Shop Manual - Wb93r-5e0
Shop Manual - Wb93r-5e0
Shop Manual - Wb93r-5e0
CONTENTS
Page
10. STRUCTURE AND FUNCTION............................................................................... 10-1
WB93R-5E0 00-1
00-2 WB93R-5E0
k SAFETY
k SAFETY
GENERAL PRECAUTIONS PREPARATIONS FOR WORK
Mistakes in operation extremely dangerous. 7. Before adding or making any repairs, park the ma-
Read all the Operation and Maintenance Manual carefully chine on hard, level ground, and block the wheels to
BEFORE operating the machine. prevent the machine from moving.
1. Before carrying out any greasing or repairs, read all 8. Before starting work, lower outrigger, bucket or any
the precautions written on the decals which are suck other work equipment to the ground. If this is not pos-
on the machine. sible, use blocks to prevent the work equipment from
2. When carrying out any operation, always wear safety falling down. In addition, be sure to lock all the control
shoes and helmet. Do not wear loose work clothes, or levers and hang warning sign on them.
clothes with buttons missing. 9. When disassembling or assembling, support the ma-
• Always wear safety glasses when hitting parts chine with blocks, jacks or stands before starting
with a hammer. work.
• Always wear safety glasses when grinding parts 10. Remove all mud and oil from the steps or other places
with a grinder, etc. used to get on and off the machine. Always use the
3. If welding repairs are needed, always have a trained, handrails, ladders or steps when getting on or off the
experienced welder carry out the work. When carrying machine.
out welding work, always wear welding gloves, apron, Never jump on or off the machine.
glasses, cap and other clothes suited for welding If it is impossible to use the handrails, ladders or steps,
work. use a stand to provide safe footing.
4. When carrying out any operation with two or more
PRECAUTIONS DURING WORK
workers, always agree on the operating procedure be-
fore starting. Always inform your fellow workers be- 11. When removing the oil filler cap, drain plug or hydrau-
fore starting any step of the operation. Before starting lic pressure measuring plugs, loosen them slowly to
work, hang UNDER REPAIR signs on the controls in prevent the oil from spurting out.
the operator’s compartment. Before disconnecting or removing components of the
hydraulic circuit and engine cooling circuit, first re-
5. Keep all tools in good condition and learn the correct
move the pressure completely from the circuit.
way to use them.
6. Decide a place in the repair workshop to keep tools 12. The water and oil in the circuits are not hot when the
and removed parts. Always keep the tools and parts in engine in stopped, so be careful not to get burned.
their correct places. Always keep the work area clean Wait for the oil water to cool before carrying out any
and make sure that there is no dirt or oil on the floor. work on the cooling water circuits.
Smoke only in the areas provided for smoking. Never
13. Before starting work, turn the battery disconnect
smoke while working.
switch to OFF position, and remove the key.
WB93R-5E0 00-3
k SAFETY
14. When raising heavy components, use a hoist or 19. Be sure to assemble all parts again in their original
crane. Check that the wire rope, chains and hooks places. Replace any damage parts with new parts.
are free from damage. When installing hoses and wires, be sure that they
Always use lifting equipment which has ample ca- will not be damaged by contact with other parts
pacity. Install the lifting equipment at the correct when the machine is being operated.
places.
20. When installing high pressure hoses, make sure
Use a hoist or crane and operate slowly to prevent
that they are not twisted. Damaged tubes are dan-
the component from hitting any other part.
gerous, so be extremely careful when installing
Do not work with any part still raised by the hoist or
tubes for high pressure circuits. Also, check that
crane.
connecting parts are correctly tightened.
15. When removing covers which are under internal
21. When assembling or installing parts, always use
pressure or under pressure from a spring, always
specified tightening torques.
leave two bolts in position on opposite sides. Slowly
When installing the parts which vibrate violently or
release the pressure, then slowly loosen the bolts to
rotate at high speed, be particulary careful to check
remove.
that they are correctly installed.
16. When removing components, be careful not to
22. When aligning two holes, never insert your fingers or
break or damage the wiring.
hand.
Damage wiring may cause electrical fires.
23. When measuring hydraulic pressure, check that the
17. When removing piping, stop the fuel or oil from spill-
measuring tool is correctly assembled before taking
ing out. If any fuel or oil drips on to the floor, wipe it up
any measurement.
immediately.
Fuel or oil on the floor can cause you to slip, or can 24. Take sure when removing or installing wheels.
even start fires.
00-4 WB93R-5E0
FOREWORD
FOREWORD
This shop manual has been prepared as an aid to improve the quality of repairs by giving the operator an accurate
understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure
you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service work-
shop.
The manual is divided into chapters on each main group of components; these chapters are further divided into the
following sections.
STANDARD MAINTENANCE
This section gives the judgement standards when inspecting disassembled parts.
NOTE
The specifications contained in this shop manual are subject to change at any time and without any no-
tice.
Contact your Komatsu distributor for the latest information.
WB93R-5E0 00-5
HOW TO READ THE SHOP MANUAL
k
work. performing the work.
Safety
FILING METHOD Extra special safety precautions
are necessary when performing
1. See the page number on the bottom of the page. the work because it is under in-
File the pages in correct order. ternal pressure.
2. Following examples show you how to read the page
Special technical precautions or
number.
other precautions for preserving
Example: a Caution
standards are necessary when
10 - 3 performing the work.
3 Tightening
item Parts that require special atten-
tion for the tightening torque dur-
3. Additional pages: additional pages are indicated by torque
ing assembly.
a hyphen (–) and number after the page number.
2
Fle as in the example. Parts to be coated with adhe-
Coat
Example: sives and lubricants etc.
5
10-4 Places where oil, water or fuel
Oil, water must be added, and their quan-
10-4-1 tity.
Added pages
6
10-4-2 Places where oil or water must
10-5 Drain be drained, and quantity to be
drained.
REVISIONS
Revised pages are shown on the LIST OF REVISED
PAGES between the title page and SAFETY page.
00-6 WB93R-5E0
HOISTING INSTRUCTIONS
4
HOISTING INSTRUCTIONS
WB93R-5E0 00-7
STANDARD TIGHTENING TORQUE
3
STANDARD TIGHTENING TORQUE
The following charts give the standard tightening torques of bolts and nuts.
Exceptions are given in section of «Disassembly and Assembly».
This torque table does not apply to bolts or nuts which have to fasten nylon or other parts non-ferrous metal washer.
a Nm (newton meter): 1 Nm = 0.102 kgm
00-8 WB93R-5E0
STANDARD TIGHTENING TORQUE
3
2. TIGHTENING TORQUE FOR NUTS OF FLARED
7/8” - 14 27 8 2 78.519.6
22 27 8 2 78.519.6
33 41 205 196.249
Sealing surface
1” - 14 30 8.2–9.2 80–90
2” - 12 57 20.4–24.4 200–240
WB93R-5E0 00-9
COATING MATERIALS
2
COATING MATERIALS
The recommended coating materials prescribed in Komatsu Shop Manuals are listed below:
ASL800010 Used to apply rubber pads, rubber gaskets and cork plugs.
Used to apply resin, rubber, metallic and non-metallic parts when a fast, strong
ASL800020
seal is needed.
Loctite 222 Used for low resistance locking of screws, check nuts and adjustment nuts.
To prevent the loosening of bolts, nuts and plugs and the leakage of oil. Used for
Loctite 242 medium resistance locking of screws and nuts of every type, and for locking
keys and bearings.
Loctite 262 Used for high resistant of threaded parts that can be removed with normal tools.
Adhesives Used for high resistant locking and for sealing threaded parts, bolts and stud
Loctite 270
bolts.
Loctite 542 Used for sealing the union threads for hydraulic tubes.
Used for sealing rather exact plane surfaces when the option of possible future
Loctite 573
dismantling is required.
Used for high resistant locking of mechanical components that can be removed
Loctite 601
only after heating
Used to lock cylindrical couplings and for the permanent locking of threaded
Loctite 675
parts, and also to lock shafts to bearings, gears, pulleys, pins, bushings, etc.
Used by itself to seal grease fittings, tapered screw fittings and tapered screw
ASL800060
fittings in hydraulic circuits of less than 50 mm in diameter.
Antifriction compound
Applied to bearings and taper shaft to facilitate press-fitting and to prevent
(Lubricant including ASL800040
sticking, burning or rusting.
Molybdenum disulfide)
Grease Applied to bearings, sliding parts and oil seals for lubrication, rust prevention
ASL800050
(Lithium grease) and facilitation of assembling work.
00-10 WB93R-5E0
ELECTRIC
ELECTRIC
ELECTRIC
In the wiring diagrams various colour and symbols are employed to indicate the thickness of wires.
This wire code table will help you understand WIRING DIAGRAMS.
Example: R–N 1.5 indicates a cable having a nominal number 1.5 and red coating with black stripe.
CLASSIFICATION BY THICKNESS
Copper wire
Nominal Cable O.D. Current rating
number Number Ø of strands Cross section (mm) (A)
strands (mm) (mm)
0.5 16 0.20 0.35 1.55 3.5
1 14 0.30 0.99 2.80 11
1.5 21 0.30 1.48 3.35 14
2.5 35 0.30 2.47 3.80 20
4 56 0.30 3.95 4.60 28
6 84 0.30 5.93 5.20 37
10 84 0.40 10.55 7.10 53
50 399 0.40 50.11 14 160
CLASSIFICATION BY COLOUR AND CODE
Primary Auxiliary
Code A A–B A/B A–G – A–N A/N A–R A/R A–V A/V
Colour Light Blue Light Blue – White Light Blue–Yellow Light Blue–Black Light Blue–Red Light Blue–Green
Code B B–G – B–N B/N B–R B/R – B/V – –
Colour White White–Yellow White–Black White–Red White–Green –
Code C C–B C/B C–L – C–N – – – – –
Colour Orange Orange–White Orange–Blue Orange–Black – –
Code G G–N G/N G–R – G–V – – – – –
Colour Yellow Yellow–Black Yellow–Red Yellow–Green – –
Code H H–L – H–N H/N – – – – – –
Colour Grey Grey–Blue Grey–Black – – –
Code L L–B L/B L–G – – L/N – – – –
Colour Blue Blue–White Blue–Yellow Blue–Black – –
Code M M–B – M–N M/N M–V – – – – –
Colour Brown Brown–White Brown–Black Brown–Green – –
Code N – – – – – – – – – –
Colour Black – – – – –
Code R R–G – R–N R/N R–V – – – – –
Colour Red Red–Yellow Red–Black Red–Green – –
Code S S–G – S–N – – – – – – –
Colour Pink Pink–Yellow Pink–Black – – –
Code V V–B – V–N V/N – – – – – –
Colour Green Green–White Green–Black – – –
Code Z Z–B Z/B Z–N Z/N – – – – – –
Colour Violet Violet–White Violet–Black – – –
WB93R-5E0 00-11
WEIGHT TABLE
WEIGHT TABLE
k This weight table is a guide for use when transporting or handling components.
Unit: kg
Machine model WB93R-5E0
Engine assembly - Muffler - Exhaust pipe 394
Radiator - exchanger 37
Hydraulic oil tank (empty) 10
Fuel tank (empty) 68
Front counterweight 372
Engine hood 32
Cabin (without seat) 595
Seat 34
Engine-gear box-pump group 740
Piston pump 36.8
Transmission 232
Front axle 295
Rear axle 435
Front wheel 65
Rear wheel 163
Work equipment
• Boom 313
• Shovel 436
• Fulcrum lever 13x4
• Tilt lever 32.5x2
• Raise cylinder 46x2
• Tilt cylinder 35x2
Work equipment 885
Boom 248
Arm 213
Boom swing bracket 162.5
Control valve 42.1
Outriggers 175
Boom cylinder 87.5
Arm cylinder 67
Bucket cylinder 52.5
Outriggers cylinder 55
Swing cylinder 34x2
Bucket 158
00-12 WB93R-5E0
TABLE OF OIL AND COOLANT QUANTITIES
Engine oil
ACEA E5 – 30 45 SAE 5W-30
ACEAE4
Engine oil pan Engine oil.
API CH-4 CI-4
–15 50 SAE 15W-40
ACEA E5 - E3
JASO DH1
– 20 45 HO46-HM
Hydraulic system Hydraulic oil
– 25 30 SAE 5W/20
Front axle
• Differential
Supercoolant AF-NAC
Engine cooling system – 30 50 AF-NAC
(note (3))
* ASTM D975 GRADE
– 30 – 10
No.1-D S15/EN590:2009
Fuel tank Diesel oil (note (4))
* ASTM D975 GRADE
– 10 45
No.2-D S15/EN590:2009
WB93R-5E0 00-13
TABLE OF OIL AND COOLANT QUANTITIES
Hydraulic transmission l 20 20
00-14 WB93R-5E0
CONVERSION TABLE
CONVERSION TABLE
METHOD OF USING THE CONVERSION TABLE
The conversion table in this section is provided to enable simple conversion of figures.
For details of the method of using the conversion table, see the example given below.
EXAMPLE
• Method of using the conversion table to convert from millimeters to inches.
1. Convert 55 mm into inches.
1 - Locate the number 50 in the vertical column at the left side, take this as A , then drow a horizontal line from
A.
2 - Locate the number 5 in the row across the top, take this as , then draw a perpendicular line down from B .
3 - Take the point where the two lines cross as C . This point C gives the value when converting from mil-
limeters to inches. Therefore, 55 mm =2.165 in.
1 - The number 550 does not appear in the table, so divide by 10 (move the decimal point one place to the left) to
convert it to 55 mm.
3 - The original value (550 mm) was divided by 10, so multiply 2.165 in. by 10 (move the decimal point one place to
the right) to return to the original value. This gives 550 mm = 21.65 in.
0 1 2 3 4 5 6 7 8 9
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
C
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
A
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
WB93R-5E0 00-15
CONVERSION TABLE
From mm to in.
1 mm = 0.03937 in.
0 1 2 3 4 5 6 7 8 9
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
From kg to lb.
1 kg = 2.2046 lb.
0 1 2 3 4 5 6 7 8 9
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.24 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
00-16 WB93R-5E0
CONVERSION TABLE
0 1 2 3 4 5 6 7 8 9
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
0 1 2 3 4 5 6 7 8 9
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.969 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 12.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
WB93R-5E0 00-17
CONVERSION TABLE
From Nm to lb.ft.
1 Nm = 0.737 lb.ft.
0 1 2 3 4 5 6 7 8 9
10 7.370 8.107 8.844 9.581 10.318 11.055 11.792 12.529 13.266 14.003
20 14.740 15.477 16.214 16.951 17.688 18.425 19.162 19.899 20.636 21.373
30 22.110 22.847 23.584 24.321 25.058 25.795 26.532 27.269 28.006 28.743
40 29.480 30.217 30.954 31.691 32.428 33.165 33.902 34.639 35.376 36.113
50 36.850 37.587 38.324 39.061 39.798 40.535 41.272 42.009 42.746 43.483
60 44.220 44.957 45.694 46.431 47.168 47.905 48.642 49.379 50.116 50.853
70 51.590 52.327 53.064 53.801 54.538 55.275 56.012 56.749 57.486 58.223
80 58.960 59.697 60.434 61.171 61.908 82.645 63.382 64.119 64.856 65.593
90 66.330 67.067 67.804 68.541 69.278 70.015 70.752 71.489 72.226 72.963
100 73.700 74.437 75.174 75.911 76.648 77.385 78.122 78.859 79.596 80.333
110 81.070 81.807 82.544 83.281 84.018 84.755 85.492 86.229 86.966 87.703
120 88.440 89.177 89.914 90.651 91.388 92.125 92.862 93.599 94.336 95.073
130 95.810 96.547 97.284 98.021 98.758 99.495 100.232 100.969 101.706 102.443
140 103.180 103.917 104.654 105.391 106.128 106.865 107.602 108.339 109.076 109.813
150 110.550 111.287 112.024 112.761 113.498 114.235 114.972 115.709 116.446 117.183
160 117.920 118.657 119.394 120.131 120.868 121.605 122.342 123.079 123.816 124.553
170 125.290 126.027 126.764 127.501 128.238 128.975 129.712 130.449 131.186 131.923
180 132.660 133.397 134.134 134.871 135.608 136.345 137.082 137.819 138.556 139.293
190 140.030 140.767 141.504 142.241 142.978 143.715 144.452 145.189 145.926 146.663
00-18 WB93R-5E0
CONVERSION TABLE
From Nm to kgm
1 Nm = 0.102 kgm
0 1 2 3 4 5 6 7 8 9
10 1.020 1.222 1.224 1.326 1.428 1.530 1.632 1.734 1.836 1.938
20 2.040 2.142 2.244 2.346 2.448 2.550 2.652 2.754 2.856 2.958
30 3.060 3.162 3.264 3.366 3.468 3.570 3.672 3.774 3.876 3.978
40 4.080 4.182 4.284 4.386 4.488 4.590 4.692 4.794 4.896 4.998
50 5.100 5.202 5.304 5.406 5.508 5.610 5.712 5.814 5.916 6.018
60 6.120 6.222 6.324 6.426 6.528 6.630 6.732 6.834 6.936 7.038
70 7.140 7.242 7.344 7.446 7.548 7.650 7.752 7.854 7.956 8.058
80 8.160 8.262 8.364 8.466 8.568 8.670 8.772 8.874 8.976 9.078
90 9.180 9.282 9.384 9.486 9.588 9.690 9.792 9.894 9.996 10.098
100 10.200 10.302 10.404 10.506 10.608 10.710 10.812 10.914 11.016 11.118
110 11.220 11.322 11.424 11.526 11.628 11.730 11.832 11.934 12.036 12.138
120 12.240 12.342 12.444 12.546 12.648 12.750 12.852 12.954 13.056 13.158
130 13.260 13.362 13.464 13.566 13.668 13.770 13.872 13.974 14.076 14.178
140 14.280 14.382 14.484 14.586 14.688 14.790 14.892 14.994 15.096 15.198
150 15.300 15.402 15.504 15.606 15.708 15.810 15.912 16.014 16.116 16.218
160 16.320 16.422 16.524 16.626 16.728 16.830 16.932 17.034 17.136 17.238
170 17.340 17.442 17.544 17.646 17.748 17.850 17.952 18.054 18.156 18.258
180 18.360 18.462 18.564 18.666 18.768 18.870 18.972 19.074 19.176 19.278
190 19.380 19.482 19.584 19.686 19.788 19.890 19.992 20.094 20.196 20.298
WB93R-5E0 00-19
CONVERSION TABLE
0 1 2 3 4 5 6 7 8 9
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.2 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 876.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
00-20 WB93R-5E0
CONVERSION TABLE
0 1 2 3 4 5 6 7 8 9
10 145.0 159.5 174.0 188.5 203.0 217.5 232.0 246.5 261.0 275.6
20 290.0 304.6 319.1 333.6 348.1 362.6 377.1 391.6 406.1 420.6
30 435.1 449.6 464.1 478.6 493.1 507.6 522.1 536.6 551.1 565.6
40 580.1 594.6 609.1 623.6 638.1 652.6 667.1 681.6 696.1 710.6
50 725.1 739.6 754.1 768.6 783.2 797.7 812.2 826.7 841.2 855.7
60 870.2 884.7 899.2 913.7 928.2 942.7 957.2 971.7 986.2 1000.7
70 1015.2 1029.7 1044.2 1058.7 1073.2 1087.7 1102.2 1116.7 1131.2 1145.7
80 1160.2 1174.7 1189.2 1203.7 1218.2 1232.7 1247.2 1261.8 1276.3 1290.8
90 1305.3 1319.8 1334.3 1348.8 1363.3 1377.8 1392.3 1406.8 1421.3 1435.8
100 1450.3 1464.8 1479.3 1493.8 1508.3 1522.8 1537.3 1551.8 1566.3 1580.8
110 1595.3 1609.8 1624.3 1638.8 1653.3 1667.8 1682.3 1696.8 1711.3 1725.8
120 1740.4 1754.9 1769.4 1783.9 1798.4 1812.9 1827.4 1841.9 1856.4 1870.8
130 1885.4 1899.9 1914.4 1928.9 1943.4 1957.9 1972.4 1986.9 2001.4 2015.9
140 2030.4 2044.9 2059.4 2073.9 2088.4 2102.9 1217.4 2131.9 2146.4 2160.9
150 2175.4 2189.9 2204.4 2218.9 2233.5 2248.0 2262.5 2277.0 2291.5 2306.0
160 2320.5 2335.0 2349.5 2364.0 2378.5 2393.0 2407.5 2422.0 2436.5 2451.0
170 2465.5 2480.0 2494.5 2509.0 2523.5 2538.0 2552.5 2567.0 2581.5 2596.0
180 2610.5 2625.0 2639.5 2654.0 2668.5 2683.0 2697.7 2712.1 2726.6 2641.1
190 2755.6 2770.0 2784.6 2799.1 2813.6 2828.1 2842.6 2857.1 2871.6 2886.1
200 2900.6 2915.1 2929.6 2944.1 2958.6 2973.1 2987.6 3002.1 3016.6 3031.1
210 3045.6 3060.1 3074.6 3089.1 3103.6 3118.1 3132.6 3147.1 3161.6 3176.1
220 3190.7 3205.2 3219.7 3234.2 3248.7 3263.2 3277.7 3192.2 3306.7 3321.2
230 3335.7 3350.2 3364.7 3379.2 3393.7 3408.2 3422.7 3437.2 3451.7 3466.2
240 3480.7 3495.2 3509.7 3524.2 3538.7 3553.2 3567.7 3582.2 3596.7 3611.2
WB93R-5E0 00-21
CONVERSION TABLE
TEMPERATURE
Fahrenheit-Centigrade conversion; a simple way to convert a Fahrenheit temperature reading into a Centigrade tem-
perature reading or vice versa is to enter the accompanying table in the center or boldface column of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit tem-
peratures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of Centigrade val-
ues and read the corresponding Fahrenheit temperature on the right.
1 °C = 33.8°F
°C °F °C °F °C °F °C °F
00-22 WB93R-5E0
10 STRUCTURE AND FUNCTION
WB93R-5E0 10-1
STRUCTURE AND FUNCTION POWER TRAIN
POWER TRAIN
1 2
3 4
RKA52470
5 7 8
6
DESCRIPTION
• The driving power for the engine (1) is transmitted • The driving power is transmitted from the
through the flywheel to the converter (2). transmission flanges (3) to the front (5) and rear (6)
The converter (2) uses hydraulic oil to convert the axles through the Cardan drive shafts (7 and 8).
torque transmitted by the engine (1) into driving • The driving power transmitted to the front (5) and rear
power. The converter (2) transmits motion to the drive (6) axles is reduced by the differentials and then
shaft of the transmission (3) and to the drive shaft of transmitted to the planetary gear through the
the hydraulic pump (4). differential shafts.
• The transmission (3) has two hydraulically-activated
clutches that can be selected by an electrically-
controlled gear selector.
It also has manual gear selection (four forward gears
and four reverse gears).
10-2 WB93R-5E0
STRUCTURE AND FUNCTION POWER TRAIN
8
4
2 7 10
RKZ09610
WB93R-5E0 10-3
STRUCTURE AND FUNCTION TRANSMISSION (4WD)
TRANSMISSION (4WD)
Diagram of the power train
Z=45
Z=27 Z=29
Z=50
Z=36
4
8
5
Z=27
9
Z=17
RKZ09620
10-4 WB93R-5E0
STRUCTURE AND FUNCTION TRANSMISSION (4WD)
WB93R-5E0 10-5
STRUCTURE AND FUNCTION TRANSMISSION
TRANSMISSION
10-6 WB93R-5E0
STRUCTURE AND FUNCTION TRANSMISSION
3 4 5
18
17
16
8 7
9
14
10
15 RKZ09650
11 13 12
Section A - A
WB93R-5E0 10-7
STRUCTURE AND FUNCTION TRANSMISSION
2 3 4 5 6 7 8 9 10
9
11
10 SectionCC- -CC
Sezione
Section B-B
Sezione B - B
13 14 15 16 17
12
SectionDD- D- D
Sezione
RKZ00991
SectionEE- E- E
Sezione
10-8 WB93R-5E0
STRUCTURE AND FUNCTION DRIVE SHAFTS
DRIVE SHAFTS
Drive shaft for forward and reverse movement
1 2
a b c
RKZ09660
6
5
4 3
a. Port commanding reverse clutch 1. Reverse gear clutch (Z=29)
b. Port commanding forward clutch 2. Forward gear clutch (Z=29)
c. Lubrication port 3. Forward clutch piston
4. Reverse clutch piston
5. Shoulder ring
6. Driven shaft
RKZ09670
8 8
1. 2nd gear driven gear (Z=44) 6. Rear output shaft
2. 1st gear driven gear (Z=50) 7. Shoulder ring
3. 4WD drive gear (Z=45) 8. Synchronizer
4. 4th gear driven gear (Z=23)
5. 3rd gear driven gear (Z=33)
WB93R-5E0 10-9
STRUCTURE AND FUNCTION DRIVE SHAFTS
a
1
5 RKZ09680
4 3
10-10 WB93R-5E0
STRUCTURE AND FUNCTION CONTROL VALVE BLOCK
Section F - F
1. Ball 9. Valve
2. Spring 10. Piston rod
3. Piston 11. Spring
4. Spring 12. Spool return spring
5. Spring 13. Spool
6. Spring-guide pin 14. Forward gear command solenoid
7. Valve 15. Reverse gear command solenoid
8. Spring 16. Differential lock solenoid valve
WB93R-5E0 10-11
STRUCTURE AND FUNCTION FRONT AXLE
FRONT AXLE
Differential
1 2 3 4
16
15
7
8
14
9
13
10
12 11
RKZ09700
10-12 WB93R-5E0
STRUCTURE AND FUNCTION FRONT AXLE
7
3
2
1 5 8
6 9
4
10
11
RKZ09710
13
22 12
17
14
18 16
21 15
20 19
WB93R-5E0 10-13
STRUCTURE AND FUNCTION FRONT AXLE
B 1
C 2 3
A RKZ09720
A
a b
7 7
5
4 Section B - B 6
Section A - A Detail C
10-14 WB93R-5E0
STRUCTURE AND FUNCTION REAR AXLE
REAR AXLE
Differential
3
4
2
1 5
6
7 7
14
13
12 8
RKZ09730
9
11 10
1. Bearing 8. Bearing
2. Planetary gear 9. Ring nut
3. Ring gear (Z=32) 10. Gasket
4. Planetary gear 11. Flange
5. Differential housing 12. Spacer
6. Ring nut 13. Bevel pinion (Z=13)
7. Half-axle 14. Differential housing
WB93R-5E0 10-15
STRUCTURE AND FUNCTION REAR AXLE
1
3 4
2
11 8 7 6
9
10 RKA52480
10-16 WB93R-5E0
STRUCTURE AND FUNCTION REAR AXLE
Brakes
1 2
3 4
7
Detail A
Particolare A
A
RKA52850
1. Bleed screw
2. Piston
3. Brake disk
4. Intermediate disk
5. Pressure disk
6. Pressure disk
7. Bushing
8. Parking brake control caliper
9. Screw
WB93R-5E0 10-17
STRUCTURE AND FUNCTION REAR AXLE
Differential lock
a
RKZ09760
3
8 7 6 5 4
10-18 WB93R-5E0
STRUCTURE AND FUNCTION HYDRAULIC PUMP
HYDRAULIC PUMP
Pd2
Ps
View X
P1L PLS
Pd P1c
Z
X
3 2
PM Pen P1
1
RKZ09410
View Z
WB93R-5E0 10-19
STRUCTURE AND FUNCTION HYDRAULIC PUMP
1. MAIN PUMP
A
View X
Z X
B B
D Pd4 Pa PM2
C C
RKZ09420
D Pe Pd5
View Z
PORT FUNCTIONS
Port Pa - Delivery control group feed
Port Pe - Delivery control signal
Port Pd4 - Drain
Port Pd5 - Drain
Port PM2 - Operating mode signal
10-20 WB93R-5E0
STRUCTURE AND FUNCTION HYDRAULIC PUMP
1 1 14
Section A - A Section C - C
4 5 6 7 8
3
13
RKZ09520
Section D - D
12 11 10 9
FUNCTION
The rotation and torque transmitted to the pump shaft is converted into hydraulic energy and pressurized oil is delivered
according to the load requirements.
The amount of oil delivered can be modified by changing the angle of the swash plate.
WB93R-5E0 10-21
STRUCTURE AND FUNCTION HYDRAULIC PUMP
8 7 6 5 1 10
3
4
RKZ09790
9 A a
STRUCTURE
• Groove a supports and makes cylinder block (1) an integral part of shaft (2), and shaft (2) is supported by front and
rear bearings (3), (4).
• The end of piston (5) is a concave ball, and shoe (6) is caulked to it to form one unit. Piston (5) and shoe (6) form a
spherical bearing.
• Swash plate (7) is supported by pump body (8) and ball (9), and has a flat surface A.
Shoe (6) remains in contact with swash plate (7) and slides in a circular movement.
Pressurised oil is introduced between shoe (6) and swash plate (7) forming a static bearing that allows shoes (6) to
slip.
• The pistons (5) perform their relative movements in an axial direction, inside cylindrical chambers fashioned in the
cylinder block (1).
• The rotation of the cylinder block (1) pressurises the oil inside the chambers of the block; pressure is adjusted by the
valve plate (10). The surface of the swash plate (10) is so designed that the oil pressure always remains within
acceptable limits. The oil in each chamber is drawn in and discharged through holes in the valve plate (10).
10-22 WB93R-5E0
STRUCTURE AND FUNCTION HYDRAULIC PUMP
OPERATION
1. Pump operation
1 - The cylinder block (1) rotates with the shaft (2), and 7 6 1
the shoe (6) slides on the flat surface A.
When this happens, the swash plate (7) rotates on the
ball (9), and the angle a between the axis of the
cylinder block (1) and the axis X of the swash plate (3) X
changes. The angle a is known as the swash plate
angle. a
2 - When the axis X of the swash plate (7) retains the
angle a in relation to the axis of the cylinder block
(1), flat surface A acts as a cam for the shoe (6).
This is why the piston (5) slides inside the cylinder
block (1), creating a difference between volumes E
and F and therefore causing the suction and
delivery of oil in a quantity that is equivalent to the 9 A RKZ09530
3 6 E
F RKZ09550
WB93R-5E0 10-23
STRUCTURE AND FUNCTION HYDRAULIC PUMP
2. Control of Delivery
1 - When angle a of the swash plate increases, the
difference between volumes E and F increases too,
and this makes delivery Q increase accordingly. 8 9 7 E
Angle a of the swash plate is varied by the servo-
piston (11).
10-24 WB93R-5E0
STRUCTURE AND FUNCTION HYDRAULIC PUMP
Pe Pd5
Ad4 Pa PM
A A
B B
RKZ09430
PORT FUNCTIONS
T port - Drain
P1 port - Delivery control group feed
Pd4 port - Drain
PE port - Delivery control signal output
PM port - Operating mode signal input
WB93R-5E0 10-25
STRUCTURE AND FUNCTION HYDRAULIC PUMP
2.1 PC VALVE
2 3 4 5
6 7 8
1
9
RKZ09770
Pd4 PPL Pa PM Pa
Section A - A
10-26 WB93R-5E0
STRUCTURE AND FUNCTION HYDRAULIC PUMP
2.2 LS VALVE
1 2 4
3 5
6
RKZ09780
WB93R-5E0 10-27
STRUCTURE AND FUNCTION HYDRAULIC PUMP
LS VALVE FUNCTION
• The LS valve controls the pump delivery according to
the stroke of the control valve lever, i.e., in function of
the delivery demands made by the actuators.
• The LS valve detects the actuator’s delivery needs
by means of the differential pressure DPLS
existing between pressure PPLS (control valve
input pressure) and pressure PLS (control valve
Pump delivery Q
output pressure). The sensing of this differential
pressure permits control of the main pump delivery
Q. (PPLS, PLS and DPLS are, respectively, the
pump pressure, the Load Sensing pressure, and
the difference in pressure between these two
values). LS differential pressure dPLS bar
• In other words, the LS valve detects the pressure
difference DPLS generated by the passage of the
oil flow through the surface freed by the control RKZ09570
10-28 WB93R-5E0
STRUCTURE AND FUNCTION HYDRAULIC PUMP
RKZ09580
WB93R-5E0 10-29
STRUCTURE AND FUNCTION HYDRAULIC PUMP
PC VALVE OPERATION
1. Spring operation
• PC valve spring loading (3) is defined by swash plate position.
• If control piston (6) moves to the right, spring (3) is compressed by lever (2) and spring loading increases.
1 5 4 PA
Check valve
D C B
PT
Engine
C B 3
F
LS valve
Solenoid
valve
G
J
RKZ09490
• The force applied by the pressure against the spool • When the control piston (2) moves, the lever (3)
(4) decreases, and the spool (5) shifts slightly to the moves to the left, and the spring (1) expands,
right. thereby reducing its load on the spool (5).
At the same time, a connection opens between ports Consequently, the spool (5) moves to the left and
C and D, and pressurised oil from valve LS is sent for stops the oil flow between ports C and D, and a
discharge (PT). passage opens between ports B and C.
• Simultaneously, ports F and G on valve LS are • As a result of that, the pressure at port C increases,
interconnected, and pressure at port J is sent for and the control piston (2) stops.
relief (PT); the control piston (2) shifts to the left.
• Pump delivery increases as a result.
10-30 WB93R-5E0
STRUCTURE AND FUNCTION HYDRAULIC PUMP
1 5 4 PA
Check valve
D C B
PT
Engine
C B 3
2
LS valve
Solenoid
valve
J G
RKZ09500
• The force applied by the pressure against the spool • When the control piston (2) moves, the lever (3)
(4) increases, and the spool (5) shifts slightly to the moves to the right, and the spring (1) compresses,
left. At the same time, a connection opens between thereby increasing its load on the spool (5).
ports C and B, and the pressure of the oil sent to valve Consequently, the spool (5) moves to the right and
LS becomes equivalent to the pump's delivery stops the oil flow between ports C and B, and a
pressure (PA). passage opens between ports D and C.
• Simultaneously, ports F and G on valve LS are • As a result of that, the pressure at port C decreases,
interconnected, and pressure at port J becomes and the control piston (2) stops.
equivalent to the pump's delivery pressure (PA), and
the control piston (2) shifts to the right.
• Pump delivery decreases as a result.
WB93R-5E0 10-31
STRUCTURE AND FUNCTION HYDRAULIC PUMP
1 5 4 PA
Check valve
D C B
PT
Engine
C B 3
LS valve
Solenoid
valve
G
J
RKZ09510
10-32 WB93R-5E0
STRUCTURE AND FUNCTION 9-SPOOL CONTROL VALVE
WB93R-5E0 10-33
STRUCTURE AND FUNCTION 9-SPOOL CONTROL VALVE
10-34 WB93R-5E0
STRUCTURE AND FUNCTION 9-SPOOL CONTROL VALVE
WB93R-5E0 10-35
STRUCTURE AND FUNCTION 9-SPOOL CONTROL VALVE
10-36 WB93R-5E0
STRUCTURE AND FUNCTION 9-SPOOL CONTROL VALVE
WB93R-5E0 10-37
STRUCTURE AND FUNCTION 9-SPOOL CONTROL VALVE
10-38 WB93R-5E0
STRUCTURE AND FUNCTION 9-SPOOL CONTROL VALVE
3 4
2 7
1
E-E K-K
5 8
F-F L-L
6 9
WB93R-5E0 10-39
STRUCTURE AND FUNCTION 9-SPOOL CONTROL VALVE
10-40 WB93R-5E0
STRUCTURE AND FUNCTION 11-SPOOL CONTROL VALVE
WB93R-5E0 10-41
STRUCTURE AND FUNCTION 11-SPOOL CONTROL VALVE
10-42 WB93R-5E0
STRUCTURE AND FUNCTION 11-SPOOL CONTROL VALVE
WB93R-5E0 10-43
STRUCTURE AND FUNCTION 11-SPOOL CONTROL VALVE
10-44 WB93R-5E0
STRUCTURE AND FUNCTION 11-SPOOL CONTROL VALVE
WB93R-5E0 10-45
STRUCTURE AND FUNCTION 11-SPOOL CONTROL VALVE
10-46 WB93R-5E0
STRUCTURE AND FUNCTION 11-SPOOL CONTROL VALVE
3 4
7
2
1 H-H
E-E
5 9
F-F K-K
8 10
J-J L-L
6 11
WB93R-5E0 10-47
STRUCTURE AND FUNCTION 11-SPOOL CONTROL VALVE
10-48 WB93R-5E0
STRUCTURE AND FUNCTION CLSS
CLSS
1. DESCRIPTION
1.1 CHARACTERISTICS
The term CLSS means Closed Center Load Sensing System, which has the following characteristics:
a) High precision control that is independent of the load applied to the movement;
b) High precision control of digging action even during delicate manoeuvres;
c) Ability to perform complex operations, guaranteed by control of oil flow in function of the aperture surfaces of the
shuttles;
d) Energy savings guaranteed by control of pump delivery.
1.2 STRUCTURE
• The CLSS system includes the variable flow pump, the control valve and the working equipment.
• The pump includes the main pump, the TCC valve and the LS. valve.
Actuator
PLS
Control valve
TCC valve
LS valve
PP
Servo
piston
RKP00661
WB93R-5E0 10-49
STRUCTURE AND FUNCTION CLSS
2. OPERATING PRINCIPLES
2.1 CONTROL OF THE ANGLE OF THE PUMPING PLATE
• The angle of the swash plate (and hence the pump delivery) is controlled in such a way that the differential pressure
DPLS between the delivery pressure PP of the pump and the pressure PLS at the outlet of the control valve towards
the actuator is maintained at a constant value. (DPLS=Pump delivery pressure PP – pressure PLS of delivery to the
actuator.
• If the differential pressure DPLS becomes lower than the set pressure of the LS, valve, the angle of the swash plate
increases.
If the differential pressure DPLS increases, the angle of the swash plate decreases.
a For details about this movement, see the description of the "HYDRAULIC PUMP".
Actuator
Control valve
Min.
PLS
Pump passage
LS passage 0 LS differential
pressure ΔPLS Set differential
pressure of LS valve
Main pump
PP RKP02931
Min. Max.
Servo piston
Δ PLS
LS valve
Differential
pressure high Differential
pressure
low
PC valve
10-50 WB93R-5E0
STRUCTURE AND FUNCTION CLSS
Load
Load
W W
Actuator Actuator
ΔP ΔP
S1 S2
Pressure Pressure
compensation compensation
valve valve
LS valve RKP02941
WB93R-5E0 10-51
STRUCTURE AND FUNCTION CLSS
10-52 WB93R-5E0
STRUCTURE AND FUNCTION CLSS
1. Unloading valve:
pressure LS + 27.5 bar
2. Max. pressure valve: 218 bar
3. Safety valve: 270 bar
4. Check valve
5. Anti-shock/anticavitation valve: 215 bar
6. Anti-shock/anticavitation valve: 220 bar
7. Anti-shock/anticavitation valve: 350 bar
8. Pressure compensation valves
9. Priority valve
10. Servocontrols reducing valve
11. Anti-shock/anticavitation valve: 165 bar
12. Not used
WB93R-5E0 10-53
STRUCTURE AND FUNCTION CLSS
10-54 WB93R-5E0
STRUCTURE AND FUNCTION CLSS
1. Unloading valve:
pressure LS + 27.5 bar
2. Max. pressure valve: 218 bar
3. Safety valve: 270 bar
4. Check valve
5. Anti-shock/anticavitation valve: 215 bar
6. Anti-shock/anticavitation valve: 220 bar
7. Anti-shock/anticavitation valve: 350 bar
8. Pressure compensation valves
9. Priority valve
10. Servocontrols reducing valve
11. Anti-shock/anticavitation valve: 165 bar
12. Not used
WB93R-5E0 10-55
STRUCTURE AND FUNCTION CLSS
Function
• When the control valve is in “NEUTRAL” position, pump delivery Q (resulting from the swash plate being at its min.
angle) is sent into the tank circuit.
When this happens, the pump's delivery pressure PP is regulated at 27.5 bar (28 kg/cm2) by means of the spring (2)
inside the valve.
(LS signal with PLS pressure=0 bar (0 kg/cm2)
PP
S1 1 S2
RKZ09190
S3
T 2 PL
Functioning
• Pump pressure PP acts on spool (1) – left, on surface S1, and right, on surface S2 – whereas Load Sensing pressure
PLS acts on surface S2.
• Since no LS signal with PLS pressure is generated when the control valve is in “NEUTRAL” position, the only
pressure acting on spool (1) in this condition is the pump's delivery pressure PP as regulated by spring compression
(2).
• As the pump's delivery pressure PP increases and the resulting force equals spring loading (2), the spool (1) shifts
to the right. The pump's delivery circuit PP is then connected to the tank circuit T by means of the holes in spool (1).
• This ensures that the pump delivery pressure PP stays regulated at 27.5 bar (28 kg/cm2).
PP = Pump circuit
PLS = Load Sensing circuit
T= Tank circuit
A = To control valve spools
10-56 WB93R-5E0
STRUCTURE AND FUNCTION CLSS
Function
• When the actuators' delivery needs during fine control are within the delivery values related to the minimum angle
of the swash plate, the pump's delivery pressure PP is regulated by pressure PLS at +27.5 bar (28 kg/cm2).
Since the unloading valve opens when the differential pressure between the pump's delivery pressure PP and
pressure PLS of the LS equals spring loading (2) (27.5 bar (28 kg/cm2)), the differential pressure DPLS becomes
27.5 bar (28 kg/cm2).
PP
S1 1 A S2
B
RKZ09200
S3
T 2 PL
Functioning
• When fine controls are performed at the control valve, a PLS pressure is generated. This pressure acts on surface
S3 on the right hand side of the spool (1). Since pressure PLS of LS is low – because the control valve passage is
small – the difference with the pump's delivery pressure PP is great.
• When the differential pressure between the pump's delivery pressure PP and pressure PLS of the LS equals spring
loading (2) (27.5 bar (28 kg/cm2)), the spool (1) shifts to the right and, in turn, the pump circuit PP connects to the tank
circuit T.
• The pump's delivery pressure PP is regulated by the combination of the pressure from the spring (27.5 bar (28 kg/
cm2)) and the pressure PLS of the LS, i.e. when the differential pressure DPLS reaches a value of 27.5 bar (28 kg/
cm2).
WB93R-5E0 10-57
STRUCTURE AND FUNCTION CLSS
Function
• When the request for oil flow from the actuators exceeds the minimum delivery of the pump during use of the control
valve, the connection to the tank circuit is eliminated and the entire pump delivery Q is sent to the actuators.
PP
S1 1 S2
RKZ09210
S3
T 2 PL
Functioning
• When the control valve spool is caused to perform a longer travel, this generates a pressure PLS of the LS, which
acts on the right hand side of the spool (1).
Since the control valve passage is wide, the difference between the pressure PLS of the LS and the pump's delivery
pressure PP is small.
• For this reason, since the differential pressure between the pump's delivery pressure PP and the pressure PLS of
the LS fails to reach the spring loading pressure value of spring (2) (27.5 bar (28 kg/cm2), the spool (1) is pushed to
the left by the spring (2).
• The result is that the connection between the pump delivery circuit PP and the tank circuit T is excluded and the
entire pump delivery Q is sent to the actuators.
10-58 WB93R-5E0
STRUCTURE AND FUNCTION CLSS
Function
• LS pressure is the actuator's pressure at control valve output.
• This pressure actually reduces the pump's PP pressure – via the pressure compensation group reducing valve (3)
– to the same A pressure of the actuator circuit and then sends it into the PLS circuit of the LS.
• In the outriggers control valve, the actuator's pressure A is introduced directly into circuit PLS of the LS
A b a
SLS
PLSS
2 3
PLS
c
PP 4
SA PA RKZ09220
Functioning
• When the spool (1) is operated, pump pressure PP starts flowing into the circuit of actuator A – from the delivery
control valve (2) and from the notch a via the duct b.
• At the same time, the pressure reducing valve (3) moves to the right thereby making the pump's pressure PP drop
as it flows through the bottleneck c, and causing the pressure to flow into the circuit PLS of the LS and into the
chamber of spring PLSS.
• At this point, the PLS circuit of the LS is connected to the tank circuit T by means of the by-pass plug (4). (See the
description of the LS by-pass plug).
• The pressure acting on the left side of the reducing valve (3) is pressure PA (= A) of the actuator, whereas the
pressure acting on the right hand side is the reduced pressure PP of pump delivery.
• The reducing valve (3) therefore balances out when pressure PA of the actuators and pressure PLSS of the spring
chamber are balanced. This in turn allows the pressure PP – now reduced by the bottleneck c – to be introduced into
the PLS circuit of the LS at the same pressure A as the actuator's circuit.
WB93R-5E0 10-59
STRUCTURE AND FUNCTION CLSS
A a PP
RKZ09240
b PLS
Functioning
• When the spool (1) is operated, pump pressure PP starts flowing into the circuit of actuator A through the duct a.
• At the same time, pressurised oil is introduced into the PLS circuit of the LS through holes b.
a The outriggers circuit differs from the working equipment circuit in that the operating pressure of actuator A is
introduced directly into the PLS circuit of the LS.
10-60 WB93R-5E0
STRUCTURE AND FUNCTION CLSS
Description
• The LS by-pass plug unloads residual pressure from the Load Sensing's PLS circuit.
• This makes the increment rate of Load Sensing's PLS pressure smoother.
Moreover, by eliminating oil (through the bottleneck), a loss of pressure is generated in the flow that is controlled by
the spool, and stability is increased as a result, thereby reducing the actual differential pressure LS.
b a
T PLS
RKZ09250
T PP
Functioning
• Pressurised oil in the Load Sensing PLS circuit flows through filter a, through orifice b and into the tank circuit T.
PP = Pump circuit
PLS = Load Sensing circuit
T = Drain circuit
WB93R-5E0 10-61
STRUCTURE AND FUNCTION CLSS
Function
• Pressure compensation occurs during simultaneous operation of several movements, specifically when the
pressure of an actuator becomes lower than the pressure of the actuator on the opposite side, and pump delivery is
on the verge of being increased.
In this specific case, the RH actuator withstands a higher pressure than the LH actuator.
W A W A
aB aB
PLSS PPA PA
2 PA RKZ09260
1
PPA
PLS
PP
Functioning
• During simultaneous operation, when RH actuator pressure increases, delivery in circuit A of the LH actuator tends
to increase.
• In this case, the PLS pressure of the LS for the RH actuator acts on chamber PLS1 of the spring and pushes the
pressure reducing valve (1) and the delivery control valve (2) to the left.
• The delivery control valve (2) produces a bottleneck between the pump's delivery PP circuit and the PPA circuit
upstream of the control valve spool.
This bottleneck generates a pressure loss between circuits PP and PPA.
• The delivery control valve (2) and the pressure reducing valve (1) are balanced out at a point where the differential
pressure between PA and PLS (these two acting on both surfaces of the pressure reducing valve (1)), equals the
loss of pressure between PP and PPA (these two acting on both surfaces of the delivery control valve (1)).
• The differential pressure between the upstream pressure PPA and the downstream pressure of both spools in the
control valves concerned in the simultaneous movements are equalised, and pump delivery is distributed
proportionally to the sections a that are responsible for opening the notches of each spool.
10-62 WB93R-5E0
STRUCTURE AND FUNCTION CLSS
Function
• In order to equalize the characteristics of each actuator, the pressure compensation valve will determine the
compensation characteristics by performing a micrometer adjustment of the surface ratio S1/S2. This is the ratio of
area S1 (delivery control valve (2) end) to area S2 (pressure reducing valve (1) end).
S1 = surface of the delivery control valve (2) – Surface of piston (3).
S2 = surface of pressure reducing valve (1) – Surface of piston (3).
T
A b
S1
S2
RKZ09230
PPA 1
2 3
PP PA PLS
WB93R-5E0 10-63
STRUCTURE AND FUNCTION CLSS
Function
• The purpose of the priority valve is to feed pressurised oil to the steering unit and to the other actuators.
• Oil distribution is determined by the position of the spool (1) of the priority valve, which is in turn determined by LS
signal, pump delivery, steering circuit pressure, and hydraulic circuit pressure.
• The position of the spool (1) is determined in such a way as to ensure that the oil delivered to the steering unit
matches the delivery needs at any time.
PP DLS
D
1
RKZ09270
P LS
10-64 WB93R-5E0
STRUCTURE AND FUNCTION CLSS
Function
• This valve regulates the servocontrol feed pressure at 37.3 bar.
• When actuator pressure is low, the sequential valve closes to permit an increase in the pump's delivery pressure PP
in order to supply pressure to the servocontrols.
PPPC
4
PP 5
2
TO ACTUATORS
1 PLS
TS RKZ09280
Functioning
• The spool (1) of the unloading valve moves, and delivery pressure is regulated at 37.3 bar.
(For details, see 3.2 UNLOADING VALVE).
• The spool (2) and valve (3) reduce the pump's delivery pressure PP to 37.3 bar.
Pressure is then sent to the servocontrols via port PC.
WB93R-5E0 10-65
STRUCTURE AND FUNCTION CLSS
PPPC
4
PP 5
2
TO ACTUATORS
1 PLS
TS RKZ09290
Functioning
• The spool (1) of the unloading valve moves to the left, and the pump's delivery pressure exceeds the pressure of the
actuator circuit (5) by an amount equivalent to LS differential pressure.
(For details, see 3.2 UNLOADING VALVE).
• If the pump's delivery pressure PP exceeds 37.3 bar, valves (2) and (3) reduce pressure PP to 37.3 bar.
The reduced pressure is then sent to the servocontrols via port PC.
• When this occurs, the sequential reducing valve (4) stays open.
10-66 WB93R-5E0
STRUCTURE AND FUNCTION CLSS
PPPC
4
PP 5
2
TO ACTUATORS
1 PLS
TS RKZ09300
• When the pump's delivery pressure PP is lower than 37.3 bar, the sequential reducing valve shifts to the right,
thereby reducing the flow of the PP pressure to the actuator circuit (5).
This generates a pressure gap between PP pressure and actuator pressure.
PP pressure is incremented in excess of 37.3 bar and is then reduced to 37.3 bar by valves (2) and (3) to guarantee
pressure feed to the servocontrols.
WB93R-5E0 10-67
STRUCTURE AND FUNCTION STEERING UNIT
STEERING UNIT
a e b
LS
L R
T P
RKP03740
c d
10-68 WB93R-5E0
STRUCTURE AND FUNCTION STEERING UNIT
OPERATION
• The steering unit is composed of a control valve and a
rotating oil dispenser, and is of the hydrostatic type.
• When the steering wheel is turned, the control valve
sends oil from the pump (by means of the rotating oil
dispenser) to one of the sides of the steering cylinder.
The rotating dispenser ensures that the volume of oil
supplied to the cylinder is proportionate to the angle of
rotation of the steering wheel.
• In the event of malfunction, the oil dispenser will
function automatically as a hand-pump, thus
guaranteeing emergency steering.
WB93R-5E0 10-69
STRUCTURE AND FUNCTION PPC VALVES
PPC VALVES
SHOVEL PPC VALVE (STANDARD)
P2 P4
P3 P1
Z
E E
D D
B
T P
A C
C A
View Z RKZ09330
10-70 WB93R-5E0
STRUCTURE AND FUNCTION PPC VALVES
5 7
4
8
3
9
2
1 10
A-A B-B
D-D
C-C
E-E
RKZ09340
1. Spool 6. Nut
2. Adjusting screw (inner) 7. Joint
3. Adjusting screw (outer) 8. Cover
4. Piston 9. Retainer
5. Disk 10. Body
WB93R-5E0 10-71
STRUCTURE AND FUNCTION PPC VALVES
OPERATION
10-72 WB93R-5E0
STRUCTURE AND FUNCTION PPC VALVES
A Control B
valve RKZ09460
WB93R-5E0 10-73
STRUCTURE AND FUNCTION PPC VALVES
P3 P1
D D
T P
B A
C C
A B
View Z RKZ08920
10-74 WB93R-5E0
STRUCTURE AND FUNCTION PPC VALVES
6
5 7
4 8
3
9
2
10
1
11
A-A C-C
D-D
RKZ08980
B-B
1. Spool 7. Joint
2. Adjusting screw (inner) 8. Cover
3. Adjusting screw (outer) 9. Retainer
4. Piston 10. Piston
5. Disk 11. Body
6. Disk
WB93R-5E0 10-75
STRUCTURE AND FUNCTION PPC VALVES
OPERATION
D D
f f
T T
P P
1 1
P2 P1 P3 P4
A Control B A Control B
valve valve RKZ08990
10-76 WB93R-5E0
STRUCTURE AND FUNCTION PPC VALVES
WB93R-5E0 10-77
STRUCTURE AND FUNCTION PPC VALVES
A Control B
valve RKZ09010
4. During fine control
(NEUTRAL o Full stroke)
When the disk (5) pushes down on the piston (4), and
the retainer (9) pushes down on the spool (1),
calibrated hole f is put in direct connection with 5
chamber PP, which is in turn conne cted to a
constantly pressurised servocontrols circuit. 4
Oil is then allowed to flow directly into section B-P1
thereby pushing the stem of the main control valve to
the end of its travel. This causes the main control
valve to send the oil contained in chamber AB
towards input P2, through calibrated hole f' and into
relief chamber D.
D
p’
T
P
f
PP
P2 P1
A Control B
valve RKZ09020
10-78 WB93R-5E0
STRUCTURE AND FUNCTION PPC VALVES
11
6. When control lever is moved from float back to 10
neutral position
The disk (5) can be moved back to neutral position by D
applying a force that exceeds the force applied by the T
solenoid. P
The floating state can also be cancelled, and the lever
can move back to neutral position, denergizing the
solenoid.
PP
P3 P4
A Control B
valve RKZ09021
WB93R-5E0 10-79
STRUCTURE AND FUNCTION PPC VALVES
P4
P2
P1 P3
P T
RKZ09360
P1 P3
RKZ09350
Z
P1 port - To control valve (8 spools) (PA7 port)
To control valve (10 spools) (PA9 port)
P2 port - To control valve (8 spools) (PB7 port)
To control valve (10 spools) (PB9 port)
P3 port - To control valve (8 spools) (PA8 port)
To control valve (10 spools) (PA10 port)
P4 port - To control valve (8 spools) (PB7 port)
To control valve (10 spools) (PB10 port)
P port - To EV1 solenoid valve group (P2 port)
Port T - To hydraulic tank
10-80 WB93R-5E0
STRUCTURE AND FUNCTION PPC VALVES
2
3
4 5
RKZ09370
6 7
1. knob
2. Nut
3. Lever
4. Boot
5. Plate
6. LH PPC valve body
7. RH PPC valve body
WB93R-5E0 10-81
STRUCTURE AND FUNCTION PPC VALVES
OPERATION
P2 P1
A Control B
valve RKZ09380
• Ports A and B of control valve and ports P1 and P2 of PPC valves are connected to the tank circuit.
• Hence, the spool is in neutral position.
10-82 WB93R-5E0
STRUCTURE AND FUNCTION PPC VALVES
P2 P1
A Control B
valve RKZ09390
• When the lever (1) is moved in the direction shown by the arrow, the valves (2) are rotated and a passage is opened
between delivery duct a and port P1, while port P2 remains connected to the tank circuit.
• Pressure at port P1 increases as the travel of lever (1) increases. Consequently, the spool of the control valve moves
to the left by a distance that is proportional to the travel of the lever (1).
WB93R-5E0 10-83
STRUCTURE AND FUNCTION PPC VALVES
P2 P1
A Control B
valve RKZ10610
• When lever (1) is moved fully to the left, the valves (2) are fully rotated.
• Port P1 is then connected directly to delivery duct a whereas port P2 is connected to tank circuit only, and the spool
of the control valve performs its full travel.
10-84 WB93R-5E0
STRUCTURE AND FUNCTION SOLENOID VALVE GROUP (EV1)
ACC P1
2 3 4
A2
UL
P2 P
PM
T
B2
Hydraulic circuit
ACC B2 A2 PM UL
P1
S2
CV1
P2
SV2
S1
SV1 SV3
P T
RKZ10270
WB93R-5E0 10-85
STRUCTURE AND FUNCTION SOLENOID VALVE GROUP (EV1)
10-86 WB93R-5E0
STRUCTURE AND FUNCTION OUTRIGGERS SAFETY VALVE
a b
A A
A-A
c d
RKP03762
TECHNICAL DATA
• Pilot ratio: 7 : 1
WB93R-5E0 10-87
STRUCTURE AND FUNCTION SHOVEL CYLINDERS
SHOVEL CYLINDERS
RAISING CYLINDER
7 2 6 1
5 4 3
8
707-00-0Y891
DUMPING CYLINDER
7 2 6 5 4 3 1
8
707-00-0Y920
CHARACTERISTICS
Cylinder Lifting Dump
Piston rod diameter 50 45
Internal cylinder diameter 90 70
Piston stroke 570 745
Max. cylinder length 1740 2145
Min. cylinder length 1170 1400
Key size for piston safety nut 55 50
10-88 WB93R-5E0
STRUCTURE AND FUNCTION SHOVEL CYLINDERS
4 IN 1 BUCKET
2 3 4 5 1
6 7
8
42N-6C-12800
1. Cylinder 5. Stem
2. Nut 6. Head
3. Gasket 7. Head bushing
4. Piston
CHARACTERISTICS
Cylinder Lifting Dump 4 in 1 bucket
Piston rod diameter 50 45 40
Internal cylinder diameter 90 70 70
Piston stroke 570 745 230
Max. cylinder length 1740 2145 705
Min. cylinder length 1170 1400 475
Key size for piston safety nut 55 50 36
WB93R-5E0 10-89
STRUCTURE AND FUNCTION BACKHOE CYLINDERS
BACKHOE CYLINDERS
BOOM CYLINDER
11 8
7 6
3 5 9
2 4
1
707-02-0Y941
10
1. Bottom bushing 6. Gasket
2. Stem 7. Guide ring
3. Head 8. Cushion plunger
4. Cylinder 9. Bottom bushing
5. Piston 10. Dowel
ARM
7 8
6
3 5
2 4 10
1
707-00-0Y871
10-90 WB93R-5E0
STRUCTURE AND FUNCTION BACKHOE CYLINDERS
BUCKET CYLINDER
8
7 6
5
3 2 4 9
1
707-00-0y901
OUTRIGGER CYLINDER
2 1 3 6 4 5 7
707-00-0Y830
WB93R-5E0 10-91
STRUCTURE AND FUNCTION BACKHOE CYLINDERS
12
707-02-07732
9 10
1. Stem 5. Gasket
2. Head 6. Guide ring
3. Cylinder
4. Piston
10-92 WB93R-5E0
STRUCTURE AND FUNCTION BACKHOE CYLINDERS
CHARACTERISTICS
Cylinder Boom Arm Bucket
Piston rod diameter 60 60 55
Internal cylinder diameter 120 115 90
Piston stroke 850 700 765
Max. cylinder length 2160 1765 1850
Min. cylinder length 1310 1065 1085
Key size for piston safety nut – 65 55
CHARACTERISTICS
Cylinder Outriggers Boom swing Jig arm
Piston rod diameter 50 50 40
Internal cylinder diameter 100 100 70
Piston stroke 515 230 1140
Max. cylinder length 1365 319.5 2590
Min. cylinder length 850 89.5 1450
Key size for piston safety nut 60 -- 46
WB93R-5E0 10-93
STRUCTURE AND FUNCTION AIR-CONDITIONING UNIT
AIR-CONDITIONING UNIT
2
Low steam pressure
1a
3 1
7
5
8
CAB INTERIOR
RKA51830
10-94 WB93R-5E0
STRUCTURE AND FUNCTION OPERATION OF THE AIR CONDITIONING UNIT
WB93R-5E0 10-95
STRUCTURE AND FUNCTION OPERATION OF THE AIR CONDITIONING UNIT
10-96 WB93R-5E0
20 TESTING AND ADJUSTMENTS
WB93R-5E0 20-1
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA
Engine oil
Entire speed range °C – –
temperature
Pumping element
mm 1.00±0.05 1.00±0.05
pre-lift
20-2 WB93R-5E0
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA
l a b c l a b c
Backhoe:
45 6.0 6.0 – – – – –
boom swing, jig arm
Control valve
WB93R-5E0 20-3
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA
• Engine stopped
Accelerator pedal • Knob lever: at the center Min. o Max. mm 80 65–95
and at 90° from the lever
• Value reading at the end
of working stroke
• Attachments on the
ground
Righto Left 3.5 3.1–3.9
Steering wheel • Instrument: metre w/ rev.
millimetre divisions Lefto Right 3.5 3.1–3.9
20-4 WB93R-5E0
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA
WB93R-5E0 20-5
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA
Shovel (Dump) – –
4 in 1 bucket (open-close) – –
Boom (lowering) – –
Bucket (curled) – –
Bucket (Dump) – –
20-6 WB93R-5E0
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA
15 min.
(Cylinder out) [ ] This value are for machines equipped with cold
[39] [56]
climate device
Complete working
equipment Measuring posture: see Fig. E 220 350
( B u c k e t t e e t h t i p • In this position check the extension of each cylinder [310] [543]
lower) and the leakage with normal load on the bucket.
• On level ground.
• With standard arm
Boom cylinders Bucket (L= 600mm, Weight =170 kg): load in bucket: 13 20
400 kg
(Cylinder out) • With jig arm
[18] [36]
Backhoe
WB93R-5E0 20-7
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA
2.0
Boom Max. 8.0
Shovel
(each cylinder)
1.6
Shovel Max. 6.0
(each cylinder)
20-8 WB93R-5E0
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA
Lifting
Arm shovel 3.9 3.5–4.3
Measuring posture: see Fig. H
Cylinders fully out • Engine speed: max.
• Oil temperature: 45–55 °C
Lowering
• Shovel speed button: applied
Shovel at the ground 2.9 2.6–3.2
Shovel
Curl
Shovel 2.1 1.9–2.3
Measuring posture: see Fig. J
Cylinders fully out • Engine speed: max.
• Oil temperature: 45–55 °C
• Shovel speed button: applied Dump
Cylinders fully in 2.6 2.3–2.9
Work equipment speed
Lifting q
• Power mode ON
Teeth bucket on level [ ] with safety valve 2.3 2.1–2.6
ground [3.3] [3.0–3.6]
Opening
3.3 3.0–3.6
Arm Measuring posture: see Fig. L [3.4] [3.1–3.7]
• Engine speed: 1700 +0 50 rpm
Backhoe
• Power mode ON
4.1 3.7–4.5
Cylinders fully out [ ] with safety valve
[4.2] [3.8–4.6]
Dump
WB93R-5E0 20-9
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA
Right q
2.7 2.4–3.0
Boom swing
Measuring posture: see Fig. N
Backhoe
Left q
2.2 2.0–2.4
Work equipment speed
Up
5.5 5.0–6.1
4.6 4.1–5.1
q Times are referred to the cylinder stroke whitout the brake phase.
NOTE.The engine speed (1700 +0 50 rpm) has to be checked with the procedure described at paragraph «MEASURING
ENGINE SPEED» in this section.
20-10 WB93R-5E0
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA
WB93R-5E0 20-11
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA
Fig. A Fig. B
a b
RKA52860
Fig. C Fig. D
80mm
~10°
RKZ10680
RKZ10860
20-12 WB93R-5E0
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA
Fig. E Fig. F
1400 mm
RKA52870
RKA52880
Fig. G Fig. H
RKA52890
RKZ10720
WB93R-5E0 20-13
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA
Fig. J Fig. K
RKA52900
RKZ10730
Fig. L Fig. M
RKA52920
RKA52910
20-14 WB93R-5E0
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA
Fig. N Fig. P
RKA52871
RKZ10790
Fig. Q Fig. R
45 °
RKA52930
RKA52940
WB93R-5E0 20-15
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA
Fig. S Fig. T
RKA52950
RKA52960
20-16 WB93R-5E0
TESTING AND ADJUSTMENTS SPECIAL TOOLS
SPECIAL TOOLS
Commercially
1 Pressure gauge 2 Full scale 60 bar
available
Commercially
2 Pressure gauge 1 Full scale 250 bar
available
Commercially
3 Pressure gauge 1 Full scale 400 bar
E available
5 Servocontrol kit
Differential digital 1 0-1000 bar
6 pressure gauge
ATR800200
1 Flow-meter 1 Delivery 0–300 l/min.
F
2 Pipe fitting kit 1 –
Commercially
1 Maintenance station 1 For coolant R134a
available
Commercially
3 Leak detector 1 For coolant R134a
available
WB93R-5E0 20-17
TESTING AND ADJUSTMENTS VALVE CLEARANCE ADJUSTING
1
2
RKZC3150
20-18 WB93R-5E0
TESTING AND ADJUSTMENTS ENGINE SPEED TESTS
1 -Start the engine and heat the hydraulic oil by 1 -With the transmission in neutral, idle the engine.
performing all normal working motions, including 2 -Dump shovel and force the movement; let the engine
travel. stabilize and then read the engine speed.
a Check hydraulic oil temperature with a probe a Normal speed: 750 rpm
plunged in the reservoir or with a probe applied to Minimum speed: 750 rpm
the reservoir wall.
Temperature should be at 50±5°C. 2. With converter stalled
1 -Increase speed to high idling and brake with the
2 -Place the machine on solid level ground with the
working brakes.
transmission in NEUTRAL.
2 -Hold the brakes while simultaneously engaging 3rd
3 -Stop the engine and apply a reading notch “B” to the gear; let the engine stabilize, and read the rpm value.
engine pulley (1) for the stroboscopic rev counter.
a Minimum speed: 2070 rpm
Maximum speed: 2070 rpm
High idling speed without load (accelerator pedal at k Hold the machine stalled as little as necessary, in
the travel end). any case for not more than 30 sec., and carry out the
• Maximum speed: 2430±50 rpm tests at least 15 sec one from the other.
a If low and high idling speed with engine without load • ANALYSIS
are not within permissible value, before going on with 1 -If readings are not within the required interval, check
other operations, check accelerator pedal stoppers the engine according to the instructions provided in
and wiring sheathings. (See "ADJUSTING manual code WEBMNEF001.
ACCELERATOR PEDAL TRAVEL AND
2 -If the engine has no conditions, adjust the pump's
ACCELERATOR LEVER").
power absorption (PC valve).
WB93R-5E0 20-19
TESTING AND ADJUSTMENTS TENSIONING THE AIR-CONDITIONING COMPRESSOR BELT
7
1
3 2
1
4
RKTA1204 RKTA1221
4
10 kg
5
6
RKT01261
3 2
RKTA1205
20-20 WB93R-5E0
TESTING AND ADJUSTMENTS BLEEDING AIR FROM CIRCUITS - ELIMINATING RESIDUAL
1 -Start the engine and run the engine at high speed for
about 5 minutes to heat the oil.
3 -Stop the engine, check and top up the oil in the tank.
3- Push brake pedal to bottom and, while keeping it
4 - Bring again the engine at high idling speed and pushed, loosen the bleeding screw (2) of the braking
repeat operation of point 2; return the engine at low unit that is being bled until the pedal reaches the end
idling speed and make a complete travel of piston of its stroke.
until the hydraulic pump reaches its maximum
4 -Keeping pedal at the end stroke, tighten bleeding
pressure.
screw (2).
5 - Repeat steps (from Step 2) for all cylinders,
5 -Release brake pedal, wait for few seconds and
frequently checking the oil level in the tank.
repeat above operations two or three times until from
• Air bleeding from braking circuit bleeding screw, oil flows out without air bubbles.
a Above operation is to be carried out every time 6 -Repeat the same steps for the opposite braking unit.
maintenance is made on braking circuit to remove or a Check frequently the oil level in the tank and
replace a component, or when air entered into the carry out filling every time level approaches to
circuit. minimum.
a Machine must be stopped with attachments on level a After air bleeding apply on screws (2) safety
ground. plugs (4).
1 -Make sure that oil in brake system tank (1) is at
maximum level.
4
2
1
RKZC3190
RKZC3170
WB93R-5E0 20-21
TESTING AND ADJUSTMENTS BLEEDING AIR FROM CIRCUITS - ELIMINATING RESIDUAL
20-22 WB93R-5E0
TESTING AND ADJUSTMENTS ADJUSTING ACCELERATOR PEDAL TRAVEL AND ACCELERATOR
2
RKZC3212
1
• Accelerator lever travel adjusting
1 -Remove the front mat.
RKZC3200
2 -Unloose nut (3) of some turns and screw nut (4) untill 2
the play of the cable is zero, pushing the accelerator
lever (5) against the low idle adjusting screw.
1
3 -Lock nut (3) against support (6).
RKZC3200
RKZC3230
WB93R-5E0 20-23
TESTING AND ADJUSTMENTS ADJUSTING ACCELERATOR PEDAL TRAVEL AND ACCELERATOR
RKZC9590
20-24 WB93R-5E0
TESTING AND ADJUSTMENTS CHECKING AND ADJUSTING THE BRAKE PEDAL STROKE
WB93R-5E0 20-25
TESTING AND ADJUSTMENTS BRAKING SYSTEM CHECKS
RKZC6051
1 4
A
E2 5
8 RKZC6081
RKZC6070
20-26 WB93R-5E0
TESTING AND ADJUSTMENTS BRAKING SYSTEM CHECKS
4 -Remove the bracket (6) and the clamp (7). a Check to ensure that the pressure tap (9) is
installed between the braking group and the cut
out valve (10).
50 200
0 250
RKZC9600 9
E2
5 -Disconnect the delivery hoses (8) from the pump that
is being tested. Connect a pressure gauge E2 (250
bar) to the pump during the inspection.
RKZ11401
a If the position of the pedal needs to be changed in k When checks and repair (if any) are complete,
order to hold the pressure, then the loss of bleed the air from the braking groups (See
pressure is to be blamed on leaks inside the "BLEEDING AIR FROM CIRCUITS -
pump, and in this case the pump needs to be ELIMINATING RESIDUAL PRESSURE").
changed. To confirm whether this is the case,
check the oil. If a leak condition exists, the oil will
be stirred.
WB93R-5E0 20-27
TESTING AND ADJUSTMENTS PARKING BRAKE ADJUSTMENT
RKZC6130
RKZC6120
20-28 WB93R-5E0
TESTING AND ADJUSTMENTS CHECKING AND SETTING PRESSURE IN THE ATTACHMENTS
STEERING UNIT
SAFETY VALVE
Komatsu Ltd. LS
TRANSMISSION
HYDRAULIC PUMP
DIESEL
CONTROL VALVE
RKZ10890
NOTE
Shown in this section is the servocontrolled
(optional) version of the control valve.
Functions are the same as on the standard version
with mechanical control.
• Introduction
1 -The machine is equipped with a single control valve
with mechanically and/or hydraulically controlled
spools. The control valve is protected against
overpressure by a single upper valve (or main valve,
referred to as "LS safety valve") with adjustable
pressure setting.
WB93R-5E0 20-29
TESTING AND ADJUSTMENTS CHECKING AND SETTING PRESSURE IN THE ATTACHMENTS
RKA54600
20-30 WB93R-5E0
TESTING AND ADJUSTMENTS CHECKING THE SETTING OF MAIN RELIEF AND SECONDARY
P1C
RKZC3270
WB93R-5E0 20-31
TESTING AND ADJUSTMENTS CHECKING THE SETTING OF MAIN RELIEF AND SECONDARY
3 -Check pressure for each movement, with the control 4 -Connect a pressure gauge E3 (600 bar) to the
lever at the end of its travel and at stabilized adapter.
pressure.
Set
Cylinder and movement
(bar)
Hammer 180–210
1
Right 225–250
Boom swing
Left 225–250
RKZC3280
Shovel Dump 235–260
5 -Start the engine, connect a weight of approx. 1500 kg
• Checking secondary valve setting to the bucket, and fully lower the outriggers.
(for boom raise movement)
6 -Slowly extend the arm and boom and take the
a Test conditions: pressure when the boom lowers.
• Engine: at operating temperature.
a Normal pressure: 320-360 bar
• Hydraulic oil: 45-55 °C
• Working brakes applied
RKA52970
RKA52980
20-32 WB93R-5E0
TESTING AND ADJUSTMENTS CHECKING THE SETTING OF MAIN RELIEF AND SECONDARY
P1C
RKZC3270
RKZC3290
WB93R-5E0 20-33
TESTING AND ADJUSTMENTS SETTING THE MAIN RELIEF VALVES AND THE REDUCING VALVES
D C
RKZC3291
3 Nut: 29.4-39.2 Nm
2 -Adjust the pressure using the nut (2).
• To INCREASE pressure turn in CLOCKWISE
a When adjustment is complete, check the setting direction.
of the main relief valve using the procedures • To DECREASE pressure turn in
used for measurements. COUNTERCLOCKWISE direction.
2 1
2
RKZ10930
RKZ10960
20-34 WB93R-5E0
TESTING AND ADJUSTMENTS SETTING THE MAIN RELIEF VALVES AND THE REDUCING VALVES
RKZC3300
1 2
RKZ10940
WB93R-5E0 20-35
TESTING AND ADJUSTMENTS CHECKING AND ADJUSTING THE LS DIFFERENTIAL PRESSURE -
RKZC3310
3 Nut: 27.4-34.3 Nm
1
2
P1C
E4
E4
RKZC3320
RKZ10970
20-36 WB93R-5E0
TESTING AND ADJUSTMENTS CHECKING AND ADJUSTING SERVOCONTROLS SUPPLY
a Test conditions:
• Engine: at operating temperature. 2
• Hydraulic oil temperature: 45–55 °C 3
1
E1
RKZ10980
RKZC3340
2 -Start the engine and run the engine at low idling with
all levers in neutral position.
3 -Check the pressure.
RKZC3350
WB93R-5E0 20-37
TESTING AND ADJUSTMENTS ADJUSTING THE PC VALVE
1 -Loosen the nut (1) and turn the adjustment screw (2).
2
RKZ10990
MAX 180
0°
MAX 180
RKZ11000
3 Nut: 27.4-34.4 Nm
20-38 WB93R-5E0
TESTING AND ADJUSTMENTS TESTING AND SETTING STEERING CONTROL SYSTEM PRESSURE
3 Plug: 50±10 Nm
pressure tap P1C on the backhoe control valve.
E3
P1C
RKZC3270
• Setting
a If pressure is not within permissible value, carry out
setting acting on upper valve (1) of the steering unit
(2).
3
5
2
RKPB1360
WB93R-5E0 20-39
TESTING AND ADJUSTMENTS CHECKING FOR LEAKS IN THE STEERING CYLINDERS
1
2
RKZC3360
20-40 WB93R-5E0
TESTING AND ADJUSTMENTS TESTING PRESSURES IN THE POWER TRAIN GROUP
P19
P18
RKA52990
3 -With the engine at MIN, check the pressure on the 7 -Remove the pressure adapter and replace the plug
pressure gauge E6. (P19).
WB93R-5E0 20-41
TESTING AND ADJUSTMENTS TESTING PRESSURES IN THE POWER TRAIN GROUP
20-42 WB93R-5E0
TESTING AND ADJUSTMENTS TESTING THE CORRECT FUNCTIONING OF THE POWER
RKZC3251
WB93R-5E0 20-43
TESTING AND ADJUSTMENTS JIG ARM CLEARANCE ADJUSTMENT
2
1
RKZ02391
A
RKZA8010
• Guide adjustment
1 -Connect the 2nd arm (1) to some hoisting tackle;
introduce the 2nd arm into the fixed arm (2) and push
it down to the end of back travel. 4 4
RKZD0030
RKZA8001
RKZD0040
20-44 WB93R-5E0
TESTING AND ADJUSTMENTS JIG ARM CLEARANCE ADJUSTMENT
8 -Lock the dowels (4) with the nuts (5) while holding
them in their angular positions.
3 Nuts: 200 Nm
RKZD0050
4 4
RKZD0030
3 Dowels: 12 Nm
RKZD0060
WB93R-5E0 20-45
TESTING AND ADJUSTMENTS ANALYSIS OF CAUSES HYDRAULIC DRIFT
FRONT EQUIPMENT
• Testing of front bucket lifting
1 -Put the machine with bucket teeth on blocks A of
about 10 cm and in vertical position compared to
ground.
RKZC3450
RKZC3380
1500 kg
20-46 WB93R-5E0
TESTING AND ADJUSTMENTS ANALYSIS OF CAUSES HYDRAULIC DRIFT
1 RKA53000
2
• Boom testing
RKZC3390
4 -Start the engine and raise the bucket up to the 1 -Set the machine with arm in vertical position and with
alignment of the bucket hinge and shovel arm hinge. bucket on level ground leaned on the side.
5 -Stop the engine and check the position of the bucket 2 -Stop the engine and release residual hydraulic
teeth for 5 minutes. pressures.
• If bucket has no swing movement, drift is due to
control valve. 3 -Disconnect hoses (1) and (2) that feed cylinder (3).
3
4
RKZ02630
2
To test the individual cylinders, proceed as follows:
6 -Lower the bucket to the ground.
1
7 -Remove from one of the cylinders the plug fitted on RKZC3400
8 -Start the engine and raise the bucket as indicated in 7 -Start the engine and extend completely the arm.
phase 4. 8 -Stop the engine and check the boom position for 5
9 -Stop the engine and check the position of the bucket minutes.
teeth for 5 minutes. • If boom has a lowering movement, drift is due to
• If the bucket teeth turn, the drift is due to the cylinder gaskets.
gasket seals of the plugged cylinder. • If boom has no lowering movement, drift is due to
control valve.
10 -Repeat operation from stage 6 to stage 9 to check the
other cylinder.
WB93R-5E0 20-47
TESTING AND ADJUSTMENTS ANALYSIS OF CAUSES HYDRAULIC DRIFT
RKA53010
• Arm testing
1 -Set the machine with arm fully extended and with
bucket teeth on ground.
RKA53030
RKA53020
450 kg
RKZC3410
20-48 WB93R-5E0
TESTING AND ADJUSTMENTS ANALYSIS OF CAUSES HYDRAULIC DRIFT
RKZC3420
RKA53050
WB93R-5E0 20-49
TESTING AND ADJUSTMENTS ANALYSIS OF CAUSES HYDRAULIC DRIFT
RKA53620
A
RKA53600
5 -Remove the tube (1) and (2) from the cylinders (3)
and plug them to prevent entry of impurities..
2
1
RKA53610
20-50 WB93R-5E0
TESTING AND ADJUSTMENTS TESTING THE AIR-CONDITIONING UNIT
1 -Connect the maintenance station to the high 25 1.0 2.5 7.5 10.5
pressure valve (H.P.) and the low pressure valve 30 1.1 2.4 9.5 13.0
(L.P.)
35 1.3 2.4 12.0 15.5
2 -Start the engine and bring it up to a speed of 1500 40 1.5 1.8 18.0 18.8
rpm.
45 1.8 1.9 21.5 22.0
3 -Switch on the A/C unit using the switch in the cab.
6 -Close the doors and windows and let the A/C unit
operate in these conditions for 5 - 10 minutes.
Ambient
20 25 30 35
temperature (°C)
Outgoing
air temperature 6-8 8-10 8-12 9-14
(°C)
WB93R-5E0 20-51
TESTING AND ADJUSTMENTS TESTING THE AIR-CONDITIONING UNIT
20-52 WB93R-5E0
TESTING AND ADJUSTMENTS EMPTYING THE AIR-CONDITIONING UNIT
RKZC3032
WB93R-5E0 20-53
TESTING AND ADJUSTMENTS TROUBLESHOOTING
TROUBLESHOOTING
FRONT AXLE TROUBLESHOOTING
Wheel vibration; front tyre resistance; halfshaft breakage
CAUSES REMEDY
Incorrect installation Correct installation
Replace the differential in case it does not survive any one of the
Defective axle
test phases
Remove excessive weight and redistribute load, following
Bent halfshaft
instructions related to the vehicle
Replace the tyre or adjust pressure to have same radius on both
Different rotation radius of the tyres
tyre
Remove excessive weight and redistribute load, following
Bent halfshaft
instructions related to the vehicle
Excess of noise
CAUSES REMEDY
Incorrect installation Correct installation
Replace the differential in case it does not survive any one of the
Defective axle
test phases
Remove excessive weight and redistribute load, following
Bent halfshaft
instructions related to the vehicle
Replace the tyre or adjust pressure to have same radius on both
Different rotation radius of the tyres
tyre
Remove excessive weight and redistribute load, following
Overloading/ incorrect weight distribution
instructions related to the vehicle
Incorrect wheel adjustment Verify group integrity and wheel side bearings.
20-54 WB93R-5E0
TESTING AND ADJUSTMENTS TROUBLESHOOTING
Contamination in the axle box or Look for foreign particles. Check assembly of the
incorrect assemblyof parts various parts of the axle.
Uneven wear of tyre
CAUSES REMEDY
Incorrect installation Correct installation
Replace the differential in case it does not survive any one of the
Defective axle
test phases
Remove excessive weight and redistribute load, following
Bent halfshaft
instructions related to the vehicle
Replace the tyre or adjust pressure to have same radius on both
Different rotation radius of the tyres
tyre
Remove excessive weight and redistribute load, following
Overloading/ incorrect weight distribution
instructions related to the vehicle
Blocked halfshaft:
Blocked halfshaft:
• Abnormal functioning of the differential or
• Verify assembly and all components
breakage/blockage of command device.
Friction noise
CAUSES REMEDY
Incorrect installation Correct installation
Replace the differential in case it does not survive any one of the
Defective axle
test phases
Remove excessive weight and redistribute load, following
Overloading/ incorrect weight distribution
instructions related to the vehicle
Check the condition of ring gear, pinion gear, bearings etc.
Spoiled or worn out axle parts
Replace when ever necessary.
Contamination in the axle box or Look for foreign particles. Check assembly of the
incorrect assemblyof parts various parts of the axle.
Incorrect adjustment of bevel gearset:
Parts of the transmission worn out. Replace or adjust as required.
(transmission gears, U joints, etc.)
WB93R-5E0 20-55
TESTING AND ADJUSTMENTS TROUBLESHOOTING
Intermittent noise
CAUSES REMEDY
Ring gear damaged Replace bevel gear set
Differential box bolts loosened Tighten to torque
Constant noise
CAUSES REMEDY
Ring gear teeth or pinion damaged Replace bevel gear set
Worn out bearings Replace
Pinion spline worn out Replace
Bent halfshaft Replace
20-56 WB93R-5E0
TESTING AND ADJUSTMENTS TROUBLESHOOTING
WB93R-5E0 20-57
TESTING AND ADJUSTMENTS TROUBLESHOOTING
20-58 WB93R-5E0
TESTING AND ADJUSTMENTS TROUBLESHOOTING
Excess of noise
CAUSES REMEDY
Incorrect installation Correct installation
Replace the differential in case it does not survive any one of the
Defective axle
test phases
Remove excessive weight and redistribute load, following
Bent halfshaft
instructions related to the vehicle
Replace the tyre or adjust pressure to have same radius on both
Different rotation radius of the tyres
tyre
Remove excessive weight and redistribute load, following
Overloading/ incorrect weight distribution
instructions related to the vehicle
Incorrect wheel adjustment Verify group integrity and wheel side bearings.
WB93R-5E0 20-59
TESTING AND ADJUSTMENTS TROUBLESHOOTING
Contamination in the axle box or Look for foreign particles. Check assembly of the
incorrect assemblyof parts various parts of the axle.
Uneven wear of tyre
CAUSES REMEDY
Incorrect installation Correct installation
Replace the differential in case it does not survive any one of the
Defective axle
test phases
Remove excessive weight and redistribute load, following
Bent halfshaft
instructions related to the vehicle
Replace the tyre or adjust pressure to have same radius on both
Different rotation radius of the tyres
tyre
Remove excessive weight and redistribute load, following
Overloading/ incorrect weight distribution
instructions related to the vehicle
Blocked halfshaft:
• Vehicles with wide steering angle may proceed • Reduce the steering angle to minimum and decelerate
with kicks, have steering difficulty or cause when the vehicle begins to kick.
pneumatic wearing at sharp turns.
Incorrect wheel adjustment Verify group integrity and wheel side bearings.
Friction noise
CAUSES REMEDY
Incorrect installation Correct installation
Replace the differential in case it does not survive any one of the
Defective axle
test phases
Remove excessive weight and redistribute load, following
Overloading/ incorrect weight distribution
instructions related to the vehicle
Check the condition of ring gear, pinion gear, bearings etc.
Spoiled or worn out axle parts
Replace when ever necessary.
Contamination in the axle box or Look for foreign particles. Check assembly of the
incorrect assemblyof parts various parts of the axle.
Incorrect adjustment of bevel gearset:
Parts of the transmission worn out. Replace or adjust as required.
(transmission gears, U joints, etc.)
20-60 WB93R-5E0
TESTING AND ADJUSTMENTS TROUBLESHOOTING
Intermittent noise
CAUSES REMEDY
Ring gear damaged Replace bevel gear set
Differential box bolts loosened Tighten to torque
Constant noise
CAUSES REMEDY
Ring gear teeth or pinion damaged Replace bevel gear set
Worn out bearings Replace
Pinion spline worn out Replace
Bent halfshaft Replace
WB93R-5E0 20-61
TESTING AND ADJUSTMENTS TROUBLESHOOTING
20-62 WB93R-5E0
TESTING AND ADJUSTMENTS TROUBLESHOOTING
WB93R-5E0 20-63
TESTING AND ADJUSTMENTS TROUBLESHOOTING
TRANSMISSION TROUBLESHOOTING
Vehicle does not move
CAUSES REMEDY
Faulty supply to solenoid valves Check/Replace
Damaged wiring connections between
Repair/Replace
transmission and vehicle
Oxidised contacts in
Clean
electrical wiring
Break in electric cable Replace
Damaged solenoids Replace
Damaged sensors Replace
Short circuits or false contacts Check/replace fuses
Damaged synchroniser Replace
Incorrect oil level Top up
Check for leaks Repair/Top up
Blocked intake filter Clean
Damaged oil pump Replace
Damaged oil pump relief valve Replace oil pump
Blocked/damaged transmission filter Replace
Damaged/jammed control valve Replace
Damaged converter Replace
Oil temperature below 0ûC Wait for oil to reach working temperature (stall test)
Damaged rotary seals Replace
Reverser locking Repair
Worn clutch unit Replace/Repair clutch unit
No drive transmission
Check/Repair/Replace
(broken gears, shafts, bearings, etc.)
20-64 WB93R-5E0
TESTING AND ADJUSTMENTS TROUBLESHOOTING
Noise
CAUSES REMEDY
Damaged converter Replace
Damaged oil pump Replace
Aeration/Cavitation Check oil level / Check oil specifications
Seizing (broken gears, shafts, bearings, etc.) Check/Repair/Replace
Worn clutch plates Replace
Worn synchronizer clutch Replace
Worn 4WD clutch Replace
Irregular actuation
CAUSES REMEDY
Damaged control valve Replace
Electrical system fault Repair/Replace
Worn clutch plates Replace
Damaged converter Replace
Low oil temperature (high oil viscosity) Wait for oil to reach working temperature (stall test)
Overheating See "overheating"
Damaged hydraulic system Repair/Replace
Gear remains engaged
CAUSES REMEDY
Damaged/jammed shuttleshaft lever Repair/Replace
Electrical system fault Repair/Replace
Damaged control valve Replace
Damaged hydraulic system Repair/Replace
Damaged clutch unit Repair/Replace
Damaged gear lever rod Replace
Damaged synchroniser Replace
No 4WD power transmission
WB93R-5E0 20-65
TESTING AND ADJUSTMENTS TROUBLESHOOTING
CAUSES REMEDY
Damaged 4WD clutch Replace
Hydraulic system fault Repair/Replace
Damaged control valve Replace
Faulty brake sensor Check/Replace
Electrical system fault Repair/Replace
20-66 WB93R-5E0
30 REMOVAL AND INSTALLATION
WB93R-5E0 30-1
REMOVAL AND INSTALLATION HOW TO READ THE MANUAL
(2) Information needed for installation is marked with the symbol [*1]; The same symbol is repeated at the end of
each removal procedure for the same item, to indicate to which installation item it refers.
(Example)
REMOVAL OF THE GROUP ● ● ● : ........................................ Title of operation
2. To the precautions to be taken during the removal or installation of the groups, must be added the specific
"PRECAUTIONS TO BE TAKEN WHILE WORKING".
Always make sure that these precautions are taken.
4. List of the tightening torques and weights, and the quantities oil, liquids or grease needed to fill tanks
and containers
(1) In the operating procedures, you will find the symbols 2,3 , 4, 5, 6; in the following
order, these represent the values of «TIGHTENING TORQUES», «WEIGHT OF PARTS OR GROUPS»,
«QUANTITIES OF OIL OR LIQUIDS TO BE INTRODUCED», «SCREW LOCKING MATERIAL, SEALANTS
AND LUBRICATION», «LUBRICATING GREASE».
NOTE
If no symbol is indicated, the values to be used are those given in the introductory sections of this manual.
30-2 WB93R-5E0
REMOVAL AND INSTALLATION PRECAUTIONS TO BE TAKEN WHILE WORKING
WB93R-5E0 30-3
REMOVAL AND INSTALLATION SPECIAL TOOLS
SPECIAL TOOLS
Nature of work Symbol Code Name Q.ty
1 CA715655 Plunger 1
2 CA119097 Plunger 1
3 CA715360 Plunger 1
4 CA715035 Plunger 1
5 CA715026 Plunger 1
6 CA715077 Plunger 1
7 CA715034 Plunger 1
8 CA715163 Plunger 1
9 CA119043 Plunger 1
10 CA715779 Plunger 1
Disassembly - assembly
D 11 CA715164 Plunger 1
front axle
12 CA119030 Ring nut spanner wrench 1
13 CA119230 Plunger 1
16 CA119225 Plunger 1
20 CA715179 Plunger 1
21 CA715701 Plunger 1
30-4 WB93R-5E0
REMOVAL AND INSTALLATION SPECIAL TOOLS
1 CA715550 Plunger 1
Removal/installation tool
2 CA715902 1
self adjusting kit
3 CA715167 Plunger 1
4 CA715901 Bushing 1
5 CA715026 Plunger 1
6 CA715477 Plunger 1
Removal/installation tool
7 CA715900 1
differential ring nut
15 CA716135 Plunger 1
16 - Plunger 1
WB93R-5E0 30-5
REMOVAL AND INSTALLATION SPECIAL TOOLS
1 CA715409 Plunger 1
2 CA715004 Plunger 1
3 CA715623 Plunger 1
4 CA715354 Plunger 1
6 CA715497 Plunger 1
7 CA715356 Calibrator 1
8 CA715501 Plunger 1
Installation/assembly tool
9 CA715358 1
clutches
Disassembly - assembly
F 10 CA715499 Protection 1
transmission
11 CA715046 Plunger 1
13 CA715746 Plunger 1
14 CA715745 Calibrator 1
16 CA715149 Plunger 1
Removal/installation tool
17 CA715493 1
stop ring
18 CA715257 Protection 1
19 CA715263 Protection 1
30-6 WB93R-5E0
REMOVAL AND INSTALLATION SPECIAL TOOLS
790-502-1003 Equipment 1
1
790-101-1102 Pump 1
2 790-102-3802 Key 1
790-302-1310 Key 65 mm 1
790-302-1280 Key 55 mm 1
3
790-302-1270 Key 50 mm 1
790-302-1390 Key 46 mm 1
4 790-102-4300 Expander 1
796-720-1670
Calibrator for boom cylinder 1
07281-01279
796-720-1660
Calibrator for arm and swing cylinders 1
07281-01159
5
796-720-1650 Calibrator for bucket and shovel arm
1
07281-01029 cylinders
790-101-5021 . Handle 1
01010-50816 . Screw 1
790-102-4300 Key 1
8
790-102-4310 Pin 2
WB93R-5E0 30-7
REMOVAL AND INSTALLATION ENGINE HOOD
ENGINE HOOD
Removal 4 -Attach lifting equipment to engine hood (3); pull out
3
3
8
1
2
RKZC0770
Installation
1
RKZC0740 • To install, reverse removal procedure.
RKZC0780
RKZC0750
8
7
RKZC0760
30-8 WB93R-5E0
REMOVAL AND INSTALLATION FRONT GUARD
FRONT GUARD
Removal 4 -Connect the guard (6) to the lifting equipment and
resting on the ground. 5 -Take out the screws (1) and remove the protection
Stop the engine and remove the ignition key. (6).
6
1
RKZC9612
1 Installation
RKZC0741
3 Screw: 300 Nm
3 4
RKA53740
5 RKZC0791
WB93R-5E0 30-9
REMOVAL AND INSTALLATION RADIATOR GROUP - INTERCOOLER
RKZC0810
RKZC0771
2 8
7
9
RKZC9611
3 -Open the cock (3) and drain the coolant liquid. [*1]
(5).
30-10 WB93R-5E0
REMOVAL AND INSTALLATION RADIATOR GROUP - INTERCOOLER
7 -Loosen and remove the four screws and the fan 12 -Loosen and remove two nuts (20), washer (21) and
guard (10). vibration dampers (22) fixing the radiator group;
move the group to the front.
10
22
21
RKZC9640 20
RKZC0883
14
11 13
RKZC9682
12
14 -Remove conveyor (24).
RKZC9650
24
9 -Remove the clamp (15) and disconnect the manifold
(16) from radiator.
10 -Disconnect the hose (18) from the oil cooler (17).
19
RKZC9691
17
15
16
18
RKZC9660
WB93R-5E0 30-11
REMOVAL AND INSTALLATION RADIATOR GROUP - INTERCOOLER
a Mark the position of pipes (26) and (27) connect. 5 Coolant liquid: 14 l
a Plug pipes, hoses and holes immediately to [*2]
prevent contamination and leak of oils.
a Fill the tank with hydraulic oil up to maximum level.
5 Hydraulic oil: 40 l
27 28 29
[*3]
25 a Ensure that the level of transmission oil is at
maximum.
30
RKZ14550
RKZC9711
30-12 WB93R-5E0
REMOVAL AND INSTALLATION INTERCOOLER
INTERCOOLER
Removal 4 -Remove the screws, remove the condenser (3) and
3
1 RKZC9621
5 -Remove tha clamps (4) and (5); loosen the clamp (6)
and disconnect the manifold (7) from intercooler.
RKZC0771
4 6
2 5
RKZC9651
6 -Remove the surge tank (8) and the right support (9).
10
9
RKZC9720
WB93R-5E0 30-13
REMOVAL AND INSTALLATION INTERCOOLER
11
RKZC9681
12
13
12
RKZC9730
Installation
• To install, reverse removal procedure.
30-14 WB93R-5E0
REMOVAL AND INSTALLATION CONDENSER
CONDENSER
Removal Installation
k Fully raise the front working equipment and engage • To install, reverse removal procedure.
the safety stop.
1 -Refill the air-conditioning unit. (For details, see "20
Also place the backhoe in its secure position.
TESTING AND ADJUSTMENTS").
1 -Drain the air conditioning unit and the supports.
(For details see "20 TESTING AND
ADJUSTMENTS").
2
1
RKZC0861
3
5 5
6
4
RKA53750
WB93R-5E0 30-15
REMOVAL AND INSTALLATION EXHAUST PIPE
EXHAUST PIPE
Removal Installation
1 -Loosen the nuts (1) on the jumper pin (2) retaining the • To install, reverse removal procedure.
muffler pipe (3) to the exhaust pipe.
3
1
RKZC0920
RKZC1010
RKZC1020
30-16 WB93R-5E0
REMOVAL AND INSTALLATION MUFFLER
MUFFLER
Removal 4 -Remove the air filter cartridges (7).
hood.
1 -Loosen the nuts (1) on the jumper pin (2) retaining the
muffler pipe (3) to the exhaust pipe.
RKA53760
1
5 -Remove the tie rod (8).
3
1
RKZC0920
RKA53770
5
RKZC0930
RKZC0951
6 Installation
• To install, reverse removal procedure.
RKZC0940
WB93R-5E0 30-17
REMOVAL AND INSTALLATION AIR FILTER
AIR FILTER
Removal 5 -Remove the screw (8).
1 -Park the machine on hard, level ground, apply the 6 -Loosen and remove the screws (9) and remove the
parking brake, stop the engine and remove the filter (10) together with the filter holder and the tie rod.
ignition key.
9
RKA53771
2
1 Installation
RKZC9740 • To install, reverse removal procedure.
6 5
RKZC9750
RKA53760
30-18 WB93R-5E0
REMOVAL AND INSTALLATION ENGINE BELT
ENGINE BELT
Replacement 5 -Replace the belt according to the instructions
RKZC9631
4
3
RKZC9721
RKZC9760
WB93R-5E0 30-19
REMOVAL AND INSTALLATION TURBOCHARGER
TURBOCHARGER
Removal 5 -Remove the screw (8).
k Fully raise the front working equipment and engage 6 -Loosen and remove the screws (9) and remove the
the safety stop. filter (10) together with the filter holder and the tie rod.
Also place the backhoe in its secure position.
3
8
9
RKA53771
1
12
RKZC9770
4
13
RKZC9781
RKA53760
30-20 WB93R-5E0
REMOVAL AND INSTALLATION AIR-CONDITIONING UNIT COMPRESSOR
1
8
3
RKZC3000
RKZC9642
3 -Disconnect fluid delivery and return pipes (5), (6)
from compressor (4). [*1] 6 -Loosen the screw (9) retaining the tensioner (10).
a Collect the O-rings. 7 -Loosen the nut (11) and turn the screw (12) to loosen
the belt.
12 11
6
4
9 10
RKZC3010
RKTA1206
WB93R-5E0 30-21
REMOVAL AND INSTALLATION AIR-CONDITIONING UNIT COMPRESSOR
15
15
13
4
14
15
RKZC3030
Installation
• To install, reverse removal procedure.
[*1]
30-22 WB93R-5E0
REMOVAL AND INSTALLATION AIR-CONDITIONING UNIT COMPRESSOR BELT
8
7
1
RKZC3031
Installation
• To install, reverse removal procedure.
[*1]
3 Bracket lock nut: 117.6 Nm
RKZC9641
RKZC0983
6 5
3 4
RKTA1207
WB93R-5E0 30-23
REMOVAL AND INSTALLATION FAN AND HEATING GROUP
6 Coolant liquid: 14 l 6
a Drain the air conditioning unit.
(For details see "20 TESTING AND
ADJUSTMENTS"). 7
1 -Remove the floor-mat (1); disconnect the connector RKZC1050
2 10 8
3
1
RKA53780
2 -Take out the screws (4) and remove the control unit
protection (5).
9
RKZC1060
11
RKZC1040
RKZC1070
30-24 WB93R-5E0
REMOVAL AND INSTALLATION FAN AND HEATING GROUP
8 -Disconnect the connector (13) from the instrument 13 -Loosen nuts and remove knobs (21) from outrigger
board (12). PPC valves.
9 -Disconnect connectors (14) and (15) from the lighter. 14 -Remove PPC valve mounting plate (22).
13
21
22
14 15 12
RKZC1080 RKZC1110
10 -Extract screws (16) and remove the hand accelerator 15 -Extract screws (23) and remove contact carrier plate
handle (17). (24) for rear wiper.
17
23
24
16
RKZC1120
18
16 -Extract the lower screws (25) retaining the right hand
RKZC1090
case (10).
25
25
10
19 20 RKZC1130
RKZC1100
WB93R-5E0 30-25
REMOVAL AND INSTALLATION FAN AND HEATING GROUP
17 -Extract three screw covers (26) and screws retaining 20 -Move the rear of the right hand case (10) towards the
the right hand case (10) at the rear. middle of the cab, remove pin (30), and disconnect
hand accelerator cable (31).
31
RKZC1140
32
18 -Extract two screw covers (27) and screws; extract
the lower screw (28) and washer. RKZC1170
33
27
28
RKZC1150
19 -Extract the upper screw (29) retaining the right hand RKZC2990
29
10
RKZC1160
RKZC1180
30-26 WB93R-5E0
REMOVAL AND INSTALLATION FAN AND HEATING GROUP
35
36
34 41
RKZC1220
36
43 43
41
RKZC1230
RKZC1200
WB93R-5E0 30-27
REMOVAL AND INSTALLATION BATTERY
BATTERY
Removal 7 -Loosen wing nut (4) and remove tie rod (5) and
RKA53810
Installation
• To install, reverse removal procedure.
1 [*1]
RKA53790
k Connect the battery positive (+) cable first, and then
the battery negative (–) cable.
5 -Disengage battery negative (–) terminal (2) from
shield and disconnect from battery.
3
2
RKA53800
30-28 WB93R-5E0
REMOVAL AND INSTALLATION FUEL TANK
FUEL TANK
Removal 4 -Disconnect the connector (5) from the level gauge
resting on the ground. 5 -Mark and disconnect the fuel inlet and return hoses
Engage the parking brake, stop the engine and (7), (8).
remove the ignition key. a Plug all pipes/hoses to prevent contamination.
1 -Take the cap (2) off the filling inlet of the fuel tank (3)
and remove also the bottom plug in order to drain the 5 8
fuel.
6
3
1 2
RKZC1310
4 Fuel tank: 68 kg
RKZC1290
4 9
RKZC1320
Installation
RKZC1300
[*1]
3 Tank retaining screws: 120 Nm
1 -Refill the fuel tank.
WB93R-5E0 30-29
REMOVAL AND INSTALLATION STEERING WHEEL AND TRANSMISSION-REVERSE, DIRECTION
RKZC1350
6
RKZC1330
3 8
RKZC1360
12
RKZC1340 9
10
11
RKZC1370
30-30 WB93R-5E0
REMOVAL AND INSTALLATION STEERING WHEEL AND TRANSMISSION-REVERSE, DIRECTION
13
14
12
11
RKZC1380
Installation
• To install, reverse removal procedure.
[*1]
a Before attempting to tighten the screws, check the
antirotation stake (15) for proper engagement into
the steering column (16).
16
15
RKZC1390
WB93R-5E0 30-31
REMOVAL AND INSTALLATION WORKING BRAKE PUMP GROUP
8
1
10
2
RKA53781
9
4 -Loosen and remove the upper screws (4) retaining
the instrument panel holder (5).
RKZC1420
5
8
RKZC1400
RKZC1430
30-32 WB93R-5E0
REMOVAL AND INSTALLATION WORKING BRAKE PUMP GROUP
17
19
5
20
11 18 RKZC1460
RKZC1440
10 -Remove the plug and (12) and draw oil from the tank
(13).
14
12
13
16
15
RKZC1450
WB93R-5E0 30-33
REMOVAL AND INSTALLATION WORKING BRAKE PUMP GROUP
Installation
• To install, reverse removal procedure.
[*1]
[*2]
21
RKZ10751
[*3]
3 Union: 20 Nm
30-34 WB93R-5E0
REMOVAL AND INSTALLATION STEERING UNIT
STEERING UNIT
Removal 4 -Loosen and remove the upper screws (4) retaining
RKZC1400
3 6
1
RKA53780
CONTROL GROUP").
7 -Slide the instrument panel holder (5) up to remove it.
RKZC1381
RKZC1441
WB93R-5E0 30-35
REMOVAL AND INSTALLATION STEERING UNIT
[*1]
RKZC1480
10
10
RKZC1490
12
11
RKZC1500
30-36 WB93R-5E0
REMOVAL AND INSTALLATION CAB
CAB
Removal 6 -Disconnect pipes (8) from steering unit (7). [*2]
k Lower the working equipment completely until it a Mark the positions of the pipes to prevent
rests on the ground. exchanging positions when reconnecting.
Engage the parking brake and stop the engine. a Plug the pipes and pipe-fittings to prevent entry
k Turn the battery disconnect switch to OFF position,
of impurities.
and remove the key.
6 Coolant liquid: 14 l
a Drain the air conditioning unit.
(For details see "20 TESTING AND
ADJUSTMENTS"). [*1] 8
8
1 -Remove the exhaust pipe.
(For details see "FAN AND HEATING GROUP").
RKZC1493
3 -Remove the steering unit guard (3). 8 -Mark and disconnect the tubes (10). [*3]
a Plug the pipes and pipe-fittings to prevent entry
of impurities.
1
1
10
2
RKZC3041
9
4 -Disconnect the injection pump control fork (5) from
RKZC9800
the pitman arm (4).
RKZC9790
WB93R-5E0 30-37
REMOVAL AND INSTALLATION CAB
9 -Take out the screws (11) and remove the hood (12). 12 -Remove screws (16) and remove control pedal (17)
for hammer.
17
12
11
16
RKZC1041
RKZC1881
13 19
18
14
14
RKZC1891
RKZC3050
15 20
RKZC1902
RKZC1871
30-38 WB93R-5E0
REMOVAL AND INSTALLATION CAB
15 -Take out four screws and remove the metal sheet 17 -Disconnect servocontrol supply hoses (26) and (27)
(21) closing off the floor. from solenoid valve group (25).
21
25
RKZC1911
27
a Cap pipes, hoses and holes to prevent 18 -Disconnect parking brake cable (28) from brake
contamination. caliper. [*5]
28
24 24
RKZC2071
24
24 19 -Disconnect connector (29); remove screw (30), and
RKZC1991
disconnect gear lever (31).
29
31
30
RKZC3110
WB93R-5E0 30-39
REMOVAL AND INSTALLATION CAB
20 -Take out the screws (32) and remove the protection 23 -Take out the screws (39) and remove the protection
(33). (40).
33
39
32 32 40
39
RKZC1301 RKZC0742
21 -Remove nuts (34) as well as front and rear screws. 24 -Disconnect hose (38) from condenser (37). [*7]
[*6]
38
37
34
34
RKZC3070
RKZC3060
36
35
RKZC3011
30-40 WB93R-5E0
REMOVAL AND INSTALLATION CAB
26 -Lift the cab by about 30 cm and place some safety 29 -Loosen straps (46) and disconnect heating hoses.
blocks “A” under it.
a Mark the pipes to avoid exchanging them during
installation.
47
46
RKZC3100
A A
RKZC3080
44
42
43
45
RKZC3090
WB93R-5E0 30-41
REMOVAL AND INSTALLATION CAB
Installation
• To install, reverse removal procedure.
[*1]
[*2]
a Bleed the air from the steering circuit. (For details,
see "20 TESTING AND ADJUSTMENTS").
[*3]
[*4]
[*5]
a Adjust the stroke of the parking brake lever. (For
details, see "20 TESTING AND ADJUSTMENTS").
[*6]
3 Union (38): 16 Nm
30-42 WB93R-5E0
REMOVAL AND INSTALLATION HYDRAULIC OIL TANK
RKZC1382
RKZC1510
8
2 -Remove the front mat (2).
RKZC1401
4
2
RKA53782
11
10
RKZC1411
WB93R-5E0 30-43
REMOVAL AND INSTALLATION HYDRAULIC OIL TANK
7 -Loosen and remove the lower screws (12) retaining 11 -Remove the fill plug (14) and draw the brake fluid.
the front trim cover (11).
a Replace plug to prevent contamination.
8 -Fully lower the steering column; extract the knob
12 -Disconnect oil level and pressure switch connectors
(13).
(15) and (16).
11 15
14
13
12
16
16
RKZC1421
RKZC1451
RKZC1431
19
20
RKZC1442
18
RKZC1481
30-44 WB93R-5E0
REMOVAL AND INSTALLATION HYDRAULIC OIL TANK
16 -Loosen and remove five screws (21) and remove the 22 -Disconnect connector (32) from washer pump (31).
metal sheet (22) closing off the cab floor.
21
31
22
32
21
RKZC1550
RKZC1520
23 24
33
26 RKZC1560
25
24 -Loosen and remove screws (35) and washers.
Remove the complete bulkhead (36) and move it to
the rear of the machine.
27
RKZC9791
30
36
RKZC9810
28
29
RKZC1540
WB93R-5E0 30-45
REMOVAL AND INSTALLATION HYDRAULIC OIL TANK
25 -Take out the screws (37) and remove the conveyor 28 -Disconnect the pump suction pipe (43).
(38).
a Plug the pipe to prevent contamination.
43
37
38
RKZC1580
RKZC1610
45
44
40
39
RKZC1590
RKZC1620
42
47
41
46
RKZC1600
RKZC1630
30-46 WB93R-5E0
REMOVAL AND INSTALLATION HYDRAULIC OIL TANK
[*1]
49 a Bleed the air from the braking circuit. (For details, see
"20 TESTING AND ADJUSTMENTS").
[*2]
a Check and adjust the stroke of the hand accelerator.
48
1 -Refill the hydraulic oil.
3 -Bleed the air from the cylinders. (For details, see "20
33 -Remove two screws (50) and washers to release the
TESTING AND ADJUSTMENTS").
complete tank (39).
4 -Stop the engine, check the oil level in the tank and, if
necessary, top it up.
39
50
RKZC1650
39
RKZC1660
WB93R-5E0 30-47
REMOVAL AND INSTALLATION PISTON PUMP
PISTON PUMP
Removal 3 -Disconnect the delivery hose (5) and the LS and
4 5
RKZC1680
9
RKZC1511
RKZC1670
30-48 WB93R-5E0
REMOVAL AND INSTALLATION PISTON PUMP
3 Screw: 38±1 Nm
a Do not remove the screw at this stage. [*2]
[*2]
3 Pump screws: 220 Nm
11
4
1 -Refill the hydraulic oil.
3 -Stop the engine and check the oil level in the tank.
10
RKZC1690
8 -Place tool “B1” under the pump until the pump fully
supported.
B1
RKZC1700
9 -Take out the upper screw (11) and remove the pump
(4).
RKZC1710
WB93R-5E0 30-49
REMOVAL AND INSTALLATION TRANSMISSION
TRANSMISSION
Removal 3 -Disconnect the connector (3) of the transmission
7
1
RKZC1671
RKZC1711
RKZC1730
RKZC1521
30-50 WB93R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
6 -Disconnect solenoid valve connectors (7), (8), (9), 11 -Remove the screws (17), (18) retaining the wiring
4 th gear sensor connector (10), and gearbox oil harness brace (19).
temperature sensor connector (11) from gearbox (6).
7
9
8 18
17 19
11
10
RKZC1770
RKZC1740
12 20
C
13
RKZC1780
15
22
RKZC6322
16
RKZC1760
WB93R-5E0 30-51
REMOVAL AND INSTALLATION TRANSMISSION
14 -Remove the nuts (23) on the vibration dampers (24), 17 -Move the gearbox group (6) towards the rear of the
the screws (25) and remove the gearbox supports machine and extract the group.
4 Transmission: 232 kg
(26). [*6] [*7]
24 24
26 26
6
23 23
25 25
RKZC1800
RKZC1820
B2
RKZC1810
27
20
6
RKZC1830
30-52 WB93R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
Installation
• To install, reverse removal procedure.
[*1]
[*2]
[*3]
3 Screw: 120 Nm
[*4]
WB93R-5E0 30-53
REMOVAL AND INSTALLATION TRANSMISSION
7 6
16
11
6
15 14
14
8
13
9
10
12
5
4
1
RKZ10520
1 -Remove the drain plug (1) and drain the oil from the 2 -Remove the two cap screws (2) which fasten the
transmission. cover for the oil screen.
RKZB8210
RKZB8220
30-54 WB93R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
4 -Remove the oil screen (4) and the O-ring (5). 7 -Remove O-Ring (10) from cover (9).
10
9
4 5
RKZB8230 RKZB8260
5 -Remove the connector for the oil filter (7) and its 8 -Remove the spool (11).
elements: plugs (6) and cover (9).
6 9
10
6 RKZB8270
RKZB8240
8
9
12
7
RKZB8280
RKZB8250
WB93R-5E0 30-55
REMOVAL AND INSTALLATION TRANSMISSION
10 -Using a puller, remove the 4WD priority valve (13). 2 -Assemble valve (13).
Do not remove or adjust the valve (13).
If valve is already damaged, replace it with a new
one.
13
RKZB8290
13
3 -Mount the spring (12).
RKZB8290
16 12
14
15
14 RKZB8280
RKZB8300
1.2 Assembly
1 -Assemble the port plugs (14), the breather (15) and
the oil temperature sensor (16). 10
3 Sensor: 30 Nm
16
RKZB8270
14
15
14
RKZB8300
30-56 WB93R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
5 -Assemble O-Ring (10) on the cover (9). 8 -Assemble filter (4) and O-ring (5) after having
washed or replaced it.
10
RKZB8260 4 5
RKZB8230
3 Screw: 23 Nm
8
9
2
3
7
RKZB8250
6 9
7
1
6
RKZB8240 RKZB8210
WB93R-5E0 30-57
REMOVAL AND INSTALLATION TRANSMISSION
2. Oil pump
2.1 Disassembly
4
3
4
RKZ10530
1 -Remove the drain plug (1) and drain the oil from the 3 -Remove the pump (2) by means of two levers.
transmission.
RKZB8320
1
RKZB8310
30-58 WB93R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
F1
4
2
RKZB8330
RKZB8340 RKZB8370
5 -Remove O-ring (4). 3 -Check that oil passage holes between pump (2) and
half-case or the visual marks aligned.
a Inspect the condition of the sealing ring (4) and
replace if necessary.
RKZB8380
RKZB8350
WB93R-5E0 30-59
REMOVAL AND INSTALLATION TRANSMISSION
RKZB8390
RKZB8400
3 Screw: 23 Nm
RKZB8410
30-60 WB93R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
4
3
4
RKZ10540
1 -Remove the drain plug (1) and drain the oil from the 3.2 Assembly
transmission.
1 -Mount the clutch pipe (3) and the fittings (1) and (2).
3 Screw: 40 Nm
2 -Remove the fittings (1) and (2) and remove the pipe
(3)
1
2 3
1
2 3
4
4
RKZB8420
4
4
RKZB8420
WB93R-5E0 30-61
REMOVAL AND INSTALLATION TRANSMISSION
30 32
20 29
18 28
19 31
27 33
17
16 26 34
13 14 15
11 35
24 25 36
12
53 23 38 37
9 10 22
7 21 39
6 40
41
46
4 42
43
3 44
45
1 47 48
8
5 49
2 50
51 52
RKZ10550
1 -Remove the drain plug (1) and drain the oil from the 3 -Remove the gasket (49).
transmission.
13
RKZB8440
RKZB8430
30-62 WB93R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
4 -Take out the screws (48) and remove the plate (50). 8 -Push down the piston (4) then remove the snap ring
(3).
50
48 4
RKZB8450
RKZB8480
5
51
RKZB8460
1 6
2 7
53
RKZB8470
RKZB8510
WB93R-5E0 30-63
REMOVAL AND INSTALLATION TRANSMISSION
34
RKZB8520 RKZB8550
10
35
RKZB8530 RKZB8560
13 -Turn the control valve (53) and remove the screws 16 -Remove the plate (36).
(33).
33
36
53
RKZB8570
RKZB8540
30-64 WB93R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
17 -Remove the outward piston (38), the springs 20 -Remove the ball (26).
(39,40,41), the pin (42) and the inward piston (43).
26
38
43 RKZB8610
RKZB8580
42 41 40 39
25
RKZB8620
RKZB8590
37
32
RKZB8630
RKZB8600
WB93R-5E0 30-65
REMOVAL AND INSTALLATION TRANSMISSION
23 -Remove the solenoid (30) and remove the O-Ring 26 -Remove the cartridge (24) and spool (21).
(29).
30 24
29
21
RKZB8670
RKZB8640
23
28
22
21
27
RKZB8680
24 23 22 21
24
RKZB8690
RKZB8660
30-66 WB93R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
17
20
RKZB8700 RKZB8730
30 -Remove the O-ring (19), the solenoid valve (18) and 33 -Check the wear conditions of removed parts.
the O-ring (17).
19
18
17 3
RKZB8790
RKZB8710
4.2 Assembly
31 -Loosen the cartridge (18).
1 -Assemble the O-Rings (17).
18
17
RKZB8720
RKZB8730
WB93R-5E0 30-67
REMOVAL AND INSTALLATION TRANSMISSION
2 -Install the cartridge (18). 5 -Install the cartridge (24) and spring (23) to spool (21),
3 Cartridge: 25-30 Nm
and the washer (22).
24
23
18 22
21
RKZB8680
RKZB8720
19
24
18
21
17
RKZB8670
RKZB8710
3 Cartridge: 21.5-24.5 Nm
4 -Install the nut (20).
3 Nut: 5-7 Nm
24
20
RKZB8660
RKZB8700
30-68 WB93R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
8 -Assemble O-Ring (27) and the solenoid (28). 11 -Screw the nut (32).
3 Nut: 7-10 Nm
12 -Mount the spring (25).
28
27
25
RKZB8650
29 26
RKZB8640
32
37
RKZB8630
RKZB8600
WB93R-5E0 30-69
REMOVAL AND INSTALLATION TRANSMISSION
42 41 40 39
35
RKZB8590 RKZB8560
16 -Mount the outward piston (38), the springs 19 -Assemble the valve cover (34).
(39,40,41), the pin (42) and the inward piston (43).
38
34
43 RKZB8550
RKZB8580
3 Screw: 9.8-11.8 Nm
17 -Mount the plate (36).
33
36
53
RKZB8570
RKZB8540
30-70 WB93R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
26 -Assemble the piston (4), the spring (5) and the bush
(6).
10
RKZB8530
9 3
RKZB8520
7
1
RKZB8510
2
53
RKZB8470
WB93R-5E0 30-71
REMOVAL AND INSTALLATION TRANSMISSION
30 -Assemble the gasket (51) on the transmission (52). 33 -Assemble the control valve (53) and the screws (13).
3 Screw: 23Nm
13
51
RKZB8460
3 Screw: 23Nm
50
48
RKZB8450
49
RKZB8440
30-72 WB93R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
1
8
7
6
2
5
3
43
RKZ10560
1 -Remove the drain plug (1) and drain the oil from the 3 -Remove the nut (8).
transmission.
4 -Remove the solenoid (7).
2 -Remove the screws (1) and remove the solenoid
valve housing (2).
7
1
2
8
RKZB8760
RKZB8750
WB93R-5E0 30-73
REMOVAL AND INSTALLATION TRANSMISSION
RKZB8770 RKZB8790
7 -Remove the gasket (4). 2 -Assemble O-rings (5) into the cartridge (6) and
cartridge (6) in the housing.
3 Cartridge: 22 Nm
RKZB8780
3 Nut: 5-8 Nm
one.
RKZB8790 RKZB8760
30-74 WB93R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
RKZB8780
3 Screw: 23Nm
1
2
RKZB8750
WB93R-5E0 30-75
REMOVAL AND INSTALLATION TRANSMISSION
6. Transmission housing
6.1 Disassembly
15 20 43
14 42 22
23
16 21
41
25 26 27 30
10
28 33
11
39 13
C 24 12
36 19
37
31 17
32 18
1 29
34
A
35 38
6 40
4
3
8 9
2
7
E 5 RKZ10570
1 -Remove bearing snap ring (1). 2 -Untighten and remove flange retaining screw (2).
3 -Use a screwdriver and two screws to avoid flange
rotation.
1
RKZB8800
2
RKZB8810
30-76 WB93R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
RKZB8820 RKZB8850
5 -Remove flange (5) and O-ring (4). 8 -Remove O-Ring (8) from cover (7).
4
3 7
8
RKZB8830 RKZB8860
6 -Take out the screws (6) (n°3). 9 -Remove the seal (9) from the cover (7).
9
7
RKZB8840 RKZB8870
WB93R-5E0 30-77
REMOVAL AND INSTALLATION TRANSMISSION
10 -Untighten and remove flange retaining screw (10). 14 -Remove out the screws (14) (n°3).
14 14
10
RKZB8910
12 -Remove the washer (11). 16 -Replace the O-ring (16) with a new one at each
disassembly.
11 15
RKZB8890
16
RKZB8920
43 42
13
RKZB8900 17
18 RKZB8930
30-78 WB93R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
19 -Use a prybar to separate the rear cover from the 23 -Remove the shift collars (21).
housing.
Remove the rear cover (18).
18
21
RKZB8970
RKZB8940 24 -Remove the two screws (22) which hold the plate
between the two shift rods.
20 -Remove the seal (19) from the rear cover.
22
19
RKZB8980
RKZB8950
23
41
20
RKZB8990
RKZB8960
WB93R-5E0 30-79
REMOVAL AND INSTALLATION TRANSMISSION
26 -Remove the two detent balls (24) from the groove 29 -Remove balls (28).
between the two shift rods.
28
24
RKZB9030
RKZB9000
26 25
29
RKZB9010
RKZB9040
27
30
RKZB9020
RKZB9050
30-80 WB93R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
32 -If to replaced, remove teflon seal ring (31) by cutting 35 -Remove the screws (34).
it.
34
31
RKZB9090
RKZB9060
35
32
RKZB9100
RKZB9070
36
F2
33
RKZB9080
RKZB9110
WB93R-5E0 30-81
REMOVAL AND INSTALLATION TRANSMISSION
39 -Remove the outer bearing cups (37) and (38). 6.2 Assembly
1 - Push the secondary shaft toward the rear of the rear
housing so that there is clearance between the snap
ring groove and the rear housing.
Install the snap ring (29).
38 37
29
RKZB9120
RKZB9040
39
39
RKZB9130
RKZB9140
39
RKZB9140
RKZB9150
30-82 WB93R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
4 -Lubricate the bearings (37) e (38) and mount them on 9 -Mount the screws (35).
3 Screw: 50 Nm
the shaft.
38 37
35
RKZB9160
RKZB9190
F3
36
40
RKZB9200
RKZB9170
34
7 F4
RKZB9180
RKZB9210
WB93R-5E0 30-83
REMOVAL AND INSTALLATION TRANSMISSION
12 -Assemble O-ring (8). 15 -Install a new O-ring (4) in the four-wheel drive flange.
Use clean transmission oil to lubricate the O-ring.
7 4
3
8
RKZB8860
RKZB8830
7 5
RKZB8850
14 -Install the three cap screws (6) which fasten the RKZB9220
3 Screw: 23 Nm
17 -Install the washer (3).
RKZB8820
RKZB8840
30-84 WB93R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
18 -Tighten the screw (2) using a screwdriver to prevent 21 -Mount the spring (27).
flange rotation.
3 Screw: 139 Nm
27
RKZB9020
2
22 -Mount the washer (26) and the screw (25).
3 Screw: 80 Nm
RKZB8810
26 25
1
RKZB9010
RKZB9230
28 25 26
RKZB9030 RKZB9240
WB93R-5E0 30-85
REMOVAL AND INSTALLATION TRANSMISSION
24 -Assemble bearing (33) on transmission shaft PTO 27 -Insert transmission shaft PTO (30) to the stroke.
(30).
30
30
33
RKZB9050
RKZB9250
24
32
RKZB9000
RKZB9260
31
RKZB8990
RKZB9270
30-86 WB93R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
30 -Apply sealant to the threads of the Allen head screws 33 -Use the F8special tool to install a new seal (19) on
(22) and fix the plate in position. rear cover.
3 Screw: 50 Nm
22 19
F8
RKZB9290
RKZB8980
34 -Position the rear cover (18).
Make sure that the pin (41) is correctly installed both
31 -Install shift collars (21) on the shift rods. in the rear housing and through the hole in the rear
cover.
Install the six cap screws (17) and the two cap screws
(42) to fasten the cover to the rear half housing.
3 Screw: 50 Nm
21 35 -Mount the O-ring (43).
43 42
RKZB8970
17
32 -Install the pins (20) to fasten the shift collars to the
shift rods.
Mount the centering pins (41).
18 RKZB8930
41
36 -Install a new O-ring (16) on the shift tower assembly
(15).
20 Use clean oil to lubricate the O-ring and assembly it
on the rear housing.
15
RKZB9280
16
RKZB8920
WB93R-5E0 30-87
REMOVAL AND INSTALLATION TRANSMISSION
37 -Tighten the bolts (14) to fasten the shift tower 41 -Tighten the screw (10) using a lever to prevent flange
assembly to the rear cover. rotation.
10
14 14
RKZB8910 RKZB8880
12
13
RKZB8900
11
RKZB8890
30-88 WB93R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
7. Shafts A - D
7.1 Disassembly
37 18 32 33
D 17 34
11
16 27
10
8
6
7
4 A
3
38
2
1 39
40
31 22
A 23
9
24
21 25
12
20
26
19 28
5 30
15 29
13 35
14 36
RKZ10580
A
RKZB9300
RKZB9310
WB93R-5E0 30-89
REMOVAL AND INSTALLATION TRANSMISSION
2 4
RKZB9320 RKZB9350
3 -Install a bearing separator under the gear as shown 6 -Remove gear (6).
(do not install the bearing separator between the
gear and the bearing).
Use a puller on the bearing separator and insert a
shaft protector between the puller and the end of the
input shaft. 6
By means of puller which operates between bearing
separator and shaft protector pull only until the
bearing is free. Pulling anyfarther can damage the
parts.
RKZB9360
7
RKZB9330
3
RKZB9370
RKZB9340
30-90 WB93R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
8 -Remove spacer (8). 11 -Use prybars to lift and to remove the clutch plate lock
ring (11) evenly.
11
RKZB9380
RKZB9410
9
17
18
RKZB9390
10
RKZB9400
RKZB9430
WB93R-5E0 30-91
REMOVAL AND INSTALLATION TRANSMISSION
14 -Place a mark on each clutch plate lock ring (11), 17 -Loosen the handles of the threaded rods to release
clutch plate (18) and clutch drive plate (17). the tension from the spring.
These marks will be used for reference during the Remove the top piece of the F9 special tool.
reassembly procedure.
F9
13
RKZB9450
RKZB9440
13
F9
13 15
RKZB9470
RKZB9450
14 RKZB9480
RKZB9460
30-92 WB93R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
20 -Introduce low pressure compressed air into the 24 -Remove snap ring (23).
delivery hole and expel piston (19).
19 23
RKZB9520
RKZB9490
24
20
RKZB9530
21
RKZB9500
25
RKZB9540
22
RKZB9510
WB93R-5E0 30-93
REMOVAL AND INSTALLATION TRANSMISSION
27 -Remove gear (26) and needle cage (12). 2 -Remove bearing (37) of shaft D by means of an
extractor.
26
37
12
RKZB9550
RKZB9610
RKZB9560
Shaft D
16
RKZB9600
30-94 WB93R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
RKZB9570
WB93R-5E0 30-95
REMOVAL AND INSTALLATION TRANSMISSION
20
RKZB9480
21
13
RKZB9500
15
RKZB9470
6 -Lower the lock spring cover (13). Insert lock ring (14).
Use tool F9.
RKZB9620
F9
19
F10 14
RKZB9640
RKZB9630
30-96 WB93R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
7 -Remove tool F9 and assemble split pin (9). 10 -To assemble the clutch pack start with the gear (6) on
the bench. Install the clutch plate lock ring (11) so that
the reference mark on top of the plate made during
disassembly is facing towards the gear.
9
11
RKZB9650
6
8 -Insert thrust washer (8)
RKZB9670
18
8
RKZB9660
RKZB9370
RKZB9690
WB93R-5E0 30-97
REMOVAL AND INSTALLATION TRANSMISSION
RKZB9700
2
14 -Assemble washer (4).
RKZB9320
RKZB9350
F2
RKZB9720
RKZB9710
F5
RKZB9730
30-98 WB93R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
19 -Slide the F5 expander/protector onto the input shaft 22 -Install the end of the F7 seal compressor with the
and on the spacer. deep chamfer onto the shaft and over the sealing
The expander/protector will stop in the correct ring.
position to install the seal ring in the groove. 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.
F5
RKZB9740
RKZB9750
RKZB9780
RKZB9560
WB93R-5E0 30-99
REMOVAL AND INSTALLATION TRANSMISSION
24 -Turn the shaft around and carry out steps 1 - 10 for 27 -Assemble the teflon seal rings (22) as follows: place
the other clutch. the F12a spacer into the F12b expander/protector.
Lubricate the ring (25) with transmission oil. Install
the ring (25) so the notch on the inside rim goes onto
the pin.
Make sure that the side with the oil grooves is down.
25
F12a F12b
RKZB9820
F11
F12b
24 RKZB9830
23
22
RKZB9840
RKZB9810
30-100 WB93R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
30 -Install the F13 pusher over the expander/protector 32 -Turn the seal compressor around and slide the end
and slide the seal ring until it reaches the groove in with the narrow chamfer over the shaft and over the
the shaft. seal ring.
Remove the pusher, expander/protector, and spacer Leave the seal compressor in place for 15 minutes
from the shaft. until the sealing ring has cooled and is properly sized
and seated in the groove. After the seal ring has
cooled, remove the seal compressor from the shaft.
For the introduction of the other three teflon rings,
repeat the operations from sequence 27 to sequence
31, using the following spacer rings:
CA715743/2 for the 2nd teflon ring,
CA715743/3 for the 3rd teflon ring,
CA715743/4 for the 4th teflon ring.
F13
RKZB9850
F3 16
F14
RKZB9860
RKZB9880
WB93R-5E0 30-101
REMOVAL AND INSTALLATION TRANSMISSION
F3 37
RKZB9890
RKZB9900
RKZB9910
30-102 WB93R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
7 6 5 4
3 23 13
8
6 5
RKZ10590
WB93R-5E0 30-103
REMOVAL AND INSTALLATION TRANSMISSION
8. Shafts B - C
8.1 Disassembly
17
20 37
16 38 13
15 36
27 14
29
30 1
C
18 33 28 2
31 C
32 34 5
35 6
25 8 7
26
24 9 3
22 10
21
23 11
6 B
5
4
12 40
42 41
B
19 39 RKZ10600
1 -Remove the shafts B and C with special tool F15. 2 -Remove the gear control forks.
F15
B
RKZB9920 RKZB9930
30-104 WB93R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
Shaft C 4 -Remove the clutch ring (5) from each side of the
synchronizer assembly.
1 -Remove bearing (1) by means of an extractor.
The synchronizer assembly component parts are
serviced as a complete unit.
The synchronizer assembly may be disassembled
for inspection and cleaning.
I f a n y o f t h e p a r t s a r e d a m a g e d , t h e e n t ir e
1 synchronizer assembly must be replaced.
RKZB9940
RKZB9970
3 -Remove third/fourth speed synchronizer assembly a Thickness must be not less than 1 mm.
(4).
Min 1mm
4
RKZ10620
RKZB9960
WB93R-5E0 30-105
REMOVAL AND INSTALLATION TRANSMISSION
6 -Remove the tapered friction ring (6) from each side of 9 -Remove fourth speed gear (12).
the synchronizer assembly.
6 12
RKZC0020
RKZB9980
15
7
RKZC0030
9 15
8
10
11
10 10 16
9 RKZC0040
9
8 8 RKZC0010
30-106 WB93R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
18
16
RKZC0050 RKZC0080
13 -Remove the shims (20) and the thrust washer (17). 16 -Remove the spacer (21).
21
20
17
RKZC0060 RKZC0090
19
22
23
RKZC0070
RKZC0100
WB93R-5E0 30-107
REMOVAL AND INSTALLATION TRANSMISSION
18 -Remove the steel ring (24) and the sintered ring (25). 21 -Remove the steel ring (28) and the sintered ring (29).
24 28
25 29
RKZC0110 RKZC0111
19 -Remove the tapered friction ring (26). 22 -Remove the tapered friction ring (30).
26 30
RKZC0120 RKZC0121
20 -Turn the synchronizer assembly (23) over and 23 -Support the sleeve on blocks.
remove the synchronizer ring (27) from the other Push down on the hub while you use a punch to push
side. the detent assemblies out of the sleeve and hub.
Remove the sleeve (31) from the hub.
27
23
31
RKZC0130
RKZC0140
30-108 WB93R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
14
36
RKZC0160 RKZC0190
37
13
RKZC0170 RKZC0200
38 39
RKZC0180
RKZC0210
WB93R-5E0 30-109
REMOVAL AND INSTALLATION TRANSMISSION
2 -Turn shaft (41) around and remove bearing (40). 3 -Assemble snap ring (38).
40 38
41
RKZC0220 RKZC0180
Shaft C
RKZC0170
13
5 -Assemble spacer (36).
RKZC0200
36
2 -Assemble 4WD gear (14).
14
RKZC0160
RKZC0190
30-110 WB93R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
6 -Assemble the first/second speed synchronizer (23). 9 -Use clean transmission oil to lubricate the sintered
Assemble on the hub (35) the spring (34), the blocks ring (29) and the steel ring (28).
(33), the balls (32), and the sleeve (31).
28
35
29
34
33
32 31
RKZC0111
RKZC0230
27
23
32
RKZC0130
RKZC0240
26
30
RKZC0120
RKZC0121
WB93R-5E0 30-111
REMOVAL AND INSTALLATION TRANSMISSION
12 -Use clean transmission oil to lubricate the sintered 15 -Assemble the second speed gear (18).
ring (25) and the steel ring (24). Install the sintered
16 -Ensure the spacer (21) and gear (18) make solid
ring (25) and the steel ring (24).
contact with the synchronizer (23).
24 18
25
RKZC0110
RKZC0080
19
22
23
RKZC0070
17
21
20
RKZC0250
RKZC0090
30-112 WB93R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
19 -Install the stop ring (16). 22 -Heat the inner race of the bearing (15) to 80–100°C
Using a feeler gauge, measure distance X between and use the tools F16 mount it on the shaft.
gear (18) and ring (17).
F16
16
17 15
RKZC0280
15
RKZC0030
16 12
20
17
RKZC0020
RKZC0061
WB93R-5E0 30-113
REMOVAL AND INSTALLATION TRANSMISSION
25 -Assemble the third/fourth speed synchronizer (4). 28 -Lubricate clutch ring (5) with transmission oil and
install to each side of the synchronizer assembly.
11
10 5
8
9 7
RKZC0231
RKZB9970
26 -Install springs (10), blocks (8), balls (9) and sleeve (7)
to hub (11). 29 -Install the third/fourth speed synchronizer assembly
Using a punch or screwdriver, push in the balls (9) to (4) onto the shaft.
complete assembly of hub (11).
11
8 9 10 4
7
RKZB9960
RKZC0241
6
2
RKZC0290
RKZC0300
30-114 WB93R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
31 -Heat the bearing (1) to 80–100°C. 3 -Using tool F16, position complete shafts B and C to
Use the tool F2 assemble bearing (1) half housing.
Complete shafts should be installed with pins and
forks.
Introduce preassembled 3rd and 4th speed forks and
F2 1st and 2nd speed forks as shown.
C
1
F16
B
RKZC0310
Shaft B
1 -Heat the inner race of the bearing (39) to 80–100°C
RKZB9931
and use the tools F16 mount the ring inside the
bearing (39).
4 -Position the group with care paying attention to the
location of fork pins in their seats.
F16
39
RKZC0320
RKZB9921
2 -Turn the shaft (41).
Heat the bearing to 80–100°C. Use the tool F2
assemble bearing (40).
F2
40
41
RKZC0330
WB93R-5E0 30-115
REMOVAL AND INSTALLATION TRANSMISSION
9. SHAFT E
9.1 Disassembly
16
14
7 13
11
9
12
15
8
12
10
4
2
1
6
E 5
3 RKZ10640
E
15
RKZC0340
RKZC0350
30-116 WB93R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
16 4
RKZC0360 RKZC0390
4 -Using tool F17, push down on the spring cover until 7 -Remove sleeve (5).
stop ring is exposed (1).
Remove stop ring (1) from its seat and remove tool
F17, then remove washer (2).
1
5
F17
2 RKZC0400
8 -Remove the two O-rings (6) and (9) from the shaft.
RKZC0380
RKZC0410
RKZC0370
WB93R-5E0 30-117
REMOVAL AND INSTALLATION TRANSMISSION
9 -Remove the teflon sealing rings (8) from the shaft. 12 -Remove O-rings (12) from cylinder (13).
8
13
12 12
RKZC0420 RKZC0450
10 -Remove snap ring (14). 13 -Remove valve (10) and spring (11) from cylinder
(13).
14
13 11 10
RKZC0430
RKZC0460
13 7
RKZC0440
RKZC0470
30-118 WB93R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
14
13 11 10
RKZC0430
RKZC0460
5 -Assemble the O-Rings (6) and (9) on the shaft.
6
13
12 12
9
RKZC0410
RKZC0450
6 -Assemble sleeve (5).
13 5
RKZC0400
RKZC0440
WB93R-5E0 30-119
REMOVAL AND INSTALLATION TRANSMISSION
7 -Assemble springs (4). 10 -Using tool F17, push down on spring cover until the
stop ring seat (1) is exposed and complete the
assembly of the stop ring (1).
Release tension and remove the tool.
Ensure that the stop ring (1) is correctly positioned in
the recess of the spring cover.
F17
RKZC0390
RKZC0490
RKZC0370
1
8 F18
RKZC0500
RKZC0480
30-120 WB93R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
12 -Install the F6 pusher over the expander/protector 14 -Turn the seal compressor around and slide the end
and slide the seal ring until it reaches the groove in with the narrow chamfer over the shaft and over the
the shaft. seal ring.
Remove the pusher, expander/protector, and spacer Leave the seal compressor in place for 15 minutes
from the shaft. until the sealing ring has cooled and is properly sized
and seated in the groove.
After the seal ring has cooled, remove the seal
compressor from the shaft.
F6
F7
RKZC0510
ring.
Use a back and forth twisting motion to allow the seal 15 -Assemble protector F19.
compressor to slip over the top of the sealing ring and Repeat steps 13 -19 to introduce the second teflon
seat the sealing ring into the groove. ring.
Be careful not to damage the seal ring.
After the sealing ring is seated in the groove, remove
the seal compressor from the shaft.
F19
F7
RKZC0530
RKZC0520
WB93R-5E0 30-121
REMOVAL AND INSTALLATION TRANSMISSION
16 -Apply air compressed at about 6 bar to 4WD clutch oil shaft. Valve (10), if operating correctly reaches the
passage (see arrow) by plugging the opposite hole end of stroke making a noise.
with a finger. The sleeve (5) should be moving when If the operation is incorrect, dismantle to find the
compressing the springs (4). problem.
The 4WD gear (15) should move freely on 4WD
10 11 9 13 12 14
4
8 8
3 6 5 16
15
RKZ10660
15
16
RKZC0360 RKZC0350
30-122 WB93R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
E B
RKZC0341
RKZC0470
WB93R-5E0 30-123
REMOVAL AND INSTALLATION TRANSMISSION
6 7
7
5
4
1
3
2
93
10
11
14
11
13
RKZ10670
1 -Untighten and remove screws (1). 2 -Remove the shift tower assembly (2) and the O-ring
For the disassembly of the two half boxes it is (3).
necessary to remove the shift tower assy.
a Replace the O-ring at each disassembly.
1 2
RKZC0540
3
RKZC0710
30-124 WB93R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
3 -Remove the clamp (4). 6 -Remove the steel stop ring (8) from transmission
lever.
a Replace the clamp at each disassembly.
4
8
RKZC0580
RKZC0550
9
RKZC0590
RKZC0560
10
RKZC0690
RKZC0570
WB93R-5E0 30-125
REMOVAL AND INSTALLATION TRANSMISSION
RKZC0700 6
A B
2
6
11 C
RKZC0720
D
RKZC0730
10
RKZC0690
30-126 WB93R-5E0
REMOVAL AND INSTALLATION TRANSMISSION
4 -Install the bushing (9). 7 -Install the boot (5) so that the edge is seated on the
pin ends.
Pay attention not to drop the pins.
9
RKZC0590
8
4
RKZC0580
6 -Install pins (7) through the holes in the case flange so RKZC0550
RKZC0570
3
RKZC0711
WB93R-5E0 30-127
REMOVAL AND INSTALLATION TRANSMISSION
3 Screws (1): 23 Nm
RKZC0540
11 -Fit the two pins (11) to lock gear control fork 3rd and
4th speed (13) and gear control 1st and 2nd speed
(14).
11
13
14
11
RKZC0721
30-128 WB93R-5E0
REMOVAL AND INSTALLATION CONVERTOR
CONVERTOR
Removal Installation
k Lower the working equipment completely until it • To install, reverse removal procedure.
rests on the ground.
a Ensure that the mating surfaces are clean and free of
Stop the engine and remove the ignition key.
dents.
k Eliminate all residual pressure from all circuits by [*1]
moving the hydraulic controls in all directions.
a To aid in mating flywheel and joint, before mating
a Drain the hydraulic oil. engine and transmission, tighten a threaded shank
6 Hydraulic oil: approx. 40 l
“A” as guide to the joint:.
RKZC1850
RKZC1840
WB93R-5E0 30-129
REMOVAL AND INSTALLATION ENGINE
ENGINE
Removal 4 -Disconnect the heating system hoses (3) and (4) and
remove the tie strap (5) retaining the gearbox oil
1 -Remove: hoses.
• ENGINE HOOD
• FRONT GUARD a Cap pipes, hoses and holes to prevent
contamination.
• FRONT COUNTERWEIGHT
• RADIATOR GROUP - INTERCOOLER
• INTERCOOLER
• MUFFLER 3
• ENGINE BELT
• PISTON PUMP
• TRANSMISSION
For details, see the individual removal procedures.
4
2 -Disconnect 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 RKZC2880
contamination.
5 -Lift the cover (6) and disconnect wiring harnesses (7)
and (8) from starter.
1
2
8
6
RKZC2860
7
3 -Remove the screws and release the straps (1) and RKZC2890
11
2 RKZC2870 10
9
RKZC2900
30-130 WB93R-5E0
REMOVAL AND INSTALLATION ENGINE
7 -Release the wiring harness (12) to the compressor 10 -Disconnect connector (16) from the engine stop
(9) from the tie straps and disconnect. solenoid valve, disconnect connector (17) from the
engine oil temperature sensor (17), and disconnect
connector (18) from the oil pressure sensor.
17
9 18
12 RKZC2910
16
8 -Disconnect wiring harness (13) from thermal starter RKTA0811
14
13
20
19
RKZC2930
21
RKZC9820
15
RKZC2920 23
22
RKTA0801
WB93R-5E0 30-131
REMOVAL AND INSTALLATION ENGINE
13 -Release the entire engine harness from the tie straps 17 -Loosen and remove nuts (25), screws (26) and
and route the harness down, and use some straps on vibration dampers (27) from front engine mounts. [*1]
the inner sides of the frame to let the wiring hang
18 -Remove the engine (28).
temporarily.
4 Engine: approx. 394 kg
27
25
26
28
RKZC9830
RKZC2980
14 -Check to ensure that all hoses to the engine are
released from straps or ties.
Installation
15 -Tighten a revolving lifting eye “A” to the muffler inner
• To install, reverse removal procedure.
mounting hole.
[*1]
3 Nuts: 200 Nm
A a Check transmission oil level before starting the
engine.
RKZC2960
28 A
24
RKZC2970
30-132 WB93R-5E0
REMOVAL AND INSTALLATION CONTROL VALVE
CONTROL VALVE
Removal Only if equipped
1 -Move backhoe fully to the right and swing the boom 5- Remove screws (2) and remove control pedals (3) for
by about 45° to the right leaving the backhoe plate jig arm and hammer.
unlocked.
2 -Lower the outriggers to the ground. Curl the bucket
and allow it to rest on the ground on its back as shown
in the illustration. 3
Apply the parking brakes and stop the engine.
3 -Release all residual pressure.
(For details see "20 TESTING AND
ADJUSTMENTS").
RKZC1880
RKA53930
4
4 -Lift rear window (1) to the top and remove the rear
mat.
1
RKZC1890
7 -Take out the screws (n°4) and remove the hood (6).
RKA53840
RKZC1900
WB93R-5E0 30-133
REMOVAL AND INSTALLATION CONTROL VALVE
8 -Take out four screws and remove the metal sheet (7) 11 -Make sure that all the hoses are marked; disconnect
closing off the floor. the upper hoses (12), together with all accessible
side hoses (13), from the control valve.
11
RKZC1910
14 8
9
RKZC1920
9
10 -Make sure that all the hoses are marked; disconnect 14
the lower hoses (10), together with all accessible
side hoses (11), from the control valve.
RKZC1921
11
10
15
11
16
10 RKZC1930
RKZC1950
30-134 WB93R-5E0
REMOVAL AND INSTALLATION CONTROL VALVE
14 -Remove pins and disconnect control tie rods (8) from 17 -Lower the control valve (17) onto a lift. [*1]
18 18
13
17
RKZC1941
RKA53850
RKZC3120
19
19
RKZC1960
WB93R-5E0 30-135
REMOVAL AND INSTALLATION FRONT AXLE
FRONT AXLE
Removal 9 -Disconnect the cardan shaft (4) from the axle (3). [*3]
1- Start the engine and force the shovel downwards in 10 -Disconnect the lines (5) from the steering cylinder
order to raise the machine and the front wheels. and plug them to prevent entry of impurities. [*4]
2 -Place two stands “A” and some blocks beneath the 11 -Disconnect the lubrication tube (6) for the axle
chassis. oscillation pin (7).
RKZC2010
6 -Remove the engine hood (1) and the front guard (2).
(For details, see "ENGINE HOOD" and "FRONT
GUARD").
4 Wheel: 65 kg
RKZC0772
30-136 WB93R-5E0
REMOVAL AND INSTALLATION FRONT AXLE
13 -Take out the nut and remove the retaining screw (8) Installation
of the axle oscillation pin (7).
• To install, reverse removal procedure.
14 -Tighten a hammer puller into the central hole of the
axle oscillation pin (7); pull out the axle oscillation pin. [*1]
[*5] 3 Nuts for front wheels: 370 Nm
15 -Lower the jack until the axle is disengaged.
[*2]
16 -Extract the entire axle (3).
3 Front closing screws: 300 Nm
4 Front axle: 295 kg [*3]
[*5]
WB93R-5E0 30-137
REMOVAL AND INSTALLATION FRONT AXLE
21 10
9
20
8
19
18
6
17
16 7
11
15 12
13 14
5
4
3
2
1
RKZ09810
1 -Unloose the guide rod (2) locknut (1) of some turns till 2 -Loosen the nuts (4) and (9) and remove the tie rods
it is over the end of the threaded pin. (3) and (10).
Beat on the nut (1) with a hammer in order to disjoin
3 -Remove the fastening screws (6) of the cylinder, then
the guide rod (2) from the swivel housing (3).
take the cylinder (7) out of its housing using a rubber
a Don’t beat on the end of the threaded pin. hammer.
a This is a destructive operation for the nut (1). a Remove only those parts that need to be
overhauled and/or replaced.
3
4
7
6
2
1 4
3 5
5
RKZB5581
RKZ07111
30-138 WB93R-5E0
REMOVAL AND INSTALLATION FRONT AXLE
4 -Detach the cylinder head (15) from the cylinder case 3 -Install ball joints (5) and (8), nuts (4) and (9) and tie
(19). rods (3) and (10) at the rod (17) ends and tighten.
14 15 5
13 18
RKZ07111
19
17
7
20 21
14 15
13 18
RKZB5461
16
RKZ07121
6 -Align the swivel housing with the axle (parallel wheel
hub).
Screw the guide rod (5) so that the ball joint can be
2 -Slide pre-assembled (17) rod into the cylinder body
inserted into the swivel housing arm.
(19).
a It is important to unscrew the locking nut (9) to
carry out this operation.
19
10
17
11
RKZB0093 9
RKZB1163
WB93R-5E0 30-139
REMOVAL AND INSTALLATION FRONT AXLE
7 -Insert the ball joint (8) (into its own housing on the 2- Using a measuring tape, measure the distance in
swivel housing. mm “M” from the farthest bar ends, and tighten or
Assemble and tighten the lock nut (1) with loosen the guide rods until the distance is the same
dynamometric wrench. on both sides.
2 3
1
RKZB1173
RKZB1200
9 -Screw in the lock nuts (4) and (9) of the tie rods (3)
and (10) only when the toe-in adjustment has been
carried out.
Toe-in adjustment
1 -Put two equal one-meter-long linear bars “A” on the
wheel sides and lock them with two nuts on the wheel
hub stud bolt.
50 cm 50 cm
RKZB1190
30-140 WB93R-5E0
REMOVAL AND INSTALLATION FRONT AXLE
3 -Check that the difference of the measurements 5 -Once adjustment is complete, tighten the retaining
between the wheel hubs diameters ends is within the nuts on the guide tie rods.
3 Nuts: 250 Nm
requested tolerance range.
The nominal toe-in (A) value is referred to the
external diameter of the wheel hubs flange, therefore
the measured toe-in value (M) at the bars ends must
be related to the ratio between length of the bar and
flange diameter.
nominal toe-in = A –0 2 mm
measured toe-in = M –0 5 mm
A -0 2 mm
RKZB1221
M
A
RKZ09820
RKZB1230
4- If toe-in is incorrect, operate with two wrenches on 2 -Adjust a goniometer to the angle of 65° and position it
the guide rods screwing in and out the two joint tie on the long bar.
rods equally till the toe-in is within the required Move a wheel side till it forms, with the two bars, the
tolerance. angle fixed by the goniometer.
RKZB1210 RKZB1240
WB93R-5E0 30-141
REMOVAL AND INSTALLATION FRONT AXLE
RKZB1251
30-142 WB93R-5E0
REMOVAL AND INSTALLATION FRONT AXLE
7
6
9
3
8
10
2
1
RKZ09830
k Before draining the oil, position the epicyclic 1 -Remove the fastening screws (1).
reduction gear (3) with the plug (2) on the upper part
and loosen it of some turns in order to eliminate any
possible inner pressure, then remove it completely.
Turn the hub upside-down till the hole is in the lowest
point.
Drain the oil completely.
2 1
3
RKZC0600
RKZB0102
WB93R-5E0 30-143
REMOVAL AND INSTALLATION FRONT AXLE
2 -Remove the planetary carrier (3) from the epicyclic 2.2 Assembly
reduction gear and remove the O-ring (10).
1 -Recover all epicyclic reduction gear components:
the planetary gears carrier (3), the gears (6), the
3 needle bearings (5) and (7), washer (8) and the snap
rings (9) of every pin (4).
8
7
RKZC0610
7 5
• Replacements of the planetary gears
(if necessary) 6
1 -Remove stop ring (9) from each pin (4).
8
7
7 5
6
6
RKZC0620
RKZ09840
9
8
RKZ09850
30-144 WB93R-5E0
REMOVAL AND INSTALLATION FRONT AXLE
RKZC0600
RKZB0102
WB93R-5E0 30-145
REMOVAL AND INSTALLATION FRONT AXLE
19 27
18
14
13 26
11 23
12
22 25
10
15
7
4 21
20
16
3
9 17
1
8
6
2 5
RKZ09860
k Before disassembling the wheel hub, it is advisable 2 -Remove the lock ring (1) from the double U-Joint
to secure it with a belt or a rope on a hoist or any other shaft and collect the washers (2), (3).
supporting device, in order to avoid its accidental fall
that could damage either the operator or the wheel
hub group.
1
1 -Insert a lever between the swivel housing (14) and
the axle beam and fit it into the double U-Joint.
With the lever push the double U-Joint in the direction
of the wheel hub to allow the lock ring (1) removal.
RKZB0133
RKZC0630
30-146 WB93R-5E0
REMOVAL AND INSTALLATION FRONT AXLE
3 -Unscrew and remove the fastening screws (5) from 8 -Remove the hub (11), using levers and a hammer to
the wheel carrier (7) group. facilitate the operation.
7 5
11
RKZB0141
4 -In order to remove the wheel carrier group (7) from its RKZB0172
RKZB0152
9
6 -Remove the stop ring (4) and disjoin the hub-lock 13
ring gear (7) from the epicyclic ring gear (3).
4
RKZC0640
WB93R-5E0 30-147
REMOVAL AND INSTALLATION FRONT AXLE
12 -Unscrew and remove the fastening screws (19) from 3.2 Assembly
the upper (18) and (17) lower (16) king pin.
1 -Force the bush (22) into the swivel housing (14) with
k Before removing the king pins, secure the the special tool D2. and a hammer or a press.
swivel housing with a belt or a rope to a hoist or
2 -Assemble the seal ring (23) on the swivel housing
any other supporting device.
(14) with the special tool D3.
13 -Remove the king pins (18) and (16) and collect he and a hammer. Lubricate the ring with grease
belleville washers (25), (27). ASL800050.
19
D2 D3
22 23
18
14
16
RKZB1013
RKZB5621
14 -Remove the swivel housing (14) from the axle beam 3 -Position the lower king pin (16) on a workbench and
and from the shaft (24). assemble the cone of the spherical joint (15) with the
special tool D4 under a press. Grease well the king
pin housings with grease ASL800050.
4 -Position the Belleville washers (25) and (27) on the
king pin housings (16) and (18).
14
27
15
24
16
RKZB0212
16 -Turn the swivel housing (14) and take the bush (22)
out, using a driver and a hammer.
14
23
22
RKZB5631
30-148 WB93R-5E0
REMOVAL AND INSTALLATION FRONT AXLE
5 -Secure the swivel housing (7) group with a rope. 8 -Position the wheel hub (11) on a workbench and
Lubricate the seal ring lip and protect the splined end force both cups of the taper roller bearings (9) e (12)
of the axle shaft by winding it with thin adhesive tape in position with the special tool D5 under a press or
to avoid damage to the seal ring. After assembly, with a hammer.
remove completely the adhesive tape. Assemble the
9 -Insert the seal ring (13) into the wheel hub (11) with
swivel housing on the axle beam.
the special tool D6 and a hammer.
6 -Assemble the two king pins, the upper (16) and the
lower (18), and tighten the retaining screws (17) and
(19). 12 13
9
3 Screw: 190 Nm
a Make sure that the Belleville washers (25) and
(27) remain in their position.
D5 D6
18 D5 11
RKZB1424
19
10 -Assemble the cone of the taper roller bearing (12) on
the swivel housing end (14).
A = 5.900-5.905 mm
B = 52.229-52.279 mm
C = 23.072-23.173 mm
RKZB1433
9 12
C A C
RKZ05743
WB93R-5E0 30-149
REMOVAL AND INSTALLATION FRONT AXLE
12 -Position the wheel carrier (7) on a workbench and 15 -Force all the hub dowel bushes completely with the
force the bushes (6) to the carrier surface level with special tool D1 and a hammer.
the special tool D1. Assemble the wheel carrier (7) fastening screws (5)
At least two bushes (diametrically-opposed) should and tighten.
3 Screw: 120 Nm
be set slightly higher than the carrier surface level to
be used as dowel pins.
7
5
6
7
RKZB1443
RKZB1093
16 -Install washers (2) and (3) to the axle shaft and install
13 -Preassemble the wheel carrier - (7) epicyclic ring
the stop ring (1) by pushing it from the end of the
gear group (7) and (4) with the special locking ring (8)
serrated hub to its seat while counteracting with a
shown in figure.
lever inserted between beam and swivel housing and
engaged onto the double U joint.
4
1
7
RKZ05733
RKZB1103
30-150 WB93R-5E0
REMOVAL AND INSTALLATION FRONT AXLE
7
8
1
2
8
7 4 5
RKZ09880
1 -Remove the U-Joint (6) from the axle beam (1). 2 -Take the seal ring (5) out of the axle (1) beam with a
lever.
4
RKZC0650
5
5
RKZC0660
WB93R-5E0 30-151
REMOVAL AND INSTALLATION FRONT AXLE
4 -Extract the upper bushings (2) and cup (3) from the 4.2 Assembly
king pin housings.
1 -Using tool D7 and a hammer, install bushing (2) and
a Examine the bushing and housing before cup (3).
removal and replace depending on wear
a To make installation easier, allow the bushings and
conditions.
cups to cool in liquid nitrogen at less than -100°C.
2
2 D7
2
1 D7
3
3
RKZ09890
3
RKZC0670
5 -Take the seal ring (7) out of the axle (1) beam with a
2 -Assemble the bush (4) on the axle beam with the
suitable tool.
special tool D9 and a hammer.
a This is a destructive operation for the seal rings.
3 -Assemble the seal ring (5) on the beam with the
Only if necessary, remove the bushings with a special tool D10 and a hammer.
standard three-gripping point extractor or a suitable Fill 3/4 of the seal ring cavity with grease ASL800050.
driver and a hammer.
4 5
7
8 1
8
RKZ09910
7
4 -Lubricate the bush (5) and the seal ring lip (6). Insert
RKZ09900
the U-Joint (7) inside the axle beam.
RKZC0650
30-152 WB93R-5E0
REMOVAL AND INSTALLATION FRONT AXLE
8 1
8
7
RKZ09900
WB93R-5E0 30-153
REMOVAL AND INSTALLATION FRONT AXLE
5. Differential support
5.1 Disassembly
6
12
5 7 11 14
10
13
4
3
1
RKZ09920
1 -Loosen and remove the screws (2) on the differential 2 -Loosen and remove the screws (6) to remove the two
support (1). Remove the differential support (1) from ring nut retainers (5).
the axle beam (14).
14
RKZ09940
2 1
RKZ09930
30-154 WB93R-5E0
REMOVAL AND INSTALLATION FRONT AXLE
3 -Before removing bolts, mark halfbridles (10) and the 6 -Take out the differential case (13).
differential carrier with permanent reference marks
a Take care not to loose the cups bearing (13) that
to avoid inverting them when re-assembling the unit.
are removed together with the differential case
Mark the area between the ring (3), (7) buts and the
(1).
differential (1) carrier as well.
a Do not mismatch the cups of the bearings (4) if
bearings are not to be replaced.
10
1
4 4
3
1
RKZ09950
4 -Unscrew the adjuster ring nuts (3), (7) using tool D12 RKZ09980
and a wrench.
5.2 Assembly
1 -Position the complete differential box (13), with the
outer cups (4) of the tapered roller bearings already
assembled, on the differential carrier (1).
D12 RKZ09960
10
RKZ09970
WB93R-5E0 30-155
REMOVAL AND INSTALLATION FRONT AXLE
2 -Place the differential (1) group and the two 4 -Install a magnetic comparator “A” to the differential
halfbridles (3) and bolts in their seat. support so that the checkhead is at right angles with
Check the positions of the bushings and halfbridles the side of a tooth from the ring gear.
using the reference marks on them and on the
differential support (1).
Install the halfbridles and secure with their respective
screws (11). A
11
10
9
RKZ10000
7 3
D12 RKZ09960
RKZ09951
30-156 WB93R-5E0
REMOVAL AND INSTALLATION FRONT AXLE
6 -If the measured backlash is lesser than the given 8 -Once pinion/ring gear backlash is determined,
tolerance range, screw the ring nut (7) from the side measure total bearing preload (T) (pinion/ring gear
opposite to the ring gear and unscrew (3) the system) using a force gauge with the cable wound
opposite one of the same measure. around the splined pinion end. The reading should be
within the following values:
6a -If the measured backlash is higher than the given
tolerance range, screw the ring nut (3) from the side T = ( P + 3. 75 )– ( P + 5. 75 ) d aN
of the ring gear and unscrew the opposite (7) one of w h e r e P is t h e e f f e c t iv e ly m e a s u r e d p in i o n
the same measure. preloading
(For details, see "6. Differential group")
13
RKZ10100
b b
a a
RKZ10010
WB93R-5E0 30-157
REMOVAL AND INSTALLATION FRONT AXLE
10 -When all adjustments are complete, install the ring 12 -Before matching surfaces, make sure that they are
nut retainers (5) and their respective screws (6), perfectly clean, degrease and clean them with
and tighten to the specified torque. appropriate detergents.
3 Screw: 266 Nm
Spread a film of adhesive on the contact surface
between the axle beam (14) and the differential
carrier (1).
6 6 2 Loctite: 510
5 a check that two dowel pins (12), (8) are in their
5 seats.
RKZ09940
14
3 Screw: 266 Nm
12
RKZ10040
10
RKZ10030
14
2 1
RKZ09930
30-158 WB93R-5E0
REMOVAL AND INSTALLATION FRONT AXLE
RKZ10070
RKZ10050
OK Z
RKZ10060
WB93R-5E0 30-159
REMOVAL AND INSTALLATION FRONT AXLE
6. Differential group
6.1 Disassembly
7 4 1
6
3
5
9
11
13 8
10
12
RKZ10080
1 -Pry the cover (13) away from the differential 2 -Remove the seal rings (12) and (11) from the cover
support using a lever. (13).
11
13 13
RKZ10100
12
RKZ10110
30-160 WB93R-5E0
REMOVAL AND INSTALLATION FRONT AXLE
3 -Fit the differential carrier (1) in a vise. 6 - Place differential support (7) on a firm flat surface
Unscrew the lock nut (10) using special tools D14- and extract bearing outer rings (3) and (8).
D15.
7
D14
8
10
RKZ10180
D15
7 -To remove bearing inner ring (3) from bevel pinion
(1), use a commercially available grip puller.
RKZ10170
Recover bearing inner ring (3) and the shim (2)
under it.
4 -Remove the ring nut (10) and collect its retaining
washer (9).
9
10 1
RKZ10190
RKZ10120
8 -Check all pinion components for wear.
5 -Tap the shaft with a soft hammer to remove the bevel a The ring nut (10) and the snap spacer (5) must be
pinion (1). replaced when reassembling the unit.
1
RKZ10200
6
4
RKZ10090
WB93R-5E0 30-161
REMOVAL AND INSTALLATION FRONT AXLE
6.2 Assembly
1 -Place differential support (7) on a work bench. 4 -Install tool D18, D19 to bearing seats in differential
Force bearing outer rings (3) and (8) into it using support (7) and retain with halfbridles.
special tool D16 and a hammer.
D18 D19
3
7
8
RKZ10220
RKZ10180
D18 D19
D19 X
D18
D17
10 RKZ10210
RKZ10230
S=X-V mm
V
8
10 3
RKZ10130
RKZ10150
30-162 WB93R-5E0
REMOVAL AND INSTALLATION FRONT AXLE
7 -Pick the (S) shim (2) from the range of shims 9 -Install the selected shim (2) to the pinion shaft (1) with
available. the chamfer facing the gear.
Force bearing (3) onto the pinion shaft (1) using a
SHIM RANGE press and driver D20, and ensure that the bearing is
Shims 2.5 2.6 2.7 2.8 2.9 3.0 3.1 3.2 3.3 3.4 fully locked into position.
Install shims (4) and (6), and a new collapsible
spacer (5).
3 6
5 4
2
1
RKZ10160
1
8 -Remove special tool D18, D19 from differential
RKZ10240
support.
Remove ring nut (10), false pinion, and bearing
10 -Install preassembled bevel pinion group (1) to the
cones (3) and (8).
differential support (7), and install bearing inner ring
(8) to pinion end as shown.
To force bearing (8), use driver D20 and a hammer.
7
a Oppose a resistance to the striking force (e.g. a
sledge hammer).
8 8
10 3
RKZ10130
1
6
4
RKZ10090
WB93R-5E0 30-163
REMOVAL AND INSTALLATION FRONT AXLE
11 -Insert a ring nut washer (9) and screw a new lock ring 13 -Measure preload P of tapered bearings (3) and (8)
nut (10) on the pinion end. using a force gauge with the string wound around the
splined end of pinion (1).
Adjustment is carried out by gradually increasing the
tightening torque of the ring nut (10), paying attention
not to overtighten.
RKZ10120
12 -Screw the ring nut in (10), using the wrench for ring
nut D14 and for pinion retainer D15.
10
D14
10
D15
RKZC0680
RKZ10170
30-164 WB93R-5E0
REMOVAL AND INSTALLATION FRONT AXLE
11
13
12
RKZ10110
13
RKZ10100
WB93R-5E0 30-165
REMOVAL AND INSTALLATION FRONT AXLE
11
1 7
2
5 9
4 10
4
8
2
7
6
3
RKZ14580
1 Lock the differential in a clamp. 4 -Disassemble the differential box in two half boxes
(3), (10) complete with the relevant components.
2 -Unscrew all the fastening screws (1) on ring bevel
gear (11). a Scribble some match marks before separating
the two half housings.
a This will make both differential half boxes (3),
(10) free, so take care not to drop the internal 5 -Recover the components from both half boxes.
components.
6 -Check the operating and wear conditions of the
3 -Remove the bevel gear crown (11). components.
11 3
10
1
RKZ14590
RKZB0571
30-166 WB93R-5E0
REMOVAL AND INSTALLATION FRONT AXLE
7 -Take the bearing (2) out of the differential half box (3) 3 -Position the ring bevel gear (3) and then fix the whole
e (10), using two levers or a three-hold extractor. by tightening the screws (4).
3 Screw: 95 Nm
3 2 Screw: Loctite 270
2
11
10 2
RKZ14600
7.2 Assembly
1 -Assemble the cones of the new taper roller bearings RKZB1291
(2) on the half boxes (3), (10) using the special tool
D13 and a hammer.
3
2
10 2
RKZ14600
3
10
RKZ14590
WB93R-5E0 30-167
REMOVAL AND INSTALLATION REAR AXLE
REAR AXLE
Removal 5 -Remove the rear wheels (2). [*1]
RKZC2050
RKZC2130 4
4 -Prepare a safety stand “A” approximately 65 cm a Cap the hose and hole to prevent contamination.
high, beneath the backhoe chassis. Pull up the
outriggers until the machine is resting on the stand
“A”.
1 5
RKZC2080
1
RKA53960
30-168 WB93R-5E0
REMOVAL AND INSTALLATION REAR AXLE
9 -Disconnect service brake pipes (7) from axle (6). [*3] 12 -Loosen and remove the screws (11) and (4). [*5]
a Disconnect pipes (7) from hoses (8); loosen and 13 -Lower the jack until the axle (6) is disengaged from
remove clamp (9) and pipes (7). the chassis.
a Cap pipes, hoses and holes to prevent 14 -Extract the entire axle.
8
7
11 11
7 6
RKZC2090
RKZC2120
[*3]
RKZC2100
a Bleed the air from the braking circuits.
(For details, see "20 TESTING AND
11 -Position a jack “C” and some blocks beneath the ADJUSTMENTS").
axle. Raise the jack until the blocks can be forced
[*4]
RKA53970
WB93R-5E0 30-169
REMOVAL AND INSTALLATION REAR AXLE
10
9
5 3
2
6
12
11
4
1
7
RKZ08460
1 -Loosen nut (1) (n°2). 2 -Loosen and remove the screws (2) (n°2).
a Proceed with care, in order to avoid damaging
the brake pads.
2
3
1
RKZB7100
RKZB7110
30-170 WB93R-5E0
REMOVAL AND INSTALLATION REAR AXLE
4 -Remove the snap ring (4) and the input flange (5). 1.2 Assembly
a Collect the shim (6) and the O-ring (7). 1 -Introduce a new seal (10) into in the central body
using special tool E1.
5 7 11
10
4
RKZ08470
RKZ08490
11
8
9
12
RKZ08480
7 -Remove the seal ring (10) from the central housing RKZ08500
2 O-ring: ASL800050
a This is a destructive operation for the seal ring.
5 7
4
RKZ08490
RKZ08470
WB93R-5E0 30-171
REMOVAL AND INSTALLATION REAR AXLE
3 9
RKZB7120
6 -Screw in the bolts (2) and tighten the nuts (1) to the
prescribed torque.
3 Nuts: 115 Nm
3 Screw: 45 Nm
1±0.5 mm
2 2 RKZ08520
30-172 WB93R-5E0
REMOVAL AND INSTALLATION REAR AXLE
1.3 Maintenance
10
5
18 2
3 6
4
20
18
11 9 19
16
13 8
15
1
17
12
RKZ08530
1 -Insert mounting bolts through sleeves (9) and thread Ball and Cam Replacement
brake mounting locking nuts as far as possible on
1 -Remove both Adjustment Locking Nuts (12, 13),
mounting bolts. This is not required if brake assembly
Thrust, stainless steel and Hardened Washer (1, 16,
comes with the sleeve/bolt sub-assy. Position the
17), Lever (11), and Boot (3) from Adjustment Bolt
brake over disc align with mounting holes in
(2).
mounting bracket.
2 -Remove outer cam (4) and Ball Assembly (8) from
2 -Thread mounting bolts (9) into mounting bracket,
Adjustment Bolt (2).
adjusting bolts until a 0.5 – 1.5 mm exists between
the Sleeves and the Locking Nuts. Tighten the 3 -Use a screwdriver, or similar tool, to gently pry inner
Locking Nuts to 115 Nm of torque against the Cam (4) protrusions on back of cam, loose from
bracket. Torque Plate (5), and remove from Adjustment Bolt
(2). Remove Seal (15) from Adjustment Bolt (2).
3 -Refer to Adjustment Procedure to set backlash of
installed brake assembly. 4 - Install new Seal (15) on Adjusting Bolt (2), inserting
through inner Cam (4) until Seal (15) bottoms out on
Brake pad looseness adjustment procedure Torque plate.
1 -Loosen adjustment nuts (12, 13). a We recommend lubricating the cams' thrust
surfaces before installing the cams (4).
2 Cam surface: ASL800050
2 -Tighten inner Adjustment Nut (12) until firm contact is
made with the disc by the linings. Torque to 13–14
Nm. 5 -Install new Cam (4) on Adjustment Bolt (2), taking
Ensure that the control lever is in the brake apply care to orient protrusions into Holes in Torque Plates
position. (5).
3 -Back off inner Adjustment nut (12) 4 to 6 faces and
6 -Install Ball Assembly (8) onto Adjusting Bolt (2),
check that disc is free to move.
orienting balls into pockets of Inner Cam (4). Install
4 -Tighten outer Locking Nut (13) against inner outer Cam (4) onto Adjustment Bolt (2), orienting
Adjustment Nut (12) to lock Adjustment Bolt (2) in pockets onto Balls of Balls Assembly (8). Install boot
place. Tighten at 61 -74 Nm. (3) over cam assembly.
WB93R-5E0 30-173
REMOVAL AND INSTALLATION REAR AXLE
7 -Install Lever (1), using protrusions on back of outer Sleeve seal replacement
Cam (4) and holes in Lever (1) to orient lever to
proper operating position. 1 -Loosen the two locking nuts on the mounting bolts
and remove the mounting bolt/sleeve assembly (9)
8 -Install remaining washer and nuts and follow from the brake.
adjustment procedure at paragraph 1.2.
2 -Insert sleeve seals (18) between the torque (5, 7) and
a Check to ensure that the coated side of shim (11)
align with the sleeve bores.
is oriented towards the steel washer (17).
a Lubricate the mounting bolt/sleeve fit before
Lining Replacement installing
1 -Loosen two adjustment Locking Nuts (12, 13) 2 Bushings: ASL800050.
enough to remove each Torque Plate (5, 7) away
from disc far enough to provide backlash to remove 3 -Install the mounting bolt / sleeve assembly through
old carrier and lining assemblies and install new the front pad support (5), the sleeve seals (18) and
ones. (It may be necessary to remove one or both the rear pad support (7).
Nuts)
4 -Mount brake per paragraph 1.1 and adjust per
2 -Collapse the two Lining retraction Springs (10) and section 1.2.
remove them from brake Head Assembly.
Replacing the cable attachment bracket
3 -Remove Torque Plates (5, 7) away from disc, move
Carrier and Lining Assemblies (6) out of pockets, and 1 -Remove the screws (19) of the bracket (20) from pad
remove from the Brake Head Assembly from the support (5).
side. Remove the bracket (20).
4 -Before installing new pads, it is necessary to 2 -Position the bracket (20) in correspondence with the
introduce grease between bushings (9) and pad threaded holes of the pad support (5).
supports (5, 7). Fix the bracket (20) to the front torque plate (5) with
2 Bushings: ASL800050
the appropriate screws (19).
3 Screw: 63 Nm
a Once grease has been applied, slide the
supports onto the bushings so as to distribute
grease evenly.
30-174 WB93R-5E0
REMOVAL AND INSTALLATION REAR AXLE
11
12 8 10
9 16
13 17
14 3
15
18
19
2 4
5
6
5
6 RKZ08540
1 -Drain the oil completely from the differential. 2 -Remove all but two of the cap screws (1).
2 Differential oil: approx. 15 l
RKZB7140
RKZB7130
WB93R-5E0 30-175
REMOVAL AND INSTALLATION REAR AXLE
3 -Connect the hub (2) to a lifting device and tension the 6 -Stand the hub up, mark the reaction plat (5) that was
rope. against the axle housing (3). Remove the reaction (6)
and brake disks (5) and pins (7).
a insert two dowel rod to enable removal.
a Check friction plate and brake separator
thickness. For details, see ("40MAINTENANCE
STANDARD")
3
2 RKZB7150
RKZB7170
2
3
2 RKZB7150
5 -Slowly pull hub (2) away from axle and the half shaft
(4), make sure that brake disks (5) and plates (6) stay
with the hub.
RKZB7180
RKZB7160
10
RKZB7190
30-176 WB93R-5E0
REMOVAL AND INSTALLATION REAR AXLE
9 -Check to ensure that screws (8) and Belleville 12 -Inspect adjuster bushing (14) for wear.
washers (9) are not damaged.
a Repeat procedure for the remaining 2 kit self
a If brake discs are being replaced, replace screws adjust.
and washers with the new kit.
8 9 14
RKZB7230
RKZB7200
10
11
12
RKZB7240
RKZB7210
10
12 E2
15
13
E2 RKZB7250
RKZB7220
WB93R-5E0 30-177
REMOVAL AND INSTALLATION REAR AXLE
15 -Remove O-rings (16) and (17) from the brake piston 2.2 Assembly
(10).
1 -Install a new O-Ring (19) onto hub (2).
16
17
19
10
RKZB7260
RKZB7280
18
18
15
RKZB7270
15
RKZB7290
16
17
19
10
RKZB7260
RKZB7280
30-178 WB93R-5E0
REMOVAL AND INSTALLATION REAR AXLE
4 - Lubricate O-rings (16), (17) and (18), and install 7 -Place bushing (14) inside calibrated ring E2 with the
complete piston (15) to brake cylinder (10) chamfer facing upwards.
2 O-ring: ASL800050
Place pin E2 into brake adjuster (14).
17
14
E2
E2 14
15
16
10 RKZB7330
RKZB7300
7 13
RKZB7340
2
RKZB7310
9 -Using driverE2, push the rings (13) until solid contact
against calibrated ring E2 is obtained.
6 -Install the complete brake cylinder (10) and remove
a Repeat procedure for the remaining 2 self adjust.
pins (7).
E2 13
10 RKZB7350
RKZB7320
WB93R-5E0 30-179
REMOVAL AND INSTALLATION REAR AXLE
10 -Insert the adjuster (12) into the brake piston, make 13 - Install Belleville washers (9) to screws (8) taking care
sure that the chaffered side is up. to orient them as shown in the previous illustration.
9
14
12
RKZB7360 RKZB7380
11 -Install the snap rings (11) into the self adjuster bore. 14 -Mount the shouldered bolts (8) and spring washers
(9) and tighten to the requested torque
3 Screw: 16 Nm
a Check to ensure that spring ring teeth are facing
the self adjust kit as shown in the following
illustration.
11
RKZB7390
RKZB7211
15 -Put the half shaft (4) and brake separator plate pins
12 -Snap ring (11) orientation and Belleville washers (9). (7) into the axle housing.
9 11
7
RKZ08550
RKZB7400
30-180 WB93R-5E0
REMOVAL AND INSTALLATION REAR AXLE
16 -Using the reference mark made during disassembly, 19 -Attach lifting equipment to hub assembly (2) and
place the inner brake separator plate (5) into the axle guide onto the axle (3).
housing (3).
a Use a piece of rope and lift and rotate the half
shaft while pushing the hub onto the axle.
3
5 RKZB7410
4
17 - Place the inner brake disk (6) and the second brake
2 RKZB7430
separator (5).
20 -Install screws (1) tighten to the required torque
5 RKZB7440
18 -Place the outer brake disk (6) and make sure the RKZB7140
6
RKZB7420
RKZB7130
WB93R-5E0 30-181
REMOVAL AND INSTALLATION REAR AXLE
3. Wheel hub
3.1 Disassembly
8
14
11
13
12
10
2
1
3
4
5
RKZ08560
1 -Loosen the screws (1). 2 -Mark side gears (2), retaining washer (3) and
indexed washer (4).
a Replace screw with a new set.
6 2
1
RKZB7460
RKZB7450
30-182 WB93R-5E0
REMOVAL AND INSTALLATION REAR AXLE
3 -Remove screws (1), retaining washer (3) and 6 -Locate the snap ring (6) slot and open it while raising
indexed washer (4). the planetary carrier (5).
6
1
3 5
RKZB7470 RKZB7500
4 -Mark the mounting position of retaining washer (3) 7 -Only if necessary: only if necessary, remove from the
and indexed washer (4) on the planetary carrier (5). planetary carrier (5) the side gears (2) and their
related rollers (7) (n° 66 per gear).
7
5
2
RKZB7480
5 8
E4
RKZB7490
RKZB7520
WB93R-5E0 30-183
REMOVAL AND INSTALLATION REAR AXLE
9 -Use suitable puller and separate hub housing (9) 12 -Remove from hub housing (9) the outer race of the
from wheel flange (10). bearing (12).
10 12
9
9
RKZB7530
9 13
11
RKZB7540
RKZB7570
14
10
11 9
RKZB7580
RKZB7550
30-184 WB93R-5E0
REMOVAL AND INSTALLATION REAR AXLE
15 -Using an angle grinder, cut the cage and etch the 3 -Install spacer (14) on wheel flange (10
bearing ring (13).
Use a chisel to cut and remove bearing inner race
(13).
14
10
10
13
RKZB7580
9
E6
10
12
RKZB7541
10
11
13
RKZB7610
RKZB7590
WB93R-5E0 30-185
REMOVAL AND INSTALLATION REAR AXLE
6 -Using spanner E4, tighten ring nut (8) to the required 9 -Attach lifting equipment to planetary carrier (5) and
torque. lower into hub (9).
9
E4
8
RKZB7650
RKZB7620
10 -During installation the locking ears of the planetary
carrier (5) must engage the ring nut (8) as shown in
7 -Apply a light coat of Lithium based grease to the
figure and in next one.
planetary carrier (5) stud to hold the needle bearings
(7) (n° 33) in place.
5
7
RKZB7660
RKZB7630
7
2
RKZ08570
RKZB7640
30-186 WB93R-5E0
REMOVAL AND INSTALLATION REAR AXLE
12 -Open the snap ring (6) and slowly lower the planetary
carrier (5).
5
RKZB7500
3
RKZB7470
WB93R-5E0 30-187
REMOVAL AND INSTALLATION REAR AXLE
6 9
7
1 4
3 5
8
1
RKZ08460
1 -Drain the oil completely from the differential. 2 -Remove the all screws (1).
RKZB7670
RKZB7130
30-188 WB93R-5E0
REMOVAL AND INSTALLATION REAR AXLE
3 -Separate from axle (2) the differential housing (3) 6 -Use the tool E7, unscrew the adjuster ring nuts (5) e
using pry bars in slots. (6).
E7
3
2
5
RKZB7680 RKZB7710
4 -Attach lifting eyes to differential housing (3) and 7 -Remove out the differential case (7). The external
remove it. rings (8) and (9) are removed together with the
differential housing.
RKZB7690
5 -Remove the bolts (4) securing the ring nuts (5) and
(6). 7
RKZB7720
4.2 Assembly
1 -Using driver E8, install bearing outer races (8) and (9)
4 to differential housing (7).
5
E8
RKZB7700
8
RKZB7730
WB93R-5E0 30-189
REMOVAL AND INSTALLATION REAR AXLE
2 -Position the complete differential box (7) with 5 -Lock the pinion and move the crown gear
bearings on the differential carrier (3). alternatively and note the pinion-ring gear backlash,
measured with the comparator.
Repeat the operation on 2 or more points (teeth),
rotating the crown gear, so that to obtain an average
value.
3 Check if the measured backlash value is within the
requested range:
0.21–0.29 mm
Adjust by operating the adjuster ring nuts. (5) and (6),
using tool E7.
7
RKZB7721
RKZB7750
E7
6 -Adjust the ring nuts (5) and (6) remembering that:
a - if the measured backlash is less than the given
tolerance range, unscrew the adjuster ring nut (6)
and screw in the adjuster ring nut (5) by the same
measure;
a - if the measured backlash is greater than the
given tolerance range, unscrew the adjuster ring
5 nut (5) and screw in the adjuster ring nut (6) by the
RKZB7710
same measure.
RKZ08590
RKZB7740
30-190 WB93R-5E0
REMOVAL AND INSTALLATION REAR AXLE
7 -Repeat the whole sequence of the above mentioned 9 -If the reading is not within the requested range,
operations till the indicated conditions are reached. thoroughly check the assembly of each component
and operate the adjuster ring nuts (5) and (6) of the
differential support:
a - if total preload is less than the specified value,
tighten the adjuster ring nuts (5) and (6) by the
same amount, while keeping the pinion/ring gear
backlash value unchanged;
b - if total preload is greater than the specified
value, loosen the adjuster ring nuts (5) and (6) by
the same amount, while keeping the pinion/ring
gear backlash value unchanged;
RKZB7740
Tr = (Pr+0.58) – (Pr+0.87) Nm
where Pr is the actual rolling torque of pinion
10 -To test the marks of the bevel gear teeth, paint the
alone.
ring gear with red lead paint.
The marking test should be always carried out on
the ring bevel gear teeth and on both sides.
E9
RKZB7760
RKZ14610
WB93R-5E0 30-191
REMOVAL AND INSTALLATION REAR AXLE
3 Screw: 10Nm
teeth surfaces will be regular.
Z - Excessive contact on the tooth tip:
Approach the pinion to the ring bevel gear and
then move the ring bevel gear away from the
pinion in order to adjust the backlash.
X - Excessive contact at the tooth base: 4
Move the pinion away from the ring bevel gear
and then approach the ring bevel gear to the
pinion in order to adjust the backlash.
Z 5
OK
RKZB7700
12 -Movements to correct:
1 - move the pinion for type X contact adjustment.
2 - move the pinion for type Z contact adjustment.
RKZB7770
3
2
RKZB7691
30-192 WB93R-5E0
REMOVAL AND INSTALLATION REAR AXLE
3 Screw: 169 Nm
17 -Refill the hydraulic oil.
RKZB7670
WB93R-5E0 30-193
REMOVAL AND INSTALLATION REAR AXLE
9
10
5
4 1
12
2
11
6
3
8
13
7
RKZ08620
1 -Loose plug (1) but do not remove it. 2 -Hold the differential lock fork (2) down to catch a
block inside of the housing, remove the plug (1).
1
RKZB7780
RKZB7790
30-194 WB93R-5E0
REMOVAL AND INSTALLATION REAR AXLE
3 -Pull the differential lock fork (2) up, place a flat piece 6 -Remove the spring (4).
of steel under the shaft (3) to keep it from moving
down.
RKZB7830
3
RKZB7800 7 -Remove the shaft (3) from differential housing.
RKZB7840
8 -Remove the fork (2), spring (7) and bushing (8) from
RKZB7810 the shaft (3).
2 8 7
3
RKZB7850
RKZB7820
WB93R-5E0 30-195
REMOVAL AND INSTALLATION REAR AXLE
9 -Remove O-Ring (9) from plug (1) and O-rings (11) 3 -Insert in the differential housing the shaft (3)
and (12) from the piston (10). complete.
10 11
12
1 3
9
RKZB7860 RKZB7840
10 11
12
1
9 RKZB7830
8 6
13
2 3 8 7
RKZB7820
RKZB7870
30-196 WB93R-5E0
REMOVAL AND INSTALLATION REAR AXLE
6 -Pull the differential lock fork (2) up, place a flat piece 9 -Tighten plug (1) to the requested torque.
3 Plug: 180 Nm
of steel under the shaft (3) to keep it from moving
down.
3 RKZB7780
RKZB7800
RKZB7810
RKZB7790
WB93R-5E0 30-197
REMOVAL AND INSTALLATION REAR AXLE
6. Differential
6.1 Disassembly
11 2
17
3
16
10
9
13
21 20 22
10 9
18
8 23 25
7 24
5 9
4 10
1 18 21
19 20
14
6 15
RKZ08630
1 -If differential bearings are to be replaced, remove 2 -Remove snap ring (4).
bearing outer rings (1) and (2).
Remove sleeve (3).
1 4
RKZB7900
RKZB7890
30-198 WB93R-5E0
REMOVAL AND INSTALLATION REAR AXLE
3 -Remove the differential housing cover (5), remove 6 -Remove the three pins (10) securing the spider pins
the anti rotation pin (6) and the thrust washer (7). in the differential.
5 7
10
RKZB7910 RKZB7940
4 -Remove the side gear (8). 7 -Remove the ring gear cap screws (11), remove the
ring gear (12).
11
12
8
RKZB7920
RKZB7950
13
9
14
RKZB7930
RKZB7960
WB93R-5E0 30-199
REMOVAL AND INSTALLATION REAR AXLE
9 -Remove the planetary gear (14) and thrust washer 12 -Remove pins (18), spider gears (20) and thrust
(15). washers (21).
18
15 18
14 20
21
RKZB7970 RKZB8000
10 -Push the pin (13) out of the housing and remove the 13 -Remove side gear (22) and thrust washer (23) from
planetary gear (16) and thrust washer (17). the housing.
13
16 17
22 23
RKZB7980 RKZB8010
11 -Push the short spider pins (18) out of the spacer (19) 14 -Remove the differential locking pins (25) from the
by pushing them through the hole in the spacer (19). housing (24).
19 25
18
18
24
RKZB7990 RKZB8020
30-200 WB93R-5E0
REMOVAL AND INSTALLATION REAR AXLE
6.2 Assembly 4 -Lubricate and install planetary gear (20) and its
respective thrust washer (21) and introduce the pins
1 -Install and lubricate new O-rings (26) on the pins
(18) forward enough to support them.
(25).
26
25
18
18
20
21
RKZB8030
RKZB8000
19
24 18
18
RKZB8020
24
3 -Lubricate and install sun gear (22) and thrust washer
(23).
a Orient pin (13) with the flats on the pin facing up.
2 Gear and pin: differential oil
22 23
RKZB8010 13
16 17
RKZB7980
WB93R-5E0 30-201
REMOVAL AND INSTALLATION REAR AXLE
7 -Lubricate and install the planetary gear (14) and 10 -Install the planetary gear (8).
thrust washer (15) and introduce the pin (13). Orient
the hole so as to align with the hole on the differential
housing (24).
15
8
24
14 RKZB7920
5 7
11
RKZB7910
12
RKZB8040
3 Caps: 25 Nm
5
RKZB8050
RKZB7930
30-202 WB93R-5E0
REMOVAL AND INSTALLATION REAR AXLE
RKZB7901
22
RKZB7891
15 -Install bearing outer rings (1) and (2) using driver E8.
E8
1
RKZB8070
WB93R-5E0 30-203
REMOVAL AND INSTALLATION REAR AXLE
7. Differential group
7.1 Disassembly
8
9
10
6
7
2
1
5
RKZ08640
1 -Fit the differential carrier (1) in a vise. 2 -Remove the ring nut (1) and collect its retaining
Unscrew the lock nut (1) using special tools E9 - E10. washer (2).
E9 2 1
RKZB8080
E10
RKZB7751
30-204 WB93R-5E0
REMOVAL AND INSTALLATION REAR AXLE
3 -Tap the shaft with a soft hammer to remove the bevel 6 -Check all pinion components for wear.
pinion (3).
a The ring nut (1) and the snap spacer (6) must be
a Take care not to drop the bevel pinion (3). replaced.
3 5
1
4
6
7
RKZ08660
5 7.2 Assembly
RKZ08650
E11
8
9
9 7
RKZB8090 RKZB8110
5 -To remove bearing inner ring (8) from bevel pinion 2 -Insert inner rings (7) and (8) in their housings.
(3), use a commercially available grip puller. Assemble the false pinion E13 and its ring nut (1).
Recover bearing inner ring (8) and the shim (10) Tighten without exceeding the ring nut, till the
under it. backlash is eliminated.
8
3
9
7
E13
8 1
10
RKZ08670
RKZB8100
WB93R-5E0 30-205
REMOVAL AND INSTALLATION REAR AXLE
3 -Install special tool E14 to the differential group 6 -In order to determine the necessary thickness value
supports (9). (S) between the pinion and the bearing, subtract the
value (V), stamped on the pinion head (V=requested
distance), from the measured value (X).
S = (X–V) mm
E14
RKZB8120
SHIM RANGE
Shims 2.5 2.6 2.7 2.8 2.9 3.0 3.1 3.2 3.3 3.4
9 RKZB8130
RKZB8150
C
X
A
B
RKZ08680
30-206 WB93R-5E0
REMOVAL AND INSTALLATION REAR AXLE
8 -Remove the special tool E14 to the differential group 11 -Install bearing outer ring (7) to pinion end.
supports (9). To install bearing (8), use special tool E3 and a
Remove the ring nut (10), the false pinion E13 and hammer.
the bearing cones (7) and (8).
8
7
9
7
E13
1
RKZB8180
RKZ08670
12 -Insert a ring nut washer (2) and screw a new lock ring
9 -Select a suitable shim (10) and install with the nut (1) on the pinion end.
chamfer facing the gear, then install bearing inner
ring (8) to pinion (3) with the help of a press and tool
E3, and check to ensure that it fits snugly in place.
2 1
10
3 RKZB8080
RKZB8160
4
6
5
RKZB8170
WB93R-5E0 30-207
REMOVAL AND INSTALLATION REAR AXLE
13 -Screw the ring nut in (1), using the wrench for ring nut 15 -Once you got the requested preloading value, caulk
E10 and for pinion retainer E9. the ring nut (1).
E9 RKZB8200
E10
RKZB7751
RKZB8190
30-208 WB93R-5E0
REMOVAL AND INSTALLATION SHOVEL PPC VALVE
k Lower the working equipment completely until it 3 -Disconnect five hoses (5) from PPC valve (4).
rests on the ground; engage the parking brake, stop a Check to ensure that hoses are marked; scribble
the engine and remove the ignition key. match marks if necessary. [*1]
k Release all residual pressure from all circuits. a Cap the hoses and holes to prevent
(For details, see "20 TESTING AND contamination.
ADJUSTMENTS").
5 RKZC2140
RKZC2130
6 4
2
RKZC2150
RKZC1051
WB93R-5E0 30-209
REMOVAL AND INSTALLATION SHOVEL PPC VALVE
Installation
• To install, reverse removal procedure.
[*1]
P3 P
Front
3
P2
P
P1
2
T
T
4
P4
RKZ10761
30-210 WB93R-5E0
REMOVAL AND INSTALLATION SHOVEL LIFT CYLINDERS
on the ground; apply the parking brake, and stop the 4 -Place a sling around the cylinder and connect it to a
engine. hoisting device.
1 -Introduce non-slip blocks “A” between the shovel a Do not engage the piston return hose with the
dump tie bar (1) and the spacer (2) of the fulcrum sling.
lever (3) on removal side. 5 -Extract pin (6) to expose piston eye and safety rod
(9).
6 -Remove rod.
3
A
1
8
9
2
RKZC2160
7
2 -Take off the snap-ring (4) and the internal retaining 6
spacer (5) for the piston attachment pin (6). RKZC2180
8
6
5
10
RKZC2170
B
RKZC2190
WB93R-5E0 30-211
REMOVAL AND INSTALLATION SHOVEL LIFT CYLINDERS
9 -Remove hoses (8) and (11), and remove hose clamp Installation
(12).
• To install, reverse removal procedure.
a Cap pipes, hoses and holes to prevent
contamination. [*1]
10 -Remove the snap-ring (13) and the spacer (14). k When aligning the positions between the hole and
the pin, turn the engine over at low idling speed.
11 -Remove cylinder (10). Do not insert fingers into the holes to check
alignment.
12 [*2]
14 2 Internal bushing: ASL800050
1 -Start the engine and bleed the air from the cylinders.
(For details, see "20 TESTING AND
ADJUSTMENTS").
8 13
RKZC2200
30-212 WB93R-5E0
REMOVAL AND INSTALLATION SHOVEL DUMP CYLINDERS
apply the parking brake, and stop the engine. a Cap the hoses and holes to prevent
contamination.
1 -Remove the strap retaining the piston return hose
(1).
A 5 1
6
4
RKZC2210
8 9
10 7
RKZC2240
WB93R-5E0 30-213
REMOVAL AND INSTALLATION SHOVEL DUMP CYLINDERS
Installation
• To install, reverse removal procedure.
[*1]
a After bleeding the air, check the oil level in the tank.
30-214 WB93R-5E0
REMOVAL AND INSTALLATION SHOVEL
SHOVEL
Removal 3 -Take out the screws (4) and remove the pins (5) of the
but without forcing it downwards. 4 -Start the engine and put the machine into reverse
gear in order to disengage the boom (6).
4 Shovel: 436 kg
1 -Stop the engine and release residual pressures.
5
RKZC2130
RKZA1471
2 -Take out the screws (1) and remove the pins (2) of the
lever (3). Installation
Rest the lever (3) on the boom. [*1] [*2]
• To install, reverse removal procedure.
[*1]
3 [*2]
RKZA1461
WB93R-5E0 30-215
REMOVAL AND INSTALLATION FRONT WORKING EQUIPMENT
4 3
RKZC2290
RKZC2270
4
RKZC2280
A
RKZC2191
30-216 WB93R-5E0
REMOVAL AND INSTALLATION FRONT WORKING EQUIPMENT
RKZC2300
WB93R-5E0 30-217
REMOVAL AND INSTALLATION SOLENOID VALVE GROUP
moving all control levers in all directions. 5 -Mark and disconnnect all hoses (7).
9
RKA53860
7
2 -Disconnect the connector (1) and remove the seat
(2).
7
8
RKZC2320
Installation
2 • To install, reverse removal procedure.
RKZC1031
RKZC1901
30-218 WB93R-5E0
REMOVAL AND INSTALLATION BACKHOE BOOM CYLINDER
3
2
RKZC2350
8
RKA53870 9
6
11
5
10
RKZC2340
RKZC2370
WB93R-5E0 30-219
REMOVAL AND INSTALLATION BACKHOE BOOM CYLINDER
9 -Place a safety block "B" under the cylinder (12) 14 -Disconnect hoses (13) and (14) from cylinder (12).
controlling the arm.
a Cap pipes, hoses and holes to prevent
contamination.
12
12
14
RKZC2380
13
10 -Sling the cylinder (12) in a band and connect it to a RKZC2410
14 4 Cylinder: 87.5 kg
12
16
15
13
RKZC2390
[*2]
RKZC2400
1 -Start the engine and bleed the air from the cylinders.
(For details, see "20 TESTING AND
ADJUSTMENTS").
a After bleeding the air, check the oil level in the tank.
30-220 WB93R-5E0
REMOVAL AND INSTALLATION ARM CYLINDER
ARM CYLINDER
Removal 6 -Remove the strap (5) retaining the hoses.
1 -Fully extend the arm (1) and fully open the bucket (2). 7 -Sling the cylinder (4) in a band and connect it to a
Manoeuvre the boom until the outer end of the boom hoisting device; apply a slight tension.
is in a level position.
a Do not engage the hoses with the band.
2 -Place and force a jack stand “A” and a non-slip block
8 -Remove the snap ring (6) retaining the cylinder
under the boom.
fulcrum pin (7) and the screw (8) retaining the piston
3 -Lower arm (3) until bucket teeth touch the ground. pin (9).
1 7 6
8
3 5
2
RKZC2440
RKA53870
4 4 11
10
RKZC2450
B
10 -Pull out the piston attachment pin (9). [*1] [*2]
RKZC2430
RKZC2460
WB93R-5E0 30-221
REMOVAL AND INSTALLATION ARM CYLINDER
11 -Pull out the cylinder attachment pin (7) until the eye of Installation
cylinder (4) is exposed. [*1] [*2]
• To install, reverse removal procedure.
12 -Remove cylinder (4) and recover shims (if any).
4 Arm cylinders: 67 kg
[*1]
a After bleeding the air, check the oil level in the tank.
RKZC2470
30-222 WB93R-5E0
REMOVAL AND INSTALLATION JIG ARM CYLINDER
k Open the arm (1) completely and lower it until it rests 7 -Disconnect the tubes (6), (7), (8) and (9).
on a trestle “A” that is roughly 40 cm high. Extend the a Cap pipes, hoses and holes to prevent
jig arm (2) until it rests on a block “B”, and let the contamination.
bucket teeth rest on the ground.
8 -Remove the clamp (10).
1 -Stop the engine and release the cylinder (3)
pressures, by moving the command pedal several 9 -Remove the screws (11) and the pin (12). [*1] [*2]
times.
10 -Remove cylinder (3).
2 -Place a sling around the cylinder (3).
3 -Take off the snap ring and remove the pin (4). [*1] [*2] 5
11 10
6
1
8
4 12
2
9 7
RKZA7951
A
Installation
B RKZA7931
[*1]
[*2]
a After bleeding the air, check the oil level in the tank.
4 -Start the engine to retract the piston.
5 -Stop the engine and release residual hydraulic
pressure from all circuits by operating the control
levers in all directions.
WB93R-5E0 30-223
REMOVAL AND INSTALLATION OUTRIGGER CYLINDER
OUTRIGGER CYLINDER
Removal 6 -Sling the outrigger cylinder (6) and remove the
2
RKA53910
RKA53920
RKA53890
8 -Remove bolt (9) and extract pin (10)
5
4
RKA53980
RKA53900
30-224 WB93R-5E0
REMOVAL AND INSTALLATION OUTRIGGER CYLINDER
[*1]
[*2]
a After bleeding the air, check the oil level in the tank.
RKA53990
WB93R-5E0 30-225
REMOVAL AND INSTALLATION OUTRIGGER ARMS
OUTRIGGER ARMS
Removal Installation
k Before removing outrigger arms, the outrigger • To install, reverse removal procedure.
RKA54000
RKA54010
RKA54020
30-226 WB93R-5E0
REMOVAL AND INSTALLATION BACKHOE SWING CYLINDERS
RKZC2560
RKA53930
5
1
RKZC2570
6 RKZC2580
RKZC2550
WB93R-5E0 30-227
REMOVAL AND INSTALLATION BACKHOE SWING CYLINDERS
7 -Take out the screws (8) and remove the pins (9). Installation
8 -Rotate the cylinders to disengage the piston heads 1 -Mount the cylinders (6) and the upper cylinder
from the swing bracket (10) and remove the cylinders fulcrum support (2). Secure the support with the four
(6). screws (3).
10
RKZC2590
5 3
7
6 RKZC2551
9
8
RKZC2591
[*2]
[*3]
30-228 WB93R-5E0
REMOVAL AND INSTALLATION BACKHOE BUCKET CYLINDER
3
2 6
RKZC2620
A
7 -Disconnect the tubes (7) and (8).
RKA53870
a Cap pipes, hoses and holes to prevent
contamination.
3 -Lower the outriggers to the ground, apply the parking
brake, and stop the engine. 8 -Take off the snap ring (9) and remove the pin (10).
9
4
RKZC2630
RKZC2610
WB93R-5E0 30-229
REMOVAL AND INSTALLATION BACKHOE BUCKET CYLINDER
Installation
• To install, reverse removal procedure.
[*1]
1 -Start the engine and bleed the air from the cylinders.
(For details, see "20 TESTING AND
ADJUSTMENTS").
a After bleeding the air, check the oil level in the tank.
30-230 WB93R-5E0
REMOVAL AND INSTALLATION BACKHOE BOOM SAFETY CYLINDER
1
RKZC2640
3
6 -Disconnect feed hose (9).
2
a Cap the hose and hole to prevent contamination.
7 -Loosen and remove the screws (10) and the cylinder
A (11).
RKA53870
RKZC2650
Installation
6
4 • To install, reverse removal procedure.
5 -Loosen and remove nut (7) and remove tie rod (8).
WB93R-5E0 30-231
REMOVAL AND INSTALLATION CYLINDER
CYLINDER
SHOVEL ARM, SHOVEL, BOOM, ARM, BUCKET, OUTRIGGERS, JIG ARM
Disassembly
1 -Position cylinder to be disassembled (1) to
equipment U1.
4 3
2 -Using wrench U2 with torque amplifier, fully unscrew
the head (2).
U1
U2 2 1 U3
U1 RKZ11440
a Arm only:
Note down direction of installation of brake
bushing (5a).
RKZ11420
3
U1
5a
RKZ11620
30-232 WB93R-5E0
REMOVAL AND INSTALLATION CYLINDER
10
U6 U7
18 15
RKZ11600
All cylinders
18
2 -Using tool U7, install scraper ring (15) and snap ring
12 (14).
17
3 -Assemble seals (16) and (17).
17
16
13
14
15
RKZ11510
WB93R-5E0 30-233
REMOVAL AND INSTALLATION CYLINDER
1 –Using tool U4 expand seal (11) and fit it on the piston. a Arm cylinder only.
Check orientation of brake bushing (5a).
2 -Calibrate seal (11) using calibrator U5.
5a 5
U5
U4 11
11
6 RKZ11610
RKZ11530
4 -Assemble the guide ring (10). 2 -Remove any existing dirt from the rod and install the
head (2).
11 10 3 -Boom cylinder only.
Thread piston (5) onto rod (6) and lock into position
12 with a wrench U3 with torque amplifier.
4 6 2
RKZ11470 U1
9 8
7
RKZ11630
30-234 WB93R-5E0
REMOVAL AND INSTALLATION CYLINDER
4 -Install safety dowel (19) and tighten until snug. Final assembly
2 Dowel: Loctite 542 1 -Lubricate piston seals (5) and head gaskets (2) and
introduce piston into cylinder (1).
4 5 2
U1
RKZ11641
WB93R-5E0 30-235
REMOVAL AND INSTALLATION CYLINDER
1 -Position cylinder (1) to equipment U1. a If removal is awkward, tighten screw until snug
and work thread with a tap.
2 -Using wrench U2 with torque amplifier, fully unscrew
the head (2).
4
U2 2 1
U1
4
RKZ11450
RKZ11420
6 -Using a wrench U8, remove the complete piston (6).
3 -Extract the complete piston (3). a If no U8 tool is used, drill 4 holes ( Ø 10) and
loosen the complete piston.
a Place a receptacle to collect the oil.
3 U8
U1 4
DH
RKZ11490
RKZ11430
3
5
U1
6
2
RKZ11480
RKZ11540
30-236 WB93R-5E0
REMOVAL AND INSTALLATION CYLINDER
8 -Remove guide ring (7), seal (8), O-ring (9) and their Assembly
respective anti-extrusion rings from piston.
a Lubricate surfaces to prevent damage to the
gaskets, seals, O-rings, scraper, etc.
U6 U7
19 16
RKZ11650
13 16
19 RKZ11511
18
17
14
15
16
RKZ11511
WB93R-5E0 30-237
REMOVAL AND INSTALLATION CYLINDER
2 -Calibrate seal (8) using calibrator U5. 2 -Remove any existing dirt from the rod and install the
head (2).
U5
U4
8
2 5 6
8
U1
RKZ11531
RKZ11541
8 7 H
U8
5
9
6
RKZ11550
12 11 10 RKZ11500
3b -With new parts:
a - Thread the piston (6) in, ensure it contacts the
rod (5), and then tighten.
3 Piston: 297±27.4 Nm
5
RKZ11560
30-238 WB93R-5E0
REMOVAL AND INSTALLATION CYLINDER
RKZ11570
Final assembly
1 -Lubricate piston seal (6) and head gasket (2) and
introduce piston into cylinder (1).
3 Head: 785±78.5 Nm
a When assembly is complete, plug cylinder union
fittings to prevent contamination.
U2 2 1
U1
RKZ11420
WB93R-5E0 30-239
REMOVAL AND INSTALLATION BACKHOE WORKING EQUIPMENT
3
2
RKZC2411
6 6
6
RKA54030
B
RKZC2701
30-240 WB93R-5E0
REMOVAL AND INSTALLATION BACKHOE WORKING EQUIPMENT
9 -Disconnect hoses (9) from bucket cylinder. 12 -Remove the screw (10) and the pin (11).
a Cap pipes, hoses and holes to prevent 13 -Start the engine, draw in the outriggers and move the
contamination. machine forward.
a Mark the pipes to avoid exchanging them during a Recover the shims between boom and swing
installation. bracket.
10 -Slide all hoses off and place them aside. 4 Backhoe working equipment: 850 kg
9
9
10
11
RKZC2680
RKZC2700
1 -Start the engine and bleed the air from all circuits.
(For details, see "20 TESTING AND
ADJUSTMENTS").
C
RKZC2690
WB93R-5E0 30-241
REMOVAL AND INSTALLATION BACKHOE BUCKET
BACKHOE BUCKET
Removal Installation
k Place the bucket on a level surface, resting on its • To install, reverse removal procedure.
back.
[*1]
7
4
6
2
5
1
3
RKZA1350
30-242 WB93R-5E0
REMOVAL AND INSTALLATION BACKHOE BOOM
BACKHOE BOOM
Removal 7 -Take out the retaining screw and remove the pin (3).
[*1] [*2]
1 -Remove the arm cylinder.
(For details see "ARM CYLINDER"). a Recover the shims (4) between boom and swing
bracket.
2 -Remove the arm.
(For details see "ARM"). 8 -Remove the boom (2).
3 -Start the engine and rest the boom on the ground. 4 Boom: 248 kg
4 -Remove the boom cylinder.
(For details see "BACKHOE BOOM CYLINDER").
3
RKZC2720
Installation
1 • To install, reverse removal procedure.
1 1 [*1]
a After bleeding the air, check the oil level in the tank.
RKA54040
WB93R-5E0 30-243
REMOVAL AND INSTALLATION ARM
ARM
Removal 7 -Start the engine and retract the piston completely.
1 -Remove the bucket. 8 -Rest cylinder (5) on a block “A” and disconnect from
(For details see "BACKHOE BUCKET"). the hoisting device.
2 -Remove the bucket cylinder and the link (1). 9 -Stop the engine.
(For details, see "BACKHOE BUCKET
10 -Connect the arm (8) to the hoisting device and apply
CYLINDER").
a slight tension to the cable.
3 -Take out the lock nut (2), and the washer and remove
the pin (3) and the links (4). [*1] [*2]
8 5
4 -Start the engine, bring the arm into a vertical position
and lower it to the ground.
A
RKZC2730
1
3
11 -Take out the screws (9) and remove the pin (10). [*1]
[*2]
6 5
RKZC2740
RKZC2441
30-244 WB93R-5E0
REMOVAL AND INSTALLATION ARM
Installation
• To install, reverse removal procedure.
[*1]
[*2]
[*3]
WB93R-5E0 30-245
REMOVAL AND INSTALLATION JIG ARM
JIG ARM
Removal Installation
1 -Remove the bucket. • To install, reverse removal procedure.
(For details see "BACKHOE BUCKET").
[*1]
1
3
RKZA1360
4 -Disconnect the jig arm hoses (5) and (6), the bucket
cylinder hoses (7) and (8), and the hoses of the
auxiliary equipment (9) and (10).
11
6
7 10
9 8
5
RKZA7970
30-246 WB93R-5E0
REMOVAL AND INSTALLATION 2nd ARM
2nd ARM
Removal 7 -Stop the engine and loosen by several turns the gib
adjustment screws.
1 -Remove the bucket (1).
(For details see "BACKHOE BUCKET"). a Loosen the screws on both sides.
2 -Remove the bucket cylinder (2) and the link (3). 8 -Slide out the 2nd arm (7).
(For details, see "BACKHOE BUCKET
CYLINDER").
1 2 RKZA8000
3
Installation
• To install, reverse removal procedure.
[*1]
5 -Connect the 2nd arm (7) to some hoisting tackle. 2 Internal bushing: ASL800050
a Use the bucket pin hole and the safety pin holes. [*3]
6 -Start the engine and, maintaining constant tension a Tighten the locknut completely, then release it half a
on the section of cable or chain connected to the turn.
bucket coupling, slowly raise the boom until both
sections of cable or chain are under slight tension.
5
3
RKZA7990
WB93R-5E0 30-247
REMOVAL AND INSTALLATION 2nd ARM GUIDES
6
7
RKZ02390
Installation
A
• To install, reverse removal procedure.
RKZA8010
[*1]
4 -Loosen and remove the screws (3), the spring 2 Guides and 2nd arm guides: ASL800040
washers and remove the upper guides (4).[*1]
1 -Adjust the clearances, keeping the jig arm (1) aligned
5 -Connect the 2nd arm (1) to some hoisting tackle. with respect to the 2nd arm (2).
(For details, see "20 TESTING AND
a Use the bucket pin hole and the safety pin holes.
ADJUSTMENTS").
6 -Slowly raise the 2nd arm (1) until it rests on the
supporting surfaces of the upper guides.
2
1
5 6 RKZA8030
RKZA8020
30-248 WB93R-5E0
REMOVAL AND INSTALLATION BACKHOE SWING BRACKET
4 Bracket: 162.5 kg
1 -Remove the equipment.
(For details see "BACKHOE WORKING
EQUIPMENT").
2 -Take out the screws (1) and remove the pins (2) that 10
connect the swing cylinders (3). [*1] [*2]
2
1
10
3
10
RKA54060
Installation
RKZC2592 • To install, reverse removal procedure.
a After bleeding the air, check the oil level in the tank.
4 -Sling the swing bracket (5)
• To install, reverse removal procedure.
5 -Take out screws (6) and (7) and remove pins (8) and
(9) from swing bracket. [*1] [*2]
5 8 6
RKA54050
WB93R-5E0 30-249
40 STANDARD MAINTENANCE
WB93R-5E0 40-1
STANDARD MAINTENANCE EXPLANATION OF TERMS FOR MAINTENANCE STANDARD
Example:
Standard size Tolerance
120 –0.022
–0.126
Example:
Tolerance
Standard size
Shaft Hole
–0.030 +0.046
60
–0.076 +0
40-2 WB93R-5E0
STANDARD MAINTENANCE EXPLANATION OF TERMS FOR MAINTENANCE STANDARD
R e p a i r l i m i t a n d a l l o w ab l e v a l u e or
allowable dimension
• The size of a part changes because of wear and
deformation while it is used. The limit of changed size
is called the “repair limit”.
• If a part is worn to the repair limit, it must be replaced
or repaired.
• The performance and function of a product lowers
while it is used. A value which the product can be used
without causing a problem is called the “allowable
value” or “allowable dimension”.
• If a product is worn to the allowable value, it must be
checked or repaired. Since the permissible value is
estimated from various tests or experiences in most
cases, however, it must be judged after considering
the operating condition and customer's requirement.
WB93R-5E0 40-3
STANDARD MAINTENANCE TRANSMISSION
TRANSMISSION
3 30 Nm
3 23 Nm
3 23 Nm 3 23 Nm
3 23 Nm 3 23 Nm
40-4 WB93R-5E0
STANDARD MAINTENANCE TRANSMISSION
3 50 Nm
3 50 Nm
3 23 Nm
3 40 Nm
3 139 Nm
2 Loctite 518
3 23 Nm RKZ10320
A-A
WB93R-5E0 40-5
STANDARD MAINTENANCE TRANSMISSION
3 23 Nm 3 80 Nm 3 25 Nm
3 50 Nm
2 Loctite 542
3 23 Nm
D D
RKZ10330
3 30 Nm 3 26-30 Nm
40-6 WB93R-5E0
STANDARD MAINTENANCE TRANSMISSION
3 9-11 Nm
3 7-10 Nm
3 21.5-24.5 Nm
D-D
3 22 Nm 3 23 Nm
3 5-8 Nm
RKZ10340
E-E
WB93R-5E0 40-7
STANDARD MAINTENANCE TRANSMISSION
3 30 Nm
I I
3 100 Nm 3 23 Nm 3 50 Nm
2 Loctite 270
F-F G-G
3 40 Nm
2 Loctite 542
2 Loctite 638
RKZ10370
H-H I-I
40-8 WB93R-5E0
STANDARD MAINTENANCE FRONT AXLE
FRONT AXLE
Differential
3 95 Nm
2 Loctite 270
3 13 Nm
3 169 Nm
2 Loctite 510
2 Loctite 638
2
3
4
RKZ10380
WB93R-5E0 40-9
STANDARD MAINTENANCE FRONT AXLE
RKZ10390
3 266 Nm
3 60 Nm
Unit: mm
40-10 WB93R-5E0
STANDARD MAINTENANCE FRONT AXLE
Planetary - Joint
3 190 Nm
3 8 Nm
3 120 Nm
1
RKZ10400
3 70 Nm
3 8 Nm
2 Loctite 270
Unit: mm
WB93R-5E0 40-11
STANDARD MAINTENANCE FRONT AXLE
3 350 Nm 3 120 Nm B
39.32°
50°
A
A 3 300 Nm
3 250 Nm
1920 -02
RKZ10410
A-A B-B
Deatil C
Unit: mm
40-12 WB93R-5E0
STANDARD MAINTENANCE REAR AXLE
REAR AXLE
1
3 10 Nm 3 10 Nm
3 155 Nm
2 Loctite 270
3
4
RKA53650
Unit: mm
No. Check item Criteria Remedy
Standard
clearance Clearance limit
1 Axle clearance
---- ----
2 Backlash of crown wheel and pinion 0.21–0.29 0.29 Adjust
Pinion rotation force (without sealing ring)
3 As measured on pinion Ø 34.8 115-138 Nm
WB93R-5E0 40-13
STANDARD MAINTENANCE REAR AXLE
3 80 Nm 2 Loctite 638 3 18 Nm
3 1500 Nm
3 60 Nm
3 226 Nm 3 10 Nm
2 Loctite 270
2 Loctite 638
2 Loctite 510
3 169 Nm
2 Loctite 638 3 80 Nm
3 120 Nm 1
2
RKA53660
40-14 WB93R-5E0
STANDARD MAINTENANCE REAR AXLE
1 2
3
2 ASL800050
2 Loctite 638
3 15.3 Nm RKA53670
Unit: mm
WB93R-5E0 40-15
STANDARD MAINTENANCE REAR AXLE
3 180 Nm
RKA53680
40-16 WB93R-5E0
STANDARD MAINTENANCE REAR AXLE
RKA53700
Unit: mm
WB93R-5E0 40-17
STANDARD MAINTENANCE REAR AXLE
3 115 Nm
3 169 Nm
3 45 Nm
3 61–74 Nm
3 13–14 Nm
2 ASL800050
2 ASL800050
2 ASL800050
2 ASL800050
3 180 Nm
3 180 Nm
RKA53690
40-18 WB93R-5E0
STANDARD MAINTENANCE HYDRAULIC PUMP
HYDRAULIC PUMP
3 19.6-24.5 Nm
View X
3 157-196 Nm
A A
3 68.6-83.4 Nm
Z
X
3 27.4-34.3 Nm
3 7.8-9.8 Nm
3 68.6-83.4 Nm
3 19.6-27.4 Nm
3 11.8-14.7 Nm RKZ10440
View Z
WB93R-5E0 40-19
STANDARD MAINTENANCE HYDRAULIC PUMP
3 27.4-34.3 Nm Z
3 27.4-34.3 Nm
X
3 27.4-34.3 Nm 3 27.4-34.3 Nm
RKZ10450
A-A
40-20 WB93R-5E0
STANDARD MAINTENANCE 9-SPOOL CONTROL VALVE
9.8-12.7 Nm
9.8-12.7 Nm
9.8-12.7 Nm
3 29.4-34.3 Nm
3 58.8-73.5 Nm
WB93R-5E0 40-21
STANDARD MAINTENANCE 9-SPOOL CONTROL VALVE
40-22 WB93R-5E0
STANDARD MAINTENANCE 9-SPOOL CONTROL VALVE
3 49–58.8 Nm
3
39.2-49 Nm
3
39.2-49 Nm
3
39.2-49 Nm
3
39.2-49 Nm
39.2-49 Nm
3
39.2-49 Nm
3 137-157 Nm
3 117.6-161.8 Nm
3
117.6-161.8 Nm
WB93R-5E0 40-23
STANDARD MAINTENANCE 9-SPOOL CONTROL VALVE
Unit: mm
Criteria Remedy
Standard size Repair limit
No. Check item
Free Installed Installed Free Installed
installed x length load installed load
Øe
Spool return spring
1 (shovel arm raise 27.1x16.2 26.7 14.4N – 11.8N
control)
Spool return spring
2 (backhoe bucket 66.5x21.1 25.4 73.5N – 58.8N
boom control)
Spool return spring
3 (shovel control) 27.2x16.6 26.7 30.38N – 34.3N
40-24 WB93R-5E0
STANDARD MAINTENANCE 9-SPOOL CONTROL VALVE
3 117.6-161.8 Nm
3 24.5-34.3 Nm
3 19.6-24.5 Nm
3 14.7-19.6 Nm
3 1.3-1.7 Nm
3 24.5-34.3 Nm
3 14.7-19.6 Nm
3 24.5-34.3 Nm
WB93R-5E0 40-25
STANDARD MAINTENANCE 9-SPOOL CONTROL VALVE
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free Installed Installed Free Installed
installed length load installed load
x Øe
Pressure compensation valve
spring
1
(Shovel arm, backhoe bucket,
15.4x6 8 7.44N – 5.96N
boom, shovel, boom swing)
Pressure compensation valve
2 spring 31.4x14.4 21.8 63.7N – 51.0N
(arm)
Pressure compensation valve
3 spring. 18.9x8.4 15 15.7N – 12.5N Replace
(Boom swing, backhoe bucket) spring
Pressure compensation valve
4 spring. 37.1x8.6 24 34.3N – 27.4N
(Front bucket)
Pressure compensation valve
5 spring. 20x8.4 15 4.32N – 3.45N
(boom, shovel arm)
6 Check valve spring 27.2x6.9 21 4.70N – 3.76N
7 Check valve spring 27.2x6.9 22 3.92N – 3.14N
8 Check valve spring 21.9x5 15.8 1.96N – 1.57N
9 Check valve spring 11.3x4.3 7.5 1.72N – 1.38N
40-26 WB93R-5E0
STANDARD MAINTENANCE 9-SPOOL CONTROL VALVE
3 65.7-82.3 Nm
3
2 2
1 1
1 2 E-E 2 1 K-K
F-F L-L
RKZ03882
L-L M-M
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free
installed Installed Installed Free Installed
length load installed load
x Øe
Spool return spring Replace
1 18.0x18 17.5 39.2N – 31.4N
(Outrigger control) spring
Spool return spring
2 20.2x14.2 10.4 30.4N – 24.3N
(Outrigger control
Control valve spring
3 13.0x8.8 11 3.92N – 3.1N
plate lock
WB93R-5E0 40-27
STANDARD MAINTENANCE 9-SPOOL CONTROL VALVE
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free Installed Installed Free Installed
installed length load installed load Replace
x Øe spring
40-28 WB93R-5E0
STANDARD MAINTENANCE 11-SPOOL CONTROL VALVE
WB93R-5E0 40-29
STANDARD MAINTENANCE 11-SPOOL CONTROL VALVE
40-30 WB93R-5E0
STANDARD MAINTENANCE 11-SPOOL CONTROL VALVE
WB93R-5E0 40-31
STANDARD MAINTENANCE 11-SPOOL CONTROL VALVE
Unit: mm
Criteria Remedy
Standard size Repair limit
No. Check item
Free Installed Installed Free Installed
installed x length load installed load
Øe
Spool return spring
1 (shovel arm raise 27.1x16.2 26.7 14.4 N – 11.8 N
control)
Spool return spring
2
(Jig arm)
- 25.4 98.1 N – 78.5 N
40-32 WB93R-5E0
STANDARD MAINTENANCE 11-SPOOL CONTROL VALVE
WB93R-5E0 40-33
STANDARD MAINTENANCE 11-SPOOL CONTROL VALVE
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free Installed Installed Free Installed
installed length load installed load
x Øe
Pressure compensation valve
spring
1
(Shovel arm, backhoe bucket,
15.4x6 8 7.44N – 5.96N
boom, shovel, boom swing)
Pressure compensation valve
2 spring 31.4x14.4 21.8 63.7N – 51.0N
(arm)
Pressure compensation valve
3 spring. 18.9x8.4 15 15.7N – 12.5N Replace
(Boom swing, backhoe bucket) spring
Pressure compensation valve
4 spring. 37.1x8.6 24 34.3N – 27.4N
(Front bucket)
Pressure compensation valve
5 spring. 20x8.4 15 4.32N – 3.45N
(boom, shovel arm)
6 Check valve spring 27.2x6.9 21 4.70N – 3.76N
7 Check valve spring 27.2x6.9 22 3.92N – 3.14N
8 Check valve spring 21.9x5 15.8 1.96N – 1.57N
9 Check valve spring 11.3x4.3 7.5 1.72N – 1.38N
40-34 WB93R-5E0
STANDARD MAINTENANCE 11-SPOOL CONTROL VALVE
3
65.7 - 82.3Nm
14.7 - 19.6Nm
2
2 1
E-E 1 H-H
1 2 2
F-F K-K
J-J L-L
WB93R-5E0 40-35
STANDARD MAINTENANCE 11-SPOOL CONTROL VALVE
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free Installed Installed Free Installed
installed length load installed load
x Øe
40-36 WB93R-5E0
STANDARD MAINTENANCE 11-SPOOL CONTROL VALVE
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free
installed Installed Installed Free Installed Replace
length load installed load
x Øe spring
Pressure compensation
1 31.7x9.2 27.5 43.1N – 34.5N
valve spring.
WB93R-5E0 40-37
STANDARD MAINTENANCE PPC VALVES
PPC VALVES
SHOVEL CONTROL
3 69–88 Nm
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free Installed Installed Free Installed
installed length load installed load
x Øe
1 Return spring (outer) (P2) 31.6 39.1 N
2 Adjusting spring (inner) (P2) 24.6 5.28 N
3 Return spring (outer) (P1) 30.6 41.2 N Replace
4 Adjusting spring (inner) (P1) 23.8 5.28 N
5 Return spring (outer) (P3) 31.9 38.5 N
6 Adjusting spring (inner) (P3) 25.3 5.28 N
7 Return spring (outer) (P4) 31.9 63.9 N
8 Adjusting spring (inner) (P4) 25.3 5.28 N
40-38 WB93R-5E0
STANDARD MAINTENANCE PPC VALVES
1 2
3 3
RKZ10470
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free
Installed Installed Free Installed
installed length load installed load
x Øe
WB93R-5E0 40-39
STANDARD MAINTENANCE SHOVEL CYLINDERS
SHOVEL CYLINDERS
DUMP CYLINDER
3 539±54 Nm 3 1250±130 Nm
1 3
2
707-00-0y920-1
LIFTING CYLINDER
3 677±67.5 Nm 3 1670±170 Nm
1 3
2
707-00-0y891-1
Unit: mm
Criteria
No. Check item Cylinder Standard Tolerance Standard Clearance Remedy
size Shaft Hole clearance limit
40-40 WB93R-5E0
STANDARD MAINTENANCE SHOVEL CYLINDERS
4 IN 1 BUCKET
3 690±69 Nm 3 540±54 Nm
1
42N-6C-12800-1
Unit: mm
Criteria
No. Check item Standard Tolerance Standard Clearance Remedy
size Shaft Hole clearance limit
WB93R-5E0 40-41
STANDARD MAINTENANCE BACKHOE CYLINDERS
BACKHOE CYLINDERS
BOOM
3 2740-2840 Nm
with Loctite 262
3 1010±100 Nm 3
1
2
707-02-0Y941-1
ARM
3 2450±240 Nm 3
3 981±98.1 Nm
1
2
707-00-0Y871-1
BUCKET
31670±170 Nm
1 3
2
707-00-0Y901-1
40-42 WB93R-5E0
STANDARD MAINTENANCE BACKHOE CYLINDERS
BOOM SWING
3 44.1-53.9 Nm 3 785±78.5 Nm
1 2
3 297±29.4 Nm
707-02-07730-1
Unit: mm
Criteria
Boom 60
– 0.030 + 0.151 0.035–
0.527
– 0.076 + 0.005 0.227
Arm 60
– 0.030 + 0.046 0.030–
0.432
– 0.076 0 0.132
Clearance between
1 piston rod and bushing
Bucket 55 – 0.030 + 0.151 0.036– 0.527 Replace
– 0.076 + 0.006 0.227 bushing
Boom 60
– 0.060 + 0.174 0.160–
1.000
– 0.106 + 0.100 0.280
WB93R-5E0 40-43
STANDARD MAINTENANCE BACKHOE CYLINDERS
OUTRIGGERS
3 1420±140 Nm
3 785±78.5 Nm
with Loctite 262
1
707-00-0Y0830_1
JIG ARM
Unit: mm
Criteria
Outriggers 40
– 0.025 + 0.064 0.050–
0.414
– 0.050 + 0.025 0.114
Clearance between
1 piston rod and head Replace
Jig arm 40
– 0.025 + 0.064 0.050–
0.414
– 0.050 + 0.025 0.114
40-44 WB93R-5E0
STANDARD MAINTENANCE FRONT WORKING EQUIPMENT
E
C E
C
D
B
B D
A
A
1 3
2
A-A B-B
C-C
5
4
D-D E-E
RKZ10480
WB93R-5E0 40-45
STANDARD MAINTENANCE FRONT WORKING EQUIPMENT
Unit: mm
Criteria
Clearance between
2 mounting pin and bushing of 45
– 0.050 + 0.240
0.130–0.329 1.000
link and bucket
– 0.089 + 0.080
Clearance between
3 mounting pin and bushing of 45 – 0.050 + 0.096 0.093–0.185 1.000 Replace
link and link
– 0.089 + 0.043
Clearance between
4 mounting pin and bushing (of 60 – 0.060 + 0.178 0.170–0.284 1.000
lift arm) and link – 0.106 + 0.110
Clearance between
5 mounting pin and bushing of 50 – 0.050 + 0.240 0.130–0.329 1.000
lift arm and frame – 0.089 + 0.080
40-46 WB93R-5E0
STANDARD MAINTENANCE SWING BRACKET
SWING BRACKET
RKA53710
WB93R-5E0 40-47
STANDARD MAINTENANCE SWING BRACKET
Unit: mm
Criteria
Clearance between
2 mounting pin and bushing of 65 – 0.060 + 0.228 0.207–0.334 1.000
swing bracket (lower) and – 0.106 + 0.147
sliding plate
Clearance between
3 mounting pin and bushing of 65 – 0.060 + 0.228 0.210–0.334 1.000
sliding plate (upper) and – 0.106 + 0.150 Replace
boom swing bracket bushing
and
Clearance between pin
4 mounting pin swing cylinder 55 –0.030 +0.097 0.068–0.173 1.000
head and bushing on swing –0.076 +0.038
bracket
40-48 WB93R-5E0
STANDARD MAINTENANCE BACKHOE WORKING EQUIPMENT
RKA53720
WB93R-5E0 40-49
STANDARD MAINTENANCE BACKHOE WORKING EQUIPMENT
Unit: mm
Criteria
Clearance between
2 mounting pin and bushing of 45
– 0.050 +0.240
0.130–0.329 1.000
arm and bucket
– 0.089 +0.080
Clearance between
3 mounting pin and bushing of 45 – 0.050 +0.240 0.130–0.329 1.000
arm and link
– 0.089 +0.080
Replace
Clearance between
4 mounting pin and bushing of 45 –0.050 +0.240 0.130–0.329 1.000
link and link – 0.089 +0.080
Clearance between
5 mounting pin and bushing of 50 – 0.050 +0.084 0.087–0.173 1.000
boom and arm – 0.089 +0.037
40-50 WB93R-5E0
90 DIAGRAMS AND DRAWINGS
WB93R-5E0 90-1
DIAGRAMS AND DRAWINGS
90-2 WB93R-5E0
DIAGRAMS AND DRAWINGS HYDRAULIC CIRCUIT DIAGRAM
WB93R-5E0 90-3
DIAGRAMS AND DRAWINGS
90-4 WB93R-5E0
DIAGRAMS AND DRAWINGS ELECTRICAL CIRCUIT DIAGRAM (1/3)
42N-06
11850
P63 42N-06
42N-06 V-Z1
11831
11210
L-N1.5
M-B1.5
M-N1.5
A 1 2 3 4 V/N1
G-V1.5
G-L1
R-N1
G-M1
H-V1
A/B1
H1.5
C-B1
L-R1
L-R1
C-L1
C-L1
L-R1
L-R1
R/N1
A-G1
C-L1
C-L1
A-G1
G-N1
H-V1
R/N1
L/R1
G-V1
A/R1
V-Z1
A/R1
V-N1
V-N1
C-L1
N1
N1
M1
N1
N1
N1
A1
R1
N1
N1
N1
N1
N1
N1
4 2 8 4 1 9 10 12 8 7 2 1
X57 X57 X57 X60 X60 X60 X60 X60 X60 X180
7 1 3 4 6 7 1 3 4 6 4 6 1 3 7 1 1 1 1
1 3 4 6 7 X140 X140 X140 X140 X140 X142 X142 X142 X142 X142 X146 X143 X136 X138
;
4 2 8 4 1 9 10 12 8 7 2 X141 X141 X141 X141 X141
X89 X89 X89 X89 X89 7 1 3 7 1 3 7 1 3
N 0 X80 X80 X80 X81 X81 X81 X82 X82 7 1 3 4 6 7 1 3 4 6
R F WASHER I 4 6 1 3 7
Dx
LAVACRISTALLO 1 3 4 6 7 0 1 E146 E143 E136 E138
7 1 3 7 1 3 7 1 3 II I 0 II I 0
HORN V180 1 1
CLAXON
1 0 0 1 0 0
5 2 8
Sx
8 2 5 8 2 5
H
S141 5 2 8 4 4 4 4
S57 9
S60 5 3 11 6
S89 8 2 5 S80 8 2 S81 8 2
S82 8 2 S140 8 2 5 S142 8 2 5 X141 X141 X141 X146 X143 X136 X138
X140 X140 X140 X142 X142 X142
9 5 3 11 6 8 2 5 8 2 8 2 8 2
N1
N1
N1
N1
G-N1.5
G-N1.5
X57 X60 X60 X60 X60 X89 X89 X89 X80 X80 X81 X81 X82 X82
L-R1
A-G1.5
A-G1.5
C-L1
C-L1
1
G-V1
G-V1
A-G1
A-G1
R1
H-R1
A-G1
X181
V1
H1
C1
A-B1
L/R1
A-G1
G/R1
C-L1
C-L1
V-Z1
V/N1
A/R1
A/R1
A/R1
A/R1
V-N1
G-M1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 9 10 11 12
X63 X64
L-B0.5
C-L0.5
A/V1
Z-B1
B-V1
A-V1
V-N1
H-V1
R-V1
M/B1
V1
M-N1
N1
H1
G-M1
G1
B-N1
A-N1
R/N1
A-N1
S-N1
R/N1
B-N1
A-B1
N1
N1
N1
N1
7 1 3 7 1 3 7 1 3
X83 X83 X83 X85 X85 X85 X84 X84
7 1 3 7 1 3 7 1 3
1
1 0 1 0 0
L/R1
S83 8 2
S85 8 2
S84 8 2
8 2 8 2 8 2
X83 X83 X85 X85 X84 X84
Z-N1
A-B1
A-B1
A-N1
R/N1
R/N1
S-N1
R/N1
R/N1
A-B1
A-B1
L-N1
H1.5
A/B1
C-B1
B-G1
G-L1
M-N1
H-L1
Z/N1
S/N1
A/V1
N1
N1
R-N1
R-G1
N1
N1
N1
G1
1
2 4 3 X55 7 1 3 4 6 7 1 3 4 6 1 3 7
1 1 1 X58 X58 X58 X86 X86 X86 X86 X86 X88 X88 X88
X53.1 X54.1 X59.1 X87 X87 X87 X87 X87
M58 7 1 3 4 6 7 1 3 4 6 1 3 7
G-V1.5
S53 S54 B59 M 0 1
53a A6 II I 0 1 0
H1.5
V1.5
A-B1
G-N1
H1.5
V1.5
53 M 53b
G1
A1
R1
31b 2
5 8
S87
31
M55 UNIT S86 8 2 5
S88 8 2
5 2 8 1 1
1 1 1 2 8 2 5 8 2 X87 X87 X87 - - - - - - - - X148.1 X152.1
X53.2 X54.2 X59.2 X55 X86 X86 X86 X88 X88
MULTIFUNCTION 01171128 X147.2 X151.2
G1.5
M-N1
G1
1
56a
56b
56a
56b
57
57
Z/N1
Z/N1
H-L1
H-L1
R
A-B1
A-B1
B-R1
N1
N1
R-G1
R-G1
M
N1
N1.5
31
31
- E147 - E151
N1.5
N1.5
N1.5
+15 MULTIFUNCTION UNIT SUPPLY
FUNCTION MACHINE UNIT SUPPLY
4th GEAR POWER SUPPLY SWITCH
N1
N1
N1
N1
N1
SELF CONTROL SOLENOID VALVE
REVERSE PPC SOLENOID VALVE
M-B1.5
L-N1.5
C-L0.5
L-B0.5
A-G1.5
A-G1.5
G-N1.5
G-N1.5
A-N1
C-L1
G-L1
G1.5
M-N1
A-B1
S/N1
V/N1
Z/N1
V-N1
H-L1
A/R1
V-Z1
B-N1
R/N1
H/R1
LIGHTS AND SWITCH 4WD
G/R1
A-B1
A-G1
G-M1
H-V1
V-N1
Gnd7.1
G-M1
V-N1
M-N1
Z-B1
B-V1
H-R1
R-N1
R-G1
A-V1
H-V1
A-G1
R-V1
G-V1
V1.5
V1.5
H1.5
H1.5
A-B1
G-N1
N1
PPC CONTROL SWITCH
A1
4WD SOLENOID VALVE
V1
M1
H1
N1
C1
R1
R1
A1
G1
N1
EC POWER SWITCH
PPC SEAT SWITCH
X10.s 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 X9.s 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 2 3 4 5 6 7 8 9 X25.s X26.s 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 19 20 21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
OUT BUZZER
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 19 20 21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
X10.p X9.p X25.p X26.p X44.p
R1 ACC BR R2 C
A-G1.5
A-G1.5
R-N1.5
G-N1.5
G-N1.5
V1.5
V1.5
R1.5
H1.5
H1.5
N2.5
A-B1
OFF ACC
G-V1
G-N1
L-B0.5
A1
L-N1.5
C-L0.5
GND
R1
G1
A-B1
H-V1
V-N1
M-N1.5
N1.5
N1.5
G/R1
ST
H-L1
42N-06
G-M1
B-V1
A-V1
G-L1
R1
V-N1
B-R1
H-V1
V-N1
R-V1
C-B1
M/B1
H-R1
R-N1
R-G1
V1
M-N1
H1
C1
G-M1
G1
M1
G1.5
Z/N1
V-Z1
G-L1
S/N1
V/N1
A/R1
V-N1
B/G1
B-N1
R/N1
H/R1
M-V1
N1
11810 S24 B
X6 A1 A2 A3 A4 A5 A6 A7 A8 B1 B2 B4 B5 B6 B7 B8 C1 C2 C3 C4 C5 C6 C7 C8
L/R1
Z-B1
H-L1
Z/N1
S/N1
A-B1
Z-N1
A-B1
C-B1
H/R1
B-N1
B/G1
B-R1
H/R1
H/N1
C-N1
H-N1
M-V1
M-V1
N1
G-M1
M1
B-R1.5
X24.r1 X24.acc X24.b X24.br X24.c X24.gnd
L6
N1.5
R6
M/N1
M/N1
B1
M/N1
A1 S2 S3 S4 S5 S6
M1
Z-N1
V/N1
S-N1
A-B1
Z-N1
C/B1
H-N1
M/N1
C-B1
M-B1
M-V1
M-N1
N1
M-B1.5
X47
1
6
B1 7
10
11
12 42N-06
L-N1.5
N1.5
C-B1
X15.p 15710
C-B1
C-B1
X15.p A-N1.5
B-N1
B-G1
C-L1
S/N1
A-R1
1
B6
M/N1
X15.p N1
A-G1
C-L1
M16
V6
2 1 2 3
N1
X42
1 1 1 2 1 S40 1 2
X17.1
Y49 X49 X555 X555 86 87
Y48 X48 X23 X23 86 87 1 M42
K56 X56 X56 K61 X61 X61 K45 X45
B
X13
A
X13
C
X13
V555 86 87
V23 86 87 86 87 M M R1 CN-F20 X6.p C-B1
1 1
H17 Z1 CN-F20 X6.p V-B1
85 30 85 30 85 30 2 2
CN-F20 X6.p
85 X56.1 85 X61.1 B 3 3
R6
1 2 2 1 2 3 4 CN-F20 X6.p
R16
X17.2 B13 X40 4 4
B-N1
B-N1 R-V1
H/N1
R6
M-V1
N1
N1
N1
R-G1
X6.p
N1
CN-F20
P43
N1
5 5
Z-B1 CN-F20 X6.p M-N1
B-N1 6 6
B-N1 CN-F20 X6.p H-L1
7 7
X43 R-G1.5 CN-F20 X6.p B1
1 R-G1 8 8
B1 CN-F20 X6.p A-V1
15 2 G-N1 9 9
10 20 CN-F20 X6.p
RPM x 100 3 R1 10 10
CN-F20 X6.p B-R1
B-N1
A-G1
5 25 4
G/R1
H-R1
11 11
R-G1.5 B1
N1.5
H-R1
CN-F20 X6.p
H-L1
5 H-N1 12 12
L6
V6
0 30
R6
Z-N1
R-G1.5
6
H-L1
V-B1
A-N1
7 6 5 4 3 2 1
7 C-L0.5 +15Key +30 +15
R-V1
8 C-B1
9 A-V1 X3.s
1 UNIT (01171166) X4.s R1
10 B-V1 2 1 1
X7.p
11 L-B0.5 B-R1.5 3 F25 F14 F13 F12 F24 F21 F7 F22 F18 F16 F17 2 R-N1.5 X7.s 1
B-N1
10A 10A 10A 5A 7,5A 10A 7,5A 7,5A 10A 10A 10A
13 M/N1 Z1 4 3 H1
1
14 Z-B1 Z-N1 5 4 V1 X5
17 V1 B1 6 5 C1 1
X3.p
18 V-B1 7 6 R1.5 X3.s 1
19 G-V1 8 7 R1.5
B-R1
2
20 N1 9 8 A-G1.5 X5
B-R1
V-B1
A-V1
H-R1 10 9 G-N1.5
B-R1 B-R1
B-G1 11
Sal2
H-R1 12
V-B1
V-B1
V-B1
86 87a 87
K2 K1 X4 X4 X4
H-N1
13
F8 F11 F10 F23 15
F15 15 F2 F9 F1 K4 8687a 87
R-V1
C-B1
M-B1.5 14 7,5A 7,5A 10A 10A 31 T 10A 31 T
15A 15A 15A
A-N1
R/N1
R/N1 16 1 X30 85 30 V-B1
X46 X4 X4 Sal3
A-N1.5 17 S46 V-B1
R-V1
R-G1
X27.s A-R1 R-V1 18 2 1 Sal1
A/C
V-B1
V-B1
1 X41.s X41.s
R-G1 19
X27.s C-B2.5
20
42N-07-11500 2
S41 2
M-N1.5 21
N1
L/R1X2.s 1 1
R4 K11
HEATING X28.s A
A-G1.5 2 F5
10A
K5 K3 K4 F6 F3 F4 F19 F20
1
X30.1
2
X30.1
V-B1
V-B1
V-B1
V-B1
V-B1
87a 87a 87a 87a
B-R1
B-R1
B-R1
B-R1
C-B1
C-B1
B-N1
R-V1
86 86 86 86
R-G1
87 87 87 87
M-N1
R1.5
N1.5
B-R1 3 15A 3A 3A 15A 15A
G1
42N-07-11300 X28.s B
R-N1 4 85 30 85 30 85 30 85 30
L-N1.5 5
N4
R-N1.5
GND1
42N-06
B1
N1
GND10
13730
V-B1
Z-B1
GND9
GND1.3
GND1.2
GND1.1
42N-06
R4
R6
R6
R6
1
Gnd11 Gnd10 Gnd9 Gnd1.1 X107 12310
X68.1 X68.2 X68.3 S107
F27
M1
C-B2.5
R-N1.5
A-N1.5
200A
H-N1
Z-B1
Z-B1
S-N1
G-N1
A-B1
B-R1
N1.5
N1.5
H-L1
B-N1
H/R1
V-N1
H-N1
H-R1
Z-N1
Z-B1
C-B1
C/B1
C-N1
A-N1
V-N1
V/N1
M-N1
N1.5
G-M1
Gnd1.3 Gnd1.2
B6
V1
G1
A1
N1
2
X107
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1 X11.p 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 X12.p 1 2 3 4 5 6 X8.p 1 2 3 4 5 6 7 8 9 10 11 12
X7.p X65.p
M-B1
X7.s 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 X128.s 1 X126.4 X11.s 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 X12.s 1 2 3 4 5 6 X8.s 1 2 3 4 5 6 7 8 9 10 11 12
42N-06
C-B2.5
A-N1.5
N1.5
N1.5
R-N1.5
Z-B1
V-Z1
H-L1
Z-B1
H-L1
Z-N1
C/B1
V/N1
C-B1
A-N1
B-N1
H/R1
V-N1
C-N1
H-N1
H-R1
M-B1
B6
M-N1
Z-B1
N1.5
V-B1
Z-N1
S-N1
A-B1
42N-06
H-N1
M-V1
V1
G-N1
A1
M1
G1
B2
CONNECT TO HARNESS
Gnd6
M16
M1
N6
11161 11450
42N-06-15960
X109 1
X109 2
X110.s 1
B-V1
B-N1
N1
H-L1
Z-B1
H-R1
H-N1
V-N1
G-N1
G-N1
A-B1
B-R1
G-N1
B-R1
C-B2.5
A B C
N1
G1
A1
N1
X111 X111 X111
Z-B1
Z-N1
R-N1.5
A-N1.5
Z-B1
H-L1
Z-N1
V/N1
N1.5
V-Z1
C/B1
C-B1
A-N1
C-N1
M-N1
R25
R70
R70
R25
R25
1
B6
V-B1
H-N1
M-V1
S-N1
N1
N1
X105 1 1 1
M16
X101.1 X101.2 X101.3 X101.4 X100.1 X100.2 X100.3 X100.4 1 X106 X108 X203
V1
N1
59c
57
57
L
L
30 50 D+ Y117 B115 B113 B112 B121 E103
M 30
G W M t
12Vcc 3 p p t 2 2 2 2
31
31
U H97 X104 X106 X108 X203
H/R1
2 2 2 2 2 2 2 2 2 2 2 -
N1
N1
N1
31 t
N70
X113 2 2 X90 X91 X92 X93 X94 X95 X96 X98 X99 X97 X103.2
N1.5
X121 X60
N6
N1
N1
N1
N1
N1
N1
N1
N1
N1
N1
N1
N1
N1
N1
N1
N1
N1
N2
Gnd3.1
Gnd5 42N-06
Gnd4
11190
WB93R-5E0 90-5
ELECTRICAL CIRCUIT DIAGRAM (1/3) DIAGRAMS AND DRAWINGS
ID Description ID Description
ID Description
H97 Horn Y91 ECOPOWER solenoid valve
A6 Multifunction unit
K1 Unrepeat start unit Y92 Back-up alarm
B59 Brake oil low level switch
K2 Flasher Y93 Rear PPC solenoid valve
B105 Oil transmission temperature switch
K3 Low beam relay Y94 Differential lock solenoid valve
B111 Fuel level sender
K4 Main beam relay Y95 Unlock arm solenoid valve
B112 Thermistor switch
K5 Front horn relay Y96 Unlock plate solenoid valve
B113 Air filter
K6 Return to DIG solenoid valve relay Y98 Closing grab solenoid valve
B115 Engine oil low pressure switch
K7 Light stop relay Y99 Opening solenoid valve
B121 Horn
K8 Assent start relay Y106 4WS Solenoid valve
CN-F20 Komtrax Interface connector
K9 Forward speed relay Y108 Forward solenoid valve
E100 Right rear light
K10 Reverse speed relay Y117 Elettrostop
E101 Left rear light
K11 Stop drive relay Y203 Reverse solenoid valve
E103 Number plate light
K45 Preheating Relay
E136 Right rear working light
K56 Starting relay
E138 Left rear working light
K61 Service relay
E143 Right front lateral working light
M42 Rear Windshield-washer
E146 Left front lateral working light
M55 Motor pump
E147 Left front light
M58 Front windshield-washer
E148 Beacon lamp
M116 Compressor
E151 Right front light
R114 Preheating
E152 Cabin lamp
S2 Solenoid valve EC Power switch
F1 Central front working light fuse 15A
S3 Lock grab switch
F2 Central rear working light fuse 15A
S4 Declutch switch
F3 Right position light fuse 3A
S5 Open grab switch
F4 Left position light fuse 3A
S6 Differential lock switch
F5 Horn fuse 10A
S24 Starting switch
F6 Lateral rear working light fuse 15A
S40 Seat Switch
F7 Windshield wiper-washer + rear horn fuse 7,5A
S46 Parking brake switch
F8 Stop light switch fuse 7,5A
S53 Stop light switch
F9 Lateral front working light fuse 15A
S57 Gear steering column
F10 Front windshield-motor supply fuse 10A
S60 Steering column light switch
F11 Optional fuse 7,5A
S80 Ride control switch
F12 Reverse speed buzzer + Steering column 10A
S81 Unlock arm button
F13 Supply level grip fuse 10A
S82 Unlock plate switch
F14 Light switch + switch optional fuse 10A
S83 E/C power button
F15 EC power fuse 7,5A
S84 EMPI solenoid valve switch
F16 Beacon light fuse 10A
S85 Rear horn button
F17 Warning switch fuse 10A
S86 General light switch
F18 Cabin lamp + cigarette lighter fuse 10A
S87 4wd switch
F19 Low beam fuse 15A
S88 PPC button
F20 Main beam light 15A
S89 Warning switch
F21 Return to DIG sender supply fuse 10A
S104 4th speed switch
F22 EC power fuse 7,5A
S107 Declutch switch
F23 +15 Steering unit fuse 10A
S140 Rear working light switch
F24 Flasher fuse 7,5A
S141 Beacon lamp switch
F25 Reverse speed buzzer + Steering column 10A
S142 Front working light switch
F27 General fuse 200A
X30 Lighter
G1 Battery
Y48 Float solenoid valve
G118 Starter
Y49 Return to dig solenoid valve
G119 Generator
Y60 Emp. solenoid valve
H17 Buzzer
Y90 PPC solenoid valve
90-6 WB93R-5E0
DIAGRAMS AND DRAWINGS ELECTRICAL CIRCUIT DIAGRAM (2/3)
H-V1 C-L1
42N-06
42N-06 R1 L/R1
N1 N1
P63 R/N1 R1 11832
14210 A 1 2 3 4 V-N1 V/N1 V/N1 A/R1
A1 N1 V-N1 V-Z1
R-N1 C-L1 A/R1
H-V1
L-N1.5
N1
M-B1.5 G-L1
V-Z1
M-B1.5
H1.5
A/B1
G-L1
H-V1
C-B1
R-N1
optional
G-M1
M-N1.5 1 1 3 4 6 7 7 1 3 7 1 3 7 1 3
M1
G-V1.5
V180 X180 X89 X89 X89 X89 X89 X80 X80 X81 X81 X81 X82 X82
G-N1
L-R1
L-R1
A-G1
C-L1
C-L1
G-V1
A-G1
C-L1
C-L1
L-R1
L-R1
4 1 9 10 12 8 7 2 1 3 4 6 7 7 1 3 7 1 3 7 1 3
;
4 2 8 X52 X52 X52 X52 X52 X52 X52 X52
N1
N1
N1
N1
N1
1 1
X57 X57 X57 1 0 0 1 0 0
0
Dx 4 1 9 10 12 8 7 2 I
R N F WASHER
R N F LAVACRISTALLO
S89 8 2 5 S80 8 2 S81 8 2
S82 8 2 7 1 3 4 6 7 1 3 4 6 4 6 1 3 7 1 1 1 1
HORN X140 X140 X140 X140 X140 X142 X142 X142 X142 X142 X146 X143 X136 X138
Sx CLAXON 1 8 2 5 8 2 8 2 8 2 X141 X141 X141 X141 X141
+ 5 3 11 6 X80 X80
S57 S52 X181 X89 X89 X89 X81 X81 X82 X82 7 1 3 4 6 7 1 3 4 6 4 6 1 3 7
0 1 E146 E143 E136 E138
9 5 3 11 6 II I 0 II I 0
L/R1
G-M1
V-N1
G/R1
C-L1
V-N1
C-L1
C-L1
V-N1
V/N1
A/R1
A/R1
V-Z1
A/R1
A/R1
X57 X52 X52 X52 X52
R1
N1
R1
N1
N1
5 2 8
S141
L-N1.5
M-B1.5
M-N1.5
2 5 2 5
H1.5
8 8
S140 S142
A/B1
G-L1
V-N1
C-B1
H-V1
H-R1
R-N1
V1
H1
C1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 9 10 11 12 5 2 8 4 4 4 4
X64 8 2 5 8 2 5 X141 X141 X141 X146 X143 X136 X138
C-L0.5
H-V0.5
X140 X140 X140 X142 X142 X142
X63
V0.5
A/V1
H-L1
B-V1
A-V1
V-N1
H-V1
R-V1
M/B1
V1
M-N1
N1
H1
G-M1
G1
A-G1.5
A-G1.5
G-N1.5
G-N1.5
L-R1
L-R1
C-L1
C-L1
A-G1
A-G1
A-G1
A-G1
G-V1
G-V1
G-N1
N1
R1
N1
N1
N1
N1
A-N1
C-L1
N1
A/R1
H-V1
R1
S-N1
N1
B-N1 S-N1
N1 A-N1 R/N1
N1
R/N1
A-B1
7 1 3 7 1 3 7 1 3
X83 X83 X83 X85 X85 X85 optional X84 X84
7 1 3 7 1 3 7 1 3
1
1 0 1 0 0
8 2 8 2
S83 S85 S84 8 2
V-N1
8 2 8 2 8 2
H-V0.5
X83 X83 X85 X85 X84 X84
C-L0.5
R/N1
S-N1
R/N1
B-V1 Z-N1 A-B1 A-N1 R/N1 R/N1
Z-N1 A-B1 A-B1
G-L1
H-L1
L-N1.5
H-L1
H1.5
A/B1
G-L1
C-B1
R-G1
M-N1.5 L-N1
A/V1
R-N1
SA2 N1
1
1 1 2 4 3 X55 N1
X53.1 X54.1 1 M58 X58 X58 X58 M55 G1 G1 S/N1
A-B1
X59.1
A-B1
Z/N1
B53 B54 B59 53a
M
N1
B-G1
53 M 31b
N1
31 7 1 3 4 6 7 1 3 4 6 1 3 7
C-L1
C-L1
A/R1
A/R1
R-V1
A-G1
G/R1
N1.5
V1
M-N1
1
N1
H1
R1
X86 X86 X86 X86 X86 X88 X88 X88 X87 X87 X87 X87 X87
V-N1
1 1 X59.2 1
X53.2 X54.2 X58 2 7 1 3 4 6 7 1 3 4 6 1 3 7
N1.5
A-G1.5
A-G1.5
G-V1.5
X55 0 1
R-N1
II I 0
B-R1
1 0
G-V1
V1.5
V1.5
H1.5
H1.5
A-B1
G-N1
V1.5
H1.5
A-B1
G-N1
V1.5
H1.5
N1
N1
R-G1 N1
N1
R1
R1
A1
G1
A1
G1
R1
5 2 8
8 2 5 8 2
S87
S86 S88 5 2 8 1 2
8 2 5 8 2 X87 X87 X87 X148.1 X152
X86 X86 X86 X88 X88
X147.3X147.2
X147.5X147.4 X151.5X151.4
X151.3X151.2
H-L1
56a
56b
56a
56b
57
57
L
R
A-B1
M
H-L1
31
31
M-V1
G1.5
M-V1
H/R1
A-B1
A-N1
V/N1
S/N1
Z/N1
Z/N1
H-L1
R/N1
A6
UNIT
R-G1
E147
G1
G1
N1
E151 1 E148 E152
X148.2
MULTIFUNCTION 01171128
N1.5
N1.5
N1.5
X152
N1
N1
N1
N1
N1
N1
L-N1.5
N1.5
L-N1
M-B1.5
R-V1
B-R1
C-B1
R-N1
H-V0.5
V1
H1
H1
N1
N1
R-N1
H-R1
M1
GND7.2
A-G1.5
A-G1.5
G-V1
V1.5
V1.5
H1.5
H1.5
A-B1
G-N1
EC POWER SWITCH
Gnd8 Gnd7.3 Gnd7.2
R1
R1
A1
G1
N1
N1.5
G1.5
Z/N1
H-L1
A-B1
S/N1
V/N1
R/N1
V-N1
H/R1
A-N1
S-N1
M-V1
N1
+ 4TH SWITCH
4WD SWITCH
OUT BUZZER
SEAT ALARM
4TH SWITCH
X44.s 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
X44.p
R1 ACC BR R2 C
GND
OFF ACC
R1
ST
A-G1.5
A-G1.5
R-N1.5
G-N1.5
G-N1.5
V1.5
V1.5
R1.5
H1.5
H1.5
N2.5
G-V1
G-N1
G1
C-L1 N1
L-N1.5
B
S24 A1 A2 A3 A4 A5 A6 A7 A8 B1 B2 B3 B4 B5 B6 B7 B8 C1 C2 C3 C4 C5 C6 C7 C8
Z-N1
X6
Z-B1
H-L1
Z/N1
S/N1
A-B1
Z-N1
C-B1
H/R1
B-N1
B-R1
H/R1
C-N1
H-N1
B-G1
G1
M-V1
M-V1
G-M1
M1
N1
B A C
A-G1
X13 X13 X13
X24.r1 X24.acc X24.b X24.c X24.br X24.gnd
L-N1.5
B-R1.5
N1.5
B/N1
L6
M/N1
M/N1
R6
H-L1
M/B1 B13
A-B1
H/N1
B-R1 A-B1
S-N1
M/N1
G-V1
H-V0.5
M-B1.5
S-N1
R-N1
H-R1
G-V1
R6
C-B1
R/N1 R/N1
A-G1.5
A-G1.5
R-N1.5
G-N1.5
G-N1.5
V1.5
V1.5
R1.5
H1.5
H1.5
N2.5
N1.5
V-Z1
Z/N1
A-B1
V/N1
V-N1
A-N1
B/N1
A-B1
C-B1
C-B1
H/R1
M/B1
A-G1
H-N1
G-N1
A1
G1
M-V1
Z/N1
Z/N1
S47
G-N1.5
N1
A-G1.5
H-R1 G-M1
A-B1
Z-N1
C/B1
C-B1
M-B1
M-V1
M-N1
N1
L-N1.5
L/R1
V0.5
C-B1
R-V1
G-M1
G-V1
B/N1
M/B1
A-G1
M-V1
V0.5
M-N1 M-N1 X47 1
C-B1 C-B1 2
H1 C/B1 C/B1 3
M-B1 M-B1 4
B6 B6 B6 5
L-N1.5
R-G1 B-G1 Z-N1 Z-N1
L-N1.5
L-N1
C-L1
6
B-N1
C-B1
H/N1
B6
R1
S/N1 B-G1 A-R1 V6 M/B1 A-B1 7
M16 N1 8
1 1 1 S40 1 3
42N-06
L6
X17.2 X49 1 86 87 Y48 X48 86 87 1 1 X42 X42 9
Y49 X56 X56 K61 X61 X61 K45 X45
X555 K56 X23
M-V1 10
V555 V23 M42
86 87 86 87 86 87
53a 11
15710
SA1
H17 53 M 31b
85 30 85 30 85 30 12
X15.p A-N1.5 2 85 X56.1 85 X61.1 2
1 1 2 X555 X56 2 X61 B X23 31
N1 1 2 3 4
L-N1.5
X17.1 X49 X48
R1 C-B1
B-N1
2 X40 CN-F20 X6.p
R16
C-B1
H/N1
M-V1
C-B1
1 1
N1 N1 Z1 V-B1
C-B1
R6
2 CN-F20 X6.p
N1
R6
N1
R1
N1
N1
M-B1
M-B1
X42 2 2
C-B1 CN-F20 X6.p
3 3
CN-F20 X6.p
N1.5
B/N1 CN-F204 4
X6.p R-V1
Z-B1 CN-F205 5
X6.p M-N1
H-V0.5
M-B1.5
M-N1.5
B-N1 CN-F206 6
R-N1
H-L1
N1
R6
X6.p
N1 R-G1.5 7 7
CN-F20 X6.p B1
8 8
B1 CN-F20 X6.p A-V1
9 9
R6 CN-F20 X6.p
10 10
N1 CN-F20 X6.p B-R1
R-N1.5 R-N1.5 R-N1.5 11
CN-F20
11
X6.p B1
12 12
X43 1 R-G1
R6
H-L1
V-B1
15 2 G-N1
10 20
RPM x 100 3 R1 R1 R1 R-V1
H-L1
B-N1
N1.5
5 25 4
H-L1
H-R1
A-G1
G/R1
H-R1
5 H-N1
0 30 1
Z-N1
L6
6
V6
R6
B-N1
M-B1
X7.p
7 6 5 4 3 2 1 X7.s 1
7 C-L0.5 X5.s
8 C-B1
R1
+15Key +30 +15 1
X3.s X5
9 A-V1 A-V1 1
V-B1
X4.s 1
10 B-V1 R-G1.5 2 1 R1 X3.p
X3.s 1
11 H-V0.5 B-R1.5 3 F25 F14 F13 F12 F24 F21 F7 F22 F18 F16 F17 2R-N1.5
A-V1
B-R1
Z1 10A 10A 10A 5A 7.5A 10A 7.5A 7.5A 10A 10A 10A H1
12 4 3 2
X5
13M/N1 Z-N1 Z-N1 5 4 B-R1
M/B1
A-N1
N1.5
V/N1
N1.5
A-G1
V1.5
R1.5
H1.5
A-B1
G-N1
N2.5
A-B1
A-V1
14Z-B1 B1 B-R1 B-R1
N1
N1
A1
G1
6 5
15 Z/N1 7 6 R1.5 Sal2
V-B1
V-B1
V-B1
86 87a 87
16 Z/N1 8 7 R1.5 X4 X4 X4
B-G1
17 V1 9 8 A-G1.5 K400
86 87a 87
R-V1
C-B1
18V-B1 H-R1 10 9 G-N1.5
85 30
19 G-V1 B-G1 11
85 30 V-B1
20 N1 H-R1 12 K2
R-G1
P43 K1 X4 X4
V-B1 Sal3
A-R1 A-R1 13 F10 F23 15 15 F2 F9 F1
F8 F11 F15 Sal1
M-B1.5 14 7.5A 7.5A 10A 10A 10A 15A 15A 15A
V-B1
V-B1
R-V1
M/B1
31 T 31 T
A-V1
G1.5 N1.5
A-N1.5
H-N1 1
16 X160.p
A-N1.5 2
17 2 X160.p
1 X30.1 3
OPTIONAL
X27.s A-R1 R-V1 18 X46 H-G1 X160.p
A/C 1
19 S46
4
M-N1.5
X160.p
C-B2.5 X30
V-B1
V-B1
V-B1
V-B1
V-B1
B-R1
B-R1
B-R1
B-R1
C-B1
C-B1
B-N1
R-V1
X27.s
R-G1
M-N1
N1 5
2 20 X160.p
42N-07-11400
Z-N1
M-N1.5 6
21 X160.p
V0.5 7
L/R1 X2.s X160.p
A1
1 2 1 1 X1 7X1 8X1 12
X1 13
X2 1X2 2X2 3X2 4X2 5X2 6X2 7X2 8X2 9X2 11
X2 12
M-B1
X28.s R4 8
N1.5
A K11
HEATING
A-R1
R1.5
86 87a 87 86 87a 87 86 87a 87 86 87a 87 X160.p
X28.s B N4 B-R1 3 15A 3A 3A 15A 15A
42N-54-11300 10
KOMTRAX UNIT
N1.5
X160.p
G1
4
N1
85 30 85 30 85 30 85 30
11
N1
X160.p
L-N1.5 5 12
A-B1
X1.s
6 1 V1.5 V1.5
N1
A-B1
7 2 H1.5 H1.5
Z-B1
G1
V1.5
8 3
C-L1 C-L1
9 4 G-N1
L-N1.5 10 5 M-V1
K10 K6 K8 K9 K7 G1 G1
11 D2 D3 D1 86 87a 87 86 87a 87 86 87a 87 86 87a 87 86 87a 87 6
H-G1
H1.5
G-N1
12 7 V1.5 V1.5 42N-06
H-G1 85 30 85 30 85 30 85 30 85 30
M1 13 8 H1.5 H1.5
M1 13730
14 9
G-N1
R-G1 15 10
G1
G1
A-G1 16 11 G1 G1
S/N1 S/N1 17
N1.5
H-L1
A-V1
C-B1
A-R1
B-R1
G-N1
A-R1
A-N1
N1.5
V-Z1
V/N1
B-N1
H-N1
M-N1
H-L1
V-N1
M-B1
V0.5
A-B1
N2.5
A-V1
C-B1
A-B1
H-G1
G-N1
N1
N1
G1
N1
N1
N1
N1
A1
N1
A-R1
C-B1
A-V1 A-V1
H-L1
V/N1 V/N1
V-Z1
Z-N1
C-B2.5
A-N1.5
R-N1.5
N1.5
Z-B1
Z-N1
S-N1
H-N1
H-R1
A-N1
N1.5
N1.5
N1.5
A-G1
V1
R16
N4
N1
R4
R6
R6
R6
N1
N1
N1
H-R1 H-R1 H-R1
X68.2 X68.3
X68.1
Z-N1
Z-B1
C-B1
C/B1
V-Z1
A-N1
V-N1
V/N1
H-L1
N1.5
G-N1
A-B1
B-R1
N1.5
B-N1
B-N1
H-G1
G-M1
H-N1
M-N1
H-L1
V-N1
M-B1
V0.5
Gnd12 Gnd10 Gnd9 Gnd1.3 Gnd1.2 Gnd1.1
N1
G1
A1
F27
B6
M16
200A
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1 X11.p 1 2 3 4 5 6 7 8 9 X11.p 12 13 14 15 X12.p 1 2 3 4 5 6 1 2 3 4 5 6 7 8 9 10 11 12
X7.p X65.p X8.p
A-N1.5
R-N1.5
N1.5
N1.5
Z-B1
V-Z1
H-L1
Z-B1
Z-N1
C/B1
V/N1
A-B1
V-B1
Z-N1
C-B1
A-N1
S-N1
C-N1
H-N1
G-N1
M-V1
A1
V1
G1
42N-06
M1
42N-06
Z-B1
H-L1
B-N1
H/R1
V-N1
Gnd6
H-N1
H-R1
M-B1
B2
M-N1
M16
B6
N6
1 42N-06
11161 11451 X107
11191
B107
2
X107
R-N1.5
A-N1.5
C-B2.5
Z-B1
H-L1
B-V1
V-N1
H/R1
B-N1
H-N1
H-R1
M-N1
N1
B-V1
Z-B1
Z-N1
V-B1
H-N1
M-V1
S-N1
Z-B1
C-N1
N1.5
H-L1
Z-N1
N1.5
V/N1
V-Z1
C/B1
C-B1
A-N1
G-N1
G-N1
A-B1
B-R1
N1.5
N1.5
G-N1
N1.5
B-R1
N1.5
R25
R70
R70
R25
R25
M16
B2
B6
V1
N1
N1
N1
G1
A1
1 1 1 A B C
1 X119.1 X116.s 1 2 3 4 1 2 3 4 X111 X111 X111 1 1
X118.1 X119.2 1 1 A B C 1 1 1 1 1 1 1 1 1 1 1 X101 X101 X101 X101 1 X100 X100 X100 X100 1 1 1 1 1 1 X109.s X110.s
G118 G119 X117 X115 1 X112 X112 X112 X121 X60 M116 X90 X91 X92 X93 X95 X96 X98 X99 X97 X103 X104 X105 Y94 X94 X106 X203 X108
G1 R114 X114 X113 Y60 Y90 Y91 Y92 Y93 Y95 Y96 Y98 Y99 Y106 Y203 Y108 B111
30 50 D+ Y117 B115 B113 B112 B121 B104 B105
59c
59c
57
57
L
M 30
G W M E103 CONNECT TO HARNESS
12Vcc 3 p p t
U 42N-06-15960
31
31
H97 t
31 2 t
X113 2 2 2 2 2 2 2 2 2 2 2 E101 2 E100 2 2 2 2 2
N70
X121 X60 X90 X91 X92 X93 X95 X96 X98 X99 X97 X103 X104 X94 X106 X203 X108 2
X109.s
H/R1
S0
N1
N1
N1
N1
N1
N1
N2
N1.5
N1.5
N1
N1
N1
N1
N1
N1
N1
N1
N1
N1
N6
N1
N1
N1
N1
GND4
GND4.1
WB93R-5E0 90-7
ELECTRICAL CIRCUIT DIAGRAM (2/3) DIAGRAMS AND DRAWINGS
ID Description ID Description
ID Description
F25 Reverse speed buzzer + Steering column 10A Y48 Float solenoid valve
A1 Komtrax unit
F27 General fuse 200A Y49 Return to dig solenoid valve
A6 Multifunction unit
G1 Battery Y60 Emp. solenoid valve
B13 Return to dig sensor
G118 Starter Y90 PPC solenoid valve
B53 Stop switch
G119 Generator Y91 ECOPOWER solenoid valve
B54 Stop light switch
H17 Buzzer Y92 Back-up alarm
B59 Brake oil low level switch
H97 Horn Y93 Rear PPC solenoid valve
B104 4th speed switch
K1 Unrepeat start unit Y94 Differential lock solenoid valve
B105 Oil transmission temperature switch
K2 Flasher Y95 Unlock arm solenoid valve
B107 Decluch trasmission switch
K3 Low beam relay Y96 Unlock plate solenoid valve
B111 Fuel level sender
K4 Main beam relay Y98 Closing grab solenoid valve
B112 Thermistor switch
K5 Front horn relay Y99 Opening solenoid valve
B113 Air filter
K6 Return to DIG solenoid valve relay Y106 4WS Solenoid valve
B115 Engine oil low pressure switch
K7 Light stop relay Y108 Forward solenoid valve
B121 Horn
K8 Assent start relay Y117 Elettrostop
CN-F20 Komtrax Interface connector
K9 Forward speed relay Y203 Reverse solenoid valve
E100 Right rear light
K10 Reverse speed relay Y303 Ride control valve
E101 Left rear light
K11 Stop drive relay Y304 Ride control valve
E103 Number plate light
K45 Preheating Relay
E136 Right rear working light
K56 Starting relay
E138 Left rear working light
K61 Service relay
E143 Right front lateral working light
K400 Start cut relay
E146 Left front lateral working light
M42 Rear Windshield-washer
E147 Left front light
M55 Motor pump
E148 Beacon lamp
M58 Front windshield-washer
E151 Right front light
M116 Compressor
E152 Cabin lamp
P43 Instruments panel
F1 Central front working light fuse 15A
P63 Front instruments
F2 Central rear working light fuse 15A
R114 Preheating
F3 Right position light fuse 3A
S0 Main switch
F4 Left position light fuse 3A
S24 Starting switch
F5 Horn fuse 10A
S40 Seat Switch
F6 Lateral rear working light fuse 15A
S46 Parking brake switch
F7 Windshield wiper-washer + rear horn fuse 7,5A
S47 Joystick
F8 Stop light switch fuse 7,5A
S52 Light steering column
F9 Lateral front working light fuse 15A
S57 Gear steering column
F10 Front windshield-motor supply fuse 10A
S80 Ride control switch
F11 Optional fuse 7,5A
S81 Unlock arm button
F12 Reverse speed buzzer + Steering column 10A
S82 Unlock plate switch
F13 Supply level grip fuse 10A
S83 E/C power button
F14 Light switch + switch optional fuse 10A
S84 EMPI solenoid valve switch
F15 EC power fuse 7,5A
S85 Rear horn button
F16 Beacon light fuse 10A
S86 General light switch
F17 Warning switch fuse 10A
S87 4wd switch
F18 Cabin lamp + cigarette lighter fuse 10A
S88 PPC button
F19 Low beam fuse 15A
S89 Warning switch
F20 Main beam light 15A
S140 Rear working light switch
F21 Return to DIG sender supply fuse 10A
S141 Beacon lamp switch
F22 EC power fuse 7,5A
S142 Front working light switch
F23 +15 Steering unit fuse 10A
V180 Current electric limitator for warning light
F24 Flasher fuse 7,5A
X30 Lighter
90-8 WB93R-5E0
DIAGRAMS AND DRAWINGS ELECTRICAL CIRCUIT DIAGRAM (3/3)
42N-06-15110
P63 H-V0.5 C-L1 42N-06 SWITCH PANEL
R1 L/R1 14311 C-L1
A-G1
G-N1
L-R1
N1 N1
L-B1
A-G1
A 1
G-V1
2 3 4
G-V1
C-B1
R/N1 R1
N1
N1
N1
N1
N1
C-L1
C-L1
V-N1 V/N1 V/N1 A/R1
A1 N1 V-N1 V-Z1
R-N1 C-L1 A/R1
H-V1
N1
M-B1.5 G-L1
V-Z1
M-B1.5
7 1 3 4 6 7 1 3 4 6 4 6 1 3 7 1 1 1 1
X140 X140 X140 X140 X140 X142 X142 X142 X142 X142 X146 X143 X136 X138
H-V1
C-B1
M-N1.5
A/B1
H1.5
X141 X141 X141 X141 X141
1 1 3 4 6 7 7 1 3 7 1 3 7 1 3
M1
V180 X180 X89 X89 X89 X89 X89 X80 X80 X81 X81 X81 X82 X82 7 1 3 4 6 7 1 3 4 6
0 1
4 6 1 3 7
E146 E143 E136 E138
A-G1
7 1 3 1 3 7 1 3 II I 0 II I 0
10
12
1 3 4 6 7 7
2
4 2 8 X52 X52 X52 X52 X52 X52 X52 X52 1 1
X57 X57 X57 1 0 0 1 0 0
5 2 8
0
S141
G-V1.5
Dx 4 1 9 10 12 8 7 2 I
R N F S140 8 2 5
S142 8 2 5
G-V1
WASHER
C-B1
L-R1
C-L1
C-L1
L-R1
L-B1
R N F LAVACRISTALLO 5 2 8 4 4 4 4
8 2 5 8 2 8 2 8 2 5 8 2 5 X141
HORN
S89 S80 S81 8 2 S82 X140 X140 X140 X142 X142 X142
X141 X141 X146 X143 X136 X138
Sx CLAXON 1 8 2 5 8 2 8 2 8 2
+ 5 3 11 6
S57 S52 X181 X89 X89 X89 X80 X80 X81 X81 X82 X82
R1
N1
N1
N1
N1
G-V1
G-V1
A-G1
A-G1
L-R1
C-L1
G-N1.5
A-G1
G-N1
A-G1.5
86
87
86
87
86
87
G-N1.5
A-G1.5
9
11
G-M1
G/R1
V-N1
C-L1
5
L/R1
6
R1
N1
R1
A/R1
A/R1
X52 X52 X52
V-N1
C-L1
C-L1
X57 X52
V-Z1
V-N1
V/N1
A/R1
A/R1
N1
N1
K340 K342 K341
M-N1.5
M-B1.5
L-N1.5
H-R1
R-N1
G-L1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 9 10 11 12
C-B1
H-V1
A/B1
H1.5
V-N1
X63 X64
C1
H1
V1
G-M0.5
G-M0.5
M-N0.5
V-N0.5
H-V0.5
H-V0.5
R-V0.5
C-L0.5
B-V0.5
A-V0.5
M/B1
A/V1
V0.5
N0.5
G0.5
H0.5
V0.5
N1
G-N1.5
A-N1
A-B1
N1
N1
30
30
30
85
85
85
S-N1
X340 X342 X341
B-N1 S-N1
N1 A-N1 R/N1
H-V0.5
N1
A/R1
G-N1.5
N1
C-L1
N1
R1
R1
N1
N1
A-G1.5
A-G1.5
R1
R/N1
A-B1
7 1 3 7 1 3 7 1 3
X83 X83 X83 X85 X85 X85 X84 X84
7 1 3 7 1 3 7 1 3
1
1 0 1 0 0
V-N1
N1
H-V0.5
8 8 2 8 2
S83 2
S85 S84
8 2 8 2 8 2
X83 X83 X85 X85 X84 X84
C-L0.5
R/N1
S-N1
R/N1
B-V0.5 Z-N1 A-B1 A-N1 R/N1 R/N1
Z-N1 A-B1 A-B1
G-L1
L-N1.5
G-L1
C-B1
A/B1
H1.5
M-N1.5 L-N1
R-G1
R-N1
A/V1
SA2 N1
G-N1.5
1
A-G1.5
1 1 2 4 3 X55 N1
X53.1 X54.1 1 M58 X58 X58 X58 M55 G1 G1
S/N1
A-B1
X59.1
B53 B54 B59 53a A-B1
Z/N1
M
N1
B-G1
53 M 31b
N1
M-N0.5
R-V0.5
A-G1
G/R1
A/R1
A/R1
N0.5
C-L1
C-L1
H0.5
V0.5
R1
1
X345.s
31 7 1 3 4 6 7 1 3 4 6 1 3 7
1 X86 X86 X86 X86 X86 X88 X88 X88 X87 X87 X87 X87 X87
1 1 X59.2
1 WORKING
2
G-N1.5
G-N1.5
A-G1.5
G-V1.5
X58 7 7 1 3
X53.2 X54.2 1 3 4 6 4 6 1 3 7 LIGHT
G-N1
G-N1
G-V1
A-B1
A-B1
H1.5
H1.5
H1.5
H1.5
V1.5
V1.5
V1.5
V1.5
X55 0 1
N1.5
G1
G1
R1
N1
R1
R1
A1
A1
B-R1
R-N1
II I 0 1 0
OTIONALS
N1
V-N1
N1
A-N1
N1.5
R-G1 N0.5
5 2 8
2 5 8 2
S87
S86 8
S88 5 2 8 1 2
8 2 5 8 2 X87 X87 X87 X148.1 X152
X86 X86 X86 X88 X88
X147.3 X147.2 X147.5 X147.4 X151.3 X151.2 X151.5 X151.4
G-M1
Z/N1
Z/N1
56a
56b
57
57
R
G-M0.5
56a
56b
L
H/R1
A-B1
A-B1
M
M-V1
G1
G1.5
G1
M-V1
31
31
A6 42N-06-15151
UNIT E147 E151 1 E148 1 E152
X148.2
MACHINE FUNCTION 01171128 X152
N1.5
N1.5
N1.5
N1
N1
N1
N1
N1
N1
R/N1
M-B1.5
H-V0.5
R-V0.5
L-N1.5
R-N1
B-R1
C-B1
N1.5
V0.5
V0.5
N1
N1
GND7.2
G-N1.5
G-N1.5
A-G1.5
A-G1.5
EC POWER SWITCH
G-N1
PPC SEAT SWITCH
G-V1
A-B1
H1.5
H1.5
V1.5
V1.5
G1
R1
R1
N1
A1
Gnd8 Gnd7.3 Gnd7.2
+ 4TH SWITCH
4WD SWITCH
OUT BUZZER
SEAT ALARM
4TH SWITCH
G1.5
N1.5
M-V1
R/N1
H/R1
A-N1
S-N1
A-B1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
V-N1
Z/N1
V/N1
N1
X44.s
X44.p
11
1
ACC R2
10
17
18
13
15
16
12
BR C
14
R1
8
GND
6
2
9
4
OFF ACC
R1
ST
A-G1.5
A-G1.5
G-V0.5
G-N1.5
G-N1.5
R1.5
R-N1.5
V1.5
V1.5
H1.5
H1.5
G-N1
G1
N2.5
C-L1 N1
X149
B
S24 A1 A2 A3 A4 A5 A6 A7 A8 B1 B2 B3 B4 B5 B6 B7 B8 C1 C2 C3 C4 C5 C6 C7 C8
B1 C1
Z-N1
X6
G0.5
G-M1
M-V1
M-V1
C-R1
C-N1
H/R1
H-N1
B-G1
B-N1
A-B1
A-B1
B-R1
H/R1
H/N1
Z-B1
S/N1
Z-N1
A-B1
Z/N1
M1
N1
B A C
A-G1
X13
C3 C4
M/N1
M/N1
L6
R6
B/N1
B-R1.5
N1.5
L-N1.5
A5
M/B1 B13
B-R1 A-B1
X149
S-N1
B8 A8 A4
M/N1
G-V0.5
M-B1.5
G-V0.5
H-V0.5
R-N1
H-R1
S-N1
R6
C8
SA4 C-B1
R/N1 R/N1
X149
G-N1.5
G-N1.5
A-G1.5
A-G1.5
R-N1.5
42N-06 PPC LEVER
B5
G-N1
M/B1
A-G1
H-N1
V-N1
A-N1
C-B1
C-B1
H/R1
A-B1
V/N1
B/N1
A-B1
V-Z1
Z/N1
N1.5
R1.5
H1.5
H1.5
N2.5
V1.5
V1.5
M-V1
G1
A1
Z/N1 15710
Z/N1 00000833 REV00
X149
C7 A1 B6 A7
S47
SA3
G-N1.5
N1
C6 C5
A-G1.5
L-N1.5
A6
H-R1
X149
M-B1
M-V1
M-N1
C-B1
A-B1
Z-N1
C/B1
N1
R-V0.5
L/R1
V0.5
S-L1
S-L1
C-R1
V0.5
PRESSURE S-L1 X47
BUZZER M-N0.5 M-N1 1
H101 SWITCH C-B1 C-B1 2
B103 1 1
H0.5 C/B1
1
X557
1
X101.2 X101.1
M-B1 M-B1
-
B-N1
C-L1
G-V1 CV002
R1
M1
B6
N1
S/N1
N1
N1 A-B1
L-N1.5
2 2 B-G1 A-R1 V6 V6 M/B1 7
L-N1
2
M-V1
X556 X558
N1 8
86
30
S40
C-B1
1 1 1 1 3
H/N1
C-B1
2
86 87 86 87 1 9
L6
X17.2 X49 1 Y48 X48 1
K104 Y49 X56 X56 K61 X61 X61 K45 X45
X42 X42
X555 K56 X23
M-V1 10
1 3
V555 86 87 86 87 86 87
V23 M42
7 4 6
11
0
1 SA1 53a
H17 53 M 31b
85 30 85 30 85 30 12
L-N1.5
X15.s X15.p
8 2 5 S100 R-N1 1 1 A-N1.5 2 85 X56.1 85 X61.1 2
R-L0.5
B-N1
X6.p
R16
8
2
85
87a
X100
M-V1
C-B1
H/N1
N1 Z1 CN-F201 1
V-B1
N1
N1
R1
N1
N1
R6
R6
2 X6.p
M-N1
C-B1
N1
M-B1
M-B1
N1
N1
N1
X42 2 2
CN-F20 X6.p
3 3
CN-F20 X6.p
R-N1 X2.p
N1.5
4 4
R-N1 1 B/N1 CN-F20 X6.p R-V1
5 5
N1 2 OPTIONAL Z-B1 CN-F20 X6.p M-N1
6 6
42N-06 DRIVER SITE HARNESS B-N1 CN-F20 X6.p H-L1
N1
M-N1.5
M-B1.5
N1
H-V0.5
7 7
R-N1
R-G1.5 B1
R6
CN-F20 X6.p
16351 KIT 8 8
B1 CN-F20 X6.p A-V1
9 9
R6 CN-F20 X6.p
10 10
N1 CN-F20 X6.p B-R1
0A050434 REV07 R-N1.5 R-N1.5 R-N1.5 CN-F20
11 11
X6.p B1
12 12
X43 1 R-G0.5 R-G0.5
R6
2 G-N0.5 G-N0.5
H-L1
V-B1
15
10 20
3 R0.5 R0.5 R0.5 R0.5 R-V1
RPM x 100
4 B-N0.5 B-N0.5
H-L1
H-L1
5 25
H-R1
A-G1
G/R1
H-R1
N1.5
5 H-N0.5
R6
1
V6
L6
0 30
Z-N0.5
R1
M-B1
6 X7.p
B-N1
7 C-L0.5 X7.s 1
7
1
X5.s
8 C-B0.5 C-B0.5 +15Key +30 +15 1
X3.s
9 A-V0.5 A-V0.5
B-V0.5
A-V0.5 1 42-N-06-15141 UNIT (01171166) X4.s
X5
1
10B-V0.5
V-B1
R-G1.5 2 1 R0.5 X3.p
11 H-V0.5 B-R1.5 3 F25 F14 F13 F12 F24 F21 F7 F22 F18 F16 F17 2 R-N1.5 X3.s 1
Z1
B-R1
H1
A-V1
12 4 10A 10A 10A 5A 7,5A 10A 7,5A 7,5A 10A 10A 10A 3
A-V0.5
2
M/B1
G-N1
A-N1
A-G1
V/N1
A-B1
N1.5
N1.5
R1.5
H1.5
N2.5
V1.5
M/N1 Z-N1 Z-N1 X5
B-R1
N1
G1
N1
A1
13 5 4
V-B1
V-B1
V-B1
16 8 7 X4 X4 X4
9 8 86 87a 87
C-B1
R-V1
18 V-B0.5 H-R1 10 9 G-N1.5
19 G-V0.5 B-G1 11
85 30
85 30 V-B1
20 N0.5 H-R1 12
R-G1
X4 X4 Sal3
P43 K2 K1 V-B1
A-R1 A-R1 13
F10 F23 15 15 F2 F9 F1
42N-06-15131 F8 F11 Sal1
M-B1.5
M/B1
14 31 T 31 T 15A A-V0.5
R-V1
10A 15A 15A
V-B1
V-B1
7,5A 7,5A 10A
G1.5 N1.5
R-G0.5
A-N1.5
A-V0.5
53S 53M
A-V0.5 1
16 H-N1 X160.p
A-N1.5 17 2
2
X160.p
1
A-R1 R-V0.5 X30.1
H-G1 3
OPTIONAL
X27.s 18 X160.p
X46
C-B0.5
A/C
C-B1
1 4
C-B2.5
19 S46 X160.p
M-N1.5
X27.s X30
M-N1
R-G1
N1
C-B1
C-B1
B-R1
B-R1
B-R1
B-R1
B-N1
5
R-V1
V-B1
V-B1
V-B1
V-B1
V-B1
20 X160.p
Z-B0.5
42N-07-11400 2
Z-N1
M-N1.5 21 6
X160.p
V0.5
L/R1X2.s 7
X160.p
A1
1 2 1 1 X1 7 X1 8 X1 12X1 13X2 1 X2 2 X2 3 X2 4 X2 5 X2 6 X2 7 X2 8 X2 9 X2 11X2 12
R4 8
M-B1
X28.s
N1.5
A-R1
V1.5
HEATING A K11 F5 K5 K3 X46 X160.p
N1
X30.1 X30.2
N1
A-G1.5 2 K4
86 87a 87 10A 86 87a 87 86 87a 87 86 87a 87
F6 F3 F4 F19 F20 9
X160.p
X28.s B N4 B-R1 3
G1
42N-54-11300
R1.5
15A 3A 3A 15A 15A 10
X160.p
KOMTRAX UNIT
N1
4 85 30 85 30 85 30 85 30
11
X160.p
L-N1.5 5
12
X1.s
6 1 V1.5 V1.5
N1
7 2 H1.5 H1.5
8 3 G0.5
C-L1
9 4 G-N0.5
L-N1.5 10 5 M-V1
K10 K6 K8 K9 K7 G1
11 D2 D3 D1 86 87a 87 86 87a 87 86 87a 87 86 87a 87 86 87a 87 6
A-B1
H-G1
G-N1
H1.5
12 7 V1.5 V1.5 KOMTRAX HARNESS 42N-06
H-G1 85 30 85 30 85 30 85 30 85 30
0A022879 REV00
M1 13 8 H1.5 H1.5 13730
- A-B1 14 9
SA5 G-N1
R-G1 15 10
A-G1 G1 G1
A-B1
16 11
42N-06 DRIVER SITE HARNESS S/N1 S/N1 17
14212 KIT
V-N0.5
A-V0.5
M-N1
M-B1
H-G1
H-N1
B-N1
C-B1
A-B1
H-L1
N2.5
V0.5
N1
N1
N1
A1
G-N0.5
G-N1
A-R1
A-N1
A-V0.5
V/N1
V-Z1
N1.5
C-B1
A-R1
B-R1
N1.5
G1
H-L1
N1
N1
N1
N1
0A051433 REV00
A-R1
C-B1
A-V0.5 A-V0.5
H-L1
V/N1 V/N1
V-Z1
Z-N1
G-M1
A-G1
N1.5
N1.5
H-N1
N1
A-N1
N1.5
H-N0.5
R-N1.5
C-B2.5
A-N1.5
Z-B0.5
H-R1
S-N1
Z-N1
N0.5
N1.5
V0.5
R16
N4
R4
R6
R6
R6
N1
N1
H-R1 H-R1
X68.2 X68.3
B-N0.5
V-N0.5
X68.1
G-N1
C-B1
A-N1
V-N1
B-R1
Z-N1
C/B1
A-B1
V/N1
A-B1
G-M1
Z-B1
V-Z1
H-L1
M-N1
N1.5
H-G1
M-B1
N1.5
B-N1
H-L1
Gnd12
V0.5
Gnd10 Gnd9 Gnd1.3 Gnd1.2 Gnd1.1
G1
A1
B6
F27
200A
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 X12.p 1 2 3 4 5 6 1 2 3 4 5 6 7 8 9 10 11 12
X65.p X11.p X11.p
X7.p X8.p
B-R1
A-B1
C-B1
C-N1
Z-N1
C/B1
A-N1
V/N1
Z-B1
V-Z1
H-L1
N1.5
G1
A1
B-N1
Z-B1
H-N1
H/R1
M-N1
H-R1
H-L1
V-N1
B2
M-B1
C-B2.5
R-N1.5
A-N1.5
M-V1
H-N1
V-B1
Z-N1
S-N1
Z-B1
M1
V1
B6
N1.5
1 A SU LINEA 42N-06-11180
X107
G-N1 B107
G1
A-B1
-
A
A1
2
B-R1 X107
B-R1
RIDE CONTROL 42N-06
HARNESS 15821
C-B2.5
R-N1.5
A-N1.5
M-N1
H-R1
H-N1
V-N1
H/R1
B-N1
B-V1
B-V1
Z-B1
H-L1
S-N1
Z-N1
M-V1
Z-B1
H-N1
V-B1
M16
0A050005 REV01
R25
R70
R70
R25
R25
N1
B2
B6
N1
V1
V-N1
V-N1
1 1 1 A B C
1 X119.1 X116.s X111 X111 X111 1 1
X118.1 X119.2 1 1 A B C 1 1 1 1 1 1 1 1 X109.s X110.s
G118 G119 X117 X115 1 X112 X112 X112 X121 X60 M116 X104 X105 Y94 X94 X106 X203 X108
G1 R114 X114 X113 Y60 Y106 Y203 Y108 B111 1 1
30 50 D+ Y117 B115 B113 B112 B121 B104 B105 X303 X304
M 30
G W M CONNECT TO HARNESS
12Vcc 3 p p t Y303 Y304
U 42N-06-15960
t
G-N1
2
B-R1
B-R1
A-B1
31 t
2 2 2 2 2 2 2
M-N1
X113
Z-B1
C-N1
C-B1
A-N1
Z-N1
V/N1
C/B1
H-L1
V-Z1
N70
G1
A1
N1
N1
N1
N1
N1
N1
N2
1 1 1 1 1 1 1 1 1 1 X154 X154 X156 X156
N1
N1
S0 1 1
H/R1
N1
N1
N1
N6
H92
59c
59c
57
57
E155 E157
MOTOR HARNESS 42N-06
31
31
GND4 GND
11161 2 2 2 2 2 2 2 2 2 2 Gnd Gnd
X90 X91 X92 X93 X94 X95 X96 X98 X99 X97 E154 4 4 E156 GND4.1
X155 X157
4 4
Gnd5 X154 X156 Gnd4 Gnd4.1
N1
N1
N1.5
N1
N1
N1
N1
N1
N1
N1
N1
N1
N1
N1
WB93R-5E0 90-9
ELECTRICAL CIRCUIT DIAGRAM (3/3) DIAGRAMS AND DRAWINGS
ID Description ID Description
ID Description
F21 Return to DIG sender supply fuse 10A S85 Rear horn button
A1 Komtrax unit
F22 EC power fuse 7,5A S86 General light switch
A6 Multifunction unit
F23 +15 Steering unit fuse 10A S87 4wd switch
A149 Stabilizers relays unit
F24 Flasher fuse 7,5A S88 PPC button
B13 Return to dig sensor
F25 Reverse speed buzzer + Steering column 10A S89 Warning switch
B53 Stop switch
F27 General fuse 200A S100 Switch overload
B54 Stop light switch
G1 Battery S140 Rear working light switch
B59 Brake oil low level switch
G118 Starter S141 Beacon lamp switch
B97 Horn
G119 Generator S142 Front working light switch
B103 Pressure switch
H17 Buzzer V180 Current electric limitator for warning light
B104 4th speed switch
H92 Back-up alarm X30 Lighter
B105 Oil transmission temperature switch
H101 Buzzer Y48 Float solenoid valve
B107 Decluch trasmission switch
K1 Unrepeat start unit Y49 Return to dig solenoid valve
B111 Fuel level sender
K2 Flasher Y60 Emp. solenoid valve
B112 Thermistor switch
K3 Low beam relay Y90 PPC solenoid valve
B113 Air filter
K4 Main beam relay Y91 ECOPOWER solenoid valve
B115 Engine oil low pressure switch
K5 Front horn relay Y93 Rear PPC solenoid valve
B121 Horn
K6 Return to DIG solenoid valve relay Y94 Differential lock solenoid valve
B321 Speed meter Sensor
K7 Light stop relay Y95 Unlock arm solenoid valve
E136 Right rear working light
K8 Assent start relay Y96 Unlock plate solenoid valve
E138 Left rear working light
K9 Forward speed relay Y98 Closing grab solenoid valve
E143 Right front lateral working light
K10 Reverse speed relay Y99 Opening solenoid valve
E146 Left front lateral working light
K11 Stop drive relay Y106 4WS Solenoid valve
E147 Left front light
K45 Preheating Relay Y108 Forward solenoid valve
E148 Beacon lamp
K56 Starting relay Y117 Elettrostop
E151 Right front light
K61 Service relay Y203 Reverse solenoid valve
E152 Cabin lamp
K104 Overload BHL line Y303 Ride control valve
E154 Left rear light
K340 Rear working light relay Y304 Ride control valve
E155 Left rear indicator light
K341 Beacon light relay
E156 Right rear light
K342 Front working light relay
E157 Right rear indicator light
K400 Start cut relay
F1 Central front working light fuse 15A
M42 Rear Windshield-washer
F2 Central rear working light fuse 15A
M55 Motor pump
F3 Right position light fuse 3A
M58 Front windshield-washer
F4 Left position light fuse 3A
M109 Motor pump
F5 Horn fuse 10A
M116 Compressor
F6 Lateral rear working light fuse 15A
P43 Instruments panel
F7 Windshield wiper-washer + rear horn fuse 7,5A
P63 Front instruments
F8 Stop light switch fuse 7,5A
R114 Preheating
F9 Lateral front working light fuse 15A
S0 Main switch
F10 Front windshield-motor supply fuse 10A
S24 Starting switch
F11 Optional fuse 7,5A
S40 Seat Switch
F12 Reverse speed buzzer + Steering column 10A
S46 Parking brake switch
F13 Supply level grip fuse 10A
S47 Joystick
F14 Light switch + switch optional fuse 10A
S52 Light steering column
F15 EC power fuse 7,5A
S57 Gear steering column
F16 Beacon light fuse 10A
S80 Ride control switch
F17 Warning switch fuse 10A
S81 Unlock arm button
F18 Cabin lamp + cigarette lighter fuse 10A
S82 Unlock plate switch
F19 Low beam fuse 15A
S83 E/C power button
F20 Main beam light 15A
S84 EMPI solenoid valve switch
90-10 WB93R-5E0