Komatsu Utility WB97S-5 Shop Manual Download

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REMOVAL AND INSTALLATION

WB97S-5

30-150

TRANSMISSION

17 -Lower the spring (28) lock washer (29).

Use tool

RKZC4303

18 -Insert snap ring (30).

Ensure that the snap ring (30) is well fitted.

RKZC4312

19 -Loosen the handles of the threaded rods to release the

tension from the spring.
Remove the top piece of the

special tool.

RKZC4301

20 -Remove tool

and assemble spring pin (22).

RKZC5550

Summary of Contents for WB97S-5

Page 1: ...WEBM007500 WB97S 5 BACKHOE LOADER SERIAL NUMBER F00003 and up WB97S 5 SHOP MANUAL ...

Page 2: ......

Page 3: ...WB97S 5 00 1 CONTENTS CONTENTS Page 10 STRUCTURE AND FUNCTION 10 1 20 TESTING AND ADJUSTING 20 1 30 DISASSEMBLY AND ASSEMBLY 30 1 40 STANDARD MAINTENANCE 40 1 90 OTHER 90 1 ...

Page 4: ...PAGE INTENTIONALLY LEFT BLANK ...

Page 5: ...10 52 10 53 10 54 10 55 10 56 10 57 10 58 10 59 10 60 10 61 10 62 10 63 10 64 10 65 10 66 10 67 10 68 10 69 10 70 10 71 10 72 10 73 10 74 10 75 10 76 10 77 10 78 10 79 10 80 10 81 10 82 10 83 10 84 10 85 10 86 10 87 10 88 10 89 10 90 10 91 10 92 10 93 10 94 10 95 10 96 10 97 10 98 10 99 10 100 10 101 10 102 10 103 10 104 10 105 10 106 10 107 10 108 10 109 10 110 10 111 10 112 10 113 10 114 10 115 ...

Page 6: ...2 30 203 30 204 30 205 30 206 30 207 30 208 30 209 30 210 30 211 30 212 30 213 30 214 30 215 30 216 30 217 30 218 30 219 30 220 30 221 30 222 30 223 30 224 30 225 30 226 30 227 30 228 30 229 30 230 30 231 30 232 30 233 30 234 30 235 30 236 30 237 30 238 30 239 30 240 30 241 30 242 30 243 30 244 30 245 30 246 30 247 30 248 30 249 30 250 30 251 30 252 30 253 30 254 30 255 30 256 30 257 30 258 30 259...

Page 7: ... s compartment 5 Keep all tools in good condition and learn the correct way to use them 6 Decide a place in the repair workshop to keep tools and removed parts Always keep the tools and parts in their correct places Always keep the work area clean and make sure that there is no dirt or oil on the floor Smoke only in the areas provided for smoking Never smoke while working PREPARATIONS FOR WORK 7 B...

Page 8: ...cause you to slip or can even start fires 18 As a general rule do not use gasoline to wash parts Inparticular use onlytheminimumof gasolinewhen washing electrical parts 19 Be sure to assemble all parts again in their original places Replace any damage parts with new parts When installing hoses and wires be sure that they will not be damaged by contact with other parts when the machine is being ope...

Page 9: ...n of each component It serves not only to give an understanding of the structure but also serves as reference material for troubleshooting TESTING AND ADJUSTMENTS This sections explains checks to be made before and after performing repairs as well as adjustments to be made at completion of the checks and repairs Troubleshooting charts correlating Problems to Causes are also included in this sectio...

Page 10: ...title page and SAFETY page SYMBOLS In order to make the shop manual greatly chelpful im portant points about safety and quality are marked with the following symbols 10 3 Item number 10 Structure and Function Consecutive page number for each item 10 4 10 4 1 10 4 2 10 5 Added pages Symbol Item Remarks k Safety Special safety precautions are necessary when performing the work Extra special safety p...

Page 11: ...the rope or slipping of the rope from its original winding position on the load which can cause dangerous accidents 4 Do not sling a heavy load with ropes forming a wide hanging angle from the hook When hoisting a load with two or more ropes the force subjected to each rope will increase with the hanging angles The table below shows the variation of allowable load kg when hoisting is made with two...

Page 12: ...lts mm Width across flat mm kgm Nm kgm Nm 6 8 10 12 14 1 1 25 1 5 1 75 2 10 13 17 19 22 8 6 8 10 12 0 96 0 1 2 3 0 2 4 6 0 5 7 8 0 8 12 5 1 9 5 1 23 2 45 4 9 77 8 122 13 1 3 0 15 3 2 0 3 6 5 0 6 11 1 17 5 2 13 5 1 5 32 2 3 5 63 6 5 108 11 172 18 16 18 20 22 24 2 2 5 2 5 2 5 3 24 27 30 32 36 14 14 17 17 19 19 5 2 27 3 38 4 52 6 66 7 191 21 262 28 372 40 511 57 644 70 27 3 37 4 53 6 73 8 92 10 268 2...

Page 13: ... 22 27 32 38 50 27 41 2 6 0 5 4 0 5 6 7 2 8 2 9 7 3 17 3 20 5 8 2 20 5 25 5 4 9 39 2 4 9 65 7 19 6 78 5 19 6 95 15 29 4 166 7 29 4 196 2 49 78 5 19 6 196 2 49 Thread diameter of nut part mm Width across flats of nut part mm TIGHTENING TORQUE kgm Nm 9 16 18 11 16 16 13 16 16 1 14 1 3 16 12 1 7 16 12 1 11 16 12 2 12 17 22 24 30 36 41 50 57 2 3 2 5 3 4 3 9 5 2 5 8 8 2 9 2 12 2 13 3 15 3 17 3 18 4 20 ...

Page 14: ...t plane surfaces when the option of possible future dismantling is required Loctite 601 Used for high resistant locking of mechanical components that can be removed only after heating Loctite 675 Used to lock cylindrical couplings and for the permanent locking of threaded parts and also to lock shafts to bearings gears pulleys pins bushings etc Gasket sealant ASL800060 Used by itself to seal greas...

Page 15: ...30 2 47 3 80 20 4 56 0 30 3 95 4 60 28 6 84 0 30 5 93 5 20 37 10 84 0 40 10 55 7 10 53 50 399 0 40 50 11 14 160 Primary Auxiliary Code A A B A B A G A N A N A R A R A V A V Colour Light Blue Light Blue White Light Blue Yellow Light Blue Black Light Blue Red Light Blue Green Code B B G B N B N B R B R B V Colour White White Yellow White Black White Red White Green Code C C B C B C L C N Colour Oran...

Page 16: ...x pump group Piston pump 36 8 Transmission 254 Front axle 525 Rear axle 545 Front wheel Rear wheel Work equipment Boom Shovel Fulcrum lever Tilt lever Raise cylinder Tilt cylinder 1100 313 436 13x4 32 5x2 46x2 35x2 Work equipment with standard arm with long arm with jig arm 850 885 1030 Boom 248 Arm Long arm Boom swing bracket 162 5 Backframe 246 Control valve 8 spool Control valve 10 spool Jig ar...

Page 17: ...CEA E7 Hydraulic system OIL API CF CF2 CD 98 40 Hydraulic system with biodegradable oil 98 40 Front axle Differential OIL UTTO FLUID 10 5 10 5 Final reduction gear ea 1 3 1 3 Rear axle Differential 10 5 10 5 Final reduction gear ea 1 3 1 3 Hydraulic transmission OIL GM DEXRON II D DEXRON is a reg istered trademark of General Motors Cor poration 20 20 Braking system 0 8 0 8 Fuel tank DIESEL OIL 150...

Page 18: ...according to the periodic maintenance intervals indicated in the operation and maintenance manual In the diesel oil sulphur content exceeds 0 5 change the engine oil according to the following table 2 When starting the engine at temperatures below 0 C use engine oil SAE 10W 20W 20 even if during the day the temperature increases by 10 C 3 Use engine oil with CD classification if oil with CC classi...

Page 19: ...ve the decimal point one place to the left to convert it to 55 mm 2 Carry out the same procedure as above to convert 55 mm to 2 165 in 3 The original value 550 mm was divided by 10 so multiply 2 165 in by 10 move the decimal point one place to the right to return to the original value This gives 550 mm 21 65 in From millimeters to inches 1 mm 0 03937 in 0 1 2 3 4 5 6 7 8 9 0 10 20 30 40 50 60 70 8...

Page 20: ... 0 315 0 709 1 102 1 496 1 890 2 283 2 677 3 071 3 465 3 858 0 354 0 748 1 142 1 536 1 929 2 323 2 717 3 110 3 504 3 898 0 1 2 3 4 5 6 7 8 9 0 10 20 30 40 50 60 70 80 90 0 22 05 44 09 66 14 88 18 110 23 132 28 154 32 176 37 198 42 2 20 24 25 46 30 68 34 90 39 112 44 134 48 156 53 178 57 200 62 4 41 26 46 48 50 70 55 92 59 114 64 136 69 158 73 180 78 202 83 6 61 28 66 50 71 72 75 94 80 116 85 138 8...

Page 21: ...8 17 700 20 341 22 983 25 625 2 113 4 755 7 397 10 039 12 680 15 322 17 964 20 605 23 247 25 889 2 378 5 019 7 661 10 303 12 944 15 586 18 228 20 870 23 511 26 153 0 1 2 3 4 5 6 7 8 9 0 10 20 30 40 50 60 70 80 90 0 2 200 4 399 6 599 8 799 10 998 13 198 15 398 17 598 19 797 0 220 2 420 4 619 6 819 9 019 11 281 13 418 15 618 17 818 20 017 0 440 2 640 4 839 7 039 9 239 11 438 13 638 15 838 18 037 20 ...

Page 22: ...31 127 501 134 871 142 241 2 948 10 318 17 688 25 058 32 428 39 798 47 168 54 538 61 908 69 278 76 648 84 018 91 388 98 758 106 128 113 498 120 868 128 238 135 608 142 978 3 685 11 055 18 425 25 795 33 165 40 535 47 905 55 275 82 645 70 015 77 385 84 755 92 125 99 495 106 865 114 235 121 605 128 975 136 345 143 715 4 422 11 792 19 162 26 532 33 902 41 272 48 642 56 012 63 382 70 752 78 122 85 492 ...

Page 23: ...6 14 586 15 606 16 626 17 646 18 666 19 686 0 408 1 428 2 448 3 468 4 488 5 508 6 528 7 548 8 568 9 588 10 608 11 628 12 648 13 668 14 688 15 708 16 728 17 748 18 768 19 788 0 510 1 530 2 550 3 570 4 590 5 610 6 630 7 650 8 670 9 690 10 710 11 730 12 750 13 770 14 790 15 810 16 830 17 850 18 870 19 890 0 612 1 632 2 652 3 672 4 692 5 712 6 732 7 752 8 772 9 792 10 812 11 832 12 852 13 872 14 892 1...

Page 24: ...7 962 0 1034 3 1106 6 1179 0 1251 3 1323 6 1396 0 28 9 101 3 173 6 245 9 318 3 390 6 462 9 535 2 607 6 679 9 752 2 824 6 896 9 969 2 1041 5 1113 9 1186 2 1258 5 1330 9 1403 2 36 2 108 5 180 8 253 2 325 5 397 8 470 2 542 5 614 8 687 1 759 5 831 8 904 1 876 5 1048 8 1121 1 1193 4 1265 8 1338 1 1410 4 43 4 115 7 188 1 260 4 332 7 405 1 477 4 549 7 622 0 694 4 766 7 839 0 911 4 983 7 1056 0 1128 3 120...

Page 25: ...3234 2 3379 2 3524 2 58 0 203 0 348 1 493 1 638 1 783 2 928 2 1073 2 1218 2 1363 3 1508 3 1653 3 1798 4 1943 4 2088 4 2233 5 2378 5 2523 5 2668 5 2813 6 2958 6 3103 6 3248 7 3393 7 3538 7 72 5 217 5 362 6 507 6 652 6 797 7 942 7 1087 7 1232 7 1377 8 1522 8 1667 8 1812 9 1957 9 2102 9 2248 0 2393 0 2538 0 2683 0 2828 1 2973 1 3118 1 3263 2 3408 2 3553 2 87 0 232 0 377 1 522 1 667 1 812 2 957 2 1102...

Page 26: ...0 9 4 8 9 8 3 7 8 7 2 6 7 6 1 5 6 5 0 4 4 3 9 3 3 2 8 2 2 1 7 1 1 0 6 0 0 0 6 1 1 1 7 2 2 2 8 3 3 3 9 4 4 5 0 5 6 6 1 6 7 7 2 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 51 8 53 6 55 4 57 2 59 0 60 8 62 6 64 4 66 2 68 0 69 8 71 6 73 4 75 2 77 0 78 8 80 6 72 4 84 2 86 0 87 8 89 6 91 4 93 2 95 0 96 8 98 6 100 4 102 2 104 0 105 8 107 6 109 ...

Page 27: ...D VALVE GROUP EV1 90 SOLENOID VALVE GROUP EV2 92 SAFETY VALVES 93 SHOVEL CYLINDERS 97 BACKHOE CYLINDERS 99 AIR CONDITIONING UNIT 103 OPERATION OF THE AIR CONDITIONING UNIT 104 FUSE AND RELAY CENTRE 105 DRIVER SEAT WIRING 106 SWITCH PANEL WIRING 107 FRONT DASH WIRING 108 LATERAL DASH WIRING 109 ROOF WIRING 110 ENGINE WIRING 111 SPEED SELECTOR WIRING 112 BACKHOE WIRING 113 JIG ARM WIRING 114 4WS PUS...

Page 28: ...the transmission 3 and to the drive shaft of the hydraulic pump 4 The transmission 3 is electro hydraulic in all its functions power shuttle direction and speed can be selected manually from a dedicated control unit and is managed by solenoid valves The driving power is transmitted from the transmission 3 to the front 5 and rear 6 axles through the cardan drive shafts 7 and 8 The driving power tra...

Page 29: ...tal 1st gear 5 533 2 909 6 923 111 43 5 533 2 477 6 923 94 48 2nd gear 3 360 67 67 3 360 57 38 3rd gear 1 532 30 85 1 532 26 16 4th gear 0 810 16 31 0 810 13 83 4 1 RKZ13480 6 9 8 7 5 2 3 1 1 Diesel engine 2 Convertor 3 Transmission 4 Hydraulic pump 5 Front axle 6 Rear axle 7 Front cardan drive shaft 8 Rear cardan drive shaft 9 Rear wheels 10 Front wheels ...

Page 30: ...5 bar st 1 TUBE TRASMISSION SUMP INPUT SHAFT OUTPUT SHAFT PRIMARY SHAFT LOCATED IN OIL PUMP OPENS AT 5 5 BAR Ø3 5 mm LOCATED IN OIL PUMP FLOW TO COOLER RPM 900 13 25 L 1 RPM 2200 20 35 L 1 LOCATED IN OIL PUMP OPENS AT 23 0 26 0 AIR BREATHER HOSE HOSE NOT SUPPLIED BAR 4WD TUBE rpm 900 13 5 16 bar rpm 2200 14 5 17 5 bar REV FWD rpm 900 13 5 16 bar rpm 2200 14 5 17 5 bar rpm 900 14 16 5 bar rpm 2200 ...

Page 31: ...nt pressure check 11 REVERSE engagement pressure check 12 FORWARD engagement 13 REVERSE engagement 14 4WD engagement disengagement 15 Modulating valve 16 Input shaft lubrication A pivot 17 Backhoe oil feed port 18 Drive engagement pressure check 19 1st gear engagement 20 2nd gear engagement 21 3rd gear engagement 22 4th gear engagement 23 Main shaft lubrication B shaft 24 Output shaft lubrication ...

Page 32: ... 3 2 b 8 4 7 12 11 10 1 Control valve group 2 Convertor 3 Oil filter 4 Oil refilling port 5 Oil drain plug 6 Oil temperature sensor 7 Vent plug 8 Revolution sensor 9 Converter input pressure check port 10 Reverse engagement pressure check port 11 Forward engagement pressure check port 12 PPC valve feed pressure check port ...

Page 33: ...10 7 WB97S 5 STRUCTURE AND FUNCTION TRANSMISSION Kinematics diagram Axis D Axis A Axis B Axis C Axis E Input shaft Output shaft RKZ11140 Output shaft E C B A D L L ...

Page 34: ...AL COMPONENTS 1 C24 2nd gear solenoid valve ED6 2 C27 4WD solenoid valve ED5 3 C26 4th gear solenoid valve ED2 4 C21 Reverse gears command solenoid valve ED4 5 C22 Forward gear solenoid valve ED3 6 C25 3rd gear solenoid valve ED7 7 C23 1st gear solenoid valve ED1 RKZ11150 6 7 1 3 2 4 5 ...

Page 35: ...ng reverse clutch b Port commanding forward clutch c Lubrication port 1 Reverse gear clutch Z 37 2 Forward gear Z 37 3 Reverse clutch piston 4 Forward clutch piston 5 Shoulder ring 6 Driven shaft Drive shaft RKZ11170 1 a 2 3 5 4 a 2nd gear port 1 3rd drive gear Z 45 2 2nd drive gear Z 28 3 4th drive gear Z 58 4 1st drive gear Z 17 5 2nd gear piston ...

Page 36: ... driven gear Z 44 2 2nd gear driven gear Z 60 3 4th gear driven gear Z 30 4 4WD drive gear Z 51 5 1st gear driven gear Z 60 6 Rear output shaft 7 1st gear piston 8 4th gear piston 9 3rd gear piston 4WD driven shaft 1 5 a 2 3 4 RKZ11190 a 4WD disengagement command port 1 Front output shaft 2 4WD disengagement piston 3 4WD gear driven Z 41 4 Piston n 3 5 Spring ...

Page 37: ...ential 1 4 5 7 8 9 10 2 1 3 6 11 12 13 14 15 16 RKZ13210 1 Planetary gear 2 Ring gear 3 Planetary gear 4 Ring nut 5 Half axle 6 Pin 7 Differential housing 8 Spacer 9 Bearing 10 Sealing ring 11 Flange 12 Ring nut 13 Bearing 14 Bevel pinion 15 Pin 16 Oil refilling plug ...

Page 38: ...15 16 17 18 19 20 22 1 RKZ13220 1 Planetary gear 2 Planetary gear 3 Ring gear 4 Crown wheel holder 5 Wheel hub 6 Sealing ring 7 Pin 8 Shim 9 Protection 10 Bushing 11 Sealing ring 12 Axle body 13 Bearing 14 Joint 15 Pin 16 Protection 17 Sealing ring 18 Bearing 19 Snap ring 20 Centering pin 21 Stud bolt 22 Plug ...

Page 39: ...ylinder 4 1 2 3 5 6 A A a b B B 7 8 RKZ13230 A Section A A Section B B Check item A 1 Steering cylinder 2 Oil refilling plug 3 Oil drain plug 4 Nut 5 Adjusting screw 6 Nut 7 Bushing 8 Bushing Port a From the steering unit L Port Port b From the steering unit R Port ...

Page 40: ...l 8 9 10 12 11 13 14 15 17 16 1 2 3 4 5 6 7 7 RKZ13240 1 Bearing 2 Planetary gear 3 Planetary gear 4 Ring gear 5 Differential housing 6 Ring nut 7 Half axle 8 Pin 9 Bearing 11 Sealing ring 12 Flange 13 Spacer 14 Bevel pinion 15 Differential housing 16 Disk 17 Steel disk ...

Page 41: ... 11 12 13 14 14 16 17 18 19 20 22 1 7 1 Planetary gear 2 Planetary gear 3 Ring gear 4 Crown wheel holder 5 Wheel hub 6 Gasket 7 Pin 8 Shim 9 Protection 10 Bushing 11 Gasket 12 Axle body 13 Bearing 14 Joint 15 Pin 16 Protection 17 Gasket 18 Bearing 19 Snap ring 20 Centering pin 21 Stud bolt 22 Plug ...

Page 42: ...lare A 2 3 1 A 9 4 5 6 10 11 7 12 8 Check item A 1 Spring 2 Bushing 3 Parking brake control shaft 4 Bleed screw 5 Parking brake control lever 6 Parking brake control cam 7 Brake disk 8 Bushing 9 Working brake control piston 10 Pressure disk 11 Intermediate disk 12 Spacer ...

Page 43: ...nit cylinder 1 Steering cylinder 2 Nut 3 Adjusting screw 4 Nut Port c From solenoid valve group ST2 Port A Port d From solenoid valve group ST2 Port B Port e From brake pump C3 2 Sezione A A 1 3 4 Particolare A A A A c d e e RKZ13270 Check item A Section A A ...

Page 44: ...tions by Load Sensing and sends the necessary quantity of oil to the steering system 6 even when other oleodynamic components supplied by the same circuit are in operation The oil passes from this group 6 into the steering cylinders 9 and 10 The solenoid valve group 8 can switch the oil flow to provide three types of steering 1 2 wheels steering Steering condition in which the rear axle is exclude...

Page 45: ...rol valve the oil passes out of Port T and drains into the tank 3 STEERING TO THE LEFT Turning the steering wheel 7 anti clockwise causes rotation of the steering metering group 6 and prepares the control valve port L to send oil through line g to solenoid valve group and thence through line f into chamber a of the cylinder 9 the pressurized oil moves the piston which then steers the wheels The oi...

Page 46: ...ch it passes port T to drain into the tank 3 STEERING TO THE LEFT Turning the steering wheel 7 anti clockwise causes rotation of the steering metering group 6 and prepares the control valve port L to send oil through line g to solenoid valve group and thence through line i into chamber c of cylinder 10 The pressurized oil moves the piston of the cylinder 10 thatsteers thewheelsand atthe sametime i...

Page 47: ...ses port T to drain into the tank 3 STEERING TO THE LEFT Turning the steering wheel 7 anti clockwise causes rotation of the steering metering group 6 and prepares the control valve port L to send oil through line g to solenoid valve group and then through line h into chamber d of cylinder 10 The pressurized oil moves the piston of the cylinder 10 that steers the wheels while simultaneously impelli...

Page 48: ...PAGE INTENTIONALLY LEFT BLANK ...

Page 49: ...344 PB4 PA4 B5 A5 DIGGING DUMP 100L min 120L min PB5 PA5 B6 A6 OPEN CLOSED PB6 PA6 90L min 75L min B7 A7 CLOSED EXTENDED 100L min 80L min PB7 PA7 B8 A8 LOWER RAISE PB8 PA8 120L min 100L min FLOAT OPTION B9 A9 RAISE LOWER PB9 PA9 50L min 50L min 50L min A10 B10 50L min PA10 RAISE LOWER PB10 Ø0 5 SS BLOCCAGGIO PIASTRA SIDE SHIFT 5 bar 5 bar P T P4 P3 P2 P1 CN S1 CN S4 P T P4 P3 P2 P1 100 µm 2 5 bar ...

Page 50: ...PAGE INTENTIONALLY LEFT BLANK ...

Page 51: ... hydraulic tank Port Ps From hydraulic tank Port P1L From control valve Port Pp Port PLS From control valve Port LS Port PM From EV1 solenoid valve group Port PM PORT FUNCTIONS Port P1 Pump delivery Port Pd Drain Port Ps Intake of oil Port P1L Pump delivery pressure input Port P1C Quick connect for pump delivery pressure Port Pd2 Drain plug Pen port Delivery control pressure check Port PLS Load Se...

Page 52: ...ION HYDRAULIC PUMP 1 MAIN PUMP PORT FUNCTIONS Port Pa Delivery control group feed Port Pe Delivery control signal Port Pd4 Drain Port Pd5 Drain Port PM2 Operating mode signal PM2 Z X RKZ09420 Pa Pd4 Pd5 Pe C D D C B B A A View X View Z ...

Page 53: ...520 1 14 2 3 4 5 6 7 8 9 10 11 12 13 Section A A Section C C Section D D Section B B 1 Bearing 2 Input shaft 3 Hydraulic pump 4 Swash plate 5 Shoe 6 Piston 7 Cylinder block 8 Swash plate 9 Cover 10 Shoe guide 11 Control piston 12 Spring 13 Sealing ring 14 Ball ...

Page 54: ...g Swash plate 7 is supported by pump body 8 and ball 9 and has a flat surface A Shoe 6 remains in contact with swash plate 7 and slides in a circular movement Pressurised oil is introduced between shoe 6 and swash plate 7 forming a static bearing that allows shoes 6 to slip The pistons 5 perform their relative movements in an axial direction inside cylindrical chambers fashioned in the cylinder bl...

Page 55: ...erefore causing the suction and delivery of oil in a quantity that is equivalent to the difference between those volumes F E delivery In other words when cylinder block 1 rotates chamber F decreases in volume causing oil to be delivered to the circuits while chamber E increases in volume causing oil to be suctioned The illustration shows the state of the pump when suction at chamber F and delivery...

Page 56: ...dingly Angle a of the swash plate is varied by the servo piston 11 2 The servo piston 11 moves in a reciprocating linear motion caused by pressure signals from the PC and LS valves The linear motion is transmitted to theswash plate 7 The swashplate issupported by the pump body 8 through the ball 9 and this is the reason why the swash plate 7 moves in a semicircular alternate motion RKZ09560 X 7 a ...

Page 57: ...CTION HYDRAULIC PUMP 2 DELIVERY CONTROL VALVE PORT FUNCTIONS T port Drain P1 port Delivery control group feed Pd4 port Drain PE port Delivery control signal output PM port Operating mode signal input RKZ09430 A A B B Ad4 Pa PM Pd5 Pe ...

Page 58: ...0 1 2 3 4 5 7 8 9 6 Pa PM Pa PPL Pd4 Section A A COMPONENTS 1 Lever 2 Spring 3 Retainer 4 Seat 5 Spool 6 Sleeve 7 Piston 8 Gasket 9 Piston PORT FUNCTIONS T port Drain PA Port Pump delivery pressure PM port Operating mode signal input PPL port Delivery control signal output ...

Page 59: ...5 6 3 PLS Pe Pa PPL Pd4 PPLS Section B B COMPONENTS 1 Spool 2 Plug 3 Seat 4 Spring 5 Nut 6 Plug PORT FUNCTIONS T port Drain PA Port Pump delivery pressure PE port Delivery control signal PLS port LS signal input PPL port Delivery control signal input PPLS port LS pump signal input ...

Page 60: ...y the pump pressure the Load Sensing pressure and the difference in pressure between these two values In other words the LS valve detects the pressure difference DPLS generated by the passage of the oil flow through the surface freed by the control valve spool and controls the pump delivery Q so as to keep the pressure drop constant It can therefore be assumed that the pump delivery is proportiona...

Page 61: ...ure pump delivery In other words when during operation the delivery Q increases and the delivery pressure PPLS also increases simultaneously the PC valve reduces the pump delivery Q When the delivery pressure PPLS decreases the PC valve increases the pump flow As pressure PC increases the relation between pressure PA and delivery Q is changed in accordance with the force applied by pressure PC In ...

Page 62: ...s slightly to the right At the same time a connection opens between passages C and D and pressurised oil from valve LS is sent for relief PT Simultaneously passagesFandG onvalve LS are interconnected pressure at passage J is sent for relief PT and the control piston 2 shifts to the left Pump delivery increases as a result When the control piston 2 moves the lever 3 moves to the left and the spring...

Page 63: ...ivalent to the pump s delivery pressure PA Simultaneously passages F and G in valve LS are interconnected and pressure at port J becomes equivalent to the pump s delivery pressure PA and the control piston 2 shifts to the right Pump delivery decreases as a result When the control piston 2 moves the lever 3 moves to the right and the spring 1 compresses thereby increasing its load on the spool 5 Co...

Page 64: ...e equilibrium between the force applied by pressure PA against spool 4 and the force applied by spring 1 against spool 5 is what determines the position at which the control piston 2 hence pump delivery stops 3 2 4 5 1 B C PT F G J RKZ09510 PA D C B LS valve Solenoid valve Engine Check valve ...

Page 65: ...PAGE INTENTIONALLY LEFT BLANK ...

Page 66: ...NCTION 8 SPOOL CONTROL VALVE 8 SPOOL CONTROL VALVE Komatsu Ltd AC AC AB AB AA AA N N M M L L K K J J F F E E D D RKZ09060 Z X B1 PPPC P B2 B3 B4 B5 B6 A6 A5 A4 A3 A2 D T A1 PA1 LS PA6 PA3 PA7 PA8 PA4 PA5 DLS PA2 ViewZ B8 A8 A7 SS B7 ...

Page 67: ... side B8 To the LH outrigger cylinder Head side LS To the hydraulic pump PLS port P From hydraulic pump P1 port D To the steering unit P Port DLS From the steering unit LS Port PP To the hydraulic pump P1L port T To hydraulic tank TS To hydraulic tank PPPC To solenoid valve group EV1 P Port SS To the backhoe plate lock cylinders PA1 From backhoe LH PPC valve port 3 PA2 From backhoe LH PPC valve po...

Page 68: ...alve LH swing 5 Anticavitation valve arm out 6 Safety valve 7 Anticavitation valve arm in 8 Anti shock anticavitation valve RH swing 9 Anti shock anticavitation valve shovel curl 10 Anticavitation valve boom lower 11 Anticavitation valve backhoe bucket dump 12 Spool shovel arm control 13 Spool backhoe bucket control 14 Spool boom control 15 Spool front bucket control 16 Spool boom swing control 17...

Page 69: ... VALVE 1 Shovel arm 2 Backhoe bucket 3 Boom 4 Front bucket 5 Boom swing 6 Arm DELIVERY CONTROL VALVE 7 Arm 8 Boom swing 9 Front bucket 10 Boom 11 Backhoe bucket 12 Shovel arm 13 Max pressure valve 14 Check valve 15 Check valve 16 Check valve 17 Check valve 18 Check valve 19 Check valve 20 Check valve 21 Check valve 22 LS DLS pressure check valve 23 LS by pass plug ...

Page 70: ...ontrol 2 Spool left outrigger control 3 Backhoe plate lock solenoid valve 4 Backhoe plate lock valve 5 Spool shovel arm control 6 Spool backhoe bucket control 7 Spool Boom control 8 Spool front bucket control 9 Spool boom swing control J J M M L L F F E E K K RKZ09100 4 3 2 1 7 8 9 6 5 ...

Page 71: ...ON 8 SPOOL CONTROL VALVE 1 Servocontrol max pressure valve 2 Max pressure valve spool 3 Sequential reducing valve 4 Blow out plug 5 Unloading valve 6 LS by pass plug 7 Spool Arm control RKZ09110 6 5 4 2 1 N N AC AC 3 AA AA AB AB 7 AE AE ...

Page 72: ...OL CONTROL VALVE 10 SPOOL CONTROL VALVE Komatsu Ltd AC AC AB AB AA AA R R N M M L L K K F F E E D D RKZ09120 N J J B1 PPPC P B2 B3 B4 B5 B6 A6 A5 A4 A3 A2 D T A1 PA1 LS PA8 PA3 PA7 PA8 PA4 PA5 DLS PA2 PA7 PA6 A7 A8 B7 B8 ViewZ B10 A10 A9 B9 Z X ...

Page 73: ...10 47 WB97S 5 STRUCTURE AND FUNCTION 10 SPOOL CONTROL VALVE RKZ09590 C C B B A A AE AE PB9 PB10 PB8 PB3 PP PB1 PB2 PB4 PB5 PB7 PB6 ...

Page 74: ...r Head side LS To the hydraulic pump PLS port P From hydraulic pump P1 port D To the steering unit P Port DLS From the steering unit LS Port PP To the hydraulic pump P1L port T To hydraulic tank TS To hydraulic tank PPPC To solenoid valve group EV1 P Port SS To the backhoe plate lock cylinders PA1 From backhoe LH PPC valve port 3 PA2 From backhoe LH PPC valve port 4 PA3 From the shovel PPC valve P...

Page 75: ... arm out 7 Safety valve 8 Anticavitation valve arm in 9 Anti shock anticavitation valve RH swing 10 Anti shock anticavitation valve shovel curl 11 Anticavitation valve boom lower 12 Anticavitation valve backhoe bucket dump 13 Anticavitation valve jig arm retract 14 Anticavitation valve 4 in 1 bucket dump 15 Spool shovel arm control 16 Spool Jig arm control 17 Spool 4 in 1 bucket control 18 Spool b...

Page 76: ...rm 3 4 in 1 bucket 4 Backhoe bucket 5 Boom 6 Front bucket 7 Boom swing 8 Arm DELIVERY CONTROL VALVE 9 Arm 10 Boom swing 11 Front bucket 12 Boom 13 Backhoe bucket 14 4 in 1 bucket 15 Jig arm 16 Shovel arm 17 Max pressure valve 18 Check valve 19 Check valve 20 Check valve 21 Check valve 22 Check valve 23 Check valve 24 Check valve 25 Check valve 26 Check valve 27 LS DLS pressure check valve 28 LS by...

Page 77: ...ontrol 2 Spool left outrigger control 3 Backhoe plate lock solenoid valve 4 Backhoe plate lock valve 5 Spool shovel arm control 6 Spool backhoe bucket control 7 Spool Boom control 8 Spool front bucket control 9 Spool boom swing control L L P P N N F F E E M M RKZ09101 4 3 2 1 7 8 9 6 5 ...

Page 78: ...N 10 SPOOL CONTROL VALVE 1 Servocontrol max pressure valve 2 Max pressure valve spool 3 Sequential reducing valve 4 Blow out plug 5 Unloading valve 6 LS by pass plug 7 Spool Arm control RKZ09111 6 5 4 2 1 R R AC AC 3 AA AA AB AB 7 AE AE ...

Page 79: ...trol of digging action even during delicate manoeuvres c Ability to perform complex operations guaranteed by control of oil flow in function of the aperture surfaces of the shuttles d Energy savings guaranteed by control of pump delivery 1 2 STRUCTURE The CLSS system includes the variable flow pump the control valve and the working equipment The pump includes the main pump the TCC valve and the LS...

Page 80: ... PLS of delivery to the actuator If the differential pressure DPLS becomes lower than the set pressure of the LS valve the angle of the swash plate increases If the differential pressure DPLS increases the angle of the swash plate decreases a For details about this movement see the description of the HYDRAULIC PUMP Max Min Swash plate angle Q 0 LS differential pressure PLS Set differential pressur...

Page 81: ...n two or more movements cylinders are activated simultaneously the pressure differences DP between the delivery at the control valve inlet and outlets of the control valve are compensated by these valves We obtain the distribution of the pump flow in proportion to the areas of passage S1 and S2 of each valve RKP02941 Load W Actuator S1 LS valve P W Load Actuator S2 P Pressure compensation valve Pr...

Page 82: ...4 1 3 4 PP D P 10 9 8 PPPC PB3 8 8 PA4 PA5 PA2 PB2 PB4 PB5 PB1 PA1 Arm Shovel Boom Bucket Right outrigger Left outrigger Boom swing Shovel raising 1 Unloading valve pressure LS 27 5 bar 2 Max pressure valve 218 bar 3 Safety valve 270 bar 4 Check valve 5 Anti shock anticavitation valve 215 bar 6 Anti shock anticavitation valve 220 bar 7 Anti shock anticavitation valve 350 bar 8 Pressure compensatio...

Page 83: ...4 PA4 PB2 PA2 PB1 PA1 RKZ09180 Arm Shovel Boom Bucket Bucket 4 in 1 Right outrigger Left outrigger Boom swing Jig arm Shovel raising 1 Unloading valve pressure LS 27 5 bar 2 Max pressure valve 218 bar 3 Safety valve 270 bar 4 Check valve 5 Anti shock anticavitation valve 215 bar 6 Anti shock anticavitation valve 220 bar 7 Anti shock anticavitation valve 350 bar 8 Pressure compensation valves 9 Pri...

Page 84: ...ol 1 left on surface S1 and right on surface S2 whereas Load Sensing pressure PLS acts on surface S2 Since no LS signal with PLS pressure is generated when the control valve is in NEUTRAL position the only pressure acting on spool 1 in this condition is the pump s delivery pressure PP as regulated by spring compression 2 Asthepump sdeliverypressurePPincreasesandthe resulting force equals spring lo...

Page 85: ...S3 B A Functioning When fine controls are performed at the control valve a PLS pressure is generated This pressure acts on surface S3 on the right hand side of the spool 1 SincepressurePLSofLSislow becausethecontrol valve passage is small the difference with the pump s delivery pressure PP is great When the differential pressure between the pump s delivery pressure PP and pressure PLS of the LS eq...

Page 86: ... generates a pressure PLS of the LS which acts on the right hand side of the spool 1 Since the control valve passage is wide the difference between the pressure PLS of the LS and the pump s delivery pressure PP is small For this reason since the differential pressure between the pump s delivery pressure PP and the pressure PLS of the LS fails to reach the spring loading pressure value of spring 2 ...

Page 87: ... 2 and from the notch a via the duct b At the same time the pressure reducing valve 3 moves to the right thereby making the pump s pressure PP drop as it flows through the bottleneck c andcausingthe pressureto flow intothe circuitPLSof the LS and into the chamber of spring PLSS At this point the PLS circuit of the LS is connected to the tank circuit T by means of the by pass plug 4 See the descrip...

Page 88: ...ump pressure PP starts flowing into the circuit of actuator A through the duct a At the same time pressurised oil is introduced into the PLS circuit of the LS through holes b a The outriggers circuit differs from the working equipment circuit in that the operating pressure of actuator A is introduced directly into the PLS circuit of the LS ...

Page 89: ...oreover by eliminating oil through the bottleneck a loss of pressure is generated in the flow that is controlled by the spool and stability is increased as a result thereby reducing the actual differential pressure LS RKZ09250 b 1 T a T PP PLS Functioning Pressurised oil in the Load Sensing PLS circuit flows through filter a through orifice b and into the tank circuit T PP Pump circuit PLS Load Se...

Page 90: ...S1 of the spring and pushes the pressure reducing valve 1 and the delivery control valve 2 to the left The delivery control valve 2 produces a bottleneck between the pump s delivery PP circuit and the PPA circuit upstream of the control valve spool This bottleneck generates a pressure loss between circuits PP and PPA The delivery control valve 2 and the pressure reducing valve 1 are balanced out a...

Page 91: ...Surface of piston 3 S2 surface of pressure reducing valve 1 Surface of piston 3 Surface ratio S1 S2 and compensation characteristics When the ratio is 1 00 Pump pressure PP Pressure PPA upstream of spool C Load Sensing PLS pressure Actuator PA pressure A Delivery is distributed proportionally to the opening surfaces of the spool When the ratio is greater than 1 00 PP PPA PLS PA A Delivery distribu...

Page 92: ...n of the spool 1 of the priority valve which is in turn determined by LS signal pump delivery steering circuit pressure and hydraulic circuit pressure The position of the spool 1 is determined in such a way as to ensure that the oil delivered to the steering unit matches the delivery needs at any time 1 Priority valve spool PP Pump circuit D Steering unit feed circuit DLS Steering unit LS signal R...

Page 93: ...delivery pressure PP in order to supply pressure to the servocontrols 3 8 1 When all actuators are in a neutral condition Functioning The spool 1 of the unloading valve moves and delivery pressure is regulated at 29 bar 30 kg cm2 For details see 3 2 UNLOADING VALVE The spool 2 and valve 3 reduce the pump s delivery pressure PP to 29 bar 30 kg cm2 Pressure is then sent to the servocontrols via port...

Page 94: ...of the actuator circuit 5 by an amount equivalent to LS differential pressure For details see 3 2 UNLOADING VALVE If the pump s delivery pressure PP exceeds 29 bar 30 kg cm2 valves 2 and 3 reduce pressure PP to 29 bar 30 kg cm2 The reduced pressure is then sent to the servocontrols via port PC When this occurs the sequential reducing valve 4 stays open RKZ09290 PP T 1 PPPC 2 3 TS PLS 5 TO ACTUATOR...

Page 95: ...ght thereby reducing the flow of the PP pressure to the actuator circuit 5 This generates a pressure gap between PP pressure and actuator pressure PP pressure is incremented in excess of 29 bar 30 kg cm2 and is then reduced to 29 bar 30 kg cm2 by valves 2 and 3 to guarantee pressure feed to the servocontrols RKZ09300 PP T 1 PPPC 2 3 TS PLS 5 TO ACTUATORS 4 ...

Page 96: ...ve is deenergized Functioning When the solenoid valve is deenergized pump delivery pressure PP flows through orifice 2 and check valve 3 and into the SS circuit of the plate lock cylinders When the entire circuit reaches pump delivery pressure PP the check valve 3 lowers thereby dividing the circuit which is therefore kept at the maximum pressure reached by the delivery circuit Lock cylinder RKZ09...

Page 97: ...is energized Functioning When the solenoid valve is energized pressurised oil in the SS circuit is sent to the tank circuit through spool 4 As a result the SS circuit pressure decreases and the plate is released so it can be shifted RKZ09320 4 T T 1 3 2 PP SS Lock cylinder ...

Page 98: ...ATION The steering unit is composed of a control valve and a rotating oil dispenser and is of the hydrostatic type When the steering wheel is turned the control valve sends oil from the pump by means of the rotating oil dispenser to one of the sides of the steering cylinder The rotating dispenser ensures that the volume of oil supplied to the cylinder is proportionate to the angle of rotation of t...

Page 99: ...ALVE STANDARD P1 port To control valve PB3 port P2 port To control valve PA3 port P3 port To control valve PA8 port P4 port To control valve PB8 port P port From EV1 solenoid valve group VL port Port T To hydraulic tank Z RKZ09330 B B E E C C A A D D P1 P4 P2 P3 T P View Z ...

Page 100: ...4 WB97S 5 STRUCTURE AND FUNCTION PPC VALVES RKZ09340 A A B B D D E E C C 6 7 8 9 10 1 2 3 4 5 1 Spool 2 Adjusting screw inner 3 Adjusting screw outer 4 Piston 5 Disk 6 Nut 7 Joint 8 Cover 9 Retainer 10 Body ...

Page 101: ...hen pressure P1 increases spool 1 is pushed upwards and calibrated hole f is connected back to discharge chamber D thereby compressing the spring 2 The floating of the spool 1 will continue until calibrated hole f is halfway between discharge chamber D and pressure chamber PP in other words until the pressure in duct P1 the pressure acting on the section of stem 1 offsets the force applied by the ...

Page 102: ...til the pressure corresponding to the control lever position is balanced Whenthespool ofthecontrol valvereturns oil flows back into chamber D throughcalibrated hole f and into chamber B of the control valve spool opposite the operating one Oil flows through duct P2 and into chamber B to ensure it is filled properly 4 During fine control NEUTRAL o Full stroke When the disk 5 pushes down on the pist...

Page 103: ...T RETURN TO DIG P1 port To control valve PB3 port P2 port To control valve PA3 port P3 port To control valve PA8 port P4 port To control valve PB8 port P port From EV1 solenoid valve group VL port Port T To hydraulic tank RKZ08920 View Z C C A A B B D D P4 P1 P2 P3 P T Z ...

Page 104: ...7S 5 STRUCTURE AND FUNCTION PPC VALVES RKZ08980 A A D D C C 6 7 8 2 3 4 5 9 10 11 1 B B 1 Spool 2 Adjusting screw inner 3 Adjusting screw outer 4 Piston 5 Disk 6 Disk 7 Joint 8 Cover 9 Retainer 10 Piston 11 Body ...

Page 105: ...PC valve ducts P1 and P2 are connected to discharge chamber D by means of the calibrated hole f in spool 1 Shovel raise PPC valve Control valve ducts A and B and PPC valve ducts P3 and P4 are connected to discharge chamber D by means of the calibrated hole f in spool 1 RKZ08990 T P f D P1 P2 1 T P D P4 P3 1 f A B A B Control valve Control valve ...

Page 106: ... is connected back to discharge chamber D thereby compressing the spring 2 The floating of the spool 1 will continue until calibrated hole f is halfway between discharge chamber D and pressure chamber PP in other words until the pressure in duct P1 the pressure acting on the section of stem 1 offsets the force applied by the spring 2 The spring 2 is compressed proportionally to the movement of the...

Page 107: ... until the pressure corresponding to the control lever position is balanced When thespoolof thecontrolvalvereturns oilflows back into chamber D through calibrated holef and into chamber B of the control valve spool opposite the operating one Oil flows through duct P2 and into chamber B to ensure it is filled properly 4 During fine control NEUTRAL o Full stroke When the disk 5 pushes down on the pi...

Page 108: ...ated by the solenoid will retain the piston 4 in place and the arm float condition will be retained even if the lever is released At the same time the control valve will also be activated and retained in the arm float position 6 When control lever is moved from float back to neutral position The disk 5 can be moved back to neutral position by applying a force that exceeds the force applied by the ...

Page 109: ... port To control valve 8 spools PB7 port To control valve 10 spools PB9 port P3 port To control valve 8 spools PA8 port To control valve 10 spools PA10 port P4 port To control valve 8 spools PB7 port To control valve 10 spools PB10 port P port To EV1 solenoid valve group P2 port Port T To hydraulic tank P4 P2 P3 P1 RKZ09350 Z RKZ09360 P4 P3 T P P1 P2 ...

Page 110: ...10 84 WB97S 5 STRUCTURE AND FUNCTION PPC VALVES 1 knob 2 Nut 3 Lever 4 Boot 5 Plate 6 LH PPC valve body 7 RH PPC valve body RKZ09370 4 3 2 1 6 5 7 ...

Page 111: ...CTION PPC VALVES OPERATION 1 Control lever in neutral position Ports A and B of control valve and ports P1 and P2 of PPC valves are connected to the tank circuit Hence the spool is in neutral position RKZ09380 A B P2 P1 Control valve ...

Page 112: ...row the valves 2 are rotated and a passage is opened between delivery duct a and port P1 while port P2 remains conected to the tank circuit PressureatportP1increasesasthetraveloflever 1 increases Consequently thespoolofthecontrolvalvemoves to the left by a distance that is proportional to the travel of the lever 1 RKZ09390 A B P2 P1 Control valve ...

Page 113: ...ator o NEUTRAL When lever 1 is moved fully to the left the valves 2 are fully rotated Port P1 is then connected directly to delivery duct a whereas port P2 is connected to tank circuit only and the spool of the control valve performs its full travel RKZ10610 A B P2 P1 a Control valve ...

Page 114: ...ntrol valve Port PB1 Out arm Port T To hydraulic tank 4 port To backhoe control valve Port PA2 LH swing boom 3 port To backhoe control valve Port PA1 In arm P port To EV1 solenoid valve group VBH port 2 port To backhoe control valve Port PB2 swing boom RKZ10250 View A A 4 T 1 P 2 3 ...

Page 115: ...1 To control valve Port PB4 raise boom Port T To hydraulic tank Port 4 To control valve Port PA5 dump bucket Port 3 To backhoe control valve Port PA4 lower boom Port P To solenoid valve group VBH port Port 2 To control valve Port PB5 curl bucket RKZ10260 View A A 4 T 1 P 2 3 ...

Page 116: ...raulic scheme 3 UL 4 A2 UBH 1 Y95 Boom unlock solenoid valve 2 Y90 Backhoe PPC solenoid valve 3 Y93 PPC solenoid valve 4 Y91 Ecopower solenoid valve Port Acc Accumulator Port P1 Pressure tap Port P2 To outriggers PPC valve Port P Port A2 To boom unlock cylinder Port UBH To backhoe PPC valves Port P Port UL To shovel PPC valve Port P Port PM To hydraulic pump Port PM Port P From control valve Port ...

Page 117: ...e PPC solenoid valve 3 Y93 PPC solenoid valve 4 Y98 Bucket curl solenoid valve 5 Y99 Bucket dump solenoid valve 6 Y91 Ecopower solenoid valve Port Acc Accumulator Port P1 Pressure tap Port P2 To outriggers PPC valve Port P Port A2 To boom unlock cylinder Port UBH To backhoe PPC valves Port P Port UL To shovel PPC valve Port P Port A1 To control valve Port PA6 Port B1 To control valve Port PB6 Port...

Page 118: ... steering cut out solenoid valve 2 Y201 Front rear steering solenoid valve 3 Y203 Phase coincidence steering solenoid valve 4 Y202 Crab steering solenoid valve 5 Y400 Safety lock solenoid valve 6 Y401 Safety lock solenoid valve 7 Port block Port F2 Accumulator Port R1 Pressure tap Port F1 To outriggers PPC valve Port P Port R2 To boom unlock cylinder ...

Page 119: ...30 35 40 45 50 10 40 50 60 70 80 90 100 b Flow Q l min Pressione p bar RKZ08050 a Port PiL To the raise cylinders Head side b Port V2 From control valve 8 spool Port A6 From control valve 10 spool Port A8 c Port C2 To the raise cylinders Bottom side COMPONENTS 1 Solenoid valve 2 Adjusting screw 3 Spring 4 Spool 5 Unlock screw CHARACTERISTICS Safety valve calibration 220 10 bar 0 ...

Page 120: ... 12 12 16 20 24 24 36 48 60 Flow Q l min RKZ08070 Pressure Dp bar Pressione Dp bar a b RKZ08060 c b a a Port PiL To the dump cylinder Bottom side b Port C2 To the dump cylinder Head side b Port V2 From control valve 8 spool B3 port CHARACTERISTICS Safety valve calibration 220 10 bar 0 ...

Page 121: ...135 Flow Q l min RKZ08090 150 120 105 60 45 15 14 28 35 b Pressure Dp bar Pressione Dp bar a a PiL port To the boom cylinder bottom side b V2 port From control valve B4 port c C2 port To the boom cylinder Head side CHARACTERISTICS Safety valve calibration 1 250 15 bar Safety valve calibration 2 200 20 bar 0 0 ...

Page 122: ...0 8 4 0 Portata Q l min 12 25 16 20 24 50 75 100 125 Flow Q l min 150 175 Pressure Dp bar Pressione Dp bar a PiL port To the arm cylinder bottom side b V2 port From control valve A1 port c C2 port To the arm cylinder Head side CHARACTERISTICS Safety valve calibration 1 300 10 bar 0 ...

Page 123: ...CYLINDERS RAISING CYLINDER 8 3 4 5 6 7 1 2 707 00 0y891 1 Bottom bushing 2 Cylinder 3 Nut 4 Gasket 5 Piston 6 Stem 7 Head 8 Head bushing DUMPING CYLINDER 8 3 4 5 6 7 1 2 707 00 0y920 1 Bottom bushing 2 Cylinder 3 Nut 4 Gasket 5 Piston 6 Stem 7 Head 8 Head bushing ...

Page 124: ...der 2 Nut 3 Gasket 4 Piston 5 Stem 6 Head 7 Head bushing CHARACTERISTICS Cylinder Lifting Dump 4 in 1 bucket Piston rod diameter 50 45 40 Internal cylinder diameter 90 70 70 Piston stroke 570 745 230 Max cylinder length 1740 2145 705 Min cylinder length 1170 144 475 Key size for piston safety nut 55 40 36 ...

Page 125: ...4 1 7 6 11 8 9 10 1 Bottom bushing 2 Stem 3 Head 4 Cylinder 5 Piston 6 Gasket 7 Guide ring 8 Cushion plunger 9 Bottom bushing 10 Dowel 11 Ball bearings no 10 ARM 5 707 00 0y871 3 2 4 1 6 7 8 10 9 1 Bottom bushing 2 Stem 3 Head 4 Cylinder 5 Brake bushing 6 Gasket 7 Guide ring 8 Piston 9 Nut 10 Bottom bushing ...

Page 126: ...ERS BUCKET CYLINDER 5 707 00 0y901 3 2 4 1 7 6 8 9 1 Bottom bushing 2 Stem 3 Head 4 Cylinder 5 Piston 6 Gasket 7 Guide ring 8 Nut 9 Bottom bushing OUTRIGGER CYLINDER 6 5 4 2 707 00 0Y0910 3 7 1 Stem 2 Head 3 Cylinder 4 Gasket 5 Guide ring 6 Piston 7 Nut ...

Page 127: ...07 02 07730 3 7 2 11 1 12 9 10 4 1 Retaining ring 2 Restriction ring 3 Stem 4 Cylinder 5 Bushing 6 Head 7 Bottom bushing 8 Piston 9 Guide ring 10 Piston seal 11 Spacer 12 Cushion plunger JIG ARM CYLINDER 4 42N 6C 13301 2 6 5 1 3 1 Stem 2 Head 3 Cylinder 4 Piston 5 Gasket 6 Guide ring ...

Page 128: ...5 90 Piston stroke 850 700 765 Max cylinder length 2160 1765 1850 Min cylinder length 1310 1065 1085 Key size for piston safety nut 55 55 Cylinder Outriggers Boom swing Jig arm Piston rod diameter 40 50 40 Internal cylinder diameter 70 100 70 Piston stroke 635 230 1140 Max cylinder length 1690 319 5 2590 Min cylinder length 1055 89 5 1450 Key size for piston safety nut 46 46 ...

Page 129: ...ompressor 2 Condenser 3 Filter dehydrator tank 4 Safety pressure switch 5 Expansion valve 6 Evaporator 7 Clutch thermostat sensor 8 Cab air circulation fans 9 Air feeder TECHNICAL DATA Circuit operating pressure with engine 2500 RPM at an ambient temperature of 25 30 C Regular pressure 15 17 bar Low pressure 1 6 1 8 bar Safe pressures High pressure 26 bar Low pressure 2 5 bar Coolant fluid R134a C...

Page 130: ...approximately 8 C The flow of air generated by centrifugal fan 8 which passes through the evaporator 6 at ambient temperature is considerably warmer than 8 C For this reason it yields heat to the coolant fluid bringing it up to boiling point and complete evaporation On leaving the evaporator 6 the coolant is drawn once more into the compressor 1 and a new cycle starts The extraction of heat from t...

Page 131: ...P 6 4X11 3X1 6 UNI1751INOX ROND EL SP 5 3X8 9X1 2 UNI1751 INOX FUSIBILE A LAMA 5 A 257005 CONNETTORE MARKII 21VIE SCHEDE CONNETTORE MARKII 17VIE SCHEDE CONNETTORE MARKII 7VIE SCHEDE CONNETTORE MARK II 9V SCHEDE CONNETTORE MARK II 11V SCHEDE CONNETTORE PORTARELE SCHEDE CENTRALINA ANTIRIPETIZIONE AVV 12V INTERMITTENZA ELETTRONICA 12V FUSIBILE A LAMA 10 A 163007 16 24 26 25 20 22 23 21 18 19 17 FUSIB...

Page 132: ... X24 acc X24 c 15 30 Gnd11 Gnd10 X56 1 X61 1 X68 2 Gnd9 X24 gnd X43 X28 s X25 p X26 p X27 s X40 X44 p X46 X47 X48 X49 X4 s X1 s X2 s X3 s X6 X12 p X11 p X10 p X9 p X8 p X7 p Gnd1 3 Gnd1 2 Gnd1 1 X42 15Key X68 1 X5 s X555 X56 X61 X17 1 X17 2 X23 Sensore retorn to dig Luce servizio Accendisigari Pulsante posteriore claxon 30 rele preriscaldo 30 rele candelette Quadro avviamento vpos R1 Alim fusibile...

Page 133: ...3 7 4 8 1 1A 150OHM 1 4 W X88 PULSANTE PPC X82 INTERRUTTORE SBLOCCO PIASTRA X81 PULSANTE SBLOCCO BRACCIO X181 LIMITATORE DI CORRENTE X180 LIMITATORE DI CORRENTE PER SPIA X89 INTERRUTTORE WARNING X84 INTERRUTTORE VALVOLE EMPI X83 PULSANTE E C POWER X80 INTERRUTTORE RIDE CONTROL X87 INTERRUTTORE 4WD X86 INTERRUTTORE GENERALE LUCI X85 PULSANTE AVV ACUSTICO POSTERIORE X26 s A L POSTO GUIDA X25 s A L P...

Page 134: ... 3 2 1 1 6 1 5 1 4 1 3 1 2 1 1 1 0 9 8 7 6 5 4 3 2 1 2 11 6 5 4 3 7 8 10 9 1 12 42N 06 11520 1 0 A linea posto guida X10 s A linea posto guida X9 s X59 1 Livello olio freni Motore tergi anteriore X58 Livello olio freni X59 2 Devio luci X60 Strumento anteriore X63 Strumento anteriore X64 Devio cambio X57 Sw luce stop X54 2 Pompetta X55 Sw stop X53 2 Sw luce stop X54 1 X53 1 Sw stop 1 2 3 4 5 8 7 9 ...

Page 135: ... CORRENTE X181 INTERRUTTORE GENERALE LUCI 2 5 6 3 7 4 8 1 X80 PULSANTE PPC X88 INTERRUTTORE 4WD X87 2 5 6 3 7 4 8 1 PULSANTE AVV ACUSTICO POSTERIORE X85 X86 2 5 6 3 7 4 8 1 2 5 6 3 7 4 8 1 2 5 6 3 7 4 8 1 INTERRUTTORE GIROFARO X167 4 7 1 6 9 5 8 3 2 A L POSTO GUIDA X166 s X83 PULSANTE E C POWER 12 11 10 8 2 5 3 6 9 1 4 7 14 15 13 2 3 1 10 12 11 8 5 6 9 4 7 20 14 17 18 15 21 16 13 19 INTERRUTTORE F...

Page 136: ...X151 3 Faro ant DX X151 2 Faro ant DX X146 Faro di lavoro anteriore SX laterale X143 Faro lavoro ant DX lat X138 Faro di lavoro posteriore SX laterale X136 Faro di lavoro posteriore DX laterale X152 2 Plafoniera X152 1 Plafoniera X147 5 Faro anteriore SX X147 1 Faro anteriore SX X148 2 Presa girofaro X148 1 Presa girofaro X151 5 Faro ant DX X151 1 Faro ant DX X142 Interruttore fari lavoro anterior...

Page 137: ... X118 1 50 START X60 Valvole emp Conn DT 2 vie M X126 4 87 rele preriscaldo X119 2 D alternatore X119 1 W alternatore Gnd6 GND X7 s A linea cabina B Conn DT 2 vie F X117 Elettrostop X116 Elettrofrizione compressore X113 Filtro aria X121 Avvisatore acustico X115 Sensore press olio motore X114 Candelette X112 Termistore 42N 06 11160 1 2 3 4 5 8 7 9 10 11 12 13 14 15 16 6 ...

Page 138: ... 1 1 Occhiello di massa X77 s A CENTRALINA ATC 24 X210 Temp olio trasmissione X211 Sensore cardano X8 s A linea posto guida X209 Galleggiante X208 Seg troppo pieno X207 Pompa travaso X206 Ev 3 marcia X205 Ev retromarcia X204 Ev doppia trazione X203 Ev 2 marcia X202 Ev 1 velocità X201 Ev marcia avanti X200 Ev 4 marcia 42N 06 11280 1 2 3 4 5 8 7 9 10 11 12 13 14 15 16 6 ...

Page 139: ...Ev sblocco piastra X96 Back up allarm X92 1 2 1 2 1 2 Ev sblocco braccio X95 Ev apertura benna X99 Ev blocco differenziale 1 2 Ev PPC X93 X98 Ev chiusura benna 1 2 1 2 X94 Ev ecopower X91 Ev PPC retro X90 1 2 Gnd2 1 Gnd2 2 Gnd2 3 X12 s A linea posto guida 1 4 3 6 2 5 1 2 1 1 1 0 8 2 5 3 6 9 1 4 7 1 4 1 5 1 3 A linea posto guida X11 s 42N 06 11450 1 2 3 4 5 8 7 9 10 11 12 13 14 15 16 6 ...

Page 140: ...7S 5 STRUCTURE AND FUNCTION JIG ARM WIRING JIG ARM WIRING 42N 06 11340 1 2 4 5 3 2 1 1 2 1 2 X5 Ev rientro X6 Ev sfilo bb X1 p A linea cabina telescopico X7 Ev martello Gnd 1 2 3 4 5 8 7 9 10 11 12 13 14 15 16 6 ...

Page 141: ...7 9 10 6 11 13 14 15 16 12 Staffa Rele 4 7 1 10 6 9 5 8 11 3 2 12 3 6 4 5 7 2 8 1 1 5 6 9 10 14 2 7 3 4 8 13 12 11 X160 s A linea posto guida X189 Pannello sterzatura 4WS X190 s A linea elettrovalvole 4WS 87 86 30 85 Connettore Relè Ev Blocco 12V TENSIONE ART ITALY 4WS PUSH BUTTONS PANEL WIRING ...

Page 142: ... A C B A C B X203 Ev sterzatura tondo X202 Ev sterzatura granchio X201 Ev 4W X200 Ev 2WS Gnd Punto di massa X205 Sensore assale posteriore X204 Sensore assale anteriore Sal1 Alim sensori 1 2 X401 Ev blocco sterzatura 1 2 X400 Ev sicurezza blocco 1 2 3 4 5 8 7 9 10 6 11 13 14 15 16 12 4WD SOLENOID VALVES WIRING ...

Page 143: ...hield washer Preheating Relay Starting relay Main beam light 15A Return sender supply DIG fuse 10A EC POWER FUSE 7 5A 15 STEERING UNIT FUSE 10A FLASHER FUSE 7 5A REVERSE SPEED BUZZER STEERING COLUMN 10A Unrepeat start unit Low beam relay Front horn relay Return to DIG solenoid valve relay Starter G118 K6 K5 K4 K3 G119 H17 K2 K1 Main beam relay Generetor Flasher BUZZER F24 F27 F25 G1 F23 F22 F20 F2...

Page 144: ...PAGE INTENTIONALLY LEFT BLANK ...

Page 145: ...IN THE ATTA CHMENTS HYDRAULIC CIRCUIT 33 Introduction 33 8 spool control valve Hammer 34 10 spool control valve Hammer 34 CHECKING THE SETTING OF MAIN RELIEF AND SECONDARY VALVES 35 SETTING THE MAIN RELIEF VALVES AND THE REDU CING VALVES 39 CHECKING AND ADJUSTING THE LS DIFFERENTIAL PRESSURE ADJUSTING THE LS VALVE 41 Control 41 Adjusting the LS valve 42 CHECKING AND ADJUSTING SERVOCONTROLS SUPPLY ...

Page 146: ......

Page 147: ...en acceleration At high idling speed Bosch index 1 5 3 0 3 0 Valve clearance Intake valve 20 C Exhaust 20 C mm mm 0 30 0 05 0 55 0 05 0 30 0 05 0 55 0 05 Compression pressure SAE30 oil Oil temperature 69 72 C Engine speed bar rpm 34 3 1 250 27 5 1 250 Engine oil pressure SAE30 oil With blow by Free exhaust mm H2O 5 10 50 0 5 10 50 0 Engine oil pressure At high idling speed At Low idling bar kPa ba...

Page 148: ...00 Control valve mm l a b c l a b c Arm shovel shovel boom boom swing 4 in 1 bucket arm jig arm cylinder outrigger backhoe bucket See Fig A 6 5 5 2 Travel of levers and pedals Shovel arm control lever Engine stopped Knob lever at the center and at 90 from the lever Value reading at the end of working stroke plus half measured backlash Attachments on the ground Instrument metre w millimetre divisio...

Page 149: ...wheel operation Shovel arm control lever Engine speed min Oil temperature 45 55 C Tool connection at centre of knob and 80 mm away from handle base see Fig B Value reading at the 10 mm before end of working stroke Instrument force gauge Ambient temperature 15 35 C kg 1 5 1 0 2 0 Shovel control lever 1 5 1 0 2 0 Control lever Boom 1 8 1 3 2 3 Arm control lever 1 8 1 3 2 3 Bucket control lever 1 3 0...

Page 150: ...OWER bar 245 235 260 Steering unit Engine speed 1500 50 rpm 175 170 185 Pressures of secondary valves circuits Shovel curled Engine speed min Oil temperature 45 55 C Check one circuit at the time Instrument 0 600 bar pressure gauge mounted on adapters at port P1C Working mode switch POWER bar 270 260 280 Shovel Dump 240 230 255 4 in 1 bucket opens closes 270 260 280 Boom raising 345 320 360 Boom l...

Page 151: ...brakes engaged Working mode switch POWER rpm 2175 50 2125 2225 With converter and hydraulic circuit Engine speed without load 2400 50 Hydraulic oil temperature 45 55 C Machine in 3rd gear Working brakes engaged Shovel raise bottom of stroke Steering held at the end of stroke Working mode switch POWER 2075 50 2025 2125 Hydraulic circuit at Low idling Engine speed 1050 50 Hydraulic oil temperature 4...

Page 152: ...800 Kg 4 in 1 bucket load 1550 kg Engine stopped Oil temperature 45 55 C Check measures as soon as engine stops Check changes every 5 min and the total change in 15 min mm 150 300 Raise cylinder Cylinder in 12 20 Shovel cylinder Cylinder out 35 50 Backhoe Complete working equipment Bucket teeth tip lower Measuring posture see Fig D In this position check the extension of each cylinder and the leak...

Page 153: ... the engine and after 1 minute check the inner cylinder feed back opposite to the boom every 5 min for a total of 15 minutes Perform the above test on both swing directions mm 15 25 Outriggers Measuring posture see Fig F Oil temperature 45 55 C Backhoe balanced Boom and arm cylinders in bucket cylinder out Outriggers at maximum extension Engine stopped Check the frame lowering for each side every ...

Page 154: ...s fully out Cylinders fully in Measuring posture see Fig H Engine speed max Oil temperature 45 55 C Power mode ON Curl 2 3 2 0 2 6 Dump 2 8 2 4 3 2 Backhoe Boom Cylinders fully in Teeth bucket on level ground Measuring posture see Fig J Engine speed 1700 50 rpm Oil temperature 45 55 C Backhoe balanced Power mode ON Lifting q 2 7 2 3 3 1 Lowering 2 0 1 7 2 3 Arm Cylinders fully in Cylinders fully o...

Page 155: ...e brake phase NOTE The engine speed 1700 50 rpm has to be checked with the procedure described at paragraph MEASURING ENGINE SPEED in this section Machine model WB97S 5 Classific ation Check item Test conditions Unit Standard value Normal value Work equipment speed Backhoe Boom swing Right end travel Left end travel Measuring posture see Fig M Engine speed 1700 50 rpm Oil temperature 45 55 C arm a...

Page 156: ...e from the beginning of machine lifting until bucket is on level ground 0 Max 2 Arm Measuring posture see Fig Q Engine speed Min Oil temperature 45 55 C Put boom at 45 open completely the arm with curled bucket Extend arm cylinder and check the time passing between arm stop at dead centre and the restart movement 0 Max 2 Bucket Measuring posture see Fig R Engine speed Min Oil temperature 45 55 C P...

Page 157: ...TESTING AND ADJUSTMENTS WB97S 5 20 13 NORMAL OR STANDARD TECHNICAL DATA Fig A Fig B Fig C Fig D F RKT01262 10 kg 6 7 8 80mm RKZ10860 10 RKZ10680 1m 1m RKZ10690 ...

Page 158: ...TESTING AND ADJUSTMENTS WB97S 5 20 14 NORMAL OR STANDARD TECHNICAL DATA Fig E Fig F Fig G Fig H RKZ13490 RKZ10830 RKZ10720 RKZ10730 ...

Page 159: ...TESTING AND ADJUSTMENTS WB97S 5 20 15 NORMAL OR STANDARD TECHNICAL DATA Fig J Fig K Fig L Fig M RKZ10740 RKZ10750 RKZ10780 RKZ13500 ...

Page 160: ...TESTING AND ADJUSTMENTS WB97S 5 20 16 NORMAL OR STANDARD TECHNICAL DATA Fig N Fig P Fig Q Fig R RKZ10790 RKZ10800 RKZ10810 45 RKZ10820 ...

Page 161: ...TESTING AND ADJUSTMENTS WB97S 5 20 17 NORMAL OR STANDARD TECHNICAL DATA Fig S RKZ10830 ...

Page 162: ...l scale 250 bar 3 Commercially available Pressure gauge 1 Full scale 400 bar 4 Commercially available Pressure gauge 1 Full scale 600 bar 5 ATR800200 Servocontrol kit Differential digital pressure gauge 1 0 1000 bar 6 F 1 Flow meter 1 Delivery 0 300 l min 2 Pipe fitting kit 1 Air conditioning unit M 1 Commercially available Maintenance station 1 For coolant R134a 2 Commercially available Thermomet...

Page 163: ...arking brake and remove the ignition key 2 Remove the intake filter and muffler For details see 30 REMOVAL AND INSTALLATION 3 Release from straps and disconnect the wiring harness 1 of the coolant liquid temperature sensor 2 4 Adjust valve clearance according to the instructions provided in the engine shop manual code WHBMNEF000 RKZC3150 1 2 ...

Page 164: ...he machine on solid level ground with the transmission in NEUTRAL RKZC3160 1 B 3 Stop the engine and apply a reading notch B to the engine pulley 1 for the stroboscopic rev counter CHECKING ENGINE WITHOUT LOAD 1 Start engine and check Low idling speed without load accelerator pedal released Minimum speed 1050 50 rpm High idling speed without load accelerator pedal at the travel end Maximum speed 2...

Page 165: ...ot more than 30 sec and carry out the tests at least 15 sec one from the other 3 With converter stalled and hydraulic pump under load 1 Increase speed to high idling and brake with the working brakes 2 While holding the brakes a engage 3rd FORWARD b raise shovel the full travel span and hold in this position c steer the wheels fully 3 In the above conditions let the engine stabilize then red the e...

Page 166: ...ension the belt 6 RKZC7870 4 5 3 6 4 Apply a 10 kg force halfway between compressor pulley 7 and engine pulley 8 5 Check the resulting arrow F a F 4 6 mm normal tensioning F 3 mm new belt k Check belt tension again after 15 minutes of operation F RKT01262 10 kg 6 7 8 6 Once proper tension is reached retain the position of the adjustment bolt 5 with the nut 4 7 Retain the adjustment bracket 9 with ...

Page 167: ...e engine at high idling speed and repeat operationof point 2 return theengine atlowidlingspeed and make a complete travel of piston until the hydraulic pump reaches its maximum pressure 5 Repeat steps from Step 2 for all cylinders frequently checking the oil level in the tank Air bleeding from braking circuit a Above operation is to be carried out every time maintenance is made on braking circuit ...

Page 168: ...bbles 6 Repeat the same steps for the opposite braking unit a Check frequently the oil level in the tank and carry out filling every time level approaches to minimum a After air bleeding apply on screws 2 safety plugs Releasing residual pressure from the circuits 1 Put work attachments on level ground stop the engine 2 Move all control levers in all directions to fully release cylinder and servoco...

Page 169: ...h the accelerator pedal 1 manually Accelerator pedal travel adjusting 1 Make sure that accelerator pedal 1 is fully raised and accelerator lever 2 is at minimum stroke RKZC3200 2 1 2 Tighten the nut 3 until spring slack is eliminated 4 and spring is preloaded to about 1 mm RKTA2255 5 4 3 3 Push accelerator pedal until accelerator lever 3 contacts the injection pump high idling adjusting screw 4 Ad...

Page 170: ...ck that the hand accelerator 3 is at end of travel at MIN 4 Loosen and unscrew the locking nut 4 RKZC3230 3 5 Start the engine and move the hand accelerator 3 to MAX 6 Tighten the nut 5 to the required speed for hand accelerator a Engine idling speed 1900 50 rpm RKZC3240 5 4 7 Return to engine low idling speed and retain the position of the nut 5 with the locking nut 4 8 Check MAX speed once more ...

Page 171: ...e mat 2 Check height A between floor and pedal lower edge 3 Depress pedals by hand and check height B to determine slack G a Standard clearance 3 8 mm RKZ11390 1 G A B Adjustment 4 Remove the front cover 2 For details see 30 REMOVAL AND INSTALLATION RKZC6050 2 5 Loosen nuts 3 and adjust slack using stoppers 4 6 When adjustment is complete secure the stoppers 4 a When stoppers are secured double ch...

Page 172: ...the axle braking groups 2 2 Seal either hose 1 a Plug the axle 2 to prevent contamination RKZC7890 1 1 2 3 Connect a pressure gauge E2 250 bar to the other hose 1 4 Apply either brake pedal until a pressure of approx 120 bar is reached a Do not exceed maximum permitted pressure 150 5 bar 5 Hold the pressure on the pedal for at least 2 minutes and verify that pressure and pedal position remain unch...

Page 173: ... being inspected 3 Seal the hole of the equalizer plug A RKZC6080 A 4 5 7 4 Remove the clamp 6 RKZC6090 6 5 Disconnect the delivery hoses 7 from the pump that is being tested Connect a pressure gauge E2 250 bar to the pump during the inspection 6 Apply the brake pedal corresponding to the pump and pressurize the circuit to approx 120 bar a Do not exceed maximum permitted pressure 150 5 bar RKZC610...

Page 174: ... cut out valve 9 3 Connect a pressure gauge E2 250 bar to the tool pressure tap and open the cut out valve 9 4 Operate the brake pump and pressurize the circuit to 150 55 bar maximum 5 Hold the pressure while simultaneously closing the valve 9 to keep the braking circuit that is being inspected under pressure 6 Release the brake pedal and monitor pressure gauge E2 for two minutes a If the pressure...

Page 175: ...enght adjusting 1 With the lever fully down turn the handbrake handle 1 clockwise until reaching the cable 2 projection A referred to the brake lever pin 3 a A 40 1 mm NOTE Direction of rotation is from the operator point of view when the operator is sitting on the driver s seat A RKZC7920 1 3 2 A 2 Mount washer 4 and two nuts 5 screw in nuts 5 up to washer 4 get in contact with pin 3 of lever 6 L...

Page 176: ...irection of movement 4 Accelerate engine revs gradually up to 1530 50 RPM k If machine attempts to move release the microswitch to return to N Neutral RKZC6120 3 5 Rotate the end of the lever 4 by 2 or 3 turns counterclockwise a Direction of rotation is from the operator point of view when the operator is sitting on the driver s seat RKZC6130 4 6 Re apply the parking brake and repeat the test a If...

Page 177: ...the servocontrolled version of the control valve Introduction 1 The machine is equipped with a single control valve with hydraulically controlled spools The control valve is protected against overpressure by a single upper valve or main valve referred to as LS safety valve with adjustable pressure setting 2 The full pump delivery supplies the control valve 3 Pump delivery is shut by the priority v...

Page 178: ... B6 Right outrigger Down A7 Up B7 Left outrigger Down A8 Up B8 Cylinder and movement Port Set bar Hammer B0 190 Arm Opens A1 270 Closes B1 270 Boom swing Right A2 230 Left B2 230 Shovel Dump A3 240 Curl B3 270 Boom Lowering A4 270 Lifting B4 345 Backhoe bucket Dump A5 Curl B5 270 4 in 1 bucket Closes A6 270 Opens B6 270 Jig arm Out A7 In B7 Shovel arm Lifting A8 Lowering B8 Right outrigger Down A9...

Page 179: ...valve cannot be pressure set if pressure changesfrom its normalvalue replacethe valve Checking main relief valve setting a Test conditions Engine at operating temperature Hydraulic oil 45 55 C Working brakes applied 1 Connect a pressure gauge E3 600 bar to pressure tap P1C of the pump RKZC3270 P1C E3 2 Start the engine move the hand accelerator lever to full throttle and check setting pressure for...

Page 180: ...retobeoperatedfromthesame check point 1 Connect a pressure gauge E3 600 bar to pressure tap P1C of the pump 2 Start the engine and bring the hand accelerator lever up to 2200 rpm 3 Check pressure for each movement with the control lever at the end of its travel and at stabilized pressure a Move piston to the end of stroke to check the pressure a Normal pressure values Cylinder and movement Set bar...

Page 181: ...sition and with bucket on level ground leaned on the side 2 Stop the engine and release residual hydraulic pressures RKZ10900 3 Disconnect the hose 1 and connect a tee fitting 2 with adapter 4 Connect a pressure gauge E3 600 bar to the adapter RKZC7960 E3 2 1 5 Start the engine connect a weight of approx 1500 kg to the bucket and fully lower the outriggers RKZ10910 6 Slowly extend the arm and boom...

Page 182: ... valve to a value 30 bar higher than the maximum pressure to be tested For details see Setting the main relief valve 4 Check pressure for each movement with the control lever at the end of its travel and at stabilized pressure a Move piston to the end of stroke to check the pressure of the working equipment a Normal pressure values a If one movement fails to reach the setting pressure then the mal...

Page 183: ...e main relief valve 1 Loosen lock nut 1 RKZC3291 1 2 Adjust the pressure using the screw 2 To INCREASE pressure turn in CLOCKWISE direction To DECREASE pressure turn in COUNTERCLOCKWISE direction 3 Lock the nut 1 3 Nut 29 4 39 2 Nm a When adjustment is complete check the setting of the main relief valve using the procedures used for measurements RKZ10930 1 2 ...

Page 184: ...tion 3 Tighten nut 1 while holding nut 2 3 Nut 1 39 49 Nm 2 RKZ10940 1 Adjusting the secondary valve for arm in shovel curl backhoe bucket curl boom raise and 4 in 1 bucket movements 1 Loosen nut 1 A hammer secondary valve B LH swing secondary valve C shovel dump secondary valve D RH swing secondary valve Komatsu Ltd RKZ10950 A B D C 2 Adjust the pressure using the nut 2 To INCREASE pressure turn ...

Page 185: ...ressure tap 2 and reconnect hose 1 RKZC3310 1 2 E4 2 Connect a differential pressure gauge E4 to adaptor 2 and to pressure tap P1C of the pump 3 Start the engine and run it at low idling 1050 50 rpm and without any movement lever in neutral position read the DP pressure a Normal value 41 4 bar a IfDPLSpressureisnotwithinthepermissiblerange replace the control valve unloading valve 4 Simultaneously...

Page 186: ...sen the retaining nut 1 and turn the adjustment screw 2 To INCREASE pressure turn in CLOCKWISE direction To DECREASE pressure turn in COUNTERCLOCKWISE direction a Each turn of the adjustment screw 2 will change the pressure by approx 13 bar RKZC3330 1 2 Lock the nut 3 3 Nut 27 4 34 3 Nm 3 When adjustment is complete check the setting of the LS valve 1 using the procedures used for checking RKZ1097...

Page 187: ...he engine and run the engine at low idling with all levers in neutral position 3 Check the pressure a Normal pressure 37 3 3 bar RKZC3340 1 2 E1 Adjusting the servocontrol valve a If the pressure value is not within the tolerance range adjust the valve 1 as follows 1 Loosen the retaining nut 2 and turn the adjustment screw 3 To INCREASE pressure rotate in CLOCKWISE direction To DECREASE pressure r...

Page 188: ...e PC valve 1 Loosen the nut 1 and turn the adjustment screw 2 a To decrease the pump s torque absorption turn the adjustment screw 2 counterclockwise a To increase the pump s torque absorption i e to increase the speed of working equipment turn the adjustment screw 2 clockwise a Turn the adjustment screw by not more than 180 in relation to the 0 line in both directions a Adjustment screw position ...

Page 189: ...total steering 3 Forcing the steering wheel at the end of stroke check pressure a Normal pressure 175 185 bar 4 Check for the other steering direction too RKZC3270 P1C E3 Setting a If pressure is not within permissible value carry out setting acting on upper valve 1 of the steering unit 2 1 Remove the plug 3 2 Insert a wrench of 4 mm and loosen screw 4 To INCREASE pressure rotate in CLOCKWISE dire...

Page 190: ...de where the rod is fully out 3 plug the hose tightly 4 Connect a provisional hose to the cylinder 1 to collect any leaking fluid 5 Start the engine and operate the engine at high idling speed 6 Force the steering wheel to the end of its travel and retain the position for 30 seconds measure any leak during the following minute 7 Release the steering wheel run the engine at low idling and then stop...

Page 191: ...ices engaged Lower cab closeout removed RKZ11010 Converter oil pressure 1 Remove the plug P3 and connect the pressure gauge E6 2 Start the engine and heat the engine and all the fluids up to working temperature In particular make sure that the power train oil reaches a temperature of 80 5 C 3 With the engine at MIN check the pressure on the pressure gauge E6 a Idle pressure 3 bar 4 Gradually incre...

Page 192: ...he normal value a Normal pressure Max 0 3 bar 6 Remove the pressure adapter and replace the plug P19 3 Plug 30 Nm 7 Repeat the same test for the FORWARD gear reading thepressure fromthe orifice protected bytheplug P17 If the pressures are different for the two travel directions there is a loss of pressure on the clutch piston with lower pressure Supply pressure 1 Remove the plug P21 and connect th...

Page 193: ...d on the brake pedals the machine starts to travel even slowly a Release the accelerator immediately and stop the engine b Checkthewearonthebrakedisksandchangethem before completing the tests For details see 30 REMOVAL AND INSTALLATION Control 1 Start the engine and heat the engine and all the fluids up to working temperature In particular make sure that the power train oil reaches a temperature o...

Page 194: ... base side and apply a temporary pipe head side to catch possible oil leakage 5 Start the engine and curl shovel until the teeth are in tilt position by about 10 6 Stop the engine and check shovel link position for 5 minutes If bucket link has no lowering movement drift is due to control valve To test the individual cylinders proceed as follows 7 Carry out with shovel a dump movement to let teeth ...

Page 195: ...l until shovel hinge pin is aligned with shovel arm hinge pin 5 Stop the engine and check the position of the shovel teeth for 5 minutes If shovel has no swing movement drift is due to control valve To test the individual cylinders proceed as follows 6 Lower the shovel to the ground 7 Remove from one of the cylinders the plug fitted on the cylinder bottom side in Phase 3 8 Start the engine and rai...

Page 196: ...Plug the two hoses to avoid impurity inlet 5 Plug the cylinder head side 6 Apply a temporary pipe on pipe 3 base side to catch possible oil leakage RKZC3400 2 3 1 4 7 Start the engine and extend completely the arm 8 Stop the engine and check the boom position for 5 minutes If boom has a lowering movement drift is due to cylinder gaskets If boom has no lowering movement drift is due to control valv...

Page 197: ... arm position for 5 minutes If arm has a lowering movement drift is due to cylinder gaskets If arm has no movement drift is due to control valve RKZ11050 Bucket testing 1 Set the machine with vertical arm and horizontal bucket leaned at level ground on the side Put in the bucket a weight of 450 kg or fill it with earth 450 kg RKZ11060 2 Stop the engine and release residual hydraulic pressures 3 Di...

Page 198: ...3 Without forcing them lower the outriggers onto the trestles RKZ11080 4 Stop the engine and release residual hydraulic pressures 5 Remove clamp 1 and disconnect from cylinders 4 the pipes 2 and 3 6 Plug cylinders pipes 2 base side and apply on head sides temporary pipes to catch possible oil leakage 7 Start the engine use force on the boom to raise the machine and remove the trestles supporting t...

Page 199: ...e inside the cab is equal to or lower than the ambient temperature a If the temperature of the cab is higher than the ambient temperature open the doors and widows and wait until the cab temperature stabilizes at the outside value 6 Close the doors and windows and let the A C unit operate in these conditions for 5 10 minutes 7 Use the thermometer M2 to check the temperature of the air at the centr...

Page 200: ...gh or normal Expansion valve blocked in closed position or obstructed Filter saturated with moisture Obstruction in the L P line or in the H P line between the filter and the evaporator L P L P normal H P normal Infiltration of hot air into the evaporator group the pipes or the cab Hot air circulating in the heating group Formation of ice on the evaporator L P high H P high Normal condition with v...

Page 201: ...relative to the drainage of the unit 2 Disconnect the group to be substituted or reconditioned immediately after switching off the maintenance station Plug the removed or disconnected connection tubes tightly and with a minimum of delay 3 Carefully check the quantity of anti freeze oil recovered and contained in the disassembled parts since the same quantity must be replaced when the air condition...

Page 202: ...t pressure to have same radius on both tyre Broken halfshaft Remove excessive weight and redistribute load following instructions related to the vehicle No differential action jamming while steering CAUSES REMEDY Incorrect installation Correct installation Defective axle Replace the differential in case it does not survive any one of the test phases Overloading incorrect weight distribution Remove...

Page 203: ...ment Verify group integrity and wheel side bearings Friction noise CAUSES REMEDY Incorrect installation Correct installation Defective axle Replace the differential in case it does not survive any one of the test phases Overloading incorrect weight distribution Remove excessive weight and redistribute load following instructions related to the vehicle Spoiled or worn out axle parts Check the condi...

Page 204: ...om axle are usually heard when vehicle moves in neutral gear but are not loud Replace or adjust see above Incorrectbacklashbetweenpinionandring sound heard while decelerating disappears while increasing the speed Replace Pinion or input flange worn out Replace Intermittent noise CAUSES REMEDY Ring gear damaged Replace bevel gear set Differential box bolts loosened Tighten to torque Constant noise ...

Page 205: ... correct lubricants fill up to the right levels and replace according to the recommended program Worn out pinion bearings Overheated ring and pinion teeth CAUSES REMEDY Prolong ed functioning at high temperatures Replace bevel gear set Use correct lubrication fill up to the right level and substitute at recommended intervals Insufficient lubrication contaminated oil incorrect lubrication Pinion te...

Page 206: ...nd or replace other differential components Side gear spline worn out CAUSES REMEDY Excessive use axial pinion Replace differential gear group Replace halfshaft if required Thrust washer surface worn out or scratched CAUSES REMEDY Insufficient lubrication contaminated oil incorrect lubrication Replace all scratched washers and those with 0 1mm thickness lower than the new ones Use correct lubricat...

Page 207: ...sure to have same radius on both tyre Broken halfshaft Remove excessive weight and redistribute load following instructions related to the vehicle No differential action jamming while steering CAUSES REMEDY Incorrect installation Correct installation Defective axle Replace the differential in case it does not survive any one of the test phases Overloading incorrect weight distribution Remove exces...

Page 208: ...MEDY Incorrect installation Correct installation Defective axle Replace the differential in case it does not survive any one of the test phases Overloading incorrect weight distribution Remove excessive weight and redistribute load following instructions related to the vehicle Spoiled or worn out axle parts Check the condition of ring gear pinion gear bearings etc Replace when ever necessary Conta...

Page 209: ...axle are usually heard when vehicle moves in neutral gear but are not loud Replace or adjust see above Incorrect backlash between pinion and ring sound heard while decelerating disappears while increasing the speed Replace Pinion or input flange worn out Replace Intermittent noise CAUSES REMEDY Ring gear damaged Replace bevel gear set Differential box bolts loosened Tighten to torque Constant nois...

Page 210: ...correct lubricants fill up to the right levels and replace according to the recommended program Worn out pinion bearings Overheated ring and pinion teeth CAUSES REMEDY Prolong ed functioning at high temperatures Replace bevel gear set Use correct lubrication fill up to the right level and substitute at recommended intervals Insufficient lubrication contaminated oil incorrect lubrication Pinion tee...

Page 211: ...nd or replace other differential components Side gear spline worn out CAUSES REMEDY Excessive use axial pinion Replace differential gear group Replace halfshaft if required Thrust washer surface worn out or scratched CAUSES REMEDY Insufficient lubrication contaminated oil incorrect lubrication Replace all scratched washers and those with 0 1mm thickness lower than the new ones Use correct lubricat...

Page 212: ...lace Damaged jammed control valve Replace Damaged converter Replace Oil temperature below 0ûC Wait for oil to reach working temperature stall test Damaged rotary seals Replace Reverser locking Repair Worn clutch unit Replace Repair clutch unit No drive transmission broken gears shafts bearings etc Check Repair Replace Vehicle has reduced power transmission CAUSES REMEDY Incorrect oil temperature W...

Page 213: ...l to reach working temperature stall test Incorrect oil specifications Replace oil and filters Damaged control valve Replace Faulty reverser locking Repair Replace Noise CAUSES REMEDY Damaged converter Replace Damaged oil pump Replace Aeration Cavitation Check oil level Check oil specifications Seizing broken gears shafts bearings etc Check Repair Replace Worn clutch plates Replace Irregular actua...

Page 214: ...EDY Damaged 4WD clutch Replace Hydraulic system fault Repair Replace Damaged control valve Replace Faulty brake sensor Check Replace Electrical system fault Repair Replace Selector malfunction Replace Control module malfunction Replace Shift electronic control malfunction Replace Gear shift won t engage CAUSES REMEDY Damage to clutch engagement assembly Repair Replace Damaged hydraulic system Repa...

Page 215: ...emoval 28 Installation 33 BATTERY 34 Removal 34 Installation 35 FUEL TANK 36 Removal 36 Installation 37 STEERING WHEEL AND TRANSMISSION REVERSE DIRECTION INDICATOR AND HEADLIGHT DIPPER BEAM CONTROL GROUP 38 Removal 38 Installation 39 WORKING BRAKE PUMP GROUP 40 Removal 40 Installation 42 STEERING UNIT 43 Removal 43 Installation 44 CAB 45 Removal 45 Installation 51 HYDRAULIC OIL TANK 53 Removal 53 ...

Page 216: ...20 Installation 320 OUTRIGGER CYLINDER 321 Removal 321 Installation 322 BACKHOE SWING CYLINDERS 323 Removal 323 Installation 325 BACKHOE BUCKET CYLINDER 326 Removal 326 Installation 327 BACKHOE BOOM SAFETY CYLINDER 328 Removal 328 Installation 329 CYLINDER 330 SHOVEL ARM SHOVEL BOOM ARM BUCKET OUTRIGGERS 330 Disassembly 330 Assembly 332 BACKHOE SWING CYLINDERS 335 Disassembly 335 Assembly 338 BACK...

Page 217: ...of operation q To install reverse removal procedure 1 Technique to be used for installation a Technique or important point to remember when installing eee 2 q Addition of water or oil Step in removal procedure a Point to remember when adding water or oil 2 To the precautions to be taken during the removal or installation of the groups must be added the specific PRECAUTIONS TO BE TAKEN WHILE WORKIN...

Page 218: ... with new ones Bend the cotter pins and stops in such a way as to secure them When coating the threads with adhesives clean the piece to remove oil and grease then apply just enough adhesive to cover the threading in a uniform manner When applying a liquid sealant clean the surface involved remove residual oil and grease check that there are no dents or dirt then apply the liquid sealant in a unif...

Page 219: ... 2 CA119143 Plunger 1 3 CA119200 False differential box 1 4 CA119202 False pinion 1 5 CA119225 Plunger 1 6 CA119226 Plunger 1 7 CA119228 False differential box 1 8 CA715004 Plunger 1 9 CA715022 Key 1 10 CA715026 Plunger 1 11 CA715027 Plunger 1 12 CA715039 Plunger 1 13 CA715042 Plunger 1 14 CA715064 Plunger 1 15 CA715108 Plunger 1 16 CA715265 Key 1 17 CA715505 Plunger 1 18 CA715506 Plunger 1 19 CA7...

Page 220: ...lunger 1 10 CA715042 Plunger 1 11 CA715056 Plunger 1 12 CA715108 Plunger 1 13 CA715128 False pinion 1 14 CA715172 Plunger 1 15 CA715265 Key 1 16 CA715380 Bearing assembly kit 1 17 CA715388 False differential box 1 18 CA715391 Plunger 1 19 CA715456 Backlash meas tool 1 20 CA715505 Plunger 1 21 CA715506 Plunger 1 22 CA715541 Plunger 1 23 CA715706 Preloading meas tool 1 24 CA715742 Plunger 25 CA71552...

Page 221: ...lation assembly tool clutches 1 10 CA715499 Protection 1 11 CA715046 Plunger 1 12 CA715743 Protection shims 1 13 CA715746 Plunger 1 14 CA715745 Calibrator 1 15 CA715732 Lifting of B C and E shafts 1 16 CA715149 Plunger 1 17 CA715744 Protection shims 1 18 CA715747 Calibrator 1 19 CA715748 Plunger 1 20 CA716009 Calibrator 1 21 CA716010 Protection 1 22 CA716018 Protection shims 1 23 CA716019 Plunger ...

Page 222: ...triggers and shovel cylinders 1 07281 00909 6 790 201 1702 Driver kit 1 790 101 5021 Handle 1 01010 50816 Screw 1 790 201 1781 Driver for boom cylinder 1 790 201 1771 Driver for bucket cylinder 1 790 201 1761 Driver for swing and shovel arm cylinder 1 790 201 1751 Driver for shovel cylinder 1 790 201 1741 Driver for outrigger cylinder 1 7 790 201 1500 Driver kit 1 790 101 5021 Handle 1 01010 50816...

Page 223: ...y 1 Loosen and remove the screws 1 and washers and remove the front grille 2 RKTA1206 9 10 11 12 2 Fully raise the engine hood 3 remove the safety pins 4 and disconnect the gas springs 5 from the chassis RKZC0750 4 5 3 Remove the snap rings 6 and washers 7 RKZC0760 6 7 8 4 Attach lifting equipment to engine hood 3 pull out fulcrum pins 8 and remove hood 3 4 Engine hood 32 kg RKZC0770 3 8 ...

Page 224: ...REMOVAL AND INSTALLATION WB97S 5 30 12 ENGINE HOOD Installation To install reverse removal procedure a Check catch 9 for proper centring RKZC0780 9 ...

Page 225: ...Loosen and remove the screws 1 and washers and remove the front grille 2 RKZC0741 1 2 1 2 Loosen the screws 3 retaining the guard 4 to eliminate torque 1 RKZC0790 3 4 3 Connect the guard 4 to the lifting equipment and slightly tension the rope 4 Take out the screws 1 and remove the protection 4 RKZC0800 4 Installation To install reverse removal procedure 1 2 Screw Loctite 242 3 Screw 300 Nm ...

Page 226: ...RKZC0771 1 2 Remove the front guard 2 For details see FRONT GUARD k Release all residual pressure in all circuits RKZC0801 2 3 Open the cock 3 and drain the coolant liquid 1 6 Coolant liquid approx 15 l For machines equipped with an air conditioning unit 4 Drain the air conditioning unit For details see 20 TESTING AND ADJUSTMENTS 2 5 Disconnect the connector 4 and remove the horn 5 RKZC0810 4 3 5 ...

Page 227: ...lug them to prevent contamination 3 6 Hydraulic oil 40 l RKZC0840 13 11 12 14 9 Disconnect gearbox oil hoses 15 and 16 from the oil cooler and plug them to prevent contamination k Mark the hoses and their respective positions for connection 4 RKZC0850 15 16 For machines equipped with an air conditioning unit 10 Disconnect the tubes 17 and 18 a Immediately plug the tubes and the orifices to prevent...

Page 228: ...ng nuts 21 n 2 washers 22 and anti vibration dampers 23 RKZC0880 22 21 23 13 Loosen and remove the screws 24 retaining the holders 25 RKZC0890 24 25 14 Move theradiatorgroup 6 tothefrontofthemachineso as to disengage it from the cooling fan 5 15 Attach lifting equipment to the group 6 and remove the group 4 Radiator group 37 kg RKZC0900 6 ...

Page 229: ...tank with hydraulic oil up to maximum level 5 Hydraulic oil 40 l 4 a Ensure that the level of transmission oil is at maximum 1 Start the engine at low idling to circulate all the fluids and to fill up the systems 2 Accelerate gradually up to 1700 rpm after about one minute stop the engine and check or top up the level a After about one minute stop the engine and top up all levels 5 a Align radiato...

Page 230: ...ront grille and the front guard For details see FRONT GUARD 3 Disconnect the tubes 1 and 2 a Immediately plug the tubes and the condenser tightly to prevent moisture from entering into the air conditioning circuit RKZC0861 2 1 4 Disconnect the connector 3 and remove the horn 4 5 Loosen and remove four screws 5 and washers and remove condenser 6 together with dehydrating filter RKZC0910 5 4 3 5 6 I...

Page 231: ...e hood 1 Loosen the nuts 1 on the jumper pin 2 retaining the muffler pipe 3 to the exhaust pipe RKZC0920 2 1 1 3 2 Loosen the jumper pin 4 disconnect the pipe 3 from the muffler 5 and remove pipe RKZC0930 3 5 4 3 Loosen the tie strap 6 retaining the muffler pipe to the turbocharger RKZC0940 6 4 Loosen and remove the four screws 7 and washers 5 Remove the muffler 5 Installation To install reverse r...

Page 232: ...ine and remove the ignition key 2 Fully open engine hood loosen straps 1 and 2 and disconnect pipes 3 and 4 RKZC0960 3 1 4 2 1 3 Disconnect connector 6 from filter clogging sensor 5 RKZC0970 6 5 4 Loosen and remove the screws 7 and remove the filter 8 together with the filter holder RKZC0980 8 7 Installation To install reverse removal procedure ...

Page 233: ...osition k Remove the ignition key 1 Disconnect the vapour recovery pipe 2 from the suction pipe 1 2 Disconnect the suction pipe 1 from the turbocharger 3 RKZC0961 3 2 1 3 Disconnect the connector 4 from the filter clogging lamp RKZC0971 4 4 Loosen and remove the screws 5 and the air filter 6 RKZC0981 5 6 5 Loosen and remove screw 7 and nut 8 and remove heat guard 9 RKZC0990 7 9 8 ...

Page 234: ...RBOCHARGER 6 Remove the muffler 10 For details see MUFFLER RKZC1000 10 7 Remove the turbocharger 3 according to the instructions provided in the engine manual manual code WHBMNEF000 RKZC0962 3 Installation To install reverse removal procedure ...

Page 235: ...s secure position k Remove the ignition key 1 Connect the outlets 1 and 2 to the maintenance station for air conditioning units and drain the cooling fluid For details see 20 TESTING AND ADJUSTMENTS 2 Release the tie strap and disconnect the connector 3 RKZC3000 1 3 2 3 Disconnect fluid delivery and return pipes 5 6 from compressor 4 1 a Collect the O rings RKZC3010 6 4 5 4 Remove the air filter 8...

Page 236: ... belt 13 from pulley 14 9 Loosen the screws 15 retaining the compressor 4 10 Take out the screws 15 and remove the compressor 4 Installation To install reverse removal procedure 1 a Check O rings for damage 2 O rings and fittings coolant oil 1 Tension the compressor belt For details see AIR CONDITIONING UNIT COMPRESSOR BELT 2 Connect the unit to the maintenance station and refill it For details se...

Page 237: ...ty stop Also place the backhoe in its secure position k Remove the ignition key 1 Take out the screws and remove the fan guards 1 RKZC0831 1 1 2 Remove the air filter 2 RKZC0983 2 3 Loosen the screw 3 retaining the tensioner bracket 4 4 Loosen nut 5 and screw 6 for belt tension RKZC7873 6 5 4 3 5 Loosen the screws 7 retaining the compressor 8 and remove the belt 9 RKZC7862 8 7 7 7 9 ...

Page 238: ...0 26 AIR CONDITIONING UNIT COMPRESSOR BELT Installation To install reverse removal procedure 1 3 Bracket lock nut 117 6 Nm 2 3 Fan fastening nuts 42 Nm 1 Carry out the belt tensioning procedure For details see 20 TESTING AND ADJUSTMENTS ...

Page 239: ...the exhaust pipe RKZC0920 2 1 1 3 2 Loosen the screws 4 on the attachment flange remove one screw but leave the second screw in place for added safety RKZC1010 4 3 Remove the screw 5 and washer from the upper vibration damper 4 Remove the second screw 4 and remove the exhaust pipe 6 RKZC1020 5 6 Installation To install reverse removal procedure ...

Page 240: ...ling liquid 6 Coolant liquid 15 l RKZC1030 2 1 3 a Drain the air conditioning unit For details see 20 TESTING AND ADJUSTMENTS 1 Remove the floor mat 1 disconnect the connector 2 and remove the seat 3 2 Take out the screws 4 and remove the control unit protection 5 RKZC6230 5 4 3 Remove four screws 6 and remove PPC valve and parking brake casing 7 RKZC6380 7 6 4 Remove four screw covers and screws ...

Page 241: ... 12 RKZC1070 12 11 8 Disconnect the connector 13 from the instrument board 12 9 Disconnect connectors 14 and 15 from the lighter RKZC1080 14 15 12 13 10 Extract screws 16 and remove the hand accelerator handle 17 11 Remove screws 18 from the accelerator lever assembly RKZC1090 16 17 18 12 Loosen and remove the screws 19 and 20 RKZC1100 19 20 ...

Page 242: ... 14 Remove PPC valve mounting plate 22 RKZC1110 22 21 15 Extract screws 23 and remove contact carrier plate 24 for rear wiper RKZC1120 24 23 16 Extract the lower screws 25 retaining the right hand case 10 RKZC6520 25 25 10 17 Extractthreescrewcovers 26 andscrewsretainingthe right hand case 10 at the rear RKZC1140 10 26 26 ...

Page 243: ...0 28 27 19 Extract the upper screw 29 retaining the right hand case 10 and its washer RKZC1160 29 10 20 Move the rear of the right hand case 10 towards the middle of the cab remove pin 30 and disconnect hand accelerator cable 31 21 Loosen nut and disconnect sheath 32 RKZC1170 32 31 30 22 Disconnect the contact carrier plate connector 33 RKZC2990 33 ...

Page 244: ... brake lever are disengaged fully remove the case RKZC6180 10 FAN 26 Disconnect the connector 34 27 Remove screw 35 then rotate fan group 36 counterclockwise RKZC1190 36 35 34 28 Extract the fan group 36 RKZC1200 36 29 Remove the clamp 37 30 Disconnect connectors 38 and 39 slide off and move to one side the fuse and relay group 40 RKZC1210 40 39 38 37 ...

Page 245: ...urn hoses 46 47 1 a Collect the O rings RKZC6200 46 43 47 45 44 OIL COOLER GROUP 33 Loosen and remove the four screws 48 and remove the group 41 Installation 1 3 Screw 6 Nm 1 Refill the coolant liquid 5 Coolant liquid approx 15 l 2 Drain and refill the air conditioning unit 5 Quantity of fluid R134a 2250 150 g Quantity of oil see the amount recovered 3 Start the engine and use a leak detector to c...

Page 246: ...ion key 1 Lift the door 1 and disconnect the catch 2 RKZC1240 1 2 2 Remove the lower right hand guard 3 of the cab 3 Remove the protection 4 RKZC1250 4 3 4 Take out the screws and remove the platform 5 and door RKZC1260 5 5 Disengage battery negative terminal 6 from shield and disconnect from battery 7 6 Use the same procedure as above to disconnect the battery positive terminal 8 1 RKZC1270 6 8 7...

Page 247: ...5 BATTERY 7 Loosen wing nut 9 and remove tie rod 10 and bracket 11 8 Remove the battery 8 RKZC1280 8 11 10 9 Installation To install reverse removal procedure 1 k Connect the battery positive cable first and then the battery negative cable ...

Page 248: ...e cap 2 off the filling inlet of the fuel tank 3 and remove also the bottom plug in order to drain the fuel 6 Fuel max 150 l 2 Reinstall the fill plug 1 and the drain plug 3 RKZC1290 2 1 3 3 Remove the lower left hand guard 4 of the cab RKZC1300 4 4 Disconnect the connector 5 from the level gauge 6 5 Mark and disconnect the fuel inlet and return hoses 7 8 a Plug all pipes hoses to prevent contamin...

Page 249: ... tank 2 remove four retaining screws 9 and washers and remove the tank 1 4 Fuel tank 68 kg RKZC1320 9 Installation To install reverse removal procedure 1 3 Tank retaining screws 120 Nm 1 Refill the fuel tank 5 Fuel max 150 l 2 Bleed the air from the fuel circuit 3 Start the engine ...

Page 250: ...he engine k Disconnectthecablefrombatterynegativeterminal For details see BATTERY 1 Use a thin bladed screwdriver placed under each spoke of the steering wheel to pry away the cover 1 RKZC1330 1 1 2 Loosen and remove the retaining nut 2 and remove the steering wheel 3 RKZC1340 2 3 3 Remove four screw covers 4 and loosen four screws 5 retaining the instrument panel RKZC1350 4 5 4 Slide off instrume...

Page 251: ...cator group 11 and transmission reverse control group 12 RKZC1370 12 10 11 9 6 Disconnect connectors 13 and 14 and remove groups 11 and 12 1 RKZC1380 11 13 14 12 Installation To install reverse removal procedure 1 a Before attempting to tighten the screws check the antirotation stake 15 for proper engagement into the steering column 16 RKZC1390 16 15 ...

Page 252: ...and the direction indicator and transmission reverse control groups For details see STEERING WHEEL AND TRANSMISSION REVERSE DIRECTION INDICATOR AND HEADLIGHT DIPPER BEAM CONTROL GROUP 2 Disconnect the connector 1 and remove the seat 2 3 Remove the front mat 3 RKZC1031 1 2 4 Loosen and remove the upper screws 4 retaining the instrument panel holder 5 RKZC1400 5 4 5 Remove the guards 6 and extract t...

Page 253: ...xtract the knob 10 RKZC1420 8 9 10 8 Slide the front trim cover 8 up to remove it RKZC1430 8 9 Take out the lower screws 11 and remove the instrument panel holder 5 RKZC6220 5 11 10 Remove the plug and 12 and draw oil from the tank 13 11 Reinstall the plug and disconnect connectors 14 and pressure switch connectors 15 and 16 12 Remove the tank 13 RKZC1450 12 13 14 15 16 ...

Page 254: ...o be removed also disconnect the pressure equalizing pipe 20 3 RKZC1460 18 20 17 19 Installation To install reverse removal procedure 1 a Bleed the air from the braking circuit For details see 20 TESTING AND ADJUSTMENTS 2 a Make sure that the push rods 21 center the seating of the pistons a When installation is complete inspect for proper brake pedal pre travel and alignment For details see 20 TES...

Page 255: ...at 1 2 Disconnect the connector 2 and remove the seat 3 RKZC1030 2 1 3 3 Remove the steering wheel and the direction indicator transmission reverse and headlight dipper beam control groups For details see STEERING WHEEL AND TRANSMISSION REVERSE DIRECTION INDICATOR AND HEADLIGHT DIPPER BEAM CONTROL GROUP RKZC1381 4 Loosen and remove the upper screws 4 retaining the instrument panel holder 5 RKZC140...

Page 256: ...tive positions of and disconnect five pipes 10 from steering unit a Plug all pipes to prevent contamination 1 RKZC1490 10 10 9 10 Loosen the screws 11 fastening the column 12 and steering unit 9 remove the steering unit Installation To install reverse removal procedure 1 a Start the engine and perform several complete steering manoeuvres in both directions to bleed the air out of the steering syst...

Page 257: ...l pressure in all circuits a Drain the engine cooling liquid 6 Coolant liquid 15 l a Only for machines equipped with an air conditioning unit Drain the air conditioning unit For details see 20 TESTING AND ADJUSTMENTS 1 1 Remove the exhaust pipe For details see EXHAUST PIPE 2 Disconnect the injection pump control rod 2 from the pitman arm 1 RKZC1531 1 2 3 Remove the front mat remove screws 3 and lo...

Page 258: ...pipes and pipe fittings to prevent entry of impurities RKZC1491 6 7 7 6 Remove nut 8 and disconnect strap 9 from frame 7 Disconnect the tubes 10 and 3 3 a Plug the pipes and pipe fittings to prevent entry of impurities RKZC1532 10 8 9 8 Take out the screws 11 and remove the hood 12 RKZC6231 12 11 9 Disconnect lower frame harness connectors 14 from fuse block 13 RKZC6240 13 14 14 ...

Page 259: ...d 20 from foot button 18 a Mark the position of connectors to avoid mixing them during installation RKZC6540 20 19 18 13 Disconnect the servocontrols upper and lower pipes 21 from the control valve 4 a Check that all the hoses are marked and note down the bends and routing patterns a Cap pipes hoses and holes to prevent contamination a Lay the hoses inside the cab to gain access to the feed and ex...

Page 260: ... pipes to avoid exchanging them during installation a Cap pipes hoses and holes to prevent contamination RKZC2322 22 24 23 15 Disconnect parking brake cable 25 from brake caliper 5 RKZC7953 25 16 Take out the screws 26 and remove the protection 27 RKZC1302 26 27 26 17 Remove nuts 28 as well as front and rear screws 6 RKZC3061 28 28 ...

Page 261: ... 29 7 a Cap the hose and hole to ward off humidity a Release the hose and route it under the cab RKZC3012 29 30 19 Take out the screws 31 and remove the protection 32 RKZC0743 32 31 31 20 Disconnect hose 34 from condenser 33 8 a Cap the hose and hole to ward off humidity a Release the hose and route it under the cab RKZC3071 33 34 ...

Page 262: ...placesomesafetyblocks A under it RKZC8000 35 23 Remove the screw 36 and disconnect the ground wire 37 24 Pull out screws 38 and remove cable guard 39 RKZC3091 38 36 37 39 25 Loosen straps 40 and disconnect heating hoses 41 a Mark the pipes to avoid exchanging them during installation a Cap pipes hoses and holes to prevent contamination 26 Ensure that all hoses harnesses and wires are free and remo...

Page 263: ...ing circuit For details see 20 TESTING AND ADJUSTMENTS 3 a Bleed the air from the braking circuit For details see 20 TESTING AND ADJUSTMENTS 4 a Perform all possible backhoe movements to bleed the servocontrol system 5 a Adjust the stroke of the parking brake lever For details see 20 TESTING AND ADJUSTMENTS 6 3 Cab retaining screws 200 Nm 7 3 Suction pipe union _________ Nm 8 3 Union 34 16 Nm 1 Re...

Page 264: ...PAGE INTENTIONALLY LEFT BLANK ...

Page 265: ...sconnectthecablefrombatterynegativeterminal For details see BATTERY 1 Remove the plug 1 and drain the hydraulic oil 6 Hydraulic oil approx 40 l RKZC8010 1 2 Remove the front mat 2 3 Disconnect the connector 3 and remove the seat 4 RKZC1032 3 4 2 4 Remove the steering wheel and remove the transmission reverse control group 5 and the direction indicator and headlight dipper beam control group 6 For ...

Page 266: ...older 8 RKZC1401 7 8 6 Remove the guards 9 and extract the upper screws 10 retaining the front trim cover 11 RKZC1411 9 11 10 7 Loosen and remove the lower screws 12 retaining the front trim cover 11 8 Fully lower the steering column extract the knob 13 RKZC1421 13 12 11 9 Slide the front trim cover 11 up to remove it RKZC1431 11 ...

Page 267: ... 14 and draw the brake fluid a Replace plug to prevent contamination 12 Disconnect oil level and pressure switch connectors 15 and 16 RKZC1451 16 14 15 16 13 Disconnect the brake fluid delivery tubes 17 1 a Plug all pipes hoses to prevent contamination RKZC1461 17 14 Loosen mounting bolt 18 15 Pull out the screws 19 and remove the protection 20 RKZC1481 19 18 20 ...

Page 268: ...ect the hand accelerator cable 25 from the relay rod 24 2 18 Disconnect the injection pump rod 26 from the relay rod 24 19 Disconnect the strap 27 holding the steering unit and working brake hoses RKZC1530 26 27 25 24 23 20 Loosen and remove nut 28 and washer 21 Disconnect the washer hoses 29 and remove the complete wiper arm 30 RKZC1540 28 30 29 22 Disconnect connector 32 from washer pump 31 RKZC...

Page 269: ...nd remove screws 35 and washers Remove the complete bulkhead 36 and move it to the rear of the machine RKZC6260 36 35 35 25 Take out the screws 37 and remove the conveyor 38 RKZC1580 38 37 26 Lift the rubber bulkhead and disconnect the discharge hose 40 from the tank 39 a Plug the pipe to prevent contamination RKZC1590 39 40 ...

Page 270: ...mination RKZC1600 41 42 28 Disconnect the pump suction pipe 43 a Plug the pipe to prevent contamination RKZC1610 43 29 Disconnect the vent hose 44 and filter and remove 30 Remove the screws and remove the fill sleeve 45 a Collect the O ring RKZC1620 45 44 31 Remove screws 46 and washers and remove the tank s front holder 47 RKZC1630 47 46 ...

Page 271: ...nstallation To install reverse removal procedure 1 a Bleed the air from the braking circuit For details see 20 TESTING AND ADJUSTMENTS 2 a Check and adjust the stroke of the hand accelerator 1 Refill the hydraulic oil 5 Hydraulic oil approx 40 l 2 Start the engine and check for leaks 3 Bleed the air from the cylinders For details see 20 TESTING AND ADJUSTMENTS 4 Stop the engine check the oil level...

Page 272: ...e the plug 1 and drain the hydraulic oil 6 Hydraulic oil approx 40 l a Replace plug to prevent contamination RKZC8010 1 2 Disconnect rear cardan shaft 3 from transmission 2 1 RKZC8020 3 2 3 Disconnect the delivery hose 5 and the LS and pump delivery pressure control hoses 6 and 7 from the pump 4 a Cap pipes hoses and holes to prevent contamination RKZC8030 6 7 5 4 4 Disconnectthesuctionpipe 8 andt...

Page 273: ...holding tool B1 to a hydraulic jack 8 Place tool B1 under the pump until the pump fully supported RKZC8050 B1 9 Take out the upper screw 11 and remove the pump 4 4 Piston pump 36 8 kg Installation To install reverse removal procedure 1 3 Screw 38 1 Nm 2 3 Pump screws 220 Nm 1 Refill the hydraulic oil 5 Hydraulic oil approx 40 l 2 Start the engine and run it at MIN to bleed any air 3 Stop the engin...

Page 274: ...oving all hydraulic controls in all directions k Disconnectthecablefrombatterynegativeterminal a Drain the hydraulic oil 6 Hydraulic oil approx 40 l RKZC1271 a Drain the oil from the gearbox 6 Hydraulic oil approx 20 l 1 1 Remove the piston pump 1 For details see PISTON PUMP 2 RKZC8061 1 2 Remove the front mat and remove the metal sheet 2 closing off the cab floor RKZC1521 2 3 Disconnect rear card...

Page 275: ...ectors 6 and shift oil temperature sensor connector 7 from gearshift 3 6 Take out the screws 8 and remove the harness holder 9 RKZC6290 3 9 8 8 6 7 7 Disconnect the connector 10 from the rev sensor 11 RKZC6310 11 10 8 Disconnect delivery hose 12 to oil cooler and return hose 13 from gearbox 3 9 Remove the clamp 14 RKZC6300 9 14 13 12 ...

Page 276: ...e centred inthehole removethe four screws 5 RKZC1760 15 16 12 Procure to support the engine 17 with a stand C placed under the flywheel bell RKZC1781 C 17 13 Disconnect the gearbox oil load and oil level control pipe 18 remove the screw 19 and remove the complete pipe 18 RKZC6320 18 19 18 14 Remove the nuts 20 on the vibration dampers 21 the screws 22 and remove the gearbox supports 23 6 7 RKZC633...

Page 277: ...f descending by about 60 cm Using the holes on the supports secure the tool B2 to the gearbox RKZC6340 B2 16 Loosen and remove the two screws 24 retaining the gearbox 3 to the engine 17 8 RKZC6350 24 24 17 17 Move the gearbox group 3 towards the rear of the machine and extract the group 4 Transmission 254 kg RKZC6360 3 ...

Page 278: ... 3 Anti vibration nuts 195 20 Nm 7 2 Support screws Loctite 262 3 Support screws 90 5 Nm 8 2 Engine gearbox screws Loctite 262 3 Engine gearbox screws 50 5 Nm a Tighten the screws using the alternating crosswise method 1 Start the engine to circulate the oil Check that there are no leaks 2 Bleed the air from the working equipment circuits For details see 20 TESTING AND ADJUSTMENTS 3 Stop the engin...

Page 279: ...sassembly and assembly 1 Plugs and filters 1 1 Disassembly RKZ11200 1 5 4 3 2 7 13 12 15 18 8 9 10 16 14 11 6 1 Remove the drain plug 1 and drain the oil from the transmission RKZC3490 1 2 Remove the two cap screws 2 which fasten the cover for the oil screen RKZC3500 2 ...

Page 280: ...ng 5 RKZC3510 3 4 5 4 Unscrew the oil filter 6 If necessary remove the connector 7 for the oil filter 6 RKZC3520 6 7 5 Unscrew and remove the oil filter protection valve 8 RKZC3530 8 6 Check the valve 8 condition a Clean with care the valve and replace the O ring 9 and 10 if necessary RKZC3540 8 9 10 ...

Page 281: ...m the transmission housing only if this part is leaking or damaged RKZC3550 11 8 To check the FORWARD clutch pressure remove the plug 12 RKZC3560 12 9 To check the REVERSE clutch pressure remove the plug 13 RKZC3570 13 10 Tocheck thelubricationpressure remove theplug 14 RKZC3580 14 ...

Page 282: ...e the speed sensor 15 RKZC3590 15 12 Rimuovere il termostato olio 16 RKZC3600 16 1 2 Assembly 1 Assemble the speed sensor 15 to the prescribed torque 3 Sensor 50 Nm RKZC3590 15 2 Assemble the thermostat 16 to the prescribed torque 3 Thermostat 30 Nm RKZC3600 16 ...

Page 283: ...aps 30 Nm RKZC3571 13 12 4 Assemble by hand the breather 11 to the transmission housing and tighten it strongly RKZC3550 11 5 Clean with care the oil filter protection valve 8 Assemble the new O ring 9 and 10 RKZC3540 8 9 10 6 Assemble the oil filter protection valves 8 Tighten the valve 8 to the prescribed torque 3 Valve 23 Nm RKZC3530 8 ...

Page 284: ...filter 6 a Put a thin coat of oil or grease on the filter gasket turn clockwise until the gasket makes contact with the base continue to turn the filter 2 3 turn RKZC3521 6 9 Assemble new O ring 5 to the filter 4 Insert the filter 4 with O ring 5 and assemble the cover 3 RKZC3620 4 5 10 Assemble the two cap screws 2 at prescribed torque to fasten the cover 3 3 Screw 23 Nm RKZC3501 2 3 ...

Page 285: ...REMOVAL AND INSTALLATION WB97S 5 30 73 TRANSMISSION 11 Assemble the drain plug 1 to the prescribed torque 3 Plug 80 Nm RKZC3490 1 ...

Page 286: ...SION 2 Torque converter and oil pump 2 1 Disassembly RKZ11210 1 5 2 3 4 6 1 Remove torque converter 1 For details see CONVERTOR RKZC3630 1 2 Remove screws 2 a Make reference mark on the pump and bell housing before untightening the screws RKZC3640 2 ...

Page 287: ... of two levers RKZC3650 3 4 Remove the oil pump 3 k Do not disassemble the oil pump 3 RKZC3660 3 5 Remove O ring 4 a Replace the O ring at each disassembly RKZC3670 4 6 If replacement is necessary remove the seal ring 5 a This is a destructive operation for the seal ring RKZC3680 5 ...

Page 288: ... Assemble new O ring 4 RKZC3670 4 a If the oil pump is being replaced verify that the oil passage holes between the pump and the half housing and the marks on the side in view match RKZC3700 3 Grease the ring 5 to keep it centred coaxial with respect to the shaft slot centre line and to make the introduction onto the pump easier RKZC3710 5 ...

Page 289: ...w 23 Nm a Check that reference marks made on the oil pump and on the bell housing coincide RKZC3640 2 6 To prevent damage to the pump sealing ring install the converter to the transmission by hand The two teeth on the converter that are responsible for driving the pump can cut the lip of the sealing ring 7 Couple transmission and converter to the engine flywheel with the screws of the bell convert...

Page 290: ... TRANSMISSION 3 Hydraulic control valve 3 1 Disassembly RKZ11220 2 4 6 5 7 10 9 8 3 11 1 1 Drain oil from transmission hydraulic circuit disconnect all electrical connections Remove screws 1 RKZC3730 1 1 1 2 Lift control valve 2 RKZC3740 2 ...

Page 291: ...emove the gasket 3 RKZC3750 3 4 Place the control valve unit on a clean workbench Remove fastening screws 4 from the valves 5 and 6 RKZC3760 5 5 6 4 5 Extract with care the valves 5 and 6 with a screwdriver RKZC3770 5 6 Remove the valves 5 and 6 RKZC3780 5 ...

Page 292: ...WB97S 5 30 80 TRANSMISSION 7 Check the valves 5 and 6 condition RKZC3790 5 8 Unscrew and remove the valve 7 RKZC3800 7 9 Check the valve 7 condition RKZC3810 7 10 Unscrew and remove the oil filter protection valve 8 RKZC3530 8 ...

Page 293: ...ZC3540 8 9 10 3 2 Assembly 1 Clean with care the oil filter protection valve 8 and assemble the new O ring 9 and 10 RKZC3540 8 9 10 2 Assemble the oil filter protection valves 8 Tighten the valve 8 to the prescribed torque 3 Valve 23 Nm RKZC3530 8 3 Assemble the ON OFF 6 and proportional 5 valves using the locations shown on the side 6 6 6 6 6 5 5 RKZ11230 ...

Page 294: ...MISSION 4 Assemble the valve mounting screws 4 RKZC3761 4 6 Assemble the new gasket 3 RKZC3750 3 7 Assemble the control valve unit 2 to the transmission 11 RKZC3820 2 11 8 Tighten the bolts 1 to the prescribed torque 3 Screws 23 Nm RKZC3830 1 1 1 ...

Page 295: ...ulic system lines 4 1 Disassembly RKZ11240 4 2 3 7 6 1 5 1 Drain oil from transmission hydraulic circuit Unscrew the connections of pipe 1 shaft lubrication and remove the pipe 1 RKZC3840 1 2 Remove the pipe 2 2nd speed unscrewing related connections RKZC3850 2 ...

Page 296: ...s a Collect connection gaskets RKZC3860 3 4 5 6 4 Remove the pipe 7 shaft lubrication unscrewing related connections RKZC3870 7 4 1 Assembly 1 Assemble the pipe 1 tightening the connections to the prescribed torque 3 Unions 30 Nm RKZC3840 1 2 Assemble the pipe 2 tightening torques the connections to the prescribed torque 3 Unions 30 Nm RKZC3850 2 ...

Page 297: ...RANSMISSION 3 Assemble the pipes 3 4 5 and 6 then tighten related connections to the prescribed torque 3 Unions 30 Nm RKZC3860 3 4 5 6 4 Assemble the pipe 7 tightening torques the connections to the prescribed torque 3 Unions 30 Nm RKZC3870 7 ...

Page 298: ...NSTALLATION WB97S 5 30 86 TRANSMISSION 5 Transmission housing 5 1 Disassembly RKZ11250 1 3 4 5 2 20 19 18 10 11 8 9 7 6 12 14 15 13 16 17 1 Drain oil from transmission Unscrew flange 2 fastening bolt 1 RKZC3880 2 1 ...

Page 299: ...use a screwdriver and two screws to stop flange rotation RKZC3900 3 Collect the washer 3 RKZC3910 3 4 Remove flange 2 and O ring 4 a Replace the O ring at each disassembly RKZC3920 2 4 5 Remove seal ring 5 a This is a destructive operation for the seal ring RKZC3930 5 ...

Page 300: ...Remove the fastening screws 6 from the flange 7 6 RKZC3940 7 Remove flange 7 RKZC3950 7 8 Extract transmission shaft PTO 8 RKZC3960 8 9 If to be replaced remove teflon seal ring 9 by cutting it a This is a destructive operation for the seal ring RKZC3970 9 ...

Page 301: ...ISSION 10 Remove snap ring 10 RKZC3980 10 11 Extract bearing 11 with tool F2 RKZC3990 11 12 Unscrew flange 13 fastening bolt 12 Use a screwdriver and two screws to stop flange rotation RKZC3901 13 13 Remove the bolt 12 and washer 14 RKZC3911 14 12 ...

Page 302: ...ace the O ring at each disassembly RKZC4000 13 15 15 Remove seal ring 16 a This is a destructive operation for the seal ring RKZC4010 16 16 Remove fastening bolts 17 from the rear 18 and front 19 half housings RKZC4020 18 17 19 17 Insert a lever in the special slot to detach the cover RKZC4030 ...

Page 303: ...20 RKZC4050 20 20 5 2 Assembly 1 Assemble three new O rings 20 to the rear half housings 18 a Accurately remove from mating surfaces any residual of sealant and clean them with a detergent RKZC4050 20 20 2 Assemble all the transmission internal parts Apply a thin film of prescribed sealant on the edge of the rear half housing 2 Loctite 510 RKZC4060 ...

Page 304: ...s in the front half housing Push the front half housing all the way down on the rear half housing RKZC4040 19 4 Assemblare fastening bolts 17 to the rear 18 and front 19 half housings Tighten the bolts to the prescribed torque 3 Screws 50 Nm RKZC4070 17 5 Assemble seal ring 5 on front shaft output Use tool F8 RKZC4080 5 6 Assemble flange 2 and a new O ring 4 RKZC3920 2 4 ...

Page 305: ... and bolt 1 RKZC3912 3 1 8 Tighten the bolt 1 to the prescribed torque Use screwdriver and two screws to stop flange rotation 3 Screws 139 Nm RKZC4090 9 Assemble seal ring 16 on rear shaft output Use tool F8 RKZC4100 16 10 Assemble flange 13 and a new O ring 15 RKZC3921 13 15 ...

Page 306: ...he washer 14 and bolt 12 RKZC3911 14 12 12 Tighten the bolt 12 to the prescribed torque Use screwdriver and two screws to stop flange rotation 3 Screws 139 Nm RKZC4090 13 Assemble bearing 11 on transmission shaft PTO 8 RKZC4110 11 14 Assemble snap ring 10 RKZC4120 10 ...

Page 307: ...ure described in paragraph 6 2 Assembly using tools F5 F6 F7 RKZC4130 9 16 Insert transmission shaft PTO 8 to the stroke RKZC3960 8 17 Apply a thin film of sealant to the flange 7 2 Loctite 510 a Verify that the two holes for oil passage A match RKZC4140 A A 7 18 Assemble the screws 6 to prescribed torque 3 Screw 50 Nm 6 RKZC3940 ...

Page 308: ...y RKZ11260 16 37 1 3 4 5 6 2 7 8 10 11 17 18 19 20 21 9 12 31 26 23 22 33 32 34 38 39 40 27 24 25 28 30 29 35 36 13 14 15 1 Grasp with pliers the input shaft assembly A Remove with shaft assembly D and lift RKZC4150 A D 2 If to be replaced remove the teflon seal ring 1 RKZC4160 1 ...

Page 309: ...separator and insert a shaft protector between the puller and the end of the input shaft Operate with the puller between bearing separator and shaft protector and pull only until the bearing is free Pulling any farther can damage the parts k Do not install the separator between gear and bearing RKZC4180 5 Remove bearing 3 RKZC4190 3 6 Remove spacer 4 RKZC4200 4 ...

Page 310: ...REMOVAL AND INSTALLATION WB97S 5 30 98 TRANSMISSION 7 Remove gear 6 RKZC4210 6 8 Remove needle cage 7 RKZC4220 7 9 Remove spacer 8 RKZC4230 8 10 Remove split pin 9 RKZC4240 9 ...

Page 311: ...11 Remove the snap ring 10 10 RKZC4250 12 Useprybarstoliftandtoremovethethrustplatelockring 11 evenly RKZC4260 11 13 Remove the clutch plates 18 and the clutch drive plates 17 RKZC4270 17 18 14 Place a mark below the groove on the friction bell RKZC4280 ...

Page 312: ...ve plate 17 These marks will be used for reference during the reassembly procedure 17 RKZC4290 11 18 Lower the spring 15 lock washer 13 Use tool F9 RKZC4300 13 F9 17 Remove snap ring 14 RKZC4310 14 18 Loosen the handles of the threaded rods to release the tension from the spring Remove the top piece of the F9 special tool RKZC4301 F9 ...

Page 313: ...30 5 21 Remove clutch piston 19 by blowing in compressed air through the delivery hole RKZC4340 19 22 If to be replaced remove teflon seal ring 20 and relevant inner O ring 20 from outer seat of piston and teflon seal rings 21 and relevant inner O ring 21 from inner of piston To remove the rings it is necessary to cut them RKZC4350 21 20 ...

Page 314: ...23 Turn the shaft If Teflon seal rings 22 are to be replaced remove the rings by cutting them RKZC4360 22 24 Remove snap ring 23 RKZC4370 23 25 Remove bearing 24 by means of an extractor RKZC4380 24 26 Remove bearing 24 and thrust washer 25 RKZC4390 24 25 ...

Page 315: ...it is within the permissible wear limit If it is not replace the clutch unit 18 with a new one Check all clutch plates for burns and inspect the friction material for damage Inspect the grooves in the friction material for being well traced Verify also that all the clutch drive plates 17 are perfectly plane and inspect for pitting or scoring In the case that at least one of the above problems occu...

Page 316: ...r damage from the tangs on the steel discs Use new parts as required during assembly RKZC4440 18 SHAFT D 1 Remove bearing 16 of shaft D by means of an extractor RKZC4450 16 2 Remove bearing 37 of shaft D by means of an extractor RKZC4460 37 6 2 Assembly SHAFT A 1 Assemble new teflon ring 20 and relevant inner O rings 20 new teflon ring 21 and relevant inner O rings 21 respectively into the piston ...

Page 317: ...ON 2 Apply a thin film of grease on the sealing rings just inserted RKZC4470 3 Insert clutch piston 19 with special tool F10 as protection of seal rings 21 RKZC4480 19 F10 4 Assemble sleeve 5 RKZC4330 5 5 Assemble spring 15 and washer 13 RKZC4320 13 15 ...

Page 318: ...e tool F9 RKZC4300 13 F9 7 Insert snap ring 14 a Ensure that the snap ring 14 is well fitted RKZC4310 14 8 Loosen the handles of the threaded rods to release the tension from the spring Remove the top piece of the F9 special tool RKZC4301 F9 9 Remove tool F9 and assemble split pin 9 RKZC4490 9 ...

Page 319: ... pack start with the gear 6 on the bench Install the thrust plate 11 so that the reference mark on top of the plate made during disassembly is facing towards the gear RKZC4510 6 11 13 Assemble clutch plates 18 and clutch drive plates 17 on the gear 6 The assembled clutch pack must contain seven clutch drive plates and six clutch plates RKZC4520 18 17 ...

Page 320: ... TRANSMISSION 14 Locate the pack assembly by means of two screwdrivers RKZC4530 15 Assemble snap ring 10 RKZC4540 10 16 Assemble washer 4 RKZC4200 4 17 Heat the bearing 3 to 80 100 C 176 to 212 F Assemble bearing 3 Use tool F2 RKZC4550 F2 3 ...

Page 321: ... spacer bearing and snap ring installed on the input shaft RKZC4170 2 19 Insert the teflon seal ring 1 as follows RKZC4560 1 20 Install the F5a spacer onto the input shaft with the chamfered end facing in RKZC4570 F5a 21 Slide the F5b expander protector onto the input shaft and on the spacer The expander protector will stop in the correct position to install the seal ring in the groove RKZC4580 F5...

Page 322: ...nto the shaft and over the sealing ring Use a back and forth twisting motion to allow the seal compressor to slip over the top of the sealing ring and seat the sealing ring into the groove Be careful not to damage the seal ring After the sealing ring is seated in the groove remove the seal compressor from the shaft RKZC4610 F7 25 Turn the seal compressor around and slide the end with thenarrowcham...

Page 323: ... theclutchis probably assembled wrong RKZC4630 17 27 Turn shaft upside down and carry out steps from 1 to 15 in this section Lubricate the washer 25 with transmission oil Install the thrust washer ensuring that the notch on the inner edge goes onto the pin Make sure that the side with the holes in it for oil passage is at the bottom RKZC4640 25 27 Heat the bearing 24 to 80 100 C 176 to 212 F Use d...

Page 324: ...aft The expander protector will stop in the correct position to install the seal ring in the groove RKZC4680 F12b 31 Heat the Teflon seal ring to 60 80 C 140 176 F for 5 minutes Install the teflon seal ring onto the expander protector RKZC4690 32 Install the F13 pusher over the expander protector and slide the seal ring until it reaches the groove in the shaft Remove the pusher expander protector ...

Page 325: ...ring After the sealing ring is seated in the groove remove the seal compressor from the shaft RKZC4710 F14 34 Turn the seal compressor around and slide the end with thenarrowchamferovertheshaftandoverthesealring Leave the seal compressor in place for 15 minutes until the sealing ring has cooled and is properly sized and seated in the groove Once the sealing ring has cooled remove the seal compress...

Page 326: ...forward gear The forward gear must not turn on the input shaft Try to move the reverse gear The reverse gear must turn freely on the input shaft If the clutches do not work correctly disassemble the clutches to find the problem 37 Apply compressed air atabout 6 bar for reverse gear clutch passage Feel the reverse gear piston move to lock its respective clutch pack Try to move the reverse gear The ...

Page 327: ... shaft bearing 16 Use tool F3 RKZC4730 16 39 Assemble D shaft bearing 37 Use tool F3 RKZC4740 37 40 Lubricate with oil the shaft seat A A RKZC4750 41 Fit shaft assembly D and shaft assembly A The operation is correct only if the two shafts are fitted at the same time RKZC4760 ...

Page 328: ... AXIS B 7 1 Disassembly RKZ11280 19 15 Asse Axis B 26 25 24 23 21 22 20 17 18 16 14 13 12 11 10 9 8 7 6 5 4 3 2 1 Asse Axis B 1 Remove screws 28 and protection 29 RKZC4770 29 28 2 Lift the three shafts B C E at the same time B C E Use tool F15 RKZC4780 F15 ...

Page 329: ...SMISSION 3 Remove seals 1 and 2 a This is a destructive operation for the seal rings RKZC4790 1 2 4 By means of an extractor remove bearing 3 and gear 4 RKZC4800 3 5 Remove The bearing 3 and the gear 4 RKZC4810 4 3 6 Remove snap ring 5 RKZC4820 5 ...

Page 330: ...EMOVAL AND INSTALLATION WB97S 5 30 118 TRANSMISSION 7 Remove spacer 6 RKZC4830 6 8 Remove the spring pin 23 RKZC4840 23 9 Remove gear 8 RKZC4850 8 10 Remove roller retainers 7 and washer 13 RKZC4860 7 13 ...

Page 331: ...WB97S 5 30 119 TRANSMISSION 11 Remove spring pin 24 and spacer 14 RKZC4870 14 24 12 Slightly press thrust plate 10 RKZC4880 10 13 Remove snap ring 9 RKZC4890 9 14 Remove thrust plate 10 by means of two screwdrivers RKZC4900 10 ...

Page 332: ... counterdiscs 12 pack RKZC4910 11 12 16 Lower the spring 17 retaining washer 16 Use tool F9 RKZC4920 F9 17 Remove snap ring 15 RKZC4930 15 18 Loosen the handles of the threaded rods to release the tension from the spring Remove the top piece of the F9 special tool RKZC4920 F9 ...

Page 333: ...50 18 21 Remove clutch piston 19 by blowing in compressed air through the delivery hole RKZC4960 19 22 If to be replaced remove teflon seal ring 20 and relevant inner O ring from outer seat of piston and teflon seal rings 21 and relevant inner O ring from inner of piston To remove the rings it is necessary to cut them RKZC4350 21 20 ...

Page 334: ...necessary on the output shaft for wear and damage the oil passages in the output shaft to be sure that the passages are open and free of foreign material the ball bearings and the needle bearings for flat areas pitting and other damage Use new parts as required 26 If the clutch discs are to be used again keep the clutch packs in the same previous assembly order separate and record which clutch pac...

Page 335: ... in clean transmission oil for at least an hour before assembly In any case lubricate the contact surfaces of clutch drive plates with clean transmission oil before assembly Under load of 163 kg 28 Inspect the bore of the shaft in the input shaft housing for damage that will cause leakage when the clucth is assembled Check the slots in the side of the input shaft housing for damage from the tangs ...

Page 336: ...y using tool F5 RKZC5000 3 Assemble new teflon ring 20 and relevant inner O ring new teflon ring 21 and relevant inner O rings respectively into the piston outer and inner seats RKZC4350 21 20 4 Apply a thin film of grease on the sealing rings just inserted RKZC4470 5 Insert clutch piston 19 with special tool F10 as protection of seal rings 21 RKZC4480 19 F10 ...

Page 337: ... TRANSMISSION 6 Assemble sleeve 18 RKZC4950 18 7 Assemble spring 17 and washer 16 RKZC4940 17 16 8 Lower the spring 16 lock washer 17 Use tool F9 RKZC4302 17 F9 9 Insert snap ring 15 a Ensure that the snap ring 15 is well fitted RKZC4311 15 ...

Page 338: ...s of the threaded rods to release the tension from the spring Remove the top piece of the F9 special tool RKZC4301 F9 11 Assemble clutch pack to shaft 22 RKZC4911 22 12 Assemble spacer 14 and spring pin 24 RKZC5010 24 14 13 Insert washer 13 and roller bearing 7 13 RKZC5020 7 ...

Page 339: ...e clutch pack RKZC5030 10 15 Assemble snap ring 9 RKZC5040 9 16 Apply compressed air at low pressure in hole in order to push the thrust plate 10 against the retaining ring 9 then align the clutch plate 11 spline RKZC5050 9 10 11 17 Assemble gear 8 paying attention it completely fit in its seat RKZC5060 8 ...

Page 340: ...ly The clutch plate lock ring must be all the way up against the lock ring Use a feeler gauge to measure the distance between the clutch plate lock ring and the first clutch plate 11 a Distance 2 20 3 05 mm a Ifthedistanceisnotwithinspecification theclutchis probably assembled wrong RKZC4631 11 21 Assemble gear 4 taking care to orientate the shelf facing the clutch and bearing 3 Use tool F16 RKZC5...

Page 341: ...ate the 2nd speed gear The 2nd speed gear must turn freely on the input shaft Apply compressed air of approximately 6 bar to the 2nd speed gear clutch passage Hear the 2nd speed gear piston moving to lock the 2nd speed gear clutch pack Try to move the 2nd speed gear The 2nd speed gear must not turn on the input shaft If the clutch does not work correctly disassemble the clutch to find the problem ...

Page 342: ...ling rings repeat steps 29 to 34 in section 6 2 Assembly using the spacer rings of tool F17 RKZC5100 1 2 24 Lift the three shafts B C E at the same time and insert into the half housing Use tool F15 RKZC4780 F15 25 Assemble protection 29 and tighten screws 28 to the prescribed torque 3 Screw 50 Nm RKZC4770 29 28 ...

Page 343: ...7 8 9 10 11 13 16 22 23 20 31 6 5 4 3 2 1 24 25 26 27 28 29 30 21 19 17 15 14 12 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 50 49 51 52 53 54 56 55 57 58 1 Remove screws 59 and protection 60 RKZC4771 60 59 2 Lift the three shafts B C E at the same time B C E Use tool F15 RKZC4780 F15 ...

Page 344: ... 5 30 132 TRANSMISSION 3 By means of an extractor remove bearing 58 RKZC5110 58 4 Remove the spacer 57 RKZC5120 57 5 Remove the gear 54 with its inner parts RKZC5130 54 6 Overturn the group Push down the thrust plate 39 RKZC5140 39 ...

Page 345: ...MISSION 7 Remove snap ring 38 RKZC5150 38 8 Remove the thrust plate 39 by means of two screwdrivers RKZC5160 39 9 Remove clutch kit 40 RKZC5170 40 10 Push down the thrust washer 42 to allow lock ring removal 41 Use the special tool F9 RKZC5180 41 ...

Page 346: ...Remove the top piece of the F9 special tool RKZC5190 F9 12 Remove the lock ring 41 the thrust washer 42 and spring 43 RKZC5800 17 13 Remove clutch piston 44 by blowing in compressed air through the delivery hole RKZC5210 44 14 If to be replaced remove teflon seal ring 45 and relevantimer O ring from outer seat of piston 44 RKZC5220 45 ...

Page 347: ...seat of gear 54 RKZC5230 53 16 Remove gear 37 with an extractor Remove bushing 47 and 56 roller bearing 46 and 55 and spacer 50 RKZC5240 37 46 50 17 Chech the condition of removed parts 46 47 50 55 and 56 RKZC5250 47 50 46 56 55 18 Remove the O rings 48 and 52 from the bush 50 destructive operation for the seal rings RKZC5260 52 50 48 ...

Page 348: ...of the teflon seal rings 49 and 51 Ifreplacement isnecessary cuttheteflonsealrings 49 and 51 to remove they from the bush 50 destructive operation for the seal rings RKZC5270 49 51 20 Remove gear 35 RKZC5280 35 21 Remove roller retainer 36 RKZC5290 36 22 Remove spacer 31 RKZC5300 31 ...

Page 349: ...0 137 TRANSMISSION 23 Push down the counterdisk 33 to set free the lock ring 34 RKZC5310 34 33 24 Remove snap ring 34 RKZC5320 34 25 Remove the thrust plate 33 by means of two screwdrivers RKZC5330 33 26 Remove clutch kit 32 RKZC5340 32 ...

Page 350: ...he spring pin 22 RKZC5350 22 28 Lower the spring 28 lock washer 29 Use tool F9 RKZC4303 F9 29 29 Remove snap ring 30 RKZC4312 30 30 Loosen the handles of the threaded rods to release the tension from the spring Remove the top piece of the F9 special tool RKZC4301 F9 ...

Page 351: ... its seat by blowing in compressed air through the delivery hole RKZC5370 33 Remove the bush 27 and clutch piston 26 RKZC5380 27 26 34 If to be replaced remove teflon seal ring 25 and relevant inner O ring from outer seat of piston and teflon seal rings 24 and relevant inner O ring from inner of piston To remove the rings it is necessary to cut them RKZC4351 25 24 ...

Page 352: ...7S 5 30 140 TRANSMISSION 35 Overturn the shaft 23 Cut and remove the seal rings 16 17 18 and 19 RKZC5390 19 18 17 16 36 By means of an extractor remove bearing 1 RKZC5400 1 37 Remove spacer 2 RKZC5410 2 38 Remove gear 3 RKZC5420 3 ...

Page 353: ...ION WB97S 5 30 141 TRANSMISSION 39 Remove roller retainers 7 and washer 8 RKZC5430 7 8 40 Remove the spring pin 21 RKZC5440 21 41 Pushdownthethrustplate 5 tosetfreethelockring 4 RKZC5311 5 4 42 Remove snap ring 4 RKZC5321 4 ...

Page 354: ...B97S 5 30 142 TRANSMISSION 43 Remove the thrust plate 5 by means of two screwdrivers RKZC5331 5 44 Remove clutch kit 6 RKZC5341 6 45 Lower the spring 11 lock washer 10 Use tool F9 RKZC4304 F9 10 46 Remove snap ring 9 RKZC4313 9 ...

Page 355: ...ion from the spring Remove the top piece of the F9 special tool RKZC4301 F9 48 Remove the lock ring 9 the thrust washer 10 and spring 11 RKZC5361 9 10 11 49 Extract clutch piston 13 from its seat by blowing in compressed air through the delivery hole RKZC5370 50 Remove the bush 12 and clutch piston 13 RKZC5381 12 13 ...

Page 356: ...ain keep the clutch packs in the same previous assembly order separate and record which clutch pack goes with each clutch 54 At each disassembly verify with a caliper that the total thickness of the clutch kit is within the wear limit Verify that all the clutch plates do not appear burned or that the friction material it is not damaged and that splines are well traced Verify also that all the clut...

Page 357: ... mm Nominal clutch kit thickness 30 5 30 7 mm Maximum clutch plate wear each side 0 20 mm Maximum clutch kit wear 1 6 mm 4th GEAR CLUTCH Under load of 163 kg Number of clutch plate 6 Number clutch steel plate 6 Nominal clutch plate thickness 2 00 0 05 mm Nominal clutch kit thickness 15 9 16 1 mm Maximum clutch plate wear each side 0 2 mm Maximum clutch kit wear 0 8 mm 55 Inspect the bore of the sh...

Page 358: ...using special tool F21 Assemble the O Ring 52 RKZC5460 54 2 Calibrate the teflon ring 53 using special tool F20 RKZC5470 3 Assemble new teflon ring 45 with relative O ring on clutch piston 44 RKZC5480 44 45 4 Apply a thin film of grease on the outer edge and in the inner part of clutch piston 44 and assemble in gear 54 RKZC5490 54 44 ...

Page 359: ...41 RKZC5500 41 42 43 6 Lower the spring 43 lock washer 42 Use tool F9 RKZC5191 F9 42 43 7 Insert snap ring 41 a Ensure that the snap ring 41 is well fitted RKZC5180 41 8 Loosen the handles of the threaded rods to release the tension from the spring Remove the top piece of the F9 special tool RKZC5510 F9 ...

Page 360: ...y The clutch plate lock ring must be all the way up against the lock ring Use a feeler gauge to measure the distance between the clutch plate lock ring and the first clutch plate 40 a Distance 1 725 2 375 mm a Ifthedistanceisnotwithinspecification theclutchis probably assembled wrong RKZC5530 40 12 Assemble new teflon ring 25 and relevant inner O ring new teflon ring 24 and relevant inner O rings ...

Page 361: ...ply a thin film of grease on the sealing rings just inserted RKZC4470 14 Insert clutch piston 26 with special tool F10 as protection of seal rings 24 RKZC4481 F10 26 15 Assemble sleeve 27 RKZC4951 27 16 Assemble spring 28 and retainer washer 29 RKZC5540 28 29 ...

Page 362: ...ool F9 RKZC4303 F9 29 18 Insert snap ring 30 a Ensure that the snap ring 30 is well fitted RKZC4312 30 19 Loosen the handles of the threaded rods to release the tension from the spring Remove the top piece of the F9 special tool RKZC4301 F9 20 Remove tool F9 and assemble spring pin 22 RKZC5550 22 ...

Page 363: ...e shaft 23 Apply a thin film of grease under washer 31 to avoid its falling when overturning the shaft RKZC5560 31 22 Assemble the washer 31 on the pin 22 RKZC5590 31 22 23 Insert clutch kit 32 on main shaft 23 RKZC4912 32 23 24 Insert the roller bearing 36 and thrust plate 33 RKZC5600 36 33 ...

Page 364: ...620 32 A 34 33 27 Measure the clutch discs clearance for each clutch assembly The clutch plate lock ring must be all the way up against the lock ring Use a feeler gauge to measure the distance between the clutch plate lock ring and the first clutch plate 32 a Distance 1 50 1 95 mm a Ifthedistanceisnotwithinspecification theclutchis probably assembled wrong RKZC4632 32 28 Insert gear 35 paying atte...

Page 365: ...on the shaft 23 by side shown in figure RKZC5630 37 23 30 Assemble the gear assembly 54 on main shaft 23 RKZC5640 54 31 Assemble the bush 47 and needle bearing 46 with special tool F2 RKZC5650 46 47 F2 32 Assemble the new O rings 48 and 52 to the bush 50 RKZC5260 52 50 48 ...

Page 366: ...3 and F24 Carry out steps 29 to 34 in section 6 2 Assembly to install RKZ11310 35 Assemble the bush 50 on main shaft 23 with special tool F2 k The reference mark must be on the top surface RKZC5660 50 23 36 Assemble the bush 56 and needle bearing 55 with special tool F2 RKZC5670 55 56 F2 36 Assemble the spacer 57 RKZC5120 57 ...

Page 367: ...g with relative teflon ring 14 into the piston 13 outer seat Assemble new O ring with relative teflon ring 15 into the piston 13 inner seat RKZC4353 13 14 15 39 Apply a thin film of grease on the sealing rings just inserted RKZC4470 40 Inseryt the clutch piston 13 with the special tool F10 as protection of seal rings 15 RKZC4482 F10 13 ...

Page 368: ... TRANSMISSION 41 Assemble sleeve 12 RKZC4331 12 42 Assemble spring 11 and washer 10 RKZC4321 10 11 43 Lower the spring 11 lock washer 10 Use tool F9 RKZC4304 F9 10 44 Insert snap ring 9 a Ensure that the snap ring 9 is well fitted RKZC4313 9 ...

Page 369: ...sen the handles of the threaded rods to release the tension from the spring Remove the top piece of the F9 special tool RKZC4301 F9 46 Assemble spring pin 21 RKZC5580 21 47 Insert clutch kit 6 on main shaft 23 RKZC4913 23 6 48 Assemble thrust plate 5 RKZC5570 5 ...

Page 370: ...ne RKZC5051 4 5 6 51 Measure the clutch discs clearance for each clutch assembly The clutch plate lock ring must be all the way up against the lock ring Use a feeler gauge to measure the distance between the clutch plate lock ring and the first clutch plate 6 a Distance 2 20 3 05 mm a Ifthedistanceisnotwithinspecification theclutchis probably assembled wrong RKZC4633 6 52 Assemble the thrust washe...

Page 371: ...he gear 3 RKZC5700 3 54 Assemble the thrust washer 2 RKZC5710 2 55 Assemble bearing 1 with the special tool F2 RKZC5720 F2 1 56 Install Teflon sealing rings 16 17 18 and 19 Use special tool F5 and carry out steps 29 to 34 in section 6 2 Assembly to install RKZC4681 F5 ...

Page 372: ... gear must not turn on the input shaft If the clutch does not work correctly disassemble the clutch to find the problem Apply compressed air of approximately 6 bar to the 3rd speed gear clutch passage Hear the 3rd speed gear piston moving to lock the 3rd speed gear clutch pack Try to move the 3rd speed gear The 3rd speed gear must not turn on the input shaft If the clutch does not work correctly d...

Page 373: ...k the three shafts B C E using the special tool F15 Lift the shafts B C E at the same time and insert the unit into the half housing Use tool F15 RKZC4780 F15 59 Assemble protection 60 and tighten screws 59 to the prescribed torque 3 Screw 50 Nm RKZC4771 60 59 ...

Page 374: ...62 TRANSMISSION 9 AXIS E 9 1 Disassembly RKZ11340 E E 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 23 22 21 20 19 1 Remove screws 24 and protection 25 RKZC4772 25 24 2 Lift the three shafts B C E at the same time Use tool F15 RKZC4780 F15 ...

Page 375: ... 3 Remove seals 22 and 23 a This is a destructive operation for the seal rings RKZC5730 22 23 4 By neans of an extractor remove bearings 21 and 1 Remove spacer 20 RKZC5740 21 20 1 5 Assemble the gear 18 RKZC5750 18 6 Remove roller bearing 19 RKZC5760 19 ...

Page 376: ... Overturn the shaft 12 Press the Belleville washers 5 and remove retaining ring 2 Use tool F25 RKZC5770 2 5 12 F25 8 Remove the shim 3 and washers 4 RKZC5780 4 3 9 Remove the Belleville washers 5 and spacer 6 RKZC5790 5 6 10 Remove snap ring 17 RKZC5800 17 ...

Page 377: ...11 Remove the thrust plate 16 and clutch kit 15 RKZC5810 16 12 Remove brake counter disk 14 RKZC5820 14 13 Estract piston 8 using pins 10 as pusher RKZC5830 14 Remove the O rings inner 7 and outer 9 a Replace the O rings at each disassembly RKZC5840 8 9 7 ...

Page 378: ...ring In the case that at least one of the above problems occurs replace the complete clutch kit with a new one If using a new clutch kit soak the clutch plates in clean transmission oil for at least an hour before assembly In any case lubricate the contact surfaces of clutch drive plates with clean transmission oil before assembly 18 Inspect the bore of the shaft in the input shaft housing for dam...

Page 379: ...gs on clutch piston 8 RKZC5840 8 9 7 2 Insert O rings 11 on the relative pins 10 RKZC5850 10 10 10 11 11 3 Insert pins 10 on clutch piston 8 RKZC5860 10 10 8 10 4 Apply a thin film of grease on O Rings and position the pins on clutch piston 8 in correspondence with the holes on output shaft RKZC5870 8 ...

Page 380: ...ully insert the clutch piston 8 RKZC5880 8 12 6 Insert brake counter disk 14 on shaft 12 with with tapered edge facing down RKZC5890 12 14 7 Mount the clutch kit 15 starting with a drive plate A followed by a clutch plate B RKZC5900 A B 8 Mount thrust plate 16 on shaft 12 RKZC5910 16 ...

Page 381: ...ION WB97S 5 30 169 TRANSMISSION 9 Assemble retaining ring 17 RKZC5920 17 10 Assemble gear 18 RKZC5930 18 11 Assemble roller bearing 19 and spacer 20 RKZC5940 19 20 12 Assemble bearing 21 using special tool F2 RKZC5950 21 F2 ...

Page 382: ...2 6 4 15 Using a thickness gauge measure quote X between washer 4 and lock ring 2 Subtract from quote X fixed quote S1 S1 1 80mm The result S is the thickness of shims 3 which has to be inser to between washer 4 and locking 2 S X S1 X 1 80mm X RKZ11350 6 4 2 16 Pick the S shim 3 from the range of shims available a Choose a shim that will provide a piston travel of 1 70 1 90 mm SHIM RANGE Shim mm 0...

Page 383: ...and lock ring 2 RKZC5990 2 4 18 Insert Belleville washer 5 a Check the Belleville washer 5 orientation RKZC6000 5 5 19 Mountwasher 4 andshims 3 withthicknessSdefined at sequence 14 RKZC6010 3 4 20 Lower Belleville washers 5 and assemble retaining ring 2 Use tool F25 RKZC5771 2 5 F25 ...

Page 384: ...nd carry out steps 29 to 34 in section 6 2 Assembly to install RKZC4681 F5 23 Use tool F4 for piston operation check and correct adjustment check RKZC6030 F4 24 In order to verify the seal of rings 7 and 9 feed the piston chamber with oil at 10 bar and check with a dial gauge located as shown in the photo if the real stroke is included between 1 7 and 1 9 mm RKZC6040 ...

Page 385: ...5 Belleville washers 25 Apply compressed oil pressure of approximately 10 bar to the 4WD clutch passage Listen to hear the piston moving to unlock the clutch pack The belleville washers compressing Try to move the 4WD gear The 4WD gear must turn freely on the 4WD shaft If the clutches do not work correctly disassemble the clutches to find the problem ...

Page 386: ... 5 30 174 TRANSMISSION 26 Lift the three shafts B C E at the same time and insert into the half housing Use tool F15 RKZC4780 F15 26 Assemble protection 25 and tighten screws 24 to the prescribed torque 3 Screw 50 Nm RKZC4772 25 24 ...

Page 387: ...draulic oil approx 40 l a Drain the oil from the gearbox 6 Gearbox oil approx 20 l 1 Remove the piston pump For details see PISTON PUMP 2 Remove the engine hood For details see TRANSMISSION 3 Remove the converter 1 1 5 7 4 6 RKZ08470 Installation To install reverse removal procedure a Ensure that the mating surfaces are clean and free of dents 1 a To aid in mating flywheel and joint before mating ...

Page 388: ...onnect the fuel inlet and return pipes 1 and 2 release them from the tie straps and position them aside a Cap pipes hoses and holes to prevent contamination RKZC2860 1 2 3 Remove the screws and release the straps 1 and 2 retaining the heating system hoses RKZC2870 1 2 2 4 Disconnect the heating system hoses 3 and 4 and remove the tie strap 5 retaining the gearbox oil hoses a Cap pipes hoses and ho...

Page 389: ...ry hoses 10 and 11 from air conditioning group compressor 9 a Cap the hoses and holes to prevent contamination RKZC2900 11 10 9 Only if equipped 7 Release the wiring harness 12 to the compressor 9 from the tie straps and disconnect RKZC2910 9 12 8 Disconnect wiring harness 13 from thermal starter and disconnect connector 14 from the coolant liquid temperature sensor RKZC2930 13 14 ...

Page 390: ...oid valve disconnect connector 17 from the engine oil temperature sensor 17 and disconnect connector 18 from the oil pressure sensor RKTA0811 16 17 18 11 Disconnect wiring harness 20 and ground wire 21 from generator 19 RKZC2940 21 20 19 12 Disconnect heating system connector and fuel temperature sensor connector 22 and 23 from the filter holder RKTA0801 23 22 ...

Page 391: ...ll hoses to the engine are released from straps or ties RKZC2950 15 Tighten a revolving lifting eye A to the muffler inner mounting hole RKZC2960 A 16 Attachaliftingdevice to liftingeye A and to engine front bracket 24 and apply a slight tension to the chains or cables RKZC2970 A 28 24 17 Loosen and remove nuts 25 screws 26 and vibration dampers 27 from front engine mounts 1 18 Remove the engine 2...

Page 392: ...everse removal procedure 1 3 Nuts 200 Nm a Check transmission oil level before starting the engine a Thoroughly check the connectors to ensure that they are properly connected 1 Start the engine and let it idle for a couple of minutes 2 Stop the engine and check all levels ...

Page 393: ...to the ground curl the bucket and allow it to rest on the ground on its back Apply the parking brakes stop the engine 3 Release all residual pressure For details see 20 TESTING AND ADJUSTMENTS RKZC8080 4 Lift rear window 1 to the top and remove the rear mat RKZC1870 1 5 Take out the screws 2 and remove the platform 3 RKZC1970 2 2 3 6 Loosen the clamp 4 on the control valve support frame 5 4 screws...

Page 394: ... hoses 8 and actuator hoses 9 from control valve a Check that all the hoses are marked and note down the bends and routing patterns a Cap pipes hoses and holes to prevent contamination a Lay the servocontrol hoses inside the cab to gain accesstothedelivery exhaust andactuatorhoses RKZC1990 8 9 8 9 9 Turn the tubes 10 that provide direct connection away from control valve and retain their position ...

Page 395: ...ur screws 14 n 3 and the relative washers RKZC1981 14 14 13 Lower the control valve 13 onto a lift 1 4 8 spool control valve _______ kg 4 10 spool control valve _______ kg Installation To install reverse removal procedure 1 a Install control valve from top 1 Start the machine to circulate the oil check to ensure that there are no leaks 2 Bleed the air from the working equipment circuits For detail...

Page 396: ...ect all hoses 2 from selonoid valve group 1 a Plug all pipes hoses to prevent contamination 2 Mark and disconnect all connectors 5 No 2 and 6 No 2 from selonoid valve 3 and 4 No 4 RKZC8120 1 2 2 2 2 3 Loose and remove bracket 8 fixing screws 7 No 2 disconnect connectors 9 and remove steering solenoid valve group 1 RKZC8130 6 3 5 4 Installation To install reverse removal procedure 1 Run the engine ...

Page 397: ...n its secure position 4 Engage the parking brake 5 Stop the engine and eliminate residual pressure from all circuits For details see 20 TESTING AND ADJUSTMENTS Remove the ignition key 6 Remove the engine hood 1 and the front guard 2 For details see ENGINE HOOD and FRONT GUARD 7 If equipped remove the front counterweight 1 4 Counterweight 372 kg 8 Remove the front wheels 2 4 Wheel _________ kg 9 Re...

Page 398: ...8 8 9 10 11 15 Loosen the screws 12 retaining the supports 6 9 to eliminate torque 6 RKZC8160 9 6 12 12 12 12 16 Position a jack B and some blocks C beneath the axle Raise the jack until the blocks can be forced under the axle arms 4 a It should be possible to lower the jack 10 cm in order to disengage the axle from the fulcrum supports 17 Remove the screws 6 9 with washers 18 Lower the jack until...

Page 399: ...0 Nm 3 3 Screws _________ Nm 4 3 Screws on gearbox side 38 Nm 5 a Bleed the air from the Load Sensing circuit For details see 20 TESTING AND ADJUSTMENTS 6 3 Support screws 550 55 Nm 2 Screw Loctite 242 1 Check the oil level in the tank and start the engine 2 Perform a few complete steering manoeuvres in both directions to bleed the air from the steering circuit ...

Page 400: ...PAGE INTENTIONALLY LEFT BLANK ...

Page 401: ...89 FRONT AXLE FRONT AXLE Disassembly and assembly 1 Flange group 1 1 Disassembly RKZ11690 6 4 7 3 2 1 5 1 Remove the lock ring 1 and flange 2 RKZ11700 1 2 2 Remove seal ring 3 a This is a destructive operation for the seal ring RKZ11720 3 ...

Page 402: ... 5 4 1 2 Assembly 1 Insert the washer 5 on the pinion end Lubricate and assemble a new O Ring 4 2 O ring oil RKZ11710 5 4 2 Assemble the seal ring 3 into the central body with the special tool D19 and a hammer RKZ11720 3 3 Install the flange 2 on the pinion end Assemble the lock ring 1 RKZ11700 1 2 ...

Page 403: ...oup 2 1 Disassembly RKZ11730 11 9 14 15 13 12 10 8 6 4 5 7 3 2 1 1 Loosen the special screw 1 Remove the rear support 2 from the differential support 8 RKZ11811 2 8 1 2 Remove the O Ring 4 from the rear support 2 a Replace the O ring at each disassembly RKZ11761 4 2 ...

Page 404: ...1800 1 2 5 4 Remove the bushes 3 from rear support 2 RKZ11790 3 2 5 Remove the bush 6 and washer 7 from differential support 8 only if necessary a Cut the bush 6 with a chisel a Replace the bush at each disassembly RKZ11780 7 6 8 6 Loosen the special screw 15 Remove the front support 13 from the axle housing 9 RKZ11750 15 13 9 ...

Page 405: ...sing 9 only if necessary a Cut the bush 11 with a chisel a Replace the bush at each disassembly RKZ11770 10 11 9 9 Remove the bushes 14 from rear support 13 RKZ11820 13 14 2 2 Assembly 1 Insert the washer 7 onto the differential support Heat the bush 6 at 110 120 C than assemble it to the differential support a If necessary use a pad and a hammer to assemble the bush 6 RKZ11780 7 6 8 ...

Page 406: ...ar support 2 a Set the bush 5 with the screw hole aligned with the screw hole in the support 2 5 Mount the special screw 1 RKZ11830 1 5 2 6 Lubricate and insert the new O ring 4 in the bush 5 in the rear support 2 a Insert the O ring into the seat on the shown side RKZ11760 4 2 5 7 Insert the rear support 2 on the differential support 8 a Be careful to avoid damaging the O ring 4 8 Tighten the scr...

Page 407: ...alant on bushes 14 contact surface 2 Bushings Loctite 542 12 Assemble the bushes 14 to the front support 13 with a pad and a hammer RKZ11820 13 14 13 Assemble the bush 12 into the front support 13 with a suitable driver and a hammer a Set the bush 12 with the screw hole aligned with the screw hole in the support 13 14 Assemble the screw 15 RKZ11840 15 13 12 15 Insert the front support 13 on the ax...

Page 408: ...e inductive magnetic steering sensor by unloosing the locking clamps screws 7 and 8 Remove the sensor 9 Collect the receptacle braket 10 RKZ11860 8 9 10 7 2 Loosen the tie rod locknut 1 and 16 of some turns till it is over the end of the threaded pin Beat the nut with a hammer to remove the steering arm from the swivel housing a Replace the nut at each disassembly RKZC6590 1 16 ...

Page 409: ...e the cylinder heads 19 and 23 and the rod 21 from cylinder body 23 Collect all the seal rings 17 18 20 22 24 e 25 from the rod and the cylinder heads RKZ11880 21 23 25 24 22 20 18 17 19 3 2 Assembly 1 Assemble new seal rings 17 18 20 22 24 e 25 on the rod 21 and on the cylinder heads 19 and 23 Insert the rod 21 into the cylinder body 23 and assemble the cylinder heads 19 and 23 RKZ11880 21 23 25 ...

Page 410: ...ary unscrew the lock nut 13 6 Repeat the whole sequence of the mentioned operations on the opposite side RKZC6610 13 15 14 7 Insert the ball joint of the tie rod 14 into its housing on the swivel housing 15 Assemble and tighten the lock nut 16 3 Nut 280 Nm 8 Repeat the whole sequence of the mentioned operations on the opposite side a Before screw the lock nuts 4 and 13 of the tie rods 3 and 14 adj...

Page 411: ...11910 11 3 2 1 4 5 6 8 9 7 10 1 Unscrew and remove both fastening screws 1 of the planetary carrier 3 with a wrench RKZ12390 1 3 1 2 Removetheplanetarycarrier 3 fromthewheelhuband collect the relative O Ring 11 3 Position the planetary carrier 3 on a workbench and check its wear conditions RKZC6640 3 11 ...

Page 412: ...h Insert the thrust washer 4 on every pin RKZ11930 4 5 6 3 2 Position the planetary carrier 3 on a workbench Insert the needles 5 the thrust washer 4 and the needles 5 in the epicyclic gears 6 a Grease well the needles 5 3 Insert the thrust washer 4 and the assembled epicyclic gears 6 in the planetary carrier 3 pins RKZC6660 6 3 5 4 Fit the thrust washers 8 and 9 to the planetary carrier 3 pins a ...

Page 413: ...AL AND INSTALLATION WB97S 5 30 201 FRONT AXLE 6 Assemble a new O Ring 11 on the wheel hub 7 Fit the epicyclic reduction gear assembly to the wheel hub 8 Screw the fastening screws 1 3 Screw 25 Nm RKZC6680 11 ...

Page 414: ...el hub group For details see 4 Epicyclic reduction gear group 1 Insert a lever between the swivel housing 14 and the axle beam and fit it into the double U Joint With the lever push the double U Joint in the direction of the wheel hub to allow the lock ring 1 removal a Be careful to avoid damaging the double U Joint RKZC6700 14 2 Remove the lock ring 1 from the double U Joint shaft Collect the dou...

Page 415: ...es 5 Remove the wheel carrier 7 with the epicyclic ring gear 4 RKZC6730 5 4 7 6 Remove the steel lock ring 8 and disjoin the wheel carrier 7 from the epicyclic ring gear 4 7 Only if necessary remove the centering bushes 6 from the wheel carrier with a hammer and the special tool D11 RKZC6740 6 7 4 8 8 Remove the wheel hub 11 using levers and a hammer to facilitate the operation a Collect the beari...

Page 416: ...n k Before removing the king pins 15 and 19 secure the swivel housing 14 with a belt or a rope to a hoist or any other supporting device observe all current safety regulations to guarantee operator s safety 13 Remove the king pins 15 and 19 RKZC6770 16 15 13 Remove the swivel housing 14 from the axle beam and from the short shaft of the double U Joint 14 Collect the belleville washers 25 and 27 RK...

Page 417: ...y the seal ring 23 2 Sealing ring POLYMER 400 Tecnolube RKZC6810 14 D15 D20 5 If the cone 18 of the spherical joint has been previously removed reassemble it to the lower king pin 19 using the special tool D13 under a press 6 Greasecarefully thekingpin 15 and 19 housings with specific grease 2 King pin ASL800050 7 Position the belleville washers 25 and 27 on the king pin 15 and 19 housings RKZ1197...

Page 418: ...ay before assembling new components check the indicated dimensions A 17 950 18 000 mm B 64 275 64 325 mm C 23 072 23 173 mm C A C B RKZ11980 12 Force both bearing cups 9 and 12 to their wheel hub 11 housings using the special tool D10 under a press or with a hammer 13 Insert the seal ring 13 into the wheel hub 11 with the special tool D2 and a hammer a Do not lubricate the seal ring 13 RKZC6840 11...

Page 419: ...ZC6860 7 6 17 Preassemble the wheel carrier 7 and the epicyclic ring gear 4 with the special locking ring 8 shown in figure RKZ11990 4 7 8 18 Assemble the wheel carrier group on the wheel hub using the two projecting bushes as dowel pins and screw the relative screws 5 inordertoputincontactthe ring bevel gear with the wheel hub RKZC6870 5 19 Force all the hub dowel bushes 6 completely with the spe...

Page 420: ...e double U Joint in the direction of the wheel hub to make easier the lock ring 1 insertion RKZC6700 14 21 Slide the thrust washers 3 and 2 onto the double U Joint shaft end 24 Insert the lock ring 1 at the end of the splined hub and push it into its housing a Check that the lock ring 1 is correctly fitted in its seat 22 Push the double U Joint thoroughly RKZC6711 1 2 3 24 ...

Page 421: ... 6 3 1 Remove the two double U Joints 6 from the axle beam 1 RKZC6890 6 1 2 Remove the seal rings 5 from the axle beam 1 a Replace the seal rings at each disassembly 3 Remove the bush 4 from the axle beam 1 only if the wear conditions require this a Be careful not to damage the bush seat RKZ12020 5 4 5 ...

Page 422: ...C with liquid nitrogen k Wear safety gloves 2 Assemble the upper bush 2 on the upper king pin seat with the special tool D12 and a hammer 3 Assemble the ball bearing cup 3 on the lower king pin seat with the special tool D12 and a hammer RKZC6900 2 3 D12 D12 4 Assemble the bush 4 on the axle beam 1 with the special tool D17 and a hammer 5 Assemble the seal ring 5 on the axle beam with the special ...

Page 423: ...REMOVAL AND INSTALLATION WB97S 5 30 211 FRONT AXLE 7 Insert the double U Joint 6 inside the axle beam 1 a Be careful not to damage the seal ring 5 RKZC6890 6 1 ...

Page 424: ... 1 2 8 10 11 12 13 14 1 Loosen and remove the 12 screws 2 on the differential support 1 Remove the differential support 1 from the axle housing 15 2 support the differential support with a rope or other appropriate means RKZ12060 15 1 2 3 Loosen and remove the screws 3 to remove the two ring nut retainers 4 RKZ12070 3 4 ...

Page 425: ...e differential support 1 as well RKZC6910 11 5 1 5 Unscrew the adjuster ring nuts 5 and 9 using tools D16 and a wrench RKZ12080 5 9 D16 6 Remove the 4 screws 12 and remove both half collars 11 a Check that the bushes 10 remains in their housings RKZ12090 11 12 10 7 Remove out the differential case 7 a The bearing cones 6 and 8 are removed together with the differential housing a Do not invert the ...

Page 426: ...erential group so to place the bevel crown gear on the pinion 4 Check that all bushes 10 are in their housings and position both half collars 11 on their seats using the previously traced reference marks Lock both collars with their fastening bolts 12 RKZ12090 11 12 10 5 Assemble the adjusting ring nuts 5 and 9 to the differential support 6 Tighten both ring nuts 5 and 9 with special tools D16 til...

Page 427: ...e bevel gear backlash by turning adjusting rings 5 and 9 with the appropriate tool D16 RKZ12140 11 Adjust the ring nuts 5 and 9 remembering that A if the measured backlash is greater than the given tolerance range unscrew the adjuster ring nut 5 and screw in the adjuster ring nut 9 by the same measure B if the measured backlash is less than the given tolerance range unscrew the adjuster ring nut 9...

Page 428: ...ings pinion crown bevel gear system with a torquemeter a Warning All preloadings must be measured without seal ring RKZC6750 16 The total rolling torque TT must be within the following range TT TP 0 55 TP 0 82 Nm where TP is the pinion bearings preloading For details see 9 2 Assembly at point 14 RKZ12150 TT 17 If the measurement is not within the requested range check well the assembly of each com...

Page 429: ... 14 15 and 16 RKZ12410 12 12 21 Before matching surfaces make sure that they are perfectly clean degrease and clean them with appropriate detergents Spread a film of adhesive on the contact surface between the axle beam 15 and the differential carrier 1 2 Sealant Loctite 510 a Check that two dowel bushes 14 are in their seats the dowel pin 13 must be in their seat on the half collar 11 RKZ12160 15...

Page 430: ...ark on the teeth surfaces will be regular Z Excessive contact on the tooth tip Approach the pinion to the ring bevel gear and then move the ring bevel gear away from the pinion in orderto adjust the backlash X Excessive contact at the tooth base Move the pinion away from the ring bevel gear and then approach the ring bevel gear to the pinion in order to adjust the backlash Z X OK RKZ12170 Movement...

Page 431: ...e the bevel gear crown 2 a Warning This will make both differential half boxes 4 16 free so take care not to drop the internal components RKZC6940 1 2 4 2 Disassemble the differential box in two half boxes 4 16 complete with the relevant components a Make alignement marks on the half boxes before separating them 3 Disassemble all the components a Check the operating and wear conditions of the comp...

Page 432: ...g differential counterplate 5 locking differential disks 6 and 7 sun gears 8 and 15 spider 11 and 12 planetary gears 10 and 13 thrust washers 9 and 14 as shown in figure a The first disk 7 must be assembled with friction material on the disks side and the flat surface on the sun gear 8 side Join the two half boxes 4 and 16 aligning the reference marks made during disassembly 4 RKZ12190 16 3 Positi...

Page 433: ...D1 and D9 a Replace the lock nut at each disassembly RKZC6960 D1 D9 10 2 Tap the shaft with a soft hammer to remove the bevel pinion 1 a Take care not to drop the pinion RKZC6970 1 3 Collectthewasher 4 and 6 thecollapsiblespacer 5 the bearing cone 8 and the retaining washer 9 RKZC7000 9 8 4 5 6 4 Remove the bearing cups 3 and 8 using a driver and a hammer RKZC6980 8 3 ...

Page 434: ...ck all pinion components for wear The ring nut 10 and the collapsible spacer 5 must be replaced when reassembling the unit RKZC7010 5 10 9 2 Assembly 1 Fit the bearings cups 3 and 8 using the special tools D14 D5 and a hammer RKZC7020 3 8 D5 D14 2 Prepare ithe kit consisting of the special tools called false pinion D4 and false differential box D3 and D7 and a depth gauge a4 RKZC7030 a4 D7 D3 D4 ...

Page 435: ...ial group support 7 and lock it with the half collars 7 RKZ12240 5 Assembly diagram of the false differential box on the left Use a depth gauge to measure distance X distance between the axis of the differential bearings and the point at which the pinion head is supported or base of the bearing X X RKZ12250 6 In order to determine the necessary thickness value S between pinion and bearing subtract...

Page 436: ...7 8 10 RKZ12230 9 Insert the chosen shim 2 with the chamfer against the gear into the pinion shaft 1 Force the bearing 3 into the pinion shaft 1 with the special tool D8 under a press making sure that it is well set Insert the shims 4 and 6 and the new collapsible spacer 5 a Use always a new collapsible spacer 1 2 3 4 5 6 1 RKZ12280 10 Insert the bevel pinion 1 unit into the differential support h...

Page 437: ...to beat slightly both pinion ends with a soft hammer so as to help setting the bearings 3 and 8 RKZC7050 D1 D9 13 Carry out the preloading measurement P of the pinion taper roller bearings 3 and 8 using a dynamometer whose cord is wound on the end of pinion spline 1 The measured value should be within the following range P 9 2 13 7 daN The adjustment is carried out by increasing the ring nut 10 to...

Page 438: ...ust be within the following range TP 1 6 2 4 Nm The adjustment is carried out by increasing the ring nut 10 torque gradually being careful not to exceed RKZ12150 TT 16 Once the requested preloading value is achieved caulk the ring nut 10 using a hammer and a chisel RKZC7080 10 ...

Page 439: ...eel sides and lock them with two nuts on the wheel hub stud bolt a The two bars should be fixed on their middle so that they are perpendicular to the supporting surface and parallel to the pinion shaft axis align the two bars RKZC7090 500 mm 500 mm 2 Measure the distance in mm M between the bars ends with a tapeline a Keep the minimum value swinging the measurement point RKZC7100 ...

Page 440: ...refore the measured value M at the bars ends must be related to the ratio between length of the bar and flange diameter nominal toe in A measured toe in M RKZ12310 A 0 2 M 0 5 A M 0 4 If toe in is incorrect operate with two wrenches on the steering arms 1 screwing in and out the two joint tie rods 3 equally till the toe in is within the requested tolerance RKZC7110 1 3 5 After adjusting screw in t...

Page 441: ... at the maximum steering RKZC7130 2 Adjust a protractor to the requested angle and position it on the long bar Move a wheel side till it forms with the two bars the angle fixed by the protractor RKZC7140 3 Adjust the mechanical steering stop screwing in or out the stop bolt 5 locking them with the locknut 4 3 Lock nut 150 Nm RKZC7150 5 4 4 Check the position of the stops on the opposite side both ...

Page 442: ...te side both screws must touch the steering stop pads at the same time RKZ12330 7 Assemble the steering sensor 6 on the cylinder with relative clamps 7 and 8 a Do not lock the clamps 8 Insert into theclamp 8 theplasticsupport 9 as shown RKZC7160 6 7 8 9 9 Connect the steering sensor 6 with the special testing system D22 Supply 18 V dc with a battery to the testing system RKZ12340 ...

Page 443: ...lowly slide again the sensor till led is off in the same direction position P2 c measure the stroke C between position P1 and P2 P1 P2 C RKZ12350 6 d set sensor right in the middle between position P1 and P2 with tolerance 1mm P1 P2 C 2 C 2 RKZ12360 e turn the sensor 6 in the shown position RKZ12370 9 0 6 f lock the sensor with the clamps 7 and 8 a The clamps must be tightened with the screw head ...

Page 444: ... wheels forward Both the wheels should get blocked after a while 4 Keeping the pinion blocked free the right wheel and rotate the left one in the line of march Rotate the right wheels in the opposite direction The wheel will move freely without difficulty and the right wheel will move in the opposite direction if the assembly has been carried out correctly Repeat the same operation in the opposite...

Page 445: ...he machine rests on jacks A then move frame back to its horizontal position RKZC2040 1 A 1 4 Foraddedsafety placethebackhoebucketwithitsback on the ground while holding the arm in its upright position Lower shovel to the ground as well RKZC8170 5 Remove the rear wheels 2 1 6 Stop the engine and completely release residual pressures from all the circuits For details see 20 TESTING AND ADJUSTMENTS R...

Page 446: ...ntamination RKZC8290 4 8 5 6 7 9 Disconnect the tubes 9 3 a Plug all pipes hoses to prevent contamination 10 Disconnect from axle 4 rear cardan shaft 10 and put aside 4 RKZC7891 4 10 9 9 11 Loose nuts 11 No 4 until release tightening torque 5 RKZC8300 11 12 Position a jack C and some blocks beneath the axle 4 Raise the jack until the blocks can be forced under the axle arms RKZC8330 4 C ...

Page 447: ...e jack up to allow axle removal 4 Rear axle 545 kg RKZC8340 11 12 Installation To install reverse removal procedure 1 3 Wheel nuts 500 9 8 Nm 2 a Bleed the air from the braking circuits For details see 20 TESTING AND ADJUSTMENTS 3 a Adjust the stroke of the parking brake lever For details see 20 TESTING AND ADJUSTMENTS 4 3 Cardan shaft screws 38 Nm 5 2 Nuts Loctite 242 3 Nuts _________ Nm ...

Page 448: ... 4 2 8 19 20 21 22 18 17 23 24 25 26 27 28 29 30 31 1 Remove nuts 2 18 and remove tie rods 7 16 from swivel housing 1 17 a If necessary use a hammer a Don t damage the threaded pin ends a Replace the nuts 2 18 at each disassembly RKZC6591 2 18 7 16 2 Remove the clamps 19 and 22 sensor 21 and receptacle bracket 20 from the cylinder 12 RKZ12450 12 19 20 21 22 ...

Page 449: ...nder 12 from the axle RKZ12470 12 5 Detach the cylinder head 29 from the cylinder case 25 and remove it from the rod 27 Remove the rod 27 from the cylinder case 25 Remove all the seals and O Rings 23 24 26 28 30 and 31 from the cylinder head 29 and piston 27 RKZ12480 24 23 25 26 27 31 30 29 28 1 2 Assembly 1 Assemble new seals and O Rings 23 24 26 28 30 and 31 on the cylinder heads 29 on the pisto...

Page 450: ...Nm Screws 13 660 Nm 2 Screw Loctite 270 5 Screw the ball joints 9 and 14 to the ends of the rod 27 3 Ball joints 300 Nm RKZ12500 27 13 14 9 10 11 12 6 Assemble the nuts 8 and 15 then the tie rods 7 and 16 to the ball joints 9 and 14 RKZ12490 15 16 9 14 7 8 7 Align the swivel housing 1 with the axle Screw the tie rod 7 so that its ball joint can be inserted into the swivel housing 1 arm a It s impo...

Page 451: ... 17 18 11 Screw in the lock nuts 8 and 15 of the tie rods 7 and 16 only when the toe in adjustment has been carried out For details see 10 1 Toe in adjustment RKZC7240 7 8 12 Assemble the sensor 21 and receptacle bracket 20 with the clamps 19 and 22 to the steering cylinder 12 RKZ12510 19 12 21 22 20 a The clamps can be completely tightened only when the toe in adjustment has been carried out For ...

Page 452: ...2 Epicyclic reduction gear group 2 1 Disassembly RKZ11910 11 3 2 1 4 5 6 8 9 7 10 1 Drain the oil completely from the epicyclic reduction gear RKZC6630 2 Unscrew and remove both fastening screws 1 of the planetary carrier 3 with a wrench RKZ12390 1 3 1 ...

Page 453: ...ake the planetary gears 6 out of the pins collect the needles bearing 5 and check their conditions collect the thrust washer 4 RKZ11920 6 9 10 8 5 4 2 2 Assembly 1 Position the planetary carrier 3 on a workbench Insert the thrust washer 4 on every pin RKZ11930 4 5 6 3 2 Position the planetary carrier 3 on a workbench 3 Insert the needles 5 the thrust washer 4 and the needles 5 in the epicyclic gea...

Page 454: ... 7 fitted on the planetary carrier 3 pins 6 Assemble the fastening bolt 10 3 Screw 79 Nm RKZC6670 8 9 7 7 Assemble a new O Ring 11 on the wheel hub Fit the epicyclic reduction gear assembly to the wheel hub Screw the fastening screws 1 3 Screw 25 Nm RKZC6680 11 8 Top up the oil on the wheel hub For details see _______ 9 Fit the plug 2 on the epicyclic reduction gear 3 3 Plug 60 Nm RKZC6690 3 2 ...

Page 455: ...27 1 Insert a lever between the swivel housing 14 and the axle beam and fit it into the double U Joint With the lever push the double U Joint in the direction of the wheel hub to allow the lock ring 1 removal a Do not damage the double U Joint RKZC6700 14 2 Remove the lock ring 1 from the double U Joint shaft Collect the double U Joint shaft washers 2 3 RKZC6710 1 2 3 ...

Page 456: ...oles Remove the wheel carrier 7 with the epicyclic ring gear 4 RKZC6730 5 4 7 5 Remove the steel lock ring 8 and disjoin the wheel carrier 7 from the epicyclic ring gear 4 Only if necessary remove the centering bushes 6 from the wheel carrier with a hammer and the special tool E7 RKZC6740 6 7 4 8 6 Remove the wheel hub 11 using levers and a hammer to facilitate the operation a Collect the bearing ...

Page 457: ...in a Before removing the king pins 16 and 18 secure the swivel housing 14 witha belt or a rope to a hoist or any other supporting device observe all current safety regulations to guarantee operator s safety 10 Remove the king pins 16 and 18 RKZC6771 15 16 11 Remove the swivel housing 14 from the axle beam and from the short shaft of the double U Joint Collect the belleville washers 27 and 28 RKZC6...

Page 458: ...ly the seal ring 24 2 Sealing ring POLYMER 400 Tecnolube RKZC6811 14 E12 E24 3 If the cone 17 of the spherical joint has been previously removed reassemble it to the lower king pin 18 using the special tool E10 under a press Grease carefullytheking pin 16 and 18 housingswith specific grease 2 King pin ASL800050 4 Position the belleville washers 25 and 27 on the king pin 16 and 18 housings RKZ11970...

Page 459: ...yway before assembling new components check the indicated dimensions A 17 950 18 000 mm B 64 275 64 325 mm C 23 072 23 173 mm C A C B RKZ11980 7 Force both bearing cups 9 and 12 to their wheel hub 11 housings using the special tool E6 under a press or with a hammer Insert the seal ring 13 into the wheel hub 11 with the special tool E2 and a hammer a Do not lubricate the seal ring 13 RKZC6841 11 11...

Page 460: ...KZC6860 7 6 10 Preassemble the wheel carrier 7 and the epicyclic ring gear 4 with the special locking ring 8 shown in figure RKZ11990 4 7 8 11 Assemble the wheel carrier group on the wheel hub using the two projecting bushes as dowel pins and screw therelativescrews 5 inordertoputincontactthe ring bevel gear with the wheel hub RKZC6870 5 12 Force all the hub dowel bushes 6 completely with the spec...

Page 461: ...e double U Joint in the direction of the wheel hub to make easier the lock ring 1 insertion RKZC6700 14 14 Slide the thrust washers 3 and 2 onto the double U Joint shaft end 26 Insert the lock ring 1 at the end of the splined hub and push it into its housing a Check that the lock ring 1 is correctly fitted in its seat 15 Push the double U Joint thoroughly RKZC6712 1 2 3 26 ...

Page 462: ...LE 4 Axle beam group 4 1 Disassembly RKZ12540 13 3 12 11 10 1 4 2 5 6 7 8 9 1 Drain the oil completely from the axle 2 Remove the screws 13 Unscrew the oil pipe nuts 11 RKZ12550 13 12 11 3 Remove the oil pipe 12 Collect the washer 10 RKZ12560 10 12 ...

Page 463: ...solutely sure to identify the coupled parts RKZ12570 a Position the axle on supports fitted to hold either the centralbody andthetwo beam trumpets evenaftertheir disjunction or secure the disjointed groups to a lifting device with ropes or belts 6 Remove the fastening screws 6 RKZC7830 6 7 Remove the beam trumpet 7 and collect the O Ring 8 a Once the beam trumpet has been removed the brake group i...

Page 464: ...quire this RKZ12590 4 5 4 2 Assembly 11 Cool the upper king pin bush 4 and the ball bearing cup 5 at a temperature lower than 100 C with liquid nitrogen k Wear safety gloves 12 Assemble the bush 4 on the upper king pin seat with the special tool E9 and a hammer Assemble the ball bearing cup 5 on the lower king pin seat with the special tool E9 and a hammer RKZC7201 4 5 E9 E9 13 Assemble the bush 7...

Page 465: ... groups properly as already pointed out for disassembly phase 15 Assemble the beam trumpet 7 on the central body 9 using the reference marks carried out during disassembly a Be careful not to damage the O ring 8 RKZ12630 7 9 16 Assemble the fastening screws 6 Tighten the fastening screws 6 to the requested torque according to the shown sequence 3 Screw see next step RKZ12640 6 ...

Page 466: ...rew 320 Nm RKZ12650 D L I C E A N H G M B F 18 Insert the double U Joint 1 inside the axle beam a Be careful not to damage the seal rings RKZC6891 1 19 Position the washer 10 on the beam trumpet 7 RKZ12561 10 7 20 Tighten the screws 13 Tighten the oil pipe nuts 11 3 Nuts 60 Nm 21 Fill the axle with specified oil RKZ12660 11 12 13 ...

Page 467: ...and half shaft For details see 4 Axle beam group RKZ12680 1 2 Remove the components from the brake flange 1 brake counterplate 7 and brake plates 8 brake disk carrier gear 9 brake counterplates 10 and plates 11 a Remember the position of the the brake disk carrier it must be reassembled in the same position RKZ12680 7 9 8 1 11 10 RKZ12690 ...

Page 468: ...ts of the self adjust kit 5 and brake mechanism return kit 6 RKZ12680 RKZ12710 5 6 5 Remove the brake piston 4 a If necessary blow in air through the brake oil input hole to eject the piston using the minimum pressure k Possible swift ejection of the piston RKZ12680 RKZ12720 1 4 6 Remove the O Rings 2 and 3 from the brake piston 4 RKZ12680 RKZ12730 3 2 4 ...

Page 469: ...g inner surface RKZC7270 2 Assemble a new O Rings 2 and 3 to the brake piston 4 2 O ring brake oil RKZ12680 RKZ12730 3 2 4 3 Insert the piston 4 into the brake cylinder 1 and position the special tool E11 on the piston a Position the brake piston 4 with a slot aligned with the hydraulic connection or with the inspection hole on the brake cylinder 5 a Do not damage the O rings 4 With a lever anchor...

Page 470: ...n kit 6 in the largest hole of the brake piston RKZC7280 6 6 Assemble the spring cover and the screw of the brake mechanism return kit 6 RKZC7290 6 7 Assemble the bush the washer and the screw of the self adjust kit 5 RKZC7300 5 8 Screw the fastening screws of both kits and tighten them to the prescribed torque 3 Screw 10 Nm RKZC7310 ...

Page 471: ...ial pad E11 and the handle E8 with a hammer a Position the pad with accuracy to do not damage the brake piston RKZC7330 4 11 Assemble the brake control group For detail see 6 Brake control group RKZ12680 RKZ12700 12 Checkthatthebrakeplate 8and11 andthebrakedrive plate 7 and 10 do not present any sign of burning on the contrary replace them Furthermore check brake plate wear and if necessary replac...

Page 472: ...r gear 9 brake counterplates 10 and plates 11 a Place the brake disk carrier 26 as shown in the next figure assemble brake disks with holes aligned RKZ12680 RKZ12750 10 11 9 7 8 a This is the correct position of the teeth on the external surfaces of the brake disk carrier 9 RKZ12680 RKZ12760 9 14 Reassemble the beam trumpet and half shaft For details see 4 Axle beam group RKZ12681 ...

Page 473: ...1 Disassembly RKZ12770 6 2 1 3 4 5 7 8 9 12 17 13 15 14 10 11 16 1 Remove the beam trumpet group For details see 4 Axle beam group RKZ12780 2 Remove from the brake flange 18 brake counter plates and brake plates and brake disk carrier For details see 5 Brake group RKZ12790 18 ...

Page 474: ...KZC7350 13 4 Unscrew and remove the fastening screw 1 RKZC7360 1 5 Remove the washer 2 RKZC7370 2 6 Put an alignment mark on the lever 3 and shaft 8 for use during installation and to distinguish between right and left control for example you can put two marks on the right and only one on the left RKZC7790 3 8 ...

Page 475: ...LATION WB97S 5 30 263 REAR AXLE 7 Loosen the lever 3 to release the tension on the spring 4 RKZC7800 3 4 8 Remove the lever 3 RKZC7810 3 9 Remove the spring 4 RKZC7820 4 10 Remove the washer 5 and the spacer 6 RKZC7860 6 ...

Page 476: ...16 14 12 Remove the bracket 14 RKZC7380 14 13 Make an alignment mark on the cam 10 near the screw 9 align with the top of the roll pin for use during assembly As already done for the control lever distinguish between right operation side and left one RKZC8350 14 Free the cam 10 unscrewing the screw 9 RKZC7400 10 9 ...

Page 477: ...30 265 REAR AXLE 15 Unscrewtheshaftscrew 12 beingcarefulthesteelball 11 does not get lost RKZC7410 12 16 Collect the steel ball 11 RKZC7420 11 17 Remove the O Ring 7 RKZC7430 7 18 Remove the shaft 8 and collect the cam 10 RKZC7440 8 10 ...

Page 478: ...e flange 18 a Refering to the marks previously done to identify the parts on the right side and on the left side RKZC7450 8 10 18 3 Align the reference mark previously done with the screw 9 hole RKZC7460 9 4 Assemble a new screw 9 to the shaft 8 a If you remove the screw 9 apply the sealant on the thread before reassemble it 2 Screw Loctite 542 RKZC7470 9 8 5 Tighten the screw 9 3 Screw 10 Nm RKZC...

Page 479: ...ew 12 RKZC7420 11 7 Put on thread of the screw 12 a slight layer of prescribed sealant 8 Tighten the screw 12 3 Screw 25 Nm 2 Screw Loctite 270 RKZC7490 12 9 Insert a new O ring 7 on the shaft RKZC7500 7 10 Position the supporting bracket 14 11 Assemble the fastening screws 16 and 17 RKZC7510 16 14 ...

Page 480: ...ry important to respect the reference marks Control brake assembly could be completed only after the assembly of brake group and of axle RKZC7540 3 WARNING during group handling and assembling phases be careful not to move the brake control lever This could cause the uncorrect positioning of the discs and of the self adjust groups with the consequent reduction of brake efficiency a Align the holes...

Page 481: ... levers setting them on braking position locked levers a The lever return springs should not be inserted Measure the distance between the middle of the connection holes at the ends of the control levers and check that it is within the foreseen range 283 291 mm If the value is not within the foreseen range correct the lever position take them out of the shaft and reinsert them shifted of one spline...

Page 482: ...ake group RKZC7580 4 3 19 Check that in rest position load of 5 daN the measure between the middle of the connection holes at the lever ends is higher than the minimum value 283 mm of the requested range For detail see the point 15 283 291 RKZ12740 20 Assemble the nuts 16 on the adjusting screws 13 Assembletheadjustingscrews 13 onthebrackets 14 and screw in them till they are in contact with the l...

Page 483: ...e same measure to be within the foreseen range for the levers in rest position 315 300 mm about 3 mm between lever and bracket will remain 315 300 RKZ12820 22 Ifthescrew isnotperpendiculartothesidesurfaceofthe lever adjust its position by moving the supporting bracket 14 RKZ12830 90 ...

Page 484: ... 7 1 Disassembly RKZ12840 10 9 8 7 6 5 3 2 1 4 MARCIA AVANTI DRIVING DIRECTION L H R H 1 Remove the brake disks and counterdisks For details see 5 Brake group RKZ12790 18 2 Secure the brake cylinder 5 to a hoist with ropes or safety belts Remove the fastening screw 4 RKZ12850 5 4 ...

Page 485: ...ferential box is free 4 Remove the O Ring 6 from the brake cylinder 5 RKZ12860 5 6 5 Remove out the differential case 8 RKZ12870 8 6 Remove the O Ring 9 from the central body 10 RKZ12880 9 7 Unscrew and remove the screw 2 and the ring nut retainer 1 from the brake cylinder 5 RKZ12890 2 1 5 ...

Page 486: ...e a driver to remove the bearing cup 7 from the brake cylinder 5 a Do not invert the bearing cups if the bearings are not replaced RKZ12910 5 7 7 2 Assembly Assemble the pinion group before assemble the differential support group For details see 9 Pinion group RKZ12920 1 Lubricate and assemble new O Ring 9 on every side of the central body 10 RKZ12930 10 9 ...

Page 487: ...emble a new well lubricated O Ring 6 on the brake cylinder 5 housing First assemble the right brake cylinder Rh to the central body 1 Insert the differential group into the central body 10 See part 10 in section Differential group a The bevel gear must be placed on the left side Lh 5 Assemble the left brake cylinder Lh a Check that the reference marks made during the disassembly between the brake ...

Page 488: ...preloaded E15 RKZC7620 3 10 Assemble the special tool E19 on the differential housing hole Position a comparator with the feeler in contact with and at 90 respect to the surface of the special tool bracket in correspondence with the reference R value RKZ12970 R 11 Move the bracket of the tool E19 installed on the differential housing hole alternately by hand Measure the backlash between pinion and...

Page 489: ...e differential housing bearings Repeat the whole sequence of the above mentioned operations till the indicated conditions are reached RKZ12980 15 Once the pinion ring gear backlash has been established measure the total preloading T of the bearings pinion crown bevel gear system 16 Useadynamometer whosecordis woundon the special tool E23 inserted on the end of pinion shaft a All the preloadings sh...

Page 490: ...ot within the requested range check well the assembly of each component and operate on the adjuster ring nuts 3 of the differential support a if the total preloading is less than the given range screw in both adjuster ring nuts by the same measure keeping the pinion ring gear backlash value unchanged A b if the total preloading is greater than the given range unscrew both adjuster ring nuts by the...

Page 491: ... mark on the teeth surfaces will be regular Z Excessive contact on the tooth tip Approach the pinion to the ring bevel gear and then move the ringbevelgear away from the pinion in order to adjust the backlash X Excessive contact at the tooth base Move the pinion away from the ring bevel gear and then approach the ring bevel gear to the pinion in order to adjust the backlash Z X OK RKZ12170 Movemen...

Page 492: ...is will make both differential half boxes 4 and 12 free so take care not to drop the internal components RKZC6940 1 2 4 2 Disassemble the differential box in two half boxes 4 12 complete with the relevant components a Mark the two half boxes before disjoining them in order to reassemble them in the same position as the one before disassembling 3 Disassemble all the components Check the operating a...

Page 493: ...alf boxes 4 and 12 only if the wear conditions require this a Replace the bush at each disassembly a Be careful not to damage the bush seat RKZ13050 4 14 12 14 8 2 Assembly 1 Assemble the bushes 14 to the half housings 4 and 12 with the special tool E14 and a hammer RKZ13050 4 14 12 14 2 Assemble the bearing cones 3 and 13 on the half housings 4 and 12 using the special tool E3 and a hammer 4 E3 1...

Page 494: ... thrust washers 11 as shown in figure a The first disk 7 must be assembled with friction material on the disks side and the flat surface on the sun gear 8 side 4 Join the two half boxes aligning the reference marks made upon them RKZ13030 12 4 5 Position the bevel crown gear 2 on the half box 4 a Check dowel pins 15 position 6 Apply the specified sealant on the thread and tighten the bolts 1 3 Scr...

Page 495: ...embly RKZ13060 8 1 7 14 12 11 13 15 16 17 9 10 3 4 6 5 2 1 Remove the lock ring 17 Remove the flange 16 and the seal ring 15 a Replace the seal ring at each disassembly RKZ13070 15 17 16 2 Remove the O ring 14 the spacer 13 the O ring 12 and the washer 11 RKZ13080 12 14 13 11 ...

Page 496: ...soft hammer to remove the bevel pinion 1 Collect the washer 9 and the bearing cone 8 RKZC7670 1 5 Once the bevel pinion 1 has been removed collect the washer 6 the collapsible spacer 5 and the washer 4 a The collapsible spacer 5 must be replaced when assembling the group RKZC7680 1 5 6 4 6 Check the bearing cups wear condition If bearings replacement is necessary remove bearing cups 3 and 8 from c...

Page 497: ... tools kit E16 E16 RKZC7700 7 2 Use the special tools false pinion E13 and false differential box E17 to measure the conic distance Insert into the seats the bearing cups 3 and 8 and the false pinion Tighten the ring nut 10 to eliminate the backlash E13 RKZC7710 10 3 Check the correct positioning of the right and left brake cylinder and differential housing supports using the reference marks on th...

Page 498: ...tial support housings E17 RKZC7730 7 5 To adjust bevel gear pinion measure the distance A with a depth gauge Calculate the value X as follows X A C B mm where B and C are known B A C X RKZ13100 6 From the value X deduct the value V stamped on the pinion head to get the value S S X V mm V RKZ12260 7 Select the shim 2 of thickness value S among the range of available shims RKZ12270 ...

Page 499: ...20 3 2 1 6 5 4 1 10 Insert the bevel pinion 1 unit into the central body 7 and the bearing 8 into the pinion shaft as shown in figure Force the bearing 8 in position with the special tool E4 and a hammer a Push the pinion against the central body to perform this operation RKZC7740 1 7 8 11 Insert the ring nut washer 9 and screw a new lock ring nut 10 on the pinion end Screw the ring nut 10 in usin...

Page 500: ...special tool E23 gauge diameter Dm 104 4 mm a All preloadings should be measured without the seal ring 15 The measured value should be within the following range Pm 31 46 N Pm Dm RKZ12991 16 Instead proceding with step 12 and 13 measure the pinion shaft bearings rolling torque TP with a torquemeter and the special wrench E5 a All preloadings should be measured without the seal ring RKZC7760 E5 17 ...

Page 501: ...ngthe next parts assemble thedifferential support group see 7 Differential support group the total preloading of the bearings in the pinion crown bevel gear system must be measured without the seal rings see 7 Differential support group at points 15 16 and 17 RKZC7780 19 Assemble the washer 11 the O ring 12 the spacer 13 the O ring 14 RKZ13080 12 14 13 11 20 Assemble the new seal ring 15 using the...

Page 502: ...n the wheel sides and lock them with two nuts on the wheel hub stud bolt k Thetwobarsshouldbefixedontheirmiddlesothatthey areperpendiculartothe supportingsurfaceandparallel to the pinion shaft axis align the two bars RKZC7090 500 mm 500 mm 2 Measure the distance in mm M between the bars ends with a tapeline a Keep the minimum value swinging the measurement point RKZC7100 ...

Page 503: ...e therefore the measured value M at the bars ends must be related to the ratio between length of the bar and flange diameter nominal toe in A 1 measured toe in M 3 RKZ13150 A M A M 3 1 5 If toe in is incorrect operate with two wrenches on the steering arms 1 screwing in and out the two joint tie rods 3 equally till the toe in is within the requested tolerance RKZC7110 1 3 6 After adjusting screw i...

Page 504: ...7130 1 Adjust a protractor to the requested angle and position it on the long bar Move a wheel side till it forms with the two bars the angle fixed by the protractor RKZC7140 2 Adjust the mechanical steering stop screwing in or out the stop bolt 4 locking them with the locknut 5 3 Nuts 150 Nm a Apply the prescribed sealant on the thread of the screws RKZC7151 4 5 k Check the position of the stops ...

Page 505: ... side both screws must touch the steering stop pads at the same time RKZ12330 4 Assemble the steering sensor 6 on the cylinder with relative clamps 8 and 9 a Do not lock the clamps 5 Insert intothe clamp 8 the plastic support 7 as shown RKZC7160 6 7 8 9 6 Connect the steering sensor 6 with the special testing system E25 Supply 18 V dc with a battery to the testing system RKZ12340 ...

Page 506: ...lowly slide again the sensor till led is off in the same direction position P2 3 measure the stroke C between position P1 and P2 RKZ13160 P1 P2 C 4 set sensor right in the middle between position P1 and P2 with tolerance 1mm P1 P2 C 2 C 2 RKZ13170 5 turn the sensor 6 in the shown position RKZ13180 9 0 6 6 lock the sensor with the clamps 8 and 9 a The clamps must be tightened with the screw head in...

Page 507: ...els forward Both the wheels should get blocked after a while 4 Keeping the pinion locked free the right wheel and rotate the left one in the line of march Rotate the right wheels in the opposite direction The wheel will move freely without difficulty and the right wheel will move in the opposite direction if the assembly has been carried out correctly Repeat the same operation in the opposite dire...

Page 508: ...PAGE INTENTIONALLY LEFT BLANK ...

Page 509: ...ure from all circuits For details see 20 TESTING AND ADJUSTMENTS RKZC2130 1 Remove four screws 1 and remove PPC valve and parking brake casing 2 RKZC6381 2 1 2 Disconnect the connector 3 3 Disconnect five hoses 5 from PPC valve 4 a Check to ensure that hoses are marked scribble match marks if necessary 1 a Cap the hoses and holes to prevent contamination RKZC2140 3 4 5 4 Loosen and remove screws 6...

Page 510: ...30 298 SHOVEL PPC VALVE Installation To install reverse removal procedure 1 a Carefully inspect the hoses for the proper position when connecting them For details see 10 STRUCTURE AND FUNCTION RKZ10760 T 4 2 P 1 3 P2 P4 T P P1 P3 Front ...

Page 511: ...2 A 2 Take off the snap ring 4 and the internal retaining spacer 5 for the piston attachment pin 6 RKZC2170 4 5 6 3 Remove the tie strap 7 retaining the piston return hose 8 4 Place a sling around the cylinder and connect it to a hoisting device a Do not engage the piston return hose with the sling 5 Extract pin 6 to expose piston eye and safety rod 9 6 Remove rod RKZC2180 6 9 7 8 7 Lower cylinder...

Page 512: ...inder approx 46 kg RKZC2200 8 11 13 14 12 Installation To install reverse removal procedure 1 k When aligning the positions between the hole and the pin turn the engine over at low idling speed Do not insert fingers into the holes to check alignment 2 2 Internal bushing ASL800050 1 Start the engine and bleed the air from the cylinders For details see 20 TESTING AND ADJUSTMENTS a After bleeding the...

Page 513: ...acer 4 of the piston fulcrum lever 5 and the link 6 a Do not engage the piston return hose with the sling 4 Take off the snap ring 7 and the internal retaining spacer 8 for the piston attachment pin 9 5 Extract pin 9 to expose piston eye 6 Start the engine to retract the piston 10 1 2 k Stop the engine and eliminate completely residual pressure from all circuits RKZC2210 A 5 6 4 1 3 2 RKZC2240 8 9...

Page 514: ...at low idling speed Do not insert fingers into the holes to check alignment 2 2 Internal bushing ASL800050 1 Start the engine and bleed the air from the cylinders For details see 20 TESTING AND ADJUSTMENTS a After bleeding the air check the oil level in the tank Machines equipped with return to dig only 2 Check sensor position and adjust as necessary For details see 20 TESTING AND ADJUSTMENTS ...

Page 515: ...Rest the lever 3 on the boom 1 2 RKZA1461 1 2 3 3 Take out the screws 4 and remove the pins 5 of the shovel fulcrum 1 2 4 Starttheengineandputthemachineintoreversegearin order to disengage the boom 6 4 Shovel 436 kg RKZA1471 4 6 5 Installation To install reverse removal procedure 1 k When aligning the positions between the hole and the pin turn the engine over at low idling speed Do not insert fin...

Page 516: ...G AND ADJUSTMENTS 1 Remove the tilt cylinders See SHOVEL DUMP CYLINDERS RKZC2270 2 Disconnect the cylinders from the boom 1 and rest them on wooden blocks A placed on the front axle See SHOVEL LIFT CYLINDERS RKZC2191 A 1 3 Openthefronthood andtakeoutthescrews 2 thatlock the axle oscillation pins 3 of the boom 4 Close the front hood RKZC2290 4 3 2 4 Put a sling round the boom 4 as shown in the figu...

Page 517: ...owed using the towing hooks of the backhoe 7 Place two stands in position and lowerthe boom until it is resting on them 4 Front equipment approx 1100 kg RKZC2300 5 4 Installation To install reverse the removal procedure if necessary using the front towing hook 1 k When aligning the positions between the hole and the pin turn the engine over at low idling speed Do not insert fingers into the holes ...

Page 518: ...G AND ADJUSTMENTS 3 Lift cab rear window up to the top RKZC8170 4 Fully raise the boot 1 5 Loosen and remove the screws 2 retaining the PPC valve 3 and armrest 4 RKZB6813 1 3 4 2 6 Raise the armrest from the rear side and remove the screw 5 retaining the rear guard 6 7 Cut the retaining clamp and lower the lower boot 7 8 Loosen and remove screw 8 and remove rear guard 6 RKZB6823 5 7 6 8 9 Disconne...

Page 519: ...5 30 307 BACKHOE PPC VALVES 11 Remove the PPC valve 11 RKZB6841 11 Installation To install reverse removal procedure a Carefully inspect the hoses for the proper position when connecting them For details see 10 STRUCTURE AND FUNCTION ...

Page 520: ...LES Removal 1 Lower the outriggers and the equipment to the ground stop the engine RKZC8170 2 Remove the rear mat 1 RKZC6400 1 3 Take out the screws 2 and remove the platform 3 RKZC6410 2 3 2 4 Fully raise the boot 4 5 Loosen and remove the screws 5 that retain the PPC valve and armrest 6 RKZB6814 4 5 6 ...

Page 521: ...8 RKZB6824 7 8 10 9 9 Loosen and remove the screws 11 and raise the boot 12 and the retaining edge 13 a Raise until the lower fulcrum and locking assembly become fully disengaged RKZB6852 11 12 13 10 Remove the retaining screws 14 from the lock actuating lever assembly 15 11 Remove the entire lever assembly 15 RKZB6861 14 15 12 Loosen the nut 16 and disengage the sheath 18 from the support 17 13 D...

Page 522: ...gage the control cable 20 from the release control lever 15 RKZB6971 15 22 20 21 Installation and adjusting To install reverse removal procedure 1 Using the tensioner 22 adjust cable tension to obtain safe locking and friction free unlocking of the column 2 Lock the nut while holding the tensioner into position 21 RKZB7071 22 21 ...

Page 523: ...RETURN GAS SPRING Removal 1 Lower the outriggers and the equipment to the ground stop the engine RKZC8170 2 Remove the rear mat 1 RKZB6772 1 3 Take out the screws 2 and remove the platform 3 RKZC6410 2 3 2 4 Fully loosen the stop knob 4 of the PPC valve support 5 you are working on RKZC6420 4 5 ...

Page 524: ...ard 10 8 Cut the retaining clamp and release the lower boot 11 9 Loosen and remove screw 12 and remove rear guard 10 RKZB6825 9 10 11 12 10 Loosen and remove the screws 13 and raise the boot 14 and the retaining edge 15 a Raise until the gas spring 16 becomes fully disengaged RKZB6853 13 14 15 11 Loosen the nut 17 and remove the snap ring 18 and washer 19 12 Disconnect the gas spring 16 and remove...

Page 525: ...evers in all directions RKZC8170 2 Disconnect the connector 1 and remove the seat 2 RKZC1031 1 2 3 Remove the rear mat and remove the metal sheet 3 closing off the floor RKZC1974 3 4 Disconnect all connectors 4 from the solenoid valves a Check to ensure that all connectors have marks scribbled on and note down their plugging positions 5 Mark and disconnnect all hoses 5 a Cap pipes hoses and holes ...

Page 526: ...TION WB97S 5 30 314 SOLENOID VALVE GROUP servocontrol and optional attachment Installation To install reverse removal procedure 1 Start the engine and perform all possible manoeuvres to eliminate the air from all circuits ...

Page 527: ...he arm until the bucket teeth touch the ground RKZC8190 1 3 2 A 4 Lower the outriggers to the ground apply the parking brake and stop the engine k Release residual pressure from all circuits by operating the control levers in all directions 5 Remove pins 4 and disconnect tie rod 6 from boom retaining lever 5 RKZC2340 5 4 6 6 Loosen and remove the screws remove the group 7 controlling the levers 5 ...

Page 528: ...lock B under the cylinder 12 controlling the arm RKZC2380 B 12 10 Sling the cylinder 12 in a band and connect it to a hoisting device apply a slight tension a Do not engage the hoses with the band 11 Pull out pin 13 and recover spacers 14 1 2 RKZC8200 13 14 12 12 Start the engine and retract the piston Stop the engine and release residual pressures 13 Remove snap ring 15 RKZC2400 15 ...

Page 529: ...n between boom and cylinder and between boom and arm 1 2 4 Cylinder 87 5 kg RKZC2420 16 15 Installation To install reverse removal procedure 1 k When aligning the positions between the hole and the pin turn the engine over at low idling speed Do not insert fingers into the holes to check alignment 2 2 Internal bushing ASL800050 1 Start the engine and bleed the air from the cylinders For details se...

Page 530: ...ine k Release residual pressure from all circuits by operating all hydraulic controls in all directions RKZC8190 1 3 2 A 5 Force a block B under the boom cylinder 4 RKZC8220 4 B 6 Remove the strap 5 retaining the hoses 7 Sling the cylinder 4 in a band and connect it to a hoisting device apply a slight tension a Do not engage the hoses with the band 8 Remove the snap ring 6 retaining the cylinder f...

Page 531: ...f any 4 Arm cylinders 67 kg RKZC2470 4 7 Installation To install reverse removal procedure 1 k When aligning the positions between the hole and the pin turn the engine over at low idling speed Do not insert fingers into the holes to check alignment 2 2 Internal bushing ASL800050 1 Start the engine and bleed the air from the cylinders For details see 20 TESTING AND ADJUSTMENTS a After bleeding the ...

Page 532: ...ydraulic pressure from all circuits by operating the control levers in all directions 6 Take out the safety pin 5 7 Disconnect the tubes 6 7 8 and 9 a Cap pipes hoses and holes to prevent contamination 8 Remove the clamp 10 9 Remove the screws 11 and the pin 12 1 2 10 Remove cylinder 3 Installation To install reverse removal procedure 1 k When aligning the positions between the hole and the pin tu...

Page 533: ...ne and release the cylinders pressures RKZC8230 1 2 Place a lifting platform A beneath outrigger 2 of cylinder to be remove Raise this until it is forced up against the outrigger RKZC2490 2 3 Remove the clamps 3 retaining the pipes 4 4 Disconnect from cylinder 5 the pipes 4 and plug them to avoid impurity entry a Plug also the union to avoid the movement of piston RKZC2500 3 4 5 4 5 Take off snap ...

Page 534: ...2520 5 7 Take out the screws and remove the pin 10 1 2 8 Remove the cylinder 5 4 Cylinder approx 27 5 kg RKZC2530 9 8 Installation To install reverse removal procedure 1 k Do not insert fingers into the holes to check alignment 2 2 Internal bushing ASL800050 1 Start the engine and bleed the air from the cylinders For details see 20 TESTING AND ADJUSTMENTS a After bleeding the air check the oil lev...

Page 535: ...and the bucket leaned on the back at level ground 1 Stop the engine and release all cylinder pressure by moving the lockout control several times RKZC8170 2 Loosen and remove screws 1 and release hose clamp 2 RKZC2540 2 1 3 Loosen and remove the four screws 3 and washers 1 RKZC2550 3 4 Lift the hoses 4 to the backhoe cylinders and retain them in position with a band RKZC2560 4 ...

Page 536: ...t 3 RKZC2570 5 6 Disconnect four tubes 6 from cylinders 7 a Cap pipes hoses and holes to prevent contamination RKZC2580 6 7 7 7 Take out the screws 8 and remove the pins 9 8 Rotate the cylinders to disengage the piston heads from the swing bracket 10 and remove the cylinders 6 4 Cylinder approx 34 kg RKZC2590 8 9 10 ...

Page 537: ...e engine and swing the boom in order to center one of two pins 6 Secure the 1st pin with the screw Perform the same operation for the other pin 2 k When aligning the positions between the hole and the pin turn the engine over at low idling speed Do not insert fingers into the holes to check alignment 3 2 Internal bushing ASL800050 4 Bleed the air from the cylinders For details see 20 TESTING AND A...

Page 538: ...ting the control levers in all directions RKZC8240 1 2 4 Sling the cylinder 4 in a band and connect it to a hoisting device apply a slight tension a Do not engage the hoses with the band RKZC2610 4 5 Take outthe lock nut 5 and thewasher andremovethe pin 6 1 2 3 6 Start the engine and retract the piston k Stop the engine and release residual pressures RKZC2620 6 5 7 Disconnect the tubes 7 and 8 a C...

Page 539: ...llation To install reverse removal procedure 1 k When aligning the positions between the hole and the pin turn the engine over at low idling speed Do not insert fingers into the holes to check alignment 2 2 Internal bushing ASL800050 3 a Tighten the locknut completely then release it half a turn 1 Start the engine and bleed the air from the cylinders For details see 20 TESTING AND ADJUSTMENTS a Af...

Page 540: ... the parking brake and stop the engine k Release residual pressure from all circuits by operating the control levers in all directions RKZC8240 1 2 4 Remove pins 4 and disconnect yokes 6 from boom retaining levers 5 RKZC2341 5 4 6 5 Loosen and remove nut 7 and remove tie rod 8 RKZC2640 8 7 8 6 Disconnect feed hose 9 a Cap the hose and hole to prevent contamination 7 Loosen and remove the screws 10...

Page 541: ...KHOE BOOM SAFETY CYLINDER Installation To install reverse removal procedure 1 Start the engine and operate the cylinder several times to eliminate the air from the circuit 2 Lift the boom and check to ensure that the safety connection is correct ...

Page 542: ...collect the oil RKZ11640 U1 3 4 Position the complete piston 3 to equipment U1 5 Using a wrench U3 with torque amplifier remove the nut 4 retaining the piston 5 from the following cylinders Shovel raise Key 55 mm Shovel dump Key 55 mm Boom Key 65 mmq Arm Key 65 mm Bucket Key 55 mm Outriggers Key 46 mm Jig arm Key 46 mm Q q Remove safety dowel first Q Lift calking first 6 Slide piston 6 and head 2 ...

Page 543: ... 9 All cylinders Remove guide ring 10 and seal 11 from piston 5 RKZ11600 5 11 10 10 Remove O ring 12 with anti extrusion ring O ring 13 snap ring 14 and scraper ring 15 from head 11 Remove gaskets 16 and 17 a Note down direction fo installation of anti extrusion ring and position of ring 12 12 Boom head Remove bushing 18 RKZ11460 12 13 14 18 17 16 15 ...

Page 544: ...d only 1 Using tool U6 install bushing 18 All cylinders 2 Using tool U7 install scraper ring 15 and snap ring 14 3 Assemble seals 16 and 17 a Check direction of installation RKZ11520 15 18 U7 U6 RKZ11510 17 14 12 13 15 18 16 Assembly piston 1 Using tool U4 expand seal 11 and fit it on the piston 2 Calibrate seal 11 using calibrator U5 3 Boom cylinder only Install anti extrusion rings and O ring 12...

Page 545: ...er only Check orientation of brake bushing 5a RKZ11610 6 5 5a Assembly complete piston 1 Install rod 6 to equipment U1 2 Remove any existing dirt from the rod and install the head 2 RKZ11441 U1 6 4 U3 2 3 Boom cylinder only Thread piston 5 onto rod 6 and lock into position with a wrench U3 with torque amplifier 3 Piston 280 290 kgm 4 Install safety dowel 19 and tighten until snug 2 Dowel Loctite 5...

Page 546: ...Q Q Calk after tightening RKZ11442 U1 5 4 U3 2 Final assembly 1 Lubricate piston seals 5 and head gaskets 2 and introduce piston into cylinder 1 2 Position cylinder 1 to equipment U1 and tighten head 2 using tool U2 tighten to the following torque 3 Shovel raise 69 6 9 kgm Shovel dump 55 5 5 kgm arm 98 9 kgm Bucket 120 140 kgm E Outriggers 55 6 5 kgmm Jig arm 55 5 5 kgm Boom 100 10 kgm E Loosen do...

Page 547: ... U2 with torque amplifier fully unscrew the head 2 RKZ11420 U1 1 2 U2 3 Extract the complete piston 3 a Place a receptacle to collect the oil RKZ11430 3 U1 4 Position the complete piston 3 to equipment U1 RKZ11540 U1 3 5 Remove safety screw 4 M8x1 25 a If removal is awkward tighten screw until snug and work thread with a tap RKZ11450 4 4 ...

Page 548: ...and loosen the complete piston RKZ11490 4 U8 DH 7 Slide piston 6 and head 2 off rod 5 RKZ11480 6 2 5 8 Remove guide ring 7 seal 8 O ring 9 and their respective anti extrusion rings from piston RKZ11650 9 8 7 9 Remove the snap ring 10 the spacer 11 and the ring 12 a Note down orientation of ring 12 and position of spacer 11 RKZ11660 10 11 12 ...

Page 549: ...ve O ring 13 with anti extrusion ring O ring 14 snap ring 15 and scraper ring 16 from head 11 Remove gaskets 17 and 18 a Note down direction fo installation of anti extrusion ring and position of ring 13 12 Remove the bushing 19 RKZ11511 18 13 14 16 19 17 15 ...

Page 550: ...8 a Check direction of installation 3 Using tool U7 install scraper ring 16 and snap ring 15 4 Assemble O ring 14 5 Install anti extrusion ring and O ring 13 RKZ11521 16 19 U7 U6 RKZ11511 18 13 14 16 19 17 15 Assembly piston 1 Using tool U4 expand seal 8 and fit it on the piston 2 Calibrate seal 8 using calibrator U5 3 Install anti extrusion rings and O ring 9 4 Assemble the guide ring 7 5 Install...

Page 551: ...fety screw 4 is perfectly aligned 3b With new parts a Thread the piston 6 in ensure it contacts the rod 5 and then tighten 3 Piston 734 49 Nm b Drill hole H for safety screw 4 on the seam of thread between rod and piston a Hole Ø 6 8 depth 31 mm Thread M8x1 25 depth 25 mm 4 Remove any dirt or shaving and install the safety screw 4 2 Screw Loctite 262 3 Screw 13 25 1 45 Nm 5 Calk screw 4 in four lo...

Page 552: ...piston seal 6 and head gasket 2 and introduce piston into cylinder 1 2 Position cylinder 1 to equipment U1 and tighten head 2 using tool U2 tighten to torque 3 Head 785 78 5 Nm a When assembly is complete plug cylinder union fittings to prevent contamination RKZ11420 U1 1 2 U2 ...

Page 553: ... Release residual pressure from all circuits by operating all hydraulic controls in all directions 5 Position a lift B and some non slip blocks under boom fulcrum RKZC8190 1 3 2 A RKZC8250 A B 6 Place a sling around the boom lift cylinder 4 connect it to a hoisting device and apply a slight tension to the cable RKZC8211 4 7 Pull out the piston attachment pin 5 8 Release boom and arm cylinder hoses...

Page 554: ...the boom lift cylinder and disconnect the hoisting device RKZC8221 C 12 Remove the screw 10 and the pin 11 13 Start the engine draw in the outriggers and move the machine rearward a Recover the shims between boom and swing bracket 4 Backhoe working equipment with standard arm 850 kg RKZC2700 10 11 Installation To install reverse removal procedure 1 Start the engine and bleed the air from all circu...

Page 555: ...ween bucket 3 and tie rods 4 1 2 2 Take out the safety pin 5 and remove the pin 6 that attaches the bucket to the arm 7 1 2 4 Bucket 158 kg RKZA1350 3 1 2 4 7 6 5 Installation To install reverse removal procedure 1 k When aligning the positions between the hole and the pin turn the engine over at low idling speed Do not insert fingers into the holes to check alignment 2 2 Internal bushing ASL80005...

Page 556: ...nging positions during re connection 6 Hook the boom 2 7 Take out the retaining screw and remove the pin 3 1 2 a Recover the shims 4 between boom and swing bracket 8 Remove the boom 2 4 Boom 248 kg RKZC8280 2 RKZC2720 3 4 Installation To install reverse removal procedure 1 k When aligning the positions between the hole and the pin turn the engine over at low idling speed Do not insert fingers into...

Page 557: ...piston completely 8 Rest cylinder 5 on a block A and disconnect from the hoisting device 9 Stop the engine 10 Connect the arm 8 to the hoisting device and apply a slight tension to the cable 11 Take out the screws 9 and remove the pin 10 1 2 a Recover the shims RKZC2441 5 6 7 12 Remove the arm 8 4 Arm ______ kg To install reverse removal procedure 1 k When aligning the positions between hole and p...

Page 558: ...d 6 the bucket cylinder hoses 7 and 8 and the hoses of the auxiliary equipment 9 and 10 a Mark the hoses to avoid exchanging them during INSTALLATION 5 Remove the clamp 11 6 Proceed with the removal as for the arm See ARM 4 Jig arm cylinder 460 kg RKZA7970 11 6 10 8 5 9 7 Installation To install reverse removal procedure 1 k When aligning the positions between hole and pin do not insert fingers in...

Page 559: ...t pin hole and the safety pin holes 6 Start the engine and maintaining constant tension on the section of cable or chain connected to the bucket coupling slowly raise the boom until both sections of cable or chain are under slight tension RKZA7990 6 3 4 5 7 Stop the engine and loosen by several turns the gib adjustment screws a Loosen the screws on both sides 8 Slide out the 2nd arm 7 4 2nd arm __...

Page 560: ... 1 to some hoisting tackle a Use the bucket pin hole and the safety pin holes 6 Slowly raise the 2nd arm 1 until it rests on the supporting surfaces of the upper guides RKZA8020 6 3 5 7 Loosen the nuts 5 and remove the adjustment dowel bolts 6 8 Raise the lower guides 7 and slide them out 1 RKZ02390 3 4 5 6 7 Installation To install reverse removal procedure 1 2 Guides and 2nd arm guides ASL800040...

Page 561: ...d remove pins 8 and 9 from swing bracket 1 2 6 Remove swing bracket 5 and shims 10 and slide the hoses off 3 4 Bracket 162 5 kg RKZC2351 4 Installation To install reverse removal procedure 1 k When aligning the positions between the hole and the pin turn the engine over at low idling speed Do not insert fingers into the holes to check alignment 2 2 Internal bushing ASL800050 3 a Insert the shims 1...

Page 562: ...m union 1 plug hose and union to prevent contamination RKZC2760 1 2 4 Disconnect feed hoses 4 from swing cylinders 3 RKZC2770 3 4 5 Connect the backframe 5 to a hoisting device 6 Loosen nuts 6 and remove washers and four screws 7 Loose partially lateral nuts 4 to remove backframe 3 from frame 8 1 RKZC2780 6 7 8 5 6 7 Put a sling round the backframe 5 and apply slight tension to the cables 8 Remove...

Page 563: ...ther with swing cylinders 4 Complete backframe approx 246 kg RKZC2800 5 Installation To install reverse removal procedure 1 2 Nuts Loctite 262 3 Nuts 980 98 Nm 1 Start the engine and bleed the air from the cylinders For details see 20 TESTING AND ADJUSTMENTS a After bleeding the air check the oil level in the tank ...

Page 564: ...r piston 6 k Be aware that the piston may be ejected rapidly Use a rag or non slip gloves to accompany the piston as it is being ejected RKZC2810 3 4 2 6 LOWER PISTON 1 Remove pipe 3 2 Introduce compressed air at low pressure max 2 bar through union 7 and recover piston 6 k Be aware that the piston may be ejected rapidly Use a rag or non slip gloves to accompany the piston as it is being ejected R...

Page 565: ...oroughlycleantheseatsandinstallnewsealsandthe guide ring 3 Lubricate the seals guide ring and piston seat 2 Seal and seat Hydraulic oil RKZC2840 A 6 4 Apply a band A for seal compression and install piston 6 RKZC2850 A Installation To install reverse removal procedure ...

Page 566: ......

Page 567: ...NDARD MAINTENANCE TRANSMISSION 2 FRONT AXLE 5 REAR AXLE 8 HYDRAULIC PUMP 12 CONTROL VALVE 14 PPC VALVES 30 SHOVEL CYLINDERS 32 BACKHOE CYLINDERS 34 FRONT WORKING EQUIPMENT 38 SWING BRACKET 40 BACKHOE WORKING EQUIPMENT 42 ...

Page 568: ... 2 WB97S 5 STANDARD MAINTENANCE TRANSMISSION TRANSMISSION RKZ11670 X Z K K View X View Z K B B A A K 3 30 Nm 3 23 Nm 3 30 Nm 3 30 Nm 3 30 Nm 3 30 Nm 3 30 Nm 3 30 Nm 3 30 Nm 3 30 Nm 3 30 Nm 3 23 Nm 3 30 Nm ...

Page 569: ...40 3 WB97S 5 STANDARD MAINTENANCE TRANSMISSION RKZ11410 A A L L 3 50 Nm 2 Loctite 510 3 139 Nm 3 50 Nm 2 Loctite 510 2 Loctite 542 3 50 Nm 3 50 Nm 2 Loctite 542 3 139 Nm ...

Page 570: ...40 4 WB97S 5 STANDARD MAINTENANCE TRANSMISSION B B RKZ11680 3 23 Nm 3 50 Nm 3 30 Nm 3 23 Nm 3 50 Nm ...

Page 571: ...crown wheel and pinion Standard clearance Clearance limit Adjust 0 20 0 30 2 Pinion rotation force without sealing ring As measured on Ø 34 8 92 137 Nm 3 Pinion crown rotation force without sealing ring As measured on Ø 34 8 P 32 P 47 N 1 2 3 RKZ13400 3 155 Nm 2 Loctite 270 2 Loctite 510 3 60 Nm 3 13 Nm 3 413 Nm 3 169 Nm ...

Page 572: ...40 6 WB97S 5 STANDARD MAINTENANCE FRONT AXLE Planetary Joint RKZ13410 3 70 Nm 2 Loctite 270 3 8 Nm 3 300 Nm 3 79 Nm 3 60 Nm 3 25 Nm 3 220 Nm 3 8 Nm ...

Page 573: ...iteria Remedy 1 Clearance between bushing and pin Standard size Tolerance Standard clearance Clearance limit Replace bushing and pin Shaft Hole Section A A Detail C Section B B A A RKZ13421 C 21 36 25 B B 2145 0 2 1 3 10 Nm 3 60 Nm 3 460 Nm 3 300 Nm 3 250 Nm 3 280 Nm 3 200 Nm 3 150 Nm 3 800 Nm ...

Page 574: ...Clearance limit Adjust 0 18 0 23 2 Pinion rotation force without sealing ring As measured on Ø 34 8 92 137 Nm 3 Pinion crown rotation force without sealing ring As measured on Ø 34 8 P 37 2 P 55 9 N RKZ13431 Section A A A A 3 4 1 2 3 220 Nm 2 Loctite 270 2 Loctite 638 3 13 Nm 3 660 Nm 2 Loctite 270 3 155 Nm 2 Loctite 270 3 13 Nm 3 320 Nm 3 220 Nm 2 Loctite 270 ...

Page 575: ...40 9 WB97S 5 STANDARD MAINTENANCE REAR AXLE Planetary RKZ13440 1 2 3 300 Nm 3 70 Nm 2 Loctite 270 3 8 Nm 3 79 Nm 3 60 Nm 3 25 Nm 3 230 Nm 3 8 Nm 3 300 Nm ...

Page 576: ...ANCE REAR AXLE Brakes Unit mm No Check item Criteria Remedy 1 Disc thickness Standard thickness Min thickness Replace 4 83 4 53 RKZ13451 300mm Min 315mm Max Detail A 1 A 3 10 Nm 3 25 Nm 2 Loctite 270 3 12 Nm 3 190 Nm 3 10 Nm 3 35 Nm ...

Page 577: ...40 11 WB97S 5 STANDARD MAINTENANCE REAR AXLE Steering unit cylinder C3 Section A A Detail B B A A RKZ13461 2145 0 2 3 150 Nm 2 Loctite 270 3 280 Nm 3 250 Nm 3 300 Nm 3 800 Nm 3 23 Nm ...

Page 578: ... WB97S 5 STANDARD MAINTENANCE HYDRAULIC PUMP HYDRAULIC PUMP RKZ10440 View X View Z Z X A A 3 19 6 24 5 Nm 3 7 8 9 8 Nm 3 11 8 14 7 Nm 3 19 6 27 4 Nm 3 27 4 34 3 Nm 3 68 6 83 4 Nm 3 157 196 Nm 3 68 6 83 4 Nm ...

Page 579: ...40 13 WB97S 5 STANDARD MAINTENANCE HYDRAULIC PUMP RKZ10450 Z X A A 3 27 4 34 3 Nm 3 27 4 34 3 Nm 3 27 4 34 3 Nm 3 27 4 34 3 Nm ...

Page 580: ...ARD MAINTENANCE CONTROL VALVE CONTROL VALVE 8 SPOOL VERSION Komatsu Ltd AC AC AB AA AA N N M M L L K K J J F F E E D D RKZ09062 Z X AB 3 29 4 34 3 Nm 3 58 8 73 5 Nm 3 9 8 12 7 Nm 3 9 8 12 7 Nm 3 9 8 12 7 Nm 3 9 8 12 7 Nm ...

Page 581: ...40 15 WB97S 5 STANDARD MAINTENANCE CONTROL VALVE RKZ09071 C C B B A A AE AE X View X ...

Page 582: ...40 16 WB97S 5 STANDARD MAINTENANCE CONTROL VALVE A A RKZ09080 10 8 5 9 4 3 2 2 1 7 B B 3 2 2 6 3 49 58 8 Nm 3 39 2 49 Nm 3 39 2 49 Nm 3 39 2 49 Nm 3 39 2 49 Nm 3 39 2 49 Nm ...

Page 583: ...0 5 34 3N 27 4N 3 Spool return spring out arm control 42 3x19 2 40 5 54 9N 43 9N 4 Spool return spring boom swing control 29x17 5 28 5 22 5N 18N 5 Spool return spring shovel control 27 2x16 6 26 7 30 38N 24 3N 6 Spool return spring backhoe bucket boom control 24 2x16 7 23 7 30 4N 24 3N 7 Spool return spring shovel arm float control 19 4x17 6 19 14 7N 11 8N 8 Spool return spring shovel arm lower co...

Page 584: ...0 18 WB97S 5 STANDARD MAINTENANCE CONTROL VALVE C C D D AD AD RKZ08341 AD AD 2 3 4 5 3 5 7 8 8 9 6 6 8 1 1 1 8 3 117 6 161 8 Nm 3 14 7 19 6 Nm 3 19 6 24 5 Nm 3 14 7 19 6 Nm 3 24 5 34 3 Nm 3 24 5 34 3 Nm ...

Page 585: ...4x6 8 7 44N 5 96N 2 Pressure compensation valve spring arm 31 4x14 4 21 8 63 7N 51 0N 3 Pressure compensation valve spring Boom swing backhoe bucket 18 9x8 4 15 15 7N 12 5N 4 Pressure compensation valve spring Front bucket 37 1x8 6 24 34 3N 27 4N 5 Pressure compensation valve spring boom shovel arm 20x8 4 15 4 32N 3 45N 6 Check valve spring 27 2x6 9 21 4 70N 3 76N 7 Check valve spring 27 2x6 9 22 ...

Page 586: ... installed x Øe Installed length Installed load Free installed Installed load 1 Spool return spring Outrigger control 18 0x18 17 5 39 2N 31 4N 2 Spool return spring Outrigger control 20 2x14 2 10 4 30 4N 24 3N 3 Control valve spring plate lock 13 0x8 8 11 3 92N 3 1N J J M M L L F F E E K K RKZ09102 7 3 1 1 2 2 1 1 2 2 3 65 7 82 3 Nm ...

Page 587: ...ria Remedy Standard size Repair limit Replace spring Free installed x Øe Installed length Installed load Free installed Installed load 1 Pressure compensation valve spring 31 7x9 2 27 5 43 1N 34 5N 1 RKZ08892 N N AC AC AA AA AB AB AE AE 3 34 44 Nm 3 34 3 44 1 Nm 3 65 7 82 3 Nm ...

Page 588: ...NDARD MAINTENANCE CONTROL VALVE 10 SPOOL VERSION Komatsu Ltd AC AC AB AB AA AA R R N M M L L K K F F E E D D RKZ09121 N J J ViewZ Z X 3 29 4 34 3 Nm 3 58 8 73 5 Nm 3 9 8 12 7 Nm 3 9 8 12 7 Nm 3 9 8 12 7 Nm 3 9 8 12 7 Nm ...

Page 589: ...40 23 WB97S 5 STANDARD MAINTENANCE CONTROL VALVE ViewX RKZ09591 C C B B A A AE AE ...

Page 590: ...40 24 WB97S 5 STANDARD MAINTENANCE CONTROL VALVE RKZ09131 A A B B K K J J 5 4 3 8 7 2 11 6 9 10 2 3 3 49 58 8 Nm 3 39 2 49 Nm 3 39 2 49 Nm 3 39 2 49 Nm 3 39 2 49 Nm 3 39 2 49 Nm ...

Page 591: ...rm control 42 3x19 2 40 5 54 9N 43 9N 4 Spool return spring boom swing control 29x17 5 28 5 22 5N 18N 5 Spool return spring shovel control 27 2x16 6 26 7 30 38N 24 3N 6 Spool return spring backhoe bucket boom control 24 2x16 7 23 7 30 4N 24 3N 7 Spool return spring shovel arm float control 19 4x17 6 19 14 7N 11 8N 8 Spool return spring shovel arm lower control 38 7x18 27 6 355 7N 284 6N 9 Priority...

Page 592: ...40 26 WB97S 5 STANDARD MAINTENANCE CONTROL VALVE RKZ09141 AD AD C C D D AD AD 7 8 8 8 8 6 6 3 4 5 3 1 1 1 5 2 3 19 6 24 5 Nm 3 14 7 19 6 Nm 3 24 5 34 3 Nm 3 24 5 34 3 Nm 3 24 5 34 3 Nm 3 47 58 8 Nm ...

Page 593: ...4x6 8 7 44N 5 96N 2 Pressure compensation valve spring arm 31 4x14 4 21 8 63 7N 51 0N 3 Pressure compensation valve spring Boom swing backhoe bucket 18 9x8 4 15 15 7N 12 5N 4 Pressure compensation valve spring Front bucket 37 1x8 6 24 34 3N 27 4N 5 Pressure compensation valve spring boom shovel arm jig arm 4 in 1 bucket 20x8 4 15 4 32N 3 45N 6 Check valve spring 27 2x6 9 21 4 70N 3 76N 7 Check val...

Page 594: ... installed x Øe Installed length Installed load Free installed Installed load 1 Spool return spring Outrigger control 18 0x18 17 5 39 2N 31 4N 2 Spool return spring Outrigger control 20 2x14 2 10 4 30 4N 24 3N 3 Control valve spring plate lock 13 0x8 8 11 3 92N 3 1N J J M M L L F F E E K K RKZ09102 7 3 1 1 2 2 1 1 2 2 3 65 7 82 3 Nm ...

Page 595: ...ria Remedy Standard size Repair limit Replace spring Free installed x Øe Installed length Installed load Free installed Installed load 1 Pressure compensation valve spring 31 7x9 2 27 5 43 1N 34 5N 1 RKZ08892 N N AC AC AA AA AB AB AE AE 3 34 44 Nm 3 34 3 44 1 Nm 3 65 7 82 3 Nm ...

Page 596: ...t mm No Check item Criteria Remedy Standard size Repair limit Replace Free installed x Øe Installed length Installed load Free installed Installed load 1 Return spring outer for ports P1 and P2 2 Return spring outer for ports P3 and P4 3 Adjusting screw inner RKZ10460 1 3 2 3 ...

Page 597: ... item Criteria Remedy Standard size Repair limit Replace Free installed x Øe Installed length Installed load Free installed Installed load 1 Return spring outer for ports P1 and P2 2 Return spring outer for ports P3 and P4 3 Adjusting screw inner RKZ10470 1 3 2 3 ...

Page 598: ...2 0 005 0 035 0 238 Replace Dump 45 0 025 0 064 0 141 0 004 0 029 0 205 2 Tolerance between bushing and piston head mounting pin Lifting 60 0 060 0 106 0 174 0 100 0 160 0 280 Replace pin and bushing Dump 45 0 050 0 089 0 142 0 080 0 130 0 231 3 Tolerance between bushing and cylinder mounting pin Lifting 60 0 060 0 106 0 174 0 100 0 160 0 280 Dump 50 0 050 0 089 0 142 0 080 0 130 0 231 2 707 00 0y...

Page 599: ... Standard size Repair limit Replace Free installed x Øe Installed length Installed load Free installed Installed load 1 Tolerance between piston rod and head 40 0 025 0 050 0 064 0 025 0 05 0 114 2 Tolerance between bushing and piston head mounting pin 40 0 150 42N 6C 12800 1 1 3 690 69 Nm 3 540 54 Nm 0 ...

Page 600: ...ANDARD MAINTENANCE BACKHOE CYLINDERS BACKHOE CYLINDERS BOOM ARM BUCKET 2 1 3 3 981 98 Nm 3 2740 2840 Nm with Loctite 262 707 00 0y871 1 2 1 3 3 961 96 1 Nm 3 1670 170 Nm 707 00 0y901 1 2 1 3 3 1176 1372 Nm 31670 170 Nm ...

Page 601: ...oom swing 50 0 030 0 076 0 164 0 007 0 037 0 240 2 Tolerance between bushing and piston head mounting pin Boom 60 0 060 0 106 0 174 0 100 0 160 0 280 Arm 50 0 050 0 089 0 142 0 080 0 130 0 231 Replace pin and bushing Bucket 45 0 050 0 089 0 142 0 080 0 130 0 231 Boom swing 55 0 060 0 106 0 174 0 100 0 160 0 280 3 Tolerance between bushing and cylinder mounting pin Boom 60 0 060 0 106 0 174 0 100 0...

Page 602: ... Standard size Tolerance Standard clearance Clearance limit Shaft Hole 1 Clearance between piston rod and head Outriggers 40 0 025 0 064 0 132 0 006 0 031 0 196 Replace Jig arm 40 0 025 0 050 0 064 0 025 0 050 0 114 707 00 0Y0910 1 1 3 539 54 Nm 3 911 91 1 Nm with Loctite 262 42N 6C 13301 1 1 3 539 54 Nm 3 1080 100 Nm ...

Page 603: ...PAGE INTENTIONALLY LEFT BLANK ...

Page 604: ...40 38 WB97S 5 STANDARD MAINTENANCE FRONT WORKING EQUIPMENT FRONT WORKING EQUIPMENT RKZ13520 E E D D C C B B A A 4 5 1 3 2 A A B B D D C E E C ...

Page 605: ...cket mounting pin 45 0 050 0 089 0 080 0 240 0 130 0 329 Replace 2 Clearance between bushing and link mounting pin 45 0 050 0 089 0 080 0 240 0 130 0 329 3 Clearance between bushing and fulcrum link mounting pin 45 0 050 0 089 0 080 0 119 0 130 0 208 4 Clearance between bushing and link mountingpin 60 0 060 0 106 0 137 0 197 0 143 0 303 5 Clearance between bushing and boom mounting pin 50 0 050 0 ...

Page 606: ...40 40 WB97S 5 STANDARD MAINTENANCE SWING BRACKET SWING BRACKET 5 RKZ10490 C C B B A A B B A C A C 1 1 2 6 3 4 ...

Page 607: ...linder bushing 60 0 010 0 085 0 090 0 060 0 070 0 175 Replace bushing and pin 2 Clearance between bushing and lower swing bracketrotating pin 65 0 060 0 106 0 190 0 264 0 250 0 370 3 Clearance between bushing and upper swing bracketrotating pin 65 0 060 0 106 0 190 0 264 0 250 0 370 4 Upper shim thickness Standard size Limit size 2 50 0 1 5 Central shim thickness 4 75 0 1 6 Lower shim thickness 4 ...

Page 608: ...40 42 WB97S 5 STANDARD MAINTENANCE BACKHOE WORKING EQUIPMENT BACKHOE WORKING EQUIPMENT RKZ10500 D D C C A A B B D D C C B A A 2 1 3 4 5 6 6 B ...

Page 609: ...lace 2 Clearance between arm bushings and bucket mounting pin 45 0 050 0 089 0 080 0 240 0 130 0 329 3 Clearance between arm bushings and lever mounting pin 45 0 050 0 089 0 080 0 240 0 130 0 329 4 Clearance between bushings and tilt lever mounting pin 45 0 050 0 089 0 080 0 240 0 130 0 329 5 Clearance between bushings and arm mounting pin 50 0 050 0 089 0 080 0 119 0 130 0 208 6 Clearance between...

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Page 611: ...90 1 WB97S 5 90 OTHER ELECTRICAL DIAGRAM STANDARD VERSION 3 ...

Page 612: ......

Page 613: ...her Preheating Relay Starting relay Main beam light 15A Return sender supply DIG fuse 10A EC POWER FUSE 7 5A 15 STEERING UNIT FUSE 10A FLASHER FUSE 7 5A REVERSE SPEED BUZZER STEERING COLUMN 10A Unrepeat start unit Low beam relay Front horn relay Return to DIG solenoid valve relay Starter G118 K6 K5 K4 K3 G119 H17 K2 K1 Main beam relay Generetor Flasher BUZZER F24 F27 F25 G1 F23 F22 F20 F21 General...

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