit checks
3.10 Hammer control electrical circuit checks
15501 9-35990

3.11 Axle lock electrical circuit checks

3.12 Throttle control electrical circuit checks
3.13 Diesel engine failed start-up
3.14 Monitor failed to operate with start-up key in "ON" position
3.15 Steering control
3.16 Test harnesses
15501 9-35990
 TS9-1-1

INTRODUCTION WX90

1. INTRODUZIONE

1.1 GENERAL INFORMATION

These six basic steps are essential for efficient
troubleshooting:

1. Study the system.

2. Ask the operator.
3. Inspect the machine.
4. Operate the machine yourself.
5. Perform troubleshooting.
6. Trace possible causes.

1.1.1 STUDY THE SYSTEM

Study the machine’s technical manuals. Know the system

and how it works, and what the construction, functions
and specifications of the system components are.

1.1.2 ASK THE OPERATOR

Before inspecting, get the full story of malfunctions from

your star witness-the operator.

(a) How is the machine being used?

(Find out if the machine is being operated correctly).

(b) When was the trouble noticed, and what types of

work was the machine doing at that time?

(c) What are the details of the trouble?

Is the trouble getting worse, or did it appear suddenly
for the first time?

(d) Did the machine have any other troubles previously?

If so, which parts were repaired before?

1.1.3 INSPECT THE MACHINE

Before starting the troubleshooting procedure, check

the machine’s daily maintenance points, as shown in
the operator’s manual.
Also, check the electrical system, including the batteries,
as troubles, in the electrical system such as low battery
voltage, loose connections and blown fuses will result in
malfunction of the controllers, causing total operational
15501 9-35990

failure of the machine.

Fuse failure is often caused by a fine crack in the fuse,
and such fine cracks are very hard to detect by visual
inspection.
 TS9-1-2

INTRODUCTION WX90

1.1.4 OPERATE THE MACHINE YOURSELF

Try to identify the trouble by operating the machine

yourself.
If the trouble cannot be confirmed, stop the engine and
obtain further details of the malfunction from the
operator.
Also, check for any incomplete connections of the wire
harnesses.

1.1.5 PERFORM TROUBLESHOOTING

CAUTION: Never attempt to disconnect harnesses

or hydraulic lines while the engine is running. The
machine may malfunction or pressurized oil may spout,
possibly resulting in personal injury. Be sure to stop the
engine before disconnecting harnesses or hydraulic
lines.

With the information obtained from the above operations

of point (1) to (4), and with the help of following
diagnosing diagrams, perform the check and
measurements in order to identify the causes of the
malfunction.

1.1.6 TRACE POSSIBLE CAUSES

Before reaching a conclusion, check the most likely

causes again. Try to identify the actual cause of the
trouble.
Based on your conclusion, make a plan for appropriate
repairs to avoid consequent malfunctions.
15501 9-35990
 TS9-2-1

HYDRAULIC SYSTEM TROUBLESHOOTING WX90

• For the hydraulic system general diagram, refer to the diagram attached at the end of section 7.

• For the electrical system general diagram, refer to the diagram attached at the end of section 8.
15501 9-35990
 TS9-2-2

HYDRAULIC SYSTEM TROUBLESHOOTING WX90

2. HYDRAULIC SYSTEM TROUBLESHOOTING

2.1 GENERALITIES
2.1.1 NO ACTUATORS MOVE WHEN CONTROL LEVERS ARE OPERATED

Set parking brake

No mode selector to No Activate power
control release
, , ,
switch.
as required.

No actuators
move when Check that brake Check that power No Shift lever down to
control levers are mode selector is Yes control lock switch work position.
operated. not set to parking located in steering
Whit correct brake mode. column is released.
reservoir oil level.

Yes Check if armrest No

power control lock
lever is lowered.

Check for the Check for power

correct operation of control pressure by
accumulator/divi- Yes applying a pressure
Yes Yes
der load valve, gauge to the
fitted to pedal special intake.
supplying power
controls.

Yes
Check oil filter.

No Clean, repair or
replace.

No Replace filter cart-

Check for the ridge.
correct operation
Yes of solenoid valve
fitted to power
15501 9-35990

control block.

Repair or replace
No and check wiring
harness. See
groupe 3.
 TS9-2-3

HYDRAULIC SYSTEM TROUBLESHOOTING WX90

Yes Repair or replace

No diesel engine
Clean, adjust. power take-off.

Check if relief Yes Check if oil is

pressure is available in pump
regular. suction

Check for the

Yes No Check if piping oil
correct operation
of gear pump fitted flow is free.
to diesel engine.

No Replace suction
No piping.
Replace.
15501 9-35990
 TS9-2-4

HYDRAULIC SYSTEM TROUBLESHOOTING WX90

2.1.2 ACTUATOR DOES NOT STOP WHEN THE PILOT VALVE LEVER IS RETURNED TO NEUTRAL

Yes Replace or repair

pilot valve.
Check if, with pilot
Actuator does not shut-off lever on the
stop when the armrest in the Yes
Repair or replace.
pilot valve lever is locked position
returned to neutral. (safety), actuator
stop to move.
Actuator is
internally leaking.
No

Control valve spool

is abnormal. Repair
No or replace control
valve.

15501 9-35990
 TS9-2-5

HYDRAULIC SYSTEM TROUBLESHOOTING WX90

2.1.3 OIL TEMPERATURE IS ABNORMALLY HIGH

Yes
Clean oil cooler.

Yes Remove blocking

Oil temperature is Is oil cooler object.
abnormally high. clogged?

Is an object
blocking the oil
cooler or engine
No compartment with Yes
modified openings? Adjust fan belt.

Yes Replace bypass

Is fan belt slip- relief valve.
No ping?

Is oil cooler bypass

relief valve faulty?
No

Is return line clog-

No ged?
15501 9-35990

Replace.
Yes
 TS9-2-6

HYDRAULIC SYSTEM TROUBLESHOOTING WX90

2.2 FRONT ATTACHMENT

2.2.1 SOME OF THE CYLINDERS DO NOT MOVE WHEN PILOT CONTROL VALVE IS OPERATED

Yes Check or repair

user cylinder.

Yes
Does pressure
reach cylinder?

Check or replace
No pipings.

Some of the Is there any

cylinders do not pressure at con-
move when pilot trol valve piloting
control valve is the concerned
operated. section?

Yes Is pipe broke,

smashed?
Check for control
Yes
valve correct
operation.
Replace control
Check for power valve.
No
control pressure.
No
15501 9-35990

* See
2.1.1.
group
No
 TS9-2-7

HYDRAULIC SYSTEM TROUBLESHOOTING WX90

2.2.2 FRONT ATTACHMENT MOVEMENTS ARE SLOW

No Check engine fuel Check engine

filter and air filter. speed.

Yes Carry out the main

Yes Is engine fast idle pump flow test.
rpm normal?
Check the ∆p
between port M and
No LS signal of main
pump should 18
bar.
Front attachment
movements are
Is hydraulic pilot Set the ∆p values
slow.
on main pump.
Yes pressure normal? No

Repair or replace
pilot relief valve on Check the priority
Check if operation Yes utility solenoid No valve.
mode control is valves assembly.
normal.

Check the compen-

sator related to the
Yes
actuator on control
valve, clean or
Check the input replace.
pilot pressure of the
control spool
No related to the slow
actuator on the
control valve.
Check the pilot line.
15501 9-35990

No
 TS9-2-8

HYDRAULIC SYSTEM TROUBLESHOOTING WX90

2.2.3 NO DIGGING POWER

Yes Is hydraulic oil level

low?

Yes Does pump make

abnormal noises?

No
Do all actuators fail
to provide digging
power?

Replace overload
Does only one
relief valve with one
actuator fail to
from a functioning
No provide digging
actuator. Does
power?
problem disappear? 15501 9-35990
 TS9-2-9

HYDRAULIC SYSTEM TROUBLESHOOTING WX90

Yes
Add hydraulic oil.

Yes Repair suction line.

Is there looseness
No in suction line?
The pump is
No failed.

Check correct set

adjustment of the
No Load Sensing valve
(330 bar) and main
over pressure
Is main pump pres- valve.
sure normal?

Check the main

Yes pump flow.

Yes Replace overload

relief valve.
Check spool of con-
trol valve for
Yes cleanliness.
Check compensator
for cleanliness or
Is the pilot pressure replacement.
input on the spool
of control valve
No
normal?

Check the pilot line.

No
15501 9-35990
 TS9-2-10

HYDRAULIC SYSTEM TROUBLESHOOTING WX90

2.2.4 FRONT EQUIPMENT DROPS WHEN THE PILOT CONTROL VALVE IS PLACED IN NEUTRAL

Pilot valve output

Yes pressure is impro-
perly adjusted. Re-
pair or replace.

Does phenomenon
change when diesel Yes Replace overload
engine is stopped? relief valve.
Replace tempo-
rarily for test
purpose only, the
overload relief
No valve with one from
a functioning actua- Yes Repair or replace
tor. Does problem Check for control control valve.
disappear? valve spool
cleanliness and
damage (broken
No
spring or loose
Repair or replace
bolt).
cylinder.
No

15501 9-35990
 TS9-2-11

HYDRAULIC SYSTEM TROUBLESHOOTING WX90

2.2.5 ACTUATOR DROPS BRIEFLY WHEN STARTING OPERATION

In slight operation,
attempt to lift the Malfunctioning control
front falling in the valve.
direction of gravity. Repair or replace.
15501 9-35990
 TS9-2-12

HYDRAULIC SYSTEM TROUBLESHOOTING WX90

2.3 SWING

2.3.1 SWING IS ROUGH

The output pilot

Yes pressure from pilot
control valve is not
delivered linearly.

Is phenomenon
Yes reversed when right
and left pilot hoses
are interchanged?

No

Is only swing Swing is rough in

function rough? one direction only.

Yes Is drain oil amount

from swing motor
normal?

Is swing parking
brake release
No pressure normal?

No
15501 9-35990
 TS9-2-13

HYDRAULIC SYSTEM TROUBLESHOOTING WX90

Yes Check the control

valve spool.

Check or replace
the pilot control
No valve.

Check the control

valve spool.

Yes Check setting of

the swing over
pressure valve.

Check swing mo-

No tor.

Check pilot line for

damage.
15501 9-35990
 TS9-2-14

HYDRAULIC SYSTEM TROUBLESHOOTING WX90

2.3.2 NO SWING MOTION

Is pilot pressure
delivered to swing
Yes
overpressure val-
ve inlet on swing
motor?

Yes Is pressure at
swing control valve
normal?

No

Are all functions

Yes
other than swinging
normal?

Only swing function

does not move?
Confirm that pilot
shut-off lever on
armrest should in
work position and
that swing lock No
lever is released.

No function work.
15501 9-35990

No
 TS9-2-15

HYDRAULIC SYSTEM TROUBLESHOOTING WX90

Yes Swing device is

abnormal.
Is swing motor
Yes drain overflowed
When the swing is normal in amount?
actuated, is the Repair or replace
No pressure delivered swing motor.
to the swing No
parking brake
Does machine not release normal?
Yes swing even though Check pilot circuit.
swing motor is No
rotating?
Check swing de-
vice (connection
between pinion and
Yes
gear).

Check control val-

Yes
ve. Repair or re-
place.
Is swing motor
drain amount
No normal?
Repair or replace
swing motor.
No

Repair or replace
left pilot control
valve.

Check swing pump

operation.

See group 2.1.1.

15501 9-35990

Move the pilot

shut-off lever to
work position.
 TS9-2-16

HYDRAULIC SYSTEM TROUBLESHOOTING WX90

2.3.3 SLOW/WEAK SWING

Yes

Both swing acce-

leration and left
swing brake are
Yes
incorrect, or both
left swing acce-
leration and right
brake are incorrect.
Acceleration force
is not available but
No braking force is
normal.

Swing acceleration No swing power in

is slow. one direction.

No

All functions other

than swing move-
No ment are normal.

Is pilot pressure
setting normal?
Yes
15501 9-35990
 TS9-2-17

HYDRAULIC SYSTEM TROUBLESHOOTING WX90

Check swing over Adjust or replace

Yes swing over pres-
pressure valve
sure valves on
Does phenomenon setting.
engine.
reverse when the
supply hoses to
swing motor are
interchanged?
Replace swing
No motor.

No Repair or replace
control valve.
Is phenomenon
reverse when right
and left pilot hoses Yes Repair or replace
are interchanged control valve.
Check if the
on swing motor?
operation of the pilot
Yes control valve is
normal. Repair or replace
pilot control valve.
No

Check swing
pump.

No Check pilot circuit

and pilot control
valve.

Is swing motor
Yes Repair or replace
drive pressure
swing motor.
Is the pressure normal?
delivered to engine
Yes
swing brake fitting,
while swing lever
Is the pressure operated, normal? Repair or replace
delivered to port shuttle valve and/
of swing parking No or throttle valve.
Yes brake shuttle valve
normal?

Check pilot circuit.

No
15501 9-35990
 TS9-2-18

HYDRAULIC SYSTEM TROUBLESHOOTING WX90

2.4 TRAVEL

2.4.1 NO TRAVEL (Other functions normal)

Check if pilot
Yes pressure reaches
control valve
spools.

Travel does not

move with any Is solenoid valve
speed if controlled. A1 operating?

Check electrical
system and see
No group 2.1.1.
15501 9-35990
 TS9-2-19

HYDRAULIC SYSTEM TROUBLESHOOTING WX90

Check if con-
Yes nection
is operating.
Repair or replace.
Check if piloting
Yes reaches trans-
mission

Check electrical
system and sole-
noid valves A6 and
No A7 and relative
wiring harness.

Check electrical
system.
No
15501 9-35990
 TS9-2-20

HYDRAULIC SYSTEM TROUBLESHOOTING WX90

2.5 BRAKE SYSTEM

2.5.1 BRAKE SERVICE FAULTY

Reduce pressure acting on ad-

Wrong pressure juster located under pedal, meas-
Strong braking.
setting. uring pressure with a gauge.

Increase pressure acting on

adjuster located under pedal,
Wrong pressure measuring pressure with a gauge;
Poor braking.
setting. TAKE CARE not to exceed
pressures set for brakes.

Insufficient feeding
Delayed braking
and discharge
and braking speed of the High viscosity of the brake oil.
release. brakes.

Minimum pressure
Fluctuating of the accumulators Check correct setting of
braking pressure. is lower than max. accumulators pressure.
brakes pressure.

Check nitrogen pressure of

accumulators, after discharging
oil from them, using the
Accumulators with
appropriate instrument than
nitrogen precharge
recharge. It is possible to measure
low or too high.
the pressure of the nitrogen
reading the pressure of the last
Continuous
portion of oil being discharged.
recharge of
accumulators.
15501 9-35990

Leakage on feeding Remove leakage.

accumulators line.
 TS9-2-21

HYDRAULIC SYSTEM TROUBLESHOOTING WX90

Check the sliding of all parts, in

detail of the charging accumulator
input valve.

A foreign body
prevents the sliding
The accumulators Check hydraulic connections for
of accumulator
do not charge. leakages.
charging valve in
the brake pedal.

Check, following overhaul of

accumulator charge valve, the
correct position of stop ring of
plunger located in front of feeding
connection.

Check the brake valve for free

Drain of brake drain. Disconnect hose N
valve not free. connection to hydraulic oil tank to
check free flow.

Brakes stay on.

Check that setting of pedal stop
allows a small play between
linkage and actuating pistons.
Pedal does not
return.

Eliminate possible clogging inside

the chamber under the pedal.

Check adjustment pressure

The indicator on the
steering column
does not give any
signal.
switch, located on charge valve,
Check pressure
the pressure setting should ensure
setting.
3 or 4 brakings from indicator
coming ON.

Sudden changes of
Shocks felt on Check free flow to the hydraulic
pressure on
pedal. oil tank.
discharge.

Incorrect adjustment Inspect the disc thickness and if

15501 9-35990

Insufficient braking. or brake discs worn the discs are usable readjust
out. brakes.

Loss of hydraulic Check and repair any leaks in

brake fluid. outside circuit or on cylinders.
 TS9-2-22

HYDRAULIC SYSTEM TROUBLESHOOTING WX90

Soft brake pedal. Air in brake circuit. Bleed brake circuit.

Too small of a
brake discs gap. Readjust the brake.

Carry out brake

Oil leaks from
Oil overheating pedal adjustment
brake pedal
with consequence or replace the
assembly when not
of vaporisation. brake pedal
actuated.
assembly.

Damage on supply
or drain circuit
Replace pipes.
pipes (restrictions
or bendings).

15501 9-35990
 TS9-2-23

HYDRAULIC SYSTEM TROUBLESHOOTING WX90

2.5.2 WORK BRAKE FAULTY

Check electrical
operation of work
Work brake sole- brake solenoid
Work brake does noid valve on brake valve, located on No Replace the
not operate. pedal assembly brake pedal
assembly, when solenoid valve.
faulty.
the switch on
dashboard is
pushed.
Yes

Check brake valve

Replace the brake
pressure in work
valve assembly.
mode.
15501 9-35990
 TS9-2-24

HYDRAULIC SYSTEM TROUBLESHOOTING WX90

2.6 STEERING SYSTEM

2.6.1 STEERING WHEEL HEAVY

Yes Is steering cylinder

working normally?

Are front tyres

inflated to correct
working pressure?

No

15501 9-35990
 TS9-2-25

HYDRAULIC SYSTEM TROUBLESHOOTING WX90

Pressure setting
No of valve defective.
Replace steer-
ing valve.
Yes Is steering pump
pressure nor-
mal?

Pump defective.
Yes Replace pump.

Faulty steering
cylinder.
No

Correct inflating
pressure of tyres
(refer to Opera-
tion and Mainte-
nance Manual).
15501 9-35990
 TS9-2-26

HYDRAULIC SYSTEM TROUBLESHOOTING WX90

2.7 DRIVE AXLES

2.7.1 NOISE

Noise during coast

Wheel bearings Replace faulty
and under power
damaged. items.
is the same.

Low lubricating oil Refill oil to proper

level. level.

Inspect through
rear cover. Replace
Ring and pinion
and adjust pinion
worn.
and ring (see Sect.
Noise under power 5).
greater than during
coast.

Worn ring and Replace faulty

pinion bearings. items (see Sect. 5).

Worn planetary Replace faulty

gears or bearings. items (see Sect. 5).

Inspect ring, pinion

and pinion bearings.
Loose pinion nut. If undamaged,
retighten nut as
described in Sect.
Noise during 5.
coast greater than
under power.

Only one bearing Replace faulty

damaged. items.
15501 9-35990

Worn spider and/or Replace faulty

Noise during turn.
side gear. items.
 TS9-2-27

HYDRAULIC SYSTEM TROUBLESHOOTING WX90

Worn or damaged Inspect and replace

cardanshaft spi- transmission
der. cardanshaft.

Inspect for wheel

and wheel stud
damage. Replace
Loose wheel(s). if needed and re-
tight the lug nuts to
the foreseen tight-
ening torque.

A noise (Stick slip)

Ball joint at steering Inspect and replace
when going from
knuckle damaged. damaged items.
forward to reverse.

Inspect through
Spider pins loose
rear cover. Replace
in differential car-
the damaged
rier.
items.

Differential side
R e p l a c e d
gear washers
damaged items.
worn.
15501 9-35990
 TS9-2-28

HYDRAULIC SYSTEM TROUBLESHOOTING WX90

2.7.2 AXLE LOCK DOES NOT OPERATE

When the A3 front axle locking control solenoid valve and located on user solenoid valves assembly is not
energised , the front axle is in lock condition.
Axle locking operates when the work brake , parking brake , axle locking . are actuated.
With work brake or parking brake switch actuated, the axle lockingin operated.

Is output pressure
Yes at port A3 of utility
solenoid valves
Is input pressure at assembly normal?
Yes port P of user
solenoid valves
assembly normal?

Is the work brake, Check pilot line.

No
parking brake and
axle locking switch
normal?

Axle locking switch

actuated. The
indicator is turned
on. No
The axle lock
operates (solenoid
valve A2 de-
energised) also
actuating the work
brake or parking
brake button.
To check
electrically the
switches and
indicators on
central dashboard.
Make reference to
electrical system
troubleshooting.
15501 9-35990
 TS9-2-29

HYDRAULIC SYSTEM TROUBLESHOOTING WX90

Replace or
Yes repair the axle
locking
Is input assembly.
pressure at port
Yes
P of axle locking
assembly
normal? Check line
leakage and
No rotary joint.
If the electrical
control signal
correctly comes
to the electrical
connector A3,
No replace the
solenoid valve
A3.

Buttons or
wiring
harnesses
faulty.

7
3 5
9

2
3

4 4

F10564
15501 9-35990

1 - User solenoid valves assembly

2 - Pilot control valve
3 - Rotary joint
4 - Axle locking cylinder
5 - Solenoid valve A3
6 - Tank
7 - Presure reducing valve
 TS9-2-30

HYDRAULIC SYSTEM TROUBLESHOOTING WX90

2.8 TRANSMISSION

2.8.1 CONTROL SHIFTING CYLINDER HYDRAULIC CHECK .

Connect a pressure
gauge (A) on input
oil supply line to the
shifting cylinder
(B) with
hydraulic pilot
pressure already No Check pilot control
checked and pressure.
engaged.
On pressure gauge Yes
should be read
about 35/40 bar.
Check operation
With engaged
of switch
should be read 0
bar. .

Yes

Hydraulic pressure
input to control
shifting cylinder is
normal.
Check transmis-
sion.

B
15501 9-35990

F9219
 TS9-2-31

HYDRAULIC SYSTEM TROUBLESHOOTING WX90

HYDRAULIC TRANSMISSION CIRCUIT

A/7 A/5
A/6 A/4
A/8 A/3 A/2 A/1

5
8
6
7

10 9

11
B
1 2
13
12
K K

14 F9145

1 - Hydraulic oil tank 8 - Transmission control solenoid valves

2 - Pilot/brake gear pump 9 - Hydraulic travel motor
3 - Pilot filter 10 - Transmission and rear axle assembly
4 - Brake valve assembly 11 - Cylinder control
5 - Priority valve
6 - To the user solenoid valves assembly 12 - Wheel alignment sensors
15501 9-35990

7 - Rotary joint 13 - Revolution number sensor

14 - Steering cylinder
 TS9-2-32

HYDRAULIC SYSTEM TROUBLESHOOTING WX90

NOTES:

15501 9-35990
 TS9-3-1

ELECTRICAL SYSTEM TROUBLESHOOTING WX90

3. ELECTRICAL SYSTEM TROUBLESHOOTING

3.1 ELECTRICAL SYSTEM COMPONENTS

3.1.1 CONTROL UNITS

1 - Fuse boxes
2 - Control unit SMC
3 - Relay boxes
4 - Controller BOX
5 - Transmission control unit
6 - Diodes
7 - Programmation switch
8 - Additional power intake 24 Volt

7 3

5
15501 9-35990

F9146
Connections for frame cable
 TS9-3-2

ELECTRICAL SYSTEM TROUBLESHOOTING WX90

3.1.2 ELECTRICAL COMPONENTS IN THE CAB

2
4 8

10

F9147

9
15501 9-35990

1 -
Radio 6 - Cigarette lighter
2 -
Antenna 7 - Control unit SMC
3 -
Loudspeakers 8 - Ceiling light
4 -
Windshield washer tank complete with 9 - Supplementary power socket
pump driven by electrical motor 10 - Electric fan.
5 - Windshield wiper motor
 TS9-3-3

ELECTRICAL SYSTEM TROUBLESHOOTING WX90

Detail A

8 7

10

12
3

11

F9148
15501 9-35990

1 - Control buttons in left pilot valve 7 - Central dashboard

2 - Control buttons on right pilot valve 8 - Windshield wiper control lever
3 - Control panel 9 - Travel speed control
4 - Left hand panel 10 - Light control lever
5 - Key starter switch 11 - Conditioner control
6 - Right hand panel 12 - Steering type control
 TS9-3-4

ELECTRICAL SYSTEM TROUBLESHOOTING WX90

3.1.3 ELECTRICAL COMPONENTS ON THE FRAME

1 - Fuel level sensor

2 - EC motor
3 - Hydraulic oil level sensor
5 - Air filter clogging switch.

15501 9-35990

F13283
 TS9-3-5

ELECTRICAL SYSTEM TROUBLESHOOTING WX90

Detail A

1 - Pressure switch, brakes system insufficient

pressure signal (90 Bar) P1
2 - Pressure switch, stop lights (5 Bar) P2
3 - Braking pressure sensor (90÷140 bar) Pt.

3 1 2

F10565

Detail B

4 - Positioner pressure switch P7 4

5 - Positioner pressure switch P8
6 - Travel pressure switch P5 6
5
7 - Travel pressure switch P4
8 - Control lever pressure P6

7
15501 9-35990

F8928
 TS9-3-6

ELECTRICAL SYSTEM TROUBLESHOOTING WX90

Detail C

6 7

10

15501 9-35990

F9213

3 - Relay, batteries cut-off 7 - Safe start-up main fuse

4 - Battery 8 - Main fuse (80 A)
5 - Ground cable 9 - Start-up fuse (40 A)
6 - Glow plug heating relay 10 - Engine ground cable
 TS9-3-7

ELECTRICAL SYSTEM TROUBLESHOOTING WX90

Detail D

1 - Selection solenoid valve assembly

2 - Utility solenoid valves assembly
3 - Steering type control solenoid valve
assembly
4 - Power control disconnection solenoid valve
5 - Clamshell bucket swing solenoid valve

4
15501 9-35990

F9214
 TS9-3-8

ELECTRICAL SYSTEM TROUBLESHOOTING WX90

3.1.4 ELECTRICAL COMPONENTS ON THE ENGINE

1 - Alternator
2 - Starter 2
3 - Water temperature thermistor
4 - Engine oil pressure switch P3
5 - Engine oil level sensor.

F9216

3.1.5 ELECTRICAL COMPONENTS ON THE UNDERCARRIAGE

3
1 - Hydraulic joint
15501 9-35990

2 - Revolution number sensor (gearbox)

3 - Wheel alignment sensor
F9225
 TS9-3-9

ELECTRICAL SYSTEM TROUBLESHOOTING WX90

3.1.6 ROAD LIGHTS AND WORKS LIGHTS

NOTE: For electrical and line references, see section 8.

6

7
2
1

1 - Direction indicator
2 - Front light
4 - Rear light
5 - Reflector
6 - Horn
7 - Work light
8 - Parking-stop lights

8 8

4
15501 9-35990

F13276

3.1.7 ELECTRICAL DIAGRAMS AND WIRING HARNESSES

- For general electrical system diagram, make reference to the diagram enclosed at the end of this Manual.
- For information concerning the wiring harnesses construction and composition, make reference to the
Section 8, Group 7.
- The electrical diagrams of the functions on which the checks to be performed, are shown on the side of
the flow diagrams.
 TS9-3-10

ELECTRICAL SYSTEM TROUBLESHOOTING WX90

3.2 RELAYS AND FUSES

3.2.1 RELAYS
RY1 Alternator relay
RY2 Safety relay
RY3 Anti Load Dump relay
A RY4 Working brake relay
RY5 Windshield washer tank relay
RY6 Lights-boom relay
RY7 Horn relay
RY8 Rotating beacon relay
RY9 Optional
RY10 Control valve 1 spool / 2 spools relay
B RY11 Windshield wiper relay
RY12 Relè SW B-C
RY13 Switch B relay
RY14 Switch E relay
RY15 Switch F relay
RY16 Switch K relay
RY17 Engine stop relay
C RY18 L.h. direction indicator relay
RY19 R.h. direction indicator relay
RY20 Safe start-up relay
RY21 Upper beams relay
RY22 Lower beams relay
RY23 Parking lights
RY24 Optional
D RY25 Switch C relay
RY26 Switch A relay
RY27 Travel auto idle relay
RY28 Equipment power control relay

D C

A
15501 9-35990

F9150
 TS9-3-11

ELECTRICAL SYSTEM TROUBLESHOOTING WX90

3.2.2 FUSES
Fuse Rating
PROTECTED CIRCUIT
No. (A)
FUSES IN THE BOX
1 Function memory 5
2 Engine control 10
3 Step-by-step motor 10
4 Power supply 5
5 Solenoid 5
6 Switch panel 5
7 OPT F5989

8 OP T
9 Bucket rot. & overturn sensor 5
10 OPT
11 Upper lights (opt) 20
12 Windshield wiper 10
13 Heater 15
14 OPT
15 Horn 5
16 Radio 5
17 Cigarette-lighter 5
18 Cab light 5
19 OPT
20 OPT
21 R.H. parking light 5
22 L.H. parking light + ceiling light 5
23 Dipped beams 10

24 Main beams 10
(unused for homologation)

25 Case (1) 20
26 Stop lights 5
27 OPT
28 Steering column panel 5
15501 9-35990

29 Attachment lights 5
30 Rotating beacon 5
31 Transmission card 10
32 L.H. lever 10
33 Case (2) 5
34 Socket 10
F7818gb
 TS9-3-12

ELECTRICAL SYSTEM TROUBLESHOOTING WX90

Fuse Rating
PROTECTED CIRCUIT
No. (AMP)
FUSES IN THE BOX
35 Compressor (opt) 5
36 OPT
37 OPT
38 OPT
39 OPT
40 OPT
CENTRAL UNIT FUSES
F6174
FUSE FUSE FUSE 2 FUSE
1

Main power supply with key 40

BOX A

(OPT)

Glow plug preheating 40

Engine start-up line

3

80
BOX B

protection
4

OPT
1 3
F7819gb

FUSE 2
FUSE 1
40 A
40 A

BOX BOX
A B

FUSE 4
FUSE 3
OPT
80 A

2 4

F5993

15501 9-35990
 TS9-3-13

ELECTRICAL SYSTEM TROUBLESHOOTING WX90

3.3 CHECKS ON ELECTRICAL COMPONENTS

3.3.1 SOLENOID VALVE CHECK

The efficiency check of the solenoid valves essentially consists of performing the checks of the relevant
system that they control.
Table 1 shows the solenoid valves list, the name, the function and the hydraulic and electrical reference
designation and the troubleshooting paragraph to which need to refer for carrying out the efficiency check
of the single solenoid valves.

TABLE 1

Location Name Function

Solenoid valve A1 Parking brake - travel pedal released

Utility solenoid valves

Solenoid valve A2 Stabilizers - 1st travel speed

Solenoid valve A3 Axle lock
assembly

Solenoid valve A4 Grass-cutter control

Solenoid valve A5 Hammer or grass-cutter control
Solenoid valve A6 Solenoid valve
Solenoid valve A7 Solenoid valve
Solenoid valve A8 3rd travel speed

Solenoid valves B1 Blade - stabilizer selector

Selector solenoid

Solenoid valves B2 Blade - stabilizer selector

valves

Solenoid valves B3 Positioner selector

Solenoid valves B4 Positioner selector
Solenoid valves B5 Swing selector
Solenoid valves B6 Swing selector
bucket swing
Clamshell

Solenoid valve C1 Left hand bucket swing

Solenoid valve C2 Right hand bucket swing
assembly
Brake
pedal

Solenoid valve D1 Work brake

controls
15501 9-35990

Power

Solenoid valve E1 Equipment power control disconnection

Trasnmission

Solenoid valve F1 Rear steering lock

assembly
control

Solenoid valve F2 Crab steering

Solenoid valve F3 Rod iron steering
 TS9-3-14

ELECTRICAL SYSTEM TROUBLESHOOTING WX90

3.3.2 PRESSURE SWITCHES CHECKS

The efficiency check of the single pressure switch is quoted in the check of the relevant system that is
included.
Table 2 shows the pressure switches list, the function, the electrical reference designation and the
troubleshooting paragraph to which need to refer for carrying out the efficiency check of the single pressure
switch.

TABLE 2

Name Function

Pressure switch P6 Pilot valve

Pressure switch P4 Travel (reverse)

Pressure switchP5 Travel (forward)

Pressure switch P1 Brake failure

Pressure switch P2 Stop light

Pressure switch P7 Rod roll-in positioner

Pressure switch P8 Rod roll-out positioner

Pressure switch P9 Parking brake

15501 9-35990
 TS9-3-15

ELECTRICAL SYSTEM TROUBLESHOOTING WX90

3.3.3 RELAY CHECKS

The efficiency check of the single relay essentially consists of performing the checks of the relevant system
on which they are installed.
Table 3 shows the relays list installed on the switching control unit, their function, the electrical reference
designation and the troubleshooting paragraph to which need to refer for carrying out the efficiency check
of the single relays.

TABLE 3
RY1 Alternator relay
RY2 Safety relay
RY3 Anti Load Dump relay
A RY4 Working brake relay
RY5 Windshield washer tank relay
RY6 Lights-boom relay
RY7 Horn relay
RY8 Rotating beacon relay
RY9 Optional
RY10 Control valve 1 spool / 2 spools relay
B RY11 Windshield wiper relay
RY12 Relè SW B-C
RY13 Switch B relay
RY14 Switch E relay
RY15 Switch F relay
RY16 Switch K relay
RY17 Engine stop relay
C RY18 L.h. direction indicator relay
RY19 R.h. direction indicator relay
RY20 Safe start-up relay
RY21 Upper beams relay
RY22 Lower beams relay
RY23 Parking lights
RY24 Optional
D RY25 Switch C relay
RY26 Switch A relay
RY27 Travel auto idle relay
RY28 Equipment power control relay
15501 9-35990
 TS9-3-16

ELECTRICAL SYSTEM TROUBLESHOOTING WX90

3.4 CHECKS ON PILOT CONTROL SYSTEM ELECTRICAL CIRCUIT

3.4.1 THE EQUIPMENT PILOT CONTROLS DO NOT OPERATE

Test condition:
- steering column switch disactivated
- left hand arm rest lowered
- brake system switch in any position except parking

Solenoid valve E1 24 V output

Teminal 1 OK.

øV

Check the ope- No Check circuit.

ration of F28. Replace the fuse.

Yes
Check on steering
column connector No Check on con-
Replace relay 28. F pin 5 if voltage is nector D pin 1 if
24 V. voltage is 24V.

Yes Yes No Yes

No Check if voltage is Check if voltage is 0
Check if voltage is
Check cab cable. Volt on SW3:
24V on R28-30. 24V on R28 - 87.
replace cable.

No Yes
Check if voltage is Check if voltage is
Check cab cable. No
24V on left hand 24V on position 2
armrest switch, on switch.
position 54C.

Yes No Yes
Check harness
between switch and Check cab cable. Replace switch.
spool E1.

E1
15501 9-35990

F9262

Pilot control cut-off solenoid valve

 TS9-3-17

ELECTRICAL SYSTEM TROUBLESHOOTING WX90

SOLENOID VALVE E1 CONTROL CIRCUIT

w P F-28
D-1
E-2
5A
T A/L

F-5
SW33

Steering column

R-28

Arm rest raised

Left hand arm rest micro switch

2 54C

Arm rest lowered

1 2

E-1
15501 9-35990

F9245
 TS9-3-18

ELECTRICAL SYSTEM TROUBLESHOOTING WX90

3.5 BRAKE SYSTEM ELECTRICAL CHECKS

3.5.1 STOP LIGHTS DO NOT OPERATE

Test condition:
- Bulbs lights checked
- Brake pedal pressed

Check switch
SW1.

No

Press brake pedal

and check if voltage Check if there is no
Check if voltage is Check if voltage is
Check operation of Yes Yes is + 24V between pin Yes voltage between
+ 24 V between pin Yes 24 V on relay R4,
fuse 26. 708 and negative. terminals 85 and 86
707 and negative. terminal 87A.
of relay R4.
No Yes No
No
No
Replace relay R4.
Check circuit. Replace pressure
Replace fuse. Check wiring har- switch.
ness. Check for line and
rear light
operation.

P2
15501 9-35990

Stop lights pressure switch (P2)

- Normally open contact -
Setting = 5 ± 0,5 bar

F10567
 TS9-3-19

ELECTRICAL SYSTEM TROUBLESHOOTING WX90

+24 VOLT
26
Stop light pressure switch
P2

707 708

675

R4

709
E-3

G-4 685
Steering column
D-1

710
28

LH stop RH stop
L10 21W L5 21W light
light
+24 VOLT
15501 9-35990

F7320
 TS9-3-20

ELECTRICAL SYSTEM TROUBLESHOOTING WX90

3.5.2 BRAKE FAILURE INDICATOR MALFUNCTION (BUZZER AND INDICATOR)

Test condition:
- Accumulators discharged
- thermal engine running

Check if voltage is Check for wiring

Check operation Yes Yes Check if voltage is Yes
24 V between 711 harness opera-tion.
of fuse 28. 24 V between 681
and negative. Replace buzzer.
and negative.
No No
No

Check the circuit.

Replace the fuse. Check wiring har- Replace pressure
ness. gauge P1.

Brake failure pressure switch (P1)

Pilot block - Normally closed contact -
Setting = 90 ± 5 bar

1 2

P1
15501 9-35990

Braking type
commutator
OFF
15 20
10 25 P
P

5 Km/h 30

0
Brake failure
indicator (L2)
F9263
 TS9-3-21

ELECTRICAL SYSTEM TROUBLESHOOTING WX90

+24 VOLT
28

Brake failure pressure switch

P1
711

681

Steering
D-6

column

L2

F7376
15501 9-35990
 TS9-3-22

ELECTRICAL SYSTEM TROUBLESHOOTING WX90

3.5.3 WORK BRAKE MALFUNCTION

Test condition:
- switch in working brake position
- brake accumulator discharged

Check if voltage is Check if voltage is Check if voltage is

Yes Yes
Check operation of Yes 24V on 690 of brake 24V on 675 and 24V on solenoid
fuse 28. switch. ground. valve D1 connector.

No No
No
No Yes

Check the circuit. Check for wiring Replace switch Check and/or
Replace the fuse. harness operation. SW1. replace solenoid
valve.

Check for wiring

harness opera-tion.

1 2

Braking type
15501 9-35990

commutator
Work brake
OFF
solenoid 15 20
P
valve D1 10 25
P

5 Km/h 30

Work brake indicator L3

F10568
 TS9-3-23

ELECTRICAL SYSTEM TROUBLESHOOTING WX90

+24 VOLT
28

675

+
677

R4

685 710

690 E-3

SW1
677

W P
D1
T A/L

Steering column To the stop lights

L3 G-4
15501 9-35990

D1
F7377
 TS9-3-24

ELECTRICAL SYSTEM TROUBLESHOOTING WX90

3.5.4 IN THE MACHINE PARKING BRAKE CANNOT BE ENGAGED

Start condition:
- Set brake system switch in parking position first, then in travel position (OFF).

Solenoid valve
A1
disenergized.

Check fuse F28.

No Yes

Check cable and/ Check if voltage is

or replace fuse 24V, on con-
F28. nector E pin 4.

Yes No
Check if voltage
is 24V on point 1 Check if voltage
of solenoid valve is 24V, on con-
A1. nector D pin 1.
Yes
No Yes
Check operation
of brake mode
Check continuity Check negative
switch and
of wire 673 on point 2 of so-
relative relay.
between point 1 lenoid valve A1.
of A1 solenoid
valve and con-
Yes
nector E pin 4.

Replace spool.

User solenoid valve assembly

A1
15501 9-35990

F9264
 TS9-3-25

ELECTRICAL SYSTEM TROUBLESHOOTING WX90

Steering column

D1

A-8 E-4

P9
673

2 1

A1
15501 9-35990

F9241
 TS9-3-26

ELECTRICAL SYSTEM TROUBLESHOOTING WX90

3.6 TRAVEL CONTROL ELECTRICAL CIRCUITS CHECKS

3.6.1 THE 1st TRAVEL SPEED DOES NOT OCCUR

Solenoid valve A2 check

Check if voltage is
24 V on points 86
Check for ope- Yes and 30 of relay R13 Yes
ration of fuse 32. wire 770. Set switch in 1 st
speed position.
No No
Check for a negative
Check wiring. on point 30 of relay
R25 wire 730.
Check circuit. Check line 730 and No
Replace fuse. switch ope-ration.
Yes

Check wiring.

No

Replace solenoid
valve.
Check for a
Yes No negative on point
Replace relay.
87a of relay R25
wire 732.
Check if voltage is
Yes
24V on solenoid
valve A2 con-
nector on wires 791
and 931.

Yes No
Check wirings. Check if voltage is 24
Volts on termi-nals 85
Check if voltage is and 86 of relay R13
24V on terminal 87 Yes wires 774/784.
of relay R13 cable
791.
No

Replace relay R12.

A2
15501 9-35990

F9247
 TS9-3-27

ELECTRICAL SYSTEM TROUBLESHOOTING WX90

THE 1st TRAVEL SPEED DOES NOT OCCUR

770 730

Diode box 1

732

Travel speed

Diode box 3

Left hand pilot control

791
A 2 931

F9248
15501 9-35990
 TS9-3-28

ELECTRICAL SYSTEM TROUBLESHOOTING WX90

3.7 STABILIZERS CONTROL ELECTRICAL CIRCUIT CHECKS

3.7.1 RIGHT HAND SIDE STABILIZERS DO NOT OPERATE

Solenoid valves B1 - B2 check

N.B.: Engage working brake keeping brake pedal pressed.

Check if voltage is
Check if voltage is Check if voltage is
24V on terminal 86
Check operation of Yes Yes 24V on terminals 86 Yes 24V between ter-
of cable 774 relay
fuse 32. and 85 of relay R12 minal 87 and ground
R12 and terminal
with button C of relay R12.
No 30 cable 772.
pressed.
Yes No
No No
Replace relay R12.

Check if voltage is
Check wiring and
24V on cables 792 No
Check the circuit. diode box 3 and/or
Check wiring. and 922, cables 923 Check wiring.
Replace the fuse. change button C
and 821 with button
on pilot control.
C pressed.
Yes

Check and/or re-

place solenoids B1
and B2.

Utility solenoid
valves assembly
15501 9-35990

F7392 B2
B1
F9266
 TS9-3-29

ELECTRICAL SYSTEM TROUBLESHOOTING WX90

STABILIZERS CONTROL CIRCUIT

Travel speed switch

773
773
774

772
783 792

782

Left hand pilot control

792

922

821

923

F9332
15501 9-35990
 TS9-3-30

ELECTRICAL SYSTEM TROUBLESHOOTING WX90

3.7.2 LEFT HAND SIDE STABILIZERS DO NOT OPERATE

Solenoid valve A2-B1-B2 check

N.B.: Engage working brake keeping brake pedal pressed.

Check if voltage is Check if voltage is Check if voltage is

24V on terminal 86
Check operation of Yes Yes 24V on terminals 86 Yes 24V between ter- No
of cable 774 relay and 85 of relay R12 Replace relay R12.
fuse 32. minal 87 and ground
R12 and terminal with button B of relay R12.
No 30 cable 772. pressed.
Yes
No
No
Check if voltage is
Check wiring and
24V on cables 792 No
Check wiring. diode box 1 and/or Check wiring.
and 922, cables 923
change button C
on pilot control. and 821 with button
B pressed.
Yes

Check the circuit. Check and/or re-

Replace the fuse. place solenoids B1
and B2.

Check if voltage is
Check if voltage is Check if voltage is
24V on terminal 86
Yes Yes 24V on terminals 86 Yes 24V between ter- No
of cable 774 relay Replace relay R13.
and 85 of relay R13 minal 87 and ground
R13 and terminal
with button B of relay R13.
30 cable 771.
pressed.
Yes
No No
Check if voltage is
24V on cables No Check wiring.
791and 931 with
Check wiring and
button B pressed.
Check wiring. diode box 1 and/or
change button B Yes
on pilot control.
Check and/or re-
place solenoid A2.
User solenoid valve assembly

A2
15501 9-35990

B2
B1
F9330
 TS9-3-31

ELECTRICAL SYSTEM TROUBLESHOOTING WX90

STABILIZERS CONTROL CIRCUIT

Travel speed switch

773

774
773

771
774

772
783 792 784 791

782

Left hand pilot control

792

922

821

923

791

931
F9331
15501 9-35990
 TS9-3-32

ELECTRICAL SYSTEM TROUBLESHOOTING WX90

3.8 BLADE CONTROL ELECTRICAL CIRCUIT CHECKS

3.8.1 BLADE CONTROL DOES NOT OPERATE

Solenoid valves B1-B2 check

No
Replace relay R12.

Check if voltage is Check if voltage is

24V on terminal 86 Check if voltage is
Check operation of Yes of cable 774 relay Yes 24V on terminals 86 Yes 24V on terminal 87
fuse 32. and 85 of relay R12
R12 and terminal with button C and ground of relay
30 cable 772. pressed. R12.
No
No Yes
No

Check if voltage is
Check wiring and
24V on cables 792
Check the circuit. Check wiring har- diode box 3 and/or No Check wiring.
and 922 and cables
Replace the fuse. ness. change button C
923 and 821 with
on pilot control.
button C pressed.

Yes
Check and/or re-
place solenoids B1
and B2.

Left pilot control

15501 9-35990

selector solenoid valve

B2
B1
F7391 F9266
 TS9-3-33

ELECTRICAL SYSTEM TROUBLESHOOTING WX90

BLADE CONTROL CIRCUIT

Travel speed switch

773
773
774

772
783 792

782

785

Left hand pilot control

792

922

821 792

923

F9270
15501 9-35990
 TS9-3-34

ELECTRICAL SYSTEM TROUBLESHOOTING WX90

3.9 POSITIONING CONTROL ELECTRICAL CIRCUIT CHECKS

3.9.1 POSITIONING CONTROL DOES NOT OPERATE

Solenoid valves B3 and B4 check

Check if voltage Check for negative

is 24V with on terminal of
Controller Box
Check opera- Yes negative on Yes No Check and/or
tion of fuses 25, termi-nals 8 and cable 636 by
replace button.
33 and 37. 5 of Controller pressing button D
Box cables 639 of right pilot
No and 706. control.

No
Yes
Check the cir-
cuit. Replace Check wiring
the fuse. harness. Check for 24V on
terminal 2 of No Replace.
Controller Box Controller Box.
with button on.

Yes

Check wiring NoCheck if voltage

harness. is 24V on sole-
noid valves B3
and B4 con-
nectors, cables
Check and/or Yes
637 and 920; 820
replace sole-
and 924.
noids B3 and B4.

B3 B4

D
15501 9-35990

P2 P1

F9274

F13284
 TS9-3-35

ELECTRICAL SYSTEM TROUBLESHOOTING WX90

POSITIONING CONTROL CIRCUIT

+24 VOLT

33 25 L16
TB 1 2
EX

Right hand pilot control

20A
5A
639

706
D 10 30
L14
2
Km/h

8 5 10
E 11 L15
3
21
F L16
4 6
3 L17
K
5 1
17

2 5A 37

636 18 R4
7

86 30
1 637
B 3 2
R27
920
1 820 85 87 87A
B 4 2

924

D8 D9

D12 D13 D14 D11

P4 P5 P7 P8 P6
15501 9-35990

F9275
 TS9-3-36

ELECTRICAL SYSTEM TROUBLESHOOTING WX90

3.10 HAMMER CONTROL ELECTRICAL CIRCUIT CHECKS

3.10.1 HAMMER CONTROL DOES NOT OPERATE

Solenoid valve A4 check

Check if voltage
is 24 V with ne-
Check operation Yes gative on termi-
No Check wiring
of fuse 9. nals 86 and 30 harness.
of relay R16
No cable 630 and
646.

Check the circuit. Yes

Replace the fuse.

Check if voltage
is 24 V between
terminals 85 and Check wiring
86 cable 630 No harness and but-
and 649 pressing ton K of pilot
button K located control.
Check wiring on right hand
harness and pilot control.
switch SW4.
Yes
No

Check if voltage Check if voltage

is 24 V on sole- is 24 V on
Yes No Replace relay
noid valve A4 switch SW4 ca- R16 and check
connector ca- ble 650 with wiring harness.
bles 652 and button K press-
925. ed.
Yes

Check and/or
replace sole-
noid A4.

A4
K
(front side)

Utility solenoid valves assembly

15501 9-35990

F9272
F13285
 TS9-3-37

ELECTRICAL SYSTEM TROUBLESHOOTING WX90

HAMMER CONTROL CIRCUIT

20
10
30

SW4

5A

9
+24 VOLT

R16

SW4

Right hand pilot control

D
2

E
3

F
4 6

K
5 1

5 A 2
924 BR

1
4 A 2
15501 9-35990

925 BR
F9273
 TS9-3-38

ELECTRICAL SYSTEM TROUBLESHOOTING WX90

3.11 AXLE LOCK ELECTRICAL CIRCUIT CHECKS

3.11.1 WITH AXLE LOCK SWITCH RELEASED THE AXLE LOCK DOES NOT OPERATE

Check if voltage is Check if voltage is

Check operation 24V on connector 24V on connector Check and/or
Yes D pin 1 between
Yes No
of fuse 28. E pin 1 cable 686 replace switch
negative cable and with switch SW1 in SW1.
No 690. OFF position .

No Yes

Check the circuit. Check wiring har-

Replace the fuse. ness.

Check if voltage is
24V on solenoid
Check and/or re- Yes
valve A3 con-
place solenoid A3. nector cables 686
and 934.

No

Check wiring har-

ness.

A3

Utility solenoid valves assembly

15501 9-35990

F9277
 TS9-3-39

ELECTRICAL SYSTEM TROUBLESHOOTING WX90

AXLE LOCK CIRCUIT

690

D1
15501 9-35990

686
934

F9276
 TS9-3-40

ELECTRICAL SYSTEM TROUBLESHOOTING WX90

3.12 THROTTLE CONTROL ELECTRICAL CIRCUIT CHECKS

3.12.1FAILURE OF EC MOTOR SENSOR

No Faulty SMC main

Check for inter- control unit.
ruptions or short-
circuits between
Yes terminal no. D15
of connection of
SMC and terminal
no. 2 of sensor
Disconnect EC EC. Wiring failure bet-
sensor connec- ween SMC and EC
Yes sensor.
tor. Check if
Yes voltage between
terminals no. 1
Disconnect EC and no. 3 of wir-
sensor con- ing connection is Wiring broke bet-
nector. No ween SMC and
5± 0,5 V.
Check if resistance EC sensor termi-
Check if voltage
between termi- nal no. 3.
• Key switch: ON between terminals
nals no. 1 and no.
no. 1 of wiring
3 of EC sensor
No connection and
connector is 1,7 ±
machine frame is
0,4 KΩ. Wiring broke bet-
5±0,5 V.
Connect test ween SMC and EC
wiring with the Yes sensor terminal no. 1.
two EC sensor • Key switch: ON
connectors. • 5±0,5 V for voltage
Turn engine change reference
speed control and values.
check if voltage
varies as
prescribed.
EC sensor faulty.
No
• After replacement see
TS9-3-47

• Unless stated otherwise, set the switches as follows:

Button E
Engine Button E Working Auto-idle
control mode button
speed selector
Turned to General Engine control
OFF OFF speed
max. posit. mode

• For measurements use Dr. EX.

• Sensor operation range.

15501 9-35990

F7399

Item Control required/Button operation

Engine control speed Minimum speed 0.3-1.0 V

Maximum speed 4.0-4.7 V
EC sensor Engine speed control at min. position 2.5±0,05 V
 TS9-3-43

ELECTRICAL SYSTEM TROUBLESHOOTING WX90

NOTES:
15501 9-35990
 TS9-3-44

ELECTRICAL SYSTEM TROUBLESHOOTING WX90

3.13 DIESEL ENGINE FAILED TO START UP

NOTE: Brake mode switch to position .

Test conditions:
- Starter is not running.
- Disconnect cables 524 and 505 on start-up relay.
- Start-up key in START position. Replace relay
R20 and check for
Check line and/or
negative cable
replace start-up
523.
key.
No
No
Check for a nega-
Yes Check if voltage is Yes Check if voltage is Yes tive on point 30 of
Check if alternator
24 V on cable 505 10 or 24V on 86 relay R20 cable
indicator is on.
start-up relay. and 85 of R20.
525.
No No Yes
Check harness
continuity from
No relay R20 point 86
Reset line.
cable 694 to
connector E pin 2
steering column.
Check for a nega- No Yes
tive on pin C14 of Check operation
monitor. of fuse 28 and/or No Check if voltage is
Yes line. 24 V on connector Yes Check brake mode
D pin 1 cable 690. switch.

Check and/or re-

place monitor.
No Check cable 525
Check wiring har- in 87a if it is nega-
ness. tive on relay R2.
Check if voltage is No
24V on pin 86 of
relay R1. Yes

Yes
Check line. No Check line from Check for a nega-
relay R2 to start-up Yes tive on cable 524
Check connection relay. point 30 relay R2.
of cable 528. Yes
No
Check if voltage is
Check line and/or
Check if voltage is No 24V on start-up
No replace start-up relay contact 24V Replace relay R2.
0 ÷ 2 V on pin 85 relay. in cables 671 and
of relay R1. 672.
Yes Yes
15501 9-35990

Check if voltage is
Yes Check and/or re-
24V on alternator
D+. place alternator.
Check electroma-
No gnet and starter.
Check and/or re- Check wiring har-
place relay R1. ness of cable 527.
 TS9-3-45

ELECTRICAL SYSTEM TROUBLESHOOTING WX90

C 14 MONITOR

694
B7
To control unit
A 17

690

R17
15 DIODE 4
18
16 4 5A

DIODE BOX 1
17
Elettrostop

525
R1

SW
523
528

R20
Start-up key
B 6 MONITOR

COLD START ADVICE

R3

R2

Solenoid Start-up DIODE 6

relay relay
FUSE LINK B

Battery
527
+24 VOLT

relay
15501 9-35990

524

672 671
Starter

F9313
 TS9-3-46

ELECTRICAL SYSTEM TROUBLESHOOTING WX90

3.14 MONITOR FAILED TO OPERATE WITH START-UP KEY IN "ON" POSITION

Check on monitor
Check fuses 1 Yes if voltage is 24 V Yes Replace and/or
and 6. on C1, C2 and check monitor.
No C12.
No

Replace fuses.

Replace and/or
check cable.

15501 9-35990
 TS9-3-47

ELECTRICAL SYSTEM TROUBLESHOOTING WX90

15501 9-35990

T083 F9278
 TS9-3-48

ELECTRICAL SYSTEM TROUBLESHOOTING WX90

3.15 STEERING CONTROL

3.15.1 STANDARD STEERING INDICATOR DOES NOT LIGHT UP

Test conditions:

- Switch in position

- Bulb operating

Check if voltage is
Check if voltage is 24 Volt on points
Yes 24 Volt on cable Yes Yes
Check fuse 31. M and L cable 735
763 point 1 of of wheel align-
controller. ment sensor.
No
No
No
Replace fuse. Check line. Check line.

Check if voltage is
Check for sensor 24 Volt on points
correct position No N and M of cables
and replace if ne- 756 and 735 of
cessary. wheel alignment
sensor.
Yes

Check line 756

No from point N of
Reset wiring. sensor to point 7 of
steering mode
switch.

Yes

Check for opera-

tion of steering
mode switch.

Steering mode switch

F1 F2 F3
15501 9-35990

Steering mode
solenoid valve

F9335

F9281
 TS9-3-49

ELECTRICAL SYSTEM TROUBLESHOOTING WX90

STEERING CONTROL CIRCUIT

24 volt

763
Steering mode switch
1 2
11

3 4 5 6 7
735
756
744

745

746

950

F9338
Wheel
alignment
15501 9-35990

sensor
 TS9-3-50

ELECTRICAL SYSTEM TROUBLESHOOTING WX90

3.15.2 DOUBLE STEERING INDICATOR LIGHTS UP BUT STEERING DOES NOT OCCUR

Test conditions:

- switch in position

Check if voltage is Check if voltage is Check if voltage is

Yes 24 V on cable 763 Yes 24 V on points 3 Yes 24 V on point 1 Yes
Check fuse 31. and 4 of steering
of switch terminal cable 744 of
mode switch, ca- Yes
1. solenoid F3.
No bles 744 and 745.
No No
No
Check and/or re-
Replace fuse. place wiring har-
ness. Check for opera- Check and/or re-
tion of steering place solenoid F3.
mode switch.

Check and/or re-

place wiring har-
ness.

Check if voltage is
No 24 V on point 1 Yes
cable 745 sole-
noid F1.
Check and/or re- Check and/or re-
place wiring har-
ness. place solenoids
F1.

Steering mode switch Steering mode

solenoid valve
F3
15501 9-35990

F1

F9282

F9284
 TS9-3-51

ELECTRICAL SYSTEM TROUBLESHOOTING WX90

STEERING CONTROL CIRCUIT

24 volt

763
Steering mode switch
1 2
11

3 4 5 6 7
735
756
744

745

746

950

F9338
Wheel
alignment
15501 9-35990

sensor
 TS9-3-52

ELECTRICAL SYSTEM TROUBLESHOOTING WX90

3.15.3 CRAB STEERING INDICATOR LIGHTS UP BUT STEERING DOES NOT OCCUR

Test conditions:

- switch in position

Check if voltage is
Check if voltage is 24 V on points3 Check if voltage is
Yes 24 V on cable 763 Yes Yes 24 V on point 1 Yes
Check fuse 31. and 4 of steering
of controller termi- cable 746 of sole-
mode switch ca- Yes
nal 1. bles 746 and 745. noid F2.
No
No No
No
Check and/or re-
Replace fuse. place wiring har- Check for opera- Check and/or re-
ness.
tion of steering place solenoid F2.
mode switch.

Check and/or re-

place wiring har-
ness.

Check if voltage is
No 24 V on point 1 Yes
cable 745 sole-
noid F1.
Check and/or re- Check and/or re-
place wiring har-
ness. place solenoids F1.

Steering mode switch

Steering mode
solenoid valve F2
15501 9-35990

F1

F9285
F9286
 TS9-3-53

ELECTRICAL SYSTEM TROUBLESHOOTING WX90

STEERING CONTROL CIRCUIT

24 volt

763
Steering mode switch
1 2
11

3 4 5 6 7
735
756
744

745

746

950

F9338
Wheel
alignment
15501 9-35990

sensor
 TS9-3-54

ELECTRICAL SYSTEM TROUBLESHOOTING WX90

3.15.4 THE THIRD SPEED CANNOT BE ENGAGED

Test conditions:

- standard steering mode

Check if voltage is
24V on point 1 Check if voltage is
Check if voltage is
Yes cable 763 of Yes 24V on point 6 Yes No
Check fuse 31. 24V on point 30
steering mode cable 742 of steer-
cable 742 of relay
switch and on ing mode switch.
R10.
No point 86 cable 739
of relay R10. Yes
No
No
Replace fuse.
Repair or replace
Check wiring.
Check wiring. steering mode
switch.

Check if voltage is
Check wiring and No 24V on points 86
travel speed switch. and 85 cable 729
and 739 of relay
R10.
Yes

Check if voltage is
24V on point 87
Replace relay No
cable 759 of relay
R10.
R10 with 3rd speed
engaged.
Yes

Check if voltage is
No 24V on points 1
Check line.
and 2 of solenoid
A8.
Utility solenoid valve Yes
assembly.
A8

Replace solenoid.
15501 9-35990

F9334
 TS9-3-55

ELECTRICAL SYSTEM TROUBLESHOOTING WX90

THIRD TRAVEL SPEED CONTROL CIRCUIT

24 volt

763
Steering mode switch

739

742
R10

729

759
6

Travel speed
switch

F9339
A8
Wheel
alignment
sensor
15501 9-35990
 TS9-3-56

ELECTRICAL SYSTEM TROUBLESHOOTING WX90

3.15.5 TRAVEL CONTROL CANNOT BE SWITCHED FROM (SLOW) TO (FAST)

Test conditions:
- Engine running
- Brake mode switch in work position
- Brake mode switch operating Check wiring.

No
Check if voltage is Check if voltage is
24 Volt on cable 24 Volt on cable Check if voltage is
Check fuses 26, Yes Yes Yes 24 Volt on point 30
707 point A of 708 point B of
28 and 31. cable 708 relay
pressure switch pressure switch
P2. P2. R4.
No Yes
No No Yes
Replace fuses.
Check wiring.
Check if voltage is Replace pressure
24 Volt on points switch P2.
10 and 3, 10 and 4 No
cables 736, 659 Check line.
and 736, 658 of
Yes
gear controller. Check if voltage is
Check brake No 24 Volt on points
Yes 86 and 85 cables
mode switch.
677 and 709 of
relay R4.
Check if voltage is Yes
24 Volt on point 1 No Replace gear con-
cable 762 of me- troller.
chanical gear
controller.
Check if voltage is
Yes No 24 Volt on point 87
Replace relay R4.
cable 642 of relay
R4.
Check if voltage is
24 Volt on points Yes
1 and 2 of cables No
Check line.
762 and 948 of
solenoid A7.
Check if voltage is
Yes No 24 Volt on point 11
Check wiring. cable 642 of me-
chanical gear
Replace solenoid
controller.
A7.
Yes

Utility solenoid valve

assembly.
Check for a nega-
A7 tive on point 5
cable 43 of me-
Check line and No chanical gear
controller with
15501 9-35990

switch.
switch in position
.

F9337
 TS9-3-57

ELECTRICAL SYSTEM TROUBLESHOOTING WX90

TRAVEL CONTROL CIRCUIT FROM (SLOW) TO (FAST)

24 volt

690
736 8 743

5
43

1
24 volt
762

677
11 708 707
642

659 658
709

642
762

743
636
948

F9314
15501 9-35990
 TS9-3-58

ELECTRICAL SYSTEM TROUBLESHOOTING WX90

3.15.6 TRAVEL CONTROL CANNOT BE SWITCHED FROM (FAST) TO (SLOW)

Test conditions:
- Engine running
- Brake mode switch in work position
- Brake mode switch operating
Check wiring.

No
Check if voltage is Check if voltage is
24 Volt on cable 24 Volt on cable Check if voltage is
No Check fuses 26, Yes Yes Yes 24 Volt on point 30
707 point A of 708 point B of
28 and 31. cable 708 relay
pressure switch pressure switch
P2. P2. R4.
Yes
No No Yes
Replace fuses.

Check wiring.
Verificare nel pun-
to 10 e 3, 10 e 4 Replace pressure
cavo 736, 659 e switch P2.
736, 658 del con- No
Check line.
trollo meccanico
cambio ci sia 24 Yes
Volt. Check if voltage is
No 24 Volt on points
Yes Check brake 86 and 85 cables
mode switch. 677 and 709 of
relay R4.
Verificare nel pun- Yes
to 8 cavo 743 del No Replace gear con-
controllo cambio troller.
meccanico ci sia
24 Volt. Check if voltage is
Yes No 24 Volt on point 87
Replace relay R4.
cable 642 of relay
R4.
Verificare nel pun-
to 1 e 2 del cavo Yes
656 e 743 del No Check line.
solenoide A6 ci
sia 24 Volt.
Check if voltage is
Yes No 24 Volt on point 11
Check wiring. cable 642 of me-
chanical gear
Replace solenoid
controller.
A6.
Yes
Utility solenoid valve
assembly.
A6 Check there is no
negative on point
5 cable 43 of me-
Check line and No chanical gear
15501 9-35990

switch. controller with

switch in position
.

F9336
 TS9-3-59

ELECTRICAL SYSTEM TROUBLESHOOTING WX90

TRAVEL CONTROL CIRCUIT FROM (FAST) TO (SLOW)

24 volt

24 volt
15501 9-35990

F9312
 TS9-3-60

ELECTRICAL SYSTEM TROUBLESHOOTING WX90

3.16 TEST HARNESSES KIT 75301702

3.16.1TEST HARNESSES

A) two pins wiring harness to check solenoid valves.

B) three pins wiring harness to check angle sensor.

C) three pins wiring harness to check brake oil pressure.

D) four pins wiring harness to check Step Motor.

E) four pins wiring harness to check rear light rotating joint.

F) optional.

G) six pins wiring harness to check steering column.

H) eight pins wiring harness to check steering column.

3.16.2 TEST HARNESS

A) TWO PINS WIRING HARNESS TO CHECK SOLENOID VALVES

15501 9-35990

F9074

1 2
 TS9-3-61

ELECTRICAL SYSTEM TROUBLESHOOTING WX90

3.16.3 TEST HARNESS

B) THREE PINS WIRING HARNESS TO CHECK ANGLE SENSOR

F9029
15501 9-35990
 TS9-3-62

ELECTRICAL SYSTEM TROUBLESHOOTING WX90

3.16.4TEST HARNESS

C) THREE PINS WIRING HARNESS TO CHECK BRAKE OIL PRESSURE

F9293

15501 9-35990
 TS9-3-63

ELECTRICAL SYSTEM TROUBLESHOOTING WX90

3.16.5 TEST HARNESS

D) FOUR PINS WIRING HARNESS TO CHECK STEP MOTOR

F9030
15501 9-35990
 TS9-3-64

ELECTRICAL SYSTEM TROUBLESHOOTING WX90

3.16.6 TEST HARNESS

E) FOUR PINS WIRING HARNESS REAR LIGHT ROTATING JOINT

F9075

4 3 2 1

15501 9-35990
 TS9-3-65

ELECTRICAL SYSTEM TROUBLESHOOTING WX90

3.16.7 TEST HARNESS

G) OPTIONAL

3.16.8 TEST HARNESS

G) SIX PINS WIRING HARNESS TO CHECK STEERING COLUMN

6 5 4 3 2 1

F9291
15501 9-35990
 TS9-3-66

ELECTRICAL SYSTEM TROUBLESHOOTING WX90

3.16.9 TEST HARNESS

H) EIGHT PINS WIRING HARNESS TO CHECK STEERING COLUMN

8 7 6 5 4 3 2 1 F9292

15501 9-35990
 INDEX WX90-10- 1

WX90

SECTION 10 OPERATIONAL PERFORMANCE TEST

INDEX

Groupe 1 - INTRODUCTION ....................................................................................... PT10-1

1.1 General information for testing of the machine

Groupe 2 - PERFORMANCE STANDARD ................................................................. PT10-2

2.1 Table of excavator performance standard

2.2 Table of hydraulic components performance standard
2.3 Main pump P-Q diagram
2.4 Swing pump P-Q diagram

Groupe 3 - PREPARATION FOR PERFORMANCE TEST ......................................... PT10-3

3.1 Introduction

Groupe 4 - EXCAVATOR PEFORMANCE TEST ........................................................ PT10-4

4.1 Engine performance (diesel engine speeds)

4.2 Swing performance
4.3 Front attachment performance
4.4 Control levers / Pedal levers / Brake pedal
4.5 Steering
4.6 Brakes system

Groupe 5 - COMPONENTS PERFORMANCE TEST ................................................. PT10-5

15501 9-35990

5.1 Pilot pressure relief valve

5.2 Pressure relief valves
5.3 Transmission drive shaft
5.4 Hydraulic pumps
15501 9-35990
 PT10-1-1

INTRODUCTION WX90

1. INTRODUCTION

1.1 GENERAL INFORMATION FOR

TESTING OF THE MACHINE

(1) Know the system

Study this Service Manual to know how the
individual components work and what their
function is in the over-all system.
Keep-up with the latest service information.
Read and file in a handy place. This
information may give a response about the
causes and the remedy for future problems.

(2) Ask the operator

Question the operator as to how the machine
acted when the failure was detected. Also
find out if any improper service was
performed.
Ask how the machine has being used and
when it was serviced. Many problems can
be traced to poor maintenance or abuse.

(3) Operate the machine

Get on the machine and operate it. Don’t rely
completely on the operator’s story; check it
yourself.
Perform a complete visual check of the unit
to detect any sign of failures or malfunctions.
Check carefully all the components for cracks
in the weldings, loose bolts, broken fixtures,
worn or leaking pipings, etc.

(4) Test the machine

Proceed with the performance tests, following
the instructions and the data provided by this
Manual.
Record all signs of troubles encountered
during the operation.
15501 9-35990
 PT10-1-2

INTRODUCTION WX90

NOTES:

15501 9-35990
 PT10-2-1

PERFORMANCE STANDARD WX90

2. PERFORMANCE STANDARD

2.1 TABLE OF EXCAVATOR PERFORMANCE STANDARD

Refer to paragraph PT10-4 for the test procedure

Groupe Description Measuring Specification Notes

reference unit

.1. ENGINE PERFORMANCE (DIESELENGINE)

.1.1 A/I Auto Idle revs/minute 1100±100
.1.2 I. Mode (Idle) revs/minute 800±50
.1.3 P. Mode
(Working mode) free revs/minute 1750±50
.1.4 Travelling
(Travelling mode) free revs/minute 2150±80
.1.5 E. Mode (Economy) idle revs/minute 1650±100
.2. SWING PERFORMANCE
.2.1 Swing speed right side seconds 19.8±1
(3 revs) left side seconds 19.8±1
.2.2 Swing stop distance mm 480±50 250±50
.2.3 Swing parking brake mm 5±1 5±1
.2.4 Slewing ring play mm 1.75±0.5
.3. FRONT EQUIPMENT PERFORMANCE
.3.1 Equipment and swing times
Three arms Lifting seconds 3.4±0.5
Lowering seconds 2.7±0.3
Position Rod roll-in seconds 4.6±0.5
Rod roll-out seconds 4.4±0.5
Penetration Roll-in seconds 3.5±0.5
arm Roll-out seconds 3±0.5
Bucket Fill seconds 2.5±0.5
Unload seconds 2.1±0.5
Swing Rod roll-in seconds 6.3±0.5
cylinder Rod roll-out seconds 7.1±0.5
.3.2 Equipment leakage control
Lifting cylinder mm/5 minute ≤15
Positioner cylinder mm/5 minute ≤5
(three arm version)
15501 9-35990

Penetration cylinder mm/5 minute ≤30

Bucket cylinder mm/5 minute ≤15
 PT10-2-2

PERFORMANCE STANDARD WX90

Group Description Measuring Specification Notes

reference unit

.4. CONTROL LEVERS/ TRAVEL CONTROL PEDALS / BRAKE PEDAL

.4.1 Operation strength of control levers / travel control pedal / brake pedal
Lifting and penetration kgf ≤1.7
Bucket and swing kgf ≤1.7
Travel / positioner kgf ≤5
.4.2 Lever stroke of control levers / travel control pedal / brake pedal
Lifting and penetration mm 75±10
Bucket and swing mm 75±10
Travel / positioner kgf ≤30
.5. STEERING
.5.1 Steering pump Idle bar 20±5
pressure check Maximum bar 160±10
6. BRAKE SYSTEM
.6.1 Negative parking brake efficiency
.6.2 Brake valve pressure check
Service bar 35±2.5
Work bar 35±2.5
.6.3 Accumulator pressure check
Pre-load pressure bar 5.5±10
Accumulator maximum pressure bar 140±10

15501 9-35990
 PT10-2-3

PERFORMANCE STANDARD WX90

2.2 TABLE OF HYDRAULIC COMPONENTS PERFORMANCE STANDARD

Refer to paragraph PT10-5 for the test procedure.

Group Description Measuring Specification Notes

reference unit

.1. PILOT CONTROL SYSTEM OVERPRESSURE VALVE

.1.1 Pilot control
system pressure Maximum bar 40±8
.2. OVERPRESSURE VALVES
.2.1 Pressures of equipment hydraulic system-travel
Front equipment, Main Relief bar 350±15 Relief valve
travel LS valve bar 330±15
Delta pressure bar 18±1
Idle bar 25±5
.2.2 Rotation
Pressure cut-off bar 310±10 pump
Main Relief bar 330±10 rotation control valve
Power valve bar 320±10 hydraulic motor
Braking valve bar 190±10 hydraulic motor
.3. DRIVE SHAFT
.3.1 Drive shaft rotation speed
1st speed Version
Standard tortoise position 30Km/h revs/minute 320-380
rd
version 3 speed Version
hare position 30Km/h revs/minute 2870-3090
st
1 speed Version
Germany tortoise position 20Km/h revs/minute 320-364
rd
version 3 speed Version
hare position 20Km/h revs/minute 1950-2090
.4. HYDRAULIC PUMPS
.4.1 Main pump delivery liters/minute 143 at 2000 revs/minute
.4.2 Rotation pump delivery liters/minute 50 at 1800 revs/minute
15501 9-35990
 PT10-2-4

PERFORMANCE STANDARD WX90

2.3 MAIN PUMP P-Q DIAGRAM

p=(bar)

340

320

310

300

PH
280

260

240

220
PS
200

180

160

140

120

110

100

80
Q=143(l/min) p=50bar
60

40
Q=30(l/min) p=50bar

20

0
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150
Q(l/min)
F8989
15501 9-35990

NOTES: - Main pump type A11V075 LRCS diagram

- Setting = 43 Kw at 2000 revs/minute (diagram PH)
- Setting = 29 Kw at 2000 revs/minute (diagram PS) with unset regulator for rotation pump operation.
- Setting ∆P for Load Sensing = 18 bar
- Maximum delivery = see setting diagram at 2000 revs/minute
- Delivery in rest minimum displacement 30 l/minute
 PT10-2-5

PERFORMANCE STANDARD WX90

2.4 SWING PUMP P-Q DIAGRAM

P(bar)
350

300

250

200

150

100

50

0 10 20 30 40 50 56
Q(l/min)
F9003
15501 9-35990

NOTES: - Swing pump type A10V028 DFLR diagram

- Setting = 14 Kw at 2000 revs/minute (see diagram)
- Cut-off setting = 310 bar
- Maximum delivery = see setting diagram at 2000 revs/minute
 PT10-2-6

PERFORMANCE STANDARD WX90

NOTES:

15501 9-35990
 PT10-3-1

PREPARATION FOR PERFORMANCE TEST WX90

3. PREPARATION FOR PERFORMANCE TEST

3.1 INTRODUCTION

Performance tests are used to check:

1 OPERATIONAL PERFORMANCE OF A NEW

MACHINE
When a new machine is delivered in the form of a
knocked-down unit, assemble it and perform the test
to verify that the operational performances meet
CASE standards.

Work
2 OPERATIONAL PERFORMANCE OF A WORKING conditions
MACHINE
In time, the machine operational performance
deteriorates, so that periodical service operations are Operating
Maintenance
time
required to restore it to its original level. conditions

3 OPERATIONAL PERFORMANCE OF A REPAIRED

MACHINE
After a machine is repaired or serviced, it must be
tested to confirm that its operational performance has
been restored by the repair and/or the service
operations done.

3.1.1 GLOSSARY

1 STANDARD
Specifications applied to brand-new machines,
components and parts. STANDARD
15501 9-35990
 PT10-3-2

PREPARATION FOR PERFORMANCE TEST WX90

3.1.2 PREPARATION FOR PERFORMANCE TEST

Observe the following rules to execute the

performance tests accurately and safely.

1 ON THE MACHINE.
Repair any defect and damage found, such
as oil or coolant leakages, loose bolts, cracks
and so on, before starting the test.

2 TEST AREA

(1) Select a hard, flat surface.

(2) Provide enough space to allow the machine
to run straight for more than 50 m (164 ft) and
to make a full swing with the front attachment
extended.
(3) If necessary, rop-off the test area and place
signboards to keep unauthorized personnel
away.

3 PRECAUTIONS

(1) Before starting the tests, establish the signals

to be employed to communicate with co-
workers. Once the test is in progress, make
sure that only the established signals are used,
and that the rules are strictly followed.
(2) Operate the machine carefully and always give
first priority to safety.
(3) During the test, always take care to avoid
accidents due to landslides or contact with
electric power lines. Make sure there is enough
space for complete rotations.
(4) Avoid polluting the machine and the
environment with oil spillages. Use adequate
containers to contain fluid leakages. Pay
special attention to this problem when
removing hydraulic pipings.

4 MAKE PRECISE MEASUREMENTS

(1) Accurately calibrate in advance the

instruments used during the tests, to obtain
correct data.
(2) Perform the tests under the exact prescribed
15501 9-35990

conditions for each test item.

(3) Repeat the same test to confirm that the data
obtained are repeatable. Use mean values of
measures, if necessary.
 PT10-4-1

EXCAVATOR PERFORMANCE TEST WX90

4. EXCAVATOR PEFORMANCE TEST

H
2
4.1 ENGINE PERFORMANCE (DIESEL ENGINE C F
SPEEDS) E

Preparation:
(1) Install a Diesel engine revolution sensor. E
A/I

(2) - Hydraulic oil at about 50°.

(3) - Diesel engine at the correct temperature.

4.1.1 ENGINE SPEED A/I CONTROL BUTTON

CHECK

With the key-start switch on the ON position (engine 2

on) and throttle control in maximum position, press the 1
OFF
A/I control button (1) to bring the engine speed to
automatic preset idle.
This speed is attained in approximately 4 seconds,
provided that all controls are in the neutral position,
with consequent fuel savings. 1 A/I

Measurement:
(1) The sensor shows the diesel engine revolution
number in idle position.

(2) Press button A/I (1) and warning light (yellow)

F5348
(2) lights up on the control panel.
Press the button again to disable the function.
At the same time the relative warning light (2)
lights off.

4.1.2 I.MODE - IDLE ENGINE REVOLUTIONS

Preparation:
(1) With the key-start switch on the ON position
(engine on), A/I control button disconnected,
yellow warning light off, turn the throttle control
(3) to idle position.

Measurement:
(1) The sensor shows the minimum diesel engine
revolutions.

3
15501 9-35990

F8990
 PT10-4-2

EXCAVATOR PERFORMANCE TEST WX90

4.1.3 P.MODE - WORK ENGINE REVOLUTIONS

With the key-start switch on the ON position (engine

on):

Preparation:
(1) Turn throttle control (3) to the maximum position,
using no hydraulic control.

Measurement:
(1) The sensor shows the diesel engine revolution
number in idle position. If operating the
penetrating arm bottom side to the cylinder end-
of-stroke, the sensor shows the diesel engine 3
revolution number in working conditions.
F8990

4.1.4 TRAVELLING - TRAVEL ENGINE REVOLUTIONS

Preparation:
(1) Position the machine with the front equipment
at 180° with respect to the blade/stabilizers. Lift
the wheels from the ground and fully lower the
blade/stabilizers and the arm (support the
machine under the axles).

(2) With the key-start switch on the ON position

(engine on), operating the travel control, the
sensor shows the revolution number in idle 5
position, in travel mode.

Measurement:
(1) If operating the travel control and the service
brake, the sensor shows the revolution number
under load in travel mode.

4.1.5 E. MODE - ECONOMY ENGINE REVOLUTIONS

Preparation:
(1) With the key-start switch on the ON position
(engine on), press button E (4) to set the diesel
engine speed to the economy value. At the same
time the yellow warning light (5) on the control
panel lights up.

Measurement:
(1) With no hydraulic motion, the sensor shows the
diesel engine revolution number in the economy
position. 4
(2) Press button E (4) to return to the start position,
disabling the function E.
15501 9-35990

F13286
Evaluation:

Refer to Group 1 - PERFORMANCE STANDARD.

 PT10-4-3

EXCAVATOR PERFORMANCE TEST WX90

4.2 SWING PERFORMANCE

4.2.1 SWING SPEED

Measure the time required to swing three complete

turns.

Preparation:

(1) Check the lubrication of the swing gear and

swing bearing.
(2) Place the machine on flat, solid ground with F13287
ample space for swinging. Do not attempt this
test on a slope.
(3) With the arm rolled-out and the bucket rolled-
in, hold the bucket so that the height of the
bucket pin is the same as the boom foot pin.
The bucket must be empty.
(4) Keep the hydraulic oil temperature at 50 ± 5°C
(122 ± 9°F).

Measurement:

(1) Select the following switch position:

Auto-idle switch

OFF

(2) Diesel engine throttle control in maximum

position.
(3) Operate the swing control lever fully.
(4) Measure the time required to swing three com-
plete turns in one direction.
(5) Operate the swing control lever fully in the
opposite direction and measure the time
required to swing three complete turns.
(6) Repeat measurements three or four times and
work-out the average values.

Evaluation:

Refer to Group 2 - PERFORMANCE STANDARD.

15501 9-35990
 PT10-4-4

EXCAVATOR PERFORMANCE TEST WX90

4.2.2 SWING FUNCTION DRIFT CHECK

Measure the swing drift on the bearing outer

circumference, when stopping, after a 180° full-speed
swing.

Preparation:

(1) Check the lubrication of the swing gear and

swing bearing.
(2) Place the machine on flat, solid ground with
ample space for swinging. Do not attempt this F13287

test on a slope.
(3) With the arm rolled-out and the bucket rolled-in,
hold the bucket so that the height of the bucket
pin is the same as the boom foot pin. The bucket
must be empty.
(4) Make two chalk marks: one on the swing bearing
and one directly below it on the track frame.
(5) Swing the upperstructure 180°.
(6) Keep the hydraulic oil temperature at 50 ± 5°C
(122 ± 9°F).

Measurement:

(1) Select the following switch position:

Auto-idle switch

OFF

(2) Diesel engine throttle control in maximum

position.
(3) Operate the swing control lever fully and return
it to the neutral position when the mark on the
upperstructure aligns with that on the track fra-
me, after swinging 180°.
(4) Measure the deviation between the two marks.
(5) Align the marks again, swing 180°, then test the
opposite direction.
(6) Repeat measurements four or five times and
work-out the average values.

Evaluation: Measure the deviation

Refer to Group 2 - PERFORMANCE STANDARD.

15501 9-35990

Mark on the bearing

Mark on the track frame

F9006
 PT10-4-5

EXCAVATOR PERFORMANCE TEST WX90

4.2.3 PARKING BRAKE/SWING LEAKAGE TEST

Measure the upperstructure drift when a load is

applied to the bucket on a slope.

Preparation:

(1) Check the lubrication of the swing gear

and swing bearing.
(2) The face of the test slope shall be even,
with a 10° gradient.
(3) With the arm rolled-out and the bucket
rolled-in, hold the bucket so that the height
of the bucket pin is the same as the boom
foot pin. Apply a rated load (W) to the
bucket.
W=M3 x 1.5
where: M3 = bucket capacity (cum)
1.5 = sand specific gravity
(4) Swing the upperstructure to a position 90°
to the slope. Make two chalk marks: one
on the swing bearing, and one directly
below on the track frame.
(5) Keep the hydraulic oil temperature at 50
Measure the deviation
± 5°C (122 ± 9°F).

Measurement:

(1) Keep the engine a low-idle. After 5

minutes, measure the deviation between Mark on the bearing
the two marks.
(2) Perform the test on both right and left Mark on the track frame
swing directions.
(3) Perform the tests three times in each
direction and work-out the average F9006
values.

Evaluation:

Refer to Group 2 - PERFORMANCE

STANDARD.
15501 9-35990
 PT10-4-6

EXCAVATOR PERFORMANCE TEST WX90

4.2.4 SWING BEARING PLAY

Measure the swing bearing play using a dial gauge to

check the wear of bearing races and balls.

Preparation:

(1) Check that the bearing mounting bolts are

tightened at the prescribed torque.
(2) Check the lubrication of the swing bearing and
that the bearing rotation is smooth and
noiseless.
(3) Install a dial gauge on the track frame, as shown,
using a magnetic base.
(4) Position the upperstructure so that the boom
aligns with the tracks facing towards the front
idlers.
(5) Position the dial gauge so that its needle point
touches the bottom face of the bearing outer
race.
(6) The bucket must be empty.

Measurement:

(1) With the arm rolled-out and the bucket rolled-in,

hold the bucket so that the height of the bucket
pin is the same as the boom foot pin. Record F9007
the dial gauge reading (h1).
(2) Lower the bucket to the ground and use it to
raise the front idlers 0.5 m (2 ft). Record the dial
gauge reading (h2).
(3) Draw-out the bearing play (H) from these data
(h1 and h2) as follows:

H = h2 - h 1

Evaluation:

Refer to Group 2 - PERFORMANCE STANDARD.

Measurement position: (h1) Measurement position: (h2)

15501 9-35990

0,5 m.

F13288 F13289
 PT10-4-7

EXCAVATOR PERFORMANCE TEST WX90

4.3 FRONT ATTACHMENT PERFORMANCE

4.3.1 HYDRAULIC CYLINDER CYCLE TIME

Measure the cycle time of the cylinders.

MONOBLOC VERSION
(Arm, bucket and boom).
TRIPLE ARTICULATION VERSION
(Arm, bucket, boom and positioner).

Preparation and measurement:

F13290

(1) Select the following switch position: Fig. 1

Auto-idle switch

OFF

(2) Diesel engine throttle control in maximum

position.
(3) Boom cylinder:
Preparation:
Fully roll-out the arm, roll-in the bucket (empty).
Lower the bucket to the ground (as shown in
fig. 1), or raise the boom to its stroke-end. Place
the control lever in neutral.
Measurement:
To measure the time taken to raise the boom,
pull-back fully the control lever, until the boom
cylinder reaches its stroke-end. To measure the 0,5 m.
time taken to lower the boom, push the control
lever fully forward, until just before the bucket
makes contact with the ground. F13291

(4) Positioning cylinder:

Preparation: Fig. 2
Extend completely the dipping, bucket and
positioning cylinders. Position the bucket about
0.5 m (2 ft) from the ground (as shown in fig. 2),
using the boom cylinders.
Measurement:
Actuate the control pedal to full stroke and retract
completely the positioning cylinder. Measure the
time required by each retraction and extension
operation.
(5) Arm/bucket cylinders:
Preparation of dipper cylinder:
Position the boom and arm so that the bucket
bottom clears the ground by at least 0.5 m (2ft)
(as shown in fig. 2).
Preparation of the bucket cylinder:
15501 9-35990

The empty bucket should be positioned at

midstroke beetween roll-in and roll-out, so that
the side plate edges are vertical to the ground.
Measurement:
To measure the time taken to fully roll-out or 90°
roll-in the arm or bucket, fully push or pull the
F8996
control levers and record the time taken by each
roll-in and/or roll-out operation. Fig. 3
 PT10-4-8

EXCAVATOR PERFORMANCE TEST WX90

(6) Swing cylinder.

Swing cylinder preparation:
Position the boom and arm so that the bucket
bottom clears the ground by at least 0.5 m (2ft)
(as shown in fig. 2).
Fully extend the swing cylinder.
Measurement:
Measure the time taken to fully roll-out or roll-in
the cylinder and Measure the time required by
each retraction and extension operation.
To measure the time taken to fully roll-out or
roll-in the arm or bucket, fully push or pull the
control levers and record the time taken by each
roll-in and/or roll-out operation.
(7) Perform the tests three times and work-out the
average values.

Evaluation:

Refer to Group 2 - PERFORMANCE STANDARD.

15501 9-35990
 PT10-4-9

EXCAVATOR PERFORMANCE TEST WX90

4.3.2 DRIFT TEST

Measure the drift of the front attachment with bucket

loaded.
The drift can be caused by oil leakages in the control
valve and/or cylinders.

NOTE: When testing the drift just after the replacement

of a cylinder, slowly operate each cylinder to
its stroke-end to bleed all the air.

Preparation:

(1) Fully load the bucket. In lieu of a bucket load,

it is possible to use a load (W) as follows:
W = M3 x 1.5
where: M3 = bucket capacity (cum)
1.5 = sand specific gravity.
(2) Position the arm cylinder and positioning
cylinder (triple articulation version) with the rod
20-30 mm (3/4 - 1 1/4 in) from fully retracted
stroke-end.
(3) Position the buket cylinder with the rod 20-30
mm (3/4 - 1 1/4 in) from fully extended stroke-
end.
(4) With the arm rolled-out and the bucket rolled-
in, hold the bucket so that the height of the
EQUAL ELEVATION
bucket pin is the same as the boom foot pin.
(5) Keep the hydraulic oil temperature at 50 ± 5°C
(122 ± 9°F).
DOWN BUCKET
F13292
Measurement:

(1) Stop the engine.

(2) After 5 minutes, measure the deviation in the
positions of the bottom of the bucket, as well
as the boom, arm and bucket cylinder.
(3) Perform the tests three times and work-out the
average values.

BOOM AND BUCKET CYLINDER RETRACTION ARM AND POSITIONING CYLINDERS EXTENSION

mark

mark mark
15501 9-35990

A
B A B

Evaluation:
Refer to Group 2 - PERFORMANCE STANDARD. F8997
 PT10-4-10

EXCAVATOR PERFORMANCE TEST WX90

4.4 CONTROL LEVERS / PEDAL LEVERS / BRAKE

PEDAL

4.4.1 CONTROL LEVER / PEDAL LEVER / BRAKE PEDAL

OPERATING FORCE

Use a spring scale to measure the maximum resistance mm

80
of each control lever at the middle of the grip.

Preparation:

(1) Start the engine.

(2) Keep the hydraulic oil temperature at 50 ± 5°C
(122 ± 9°F).

Measurement:
(1) Select the following switch position:
F9000

Auto-idle switch

OFF

(2) Operate each boom, arm, bucket lever and

swing lever at full stroke, measuring each
maximum operating force.
Repeat the step for the travel pedal lever and m
for the brake pedal. m
5
12
(3) Repeat step (2) three times and work-out the
average values.

Evaluation:
Refer to Group 2 - PERFORMANCE STANDARD. m
m
40

4.4.2 CONTROL LEVER / PEDAL LEVER / BRAKE

PEDAL STROKE

Measure each lever stroke at the lever top using a ruler. F10562

Repeat this step for the travel control pedal and the
brake pedal.

NOTE: If the lever/control pedal/pedal has a little

tolerance, add half of this value to the measured
stroke.

Preparation:
(1) Start the engine.
(2) Keep the hydraulic oil temperature at 50 ± 5°C 0m
m
(122 ± 9°F). 10

m
Measurement: 5
m
12
(1) Stop the engine.
15501 9-35990

(2) Measure each lever stroke at the lever top from

neutral to stroke-end, using a ruler as reference.
(3) Repeat step (2) three times and work-out the
average values.

Evaluation:
Refer to Group 2 - PERFORMANCE STANDARD. F9135
 PT10-4-11

EXCAVATOR PERFORMANCE TEST WX90

4.5 STEERING

4.5.1 STEERING PUMP PRESSURE CHECK

Preparation:

(1) Stop the engine.

(2) Depressurize the air from the hydraulic oil
reservoir removing the bleeding plug.
(3) Install a 0 to 200 bar pressure gauge in the
pressure intake.
(4) Start the engine and check for oil leakages.
(5) Keep the oil temperature at 50 ± 5°C (122 ± 9°F).

Measurement:

(1) Select the following position:

F9008

Auto-idle switch

OFF

(2) Diesel engine throttle control in maximum

position.
(3) Turn the steering wheel right and left a few times.
(4) Measure the pressure value on the pressure
gauge (maximum).
(5) Repeat the operation three times and work out
an average value (neutral).
(6) Measure the pressure value on the pressure
gauge, not operating power steering.

Evaluation:

Refer to Group 2 - PERFORMANCE STANDARD.

15501 9-35990
 PT10-4-12

EXCAVATOR PERFORMANCE TEST WX90

4.6 BRAKES SYSTEM

4.6.1 PARKING BRAKE CHECK

(NEGATIVE)

Measure the parking brake function on a slope.

Warning:
This test is important for safety.

0,3 ÷ 0
,5m
Preparation:

(1) Park the machine on a smooth and dried slope

with a gradient of 10°. F13293
(2) Keep the hydraulic oil temperature at 50 ± 5°C
(122 ± 9°F).

Measurement:

Turn the start-up key on the central dashboard to insert

the parking (negative) brake.

Evaluation:

Keep the machine parked on the slope confirm that the

brake des not slip.

Refer to Group 2 - PERFORMANCE STANDARD.

15501 9-35990
 PT10-4-13

EXCAVATOR PERFORMANCE TEST WX90

4.6.2 BRAKE VALVE PRESSURE TEST

Preparation:

(1) Stop the engine.

(2) Depressurize the air from the hydraulic oil
reservoir removing the bleeding plug.
(3) Connect two pressure gauge with 0 to 200 bar
scale between T1 and T2 hoses connecting brake
valve and rotary joint as shown.

Measurement for SERVICE condition:

(1) Start the engine and operate the brakes a few

times and check for leakages of oil from the
connections.
(2) Keep the temperature of the hydraulic oil at
50 ± 5°C (122 ± 9°F).
(3) Select the following position:

Auto-idle switch

OFF

(4) Measure the pressure on the pressure gauge.

(5) Repeat the operation three or four times and
work out an average value.

T2

Measurement for WORK condition: T1

(1) Start the engine, push the work brake switch on

central panel and check for leakages oil from
the connections. F10563

(2) Keep the temperature of hydraulic oil at 50 ± 5°C

(122 ± 9°F).
(3) Select the following position:

Auto-idle switch

OFF

(4) Measure the pressure on the both pressure

gauges.
(5) Repeat the operation three or four times and
work out an average value.
15501 9-35990

Evaluation:

Refer to Group 2 - PERFORMANCE STANDARD.

 PT10-4-14

EXCAVATOR PERFORMANCE TEST WX90

4.6.3 ACCUMULATORS PRESSURE CHECK

Preparation:

(1) Stop the engine.

(2) Depressurize the air from the hydraulic oil
reservoir removing the bleeding plug.
(3) Connect a 0 to 200 bar pressure gaugein the
special pressure intake.
(4) Start the engine and brake a few times to cause
the automatic charge and check for oil leakages
from the connections.
(5) Keep the temperature of the hydraulic oil at
50 ± 5°C (122 ± 9°F).

Measurement:

(1) Select the following position:

F9005
Auto-idle switch

OFF

(2) The accumulators are pre-charged with

pressurized nitrogen.
To check the gas pressure in the accumulator,
use the appropriate tooling with pressure gauge
while the accumulators are discharged of the
hydraulic oil. To check the pressure of the gas
through the pressure of the oil, connect a
pressure gauge to the accumulator (on the
connecting pipe), charge the accumulators and,
with engine OFF, discharge the accumulators
actuating the brakes several times or loosening
a connection. The pressure will drop slowly to a
certain value than drops to zero suddenly.
The last reading corresponds to the pre-charge
pressure of the gas.

The test must be repeated on all three

accumulators.

Evaluation:

Refer to Group 2 - PERFORMANCE STANDARD.

15501 9-35990
 PT10-5-1

COMPONENTS PERFORMANCE TEST WX90

5. HYDRAULIC COMPONENTS
PERFORMANCE TEST

5.1 PILOT PRESSURE RELIEF VALVE

5.1.1 PILOT PRESSURE

Preparation:

(1) Stop the engine.

(2) Depressurize the air from the hydraulic oil
reservoir by removeing the air breather cap.
(3) Install a pressure gauge with a 0 to 100 bar sca-
le, on quick connection, as shown.
(4) Start the engine and check for oil leakages from
the connections. F9005

(5) Keep the hydraulic oil temperature at 50 ± 5°C.

Measurement:

(1) Select the following switch position:

Auto-idle switch

OFF

(2) Measure the pilot pressure in slow-idle.

(3) Perform the tests three times and work-out the
average values.

Evaluation:

Refer to Group 2 - PERFORMANCE STANDARD.

15501 9-35990
 PT10-5-2

COMPONENTS PERFORMANCE TEST WX90

5.2 PRESSURE RELIEF VALVES

5.2.1 MEASUREMENT OF FRONT ATTACHMENT AND

TRAVEL OVERPRESSURE
(Main pump circuit)

Preparation:

(1) Open the engine hood and the right side door.
(2) Install a pressure gauge with a 0÷400 bar scale
to the pressure intake with (LS).
(3) Install a pressure gauge with a 0÷400 bar scale
to the pressure intake with (PUMP).
(4) Start the engine and check for leakages from
the connections.
(5) Keep the temperature of the hydraulic oil at
50 ± 5°C (122 ± 9°F).
F9013

Measurement:

(1) Select the following position:

Auto-idle switch

OFF

(2) Diesel engine throttle control in maximum

position.
(3) Slowly actuate one of control function: raising,
dipper stick, bucket and positioning (triple
articulation version) to full stroke and measure
the pressure:
(PUMP) Relief valve,
(LS) LS valve,
(PUMP) Neutral (idle).
(4) Actuate the travel function and at the same time,
stop the undercarriage applying the brake pedal,
than measure the pressure.
(5) Repeat steps (2) and (3) three times and work
out the average values.

Evaluation:

Refer to Group 2 - PERFORMANCE STANDARD.

15501 9-35990
 PT10-5-3

COMPONENTS PERFORMANCE TEST WX90

Front attachment and travel overpressure

adjustment (main pump - LS)

Preparation:

(1) Open the engine hood and the right side door. A
(2) Install a pressure gauge with a 0÷400 bar scale
to the pressure intake with (LS).
(3) Adjust the pressure by acting on cut off valvef
(A) (LS) on control valve as shown.
(4) Act on cut-off valve (A) until obtaining the required
value, measured by the pressure gauge installed
as per procedure 2.1.
Pay attention when tightening cut-off valve (A)
(LS) lock nut.
(5) Install a pressure gauge with a 0÷400 bar scale
to the pressure intake with (PUMP).
(6) Start the engine and check for leakages from B
the connections. F9014
(7) Keep the temperature of the hydraulic oil at
50 ± 5°C (122 ± 9°F).

NOTE: If it is not possible to obtain the required value,

check the maximum setting of main relief valve
(B) (PUMP). In order to check the main relief
valve (B) setting, it needs to increase the cut off
valve (A) setting, by screwing completely the
adjusting screw.
Check the main relief valve (B) setting should
be 320 +5 - 0 bar by means of a pressure gauge
connetected as per procedure 2.1.

Measurement:

(1) Select the following position:

Auto-idle switch

OFF

(2) Diesel engine throttle control in maximum

position.
F9013
(3) Slowly actuate one of control function: raising,
dipper stick, bucket and positioning (triple
articulation version) to full stroke and measure
the pressure:
(PUMP) Relief valve,
(LS) LS valve.
(4) Actuate the travel function and at the same time,
stop the undercarriage applying the brake pedal,
15501 9-35990

than measure the pressure.

(5) Repeat steps (2) and (3) three times and work
out the average values.

Evaluation:

Refer to Group 2 - PERFORMANCE STANDARD.

 PT10-5-4

COMPONENTS PERFORMANCE TEST WX90

5.2.2 MEASUREMENT OF SWING OVERPRESSURE

Preparation:

(1) Open the engine hood and the right side door.
(2) Install a pressure gauge with a 0÷400 bar scale
to the pressure intake with (SWING).
(3) Start the engine and check for leakages from
the connections.
(5) Keep the temperature of the hydraulic oil at
50 ± 5°C (122 ± 9°F).

Measurement:

(1) Select the following position:

Auto-idle switch
F9132

OFF

(2) Diesel engine throttle control in maximum

position.
(3) By means of swing pilot valve, set the bucket
against a solid object.
(4) Insist to hold the swing pilot valve at fully stroke
end. At the same time read the pressure when
the valve releasing.
(5) Repeat steps (2) and (3) three times and work
out the average values.
(6) If it is not correct, act on cut-off valve (5). 5

Evaluation:

Refer to Group 2 - PERFORMANCE STANDARD.

5.2.2.1 Setting of swing hydraulic system valves

In order to perform the swing overpressure valve

setting, it needs first to increase the setting level of cut
off (5) valve of secondary pump controller of about 1
turn.

Preparation:

(1) Open the engine hood and the right side door.
(2) Install a pressure gauge with a 0÷400 bar scale
to the pressure intake with (SWING).
15501 9-35990

(3) Start the engine and check for leakages from

the connections.
(4) Keep the temperature of the hydraulic oil at
50 ± 5°C (122 ± 9°F).

F9141
 PT10-5-5

COMPONENTS PERFORMANCE TEST WX90

5.2.2.2 Main valve adjustment of swing control valve

For main valve adjustment check (D) (set at 330 bar):

D
Preparation:

(1) Stop the engine.

(2) Depressurize the air from the hydraulic oil tank
removing the bleeding plug.
(3) Connect a 0÷400 bar pressure gauge in the
pressure gauge intake on the machine right side
(position SWING).
(4) Start the engine and check for leakages from
the connections.
(5) Keep the temperature of the hydraulic oil at 50
± 5°C (122 ± 9°F). F8458

(6) Increase cut-off valve setting screwing the

adjustment screw by one turn.
(7) Check or adjust the main valve on swing control
valve. Readjust swing pump control valve at 310
bar, as per procedure 2.2.1.

Measurement:

(1) Select the following position:

Auto-idle switch

OFF

(2) Diesel engine throttle control in maximum

position.
(3) Act on swing control and set the bucket (the
whole front equipment) against a solid object.
(4) Insist with swing. At the same time measure the
pressure relative to the valve release.
(5) Measure after increasing cut-off valve
adjustment. Check if main overpressure valve
adjustment is 330 bar.
(6) Repeat steps (2) and (3) three times and work
out the average values.

Evaluation:

Refer to Group 2 - PERFORMANCE STANDARD.

15501 9-35990
 PT10-5-6

COMPONENTS PERFORMANCE TEST WX90

5.2.2.3 Main valve adjustment of swing control valve

Measurement:

(1) Disconnect the pilot hoses after position marking

to avoid inversion during reassemble.
(2) Install plugs to avoid oil spilling.
(3) Loosen lock nut (3), then fully close the bush
(4) to simulate the pilot pressure.
(4) Loosen lock nut (1), then turn the ring nut (2)
until to reach the maximum pressure (320 bar
at valve releasing) measurable by pressure
gauge connected as per procedure 2.2.
(5) Unscrew the bush (4) until to reach the braking
pressure (190 bar), measurable by pressure
gauge connected as per procedure 2.2, making
care to maintain the ring nut (2) locked. F9142
(6) Select the following position:

Auto-idle switch

OFF

(7) Diesel engine throttle control in maximum

position.
(8) By means of swing pilot valve, set the bucket
against a solid object.
(9) Insist to hold the swing pilot valve at fully stroke
end. At the same time read the pressure when
the valve releasing.
(10) Repeat steps (7) and (8) three times and work
out the average values.
(11) Tighten the lock nut (3), then reconnect the pilot
hoses to the relate valves.
(12) The swing motor valves are two. Repeat the step
for both directions.

NOTE:
• For further accuracy of adjustment, recheck
the pressure of the valve releasing.

• Repeat the procedure shown in paragraph

2.2.1 for resetting of the cutt-off valve of swing 1
pump regulator.

Evaluation: 2
15501 9-35990

Refer to Group 2 - PERFORMANCE STANDARD.

4
 PT10-5-7

COMPONENTS PERFORMANCE TEST WX90

5.3 TRANSMISSION DRIVE SHAFT

5.3.1 TRANSMISSION DRIVE SHAFT SPEED

Check the revolution speed of the transmission drive

shaft.

Preparation:

(1) Open the engine hood and the right side door.
(2) Install a pressure gauge with a 0÷600 bar scale
to the pressure intake with (PUMP).
(3) Install a pressure gauge with a 0÷600 bar scale
to the pressure intake with (LS).
(4) Keep the temperature of the hydraulic oil at
50 ± 5°C (122 ± 9°F).
(5) Apply a reflective label on the drive shaft in order
to measure the drive shaft revolution speed with F9138
an electronic digital tachometer.
(6) Lift the excavator of the ground using the side
stabilizers, blade and front attachment; then lock
the oscillating point.

First speed measurement

(Machine version 30 Km/h)

(1) Select the following position:

Auto-idle switch

OFF

(2) Diesel engine throttle control in maximum

position.
(3) Insert the off-road speed position (TORTOISE)
- select the 1st speed
- operate the travel pedal forward.
(4) Stabilize the travel speed with the hydraulic oil
temperature at 50 ± 5°C (122 ± 9°F).
Measure the drive shaft revolution speed using
an electronic digital tachometer.
(5) Check the ∆P value = 18–0 +1
bar by means of
digital pressure gauge, computing it by the
difference between points (PUMP) and (LS).
15501 9-35990

WARNING

Pay the utmost care to the wheel and drive shaft

revolutions in order to avoid injury to the people.
 PT10-5-8

COMPONENTS PERFORMANCE TEST WX90

Third speed measurement

(version 30 Km/h)
(1) Set the controls as follows:
- engine speed to maximum
- set fast speed position (HARE)
- select second speed gear
- operate the travel pedal to forward stroke-end.
(2) Stabilize the travel pressure from 190 to 200 bar
with the hydraulic oil temperature at 50 ± 5°C
(122 ± 9°F).
Measure the drive shaft revolution speed using
an electronic digital tachometer.
(3) Check the ∆P value = 18+1 –0 bar by means of digital
pressure gauge, computing it by the difference
between points (PUMP) and (LS).
■ If the ∆p pressure value obtained is out of
tolerance expected ∆P = 18+1 -0 bar, should need
to remove the seal of lead and operate on the
screw located on pump controller of main pump.

WARNING

Pay the utmost care to the wheel and drive shaft

revolutions in order to avoid injury to the people.

Third speed measurement

(version 20 Km/h) version GERMANY

NOTE:
Before starting check procedure, verify the
recessing of the travel motor displacement
adjusting screw,
(1) Set the controls as follows:
- engine speed to maximum F9015

- set fast speed position (HARE)

- select third speed gear
- operate the travel pedal to forward stroke-end.
(2) Stabilize the travel pressure with the hydraulic
oil temperature at 50 ± 5°C (122 ± 9°F).
Measure the drive shaft revolution speed using
an electronic digital tachometer.

In case of transmission shaft minimum speed not

within the specification, act as follows:
■ Act on the adjustment screw of min. engine
displacement. Tighten to increase or untighten to
decrease the hydraulic motor minimum
displacement.
15501 9-35990

WARNING

Pay the utmost care to the wheel and drive shaft

revolutions in order to avoid injury to the people. F9016

Evaluation:
Refer to Group 2 - PERFORMANCE STANDARD.
 PT10-5-9

COMPONENTS PERFORMANCE TEST WX90

5.4 HYDRAULIC PUMPS

5.4.1 MAIN PUMP FLOW TEST

C
Measure the pressure and flow of the main pump, by
installing a flowmeter, complete with test hoses and
turbine of delivery hoses, between the pump and the
control valve.

Preparation:

(1) Lift the wheels from the ground, then stop the
engine and actuate repeatedly the pilot valves
in order to allow the oil pressure to release.

Be sure that hydraulic oil should not

pressurized and overheated.
(2) Bleed the air pressure from hydraulic tank,
unscrewing the bleed cap.
(3) Connect a vacuum pump to the oil tank supply
port.
(4) Actuate the vacuum pump, then disconnect the
delivery hoses.
(5) Install a flowmeter (C) complete of test hoses E D
and turbine (D) by means of two adapters
originating the system shown.
(6) Disconnect the vacuum pump, then close the
bleed cap. F9139

(7) Connect the engine tachometer sensor in order

to verify the engine speed during all the check
procedure.
(8) Keep the temperature of the hydraulic oil at
50 ± 5°C (122 ± 9°F).

Measurement:

ATTENTION: Before starting the engine, make

sure that the flowmeter loading valve (E) should
be fully open.

(1) Start the engine and check for oil leakages from
the connections.
(2) Maintain the hydraulic oil temperature at 50 ± 5°C
(122 ± 9°F).
(3) Select the following switch position:

Auto-idle switch

OFF
15501 9-35990

(4) Verify, by means of the tachometer, that the

engine speed should be 2000 ± 50 rev/min.
 PT10-5-10

COMPONENTS PERFORMANCE TEST WX90

(5) Actuate the travel control pedal and keep it in

this position with wheels operating.
(6) Select the 3rd speed.
(7) Read the pump flow indication on the flowmeter
and the pressure on related gauge.

NOTES:
• In these conditions it is possible to check the
pump flow.

Evaluation:

Refer to Group 2 - PERFORMANCE STANDARD.

(main pump P-Q diagram)

If the foreseen values in the P - Q, curve can not be met, this does not mean a failure of the pump, but
could be caused by a setting change of the pump controller.
In order to make sure of the pump efficiency, the measurement of the oil quantity that drains from pump
housing (drain port T1 of main pump), can be required.
For your information, the maximum values used for new pumps releasing are quoted below.

Maximum acceptable limit of standard drain for new pumps

Pump pressure Oil quantity (*)

P (bar) Q max (l/min)

100 4.3

200 8.8

300 13.2

(*) With oil viscosity 18 mm2/s

15501 9-35990

For the in service pumps, if the drain value is greater than three times the standard values quoted above,
the pump replacemend is recommended.( i.e.: At 300 bar Qmax = 13,2 l/min replace the pump with Q = 39,6
l/min).

NOTE: An excessive drain can determine an increasing pressure in the inside of the pump housing, that
in any way, must not exceed the 2 bar (absolute).
 PT10-5-11

COMPONENTS PERFORMANCE TEST WX90

5.4.2 SWING PUMP FLOW TEST

Measure the pressure and flow of the swing pump, by

installing a flowmeter, complete with test hoses and C
turbine of delivery hoses, between the pump and the
control valve.

Preparation:

(1) Lift the equipment to the ground fully extended,

then stop the engine and actuate repeatedly the
pilot valves in order to allow the oil pressure to
release.

Be sure that hydraulic oil should not

pressurized and overheated.
(2) Bleed the air pressure from hydraulic tank,
unscrewing the bleed cap.
(3) Connect a vacuum pump to the oil tank supply
port.
(4) Actuate the vacuum pump, then disconnect the
delivery hoses.
(5) Install a flowmeter (C) complete of test hoses
and turbine (D) by means of two adapters E D
originating the system shown.
(6) Disconnect the vacuum pump, then close the
bleed cap.
(7) Connect the engine tachometer sensor in order
to verify the engine speed during all the check F9137

procedure.
(8) Keep the temperature of the hydraulic oil at
50 ± 5°C (122 ± 9°F).

Measurement:

ATTENTION: Before starting the engine, make

sure that the flowmeter loading valve (E) should
be fully open.

(1) Start the engine and check for oil leakages from
the connections.
(2) Maintain the hydraulic oil temperature at 50 ± 5°C
(122 ± 9°F).
(3) Select the following switch position:

Auto-idle switch

OFF

(4) Verify, by means of the tachometer, that the

15501 9-35990

engine speed should be 1800 ± 50 rev/min.

 PT10-5-12

COMPONENTS PERFORMANCE TEST WX90

NOTES:
• In these conditions it is possible to check the
pump flow.

Evaluation:

Refer to Group 2 - PERFORMANCE STANDARD.

(swing pump P-Q curve)

If the foreseen values in the P - Q, curve can not be met, this does not mean a failure of the pump, but
could be caused by a setting change of the pump controller.
In order to make sure of the pump efficiency, the measurement of the oil quantity that drains from pump
housing (drain port L secondary pump).
For your information, the maximum values used for new pumps releasing are quoted below.

Maximum acceptable limit of standard drain for new pumps

Pump pressure Oil quantity (*)

P (bar) Q max (l/min)

100 1.6

200 3.2

300 4.8

(*) With oil viscosity 18 mm2/s

For the in service pumps, if the drain value is greater than three times the standard values quoted above,
the pump replacemend is recommended.(

NOTE: An excessive drain can determine an increasing pressure in the inside of the pump housing, that
in any way, must not exceed the 2 bar (absolute).
15501 9-35990
 INDEX WX90 -11-1

WX90

SECTION 11 ENGINE

INDEX

Group 10 - GENERAL INFORMATION .................................................................... EM11-10

10.1 Intorduction
10.2 Engine view
10.3 Engine identification
10.4 Safety
10.5 Engine lift equipment
10.6 Viton Sels
10.7 CASE powerpart recommended consumable products

Group 11 - SPECIFICATIONS .................................................................................. EM11-11

11.1 Basic engine data

11.2 Reccomended torque tensions
11.3 Compression test data

Group 12 - CYLINDER HEAD ASSEMBLY .............................................................. EM11-12

12.1 General description

12.2 Rocker cover
12.3 Rocker assembly
12.4 Cylinder head assembly
12.5 Valve springs
12.6 Cylinder head assembly
12.7 Valves and valve springs
12.8 Valve guides
12.9 Cylinder head
12.10 Data and dimensions
15501 9-35990

Group 13 - PISTON AND CONNECTION ROD ........................................................ EM11-13

13.1 General description

13.2 Big and bearing
13.3 Piston and connection rod
13.4 Piston rings

(to be continued)
 INDEX WX90 -11-2
INDEX (continues)

13.5 Piston and connection rod

13.6 Piston and piston rings
13.7 Connection rod
13.8 Small end bush
13.9 Piston cooling jets
13.10 Data and dimensions

Group 14 - CRANKSHAFT ....................................................................................... EM11-14

14.1 General description

14.2 Crankshaft pulley
14.3 Rear oil seal assmbly
14.4 Thrust washers
14.5 Main bearings
14.6 Crankshaft
14.7 Balancer unit
14.8 Data and dimensions

Group 15 - TIMING CASE COVER AND DRIVE ...................................................... EM11-15

15.1 General description

15.2 Timing case cover
15.3 Front oil seal
15.4 Idler gear and hub
15.5 Fuel pump gear
15.6 Camshaft gear
15.7 Crankshaft gear
15.8 Timing case
15.9 Camshaft and tappets
15.10 Data and dimensions

Group 16 - GENERAL DESCRIPTION ..................................................................... EM11-16

16.1 General description

16.2 Cylinder block
16.3 Cylinder liner
16.4 Cylinder bore, engine type AK
16.5 Data and dimensions

Group 17 - ENGINE TIMING ..................................................................................... EM11-17

17.1 General description

17.2 Data abd dimensions

Group 19 - LUBRICATION SYSTEM ........................................................................ EM11-19

19.1 Filter canister

19.2 Filter head
15501 9-35990

19.3 Sump
19.4 Oil strainer and suction pipe
19.5 Lubricating oil pump
19.6 Relief valve
19.7 Data and dimensions

(to be continued)
 INDEX WX90 -11-3

INDEX (continues)
Group 20 - FUEL SYSTEM ....................................................................................... EM11-20

20.1 General description

20.2 Fuel filters
20.3 Atomisers
20.4 Fuel lift pump
20.5 Lucas DP200 series fuel injection pump
20.6 Data and dimensions

Group 21 - COOLING SYSTEM................................................................................ EM11-21

21.1 General description

21.2 Thermostats
21.3 Cooland pump - ealy gear driven
21.4 Fan drive
21.5 Data and dimensions

Group 22 - FLYWHEEL AND FLYWHEEL DESCRIPTION ...................................... EM11-22

22.1 General description

22.2 Flywheel
22.3 Ring gear
22.4 Flywheel housing
22.5 Data and dimensions

Group 23A - ELECTRICAL EQUIPMENT.............................................................. EM11-23A

23A.1 Electrical equipment

23A.2 Precautions
23A.3 Alternator
23A.4 Fault diagnosis
23A.5 Data and dimensions

Group 23B - ELECTRICAL EQUIPMENT ............................................................. EM11-23B

23B.1 General description

23B.2 Starter motor
23B.3 Data and dimensions

Group 23C - ELECTRICAL EQUIPMENT ............................................................. EM11-23C

23C.1 General description

23C.2 Starting aid
23C.3 Data and dimensions

Group 25 - AUXILIARY EQUIPMENT ....................................................................... EM11-25

15501 9-35990
15501 9-35990
 EM11-10-1
GENERAL INFORMATION WX90

10. GENERAL INFORMATION

10.1 INTRODUCTION

This workshop manual has been written to provide assistance in the service and overhaul of Perkins New 1000
Series engines. For overhaul procedures the assumption is made that the engine is removed from the
application.
The engine conforms with USA (EPA/CARB) stage 1 and EEC stage 1 emissions legislation for industrial
applications.
Most of the general information which is included in the relevant User’s Handbook (sections 1 to 9)
has not been repeated in this workshop manual and the two publications should be used together.
Where the information applies only to certain engine types, this is indicated in the text.
The details of some operations will be different according to the of fuel injection pump which is fitted. The
specific pump type used can be found by reference to the manufacturer’s identification plate on the pump body.

The type of pump fitted is :

Lucas DP200 Series.

When reference is made to the “left” or “right” side of the engine, this is as seen from the flywheel end of the
engine.

Special tools have been made available and a list of these is given in group 15. Reference to the relevant
special tools is also made at the beginning of each operation, where relevant.

Recommended consumable products are listed in group 10. Reference to the relevant consumable products
is also made at the beginning of each operation, where relevant.

Data and dimensions are included at the end of each section.

Read and remember the “Safety precautions”. They are given for your protection and must be used
at all times.

Danger is indicated in the text by two methods:

WARNING! This indicates that there is a possible danger to the person.

CAUTION: This indicates that there is a possible danger to the engine.

NOTE: Is used where the information is important, but there is not a danger.
15501 9-35990
 EM11-10-2
GENERAL INFORMATION WX90

10.2 ENGINE VIEW

F7841

15501 9-35990
 EM11-10-3
GENERAL INFORMATION WX90

10.3 ENGINE IDENTIFICATION

The correct identification of the engine is by the

full engine number.

The engine number is stamped on a label which

is fastened to the left side (A2) of the cylinder
block. An example of an engine number is:

AR 81046*U510256B*

Code letters Engine type

AR Four cylinder, naturally aspirated, 103 mm

cylinder bore

If you need parts, service or information for your

engine, you must give the complete engine
number to your CASE distributor.
AR81046*U510256B*
Other identification labels fitted to the engine
include: AJ39770 TPL N°212

An emissions legislation label (A3) fitted to the

side of the cylinder block.

A label (A1) with the fuel injection pump part

numbers.

If a short engine has been fitted in service two

engine serial numbers and a TPL number are
stamped on the engine serial number pad (B3):

Examples of the serial numbers are shown in (B).

If parts for the short engine are needed in service,

use the serial number (B4). If parts which were
moved from the original engine to the short engine
are needed, use the serial number (B1) and the
TPL number (B2).
15501 9-35990
 EM11-10-4
GENERAL INFORMATION WX90

10.4 SAFETY

General safety precautions.

These safety precautions are important. You must refer also to the local regulations in the country of use.
Some items only refer to specific applications.

• Only use these engines in the type of application for which they have been designed.
• Do not change the specification of the engine.
• Do not smoke when you put fuel in the tank.
• Clean away fuel which has been spilt. Material which has been contaminated by fuel must be moved to a
safe place.
• Do not put fuel in the tank while the engine runs (unless it is absolutely necessary).
• Do not clean, add lubricating oil, or adjust the engine while it runs (unless you have had the correct training;
even then extreme care must be used to prevent injury).
• Do not make adjustments that you do not understand.
• Ensure that the engine does not run in a location where it can cause a concentration of toxic emissions.
• Other persons must be kept at a safe distance while the engine or auxiliary equipment is in operation.
• Do not permit loose clothing or long hair near moving parts.
• Keep away from moving parts during engine operation.
Warning! Some moving parts cannot be seen clearly while the engine runs.
• Do not operate the engine if a safety guard has been removed.
• Do not remove the filler cap or any component of the cooling system while the engine is hot and while the
coolant is under pressure, because dangerous hot coolant can be discharged.
• Do not use salt water or any other coolant which can cause corrosion in the closed circuit of the cooling
system.
• Do not allow sparks or fire near the batteries (especially when the batteries are on charge) because the
gases from the electrolyte are highly flammable. The battery fluid is dangerous to the skin and especially
to the eyes.
• Disconnect the battery terminals before a repair is made to the electrical system.
• Only one person must control the engine.
• Ensure that the engine is operated only from the control panel or from the operators position.
• If your skin comes into contact with high-pressure fuel, obtain medical assistance immediately.
• Diesel fuel and lubricating oil (especially used lubricating oil) can damage the skin of certain persons. Protect
your hands with gloves or a special solution to protect the skin.
• Do not wear clothing which is contaminated by lubricating oil. Do not put material which is contaminated with
oil into the pockets of clothing.
• Discard used lubricating oil in a safe place to prevent contamination.
• Ensure that the control lever of the transmission drive is in the “out-of-drive” position before the engine is
started.
• Use extreme care if emergency repairs must be made in adverse conditions.
• The combustible material of some components of the engine (for example certain seals) can become
extremely dangerous if it is burned. Never allow this burnt material to come into contact with the skin or with
the eyes, see page EM11-10-6.
• Read and use the instructions relevant to lift equipment which are given on page EM11-10-6.
• Always use a safety cage to protect the operator when a component is to be pressure tested in a container
of water. Fit safety wires to secure the plugs which seal the hose connections of a component which is to
be pressure tested.
• Do not allow compressed air to contact your skin. If compressed air enters your skin, obtain medical help
immediately.
15501 9-35990

• Do not clean an engine while it runs. If cold cleaning fluids are applied to a hot engine, certain components
on the engine may be damaged.
• Fit only genuine CASE parts.
 EM11-10-5
GENERAL INFORMATION WX90

10.5 ENGINE LIFT EQUIPMENT

The maximum weight of the engine without

coolant, lubricant or a gearbox fitted will vary for
different applications. It is recommended that lift
equipment of the minimum capacity listed below
is used:
Four cylinder engines ...... 500 kg

Before the engine is lifted:

• Always use lift equipment of the approved type

and of the correct capacity to lift the engine. It is
recommended that lift equipment of the type
shown in (A) is used, to provide a vertical lift
directly above the engine lift brackets (A1).
Never use a single lift bracket to raise an
engine.

• Check the engine lift brackets for damage and

that they are secure before the engine is lifted.
The torque for the setscrews for the engine lift
brackets is 44 Nm (33 Ibf ft) 4,5 kgf m.

• To prevent damage to the rocker cover, ensure

that there is clearance between the hooks and
the rocker cover.

• Use lift equipment or obtain assistance to lift

heavy engine components such as the cylinder
block, cylinder head, balancer unit, flywheel
housing, crankshaft and flywheel.
15501 9-35990
 EM11-10-6
GENERAL INFORMATION WX90

10.6 VITON SEALS

Some seals used in engines and in components fitted to engines are made of Viton.
Viton is used by many manufacturers and is a safe material under normal conditions of operation.
If Viton is burned, a product of this burnt material is an acid which is extremely dangerous. Never allow this
burnt material to come into contact with the skin or with the eyes.

If it is necessary to come into contact with components which have been burnt, ensure that the precautions
which follow are used:

• Ensure that the components have cooled.

• Use neoprene gloves and discard the gloves safely after use.

• Wash the area with calcium hydroxide solution and then with clean water.

• Disposal of components and gloves which are contaminated must be in accordance with local regulations.

If there is contamination of the skin or eyes, wash the affected area with a continuous supply of clean water
or with calcium hydroxide solution for 15-60 minutes. Obtain immediate medical attention.

15501 9-35990
 EM11-10-7
GENERAL INFORMATION WX90

10.7 CASE RECOMMENDED CONSUMABLE PRODUCTS

CASE have made available the products recommended below in order to assist in the correct operation,
service and maintenance of your engine and your machine. The instructions for the use of each product are
given on the outside of each container. These products are available from your CASE distributor.

Antifreeze
Protects the cooling system against frost and corrosion. See page 60403640 of the User’s Handbook.

Easy Flush
Cleans the cooling system.

Jointing compound
Universal jointing compound which seals joints. Hylomar.

Silicone rubber sealant

Silicone rubber sealant which prevents leakage through gaps. Hylosil.

Lay-Up 1
A diesel fuel additive for protection against corrosion.

Lay-Up 2
Protects the inside of the engine and of other closed systems.

Lay-Up 3
Protects outside metal parts.

Chisel
Allows easy removal of old gaskets and joints. Loctite chisel.

Repel
Dries damp equipment and gives protection against corrosion. Passes through dirt and corrosion to lubricate
and to assist removal of components. Loctite repel.

Threadlock
To retain small fasteners where easy removal is necessary.

Studlock
To permanently retain large fasteners and studs. Loctite 222E.

Nutlock
To retain and seal threaded fasteners and cup plugs where easy removal is necessary. Loctite 242E.

Liquid gasket
To seal flat faces of components where no joint is used. Especially suitable for aluminium components. Loctite
518.

Threadlock (hydraulic/pnuematic)
To retain and seal pipe connections with fine threads. Especially suitable for hydraulic and pneumatic
systems. Loctite 542.
15501 9-35990

Threadlock (pipe)
To retain and seal pipe connections with coarse threads. Pressure systems can be used immediately. Loctite
575.

Retainer (oil tolerant)

To retain components which have a transition fit. Loctite 603.
 EM11-10-8
GENERAL INFORMATION WX90

Retainer (high strength)

To retain components which have an interference fit. Loctite 638.

Atomiser thread sealant

To seal the threads of the atomiser into the cylinder head. Hylomar Advance Formulation.

Compound
To seal the outer diameter of seals. Currently Loctite Forma Gasket No 2.

Platelock
For tight fitted metal surfaces. Suitable for metal plated surfaces and stainless steel. Loctite 243.

Gasket eliminator
Improves flange sealing when a gasket is not used. It provides a seal with temperature resistance that is
flexible in positions where vibration and pressure occur. Loctite 515.

Silicone adhesive
An RTV silicone adhesive for application where lowpressure tests occur before the adhesive sets. Used to
prevent leakage where movement of the joint occurs. Loctite 5900.

15501 9-35990
 EM11-11-1
SPECIFICATIONS WX90

11. SPECIFICATIONS

11.1 BASIC ENGINE DATA

Number of cylinders:

AR ................................................................................................................................................................ 4

Cylinder arrangement .......................................................................................................................... In line

Cycle ........................................................................................................................................... Four stroke
Direction of rotation ................................................................................................. Clockwise from the front

Induction system
AR .................................................................................................................................... Naturally aspirated

Combustion system ............................................................................................................... Direct injection

Nominal bore
AR .................................................................................................................................... 103 mm (4.055 in)

Stroke ................................................................................................................................. 127 mm (5.00 in)

Compression ratio
AR ........................................................................................................................................................ 18.5:1

Cubic capacity
AR .................................................................................................................................... 4.23 litres (258 in3)

Firing order
AR ...................................................................................................................................................... 1.3.4.2.
Valve tip clearances (hot or cold)
Inlet ................................................................................................................................. 0.20 mm (0.008 in)
Exhaust ........... ............................................................................................................... 0.45 mm (0.018 in)

Lubricating oil pressure (1)

AR ................................................................................................................... 207 kPa (30lbf/in2)2.1 kgf/cm2

(1) minimum at maximum engine speed and normal engine temperature

15501 9-35990
 EM11-11-2
SPECIFICATIONS WX90

11.1.1 GENERAL INFORMATION

Thread sealant

When setscrews or studs are fitted into holes which are tapped through the cylinder block, a suitable sealant
must be used to prevent leakage.

Micro encapsulated anaerobic sealant (M.E.A.S) fasteners have been introduced instead of jointing
compounds or other sealants when the fasteners are fitted in through holes into oil or coolant passages. The
identification of these fasteners, as supplied, is by a red, blue, or other colour sealant around the fastener
threads.

With M.E.A.S. sealed studs, the sealed end must be fitted into the cylinder head / cylinder block etc. Ensure
that the threaded holes have a 1.59 mm (0.0625 in) 45° chamfer, to ensure that when the new fasteners are
fitted the M.E.A.S. sealant is not removed. If the fasteners have to be removed and fitted again, the threads
must be cleaned and a suitable sealant used.

15501 9-35990
 EM11-11-3
SPECIFICATIONS WX90

11.2 RECOMMENDED TORQUE TENSIONS

Most of the torque tensions on the engine are standard. Special torque tensions are listed in the separate
special torque tables. The standard torque tensions listed in the tables below can be used when a special
torque is not necessary.

The torque tensions below apply to components lubricated lightly with clean engine oil before they are fitted.

Standard torques for setscrews and nuts

Torque

Thread size Nm kgf m

M6 x 1.00 9 0.9
M8 x 1.25 22 2.2
M10 x 1.50 44 4.5
M12 x 1.75 78 8.0
M14 x 2.00 124 12.6
M16 x 2.00 190 19.3
F8159gb

Standard torques for studs (metal end)

Torque

Thread size Nm kgf m

M6 x 1.00 5 0.5
M8 x 1.25 11 1.1
M10 x 1.50 18 1.8
M12 x 1.75 25 2.5
F8160gb

Standard torques for pipe unions, plugs, and adaptors

Torque

Thread size Nm kgf m

15501 9-35990

1/8 PTF 9 0.9

1/4 PTF 17 1.7
3/8 PTF 30 3.0
3/4 PTF 45 4.5
F8161gb
 EM11-11-4
SPECIFICATIONS WX90

11.2.1 SPECIAL TORQUE TENSIONS

The torque tensions below apply to components lubricated lightly with clean engine oil before they are fitted.
Special torques for setscrews and nuts.
Special torques for setscrews and nuts

Torque

Thread
Description Nm kgf m
Size
Cylinder head assembly
Setscrews, cylinder head 1/2 UNF (see operation 12A-07)
Setscrews, cylinder head (Engine types AR and AS) M10 (see operation 12A-07)
1/2 UNF
Fasteners, rocker shaft brackets:
- Aluminium brackets M12 40 4.1
- Cast iron and sintered steel brackets M12 75 7.6
Cap nuts, composite plastic rocker cover M12 20 2.1
Cap nuts, aluminium rocker cover M12 30 3.0
Setscrews, inlet manifold to cylinder head M10 44 4.5
Fasteners, exhaust manifold to cylinder head M10 44 4.5
Setscrews, engine lift bracket M10 44 4.5
Piston and connecting rod assemblies
Nuts, connecting rods 1/2 UNF 125 12.7
Setscrews, connecting rods 1/2UNF 155 15.8
Banjo bolts, piston cooling jets 3/8 UNF 27 2.7
Crankshaft assembly
Setscrews, main bearings 5/8 UNF 265 27.0
Setscrews, crankshaft pulley 7/16 UNF 115 11.8
Setscrews, viscous damper to crankshaft pulley M12 75 7.6
Cap screws, viscous damper to crankshaft pulley M8 35 3.6
Cap screws, crankshaft bonded damper to crankshaft pulley M8 35 3.6
Setscrews, rear oil seal housing to cylinder block M8 22 2.2
Cap screws, bridge piece to cylinder block M6 16 1.6
Cap screws, rear oil seal housing to bridge piece M6 13 1.3
Torxscrew, rear oil seal housing to bridge piece M8 18 1.9
15501 9-35990

Setscrew, idler gear hub of balancer unit M12 93 9.5

Nut, drive gear of balance weight 1/2 UNF 82 8.4
Setscrews, rear cover of balancer frame M10 54 5.5
Setscrews, oil transfer plate (balancer unit) M10 30 3.1
Setscrews, oil pump to balancer frame M8 27 2.8
Setscrews, balancer to cylinder block M10 54 5.5
F8162gb
 EM11-11-5
SPECIFICATIONS WX90

Special torques for setscrews and nuts

Torque
Thread
Description Nm kgf m
Size
Timing case and drive assembly
Setscrews, timing case to cylinder block M8 22 2.2
Setscrews, timing case to cylinder block M10 44 4.5
Setscrews, hub of idler gear M10 44 4.5
Setscrew, camshaft gear M12 95 9.5
Setscrews, timing case cover to timing case M8 22 2.2
Nuts, timing case cover to timing case M8 22 2.2
Cylinder block
Setscrews, fitted instead of piston cooling jet (s) 3/8 UNF 27 2.7
Fuel system
Nuts, high-pressure fuel pipes M12 22 2.2
Bolt banjo, leak-off connection M8 9 0.9
Gland nut, atomiser body - 40 4.1
Setscrews, for the gear of the fuel injection pump M10 28 2.8
Torxscrew, for the gear of the fuel injection pump M10 22 2.2
Setscrews, fuel lift pump M8 22 2.2
Nuts for flange of fuel injection pump M8 22 2.2
Locking screw of DP200 fuel injection pump 10 A/F 10 1
Lubrication system
Plug, lubricating oil sump 3/4 UNF 34 3.5
Setscrews, oil pump to front bearing cap M8 22 2.2
Setscrews, cover for oil pump M8 28 2.9
Fasteners, lubricating oil sump M8 22 2.2
Cooling system
Setscrews, fan drive housing to timing case M10 44 4.5
Setscrews, fan drive pulley to hub M8 22 2.2
Setscrews, fan drive pulley to hub M10 44 4.5
Setscrews, fan M8 22 2.2
Connector, oil cooler to oil filter head 3/4 UNF 58 5.8
15501 9-35990

Setscrews, coolant pump to body of pump (Engine type AS) M8 29 2.9

Screw, cassette type cooler to oil filter head 3/4 UNF 37 3.7
F8163gb
 EM11-11-6
SPECIFICATIONS WX90

Special torques for setscrews and nuts

Torque
Thread
Description Nm kgf m
size
Flywheel and housing
Setscrews, flywheel to crankshaft 1/2 UNF 105 10.7
Setscrews, cast iron flywheel housing to cylinder block M10 44 4.5
- Head stamped 8.8 M12 75 7.6
- Head stamped 10.9 M 10 63 6.4
- Head stamped 10.9 M 12 115 11.7
Setscrews, aluminium flywheel housing to cylinder block M10 70 7.1
Setscrews, flywheel housing to cylinder block (paper joint) M10 70 7.1
Aspiration system
Nuts, turbocharger to manifold M10 44 4.5
Electrical equipment
Nut, alternator pulley:
- CAV AC5RA and AC5RS 5/8 UNF 55 5.6
- Thin nut A127, and motorola pulley, 22 mm A/F M17 60 6.1
- Thick nut A127, and motorola pulley, 24 mm A/F M17 80 8.2
- Bosch 55A M14 45 4.5
- Bosch 55A M16 50 5.1
- Butec 5524 5/8 UNF 78 8.0
Fuelled start aid to induction manifold 7/8 UNF 31 3.1
Port heater to induction manifold M22 60 6.1
Nut/screw, starter motor 3/8 UNF 30 3.0
Auxiliary equipment
Nut, compressor drive gear to compressor crankshaft 5/8 UNF 120 12.0
Nut, (30 A/F) Compressor gears M20 130 13.0
Cap screw, bracket to idler hub M10 60 6.0
Cap screw, bracket to timing case M8 35 3.5
F8164gb
15501 9-35990
 EM11-11-7
SPECIFICATIONS WX90

11.3 COMPRESSION TEST DATA

Tests have shown that many factors affect compression pressures. Battery and starter motor condition,
ambient conditions and the type of gauge used can give a wide variation of results for a given engine. It is not
possible to give accurate data for co mpress i on pressu re , but tests h ave shown th at the results should be
within 2000/3500 kPa (300/500 Ibf/in2) 21,0/35,0 kgf/cm2 for diesel engines.

Compression tests should only be used to compare between the cylinders of an engine. If one or more
cylinders vary by more than 350 kPa (50 Ibf/in2) 3,5 kgf/cm2, then those cylinders may be faulty.

Co mpressio n tests s hou ld not be the on ly m eth od used to show the condition of an engine, but they should
be used together with other symptoms and tests.

How to do a compression test

CAUTION: Before the compression test, ensure that the battery is in good condition and that it is fully charged.
Also ensure that the starter motor is in good condition.

1 Ensure that the valve tip clearances are set correctly.

2 Remove the atomisers.

3 Fit a suitable gauge into the atomiser hole of the cylinder to be tested.

4 Ensure that the engine cannot start:

Disconnect the stop solenoid or put the stop control in the no-fuel position.

Operate the starter motor and note the pressure indicated on the gauge.

5 Repeat for each cylinder.

15501 9-35990
 EM11-11-8
SPECIFICATIONS WX90

NOTES:

15501 9-35990
 EM11-12-1
CYLINDER HEAD WX90

12. CYLINDER HEAD ASSEMBLY

12.1 GENERAL DESCRIPTION

In a diesel engine there is little carbon deposit and for this reason the number of hours run is no indication of
when to overhaul a cylinder head assembly. The factors which indicate when an overhaul is necessary are
how easily the engine starts and its general performance.

The cylinder head assembly has two valves fitted for each cylinder, each fitted with single valve springs.

The ports for the inlet and exhaust are on the right side of the cylinder head.

The face angle of the valves is either 45° or 30°. The angle of the valve seats in the cylinder head is either
46° or 31°.

The valves move in phosphated steel guides which can be renewed. The exhaust valve guide has a
counterbore to prevent seizure of the valve stem caused by a build up of carbon under the head of the valve.

Both valve stems are fitted with oil seals that fit over the top of the valve guides.

The engines have steel valve seat inserts fitted in the cylinder head for both inlet and exhaust valves.
15501 9-35990
 EM11-12-2
CYLINDER HEAD WX90

12.2 ROCKER COVER

To remove and to fit 12A-01

Engines are supplied with rocker covers (A) made

of a plastic material or aluminum.

12.2.1 TO REMOVE

1 Disconnect the breather pipe.

2 Remove the cap nuts and rubber seal (A1)

from the top of the rocker cover and remove
the heat shield, if one is fitted.

3 Lift off the rocker cover and the joint.

CAUTION: When the rocker cover is fitted, the

cap nuts are tightened onto the nuts of the rocker
brackets. During removal of the cap nuts, it is
possible to loosen the nuts of the rocker brackets.
The nuts of the rocker brackets should be
tightened to the correct torque every time the
cover is removed.

12.2.2 TO FIT

1 Check the seal of the oil filler cap (B1) and the
sealing washers (B3) for the cap nuts (B2).

WARMING! The rocker cover joint may be made

from viton, read the safety precautions in section
10 for viton seals.

2 Check the condition of the rocker cover joint

(B4). If necessary, the joint can be removed
and renewed.

3 Clean the joint face of the cylinder head and fit

the rocker cover.

4 Fit the sealing washers, the heat shield, if one

is fitted, and the cap nuts.

CAUTION: Damage to the sealing washer can

occur if the cap nut is not tightened centrally
through the sealing washer and the rocker cover.
If the sealing washer is damaged, it must be
renewed.
15501 9-35990

5 Tighten the rocker cover cap nuts to:

20 Nm (15 lbf ft) 2.1 kgf m for plastic covers.
30 Nm (22 lbf ft) 3.0 kgf m for aluminium
covers.

6 Fit the breather pipe.

 EM11-12-3
CYLINDER HEAD WX90

12.3 ROCKER ASSEMBLY

To remove and to fit 12A-02

12.3.1 TO REMOVE

1 Remove the rocker cover, operation 12A-01.

2 Release evenly and gradually the fasteners of

the rocker shaft brackets; begin with the end
brackets and move toward the centre. Remove
the fasteners and lift off the rocker assembly.

3 Remove the rubber oil seal (A) from the oil

supply connection or from the oil supply hole
in the cylinder head.

12.3.2 TO FIT

1 Fit a new rubber oil seal in the oil supply hole

in the cylinder head.

2 Check that the push rods fit correctly in the

sockets of the tappets. Fit the rocker assembly;
ensure that the oil supply connection is fitted
correctly into the oil seal. Check that the ends
of the adjustment screws fit correctly in the
sockets of the push rods.

3 Fit the fasteners of the rocker shaft brackets

and tighten the fasteners evenly and gradually;
begin with the inner fasteners and work towards
the end fasteners. Tighten the fasteners evenly
to the correct torque according to the material
of the rocker shaft brackets:
Aluminium 40 Nm (30 lbf ft) 4.1 kgf m.
Cast iron 75 Nm (55 lbf ft) 7.6 kgf m.
Sintered steel 75 Nm (55 lbf ft) 7.6 kgf m.

4 Check and adjust the valve tip clearances, see

operation 12A-05.
15501 9-35990
 EM11-12-4
CYLINDER HEAD WX90

12.3.3 TO DISMANTLE 12A-03

1 Remove the clips from both ends of the rocker shaft. Ensure that the ends of the rocker shaft are not
damaged. Release the location screw (A1) for the oil supply connection.

2 Dismantle the assembly and make a note of the position of each component to ensure that they can be
assembled more easily.

12.3.4TO ASSEMBLE

1 Ensure that the oil holes in the rocker shaft and in the rocker levers are not restricted.

2 Lubricate the components with clean engine lubricating oil before assembly. Assemble the components
in the correct order (A) with the arrows (A2) on the pedestals in the position shown. Ensure that the location
screw (A1) for the oil supply connection is fitted correctly in the rocker shaft. Fit the clips to the ends of the
rocker shaft.

To inspect and to correct

12A-04
12.3.5 TO INSPECT

1 Clean and inspect all the components for wear and any other damage. Check the clearance of the rocker
levers on the rocker shaft. If the clearance is larger than 0.13 mm (0.005 in), renew the rocker lever bush
and/or the rocker shaft.

12.3.6 TO CORRECT

1 To renew the rocker lever bush, press out the old bush with a suitable mandrel.

2 Align the lubrication hole of the new bush on the same side as the rocker lever lubrication hole and press
the bush into position.

3 Ream the bush in the rocker lever to give a clearance on the rocker shaft of 0.03/0.09 mm (0.001/0.004
in). Clean thoroughly the bush and check that the oil hole is free from debris.

15501 9-35990
 EM11-12-5
CYLINDER HEAD WX90

12.4 CYLINDER HEAD ASSEMBLY

Valve tip clearances 12A-O5

NOTES:
• The valve tip clearance is measured between
the top of the valve stem and the rocker lever
(A). With the engine hot or cold, the correct
clearances are 0.20 mm (0.008 in) for the inlet
valves and 0.45 mm (0.018 in) for the exhaust
valves. The valve positions are shown at (B).
• The sequence of valves from number 1 cylinder
is shown in the table below. Number 1 cylinder
is at the front of the engine.

Four cylinder engines

1 Rotate the crankshaft in the normal direction

of rotation until the inlet valve (B7) of number
4 cylinder has just opened and the exhaust
valve (B8) of the same cylinder has not closed
completely. Check the clearances of the valves
(B1 and B2) of number 1 cylinder and adjust
them, if necessary.

2 Set the valves (B3 and B4) of number 2

cylinder as indicated above for number 4
cylinder. Then check / adjust the clearances of
the valves (B5 and B6) of number 3 cylinder.

3 Set the valves (B1 and B2) of number 1

cylinder. Then check / adjust the clearances of
the valves (B7 and B8) of number 4 cylinder.

4 Set the valves (B5 and B6) of number 3

cylinder. Then check / adjust the clearances of
the valves (B3 and B4) of number 2 cylinder.

1 2 3 4
Cylinder and
Valve number
1 2 3 4 5 6 7 8

Valve
15501 9-35990

I=Inlet I E I E I E I E
E=Exhaust
F8166
 EM11-12-6
CYLINDER HEAD WX90

12.5 VALVE SPRINGS

To change the valve springs 12A-06

(with cylinder head fitted)

Special tools:
Valve spring compressor, PD.6118B

Stud adaptor used with PD.611 8B, PD.61 1 8-7

Setscrew adaptor used with PD.6118B, PD.6118- 8

NOTE: Paragraphs 1 to 12 refer to a change of

valve springs for a single cylinder.

WARMING! Wear eye protection during this

operation.

1 Remove the rocker cover, operation 12A-01.

2 Rotate the crankshaft in the normal direction

of rotation until the inlet valve of the relevant
cylinder has just opened and the exhaust
valve has not fully closed. In this position the
piston will be at approximately top dead centre
(TDC).

3 Remove the rocker assembly, operation 1 2A-

02.

4 Fit the valve spring compressor (A1) and the

relevant adaptor (A2 or A3).

5 Compress the valve spring and remove the

collets. Ensure that the valve spring is
compressed squarely or damage to the valve
stem can occur.

CAUTION: Do not rotate the crankshaft while

the valve springs are removed.

6 Release the valve spring compressor and

remove the valve spring caps and valve spring.

CAUTION: The outer diameter of the exhaust

valve guide is 1 mm larger than the inlet valve
guide. To prevent leakage past the inlet valve
stem it is important that the larger exhaust
valve seal is not fitted onto the inlet guide. The
15501 9-35990

seals have a colour code for identification.

 EM11-12-7
CYLINDER HEAD WX90

7 Fit new valve stem seals on the valve guides.

ensure that the brown seal is fitted to the
exhaust valve and green seal is fitted to the
inlet valves.

8 Put the new valve springs in position.

9 Fit the valve spring caps.

CAUTION: Ensure that the valve spring is

compressed squarely or damage can occur
to the valve stem.

10 Fit the valve spring compressor, compress the

valve spring and fit the collets. Remove the
valve spring compressor.

11 Fit the rocker assembly, operation 12A-02.

12 Check the valve tip clearances, operation 12A-

05.

13 Fit the rocker cover, operation 12A-01.

NOTE: If other or all of the valve springs are

to be changed, they can be changed two
cylinders at a time. The sets of cylinders are:

For 4 cylinder engines: 1 and 4, 2 and 3.

If the rocker assembly has been removed, piston

TDC can be found as follows:

1 Fit the valve spring compressor and compress

the valve springs to open the valve.

2 Rotate the crankshaft, by hand, in the normal

direction of rotation until the piston touches the
valve.

3 Continue to rotate the crankshaft, and at the

same time, release pressure on the valve
spring compressor until the piston is at TDC
(A).
15501 9-35990
 EM11-12-8
CYLINDER HEAD WX90

12.6 CYLINDER HEAD ASSEMBLY

To remove and to fit 12A-07

12.6.1 TO REMOVE

1 Drain the cooling system.

2 Disconnect the battery terminals.

3 Remove the air filter/cleaner hose at the

induction manifold.

4 Remove the pipe which is fitted between the

fuelled starting aid in the induction manifold
and the fuel filter. Disconnect the electrical
connection.

5 For engines fitted with a boost control device:

Remove the boost control pipe which is fitted
between the induction manifold and the top of
the fuel injection pump.

6 Remove the induction manifold.

For induction manifolds fitted to engine types
AR and AS: The top half of the induction
manifold (A1) is sealed to the bottom half (A2)
with a liquid joint and fastened together by six
cap screws.
The top half of the manifold must be removed
to obtain access to four of the manifold
fasteners (A3), fitted inside the manifold. These
fasteners retain the bottom half of the manifold
to the cylinder head.

7 Release the exhaust manifold fasteners in the

reverse sequence to that shown in (B). The
front of the engine is shown at (B1).

8 Remove the low-pressure fuel pipes which are

fitted between the fuel injection pump and the
fuel filter.
Remove the fuel pipe fitted between the fuel lift
pump and the fuel filter. Remove the fuel filter
bracket together with the fuel filter.

CAUTION: Where access to the fluel injection

pump outlet unions is possible, ensure that a
separate spanner is used to prevent
movement of the fuel injection pump outlets
15501 9-35990

when the connections of the high-pressure

pipes are released. Fit suitable covers to all
open connections on the fuel injection pump.
 EM11-12-9
CYLINDER HEAD WX90

9 Remove the high-pressure fuel pipes.

10 Remove the atomiser leak-off pipe.

11 Remove the atomisers, operation 20A-02. Fit

suitable covers to the nozzles and the open
connections.

12 If a compressor is fitted: Remove the coolant

pipe which is fitted between the cylinder head
and the compressor. Then remove the coolant
pipe which is fitted between the by-pass
connection and the compressor.

13 Release the clip of the coolant by-pass hose

at the cylinder head. Release the setscrews
and remove the coolant by-pass connection
and the hose.

14 Disconnect the coolant temperature sender

unit.

15 Four cylinder engines: Remove the oil cooler

if it is integral with the cylinder block, see
operation 21 A-07A.

16 Remove the rocker cover, operation 1 2A-01.

17 Remove the rocker assembly, operation 1

2A-02.

18 Remove the push rods.

19 Release the cylinder head setscrews evenly

and gradually in the reverse sequence to that
shown in (A or B). Check the setscrews for
distortion with a straight edge (C1) held along
the setscrew (C2). If there is a visual reduction
in the diameter of the thread (C3) that has not
been in engagement with the cylinder block,
the setscrew must be discarded.

CAUTION: Do not use a lever to separate

the cylinder head from the cylinder block.

20 Remove the cylinder head and put it on a

surface that will not damage the face of the
cylinder head.
15501 9-35990
 EM11-12-10
CYLINDER HEAD WX90

12.6.2 TO FIT
(Engine types AR)

Special tools:
Angle gauge, to tighten cylinder head setscrews,
MS.1 531

1 Clean the bottom face of the cylinder head and

the top face of the cylinder block. Ensure that
there is no debris in the cylinder bores.

NOTE: The engines have two location pins

(A3), one at each end of the cylinder head,
pressed into the cylinder block to hold the
cylinder head and cylinder head gasket in the
correct position when the cylinder head is
fitted.

CAUTION:
• To prevent damage to the cylinder head gasket,
ensure that the location pins are pressed in the
cylinder block before the cylinder head is fitted.
• The cylinder head gasket must be fitted without
jointing compound.

2 Put the cylinder head gasket in position; It is

stamped “FRONT TOP” (A2) for correct
assembly.

3 To ensure the cylinder head is fitted into the

correct position, fit two suitable M10 guide
studs (A1) in positions 16 and 21(B). Put the
cylinder head in position. Ensure that the two
location pins are fully engaged in the cylinder
head.

4 Lightly lubricate the threads of the cylinder

head setscrews and the thrust faces of the
setscrew heads. Engage some of the
setscrews in their correct positions and remove
the guide studs. Engage the remainder of the
setscrews in their correct positions. The four 1/
2 UNF setscrews are fitted in positions 2, 8, 13
and 18, refer to (B).

5 Gradually and evenly tighten the setscrews to

45 Nm (33 Ibf ft) 4.5 kgf m in the sequence
shown in (B).

6 Repeat paragraph 5 to ensure that all the

setscrews are tightened to the correct torque.
15501 9-35990
 EM11-12-11
CYLINDER HEAD WX90

7 Gradually and evenly tighten the four 1/2II UNF

setscrews, to 110 Nm (80 Ibf ft) 11.1 kgf m in
the sequence 2, 8, 13 and, shown in (B).

8 Repeat paragraph 7 to ensure that all the

setscrews are tightened to the correct torque.

9 Tighten the M10 setscrews, in the correct

sequence, a further part of a turn according to
the length of the setscrews, see (A) and (C).
Short setscrews (S) must be turned a further
120° (2.5 flats). Medium length setscrews (M)
must be turned a further 120° (2 flats). Long
setscrews (L) must be turned a further 150°
(2.5 flats). The four 1/2II UNF setscrews in
positions 2, 8, 13 and 18 must be turned 180°
(3 flats).
A special tool (B) can be used to tighten all
setscrews, instead of the method described in
paragraph 9. Fit the tool between the socket
and the handle. Position the stop (B1) against
a suitable protrusion on the cylinder head to
prevent movement of the degree dial in a
clockwise direction. Rotate the pointer to align
with the relevant angle on the degree dial for
the length of setscrew. Tighten the setscrew
until the pointer on the tool is aligned with the
zero position on the degree dial.
If no tool is available, make a suitable mark on
the cylinder head in line with a corner of each
setscrew (C). Make another mark, at the correct
angle (counter-clockwise), on the edge of the
flange of each fastener according to the length
of the setscrew. Tighten each setscrew in the
correct sequence until the marks on the flange
are next to, and in line with, the marks on the
cylinder head.

10 Put the push rods in position. Ensure that the

end of each push rod fits correctly in the tappet
socket.

11 Fit the rocker assembly, operation 12A-01.

12 Set the valve tip clearances, operation 12A-

05.

13 Fit the atomisers, operation 20A-02.

14 Fit the high-pressure fuel pipes; tighten the

connection nuts to 22 Nm (16 Ibf ft) 2.2 kgf m.
15501 9-35990
 EM11-12-12
CYLINDER HEAD WX90

CAUTION: Where access to the fuel injection

pump outlet unions is possible, ensure that a
separate spanner is used to prevent movement
of the fuel injection pump outlets when the
connections of the high pressure pipes are
tightened.

15 Fit the fuel filter and the bracket. Fit the low
pressure fuel pipes between the fuel injection
pump and the fuel filter.

16 Fit the coolant by-pass connection; tighten the

setscrews and hose clip.

17 Fit the induction and exhaust manifolds:

NOTE: The manifold joints are fitted without

jointing compound.

For four cylinder engines: Ensure that the two

inlet and exhaust manifold joints (A1) and
(A2) are fitted correctly, the rear joint (A1)
must be fitted with the two location tabs (A3)
towards the sump. Fit the joints without jointing
compound. The latest joints are supplied as
one piece.
CAUTION: Damage to the exhaust manifold
can occur if it is not aligned and tightened
correctly.

Some exhaust manifolds have large clearance

holes for the fasteners, if these manifolds are
renewed it is important that the two alignment
bushes (B), supplied with the new manifold,
are in position. New alignment bushes are not
necessary when the original manifold is
removed and fitted.

18 Fit the exhaust manifold. Tighten the manifold

fasteners evenly and gradually to 44 Nm (33
Ibf ft) 4.5 kgf m in the sequence shown in
(B). The front of the engine is shown by the
arrow (B1).

19 Fit the induction manifold. Tighten the

manifold fasteners evenly and gradually to
44 Nm (33 Ibf ft) 4.5 kgf m.

20 The top half of the induction manifold (A1) is

sealed to the bottom half (A2) with a liquid joint
and fastened together by six cap screws. The
15501 9-35990

top half of the manifold must be removed to

obtain access to four of the manifold fasteners
(A3) inside the manifold. These fasteners and
the four fasteners (A4) on the outside of the
manifold retain the bottom half of the manifold
to the cylinder head.
 EM11-12-13
CYLINDER HEAD WX90

NOTE: The fasteners (A3) and (A4) which

retain the manifold to the cylinder head have
M.E.A.S. applied to the threads. If the
fasteners are removed and fitted again, the
threads must be cleaned and Threadlock
sealant used.

CAUTION:
• Before the inlet manifold fasteners are fitted
again, any loose M.E.A.S in the cylinder
head holes must be removed to allow the
manifold to be fully tightened.
• Do not scratch or damage the flange faces of
the inlet manifold.

A paper joint (A5) is used in service instead of

a liquid joint. The liquid joint must be removed
and the flange faces thoroughly cleaned with
a suitable nylon scraper or solvent before the
paper joint is fitted, the paper joint is fitted dry.

21 Fit the fuel pipe between the fuel filter and the
fuel lift pump.

22 Fit the fuel pipe between the fuel filter and the
fuelled starting aid in the induction manifold.
Connect the electrical connection to the cold
start device.

23 Fit the electrical connection to the coolant

temperature sender unit.

24 Connect the coolant outlet and the hoses for

the cab heater. Tighten the clips.

25 Fill the cooling system.

26 Connect the air filte recleaner.

27 Connect the battery.

28 Eliminate air from the fuel system, operation

20A-08A.

29 Start the engine and run it at low speed. Check

that oil flows from the holes in the rocker
levers. If the oil flow is correct, fit the rocker
cover, operation 12A-01.

NOTE: It is not necessary to tighten the

cylinder head setscrews again with the engine
15501 9-35990

hot or after a limited period in service.

 EM11-12-14
CYLINDER HEAD WX90

12.7 VALVES AND VALVE SPRINGS

To remove and to fit 12A-08

Special tools:
Valve spring compressor, PD.6118B
Stud adaptor, PD.6118-7
Setscrew adaptor, PD.6118-8

12.7.1 TO REMOVE

WARNING! Wear eye protection during this

operation.

1 Remove the cylinder head, operation 12A-07.

2 Clean the bottom face of the cylinder head and

check the depth of the heads of the valves
below the face of the cylinder head, see
operation 12A-09.

3 Make a suitable mark on the heads of the

valves to ensure that the valves can be fitted
in their original positions, if they are to be used
again.

CAUTION: Ensure that the valve springs are

compressed squarely or the valve stem can
be damaged.

4 Use the valve spring compressor and the

relevant adaptor to compress the valve spring
(A3) and remove the collets (A2).
5 Release the valve spring compressor and
remove the valve spring cap (A1), valve spring
and valve stem seal (A4).
6 Repeat items 4 and 5 for the other valves.
2 Fit new valve stem seals on the valve guides.
Ensure that the brown seal is fitted to the
exhaust valve and green seal is fitted to the
inlet valves.
3 Put the valve springs in position, they can be
fitted with either end to the cylinder head. Fit
the valve spring cap.

12.7.2 TO FIT CAUTION: Ensure that the valve spring is

compressed squarely or damage can occur
WARNING! Wear eye protection during this to the valve stem.
operation.
4 Use the valve spring compressor and the
NOTE: The components of the valve assembly relevant adaptor to compress the valve
are shown in A. spring and fit the collets.

1 Lubricate the valve stem (A5) with clean engine

oil and fit the valves in their respective guides.
15501 9-35990

CAUTION: The outer diameter of the exhaust

valve guide is 1 mm larger than the inlet valve
guide. To prevent leakage past the inlet valve
stem it is important that the larger exhaust
valve seal is not fitted onto the inlet guide. The
seals in the service kit have different colours
for identification.
 EM11-12-15
CYLINDER HEAD WX90

To inspect and to correct 12A-09

Special tool:
Gauge, valve depth, PD.41 D
Dial gauge for use with PD.41D,
PD.208

1 Check the depth of the valves below the face

of the cylinder head before the valve springs
are removed.

2 Ensure that the heads of the valves and the

bottom face of the cylinder head are clean.

3 Put the valve depth gauge on the face of the

cylinder head and zero the dial gauge.

4 Carefully put the valve depth gauge in position

over the head of each valve (A) and make a
note of the measurement. The maximum depth,
in service, is given in the data and dimensions.

5 If a valve is below the depth limit, check the

valve depth with a new valve in position. If the
valve depth is still below the limit and a valve
seat insert is fitted, the insert must be renewed.

6 Check the valves for cracks. Check the stems

of the valves for wear and for correct fit in their
valve guides.

CAUTION: Fit new damaged valves, the

special heat resistant layer on the face of the
valve will be detroyed if valves are lapped.

7 Check that the seat faces of the valves are not

badly burnt or damaged. Seat faces of valves
which are damaged can be ground on a special
machine. When new valves are fitted, the
valve depths must be checked after the valve
springs are fitted.

8 Check that the load on the valve springs is

correct at their fitted length, see the data and
dimensions. Fit new valve springs at every
complete engine overhaul.
15501 9-35990
 EM11-12-16
CYLINDER HEAD WX90

12.8 VALVE GUIDES

To inspect 12A-10

To check the valve guides for wear: The maximum

permissible clearance (A5) with a valve lift of 15,0
mm (0.6 in), between the valve stem and the bore
of the guide is 0.100 mm (0.008 in) for inlet valves
and 0.121 mm (0.011 in) for exhaust valves. If the
clearance, with a new valve fitted, is more than
the limit, then a new valve guide (A4) must be
fitted.

It is recommended that the procedure given below

is used to check the valve guide clearance:

1 Put a new valve in the valve guide.

2 Put a dial test indicator with a magnetic base

(A1) onto the face of the cylinder head

3 With the valve lifted 15.0 mm (0.6 in) and the

gauge (A2) in contact with the edge of the
valve head (A3), move the valve radially away
from the gauge. With the valve held in this
position, set the gauge to zero.

4 Move the valve radially across the axis of the

cylinder head towards the gauge. Make a note
of the reading on the gauge. If the reading is
equal to or greater than the data given below,
a new valve guide (A4) must be fitted.

NOTE: The partially finished valve guides are

reamed and the valve seats are cut in one
operation with a special tool. The valve seat
and the guide are cut in one operation to
ensure the concentricity of the valve seat to
the valve guide. This will ensure a good seal
between the guide and its seat. New valves
and new valve seat inserts must be fitted each
time a new valve guide is fitted. Valves must
not be lapped, refer to operation 12A-13. If all
or most of the original valve guides need to
be renewed it may be cost effective to overhaul
or exchange the cylinder head.
15501 9-35990
 EM11-12-17
CYLINDER HEAD WX90

To remove and to fit 12A-11

Special tools:
Remover/replacer for valve guides (main tool),
PD.1D
Adaptor PD. 1 D-13 used with PD. 1D, PD. 1C-6
and PD.248
Distance piece, inlet guide, PD.1C-6 used with
PD.1D and PD.1D-13
Distance piece, exhaust guide, PD.248 used with
PD.1D and PD.1D-13

The partially finished valve guides are reamed

and the valve seats are cut in one operation with
a special tool. The valve seat and the guide are
cut in one operation to ensure the concentricity of
the valve seat to the valve guide. This will ensure
a good seal between the guide and its seat. New
valves and new valve seat inserts must be fitted
each time a new valve guide is fitted. Valves must
not be lapped, refer to operation 12A-13. If all or
most of the original valve guides need to be
renewed it may be cost effective to overhaul or
exchange the cylinder head.

12.8.1 REMOVE

1 Fit the adaptor (A4) into the remover/replacer

tool (A3).

2 With the adaptor fitted to the tool, put the

spacer (A5) in position on the tool. Pass the
adaptor through the valve guide (A6) and put
the spacer and tool in position on the valve
seat.

3 Fit the attachment (A7) to secure the adaptor

to the valve guide.

4 Hold the top handle (A1) and turn the bottom

handle (A2) clockwise to pull the valve guide
out of the cylinder head.
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CYLINDER HEAD WX90

12.8.2 FIT

1 Clean the parent bore in the cylinder head for

the valve guide.

2 Lubricate the outer surface of the new valve

guide (A6) with clean engine lubricating oil.

3 Fit the adaptor (A5) into the remover/replacer

tool (A3).

4 With the adaptor fitted to the tool, put the

spacer (A4) in position on the tool. Pass the
adaptor through the cylinder head and put the
spacer and tool assembly in position on the
valve seat.

5 Put the valve guide in position on the adaptor

and fit the distance piece (A7), PD.1 C-6 for
inlet valve guides and PD.248 for exhaust
valve guides. Fit the attachment (A8) to secure
the valve guide to the adaptor.

NOTE: The internal recess in the valve guide

must be towards the tool.

6 Hold the top handle (A1) and turn the bottom

handle (A2) clockwise to pull the valve guide
until the distance piece contacts the cylinder
head.

7 When the valve guide is fitted correctly, the

top of the valve guide will have a protrusion
(A9) of 14.85/15.15 mm (0.585/0.596 in) above
the valve spring seat.

8 Ream the valve guide to the finished size,

refer to operation 12A-13.

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CYLINDER HEAD WX90

12.9 CYLINDER HEAD

To inspect and to correct 12A-12

1 Remove the cylinder head assembly, operation 12A-07.

2 Remove the thermostat housing.

3 Inspect the cylinder head for signs of gas or coolant leakage.

4 Remove the valve springs and the valves, operation 12A-08.

5 Clean the face of the cylinder head and the passages for coolant and for lubricating oil. The water jacket
can be cleaned with a special solvent which must be used in accordance with the manufacturer’s
instructions.

6 Test the cylinder head for leaks at the pressure given in the data and dimensions.

7 When the cylinder head is thoroughly clean, check it for cracks. Inspect carefully the areas around the valve
seats and around the holes for the atomiser nozzles.

8 The bottom face of the cylinder head can be machined if there is distortion, see paragraph 9; there are deep
scratches; or, for engines without valve seat inserts, the valve depths are below the service limit.

9 Use a straight edge and feeler gauges to check the cylinder head for distortion across and along its bottom
face, see the data and dimensions. If the distortion is more than the limit given in the data and dimensions,
the bottom face can be machined, see the data and dimensions for the surface grade finish of the cylinder
head face.

CAUTION: Remove only the minimum material and ensure that the thickness of the cylinder head will
not be less than 102.48 mm (4.035 in) after the cylinder head has been machined.

CAUTION: After the cylinder head has been machined the valve seats must be corrected to give the
correct valve head depth. Work to the minimum limit to allow for later wear.

10 Check the valve seats for wear and for damage.

11 Before any work is done on the valve seats, new valve guides must be fitted, operation 12A-11 .

12 More badly damaged valve seats can be corrected by use of the cutter tool, operation 12A-13, or new
inserts can be fitted, operation 12A-14.
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CYLINDER HEAD WX90

To correct a valve seat with a

valve seat cutter 12A-13

Special tools:
Cutter (31° or 46°) for inlet and exhaust valve
seats and valve guides reamer PD.242.

CAUTION: Valves must not be lapped.

The valve seats are cut and the valve guides are
reamed in one operation with a special tool (A).
The valve seat and the guide are cut in one
operation to ensure the concentricity of the valve
seat to the valve guide. This will ensure a good
seal between the guide and its seat. New valves
and new guides must be fitted each time a new
seat insert is fitted. Valves must not be lapped.

1 Before any work is done on the valve seats,

new valve guides must be fitted, operation
12A-11.

CAUTION:
• Ensure that the correct cutter is fitted, 31°
or 46° valve seats may be fitted.
• Ensure that the valve seat cutter is not
allowed to fall on to the seat as this can
damage the blades.

2 Select the relevant valve seat cutter, 31° or

46°, (A2) and the valve guide reamer (A3). Set
the blades of the cutters to the diameter of the
valve seat to be cut. Fit the cutter onto the 6 Fit the valve.
reamer and push the handle fully onto the
reamer. Ensure that the flat part of the reamer 7 Check that the valve depth is within limits,
shank is towards the grub screw (A1) and see data and dimensions.
tighten the grub screw to secure the reamer to
the handle. The blades of the reamer must not NOTE: If a valve seat has become too
cut the valve guide when the seat is cut. damaged or too worn to correct, a valve
seat insert can be fitted, operation 12A-14.
3 Fit the reamer/cutter assembly into the valve If all or most of the original valve seat inserts
guide. Ensure that the valve seat cutter is not need to be renewed, it may be cost effective
allowed to fall on to the seat as this can to overhaul or exchange the cylinder head.
damage the blades. Carefully turn the handle
in a clockwise direction (A4) and gradually
move the reamer into the valve guide until the
valve guide is reamed to the finished size. A
lubricant is not necessary.

4 Continue to turn the handle in a clockwise

direction to cut the valve seat. Remove only
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the minimum material to ensure a good valve

seat. Keep the seat as narrow as possible.

5 When the seat is cut, remove the reamer/

cutter assembly. Remove any debris from the
area of the valve guide, valve seat and the
port.
 EM11-12-21
CYLINDER HEAD WX90

To fit valve seat inserts 12A-14

1 Remove the valve guide and clean the bore into which the guide is to be fitted.

2 Fit new partially finished valve guides, operation 12A-11.

3 With the bore of the new partially finished valve guide used as a pilot, machine the recess in the cylinder
head to the dimensions shown in data and dimensions at the end of this section, or machine out the old
insert. Remove all debris and clean the insert recess.

4 If the bottom face of the cylinder head has been machined, the insert will have to be surface ground on the
back face to ensure that there is no protrusion of the insert above the bottom face of the cylinder head. After
the back of the insert has been ground, ensure that the outer edge of the back face has a 0.9/1.3 mm (0.035/
0.051 in) chamfer at 30° to the vertical.

5 With the bore of the new, partially finished, valve guide used as a pilot, and with the rear face of the insert
towards the cylinder head, press in the insert with the valve seat insert tool, see data and dimensions. Do
not use a hammer on the insert and do not use lubrication. Use a hydraulic press or a hand press in one
continuous movement. Ensure that the bottom of the insert is in contact with the bottom of the recess.

6 Ream the valve guide and cut the valve seat at an included angle of 88° for 46° valve seats or 118° for 31°
valve seats, operation 12A-13. Ensure that the depth of the valve head below the face of the cylinder head
is within the production limits, see data and dimensions. Work as near as possible to the minimum figure
to allow for future wear on the valve seat.
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CYLINDER HEAD WX90

12.10 DATA AND DIMENSIONS

NOTE: This information is given as a guide for personnel engaged on engine overhauls. The dimensions
which are shown are those which are mainly used in the factory. The information applies to all engines,
unless an engine type code is shown.

12.10.1 CYLINDER HEAD

Angle of valve seat:

- Inlet .......................................................................... 46° (88° included angle) o 31 ° (118° included angle)
- Exhaust .................................................................... 46° (88° included angle) o 31 ° (118° included angle)
Leak test pressure ................................................................................ .......200 kPa(23 lbf/in2) 2,04 kgf/cm2
Head thickness ..................................................................................... 102.79/103.59 mm (4.047/4.078 in)
Finish grade of head face for cylinder head gasket ................................................... 1.10/3.20 micrometers
Diameter of parent bore for valve guide
- Inlet ................................................................................................... 13.00/13.027 mm (0.5118/0.5128 in)
- Exhaust ............................................................................................. 14.00/14.027 mm (0.5512/0.5222 in)
Minimum permissible thickness after head face has been machined ......................... 102.48 mm (4.035 in)

12.10.2 INLET VALVES

Diameter of valve head ......................................................................... 8.953/8.975 mm (0.3525/0.3533 in)

Clearance in valve guide ......................................................................... 0.025/0.069 mm (0.001/0.0027 in)
Maximum permissible clearance in valve guide:
- Production limit ......................................................................................................... 0.089 mm (0.0035 in)
- Service limit ................................................................................................................ 0.100 mm (0.008 in)
Diameter of valve head
- Engine types AR ..................................................................................... 44.88/45.12 mm (1.776/1.767 in)
Angle of valve face ......................................................................................................................... 45° or 30°
Full length, engine types AR ................................................................. 123.75/124.40 mm (4.872/4.987 in)
Seal arrangement ................................................................ Rubber seal fitted to valve guide, colour green
Depth of valve head below the face of cylinder head
- Production limits, engine types AR ............................................................. 0.40/0.60 mm (0.016/0.024 in)
- Service limit, engine types AR .................................................................................... 0.805 mm (0.032 in)

12.10.3 EXHAUST VALVES

Diameter of valve stem ......................................................................... 8.938/8.960 mm (0.3519/0.3528 in)

Clearance in valve guide ......................................................................... 0.040/0.84 mm (0.0016/0.0033 in)
Maximum permissible clearance in valve guide
- Production limits ....................................................................................................... 0.104 mm (0.0041 in)
- Service limit ................................................................................................................ 0.121 mm (0.011 in)
Diameter of valve head
- Engine types AR .................................................................................... 41.88/42.12 mm (1.649/1.658 in)
Angle of valve face ......................................................................................................................... 45° or 30°
Full length, engine types AR ................................................................. 123.75/124.40 mm (4.872/4.897 in)
Seal arrangement ................................................................ Rubber seal fitted to valve guide, colour green
Depth of valve head below face of cylinder head:
- Production limits, engine types AR ........................................................... 0.40/0.60 mm (0.0016/0.024 in)
- Service limit, engine types AR .................................................................................... 0.805 mm (0.032 in)
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CYLINDER HEAD WX90

12.10.4 MAXIMUM PERMISSIBLE DISTORTION OF

CYLINDER HEAD (A)

Four cylinder engines

A1 ........................................ 0.08 mm (0.003 in)

A2 ........................................ 0.15 mm (0.006 in)
A3 ........................................ 0.15 mm (0.006 in)

12.10.5 DIMENSIONS OF RECESSES FOR VALVE

SEAT INSERTS, ENGINE TYPE AR (B)

Inlet

B1 .......... 10.585/10.715 mm (0.4167/0.4219 in)

B2 .......... 48.035/48.060 mm (1.7927/1.7937 in)
B3 ........... Radius 0.38 mm (0.015 in) maximum

Exhaust

B1 .......... 10.585/10.715 mm (0.4167/0.4219 in)

B2 ........... 44.035/44.060 mm (1.7336/1.7346in)
B3 ........... Radius 0.38 mm (0.015 in) maximum
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CYLINDER HEAD WX90

Valve seat insert tool (A)

12.10.6 INLET (FOR 45° VALVES), ENGINE TYPE

AR

A1 ............................................ 1.5 mm (0.06 in)

A2 ........................................... 20 mm (0.800 in)
A3 ............................................ 7.0 mm (0.28 in)
A4 ........................................... 100 mm (4.00 in)
A5 .................. 37.82/38.02 mm (1.467/1.474 in)
A6 .................. 47.25/47.50 mm (1.772/1.762 in)
A7 ............. Radius 1.4 mm (0.055 in) maximum
A8 ................................ Radius 1.5 mm (0.06 in)
A9 ............................................ 1.5 mm (0.06 in)
A10 .................. 8.54/18.57 mm (0.336/0.337 in)

Exhaust (for 45° valves), engine types AR

A1 ............................................ 1.5 mm (0.06 in)

A2 ........................................... 20 mm (0.800 in)
A3 .......................................... 7.0 mm maximum
A4 ........................................... 100 mm (4.00 in)
A5 .................. 36.62/36.82 mm (1.441/1.449 in)
A6 .................. 43,25/43,50 mm (1.702/1.712 in)
A7 ............. Radius 1.4 mm (0.055 in) maximum
A8 ................................ Radius 1.5 mm (0.06 in)
A9 ............................................ 1.5 mm (0.06 in)
A10 .................. 8.54/18.57 mm (0.336/0.337 in)

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CYLINDER HEAD WX90

12.10.7 VALVE GUIDES

Inside diameter of partially finished guide ............................................. 8.600/8.700 mm (0.3386/0.3425 in)

Inside diameter of finished guide ......................................................... 9.000/9.022 mm (0.3543/0.3552 in)
Outside diameter
Inlet ................................................................................................... 13.034/13.047 mm (0.5131/0.5137 in)
Exhaust ............................................................................................. 14.034/14.047 mm (0.5525/0.5530 in)
Interference fit of valve guide in cylinder head...................................... 0.047/0.007 mm (0.0003/0.0019 in)
Full length ..................................................................................................................... 51.25 mm (2.018 in)
Protrusion from bottom of recess for valve spring. ................................... 14.85/15.15 mm (0.585/0.596 in)

12.10.8 VALVE SPRINGS

Fitted length ...................................................................................................................... 39.0 mm (1.54 in)

Load at fitted length
- Engine type AR ............................................................................................. 136.3/153.7 N (13.9/15.7 kgf)
Number of active coils ............................................................................................................................... 3.3
Number of damper coils ............................................................................................................................... 0
Direction of coils .............................................................................................................................. Left hand

12.10.9 TAPPETS

Diameter of tappet stem ........................................................................ 18.99/19.01 mm (0.7475/0.7485 in)

Diameter of tappet bore in cylinder block.............................................. 19.05/19.08 mm (0.7500/0.7512 in)
Clearance of tappet in cylinder block ........................................................ 0.04/0.09 mm (0.0015/0.0037 in)

12.10.10 ROCKER SHAFT

Outside diameter ................................................................................... 19.01/19.04 mm (0.7485/0.7495 in)

12.10.11 ROCKER LEVERS AND BUSHES

Diameter of parent bore for bush ........................................................ 22.23/122.26 mm (0.8750/0.8762 in)

Outside diameter of bush ...................................................................... 22.28/22.31 mm (0.8770/0.8785 in)
Interference fit of bush in rocker lever ................................................... 0.020/0.089 mm (0.0008/0.0035 in)
Internal diameter of fitted bush when reamed....................................... 19.06/19.10 mm (0.7505/0.7520 in)
Clearance between rocker lever bush and rocker shaft.............................. 0.03/0.09 mm (0.001/0.0035 in)
Maximum permissible clearance between rocker lever bush and rocker shaft............... 0.13 mm (0.005 in)
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CYLINDER HEAD WX90

NOTES:

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 EM11-13-1
PISTON AND CONNECTING ROD WX90

13. PISTON AND CONNECTING ROD

13.1 GENERAL DESCRIPTION

The pistons used in the New 1000 Series engines

have a “Fastram” combustion chamber in the top
of the piston (A). The piston (B) for engine types
AR and AS has two recesses in the top face for the
valves. The combustion chamber is designed to
give an efficient mix of fuel and air.
The pistons and connecting rods are matched to
the relevant cylinder.
The pistons have two compression rings and an
oil control ring. The groove for the top ring has a
hard metal insert to reduce wear of the groove.
The piston skirt has a layer of graphite to improve
the wear characteristics.
Axial location of the fully floating gudgeon pin is by
circlips. The gudgeon pin is off-centre to reduce
the noise level.
Piston cooling jets are fitted in the cylinder block
to spray lubricating oil onto the inner surface of
the pistons.

NOTE: Engine types AR and AS have only one

cooling jet fitted to spray the number one piston
1.

The correct piston height is important to ensure

that the piston does not contact the cylinder head
and to ensure the efficient combustion of fuel.
The piston height is controlled by the length of the
connecting rod. In the factory there are six length
grades of connecting rods and one piston are
used to obtain the correct piston height.
To obtain the different grades, the small-end bush
is machined off-centre. The amount that the bush
is off-centre gives the different length grades.
In service, a partially finished small-end bush is
available, which can be fitted to the original
connecting rod and machined to obtain the correct
length grade, refer to operation 1 3A-08. Specialist
equipment and personnel with the correct training
are needed to machine the partially finished
smallend bush. Connecting rod kits are also
available with the small end bush fitted and
machined to obtain the correct connecting rod
grade. For further information refer to your nearest
CASE distributor.
15501 9-35990
NOTES:
• If the crankshaft or the cylinder block is to
be renewed, it may be necessary to change
the grade of the connecting rods, operation
13A-08. This will occur if the correct piston
height above the cylinder block face cannot
be maintained with the original connecting
rod assemblies, operation 13A-03A.
• Engine types AR and AS do not have cylinder
liners fitted and the cylinder bores must be
machined oversize to correct a worn cylinder
bore. Two oversize pistons and piston rings
are available in service 0.5 mm (0.020 in)
and 1.00 mm (0.040 in).

NOTE: Always use the engine identification

number to order new parts.
 EM11-13-2
PISTON AND CONNECTING ROD WX90

The connecting rods are machined from “H”

section forgings of molybdenum steel. They have
wedge shaped small ends.

Location of the bearing cap to the connecting rod

is made by dowels (A1) fitted in the bearing cap.
The faces of the connecting rods and caps are
flat and the caps are retained by two setscrews.

Some engines have bearing caps with serrations

(B1) which are used to ensure the correct location
of the bearing caps to the connecting rods. These
caps are retained by two nuts and bolts.

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PISTON AND CONNECTING ROD WX90

13.2 BIG END BEARING

To remove and to fit 13A-01

There are location thimbles (B1) fitted to the latest

bolts used with connecting rods that have serrated
faces.

The location thimbles are used in the factory to

prevent movement of the bolts when the nuts for
the big end cap are tightened by automatic
equipment.

When the connecting rods are fitted in service it is

not necessary to use the location thimbles and
they can be discarded.

13.2.1 TO REMOVE

1 Drain the engine lubricating oil.

2 Remove the lubricating oil sump, operation

19A-03.

3 Remove the lubricating oii strainer and suction

pipe, operation 19A-04 or remove the balancer
unit, operation 14A-10.

4 Release the nuts (B4) and remove the bearing

cap (B3). Remove the bolts from the connecting
rod (B2). If the bearing cap is retained by
setscrews (A4), the location of the bearing cap
(A3) will be by two dowels (A2). To remove
these bearing caps, release the setscrews by
approximately four turns. Lightly hit the heads
of the setscrews with a soft face hammer to
separate the connecting rod (A1) from the
bearing cap. Remove the setscrews and the
bearing cap.

5 Rotate the crankshaft until the relevant

connecting rod is at its lowest position.

6 Remove the lower half of the shell bearing

from the cap, but keep it with its relevant cap.

7 Carefully push the connecting rod up the

cylinder bore just enough to allow access to
the upper half of the shell bearing. Remove the
bearing from the connecting rod. Keep the
bearings from the connecting rod and cap
15501 9-35990

together.

CAUTION: Do not allow the connecting rod

to hit the piston cooling jet, if fitted.
 EM11-13-4
PISTON AND CONNECTING ROD WX90

13.2.2 TO FIT

1 Clean the bearing faces of the connecting rod

and the crank pin.

2 Ensure that the protrusion for the location

dowels is 3.0/4.5 mm (0.12/0.1 8 in) above the
cap faces. Clean the complete bearing and
lubricate the bearing surface and the crank pin
with clean engine lubricating oil.
Fit the upper half of the shell bearing to the
connecting rod; ensure that the location tag is
fitted correctly in its recess (A1). Fit the
connecting rod to the crank pin; ensure that
the assembly number on the connecting rod is
on the same side as the other connecting rods.

3 Clean, lubricate and fit the lower half of the

shell bearings into the cap; ensure that the
location tag is fitted correctly in its recess (A1).
Fit the connecting rod setscrews. Fit the cap to
the connecting rod. Ensure that the assembly
number on the cap is the same as that on the
connecting rod and that both of the assembly
numbers are on the same side (B1).

4 Tighten the fasteners gradually and evenly to

the recommended torque of 155 Nm (114 Ibf
ft) 15.8 kgf m for setscrews, or 125 Nm (92 Ibf
ft) 12.7 kgf m for nuts.

5 Ensure that the crankshaft rotates freely.

6 Fit the lubricating oil strainer and suction pipe,

operation 19A-04.

7 Fit the lubricating oil sump, operation 19A-03

and fill the sump to the correct level with
lubricating oil of an approved grade.

To inspect 13A-02

Check the bearings and the crank pin for wear or

other damage.
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PISTON AND CONNECTING ROD WX90

13.3 PISTON AND CONNECTING ROD

To remove and to fit 13A-03

13.3.1 TO REMOVE

1 Drain the lubricating oil and the cooling system.

2 Remove the cylinder head assembly, operation 12A-07.

3 Remove all carbon from the top of the bores of the cylinder liners.

4 Remove the lubricating oil sump, operation 19A-03.

5 Remove the lubricating oil strainer and suction pipe, operation 19A-04.

CAUTION: The pistons and connecting rods are matched to the relevant cylinder. Note the position of
each connecting rod and piston for correct assembly.

6 Remove the big end caps and the big end bearings from the connecting rods, operation 13A-01.

CAUTION: Do not allow the connecting rods to hit the piston cooling jets. If a cooling jet is hit, check its
alignment, operation 13A-10, and renew it, if necessary.

7 Rotate the connecting rods 90° to prevent contact with the piston cooling jets. Push the pistons and the
connecting rods out through the top of the cylinder liners. Keep the bearings and caps together to ensure
that they can be fitted in their original positions.

8 Inspect the crank pins for damage.

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PISTON AND CONNECTING ROD WX90

13.3.2 TO FIT

Special tools:
Piston replacer tool, PD.206

1 Ensure that the piston, the cylinder bore, the

crank pin and the big end of the connecting
rod are clean. Lubricate the piston and the
cylinder liner with clean engine lubricating oil.

2 Rotate the crankshaft until the relevant crank

pin is at its lowest position. Lubricate the
crank pin with clean engine lubricating oil.

3 Fit the upper half of the shell bearings to the

connecting rod. Ensure that the location tag is
fitted correctly in its recess. Lubricate the
bearing with clean engine lubricating oil.

4 Put the piston replacer tool in position at the

top of the relevant cylinder. The tool has a
tapered bore to compress the piston rings
when the piston and connecting rod assembly
is fitted. Ensure that the smaller end of the
tapered bore is towards the face of the cylinder
block.

5 Put the piston ring gaps 120° apart. Pass the

connecting rod through the piston replacer
tool and allow the piston to enter the tool. The
arrow mark on the top of the piston (B) must
be towards the front of the engine.

CAUTION: Ensure that the connecting rod will

not hit the piston cooling jet as the connecting
rod assembly is fitted.

6 Push the piston and connecting rod assembly
through the piston replacer tool (A) and onto
the crank pin. The piston and connecting rod
assembly must be rotated to ensure that the
connecting rod will not hit the piston cooling
jet as the assembly is fitted. When the
connecting rod has passed the piston cooling
jet, rotate the connecting rod until the arrow
mark on top of the piston is towards the front
of the engine.
8 Check that the crankshaft will rotate freely.
9 Check the piston height above the top face
of the cylinder block, operation 13A-03A.
10 Fit the lubricating oil strainer and suction
pipe, operation 19A-04.
11 Fit the lubricating oil sump, operation 19A-
03.

7 Clean the connecting rod cap and the lower 12 Fit the cylinder head assembly, operation
half of the shell bearings. Fit the bearing to the 12A-07.
cap; ensure that the location tag is fitted
15501 9-35990

correctly in its recess. Lubricate the bearing 13 Fill the sump to the correct level with
with clean engine lubricating oil. Fit the cap lubricating oil of an approved grade.
and ensure that the assembly number is the
same as that on the connecting rod and that 14 Fill the cooling system.
the numbers are on the same side. Tighten
the fasteners gradually and evenly to the
recommended torque of 155 Nm (114 Ibf ft)
15.8 kgf m for setscrews, or 125 Nm (92 Ibf ft)
12.7 kgf m for nuts.
 EM11-13-7
PISTON AND CONNECTING ROD WX90

To check the piston height above

the cylinder block 13A-03A

Special tools:
Piston height tool, PD.41D
Dial gauge for use with PD.41D, PD.208

CAUTION: If the correct piston height above the

cylinder block is not obtained, damage to the
engine can occur.

Put the piston height tool (A) on the face of the

cylinder block and rotate the gauge dial to the
zero position. Rotate the crankshaft until the
piston crown is approximately at top dead centre
(TDC). Carefully put the tool over the top of the
piston with the plunger of the gauge in contact
with the piston above the axis of the gudgeon pin.
Rotate the crankshaft to ensure that the piston is
at the highest position and make a note of the
gauge indication.
The piston height above the top face of the
cylinder block should be 0.36/0.50 mm (0.014/
0.020 in).

NOTES:
• The top of the piston should not be machined.
• If the original piston is used, ensure that it is
assembled to the correct connecting rod and is
used in the original cylinder.

If any of the components listed below are renewed,

refer to the relevant operation:
• The connecting rod, refer to operation 13A-
05A.
• The small end bush, refer to operation 13A-08.
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 EM11-13-8
PISTON AND CONNECTING ROD WX90

13.4 PISTON RINGS

To remove and to fit 13A-04

The pistons have two compression rings and an

oil control ring. All the piston rings are above the
gudgeon pin. To ensure that the correct type is
obtained always use the engine identification
number to order new parts.

CAUTION: Only expand the ring gaps enough to

ensure that the ends of the rings do not damage
the piston when the ring is removed or put into
position.

13.4.1 TO REMOVE

Remove the piston rings with a suitable ring

expander. Keep the rings with their relevant piston.

13.4.2 TO FIT

Use a suitable piston ring expander to fit the

piston rings.

1 Fit the spring of the oil control ring in the

bottom groove with the latch pin (A1) inside
both ends of the spring (A). Fit the oil control
ring over the spring (B3) or (C3). Ensure that
the ring gap is at 180° to the latch pin.

2 Fit the cast iron ring with the taper face into the
second groove, with the word “TOP” towards
the top of the piston.
New second rings have a green identification
mark which must be on the left of the ring gap
when the ring is fitted and the piston is upright.
The second ring has a step (B2) or (C2) at the
bottom of the tapered face.

3 Fit the tapered, top ring (B1) or (C1) with the

word ‘TOP’ towards the top of the piston.

NOTE: The top ring (C1) of engine types AR

and AS is parallel.

New top rings have a red identification mark

which must be on the left of the ring gap when
the ring is fitted and the piston is upright.

4 Ensure that the ring gaps are 120° apart.

15501 9-35990
 EM11-13-9
PISTON AND CONNECTING ROD WX90

13.5 PISTON AND CONNECTING ROD

To dismantle and to assemble 13A-05

CAUTION: The pistons and connecting rods are

matched to the relevant cylinder. Note the
position of each connecting rod and piston for
correct assembly.

13.5.1 TO DISMANTLE

1 Remove the piston rings, operation 13A-04.

2 Remove the circlips which retain the gudgeon

pin.

CAUTION: Make a temporary mark on the piston.

Do not scratch, etch or stamp the piston surface.

3 Put a temporary mark on the piston to indicate

the cylinder number as shown on the
connecting rod. Put the temporary mark on
the piston on the same side as the mark on the
big end to ensure that they are assembled
correctly (A).

4 Push the gudgeon pin out by hand. If the

gudgeon pin is tight, heat the piston to 40/
50°C (100/1 20°F) for easy removal of the
gudgeon pin.

5 Inspect the piston and connecting rod

assembly, operation 13A-06 and operation
13A-07.

13.5.2 TO ASSEMBLE

1 Clean the bore of the small end bush and
lubricate it with clean engine lubricating oil.
2 Fit a new circlip in the circlip groove of one of
the gudgeon pin bosses. Ensure that it fits
correctly in the groove.
4 Lubricate the gudgeon pin bosses with clean
engine lubricating oil and push in the
gudgeon pin towards the circlip. If the
gudgeon pin is a tight fit in the piston, heat
the piston to 40/50°C (100/120°F) before
the gudgeon pin is fitted.

3 With the piston upside down, put the 5 Fit a new circlip in the groove in the other
connecting rod in position with the recess for gudgeon pin boss. Ensure that it fits correctly
the location of the big end bearing (B1) on the in the groove.
same side as the recess in the gudgeon pin
boss (B2). If the original piston is used, ensure 6 Fit the piston rings, operation 13A-04.
that it is assembled to the correct connecting
rod and is used in the original cylinder. New
15501 9-35990

1000 Series engines have six connecting rod

length grades, if a new connecting rod is
fitted, ensure that it is of the correct length
grade, see operation 13A-05B.
 EM11-13-10
PISTON AND CONNECTING ROD WX90

To check the length of a connecting

rod 13A-05A

A partially finished small end bush, which can be

fitted to the original connecting rod and machined
to obtain the correct length grade is available,
refer to operation 13A-08. Specialist equipment
and personnel with the correct training are needed
to machine the partially finished small end bush.
Connecting rod kits are also available with the
small end bush fitted and machined to obtain the
correct connecting rod grade.

CAUTIONS:

• It is important that the piston does not contact

the cylinder head. Ensure that the piston height
above the cylinder block is correct.

• Ensure that the connecting rods are fitted in the

correct cylinder. Record the position of the
connecting rod and its relevant cylinder when it
is removed from the engine.

To ensure that the piston height above the cylinder

block is correct, the engine may have up to six
length grades (F to L) of connecting rods fitted.

Identification of the length grade is by a letter or

colour which is marked on the side of each
connecting rod (A1). The letter F is the longest
grade of connecting rod and letter L is the shortest
grade. The difference between grades is 0.046
mm (0.0018 in).

If the grade letter or colour on the side of the

connecting rod cannot be seen the length can be
checked by the measurement of the dimension
(x) shown in (A). Before the length of the
connecting rod is measured, ensure that the
bores of the big end and the small end are square
and parallel, operation 13A-08. The length is
checked with the big end bearing removed and
the original small end bush fitted. The dimensions
for each grade are listed in the table below:

Grade Colour
Length (mm)
letter Code
F Red 165.728/165.761
15501 9-35990

G Orange 165.682/165.715
H White 165.637/165.670
J Green 165.591/165.624
K Purple 165.545/165.578
L Blue 165.499/165.532
F8167gb
 EM11-13-11
PISTON AND CONNECTING ROD WX90

13.6 PISTON AND PISTON RINGS

To inspect 13A-06

1 Check the piston for wear and other damage.

2 Check that the piston rings are free to move in

their grooves and that the the rings are not
broken.

3 Remove the piston rings, operation 13A-04,

and clean the piston ring grooves and the
piston rings.

4 Fit new piston rings in the grooves and check

for wear of the grooves with feeler gauges (A).
Compare the piston ring clearance in the
groove to that given for new components in the
data and dimensions and renew the piston, if
necessary.

NOTE: The pistons have a tapered top groove

and the piston ring is wedge shaped (13A.10/
B); the top piston ring clearance cannot be
checked by this method.

5 Clean all carbon from the top of the cylinder

liners. Fit each piston ring in the top part of the
cylinder liner and measure the ring gap with
feeler gauges (B). The coil spring must be
fitted to the oil control ring when the gap of this
piston ring is measured. The piston ring gaps
for new components are given in the data and
dimensions.
15501 9-35990
 EM11-13-12
PISTON AND CONNECTING ROD WX90

13.7 CONNECTING ROD

To inspect 13A-07

1 Check the small end bush for wear or for other

damage and renew it, if necessary.

NOTE: Connecting rod kits are available with

a new small-end bush fitted and finished to
the correct grade, refer to operation 13A-05B
to identify the correct connecting rod grade.

A partially finished small end bush, which can

be fitted to the original connecting rod and
machined to obtain the correct length grade
is also available, refer to operation 13A-08.

2 Check the connecting rod for distortion (A).
Use the data and dimensions, in the workshop
manual, to identify the correct mandrel sizes.
NOTE: The large and small end bores must
be square and parallel with each other within
the limits of +/- 0,25 mm (0.010 in) measured
127 mm (5.0 in) each side of the connecting
rod axis on a test mandrel. With the small end
bush fitted, the limits are reduced to +/- 0,06
mm (0.0025 in).
3 Check the fit of the gudgeon pin in the small
end bush and check the gudgeon pin for wear,
see the data and dimensions.
13.8 SMALL END BUSH
To remove and to fit 13A-08
1 Press out the old bush with a suitable adaptor.
4 Machine the partially finished bush. To obtain
the correct connecting rod grade, refer to
operation 13A-05A, see the data and
dimensions.
To obtain the correct clearance between the
gudgeon pin and the bush, refer to the data
and dimensions in the workshop manual.
NOTE: The small end is wedge shaped.
After the small end bush has been fitted,
machine the bush to the shape of the small
end and remove any sharp edges.
CAUTION: Do not use a letter stamp to
mark the connecting rod.
5 Check that the grade letter on the connecting
rod is correct, if necessary, delete the letter
and etch a new letter on to the side of the
rod.

2 Clean the parent bore of the connecting rod

and remove any sharp edges.

3 Press in the partially finished bush. Ensure

that the lubrication hole in the bush is on the
same side as, and is aligned with, the hole in
the top of the connecting rod.

CAUTION: Do not use a reamer, specialist

equipment and personnel with the correct trai-
ning are needed to machine the partially
finished small end bush. For further
15501 9-35990

information refer to your nearest CASE

distributor.
 EM11-13-13
PISTON AND CONNECTING ROD WX90

13.9 PISTON COOLING JETS

To remove and to fit 13A-O9

13.9.1 TO REMOVE

Release the valve assembly and remove the

piston cooling jet assembly (A).

NOTES:

• The crankshaft is removed in (A) to show

clearly the piston cooling jet.

• Engine types AR and AS have a single piston

cooling jet, fitted to the number one cylinder
position. The piston cooling jet positions for
cylinders 2, 3 and 4 have a blanking plug fitted.

13.9.2 TO FIT

1 Check that the ball moves freely against spring

pressure in the valve assembly and that the jet
tube is not damaged. Renew the valve
assembly and/or the body as necessary.

2 Fit the piston cooling jet; ensure that the

assembly is fitted correctly on the dowel in the
cylinder block. Tighten the valve assembly to
20Nm (151fft) 2.0kgfm.

To check the jet alignment 13A-10

Insert a 1.70 mm (0.067 in) diameter rod, of

suitable length, into the jet. If a suitable rod is not
available, reduce the end of a thicker rod to 1.70
mm (0.067 in) diameter for a length of 16.00 mm
(0.630 in). When the rod is inserted into the jet it
must extend out of the top of the cylinder within
the area shown in B. For engine types AR and AS
use the dimensions shown in C.
15501 9-35990
 EM11-13-14
PISTON AND CONNECTING ROD WX90

13.10 DATA AND DIMENSIONS

NOTE: This information is given as a guide for person nel engaged on eng ine overhauls. The di mensions
which are shown are those which are mainly used in the factory. The information applies to all engines,
unless an engine type code is shown.

13.10.1 PISTONS

Type ................................................................................................................... ”Fastram” combustion bowl

Inserted top ring groove, graphite skirt
Diameter of bore for gudgeon pin ..................................................... 39.703/39.709 mm (1.5631/1.5633 in)
Height of piston above top face of cylinder block.......................................... 0.38/0.50 mm (0.015/0.020 in)
Width of groove for top ring
- Engine type AR ....................................................................................... 2.60/2.62 mm (0.1023/0.1031 in)
Width of groove for second ring .............................................................. 2.56/2.58 mm (0.01008/0.1016 in)
Width of groove for third ring
- Engine type AR ..................................................................................... 3.53/13.55 mm (0.1389/0.1397 in)

Piston cooling jets

Valve open pressure ................................................................... 178/250 kPa (26/36 lbf/in2) 1,8/2,6 kgf/cm2

13.10.1 PISTON RINGS

Top compression ring:

- Engine type AR ...................................................................... Barrel face, molybdenum insert, rectangular
Second compression ring ........................................................... Taper face, cast iron, outside bottom step
Oil scraper ring ...................................................................................... Coil spring loaded, chromium faced
Width of top ring:
- Engine type AR ......................................................................................... 2.475/2.49 mm (0.097/0.098 in)
Width of second ring ..................................................................................... 2.48/2.49 mm (0.097/0.098 in)
Width of third ring ...................................................................................... 3.47/3.49 mm (0.1366/0.1374 in)
Clearance of top ring in groove:
- Engine type AR ....................................................................................... 0.110/0.145 mm (0.004/0.006 in)
Clearance of second ring in groove ................................................................. 0.07/0.1 mm (0.0030.004 in)
Clearance of third ring in groove ................................................................... 0.05/0.09 mm (0.002/0.003 in)
Gap of top ring:
- Engine type AR ........................................................................................... 0.28/0.51 mm (0.011/0.020 in)
Gap of second ring:
- Engine type AR ........................................................................................... 0.30/0.63 mm (0.012/0.025 in)
Gap of third ring:
- Engine type AR ........................................................................................... 0.30/0.63 mm (0.012/0.025 in)
15501 9-35990
 EM11-13-15
PISTON AND CONNECTING ROD WX90

13.10.3CONNECTING RODS

Type ...................................................................................................... ‘H’ section, wedge shape small end

Location of cap to connecting rod .................................................... Flat joint face with dowels or serrations
Diameter of parent bore for big end ..................................................................................... 67.21/67.22 mm
Diameter of parent bore for small end ................................................................................. 43.01/43.04 mm
Length grades ........................................................................................................................ F, G, H, J, K, L
Length between centres........................................................................ 219.05/219.10 mm (8.624/8.626 in)

Big end bearings

Width:
- Naturally aspirated engines: ..................................................... Steel back, aluminium/tin bearing material
Width:
- Naturally aspirated engines: ................................................................... 31.62/31.88 mm (1.245/1.255 in)
Thickness at centre of bearings:
- Naturally aspirated engines: ............................................................... 1.835/1.842 mm (0.0723/0.0725 in)
Bearing clearance:
- Naturally aspirated engines: ............................................................... 0.035/0.081 mm (0.0014/0.0032 in)
Available undersize bearings: ..................... -0.25 mm (0.010 in); -0.51 mm (0.020 in); -0.76 mm (0.030 in)

Gudgeon pins
Production:
Type .......................................................................................................................................... Fully floating
Outside diameter ............................................................................... 39.694/39.700 mm (1.5628/1.5630 in)
Clearance fit in piston boss ................................................................... 0.003/0.015 mm (0.0001/0.0006 in)

Small end bushes

Type ........................................................................................ Steel back, lead bronze tin bearing materials
Outside diameter ................................................................................... 43,11/43,15 mm (1.6972/1.6988 in)
Inside diameter ................................................................................ 39,723139,738 mm (1.5638/1.5645 in)
Surface finish grade ....................................................................................................... Ra 0,8 micrometers
Clearance between bush in small end and gudgeon pin ...................... 0,023/0,044 mm (0.0009/0.0017 in)
15501 9-35990
 EM11-13-16
PISTON AND CONNECTING ROD WX90

NOTES:

15501 9-35990
 EM11-14-1
CRANKSHAFT WX90

14. CRANKSHAFT

14.1 GENERAL DESCRIPTION

The crankshaft is a chrome-molybdenum forging

which has five main journals for four cylinder
engines.

End-float is controlled by thrust washers on both

sides of the centre main bearing.

The main bearings have steel backs with a

aluminium/tin. The main bearing caps are made
of cast iron or spheroidal graphite (SG) iron.

The front and the rear oil seals are Viton lip seals
with a dust lip to the outside of the main lip and
with oil return grooves on the face of the main iip.

WARNING! Read the safety precautions for

“Viton” seals on page EM 11-10-16.

The crankshaft pulley (A3) of the four cylinder

engine, usually fitted without a damper, is held in
position by a plain thrust block (A1) and three
setscrews (A2). The nose of the crankshaft is
serrated for location.

A balancer unit is fitted to certain four cylinder

engines which have rigid mountings or which are
part of the chassis or frame. The purpose of the
balancer unit is to reduce the effect of the out-
ofbalance forces.
15501 9-35990
 EM11-14-2
CRANKSHAFT WX90

14.2 CRANKSHAFT PULLEY

To remove and to fit-

four cylinder engines 14A-01A

14.2.1 TO REMOVE

1 Remove the drive belt(s), operation 23A-03.

2 Release the three setscrews (A2) which hold

the pulley and remove the setscrews, the
thrust block (A1) and the pulley (A3).

3 Clean the components and check for damage.

Renew damaged components.

14.2.2 TO FIT

1 Put the pulley in position on the crankshaft.

Lubricate lightly the threads of the setscrews
with engine lubricating oil. Lubricate the main
lip of the seal with clean engine oil. Fit the
thrust block and the setscrews and tighten the
setscrews gradually and evenly to 115 Nm (85
Ibf ft) 11.8 kgf m.

2 Check each setscrew again to ensure that

they are still to the correct torque.

3 Fit the drive belt(s), operation 23A-03.

15501 9-35990
 EM11-14-3
CRANKSHAFT WX90

14.3 REAR OIL SEAL ASSEMBLY

To remove and to fit 14A-02

Special tools:
Replacer tool for rear oil seal, PD.145D
Consumable products:
Threadlock (pipe) Loctite 575
Silicone rubber sealant, Hylosil

1 Remove the drive components from the rear

end of the engine.

2 Remove the flywheel and the flywheel

housing, see group 22.

3 Remove the setscrews and the cap screws

from the housing and remove the housing
and seal assembly.

4 Inspect the seal for wear or for damage to the

main lip and renew the seal, if necessary. If
there is only a small scratch across the lip,
renew the seal.

5 Clean the faces of the cylinder block, the oil

seal housing and the crankshaft flange.

6 Check that the seal and the outer

circumference of the crankshaft flange are
not damaged. Where a new seal has been
fitted, check that it is in the correct position in
the housing.

7 Ensure that the two dowels (A4) are fitted in

the cylinder block. Put a new joint (A3) in
position on the dowels, no jointing compound
is necessary.

8 Put the seal replacer tool on the crankshaft

flange. Lubricate the crankshaft flange, the
main lip of the seal and the seal replacer tool
with clean engine lubricating oil. The
lubrication of the seal is necessary to prevent
damage to the seal when the engine is first
started.

9 Put the seal and housing (A2) on the replacer

tool (A1) and carefully push the assembly
into position on the crankshaft flange and
onto the dowels. Remove the tool, fit the
15501 9-35990

setscrews and the torx screws (B1). Tighten

the setscrews and the torx screws to 22 Nm
(16 Ibf ft) 2.2 kgf m.
 EM11-14-4
CRANKSHAFT WX90

To renew the rear oil seal 14A-03

Special tools:
Replacer tool for rear oil seal, PD.145D

There are three positions in which the seal can be

fitted in the housing (A).

Position “1 “ (A1) is used when a new seal is first

fitted in service.

Position “2” (A2) is used when a new seal is fitted

in service and the crankshaft flange is worn in
positions “ 1”.

Position “3” (A3) can be used with a new seal in

service, if a wet clutch is not used and the
crankshaft is new or the crankshaft palm area has
been corrected. Ensure that the seal is fitted
square in the housing.

If all positions have been used it is permissible to

grind the crankshaft flange, see section 11C.

1 Remove the seal and housing assembly,

operation 14A-02.

2 Put the engine side of the housing on a

suitable support and press out the seal with a
suitable adaptor.

3 Lubricate the outer circumference of the seal

and the bore of the seal housing with clean
engine lubricating oil.

4 Put the engine side of the housing on a

suitable support. Put the seal into position on
the flywheel end of the bore with the spring of
the seal towards the housing.

5 Use a press and the replacer tool, PD.145D,

to fit the seal at the correct depth. The special
tool has two sides and is used in accordance
with either position “1” or “2”. Press the seal
into the housing to the correct position with the
relevant side of the tool.
15501 9-35990
 EM11-14-5
CRANKSHAFT WX90

14.4 THRUST WASHERS

To check crankshaft end-float 14A-04

The axial movement of the crankshaft is controlled

by thrust washers fitted both sides of the centre
main bearing (A). The end-float can be checked
with a feeler gauge between a thrust washer and
the crankshaft (B), or with a dial test indicator on
one end of the crankshaft to check the movement
(C).

If the end-float is more than the tolerance given in

data and dimensions, thrust washers which are
0,019 mm (0.0075 in) oversize can be fitted.

The oversize thrust washers can be fitted to one

or to both sides of the main bearing. They are
fitted instead of the standard size washer, to
reduce the end-float to the factory tolerances.
15501 9-35990
 EM11-14-6
CRANKSHAFT WX90

To remove and to fit 14A-05

14.4.1 TO REMOVE

1 Drain the lubricating oil and remove the

lubricating oil sump, operation 19A-03.

2 If necessary, remove the balancer unit,

operation 14A-10.

3 If necessary, remove the lubricating oil strainer

and suction pipe, operation 19A-04.

4 Release the setscrews of the centre main

bearing and remove the main bearing cap
complete with the lower halves of the thrust
washers.

5 Use a suitable tool (A1) made of a soft material

to push the upper halves of the thrust washers
from their recesses. Where necessary, move
the crankshaft to the front or to the rear to
loosen a tight washer.
Use a suitable tool (A1) made of a soft material
to push the upper halves of the thrust washers
from their recesses.

14.4.2 TO FIT

1 Lubricate the thrust washers with clean engine

lubricating oil.

2 Slide the upper halves of the thrust washers

into their recesses in the cylinder block. Ensure
that the sides of the thrust washers that have
the grooves (B1) are against the crankshaft.

3 Fit the lower half thrust washers to the main

bearing cap with the location tags in their
recesses.

4 Ensure that the location thimbles are fitted

correctly in the main bearing cap or in the
cylinder block.

5 Ensure that the bearing is fitted correctly in the

cap and that the the bearing and the crankshaft
journal are clean. Lubricate the bearing with
clean engine lubricating oil.
15501 9-35990
 EM11-14-7
CRANKSHAFT WX90

6 Fit the cap with the location tags of both halves

of the shell bearings to the same side (A1).
Tighten the main bearing setscrews gradually
and evenly to 265 Nm (196 Ibf ft) 27,0 kgf m.

7 Check the crankshaft end-float, operation

14A-04.

8 If necessary, fit the balancer unit, operation

14A-10.

9 If necessary, fit the lubricating oil strainer and

the suction pipe, operation 19A-04.

10 Fit the lubricating oil sump, operation 1 9A-03,

and fill it to the correct level with an approved
lubricating oii.
15501 9-35990
 EM11-14-8
CRANKSHAFT WX90

14.5 MAIN BEARINGS

To remove and to fit (with the crankshaft

in position) 14A-06

If the rear main bearing is to be removed with the

crankshaft in position, the flywheel, the flywheel
housing, the rear oil seal housing and the bridge
piece will have to be removed. Except for engines
with a balancer unit fitted, the front main bearing
can only be removed if a suitable spanner is
available that will enable the torque to be applied
correctly to the setscrews of the main bearing
cap. If a suitable spanner is available, the front
main bearing cap can be removed together with
the oil pump. For four cylinder engines, either the
balancer unit or the suction pipe and strainer, the
delivery pipe and the relief valve will have to be
removed.

14.5.1 TO REMOVE

1 Drain the lubricating oii and remove the sump,

operation 19A-03.

2 Remove all necessary components to get

access to the specific bearing cap.

3 Release the setscrews of the bearing cap and

remove the bearing cap. Remove the lower
half of the shell bearing from the cap.

4 With a suitable tool (A1), push the upper half

of the shell bearing from the side opposite to
the location tag (A2) to remove the bearing
tag from its recess (A3) in the bearing housing.
Carefully rotate the crankshaft to release the
bearing from its housing. Keep the bearing
halves in their relevant positions.

15501 9-35990
 EM11-14-9
CRANKSHAFT WX90

14.5.2 TO FIT

1 Clean the upper half of the shell bearing and

lubricate the bearing surface with clean engine
lubricating oil.

CAUTION: Only the upper half of the bearing

has lubrication holes and must be fiffed to the
cylinder block.

2 Fit the plain end of the upper half of the

bearing between the crankshaft journal and
the side of the bearing housing which has the
recess for the location tag. Slide the bearing
into its housing until the tag on the bearing is
fitted correctly in its recess in the housing.

3 Clean the lower half of the bearing and the

cap, lubricate the bearing surface with clean
engine lubricating oil.

4 Fit the bearing into the cap with the tag of the
bearing fitted correctly in the recess in the
cap.

5 Ensure that the location thimbles are fitted

correctly to the cap or to the cylinder block. Fit
the bearing cap with the location tags of both
bearings on the same side (A1).

6 Inspect the setscrews for damage and for

distortion and renew them if necessary. Lightly
lubricate the setscrew threads with clean
engine lubricating oil. Fit the setscrews and
tighten the setscrews gradually and evenly to
265 Nm (196 Ibf ft) 27.0 kgf m.

7 Ensure that the crankshaft turns freely. If the

thrust washers have been removed and fitted,
check the crankshaft end-float, operation 14A-
04.

8 Fit all the components which were removed

for access to the main bearing cap.

9 Fit the lubricating oil sump, operation 19A-03

and fill it to the correct level with an approved
lubricating oil.

To inspect 14A-07
15501 9-35990

Inspect the bearings for wear and for other

damage. If a bearing is worn or damaged,
renew both halves of the shell bearings and
check the condition of the other bearings.
 EM11-14-10
CRANKSHAFT WX90

14.6 CRANKSHAFT

To remove and to fit 14 A - 08

Consumable products:

Silicone rubber sealant, Hylosil

Liquid gasket, Loctite 518

NOTE: If the crankshaft is to be renewed, it may be necessary to change the grade of the connecting rods,
operation 13A-08. This will occur if the correct piston height above the block face cannot be maintained with
the original piston and connecting rod assemblies, operation 13A-03A.

WARNING! Use lift equipment or obtain assistance to lift heavy engine components such as the flywheel,
flywheel housing and the crankshaft.

14.6.1 TO REMOVE

1 Before the engine is removed from the vehicle or from the machine, drain the lubricating oil and the coolant.

2 Remove the lubricating oil sump, operation 19A-03.

3 Remove the fan, the drive belts, the fan drive pulley and housing and the coolant pump, see group 21.

4 Remove the fuel injection pump, see group 20.

5 Remove the crankshaft pulley, operation 14A-01 A or B.

6 Remove the alternator and its mounting bracket, see group 23.

7 Remove the compressor and its drive assembly or remove the exhauster, see group 24.

8 Remove the timing case cover, operation 15A-01.

9 Remove the timing gears and the timing case, see group 15.

10 Remove the flywheel and the flywheel housing, see group 22.

11 Remove the rear oil seal housing, operation 14A-02.

12 If a balancer unit is fitted, remove it, operation 14A-10. If a balancer unit is not fitted, remove the lubricating
oil suction pipe and strainer, the lubricating oil pump, the delivery pipe and the relief valve (four cylinder
engines) and the lubricating oil crossover pipe, if fitted, see group 19.
13 Remove the bridge piece.

WARNING! The engine should be upside down before the fasteners for the crankshaft are removed. If the
engine cannot be tumed upside down support the crankshaft before the fasteners are removed.

14 Remove the caps of the connecting rods. Keep the bearings and caps together. Remove the bolts of the
connecting rods and carefully push the pistons towards the top their bores.
15501 9-35990

15 Ensure that the tops of the main bearing caps are stamped with their relevant position number. Remove
the main bearing caps, the lower half of the shell bearings and the upper and lower thrust washers. Keep
the bearings with their relevant caps.

16 Lift out the crankshaft. Remove the upper half of the bearings and keep each bearing with its relevant lower
half and cap.
 EM11-14-11
CRANKSHAFT WX90

14.6.2 TO FIT

1 Ensure that all lubricating oil passages are clean and free from restriction.

2 Clean the main bearing housings and the upper half of the bearings. Fit the shell bearings with the location
tags fitted correctly in their recesses. Lubricate the bearings with clean engine lubricating oil.

3 Ensure that the main journals of the crankshaft are clean. Put the crankshaft in position on the upper
bearings.

4 Clean and lubricate the upper halves of the thrust washers and slide them into their recesses on both sides
of the bearing housing. Ensure that the slotted sides of the thrust washers are towards the crankshaft.

5 Clean the bearing caps and the lower half of the bearings. Fit the bearings to the caps with the location
tags fitted correctly in their recesses. Lubricate the bearings with clean engine lubricating oil.

6 Clean the lower halves of the thrust washers and lubricate them with clean engine lubricating oil. Fit the
thrust washers on both sides of the bearing cap for the centre main bearing.

7 Check that the location thimbles for the main bearing caps are fitted correctly in the caps or in the cylinder
block. Fit the bearing caps in their correct positions (as shown by the position number stamped on the top
of the cap) with the location tags of the bearings on the same side. In this position the serial numbers
stamped on the bearing caps will be in line. The serial number stamped on the bearing caps must be the
same as the number stamped on the bottom face of the cylinder block.
15501 9-35990
 EM11-14-12
CRANKSHAFT WX90

8 Fit the setscrews to the main bearing caps and

tighten them gradually and evenly to 265 Nm
(196 Ibf ft) 27.0 kgf m.

9 Clean the bridge piece and the location areas

for the bridge piece in the cylinder block. Use
a straight edge (A2) to ensure that the bridge
piece is in line with the rear face of the cylinder
block. Tighten the bridge piece cap screws
(A1) to 16 Nm (12 Ibf ft) 1.6 kgf m.

10 When the bridge piece is in position, inject

Silicone adhesive or Silicone rubber into the
groove (B2) at each end of the bridge piece.
Continue to inject sealant until the groove is
completely full and the sealant leaves the
lower groove (B1) at the front and rear of the
bridge piece.
It may be necessary to stop the sealant at one
side of the lower groove in order to ensure it
will fiow from the opposite side of the groove.

CAUTION: When the sump joint is removed,

damage can occur to the seal in the grooves
of the bridge piece. If the seal is damaged,
apply enough sealant to completely fill the
grooves.

NOTE: Most of the latest engines have

setscrews in place of studs to fasten the sump
to the bridge piece. The threads of the
setscrews have a sealant applied by the
manufacturer. When the setscrews are to be
used again, ensure that the threads of the
setscrews and of the bridge piece are clean
and a sealant is applied to the threads of the
setscrews. These instructions also apply to
studs.

11 Fit the connecting rod caps, operation 13A-

01. Rotate the crankshaft two turns to ensure
free movement.

12 On four cylinder engines, if necessary, fit the

balancer unit, operation 14A-10. If a balancer
unit is not used, fit the lubricating oil pump, the
lubricating oil suction pipe and strainer, the
delivery pipe and the relief valve (four cylinder
engines) and if necessary, the lubricating oil
crossover pipe, see group 19.
15501 9-35990

13 Fit the rear oil seal housing, operation 14A-02.

 EM11-14-13
CRANKSHAFT WX90

14 Fit the flywheel housing and the flywheel, see group 22.

15 Fit the timing case and the timing gears, see group 15.

16 Fit the timing case cover, operation 15A-01.

17 Fit the compressor and its drive assembly or fit the exhauster, see section 24. 18 Fit the alternator and its
mounting bracket, see group 23.

19 Fit the crankshaft pulley, operation 14A-O1A or 14A-O1B.

20 Fit the fuel injection pump, see group 20.

21 Fit the coolant pump, the fan drive pulley and housing, the drive belts and the fan, see group 21.

22 Fit the lubricating oil sump, operation 19A-03.

23 After the engine has been installed, fill the lubricating oil sump to the correct level with an approved oil. Fill
the cooling system.

To inspect 14A-09

Check the crankshaft for wear and other damage. The maximum permissible wear and ovality on the
crankshaft journals and crank pins is O.04 mm (0.0016 in).
The main journals and the crank pins of standard size crank shafts can be machined to 0.25mm (0.010 in),
0.50mm (0.020 in) or 0.75 mm (0.030 in) undersize on diameter, see the data and dimensions. Special
undersize bearings are available.
If the seal has been used in all of the service positions, the crankshaft palm can be machined to remove the
wear marks. Further information can be found in the data and dimensions.
15501 9-35990
 EM11-14-14
CRANKSHAFT WX90

14.7 BALANCER UNIT

To remove and to fit 14A-10

14.7.1 TO REMOVE

1 Drain the lubricating oil from the sump and

remove the sump, operation 19A-03.

2 Provide a support for the balancer unit before

release of the setscrews from the engine.

3 Release the setscrews and lower carefully the

balancer unit. Make a note of the positions of
the setscrews of different lengths.

14.7.2 TO FIT

1 Ensure that the contact faces of the cylinder

block and of the balancer unit are clean and
that the two thimbles (A1) are fitted correctly
to the cylinder block.

2 Set the piston of number 1 cylinder to TDC,

operation 17A-01.

3 Before the balancer unit is fitted, ensure that

the flat faces of the balance weights are level
with each other (B1) and the weights hang
down away from the cylinder block (B2). The
timing of the balance weights to the drive shaft
is correct when the large hole and small hole
in the front of the drive shaft gear are in the
positions shown in the illustration (B).

NOTE: If the gear position shown in (B)

cannot be obtained, then the balancer must
be partially dismantled and the timing
corrected (14A.23/A).

4 Fit the balancer unit to the cylinder block with

the correct screws in the centre positions of
the balancer frame. Ensure, when the idler
and crankshaft gears are in mesh, that the flat
faces of the balance weight are level with each
other and that they are towards the cylinder
block. Check that the balancer unit is fitted
correctly on the thimbles and fit the remainder
of the setscrews in their correct position.
Tighten the setscrews to 54 Nm (40 Ibf ft) 5.5
kgf m.
15501 9-35990

5 Rotate the crankshaft through two turns to

ensure that it is free to rotate.

6 Fit the lubricating oil sump, operation 19A-03

and fill the sump to the correct level with an
approved oil.
 EM11-14-15
CRANKSHAFT WX90

To dismantle and to assemble 14A-11

Consumable products: Nutlock, Loctite 242E

14.7.3 TO DISMANTLE

1 Remove the balance weight cover (A8).

2 Release the setscrew and remove the idier gear assembly (A1). Keep the components together as an
assembly to protect the needie roller bearing.

3 Prevent movement of the drive shaft (A2) and loosen the nut (A4) of the drive gear for the balance weights
(A3). Put a suitable flat distance piece in position between the nut and the balancer frame. Turn the nut
until it is against the face of the distance piece. Continue to turn the nut with a suitable spanner until the
Loctite seal on the splines of the drive shaft is broken and the gear is loose on the shaft. Remove the nut
and the drive gear and remove the drive shaft. Ensure that the needle roller bearings are not damaged
when the drive shaft is removed.

4 Release the setscrews which hold the lubricating oll pump and the suction pipe (A10 and A9) to the
balancer frame and remove the lubricating oil pump and the suction pipe.

5 Release the setscrews and remove the transfer plate and joint for the lubricating oil (A7) from the rear of
the balancer unit. Make a note of the position of the direction arrows on the outside of the transfer plate
(14A.23/B or C) to ensure that it can be assembled correctly .
15501 9-35990
 EM11-14-16
CRANKSHAFT WX90

NOTES:

• The latest oil transfer plate is fitted without

a joint or sealant; always give the correct
engine number when parts are needed.

• There are two plugs in the balancer frame,

a short tapered plug with a hexagonal
socket head and a long plug with a square
socket head. These plugs control the flow
of oil through the balancer frame. The
position of the plugs is decided by which
side of the engine the filter is fitted. When
the filter is fitted on the left side, the short
plug is fitted in the side of the balancer and
the long plug is fitted in the bottom. When
the filter is fitted on the right side of the
engine, the short plug is fitted in the bottom
of the balancer and the long plug is fitted in
the side.

CAUTION: Removal of these plugs can cau-

se damage to the threads in the balancer fra-
me and a new balancer frame will be needed.
When a balancer unit is to be fitted, ensure
that the lubricating oil flow through the
balancer frame is correct for the position of
the lubricating oil f ilter.

6 Release the setscrews and remove the rear

cover of the balancer frame (14A.20/A6). A
hammer and a suitable drift will be necessary
to remove the rear cover from the dowels.

7 Remove the balance weights (14A.20/A5).

Ensure that the gear of the driven weight does
not damage the bush in the balancer frame.

8 Dismantle the lubricating oil relief valve,

operation 19A-09.

9 Clean the lubricating oil passages with an

approved kerosene cleaning solution and dry
them with low pressure compressed air.
15501 9-35990
 EM11-14-17
CRANKSHAFT WX90

14.7.4 TO ASSEMBLE

1 Ensure that the location spigot (A8) on the rear face of the lubricating oil pump is clean. Clean the contact
faces of the lubricating oil pump and the balancer frame. Fit the lubricating oil pump (A16) to the balancer
frame and tighten the setscrews to 27 Nm (20 Ibf ft) 2.8 kgf m.

2 Assemble the lubricating oil relief valve, operation 19A-09.

3 Lubricate the needle roller bearings (A7 and A10) with clean engine lubricating oil. Fit the drive shaft (A9)
and engage the splines for the lubricating oil pump with the pump rotor. Ensure that the needle roller
bearing at the front of the balancer frame is not damaged by the splines on the drive shaft.

4 Clean and dry the splines (A6) and the thread on the end of the drive shaft. Apply a small amount of Loctite
Nutlock to the splines and to the thread. Fit the drive gear of the balance weights (A1) with the flat face of
the gear towards the rear of the balancer unit. Fit and tighten the nut (A2) to 82 Nm (60 Ibf ft) 8,4 kgf m.
To tighten the nut, a peg spanner must be made to fit into the two holes in the front of the drive shaft and
be suitable for use with a torque wrench. Fit the peg spanner to the front of the drive shaft. Hold the nut
with a suitable spanner and apply the torque to the peg spanner.

5 Ensure that the drive shaft turns freely. Check the end-float of the drive shaft with feeler gauges between
the front face of the drive gear for the balance weights and the frame (A).
15501 9-35990
 EM11-14-18
CRANKSHAFT WX90

6 Put the balancer frame upside down on the

bench (A1). Turn the gear of the drive shaft
(A3) until the larger of the two outer holes (A2)
in the front face of the drive gear is in the
position shown in (A). Ensure that the drive
shaft will not move from this position. Lubricate
the bushes in the rear of the balancer frame
with clean engine lubricating oil and fit the
balance weights in the position shown in figu-
re A. Ensure that the flats on the balance
weights are level with each other (A4). With
the balance weights in the correct position,
check that the drive shaft is still in the correct
position.

7 Fit the two dowels to the rear face of the

balancer frame. Lubricate the bushes in the
rear cover of the balance frame with clean
engine lubricating oil. Put the rear cover
(14A.24/A4) in position with the rear spigots of
the balance weights in the bushes of the
cover. Hit lightly the rear cover with a soft face
hammer to fit the cover onto the dowels. Fit
the cover setscrews and tighten them to 54
Nm (40 Ibf ft) 5.5 kgf m. Check the end-float of
the balance weights with feeler gauges
between the rear face of the balance weights
and the front face of the rear cover (14A.27/
B). The correct end-float is given in the data
and dimensions. Check the backlash between
the drive gear of the balance weights and the
driven gear on the balance weight. The correct
backlash is given in the data and dimensions.

8 Fit the oil transfer plate to the rear of the rear

cover and tighten the setscrews to 30 Nm (22
Ibf ft) 3.1 kgf m. Ensure that the plate is fitted
correctly for the oil filter position. The direction
arrow (B or C) indicates the direction of
lubricating oil flow for left side (B) and right
side (C) oil filter positions. The symbols and
arrows (B or C) indicate the position of the
plugs in the balancer frame and the shape of
their socket heads. Ensure that the plug on
the bottom face of the frame is just below the
face. If a new frame and plugs are used,
ensure that the plugs are fitted correctly for
the oil filter position and the symbols on the oil
transfer plate.
15501 9-35990
 EM11-14-19
CRANKSHAFT WX90

9 If necessary, press a new bearing (A14) into the idler gear (A12). Lubricate the bearing with clean engine
lubricating oil. Fit the hub (A13) into the bearing and fit the thrust washer (A15) onto the rear of the hub.
Ensure that the threads of the setscrew are clean and dry. Fit the setscrew through the assembly and apply
a small amount of Loctite Nutlock to the thread. Fit the assembly to the front of the balancer unit with the
idler gear in mesh with the gear of the drive shaft (A11). Tighten the setscrew to 93 Nm (68 Ibf ft) 9.5 kgf
m. Check the end-float of the idler gear with a feeler gauge between the front face of the idler gear and the
hub (A). Check the backlash between the idler gear and the drive shaft gear. The correct backlash is given
in the data and dimensions.

10 Fit the balance weight cover and tighten the setscrews.

11 Fit the suction tube and the joint and tighten the setscrews.
15501 9-35990
 EM11-14-20
CRANKSHAFT WX90

To inspect 14A-12

1 Clean all the components before inspection.

2 Check the gear teeth and the splines of the
drive shaft for wear or other damage. Renew
the drive shaft if necessary.
3 Check the idler gear, needle roller bearing,
hub and thrust washer for wear or other
damage. Renew the components if necessary.
4 Check the drive gear for the balance weights
for wear or other damage. Renew the gear if
necessary.
5 Check the balance weights for wear or other
damage. If either balance weight is worn or
damaged, both balance weights must be
renewed.
6 Check the needle roller bearings for the drive
shaft for wear or other damage. Renew the
bearings, operation 14A-13, if necessary.
7 Check the bushes for the balance weights for
wear or other damage. Renew the bushes,
operation 14A-14, if necessary.
8 To inspect the lubricating oil pump, see
operation 19A-07.

To remove and to fit the needle roller

bearings for the drive shaft 14A-13

1 Press out the bearings with a suitable adaptor.

2 Clean the parent bores and lubricate them
with clean engine lubricating oil.
3 Make a suitable adaptor to the dimensions
given in (A2). Fit the rear bearing (14A.24/A7)
onto the adaptor with the stamped face of the
bearing towards the shoulder of the adaptor.
Press the bearing into the parent bore in a
continuous movement until the shoulder of
the adaptor is against the front face of the
balancer frame. In this position the front face
of the bearing should be 130.0/131.0 mm
(5.12/5.16 in) from the front face of the balancer
frame (14A.24/A).
4 Make a suitable adaptor to the dimensions
given in (A1). Fit the front bearing (14A.24/
A10) onto the adaptor with the stamped face
of the bearing toward the shoulder. Press the
bearing into the parent bore in a continuous
movement until the shoulder of the adaptor is
against the front face of the balancer frame. In
this position the front face of the bearing
15501 9-35990

should be 2.5/3.0 mm (0.01/0.12 in) from the

front face of the balancer frame (14A.24/A).
 EM11-14-21
CRANKSHAFT WX90

To remove and to fit the bushes

for the balance weights 14A-14

1 Press the bushes out of the balancer frame

and the rear cover with a suitable adaptor.

2 Clean the parent bores and lubricate them

with clean engine lubricating oil.

3 Make a suitable adaptor to the dimensions

given in (A3). Fit a bush onto the adaptor.
Press the bush (B4) into the parent bore in the
rear of the balancer frame (B3), in a continuous
movement, until the shoulder of the adaptor is
against the rear face of the balancer frame. In
this position the rear face of the bush should
be 3.25/3.30 mm (0.128/0.130 in) from the
rear face of the balancer frame (B). Repeat
this operation for the other bush.

4 Fit a bush (B1) onto the adaptor and put it into

position at the front end of one of the parent
bores in the rear cover (B2). Press in the bush,
in a continuous movement, until the shoulder
of the adaptor is against the front face of the
rear cover. In this position the front face of the
bush should be 3.25/3.30 mm (0.128/0.130
in) from the front face of the rear cover (B).
Repeat this operation for the other bush.
15501 9-35990
 EM11-14-22
CRANKSHAFT WX90

14.8 DATA AND DIMENSIONS

NOTE: This information is given as a guide for personnel engaged on engine overhauls. The dimensions
which are shown are those which are mainly used in the factory. The information applies to all engines,
unless an engine type code is shown.

14.8.1 CRANKSHAFT

Diameter of main journals:

- Four cylinder engines ............................................................................. 76.16/76.18 mm (2.998/2.999 in)

Maximum wear and ovality on journals and crank pins ................................................ 0.04 mm (0.0016 in)
Width of front journal ................................................................................. 36.93/37.69 mm (1.454/1.484 in)
Width of centre journal .............................................................................. 44.15/44.22 mm (1.738/1.741 in)
Width of all other journals ......................................................................... 39.24/39.35 mm (1.545/1.549 in)
Diameter of crank pins .............................................................................. 63.47/63.49 mm (2.499/2.500 in)
Width of crank pins ................................................................................... 40.35/40.42 mm (1.589/1.591 in)
Diameter of flange .................................................................................. 133.27/133.37 mm (5.247/5.251in)
Depth of recess for spigot bearing:
- Four cylinder engines ............................................................................. 20.22/20.98 mm (0.796/0.826 in)
Bore of recess for spigot bearing:
- Four cylinder engines ............................................................................. 46.96/46.99 mm (1.849/1.850 in)
Crankshaft end-float ...................................................................................... 0.05/0.38 mm (0.002/0.015 in)
Maximum permissible end-float ...................................................................................... 0,51 mm (0.020 in)
Fillet radii of journals and crank pins ............................................................. 3.68/3.96 mm (0.145/0.156 in)
Undersize journals and crank pins ............... -0,25 mm (0.010 in); -0,51 mm (0.020 in);-0.76 mm (0.030 in)
Crankshaft heat treatment:
- Induction hardened ............................................................................................. Part numbers 3131 H024
- Nitrocarburised ............................................. Part numbers 3131 H022, 31315991, 31315995, 31315681
- 60 hour Nitride ..................................................................................................... Part numbers 3131H021

14.8.2 CRANKSHAFT OVERHAUL

NOTES:
• Induction hardened crank shafts need not be hardened after they have been machined undersize.
• Nitrocarburised crankshafts must be hardened again each time they are machined. These crankshafts must
be nitrocarburised or, if this process is not available, they can be nitrided for 20 hours. If neither process is
available a new crankshaft, or Power Exchange crankshaft, must be fitted.
• Crankshafts which have been nitrided for 60 hours can be reground 0,25 mm (0.010 in) without the need
to harden them again.
• Check the crankshaft for cracks before and after it is ground. Demagnetise the crankshaft after it has been
checked for cracks.
• After the crankshaft has been machined remove any sharp corners from the lubricating oil holes.
• Surface finish and fillet radii must be maintained.
15501 9-35990
 EM11-14-23
CRANKSHAFT WX90

The finished sizes for crankshaft journals (A) which have been ground undersize are given in the table below:

Item 0.25 mm 0.51 mm 0.76 mm

1 75.905/75.926 mm 75.651/75.672 mm 75.397/75.418 mm

2 63.216/63.236 mm 62.962/62.982 mm 62.708/62.728 mm

3 39.47 mm maximum - -

4 37.82 mm maximum - -

5 44.68 mm maximum - -

6 40.55 mm maximum - -

7 133.17 mm maximum - -

8 Do not machine this diameter - -

9 3.6813.96 mm - -
F8468gb

Surface finish for journals, crank pins and fillet radii must be 0,4 microns (16 micro inches). Surface finish for
seal area of crankshaft palm must be 0,4/1,1 microns (16/43 micro inches).

With the crankshaft on mountings at the front and rear journals, the maximum run-out (total indicator reading)
at the journals must not be more than shown below:

Journal 4 cylinder crankshafts

1 Mounting

2 0.08 mm

3 0.15 mm
15501 9-35990

4 0.08 mm

5 Mounting
F8469gb
Run-out must not be opposite. The difference in run-out between one journal and the next must not
be more than 0,10 mm (0.004 in).
Run-out on the crankshaft pulley diameter, rear oil seal diameter and the rear flange diameter must
not be more than 0,05 mm (0.002 in) total indicator reading.
 EM11-14-24
CRANKSHAFT WX90

14.8.3 MAIN BEARINGS

Four cylinder engines ......................................................... Steel back, 20% tin-aluminium bearing material

Bearing width

Four cylinder engines:

Centre bearing .......................................................................................... 36.32/36.70 mm (1.430/1.445 in)
All other bearings ...................................................................................... 31.62/31.88 mm (1.245/1.255 in)

Bearing thickness at centre

Four cylinder engines .............................................................................. 2.083/2.089 mm (0.0820/0.823 in)

Bearing clearance:

Four cylinder engines:

All bearings ............................................................................................ 0.057/0.117 mm (0.022/0.0046 in)
Available undersize bearings ..................... -0.25 mm (0.010 in); -0.51 mm (0.020 in); -0.76 mm (0.030 in)

Crankshaft thrust washers

Type ............................................................................................. Steel back, lead bronze bearing material

Position .................................................................................................... Each side of centre main bearing
Thickness:
- Standard .................................................................................................... 2.26/2.31 mm (0.089/0.091 in)
- Oversize ..................................................................................................... 2.45/2.50 mm (0.096/0.098 in)

14.8.4 BALANCER UNIT

Diameter of drive shaft for front bearing .......................................... 28.562/28.575 mm (1.1245/1.1250 in)
Diameter of drive shaft for rear bearing ........................................... 23.787/23.800 mm (0.9365/0.9370 in)
Number of teeth on gear of drive shaft .....................................................................................................21
Backlash from gear of drive shaft to idler gear ............................................ 0.17/0.29 mm (0.007/0.011 in)
End-float of drive shaft ................................................................................. 0.13/0.30 mm (0.005/0.012 in)
Diameter of bore for front bearing of drive shaft .............................. 34.912/34.937 mm (1.3745/1.3755 in)
Diameter of bore for rear bearing of drive shaft ............................... 29,972/29.993 mm (1.1800/1.1808 in)
Diameter of bore for idler gear ............................................................. 47.64/47.65 mm (1.8755/1.8760 in)
Diameter of hub of idler gear ............................................................... 38.09/38.10 mm (1.4996/1.5000 in)
End-float of idler gear ................................................................................... 0.07/0.23 mm (0.003/0.009 in)
Thickness of thrust washer for idler gear ..................................................... 4.14/4.29 mm (0.163/0.169 in)
Number of teeth on idler gear ...................................................................................................................37
Inside diameter of bushes in balancer frame
and end cover (fitted) ....................................................................... 38.133/38.174 mm (1.5013/1.5029 in)
Diameter of spigots for balance weights .......................................... 38.054/38.069 mm (1.4982/1.4988 in)
Fit of spigot in bush ............................................................................. 0.064/0.120 mm (0.0025/0.0047 in)
End-float of balance weights ........................................................................ 0.19/0.40 mm (0.007/0.016 in)
Backlash of gears on balance weights......................................................... 0.10/0.27 mm (0.004/0.011 in)
Backlash of drive gear to spline on balance weight ..................................... 0.05/0.20 mm (0.002/0.008 in)
Number of teeth on drive gear ..................................................................................................................24
Number of teeth on spline on balance weight ........................................................................................... 16
15501 9-35990
 EM11-15-1
TIMING CASE COVER AND DRIVE WX90

15. TIMING CASE COVER AND DRIVE

15.1 GENERAL DESCRIPTION

The timing case (A) is for engines fitted with a

gear driven coolant pump. The timing case (B) is
for engines fitted with a belt driven coolant pump.
The timing case is made of either aluminium or
cast iron.

The timing gears on most engines are made of

steel, but cast iron gears are used on certain low
rated engines. A power take-off is available on
the left side of the aluminium timing case or from
both sides of the timing case made of cast iron.
Some applications that need a power take-off
from both sides of the timing case can have an
idler gear assembly that uses needle roller
bearings.

The drive from the crankshaft gear passes through

an idler gear to the camshaft gear and to the gear
of the fuel injection pump. The drive from the
crankshaft gear also passes through a lower idler
gear to the gear of the lubricating oil pump or, on
some four cylinder engines, to the gear of the
balancer unit. The gear driven coolant pump is
driven by the gear of the fuel injection pump. The
camshaft and the fuel injection pump run at half
the speed of the crankshaft.

The aluminium cover of the timing case contains

the front oil seal; this is made of viton and has a
dust lip in front of the main lip. On some engines
the cover has a noise shield fitted to its front face.

WARNING! Read the safety precautions for

“Viton” seals on page EM 11-10-06.

The camshaft is made of cast iron. The cam lobes

and the eccentric for the fuel lift pump are chill
hardened.
15501 9-35990
 EM11-15-2
TIMING CASE COVER AND DRIVE WX90

15.2 TIMING CASE COVER

To remove and to fit 15A-01

15.2.1 TO REMOVE

1 Remove the fan, operation 21A-04.

2 Remove the alternator, operation 23A-04.
3 Remove the crankshaft pulley, operation 14A-
01 A or B.
4 Drain the coolant and remove the coolant
pump, see section 21. Gear driven pumps
only.
5 Release the setscrews and nuts of the cover
(A5) and remove the cover, from the timing
case assembly (A2).
6 Discard the joint (A4).

15.2.2 TO FIT

Special tools:
Centralising tool, PD.162B (4 cylinder engines)

1 Clean the joint faces of the timing case cover

and top cover.

2 Put the cover and a new joint in position on the

timing case. Ensure that the two studs (A3)
are tightened correctly. Loosely fit two
setscrews (A1) which are in opposite locations
to hold the cover in position. Fit the centralising
tool in the oil seal housing (B) and use the
special washer and the crankshaft pulley
setscrews to put the cover in its correct position.
Do not overtighten the setscrews. Fit the
remainder of the setscrews and nuts and
tighten all of the cover fasteners to 22 Nm (1
6 Ibf ft) 2.2 kgf m. Remove the centralising
tool.

CAUTION: For engines with gear driven

coolant pumps, it is important that the cover
of the timing case is centred correctly. If the
cover is not centred, the backlash between
the fuel pump gear and coolant pump gear
could be affected. This could cause the
seizure of the fuel injection pump.

3 Fit the coolant pump, see group 21. Gear

driven pumps only.
15501 9-35990

4 Fit the crankshaft pulley, operation 14A-01 A

or B.
5 Fit the alternator, operation 23A-04.
6 Fit the drive belts, operation 23A-03 and adjust
the belt tension, operation 23A-02.
 EM11-15-3
TIMING CASE COVER AND DRIVE WX90

15.3 FRONT OIL SEAL

To remove and to fit 15A-02A

Special tools:
Replacer tool for front oil seal (main tool), PD170
Pressure plate for use with PD.170, PD.170-1
Sleevefor use with PD.170, PD.170-2
Fastener plate for use with PD.170, PD.170-3
Adaptor for use with PD.1 70 (1)
(1) Refer to your nearest CASE distributor.

15.3.1 TO REMOVE

1 Remove the fan, operation 21A-04 and the

drive belts, operation 23A-03.

2 Remove the crankshaft pulley, operation 14A-

01 A or B.

3 Remove the oil seal with a suitable lever

behind the main lip of the oil seal. Do not
damage the edge of the oil seal housing.

15.3.2 TO FIT

NOTE: The seal is fitted to a depth of 10.20/
10.70 mm (0.402/0.421 in) from the front face
of the oil seal housing to the flat front face of
the oil seal. If, in service, there is wear in the
seal location area of the crankshaft pulley, oil
will continue to leak after a new oil seal is
fitted. To renew a worn crankshaft pulley, refer
to operation 15A-02B.
1 Clean the oil seal housing. Inspect the new
seal for damage. If a scratch can be seen
across the lip of the seal, do not fit the seal.
2 Lubricate the outer circumference of the oil
seal with clean engine lubricating oil and enter
the seal into the housing. Ensure that the
spring loaded lip of the oil seal is towards the
inside of the timing case cover and that the oil
seal is square to the bore of the seal housing.
Fit a rod through the hole in the end of the
threaded bar to prevent movement of the
bar when the nut is tightened. Tighten the
nut to push the seal into the housing to the
correct depth.
4 Remove the replacer tool and lightly lubricate
the seal location area of the crankshaft
pulley with clean engine lubricating oil. Fit
the crankshaft pulley, operation 14A-01 A or
B.
5 Fit the drive belts, operation 23A-03 and
adjust the belt tension, operation 23A-02.
6 Fit the fan, operation 21A-04.

3 Assemble the oil seal replacer tool (A). Fit the

fastener plate, PD.170-3, (A3) to the front of
the crankshaft. Put the adaptor, (A5) on the
nose of the crankshaft and against the seal.
15501 9-35990

Ensure that the adaptor has the side stamped

10.5 mm towards the seal.
Assemble the pressure plate, PD.170-1, (A2)
together with the sleeve, PD.170-2, (A4) onto
the threaded bar, PD.170, (A1). Put the tool
assembly in position on the adaptor, and
tighten the threaded bar onto the stud of
PD.170-3 (A3).
 EM11-15-4
TIMING CASE COVER AND DRIVE WX90

To fit a wear sleeve 15A-02B

To renew a worn crankshaft pulley, a wear sleeve

(A2) is fitted over the spigot (A1).

1 Remove the crankshaft pulley, operation 14A-

01A or B.

NOTE: Full instructions and a special tool to

fit the wear sleeve are in each service kit.

2 Fit the wear sleeve, in accordance with the

manufacturer’s instructions.
It is not necessary to remove the flange (A3)
of the wear sleeve after it has been fitted.
A new front oil seal (A4) must be used when
a wear sleeve is fitted.
The dimension, to press the new oil seal into
the timing case, with a wear sleeve fitted, is
10.20/10.70 mm (0.402/0.421 in), from the
front face of the timing case.

3 Fit the crankshaft pulley, operation 14A-01A

or B.

15501 9-35990
 EM11-15-5
TIMING CASE COVER AND DRIVE WX90

15.4 IDLER GEAR AND HUB

To remove and to fit 15A-03A

15.4.1 TO REMOVE

1 Remove the timing case cover, operation

15A-01.

2 Rotate the crankshaft until the marked teeth of

the crankshaft gear and the camshaft gear
and the fuel pump gear are all aligned with the
marked teeth of the idler gear (A).

NOTE: The marked teeth of the idler gear will

not necessarily be in mesh with the marked
teeth of the other gears because of the
different speed of rotation of the idler gear.

3 Release the three setscrews (B8), remove

the plate (B1) of the idler gear and remove the
gear (B3) from the idler gear hub (B5). The
drive gear of the fuel injection pump may
rotate counterclockwise when the idler gear is
removed.

4 Remove the idler gear hub, note the position

of the oil hole (B6).

CAUTION: The valve timing and fuel injection

pump timing will be lost if the crankshaft is
rotated when the idler gear is removed.

5 Inspect the gear and the bushes (B2) and

(B7) for wear and other damage and renew as
necessary. The gear and bushes are available
as an assembly or separate bushes are
available.

6 If the bushes are to be changed, remove them

with a suitable puller. If a puller is not available,
machine off the face of one of the bushes and
press them out. Press in new bushes, machine
the bores to get the correct clearance on the
hub and machine the faces to get the correct
end clearance, see the data and dimensions
and the end of this section.

7 For engines that use the idler gear assembly

with needle roller bearings - Release the three
15501 9-35990

setscrews, remove the plate of the idler gear

(C1). Remove the front thrust washer (C2),
the front spacer (C3) and the gear (C4).
Remove the two needle roller bearings (C5),
if these are to be used again, they should be
fitted in their original positions. Remove the
rear thrust washer (C6) and the rear spacer
(C7). Remove the hub (C8).
 EM11-15-6
TIMING CASE COVER AND DRIVE WX90

15.4.2 TO FIT

1 Use the three idler gear setscrews to ensure

the correct position of the idler gear hub (A2)
with the lubrication hole (A1) at the top. Push
the hub into position and remove the setscrews.

2 Lubricate the idler gear bushes with clean

engine lubricating oil. Align the timing marks
on the idler gear with the marks on the
crankshaft and camshaft gears. If necessary,
rotate the gear of the fuel injection pump
clockwise to align the relevant timing mark
with the marks on the idler gear and slide the
idler gear into position. Check that all the
timing marks are in correct mesh (B), or (C) for
engines fitted with a belt driven coolant pump.
Fit the plate and the setscrews to the idler gear
hub and tighten the setscrews to 44 Nm (33 Ibf
ft) 4.5 kgf m.

3 For engines that use the idler gear assembly

with needle roller bearings - Inspect the
components for wear and other damage and
renew them as necessary. Lightly lubricate
the components with clean lubricating oil before
assembly onto the hub. Fit the hub (D8) as
shown in paragraph 1. Put the rear spacer
(D7) in position on the hub. Put the rear thrust
washer (D6) in position on the rear spacer. Put
the bearings (D5) in position on the hub in the
same position as they were before they were
removed. Lightly lubricate the bore and thrust
washer faces of the gear (D4) with clean
lubricating oll and put the gear in position on
the bearings. Put the front spacer (D3) in
position on the hub then put the front thrust
washer (D2) in position on the spacer. Put the
plate (D1) in position. The plate has TOP
stamped on the front face as the holes in the
plate are not equally spaced. Fit the setscrews
and tighten them to 44 Nm (33 Ibf ft) 4.5 kgf m).
15501 9-35990
 EM11-15-7
TIMING CASE COVER AND DRIVE WX90

4 Check the idler gear end-float (A) and the

timing gear backlash (B).

5 Fit the timing case cover, operation 15A-01.

6 Fit the coolant pump, operation 21A-02.

7 Fit the crankshaft pulley, operation 14A-01A

or B.

8 Where necessary, fit the fan drive pulley,

operation 21A-05.

9 Fit the drive belts, operation 23A-03 and adjust

the belt tension, operation 23A-02.

10 Fit the fan, operation 21A-04.

11 Fill the cooling system.

15501 9-35990
 EM11-15-8
TIMING CASE COVER AND DRIVE WX90

15.5 FUEL PUMP GEAR

The fuel injection timing is set with specialist tools

in the factory after the engine has been accurately
set to TDC, number 1 cylinder on the compression
stroke. The fuel pump gear has timing marks (A)
which can be used to find the approximate position
of TDC on number 1 cylinder compression stroke.
The marked teeth of the crankshaft, the camshaft
and the fuel pump gears will be in mesh with the
idler gear when number 1 piston is close to top
dead centre (TDC) on the compression stroke.
The marked teeth of the idler gear may not
necessarily be in mesh in this position, because
of the different speeds at which the gears rotate.
The fuel injection pump is timed at TDC on the
compression stroke of number 1 cylinder. It is
important that fuel injection timing is accurate to
conform to emissions legislation. Always use
operations, 17A-01A or B to obtain TDC on the
compression stroke of number 1 cylinder
accurately.

To remove and to fit 15A-04

15.5.1 TO REMOVE

Special tools:
Lucas fuel injection pump timing pin, PD.246

1 Remove the timing case cover, operation

15A-01.

CAUTION: Do not lock the shaft of the fuel
injection pump, see operation 20A-06A or B.
2 Set the number one piston to TDC on the
compression stroke, operation 17A-01A or B.
Fit the timing pin (B3) until the small end of the
pin (B2) is pushed fully into the hole in the fuel
pump body (B4). The pin can only be fitted
when the number one piston is correctly in
position at TDC on the compression stroke. If
the timing pin cannot be pushed into the pump
body, check the timing of the fuel injection
pump, see operation 17A-03.
3 Remove the four fasteners (A1) from the
fuel pump gear and remove the gear from
the hub of the fuel pump.
NOTE: On the latest engines with belt driven
coolant pumps, four tamper proof fasteners
retain the fuel pump gear. Special tools are
needed to remove these fasteners, refer to
your CASE distributor.
4 Inspect the gear for wear and other damage
and renew it, if necessary.
15501 9-35990

CAUTION: Do not remove the nut (B5) which

retains the hub (B1) to the shaft of the fuel
injection pump. The hub is fitted permanently
to the shaft. If the hub is moved, it will be
necessary for a fuel injection pump specialist
to correctly position the hub on the shaft with
special test equipment.
 EM11-15-9
TIMING CASE COVER AND DRIVE WX90

15.5.2 TO FIT

The fuel pump gear will only fit in one position.

The gear is fitted with the letters C and M at the
front.

CAUTION: Check that the shaft of the fuel

injection pump is released, see operations
20A-06B for Bosch pumps or 20A-06A for
Lucas DP 200 Series pumps.

1 Ensure that the engine is set to TDC with the

number one piston on the compression stroke,
operation 17A-01 A or B.

2 If the pin (B3) has been removed before the

gear is fitted rotate the hub (B1) until the hole
(B4) can be seen in the slot. Fit the small end
of the pin (B2) fully into the hole in the pump
body. Leave the pin (B5) in position.

3 Fit the fuel pump gear (C1), over the pin (C3)
and into mesh with the idler gear (C2).

4 Loosely fit the four fasteners in the centre of

the slots (C1) in the gear.

Carefully rotate the gear (B6) counter-

clockwise until the backlash between the idler
gear and the fuel pump gear has been
removed. Do not rotate the crankshaft or it will
be necessary to set TDC again.

5 Tighten the four fastenerss (A3) to retain the

gear to 28 Nm (20 lb ft) 2.8 kgf m. Remove the
timing pin.

6 If a new gear has been fitted, use a feeler

gauge to check the backlash.

7 Fit the timing case cover, operation 15A-01.

8 Fill the cooling system.

15501 9-35990
 EM11-15-10
TIMING CASE COVER AND DRIVE WX90

15.6 CAMSHAFT GEAR

To remove and to fit 15A-05

15.6.1 TO REMOVE

Special tools:
Gear puller, PD. 155C
Adaptors for use with PD.155C, PD.155B-5

1 Remove the timing case cover, operation

15A-01.

2 Rotate the crankshaft until the marked teeth of

the crankshaft gear and the camshaft gear are
in mesh with the idler gear. The marked teeth
of the idler gear will not necessarily be in mesh
with the marked teeth of the other gears
because of the different speed of rotation of
the idler gear.

3 Remove the setscrew and washer of the

camshaft gear. Put a suitable adaptor onto the
end of the camshaft and remove the gear with
the puller and adaptor (A). Ensure that the key
in the camshaft is not lost.

4 Inspect the gear for wear and any other

damage and renew it, if necessary.

15.6.2 TO FIT

1 Ensure that the key in the camshaft is fitted

correctly.

2 Remove the idler gear, operation 15A-03A.

3 Fit the camshaft gear to the camshaft with the

marked teeth towards the front and the keyway
correctly aligned with the key. If necessary,
lightly hit the gear with a soft face hammer to
engage the key into the keyway.

4 Fit the idler gear with the marked teeth in

correct mesh, operation 15A-03A. If the
camshaft has to be turned and a valve hits a
piston, disengage the rocker assembly.

5 Fit the washer and the setscrew for the

camshaft gear and tighten the setscrew to
15501 9-35990

press the camshaft gear into position. Tighten

the setscrew to 78 Nm (58 Ibf ft) 8.0 kgf m. If
a new camshaft gear has been fitted, check
the backlash.

6 Fit the timing case cover, operation 15A-01.

 EM11-15-11
TIMING CASE COVER AND DRIVE WX90

15.7 CRANKSHAFT GEAR

To remove and to fit 15A-06

15.7.1 TO REMOVE

1 Remove the timing case cover, operation 15A-01.

2 Rotate the crankshaft until the marked teeth of the crankshaft gear and the camshaft gear are in mesh with
the idler gear. The marked teeth of the idler gear will not necessarily be in mesh with the marked teeth of
the other gears because of the different speed of rotation of the idler gear.
3 Remove the idler gear, operation 15A-03A.
4 The crankshaft gear is a transition fit on the crankshaft. It may slide off easily or, if it is a tight fit and the
gear is to be renewed, it may be necessary to remove the crankshaft, operation 14A-08, to remove the gear
safely.

15.7.2 TO FIT

1 The gear can fit easily, or it may be necessary to heat the gear before it will fit onto the crankshaft. If the
gear is to be heated, heat it in an oven to not more than 180 °C (226 °F). If an oven is not available, heat
it in coolant which is at its boiling point. Do not use a flame as this can cause local damage. Fit the gear
with the timing marks to the front.
2 Fit the idler gear, operation 15A-03A and ensure that all the timing marks are correctly aligned.
3 Fit the timing case cover, operation 15A-01.

15.8 TIMING CASE

To remove and to fit 15A-07

Consumable products:
Jointing compound, Hylomar
Nutlock, Loctite 242E

15.8.1 TO REMOVE

1 Remove the fan, operation 21A-04.

2 Remove the drive belts, operation 23A-03.
3 Remove the crankshaft pulley, operation 14A-01 A or B.
4 If necessary, remove the fan drive assembly, operation 21A-05.
5 Drain the coolant and remove the coolant pump, operation 21A-02.
6 Remove the alternator together with its mounting bracket and front support plate.
7 Remove the compressor the drive assembly, and the exhauster, if fitted, see group 24.
8 Remove the timing case cover, operation 15A-01.
9 Rotate the crankshaft until the marked teeth of the crankshaft gear and the camshaft gear are in mesh with
the idler gear. The marked teeth of the idler gear will not necessarily be in mesh with the marked teeth of
the other gears because of the different speed of rotation of the idler gear.
10 Remove the fuel injection pump, see group 20.
11 Remove the idler gear, operation 15A-03A and the camshaft gear, operation 15A-05.
12 Remove the setscrews which hold the timing case to the cylinder block and the setscrews which hold the
15501 9-35990

sump to the bottom of the timing case.

13 Remove the timing case and the joint, do not allow the idler gear hub to fall. Ensure that the camshaft thrust
washer is not lost.
 EM11-15-12
TIMING CASE COVER AND DRIVE WX90

15.8.2 TO FIT

1 Ensure that the sump joint is not damaged. If

the joint is damaged, remove the sump and fit
it with a new joint after the timing case has
been fitted. The front section of the joint can
be cut away and the front section of a new joint
fitted, without the removal of the sump, but
extreme care must be used to prevent possible
leaks.

2 If the sump has been removed, fit the idler

gear hub (A2) or (B2) to the front of the
cylinder block; use the three setscrews of the
idler gear to hold the hub in position. Ensure
that the oil hole is at the top.

3 Ensure that the thrust washer for the camshaft

is in position.

4 Fit a new joint for the timing case to the

cylinder block. Cut the bottom ends of the joint
to fit correctly. Apply Jointing compound to the
bottom ends of the joint.

5 Put the timing case in position. If the sump has

not been removed, fit the idler gear hub, see
paragraph 2. Fit the four setscrews (A1), or
three setscrews (B1) for engines fitted with a
belt driven coolant pump, around the idler
gear hub. Ensure that the bottom of the timing
case is correctly aligned with the bottom of the
cylinder block before the setscrews are
tightened. Put the fan drive assembly and/or
the alternator and its front support plate in
position and fit and tighten the remainder of
the setscrews of the timing case. If the front
support plate has been separated from the 9 Fit the compressor and its drive assembly,
alternator bracket, ensure that the right side of if fitted, see operation 24A-01.
the plate is level with the machined face on the
cylinder block where the alternator bracket is 10 Fit the timing case cover, operation 15A-01.
fitted. If a new timing case is fitted, remove the
two studs from the timing case and clean the 11 Fit the coolant pump, operation 21A-02.
threads which fit into the timing case. Seal the
threads with Nutlock and fit the studs into the 12 Fit the crankshaft pulley, operations 14A-
new timing case. Remove the setscrews from 01A or B.
the idler gear hub.
13 If necessary, fit the fan drive pulley, operation
6 If necessary, fit the lubricating oil sump, 21A-05.
operation 19A-03A, and fill it to the correct
level with an approved oil. 14 Fit the alternator, operation 23A-04 and the
15501 9-35990

alternator front bracket.

7 Fit the camshaft gear,operation 15A-05 and
the idler gear, operation 15A-03A. Ensure that 15 Fit the drive belts, operation 23A-03 and
all the timing marks are correctly aligned. adjust the belt tension, operation 23A-02.

8 Fit the fuel injection pump and the drive gear, 16 Fit the fan, operation 21A-04.
see group 20. Eliminate air from the fuel
system, see group 20. 17 Fill the cooling system.
 EM11-15-13
TIMING CASE COVER AND DRIVE WX90

15.9 CAMSHAFT AND TAPPETS

To remove and to fit 15A-08

15.9.1 TO REMOVE

1 Before the engine is removed from the vehicle

or the machine, drain the lubricating oil and
the coolant.

2 Remove the timing case, operation 15A-07.

3 Remove the rocker cover, the rocker assembly

and the push rods, see group 12.

4 Remove the fuel lift pump, operation 20A-03.

5 Turn the engine upside down and remove the

lubricating oil sump, operation 19A-03.

6 Remove the camshaft thrust washer (B1) and

carefully remove the camshaft (A).

7 Remove the tappets.

8 Inspect the camshaft and the tappets for wear

and other damage, also inspect the camshaft
bush. Renew the components as necessary.

15.9.2 TO FIT

1 Ensure that all components are clean and are

lubricated with clean engine lubricating oil.

2 Fit the tappets in position. 9 Fit the fuel injection pump, see group 20.

3 Carefully fit the camshaft.
4 Fit the camshaft thrust washer. Ensure that it
is fitted correctly on the hollow dowel (B2).
5 Fit the timing case together with a new joint,
operation 15A-07.
6 Check that the camshaft end-float is within the
limits shown in data and dimensions.
7 Rotate the camshaft until the cam for the fuel
lift pump is at the minimum lift position and fit
the fuel lift pump, operation 20A-03.
15501 9-35990
10 Fit the push rods and the rocker assembly,
see group 12.
11 Set the valve tip clearances, operation 12A-
05.
12 Fit the timing case cover, operation 15A-01
and the lubricating oil sump, operation 19A-
03.
13 After the engine has been installed: Fill the
cooling system. Fill the lubricating oil sump
to the correct level with an approved
lubricating oil. Eliminate air from the fuel

system, see group 20.

8 Turn the engine to an upright position. Rotate
the crankshaft until the keyway in the
crankshaft is at the top. Fit the timing gears,
operations 15A-03A, 15A-04 and 15A-05, and
ensure that all the timing marks are correctly
aligned.
 EM11-15-14
TIMING CASE COVER AND DRIVE WX90

15.10DATA AND DIMENSIONS

NOTE: This information is given as a guide for personnel engaged on engine overhauls. The dimensions
which are shown are those which are mainly used in the factory. The information applies to all engines,
unless an engine type code is shown.

15.10.1TIMING CASE AND DRIVE ASSEMBLY

Camshaft

Diameter of number 1 journal ............................................................... 50.71/50.74 mm (1.9965/1.9975 in)

Diameter of number 2 journal ............................................................... 50.46/50.48 mm (1.9865/1.9875 in)
Diameter of number 3 journal:
- Four cylinder engines ......................................................................... 49.95/49.98 mm (1.9665/1.9675 in)
Clearance of all journals ........................................................................... 0.06/0.14 mm (0.0025/0.0055 in)
Cam lift:
- Inlet, engine types AR ................................................................................................. 8.58 mm (0.3378 in)
- Exhaust, engine types AR .......................................................................................... 8.80 mm (0.3464 in)
Maximum permissible ovality and wear on journals ........................................................ 0.05 mm (0.021 in)
End-float:
- Production limits ......................................................................................... 0.10/0.41 mm (0.004/0.016 in)
- Service limit .................................................................................................................. 0.53 mm (0.021 in)
Width of spigot for thrust washer .................................................................. 5.64/5.89 mm (0.222/0.232 in)
Camshaft thrust washer
Type ....................................................................................................................................................... 360°
Depth of recess in cylinder block for thrust washer ...................................... 5.46/5.54 mm (0.215/0.218 in)
Thickness of thrust washer ........................................................................... 5.49/5.54 mm (0.216/0.218 in)
Relationship of thrust washer to front face of cylinder block ................... -0.05/+0.08 mm (-0.002/+0.003 in)

Camshaft gear

Number of teeth ......................................................................................................................................... 56

Diameter of bore ................................................................................... 34.93/34.95 mm (1.3750/1.3760 in)
Outside diameter of hub of camshaft .................................................... 34.90/34.92 mm (1.3741/1.3747 in)
Clearance fit of gear on hub .................................................................. 0.008/0.048 mm (0.0003/0.0019 in)

Fuel pump gear

Number of teeth ......................................................................................................................................... 56
Bore .............................................................................................................. 3600/3606 mm (1417/1419 in)
Clearance fit on hub .............................................................................. 0.003/0.075 mm (0.0001/0.0030 in)

Crankshaft gear

Number of teeth ......................................................................................................................................... 28

Diameter of bore .............................................................................................................. 47.625/47.650 mm
Diameter of hub for gear on crankshaft ........................................................................... 47.625/47.645 mm
Transition fit of gear on crankshaft ................................................................................... -0.020/+0.048 mm

Idler gear and hub

15501 9-35990

Number of teeth ......................................................................................................................................... 63

Diameter of bore of gear ...................................................................................................... 57.14/57.18 mm
- with needle roller bearings ................................................................................................. 69.01/69.03 mm
Width of gear and split bush assembly (fitted in position) .................................................... 30.14/30.16 mm
Inside diameter of flanged bushes (fitted in position) ........................................................... 50.78/50.80 mm
Outside diameter of hub ....................................................................................................... 50.70/50.74 mm
-with needle roller bearing ................................................................................................ 54.987/55.000 mm
Clearance of bushes on hub .................................................................................................... 0.04/0.10 mm
 EM11-15-15
TIMING CASE COVER AND DRIVE WX90

End float of gear:

- Production limits ......................................................................................... 0.10/0.20 mm (0.004/0.008 in)
- with needle roller bearings ........................................................................... 0.24/0.33 mm (0.009/0.013in)
- Service limit .................................................................................................................. 0.38 mm (0.015 in)
Backlash for all gears ....................................................................................... 0.08 mm minimum (0.003 in)

Timing case front cover

Front cover oil seal depth .......................................................................... 10.20/10.70 mm (0.402/0.421 in)

15501 9-35990
 EM11-15-16
TIMING CASE COVER AND DRIVE WX90

NOTES:

15501 9-35990
 EM11-16-1
GENERAL DESCRIPTION WX90

16. GENERAL DESCRIPTION

16.1 GENERAL DESCRIPTION

The cylinder block is made of cast iron and provides a full length support for the dry liners which are also made
of cast iron. Production liners are a press fit in the block. In service two liners are available:

• A finished liner, which has a transition fit in the parent bore.

• A partially finished liner, which is an interference fit in the parent bore and must be machine finished after
it has been installed.

All liners are honed with silicon carbide tools to a controlled finish to ensure long life and low oil consumption.
The cylinder liners have a flame ring above the flange. A bush is fitted in the cylinder block for the front camshaft
journal and the other camshaft journals run directly in the block.

Engine types AR and AS do not have cylinder liners fitted and the cylinder bores must be machined oversize
to correct a worn cylinder bore, refer to the data and dimensions at the end of this section for further details.

NOTE: Short engines are also available.

Your CASE distributor has specialist equipment and personnel with the correct training to repair worn cylinder
bores.

16.2 CYLINDER BLOCK

To dismantle and to assemble 16A-01

Consumable products:
Nutlock, Loctite 242E

NOTE: If the cylinder block is to be renewed, it may be necessary to change the grade connecting rods,
operation 13A-08. This will occur if the correct piston height above the block face cannot be maintained with
the original piston and connecting rod assemblies, operation 13A-03A.

16.2.1 TO DISMANTLE

1 Drain the cooling system and the lubricating oil.

2 Remove the engine from the vehicle or machine.
3 Remove the alternator drive belts and the alternator and its mounting brackets, see group 23.
4 Remove the fan, the fan drive and the water pump, see group 21.
5 Remove the compressor or the exhauster, where fitted, see group 24.
6 Remove the fuel filter, the atomisers and the fuel injection pump, see group 20.
7 Remove the lubricating oil cooler, where fitted, operation 21A-07.
8 Remove the lubricating oil filter assembly and the lubricating oil sump, see group 19.
9 If necessary, remove the turbocharger, operation 18A-01.
10 Remove the fuel lift pump, operation 20A-03 or 20B-03.
11 Remove the starter motor, operation 23B-01.
12 Remove the cylinder head assembly, operation 12A-07.
13 Remove the timing case and the timing gears, see group 15. Remove the lubricating oil pump and the
15501 9-35990

pressure relief valve, see section 19, or remove the balancer unit, operation 14A-10.
15 Remove the piston and connecting rod assemblies, operation 13A-03.
16 Remove the camshaft and the tappets, operation 15A-08.
17 Remove the flywheel and the flywheel housing, see group 22.
18 Remove the rear oil seal assembly and the crankshaft, see group 14.
19 Remove the piston cooling jets, operation 13A-09.
 EM11-16-2
GENERAL DESCRIPTION WX90

16.2.2 TO ASSEMBLE

1 Clean thoroughly the new cylinder block. Ensure that all the oil passages are clean and free from debris.

2 Remove the threaded plugs from the old cylinder block and clean the threads. Seal the threads with
Nutlock, or a similar sealant, and fit the threaded plugs into the new cylinder block.

3 Fit the piston cooling jets, operation 13A-09.

4 Fit the crankshaft and the rear oil seal assembly, see group 14.

5 Fit the piston and connecting rod assembly, operation 13A-03.

6 Fit the flywheel housing and the flywheel, see group 22.

7 Fit the tappets and the camshaft, operation 15A-08.

8 Fit the lubricating oil pump and the pressure relief valve, see section 19, or fit the balancer unit, operation
14A-10.

9 Fit the timing case and the timing gears, see group 15.

10 Fit the cylinder head assembly, operation 12A-07.

11 Fit the starter motor, operation 23B-01.

12 Fit the fuel lift pump, operation 20A-03.

13 If necessary, fit the turbocharger, operation 18A-01.

14 Fit the lubricating oil filter assembly and the lubricating oil sump, see group 19.

15 If necessary, fit the lubricating oil cooler, operation 21A-07.

16 Fit the fuel filter, the atomisers and the fuel injection pump, see group 20.

17 If necessary, fit the compressor or the exhauster, see group 24.

18 Fit the fan, the fan drive and the water pump, see group 21.

19 Fit the alternator and its mounting brackets and the alternator drive belts, see group 23.

20 Install the engine into the vehicle or machine.

21 Fill the cooling system.

22 Fill the lubricating oil sump to the correct level with an approved lubricating oil.

23 Eliminate air from the fuel system, see group 20.

To inspect 16A-02
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1 Clean the passages for the coolant and for the oil.
2 Check the cylinder block for cracks and for other damage.
3 The top face of the cylinder block must not be machined as this will affect the liner flange depth and the
piston height above the top face of the cylinder block.
4 Check the camshaft bush for wear. If the bush is to be renewed, use a suitable adaptor to press it out of
the bore. Ensure that the lubricating oil hole in the new bush will be towards the front of the engine, when
fitted. Press in the bush with the oil hole on the same side and aligned with the oil hole in the block until
the front end of the bush is aligned with the face of the recess.
 EM11-16-3
GENERAL DESCRIPTION WX90

16.3 CYLINDER LINER

To inspect 16A-03

To ensure the best performance during the life of the engine it is important that worn or damaged cylinder liners
are renewed. If a change of liner becomes necessary in service, transition fit liners and partially finished liners
are available.

The condition of a cylinder liner is decided by:

• The amount and location of any polished areas.

• Wear.

• Damage to the liner wall.

NOTES: It will not be necessary to renew the liners if:

• The honed finish can still be clearly seen.

• The engine performance and oil consumption is acceptable.

16.3.1 TO CHECK THE CONDITION OF A CYLINDER LINER

1 Inspect the liner surface for cracks and deep scratches.

2 Check the liner wall for areas where the honed finish has been polished away. Check especially the area
around the top of the liner bore just below the carbon ring. In this area, thrust from the top piston ring is
at its maximum.

CAUTIONS:
• Do not use “Flex-hone” to repair cylinder liners.

• Damaged or worn liners must be discarded.

• New piston rings must be fitted when the cylinder liner is renewed.

• An engine can have high oil consumption with very little wear of the liner bores, if the surfaces of the liners
are glazed.

• Specialist training and equipment is needed to machine the finish of a partially finished liner.

Partially finished cylinder liners must be bored and then diamond honed, silicon carbide base honed and
silicon carbide plateau honed to the finished size to conform to the dimensions in the data and dimensions
at the end of this section. Specialist training and equipment is needed to machine a partially finished liner. For
further information contact your nearest CASE Distributor.
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 EM11-16-4
GENERAL DESCRIPTION WX90

To remove and to fit 16A-05

Special tools:
Remover/replacer for cylinder liner (main tool),
PD.150B
Adaptors for use with PD.150B, PD.150B-17A
Depth gauge, liner flange, PD.41 D
Dial gauge for use with PD.41 D, PD.208

Consumable products: (See Group 10)

Retainer (oil tolerant) Loctite 603
Loctite Safety Solvent or a similar product

Where several liners are to be removed or a very

tight production liner is fitted, a press should be
used. Where a single liner is to be removed or the
crankshaft is to remain in position, a tool for hand
operation is available.

16.3.2 TO REMOVE

1 Drain the lubricating oil and remove the

lubricating oil sump, operation 19A-03.

2 Remove the cylinder head assembly, operation

12A-07.

3 Remove the piston and connecting rod

assembly, see operation 13A-03.

4 Carefully remove the piston cooling jet, where
fitted, operation 13A-09.
5 Rotate the crankshaft to give access to the
cylinder liner. Protect the crank pin.
9 Lubricate the ratchet of the handle and the
threaded rod with Shell Spirax oil or an
equivalent oil. Operate the handle and pull
the cylinder liner out of the top of the cylinder
block.

6 Put the tool (A4) on the top face of the cylinder

block and over the centre of the liner (A5).
Ensure that the base of the tool is not on top
of the liner flange of the next cylinder.

7 Put the bearing (A3) in the recess in the top of

the tool with the flat face of the bearing to the
bottom of the recess.

8 Fit the threaded rod (A2) through the bearing

and the top of the tool until the handle (A1) is
in the recess in the top of the bearing. In this
position adjust the threaded rod until the end
is below the bottom of the cylinder liner. Fit the
adaptor PD.150B-1 7/1 (A6) onto the threaded
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rod and against the bottom of the cylinder

liner. Ensure that the two lugs on the top of the
adaptor engage with the flats on the threaded
rod. Fit the washer and nut and tighten the nut
onto the adaptor.
 EM11-16-5
GENERAL DESCRIPTION WX90

16.3.3 TO FIT A SERVICE LINER

A service liner is a transition fit of +/- 0.03 mm (+/

- 0.001 in) in the parent bore. A special tool will not
be necessary to fit some liners, but where a liner
is a tight fit, tool PD.150B can be used.

CAUTION: Do not hit a liner with a hammer.

1 Clean thoroughly the parent bore. Clean the

top 50 mm (2.0 in) and the recess for the liner
flange with Loctite Safety Solvent or a similar
product; use it in accordance with the
manufacturer’s instructions.

2 Clean thoroughly the outer surface of the liner

with Loctite Safety Solvent.

3 Lubricate lightly the parent bore with clean

engine lubricating oll, except for the top 50
mm (2.0 in).

4 Engage the cylinder liner (A5) into the parent

bore; ensure that the liner is vertical. Put the
adaptor PD.150B-17/2 (A4) onto the top of the
liner with the shoulder of the adaptor on the
liner flange. Put the bearing (A3) into position
in the recess in the top of the adaptor with the
flat face of the bearing to the bottom of the
recess.

5 Fit the threaded rod (A1) through the bearing,

the adaptor and the liner until the handle (A2)
is against the recess in the bearing. In this
position adjust the threaded rod until the end
is below the bottom face of the cylinder block.

6 Fit the adaptor PD.1 50B/6 (A6) onto the

threaded rod; ensure that the flat face of the
adaptor is against the bottom face of the
cylinder block. Fit the washer and the nut;
ensure that the threaded rod is in the centre of
the liner and tighten the nut onto the adaptor.
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 EM11-16-6
GENERAL DESCRIPTION WX90

7 Lubricate the ratchet of the handle and the

threaded rod with Shell Spirax oil or an
equivalent oil. Operate the handle and press
the liner into the parent bore to within 50 mm
(2.0 in) of the fitted position. Clean the area
below the flange of the liner with Loctite Safety
Solvent. Apply Retainer (oil tolerant) to the top
25 mm (1.0 in) of the outer surface of the liner
and under the flange; also apply Retainer (oil
tolerant) to the bottom of the flange recess in
the parent bore.

8 Press the liner in to the fully fitted position.

Remove the tool and clean the retainer from
the top of the cylinder block.

9 Allow 15 minutes to elapse before the liner

bore dimension is checked. The retainer will
reach full strength after 6 hours.

The inside diameter of a service liner, when

fitted, should be 100.00/100.06 mm (3.937/
3.939 in)

10 Use tool PD.41 D to check that the liner flange

is between 0.10 mm (0.004 in) above to 0.10
mm (0.004 in) below the top face of the
cylinder block (A).

11 Fit new piston rings, operation 13A-04.

12 Fit the piston and connecting rod assembly,

operation 13A-03.

13 If necessary, fit the piston cooling jet, operation

13A-09.

14 Fit the cylinder head assembly, operation

12A-07.

15 Fit the lubricating oil sump, operation 19A-03,

and fill it to the correct level with an approved
lubricating oil.

CAUTION: After a new service liner has bean

fitted, these recommendations are advised for the
first 5 hours of operation:

• Do not operate the engine at full load.

• Do not operate the engine at high speed.

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• Do not allow the engine to run at low idle speed

for long periods.
 EM11-16-7
GENERAL DESCRIPTION WX90

16.3.4 TO FIT A PARTIALLY FINISHED LINER

The liner is an interference fit in the parent bore.

A special tool will be necessary to fit the liners,
tool PD.1 50B can be used. If a liner is a very tight
fit it may be necessary to use a hydraulic press.

CAUTION: Do not hit a liner with a hammer.

1 Clean thoroughly the parent bore of the cylinder

block with an approved degreasing fluid.

2 Inspect the parent bore for damage and

corrosion. Damaged cylinder blocks should
be discarded.

3 Clean thoroughly the outer surface of the liner

with an approved degreasing fluid.

4 Apply a small amount of engine oil around the

top of the parent bore to assist the entry of the
liner.

5 Engage the cylinder liner (A5) into the parent

bore; ensure that the liner is vertical. Put the
adaptor PD.150B-1 7A (A4) onto the top of the
liner with the flame ring in the groove of the
adaptor. Put the bearing (A3) into position in
the recess in the top of the adaptor with the flat
face of the bearing to the bottom of the recess.

6 Fit the threaded rod (A1) through the bearing,

the adaptor and the liner until the handle (A2)
is against the recess in the bearing. In this
position adjust the threaded rod until the end
is below the bottom face of the cylinder block.

7 Fit the adaptor PD.150B/6 (A6) onto the

threaded rod; ensure that the flat face of the
adaptor is against the bottom face of the
cylinder block as shown (A). Fit the washer
and the nut; ensure that the threaded rod is in
the centre of the liner and tighten the nut onto
the adaptor.

8 Lubricate the ratchet of the handle and the

threaded rod with Shell Spirax oil or an
equivalent oil. Operate the handle and press
the liner into the fully fitted position.

9 Remove the tool PD.150B and thoroughly

15501 9-35990

clean the top of the cylinder block.

 EM11-16-8
GENERAL DESCRIPTION WX90

10 Use tool PD.41D to check that the flange of

the cylinder liner is between 0.10 mm (0.004
in) above to 0.10 mm (0.004 in) below the top
face of the cylinder block (A).

This measurement must be from the flange

(A2) of the cylinder liner, not the top of the
flame ring (A1).

CAUTION: Specialist training and equipment

is needed to machine the finish of a partially
finished liner.

Partially finished cylinder liners must be bored

and then diamond honed, silicon carbide base
honed and silicon carbide plateau honed to
the finished size to conform to the dimensions
in the data and dimensions at the end of this
section. Specialist training and equipment is
needed to machine the partially finished liner.
For further information contact your nearest
CASE distributor.

11 Fit new piston rings, operation 13A-02.

12 Fit the piston and connecting rod assembly.

13 If necessary, fit the piston cooling jet, operation

13A-09.

14 Fit the cylinder head assembly, operation

12A-07.

15 Fit the lubricating oil sump, operation 19A-03

and fill it to the correct level with an approved
lubricating oil.

CAUTION: After a new cylinder liner has been

fitted, these recommendations are advised for the
first 5 hours of operation:

• Do not operate the engine at full load.

• Do not operate the engine at high speed.

• Do not allow the engine to run at low idle speed

for long periods.
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 EM11-16-9
GENERAL DESCRIPTION WX90

16.4 CYLINDER BORE, ENGINE TYPE AR

To inspect 16A-03A

To ensure the best performance during the life of the engine it is important that worn or damaged cylinder bores
are corrected.

The condition of a cylinder bore is decided by:

• The amount and location of any polished areas.

• Wear.
• Damage to the cylinder wall.

NOTES: It will not be necessary to correct the bore if:

• The honed finish can still be clearly seen.

• The engine performance and oil consumption is acceptable.

1 Inspect the surface of the cylinder bore for cracks and deep scratches.

2 Check the bore wall for areas where the honed finish has been polished away. Check especially the area
around the top of the liner bore just below the carbon ring. In this area, thrust from the top piston ring is
at its maximum.

CAUTIONS:

• Do not use “Flex-hone” to repair cylinder bores.

• An engine can have high oil consumption with very little wear of the cylinder bores, if the surfaces of the bores
are glazed.
• Specialist training and equipment is needed to machine the finish of a cylinder bore.

If necessary, the cylinder bores can be bored and honed 0.50 mm (0.0197 in) and 1.00 mm (0.0197 in) oversize
in diameter and oversize pistons fitted.

To obtain oversize cylinder bores they must be bored and then diamond honed, silicon carbide base honed
and silicon carbide plateau honed to the finished size to conform to the dimensions in the data and dimensions
at the end of this section. Specialist training and equipment is needed to machine a cylinder bore. For further
information contact your nearest CASE distributor.
15501 9-35990
 EM11-16-10
GENERAL DESCRIPTION WX90

16.5 DATA AND DIMENSIONS

NOTE: This information is given as a guide for personnel engaged on engine overhauls. The dimensions
which are shown are those which are mainly used in the factory. The information applies to all engines,
unless an engine type code is shown.

16.5.1 CYLINDER BLOCK ASSEMBLY

Cylinder block

Height between top and bottom faces .............................................. 441.12/441.33 mm (17.367/17.375 in)
Diameter of parent bore for cylinder liner .............................................. 104.20/104.23 mm (4.103/4.104 in)
Depth of recess for flange of cylinder liner .................................................... 3.81/3.91 mm (0.150/0.154 in)
Diameter of recess for flange of cylinder liner....................................... 107.82/107.95 mm (4.245/4.250 in)
Diameter of cylinder bore, engine type AR only ............................ 103.000/103.025 mm (4.0551/4.0561 in)
Maximum permissible bore wear, engine type AR only .................................................. 0.15 mm (0.006 in)
Diameter of first oversize cylinder bore,
engine type AR only ...................................................................... 103.500/103.525 mm (4.0748/4.0757 in)
Diameter of second oversize cylinder bore,
engine type AR only ...................................................................... 104.000/104.025 mm (4.0944/4.0954 in)
Diameter of parent bore for main bearing ......................................... 80.416/80.442 mm (3.1660/3.1670 in)

Camshaft bore diameter:

- Four cylinder engines:

Number 1 (for bush) .................................................................................. 55.56/55.59 mm (2.188/2.189 in)
Number 2 .................................................................................................. 50.55/50.60 mm (1.990/1.992 in)
Number 3 .................................................................................................. 50.04/50.09 mm (1.970/1.972 in)
Bore of bush for number 1 camshaft journal ............................................. 50.79/50.85 mm (2.000/2.002 in)

Cylinder liners
Type:
- Production .............................................................................. Dry, interference fit, flanged, with flame ring
- Service ........................................................................................ Dry, transition fit, flanged, with flame ring
- Partially finished liner ............................................................. Dry, interference fit, flanged, with flame ring
Outside diameter of production liner ..................................................... 104.25/104.28 mm (4.105/4.106 in)
Interference fit of production liner ................................................................. 0.03/0.08 mm (0.001/0.003 in)
Inside diameter of production liner ........................................................ 100.00/100.03 mm (3.937/3.938 in)
Transition fit of service liner ................................................................................... +/- 0.03 mm (+/- 0.001 in)
Inside diameter of service liner with a flame ring (fitted) ....................... 100.0/100.063 mm (3.937/3.939 in)
Maximum permissible wear of liner bore ........................................................................ 0.25 mm (0.010 in)
Thickness of flange ....................................................................................... 3.81/3.86 mm (0.150/0.152 in)
Relative position of top of liner flange to top face of cylinder block ...................... 0.10 mm (0.004 in) above
0.10 mm (0.004 in) below

16.5.2 CYLINDER LINER SPECIFICATIONS

CAUTION: Specialist training and equipment is needed to machine the finish of a partially finished liner. For
further information contact your nearest CASE Distributor.
15501 9-35990

Partially finished liner

Interference fit of liner in parent bore ........................................................ 0.025/0.076 mm (0.003/0.001 in)
Inside diameter of partially machined liner ........................................ 99.162/99.415 mm (3.9040/3.9139 in)

Preliminary bore
Final size of liner before it is honed .................................................. 99.873/99.924 mm (3.9320/3.9340 in)
Surface finish ....................................................................................................... Ra 3.2 to 4.0 micrometers
Maximum ovality and taper ........................................................................................... 0.02 mm (0.0008 in)
 EM11-16-11
GENERAL DESCRIPTION WX90

Diamond hone
Hone angle (cross hatch) ......................................................................................................................... 35°
Finish size, diamond honed ........................................................................................ 99.95 mm (3.9350 in)
Surface finish ....................................................................................................... Ra 2.2 to 3.0 micrometers
Maximum ovality and taper ......................................................................................... 0.012 mm (0.0005 in)

Silicone carbide base hone

Hone angle (cross hatch) ......................................................................................................................... 35°
Finish size, silicon carbide base hone .................................................................... 100.012 mm (3.9374 in)
Surface finish ....................................................................................................... Ra 1.3 to 1.6 micrometers
Maximum ovality and taper ......................................................................................... 0.010 mm (0.0004 in)

Silicone carbide plateau hone

Final finish size, silicon carbide (plateau hone) ...................................................... 100.017 mm (3.9376 in)
Final surface finish grade ............................................................................................. 0.65/1.3 micrometers

16.5.3 CYLINDER BORE SPECIFICATIONS, ENGINE TYPE AR

NOTE: Two oversize pistons are available in service:- 0.5 mm (0.020 in) and 1.0 mm (0.040 in).

CAUTION: Specialist training and equipment is needed to machine the cylinder bore. For further information
contact your nearest CASE Distributor.

Preliminary bore
Final size of standard bore before it is honed ............................... 102.873/102.924 mm (4.0501/4.0521 in)
First oversize of bore before it is honed ........................................ 103.373/103.424 mm (4.0698/4.0718 in)
Second oversize of bore before it is honed................................... 103.873/103.924 mm (4.0894/4.0914 in)
Surface finish ....................................................................................................... Ra 3.2 to 4.0 micrometers
Maximum ovality and taper ........................................................................................... 0.02 mm (0.0005 in)

Diamond hone

Hone angle (cross hatch) ......................................................................................................................... 35°

Finish size of standard bore, diamond honed .............................. 102.949/102.961 mm (4.0531 /4.0536 in)
Finish size of first oversize of bore, diamond honed .................... 103.449/103.461 mm (4.0727 /4.0732 in)
Finish size of second oversize of bore, diamond honed .............. 103.949/103.961 mm (4.0924 /4.0929 in)
Surface finish ....................................................................................................... Ra 2.2 to 3.0 micrometers
Maximum ovality and taper ......................................................................................... 0.012 mm (0.0005 in)

Silicone carbide base hone

Hone angle (cross hatch) ......................................................................................................................... 35°

Finish size of standard bore, silicon carbide base hone .............. 103.000/103.025 mm (4.0551 /4.0561 in)
Finish size of first oversize of bore, silicon carbide honed ........... 103.500/103.525 mm (4.0748 /4.0757 in)
Finish size of second oversize of bore, silicon carbIde honed ..... 104.000/104.025 mm (4.0944 /4.0954 in)
Surface finish ....................................................................................................... Ra 1.3 to 1.6 micrometers
Maximum ovality and taper ......................................................................................... 0.010 mm (0.0004 in)

Silicone carbide plateau hone

15501 9-35990

Final finish size of standard bore,

silicon carbide (plateau hone) ...................................................... 103.000/103.025 mm (4.0551 /4.0561 in)
Final finish size of first oversize of bore,
silicon carbide (plateau hone) ...................................................... 103.500/103.525 mm (4.0748 /4.0757 in)
Final finish size of second oversize of bore,
silicon carbide (plateau hone) ...................................................... 104.000/104.025 mm (4.0944 /4.0954 in)
Final surface finish grade ....................................................................................... Ra 0.65/1.3 micrometers
 EM11-16-12
GENERAL DESCRIPTION WX90

NOTES:

15501 9-35990
 EM11-17-1
ENGINE TIMING WX90

17. ENGINE TIMING

17.1 GENERAL DESCRIPTION

To reach the accurate fuel injection needed for

engines to conform to emissions legislation, the
latest fuel injection pumps operate at a static
timing very close to TDC.

The timing gears are stamped with timing marks

to ensure that they are assembled correctly (A).
The marked teeth of the crankshaft, the camshaft
and the fuel pump gears will be in mesh with the
idier gear when number 1 piston is close to top
dead centre (TDC) on the compression stroke.
The marked teeth of the idler gear may not
necessarily be in mesh in this position, because
of the different speeds at which the gears rotate.

The fuel injection pump is timed at TDC on the

compression stroke of number 1 cylinder. It is
important that fuel injection timing is accurate to
conform to emissions legislation. Always use
operations, 17A-01A or B to obtain TDC on the
compression stroke of number 1 cylinder
accurately.

CAUTION: The fuel injection pump has a lock

screw (B1) which locks the shaft. It is important
that the lock screw is released and the pump
shaft is free to turn. The drive shaft of the pump
must not be rotated without the spacer (B2) in
position under the locking screw. If the drive shaft
is rotated with the locking screw tightened on to
the shaft, the drive shaft will be damaged.
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 EM11-17-2
ENGINE TIMING WX90

The latest fuel injection pumps have a hub (A2)

which is mounted permanently onto the drive
shaft.

The manufacturer fits the hub to the pump to

ensure very accurate timing. Engines that have
this arrangement have the drive gear fastened to
the hub instead of to the shaft of the pump. A pin
(A1) is used to accurately time these pumps in
service.

CAUTION: Do not release the nut (A3) from the

fuel injection pump. Illustration (B) shows the nut
(B2) in position when the fuel pump is fitted to the
engine. The fuel pump hub is fitted to the shaft in
the factory to ensure that the fuel pump is in the
correct position for timing. If the nut is removed
and the hub moves, the hub will need to be
accurately fitted to the pump by use of specialist
equipment before the pump can be fitted to the
engine.

The fuel pump gear is fastened to the hub of the

fuel pump by four setscrews. The setscrews pass
through slots in the gear which allow removal of
the backlash.

NOTE: On the latest engines with belt driven

coolant pumps, four tamper proof fasteners retain
the fuel pump gear. Special tools are needed to
remove these fasteners, refer to your CASE
distributor.

To remove the fuel injection pump from the engine

it is only necessary to remove the four setscrews
(B1) which secure the fuel pump gear to the hub,
see operation 20A-06.

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 EM11-17-3
ENGINE TIMING WX90

17.1.1 TO SET NUMBER 1 PISTON TO TDC ON THE

COMPRESSION STROKE 17A-01A

Special tools:
Valve spring compressor, PD.611 8B
Stud adaptor for use with PD.611 8B, PD.6118B-7
Setscrew adaptor for use with PD.611 8B, PD.61
18B-8

1 Fasten a temporary pointer to the timing case

cover with its tip near to the outer edge of the
crankshaft pulley or damper (A1).

2 Loosen the gland nuts that retain the atomisers,

see operation 20A-02.

3 Remove the rocker cover, operation 12A-01.
4 Rotate the crankshaft, clockwise from the
front, until the push rod for the inlet valve of the
rear cylinder just tightens.
9 Rotate the crankshaft approximately 45°
5 Remove the spring clip and the spacer from
the front of the rocker shaft. Release the
fasteners of the front two pedestals of the
rocker shaft and remove the front rocker lever;
tighten the fasteners of the rocker shaft
pedestals.
another mark on the pulley or damper to
align with the pointer. Mark the centre point
between the two marks on the pulley or
damper and remove the other two marks.
counter clockwise from the front and then
clockwise until the mark on the pulley or
damper is aligned with the pointer. Number
1 piston is now at TDC on the compression
stroke.

6 Remove the valve springs from the front valve

with the valve spring compressor PD.6118B
and the adaptor PD.6118-7, for pedestal studs,
or the adaptor PD.6118-8, for pedestal
setscrews.

CAUTION: Fit a suitable collar near the top

of the valve to hold the valve if the crankshaft
is rotated too far.

7 Allow the valve to be held by the top of the

piston.

8 Fasten a dial test indicator with its plunger in

contact with the top of the valve stem (A2) and
with a reading shown on the gauge. Rotate
slowly the crankshaft, clockwise from the front,
until the clockwise movement of the dial gauge
pointer just stops. Make a suitable mark on the
crankshaft pulley or damper to align with the
temporary pointer.
15501 9-35990

Continue to rotate the crankshaft, in the same

direction, until the gauge pointer just begins to
move in a counter-clockwise direction. Make
 EM11-17-4
ENGINE TIMING WX90

Another method to set number 1 piston to TDC on the compression stroke 17A-01B

1 Fasten a temporary pointer to the timing case cover (or other suitable position) with its tip near to the outer
edge of the crankshaft damper or pulley.
2 Loosen the gland nuts that retain the atomisers, see operation 20A-02.
3 Remove the rocker cover.
4 Rotate the crankshaft clockwise, from the front, until the push rod for the inlet valve of the rear cylinder just
tightens.
5 Rotate the crankshaft a further 1/8 of a turn clockwise. Insert a suitable lever between the rocker lever and
the valve spring cap of number 1 inlet valve. Open the inlet valve and put a spacer approximately 5.0 mm
(0.2 in) thick between the valve tip and the rocker lever.
6 Slowly rotate the crankshaft counter-clockwise until the piston makes contact with the open valve. Make
a temporary mark on the damper or pulley to align accurately with the tip of the pointer.
7 Rotate the crankshaft clockwise one or two degrees and remove the spacer between the valve and the
rocker lever. Rotate the crankshaft 1/4 of a turn counter-clockwise. Put the spacer between the valve tip
and the rocker lever.
8 Slowly rotate the crankshaft clockwise until the piston makes contact with the open valve. Make another
temporary mark on the damper or pulley to align accurately with the tip of the pointer.
9 Make a temporary mark at the centre point between the two marks on the damper or pulley and remove
the other two marks. Rotate the crankshaft counter-clockwise 1/8 of a rotate and remove the spacer
between the valve and the rocker lever. Slowly rotate the crankshaft clockwise until the mark on the damper
or pulley aligns accurately with the tip of the pointer. Number 1 piston is now at TDC on the compression
stroke.

To check the valve timing 17A-02

1 Set the piston of number 1 cylinder to TDC on the compression stroke, operation 17A-01A.
2 Remove the dial test indicator from number 1 inlet valve and fit the valve springs and the rocker lever.
Ensure that the fasteners for the rocker shaft pedestals are to the correct torque.
3 Rotate the crankshaft, clockwise from the front, until the inlet valve of the rear cylinder is fully open.
4 Set the valve tip clearance of number 1 cylinder inlet valve to 1.5 mm (0.059 in).
5 Rotate the crankshaft, clockwise from the front, until the push rod of number 1 cylinder inlet valve just
tightens. In this position, check if the mark on the crankshaft pulley or damper is within +/- 2 1/2° of the
temporary pointer. Use the formula below to find the measurement which is equal to 2 1/2° on the pulley
or damper.

CxP
360

C = circumference of pulley or damper

P = 2.5 degrees

6 If the timing is more than 2 1/2° out of position, the timing gears are probablely not in correct mesh.

NOTE: One tooth on the camshaft gear is equivalent to 23 mm (0.9 in) at the circumference of a pulley of
203 mm (8 in) diameter. If a large damper is fitted, one tooth on the camshaft gear is equivalent to 35 mm
(1.4 in) at the circumference of a damper of 310 mm (12.2 in) diameter, or 37 mm (1.5 in) at the circumference
of a damper of 327 mm (12.8 in) diameter.

7 Rotate the crankshaft, clockwise from the front, until the inlet valve of the rear cylinder is fully open. Set
15501 9-35990

the valve tip clearance of the inlet valve of number 1 cylinder to 0.20 mm (0.008 in).
8 Fit the rocker cover, operation 12A-01.
9 Remove the temporary pointer from the timing case and the timing mark from the pulley or damper.
 EM11-17-5
ENGINE TIMING WX90

To check the timing of the fuel

injection pump 17A-03

Special tools:
Timing pin PD.246, Lucas fuel injection pumps

CAUTION: Do not remove the nut (A2) which

retains the hub (A4) to the shaft of the fuel
injection pump. The hub is fitted permanently to
the shaft. If the hub is moved, it will be necessary
for a fuel injection pump specialist to correctly
position the hub on the shaft with special test
equipment available to CASE distributors.

1 Set the piston of number 1 cylinder to TDC on

the compression stroke, operation 17A-01A
or B.

2 Remove the gear cover from the cover of the

timing case. For gear driven coolant pumps:
Remove the coolant pump, operation 21A-
02A.

NOTE: On the latest engines with belt driven

coolant pumps, four tamper proof fasteners retain
the fuel pump gear. Special tools and personnel
with the correct training are necessary to remove
these fasteners, refer to your nearest CASE
distributor.

3 Insert the timing pin (A1) through the hole (A5)

in the fuel pump gear and the slot of the hub
(A4). Push the pin fully into the hole (A3) in the
body of the fuel pump. If the pin can be fully
inserted then the pump timing is correct. There
should be no resistance when the pin is
inserted.

NOTE: The position for the timing pin for Lucas

fuel injection pump is (A1).

4 Remove the timing pin.

5 If the timing pin cannot be pushed into the

pump body, check that the engine is correctly
set at TDC on the number 1 cylinder
compression stroke, operation 1 7A-01A or B.

If the engine is set correctly at TDC on the

number 1 cylinder compression stroke, but
15501 9-35990

the pin does not fit into the hole, the fuel pump
must be removed and set by a specialist.

6 Fit the gear cover to the cover of the timing

case. For gear driven coolant pumps: Fit the
coolant pump, operation 21A-02A.
 EM11-17-6
ENGINE TIMING WX90

17.2 DATA AND DIMENSIONS

NOTE: This information is given as a guide for personnel engaged on engine overhauls. The dimensions
which are shown are those which are mainly used in the factory. The information applies to all engines,
unless an engine type code is shown.

17.2.1 FUEL SYSTEM

Lucas fuel injection pump

Make .......................................................................... Lucas DP200 Series, pin timed, with a locking screw
Direction of rotation ............................................................................................... Clockwise from drive end

15501 9-35990
 EM11-19-1
LUBRICATION SYSTEM WX90

19. LUBRICATION SYSTEM

19.1 FILTER CANISTER

To renew 19A-01

WARNING! Discard the used canister (B4) and

lubricating oil in a safe place and in accordance
with local regulations.

CAUTION: The canister contains a valve and

special tube to ensure that lubricating oil does not
drain from the filter. Therefore, ensure that the
correct CASE canister is used.

The filter can have one or two canisters (B4) or

(A1) fitted. When two canisters are fitted, both
must be renewed at the same time. On some
engines an oil cooler (B2) is fitted to the filter
head. This arrangement is fitted on the left side or
the right side of the engine.

On some four and six cylinder engines the adaptor

(A2) or (B1) is sealed into the filter head. A new
filter head is supplied without the adaptor fitted; if
either the adaptor or the filter head is to be
renewed, both parts will be necessary.

1 Put a tray under the filter to contain spilt

lubricating oil.

2 Remove the filter canister with a strap wrench

or a similar tool and then discard the canister.

NOTE: If the adaptor is to be renewed, insert the

end of the adaptor, which has the thread sealant
applied during manufacture, into the filter head.
3 Clean the seal face of the filter head (A3).
CAUTION: Ensure that the adaptor (A2) or (B1)
is secure in the filter head.
4 Add clean engine lubricating oil to the new
canister. Give the oil time to fill the canister
through the filter element.
5 Lubricate the top of the canister seal (B3) with
clean engine lubricating oil.
engine will not start and operate the starter
motor until oil pressure is obtained. To ensure
that the engine will not start, either put the
manual stop control in the “stop” position or
disconnect the electrical stop control of the
fuel injection pump. Oil pressure is indicated
when the warning light is extinguished or by
a reading on the gauge.
7 After the lubricating oil has been added to
the sump, operate the engine and check for
leakage from the filter. When the engine has
cooled, check the oil level on the dipstick
and add oil to the sump, as necessary.

6 Install the new canister and tighten it by hand

15501 9-35990

only. Do not use a strap wrench.

For turbocharged engines: Ensure that the

 EM11-19-2
LUBRICATION SYSTEM WX90

19.2 FILTER HEAD

To remove and to fit 19A-02

Consumable products: Nutlock, Loctite 242E

1 Put a tray under the filter head to contain spilt

lubricating oil.

2 Remove the filter canister(s), operation 19A-

01.

3 Remove the canister type oil cooler from the

filter head, if one is fitted, operation 21A-07C.

4 Remove the flexible pipes from the filter head,

if they are fitted, operation 19A-11.

5 Release the setscrews and remove the filter

head (A) from the cylinder block. Discard the
joint (A3).

6 Clean the joint face of the filter head (A4) and

the cylinder block.

7 Fit the new joint to the filter head, the joint is

fitted dry.

NOTE: Some engines have an adaptor (A1)

between the cylinder block and the filter head. If
an adaptor is used, two joints are fitted (A2) and
(A3).

Apply nutlock to the first three threads of the

setscrews and tighten the setscrews.

8 Fit the oil cooler to the filter head. If a canister

type oil cooler is fitted, see operation 21A-
07C.

9 Fit the flexible pipes to the filter head, if they

are fitted, operation 19A-11.

10 If the oil cooler is integral with the cylinder

block, fit a new joint to the flange of the oil
cooler pipes. Fit the flange to the filter head
and tighten the setscrews.

11 Fit a new filter canister, operation 19A-01.

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 EM11-19-3
LUBRICATION SYSTEM WX90

19.3 SUMP

To remove and to fit 19A-03

WARNING! Discard the used lubricating oil in a

safe place and in accordance wilh local
regulations.

1 Operate the engine until it is warm.

2 Stop the engine, remove the sump drain plug

(B1) and its “O” ring and drain the oil. Where
necessary, remove the dipstick and the dipstick
tube.

3 Provide a support for the sump and remove

the setscrews and the two nuts which fasten
the sump to the cylinder block and to the
timing case. Lower the sump and remove the
joint.

4 Wash the sump with an approved cleaning

fluid, ensure all the cleaning fluid is removed.
Clean the flange face of the sump and of the
cylinder block. If necessary, renew the felt
dust seal which is fitted to the rear of the sump
flange on some engines.

5 Fit the sump together with a new joint and

ensure the correct location with a setscrew on
each side. Fit the remainder of the setscrews
and the nuts and tighten all the fasteners to 22
Nm (16 Ibf ft) 2,2 kgf m. Fit the drain plug
together with a new “O” ring and tighten the
plug to 34 Nm (25 Ibf ft) 3,5 kgf m. Where 1 Remove the sump, operation 19A-03.
necessary, fit the dipstick tube and the dipstick.
2 Release the setscrew which holds the
Fill the sump to the mark (B2) on the dipstick bracket to the main bearing cap (A2).
with new and clean lubricating oil of an
approved grade. 3 Release the setscrews from the flange of
the suction pipe (A1). Remove the suction
19.4 OIL STRAINER AND SUCTION PIPE pipe and strainer. Remove and the old joint
or the “O” ring. Clean the flange face of the
To remove and to fit 19A-04 oil pump and of the suction pipe.

The oil strainer is an integral part of the suction
pipe. No regular service is necessary but wash
the strainer when it is removed. On four cylinder
engines which have a balancer fitted, the suction
pipe is normally a short pipe which is fastened to
the balancer frame and a pipe bracket is not
15501 9-35990
4 Loosely assemble the bracket of the suction
pipe to the correct main bearing cap. Fit the
suction pipe to the oil pump together with a
new joint or an “O” ring. Tighten the
setscrews. Tighten the setscrew of the
suction pipe bracket. If the clamp type

fitted. bracket, used on some four cylinder engines,

Some four cylinder engines have an oil strainer
and suction pipe which are made of a composite
material. This arrangement has an “O” ring seal
on the flange face of the oil pump instead of a
joint.
has been removed, ensure that the clamp,
the bracket and the pipe are correctly aligned
before the setscrews are tightened. Ensure
that there is no stress on the suction pipe.
5 Fit the sump, operation 19A-03.
 EM11-19-4
LUBRICATION SYSTEM WX90

To inspect and to correct 19A-05

1 Wash the assembly in an approved cleaning

fluid and dry it thoroughly.

2 Check the pipe, the strainer and the welded

joints for cracks and other damage. Check
that the mounting bracket is secure.

3 If the damaged component cannot be welded

correctly, renew the assembly.

4 Composite material parts must be renewed if

they have cracks or damage.

19.5 LUBRICATING OIL PUMP

To remove and to fit 19A-06

For four cylinder engines fitted with a balancer

unit, the oil pump is integral with the balancer unit,
see group 14 for removal instructions.

The lubricating oil pump has a channel (B1) in the

body of the pump. Lubricating oil from the front
main bearing passes down the channel in the
body of the pump to an oil hole in the idler shaft.
The lubricating oil then passes through the hole
in the idler shaft to the bush in the idler gear.

19.5.1 TO REMOVE

1 Drain the lubricating oil and remove the

lubricating oil sump, operation 19A-03.

2 Remove the suction pipe and strainer,

operation 19A-04.

3 For four cylinder engines: Remove the oil

pressure relief valve, operation 19A-08, and
the delivery pipe.

4 The oil pump is fitted to number 1 main bearing

cap. The oil pump can be removed with the
main bearing cap, if a suitable spanner is
available that will enable the torque to be
applied correctly to the setscrews of the main
bearing cap when it is fitted. If a suitable
spanner is not available, the timing case must
be removed, operation 15A-07.
15501 9-35990

5 Release the circlip which retains the idler gear

of the oil pump and remove the washer (A1)
and the idler gear (A2).

6 Release the setscrews and remove the oil

pump (B).
 EM11-19-5
LUBRICATION SYSTEM WX90

19.5.2 TO FIT

1 Fill the oil pump with clean engine lubricating

oil. Fit the oil pump to the main bearing cap
and tighten the setscrews to 22 Nm (16 Ibf ft)
2.2 kgf m.

2 Check the idler gear and the bush for wear

and other damage. If the gear and/or bush are
damaged, they can be renewed as an
assembly or the bush can be renewed as a
single item. Check the shaft of the idler gear
for wear or other damage. If the shaft is worn
or damaged, renew the shaft, operation 19A-
06A. Lubricate the bush (A3) with clean engine
lubricating oil and fit the idler gear (A2), the
washer (A1) and the circlip. Check that there
is a minimum of 0.076 mm (0.003 in) backlash
between the oil pump gear and the idler gear
(B)

3 If number 1 main bearing cap was removed,

lubricate the bearing with clean engine
lubricating oil and fit the bearing cap. Tighten
the setscrews to 265 Nm (196 Ibf ft) 27.0 kgf
m. If the timing case was removed, fit the
timing case, operation 15A-07. Check that
there is a minimum of 0.076 mm (0.003 in)
backlash between the oil pump idler gear and
the crankshaft gear.

The end-float for the idler gear is as follows:

• Four cylinder engines 0.012/0.643 mm

(0.0005/0.0253 in)

4 Fit the suction pipe and strainer, operation

19A-04.

5 For four cylinder engines: Fit the delivery pipe

and oil pressure relief valve, operation 19A-
08.

6 Fit the lubricating oil sump, operation 19A-03.

15501 9-35990
 EM11-19-6
LUBRICATION SYSTEM WX90

To renew the shaft

for the idler gear 19A-06A

Consumable products:
Retainer (oil tolerant) Loctite 603

19.5.3 TO FIT THE IDLER SHAFT (WHERE A PIN

WAS NOT FITTED)

1 Follow the procedure to fit the idler shaft,

paragraphs 1 and 2.

2 Put the drill guide (A1) into position in the right

hand (seen from the front face of the bearing
cap) setscrew hole of the bearing cap. Ensure
that the countersink in the guide faces to the
outside and that the edge of the guide is
aligned with the front edge of the bearing cap.
Use a 5/16 UNF setscrew (A3) and a plain
washer (A2) to retain the guide in position.

3 Drill a 6.35 mm (0.25 in) diameter hole in the

bearing cap 25.4 mm (1.0 in) deep.

4 Remove the drill and the drill guide.

5 Fit a pin, part number 2116087, into the bearing

cap and idler shaft.

19.5.4 TO REMOVE AND TO FIT THE IDLER

SHAFT

- For four cylinder engines:

1 Support the front of the bearing cap. Put a

suitable adaptor on the small diameter of the
idler shaft and press the idler shaft out of the
bearing cap.

2 Ensure that the idler shaft and the hole in the

bearing cap are clean. Support the rear of the
bearing cap and ensure that the cap will not
move when the idler shaft is pressed in. Apply
Retainer to the small diameter of the idler
shaft. The idler shaft for four cylinder engines
is not retained by a pin.

If the idler shaft (B3) has an oil hole ensure

that the hole (B2) in the idler shaft is at the top
and that the flat (B1) is at the bottom before
the shaft is pressed into the bearing cap.
15501 9-35990

Enter the chamfer of the idler shaft into the

hole. Ensure that the idler shaft is square to
the bearing cap and press in the shaft onto its
shoulder. Remove the surplus Retainer.
 EM11-19-7
LUBRICATION SYSTEM WX90

To inspect 19A-07

If any part is worn enough to have an effect on the

performance of the oil pump, the complete oil
pump must be renewed.

1 Release the setscrews and remove the cover

of the oil pump. For pumps which are fitted to
a balancer unit, remove the single setscrew
and the cover.

2 Remove the outer rotor and clean thoroughly

all the parts. Check for cracks and any other
damage.

3 Fit the outer rotor and check the outer rotor to

body clearance (A).

4 Check the inner rotor to outer rotor clearance

(B).

5 Check the rotor end-float with a straight edge

and a feeler gauge (C). For all the above
clearances, see the data and dimensions.

6 Clean the top face of the oil pump and the

bottom face of the cover and fit the cover.
Tighten the setscrews to 28 Nm (21 Ibf ft) 2.9
kgf m. For pumps which are fitted to a balancer
unit, put the cover in position and tighten the
single setscrew to 22 Nm (16 Ibf ft) 2.2 kgf m.
15501 9-35990
 EM11-19-8
LUBRICATION SYSTEM WX90

19.6 RELIEF VALVE

To remove and to fit 19A-08

Four cylinder engines that have a balancer unit

have a relief valve fitted inside the balancer
frame. The relief valve of these engines cannot
be removed as an assembly.

1 Drain the lubricating oil and remove the sump,

operation 19A-03.

2 For four cylinder engines: Release the

setscrew and rotate the relief valve to withdraw
the thimble from the cylinder block (A1). Pull
the relief valve from the delivery pipe and pull
the delivery pipe from the oil pump. Renew the
“O” rings (A2). Lightly lubricate the “O” rings
with clean engine lubricating oil and push the
delivery pipe into the oil pump. Push the relief
valve onto the delivery pipe and fit the relief
valve to the cylinder block; ensure that the
thimble is correctly fitted and tighten the
setscrew.

15501 9-35990
 EM11-19-9
LUBRICATION SYSTEM WX90

To dismantle and to assemble 19A-09

If necessary, the relief valve can be dismantled

and assembled while it is fitted to the engine.

1 Apply pressure to the end plate (A4 or B5) of

the spring assembly; release the circlip (A5)
or remove the pin (B1) and carefully release
the pressure to remove the end plate and the
spring (A3 or B4) from the valve body. Remove
the plunger (A2 or B3) from the bore of the
body (A1 or B2).

2 Ensure that all the components are cleaned

and then lubricated lightly with clean engine
lubricating oil.

3 Fit the plunger into the bore with its hollow end
to the inside. Fit the spring and the end cap
into the bore with the ends of the spring fitted
around the bosses of the plunger and the end
plate. Apply pressure to the end plate and fit
the circlip into its groove or fit the pin into the
holes in the balancer frame.

To inspect 19A-10

Do not try to change the operation pressure of the

relief valve by a method other than the installation
of new components.

1 Check the spring for wear and other damage

and, if possible, check the load necessary to
compress the spring to its fitted length, see
the data and dimensions.

2 Check the plunger for wear and other damage

and ensure that it slides easily in the bore of
the relief valve.

3 Check the body and the end plate for wear and
other damage.

4 Renew worn or damaged components.

15501 9-35990
 EM11-19-10
LUBRICATION SYSTEM WX90

19.7 DATA AND DIMENSIONS

NOTE: This information is given as a guide for personnel engaged on engine overhauls. The dimensions
which are shown are those which are mainly used in the factory. The information applies to all engines,
unless an engine type code is shown.

19.7.1 LUBRICATION SYSTEM

Lubricating oil pump - four cylinder engines

Type ................................................................................................................. Differential rotor, gear driven
Number of lobes ................................................................................................... Inner rotor 6, outer rotor 7
Clearance of outer rotor to body:
- Without balancer unit .................................................................................. 0.15/0.34 mm (0.006/0.013 in)
- With balancer unit ....................................................................................... 0.31/0.45 mm (0.012/0.017 in)
Clearance of inner rotor to outer rotor ....................................................... 0.04/0.13 mm (0.0015/0.0050 in)
End-float of rotor assembly ........................................................................... 0.03/0.10 mm (0.001/0.004 in)

Idler gear for lubricating oil pump

End float:
- Four cylinder engines ......................................................................... 0.012/0.642 mm (0.0005/0.0253 in)
Inside diameter of bush (fitted) ................................................................. 22.23/22.26 mm (0.875/0.866 in)
Outside diameter of idler shaft .................................................................. 22.19/22.21 mm (0.873/0.874 in)
Clearance of bush of idler gear on shaft ............................................... 0.020/0.066 mm (0.0008/0.0026 in)

Oil pressure relief valve (standard)

Diameter of bore for plunger ..................................................................... 18.24/18.27 mm (0.718/0.719 in)

Outside diameter of plunger ...................................................................... 18.16/18.18 mm (0.715/0.716 in)
Clearance of plunger in bore ......................................................................... 0.06/0.11 mm (0.002/0.004 in)
Length of spring (fitted):
- Four cylinder engines ....................................................................................................... 59.8 mm (2.4 in)
Load on spring (fitted):
- Four cylinder engines ............................................................................................ 5.9/23.1 N (1.6/2.4 kgf)

Pressure to open valve (Four cylinder engines):

- Without piston cooling jets ........................................................................... 340/395 kPa (3.4/4.0 kgf/cm2)
- With piston cooling jets ................................................................................ 415/470 kPa (4.2/4.8 kgf/cm2)

Oil pressure relief valve (with balancer)

Diameter of bore for plunger ..................................................................... 16.00/16.03 mm (0.630/0.631 in)

Outside diameter of plunger ...................................................................... 15.95/15.98 mm (0.628/0.629 in)
Clearance of plunger in bore ....................................................................... 0.02/0.08 mm (0.0008/0.003 in)
Length of spring (fitted) ....................................................................................................... 42.7 mm (1.7 in)
Load on spring (fitted) .................................................................................................. 34/38 N (3.5/3.9 kgf)
Pressure to open valve ............................................................................................... 523 kPa (5.3 kgf/cm2)

Oil filter

Type ........................................................................................................... Full flow, screw-on type canister

15501 9-35990

Pressure to open by-pass valve in filter ............................................................. 55/83 kPa (0.6/0.8 kgf/cm2)
Pressure to open by-pass valve in oil cooler .............................................................. 172 kPa (1.8 kgf/cm2)
 EM11-20-1
FUEL SYSTEM WX90

20. FUEL SYSTEM

20.1 GENERAL DESCRIPTION

CAUTIONS:
• The fuel injection equipment must only be
checked and adjusted by personnel who have
had the correct training.

• Do not clean an engine while it runs. If cold

cleaning fluids are applied to a hot engine,
certain components on the engine may be
damaged.

New 1000 Series engines are used for industrial

applications and use various fuel injection pumps,
more precisely Lucas (B).

All of the fuel pumps conform to emissions

legislation. Both the pump timing and the speed
adjustment are tamper proof.

All of the fuel injection pumps have mechanical

governors to control the engine speed.

Lucas fuel injection pump is equippedwith locking

screws (A2) and (B1) which lock the shaft. It is
important that the lock screw is released and
the pump shaft is free to turn when the pump is
fitted to the engine.

All of the fuel injection pumps have a pin timing

hole (A1), refer to group 17 for the correct method
to time the pump.

A data plate is fitted to the bracket of the fuel

injection pump. The data plate information is
shown below:

CASE part number

Fuel pump serial number
Manufacturer’s model number

The maximum no-load speed is shown on the

emissions data plate fitted to the left side of the
cylinder block.
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 EM11-20-2
FUEL SYSTEM WX90

20.1.1 LUCAS DP200 SERIES FUEL INJECTION

PUMP

Lucas DP200 Series fuel injection pumps are

fitted to naturally aspirated engines and
turbocharged engines.

These pumps have an electrically operated cold

start device (B3) which retards the timing for
normal operation. Another feature of this pump is
a stop solenoid (B2). These pumps are fitted with
a self-vent feature.

20.1.2 ATOMISERS

The atomisers, which are of the valve covered

orifice (VCO) type, have nozzles with five holes.
The atomisers inject fuel in a very fine spray into
the combustion chamber in the top of each piston.
Each atomiser is fastened to the cylinder head by
a gland nut.

The atomisers are set in the factory, but they must

be checked in accordance with the preventive
maintenance schedules. The pressure at which
atomisers operate can be adjusted by a change
of shims fitted above the spring.

For details of the atomiser setting pressures for

the engine, see the data and dimensions at the
end of this section.

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 EM11-20-3
FUEL SYSTEM WX90

20.1.3 COLD START ADVANCE UNIT

The Lucas rotary fuel injection pump is a cold start advance unit that holds the timing of the pump in an
advanced position when the engine is cold.

CAUTION: It is important that the electrical connections to the sender unit are connected correctly.
Failure of the starting aid to operate correctly could result in damage to the engine as the timing will be
fully advanced for normal operation.

The sender unit, for engines fitted with belt driven coolant pumps, is on the top of the thermostat housing.
The sender unit, for engines fitted with gear driven coolant pumps, is on the rear of the timing case on
the left side of the engine.

As the engine warms, the sender unit energises to retard the pump timing to the correct timing for normal
operation of the Lucas fuel injection pump.

NOTE: The wiring diagram on page EM 11-20-4 shows the sender unit (component 3) position when
the engine is cold.

To ensure that the engine conforms to the emissions legislation, it is important that the electrical
connections of the engine cold start advance unit are fitted correctly before the engine is operated.

CAUTION: Damage to the engine will occur if the engine is load tested at more than 80% of full load
with the cold start device disconnected.

Wiring diagram for the cold start advance unit

fitted to some Lucas DP200 Series fuel injection
pump. For easy identification the cables are
shown in circles on the illustrations.
The amperage of each of the cables is listed in
the cable identification table below.

The identification numbers for the electrical

components on the wiring diagram are shown
in triangles.
Refer to the component identification list for
the relevant wiring diagram to find a component.

Cable identification table Component identification list

For numbers shown in circles For numbers shown in triangles

Cable Current Component Description

(Number) (Amperes)
15501 9-35990

1 Fuel injection pump

1 3
2 Engine stop solenoid
2 3
3 Sender unit
3 6
F8470gb 4 Start switch
5 Cold start advance unit
F8471gb
 EM11-20-4
FUEL SYSTEM WX90

20.1.4 TYPICAL FUEL SYSTEM (FOUR CYLINDER ENGINES)

Fuel systems vary from application to application, this information is provided for training purposes only.

Fuel (A9) from the tank (A2) leaves the pre-filter (A4) and then passes to the diaphragm type lift pump
(A1), which is driven by an eccentric on the camshaft.
Fuel leaves the lift pump under pressure and passes through a full flow filter (A5) to the fuel injection
pump (A8).

Some fuel injection pumps have a self-vent pipe (A7) to remove air from the fuel system back into the
fuel tank.
The fuel in the injection pump also lubricates and cools the pump. A fuel heater or cooler may be fitted
between the filter head and filter canister. The pump has a mechanical governor to control the engine
speed.

The pumps also have an electrical stop solonoid and an electrically operated cold start advance unit
fitted.

The fuel injection pump increases the fuel pressure and injects high-pressure fuel at the correct time and
sequence through pipes to the atomisers (A11). A fuel leak-off rail is fitted to the top of each atomiser
and leak-off fuel (A10), used to lubricate the atomisers, is returned to the fuel tank through a pipe (A3).

2
15501 9-35990

8 7 6 5 4 F9317

10
 EM11-20-5
FUEL SYSTEM WX90

20.2 FUEL FILTERS

CAUTIONS:

• It is important that only the genuine CASE parts

are used. The use of a wrong canister or
element can damage the fuel injection pump.

• The pre-filter and main filter canisters must be

renewed at the same time.

• Do not allow dirt to enter the fuel system. Before

a connection is disconnected, clean thoroughly
the area around the connection. After a
component has been disconnected, fit a suitable
cover to all open connections.

There are three types of fuel filter element in use:

The separate element type (A2) where the filter

element is held between the filter head (A1) and
the bottom cover (A3). The filter can have two
elements (A).

The canister type where the filter element has an

internal thread at the top (B2) and is fastened to
a threaded adaptor in the filter head (B1).
15501 9-35990
 EM11-20-6
FUEL SYSTEM WX90

To renew 20A-01

WARNING! Discard the used canister and fuel

oil in a safe place and in accordance with local
regulations.

CAUTIONS:

• It is important that only the genuine CASE parts

are used. The use of a wrong canister or element
can damage the fuel injection pump.
• Do not allow dirt to enter the fuel system. Before
a connection is disconnected, clean thoronghly
the area around the connection. After a
component has been disconnected, fit a suitable
cover to all open connections.

20.2.1 SEPARATE ELEMENT TYPE

1 Clean the outside surfaces of the fuel filter

assembly. If a drain tap is fitted to the bottom
of the filter bowl, drain the fuel from the filter.

2 Hold the bottom cover of the filter element and

release the setscrew (A3) which is fitted
through the filter head (A1) above the centre
of the element.

3 Lower the bottom cover of the filter.

4 Remove the element (A4) and discard it.

5 Clean the inside surfaces of the filter head and

of the cover.

6 Renew the seals (A2) and (A5) and lightly

lubricate them with clean fuel.

7 Put the bottom cover under the new element

and hold the element squarely to the filter
head. Ensure that the element is fitted in the
centre against the joint in the filter head. With
the assembly in this position, engage and
tighten the setscrew.

8 Eliminate the air from the fuel filter, operation

(s) 20A-08A/B/C.
15501 9-35990
 EM11-20-7
FUEL SYSTEM WX90

20.2.2 CANISTER TYPE

WARNING! Discard the used canister and fuel

oil in a safe place and in accordance with local
regulations.

CAUTIONS:
• It is important that only the genuine CASE parts
are used. The use of a wrong canister or element
can damage the fuel injection pump.

• Do not allow dirt to enter the fuel system. Before

a connection is disconnected , clean thorunghly
the area around the connection. After a
component has been disconnected, fit a suitable
cover to all open connections.

1 Thoroughly clean the outside surfaces of the

fuel filter assembly.

2 Loosen the drain device at the bottom of the

filter (A1) and allow the water/ fuel to drain into
a suitable container.

3 Use a strap wrench or similar tool to loosen

the filter canister and remove the canister.

4 Ensure that the threaded adaptor (B1) is

secure in the filter head and that the inside of
the head is clean.

5 Lubricate lightly the top seals (B2) of the new

canister with clean fuel. Fit the new canister to
the filter head and tighten, by hand only.

6 Eliminate the air from the fuel filter, operation(s)

20A-08A/B/C.
15501 9-35990
 EM11-20-8
FUEL SYSTEM WX90

20.3 ATOMISERS

Atomiser fault

Regular maintenance of the atomisers is not

necessary. The atomiser nozzles should be
renewed and not cleaned, and renewed only if an
atomiser fault occurs. The major problems that
may indicate that new nozzles are needed are
listed below:

Engine will not start or is difficult to start

Not enough power

Engine misfires or runs erratically

High fuel consumption

Black exhaust smoke

Engine knocks or vibration

Excessive engine temperature

WARNINGS!

• If your skin comes into contact with high pressure

fuel, obtain medical assistance immediately.

• Keep away from moving parts during engine

operation. Some moving parts cannot be seen
clearly while the engine runs.
In order to find which atomiser is defective, ope-
rate the engine at a fast idle speed. Loosen and
tighten the union nut of the high-pressure fuel
pipe at each atomiser. Do not loosen the union
nut more than half a turn. When the union nut of
the defective atomiser is loosened, there is little
or no effect on the engine speed.
2 Remove the union nuts of the high-pressure
pipe from the atomiser and from the fuel
injection pump. Do not bend the pipe. If
necessary, remove the pipe connection. Fit
a plastic cap (A1) to cover the fuel inlet
connection and the nozzle.
3 Release the gland nut (A3) and remove the
atomiser and its seat washer from the recess
in the cylinder head.

To remove and to fit 20A-02

Consumable products:
Atomiser thread sealant, Hylomar Advance
Formulation

20.3.1 TO REMOVE

CAUTION: Do not allow dirt to enter the fuel

15501 9-35990

system. Before a connection is disconnected,

clean thoroughly the area around the connection.
Affer a component has been disconnected, fit a
suitable cover to all open connections.

1 Remove the fuel leak-off pipe from the

connection (A2).
 EM11-20-9
FUEL SYSTEM WX90

20.3.2 TO FIT

1 Thoroughly clean the threads of the gland nut

(A3) and the cylinder head.

CAUTION: Do not allow any thread sealant to

get below the gland nut threads.

2 Ensure that the wire clip (A4) is in position. Put

a 2 mm (0.08 in) bead of atomiser thread
sealant onto the first two threads of the gland
nut. The bead should extend approximately 6
mm (0.24 in) around each of the threads.
Ensure that the sealant does not contact the
body of the atomiser.

CAUTION: Remove and discard the original seat

washer (A6). If the original seat washer remains
in the recess for the atomiser, the nozzle
protrusion will be incorrect when a new seat
washer is added.

Put the new seat washer (A6) into the seat recess
in the cylinder head.

Put the atomiser in position, ensure that the

location ball (A7) is fitted in the groove (A5)
correctly. Carefully engage the threads of the
gland nut (A3) with the threads in the cylinder
head.

CAUTION: Do not move the thread after it has 3 Remove the plastic cap (A1) and fit the high
been tightened, the seal that is made when torque pressure fuel pipe and tighten the union
has been applied will be broken and leakage past nuts to 22 Nm (16 Ibf ft) 2.2 kgf m. If
the atomiser seat may occur. necessary, fit the pipe connections.

Tighten the nut gradually and evenly to 40 Nm (30 4 Renew the sealing washers and fit the leak-
Ibf ft) 4.1 kgf m. As the nut is tightened the off pipe to the leak off connection (A2).
atomiser will rotate clockwise as the ball moves in Tighten the banjo bolt to 9.5 Nm (7.0 Ibf ft)
the slot, this is acceptable. Remove any excess 1.0 kgf m.
thread sealant.
5 Operate the engine and check for leakage
CAUTION: Do not tighten the union nuts of the of fuel and air.
high pressure pipes more than the recommended
torque tension. If there is a leakage from the union
nut, ensure that the pipe is correctly aligned with
the atomiser inlet. Do not tighten the atomiser
union nutnore, as this can cause a restriction at
the end of the pipe. This can affect the fuel
delivery.
15501 9-35990
 EM11-20-10
FUEL SYSTEM WX90

20.4 FUEL LIFT PUMP

To remove and to fit 20A-03

Consumable products: Nutlock, loctite 242E

1 If a heat shield is fitted, remove it. Disconnect

the fuel pipes from the fuel lift pump.

2 Release the setscrews, remove the fuel lift

pump (A). The lift pump may be difficult to
remove from the engine. If this occurs, the
crankshaft must be rotated until the camshaft
eccentric, which operates the lift pump, is in a
position that will free the rocker lever of the lift
pump.

3 Ensure that the camshaft eccentric is in the

minimum lift position before the lift pump is
fitted. Clean the joint face of the lift pump (A2)
and the cylinder block and fit the lift pump
together with a new joint (A1). Apply Nutlock
to the first three threads of the setscrews and
tighten them gradually and evenly to 22 Nm
(16 Ibf ft) 2.2 kgf m.

4 Connect the fuel pipes and, if necessary, fit

the heat shield.

5 Release the vent screw on the fuel filter head

and operate the priming lever of the fuel lift
pump to eliminate any air between the lift
pump and the fuel filter. Operate the lift pump
until fuel, free of air, comes from the vent
screw. Tighten the vent screw.

6 Operate the engine and check for any fuel or

air leakage.
15501 9-35990
 EM11-20-11
FUEL SYSTEM WX90

To dismantle and to assemble 20A-04

20.4.1 TO DISMANTLE

1 Clean the outside surfaces of the fuel lift

pump.

2 Make a mark across the flanges of the two

halves of the pump to ensure correct
relationship when the pump is assembled.

3 Remove the cover (A1) and the gauze (A2).

Release the setscrews and separate the two
halves of the pump.

4 Turn the diaphragm assembly (A5) 90° to

release the pull rod from the link arm (A8) and
remove the diaphragm assembly. Remove
the stem seal (A6), the spring seat washer
(A7) and the spring (A12) from the pull rod.
The diaphragm and pull rod assembly is
renewed as an assembly and no service is
possible on the diaphragm.

5 The valves (A4) are peened in and can be

removed with a suitable lever. Some of the
peened metal will have to be removed before
the valves can be removed.

6 To remove the link arm: Hold the rocker lever 3 With a light hammer and a suitable adaptor,
(A11) in a vice and hit the body of the lift pump fit two new retainers (A10) in their grooves
with a soft face hammer to release the two in the casing until they fasten the pin. Peen
retainers (A10). Be careful not to damage the the open ends of the grooves to fasten the
joint face of the pump body. Remove the retainers in position.
rocker lever, the pin (A9), the link arm and the
return spring. Check the components for wear 4 Fit the diaphragm spring (A12) into its
and other damage. location under the diaphragm (A5) and put
the spring seat washer (A7) and a new stem
20.4.2 TO ASSEMBLE seal (A6) into position on the pull rod. Ensure
that the small diameter at the top of the seal
1 Thoroughly clean the valve housings. Fit new is on the round section of the pull rod.
seat washers (A3) and push the new valves
(A4) into position. As the valves are the same,
but one valve is fitted in reverse of the other,
it is possible to fit the valves upside down. To
ensure that the valves are fitted correctly, fit
them as shown in A. When the valves are
correctly fitted, peen the edge of the valve
housings in six places, evenly divided, to keep
the valves in position.
15501 9-35990

2 Fit the rocker lever (A11), pin (A9) and link

arm assembly (A8) into the bottom half of the
lift pump. Fit the return spring; ensure that the
ends of the spring are in their correct location.
 EM11-20-12
FUEL SYSTEM WX90

5 Put the diaphragm assembly in position over

the lower half of the body with the blade of the
pull rod aligned with the slot in the link arm.
Press lightly down on the diaphragm until the
notch in the pull rod is in the slot in the link arm
and turn the diaphragm 90° in either direction.
This action will engage and retain the pull rod
in the slot of the link arm.

6 Push the rocker arm towards the pump body

until the diaphragm is level with the body
flange and fit the top half of the body in
position with the marks on the flanges aligned.
Keep the pressure on the rocker arm; fit the
spring washers and the screws and tighten
them evenly.

7 Fit the gauze filter (A2) and the cover (A1),

ensure that the rubber seal (A13) is fitted
correctly and tighten the screw.

To test 20A-05

1 Disconnect the fuel outlet pipe from the fuel lift

pump. Fit a 0-70 kPa (0-10 Ibf/in2) 0-0,7 kgf/
cm2 pressure gauge to the outlet of the lift
pump. Release the connection at the gauge
and operate the priming lever of the lift pump
to eliminate air from the pipe. When fuel, free
of air, flows from the pipe tighten the
connection. Ensure that there are no leaks at
the connections between the pump and the
gauge.

2 Operate the starter motor for 10 seconds with

the engine stop control in the stop position or
with the stop solenoid disconnected.

3 Note the maximum pressure indicated on the

gauge. If the pressure indicated is less than
the test pressure shown in the data and
dimensions, repair or renew the pump. Also
check the rate at which the pressure reduces
to half the maximum pressure obtained. If this
is less than 30 seconds, repair or renew the
pump.

4 Remove the gauge and connect the outlet

pipe to the lift pump. Release the vent screw
on the fuel filter head and operate the priming
lever until fuel, free of air, flows from the vent
15501 9-35990

screw. Tighten the vent screw.

5 Connect the engine stop solenoid.

 EM11-20-13
FUEL SYSTEM WX90

20.5 LUCAS DP 200 SERIES FUEL

INJECTION PUMP

To remove and to fit

20A-06B

Special tools:
Timing pin PD.246, Lucas fuel injection pumps

General description

CAUTION: Do not release the nut (C2) from the

fuel injection pump. Illustration (C) shows the nut
in position when the fuel pump is fitted to the
engine. The fuel pump hub is fitted to the shaft in
the factory to ensure that the fuel pump is in the
correct position for timing. If the nut is removed
and the hub moves, the hub will need to be
accurately fitted to the pump by use of specialist
equipment before the pump can be fitted to the
engine.

The manufacturer fits the hub (A2) to the pump to

ensure very accurate timing. Engines that have
this arrangement have the drive gear fastened to
the hub instead of to the shaft of the pump.

The hub is permanently mounted onto the drive

shaft by the pump manufacturer to allow the
pump timing to be set accurately when the engine
is in service.

To prevent incorrect adjustments to the engine

timing by rotation of the fuel pump, the mounting
flange (B1) has holes instead of slots.

Accurate timing of the pump to the engine is by a

pin (C1) used to align the fuel pump gear and the
the hub (C4), with a hole in the body (C3) of the
fuel pump. The gear is passed over the pin and
fastened to the hub with four fasteners (C6).

NOTE: On the latest engines with belt driven

coolant pumps, four tamper proof fasteners retain
the fuel pump gear. Special tools to remove these
fasteners are available at your CASE distributor.

CAUTION: A new fuel injection pump may be

supplied with the pump shaft in the locked
position. The drive shaft of the pump must not
be turned without the spacer (B2) in position
15501 9-35990

under the locking screw (B3).

The fuel injection pump has a locking screw (A3)

and (B3) and a spacer (B2). The locking screw
prevents the rotation of the drive shaft.
An “O” ring (A1) is fitted into a groove in the pump
flange. This “O” ring is fitted instead of a joint
between the pump flange and the timing case.
 EM11-20-14
FUEL SYSTEM WX90

20.5.1 TO REMOVE

Before the crankshaft is turned or the pump is

fitted, put the spacer (A1) into position under the
locking screw (A2) to ensure that the pump drive
shaft is released.

1 Disconnect the battery before the fuel injection

pump is removed from the engine.

2 Set the engine to TDC on the number 1

cylinder on the compression stroke, operation
17A-01A or B.

3 Remove the gear cover from the cover of the

timing case. For gear driven coolant pumps:
Remove the coolant pump, operation 21A-
02A.

4 Insert the timing pin (B1) through the hole

(B5) in the fuel pump gear and the slot of the
hub (B4). Push the pin fully into the hole (B3)
in the body of the fuel pump. If the pin can be
fully inserted then the pump timing is correct.
There should be no resistance when the pin is
inserted.

CAUTION: Use a second spanner to prevent

movement of the high-pressure outlet when
the union nut for each high-pressure pipe is
released.

5 Remove the pipes, the cables and the

connections for the cold start device and the
electrical stop solenoid from the fuel pump.

CAUTIONS: 6 Remove the four fasteners (B6) and release

• Do not rotate the crankshaft when the pump the fuel pump gear from the hub of the fuel
is not on the engine; the loose fuel pump injection pump.
gear may damage the timing case. If it is
necessary to rotate the crankshaft, fit the 7 Remove the nuts from the flange of the fuel
fuel pump temporarily to ensure that the pump and remove the pump.
gear is in the correct position. If the fuel
pump is fitted temporarily in order to rotate
the crankshaft, the locking screw (A2) must
be released and a spacer (A1) fitted.

• Do not release the nut (B2) from the fuel

injection pump. The fuel pump hub is fitted
to the shaft in the factory to ensure that the
fuel pump is in the correct position for
15501 9-35990

timing. If the hub is removed, the hub will

need to be accurately fitted to the pump by
use of special equipment available to CASE
distributors.
 EM11-20-15
FUEL SYSTEM WX90

20.5.2 TO FIT

CAUTIONS:

• The engine must be set to TDC number 1

cylinder, compression stroke before the pump
is fitted. If the crankshaft needs to be rotated,
the pump must be fitted temporarily, or the
loose gear could damage the timing case.
• The drive shaft of the pump must not be rotated
without the spacer (A1) in position under the
locking screw (A2). If the drive shaft is rotated
with the locking screw tightened on to the shaft,
the drive shaff will be damaged.

1 Inspect the “O” ring (B1) in the pump flange

and, if necessary, fit a new “O” ring.

2 Lightly lubricate the “O” ring with clean engine

lubricating oil and put the pump into position
on the timing case.

3 Put the fuel pump in position on the three

studs and fit the flange nuts.

4 Fit the setscrew and nut of the support bracket.

Ensure that force is not applied to the fuel
pump when the support bracket is fitted.

5 Tighten the flange nuts of the fuel pump to 28

Nm (20 Ibf ft) 2.8 kgf m.

CAUTION: Do not remove the nut (C2) from the

shaft of the fuel injection pump. The fuel pump
hub is fitted to the shaft in the factory to ensure
that the fuel pump is in the correct position for
timing. If the hub is removed, the hub will need
to be accurately fitted to the pump by use of
special equipment available to CASE distributors.

6 Put the fuel pump gear onto the hub of the fuel
pump. The fasteners (C6) for the fuel pump
gear should be in the centre of the slots to
allow for the removal of the backlash. Tighten
the setscrews finger tight.

NOTE: The fuel pump gear will only fit in one

position. The gear is fitted with the letters C and
M at the front.

7 Insert the timing pin (C1) through the hole

15501 9-35990

(C5) of the fuel pump gear and the slot of the

hub (C4) until it can be pushed fully into the
hole (C3) in the body of the fuel pump. If the
timing pin cannot be pushed into the pump
body, check that the engine is correctly set at
TDC on the number 1 cylinder, operation 1
7A-01A or B.
 EM11-20-16
FUEL SYSTEM WX90

CAUTION: The fuel pump gear must be fitted to

the engine before the crankshaft is rotated.

8 Carefully turn the gear counter-clockwise, by

hand (A1), to remove the backlash between
the idler gear and the fuel pump gear. Do not
rotate the crankshaft or the fuel pump shaft.
Tighten the setscrews for the fuel pump gear
to 28 Nm (20 Ibf ft) 2.8 kgf m.

9 Remove the timing pin.

10 Fit the gear cover to the cover of the timing

case. For gear driven coolant pumps: Fit the
coolant pump, operation 21A-02A.

CAUTION: Do not tighten the union nuts of the

highpressure pipes more than the recommended
torque tension. If there is a leakage from the union
nut, ensure that the pipe is correctly aligned with
the atomiser inlet. Do not tighten the atomiser
union nut more, as this can cause a restriction at
the end of the pipe. This can affect the fuel
delivery.

11 Fit all the pipes. Connect the control rod of the

fuel injection pump. Fit the cables and
connection for the cold start device and
electrical stop solenoid to the pump. Ensure
that a spanner is used to prevent movement of
the pump outlets when the high-pressure pipes
are fitted and tighten the union nuts to 22 Nm
(16 Ibf ft) 2.2 kgf m.

12 Eliminate air from the fuel system, operation

20A-08B.

13 Fit the cylinder head rocker cover.

14 Operate the engine and check for leakage.

With the engine at the normal temperature of
operation, check that the idle speed and the
maximum no-load speed are correct, operation
20A07B.
15501 9-35990
 EM11-20-17
FUEL SYSTEM WX90

To adjust 20A-07B

The engine conforms with USA (EPA/CARB)

stage 1 and EEC stage 1 emissions legislation for
agricultural and industrial applications.

The idle or maximum speed settings must not be

changed by the engine operator, because this
can damage the engine or the transmission.

Specialist equipment, which is available at your

CASE Distributor, is needed to adjust the idle or
maximum speed settings. The warranty of the
engine can be affected if the seals on the fuel
injection pump are broken during the warranty
period by a person who is not approved by CASE.

1 Operate the engine until it reaches its normal

temperature of operation and check the idle
speed. If necessary, adjustment can be made
by the outer adjustment screw (A2). Release
the lock nut and rotate the adjustment screw
clockwise to increase the speed, or counter-
clockwise to decrease the speed. When the
speed is correct, tighten the lock nut. The
setting of the idle speed can change for different
applications. Normally the correct speed will
be given in the manufacturer’s handbook for
the application. If it is not given, refer to your
nearest CASE distributor.

CAUTION: The setting for the maximum no load

speed can change for different applications. For
the correct maximum no-load speed, check the
emissions data plate fitted to the left side of the
cylinder block before any adjustment is made to
the maximum no load speed.

2 With the engine at its normal temperature of

operation, check the maximum no load speed.
A typical maximum no load speed is 2860 rev/
min. If necessary, this speed can be adjusted
by the inner adjustment screw (A1). Release
the lock nut and rotate the adjustment screw
counter-clockwise to increase the speed or
clockwise to decrease the speed. When the
speed is correct, tighten the lock nut and seal
the screw.

The person who fits the pump must ensure

that the adjustment screw is suitably sealed
15501 9-35990

against interference after it has been set

initially.
 EM11-20-18
FUEL SYSTEM WX90

To eliminate air from the

fuel system Lucas DP200 pump 20A-08B

Air will usually be removed from the fuel pump

automatically when the engine is in operation. If
the fuel pipes are disconnected or if the canister
of the fuel filter has been renewed, or the engine
runs out of fuel, it will be necessary to eliminate air
from the fuel system.

CAUTION: If the fuel system is empty or if the

canister(s) of the fuel filter have been renewed,
it will be necessary to eliminate air from the fuel
system, especially the fuel injection pump.

1 Release the vent plug on the fuel filter head

(A1).
2 Operate the priming lever of the fuel lift pump
(B) until fuel, free of air, comes from the vent
plug. Tighten the vent plug. If the drive cam of
the fuel lift pump is at the point of maximum lift,
it will not be possible to operate the priming
lever. In this situation, the crankshaft must be
rotated one revolution.

CAUTION: Use a spanner to prevent movement

of the fuelled starting aid (C1) when the union
nut (C2) is loosened or tightened.

3 Loosen the union nut (C2) at the fuelled starting

aid and operate the priming lever of the fuel lift
pump until fuel, free of air, comes from the
connection. Tighten the union nut at the starting
aid.

4 Loosen the union nut at the outlet connection

of the low pressure fuel leak off pipe which is
on top of the governor housing of the fuel
injection pump.
Operate the priming lever of the fuel lift pump
until fuel, free of air, comes from the connection.
Tighten the union nut.

CAUTION: Do not tighten the union nuts of the

high pressure pipes more than the recommended
torque tension. If there is a leakage from the union
nut, ensure that the pipe is correctly aligned with
the atomiser inlet. Do not tighten the atomiser
union nut more, as this can cause a restriction at
the end of the pipe. This can affect the fuel
delivery.
15501 9-35990

5 Loosen the high-pressure connections at two

of the atomisers (D1).
 EM11-20-19
FUEL SYSTEM WX90

CAUTION: Damage to the fuel injection pump, battery and starter motor can occur if the starter motor is
used excessively to eliminate air from the fuel system.

6 Put the electrical system switch to the “ON” position. Ensure that the manual stop control, if one is fitted,
is in the “run” position. Operate the starter motor until fuel, free from air, comes from the pipe connections.
Tighten the high-pressure pipe connections to 22 Nm (16 Ibf ft) 2,2 kgf m. Return the switch to the “OFF”
position.

7 The engine is now ready to start.

CAUTION: Operate the engine at low idle speed for a minimum of five minutes immediately after air has
been removed from the fuel system. This will ensure that the pump is completely free of air and prevent any
damage to the pumps internal parts by metal to metal contact.

If the engine runs correctly for a short time and then stops or runs roughly, check for air in the fuel system.
If there is air in the fuel system, there is probablaly a leakage in the low pressure system.

20.6 DATA AND DIMENSIONS

NOTE : This information is given as a guide for personnel engaged on engine overhauls. The di mensions
which are shown are those which are mainly used in the factory. The information applies to all engines,
unless an engine type code is shown.

20.6.1 FUEL SYSTEM

Lucas fuel injection pump

Make .......................................................................... Lucas DP200 Series, pin timed, with a locking screw
Direction of rotation ............................................................................................... Clockwise from drive end

Fuel lift pump - four cylinder engines

Type ............................................................................................................ Diaphragm, A.C.Delco, type XD
Method of drive .......................................................................................... Eccentric on camshaft of engine
Static pressure (no delivery) ............................................................ 42/70 kPa (6/10 lbf/in2) 0.4/0.7 kgf/cm2
Test pressure (75% of minimum static pressure) ....................................... 31 kPa (4.5 lbf/in2) 0.32 kgf/cm2

Fuel filter

Type ...................................................................................................... Twin parallel flow or single element

15501 9-35990
 EM11-20-20
FUEL SYSTEM WX90

Atomiser service setting

Set and reset pressure

Code Holder Nozzle ATM MPa

KB 2645A308 2645A624 300 30.4
KC 2645A309 2645A625 290 29.4
KD 2645A310 2645A626 290 29.4
KE 2645A311 2645A627 290 29.9
KF 2645A311 2645A628 295 29.9
KG 2645A314 2645A629 300 30.4
KH 2645A314 2645A630 290 29.4
KJ 2645A315 2645A631 250 25.3
KK 2645A312 2645A632 300 30.4
KL 2645A633 2645A633 300 30.4
KM 2645A313 2645A634 300 30.4
KN 2645A315 2645A635 290 29.4
KP 2645A311 2645A636 290 30.4
KR 2645A311 2645A608 290 29.4
KT 2645A311 2645A638 290 29.4
KS 2645A316 2645A637 290 29.4
KU 2645A317 2645A627 290 29.8
KV 2645A304 2645L615 250 25.3
KW 2645A311 2645K609 290 29.4
NX 2645L306 2645L617 290 29.4
NY 2645L308 2645L618 290 29.4
NZ 2645L307 2645L619 290 29.4
PA 2645L309 2645L620 290 29.4
PB 2645L310 2645L621 290 29.4
PC 2645L310 2645L622 290 29.4
PD 2645L310 2645L622 275 27.9
RZ 0430 133 005 DSLA140P707 250 25.3
SA 2645F316 2645F620 250 25.3
SB 2645F316 2645F621 250 25.3
SC 043013306 DSLA150PV3378123 250 25.3
F7726gb

The code letters are stamped on the side of the atomiser body just below the connection for the nut of the
high pressure pipe.
15501 9-35990
 EM11-21-1
COOLING SYSTEM WX90

21. COOLING SYSTEM

21.1 GENERAL DESCRIPTION

Coolant from the bottom of the radiator passes through the centrifugal coolant pump, which is fitted onto the
front of the timing case to assist the flow of the coolant through the system.
The pump is gear driven from the gear of the fuel injection pump.
On certain four cylinder applications the pump is driven by a “V” belt from the crankshaft pulley.
Some engines are fitted with a belt driven coolant pump in a high position, these are identified by the thermostat
housing which is part of the pump rear body. The rear body of these pumps has a connection to a coolant
transfer plate, which allows coolant from the pump impeller to pass into the cylinder block.
Two types oil cooler are available for use on four cylinder engines: An integral oil cooler which is fitted to the
left side of the cylinder block or a separate (cassette type cooler) fitted to the filter head.
The integral oil cooler has an aluminium cover with plate element and is fitted to the left side of the cylinder
block.
The latest integral oil coolers for 6 cylinder engines have a pressed steel cover.

21.1.1 FOUR CYLINDER ENGINES

From the pump, the coolant passes through a passage in the timing case to the water jacket in the left side
of the cylinder block. Coolant pumps driven by a “V” belt do not pass the coolant through a passage in the timing
case but direct to the front of the cylinder block. The coolant continues to the rear of the cylinder block where
some of the coolant passes into the lubricating oil cooler, if one is fitted. Some of the coolant passes around
the element of the integral cooler and then to the rear of the cylinder block.
Some four cylinder engines have a cassette type oil cooler fitted between the oil filter canister and the oil filter
head. If the cassette oil cooler is fitted on the left side of the engine, coolant from the by-pass connection at
the rear of the coolant pump passes through a pipe to the oil cooler. If the cassette oil cooler is fitted to the
right side of the engine, a pipe is connected between the thermostat housing and the oil cooler. The coolant
passes around the plates of the cooler and passes through a pipe to the cylinder block.
The coolant then passes from the rear of the cylinder block and into the cylinder head. The coolant leaves the
cylinder head at the front and passes into the thermostat housing.
If the thermostat is closed, the coolant goes directly through a by-pass to the inlet side of the coolant pump.
If the thermostat is open, the thermostat closes the by-pass and the coolant passes to the top of the radiator.
Some engines are fitted with two thermostats.
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 EM11-21-2
COOLING SYSTEM WX90

21.2 THERMOSTATS

Most engines are fitted with a single thermostat

(A), some engines have twin thermostats fitted
(B). Identification of the thermostat is by the
nominal temperature which is stamped on the by-
pass valve (A6) of the thermostat.

To remove, to fit and to test 21A-01

21.2.1 TO REMOVE

1 Drain the coolant level in the cooling system to

below the thermostat position and disconnect
the top hose from the coolant outlet connection.

2 Release the four setscrews and remove the

thermostat housing (A1) from the lower body.
Discard the joint (A5).

3 Press the retainer clips (A4) inwards, and lift

the plastic collar from the thermostat housing.

4 Remove the thermostat and “O” ring assembly

(A3) from the thermostat housing. Discard the
“O” ring.

21.2.2 TO FIT

1 Clean the thermostat housing, ensure that the

groove (A2) for the clip retainers and the seat
for the “O” ring are free of debris.

2 Ensure that the joint faces of the thermostat

housing and the lower body are clean and that
the jiggle pin (B1) in the thermostat is free to
move.

3 Renew the “O” ring and put the new thermostat

in position in the housing.

4 Press the retainer clips inwards, and push the

plastic collar into the thermostat housing until
the clip retainers engage the groove.

5 Fit a new joint, the joint is fitted dry. Fit and

tighten the setscrews.

6 Connect the top hose and fill the cooling 2 Heat the coolant gradually. Use a
system. thermometer to check the temperature at
which the valve starts to open and at which
15501 9-35990

21.2.3 TO TEST it is fully open. The correct temperatures are

given in the data and dimensions.
1 Hang the thermostat in a suitable container
filled with coolant. CAUTION: If the thermostat does not ope-
rate correctly, it must be renewed. Do not
try to adjust the settings.
 EM11-21-3
COOLING SYSTEM WX90

21.3 COOLANT PUMP - EALY GEAR DRIVEN

To dismantle and to assemble 21A-03

21.3.1 TO DISMANTLE

The coolant pump will need an overhaul if coolant

leaks from the hole (A4) in the body of the pump.
When this occurs coolant has passed through the
coolant seal (A7) and has contaminated the
bearings.

Special tool:
Gear puller, MS.99

Consumable products:
Retainer (high strength) Loctite 603
Nutlock, Loctite 242E

The coolant pump has a bearing assembly which

has an integral oil seal. Identification of the new
coolant pump is by the last four digits of the part
numbers, (4131E011) stamped on the front of the
coolant pump body and by the bearing which
extends approximately 5 mm (0.2 in) past the end
of the pump body.

1 Remove the coolant pump, operation 21A-

02A.

2 Remove the “O” ring (A2) from the pump body

(A4).

3 Remove the front cover (A8) and the joint

(A9).

4 Remove the gear (A1) with the puller MS.99.

5 With a support under the drive end of the

pump, use a suitable adaptor to press out the
shaft and bearing assembly (A3) and discard
it. Remove and discard the impeller (A6) from
the body.

6 With a suitable support under the impeller end

of the pump, press out the coolant seal and
discard it.
15501 9-35990
 EM11-21-4
COOLING SYSTEM WX90

21.3.2 TO ASSEMBLE

CAUTION: It is important that all of the

components in the coolant pump kit are used
during the overhaul of the pump. Coolant pump
kits include the latest components which may be
of a different design to the original components
fitted to the engine.

1 Clean thoroughly the inside of the pump body

(A5). Ensure that the bore for the bearing and
the chamfer at the coolant seal end of the bore
are clean and free from corrosion.

2 Make a suitable adaptor which will apply force

to the outer edge of the bearing and not to the
shaft. Apply a thin layer of Retainer (high
strength) to the outer surface of the bearing
(A3), but keep the retainer away from the
ends of the bearing.

3 Provide a suitable support under the impeller

end of the pump body. Put the bearing and
shaft assembly in position with the bearing
square to the pump body and the longest end
of the shaft in the pump body. Use the adaptor
to press in the bearing and shaft assembly.
Press in the bearing until the rear face of the
bearing is 21.0/21.5 mm (0.83/0.85 in) (A11)
above the rear face of the pump body.

4 If the original gear is used, Retainer (high

strength) must be applied to the bore of the
gear. Press the gear (A1) onto the shaft until
the clearance between the front face of the
gear and the rear face of the bearing (A12) is
0.47/1.53 mm (0.018/0.060 in). Remove all
excess retainer after the gear has been fitted.

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 EM11-21-5
COOLING SYSTEM WX90

5 A tool (A) can be made to press the coolant

seal into position. The tool should be made of
a suitable material to the dimensions listed
below:

A 44.0 mm (1.73 in)

B 40.0 mm (1.57 in)
C 11.6 mm (0.46 in)
D 35.8 mm (1.41 in)
E 16.1 mm (0.63 in)
F 1.00 mm (0.04 in) at 45°
G 2.00 mm (0.08 in) at 45°

The dimensions of the tool to fit the coolant

seal, will ensure that the seal is the correct
length after it is installed. It will also prevent
axial distortion of the seal when it is pressed
onto the shaft.

Turn the pump over and support the drive end

of the body. Do not lubricate the coolant seal
(B4). It is important that the seal is not
contaminated by oil or grease and if it is held
in the hand, it should be held by the edge of
the flange. Do not damage the ring of green
sealant applied to the body of the coolant seal
just behind the flange. Put the seal into position
on the end of the shaft. Ensure that the ring of
sealant is towards the bearing. Use the tool to
press the seal onto the shaft until the bottom
of the seal flange is in complete contact with
the pump body.

6 Hold the pump with the drive end of the shaft

on a suitable support. With the use of a
suitable distance piece and a flat bar, press
the new impeller (B3) onto the shaft until the
front face of the impeller is 6.7/7.0 mm (0.26/
0.28 in) below the front face of the pump body
(B1). Remove the flat bar and distance piece
and ensure that the shaft is free to rotate.

7 Clean the threads in the front face of the pump

body. Fit a new joint (B6) and the cover (B5).
Fit the setscrews and tighten them to 9 Nm (6
Ibf ft) 0.9 kgf m. If the setscrews are new, a
sealant will have been applied to the threads
by the manufacturer. If the original setscrews
are to be used again, the threads should be
cleaned and a Nutlock applied.
15501 9-35990

8 Fit a new “O” ring (B2) to the body of the pump.

 EM11-21-6
COOLING SYSTEM WX90

21.4 FAN DRIVE

To remove and to fit 21A-05

21.4.1 TO REMOVE

1 Loosen the pivot fasteners of the alternator and the fasteners of the adjustment link. Remove the drive
belt(s).

2 Release the setscrews and remove the fan. Remove the fan extension, if fitted, and the pulley.

3 Check the end-float of the drive shaft. If it is more than 0.25 mm (0.010 in), the assembly must be renewed.

4 Release the setscrews and remove the fan drive.

21.4.2 TO FIT

1 Fit the fan drive and tighten the setscrews to 44 Nm (33 Ibf ft) 4.5 kgf m.

2 Fit the fan, operation 21A-04.

3 Fit the belt(s) and adjust the tension, operation 23A-02.

15501 9-35990
 EM11-21-7
COOLING SYSTEM WX90

21.5 DATA AND DIMENSIONS

NOTE: This information is given as a guide for personnel engaged on engine overhauls. The dimensions
which are shown are those which are mainly used in the factory. The information applies to all engines,
unless an engine type code is shown.

21.5.1 COOLANT PUMP, GEAR DRIVEN

Type ..............................................................................................................................................Centrifugo
Outside diameter of shaft ...................................................................... 18.95/18.96 mm (0.7460/0.7465 in)
Diameter of bore of drive gear .............................................................. 18.90/18.92 mm (0.7441/0.7449 in)
Interference fit of drive gear on shaft ........................................................ 0.03/0.06 mm (0.0012/0.0024 in)
Diameter of bore of impeller .................................................................. 15.87/15.89 mm (0.6249/0.6257 in)
Outside diameter of shaft for impeller ................................................... 15.91/15.92 mm (0.6264/0.6268 in)
Interference fit of impeller on shaft ............................................................ 0.02/0.05 mm (0.0007/0.0020 in)
Diameter of bore for bearing ................................................................. 38.06/38.08 mm (1.4983/1.4993 in)
Diameter of bearing .............................................................................. 38.09/38.10 mm (1.4995/1.5000 in)
Interference fit of bearing in pump body ................................................... 0.01/0.04 mm (0.0004/0.0016 in)
Dimension of impeller boss to front face of pump body (fitted) ......................... 7.7/8.0 mm (0.303/0.846 in)
Dimension of gear from rear flat face of pump body (fitted).......................... 21.0/21.5 mm (0.827/0.315 in)
Dimension of gear from rear face of bearing (fitted) ..................................... 0.47/1.53 mm (0.018/0.060 in)

Nominal temperature
"Start open" "Fully open" Minimum valve lift,
Part number stamped on thermostat
temperature temperature fully open
by-pass valve
2485613 82 ° C 77/85 ° C 92/98 ° C 9 mm
2485604 82 ° C 77/85 ° C 92/98 ° C 9 mm
2485C023 82 ° C 80/84 ° C 96 ° C 9 mm
2485C025 82 ° C 80/84 ° C 96 ° C 9 mm
F8048gb

21.5.2 THERMOSTAT

Type:
- Single ......................................................................................................... wax element, by-pass blanking

21.5.3 FAN DRIVE HOUSING

Bore of housing for bearing........................................................... 41.9655/41.9785 mm (1.6259/1.6522 in)
Outside diameter of bearing ................................................................ 41.987/42.00 mm (1.6535/1.6530 in)
Interference fit of bearing in housing............................................. 0.0085/0.0345 mm (0.00136/0.00033 in)
Bore of hub ....................................................................................... 21.938/21.958 mm (0.8637/0.8645 in)
Outside diameter of shaft .................................................................. 21.987/22.000 mm (0.8656/0.8661 in)
15501 9-35990

Interference fit of shaft in hub ............................................................... 0.029/0.062 mm (0.0011/0.0024 in)

Maximum permissible end-float of shaft ..................................................................... 0,200 mm (0.0079 in)
 EM11-21-8
COOLING SYSTEM WX90

NOTES:

15501 9-35990
 EM11-22-1
FLYWHEEL AND FLYWHEEL HOUSING WX90

22. FLYWHEEL AND HOUSING

22.1 GENERAL DESCRIPTION

The steel flywheel is fitted with a hardened starter

ring. Generally the starter rings have 126 or 115
teeth.
The flywheel housing is normalli made of cast
iron, but fluwheel housings are made of aluminium
alloy.

22.2 FLYWHEEL

To remove and to fit 22A-01

WARNING! The flywheel is heavy, use lift

equipment or get help to assist with the lift
operation before removal of the flywheel
fasteners.

22.2.1 TO REMOVE

1 Remove two opposite setscrews from the

flywheel and fit temporarily two guide studs to
ensure safety when the flywheel is removed
and fitted.

2 Remove the remainder of the setscrews and

washers and remove the flywheel.

3 Check the flywheel and ring gear for damage

and renew, if necessary.

22.2.2 TO FIT 22.3 RING GEAR

1 Ensure that the location faces of the crankshaft
and the flywheel are clean and free from
damage.
2 Fit the flywheel over the guide studs. Fit four
setscrews and their washers. Remove the
guide studs and fit the remainder of the
setscrews and the washers. Tighten the
setscrews to 105 Nm (77 Ibf ft) 10.7 kgf m.
3 Check the flywheel run-out with a dial test
indicator (A). This must be less than 0.30 mm
(0.012 in) total indicator reading.
4 Check the alignment of the fiywheel face (B).
15501 9-35990
To remove and to fit 22A-02
22.3.1 TO REMOVE
WARNING! Wear eye protection during this
operation.
Before the ring gear is removed, check the
position of the chamfer on the teeth.To remove
the ring gear use a hammer and a chisel to
break the ring. Ensure that the flywheel is not
damaged during this operation.
22.3.2 TO FIT

The error in alignment must not be more than
0.03 mm (0.001 in) total indicator reading for
every 25 mm (1.0 in) of the flywheel radius
from the crankshaft axis to the indicator
plunger. During this check, keep the crankshaft
pressed toward the front to remove the effect
of crankshaft end-float.
The ring gear is heated onto the flywheel.
When a new gear is to be fitted, ensure that it
is not heated to more than 250°C (480°F).
Ensure that the chamfer on the teeth of the gear
is in the correct direction.
 EM11-22-2
FLYWHEEL AND FLYWHEEL HOUSING WX90

22.4 FLYWHEEL HOUSING

To remove and to fit 22A-03

WARNING! The flywheel housing is heavy, use

lift equipment or get help to assist with the lift
operation before removal of the flywheel housing
fasteners.

22.4.1 TO REMOVE

1 Remove the starter, operation 23B-01, and

the flywheel, operation 22A-01.

2 Release the housing setscrews and with a

soft face hammer, hit carefully the housing to
remove it from the dowels.

22.4.2 TO FIT

1 Ensure that the rear face of the cylinder block

and the faces of the housing are clean and
free from damage. Ensure that the location
dowels are fitted correctly. If a felt seal is fitted
to the rear flange of the sump, renew the seal.

2 Fit the housing onto the dowels and tighten

lightly the setscrews.

3 Check the housing concentricity with a dial

test indicator (A). The run-out limit is given in
the data and dimensions. If any adjustment is
necessary, it must be made on the housing
and the concentricity checked again.

4 Tighten the setscrews to the torque

recommended in section 11B.

5 Check the housing alignment (B). The

maximum tolerance is given in the data and
dimensions. Any necessary adjustment must
be made on the housing and not on the
cylinder block.

6 Fit the flywheel, operation 22A-01 and the

starter motor, operation 23B-01.
15501 9-35990
 EM11-22-3
FLYWHEEL AND FLYWHEEL HOUSING WX90

22.5 DATA AND DIMENSIONS

NOTE: This information is given as a guide for personnel engaged on engine overhauls. The dimensions
which are shown are those which are mainly used in the factory. The information applies to all engines,
unless an engine type code is shown.

22.5.1 FLYWHEEL AND HOUSING

Limits for flywheel housing run-out and alignment (total indicator reading)

Diameter of housing flange bore Maximum limit (total indicator reading)

mm mm
362 0.23
410 0.25
448 0.28
511 0.30
584 0.36
648 0.41
787 0.48
F8353gb
15501 9-35990
 EM11-22-4
FLYWHEEL AND FLYWHEEL HOUSING WX90

NOTES:

15501 9-35990
 EM11-23A-1
ELECTRICAL EQUIPMENT WX90

23A. ELECTRICAL EQUIPMENT

23A.1 GENERAL DESCRIPTION

The alternator is driven from the crankshaft pulley by single or double belt(s).

The Lucas AC5RS, Magneti Marelli A127 and the Bosch KI 12 volt and NI 24 volt alternators have solid state
regulators fitted at the rear. The regulator of the Magneti Marelli A127 alternator includes the brush box as
a part of the unit. The regulators of both alternators are sealed and repair is not possible.

23A.2 PRECAUTIONS

To prevent damage to the diodes and to the resistors, the precautions given below must be followed:

• Do not disconnect the battery while the engine is in operation. This will cause a voltage surge in the alternator
charge system which will immediately cause damage to the diodes or to the transistors.

• Do not disconnect an electrical wire before the engine is stopped and all electrical switches are in the “off”
position.

• Do not cause a short circuit by the connection of electrical wires to the wrong terminals. The correct electrical
wire must be connected to the correct terminal. A short circuit or wrong connection which gives reverse
polarity will immediately cause permanent damage to the diodes and to the transistors.

• Do not connect a battery into the system until it has been checked for correct polarity and voltage.

• Do not check for current flow with a spark contact as damage can be caused to the transistors.
15501 9-35990
 EM11-23A-2
ELECTRICAL EQUIPMENT WX90

23A.2.1 DRIVE BELTS

To check 23A-01

1 Check the belt(s) for wear and damage and

renew the belt(s), if necessary. If twin belts are
fitted, they should both be renewed.

2 Check the belt tension. If twin belts are fitted,

check/adjust the tension on the tighter belt. To
ensure maximum belt life, it is recommended
that a belt tension gauge is used. Fit the gauge
(A1) at the centre of the longest free length
and check the tension. If a Burroughs gauge
is used, the correct tension is 355 N (80 Ibf) 36
kgf. If the tension is equal to or less than 220
N (50 Ibf) 22 kgf, adjust it to 355 N (80 Ibf) 36
kgf, operation 23A-02. If no gauge is available,
press down the belt with the thumb at the
centre of the longest free length and check the
deflection (B). With moderate thumb pressure,
45 N (10 Ibf) 4.5 kgf, the correct belt deflection
is 10 mm (3/8 in).

To adjust tension 23A-02

1 Loosen the pivot fasteners (B1) of the

alternator and the fasteners of the adjustment
link (B2).

2 Change the position of the alternator to give

the correct tension. Tighten the adjustment
link fasteners and then the pivot link fasteners.
If there are two pivot fasteners, tighten the
front fastener and then the rear fastener.

3 Check the belt tension again to ensure that it

is still correct.

To remove and to fit 23A-03

Where twin belts are fitted, they are supplied as

a set and must be renewed as a set.

1 Loosen the pivot fasteners (B1) of the

alternator and the adjustment link fasteners
(B2).

2 Release all of the tension from the belt(s) and

remove the belt(s).
15501 9-35990

3 Fit the new belt(s) and adjust the tension,

operation 23A-02. The belt tension must be
checked again after the first 1000 km (600
miles) or 20 hours of operation.
 EM11-23A-3
ELECTRICAL EQUIPMENT WX90

23A.3 ALTERNATOR

To remove and to fit 23A-04

23A.3.1 TO REMOVE

1 Disconnect the electrical connection.

2 Loosen the pivot fasteners of the alternator and the fasteners of the adjustment link.
3 Release all the belt tension and remove the belt(s).
4 Remove the adjustment link from the alternator and remove the pivot bolt(s). Make a note of the position
of the washers and distance pieces to ensure that they are fitted correctly. Remove the alternator.

23A.3.2 TO FIT

1 Put the alternator in position and assemble loosely the pivot fasteners and the adjustment link and its
fasteners. Ensure that the washers and the distance pieces are fitted in their correct positions and that the
alternator pulley is aligned to the crankshaft pulley within +/- 2.4 mm (3/32 in).
2 Fit the drive belt(s) and adjust the drive belt tension, operation, 23A-02. Tighten the fasteners and check
the tension again.
3 Connect the electrical connection.

23A.3.3 TO MAINTAIN

1 Ensure that the drive belts are not worn and that the belt tension is correct.
2 Keep the alternator clean. To clean the alternator, use a material which is damp with kerosene or a special
fluid used for this purpose. Ensure that the fluid does not enter the cover of the alternator.
3 Ensure that air can pass easily over the casing to keep it cool.

23A.4 FAULT DIAGNOSIS

The alternator is designed in such a way that a flow of current (indicated by no light at the warning light or a
reading shown on an ammeter) shows that the system is in correct operation. If the system is in correct
operation, no open circuit, voltage or current output checks need to be done on the installation unless:

The warning light does not show when the alternator is stationary and the switch is in the “on” position or it
shows a light when the alternator is in operation.

• No charge current is shown on the ammeter.

• The battery is discharged.
• The battery is hotter than normal which is an indication of loss of voltage control.
• If one or more of the above symptoms occur, the procedure indicated below should be applied.

1 Ensure that the battery is fully charged.

2 Connect a moving-coil voltmeter of good quality, with a range of 0-50 volts, across the positive and negative
terminals of the alternator. If an ammeter is not fitted in the electrical circuit, fit a moving-coil ammeter of
good quality, with a range of 0-100 ampere, in the wire between the alternator and the positive terminal
of the battery.
15501 9-35990

3 Turn the warning light switch to the “on” position (main switch on instrument panel); the warning light should
be illuminated.
4 Switch on a 10-15 ampere load, for example, lights, fans, etc.
5 Start the engine and operate it at a fast idle speed; either the warning light should be extinguished or the
ammeter indicates a small change in the current in relationship to the engine speed.
6 Increase the engine speed for a moment to near maximum speed, when the charge current should be
approxi mate ly eq ual to the rati ng for the alternator, as shown in the data and dimensions.
 EM11-23A-4
ELECTRICAL EQUIPMENT WX90

7 Operate the alternator at approximately half speed (engine speed approximately 1500 rev/min) and
remove the electrical load. The voltage should go up to 14 volts for a 12 volt system or 28 volts for a 24
volt system and then remain constant. At the same time the current reading should show a reduction.

Any change in the above data can indicate a fault and the procedure that follows should be used before
any components are disconnected. This procedure is not suitable for A127 alternators and, if a fault is
found, the alternator should be removed for test by a specialist.

The regulator is a sealed unit and a repair is not possible. If there is a regulator fault, the regulator must
be renewed.

If the warning light is not illuminated when the switch is in the “on” position:

Check the bulb.

If no fault:
Check all the connections at the regulator, at the alternator and at the battery.

If no fault:
Turn the switch to the “off” position. Disconnect the wire from the “F” terminal on the alternator and connect
a wire between the “F” terminal and the negative terminal on the alternator. Turn the switch to the “on” position.
If the warning light shows, the fault is in the regulator.
If the warning light does not show, the fault is in the alternator.

If the warning light continues to show and the ammeter shows no output when the alternator is in
operation:

Check all the connections at the regulator, alternator and battery.

If no fault:
Turn the switch to the “off” position. Disconnect the wire from the “F” terminal on the alternator and connect
a wire between the “F” terminal and the negative terminal on the alternator. Turn the switch to the “on” position
and operate the engine at fast idle.
If there is no output, there is a fault in the alternator.
If there is an output, there is a fault in the regulator.

If the warning light continues to show when the alternator is in operation and the ammeter shows a
reduced output with maximum output only at maximum engine speed or, if the warning light does not
show, but there is a reduced output from the alternator with maximum output only at maximum engine
speed:

There is a fault in the alternator.

If there is an intermittent light from the warning light and the ammeter needle is not stationary when
the battery is charged fully and no load is applied:

Check for a higher than normal resistance in the negative control wire of the regulator.
If the resistance is normal, there is a fault in the regulator.
If the battery charge is too high and the ammeter indicates high or maximum output at all times:
Check the positive control wire and its connection at the regulator.
If the wire and its connection are correct, there is a fault in the regulator.
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ELECTRICAL EQUIPMENT WX90

23A.5 DATA AND DIMENSIONS

NOTE: This information is given as a guide for personnel engaged on engine overhauls. The dimensions
which are shown are those which are mainly used in the factory. The information applies to all engines,
unless an engine type code is shown.

23A.5.1 ELECTRICAL EQUIPMENT

The information which follows is general and can change with specific applications.

Alternators

Make and type ................................................................................................................................Bosch NI

Rating:

Bosch Nl .......................................................................................................................................... 24V/55A

Rotation ................................................................................................................. Clockwise from drive end
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NOTES:

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 EM11-23B-1
ELECTRICAL EQUIPMENT WX90

23B. ELECTRICAL EQUIPMENT

23B.1 GENERAL DESCRIPTION

The Magneti Marelli M127 starter motor is

operated by a solenoid and has a six roller clutch.
The solenoid engages the starter drive in two
operations to ensure that the motor gets its
maximum torque only when the starter motor is
engaged fully with the flywheel. The clutch
prevents rotation of the armature at high speed if
the starter is held in the engaged position. The
Lucas S115 starter motor has a smooth surface
with no protrusions. This is because the solenoid
and the main switch assemblies are inside the
drive end cover around (co-axially with) the arma-
ture shaft. The main feature of the co-axial starter
is that only the pinion assembly moves axially to
engage the engine flywheel. There is no axial
movement of the whole armature as with the axial
type motor. To ensure smooth engagement of 23B.2.2 TO FIT
the pinion, full load is not applied until the pinion
is completely engaged with the flywheel. 1 Clean the flange face of the starter motor,
the distance piece, if one is fitted, and the
face of the flywheel housing.
23B.2 STARTER MOTOR
If the engine has a flywheel housing which
To remove and to fit 23B-01 is oil filled, the starter motor must be sealed
before it is fitted. Apply a 2.0 mm (0.080 in)
Consumable products: continuous bead of Silicone rubber sealant
Silicone rubber sealant, Hylosil to the flange face of the starter motor (A2)
and to the flywheel housing (A3).
WARNING: Always disconnect the battery
terminals before the removal of any component CAUTION: For engines fitted with a distance
of the electrical system. piece: Do not fit the starter motor without the
distance piece.
23B.2.1 TO REMOVE
2 If one is fitted, ensure that the distance
If the engine has a flywheel housing which is oil piece (A4) is fitted in position, with its location
filled, drain the flywheel housing before the starter lip to the flywheel housing, and that the cap
motor is removed. screws (A5) are tight.

1 Disconnect the battery. 3 Fit the starter motor and tighten the fasteners.

2 Disconnect the starter motor cables. 4 Connect the starter motor cables.

3 Release the fasteners and remove the starter 5 Connect the battery.
motor and the distance piece, if one is fitted.
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To maintain the brush gear and the commutator 23B-02

S115 starter motors

Inspect the brushes at intervals to ensure that they are free in their guides and that the wire connections are
free to move. To check this, lift the spring from the brush and pull carefully on the flexible connections. If the
brush does not move freely, remove it from its holder and clean the sides with a material which is damp with
gasolene.

Ensure that the brushes are fitted in their original positions to keep the original wear seat. The brushes must
have good seats which conform to the shape of the commutator. If the brush seat is not correct, put a piece
of very fine carborundum paper or similar material tight around the commutator with the rough face to the
outside. With the brush in position, turn the armature by hand, in the normal direction of rotation, until the brush
has the correct shape. If the brushes are worn and the springs do not give enough pressure, they must be
renewed. Check the spring pressure with the hook of a spring balance under the spring lip. The correct tension
is 8.34/11.00 N (30/40 ozf) 0.85/1.13 kgf.

The new brushes must be the exact same grade as the original brustes. To ensure that correct brushes are
fitted, use only paris from the approved manufacturer. To remove the brushes, remove the four setscrews that
hold the brushes, one for each brush. When the new brushes are assembled, connect carefully the field coil
and connector wires, held by two of the setscrews. Before the brushes are inserted in their holders, it is advised
that the holders are cleaned with compressed air or with a material which is damp with gasolene.

The commutator must be completely clean; dirt or oil must be removed by a piece of clean dry material (with
no loose fibres) pressed against it, while the armature is turned by hand. If the commutator is dirty and has
a colour other than its natural colour, lift the brushes and put a strip of fine carborundum paper or similar
material around the commutator, with the rough surface to the inside. Turn the armature by hand until the
surface has returned to its natural colour. Clean the commutator with a material which is damp with gasolene.

If a repair is necessary to the commutator or switch gear, etc. the starter must be removed for specialist repair.

M127 Starter motor

Repair of this starter motor is more difficult. If necessary, remove the starter motor for specialist repair.

To test on the engine 23B-03

Ensure that the battery is fully charged.

Turn on the lights and operate the starter switch. If no lights are fitted to the machine, connect a voltmeter
across the battery terminals and operate the starter switch.

If the starter does not operate but the lights keep their power or there is no voltage drop across the battery,
check the switch and all the connections and wires. Slow action of the starter can be caused by faulty
connections.

Failure to engage smoothly between the starter and the flywheel can be caused, on some types of starter
motor, by dirt on the helical grooves of the starter motor drive, which can prevent free pinion movement. Clean
the shaft thoroughly with gasolene, or a fluid made especially for the purpose, and apply a small quantity of
Aero Shell 6B or its equal.
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ELECTRICAL EQUIPMENT WX90

23B.3 DATA AND DIMENSIONS

NOTE: This information is given as a guide for personnel engaged on engine overhauls. The dimensions
which are shown are those which are mainly used in the factory. The information applies to all engines,
unless an engine type code is shown.

23B.3.1 ELECTRICAL EQUIPMENT

The information which follows is general and can change with specific applications.

Starter motors

Make and type ................................................................ Lucas S115 or Magneti Marelli M127 or Bosch JF
Voltage:
Lucas S115 .................................................................................................................................. 12V or 24V
Magneti Marelli M127 .............................................................................................................................. 12V
Bosch JF ...................................................................................................................................... 12V or 24V
Number of teeth on pinion.......................................................................................................................... 10
Maximum starter cable resistance at 200 °C (680 °F):
- 12V ......................................................................................................................................... 0.0017 ohms
- 24V ......................................................................................................................................... 0.0034 ohms
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NOTES:

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23C. ELECTRICAL EQUIPMENT

23C.1 GENERAL DESCRIPTION

There are two types of electrical starting aid in

use: The fuelled starting aid and the port heater.

The fuelled starting aid (B1) is a device which is

operated electrically and ignites a controlled
amount of diesel fuel in the induction manifold to
heat the induction air. A heater coil in the body
expands a valve holder to allow fuel to flow into
the device. The fuel is ignited by the hot coil and
heats the air which passes through the induction
manifold when the starter motor is operated.

The port heater has an electrically heated coil

that heats the air as it enters the induction manifold.
Port heaters are used in a group of two or three.

23C.2 STARTING AID

To remove and to fit a fuelled

starting aid 23C-01A

23C.2.1 TO REMOVE

1 Disconnect the fuel pipe (A2) and the electrical

connection (A3).

2 Turn the spanner (A1) counter-clockwise and

remove the starting aid.

23C.2.2 TO FIT

1 Ensure that the contact faces of the manifold

and the starting aid are clean. Put the sealing
washer into position and fit the starting aid.
Tighten the starting aid to 31 Nm (23 Ibf ft) 3.2
kgf m.

2 Check the fuel pipe and, if it is still full of fuel,

connect it to the starting aid. If the fuel has
drained from the pipe, eliminate the air from
the pipe as shown in paragraph 3 of operation
20A-08.

3 Connect the electrical connection (A2).

Some engines which have water-to-air
intercoolers are fitted with twin fuelled starting
15501 9-35990

alds (B3). These starting aids are in a recess

on top of the induction manifold. In this
situation, access to the electrical terminals
(B2) can be restricted if the starting aids are
not fitted correctly, see page 23C.03.
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ELECTRICAL EQUIPMENT WX90

23C.2.3 TWIN FUELLED-STARTING-AID

The correct procedure to remove and to fit twin

fuelled starting alds is as follows:

23C.2.4 TO REMOVE

1 Disconnect the fuel connections and the

electrical connections.

2 Remove the starting aids.

23C.2.5 TO FIT

1 Ensure that the seat faces of the manifold and

the fuelled starting aids are free of dirt.

2 Fit the nylon spacer(s) (A3) over the threads

of the starting aid. Screw the fuel starting aid
into the manifold and tighten to 31 Nm (23 Ibf
ft) 3.1 kgf m. Ensure that the electrical
connector(s) (A2) are in the correct position.
It is not necessary to use Threadlock.

CAUTION: To prevent electrical contact when

the circuit is on and for easy removal during
maintenance, it is important that the electrical
terminals face away from the casing.

3 When the fuelled starting aids are tightened

fully into the manifold. If necessary, rotate
them back, no more than half of one complete
turn, until the electrical terminals face away
from the casing.

4 Check the fuel pipes and if they are still full of

fuel, connect them to the starting aids. If the
fuel has drained from the pipes, eliminate the
air from the pipes, refer to section 20A.

5 Connect the electrical connections. 15501 9-35990

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ELECTRICAL EQUIPMENT WX90

23C.2.6 HOW TO CHECK THE FUELLED STARTING AID

If the inside of the induction manifold is wet, check that there is not a fuel leak from the fuelled starting aid.

1 Disconnect the fuel pipe and the electrical connection at the starting aid. Remove the starting aid from the
manifold and fit a suitable plug in the manifold.

2 Connect the fuel pipe to the starting aid, but leave the connection loose. Do not fit the electrical connection,
but ensure that the connector has a suitable insulator fitted. Operate the priming lever of the fuel lift pump
until fuel free of air comes from the connection. Tighten the connection.

3 Start the engine and operate it at low speed. Check that there is no fuel leakage from the valve of the starting
aid.

4 If there is no leakage, remove the plug from the induction manifold and fit the starting aid. Connect the fuel
pipe to the starting aid and remove the air from the pipe as shown above. Connect the electrical connection.

If there is a leak from the valve of the starting aid, fit a new starting aid.

To remove and to fit a port heater 23C-01 B

1 Disconnect the electrical connection.

2 Remove the port heater from the induction manifold or from the elbow.

3 Fit the port heater and tighten it to 60 Nm (44 Ibf ft) 6.1 kgf m.

4 Connect the electrical connection.

23C.3 DATA AND DIMENSIONS

NOTE: This information is given as a guide for personnel engaged on engine overhauls. The dimensions
which are shown are those which are mainly used in the factory. The information applies to all engines,
unless an engine type code is shown.

23C.3.1 ELECTRICAL EQUIPMENT

The information which follows is general and can change with specific applications.

Starting aid

Type ..................................................................................... Electrically operated heater, with a fuel supply

Voltage .................................................................................... 12V (dropping resistor used on 24V system)
Flow rate of fuel through starting aid....................................................................................... 3.5/5.9 ml/min
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NOTES:

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AUXILIARY EQUIPMENT WX90

25. AUXILIARY EQUIPMENT

Number Description lllustration

PD.1D Remover /replacer for valve guides (main tool)

Part number 21825478

PD.1D-13 Adaptor for use with PD.1 D.

Part number 27610019

Inlet valve guide adaptor for use with PD.1 D e

PD.1C-6 PD.1 D-1A.
Part number 21825482

Exhaust valve guide adaptor for use with PD.1D

PD.248 and PD.1D-1A.
Part number 27610029

PD.245 Timing pin for Bosch fuel injection pumps.

Part number 27610032

Timing pin for Lucas and Stanadyne fuel

PD.246 injection pumps.
Part number 27610033
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Gauge for piston height, valve depth and

PD.41D cylinder liner flange; for use with PD.208.
Part number 21825496
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AUXILIARY EQUIPMENT WX90

Number Description lllustration

PD.145D Replacer tool for crankshaft rear seal.

Part number 21825540

PD.150B Remover / replacer for cylinder liner (main tool).

Part number 21825543

PD.150B-17A Adaptors for use with PD.150B.

Part number 21825563

PD.155C Basic puller for camshaft gear.

Part number 21825565

PD.155B-5 Adaptors for use with PD.155C.

Part number 21825930

Centralising tool for timing case cover

PD.162B (four cylinder engines).
Part number 21825936
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Number Description lllustration

Centralising tool for timing case cover (Six cylinder

PD.163A engines).
Part number 21825574

Crankshaft rotation adaptor for use with a 12.7

PD.165B mm (0.5 in) square drive.
Part number 21825576

Replacer tool for seal of timing case cover (main

PD.170 tool).
Part number 21825577

PD.170-1 Pressure plate for use with PD.170.

Part number 21825578

PD.170-2 Sleeve for use with PD.170.

Part number 21825579

PD.170-3 Fastener plate for use with PD.170.

Part number 21825580
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PD.(1) Adaptor for front seal for use with PD.170. Part
number (1)

(1) Refer to your nearest CASE distributor.

 EM11-25-4
AUXILIARY EQUIPMENT WX90

Number Description Illustration

Spanner for flange nuts of the Bosch fuel

PD.239 injection pump.
Part number 21825964

PD.206 Replacer tool for pistons.

Part number 21825615

PD.208 Dial gauge for use withPD.41D.

Part number 21825617

PD.6118B Valve spring compressor.

Part number 21825666

PD.6118-7 Stud adaptor for use with PD.6118B.

Part number 21825672

PD.6118-8 Setscrew adaptor for use withPD.6118B.

Part number 21825673
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Number Description Illustration

PD.198 Angle gauge to tighten cylinder head setscrews.

(MS.1531) Part number 21825607

Combined reamer/cutters and handle for val-

PD.242 ve guides and 31°/ 46° valve seat inserts. Part
number 27610030

PD.247 Coolant pump, oil seal replacer tool.

Part number 27610031
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NOTES:

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