WEBM001004

SHOP MANUAL

WB97R -2
BACKHOE LOADER
SERIAL NUMBER
WB97R-2 97F21409 and up
 CONTENTS
Page
10 STRUCTURE AND FUNCTION........................................................................................ 10-1

20 TESTING AND ADJUSTING ............................................................................................ 20-1

30 DISASSEMBLY AND ASSEMBLY .................................................................................. 30-1

40 MAINTENANCE STANDARD........................................................................................... 40-1

WB97R-2 00-1
PAGE INTENTIONALLY
LEFT BLANK
 REVISED PAGES

The affected pages are indicated by the use of the Mark Indication Action required
following marks. It is requested that necessary ac-
tions be taken to these pages according to table be-
low. ❍ Page to be newly Add

● Page to be replaced Replace

( ) Page to be delete Discard

Pages having no marks are those previously revised or

made additions.
LIST OF REVISED PAGES
Time of Time of Time of Time of Time of
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WB97R-2 00-2-1
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Time of Time of Time of Time of Time of

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00-2-2 WB97R-2
 SAFETY

IMPORTANT SAFETY NOTICE

Proper service and repair is extremely important for the safe operation of your machine.
The service and repair techniques recommended by Komatsu Utility and describe in this manual are both effective and
safe methods of operation. Some of these operations require the use of tools specially designed by Komatsu Utility for
the purpose.
To prevent injury to workers, the symbols and are used to mark safety precautions in this manual. The cautions
accompanying these symbols should always be carefully followed. If any danger arises or may possibly arise, first con-
sider safety, and take necessary steps to face.

SAFETY
GENERAL PRECAUTIONS PREPARATIONS FOR WORK
Mistakes in operation extremely dangerous. 7. Before adding or making any repairs, park the ma-
Read all the Operation and Maintenance Manual care- chine on hard, level ground, and block the wheels to
fully 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
on the machine. possible, use blocks to prevent the work equipment
2. When carrying out any operation, always wear safe- from falling down. In addition, be sure to lock all the
ty shoes and helmet. Do not wear loose work control levers and hang warning sign on them.
clothes, or clothes with buttons missing. 9. When disassembling or assembling, support the
• Always wear safety glasses when hitting parts machine with blocks, jacks or stands before starting
with a hammer. work.
• Always wear safety glasses when grinding 10. Remove all mud and oil from the steps or other plac-
parts with a grinder, etc. es used to get on and off the machine. Always use
3. If welding repairs are needed, always have a the handrails, ladders or steps when getting on or off
trained, experienced welder carry out the work. the machine.
When carrying out welding work, always wear weld- Never jump on or off the machine.
ing gloves, apron, glasses, cap and other clothes If it is impossible to use the handrails, ladders or
suited for welding work. steps, 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
before starting. Always inform your fellow workers 11. When removing the oil filler cap, drain plug or hy-
before starting any step of the operation. Before draulic pressure measuring plugs, loosen them
starting work, hang UNDER REPAIR signs on the slowly to prevent the oil from spurting out.
controls in the operator’s compartment. Before disconnecting or removing components of
the hydraulic circuit and engine cooling circuit, first
5. Keep all tools in good condition and learn the correct
remove the pressure completely from the circuit.
way to use them.
12. The water and oil in the circuits are not hot when the
6. Decide a place in the repair workshop to keep tools
engine in stopped, so be careful not to get burned.
and removed parts. Always keep the tools and parts
Wait for the oil water to cool before carrying out any
in their correct places. Always keep the work area
work on the cooling water circuits.
clean and make sure that there is no dirt or oil on the
floor. 13. Before starting work, remove the leads from the bat-
Smoke only in the areas provided for smoking. Nev- tery. Always remove the lead from the negative ( – )
er smoke while working. terminal first.

WB97R-2 00-3
 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
break or damage the wiring. or 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.
18. As a general rule, do not use gasoline to wash parts.
In particular, use only the minimum of gasoline
when washing electrical parts.

00-4 WB97R-2
 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.

STRUCTURE AND FUNCTION

This section explains the structure and function of each component. It serves not only to give an understanding
of the structure, but also serves as reference material for troubleshooting.

TESTING AND ADJUSTING

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

DISASSEMBLY AND ASSEMBLY

This section explains the order to be followed when removing, installing, disassembling or assembling each
component, as well as precautions to be taken for these operations.

MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.

NOTE

The specifications contained in this shop manual are subject to change at any time and without any no-
tice.
Contact your Komatsu Utility distributor for the latest information.

WB97R-2 00-5
 HOW TO READ THE SHOP MANUAL

HOW TO READ THE SHOP MANUAL

VOLUMES SYMBOLS
Shop manual are issued as a guide to carry out repairs. In order to make the shop manual greatly chelpful, im-
These various volumes are designed to avoid duplicat- portant points about safety and quality are marked with
ing the same information. the following symbols.

Symbol Item Remarks

DISTRIBUTION AND UPDATING
Any additions, amendments or other changes will be Special safety precautions
sent to Komatsu Utility distributors. are necessary when
Get the most up-to-date information before you start any performing the work.
work.
Safety
Extra special safety precautions
are necessary when performing
FILING METHOD the work because it is under in-
1. See the page number on the bottom of the page. ternal pressure.
File the pages in correct order.
Special technical precautions or
2. Following examples show you how to read the page
number. ★ Caution
other precautions for preserving
standards are necessary when
Example: performing the work.

10 - 3 Weight of parts or systems.

Caution necessary when select-
Weight
ing hoisting wire, or when work-
Item number (10. Structure and ing posture is important, etc.
Function)
Parts that require special atten-
Consecutive page number for each Tightening
tion for the tightening torque dur-
item torque
ing assembly.

Parts to be coated with adhe-

3. Additional pages: additional pages are indicated by Coat
sives and lubricants etc.
a hyphen (–) and number after the page number.
Fle as in the example. Places where oil, water or fuel
Example: Oil, water must be added, and their quan-
tity.
10-4 Places where oil or water must
10-4-1 Drain be drained, and quantity to be
Added pages drained.
10-4-2
10-5

REVISED EDITION MARK

(➀➁➂....)
When a manual is revised, an edition mark is recorded
on the bottom outside corner of the pages.

REVISIONS
Revised pages are shown on the LIST OF REVISED
PAGES between the title page and SAFETY page.

00-6 WB97R-2
 HOISTING INSTRUCTIONS

HOISTING INSTRUCTIONS
Hooks have maximum strength at the middle por-
tion.
Heavy parts (25 kg or more) must be lifted
with a hoist etc. In the Disassembly and Assem-
bly section, every part weighing 25 kg or more is
clearly indicated with the symbol

1. If a part cannot be smoothly removed from the ma-

chine by hoisting, the following checks should be
made:
• Check for removal of all bolts fastening the part 3) Do not sling a heavy load with one rope alone, but
to the relative parts. sling with two or more ropes symmetrically wound
• Check for any part causing interference with on to the load.
the part to be removed. Slinging with one rope may cause turning of the load
during hoisting, untwisting of the rope, or slipping of
the rope from its original winding position on the
2. Wire ropes load, which can cause dangerous accidents.
1) Use adequate ropes depending on the weight of 4) Do not sling a heavy load with ropes forming a wide
parts to be hoisted, referring to the table below: hanging angle from the hook.
When hoisting a load with two or more ropes, the
WIRE ROPES force subjected to each rope will increase with the
(Standard «S» or «Z» twist ropes hanging angles.
without galvanizing) The table below shows the variation of allowable
load (kg) when hoisting is made with two ropes,
Rope diameter (mm) Allowable load (tons) each of which is allowed to sling up to 1000 kg ver-
tically, at various handing angles.
10.0 1.0
When two ropes sling a load vertically, up to 2000 kg
11.2 1.4 of total weight can be suspended.
This weight becomes 1000 kg when two ropes
12.5 1.6
make a 120° hanging angle.
14.0 2.2 On the other hand, two ropes are subjected to an ex-
cessive force as large as 4000 kg if they sling a 2000
16.0 2.8
kg load at a lifting angle of 150°.
18.0 3.6
20.0 4.4
22.4 5.6
30.0 10.0
40.0 18.0
50.0 28.0
60.0 40.0

The allowable load value is estimated to be one-

sixth or one-seventh of the breaking strength of the
rope used.
2) Sling wire ropes from the middle portion of the hook.
Slinging near the edge of the hook may cause the
rope to slip off the hook during hoisting, and a se-
rious accident can result.

WB97R-2 00-7
 STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE

The following charts give the standard tightening torques of bolts and nuts.
Exceptions are given in section of «Disassembly and Assembly».

1. STANDARD TIGHTENING TORQUE OF BOLTS AND NUT

Width across flat

Thread Pitch of (mm)
diameter of bolts bolts
(mm) (mm) kgm Nm kgm Nm

6 1 10 8 0.96±0.1 9.5±1 1.3±0.15 13.5±1.5

8 1.25 13 6 2.3±0.2 23±2 3.2±0.3 32.2±3.5

10 1.5 17 8 4.6±0.5 45±4.9 6.5±0.6 63±6.5

12 1.75 19 10 7.8±0.8 77±8 11±1 108±11

14 2 22 12 12.5±1 122±13 17.5±2 172±18

16 2 24 14 19.5±2 191±21 27±3 268±29

18 2.5 27 14 27±3 262±28 37±4 366±36

20 2.5 30 17 38±4 372±40 53±6 524±57

22 2.5 32 17 52±6 511±57 73±8 719±80

24 3 36 19 66±7 644±70 92±10 905±98

27 3 41 19 96±10 945±100 135±15 1329±140

30 3.5 46 22 131±14 1287±140 184±20 1810±190

33 3.5 50 24 177±20 1740±200 250±27 2455±270

36 4 55 27 230±25 2250±250 320±35 3150±350

39 4 60 ---- 295±33 2900±330 410±45 4050±450

This torque table does not apply to bolts or nuts which have to fasten nylon or other parts non-ferrous metal washer.
★ Nm (newton meter): 1 Nm = 0.102 kgm

00-8 WB97R-2
 STANDARD TIGHTENING TORQUE

2. TIGHTENING TORQUE FOR NUTS OF FLARED

Use these torques for nut part of flared.

Thread diameter Width across flats TIGHTENING TORQUE

of nut part of nut part
(mm) (mm) kgm Nm

1/2” - 20 17 2.6±0.5 25.5±4.9

9/16” - 18 17 4±0.5 39.2±4.9

3/4” - 16 22 6.7±2 65.7±19.6

7/8” - 14 27 8±2 78.5±19.6

1.1/16 - 12 32 9.7±3 95.15±29.4

1.5/16 - 12 38 17±3 166.7±29.4

1.5/8 - 12 50 20±5 196.2±49

22 27 8±2 78.5±19.6

33 41 20±5 196.2±49

Sealing surface

Thread diameter Width across flats TIGHTENING TORQUE

of nut part of nut part
(mm) (mm) kgm Nm

9/16” - 18 17 2.3–2.5 23–25

11/16” - 16 22 3.4–3.9 33–38

13/16” - 16 24 5.2–5.8 51–57

1” - 14 30 8.2–9.2 80–90

1.3/16 - 12 36 12.2–13.3 120–130

1.7/16 - 12 41 15.3–17.3 150–170

1.11/16 - 12 50 18.4–20.4 180–200

2” - 12 57 20.4–24.4 200–240

WB97R-2 00-9
 COATING MATERIALS

COATING MATERIALS
The recommended coating materials prescribed in Komatsu Utility Shop Manuals are listed below:

Nomenclature Code Applications

ASL800010 Used to apply rubber pads, rubber gaskets and cork plugs.

Used to apply resin, rubber, metallic and non-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.

Used by itself on mounting flat surface

Gasket sealant Loctite 510
(Clearance between surfaces within 0.2 mm)

Used by itself on mounting flat surface

Loctite 518
(Clearance between surfaces within 0.5 mm

Antifriction compound
Applied to bearings and taper shaft to facilitate press-fitting and to prevent
(Lubricant including ASL800040
sticking, burning or rusting.
Molybdenum disulfide)

Grease Applied to bearings, sliding parts and oil seals for lubrication, rust prevention
ASL800050
(Lithium grease) and facilitation of assembling work.

Vaseline ----- Used for protecting battery electrode terminals from corrosion

00-10 WB97R-2
 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 – – –

COMPOSITION OF THE COLOURS

The coloration of two-colour wires is indicated by the composition of the symbol listed.
Example:G–V = Yellow-Green with longitudinal colouring
G/V = Yellow-Green with transversal colouring

WB97R-2 00-11
 WEIGHT TABLE

WEIGHT TABLE
This weight table is a guide for use when transporting or handling components.
Unit: kg
Machine model WB97R-2
Engine assembly - Muffler - Exhaust pipe 410
Radiator - exchanger 37
Hydraulic oil tank (empty) 77
Fuel tank (empty) 73
Front counterweight 300
Engine hood 27
Cabin (without seat) 595
Seat 34
Engine-gear box-pump group 740
Piston pump 38
Transmission 230
Front axle 316
Rear axle 511
Front wheel 65
Rear wheel 163
2-spool control valve 24
3-spool control valve 30
Work equipment 960
• Boom 370
• Bucket 427
• Fulcrum lever 13x4
• Tilt lever 48x2
• Raise cylinder 40x2
• Tilt cylinder 45x2
Work equipment
• with standard arm 850
• with long arm 885
• with jig arm 1030
Boom 323
Arm 213
Long arm 245
Boom swing bracket 133
Backframe 237
Control valve (6-spool) 47
Control valve (7-spool) 53
Control valve (8-spool) 59
Jig arm 392
Outriggers 57
Boom cylinder 78
Arm cylinder 69
Bucket cylinder 49
Outriggers cylinder 42
Swing cylinder 30
Bucket 156

00-12 WB97R-2
 TABLE OF OIL AND COOLANT QUANTITIES

TABLE OF OIL AND COOLANT QUANTITIES

AMBIENT TEMPERATURE CAPACITY (ᐉ)
KIND OF
RESERVOIR -- 30 -- 20 -- 10 0 10 20 30 40 50°C
FLUID
Specified Refill

SAE 10W

OIL SAE 20W-20

Crankcase sump 7.9 7.9
• API CD
SAE 30
SAE 40

OIL
Hydraulic circuit SAE 10W-30 150 92
• API CD

Hydraulic circuit
with biodegradable 150 92
oil

Front axle
6.5 6.5
• Differential

• Final reduction gear

1 1
(each.) OIL
Rear axle: • UTTO FLUID
14.5 14.5
• Differential

• Final reduction gear

1.5 1.5
(each.)

Hydraulic OIL
24.5 24,5
transmission GM DEXRON® II D
(DEXRON® is a
registered
Braking system General Motors 0.8 0.8
Corporation)

✽
Fuel tank FUEL 130 –
ASTM D975 N.2

WATER +
14 –
ANTI-FREEZE

Engine coolant
WATER 14 –
system

PERMANENT
14 –
LIQUID

✽ ASTM D975 N.
ASTM: America Society of Testing and Materials
SAE: Society of Automotive Engineers
API: American Petroleum Institute
MIL: Military Specification
CCMC: Common Market Constructors Committe
First filling quantity:
total quantity of oil, including the oil for the components and pipes.
Oil change quantity:
quantity of oil necessary to fill the system or unit during the normal inspection and maintenance operations.

WB97R-2 00-13
 TABLE OF OIL AND COOLANT QUANTITIES

NOTE:
(1) When the diesel oil sulphur content is less then 0.5%, change the engine oil according to the periodic maintenance
intervals indicated in the operation and maintenance manual. In the diesel oil sulphur content exceeds 0.5% change
the engine oil according to the following table:

Sulphur content Engine oil change interval

from 0.5 to 1.0% 1/2 of regular interval
over 1.0% 1/4 of regular interval

(2) When starting the engine at temperatures below 0 °C, use engine oil SAE 10W, 20W-20 and 10W-30, even if during
the day the temperature increases by 10 °C.
(3) Use engine oil with CD classification; if oil with CD classification is used, reduce the engine oil change interval by a
half.
(4) Use original products, which have characteristics specifically formulated and approved for the engine, the hydraulic
circuit of equipment and for reductions.

00-14 WB97R-2
 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.

2. Convert 550 mm into inches

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.

2 - Carry out the same procedure as above to convert 55 mm to 2.165 in.

3 - The original value (550 mm) was divided by 10, so multiply 2.165 in. by 10 (move the decimal point one place to
B
the right) to return to the original value. This gives 550 mm = 21.65 in.

From millimeters to inches

1 mm = 0.03937 in.

0 1 2 3 4 5 6 7 8 9

0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

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
C
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929

A
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

WB97R-2 00-15
 CONVERSION TABLE

From mm to in.
1 mm = 0.03937 in.

0 1 2 3 4 5 6 7 8 9

0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

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

0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84

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 WB97R-2
 CONVERSION TABLE

From liter to U.S. Gall.

1 ᐉ = 0.2642 U.S. Gall.

0 1 2 3 4 5 6 7 8 9

0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378

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

From liter to U.K. Gall.

1 ᐉ = 0.21997 U.K. Gall.

0 1 2 3 4 5 6 7 8 9

0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980

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

WB97R-2 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

0 0 0.737 1.474 2.211 2.948 3.685 4.422 5.159 5.896 6.633

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 WB97R-2
 CONVERSION TABLE

From Nm to kgm
1 Nm = 0.102 kgm

0 1 2 3 4 5 6 7 8 9

0 0 0.102 0.204 0.306 0.408 0.510 0.612 0.714 0.816 0.918

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

WB97R-2 00-19
 CONVERSION TABLE

From kgm to lb.ft.

1 kgm = 7.233 lb.ft.

0 1 2 3 4 5 6 7 8 9

0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1

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 WB97R-2
 CONVERSION TABLE

From bar to psi (lb/in2)

1 bar = 14.503 psi

0 1 2 3 4 5 6 7 8 9

0 0 14.5 29.0 43.5 58.0 72.5 87.0 101.5 116.0 130.5

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

WB97R-2 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

–40.4 –40 –40.0 –11.7 11 51.8 7.8 46 144.8 27.2 81 117.8

–37.2 –35 –31.0 –11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
–34.4 –30 –22.0 –10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
–31.7 –25 –13.0 –10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
–28.9 –20 –4.0 –9.4 15 59.0 10.0 50 122.0 29.4 85 185.0

–28.3 –19 –2.2 –8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

–27.8 –18 –0.4 –8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
–27.2 –17 1.4 –7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
–26.7 –16 3.2 –7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
–26.1 –15 5.0 –6.7 20 68.0 12.8 55 131.0 32.2 90 194.0

–25.6 –14 6.8 –6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

–25.0 –13 8.6 –5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
–24.4 –12 10.4 –5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
–23.9 –11 12.2 –4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
–23.3 –10 14.0 –3.9 25 77.0 15.6 60 140.0 35.0 95 203.0

–22.8 –9 15.8 –3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

–22.2 –8 17.6 –2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
–21.7 –7 19.4 –2.2 28 72.4 17.2 63 145.4 36.7 98 208.4
–21.1 –6 21.2 –1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
–20.6 –5 23.0 –1.1 30 86.0 18.3 65 149.0 37.8 100 212.0

–20.0 –4 24.8 –0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

–19.4 –3 26.6 0.0 32 89.6 19.4 67 152.6 43.3 110 230.0
–18.9 –2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
–18.3 –1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
–17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0

–17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

–16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
–16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
–15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 2930
–15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0

–14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

–13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
–13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
–12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
–12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0

00-22 WB97R-2
 STRUCTURE AND FUNCTION

POWER TRAIN ......................................................... 2 SHOVEL CYLINDERS .............................................93

TRANSMISSION ....................................................... 4 BACKHOE CYLINDERS ..........................................94
TRANSMISSION ....................................................... 5 AIR-CONDITIONING UNIT ......................................98
TRANSMISSION ....................................................... 7 HOW THE AIR-CONDITIONING UNIT
DRIVE SHAFTS ........................................................ 8 FUNCTIONS ............................................................99
CONTROL VALVE BLOCK ..................................... 10 ENGINE WIRING HARNESS.................................101
FRONT AXLE .......................................................... 12 FRONT LINE WIRING HARNESS .........................102
REAR AXLE ............................................................ 15 LATERAL PLATFORM WIRING HARNESS ..........103
HYDRAULIC PUMP ................................................ 20 LATERAL DASHBOARD WIRING HARNESS.......104
STEERING UNIT..................................................... 41 BACKHOE SERVOCONTROL WIRING
HYDRAULIC CIRCUIT STANDARD ....................... 43 HARNESS (FRAME) .............................................105
HYDRAULIC CIRCUIT (WITH PPC VALVE)........... 44 BACKHOE SERVOCONTROL WIRING
HARNESS (CABIN)................................................106
HYDRAULIC CIRCUIT (WITH PPC VALVE)........... 45
WORK LIGHT WIRING HARNESS........................107
SHOVEL CONTROL VALVE................................... 46
ATC24 WIRING HARNESS ...................................108
SHOVEL CONTROL VALVE................................... 47
FUSES BOX (1/2) ..................................................109
BACKHOE CONTROL VALVE ................................ 52
FUSES BOX (2/2) ..................................................110
CLSS (Closed Center Load Sensing System) ......... 65
FUSES BOX ATC24 (1/2) ......................................111
PPC VALVE (OPTIONAL) ....................................... 79
FUSES BOX ATC24 (2/2) ......................................112
SOLENOID VALVE ................................................. 81
ELECTRICAL DIAGRAM EGM ..............................113
SAFETY VALVE ...................................................... 87
ELECTRICAL DIAGRAM ATC24 ...........................115
BRAKE PUMP ......................................................... 92

WB97R-2 10-1
STRUCTURE AND FUNCTION POWER TRAIN

POWER TRAIN

1 2
3 4

5 7 8
6
RKZ01061

DESCRIPTION
• The driving power for the engine (1) is transmitted • The driving power is transmitted from the transmis-
through the flywheel to the converter (2). sion flanges (3) to the front (5) and rear (6) axles
The converter (2) uses hydraulic oil to convert the 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
power. The converter (2) transmits motion to the rear (6) axles is reduced by the differentials and then
drive shaft of the transmission (3) and to the drive transmitted to the planetary gear through the differ-
shaft of the hydraulic pump (4). ential shafts.
• The transmission (3) has two hydraulically-activat-
ed clutches that can be selected by an electrically-
controlled gear selector. It also has manual gear se-
lection (four forward gears and four reverse gears).

10-2 WB97R-2
STRUCTURE AND FUNCTION POWER TRAIN

Front axle Rear axle

Gears
Transmission Differential Planetary Total Transmission Differential Planetary Total
1st gear 4.374 62.592 5.440 92.893
2nd gear 2.436 34.859 3.030 51.740
2.436 6.000 2.846 6.000
3rd gear 1.232 17.630 1.532 26.160
4th gear 0.651 9.316 0.810 13.832

Z=37
6

Z=15
Z=75
4
Z=13

9
8
3

1 10

Z=13

Z=15

5 Z=31 Z=75

RKZ01031

1. Diesel engine 5. Front axle 9. Rear wheels

2. Convertor 6. Rear axle 10. Front wheels
3. Transmission 7. Front Cardan drive shaft
4. Hydraulic pump 8. Rear Cardan drive shaft

WB97R-2 10-3
STRUCTURE AND FUNCTION TRANSMISSION

TRANSMISSION
Diagram of the power train

4
Z=17 Z=59 5

Z=58 Z=51

Z=27 Z=37 Z=41

3
Z=30

Z=27
Z=58

Z=37

Z=30 Z=44

Z=45
6
2

RKZ04470

1. Engine 4. Hydraulic pump

2. Convertor 5. Rear flange
3. Transmission 6. Front flange

10-4 WB97R-2
STRUCTURE AND FUNCTION TRANSMISSION

TRANSMISSION
Hydraulic convertor-transmission circuit diagram

1st Gear clutch 3rd Gear clutch Forward clutch Reverse clutch 4th Gear clutch 4WD Clutch 2nd Gear clutch

11–13 bar - 900 rpm 11–13 bar - 900 rpm 13.5–15.5 bar - 900 rpm
12–14 bar - 2200 rpm 12–14 bar - 2200 rpm 15–17 bar - 2200 rpm
14 15 13.5–15.5 bar - 900 rpm
14.5–16.5 bar - 2200 rpm
13.5–15.5 bar - 900 rpm
14.5–16.5 bar - 2200 rpm
16 26 17
1.5–2.0 bar 1.5–2.0 bar 21 23 1.5–2.0 bar 1.5–2.0 bar
32
31 33 20 22 24 Tube 25 Tube 27
18 19
13–15 bar - 900 rpm 13–15 bar - 900 rpm 13–15 bar - 900 rpm 14–16 bar - 900 rpm 13.5–15.5 bar - 900 rpm
Tube Tube 14.5–16.5 bar - 2200 rpm 15–17.5 bar - 2200 rpm 15–17 bar - 2200 rpm Tube
14.5–16.5 bar - 2200 rpm 14.5–16.5 bar - 2200 rpm

5 6 7 8 9 10 11 13
9–11 bar
28 2
1–4.5 bar - 900 rpm 30
Selector valve 6–11 bar - 2200 rpm 14–16 bar - 900 rpm
15.5–18 bar - 2200 rpm

29 12 Max oil pressure 11 bar

Max oil temperature 127 °C Opens at
3.45 bar Delivery filter
0.2–1.8 bar - 900 rpm 112–118 °C 10 µm
0.7–2.5 bar - 2200 rpm Motor
Oil flow 20+26 L/1° - 900 rpm
Oil cooler
3 50+65 L/1° - 2200 rpm
Oil Max 18 Bar
Hose Hose
pump
Ø 3.5mm
Bearing
Opens at
Output shaft

Flow 14+27 L/1° - 900 rpm

Input shaft

Primary shaft

25+45 L/1° - 2200 rpm Motor 23–26 bar

1
Suction filter
250 µm
Air breather
Opens at
5.5 bar
4
Transmission sump
RKZ06331

1 - Filter pressure relief valve 10 - 4WD clutch solenoid valve 19 - 3rd gear clutch - pressure check point 28 - Torque converter - pressure check point
2 - Oil flow divider 11 - 2nd gear clutch solenoid valve 20 - Forward gear clutch - pressure check point 29 - Lubrication - pressure check point
3 - Torque converter 12 - Oil temperature sensor (alarm) 21 - Forward gear clutch - pressure check point 30 - General oil clutch - pressure check point
4 - Torque converter pressure relief valve 13 - Oil pressure sensor (alarm) 22 - Reverse gear clutch - pressure check point 31 - 1st gear - antishock valve
5 - 1st gear clutch solenoid valve 14 - 1st gear filling - pressure sensor 23 - Reverse gear clutch - pressure check point 32 - 2nd gear - antishock valve
6 - 3rd gear clutch solenoid valve 15 - 3rd gear filling - pressure sensor 24 - 4th gear clutch - pressure check point 33 - 3rd gear - antishock valve
7 - Forward clutch proportional solenoid valve 16 - 4th gear filling - pressure sensor 25 - 4WD gear clutch - pressure check point
8 - Reverse clutch proportional solenoid vulvae 17 - 2nd gear filling - pressure sensor 26 - 4WD gear clutch - pressure check point
9 - 4th gear clutch solenoid valve 18 - 1st gear clutch - pressure check point 27 - 2nd gear clutch - pressure check point

WB97R-2 10-5
STRUCTURE AND FUNCTION TRANSMISSION

1 b 2 c 3
7
a

A
X

4 A

9 5 12

11

6 10
View
VistaXX
RKZ03042

a. From the oil cooler 5. Plug

b. To the oil cooler 6. Suction filter
c. To the solenoid valve group ST1 (P Port) 7. Oil temperature sensor (C16)
d. From the solenoid valve group ST1 (T Port) 8. 4th gear filling pressure sensor (C11)
9. 1st gear filling pressure sensor (C08)
1. Control valve group
10. Speedmeter sensor (C02)
2. Convertor
11. 3rd gear filling pressure sensor (C10)
3. Filter
12. 2nd gear filling pressure sensor (C09)
4. Plug

10-6 WB97R-2
STRUCTURE AND FUNCTION TRANSMISSION

TRANSMISSION

2 3

5
6

7
9

8 Section A
A --AA
Sezione RKZ03052

1. Hydraulic pump drive shaft 6. Flange

2. Propeller shaft 7. Front output shaft
3. Reverse gears idler shaft 8. 4WD engagement device
4. Drive shaft 9. Flange
5. Rear output shaft

WB97R-2 10-7
STRUCTURE AND FUNCTION DRIVE SHAFTS

DRIVE SHAFTS
Drive shaft for forward and reverse movement

1 2

a b c

6
5

4 3
RKZ03070

a. Port commanding reverse clutch 1. Reverse gear clutch (Z=37) 4. Forward clutch piston
b. Port commanding forward clutch 2. Forward gear clutch (Z=37) 5. Thrust ring
C. Lubrication port 3. Reverse clutch piston 6. Driven shaft

Drive shaft

3
1
2
4
a

5 RKZ03090

a. Drive gear for 2nd gear 3. Drive gear 4th gear (Z=58)
4. Drive gear 1st gear (Z=17)
1. Drive gear 3rd gear (Z=45)
5. Control piston 2nd gear
2. Drive gear 2nd gear (Z=30)

10-8 WB97R-2
STRUCTURE AND FUNCTION DRIVE SHAFTS

Driven gear shaft

5
2
4
1
3 c
a b 6

10
9 8 7
RKZ03060

a. Port commanding 4th gear 5. Driven gear for 1st gear (Z=59)
b. Port commanding 3rd gear 6. Rear output shaft
c. Port commanding 1st gear 7. Control piston 1st gear
1. Driven gear for 3rd gear (Z=44) 8. Control piston 4th gear
2. Driven gear for 2nd gear (Z=58) 9. Control piston 3rd gear
3. Driven gear for 4th gear (Z=30) 10. Speedmeter disc
4. Drive gear for 4WD (Z=51)

Driven shaft 4WD

2 3

1 a

5
4 RKZ03080

a. 4WD disengagement command port 3. 4WD driven gear

1. Front output shaft 4. Piston (No. 3)
2. 4WD disengagement command piston 5. Spring

WB97R-2 10-9
STRUCTURE AND FUNCTION CONTROL VALVE BLOCK

CONTROL VALVE BLOCK

1 2 3 4 5 6 7
8

M2 MP M4 M3

2ª 4WD 4ª IND AV 3ª 1ª

M2ª M4WD M4ª M3ª M1ª

RKZ03101

ELECTRICAL COMPONENT CHECK POINT

1. C24 - 2nd gear clutch solenoid valve (ED6) M2ª 2nd gear pressure
2. C27 - 4WD disengagement clutch solenoid valve (ED5) M2 Torque converter pressure
3. C26 - 4th gear clutch solenoid valve (ED2) M4WD 4WD disengagement pressure
4. C21 - Reverse clutch proportional solenoid valve (ED4) M4ª 4th gear pressure
5. C22 - Forward clutch proportional solenoid valve (ED3) MP General oil clucth pressure
6. C25 - 3rd gear clutch solenoid valve (ED7) M4 Reverse clucth pressure
7. C23 - 1st gear clutch solenoid valve (ED1) M3 Forward clucth pressure
8. C07 - Oil pressure sensor (alarm) M3ª 3rd gear pressure
M1ª 1st gear pressure

10-10 WB97R-2
PAGE INTENTIONALLY
LEFT BLANK
STRUCTURE AND FUNCTION FRONT AXLE

FRONT AXLE
Differential

1 2 3 1

4
5

6
7 7
17 16
15
8
14
9
13
10
12

RKZ00581
11

1. Planetary gear 11. Flange

2. Ring bevel gear (Z=31) 12. Cover
3. Bevel gear 13. Lock nut
4. Lock nut 14. Bearing
5. Half-axle 15. Bevel pinion (Z=13)
6. Pin 16. Pin
7. Differential housing 17. Oil drain plug
8. Spacer
9. Bearing
10. Seal

10-12 WB97R-2
STRUCTURE AND FUNCTION FRONT AXLE

Final reduction - joint

7
3 5 8 9
2 4 6
1
10 11

24

23

13
22 17 12
14
18 16
15
21 20 19 RKZ00611

1. Planetary carrier 14. Joint

2. Planetary (Z =29) 15. Pin
3. Ring gear (Z=75) 16. Protection
4. Ring gear carrier 17. Seal
5. Wheel hub 18. Bearing
6. Seal 19. Snap ring
7. Pin 20. Steady pin
8. Shim 21. Stud bolt
9. Protection 22. Plug
10. Bushing 23. Sun gear (Z=15)
11. Seal 24. Snap ring
12. Axle body
13. Bearing

WB97R-2 10-13
STRUCTURE AND FUNCTION FRONT AXLE

Steering cylinder

B 1

C 2 3

A
A
a b

7 7

5
4 Section
Sezione B
B -- B
B 6
Section
Sezione A
A- A
A Detail C
Particolare C
RKZ00591

1. Steering cylinder a Port - From the steering unit (L Port)

2. Oil refilling plug b Port - From the steering unit (R Port)
3. Oil drain plug
4. Nut
5. Adjustment screw
6. Nut
7. Bushing

10-14 WB97R-2
STRUCTURE AND FUNCTION REAR AXLE

REAR AXLE
Differential

7 1 2 3 4 5 6 7

15
14
8
13 9

10
12 11

RKZ04970

1. Bearing 9. Bearing
2. Planetary gear 10. Nut
3. Bevel gear 11. Seal
4. Ring bevel gear (Z=37) 12. Flange
5. Differential housing 13. Spacer
6. Lock nut 14. Bevel pinion (Z=13)
7. Half-axle 15. Differential housing
8. Pin

WB97R-2 10-15
STRUCTURE AND FUNCTION REAR AXLE

Final reduction

4 2 3

5
6 7 8
1

16

10

15
9
14 11

13 12 RKZ04980

1. Planetary gear carrier 12. Snap ring

2. Stud bolt 13. Ring gear (Z=75)
3. Wheel hub 14. Oil plug
4. Planetary gears (Z=28) 15. Steady pin
5. Ring bevel gear carrier 16. Pin
6. Bearing
7. Seal
8. Joint
9. Half-axle
10. Planetary gear (Z=15)
11. Bushing

10-16 WB97R-2
STRUCTURE AND FUNCTION REAR AXLE

Brakes

1 A
9 7

8
3 10
4
2
6

5
1
Detail B B
Particolare

Section
Sezione A - A
A
RKZ04990

1. Bushing 6. Brake disk

2. Parking brake control rod 7. Piston
3. Bleeder valve 8. Spring
4. Parking brake lever 9. Pressure disk
5. Parking brake control cam 10. Intermediate disk

WB97R-2 10-17
STRUCTURE AND FUNCTION REAR AXLE

Differential locking

1 2

7
RKZ05000
6 5 4 3

a. From the solenoid valve block ST1 (Port 2)

1. Sleeve
2. Pin
3. Control rod
4. Spacer
5. Fork
6. Piston
7. Cover
8. Snap ring

10-18 WB97R-2
PAGE INTENTIONALLY
LEFT BLANK
STRUCTURE AND FUNCTION HYDRAULIC PUMP

HYDRAULIC PUMP

A 3
D

c
B B

D
A
a b

RKZ04930

1. Delivery variation group a. Port B - To the shovel control valve (Port P)

2. Y1 solenoid valve working mode b. Port X2 - From the shovel control valve
3. Delivery control valve (Port LS)
c. Port L - To the hydraulic oil tank
d. Port S - To the hydraulic oil tank

10-20 WB97R-2
STRUCTURE AND FUNCTION HYDRAULIC PUMP

C C 3 4

2
1

SezioneA
Section A -- A

7 8 9
6

12 11 Section
Sezione B
B -- B
B 10 RKZ00380

1. Seal 7. Positioning piston

2. Bearing 8. Spring
3. Central spring 9. Cylinder block
4. Bearing 10. Positioning piston
5. Control rod 11. Piston
6. Swash plate 12. Guide shoe

WB97R-2 10-21
STRUCTURE AND FUNCTION HYDRAULIC PUMP

1 2 3 4 5

7 6
Section
Sezione C
C- C

8 9 10

15 14 13 12 11
Section
SezioneDD -- D RKZ00642

POWER GOVERNOR LS VALVE

1. Spring 11. External spring
2. Piston rod 12. Internal spring
3. Bushing 13. Throttles
4. Initial adjustment spring 14. Throttles
5. Pressure cut calibration spring 15. Spool
6. Pressure cut calibration screw
7. Initial adjustment calibration screw

PC VALVE
8. Spool
9. Spring (internal)
10. Spring (external)

10-22 WB97R-2
STRUCTURE AND FUNCTION HYDRAULIC PUMP

FUNCTION
• The rotation and torque transmitted to the pump
shaft is converted into hydraulic energy and pres-
surized oil is delivered according to the load require-
ments.
• The amount of oil delivered can be modified by
changing the angle of the swash plate.

1 2 3 4 5 6 7

B A a RKZ01120

STRUCTURE
• The cylinder block (6) is supported and connected to • The pistons (5) perform their relative movements in
the shaft (1) by the spline a and the shaft (1) is sup- an axial direction, inside cylindrical chambers fash-
ported by the front and rear bearings. ioned in the cylinder block (6).
• The tip of the piston (6) is ball-shaped. The shoe (4) • The oil is brought up to pressure in the chambers of
is caulked to it to form one unit in such a way that the the cylinder block (6) by the rotatory movement of
piston (5) and the shoe (4) together form a spherical the block itself. The areas of pressure and suction
bearing. are determined by the swash plate (7).
• The swash plate (3) has a flat surface A and the shoe The surface of the swash plate is so designed that
(4) remains pressed against this surface while slid- the oil pressure always remains within acceptable
ing in a circular movement. limits.
The swash plate brings highly pressurized oil onto The oil in each chamber is drawn in and discharged
the cylindrical surface B fashioned in the pump body through holes in the valve plate (7).
(2), which means that the swash plate (3) slides on a
hydrostatically-supported bearing.

WB97R-2 10-23
STRUCTURE AND FUNCTION HYDRAULIC PUMP

OPERATION
1. Pump operation
1 - The cylinder block (7) rotates together with the
shaft (1) and the shoe (4) slides on the flat sur- A 4 5 6
1 3 D
face A. The swash plate (3) moves along the cy-
lindrical surface B. The angle α formed
between the center line of the shaft (1) and the
center line X of the swash plate (3) changes,
thus modifying the axial position of the pistons
in relation to the cylinder block.
The angle α is known as the swash plate angle.

2 - When the center line X of the swash plate (3) a

maintains the angle α in relation to the center
line of the shaft (1), and hence also of the cyl- X
inder block (6), the flat surface A acts as a cam
for the shoe (4). As the piston (5) rotates and
slides inside the cylinder block (6), it therefore
creates a difference between the volumes C B C
RKZ01100
and D which provokes intake and discharge of
the oil in quantities equal to the difference be-
tween the volumes (D – C=delivery).
In other words, as the cylinder block (6) rotates,
chamber D loses volume while the volume of
chamber C is increased, thus provoking an in-
take of oil. 3 6 D
(The figure indicates the state of the pump when
the intake of chamber D and the delivery of
chamber C have been completed).
a=0
3 - When the center line X of the swash plate (3)
and the center line of the cylinder block (6) are
perfectly aligned (the swash plate angle α=0),
the difference between the volumes C and D X
within the cylinder block (6) becomes 0 and the
pump does not take in or deliver any oil. (In prac-
tice the swash plate angle α never becomes=0)

4 - In other words, pump delivery is directly pro-

portional to the swash plate angle α.
C
RKZ01110

10-24 WB97R-2
STRUCTURE AND FUNCTION HYDRAULIC PUMP

2. Control of Delivery
1 - As the swash plate angle α grows larger, the dif-
2 3 9 D
ference between volumes C and D increases,
and the delivery Q also increases.
The swash plate angle is modified by servo-pis-
tons (8) and (9).

2 - The servo-piston (8) moves in a reciprocating

linear motion ( ) caused by pressure sig-
nals from the PC and LS valves.
The linear movement is transmitted to the
swash plate (3), which is supported by the cy-
lindrical surface of the cradle (2). The swash a
plate therefore has a semi-circular reciprocat-
ing movement ( ).
3 - The surfaces of the servo-pistons receiving the
pressures PP and LS are dissimilar. The deliv-
ery pressure PP of the main pump is always
passed into the smaller (upper) pressure cham- 8 C
ber, whereas the pressure PEN coming from RKZ01130

the LS valve is passed into the larger (lower)

pressure chamber.
The movement of the servo-piston is governed
by the relationship between pressures PP and
PEN, as well by the proportions between the
surfaces (larger and smaller) of the servo-pis-
ton.

WB97R-2 10-25
STRUCTURE AND FUNCTION HYDRAULIC PUMP

PC VALVE, LS VALVE, SERVO PISTON

1 2

Control valve

To the actuator

7 6 RKZ01141

SERVO-PISTON PC VALVE
1. Spring 6. Servo-piston
2. Servo-piston 7. Spring
3. Servo-piston

LS VALVE
4. Piston
5. Spring

10-26 WB97R-2
STRUCTURE AND FUNCTION HYDRAULIC PUMP

LS VALVE
FUNCTION
• The LS valve controls the pump delivery according
to the stroke of the control valve level, 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 ∆PLS existing
between the pump delivery pressure PP and the
pressure PLS coming from the control valve. This
reading permits control of the main pump delivery Q.
(PP, PLS and ∆PLS are, respectively, the pump
pressure, the Load Sensing pressure, and the dif-
ference in pressure between these two values).
• In other words, the LS valve detects the pressure dif-
ference ∆PLS generated by the passage of the oil
flow through the surface freed by the control valve
spool, and controls the pump delivery Q so as to
keep the pressure drop constant.
It can therefore be assumed that the pump delivery
is proportional to the demands made known by the
control valve.

WB97R-2 10-27
STRUCTURE AND FUNCTION HYDRAULIC PUMP

OPERATION

1. When the control valve is in a «NEUTRAL» position

PP T PLS
c d a 6

To the actuator

Control valve

Min Max

PP

M 3 X

Y
2 RKZ01151

• The pressure PLS of the LS coming from the control • For this reason the piston (4) is thrust to the right
valve outlet passes into chamber a of the spring of ( ) and a passage is formed between the delivery
the LS valve. The pressure PP of the pump passes lines c and d. This opening enables the pump pres-
into chamber b of the opposite side. sure PP to enter chamber X of the servo-piston (3).
• The piston rod movement (4) is determined by the • Although the pump pressure PP is always passed
combination of the force generated by the pressure into chamber Y of the servo-piston (2), since the
PLS, the force of the spring (6) and the force gen- force exerted by that pressure on piston (3) exceeds
erated on the side opposite the piston rod by the the force exerted on piston (2), the servo-piston (1)
pressure PP. moves to the right ( ), i.e. towards the side of the
• Before the engine is started the servo-piston (3) is minimum angle of the swash plate.
pushed to the right by the spring (1) (corresponding
to the maximum angle of the swash plate).
• If all the control valve spools are in their «NEU-
TRAL» position when the engine is started, the
pressure PLS of the LS will remain at 6±2 bar be-
cause no oil is flowing through the control valve.
At the same time the pump pressure PP increases
and is maintained at a value of about 27 bar.

10-28 WB97R-2
STRUCTURE AND FUNCTION HYDRAULIC PUMP

2. When a control valve lever is activated

PP T PLS
c d e a 6

To the actuator

Control valve f
Min Max

PP

M 3 X
1

Y
2 RKZ01161

• When the control valve lever is moved out of its • Equilibrium is re-established in the system when the
NEUTRAL position, the opening f is determined, al- pressure ∆PLS generates on the spool (4) the dif-
lowing an LS signal to be generated. ference in force exerted by the spring (6), and the
• Until the ∆PLS generates a force less than the force passage between delivery lines c and d is re-
exerted by the spring (6) on the spool (4), the system opened.
will remain stable.
When the opening f is such as to provoke a reduc-
tion in ∆PLS, the spool (4) moves to the left ( ) to
form a passage between delivery lines d and e. The
chamber X loses pressure and the servo-piston
causes the swash plate to move towards maximum
displacement.

WB97R-2 10-29
STRUCTURE AND FUNCTION HYDRAULIC PUMP

3. When the control valve opening is at its maximum (lever at the end of its stroke)

PP T PLS
c d e a 6

To the actuator

Control valve f
Min Max

PP

M 3 X
1

Y
2 RKZ01161

• When the control lever is moved to full stroke, in oth- • The pressurized oil present in the chamber X of the
er words, when the spool opening reaches its max- servo-cylinder (3) flows through the lines d and e
imum, the difference between the pump pressure and reaches the pump drainage chamber, so that
PP and the LS pressure PLS becomes smaller (dif- the pressure in chamber X of the servo-cylinder (1)
ferential pressure ∆PLS). becomes equal to the drainage pressure.
• The LS pressure PLS introduced into the chamber a • The servo-piston (3) is thus moved to the right ( )
of the LS valve becomes about the same as the by swash plate movement due to the pressure PP in
pump pressure PP and the piston (4) is moved to the the chamber Y of the servo-cylinder (2).
left ( ) by the combined forces generated by the In other words, it is drawn in the direction of the in-
pressure PLS and the spring (6). crease in angle of the swash plate.
The piston movement closes the delivery line c and
forms a passage between lines d and e.

10-30 WB97R-2
STRUCTURE AND FUNCTION HYDRAULIC PUMP

4. When the spool makes very small movements (fine-control)

PP T PLS
c d e a 6

To the actuator

Control valve
f
Min Max

PP

M 3 X
1

Y
2 RKZ01171

• When the control valve lever moves in very small in- • If the differential pressure ∆PLS generates on the
crements towards the «NEUTRAL» position, i.e. spool (4) a force difference that does not exceed the
when the control valve opening f diminishes, the dif- force exerted by the spring (6), the spool (4) moves
ferential pressure ∆PLS between the pump pres- to the left ( ) and a passage is formed between
sure PP and the LS pressure PLS increases. the delivery lines d and e.
• If the differential pressure ∆PLS generates on the The chamber X loses pressure and the servo-piston
spool (4) a difference in force that exceeds the force provokes a movement of the swash plate towards
exerted by the spring (6), the spool moves to the maximum displacement.
right ( ) and a passage is formed between the de- • Equilibrium is re-established in the system when the
livery lines c and d. The pressure PP is introduced pressure ∆PLS generates on the spool (4) the dif-
into the chamber X and the swash plate moves to- ference in force exerted by the spring (6), and hence
wards its minimum angle. the passage between delivery lines c and d is also
• When the control valve lever performs small move- re-opened.
ments towards the position of maximum opening,
i.e. when the opening f of the control valve increas-
es, the differential pressure ∆PLS diminishes.

WB97R-2 10-31
STRUCTURE AND FUNCTION HYDRAULIC PUMP

5. When pump flow matches the demands of the control valve

PP T PLS
c
d g e a 6

To the actuator

Control valve
PEN
Hold

PP
A1

M 3 X
PP 1
A2

Y
2 RKZ01181

• Let A1 be the surface of the servo-piston (3), A2 the A flow of oil is introduced into the servo-cylinder (3)
surface of the servo-piston (2), PEN the pressure at a pressure that balances the force generated by
acting on the piston (1) and PP the pressure acting the pump pressure PP in the cylinder (2).
on the piston side (2). (PEN x A1=PP x A2).
When pump delivery reaches the quantity demand- • The stability of the equilibrium is guaranteed by a
ed by the control valve, the pump pressure PP in flow stabilized by the throttle g.
chamber b of the LS valve is in equilibrium with the • The force of the spring (6) is regulated so that the
combined forces of the LS pressure PLS in cham- piston (4) is in equilibrium when
ber a, and the force exerted by the spring (6). PP – PLS = ∆PLS =18 bar.
Once equilibrium has been reached the piston (4) • In practice, the pump flow is made proportional to
stops in the central position. the section of the opening of the control valve, which
• In this condition the passage from chamber c to maintains the differential pressure
chamber d remains only slightly open in order to ∆PLS = 18 bar.
maintain pressure in chamber d.

10-32 WB97R-2
STRUCTURE AND FUNCTION HYDRAULIC PUMP

PC VALVE
FUNCTION
• The PC valve performs an approximate power
check, and ensures that the hydraulic horse-power
absorbed by the pump does not exceed the horse-
power delivered by the endothermal engine.
This is achieved by limiting the pump delivery Q in

Pump discharge amount Q

function of the delivery pressure PP, even if the LS
valve requests an increase in delivery Q due to the
larger section freed by the control valve spool, in the
presence of high pressure pump delivery.
• In other words, when during operation the delivery Q
increases and the delivery pressure PP also in-
creases simultaneously, the PC valve reduces the
pump delivery Q. When the delivery pressure PP de-
creases, the PC valve increases the pump flow.
• The relationships between the pump delivery pres- Pump discharge pressure PP

sure PP and the delivery Q are shown in the dia- RKP01181

gram.

WB97R-2 10-33
STRUCTURE AND FUNCTION HYDRAULIC PUMP

OPERATION

1. When the load on the actuators is heavy (high pump delivery pressure)

f 5 g 6 7
∆p

PPC
e
c
d

3 a b 4

PPC PP PEN T LS

To the actuator

Control valve
2 1
PP

Min Max

M 8 X

RKZ01191

• When a higher delivery is required, the LS valve re- chambers f and g at the sides opposite the spool (5).
ceives a signal from the control valve to bring the (∆P =PP – PPC)
pump up to maximum displacement. • When the value of PP exceeds the value of the
When the swash plate moves it also moves the spring loading (7) the spool (5) moves to the right
bushing (2) joined to it (by the pin (1)), which re- ( ) opening the passage between the delivery
leases the spring (3). lines d and e and sending the pump pressure PP to-
• As the pressure of the actuators increases, pres- wards the servo-cylinder (8).
sure also increases in the delivery line c. When the • The pressure PP introduced into chamber X of the
calibrated setting of the spring (3) is reached, the cylinder (8) pushes it towards the minimum angle of
piston rod (4) is thrust to the left ( ) and the pas- the swash plate ( ).
sage between chamber b and the pump drainage
chamber a is opened.
• The opening of the passage between the chambers
b and a generates a flow of oil and hence, due to the
calibrated hole (6), a ∆ P is generated between

10-34 WB97R-2
STRUCTURE AND FUNCTION HYDRAULIC PUMP

2. When equilibrium has been reached

f 5 g 6 7
∆p

c PPC
e

a 2 b 4

PPC PP PEN LS

10

To the actuator

Control valve
PP

Hold
A1

M 8 X

A2

9 RKZ01201

• When the piston (8) is pushed to the left ( ) the • In this condition the passage from chamber d# to
bushing (2) is also moved. chamber e remains only slightly open in order to
The oil flow between the chambers b and a is re- maintain pressure in chamber e. A flow of oil is in-
duced and the PPC pressure tends to approach the troduced into the cylinder (8) at a pressure that bal-
PP pressure value. ances the force generated by the pump pressure PP
The ∆P decreases and the spool (5) is pushed to the acting on the cylinder (9). (PEN x A1 = PP x A2)
left ( ) by the force of the spring (7). • The stability of this equilibrium is generated by a
• Equilibrium is reached when the force generated by continuous stabilized flow from the throttle (10).
the PP pressure, the force generated by the PPC
pressure, and the force of the spring (7) are all bal-
anced. (The force generated by PP = the force gen-
erated by the PPC + the spring force (7)).

WB97R-2 10-35
STRUCTURE AND FUNCTION HYDRAULIC PUMP

3. When the load on the actuators decreases (pump delivery pressure drops)

5 6 7

c
PPC
e

a b 4

PPC PP PEN LS
g

To the actuator

Control valve

PP

Hold

M 8 X

9 Y RKZ01211

• When the load on the actuators diminishes and the • The pressurized oil present in chamber X of the ser-
pump delivery pressure PP drops, the PPC. pres- vo-cylinder (8) passes through chambers e and g
sure also drops. and reaches the pump drainage chamber, so that
• The reduction in the PPC causes the spool (4) to the pressure in chamber X of the servo-cylinder (7)
move and the passage between chambers b, d and becomes equal to the drainage pressure.
a is closed. • Therefore the servo-piston (7) is caused to move by
The PPC pressure and the PP pressure of the pump the PP pressure in chamber Y of the servo-cylinder
are equalised due to the interruption of the oil flow (9), i.e. in the direction of the increase in the angle of
through the calibrated hole (6) and hence the ∆P be- the swash plate.
comes zero (∆P = PP – PPC=0).
• The spring (7) pushes the spool (5) to the left ( )
closing the passage between the chambers d and e
and opening the passage between chambers e and
g.

10-36 WB97R-2
STRUCTURE AND FUNCTION HYDRAULIC PUMP

4. The function of the spring

3 11 4

PP PLS T LS

To the actuator

Control valve

M 8

RKZ01221

• The loading on the springs (3) and (11) of the PC

valve changes in proportion to the angle of inclina-
tion of the pump swash plate.
Spring (3) + spring (11)
• The compression of the spring (3) varies with the
Pump discharge amount Q

movements of the servo-piston (8).

• When the piston (8) moves to the left ( ), the Spring (3)
spring (3) is compressed.
If the piston (8) moves even further to the left ( ),
the spring (11) comes into action to increase the
loading.
In other words, the overall loading of the springs is
varied by the piston (8), which either compresses or
releases them.
• The pump absorption torque curve, which indicates Pump discharge pressure PP

the relationship between the pump delivery pres- RKZ01241

sure PP and the delivery Q, is a broken line (as il-

lustrated in the diagram).

WB97R-2 10-37
STRUCTURE AND FUNCTION HYDRAULIC PUMP

• The position in which the piston (8) stops, i.e. the

pump absorption torque, is determined by the posi-
tion in which the PPC pressure applied to the spool
(4) is balanced by the force exerted by the springs
(3) and (11).
• In practice, as the pump delivery pressure PP in-
creases, the delivery Q decreases, and as the pres-
sure PP diminishes the pump delivery Q increases.

10-38 WB97R-2
STRUCTURE AND FUNCTION HYDRAULIC PUMP

WORKING MODE SOLENOID VALVE

FUNCTION
• Calibration of the pump absorption torque is nor-

Pump discharge amount Q

mally performed for the working mode E.
When the solenoid valve of the working mode is Working mode P
commutated the absorbed power of the pump is in-
Working mode E
creased, as indicated by the working mode curve.

Pump discharge pressure Pp

RKZ01251

OPERATION

1. WORKING MODE E

3
2 ∆ P1
4
a

1
6

12V
DC

RKZ04940

• During normal operation (Working mode E), the PC • The ∆P1 is generated by the calibrated hole (3) in
valve intervenes when a ∆P1 is generated equal to the spool of the PC valve (2) when, at a determined
the loading on the spring (4). pump delivery pressure P1, the valve (1) puts the
delivery line a into discharge, thus generating a flow
F1 in the delivery line a.

WB97R-2 10-39
STRUCTURE AND FUNCTION HYDRAULIC PUMP

2. WORKING MODE P

3
2
4
5

∆ P2
6
1

12V
DC

RKZ04950

• When the solenoid valve (6) is commutated (Work- • The increase in flow causes an increment of the
ing Mode P) the pressurized oil coming from the ∆P2 which, when the loading value of the spring is
pump changes its route and passes through the reached, allows the spool to shift to the right ( ).
throttle (5), which has a larger diameter than the cal- • The pump starts to work in normal fashion once
ibrated hole (3). again, and all the valves recommence normal func-
• Because the throttle (5) has a larger diameter, the tioning.
∆P2 generated is less than is needed to overcome
the force generated by the spring (4). The spool of
the PC valve (2) is therefore pushed to the left ( )
by the force of the spring (4).
• This shift obliges the pump to increase displace-
ment and hence the delivery (See «PC VALVE: 3.
When the load on the actuators decreases» third
paragraph).

10-40 WB97R-2
STRUCTURE AND FUNCTION STEERING UNIT

STEERING UNIT

a b d

e c

L D

240 bar 240 bar

LS

175
bar

T P

RKZ00831

a. Port LS - From the shovel control valve TECHNICAL DATA

(Port DLS) Steering unit type: LAGCSDS160P
b. Port T - To the hydraulic oil tank Displacement: 160 cc/rev.
c. Port L - To the steering cylinder (Port a)
OPERATION
d. Port R - To the steering cylinder (Port b)
• The steering unit is composed of a control valve and
e. Port P - From the shovel control valve (Port D)
a rotating oil dispenser, and is of the hydrostatic
type.
• When the steering wheel is turned, the control valve
sends oil from the pump P2 (by means of the rotating
oil dispenser) to one of the sides of the steering cyl-
inder.
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 guar-
anteeing emergency steering.

WB97R-2 10-41
PAGE INTENTIONALLY
LEFT BLANK
STRUCTURE AND FUNCTION HYDRAULIC CIRCUIT STANDARD

HYDRAULIC CIRCUIT STANDARD

HAMMER
MARTELLO
HAMMER (OPT)
(OPT WITH PRIORITY VALVE) ARM BUCKET BOOM EXTENDED ARM (OPT)
MARTELLO SWING BOOM L. VERT. OUTRIGGER R. VERT. OUTRIGGER
2° BRACCIO ROTAZ.BRACCIO STABIL. VERT. SX STABIL. VERT. DX BENNA 1° BRACCIO TELESCOPICO LOCKER
LS BLOCCAGGIO

OU OU
8 bar
E P
IN IN
80 l/min
160 bar P
T bar

A A A

l/mn

l/mn

l/mn

l/mn

l/mn

l/mn

l/mn

l/mn

l/mn

l/mn

l/mn

l/mn

l/mn

l/mn

l/mn

l/mn
120

150

150

150

100

135

120
150

**90

**90
80

70

70

70

70

80
T P M LS B7 A7 B1 A1 B2 A2 B3 A3 B4 A4 B5 A5 B6 A6 B8 A8 C

T
P

24 b b b b b b b b
bar

T LS

a a a a a a a a

T3

A T A T T B A T T B T B A T T B
A T
*160 *230 *230 *230 *230 *230 *300
bar bar bar bar bar bar bar

T1

B1
STEERING A2
N
SERVOSTERZO B2
A1

L R
b2 REAR
a3 b3
b7
+20 +20
225 bar 0 225 bar 0 a2 b6 a5

a7
BHL
+5
170 bar 0

X1 X2 LOADER ARM LOADER BUCKET BUCKET 4 IN 1 (OPT)

P LS T
WITH FLOAT (OPT) WITH RETURN TO DIG (OPT) BENNA 4 IN 1
SOLLEV. BENNA ROVESC. BENNA

FRONT

b1

a2 b2
P a1
bar

l/mn
l/mn

l/mn

l/mn

l/mn
l/mn
150

150

120
150

90

75
LOADER
B M LS D B1 A1 B2 A2 B3 A3

DLS
b
b b
5 bar

P
5 bar

a a a

S L1 L T T3
T B A T T B A T
1.5 bar

*170 *230 *230 *230

bar bar bar bar

C C

ß = 25 µm ß = 25 µm
75 75

R
RKZ07690

WB97R-2 10-43
 STRUCTURE AND FUNCTION HYDRAULIC CIRCUIT (WITH PPC VALVE)

HYDRAULIC CIRCUIT (WITH PPC VALVE)

(JIG ARM - HAMMER)

HAMMER (OPT)
MARTELLO ARM SWING BOOM L. VERT. OUTRIGGER R. VERT. OUTRIGGER BUCKET BOOM
2° BRACCIO ROTAZ.BRACCIO STABIL. VERT. SX STABIL. VERT. DX BENNA 1° BRACCIO
EXTENDED ARM (OPT) LOCKER
TELESCOPICO BLOCCAGGIO
OU

IN

A A A
P

l/mn

l/mn

l/mn

l/mn

l/mn

l/mn

l/mn

l/mn

l/mn

l/mn

l/mn

l/mn

l/mn

l/mn

l/mn

l/mn
120

150

150

150

100

135

120
150

**90

**90
bar

80

70

70

70

70

80
M PB7 B7 A7 PB1 B1 A1 PB2 B2 A2 PB3 B3 A3 PB4 B4 A4 PB5 B5 A5 PB6 B6 A6 PB8 B8 A8 C

LS

24
bar
LEFT RIGHT

3 1
T3 2 2
N
N 4
4
T
A T A T T B A T T B T B A T T B 1 3
A T
*160 *230 *230 *230 *230 *230 *300
bar bar bar bar bar bar bar
3
T1 PA7 PA1 PA2 PA3 PA4 PA5 PA6 PA8 2 4 REAR

1 3

2 4

LEFT B/H BHL

P T RIGHT B/H P T

0.6mm

0.6mm
P 0.35L-12bar

STEERING B1
A
SERVOSTERZO T

0.6mm
A1
34bar ±3 ACC
L R 1 3 4 2 1 3 4 2
T P

0.6mm
S1

+20
225 bar 0
+20
225 bar 0 S2 0.6mm
0.9mm
A2 A1 A PATTER CH.
(OPT.)
B2 B1
+5
170 bar 0
0.6mm
1.3mm

X1 X2 LOADER ARM LOADER BUCKET BUCKET 4 IN 1 (OPT)

P LS T
WITH FLOAT (OPT) WITH RETURN TO DIG (OPT) BENNA 4 IN 1
SOLLEV. BENNA ROVESC. BENNA

FRONT

b1

a2 b2
P a1
bar

l/mn
l/mn

l/mn

l/mn

l/mn
l/mn
150

150

120
150

90

75
B LOADER
M LS D B1 A1 B2 A2 B3 A3

DLS
b
b b
5 bar

P
5 bar

a a a

S L1 L T T3
T B A T T B A T
1.5 bar

*170 *230 *230 *230

A bar bar bar bar

A
ß = 25 µm
ß = 25 µm 75
75

RKZ07610

10-44 WB97R-2
STRUCTURE AND FUNCTION HYDRAULIC CIRCUIT (WITH PPC VALVE)

HYDRAULIC CIRCUIT (WITH PPC VALVE)

(JIG ARM - HAMMER - SIDE DIGGING BOOM)

OFFSET BOOM (OPT.)

ARM SWING BOOM L. VERT. OUTRIGGER R. VERT. OUTRIGGER BUCKET BOOM
BR.DEPORTABILE
2° BRACCIO ROTAZ.BRACCIO STABIL. VERT. SX STABIL. VERT. DX BENNA 1° BRACCIO
LS EXTENDED ARM (OPT) LOCKER
TELESCOPICO BLOCCAGGIO
OU
8 bar
E P
IN HAMMER
80 l/min
160 bar
MARTELLO
T (OPT WITH PRIORITY VALVE)
A A A
P

l/mn

l/mn

l/mn

l/mn

l/mn

l/mn

l/mn

l/mn

l/mn

l/mn

l/mn

l/mn

l/mn

l/mn

l/mn

l/mn
120

150

150

150

150

100

135

120
**90

**90
bar

80

70

70

70

70

80
M PB7 B7 A7 PB1 B1 A1 PB2 B2 A2 PB3 B3 A3 PB4 B4 A4 PB5 B5 A5 PB6 B6 A6 PB8 B8 A8 C

LS

24
bar LEFT RIGHT

3 1

T3 2 2
N
N 4
4
T
1 3
T B A T A T T B A T T B T B A T T B
A T
*270 *160 *230 *230 *230 *230 *230 *300
bar bar bar bar bar bar bar bar
3
T1 PA7 PA1 PA2 PA3 PA4 PA5 PA6 PA8 2 4 REAR

1 3

2 4

LEFT B/H BHL

P T RIGHT B/H P T

0.6mm

0.6mm
P 0.35L-12bar

STEERING B2 B1
SERVOSTERZO T
A2 A1

0.6mm
34bar ±3 ACC
L R 1 3 4 2 1 3 4 2
T P

0.6mm
S1

+20
225 bar 0
+20
225 bar 0 S2 0.6mm
0.9mm
A2 A1 A PATTER CH.
(OPT.)
B2 B1
+5
170 bar 0
0.6mm
1.3mm

X1 X2 LOADER ARM LOADER BUCKET BUCKET 4 IN 1 (OPT)

P LS T
WITH FLOAT (OPT) WITH RETURN TO DIG (OPT) BENNA 4 IN 1
SOLLEV. BENNA ROVESC. BENNA

FRONT

b1

a2 b2
P a1
bar

l/mn
l/mn

l/mn

l/mn

l/mn
l/mn
150

150

120
150

90

75
B LOADER
M LS D B1 A1 B2 A2 B3 A3

DLS
b
b b
5 bar

P
5 bar

a a a

S L1 L T T3
T B A T T B A T
1.5 bar

*170 *230 *230 *230

A bar bar bar bar

A
ß = 25 µm
75
ß = 250 µm
75

RKZ07620

WB97R-2 10-45
STRUCTURE AND FUNCTION SHOVEL CONTROL VALVE

SHOVEL CONTROL VALVE

2 SPOOL

D C A
a b c d
e

h g
D C A

1 2
B

6
B
i
Section
Sezione A
A -- A
A Section B
Sezione B -- BB
RKZ01082

a. Port D - To the hydraulic steering unit (Port P) 1. Plug

b. Port A2 - To the bucket cylinders (Head side) 2. Plug
c. Port A1 - To the shovel-raising cylinders 3. Ball
(Base side) 4. Spring
d. Port LS - To the pump (Port X2) 5. Priority valve piston rod
e. Port T - To the hydraulic oil tank 6. Priority valve spring
f. Port P - From the pump (Port B)
g. Port B1 - To the shovel-raising cylinders
(Head side)
h. Port B2 - To the bucket cylinders (Base side)
i. Port DLS - To the hydraulic steering unit
(Port LS)

10-46 WB97R-2
STRUCTURE AND FUNCTION SHOVEL CONTROL VALVE

SHOVEL CONTROL VALVE

E 5 E
1
2
6

4
4

3 5 3
E
E
Section CC--CC
Sezione
Section D-D
Sezione D - D

7 8

7
8

Section E - E
Sezione E - E RKZ00660

1. Plug
2. Raising command spool
3. Spool return spring
4. Compensator
5. Antishock/anticavitation valve
6. Bucket dump command spool
7. Spring
8. Check valve

WB97R-2 10-47
STRUCTURE AND FUNCTION SHOVEL CONTROL VALVE

3 SPOOL
E

D C A
a b c d e
f

l i h
D C A
1 2 E
B

6
B
7
m
Section
SezioneAA -- A
A Section
Sezione B
B -- B
B
RKZ01072

a. Port D - To the hydraulic steering unit (Port P) 1. Plug

b. Port A3 - To the auxiliary equipment (Left side) 2. Plug
c. Port A2 - To the bucket cylinders (Head side) 3. Ball
d. Port A1 - To the shovel-raising cylinders 4. Spring
(Base side) 5. Priority valve piston rod
e. Port LS - To the pump (Port X2) 6. Priority valve spring
f. Port T - To the hydraulic oil tank 7. Plug
g. Port P - From the pump (Port B)
h. Port B1 - To the shovel-raising cylinders
(Head side)
i. Port B2 - To the bucket cylinders (Base side)
l. Port B3 - To the auxiliary equipment
(Right side)
m. Port DLS - To the hydraulic steering unit
(Port LS)

10-48 WB97R-2
STRUCTURE AND FUNCTION SHOVEL CONTROL VALVE

1 F 8 F

2 9

3 7
7
4
1
5 10
8 F
F Section D - D
F Sezione D - D
6 12
Section C - C
Sezione C - C

11

8 14
15

14
15

Section F - F
8 13 Sezione F - F

F
Section E - E
Sezione E - E RKZ00691
1. Plug 9. Bucket dump command spool
2. Raising command spool 10. Spool return spring
3. Spool return spring 11. Optional equipment command spool
4. Spring 12. EV1 Opened bucket 4 in 1 solenoid valve
5. Ball 13. EV2 Closed bucket 4 in 1 solenoid valve
6. Ball 14. Spring
7. Compensator 15. Check valve
8. Antishock/anticavitation valve

WB97R-2 10-49
STRUCTURE AND FUNCTION SHOVEL CONTROL VALVE

3 SPOOL (WITH RETURN TO DIG)

D C A
b c d e
a
f

l i h
C A

1 2 E D
B

6
B 7
m Section A
A --AA
Sezione Section
Sezione B
B -- B
B
RKZ01092

a. Port D - To the hydraulic steering unit (Port P) 1. Plug

b. Port A3 - To the auxiliary equipment (Left side) 2. Plug
c. Port A2 - To the bucket cylinders (Head side) 3. Ball
d. Port A1 - To the shovel-raising cylinders 4. Spring
(Base side) 5. Priority valve piston rod
e. Port LS - To the pump (Port X2) 6. Priority valve spring
f. Port T - To the hydraulic oil tank 7. Plug
g. Port P - From the pump (Port B)
h. Port B1 - To the shovel-raising cylinders
(Head side)
i. Port B2 - To the bucket cylinders (Base side)
l. Port B3 - To the auxiliary equipment
(Right side)
m. Port DLS - To the hydraulic steering unit
(Port LS)

10-50 WB97R-2
STRUCTURE AND FUNCTION SHOVEL CONTROL VALVE

1 F
F 8

9
2

7
3 10
7
4
1 8 11
5

F F
Section C -- CC 6 F
Sezione C

8 Section
12 Sezione D
D -- D
D

13
14

13
14
7

8 F Section
SezioneFF- -FF

Section
Sezione E
E -- E
E
RKZ00940

1. Plug 8. Antishock/anticavitation valve

2. Raising command spool 9. Bucket dump command spool
3. Spool return spring 10. Spool return spring
4. Spring 11. Coil
5. Ball 12. Optional equipment command spool
6. Ball 13. Spring
7. Compensator 14. Check valve

WB97R-2 10-51
STRUCTURE AND FUNCTION BACKHOE CONTROL VALVE

BACKHOE CONTROL VALVE

6 SPOOL (STANDARD)

H F E D D C B A
b L e f g h i
c d

r L q p o n m l
H F E D D C B A
G
3
2 4
1

Section A - A 3 5
Sezione A - A
G
Section B - B
Sezione B - B
RKZ00230

a. Port P - From the pump (Port B) l. Port A6 - To the boom cylinder (Base side)
b. Port T - To the hydraulic oil tank m. Port A5 - To the bucket cylinder (Head side)
c. Port B1 - To the arm cylinder (Head side) n. Port A4 - To the LH outrigger cylinder
d. Port B2 - To the arm LH swing cylinder (Head side)
(Base side) o. Port A3 - To the RH outrigger cylinder
e. Port B3 - To the RH outrigger cylinder (Head side)
(Base side) p. Port A2 - To the RH boom swing cylinder
f. Port B4 - To the LH outrigger cylinder (Base side)
(Base side) q. Port A1 - To the arm cylinder (Base side)
g. Port B5 - To the bucket cylinder (Base side) r. Port T1 - To the hydraulic oil tank
h. Port B6 - To the boom cylinder (Head side) s. Port LS - To the pump (Port X2)
i. Port C - To the backhoe backframe
lock cylinders

10-52 WB97R-2
STRUCTURE AND FUNCTION BACKHOE CONTROL VALVE

G G G
3 3
7 9 10 11

6
6 6

9 3
8 G 5 5
G 5 G
Section
Sezione C
C -- C
C Section D -- D
Sezione D D Section
Sezione E
E -- E
E

G
9
12

13 14

13 14

Section G -- G
Sezione G G
3 G 5
Section
SezioneFF--FF
RKZ00760

1. Ball 8. Anticavitation valve

2. Backhoe backframe lock solenoid valve 9. Plug
3. Antishock/anticavitation valve 10. Outrigger command spool
4. Boom command spool 11. Boom swing command spool
5. Spool return spring 12. Arm command spool
6. Compensator 13. Spring
7. Bucket command spool 14. Check valve

WB97R-2 10-53
STRUCTURE AND FUNCTION BACKHOE CONTROL VALVE

3 2

4 5
Section
Sezione H
H -- H
H Section
Sezione L
L -- L
L
RKZ00790

1. Valve 4. Pressure cut-out valve

2. Spring 5. Unloading valve
3. Plug

10-54 WB97R-2
STRUCTURE AND FUNCTION BACKHOE CONTROL VALVE

6 SPOOL (OPTIONAL)

Pc Pd Pe Pf Pg Ph
H F E D D C B A
b L e f g h
c d
i r
a

L q p o n m l
H F E D D C B A

Pq Pp Po Pn Pm Pl RKZ07700

a. Port P - From the pump (Port B) Pc - Port PB1- From LH PPC valve (Port 3)
b. Port T - To the hydraulic oil tank Pd - Port PB2- From LH PPC valve (Port 4)
c. Port B1 - To the arm cylinder (Head side) Pe - Port PB3- From ST2 solenoid valve group
d. Port B2 - To the arm LH swing cylinder (Port B2)
(Base side) Pf - Port PB4- From ST2 solenoid valve group
e. Port B3 - To the LH outrigger cylinder (Port B1)
(Base side) Pg - Port PB5- From RH PPC valve (Port 2)
f. Port B4 - To the RH outrigger cylinder Ph - Port PB6- From RH PPC valve (Port 3)
(Base side) Pl - Port PA6- From RH PPC valve (Port 1)
g. Port B5 - To the bucket cylinder (Base side) Pm - Port PA5- From RH PPC valve (Port 4)
h. Port B6 - To the boom cylinder (Head side) Pn - Port PA4- From ST2 solenoid valve group
i. Port C - To the backhoe backframe (Port A1)
lock cylinders Po - Port PA3- From ST2 solenoid valve group
l. Port A6 - To the boom cylinder (Base side) (Port A2)
m. Port A5 - To the bucket cylinder (Head side) Pp - Port PA2- From LH PPC valve (Port 2)
n. Port A4 - To the RH outrigger cylinder Pq - Port PA1- From LH PPC valve (Port 1)
(Head side)
o. Port A3 - To the LH outrigger cylinder
(Head side)
p. Port A2 - To the RH boom swing cylinder
(Base side)
q. Port A1 - To the arm cylinder (Base side)
r. Port M - From ST2 solenoid valve group
(Port P)
s. Port LS - To the pump (Port X2)

WB97R-2 10-55
STRUCTURE AND FUNCTION BACKHOE CONTROL VALVE

G G
5 5

3 3
4 7
2
1

6
6

3
3
5 5
G G
Section A-A Section Section C - C
Sezione A - A Sezione B
B -- B
B Sezione C - C

G G

10 3 11
9

6
6

9
3 5
5
G G
Section D - D Section E-E
Sezione D - D Sezione E - E
RKZ07710

1. Ball 7. Bucket command spool

2. Backhoe backframe lock solenoid valve 8. Anticavitation valve
3. Antishock/anticavitation valve 9. Plug
4. Boom command spool 10. Outrigger command spool
5. Spool return spring 11. Boom swing command spool
6. Compensator

10-56 WB97R-2
STRUCTURE AND FUNCTION BACKHOE CONTROL VALVE

9 12
13 14

13 14

Section G -- G
Sezione G G
3 5
G
Section
SezioneFF--FF

15

17 16

18 19
Section H - H Section
Sezione H - H SezioneLL -- L
L

RKZ07720
12. Arm command spool
13. Spring
14. Check valve
15. Valve
16. Spring
17. Plug
18. Pressure cut-out valve
19. Unloading valve

WB97R-2 10-57
STRUCTURE AND FUNCTION BACKHOE CONTROL VALVE

7 SPOOL STANDARD

For jig arm

A
a

b
A RKZ00240

For side digging boom

B
c

d B RKZ00250

For hammer
C
e

C
RKZ00260

a. Port B7 - To the jig arm cylinder (Base side) d. Port A7 - To the side digging boom cylinder
b. Port A7 - To the jig arm cylinder (Head side) (Head side)
c. Port B7 - To the side digging boom cylinder e. Port B7 - To the hydraulic hammer (Left side)
(Base side)

10-58 WB97R-2
STRUCTURE AND FUNCTION BACKHOE CONTROL VALVE

1 2 6 7

5 5

4 3 6 3
Section
Sezione A
A -- A
A Section
Sezione B
B -- B
B

4 8

6 3
Section C-C
Sezione C - C RKZ00960

1. Anticavitation valve 5. Compensator

2. Jig arm command spool 6. Anti-shock/anticavitation valve
3. Spool return spring 7. Side digging boom command spool
4. Plug 8. Hammer command spool

WB97R-2 10-59
STRUCTURE AND FUNCTION BACKHOE CONTROL VALVE

7 SPOOL OPTIONAL

For jig arm

Pa
A

b
A RKZ07780

Pb
For side digging boom
Pc
B

d
B RKZ07730

Pd

10-60 WB97R-2
STRUCTURE AND FUNCTION BACKHOE CONTROL VALVE

For hammer

Pe
C

f
C RKZ07740

Pf
a. Port B7 - To the jig arm cylinder (Base side) Pa Port PB7 - From solenoid valve group (OP1)
b. Port A7 - To the jig arm cylinder (Head side) (Port B)
c. Port B7 - To the side digging boom cylinder Pb Port PA7- From solenoid valve group (OP1)
(Base side) (Port A)
d. Port A7 - To the side digging boom cylinder Pc Port PB7- From solenoid valve group(OP1)
(Head side) (Port B)
e. Port B7 - Not used Pd Port PA7- From solenoid valve group (OP1)
f. Port A7 - To the hydraulic hammer (Left side) (Port A)
Pe Port PB7- From solenoid valve group (OP2)
(Port T)
Pf Port PA7- From solenoid valve group (OP2)
(Port A)

WB97R-2 10-61
STRUCTURE AND FUNCTION BACKHOE CONTROL VALVE

3 3
1 6

7
2

5 5

4 3 6 3

Section
SezioneAA--A
A Section B - B
Sezione B - B

3
4

6
Section C - C
3
Sezione C - C RKZ07770

1. Anticavitation valve 5. Compensator

2. Jig arm command spool 6. Anti-shock/anticavitation valve
3. Spool return spring 7. Side digging boom command spool
4. Plug 8. Hammer command spool

10-62 WB97R-2
STRUCTURE AND FUNCTION BACKHOE CONTROL VALVE

8 SPOOL STANDARD

For hammer and jig arm

a b

c RKZ00270

For side digging boom and jig arm

d b

e c RKZ00280

a. Port B7 - To the hydraulic hammer (L.H. side)

b. Port B8 - To the jig arm cylinder (Base side)
c. Port A8 - To the jig arm cylinder (Head side)
d. Port B7 - To the side digging boom cylinder (Base side)
e. Port A7 - To the side digging boom cylinder (Head side)

WB97R-2 10-63
STRUCTURE AND FUNCTION BACKHOE CONTROL VALVE

8 SPOOL STANDARD

For hammer and jig arm

Pa Pb

a b

d c
RKZ07750

Pd Pc
For side digging boom and jig arm
Pe Pb

e b

f c
RKZ07760

Pf Pc
a. Port B7 -
Not used Pc Port PA8 - From solenoid valve group (OP3)
b. Port B8 -
To the jig arm cylinder (Base side) (Port B1)
c. Port A8 -
To the jig arm cylinder (Head side) Pd Port PA7 - From solenoid valve group (OP3)3
d. Port A7 -
To the hydraulic hammer (L.H. side) (Port A)
e. Port B7 -
To the side digging boom cylinder Pe Port PB7 - From solenoid valve group (OP3)
(Base side) (Port A2)
f. Port A7 - To the side digging boom cylinder Pf Port PB8 - From solenoid valve group (OP3)
(Head side) (Port A1)
Pa Port PB7 - From solenoid valve group (OP3) Pg Port PA8 - From solenoid valve group (OP3)
(Port T) (Port B1)
Pb Port PB8 - From solenoid valve group (OP3) Ph Port PA7 - From solenoid valve group (OP3)
(Port A1) (Port B2)

10-64 WB97R-2
STRUCTURE AND FUNCTION CLSS (Closed Center Load Sensing System)

CLSS (Closed Center Load Sensing System)

1. DESCRIPTION

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.

STRUCTURE
• The CLSS system includes the variable flow pump, the control valve and the working equipment.
• The pump includes the main pump, the PC valve and the LS valve.

Attachment

PLS
Control valve

PC Valve

LS Valve

PP Piston

Piston

RKZ01711

WB97R-2 10-65
STRUCTURE AND FUNCTION CLSS (Closed Center Load Sensing System)

2. OPERATING PRINCIPLES

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
∆PLS 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. (∆PLS=pump delivery pressure PP – pressure PLS of delivery to the
actuator).
• If the differential pressure ∆PLS becomes lower than the set pressure of the LS valve, the angle of the swash plate
increases (delivery increasing).
If the differential pressure ∆PLS increases, the angle of the swash plate decreases.
★ For details about this movement, see the description of the «HYDRAULIC PUMP».

Attachment

Control valve

Pump delivery

Piston

Piston PUMP

PC Valve

High
pressure

LS Valve

High
pressure

RKZ01721

10-66 WB97R-2
STRUCTURE AND FUNCTION CLSS (Closed Center Load Sensing System)

2. Pressure compensation control

• The pressure compensation valves are installed downstream from the control valve in order to balance the dif-
ferential pressure between the loads.
When two or more movements (cylinders) are activated simultaneously, the pressure differences ∆P between the
delivery at the control valve inlet and outlets of the control valve are compensated by these valves.
We obtain the distribution of the pump flow in proportion to the areas of passage S1 and S2 of each valve.

Load
Load

Actuator
Actuator

Pressure Pressure
compensation compensation
valve valve

⌬P S1 S2 ⌬P

PUMP

RKZ01731

WB97R-2 10-67
STRUCTURE AND FUNCTION CLSS (Closed Center Load Sensing System)

3. UNLOADING VALVE
FUNCTION
1. When the control valve is in «NEUTRAL» position, the flow Q of the pump (due to the swash plate being in the min-
imum angle position) is sent to the control valve.
In these conditions, the pump delivery pressure PP is regulated to 27 bar by the spring (2) inside the valve.
(PP=PLS + spring load with PLS=6 bar)

2 1 PP

PLS T
RKZ01740

OPERATION
When the control valve is in «NEUTRAL» position • This system ensures that the pump delivery pres-
• On the two surfaces of the shuttle (1), the pump sure PP stays regulated at 27 bar.
pressure PP acts on the right-hand side, while the
LS signal with pressure PLS acts on the left-hand
side.
• Because a LS signal is generated with a pressure
PLS 6±2 bar, when the control valve is in «NEU-
TRAL» position, the pump delivery pressure PP is
regulated by the combination of the pressure pro-
vided by the spring and by the LS pressure PLS.
• While the pump delivery pressure PP increases until
it compensates for the loading on the spring (2) and
for the LS pressure 27 bar, the shuttle (1) moves to
the left ( ) and the PP circuit is put into commu-
nication with the tank circuit T.

10-68 WB97R-2
STRUCTURE AND FUNCTION CLSS (Closed Center Load Sensing System)

2. If, during the precision regulations of the control valve, the request for oil flow to the actuators in equal or less than
the delivery values given by the minimum angle of the swash plate, the pump delivery pressure PP is regulated by
the pressure PLS+21 bar.
Because the unloading valve opens when the differential pressure between the pump delivery pressure PP and the
PLS LS pressure becomes equivalent to the loading of the spring (2) (21 bar), the differential LS pressure ∆PLS del
LS becomes 21 bar.

2 1 PP

PLS T RKZ01750

OPERATION

Final control of control valve

• When final control are performed with the control Consequently the exceeding pump delivery Q, rel-
valve, a pressure PLS is generated that pressuriz- ative to the actuator request, is sent to the tank cir-
ing the spring chamber, acts on the left-hand ex- cuit.
tremity of the valve (1). • The pump delivery pressure PP is regulated by the
The actuator pressure is introduced into the LS cir- combination of the pressure provided by the spring
cuit and then into the spring chamber. (21 bar) and by the LS pressure PLS, i.e. when the
As a result, the pump pressure PP tends to increase. pressure differential ∆PLS reaches the value of 21
• When the differential pressure between the pump bar.
delivery pressure PP and the LS pressure PLS has
the same value as the loading on the spring (2) (21
bar), the shuttle (1) moves to the left ( ) and the
pump circuit PP puts itself into communication with
the tank circuit T.

WB97R-2 10-69
STRUCTURE AND FUNCTION CLSS (Closed Center Load Sensing System)

3. 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.

2 1 PP

PLS T RKZ01760

OPERATION

When the control valve is in use

• When the control valve shuttle is operated to exe- • The result is that the connection between the pump
cute a bigger stroke, the opening section of spool delivery circuit PP and the tank circuit T is excluded
becomes bigger and consequently the controlled and the entire pump delivery Q is sent to the actu-
delivery. ators.
Because the control valve passage is large, the dif-
ference between the LS pressure PLS and the
pump delivery pressure PP is reduced up to 18 bar
(LS pump valve setting).
• Because the differential pressure between the
pump delivery pressure PP and the LS pressure
PLS is not equal to the pressure given by the spring
loading (2) (21 bar), the shuttle (1) is pushed to the
right ( ) of the spring (2).

10-70 WB97R-2
STRUCTURE AND FUNCTION CLSS (Closed Center Load Sensing System)

4. INTRODUCTION OF THE LS PRESSURE

• The LS pressure is the pressure generated by external forces acting on the actuators at the outlet of the control
valve.

A
4 To the pump

PP
c d
1
RKZ01781

OPERATION
• When the shuttle (1) is activated, the pump pressure • The PLS circuit of the LS is thus in communication
PP starts to flow into the actuator circuit A through with the tank circuit T by means of the LS decom-
the duct b. pression valve (3).
• At the same time the compensator (2) moves up- (See the description of the LS decompression
wards ( ) so that the flow controlled by spool (1) can valve).
flow towards the actuator A. • The system stabilizes when a pressure difference of
(Check valve (4) do not allow any flow up to when 18 bar is generated across the shuttle (1) between
pressure in chamber c is higher than pressure in pump pressure PP and PLS pressure.
chamber b).
Pressure downstream spool (1) flows in the PLS cir-
cuit downstream the compensator valve throught
the orifice d.

WB97R-2 10-71
STRUCTURE AND FUNCTION CLSS (Closed Center Load Sensing System)

5. DELIVERY COMPENSATION

INTRODUCTION
The flow sent to each actuator is controlled by the opening area of each spool.
While performing complex control, in traditional control valves the difference between actuators pressure might cause
sudden and unexpected movements acceleration in those actuators operal at lower pressure.
The adoption of the pressure compensation valve allow to control those situation guaranting the proportionality between
each actuator.
FUNCTION
Compensation of actuator deliveries occurs when, during the simultaneous activation of two or more movements, the
pressure of one actuator drops lower than that of the other, and pump delivery, if not controlled, tends to be supplied the
actuator operating at lower. (In the diagram the actuator on the left is requesting higher pressure).

A B
PB
PA
PLS

C 2

4 b

PBV
d
a
PAV

3
PP 1

RKZ02310
OPERATION
1. When activating an actuator at a pressure lower than the one already working.
(While operating actuator A starts operating actuator B)
• Until the pressure PBV downstream from the shuttle creasing the swash plate angle.
(1) reaches the same value requested by actuator (For the detail see «Hydraulic pump»).
B, no oil passes. • Until the pump does not realize a ∆P of 18 bar, i.e.
• When the pressure requested by actuator B is ex- until the increase in oil flow compensates the re-
ceeded, movement can commence. This creates a quirements of the two actuators, the pump will con-
flow that adding to the one controlled by spool (3) re- tinue to increase delivery.
duces the pressure upstream of spool (1) and (3) • ∆P of 18 bar will stabilize as soon as it is restored to.
and therefore the ∆P between PLS and PP. • The compensator (2) is moved upwards by the oil
• The pump compares the delivery pressures PP and flow and stops when the aperture between the
PLS and senses that the difference ∆P<18 bar. This chambers a and b reduces the passage sufficiently
variation in ∆P causes an increase in oil flow in- to reduce the pressure in chamber b to be sent to the
actuator.

10-72 WB97R-2
STRUCTURE AND FUNCTION CLSS (Closed Center Load Sensing System)

2. When a low pressure actuator needs to work at a higher pressure than the other

A B
PB
PA
PLS

C 2

4 b

PBV
d
a
PAV

3
PP 1

RKZ02320

• If the actuator B needs to work at a higher pressure • Simultaneously the increase in pressure upstream
(PB>PA), the pressure PB will start to increase. from the shuttle (3) generates an increase in ∆P up-
• Since pressure PB is increasing, the compensator stream and downstream from the shuttle.
(2) moves upwards to restore the ∆P between the (PAV<PLS<PP)
chambers a and b, and therefore the ∆P does not • Because the pressure PLS which is equal to the
vary upstream or downstream from the shuttle (1). pressure PB acts on the upper side of the compen-
• When pressure PB exceeds pressure PA, the com- sator (4), and since the pressure PAV is lower, the
pensator (2) is fully open and the pressure PB is in- compensator (4) is pushed downwards.
troduced into the LS circuit. • The compensator stops when the aperture between
• The increase in pressure in the LS circuit obliges the the chambers c and d generates a reduction of the
pump to increase delivery until the ∆P is restored to passage sufficient to reduce the pressure to be sent
18 bar. to the actuator, and to increase the pressure PAV
until the ∆P is restored to the 18 bar necessary for
equilibrium.

WB97R-2 10-73
STRUCTURE AND FUNCTION CLSS (Closed Center Load Sensing System)

3. When an increase in delivery is required by an actuator

A B
PB
PA
PLS

C 2

4 b

PBV
d
a
PAV

3
PP 1

RKZ02330

• When an increased delivery is required by actuator A,

i.e. when the shuttle (3) is asked to execute a bigger
movement, the section of the aperture increases.
• The increase in aperture provokes a drop in ∆P be-
tween the two sides of the shuttles (2) and (3), because
the flow, which has remained unchanged until now, is
divided between both the actuators.
• At the same time the pump senses the variation in ∆P
and increases the oil flow until the ∆P is restored to ∆P
of 18 bar between the two sides of the shuttle (1) and the
compensator (4) changes position in order to restore
the ∆P upstream and downstream from the shuttle (3).

10-74 WB97R-2
STRUCTURE AND FUNCTION CLSS (Closed Center Load Sensing System)

6. “LIFD” CONTROL SYSTEM

FUNCTION
• The Load Independence Flow Divider (LIFD) intervenes automatically when the oil-flow requested by the actuators
exceeds the maximum delivery guaranteed by the pump.
In this case, the oil-flow is divided between the various actuators in proportion to their requirements.

C B A

6 4 2

PCV PBV PAV

5 3 1

RKZ02340

OPERATION becomes equal to the pressure PAV downstream

• When, during the simultaneous operation of more from the shuttle (1). This equalizes the pressure ∆P
than one actuator, one of them needs a higher pres- of the shuttle (1).
sure and the characteristics of the pump are ex- • Thus the flow of each actuator is reduced by a per-
ceeded, the pump guarantees a delivery limited by centage equal to the reduction or absence of pump
its calibration curve. delivery.
• At this point less oil than requested is distributed to • In other words, when the request for performance is
all the actuators. excessive, the system can nevertheless guarantee
• Because the sections of the apertures remain un- proportionality and graduality for the movements in
changed, the pressure upstream and downstream any load conditions.
from the shuttles drops. Since the position of the • If an increase in delivery is requested, rather than an
compensator (4) is determined by the pressure of increase in pressure, and the characteristics of the
the LS signal, by the pressure PBV downstream pump are exceeded, the system will function in the
from the shuttle (3) and by the flow of oil needed for same way as described for the above case.
the movement, the compensator is pushed down-
wards by the higher pressure in the upper chamber
until the pressure PBV downstream from the shuttle

WB97R-2 10-75
STRUCTURE AND FUNCTION CLSS (Closed Center Load Sensing System)

7. LS DECOMPRESSION VALVE
DESCRIPTION
The LS decompression valve is a throttle that continuously releases a small quantity of oil from the LS circuit and that,
when the shuttles are brought back to a neutral position, releases the residual LS pressure.
This continued flow renders the PLS pressure increment more gentle and gradual, and increases stability and control
during the phases of reducing the LS pressure..

2 d

Q (ᐍ / min)
1
1,3
c

0,8
b a
0 20 250 P (bar)
RKZ02350 RKZ02360

OPERATION
• When the LS pressure reaches chamber a of the • The shuttle is pushed downwards ( ) and passage
valve, it generates a force that opposes the force of c is opened.
the spring (2). • The system is in equilibrium (i.e. the shuttle is at
• Until the force generated by the LS pressure ex- rest), when the quantity of oil allowed to flow into the
ceeds the force of the spring (2) (LS pressure low) tank circuit is equivalent to the quantity that gener-
the shuttle (1) remains «at rest» and oil flows ates a pressure difference ∆P such that
through the calibrated orifice b in the tank circuit. (PLSxS)=[(PLS1xS)+F] where:
• When the force generated by the LS pressure ex- PLS=LS pressure
ceeds the force of the spring (2), the shuttle is PLS1=LS pressure contained in chamber d
pushed upwards ( ) and the passages c are closed. S=section of the shuttle
Oil continues to flow into the chamber d until the F=force of the spring
force generated by the pressure contained in cham-
ber d, together with the force of the spring (2), ex-
ceeds the force generated by the LS pressure.

10-76 WB97R-2
STRUCTURE AND FUNCTION CLSS (Closed Center Load Sensing System)

8. PRESSURE CUT-OFF VALVE

DESCRIPTION
The function of the pressure cut-off valve is to regulate the maximum pressure of the Load Sensing signal and hence also
the pressure of the pump.

1
b
1

RKZ01770

OPERATION
• The pressurized oil of the LS reaches the chamber a of
the valve.
• When the force generated by the LS pressure on the
valve (1) exceeds the force of the spring (2), the valve
(1) is pushed upwards ( ) opening the passage be-
tween the chamber a and the tank circuit.

WB97R-2 10-77
STRUCTURE AND FUNCTION CLSS (Closed Center Load Sensing System)

9. PRIORITY VALVE (ONLY FOR THE 2-3 SPOOL CONTROL VALVE)

FUNCTION
The function of the priority valve is to distribute oil to the steering unit and to the other hydraulic components. Distribution
is determined by the position of the valve of the priority valve in function of the LS signal, oil delivery from the pump, the
pressure of the steering unit and the pressure of the hydraulic circuit. The position of the valve is such as to guarantee that
delivery to the steering unit will always correspond to the actual need.

P LS

D DLS

To the actuator
RKZ02371

10-78 WB97R-2
STRUCTURE AND FUNCTION PPC VALVE (OPTIONAL)

PPC VALVE (OPTIONAL)

LEFT

e
b
1 T

2 P 4

3
f c

d View
VistaAA

A RKZ07790

a. Port 1 - To backhoe control valve (Port PA1) (In arm)

b. Port T - To hydraulic tank
c. Port 4 - To backhoe control valve (Port PB2) (RH swing boom)
d. Port 3 - To backhoe control valve (Port PB1) (Out arm)
e. Port P - To solenoid valve group (ST2) (Port S1)
f. Port 2 - To backhoe control valve (Port PA2) (LH swing boom)

WB97R-2 10-79
STRUCTURE AND FUNCTION PPC VALVE (OPTIONAL)

RIGHT

e
b
1 T

2 P 4

3
f c

d View A
Vista A

A RKZ07800

a. Port 1 - To backhoe control valve (Port PA6) (Lower boom)

b. Port T - To hydraulic tank
c. Port 4 - To backhoe control valve (Port PA5) (Dump bucket)
d. Port 3 - To backhoe control valve (Port PB6) (Raising boom)
e. Port P - To solenoid valve group (ST2) (Port S1)
f. Port 2 - To backhoe control valve (Port PB5) (Curled bucket)

10-80 WB97R-2
STRUCTURE AND FUNCTION SOLENOID VALVE

SOLENOID VALVE
SOLENOID VALVE GROUP ST1
(Differential locking - Backhoe boom locking)

d
a

b c

1 2

RKZ04960

1. EV4 - Backhoe boom locking

2. EV3 - Differential locking
a. Port T - To the transmission
b. Port 1 - Boom-locking cylinder
c. Port 2 - To the rear axle
d. Port P - From the transmission

WB97R-2 10-81
STRUCTURE AND FUNCTION SOLENOID VALVE

SOLENOID VALVE GROUP ST2 (Servocontrol) (Optional)

2 4

3
1

e
a

b
h
c g f

RKZ07810

1. Y14: PPC VALVE

2. Y23: RH outrigger lowering
3. Y16: RH outrigger raising
4. Y24: LH outrigger raising
5. Y15: LH outrigger lowering

a. Port Acc - Accumulator

b. Port P - To backhoe control valve (Port M)
c. Port S1 - To PPC valve (Port P)
d. Port A1 - To backhoe control valve (Port PA4)
e. Port A2 - To backhoe control valve (Port PA3)
f. Port B2 - To backhoe control valve (Port PB3)
g. Port B1 - To backhoe control valve (Port PB4)
h. Port T - To hydraulic tank

10-82 WB97R-2
STRUCTURE AND FUNCTION SOLENOID VALVE

SOLENOID VALVE GROUP OP1 (Side digging boom, jig arm)

a b

1 2
RKZ07820

1 . Y22: Jig arm (Out)

2 . Y18: LH side digging boom
3. Y21: Jig arm (In)
4. Y17: RH side digging boom

a. Port A - To backhoe control valve (Port PA2) (for jig arm)

To backhoe control valve (Port PA7) (for side digging boom)
b. Port B - To backhoe control valve (Port PB8) (for side digging boom)
To backhoe control valve (Port PB7) (for jig arm)
c. Port P - To solenoid valve group ST2 (Port S1)
d. Port T - To hydraulic tank

WB97R-2 10-83
STRUCTURE AND FUNCTION SOLENOID VALVE

SOLENOID VALVE GROUP OP2 (Hammer)

1
RKZ07830

1. Y20: Hammer

a. Port A - To backhoe control valve (Port PA7)

b. Port P - To solenoid valve group ST2 (Port S1)
c. Port T - To hydraulic tank - To backhoe control valve (Port PB7)

10-84 WB97R-2
STRUCTURE AND FUNCTION SOLENOID VALVE

SOLENOID VALVE GROUP OP3 (Hammer + jig arm)

1
3

b c
e

d
a

RKZ07840

1. Y20: Hammer
2. Y22: Jig arm (out)
3. Y21: Jig arm (in)

a. Port T - To hydraulic tank - To backhoe control valve (Port PB7))

b. Port P - To solenoid valve group ST2 (Port S1)
c. Port A1- To backhoe control valve (Port PB8)
d. Port B1- To backhoe control valve (Port PA8)
e. Port A - To backhoe control valve (Port PA7)

WB97R-2 10-85
STRUCTURE AND FUNCTION SOLENOID VALVE

SOLENOID VALVE GROUP OP4 (Side digging boom + jig arm)

3
1

2 4

c e

d f

RKZ07850

1. Y22: Jig arm (out)

2. Y21: Jig arm (in)
3. Y18: LH side digging boom
4. Y17: RH side digging boom

a. Port P - To solenoid valve group ST2 (Port S1)

b. Port T - To hydraulic tank
c. Port B1- To backhoe control valve (Port PA8)
d. Port A1- To backhoe control valve (Port PB8)
e. Port B2- To backhoe control valve (Port PA7)
f. Port A2- To backhoe control valve (Port PB7

10-86 WB97R-2
STRUCTURE AND FUNCTION SAFETY VALVE

SAFETY VALVE
SHOVEL RAISE
a
A

b b

3 4
2

5
Pressione ∆p (bar)
Pressure ∆p (bar)

50
45
40
35
30
25 a
20 b
15
10
c
1 5
0 0
10 20 30 40 50 60 70 80 90 100

Portata Q (l / min)
Flow Q (l / min)

RKZ08040
Section
SezioneAA -- A
A RKZ08050

a. Port PiL - To the raising cylinders (Head side) 4 - Spool

b. Port V2 - From the shovel control valve 5 - Screw
(Port A1)
CHARACTERISTICS
c. Port C2 - To the raising cylinders (Base side)
Safety valve calibration: 220 +0 10 bar
COMPONENTS
1 - Solenoid valve
2 - Adjusting screw
3 - Spring

WB97R-2 10-87
STRUCTURE AND FUNCTION SAFETY VALVE

SHOVEL DUMP

c b

RKZ08060
Pressione ∆p (bar)
Pressure ∆p (bar)

24

20

16
b
a

12

0 12 24 36 48 60
Portata Q (l / min)
Flow Q (l / min)

RKZ08070

a. Port PiL - To the dump cylinders (Head side) CHARACTERISTICS

b. Port C2 - From the shovel control valve (Port Safety valve calibration: 220 +0 10 bar
B2)
c. Port V2 - To the dump cylinders (Base side)

10-88 WB97R-2
STRUCTURE AND FUNCTION SAFETY VALVE

BOOM
a

1 b

2
RKZ08080
Pressione Dp (bar)

35
Pressure Dp (bar)

28

21
a b
14

0 15 30 45 60 75 90 105 120 135 150

Portata Q (l / min)
Flow Q (l / min)

RKZ08090

a. Port PiL - To the boom cylinder (Head side) CHARACTERISTICS

b. Port V2 - From the backhoe control valve Safety valve calibration 1: 230 +0 15 bar
(Port A6) Safety valve calibration 2: 130 +0 20 bar
c. Port C2 - To the boom cylinder (Base side)

WB97R-2 10-89
STRUCTURE AND FUNCTION SAFETY VALVE

ARM

b
RKZ08100
Pressione Dp (bar)
Pressure Dp (bar)

24

20

16
b
12
a

0 25 50 75 100 125 150 175

Portata Q (l / min)
Flow Q (l / min)

RKZ08110

a. Port P - To the arm cylinder (Head side) CHARACTERISTICS

b. Port V2 - From the backhoe control valve Safety valve calibration 1: 300 +0 10 bar
(Port B1)
c. Port C2 - To the arm cylinder (Base side)

10-90 WB97R-2
STRUCTURE AND FUNCTION SAFETY VALVE

SIDE DIGGING BOOM

a b
A A

1 1

2 3 3 2
Section
Sezione A
A -- A
A

c d

RKP04070

22
Pressione Dp (bar)
Pressure Dp (bar)

20
b
a

16

12

0
0 12 24 36 48 60
Portata Q (l / min)
Flow Q (l / min)
RKZ08120

1. Adjusting screw CHARACTERISTICS

2. Plug Ratio: 4.25 : 1
3. Valve
a. Port C1- To side digging boom cylinder (Head side)
b. Port C2- To side digging boom cylinder (Base side)
c. Port V1- From the backhoe control valve (Port A7)
d. Port V2- From the backhoe control valve (Port B7)

WB97R-2 10-91
STRUCTURE AND FUNCTION BRAKE PUMP

BRAKE PUMP

1 2 3 4 5 6

7
17 16 15 14 13 12 11 10 8
RKZ07860

1. Pump body CHARACTERISTICS:

2. Main piston Stroke: 36 mm
3. Seal Displacement: 15 – 28 cc
4. Differential piston Max. pressure: 150 bar
5. Spring
6. Pump spring
7. Spring
8. Check valve
9. Ball
10. Seal
11. Pin
12. Seal
13. Seal
14. Seal
15. Ball
16. Spring
17. Seal

10-92 WB97R-2
STRUCTURE AND FUNCTION SHOVEL CYLINDERS

SHOVEL CYLINDERS
RAISING CYLINDER

2 3 4 5 6 7
1 8

RKZ00310

DUMPING CYLINDER

2 3 4 5 6 7
1 8

RKZ00300

1. Bushing, base side 5. Piston

2. Cylinder 6. Piston rod
3. Nut 7. Cylinder
4. Piston seal 8. Bushing, head side

CHARACTERISTICS
Cylinder Raising Dumping
Piston rod diameter 50 50
Internal cylinder diameter 85 85
Piston stroke 730 755
Max. cylinder length 1880 2145
Min. cylinder length 1150 1390
Key size for piston safety nut 55 55

WB97R-2 10-93
STRUCTURE AND FUNCTION BACKHOE CYLINDERS

BACKHOE CYLINDERS
BOOM
2 3 4 5 6 7
8 9
1

11 10 RKZ00200

1. Head bushing, piston rod side 5. Piston 9. Bottom bushing

2. Piston rod 6. Piston ring 10. Dowel bolt
3. Cylinder head 7. Guide ring 11. Ball-bearings (9)
4. Cylinder 8. Cushion plunger

ARM

3 4 5 6 7 8 9
10
1 2

RKZ00220

1. Head bushing 5. Bushing 9. Nut

2. Piston rod 6. Piston ring 10. Bottom bushing
3. Cylinder head 7. Guide ring
4. Cylinder 8. Piston

BUCKET

2 3 4 5 6 7 8 9
1

RKZ00290

1. Head bushing 4. Cylinder 7. Guide ring

2. Piston rod 5. Piston 8. Nut
3. Cylinder head 6. Piston ring 9. Bottom bushing

10-94 WB97R-2
STRUCTURE AND FUNCTION BACKHOE CYLINDERS

OUTRIGGERS
1 2 3 4 5 6 7 8

RKZ00410

1. Piston rod 4. Spacer 7. Piston

2. Cylinder head 5. Piston ring 8. Nut
3. Cylinder 6. Guide ring

BOOM SWING
5

1 2 3 4 6
7

12 11 10 9 8
RKZ00360

1. Retaining ring 5. Swing bushing 9. Guide ring

2. Throttling ring 6. Cylinder head 10. Piston ring
3. Piston rod 7. Head bushing 11. Spacer
4. Cylinder 8. Piston 12. Cushion plunger
ARM (FOR SIDE DIGGING BOOM)
2 4 5 6
3 7 8
1

11 10 9 RKZ00210

1. Head bushing 5. Guide ring 9. Piston

2. Cylinder head 6. Nut 10. Piston rod
3. Bushing 7. Bearing 11. Cylinder
4. Piston ring 8. Snap ring

WB97R-2 10-95
STRUCTURE AND FUNCTION BACKHOE CYLINDERS

SIDE DIGGING BOOM

1 2 3 4 5 6 7 8 9 10

11 RKZ00390

1. Head bushing 5. Cylinder head 9. Nut

2. Piston rod 6. Cylinder 10. Bottom bushing
3. Ring nut 7. Piston ring 11. Spacer
4. Gasket 8. Ring

JIG ARM

1 2 3 4 5 6 7

RKZ00320

1. Piston rod 4. Piston 7. Nut

2 Cylinder head 5. Piston ring
3. Cylinder 6. Guide ring

10-96 WB97R-2
STRUCTURE AND FUNCTION BACKHOE CYLINDERS

CHARACTERISTICS
Arm
Cylinder Boom With side Bucket
Standard
digging boom
Piston rod diameter 55 60 60 60
Internal cylinder diameter 115 110 110 95
Piston stroke 849 920 910 765
Max. cylinder length 2049 2175 2170 1850
Min. cylinder length 1200 1255 1260 1085
Key size for piston safety nut 65 55 55 55

CHARACTERISTICS
Side digging
Cylinder Outriggers Boom swing
boom
Jig arm

Piston rod diameter 40 50 45 40

Internal cylinder diameter 80 100 85 70
Piston stroke 635 230 365 1140
Max. cylinder length 1690 319 830 2590
Min. cylinder length 1055 89 565 1450
Key size for piston safety nut 46 -- 46 46

WB97R-2 10-97
STRUCTURE AND FUNCTION AIR-CONDITIONING UNIT

AIR-CONDITIONING UNIT

2
Low pressure steam

Low pressure liquid/steam

High pressure steam

AIR AT AMBIENT TEMPERATURE High pressure liquid

1a

3 1

8
5

7
9
INTERIOR OF CAB
RKZ03130

1. Compressor TECHNICAL DATA

2. Condenser Operating pressure in circuit with engine at 2500 rpm
3. Drying-filter tank and ambient temperature at 25–30°C:
4. Safety pressure Normal pressure: 15 –17 bar
5. Expansion valve Low pressure: 1.6 –1.8 bar
6. Evaporator Safety pressures:
High pressure: 26 bar
7. Thermostatic clutch control sensor
Low pressure: 2.5 bar
8. Air-circulation fan in cab
Coolant fluid: R134a
9. Air conveyor
Quantity of coolant: 2250 ±150 g

10-98 WB97R-2
STRUCTURE AND FUNCTION HOW THE AIR-CONDITIONING UNIT FUNCTIONS

HOW THE AIR-CONDITIONING UNIT FUNCTIONS

The compressor (1) is driven directly by the engine shaft On leaving the evaporator (6) the coolant is drawn once
by means of a belt, and made to rotat by a pulley fitted more into the compressor (1) and a new cycle commenc-
with an electromagnetically-engaged clutch (1a). es.
A thermostatic sensor (7) controls the engagement and The yielding of heat from the atmosphere in which the
disengagement of the clutch. It disengages the clutch evaporator is positioned leads to the condensation of the
when the evaporator reaches the lower temperature limit water suspended in the air, and hence to dehumidifica-
and engages the clutch when the evaporator reaches tion. The condensate is deposited on the evaporator fins
the upper temperature limit. where, if a temperature higher than 0°C is not main-
The coolant fluid (in gaseous phase) is drawn into the tained, it freezes and inhibits the functioning of the evap-
compressor where it is subjected to compression and an orator.
intense heating process. In these conditions the fluid is The task of keeping the temperature of the evaporator
then sent into the condenser (2) where, due to the heat above 0°C (and thus within the optimum limits for heat
extracted by ambient temperature air flowing over fins, it exchange) is entrusted to a thermostatic sensor (7).
reaches condensation temperature, and passes into a The condensate that forms on the evaporator fins (6)
high-pressure liquid state. also contains dust, pollens and particles suspended in
Subsequently the coolant passes into the drying-filter the air. Continual condensation therefore effectively pu-
group (3) which performs three functions: it filters out im- rifies the air, and the droplets of condensate are dis-
purities, absorbs any moisture present in the circuit and, charged to the exterior.
finally, also functions as a reserve tank. A fixed quantity of anti-freeze oil is also introduced into
The coolant in its liquid state is then transferred to the the circuit, with the function of lubricating all the mechan-
evaporator (6), first passing through an expansion valve ical parts of the unit. A percentage of this oil circulates
(5). The task of this valve is the constant metering of the constantly throughout the unit in nebulized form, lubri-
quantity of fluid in order to maintain optimum evapora- cating the compressor (pistons and bearings) and the
tion. expansion valve.
In the evaporator the coolant fluid is subjected to expan- A pressure switch (4) has been inserted in the electrical
sion, bringing it up to the critical evaporation point at a control circuit to protect the unit in the case of a lack of
temperature of approximately – 8°C. coolant fluid or if the quantity becomes insufficient due to
The flow of air generated by centrifugal fan (8) which leakages. This switch will inhibit the engagement of the
passes through the evaporator (6) at ambient tempera- electromagnetic clutch and hence the functioning of the
ture is considerably warmer than – 8°C. For this reason air-conditioning unit.
it yields heat to the coolant fluid, bringing it up to boiling
point and complete evaporation.

WB97R-2 10-99
PAGE INTENTIONALLY
LEFT BLANK
STRUCTURE AND FUNCTION ENGINE WIRING HARNESS

ENGINE WIRING HARNESS

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

XT1
TEMPORIZZATORE
ELETTROSTOP
FUEL SHUT OFF TIMER XT2
TEMPORIZZATORE
CANDELETTE
PREHEATING TIMER
EXCITATION X64
ECCITAZIONE RELE'
CANDELETTE
HEATING START
RELAY
KT2 HA1
AVVISATORE ACUSTICO
RELE' CANDELETTE HORN
HEATING START RELAY
X16
R30 FRIZIONE CONDIZIONATORE
CONDITIONER CLUTCH
CANDELETTE
80A HEATING START
R32
40A TEMP. ACQUA
WATER TEMP.

60A
GND2
S22
30A
PRESSOSTATO INTASAMENTO
FILTRO ARIA
AIR FILTER BLOCKED SWITCH

K03
RELE' ELETTROSTOP
FUEL SHUT OFF RELAY

S21
MAX TEMP. ACQUA
MONTARE SULLA PIASTRA WATER TEMP. MAX
POWER BOX cod. 1C020714

COLLEGARE A GRUPPO "X61"

CONNECT TO "X61" GROUP
X61
RELE' SICUREZZA
SAFETY RELAYS
1
8

2
9 1

X10
0

4
5

A LINEA ANTERIORE
11

6
12

TO FRONT LINE
7
13

CAVO ROSSO CAVO GIALLO

GRUPPO "UU" GRUPPO "TT"

+30
X62

X63
S23
GND1 GND1 GND1
MASSE
GROUND MASSE MASSE
GROUND GROUND
A
B W
W CONTAGIRI +
RPM INSTRUMNET
-
XAM
X11 ELETTROSTOP - +
+30 XA
ELECTROSTOP +50
ALTERNATORE
+30 GENERATOR
M9
POMPA GASOLIO
FUEL PUMP

COLLEGARE A GRUPPO "I"

CONNECT TO "I" GROUP
PIN WIRE TO PIN
PIN WIRE TO PIN
M1 X10 2
M1 X10 2
M1 X10 3 A RESISTENZA
TO RESISTOR
PIN WIRE TO PIN

M1 X10 2

COLLEGARE A GRUPPO "F1"

CONNECT TO "F1" GROUP
PIN WIRE TO PIN PIN WIRE TO PIN
G4 X10 2 M1 X10 2
R4 X10 3 CONTATTI SAFETY RELE'
SAFETY RELAY CONTACTS
PIN WIRE TO PIN

M1 X10 2

WB97R-2 10-101
 STRUCTURE AND FUNCTION FRONT LINE WIRING HARNESS

FRONT LINE WIRING HARNESS

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

X1
CENTRALINA S16
ELECTRONIC BOARD
SW LIVELLO OLIO FRENI INTERRUTTORE STOP
X3 10 11 7 8 9 BRAKE OIL LEVEL SWITCH
S17
STOP LIGHT SWITCH
5 6 4 1 2 3
CENTRALINA
ELECTRONIC BOARD
7
8
9 1

X22
2
10 3
11 4
5
6
POMPETTA LAVAVETRO
WASHER PUMP S18

X60
OPTIONAL

+30 X34
+30 CENTRALINA FARO ANT. DX
ELECTRONIC BOARD (+30) FRONT RIGHT LIGHT

MASSA
GROUND

GND2
GND3

MASSA
GROUND

B
A
POWER(+30 +50)

X11
1
4

OPTIONAL
3

POWER BOX
5

X23
X18
7
6
5 13
4 12
11
3
2
1 10
9
8
CONN. A RETE MOTORE
TO ENGINE CABLE

X10
FARO ANT. SX
6 5 4 FRONT LEFT LIGHT

X35
3 2 1
A
B
A L. PIATTAFORMA
TO PLATFORM CABLE

X59
POWER (+30 +50)

X12

RKZ08030

10-102 WB97R-2
STRUCTURE AND FUNCTION LATERAL PLATFORM WIRING HARNESS

LATERAL PLATFORM WIRING HARNESS

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

X21 Y3 S2
X30
GALLEGGIANTE E/V SBLOCCO PIASTRA INT. EV SBLOCCO
FUEL FLOAT POMPA GASOLIO PLATE UNLOCK VALVE
X26
T
1° BRACCIO RETRO
FUEL PUMP X20 LINEA FANALI POSTERIORI X32 S1
HA3 REAR LIGHT CABLE INT. ECONOMY POWER
REAR ARM UNLOCK
MOTORINO RISCALDAMENTO PRESA AUTORADIO VALVE SWITCH
HEATER MOTOR CLAXON POSTERIORE ECONOMY POWER SW
RADIO
HA4 REAR HORN
ALLARME BACKUP
BACKUP ALARM
X12
2
ALIMENTAZIONI
POWER SUPPLY X29
2°PULSANTE
B
A
X43 STACCO CONVERT. XC1
CONVERT. DETACHMENT ACCENDISIGARI
A RELE' 4°MARCIA
TO 4°GEAR RELAY
2nd BUTTON X67 CIGARETTE LIGHTER S3
X5
g
Y1 SENSORE SEDILE INT. FERMO
PIASTRA
E/V ECONOMY POWER SEAT SENSOR
MASSE PLATE LOCK
ECONOMY POWER
GROUND SWITCH
X59
INTERFACCIA LINEA ANTERIORE 2
FRONT WIRING INTERFACE 1 S15 f

SW FRENO DI
STAZIONAMENTO
PARKING BRAKE
SWITCH
S6
X15 QUADRO AVVIAMENTO
+15 CENTRALINA STARTING SWITCH
+15 ELECTRONIC BOARD

X19
6 7
1 2

11 10
21 20
A CRUSC. ANTERIORE
3

9
19
8
18
4 5
8 9

TO FRONT DASHBOARD

7
17
X17

6
5
CRUSCOTTO LATERALE

16
4
15
LATERAL DASHBOARD

3
14
2
13
1
12
X31

3
5
CABINA

2
1
CABIN

4
SENSORE RETURN TO DIG
RETURN TO DIG SENSOR
X53
X39 KIT CONDIZIONATORE
eb
CODITIONER AIR
MANIPOLATORE
JOYSTICK

17 16 15 14 13 12 11 10
X28
9 8 7 6 5 4 3 2 1

3
4

ELETTROVALVOLE
1 2 3 4 5 6
CENTRALINA
SOLENOID VALVES
+

S4
7 8 9 10 11 ELECTRONIC BOARD 1
RISCALDAMENTO

2
HEATER
X8 X27 E/V RETURN TO DIG
CENTRALINA R. TO D. VALVE

ART
MODU
PER FUN

01
ELECTRONIC BOARD

171010
T

LO RE
53S

ZIONE

ITALY
53M
15
Y6 RELE'
K13

31

LE’
TERNA
TENS
12V
RELAY

IONE
X5

MASSE
K06
GROUND POWER/ECONOMY UNIT
SOCKET
GND4

K12
RELE SEDILE OPT.
OPT. SEAT RELAY
PONTE
ELECTRIC BRIDGE

X25
K05
K13 K12 K06 K04 KC
RELE' RETURN TO DIG
RELE' DI CARICO
RETURN TO DIG RELAY LOAD FAN RELAY
RELE' 3° VELOCITA (A/C) K05 KC
3° SPEED FAN RELAY (A/C)

COLLEGARE K04
COLLEGARE
RKZ07900

WB97R-2 10-103
 STRUCTURE AND FUNCTION LATERAL DASHBOARD WIRING HARNESS

LATERAL DASHBOARD WIRING HARNESS

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

15
10 20
RPM x 100

5 25

0 30
electronic

00000 00

+15
+15
XS
MASSA MASSA
+15
GROUND GROUND
0PT 0PT R

+15
MASSA
GROUND
+15
SPIA
FILTRO ARIA MOTORE
ENGINE AIR FILTER
WARNING LIGHT +15
MASSA
GROUND
LUCI
LIGHT SPIA
SPIA PRESSIONE OLIO MOTORE
CANDELETTE ENGINE OIL PRESSURE
+15 WARNING LIGHT
PREHEATING
WARNING LIGHT MASSA
+15 GROUND
S5L
SPIA INTERRUTTORE S5
+15 BATTERIA SWITCH S5 MASSA
BATTERY GROUND X33
WARNING LIGHT S4L CABINA
+15

5
1
INTERRUTTORE S4 CABIN

6
2
SWITCH S4

7
INDICATORE

4
10
0
LIVELLO d

CARBURANTE
+15 FUEL LEVEL
INSTRUMENT

+15

+15
X65
FARI LAVORO POSTERIORI
REAR WORKING LIGHT
MASSA
GROUND

MASSA
GROUND X66
FARI LAVORO POSTERIORI
REAR WORKING LIGHT
MASSA
GROUND

MASSA
GROUND

MASSA
GROUND

SPIE
LAMP

aa
SPIE
LAMP

40
LUCE
SPIE LIGHT
LAMP
INT. FARI LAVORO 2
1
12
HA WORKING LIGHT SWITCH
5
4
3
14
13

S1L INT. TERGI 6 16

15

WINDSHIELD SWITCH 7
9
8
18
17 X17
S2L INT. GIROFARO 11
10
20
19
BECON LAMP SWITCH 21 A LINEA PIATTAFORMA
TO PLATFORM CABLE
S3L
RKZ07910

10-104 WB97R-2
STRUCTURE AND FUNCTION BACKHOE SERVOCONTROL WIRING HARNESS (FRAME)

BACKHOE SERVOCONTROL WIRING HARNESS (FRAME)

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

GND
MASSA
1
2
3
7
GROUND
8

Y15
4
5 10
6
11
12
13
14

ELETTROVALVOLA STAB. SX DISCESA

15
16
17
18

Y25 DOWN LEFT STABILIZER SOLENOID VALVE

ELETTROV. BLOCC. BRACCIO

ARM BLOCK SOLENOID VALVE
Y14 Y16
1
2
3
ELETTROVALVOLA PPC ELETTROVALVOLA STAB. DX SALITA
PPC SOLENID VALVE DOWN RIGHT STABILIZER SOLENOID VALVE
7

9
4 10
5
11
6
12
13
14

15
16
17
18

Y21 Y20
TELESCOPICO RIENTRO ELETTROVALVOLA MARTELLO
TELESCOPICO RETRACT HAMMER SOLENID VALVE

Y22
TESCOPICO SFILO
TELSCOPIC EXTENSION

S43
PEDIPOLATORE MARTELLO
FOOT SWITCH HAMMER
X55
DA LINEA CABINA
FROM CABIN WIRING

Y18
ELETTROVALVOLA DEPORT. SX
TURN SOLENOID VALVE LEFT

Y17

ELETTROVALVOLA DEPORT. DX
TURN SOLENOID VALVE RIGHT

ELETTROVALVOLA STAB. SX SALITA

DOWN LEFT STABILIZER SOLENOID VALVE
X57
MANIPOLATORE SX
Y24 LEFT LEVER
ELETTROVALVOLA STAB. DX DISCESA
DOWN RIGHT STABILIZER SOLENOID VALVE
Y23

X58
MANIPOLATORE DX HA3
RIGHT LEVER CLAXON
HORN

CLAXON
HORN

HA4

EV. BLOCC. PISTRA

PLATE BLOCK SOLENOID VALVE
Y19
RKZ07920

WB97R-2 10-105
 STRUCTURE AND FUNCTION BACKHOE SERVOCONTROL WIRING HARNESS (CABIN)

BACKHOE SERVOCONTROL WIRING HARNESS (CABIN)

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

F9
K10 K11 K11 K10 F9
RELE' ELETTRONICO RELE'
ELECTRONIC RELAY RELAY X56
FUSIBILE 15A
Y
FUSE 15A
ITAL

70923 E
011 ISTABIL T
T
AR

E
L¨ B RES
RE N
CO NS
IONE
TE
53M
12V
53S
31
15

BR
+15

X55
A LINEA TELAIO DOWN
TO FRAME WIRING

S42
UP STABILIZZATORE DX
RIGHT STABILIZER

POWER SUPPLY

DOWN

UP

S41
STABILIZZATORE SX
POWER SUPPLY LEFT STABILIZER

BLOCCO PIASTRA SCORREVOLE

LOCKING SLIDING PLATE
S3
BLOCCAGGIO 1 BRACCIO
ARM BLOCKED
ABILITAZIONE PPC S2
PPC ENABLE
S40

RKZ07930

10-106 WB97R-2
STRUCTURE AND FUNCTION WORK LIGHT WIRING HARNESS

WORK LIGHT WIRING HARNESS

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

FUS
R1 R2 F1 PORTA FUSE PICCOLO
FUSE CONNECTOR
B
FARO DI LAVORO ANTERRIORE N∞1
FRONT WORKING LAMP N∞1

1
2
F
RELE' ANTERIORE
FRONT RELAY

C
FARO DI LAVORO ANTERRIORE N∞2
M

1
2
FRONT WORKING LAMP N∞2

G
A RELE' POSTERIORE
POST RELAY H

2
1
FARO DI LAVORO POSTERIORE N∞1
POST WORKING LAMP N∞2

1
6
2
7

3
4
8
5
R

9
E L

2
1
MASSE
FARO DI LAVORO POSTERIORE N∞2 GROUND
POST WORKING LAMP N∞2

N O P Q
1
2

1
2

NN OO PP QQ
1
2

1
2

RKZ07940

WB97R-2 10-107
 STRUCTURE AND FUNCTION ATC24 WIRING HARNESS

ATC24 WIRING HARNESS

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

XD4
S35

XA
CONN. DEVIO CAMBIO
SHIFTER SWITCH CONN. X10A C16
SENS. TEMPERATURA OLIO CONVERTITORE
CONVERTER OIL TEMPERATURE SENSOR
X10 1
CONN. INTERFACCIA CENTRALINA FUSIBILI

ITA
FUSE UNIT INTERFACE CONNECTOR

CE
CO

LY
NT
MA
TE

RA
ND
98

NS
20 1
1

LIN

011
ON
91
76

ION

AR 014
8 1

AA

71
T.
EG
E
716

TC
9

AT
151

24
12V
8
20

54
413

IVO
7
19 1

32
12 1
6
81

1
110
7
16
15

5
4
14
CENTRALINA DIODI ATC24

3
13

2
12
ATC24 DIODE UNIT

11 1

1
0
XC
X69

¯10

GND

GND5

X7

4 5
8 9
X7

6 7 3
CONN. CENTRALINA FUSIBILI

1 2
FUSE UNIT CONN.

CONN. CENTRALINA ATC24

2
GEAR C. UNIT ATC24 CONN.

X24

2
Y10 ELETTROVALVOLA 1°ELOCITA'
FIRST SPEED SOLENOID VALVE
X70 C23 2

2
ELETTROVALVOLA 3°VELOCITA'
Y9 THIRD SPEED SOLENOID VALVE 2

C25
2

ELETTROVALVOLA MARCIA AVANTI 2

Y7 FORWARD GEAR SOLENOID VALVE
ELETTROVALVOLA 2° VELOCITA'
C22 SECOND SPEED SOLENOID VALVE
ELETTROVALVOLA RETROMARCIA C24
Y8 REAR GEAR SOLENOID VALVE
C21 Y11
ELETTROVALVOLA 4° VELOCITA'
FOURTH SPEED SOLENOID VALVE
Y12
4 5
8 9

ELETTROVALVOLA 4WD
C26 4WD SOLENOID VALVE
Y13
3

C27
2
6 7
1

AL VECCHIO CONN. DEVIO LUCI

CONN. DEVIO LUCI TO OLD LIGHT COLUMN SWITCH CONN.
LIGHT COLUMN SWITCH CONN.

XZ XD1

XD3 XD1
RKZ07990

10-108 WB97R-2
STRUCTURE AND FUNCTION FUSES BOX (1/2)

FUSES BOX (1/2)

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

ITALY

ART 00105013
INT.ELETTRONICA
53M I
TENSIONE

12V
53S

T 15 31

D2

X1 X4 P4 X6 X8
3A

D18
D3

NAIS K8 NAIS NAIS NAIS

D19

K3

D14
JJM1-12V JJM1-12V JJM1-12V JJM1-12V

D15
X10 D17 AJJM131 AJJM131 AJJM131 AJJM131

D10

D16
D11
D5
D8

D9
D6
D4
K7 K1 K2

NAiS
15 10 7.5 7.5 10 15 7.5
K10
12V

K6
NAiS 3 15 7.5 10 15 7.5 10

12V

K5
NAiS 3 10 7.5 15 15 10 7.5 K3

12V F1 D13 F2 D12 F3 D1 F4 D5 F5 F6 F7

X2 X3 X5 3A X7 X9

RKZ07950

WB97R-2 10-109
 1

RKZ07960
2
FUSES BOX (2/2)

GND
+15 MONITOR
ALTERNATOR

MAX TEMP. H2O

OUT BUZZER
MONITOR LIGHT

ENGINE OIL PRESSURE

BRAKE OIL LOW LEVEL

TEMP. HYDRAULIC OIL

AIR FILTER BLOCKED

HYDRAULIC OIL BLOCKED
+15
+30

11
M5
M6

10

1
2
3
4
5
6
7
8
9
3

X4

MARK 11 VIE
1A
1A
1A
1A

12A
7.5A
F7C

FRONT WIRING
MARK 11 VIE VERDE
X1
10A
5A
ENABLE TO START 11
GND 10
4

U10

10A
X8

+15 9
MARK 17 VIE
TO LATERAL PLATFORM WIRING

HORN 8

D11
10A

7.5A
+15 FUEL SHUT OFF SOLENOID 7 1 E.V. DIFFERENTIAL LOCK

F7A
1N4007
1A 1A ALTERNATOR LAMP
ALTERNATOR WARNING LAMP 6 2
RPM SIGNAL (ALTERNATOR) 5 3 HYDRAULIC OIL FILTER BLOCKED LAMP
1A 5A WASHER MOTOR
ENGINE OIL PRESSURE SWITCH 4 4
AIR FILTER BLOCKED SENSOR 3 5 WATER TEMPERATURE SENDER
1A 1A MAX WATER TEMPERATURE LAMP
MAX TEMP. H2O 2 6
WATER TEMP. SENDER H2O 1 7 AIR FILTER BLOCKED LAMP
1A ENGINE OIL LAMP
8
9 W RPM SIGNAL
NO CONTACT SEAT SENSOR
5

10
11 + INTRUMENTS LIGHT
15A 12 + RETURN TO DIG RELAY, LATERAL INTRUMENTS

D10
22A + POWER MODE UNIT,SEAT UNIT, LOAD FAN RELAY
13
22A + REAR WORKING LIGHT

7.5A
14

D9 1N4007
D8 1N4007
1N4007
F3B
22A + REAR HORN
15
16 + BUZZER

D2
15A + CIGARETTE LIGHTER, BEACON LIGHT
17

D4
10A
10A

1N4007
F7B
F5A

1N4007
10A
6

3A

MARK 9 VIE VIOLA

X6
15A

D3

GEAR VALVE WIRING

F5B

E.V. 4WD 9

D7
10A
U2

N.C. 8
15A

1N4007
U3

E.V. BACKWARD 10A

15A

7
F6A

N.C. 6
0ohm

D17

P4
N.C.
1N4007

5
U7

10A

NOT USED
E.V. FOWARD 4
K5

1A
NAIS 12V

HIGH TEMP. TRANSMISSION OIL

7.5A

3
F3A
85
86

N.C. 2
85
86

HYDRAULIC OIL FILTER BLOCKED 1

1A
30
87
7

30
87
87a

JJM1 12V

87a
U6

15A
K4

F1A
0ohm

D19
1N4007
85
K6 86
X9
MARK 17 VIE VIOLA

85
86
TO FRONT DASHBOARD

JJM1 12V
30
87

K8
1 4WD LAMP

30
87
1A DIRECTION LIGHT LAMP
2
87a
8

15A
10A
F2C

3 + DIRECTION LIGHT UNIT

NAIS 12V

87a
F4C

15A +30 HAZARD

4
5 LOW BRAKES OIL LEVEL
F6C 10A 15A
6 +15 DIRECTION LIGHT UNIT
F5C 15A 22A + FRONT WORKING LIGHT

X2
7

MARK 9 VIE VERDE

FRONT DASHBOARD
F4A 7.5A 12A
8 + 4WD SWITCH
SHIFTER FOWARD 1A DIFFERENTIAL LOCK LAMP
9 9
LOW BEAM SWITCH 1A 4WD SWITCH
8 10
GND 7 11 DIRECTION LIGHT UNIT OUT
1A
7.5A

HORN BUTTON 6 12 INSTRUMENT LIGHTS

F6B

SHIFTER BACKWARD 1A + SWITCH LIGHT

5 13
10A
9

+ SHIFTER 4 14 NEUTRAL SHIFT LEVER

HIGH BEAM SWITCH 1A 1A MAX WATER TEMPERATURE LAMP
3 15
+ LIGHTS SELECTOR 12A 1A MAX TRANSMISSION OIL TEMPERATURE
2 16
SIDE LIGHT SWITCH 10A 1A HIGH BEAM LAMP
1 17
J1
3A
1N4007

F1C
D13

3
2
1
10A
F4B
3A
10

F1B
10A

RELE'

10A
K3

JJM1 12V
0ohm
K7

D16

10-110
1N4007
85
86

PREDISPOSIZIONE
30
87
X5
MARK 11 VIE GIALLO

87a
TO LATERAL PLATFORM WIRING

1N4007
D12

1A
11

1 HAND BRAKE SWITCH

K2

JJM1 12V

REAR HORN
X3

2
FRONT WIRING
MARK 11 VIE VIOLA
85
86
15A

20A

3 KICK DOWN BUTTON

F2B

20A
D6

11
15A 4 + AUTORADIO, COURTESY LAMP
30
87

LOW BEAM 10 5 DECLUTCH BUTTON

9 6 RIGHT REAR SIDE LIGHT
87a

RIGHT FRONT SIDE LIGHT

1N4007

8
5A 7 EGM SIGNAL FOR DIFFERENTIAL LOCK
HIGH BEAM
PRESSURE SWITCH PEDAL BRAKE 7 8 SHIFTER NEUTRAL POSITION
7.5A

LEFT REAR SIDE LIGHT

F3C

6 9
0ohm

GND
U1

10A 12A + EV HAMMER VALVE

+ STOP LIGHT 5 10
4 11 +50 KEY START
BRAKE OIL LEVEL 5A D15
WASHER PUMP 3 1N4007
12
STRUCTURE AND FUNCTION

2
5A
LEFT FRONT SIDE LIGHT 1
C1

NAIS 12V
K10
22 mF
U8

85
86
10A
U9

F2A

30
87
U4
0ohm

1A

87a

D1
3A
D5
13

U5

1N4007
0ohm
U11

5A
0ohm

1A

5A
1A
1A
3A
15A

4
3
2
1
9
8
7
6
5
4
3
2
1

X10
X7
T

EGM
FLASHER

MOLEX 4 VIE
K9

GND

MARK 9 VIE
14

15

53M

+15 EGM

N.POSITION
DECLUTCH

KICK DOWN
53S

D.T. CON ATC 24

BUZZER ALARM

BACK UP ALARM
IN BRAKE PEDAL

ENABLE TO START

TEMP. OLIO TRASM.

31

E.V. DOPPIA TRAZIONE

TOP VIEW

OUT DIFFERENTIAL LOCK

IN THIS

VERSION
15

NOT CONNECTED
16
FUSES BOX (2/2)

WB97R-2
STRUCTURE AND FUNCTION FUSES BOX ATC24 (1/2)

FUSES BOX ATC24 (1/2)

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

ITALY

ART 00105013
INT.ELETTRONICA
53M I
TENSIONE

12V
53S

T 15 31

D2

X1 X4 P4 X6 X8
3A

D18
D3

NAIS K8 NAIS NAIS NAIS

D19

K3

D14
JJM1-12V JJM1-12V JJM1-12V JJM1-12V

D15
X10 D17 AJJM131 AJJM131 AJJM131 AJJM131

D10

D16
D11
D5
D8

D9
D6
D4
K7 K1 K2

NAiS
15 10 7.5 7.5 10 15 7.5
K10
12V

K6
NAiS 3 15 7.5 10 15 7.5 10

12V

K5
NAiS 3 10 7.5 15 15 10 7.5 K3

12V F1 D13 F2 D12 F3 D1 F4 D5 F5 F6 F7

X2 X3 X5 3A X7 X9

RKZ07970

WB97R-2 10-111
 1

RKZ07980
2

ALTERNATOR

MAX TEMP. H2O

AIR FILTER BLOCKED
TEMP. HYDRAULIC OIL

+15 MONITOR
OUT BUZZER

GND

HYDRAULIC OIL BLOCKED

BRAKE OIL LOW LEVEL
ENGINE OIL PRESSURE
MONITOR LIGHT
+30

+15
FUSES BOX ATC24 (2/2)

10
11

1
2
3
4
5
6
7
8
9
M5
M6

X4
3

MARK 11 VIE
1A
1A
1A
1A

12A
7.5A
F7C

X1
10A

FRONT WIRING
MARK 11 VIE VERDE
ENABLE TO START 5A
11
U10

GND 10
0 ohm
X8
4

+15 10A
9
MARK 17 VIE
TO LATERAL PLATFORM WIRING

HORN 8

D11

1N4007
10A

7.5A
+15 FUEL SHUT OFF SOLENOID E.V. DIFFERENTIAL LOCK

F7A
7 1
ALTERNATOR WARNING LAMP 1A 1A ALTERNATOR LAMP
6 2
RPM SIGNAL (ALTERNATOR) 5 3 HYDRAULIC OIL FILTER BLOCKED LAMP
ENGINE OIL PRESSURE SWITCH 1A 5A WASHER MOTOR
4 4
AIR FILTER BLOCKED SENSOR 3 5 WATER TEMPERATURE SENDER
MAX TEMP. H2O 2
1A 1A 6 MAX WATER TEMPERATURE LAMP
WATER TEMP. SENDER H2O 1 7 AIR FILTER BLOCKED LAMP
1A 8 ENGINE OIL LAMP
9 W RPM SIGNAL
5

10 NO CONTACT SEAT SENSOR

11 + INTRUMENTS LIGHT
15A + RETURN TO DIG RELAY, LATERAL INTRUMENTS
12

D9
D8
D10
22A + POWER MODE UNIT,SEAT UNIT, LOAD FAN RELAY
13
22A + REAR WORKING LIGHT
7.5A
14
F3B

22A

1N4007
1N4007
1N4007
15 + REAR HORN
16 + BUZZER

D2
15A + CIGARETTE LIGHTER, BEACON LIGHT
17

D4
10A
10A

F7B
F5A
6

1N4007
1N4007
10A

X6
MARK 9 VIE VIOLA
GEAR VALVE WIRING
3A
D3
15A
F5B

E.V. 4WD 9

D7
15A 10A
N.C. 8

NOT USED
U3
U2

10A
15A

1N4007
E.V. BACKWARD 7
F6A

N.C. 6
D17

P4
1N4007

N.C. 5
U7

10A
E.V. FOWARD 4
K5

1A
7.5A

HIGH TEMP. TRANSMISSION OIL 3

7

F3A
85
86

NAIS 12V

N.C. 2
85
86

1A
HYDRAULIC OIL FILTER BLOCKED 1
30
87

30
87
87a

JJM1 12V

87a
U6

K4

15A
F1A
0 ohm

K6

D19

1N4007
85
86
8

X9
TO FRONT DASHBOARD

85
86
MARK 17 VIE VIOLA

JJM1 12V
30
87

1 4WD LAMP

K8

30
87
1A DIRECTION LIGHT LAMP
2
87a
10A

15A

3 + DIRECTION LIGHT UNIT

F2C

87a
F4C

15A
NAIS 12V

4 +30 HAZARD
5 LOW BRAKES OIL LEVEL
F6C 10A 15A
6 +15 DIRECTION LIGHT UNIT
F5C 15A 22A

X2
7 + FRONT WORKING LIGHT

MARK 9 VIE VERDE

FRONT DASHBOARD
F4A 7.5A 12A + 4WD SWITCH
8
1A
SHIFTER FOWARD 9 9 DIFFERENTIAL LOCK LAMP
9

LOW BEAM SWITCH 8

1A 10 4WD SWITCH
GND DIRECTION LIGHT UNIT OUT
7.5A

7 11
F6B

HORN BUTTON 6
1A 12 INSTRUMENT LIGHTS
SHIFTER BACKWARD 1A + SWITCH LIGHT
5 13
+ SHIFTER
10A NEUTRAL SHIFT LEVER
4 14
HIGH BEAM SWITCH
1A 1A MAX WATER TEMPERATURE LAMP
3 15
+ LIGHTS SELECTOR
12A 1A MAX TRANSMISSION OIL TEMPERATURE
2 16
SIDE LIGHT SWITCH 10A 1A HIGH BEAM LAMP
1 17
3A

J1
F1C
10

D13

3
2
1
7.5A
F4B
3A

10-112
F1B
1N4007

RELE'
10A

10A
K7

K3

D16
0 ohm

JJM1 12V

1N4007
11

85
86

PREDISPOSIZIONE
30
87
X5
MARK 11 VIE GIALLO
TO LATERAL PLATFORM WIRING

87a
D12

1N4007

1A HAND BRAKE SWITCH

1
K2

X3

2 REAR HORN
MARK 11 VIE VIOLA
FRONT WIRING
85
86

JJM1 12V

3 KICK DOWN BUTTON

F2B
15A

D6

20A
20A

11
15A 4 + AUTORADIO, COURTESY LAMP
30
87

LOW BEAM 10 5 DECLUTCH BUTTON

12

RIGHT FRONT SIDE LIGHT 9 6

STRUCTURE AND FUNCTION

RIGHT REAR SIDE LIGHT

87a

HIGH BEAM 8
5A 7 EGM SIGNAL FOR DIFFERENTIAL LOCK
1N4007

PRESSURE SWITCH PEDAL BRAKE 7 8 SHIFTER NEUTRAL POSITION

7.5A
F3C

GND 6 9 LEFT REAR SIDE LIGHT

+ STOP LIGHT
10A 12A + EV HAMMER VALVE
5 10
BRAKE OIL LEVEL 4 11 +50 KEY START
U1

5A D15 1N4007
WASHER PUMP 3
2
LEFT FRONT SIDE LIGHT
5A
1
K10
13

NAIS 12V
85
86
U9

U4
0 ohm
U8

10A
F2A

30
87
0 ohm

1A
3A

87a
D5

U5

D1
1N4007
14

5A
U11

5A
1A
1A
3A
1A
15A

4
3
2
1
9
8
7
6
5
4
3
2
1

X10
EGM
X7
T

FLASHER

MARK 9 VIE
K9

GND

E.V. 4WD

CONN. MOLEX 4 VIE

15

53M

+15 EGM
DECLUTCH

4WD SIGNAL
KICK DOWN
15

53S

BUZZER ALARM

BACK UP ALARM

NEUTRAL POSITION
IN BRAKE PEDAL

ENABLE TO START
31
TOP VIEW

OUT DIFFERENTIAL LOCK

TRASM. OIL MAX TEMPERATURE

16

WB97R-2
FUSES BOX ATC24 (2/2)
STRUCTURE AND FUNCTION ELECTRICAL DIAGRAM EGM

ELECTRICAL DIAGRAM EGM

WINDSHIELD WIPER MOTOR

X46

MOTORINO TERGI
4
3
2
1

H19
MOTORINO TERGI ANT.
P1 P3 P4 HA2
1 9 2 8 5 10 R1 ACC BR R2 C 1 9 2 6 7 9 1 9 1 9 1 9 H36 H37 H38

57

59c

57

59c
1 0 1 0 H9 H10 H11 H12 H13 H14 H22 H23 H24 H25 H1 H2 H3 H4 H5 H6 H7 - - - 1 0 2
1 1 0 1 0 1 0 M H17 H18 H21 H20
FRONT WINDSHIELD WIPER MOTOR rpm q t∞ i
S i S i S
5 10 4 6 3 1 7
312612180 + + +
5 10 3 5 10 5 10 5 10 5 10

31

31
B

10
S3A S4A S6 S1L S2L S3L S4L S5L

9
5 4 3 2 1 RIGHT

X24
H39

5
6
6 5 4 3 2 1 2 1

X47
XS
-

3
S2A
X33
7
6
5
4
3 -

10
2

S1A NOT CONNECT

1
LEFT
312612178 312612066
S37

X66
X65
7

5
TO ADDITIONAL TO ADDITIONAL

1
LIGHTS KIT LIGHTS KIT 885270558
21201918 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 5 4 3 2 1

X17

X31
X26
JUMPER M4 MOTORINO
X18
( REMOVE IT WITH RISCALDAMENTO X29 S10
5
4 86 87 AIR-CONDITION KIT ) 2
2 3 4
3 K05 86 87a 87 X39 K04 CONNECTED ONLY 2 HEATING MOTOR 1
2 S27 0 1 3 Y3 15/1 30/3 L/6 15/1 30/3 L/6 15/1 30/3 L/6
WITH AIR-CONDITION KIT 0 1 0 1
1 C S3 NON MONTATO

Y6
B 85 30
85 30 NOT CONNECTED
A
S4 + 1
2 1 4 3 2 1 49/4 30B/2 R/7 49/4 30b/2 R/7 49/4 30b/2 R/7
312612219
1 S2 S1 X45
2 312612175 312612203

X25

X20
3 53S

K06
4 15 15 I
5 KC 85 87a 87 53M 53M
T
XD2 31 T
31
86 30
X19
9
8
312608066
7
6
5
4

MANIPOLATORE
3 X28
2

JOYSTICK
1 12
11
10
9
8
7
6
5
4
3
2
LIGHTS SWITCH

1 1
DEVIO LUCI

2
3
4
5
6
7 1
8 2
9 3
Y1

1
JUMPER
4
XD1 5
6
7
8

2
9
10
11
12
13 EV4
X40
X27
6

X9
X2

X8

X5
5

X32

X53
4
S15 XC1 H15 HA3 3 EV2

X43
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 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 1 2 3 4 5 6 7 8 9 10 11 HA4 2
+15 1 2 7 6 5 4 3 2 1 1

ALIMENTAZIONE AL KIT
EV1 OPENED GRAB SOLENOID VALVE H25 DIFFERENTIAL LOCK WARNING

XK13
D16 K3 86 87a 87
AUTORADIO CONDIZ. EV1
EV2 CLOSED GRAB SOLENOID VALVE LIGHT D11 D5
RADIO TO CONDITIONING CIAM 0A006147
31 53M 15 53S T I
85 30 POWER SUPPLY KIT K13
EV3 DIFFERENTIAL LOCK SOLENOID VALVE H28 RIGHT FRONT LIGHT U1
0W

XK12
H29 LEFT FRONT LIGHT CAO138553

X21
EV4 REAR 1^BOOM UNLOCK SOLENOID VALVE

X30

X67
EV3
K9
H36 REAR RIGHT SIDE LIGHT, +15

D9
D10
F1A LOW BEAM FUSE 15A +15

2
53S 53M 31 I 15 T 1 2 3 A B C

1
R
D17 K4 UP F K12
F1B RIGHT TRAFFIC LIGHT FUSE 3A DIRECTION LIGHT, SIDE LIGHT F3C K7 C +
F4A F3B F3A
86 87a 87
F2B F5A F5B F6A
7.5A 0W
F2C F6C F5C U6
N 312612068
F1C LEFT TRAFFIC LIGHT 3A H37 REAR LEFT SIDE LIGHT, 10A 10A 15A
7.5A 10A 7.5A 0W 85 30 15A 10A 15A 15A DOWN

R AUT M5
F2A FUSE 10A NOT USED DIRECTION LIGHT, SIDE LIGHT U5
D8 D7 D6
R31
S24 M
S19
+15 +15 +30 +15 +15 +15
F2B RADIO, CABIN LAMP, BEACON LIGHT, H38 COURTESY LIGHT D13 D12
+30 +15 +15
U2
0W
0W

U8
6 5 4 3 2 1

XEGM
A B C D E F G H J K L MN P R S T U V WX Y Z a b c d e f g h i

X12
5 4 3 2 1 1 2 3 4 5 6 7 8 9 B A

X49

X59
X48
CIG, LIGHTER FUSE 15A H39 PLATE LIGHT U11
0W
0W

3126112198
Y7
F2C HAZARD FUSE 10A HA1 HORN X4
X7
1

F3A STOP LIGHT, SEAT SENS., DIFF. LOCK HA2 BUZZER 2

3
4
1
2
3

FUSE 7,5A HA3 REAR HORN 5

6
7
4
5
6
Y8

F3B INSTRUM.+WARNING LIGHT+RETURN TO HA4 BACK-UP ALARM 8

9
10
7
8
9 R32
S22 S23 S21 HA1
DIG FUSE 7,5A K01 STARTER RELAY 11
D4
p p t
F7A S30 Y9
F3C 4x1 BUCKET, RELAY DECLUTCH K02 PREHEATING RELAY 7.5A
D1
p t ONLY WITH AIR-CONDITION KIT

K03 FUEL SHUT OFF RELAY 312612174

TRANSMISSION FUSE 7,5A C1
+15 X16
F4A 4WD VALVE+FR. QINDSHIELD WIPER/ (OULL SOLENOID) +15
Y10 B
COMPRESSOR
ELECTROMAGNETIC
F4B +30 +30 A

WASHER FUSE 7,5A K04 3^ SPEED BLOWER RELAY 10A

F4C F1A
S31 CLUTCH
p
15A 15A
F4B FORWARD-REVERSE SPEED+BACK UP (ONLY A/C CABIN VERSION) +15

ALARM FUSE 10A K05 RETURN TO DIG RELAY K6 86 87a 87 K5 86 87a 87

K8 86 87a 87 F7C
7.5A
K10 86 87a 87
F1C
3A
F1B
3A
Y11

F4C HIGH BEAM FUSE 15A K06 POWER ECONOMY UNIT 85 30 85 30

D19 85 30
D3 85 30 S32
F5A RELAY HEATER MOT, POW/ECO UNIT, KC LOAD FAN HEATER RELAY XT2

KT2
C1 K2 86 87a 87
p
D15 Y12 1 53S

SEAT UNIT FUSE 10A K2 REVERSE SPEED RELAY 22µF 85 30

NOT CONNECT
D2 F2A
X11
2
3
4
15

53M
10A
F6B F7B
F5B REAR WORKING LIGHT SWITHC FUSE 15A K3 4 WHEELS DRIVE RELAY 7.5 10A
S34 S36 S35 1 R33
31

p 100 ohm
P4 +30 t
F5C FRONT WORKING LIGHT SWITCH FUSE 15A K4 GEAR NEUTRAL POSITION RELAY 1

J2
2 3
S33 Y13
X6

p
(SHIFT ONLY) +30 312612194 K01
F6A REAR WINDSHIELD WIPER + 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 10 11 +15 +15 1 2 3 4 5 6 7 8 9 10 11
312612067
SAFETY RELAY
K5 LOW BEAM RELAY

X1
X3

FRONT HORN RELAY FUSE 15A 2 1

X63
F6B LIGHTS SELECTOR + K6 MAIN BEAM RELAY
S23 ENGINE OIL LOW PRESSURE X10
FRONT HORN RELAY FUSE 7,5A K8 FRONT HORN RELAY 4 3 2 1

SWITCH
F6C DIRECTION LIGHTS FUSE 10A K9 FLASHER UNIT
S24 FUEL GAUGE
F7A FUSE 7,5A NOT USED K10 EG POWER SUPPLY
X60

S27 NPN SENSOR (RETURN TO DIG)

F7B FRONT HORN FUSE 10A K12 SEAT UNIT
S30 1^ SPEED PRESSURE SWITCH
F7C FUEL SHUT OFF FUSE 7,5A K13 STOP LIGHT, DIFF. LOCK UNIT
S31 2^ SPEED PRESSURE SWITCH
FUG1 KEY SWITCH FUSE 60A KT1 FUEL SHUT OFF TIMER
S32 3^ SPEED PRESSURE SWITCH R30
FUG2 PREHEATING FUSE 80A KT2 PREHEATING TIMER
S33 4^ SPEED PRESSURE SWITCH
FUG3 FUEL SHUT OFF POWER FUSE 40A M1 STARTER MOTOR
X35

X34
S34 GENERAL GEAR OIL
FUG4 HEATER MOTOR, AIR-CONDITIONING M2 WASHER PUMP
X23

X22
S16 S18 S17
PRESSURE SWITCH 1 2 3 4 5 6 1 2 3 4 5 6

FUSE 40A M3 WINDSHIELD WIPER MOTOR

S35 GEAR OIL TEMPERATURE SWITCH 1 2 l -

G1 BATTERY M4 BLOWER MOTOR H29 H28 312612175 K02

56a

56b

57

56a

56b

57
S36 RPM SENSOR OPTIONAL
POMPETTA FUG1 FUG2 FUG3 FUG4 86 87

G2 GENERATOR M5 TRANSFER FUEL PUMP LAVAVETRO 60A 80A 40A 40A

S37 REAR DOOR SWITCH
31

31
H1 PREHEATING WARNING LIGHT M8 WINDSHIELD WIPER MOTOR WINSHIELD WASHER PUMP 85 30

S1L REAR WORKING LIGHT SWITCH

H2 GENERATOR WARNIGN LIGHT M9 FUEL PUMP
ON LAT. DASHBOARD
H3 ENGINE WATER HIGH TEMPERATURE P1 RPM INSTRUMENT XT1

KT1
S2A WINDSHIEL WIPER-WASHER S13
1 53S

WARNING LIGHT P2 HOUR COUNTER - l 2

3
53M

SWITCH ON FRONT DASHBOARD 4 31

XA
H4 ENGINE OIL PRESSURE WARNIGN LIGHT P3 FUEL LEVEL INDICATOR Y9 3^ SPEED SOLENOID VALVE X17 LATERAL DASHBOARD 21 WAY X33 WINDSHIELD WIPER AND X63 ALTERATOR RESISTANCE CONNECTOR M1 G2
15

S2L WINDSHIELD WIPER-WASHER

H5 AIR FILTER WARNING LIGHT P4 WATER TEMPERATURE Y10 1^ SPEED SOLENOID VALVE CONNECTOR BEACON 7 WAY CONNECTOR X65 OPTIONAL LIGHT CONNECTOR 30
M
50
30
D+
G W
SWITCH ON LAT. DASHBOARD 3 K03
H6 HYDRAULIC OIL FILTER WARNING LIGHT INSTRUMENT Y11 2^ SPEED SOLENOID VALVE X18 FRONT CABLE 5 WAY CONNECTOR X34 RIGHT FRONT BEAM 6 WAY X66 OPTIONAL LIGHT CONNECTOR G1
U 86 87

S3A FRONT WORKING LOIGH SWITCH

H7 OPTIONAL WARNING LAMP R30 HEATING START Y12 4^ SPEED SOLENOID VALVE X19 FRONT DASHBOARD 9 WAY CONNECTOR X67 SEAT SENSOR 3 WAY CONNECTOR 12Vcc 31
85 30
ON FRONT DASHBOARD
H8 OPTIONAL WARNING LAMP R31 FUEL LEVEL SENDER Y13 4WD SOLENOID VALVE CONNECTOR X35 LEFT FRONT BEAM 6 WAY XA GENERATOR 2 WAY CONNECTOR
S3L BEACON SWITCH ON FRONT
H9 ENGINE WATER HIGH TEMPERATURE R32 WATER TEMPERATURE SENDER C1 COMPRESSOR ELECTROMAGNETIC CLUTCH X20 BLOWER MOTOR 4 WAY CONNECTOR CONNECTOR XAM FUEL SHUT OFF VALVE 3WAY CONNECTOR
DASHBOARD XAM
WARNING LAMP R33 ALTERNATOR XC1 CIGARETTE LIGHTER SOCKET X21 FUEL LEVEL INDICATOR 3 WAY X38 FORWARD-REVERSE SPEED VALVES XD1 LIGHTS SWITCH 9 WAY CONNECTOR 1
Y0
S4L HORN SWITCH ON LAT. 2

H10 COVERTER OIL HIGH TEMPERATURE S1 ECONOMY POWER X1 FRONT LINE (ENGINE) 11 WAY CONNECTOR CONNECTOR 4 WAY CONNECTOR XD2 GEAR SHIFT 5 WAY CONNECTOR 3

DASHBOARD
WARNING LIGHT PUSH BUTTOM X2 LIGHTS SWITCH AND GEAR SHIFT LINE X22 WINDSHIELD WASHER PUMP 2 WAY X39 PROXIMITY 3 WAY CONNECTOR XEGM EGM CONTROLLER CONNECTOR M9
S5L OPTIONAL SWITCH ON LAT. XM9
H11 4WD WARNING LIGHT S2 REAR 1^ BOOM UNLOCK SWITCH 9 WAY CONNECTOR CONNECTOR X40 FLASHER UNIT 13 WAY CONNECTOR XM9 FUEL PUMP 2 WAY CONNECTOR -
M
DASHBOARD +

H12 FUEL RESERVE WARNING LIGHT S3 PLATE UNLOCK SWITCH X3 FRONT LINE 11 WAY CONNECTOR X23 OPTIONAL 2 WAY CONNECTOR X41 4WD 2 WAY CONNECTOR XS MULTIFUNCTION INSTRUMENT
SM1 KICK DOWN BUTTON
H13 KOMATSU LOGO LIGHT (ONLY EUROPE VERS.) X4 (4WS MONITOR 11 WAY CONNECTOR) X24 WINDSHIELD WIPER 4 WAY X43 RELAY DIFF. LOCK, BRAKE 4WD CONN. 6 WAY CONNECTOR
SM2 POWER BUTTON
H14 KOMATSU LOGO LIGHT S4 BLOWER MOTOR SWITCH X5 CABIN COMMAND 11 WAY CONNECTOR CONNECTOR (ONLY SHUTTLE) XT1 FUEL SHUT OFF TIMER 4 WAY CONNECTOR
SM3 CLOSED GRAB BUTTON
H15 CIGARETTE LIGHTER LAMP (OPTIONAL) S6 TARTING SWITCH X6 SOLENOID VALVES LINE 9 WAY CONNECTOR X25 POWERED BLOWER MOTOR 2 WAY X45 POWER ECONOMY UNIT CONNECTOR XT2 PREHEATING TIMER 4 WAY CONNECTOR
SM4 CONVERTER DECLUTCH BUTTON
H16 CABIN LAMP S10 DECLUTCH BUTTOM X7 NOT CONNECTED 9 WAY CONNECTOR CONNECTOR X48 WINDSHIELD WIPER 4 WAY CONNECTOR XK12 SEAT CONTROL UNIT
SM5 OPENED GRAB BUTTON
H17 FRONT WORKING LAMP S13 BATTERY STOP SWITCH X8 LATERAL DASHBOARD 17 WAY CONNECTOR X26 REAR LINE 8 WAY CONNECTOR X47 12 VOLT CURRENT INTAKE XK13 STOP LIGHT, DIFFERENTIAL LOCK UNIT
SM6 DIFFERENTIAL LOCK BUTTON
H18 FRONT WORKING LAMP S15 HAND BRAKE SWITCH X9 FRONT DASHBOARD 17 WAY X27 VALVES LINE 6 WAY CONNECTOR (BEACON LIGHT)
Y0 FUEL SHUT OFF SOLENOID VALVE
H19 BACON LAMP S16 BRAKE OIL LOW LEVEL SWITCH CONNECTOR X28 JOYSTICK 12 WAY CONNECTOR X48 OPTIONAL TACHOMETER 5 WAY CONN.
Y1 ECONOMY POWER SOLENOID VALVE
H20 REAR WORKING LIGHT S17 BRAKE PRESSURE SWITCH X10 FRONT LIN-ENGINE 13 WAY CONNECTOR X29 CONVERT DECLUTCH BUTTON 2 WAY X49 EGM PROGRAMMING CONNECTOR
Y3 PLATE UNLOCK SOLENOID VALVE
H21 REAR WORKING LIGHT S18 BRAKE PRESSURE SWITCH X11 POWER 2 WAY CONNECTOR CONNECTOR X53 AIR-CONDITION KIT INTERFACE
(ONLY EUROPE VER.)
H22 INDICATORS WARNING LIGHT S19 SEAT SENSOR X12 FRONT LINE-CROSS 2 WAY X30 TRANSFER FUEL PUMP 2 WAY 1 WAY CONN.
Y6 RETURN TO DIG MAGNET
H23 HIGH BEAM WARNING LIGHT S21 ENGINE WATER HIGH CONNECTOR CONNECTOR X59 FRONT LINE-CROSS LINE
Y7 FORWARD SOLENOID VALVE
H24 LOW LEVEL BRAKE OIL WARNING TEMPERATURE SWITCH X16 CONDITIONER CLUTCH 2 WAY X31 CABIN 5 WAY CONNECTOR 6 WAY CONNECTOR
Y8 BACKWARD SOLENOID VALVE
LIGHT S22 AIR FILTER BLOCKED SWITCH CONNECTOR X32 RADIO POWER 2 WAY CONNECTOR X60 OPTIONAL 1 WAY CONNECTOR

WB97R-2 10-113
STRUCTURE AND FUNCTION ELECTRICAL DIAGRAM ATC24

ELECTRICAL DIAGRAM ATC24

X46
N1 4
EV1 OPENED GRAB SOLENOID VALVE V1
R1
G1
3
2
MOTORINO TERGI
1

EV2 CLOSED GRAB SOLENOID VALVE WINDSHIELD WIPER MOTOR

R/N1
EV3 DIFFERENTIAL LOCK SOLENOID VALVE

N1
R-N1

N1

N1
N1

N1

N1

N1

N1

N1

N1

N1
R-N1 M-V1 R/N1

V-N1

V-N1
R/N1

G1

N1
G-R1
R/N1

A-B1
R/N1
A-N1 A4 L1.5 B-R1.5 A-N1

R/N1

R/N1

R/N1

R/N1

R/N1

R/N1

R/N1

R/N1
EV4 REAR 1° BOOM UNLOCK H19

R1
A1
A4 B1 A-N1 A-R1 A-R1 L-G1.5 R/N1

59c R1
MOTORINO TERGI
A-R1
P1 P3 P4 HA2

59c
R1 ACC BR R2 C H36 H37 H38

57

57

L
1 9 2 8 5 10 1 9 2 6 7 9 1 9 1 9 1 9

R
SOLENOID VALVE WINDSHIELD WIPER
MOTOR
1 0 1 0 H9 H10 H11 H12 H13 H14 H22 H23 H24 H25 R1OFFACCST
H1 H2 H3 H4 H5 H6 H7 -
rpm q
-
t∞
- 1 0 2
1
0 1 0 1 0 1 0
M H17 H18 H21 H20
S i S i S i
F1A LOW BEAM FUSE 15A 312612182 + + +

N1 31

N1 31
5 10 4 6 3 1 7 5 10 3 5 10 5 10 5 10 5 10

10
B

9
S3A S4A S6 S1L S2L S3L S4L S5L

M-N1

M-N1

M-N1
G-R1

G-R1
G/N1

A-G1
R-V1

R/N1

H/N1

R/N1
Z-N1

A-V1

B/N1
A/V1
V-N1

Z/B1

L/N1

R1.5
V-B1

V-B1

G1

G1
N1

S1

B1

S1

V1

A/R1
L/B1
B-R1

B/R1

A/N1
G1.5

L/N1

G-N1
B-R1
B-R1

B-R1
F1B RIGHT TRAFFIC LIGHT FUSE 3A

B-G1
B-G1
N1

R1

N1

N1
RIGHT

R10
5 4 3 2 1

X24
F1C LEFT TRAFFIC LIGHT 3A L-B1
H39

5
6
6 5 4 3 2 1 2 1

F2A FUSE 10A ATC24 POWER SUPPLY A-R1

X47
XS
-

R/N1
Z/N1
F2B RADIO, CABIN LAMP, BEACON

G-N1
A-N1

G1
N1

N1
S2A
0
X33

1
R1

LIGHT, CIG. LIGHTER FUSE

2
7
L-G1.5 G-N1
6
A-R1 B-V1
5
A/R1 V1
F2C HAZARD FUSE 10A N1 A-N1
4
3
G1 -

9
B-G1 V-N1

10
2
B-G1 V-N1
F3A STOP LIGHT, SEAT SENS., 1

LEFT

8
Z-N1

N1

N1

N1

N1
N1
N1
N1
N1
N1
N1
N1
DIFF. LOCK FUSE 7.5A 312612066

G-N1

B-G1
6

B-V1
2
R-N1
S37 N1
F3B INSTRUM + WARNING LIGHT + 312612178

X66
X65
7
A-R1
RETURN TO DIG FUSE 7.5A

M-N1
M-N1
B-R1.5
5

G-R1

M1
A-B1

N1
G-N1

A-G1
A-N1

B-R1

R-V1

R/N1

H/N1
B/N1

Z/N1
L/N1

R1.5

Z/B1
L/B1

V-B1
L1.5

G1
R1
R1
N1
N1

A1
G1
N1

V1

S1
TO ADDITIONAL TO ADDITIONAL

1
LIGHTS KIT LIGHTS KIT 885270558
F3C 4x1 BUCKET, RELAY DECLUTCH

S1A
1 0
21201918 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 5 4 3 2 1

TRANSMISSION FUSE 7.5A Z-N1

X31
X17

X26
Z-B1

AIR-CONDITION KIT )
V-N2.5

( REMOVE IT WITH
V1

JUMPER
R/N1
X18

S-G1

C-L1

C-L1
M4 MOTORINO

G/N1
G/N1
A-R1

R-V1
N2.5
B-R1.5

R/N1.5
F4A 4WD VALVE + FR. WINDSHIELD

G-R1
L/N1

A-B1
S10

G-N1

R-G1

A-G1
A-N1

B-N1

H/N1
Z/N1
R1.5

N1.5

Z/B1
L/B1

V-B1
L1.5
X29

G1
R1
R1
N1
N1

A1
G1

V1

S1

A1.5

B1.5

V1.5

N1

N1
N0.5
R-V1 R-V1

N1
L0.5
RISCALDAMENTO

B1

B1
5
M-V1 M-V1 86 87 N1

M1
4 2
L-B1 L-B1 K04 CONNECTED 2 3 4 HEATING MOTOR M/N1
WIPER/WASHER FUSE 7.5A 3 K05 X39 1

V2.5
V2.5
A1 A1 86 87a 87 ONLY 0 1 2
A-B1
2
A-B1 L0.5
S27 WITH 3 Y3 15/1 30/3 L/6
0 1
15/1 30/3 L/6
0 1
15/1 30/3 L/6
1
N0.5
C AIR-CONDITION KIT S3 NON MONTATO
F4B ATC24 POWER RELAY SIGNAL +

Y6
B
85 30 M1 85 30 NOT CONNECTED
A
+ 1
S4

R2.5
2 1 4 3 2 1 49/4 30B/2 R/7 49/4 30b/2 R/7 49/4 30b/2 R/7

R/N1

R/N1
H-G1.5
S2 S1

N0.5
BACK UP ALARM FUSE 7.5A X45

A-N2.5

S-G1

S-G1
1

N1

C-N1
B-N1
B-N1
312612175

V/N1

V/N1
N1
2
312612219

X25

X20
C-N1

N1
SX

3 53S
DX

K06
Z1.5 A-R1 15 I
F4C HIGH BEAM FUSE 15A 4
H-R1
15

V-N2.5
N1

V-N2.5
KC

N2.5
B1.5

A1.5
V1.5
5 85 87a 87 53M 53M
B-N1
T
C/N1
54D

XD2 T
F5A RELAY HEATER MOT. POW/ECO 31
31
L

86 30
49 54S

X19
UNIT, SEAT UNIT FUSE 10A

R4
31

A1 A1
9
312608086

SM2
A-B1 A-B1
8
F5B REAR WORKING LIGHT SWITCH C-B1 N1 N1
V-B1
7
B/V1
H1
C-L1
15

1 1 6 C-N1
G1 A-B1 A/B1 M-V1 M-V1
LIGHTS COLUMN SWITCH

2 2 5
57/58

FUSE 15A V1 R1 C1 R-V1 R-G1

30

A-R1
3 3 4

SM3
V1 V1.5
4
H-N1 G1
4
G-V1.5 G/N1
3
G/N1 X28
56b

5 5 2
F5C FRONT WORKING LIGHT SWITCH 6
N1
R1
A-G1
L1
6
A-G1
L1
G/N1
1
G/N1
12 C/B1

MANIPOLATORE
7 7 11
56a

C-B1 H-N1 H-N1.5 M-V1

8 8 10

SM4

JOYSTICK
A-B1 C-B1 R-N1.5 G-V1
FUSE 15A 9
10
L1
A-G1
9
N1
C-L1
9
8
N1
11 XD1 C-N1
7 M/N1

F6A REAR WINDSHIELD WIPER-WASHER + 12

M-B1
6
5

SM5
M/N1
XD3 C/B1
4

REAR HORN FUSE 15A 3

0

C-B1 C-B1
2
M-N1
1

SM6
F6B LIGHTS SELECTOR + M-V1
M-N1
FRONT RELAY FUSE 7.5A 1
B-R1
B/R1 C-N1
2
F6C DIRECTION LIGHTS FUSE 10A 3
A-N1

1
A1 Y1

JUMPER
4
L1
5
F7A FUSE 7.5A NOT USED 6
7
N1
L/N1
8

2
F7B FRONT HORN FUSE 10A 9
10
R-G1
A/N1
A-G1
N1
ATC24 GEAR UNIT 11
F7C FUEL SHUT OFF FUSE 7.5A 12
A-B1
A/B1
V/N1
EV4

N1.5

N2.5

N2.5
N2.5
L0.5
N1

N1

N1
N1

N1
N1
N1

N1
13

H-G1.5
G-V1.5
R-N1.5

H-N1.5

R/N1.5

B-R1.5
M-N1
H-R1

A-G1

H-N1
H/N1

A-R1
Z/N1
Z/B1

L/N1
R1.5
V1.5

L/B1

V-B1
Z1.5

L1.5
G1
C1
N1

S1

V1
FUG1 KEY SWITCH FUSE 60A X40

M-N1
R-G1

G-R1

G-N1

M-B1

M/N1
G-R1
R-N1

G-V1
A-R1

A-N1

R/N1
B-N1

R-V1

C/N1
Z-N1
A-V1

A/V1

G1.5

Z-B1

H-L1

C-L1
V-N1

G1
R1

S1

B1

A4
A4

B1
X27

G-N1

A-N1
H-L1

R1.5

N2.5
G1

N1

N1
N1
N1
N1
N1
N1
N1
N1 N1 N1
FUG2 PREHATING FUSE 80A 6

X9
X2

X8

X5
V/N1 V/N1

R-V1

A-V1

N1.5
5

N1
H1 C/B1
4
HA3

N1
S15 XC1 H15 C/B1 C/B1 EV2
FUG3 FUEL SHUT OFF POWER FUSE 40A P/N 148852
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 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 1 2 3 4 5 6 7 8 9 10 11 HA4 C-B1
3
2
C-B1

X32

X53
S/N YYWKXX M-N1 M-N1
SW Rel. 2.0
+15 1

FUG4 HEATER MOTOR, Data Set 1.0

N1

N1.5

N1.5
1 2

N1

N1

N1
AIR-CONDITIONING FUSE 40A Customer C-B1

M-V1
H-N1
B-N1

B/R1

L-G1
P/N 148852 K3 EV1
D16 86 87a 87
D5 ALIMENTAZIONE AL KIT
D11

R1
G1 BATTERY

XK13
Madein Italy AUTORADIO CONDIZ.
85 30
312612192

H-G1
H-V1

C/N1

A-R1

B-N1
L/N1

N1.5

H-G1
H-N1
B/V1

H-V1
RADIO TO CONDITIONING
G2 GENERATOR

N1

B2
N1
N1
POWER SUPPLY KIT 31 53M 15 53S T I
K13 M-N1

XK12

X21

X30

X67
H1 PREHEATING WARNING LIGHT U9
EV3

D10
0W

D9
+15 K9
H2 GENERATOR WARNING LIGHT +15

2
53S 53M 31 I 15 T 1 2 3 A B C

1
R K12

D17
K4 N1

B/N1

G1
86 87a 87

B/V1

N1
L1
H3 ENGINE WATER HIGH F3C

R-N1.5
N1

N1.5
C +
F4A F3B F3A
X70

7.5A F2C F6C F5C F2B F5A F5B F6A

K7 7.5A 10A 7.5A 312612068

B2
85 30 K1 K2 K3
TEMPERATURE WARNING LIGHT 0W 10A 10A 15A 15A 10A 15A 15A
86 87 87a 86 87 87a 86 87 87a

H-N1
L-G1

A/N1
B/R1
H-L1
U6 D1 D2 D3

N1

B-N1

A/N1
B/R1
A-V1
H-L1
1 2 3 4 5 6 7 8 9 10 11 12 M5
D8 D7 D6

R10
0W

R4
R31 S19
H4 ENGINE OIL PRESSURE 85 30 85 30 85 30 K1 86 87 87a S24 M
G-M1

G-N1
A-G1
A-N1
A-B1

M0.5

G-L1
N0.5
H0.5

S0.5

D2
L0.5

+15 +15 U10

R1

D13 D12 U4
+30 +15 +15 +30 +15 +15 +15
WARNING LIGHT GEAR SHIFT LEVER 0W 0W
7 6 5 4 3 2 1 6 5 4 3 2 1
D1

X12
B A

X59
X43
85 30

H5 AIR FILTER WARNING LIGHT 4

312612198

B-N1

A/N1
B/R1
A-V1
H-L1
3∞ GEAR

R10
R4
H1
3
SW4
X4
H6 HYDRAULIC OIL FILTER 2∞ GEAR
1
2
1
X7
S-N1
4∞ GEAR 4 2 1
WARNING LIGHT R1

A-N1.5
3 3 2
B1

H/N1
SW3 4 3
2 R1
1 5 4

S1
H7 OPTIONAL WARNING LAMP 1∞ GEAR 1
2
M0.5 6 5
N1

V1
3
L0.5 7 6

V-B1
F 4
H0.5 8 7

H8 OPTIONAL WARNING LAMP NEUTRAL

SW2
N
R
5
6
A0.5
G1
Z1
9
10
8
9
H/N1
A0.5
S22 S23 S21
R32 HA1
7 11
S0.5 D4
H9 ENGINE WATER HIGH FOWARD F
SW1 N
8

F7A
p p t
REVERSE R XD4 D1
TEMPERATURE WARNING LAMP 7.5A t ONLY WITH AIR-CONDITION KIT

N1
312612174

N1.5
N1

N1

N1
H10 CONVERTER OIL HIGH +15 X16 C1
COMPRESSOR
+15
TEMPERATURE WARNING LAMP X10A
F4B +30 +30
N1
A-V1
B
A
N1
A-V1 ELECTROMAGNETIC
G1
1
H11 4WD WARNING LIGHT C-N1
V1
2
3
7.5A F4C F1A CLUTCH
Z1 15A 15A +15

N1.5
4
H12 FUEL RESERVE WARNING LIGHT

N1
N1
N1
N1

N1
N1
D3
K8
312612190 F7C F1C F1B
H13 KOMATSU LOGO LIGHT K6 86 87a 87 K5 86 87a 87
86 87a 87
7.5A 3A 3A
S35

D19
H14 KOMATSU LOGO LIGHT t 85 30 85 30
85 30

S1
K10 86 87a 87 XT2
H15 CIGARETTE LIGHTER LAMP K2

KT2
86 87a 87
D15 N1 1 53S
Y10 2
G/N1 2 15
R-V1
(OPTIONAL) 85 30
F6B F7B
D2 85

F2A
30
X11 M1
3
4 53M
31
R10 R10 R33
H16 CABIN LAMP N1 1 J2 7.5 10A 10A
+30 R4
R4
R4
1
2
R4
R4
100 ohm
1 2 3 P4
H17 FRONT WORKING LAMP Y9
L1
+30 KUE 312612189
2 K01
+15 +15
H18 FRONT WORKING LAMP 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8 9 10 11
SAFETY RELAY

X1
X6

X3

1 2 1
H19 BEACON LAMP N1

R-N1.5
A-N1.5
G-R1
A-G1

H/N1

B-R1

B-N1
B/R1

H-L1

Z/N1
Z-B1
L-B1

N1.5

N1.5
V-B1
M1
M1
G1
B1

B1

S1

V1

X63
H20 REAR WORKING LIGHT G-M1

M1
Y7

B-R1
Z-B1
2 X10

R4
4 3 2 1
H21 REAR WORKING LIGHT A-N1.5
H/N1
S1
1
2
A-N1.5
H/N1
S1
G/N1
G4
1 3
H22 INDICATORS WARNING LIGHT G-N1
X69
V1
R-N1.5
4
V1
R-N1.5

B-R1
B-N1
Z/N1
5

N1
V-B1 V-B1
6
X60

A-B1 Z/N1 Z/N1

H23 HIGH BEAM WARNING LIGHT Y8 2
G-L1
L1
L0.5
20
19
B-R1
Z-B1
7
8
B-R1
Z-B1
S-N1

18 9
H1 M-V1 M-V1
H24 LOW LEVEL BRAKE OIL 1
H0.5
A0.5
17
16
15
B-N1
R-V1
10
11
12
B-N1
R-V1
A-G1 M1 A-V1 A-V1
K1
WARNING LIGHT M0.5
S1
14
13
12
K4 86 87 87a 86 87 87a
K2
86 87 87a
13

H1 S0.5 D7 D8
H25 DIFFERENTIAL LOCK WARNING Y12 2
N1
H/N1
11
10
9 R30
G1 85 30 85 30 85 30

LIGHT 8
A-B1
G-R1

R1
7
R1
M1

M1
G1
B1

B1
SCHEMA ELETTRICO "MINOR CHANGE" WB97R ATC24 CABIN m/c

A1
1 6
N1 A-N1
A-G1

S-N1

B-N1
A/N1

L-B1
5
H28 RIGHT FRONT LIGHT
X35

X34
N1

N1

N1
N1
4
V1 S-N1
3
Y13 B1
N1.5
N1.5
N1.5
N1.5

2 2

M10
X23

X22
H29 LEFT FRONT LIGHT
N1
N1

G1 S16 S18 S17

1 1 2 3 4 5 6 1 2 3 4 5 6

R4
R4

R4
R4
H36 REAR RIGHT SIDE LIGHT, l -
312612175

N1.5

N2.5

N2.5
1 1 2

M10
R10

M1
N1
N1

M-V1
D1 D2 D3 D4
B-N1

B-N1

K3

56b
56a
N1

86 87 87a

57
DIRECTION LIGHT, SIDE LIGHT K02

R
M1
56b
56a

H29 H28
57
L

Y11 2 D9 POMPETTA FUG1 FUG2 FUG3 FUG4

OPTIONAL LAVAVETRO 86 87
60A 80A 40A 40A
H37 REAR LEFT SIDE LIGHT, 85 30 D5 D6

31
31

85 30
1 WINSHIELD
N1 K14
DIRECTION LIGHT, SIDE LIGHT CIAM 01171014

M10
WASHER PUMP

N1
H38 COURTESY LIGHT

Z-B1
R1
R70
XT1
H39 PLATE LIGHT X24 WINDSHIELD WIPER 4 WAY X46 WINDSHIELD WIPER 4 WAY

Z/N1

KT1
R10

R10
G4
N1 53S
312612191 S13 - l
B-R1
1
2 53M
G1
HA1 HORN CONNECTOR CONNECTOR B/R1 3
4 31

XA
15

HA2 BUZZER X25 POWERED BLOWER MOTOR X47 12 VOLT CURRENT INTAKE M1 G2

N1.5
N1

N1

N1

N1
R70
30 50 D+
M

B/R1
Y7 FOWARD SOLENOID VALVE X9 FRONT DASHBOARD 17 WAY

B2.5
HA3 REAR HORN KT1 FUEL SHUT OFF TIMER S10 DECLUTCH BUTTON S2L WINDSHIELD WIPER- WASHER 2 WAY CONNECTOR (BEACON LIGHT) 3
30
G W
K03
G1
HA4 BACK-UP ALARM KT2 PREHEATING TIMER S13 BATTERY STOP SWITCH SWITCH ON LAT. DASHBOARD Y8 BACKWARD SOLENOID VALVE CONNECTOR X26 REAR LINE 8 WAY CONNECTOR X53 AIR-CONDITION KIT 31
U
86 87

12Vcc

K01 STARTER RELAY M1 STARTER MOTOR S15 HAND BRAKE SWITCH S3A FRONT WORKING LIGHT SWITCH Y9 3° SPEED VALVE X10 FRONT LINE-ENGINE LINE 13 WAY X27 VALVES LINE 6 WAY CONNECTOR INTERFACE 1 WAY CONN. 85 30

G1

R4
K02 PREHEATING RELAY M2 WASHER PUMP S16 BRAKE OIL LEVEL SWITCH ON FRONT DASHBOARD Y10 1° SPEED SOLENOID VALVE CONNECTOR X28 JOYSTICK 12 WAY CONNECTOR X59 FRONT LINE-CROSS LINE

N70
K03 FUEL SHUT OFF RELAY M3 WINDSHIELD WIPER MOTOR S17 BRAKE PRESSURE SWITCH S3L BEACON SWITCH ON Y11 2° SPEED SOLENOID VALVE X10A FUSE UNIT-ATC24 INTERFACE 4 X29 CONVERT DECLUTCH BUTTON 6 WAY CONNECTOR XAM
N1.5 N1.5
Y0
(PULL SOLENOID) M4 BLOWER MOTOR S18 BRAKE PRESSURE SWITCH LAT. DASHBOARD Y12 4° SPEED SOLENOID VALVE WAY CONN. 2 WAY CONNECTOR X60 OPTIONAL 1 WAY CONNECTOR R-N1.5
B2.5
1
2
3
R-N1.5
B1.5

K04 3° SPEED BLOWER RELAY M5 TRANSFER FUEL PUMP S19 SEAT SENSOR S4A WARNING SWITCH ON Y13 4WD SOLENOID VALVE X11 POWER 2 WAY CONNECTOR X30 TRANSFER FUEL PUMP X63 ALTERNATOR RESISTANCE
M9
(ONLY A/C CABIN VERSION) M8 WINDSHIELD WIPER MOTOR S21 ENGINE WATER HIGH FRONT DASHBOARD C1 COMPRESSOR X12 FRONT LINE-CROSS LINE 2 WAY 2 WAY CONNECTOR CONNECTOR XM9
N1 M
K05 RETURN TO DIG RELAY M9 FUEL PUMP TEMPERATURE SWITCH S4L HORN SWITCH ON LAT. ELECTROMAGNETIC CLUTCH CONNECTOR X31 CABIN 5 WAY CONNECTOR X65 OPTIONAL LIGHT CONNECTOR R-N1
-
+

K06 POWER ECONOMY UNIT P1 RPM INSTRUMENT S22 AIR FILTER BLOCKED SWITCH DASHBOARD XC1 CIGARETTE LIGHTER SOCKET X16 CONDITIONER CLUTCH 2 WAY X32 RADIO POWER 2 WAY X66 OPTIONAL LIGHT CONNECTOR
KC LOAD FAN HEATER RELAY P2 HOUR COUNTER S23 ENGINE OIL LOW S5L OPTIONAL SWITCH ON LAT. X1 FRONT LINE (ENGINE) CONNECTOR CONNECTOR X67 SEAT SENSOR 3 WAY CON-
K2 REVERSE SPEED RELAY P3 FUEL LEVEL INDICATOR PRESSURE SWITCH DASHBOARD 11 WAY CONNECTOR X17 LATERAL DASHBOARD 21 WAY X33 WINDSHIELD WIPER AND NECTOR
K3 4 WHEELS DRIVE RELAY P4 WATER TEMPERATURE INSTRUMENT S24 FUEL GAUGE SM2 POWER BUTTON X2 LIGHTS SWITCH AND GEAR SHIFT CONNECTOR BEACON 7 WAY CONNECTOR X69 ATC24 DIODE UNIT
K4 GEAR NEUTRAL POSITION RELAY R30 HEATING START S27 NPN SENSOR SM3 CLOSED GRAB BUTTON LINE 9 WAY CONNECTOR X18 FRONT CABLE 5 WAY X34 RIGHT FRONT BEAM 6 WAY CONNECTOR
(SHIFT ONLY) R31 FUEL LEVEL SENDER S35 CONVERT. OIL HIGH SM4 CONVERTER DECLUTCH BUTTON X3 FRONT LINE 11 WAY CONNECTOR CONNECTOR CONNECTOR X70 ATC24 GEAR UNIT XD3 LIGHTS SWITCH 12 WAY XT2 PREHEATING TIMER
K5 LOW BEAM RELAY R32 WATER TEMPERATURE SENDER TEMPERATURE SWITCH SM5 OPENED GRAB BUTTON X4 (4WS MONITOR 11 WAY CONNECTOR) X19 FRONT DASHBOARD 9 WAY X35 LEFT FRONT BEAM 6 WAY CONNECTOR CONNECTOR 4 WAY CONNECTOR
K6 MAIN BEAM RELAY R33 ALTERNATOR LAMP RESISTANCE S37 REAR DOOR SWITCH SM6 DIFFERENTIAL LOCK BUTTON X5 CABIN COMMAND 11 WAY CONNECTOR CONNECTOR XA GENERATOR 2 WAY XD4 GEAR SHIFT 8 WAY XK12 SEAT CONTROL UNIT
K8 FRONT HORN RELAY S1 ECONOMY POWER PUSH BUTTON S1A 4WD SWITCH ON FRONT Y0 FUEL SHUT OFF SOLENOID VALVE CONNECTOR X20 BLOWER MOTOR 4 WAY X39 PROXIMITY 3 WAY CONNECTOR CONNECTOR CONNECTOR(ATC24) XK13 STOP LIGHT DIFFERENTIAL
K9 FLASHER UNIT S2 REAR 1°BOOM UNLOCK SWITCH DASHBOARD Y1 ECOMOMY POWER X6 SOLENOID VALVES LINE 9 WAY CONNECTOR X40 FLAHSER UNIT 13 WAY XAM FUEL SHUT OFF VALVE 3 WAY XM9 FUEL PUMP 2 WAY LOCK UNIT
K10 ATC24 UNIT POWER RELAY S3 PLATE UNLOCK SWITCH S1L REAR WORKING LIGHT SWITCH SOLENOID VALVE CONNECTOR X21 FUEL LEVEL INDICATOR 3 WAY CONNECTOR CONNECTOR CONNECTOR
K12 SEAT UNIT (ONLY EUROPE VERS.) ON LAT. DASHBOARD Y3 PLATE UNLOCK SOLENOID VALVE X7 NOT CONNECTED 9 WAY CONNECTOR X43 RELAY DIFF. LOCK BRAKE XD1 LIGHTS SWITCH 9 WAY XS MULTIFUNCTION INSTRUMENT
K13 STOP LIGHT, DIFF. LOCK UNIT S4 BLOWER MOTOR SWITCH S2A WINSHIELD WIPER-WASHER (ONLY EUROPE VERS.) CONNECTOR X22 WINDSHIELD WASHER PUMP 4WD 2 WAY AMP CONNECTOR 6 WAY CONNECTOR
K14 ATC24 DIODE UNIT S6 STARTING SWITCH SWITCH ON FRONT DASHBOARD Y6 RETURN TO DIG MAGNET X8 LATERAL DASHBOARD 17 WAY 2 WAY CONNECTOR X45 POWER ECONOMY UNIT XD2 GEAR SHIFT 5 WAY XT1 FUEL SHUT OFF TIMER
CONNECTOR X23 OPTIONAL 2 WAY CONNECTOR CONNECTOR CONNECTOR 4 WAY CONNECTOR
WB97R-2 10-115
 TESTING AND ADJUSTMENTS

NORMAL OR STANDARD TECHNICAL DATA..............2 CHECKING AND CALIBRATING THE

SPECIAL TOOLS..........................................................25 SERVO CONTROL FEED VALVE (Optional) .............. 55
MEASURING ENGINE SPEED ....................................26 TESTING BRAKE SYSTEM ......................................... 56
ADJUSTING VALVE CLEARANCE ..............................27 CONTROL OF THE ENGINE SPEED
MEASURING COMPRESSION PRESSURE................31 UNDER LOAD .............................................................. 58
TESTING AND ADJUSTING FUEL INJECTION TESTING PRESSURES IN THE
TIMING..........................................................................33 POWER TRAIN GROUP .............................................. 60
CHECKING AND TIGHTENING THE FAN - BELT.......35 TESTING THE CORRECT FUNCTIONING
OF THE POWER TRAIN CLUTCHES.......................... 62
CHECKING AND TIGHTENING THE
COMPRESSOR FAN - BELT........................................36 ADJUSTING THE SENSOR FOR
RETURN TO DIG DEVICE........................................... 63
MEASURING ACCELERATOR PEDAL OPERATING
TRAVEL AND ACCELERATOR LEVER.......................37 ANALYSIS OF CAUSES HYDRAULIC DRIFT............. 64
ADJUSTING BRAKE PEDAL TRAVEL, TESTING THE AIR-CONDITIONING UNIT.................. 69
BRAKE ALIGNMENT ....................................................39 EMPTYING THE AIR-CONDITIONING UNIT .............. 71
AIR BLEEDING - RELEASING RESIDUAL FRONT AXLE TROUBLESHOOTING.......................... 74
PRESSURE ..................................................................40 REAR AXLE TROUBLESHOOTING ............................ 79
CHECKING AND SETTING PRESSURE IN TRANSMISSION TROUBLESHOOTING ..................... 84
THE ATTACHMENTS HYDRAULIC CIRCUIT..............43 CHECKING AND INSPECTION OF
TESTING AND ADJUSTING OF LOAD THE ELECTRONIC CONTROL UNIT .......................... 87
SENSING SIGNAL (LS VALVE) ...................................49
TESTING AND ADJUSTING OF
UNLOADING VALVE ....................................................50
CHECKING UNLOADING VALVE
FUNCTIONALITY..........................................................51
TESTING PRIORITY VALVE OPERATION..................52
TESTING AND SETTING STEERING
CONTROL SYSTEM PRESSURE ................................54

When carrying out controls, adjustments or analyses for troubleshooting, park the machine on firm, level ground.
Apply all the machine safety devices and use blocks to prevent any machine movement.
When more than one person is engaged in the work, use the prescribed notices that indicate that the machine is un-
dergoing maintenance. Do not allow any unauthorised persons to remain in the vicinity.
When checking the level of the cooling liquid, wait until this liquid has cooled. If the radiator cap is removed while the
liquid is still hot and under pressure, it may cause severe burns.
Take great care not to get entangled in moving parts (fan, alternator belt or any of the rotating elements).

WB97R-2 20-1
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA

NORMAL OR STANDARD TECHNICAL DATA

FOR ENGINE

Machine model WB97R-2

Standard Permissible
Check item Test conditions Unit
value value
High idling rpm 2350±50 2300–2400
Engine speed Low idling rpm 1050±50 1000–1100
Set speed rpm 2050±100 --
Exhaust gas Sudden acceleration Bosch
4.0 4.0
colour At high idling speed index
Intake valve (20°C) mm 0.25±0.10 Max. 0.35
Valve clearance
Exhaust valve (20°C) mm 0.25±0.10 Max. 0.35
Compression
Oil temperature 69 – 72°C bar 34.3±1 27.5±1
pressure
(Engine speed) rpm 250 250
(SAE30 oil)
Max. idling (in cold state) bar – –
Engine oil
At set speed bar 4.4 –
pressure
At low idling bar 0.6 –
Oil
Entire speed range °C 120 Max. 120
temperature
Fuel injection
B.T.D.C. degrees 12.5 11.5–13.5
timing
Fan belt Deflection when pressed with finge force
mm 10 10–15
tension of approx. 10 kg

20-2 WB97R-2
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA

FOR STANDARD MACHINE

Machine model WB97R-2

Classifi- Standard Permissible
Check item Test conditions Unit
cation value value

Max. 2350±50 2300–2400

• Hydraulic oil temperature: 45 – 55 °C
• Converter oil temperature: 80 °C
Accelerator pedal
• Engine oil temperature cooling circuit:
in the limits
Engine speed

Min. 1050±50 1000–1100

rpm

Max. 1900±50 1850–1950

• Hydraulic oil temperature: 45 – 55 °C
• Converter oil temperature: 80 °C
Accelerator fuel
• Engine oil temperature cooling circuit:
in the limits
Min. 1050±50 1000–1100

All controls ᐉ ᐉ a b c ᐉ a b c
(front bucket and
Control valve

a b c
backhoe) 41.5 8 8 -- -- -- -- --
mm
For front shovel arm
command only 41.5 8 8 -- -- -- -- --
(with floating arm) RKZ02580

Front bucket tilt lever Raise

Neutral 75 60–90
control Lower
Front bucket control Dump
Neutral 85 70–100
lever Curled
Boom backhoe control Raise
Neutral 100 90–110
lever Lower
Arm backhoe control Opening
Travel of levers and pedals

• Engine stopped Neutral 100 90–110

lever Closing
• Knob lever:
Bucket backhoe control at the center and at Opening
Neutral 100 90–110
lever 90° from the lever Closing
• Value reading
Boom swing mm
at the end of Right
backhoe working stroke Neutral 100 90–110
Left
control lever + half clearance
• Attachments
Outriggers control on the ground Up
Neutral 50 40–60
lever Down
Fuel control
Min. Max. 70 55–85
lever
Jig arm control Out 55±5.5 49.5–60.5
Neutral
pedal In 55±5.5 49.5–60.5
Hammer and side digging Right 55±5.5 49.5–60.5
Neutral
boom control pedal Left 55±5.5 49.5–60.5

WB97R-2 20-3
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA

FOR STANDARD MACHINE

Machine model WB97R-2

Classifi- Standard Permissible
Check item Test conditions Unit
cation value value
Travel of levers and

• Engine stopped
Accelerator pedal • Knob lever: Min. Max. mm 70 55–85
at the center and at 90°
pedals

from the lever

• Value reading at the end
of working stroke Right Left
Wheel swing • Attachments rev. Max. 5 5
Left Right
on the ground

Front bucket tilt lever • Tool connection at the centre of knob

and at 90° from the lever. 2.5 1.5–3.5
control
• Value reading at the 10 mm before end of
working stroke.
Front bucket control
• Distance between knob and casing: 95 mm 1.7 1.2–2.2
lever

Boom control
1.6 1–2.2
Force for levers and pedals operation

lever
Arm control
• Engine speed: min. 1.6 1–2.2
lever
• Oil temperature: 45 – 55 °C
Bucket control lever • Tool connection at the centre of knob 1.6 1–2.2
and at 90° from the lever.
Boom swing • Tool connection on edge kg 1.6 1–2.2
control lever (for pedals)
• Value reading at the 10 mm before end of
Outriggers control working stroke. 3.8 2.3–5.3
lever
Fuel control
4 3–5
lever
In 2±0.2 1.9–2.2
Jig arm control pedal
Out 2±0.2 1.9–2.2
Hammer and side digging
8 6–10
boom control pedal
Accelerator pedal 4 2.5–5.5

20-4 WB97R-2
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA

FOR STANDARD MACHINE

Machine model WB97R-2

Classifi- Standard Permissible

Check item Test conditions Unit
cation value value

2-3-Spool control valve 205 205±10

Main valve pressure

• Engine speed: max.

• Oil temperature: 45 – 55 °C
• Without steering
bar
6-7-8-Spool control valve 205 200±10

Steering unit • Engine speed: 1500±50 rpm 175 175±10

Front bucket
235 235±10
(curled)

Front bucket
185 185±10
(dump)
Pressures of secondary valves circuits

Attachment
235 235±10
(3rd spool)

Boom
300 303±10
(raising)
• Engine speed: min.
• Oil temperature: 45 – 55 °C
Boom (lowering) bar 235 235±10
• Check one circuit at the time
Arm (Closing) • Pump: Economy 235 235±10

Boom swing 245 245±10

Bucket (curled) 235 235±10

Side digging boom

275 275±10
(right-left)

Hammer (delivery) 170 170±10

Steering unit (safety) 240 240±7

WB97R-2 20-5
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA

FOR STANDARD MACHINE

Machine model WB97R-2

Classifi- Standard Permissible
Check item Test conditions Unit
cation value value

• Engine speed (without load): 2350±50

• Hydraulic oil temperature: 45 – 55 °C
With converter • Converter oil temperature: 80°C 2200±50 2150–2250
• Machine in 4th gear
• Working brakes applied
Engine speed (with load) - Converter

• Engine speed (without load): 2350±50

• Hydraulic oil temperature: 45 – 55 °C
• Converter oil temperature: 80°C
With converter and
• Machine in 4th gear 2050±50 1950–2150
hydraulic circuit • Working brakes applied
• Front bucket curled stop
• Steering at the end of stroke
rpm

• Engine speed (without load): 2350±50

• Hydraulic oil temperature: 45 – 55 °C
With converter
• Converter oil temperature: 80°C 2200±50 2150–2250
(TBG version) • Machine in 3rd gear
• Working brakes applied

• Engine speed (without load): 2350±50

With converter and • Hydraulic oil temperature: 45 – 55 °C
• Converter oil temperature: 80°C
hydraulic circuit 2050±50 1950–2150
• Machine in 3rd gear
(TBG version) • Working brakes applied
• Front bucket curled stop

20-6 WB97R-2
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA

★ The technical data of follow table are refered to a machine with max 500 kg shovel bucket, 600 mm (max. 160 kg)
backhoe bucket and standard arm (or jig arm) closed.
FOR STANDARD MACHINE

Machine model WB97R-2

Classifi- Standard Permissible
Check item Test conditions Unit
cation value value

Complete working
Measuring posture
equipment
250 250
(Tip lowering of ~10°
bucket teeth)
Front bucket

RKZ00530
Cylinders • In this position check in feedback of each cylinder
and the leakage with applied load on the tip of mm
24 24
(cylinder in)
bucket teeth.
• Ground level.
• Bucket: normal load (1500 kg)
• Engine stopped
• Oil temperature: 45 – 55°C
Bucket cylinder • Check measures as soon as engine
10 10
(cylinder in) stops.
• Check changes every 5 min. and the total change
in 15 min

Complete working
Measuring posture
Hydraulic drift working equipment

equipment
325 325
(Tip lowering of
bucket teeth)

1m 1m
Boom cylinders
RKZ08130
24 24
(cylinder out)
• In this position check the extension of each cyl-
inder and the leakage with normal load on the
bucket.
Arm cylinder • On level ground. 13 13
(cylinder out) • Bucket: normal load (450 kg)
• Engine stopped
• Oil temperature: 45 – 55°C
Bucket cylinder • Check measures as soon as engine stops.
Backhoe

• Check changes every 5 min. and the total change 10 10

(Cylinder in) mm
in 15 min.

Measuring posture

Jig arm cylinder 2 2

RKZ08140

• Jig arm : at max. extension

• No load

WB97R-2 20-7
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA

★ The technical data of follow table are refered to a machine with max 500 kg shovel bucket, 600 mm (max. 160 kg)
backhoe bucket and standard arm (or jig arm) closed.
FOR STANDARD MACHINE

Machine model WB97R-2

Classifi- Standard Permissible
Check item Test conditions Unit
cation value value
Measuring posture

RKZ02670

Boom swing 20 30
• Oil temperature: 45 – 55 °C
• Backhoe balanced on the guides bucket in trans-
port condition.
• Arm and bucket cylinder in. Put the bucket link pin
at 1 meter from ground and swing at end of boom
stroke in one of the two direction.
Hydraulic drift working equipment

• Move the machine on a chute of 15° and apply the

parking brake.
• Stop the engine and, after 1 minute, check the in-
ner cylinder feed back opposite to the boom every
5 min. for a total of 15 minutes.
Backhoe

• Eseguire la prova per i due sensi di

rotazione mm

Measuring posture

Outriggers Max 5 5
RKZ00490

• Oil temperature: 45 – 55 °C
• Backhoe balanced.
• Boom and arm cylinders in,
bucket cylinder out
• Outriggers at maximum extension.
• Engine stopped.
• Check the frame lowering for each side every 5
min. for a total of 15 minutes.

20-8 WB97R-2
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA

★ The technical data of follow table are refered to a machine with max 500 kg shovel bucket, 600 mm (max. 160 kg)
backhoe bucket and standard arm (or jig arm) closed.
FOR STANDARD MACHINE

Machine model WB97R-2

Classifi- Standard Permissible
Check item Test conditions Unit
cation value value

2.0
Front bucket

Boom Max. 8.0

(each cylinder)

1.6
Bucket Max. 6.0
(each cylinder)

Boom 3.3 Max. 13.5

Arm 3.0 Max. 12.0

• Engine: Max. speed
Cylinder leaking

• Oil temperature: 45--55°C

• Leaking check: on the cylinder opposite side to the
cm³/
Bucket pressure one. 2.4 Max. 9.5
• Check 1 cylinder at a time. min
• For tilt front bucket, front bucket and for swing,
Backhoe

check the two cylinders separately.

Boom swing 3.2 Max. 13.0

Outrigger 3.3 Max. 13.5

Side digging boom 2.0 Max. 8.0

Jig arm 1.6 Max. 6.0

WB97R-2 20-9
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA

★ The technical data of follow table are refered to a machine with max 500 kg shovel bucket, 600 mm (max. 160 kg)
backhoe bucket and standard arm (or jig arm) closed.
FOR STANDARD MACHINE

Machine model WB97R-2

Classifi- Standard Permissible
Check item Test conditions Unit
cation value value
Measuring posture
Tilt lever front

Raised
bucket 3.5 3.2–3.8

Cylinders
extended out

Lowered
RKZ07510
2.6 2.3–2.9
Bucket on
Front bucket

• Engine speed: Max.

level ground • Oil temperature: 45 – 55°C
• Speed up
Measuring posture

Curled
Bucket 2.5 2.1–2.9

Cylinder out

RKZ00510
Dump

Cylinder in • Engine speed: Max.

3.2 2.8–3.6
• Oil temperature: 45 – 55°C
• Speed up

Measuring posture
Lifting ●
Work equipment speed

Boom
2.6 2.3–2.9

Cylinder in
sec.
Lowered

Teeth bucket on level RKZ00430

• Engine speed: 1800 +0 50 rpm 2.2 1.8–2.6
ground • Oil temperature: 45 – 55°C
• Backhoe balanced
• Power mode
Measuring posture
Opening

Arm 3.4 3–3.8

Backhoe

Cylinder in
Closing ●

RKZ00440
Cylinder out • Engine speed: 1800 +0 50 rpm 4.4 4–4.8
• Oil temperature: 45 – 55°C
• Backhoe balanced
• Power mode

Measuring posture
Dump

Bucket 2.2 1.8–2.6

Cylinder in
RKZ08150
Curled

Cylinder out • Engine speed: 1800 +0 50 rpm

• Oil temperature: 45 – 55°C 3 2.6–3.4
• Backhoe balanced
• Power mode

20-10 WB97R-2
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA

★ The technical data of follow table are refered to a machine with max 500 kg shovel bucket, 600 mm (max. 160 kg)
backhoe bucket and standard arm (or jig arm) closed.
FOR STANDARD MACHINE

Machine model WB97R-2

Classifi- Standard Permissible
Check item Test conditions Unit
cation value value
Measuring posture

Right ●
3.6 2.9–4.3
Work equipment speed

Boom swing
Backhoe

Right end travel sec.

Left end travel RKZ02670

Left ●
0
• Engine speed: 1800 + 50 rpm 3.6 2.9–4.3
• Oil temperature: 45 – 55°C
• Arm horizontal
• Power mode

● This time are refered to the cylinder stroke whitout the brake phase.

NOTE. The engine speed (1800 +0 50 rpm) has to be checked with the procedure described at paragraph
«MEASURING ENGINE SPEED» in this section.

WB97R-2 20-11
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA

★ The technical data of follow table are refered to a machine with max 500 kg shovel bucket, 600 mm (max. 160 kg)
backhoe bucket and standard arm (or jig arm) closed.
FOR STANDARD MACHINE

Machine model WB97R-2

Classifi- Standard Permissible
Check item Test conditions Unit
cation value value
Measuring posture

Raising
3.5±0.3 Max. 3.5
Tilt lever front
bucket
Lowering
RKZ00500 2.6±0.3 Max. 2.6

• Engine speed: Min.

• Oil temperature: 45 – 55°C
• Check the time necessary to lift bucket from level
ground.

Measuring posture
Work equipment speed

Time lags

Boom sec. 2 Max. 2

RKZ00460

• Engine speed: Min.

• Oil temperature: 45 – 55°C
• With attachments fully extended, lower the boom
and check the necessary time from the beginning
of machine lifting until bucket is on level ground.

Measuring posture

45°

Arm 2 Max. 2
RKZ00471

• Engine speed: Min.

• Oil temperature: 45 – 55°C
• Put boom at 45°, open completely the arm with
curled bucket. Extend arm cylinder and check the
time passing between arm stop at dead centre and
the restart movement.

20-12 WB97R-2
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA

★ The technical data of follow table are refered to a machine with max 500 kg shovel bucket, 600 mm (max. 160 kg)
backhoe bucket and standard arm (or jig arm) closed.
FOR STANDARD MACHINE

Machine model WB97R-2

Classifi- Standard Permissible
Check item Test conditions Unit
cation value value
Measuring posture

Bucket 2 Max. 2
RKZ00480

• Engine speed: Min.

• Oil temperature: 45 – 55°C
• Put arm in horizontal position. Tilt back bucket cyl-
inder an then extend it.
Work equipment

Check the time passing between bucket stop at

Time lags

dead centre and the restart movement.

Measuring posture sec.

Outriggers 0 Max. 2
RKZ00520

• Engine speed: Min.

• Oil temperature: 45 – 55°C
• Boom, arm and bucket fully retracted and putted in
machine centre position.
• Check the time necessary for outriggers to raise
the machine from when they lean on level ground.
• Check each outrigger at a time.

WB97R-2 20-13
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA

FOR MACHINE WITH SERVOCONTROL

Machine model WB97R-2

Classifi- Standard Permissible
Check item Test conditions Unit
cation value value

Max. 2375±50 2325–2425

• Hydraulic oil temperature: 45 – 55 °C
• Converter oil temperature: 80 °C
Accelerator pedal
• Engine oil temperature cooling circuit:
in the limits
Engine speed

Min. 1050±50 1000–1100

rpm

Max. 1900±50 1850–1950

• Hydraulic oil temperature: 45 – 55 °C
• Converter oil temperature: 80 °C
Accelerator fuel
• Engine oil temperature cooling circuit:
in the limits
Min. 1050±50 1000–1100

All controls ᐉ ᐉ a b c ᐉ a b c
(front bucket and
Control valve

a b c
backhoe) 41.5 8 8 -- -- -- -- --
mm
For front shovel arm
command only 41.5 8 8 -- -- -- -- --
(with floating arm) RKZ02580

Front bucket tilt lever Raise

Neutral 100 90–110
control Lower
Front bucket control Dump
Neutral 100 90–110
lever Curled
Travel of levers and pedals

• Engine stopped
Boom backhoe control Raise
• Knob lever: Neutral 55 49.5–60.5
lever at the center and at Lower
Arm backhoe control 90° from the lever Opening
• Value reading Neutral 55 49.5–60.5
lever Closing mm
at the end of
Bucket backhoe control working stroke Opening
+ half clearance Neutral 55 49.5–60.5
lever Closing
• Attachments
Boom swing on the ground
Right
backhoe Neutral 55 49.5–60.5
Left
control lever
Fuel control
Min. Max. 70 55–85
lever

20-14 WB97R-2
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA

FOR MACHINE WITH SERVOCONTROL

Machine model WB97R-2

Classifi- Standard Permissible
Check item Test conditions Unit
cation value value
Travel of levers and

• Engine stopped
Accelerator pedal • Knob lever: Min. Max. mm 70 63–77
at the center and at 90°
pedals

from the lever

• Value reading at the end
of working stroke Right Left
Wheel swing • Attachments rev. Max. 5 5
Left Right
on the ground

Front bucket tilt lever • Tool connection at the centre of knob

2.5 1.9–3.1
Force for levers and pedals operation

control and at 90° from the lever.

• Value reading at the 10 mm before end of
Front bucket control working stroke.
2.5 1.9–3.1
lever • Distance between knob and casing: 95 mm

Boom control
2 1.8–2.2
lever
• Engine speed: min. kg
Arm control
• Oil temperature: 45 – 55 °C 2 1.8–2.2
lever
• Tool connection at the centre of knob
Bucket control lever and at 90° from the lever. 1.4 1.3–1.5
• Value reading at the 10 mm before end of
Boom swing working stroke. 1.4 1.3–1.5
control lever
Fuel control lever 8 6–10

WB97R-2 20-15
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA

FOR MACHINE WITH SERVOCONTROL

Machine model WB97R-2

Classifi- Standard Permissible
Check item Test conditions Unit
cation value value

2-3-Spool control valve 200 200±7

Main valve pressure

• Engine speed: max.

• Oil temperature: 45 – 55 °C
• Without steering
bar
6-7-8-Spool control valve 200 200±7

Steering unit • Engine speed: 1500±50 rpm 175 175±7

Front bucket
235 235±7
(curled)
Front bucket
175 175±7
Pressures of secondary valves circuits

(dump)
Attachment
235 235±7
(3rd spool)
Boom
305 305±7
(raising) • Engine speed: min.
• Oil temperature: 45 – 55 °C
Boom (lowering) bar 235 235±7
• Check one circuit at the time
Arm (Closing) • Pump: Economy 235 235±7
Boom swing 245 245±7
Bucket (curled) 235 235±7
Side digging boom
275 275±7
(right-left)
Hammer (delivery) 165 165±7
Steering unit (safety) 240 240±7

20-16 WB97R-2
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA

FOR MACHINE WITH SERVOCONTROL

Machine model WB97R-2

Classifi- Standard Permissible
Check item Test conditions Unit
cation value value

• Engine speed (without load): 2350±50

• Hydraulic oil temperature: 45 – 55 °C
With converter • Converter oil temperature: 80°C 2275±50 2225–2525
• Machine in 4th gear
• Working brakes applied
Engine speed (with load) - Converter

• Engine speed (without load): 2350±50

• Hydraulic oil temperature: 45 – 55 °C
• Converter oil temperature: 80°C
With converter and
• Machine in 4th gear 2250±50 2200–2300
hydraulic circuit • Working brakes applied
• Front bucket curled stop
• Steering at the end of stroke
rpm

• Engine speed (without load): 2350±50

• Hydraulic oil temperature: 45 – 55 °C
With converter
• Converter oil temperature: 80°C 2275±50 2225–2525
(TBG version) • Machine in 3rd gear
• Working brakes applied

• Engine speed (without load): 2350±50

With converter and • Hydraulic oil temperature: 45 – 55 °C
• Converter oil temperature: 80°C
hydraulic circuit 2250±50 2200–2300
• Machine in 3rd gear
(TBG version) • Working brakes applied
• Front bucket curled stop

WB97R-2 20-17
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA

★ The technical data of follow table are refered to a machine with max 500 kg shovel bucket, 600 mm (max. 160 kg)
backhoe bucket and standard arm (or jig arm) closed.
FOR MACHINE WITH SERVOCONTROL

Machine model WB97R-2

Classifi- Standard Permissible
Check item Test conditions Unit
cation value value
Measuring posture
Complete working
equipment
250 250
(Tip lowering of ~10°
bucket teeth)
Front bucket

RKZ00530
Cylinders • In this position check in feedback of each cylinder
and the leakage with applied load on the tip of mm 24 24
(cylinder in)
bucket teeth.
• Ground level.
• Bucket: normal load (1500 kg)
• Engine stopped
• Oil temperature: 45 – 55°C
Bucket cylinder • Check measures as soon as engine
10 10
(cylinder in) stops.
• Check changes every 5 min. and the total change
in 15 min

Complete working Measuring posture

equipment
Hydraulic drift working equipment

300 300
(Tip lowering of
bucket teeth)

Boom cylinders 1m 1m
24 24
(cylinder out) RKZ08130
• In this position check the extension of each cyl-
inder and the leakage with normal load on the mm
bucket.
Arm cylinder • On level ground.
• Bucket: normal load (450 kg) 13 13
(cylinder out)
• Engine stopped
• Oil temperature: 45 – 55°C
• Check measures as soon as engine stops.
Backhoe

Bucket cylinder • Check changes every 5 min. and the total change
in 15 min. 10 10
(Cylinder in)

Measuring posture

Jig arm cylinder 2 2

RKZ08140

• Jig arm : at max. extension

• No load

20-18 WB97R-2
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA

★ The technical data of follow table are refered to a machine with max 500 kg shovel bucket, 600 mm (max. 160 kg)
backhoe bucket and standard arm (or jig arm) closed.
FOR MACHINE WITH SERVOCONTROL

Machine model WB97R-2

Classifi- Standard Permissible
Check item Test conditions Unit
cation value value
Measuring posture

RKZ02670

Boom swing 20 30
• Oil temperature: 45 – 55 °C
• Backhoe balanced on the guides bucket in trans-
port condition.
• Arm and bucket cylinder in. Put the bucket link pin
at 1 meter from ground and swing at end of boom
stroke in one of the two direction.
Hydraulic drift working equipment

• Move the machine on a chute of 15° and apply the

parking brake.
• Stop the engine and, after 1 minute, check the in-
ner cylinder feed back opposite to the boom every
5 min. for a total of 15 minutes.
Backhoe

• Eseguire la prova per i due sensi di

rotazione mm

Measuring posture

Outriggers Max 5 5
RKZ00490

• Oil temperature: 45 – 55 °C
• Backhoe balanced.
• Boom and arm cylinders in,
bucket cylinder out
• Outriggers at maximum extension.
• Engine stopped.
• Check the frame lowering for each side every 5
min. for a total of 15 minutes.

WB97R-2 20-19
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA

★ The technical data of follow table are refered to a machine with max 500 kg shovel bucket, 600 mm (max. 160 kg)
backhoe bucket and standard arm (or jig arm) closed.
FOR MACHINE WITH SERVOCONTROL

Machine model WB97R-2

Classifi- Standard Permissible
Check item Test conditions Unit
cation value value

2.0
Front bucket

Boom Max. 8.0

(each cylinder)

1.6
Bucket Max. 6.0
(each cylinder)

Boom 3.3 Max. 13.5

Arm 3.0 Max. 12.0

• Engine: Max. speed
Cylinder leaking

• Oil temperature: 45--55°C

• Leaking check: on the cylinder opposite side to the
cm³/
Bucket pressure one. 2.4 Max. 9.5
• Check 1 cylinder at a time. min
• For tilt front bucket, front bucket and for swing,
Backhoe

check the two cylinders separately.

Boom swing 3.2 Max. 13.0

Outrigger 3.3 Max. 13.5

Side digging boom 2.0 Max. 8.0

Jig arm 1.6 Max. 6.0

20-20 WB97R-2
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA

★ The technical data of follow table are refered to a machine with max 500 kg shovel bucket, 600 mm (max. 160 kg)
backhoe bucket and standard arm (or jig arm) closed.
FOR MACHINE WITH SERVOCONTROL

Machine model WB97R-2

Classifi- Standard Permissible
Check item Test conditions Unit
cation value value
Measuring posture
Tilt lever front

Raised
bucket 3.9 3.5–4.3

Cylinders
extended out

Lowered
RKZ07510
2.6 2.3–2.9
Bucket on
Front bucket

• Engine speed: Max.

level ground • Oil temperature: 45 – 55°C
• Speed up
Measuring posture

Curled
Bucket 2.6 2.3–2.9

Cylinder out

RKZ00510

Cylinder in • Engine speed: Max. Dump 3.5 23.1–3.9

• Oil temperature: 45 – 55°C
• Speed up

Measuring posture
Lifting ●
Work equipment speed

Boom
2.6 2.3–2.9

Cylinder in
sec.
Lowered

Teeth bucket on level RKZ00430

• Engine speed: 1800 +0 50 rpm 21.9 1.6–2.2
ground • Oil temperature: 45 – 55°C
• Backhoe balanced
• Power mode
Measuring posture
Opening

Arm 3.6 3.2–4

Backhoe

Cylinder in
Closing ●

RKZ00440
Cylinder out • Engine speed: 1800 +0 50 rpm 4.5 4.1–4.9
• Oil temperature: 45 – 55°C
• Backhoe balanced
• Power mode

Measuring posture
Dump

Bucket 2.6 2.4–2.8

Cylinder in
RKZ08150
Curled

0
Cylinder out • Engine speed: 1800 + 50 rpm
3.1 2.8–3.4
• Oil temperature: 45 – 55°C
• Backhoe balanced
• Power mode

WB97R-2 20-21
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA

★ The technical data of follow table are refered to a machine with max 500 kg shovel bucket, 600 mm (max. 160 kg)
backhoe bucket and standard arm (or jig arm) closed.
FOR MACHINE WITH SERVOCONTROL

Machine model WB97R-2

Classifi- Standard Permissible
Check item Test conditions Unit
cation value value
Measuring posture

Right ●
3.5 3.1–3.9
Work equipment speed

Boom swing
Backhoe

Right end travel sec.

Left end travel RKZ02670

Left ●
0
• Engine speed: 1800 + 50 rpm 3.5 3.1–3.9
• Oil temperature: 45 – 55°C
• Arm horizontal
• Power mode

● This time are refered to the cylinder stroke whitout the brake phase.

NOTE. The engine speed (1800 +0 50 rpm) has to be checked with the procedure described at paragraph
«MEASURING ENGINE SPEED» in this section.

20-22 WB97R-2
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA

★ The technical data of follow table are refered to a machine with max 500 kg shovel bucket, 600 mm (max. 160 kg)
backhoe bucket and standard arm (or jig arm) closed.
FOR MACHINE WITH SERVOCONTROL

Machine model WB97R-2

Classifi- Standard Permissible
Check item Test conditions Unit
cation value value
Measuring posture

Raising
3.5±0.3 Max. 3.5
Tilt lever front
bucket
Lowering
RKZ00500 2.6±0.3 Max. 2.6

• Engine speed: Min.

• Oil temperature: 45 – 55°C
• Check the time necessary to lift bucket from level
ground.

Measuring posture
Work equipment speed

Time lags

Boom sec. 2 Max. 2

RKZ00460

• Engine speed: Min.

• Oil temperature: 45 – 55°C
• With attachments fully extended, lower the boom
and check the necessary time from the beginning
of machine lifting until bucket is on level ground.

Measuring posture

45°

Arm 2 Max. 2
RKZ00471

• Engine speed: Min.

• Oil temperature: 45 – 55°C
• Put boom at 45°, open completely the arm with
curled bucket. Extend arm cylinder and check the
time passing between arm stop at dead centre and
the restart movement.

WB97R-2 20-23
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA

★ The technical data of follow table are refered to a machine with max 500 kg shovel bucket, 600 mm (max. 160 kg)
backhoe bucket and standard arm (or jig arm) closed.
FOR MACHINE WITH SERVOCONTROL

Machine model WB97R-2

Classifi- Standard Permissible
Check item Test conditions Unit
cation value value
Measuring posture

Bucket 2 Max. 2
RKZ00480

• Engine speed: Min.

• Oil temperature: 45 – 55°C
• Put arm in horizontal position. Tilt back bucket cyl-
inder an then extend it.
Work equipment

Check the time passing between bucket stop at

Time lags

dead centre and the restart movement.

Measuring posture sec.

Outriggers 0 Max. 2
RKZ00520

• Engine speed: Min.

• Oil temperature: 45 – 55°C
• Boom, arm and bucket fully retracted and putted in
machine centre position.
• Check the time necessary for outriggers to raise
the machine from when they lean on level ground.
• Check each outrigger at a time.

20-24 WB97R-2
TESTING AND ADJUSTMENTS SPECIAL TOOLS

SPECIAL TOOLS

Measurement check point Symbol Code Name Q.ty Note

Commercially
Valve clearance A 1 Feeler gauge 1 --
available
1 Compression gauge 1 Kit Yanmar
Compression pressure B ATR800280
2 Adapter 1 TOL-97190080

Commercially
1 Multiscale tachometer 1 20 - 4000 rpm
Engine speed C available
2 ATR800060 Stroboscopic tachometer 1 6 - 30000 rpm
Commercially
Oil and water temperature D 1 Digital thermometer 1 -- 50 - 1200 °C
available
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
Hydraulic pressure Commercially
4 Pressure gauge 1 Full scale 600 bar
available
5 Servocontrol kit
Differential digital 1 0 – 1000 bar
6 pressure gauge
ATR800200
1 Flow-meter 1 Delivery 0 – 300 ᐉ/min.
F
2 Pipe fitting kit 1 --
Air bleeding G 1 ATR201490 Tank cap 1 Pump air bleeding
Commercially
Hand brake L 1 Spring dynamometer 1 Full scale 20 kg
available
Commercially
1 Maintenance station 1 For coolant R134a
available
Commercially Sampling every 15
Air-conditioning unit M 2 Thermometer-hygrometer 1
available seconds
Commercially
3 Leak detector 1 For coolant R134a
available

WB97R-2 20-25
TESTING AND ADJUSTMENTS MEASURING ENGINE SPEED

MEASURING ENGINE SPEED

When checking engine speed, be careful not to touch
high temperature parts and not to get caught in rotating
parts.
1
★ Check speed when following condition are reached:
• Engine water cooling temperature: 68 – 80 °C.
• Hydraulic oil temperature: 45 – 55 °C.

1 - Remove the air filter (1).

2 - Install and connect C1 tachometer.

★ If using C2 stroboscopic tachometer, mark a light
notch on, engine pulley for an easier reading.
RKZB6220
3 - Start engine and check:
• Low idling speed without load (accelerator pedal
and hand accelerator released in «minimum» po-
sition).
• High idling speed without load (accelerator pedal at
the travel end).
C1
★ Low idling speed: 1050±50 rpm
★ High idling speed:
standard version: 2350±50 rpm
versione with servocontrol: 2375±50 rpm
★ If low and high idling speed with engine without load
are not within permissible value, before going on
with other operations, check accelerator pedal
stoppers and wiring sheathings. (See «ACCELER- RKZB6230

ATOR LEVER ADJUSTING»).

20-26 WB97R-2
TESTING AND ADJUSTMENTS ADJUSTING VALVE CLEARANCE

ADJUSTING VALVE CLEARANCE

★ Engine: in cold state.
★ Adjust clearance between valves and rocker levers as
follows:
Unit: mm
Intake-exhaust
At cold engine
0.30±0.05

★ Firing order: 1-3-4-2-1..... at 180° step.

★ Normal rotation sense: counterclockwise from flywheel
★ The cylinder N° 1 is on the opposite fan side.
★ Adjust all the valve.

Adjusting procedure

1 - Remove the air filter (1) and the muffler (2). 2

1

RKZB5020

2 - Loosen the muffler support screws (3) and remove the

air intake duct (4).

RKZB6240

3 - Disconnect the fuel feed pipes (5).

4 - Remove clamp (6) and loosen clamp (7).
5

6 5

RKZB6250

WB97R-2 20-27
TESTING AND ADJUSTMENTS ADJUSTING VALVE CLEARANCE

5 - Loosen the fittings (8) connecting to the pump (9) on the

fuel feed pipes (5).

5
8

RKZB6260

6 - Rotate the pipes (5) until they become disengaged from

the valve cover (10).

7 - Remove the feed-through fittings (11) and their seals.

11 10

RKZB6270

8 - Loosen and remove the screws (12) retaining the valve

cover (10).
★ Inspect the grommets.
12
10

RKZB6280

9 - Remove the valve cover (10).

★ Inspect the seal. Replace the seal if it is damaged or
cracked. 10

RKZB6290

20-28 WB97R-2
TESTING AND ADJUSTMENTS ADJUSTING VALVE CLEARANCE

10 - Rotate the crankshaft in the normal direction until the

piston of the cylinder you want to check reaches the
compression position at Top Dead Centre (TDC).
★ In this position, the intake and exhaust valves are
closed.

RKZB6300

11 - Loosen the retaining nut (13) and unscrew the tappet by

about one half turn (14). 14

13

RKZB6310

12 - Introduce the A1 feeler gauge between the valve link

(15) and the rocker arm (16); tighten the tappet (14) until
rubbing against the A1 feeler gauge. A1 16
Lock the tappet (14) using the nut (13).

Nut: 22–28 Nm

14

13
15
RKZB6960

WB97R-2 20-29
TESTING AND ADJUSTMENTS ADJUSTING VALVE CLEARANCE

13 - Loosen the nut (17) and, while applying pressure to the

valve link (15), tighten the tappet (18) until it bottoms on
the valve (19) and zeroes the clearances.
Lock the tappet using the nut (17). 17

Nut: 22–28 Nm
★ If the nut (17) is very tight, use pliers to hold the 18
valve link in position (15).

15
19
RKZB6980

18 17
15
0mm 0mm

RKS02280

14 - Reinstall all previously removed parts.

Valve cover screws: 16.7–22.5 Nm

Injectors-pump fittings: 19.6–24.5 Nm
Clamp screws: 7.8–9.8 Nm

20-30 WB97R-2
TESTING AND ADJUSTMENTS MEASURING COMPRESSION PRESSURE

MEASURING COMPRESSION PRESSURE

When measuring the compression pressure be careful
not to get caught in cooling fan, in the alternator belt or in
other rotating parts.
For this measurement the engine should be up to work-
ing temperature. Take every precaution against burns.
Check all cylinders.

★ Test condition:
• Valve clearance:
adjusted (see «ADJUSTING VALVE»)
• Engine: at operating temperature
• Hydraulic oil: 55 – 60°C.
• Battery: at full charge
1 - Access the valves using the same procedure as in «AD-
JUSTING VALVE CLEARANCE».
2 - Loosen and remove the fittings (1) retaining the fuel re-
covery piping (2) and the seals. 1 1
3 - Loosen the fitting (3) and rotate the piping (2) outward.
1

RKZB6320

4 - Loosen and remove the screw (4) retaining the bracket

(5) retaining the injector (6).
4
5

RKZB6330

5 - Turn the bracket (5) over and pull out the injector (6).
★ Use care not to allow dirt inside the injector and/or
its seat.
5

RKZB6340

WB97R-2 20-31
TESTING AND ADJUSTMENTS MEASURING COMPRESSION PRESSURE

6 - Disconnect the engine shutdown connector (7) and en-

sure that the accelerator is fully released (no fuel flow).
7

RKZB6350

7 - Using the starter motor, have the engine complete a few

revs.
A
8 - Apply the adaptor of the A equipment included the YAN-
MAR kit, code TOL-97190080, and follow the instruc-
tions provided with the equipment.
★ Check for a seal inside the adaptor and verify that
the seal is not damaged.
A

RKZB6360

9 - Crank engine with starting motor and measure com-

pression pressure.
★ Measure the compression pressure at the point
Compression pressure
(kg/cm2)

40
where the pressure gauge indicator remains
steady. 35

★ When measuring the compression pressure, 30

check also engine speed with C2 stroboscopic ta-
25
chometer; if speed is not within the specified range,
refer to diagram. 20
★ Compression value:
Normal: : 35±1kg/cm² at 250 rpm 200 250 300 350 400
Engine speed (giri/min)
Minimum permissible:
RKS01511
28±1kg/cm² (2.75 MPa) at 250 rpm
★ Difference between cylinders:
2-3 kg/cm² (0.2-0.3 MPa).

10 - After completing the compression pressure measure-

ment procedure, reinstall the injector (6), reconnect the
fuel return pipe and complete the assembly procedure.

1
Fuel recovery fittings: 7.8–9.8 Nm

Injection pump fitting: 19.6–24.5 Nm

20-32 WB97R-2
TESTING AND ADJUSTMENTS TESTING AND ADJUSTING FUEL INJECTION TIMING

TESTING AND ADJUSTING FUEL INJECTION TIMING

Remove the ignition key.
★ Check fuel injection timing of N.1 cylinder by means of Nº1 Cylinder
N.1 delivery valve of injection pump.
★ Cylinders are numbered 1-2-3-4 starting from flywheel
side.

1 - Rotate crankshaft using engine pulley and put N. 1

1cylinder piston at top dead centre (PMS).

Flywheel
RKZ01961

★ Top dead centre (PMS) is shown by notch (4) on pulley

(1) positioned on «zero» of the scale (5) and by closing 4
of both cylinder N. 1 valves.
★ If the notch (4) of pulley (1) is in «zero» position on the
scale (5) but cylinders N. 1 valves are not closed, rotate
the crankshaft of 1 turn.
★ After recognition of PMS, rotate the crankshaft in coun- 5
terclockwise direction (from pulley side view) of about
20°.

1
RKZB6380

2 - Disconnect cylinder N.1 high pressure pipe (2) from in-

jection pump. 2
3 - Rotate crankshaft slowly in clockwise direction from
pulley side view, checking fuel level into the N. 1 delivery
of injection pump.

N°-1

RKZB6390

4 - Stop pulley (1) rotation as soon as fuel level starts to in-

Level
crease. Nº 1
Uni on

RKZ01971

WB97R-2 20-33
TESTING AND ADJUSTMENTS TESTING AND ADJUSTING FUEL INJECTION TIMING

5 - Check notch (4) position on crankshaft pulley (1) com-

pared with scale (5); reading value corresponds to an- 5
gle of fuel injection timing.

★ Standard fuel injection timing: 12.5°±1°

NOTA. Repeat checking more than once.
4

1
RKZB6400

6 - If injection timing is not on standard value, rotate injec-

tion pump (6) toward external or toward engine after
loosening pump nuts (7) (quantity 4) and pump lock nuts
(8) fixing the bracket (9) to injection pump.
• To RETARD injection, rotate pump (6) toward ex-
ternal.
• To ADVANCE injection, rotate pump (6) toward cyl-
inders block.

RKZB6410

7 - Tight the pump lock nuts (7) at cylinder block and pump
lock nut (8) at bracket (9).

Nuts: 34.2 – 44.1 Nm

Bracket lock nut: 44.1 – 53.9 Nm

8 - Connect fuel delivery pipe (2) to pump.

Delivery pipe union: 19.6 – 24.5 Nm 7

RKZB6420

20-34 WB97R-2
TESTING AND ADJUSTMENTS CHECKING AND TIGHTENING THE FAN - BELT

CHECKING AND TIGHTENING THE FAN - BELT

1. Tension check
1 - Push fan belt (1) at midway point between alternator (2) 2
and pulley (3) operating water pump; check the deflec-
tion.
With a pressure of 10 kg, deflection should be of 10 – 15
mm; if this value is not reached, tension fan belt.
★ With new belt, deflection must be of 7 – 9 mm.

RKZB5390

2. Fan belt tension

1 - Loosen mounting bolt (4) of the alternator (2) and 4
mounting bolt (5) of adjustment plate. 2
2 - Rotate the alternator (2) to give correct tension to fan
belt (1) and tighten mounting bolts (4) and (5).

3 - Check fan belt (1) tension.

★ If belt has been replaced, check tension again after 3
about 20 operating hours.
Bolts (4): 44.1 – 53.9 Nm
1
RKZB5030
Bolts (5): 22.5 – 28.4 Nm

Water pump
pulley

10-15 mm

Alternator

Crankshaft
pulley
RKZ01981

WB97R-2 20-35
TESTING AND ADJUSTMENTS CHECKING AND TIGHTENING THE COMPRESSOR FAN - BELT

CHECKING AND TIGHTENING THE COMPRESSOR FAN - BELT

1. Checking tension
1 - Push fan belt (1) at midway point between compressor
7-10 mm
(2) and pulley (3). Check the deflection.
With a pressure of 10 kg, deflection should be of 7 – 10
mm; if this value is not reached, tension fan belt. 2
3
★ With new belt, deflection must be of 4 – 6 mm.

RKZO3261

2. Fan belt tension

1 - Loosen mounting bolt (4) of the eccentric (5).

2 - Apply tube on eccentric (5), give correct tension to fan 4

belt and lock with bolt (4). 5
3 - Check fan belt (1) tension.
★ If belt has been replaced, check tension again after
about 20 operating hours. 1
Bolt: 123 Nm

RKZB5040

20-36 WB97R-2
TESTING AND ADJUSTMENTS MEASURING ACCELERATOR PEDAL OPERATING TRAVEL AND

MEASURING ACCELERATOR PEDAL OPERATING

TRAVEL AND ACCELERATOR LEVER
★ Work condition:
• Machine: in safety conditions.
• Engine stopped and at working temperature. 2
• Low and high idling speed: within permissible val- 1
ue.
★ In order to check high speed engine idling, push the
accelerator pedal (1) manually.

1. Accelerator pedal travel adjusting

1 - Make sure that accelerator pedal (1) is fully raised and
accelerator lever (2) is at minimum stroke.
RKZA9330

2 - Check that accelerator lever (3) is in contact with low

idling speed adjusting screw (4).
★ Low idling speed: 1050±50 rpm

RKZB6430

3 - Adjust nut (5) and lock nut (6) of accelerator pedal ca-
bles and hand accelerator at a distance of 3.5 – 4.0 mm 8
from lever (7).
5 6
4 - Push accelerator pedal until accelerator lever (3) con-
tacts the high idling adjusting screw (8).
★ High idling :
standard version: 2350±50 rpm
version with servocontrol: 2375±50 rpm

7
RKZB6440

1
5 - Adjust the end travel stopper (9) of accelerator pedal (1)
in this position and lock it with nut (10).

6 - Release the accelerator pedal (1). 10

9

RKZA9340

WB97R-2 20-37
TESTING AND ADJUSTMENTS MEASURING ACCELERATOR PEDAL OPERATING TRAVEL AND

2. Accelerator lever travel adjusting

1 - Remove mat and lateral cover (1).

RKZA9350

2 - Loosen nut (2) and tight the end lever travel bolt (3) of
some turns.

3 - Start engine and, with lever (4), bring it to the defined 3

idling speed for hand accelerator.
★ Check using the stroboscopic tachometer C2. 4
★ Engine idling speed
Max. 1900±50 rpm
Min. 1050±50 rpm
2
4 - Loosen end lever travel bolt (3) up to it is in contact with
lever (4) and looked with nut (2).

5 - Bring engine at low idling and check accelerator lever RKZA9360

idling speed again pushing lever at end stroke.

20-38 WB97R-2
TESTING AND ADJUSTMENTS ADJUSTING BRAKE PEDAL TRAVEL, BRAKE ALIGNMENT

ADJUSTING BRAKE PEDAL TRAVEL, BRAKE ALIGNMENT

★ Working condition:
• Engine stopped
• Machine with attachments on ground level 1
1 - Check that pedal (1) is near to the stopper (2) and the
pedals side are at “A” measure from cab level.
If necessary, adjust height acting on the stopper (2).
★ “A” measure: 313±3 mm
★ Check that pin (3) can freely run and lock the pedals
(1). 3

RKZB0020

Master cylinder rod adjustment

2 - Loosen nut (4) locking the adjusting rod (5) and loosen
until it touches the brake pump piston seat.

3 - Tighten the adjusting rod (5) of one turn (360°) and lock
it with nut (4). 2

4 - Repeat operations 3. and 4. for the other pedal.

★ After tightened nuts (4), check that the adjusting
rod (5) touch the brake pump piston seat simulta-
neously.

Checking adjustment
5 - Verify measure like shown in figure.
“A” measure: at pedal in neutral position
“B” measure: at master cylinder rod touching the pump
1

A = 313 ± 3 mm
B = 302 mm

RKZ08200

5 4 RKZ08210

WB97R-2 20-39
TESTING AND ADJUSTMENTS AIR BLEEDING - RELEASING RESIDUAL PRESSURE

AIR BLEEDING - RELEASING RESIDUAL PRESSURE

1. Air bleeding from pump
★ Air bleeding from pump (that means the filling of pump
body) is necessary:
1 - When removing pump.
2 - When removing or replacing connection hoses be-
tween pump and hydraulic tank.
3 - When replacing hydraulic oil and hydraulic tank
overhaul.

The air bleeding is obtained as follows:

G1
1 - Carry out tank oil filling and close hydraulic tank with
RKZA8180
plug G1.

2 - Remove plug (1) of breather pipe (2).

3 - Connect plug G1 to low pressure air compressed con-

nection. 1 2
4 - Introduce slowly and intermittently air compressed in
the hydraulic tank until when flows out oil without air
bubbles from hole of the screw (1).
★ Max. pressure in tank: 0.5 bar
5 - Mount plug (1) and lock it.

6 - Depressurize slowly hydraulic tank, check level and, if

necessary, refill tank oil at correct level.
RKZA9380

7 - Start engine and run it for few minutes before bleeding

air from the whole system.

2. Air bleeding from cylinders

★ When hydraulic cylinders or pipe fitting have been re-
moved, it is necessary to bleed air before to use again
the machine.
★ Operate on a movement at a time starting from main cyl-
inders (lifting).

1 - Start engine and run it at high idling speed for about 5

min. to worm up oil and to pressurise hydraulic system.

2 - Return engine at low idling speed, extend and retract

the interested piston 4-5 times.
★ Extend, lower and retract pistons until about 100
mm from their end of stroke.

3 - Bring again the engine at high idling speed and repeat

operation of point 2; return the engine at low idling
speed and make a complete travel of piston until the hy-
draulic pump reaches its maximum pressure.

4 - Repeat above operation (starting from point 2) for all

cylinders.

20-40 WB97R-2
TESTING AND ADJUSTMENTS AIR BLEEDING - RELEASING RESIDUAL PRESSURE

3. Air bleeding from oil tank

1 - Put the machine in oil level check position and remove
the tank plug.
★ If necessary add oil until reaching the correct level.
2 - After stopping the engine wait for some minutes, until air
bubbles on oil surface are fully disappeared.
3 - Install tank plug.

4. Hydraulic oil tank pressurization

1 - With engine at low idling speed extend slowly, up to end
of stroke, all cylinders.
2 - Stop the engine and remove tank plug.
3 - Check the condition of gasket and reassemble plug.
★ Avoid to increase the engine speed before com-
pleting all air bleeding procedures and after the
pressurization of oil tank.
★ After air bleeding procedures, operate engine at
low Idling speed for about 10 minutes before start-
ing to work.

5. Releasing residual pressure from the circuits

1 - Put work attachments on level ground, stop the engine.
2 - Move all control levers in all directions to release com-
pletely cylinders and main circuit remain pressure.
3 - Loosen slowly oil filler tank to remove remain pressure.

6. Air bleeding from braking circuit

★ Above operation is to be carried out every time main-
tenance is made on braking circuit to remove or replace
a component, or when air entered into the circuit.
★ Machine must be stopped with attachments on level MAX.
ground.
MIN.
1 - Make sure that oil in brake system tank (1) is at maxi-
mum level. 1
2 - Remove pedal lock pin.

RKZA9390

3 - Remove safety plugs and applied to bleeding screws (2)

a vinyl hose to catch oil.
4 - Push brake pedals to bottom and, keeping it pushed,
loosen bleeding screw (2) of the left braking unit until the
pedals reach end of their stroke.
5 - Keeping pedal at the end stroke, tighten bleeding screw
(2).

RKZA5470

WB97R-2 20-41
TESTING AND ADJUSTMENTS AIR BLEEDING - RELEASING RESIDUAL PRESSURE

6 - Release brake pedals, wait for few seconds and repeat

above operations two or three times until from bleeding
screw, oil flows out without air bubbles.
7 - Repeat same operations for the right braking unit.
8 - Disconnect pedal lock pin.
9 - Push one brake pedal to bottom and, keeping it pushed,
loosen bleeding screw (2) of one of two braking units un-
til the pedal reaches end of its stroke.
★ Check that oil flows out without air bubbles from
bleeding screw (2).
10 - Repeat same operations for the other braking unit.
★ Check frequently the oil level in the tank and carry
out filling every time level approaches to minimum.
★ After air bleeding apply on screws (2) safety plugs.
7. Checking air bleeding from braking circuit
1 - Start engine and lower the backhoe outrigger and force
them downwards in order to raise the rear wheels.
2 - Engage forward/reverse gear in order to move wheels.
3 - Return the machine in neutral and lower it and stop the
engine.
4 - Apply 50 kg on the pedal and verify measure “D”.
5 - Insert pedal lock pin and applying the same mass verify
the measure “D”.
★ “D” measure with one pedal pushed:
not less than 165 mm
★ “D” measure with both pedal pushed:
not less than 170 mm

RKZ08220

20-42 WB97R-2
TESTING AND ADJUSTMENTS CHECKING AND SETTING PRESSURE IN THE ATTACHMENTS

CHECKING AND SETTING PRESSURE IN THE ATTACHMENTS

HYDRAULIC CIRCUIT
STEERING UNIT

FRONT SHOVEL
CONTROL VALVE
(2-3 SPOOL)

POWER TRAIN

DIESEL

P1

MAIN RELIEF
VALVE

BACKHOE
CONTROL VALVE
(6-7-8 SPOOLS)

RKZ02491

NOTE. The drawings show the standard control • The two control valves are protected against over-
valve; the controls are the same for optional pressure by a main relief valve (or general and
control valve (version with servocontrol). named Pressure cut off valve) with adjustable set-
1. Introduction ting.
• On the machine configuration, one or two spool. • Control valves are feeded by P1 pump total delivery.
Mechanical control valves have been installed with • P1 pump delivery is checked by a priority valve (in-
following function: ternal to the control valve N. 1) when steering unit is
Control valve No. 1 (2-3-spools): used.
for front work attachments control.
Control valve No. 2 (6-7-8-spools):
for rear work attachments control.

WB97R-2 20-43
TESTING AND ADJUSTMENTS CHECKING AND SETTING PRESSURE IN THE ATTACHMENTS

• Control valves include spools with following functions:

2-SPOOL CONTROL VALVE

Control Port

Loader arm (lifting - lowering) A1 - B1 A

1 2
Front bucket (curled - dump) A2 - B2
B

RKZ02040

3-SPOOL CONTROL VALVE

Control Port

Loader arm (lifting - lowering) A1 - B1

Front bucket (curled - dump) A2 - B2 A

3 2 1
Optional attachment A3 - B3
B

RKZ02061

6-SPOOL CONTROL VALVE

Control Port

Arm (closing - opening) A1 - B1

Boom swing (left - right) A2 - B2

B
L.H. outrigger (up - down) A3 - B3 1 2 3 4 5 6
R.H. outrigger (up - down) A4 - B4
A

Bucket (dump - curled) A5 - B5

Boom (lifting - lowering) A6 - B6

RKZ06690

7-SPOOL CONTROL VALVE

(For jig arm)
Control Port

Jig arm (in - out) A7 - B7

B
7
A

RKZ06680

20-44 WB97R-2
TESTING AND ADJUSTMENTS CHECKING AND SETTING PRESSURE IN THE ATTACHMENTS

7-SPOOL CONTROL VALVE

(For hammer - side digging boom)
Control Port

Hammer (L.H. side) B7

Side digging boom (left - right) A7 - B7

B
7

RKZ06670

8-SPOOL CONTROL VALVE

(For hammer and jig arm)
Control Port

Hammer (L.H. side) B7

Jig arm (in - out) A8 - B8

B B
7 8
A

RKZ06660

Standard version
2. Testing and setting general valves
(Pressure cut off valve)
E3
★ Test condition: 1
• Engine: at operating temperature
• Hydraulic oil: 45 – 55 °C
• Working brakes applied

1 - Connect the pressure gauge E3 (400 bar) to the pres-

sure adapter (1) of the front shovel control valve (2).

2 - Start the engine, bring the hand accelerator lever up to

2
max. speed and check the nominal pressure of the main RKZA5480

relief valve (pressure cut-off valve) by forcing the front

bucket to rise to the end of its stroke. Version with servocontrol
★ Nominal pressure:
standard version: 205±10 bar
version with servocontrol: 200±7 bar
★ If the main relief valve pressure do not correspond
to the nominal values, they must be re-set (See E3
«SETTING THE MAIN RELIEF VALVES AND THE
REDUCING VALVES»). 1

RKZB6450

WB97R-2 20-45
TESTING AND ADJUSTMENTS CHECKING AND SETTING PRESSURE IN THE ATTACHMENTS

3. Testing and setting secondary valves

★ Test condition: E3
• Engine: at operating temperature.
1
• Hydraulic oil: 55 – 60 °C.
• Parking brake: applied.
★ The pressure readings are to be operated from the
same check point.
1 - Connect the pressure gauge E3 (400 bar) to the pres-
sure adapter (1) of the backhoe control valve (2).
2 - Start the engine and bring the hand accelerator lever up
2
to 1050 rpm. RKZA5480

3 - Set the main relief valve (pressure cut-off valve) to a val-

ue 30 bar higher than the maximum pressure to be test-
ed.
4 - Check the single movements pressure.
The secondary valve of backhoe boom lifting, must be
checked and settled on test bench only.

Setting 2-spool control valve secondary valves

Unit: bar
Setting
Cylinder and movement Port Version with
Standard version
servocontrol
Lifting A1 -- –
Front bucket
Lowering B1 -- –
Curled A2 235±10 235±7
Front bucket
Dump ✽ B2 185±10 175±7

✽ This setting can be carried without modifing the general valve pressure.

Setting 3-spool control valve secondary valves

Unit: bar
Setting
Cylinder and movement Port Version with
Standard version
servocontrol
Lifting A1 --
Front bucket
Lowering B1 --
Curled A2 235±10 235±7
Front bucket
Dump ✽ B2 185±10 175±7
A3 235±10 235±7
Optional attachment
B3 235±10 235±7

✽ This setting can be carried without modifing the general valve pressure.

20-46 WB97R-2
TESTING AND ADJUSTMENTS CHECKING AND SETTING PRESSURE IN THE ATTACHMENTS

Setting 6-spool control valve secondary valves

Unit: bar
Setting
Cylinder and movement Port Version with
Standard version
servocontrol
Closing A1 235±10 235±7
Arm
Opening B1 -- –
Left A2 245±10 245±7
Boom swing
Right B2 245±10 245±7
Up A3 -- –
Right outrigger
Down B3 -- –
Up A4 -- –
Left outrigger
Down B4 -- –
Curled A5 -- –
Bucket cylinder
Dump B5 235±10 235±7
Lifting ✽ A6 300±10 305±7
Boom cylinder
Lowering B6 235±10 235±7

✽ The setting must be carried on test bench only.

Nominal values of the reducing valves of the 7-8 element control valve
(for the other settings, please refer to the 6-element control valve)
Unit: bar
Setting
N° elementi Cylinder and movement Port Version with
Standard version
servocontrol
Right A7 170±10 165±7
Hammer
Left ✽ B7 -- –
Right A7 275±10 275±7
7 Side digging boom
Left B7 275±10 275±7
In A7 -- –
Jig arm
Out B7 -- –
Right A7 – –
Hammer
Left ✽ B7 -- –
8
In A8 -- –
Jig arm
Out B8 -- –

✽ This setting can be carried without modifing the general valve pressure.
★ If valve setting pressure do not correspond to the indicated ones, provide to set them (see «SETTING MAIN AND
SECONDARY VALVES»).

4 - Set the general valve pressure to the standard value.

WB97R-2 20-47
TESTING AND ADJUSTMENTS CHECKING AND SETTING PRESSURE IN THE ATTACHMENTS

4. Main and secondary valves setting

• General valves (Pressure cut off valve (1)

For setting, prepare machine as per pressure testing.

1

1 - Loosen lock nut (2).

2 - Force to the end of its stroke the lever commanding

whichever movement is being used for the tests.

3 - Adjust pressure with adjusting screw (2).

• To INCREASE pressure, rotate in CLOCKWISE di-
rection.
RKZA8100
• To DECREASE pressure, rotate in COUNTER-
CLOCKWISE direction.

4 - Lock position with nut (2).

3
RKZ02241

• Secondary valves

For setting, prepare machine as per pressure testing.

★ This setting is valid for all the secondary valve and 2
has to be carried forcing the movement to be 1
checked at its end of stroke.
3
1 - Loosen lock nut (1).

2 - Adjust pressure with adjusting screw (2).

• To INCREASE pressure, rotate in CLOCKWISE di-
rection.
• To DECREASE pressure, rotate in COUNTER-
CLOCKWISE direction.

3 - Lock position with nut (1).

Lock nut: 10±1 Nm

When terminated the setting, Apply safety plug (3)

to avoid not authorised tamperings.

4 - Set the general valve pressure to the standard value.

RKZ02010

20-48 WB97R-2
TESTING AND ADJUSTMENTS TESTING AND ADJUSTING OF LOAD SENSING SIGNAL (LS VALVE)

TESTING AND ADJUSTING OF LOAD SENSING SIGNAL (LS VALVE)

★ Testing conditions:
• Engine: stopped but at working temperature.
• Hydraulic oil: 45 – 55 °C.
1
• Machine: front equipment on the ground, parking
brake applied and boom and arm fully extended.
• Working mode: Power
3

1 - Disconnect hose (1) from the Load Sensing line. Install

an tee and reconnect hose (1). 2
2 - Remove plug (2) and install a pressure adapter (M8x1). RKZB5640

3 - Connect the pressure gauge E5 to adapter.

4 - Start the engine and bring it to 1050±50 rpm and, with- 3

1
out any movement (lever in neutral position), read the
∆P pressure. E5
Normal value: 24±1 bar
★ If the ∆P value is not inside the limits, adjusting the
Unloading valve.
(For details see «TESTING AND ADJUSTING OF
UNLOADING VALVE»).
2
5 - Raise boom up to end of stroke and read the the ∆P
pressure. RKZ07391

Normal value:21 ±1 bar

★ If the ∆P value is not inside the limits, carry out the
Load Sensing valve (3) setting.

1. Adjusting of the Load Sensing valve

1 - Remove nut (4).

2 - Loosen nut (5).

3 - Adjust pressure using adjusting screw (6).

• To INCREASE pressure, rotate in CLOCKWISE di-
4 6 5
rection.
• To DECREASE pressure, rotate in COUNTER-
CLOCKWISE direction.

4 - Lock the position with nut (5).

7
Lock nut: 21 Nm

5 - Check gasket (7) and mount nut (4).

Nut: 21 Nm RKZ07440

WB97R-2 20-49
TESTING AND ADJUSTMENTS TESTING AND ADJUSTING OF UNLOADING VALVE

TESTING AND ADJUSTING OF UNLOADING VALVE

★ Testing conditions:
• Engine: stopped but at working temperature.
• Hydraulic oil: 45 – 55 °C.
1
• Machine: front equipment on the ground, parking
brake applied and boom and arm fully extended.
• Working mode: Power

1 - Disconnect hose (1) from the Load Sensing line. Install

an tee and reconnect hose (1).

2 - Remove plug (2) and install a pressure adapter (M8x1).

2
RKZB5641

3 - Connect the pressure gauge E5 to adapter.

4 - Start the engine and bring it to 1050±50 rpm and, with-

1
out any movement (lever in neutral position), read the
∆P pressure. E5
Normal value: 21±1 bar
★ If the ∆P value is not inside the limits, adjusting the
Unloading valve (3).

2
RKZ07390

RKZ07410

1. Adjusting the unloading valve

1 - Remove plug (4), spring (5), washers (6) and body valve 8
(7).

2 - Place a shim (8) under the spring (5) and mount the
valve.
• One shim of 1 mm increase pressure ∆P of 3 bar.

Plug: 100 Nm

4 5 6 7
RKZ07420

20-50 WB97R-2
TESTING AND ADJUSTMENTS CHECKING UNLOADING VALVE FUNCTIONALITY

CHECKING UNLOADING VALVE FUNCTIONALITY

★ Test condition:
• Engine: stopped but at working temperature.
1
• Low idling: in the permissible limit.
• Hydraulic oil: 45 – 55 °C.
• Machine: in safety condition, parking brake ap- E1
plied.
• Control valve lever at neutral position. 2

1 - Disconnect hose (1) from the Load Sensing line. Install

an thee (2) and reconnect hose (1).

2 - Connect to thee (2) a pressure port and gauge E1 (60

RKZA9420
bar).
Standard version
3 - Connect gauge E1 (60 bar) to rear control valve pres-
sure port (3).
E1
4 - Start the engine at low idling and without any movement
check pressure on both gauges. 3
★ Normal pressure (P) control valve gauge:
27±3 bar
★ Normal pressure Load Sensing line gauge (PLS):
6±2 bar
(This value is due to the influence of the counter-
pressure present in the steering circuit).
★ If any variations are found, they do not represent a
problem provided that the difference of 21±1 bar RKZA5511

between the two readings is respected.

Version with servocontrol

E1

RKZB6451

5 - If the difference between the two readings is higher than

21±1 bar, stop the engine and release residual pres-
sures.

6 - Thoroughly clean the valve (4) and re-install it.

4
Valve: 20 Nm

7 - If, in spite of cleaning the valve (4), the value of 21±1 bar
still does not fall within the tolerance limits, install a new
valve.

RKZA8102

WB97R-2 20-51
TESTING AND ADJUSTMENTS TESTING PRIORITY VALVE OPERATION

TESTING PRIORITY VALVE OPERATION

Standard version
★ Test condition:
• Engine: operating temperature. E2
• Hydraulic oil: 45 – 55 °C. 1
• Parking brakes: applied.
• Hydraulic pump: Economy mode

1. Testing priority valve operation

1 - Connect a pressure gauge E2 (250 bar) to the pressure
adapter (1) of the backhoe control valve.

2 - Start the engine and bring it to idle speed of 1500±50

rpm. RKZA5540

3 - Check on gauge E2 pressure value with stopped steer- Version with servocontrol
ing wheel (21 bar).

4 - Start a slight steering and check that pressure increas-

es.
E2

RKZB6452

5 - Continue the steering up to end of stroke and check that,

forcing the steering wheel, pressure increases till nor-
mal value. 2
★ Normal pressure:
standard version: 175±10 bar
version with sercontrol: 175±7 bar
★ If the pressure does not reach the normal value, re-
set the pressure of the steering unit
★ If turning the steering wheel the pressure shown by
gauge does not change and stress on steering
wheel necessary to carry out steering is high, clean
the priority valve (2).
RKZA5550

20-52 WB97R-2
TESTING AND ADJUSTMENTS TESTING PRIORITY VALVE OPERATION

2. Cleaning priority valve

1 - Remove priority valve plug (3), spring (4) and rod (5)
★ Check and make notes on the direction of assem-
bly.
6
2 - Dismantle the plug (6) and remove the ball (7) of the in-
side valve and the spring (8). 8
3 - Check that the hole (9) and the nozzle (10) are perfectly
clean. 7 9
4 - Replace the spring (8), the ball (7) and the plug (6).
Plug: Loctite 542

Plug: 20 Nm
5
★ Do not allow any Loctite to enter the hole (9). 4
★ Remove all excess Loctite from the rod (5).
10
5 - Lubricate the rod (5) and mount it in its seating, ensuring
that it slides freely.

6 - Insert the spring (4) and mount the plug (3).

3
Plug: 100 Nm.

7 - Start the motor, execute several steering manoeuvres

and, if the fault is not corrected, replace the complete
steering column with a new one. RKZ02220

WB97R-2 20-53
TESTING AND ADJUSTMENTS TESTING AND SETTING STEERING CONTROL SYSTEM PRESSURE

TESTING AND SETTING STEERING CONTROL SYSTEM PRESSURE

Standard version
★ Test condition:
• Engine: operating temperature E2
• Hydraulic oil: 45 – 55 °C 1
Testing
1 - Connect a pressure gauge E2 (250 bar) to the pressure
adapter (1) of the backhoe control valve.

2 - Start the engine and bring it to idle speed 1500±50 rpm

and carry out a total steering.

3 - Forcing the steering wheel at the end of stroke, check

RKZA5540
pressure.
★ Normal pressure: Version with servocontrol
standard version: 175±10 bar
version with sercontrol: 175±7 bar

4 - Check for the other steering direction too.

E2

RKZB6452

Setting
If pressure is not within permissible value, carry out setting
acting on upper valve (3) of the steering unit.
6 5 4 7

1 - Remove plug (4).

2 - Insert a wrench of 4 mm and loosen screw (5).

3 - Adjust pressure with screw (6).

• To INCREASE pressure rotate in CLOCKWISE di-
rection.
• To DECREASE pressure rotate in COUNTER- 3
CLOCKWISE direction. RKZA9430

4 - Stop engine, lock the adjusting screw (6) position tight-

ening screw (5).

5 - Reassemble plug (4) checking that gasket (7) is on its

seat.

20-54 WB97R-2
TESTING AND ADJUSTMENTS CHECKING AND CALIBRATING THE SERVO CONTROL FEED VALVE

CHECKING AND CALIBRATING THE SERVO CONTROL

FEED VALVE (Optional)
★ Test conditions:
• Engine: not running but at operating temperature.
• Engine speed at IDLE: within the permissible limits.
1
• Hydraulic oil: 45–55 °C
• Machine in safety conditions with parking brakes E1
applied.

RKZB6460

Checking procedure
1 - Connect an E1pressure gauge (60 bar) to the valve
pressure tap (1).

2 - Crank the engine and let it run it at IDLE; perform any

backhoe movement, bringing the cylinder to the travel
limit; check the pressure on the E1 pressure gauge.
• Normal pressure: 34±3 bar

3 - If the pressure value is not within tolerance, perform the

valve calibration procedure.

Calibration procedure
1 - Loosen the nut (2).
2 - Adjust pressure using the screw (3).
• To INCREASE pressure, rotate COUNTER
2
CLOCKWISE.
• To REDUCE pressure, rotate CLOCKWISE. 3
3 - Lock the position using the nut (2).
- +

RKZB6470

WB97R-2 20-55
TESTING AND ADJUSTMENTS TESTING BRAKE SYSTEM

TESTING BRAKE SYSTEM

★ Test condition:
• Engine: stopped
• Machine: on solid and level ground, with equipment
raised and safety devices engaged.
• Brake pedals: independent, with the container level
at maximum.
1
The system testing provides in two stages:

1 - Testing circuit and brake pump tightness.

3
2 - Leaktightness test of the braking group. 2
RKZA5570
If both the tests give a positive result, the leaks must
be sought in the pipelines of the braking system

4
1. Testing circuit and brake pump tightness
1 - Disconnect the connecting pipe (2) of the equalizers
from the brake pumps (1) of the circuit to be tested.

2 - Securely plug the equalizer orifice (plug A). 2

3 - Remove the clamp (3) and disconnect the delivery lines
(4) from the pumps. Connect a pressure gauge E2 (250
bar) to the pump (1) being tested.

4 - Move the brake pedal corresponding to the pump and A RKZA5580

bring the circuit up to a pressure of approximately 120

bar.
★ Do not exceed maximum permissible value that is
of 150±5 bar.

5 - Keep the pedal pushed for at least 2 minutes and check E2

that pedal pressure and position remain steady.
★ If the position of the pedal must be changed to
maintain pressure, the pressure loss is due to leak-
ages inside the pump.
This can be confirmed by checking the oil. If there
are leakages, it will show signs of mixing. 1

6 - Repeat test for the other brake pump.

RKZA5590

2. Testing braking group leaktightness

From brake pump
1 - Disconnect the delivery tube (5) of the braking group be- 5
ing tested.

2 - Connect the tool between the delivery line (5) and the
braking group.
7
100 150

50 200

★ Check that the pressure adapter (6) is inserted be- 0 250

tween the braking group and the exclusion valve

(7). E2
3 - Connect a pressure gauge E2 (250 bar) to the pressure 6
adapter of the tool and open the cock (7).
RKZ05011

20-56 WB97R-2
TESTING AND ADJUSTMENTS TESTING BRAKE SYSTEM

4 - Operate brake pump to feed pressure into the circuit to

maximum pressure of 150±5 bar.

5 - Maintaining pressure, close the valve (7) to maintain

pressure in the braking group being tested.

6 - Release the brake pedal and check for 2 minutes the

pressure indicated by gauge E2.
★ If the pressure value shows a negative change, it
means that the braking piston seals are defective.
Further confirmation of the leak can also be ob-
tained by an increase in the oil level in the axle,
which leads to a mixing of the oils. Change all the
sealing rings between the axle sections, and carry
out a complete lubrication oil change.

7 - Repeat the test for the other braking group, following the
same method.

8 - Re-assemble the braking circuit

After testing and possible repairs, bleed air from

brake units (see «AIR BLEEDING OF BRAKE CIR-
CUIT»).

WB97R-2 20-57
TESTING AND ADJUSTMENTS CONTROL OF THE ENGINE SPEED UNDER LOAD

CONTROL OF THE ENGINE SPEED UNDER LOAD

★ Test conditions:
• Engine: stopped but at working temperature.
• Hydraulic oil: 45 – 55 °C
• Power train oil: up to working temperature.
• Brake pedals: connected by a cotter-pin.
• Machine: on solid and level ground with the equip-
ment raised and safety devices engaged.

Two tests must be performed:

1 - Speed test with the torque converter under stress.

2 - Speed test with the torque converter and the hydraulic RKZA8580

system under stress.

★ The tests must be performed after a no-load test of
the engine speed.
(For details, see «ENGINE SPEED TESTS»).
During the following tests, while accelerating the
engine with the gear engaged, the condition of the
brake disks can also be checked.
If, while force is being exerted on the brake pedals,
the machine starts to travel (even slowly)
a - Release the accelerator immediately and stop
the engine.
b - Check the wear on the brake disks and change
them before completing the tests (See: «30.
DISMANTLING AND ASSEMBLY - REAR AX-
LE»).

1. Preparing the machine

1 - Prepare the rev. counter C1 to measure the engine rpm.
★ If mounting an electronic pressure transducer rev. C1
counter on a diesel delivery line to the injection noz-
zles, make sure that it is placed far away from the
clamp.
★ If using a stroboscopic tachometer C2, make a
clearly visible notch on the engine pulley to facili-
tate the reading.
Make sure that the brake pedals are fastened to- RKZB6230
gether by the cotter pin (1).

RKZB0021

20-58 WB97R-2
TESTING AND ADJUSTMENTS CONTROL OF THE ENGINE SPEED UNDER LOAD

2. Testing with the torque converter under stress

1 - Start the motor at MIN. Engage the highest FORWARD
gear and brake hard.
2 - Keeping the machine on the brake, accelerate the en-
gine gradually up to high idling and measure the speed
reached.
★ Speed: 2200±50 giri/min

3 - Release the accelerator pedal and move on to the next

test.

3. Testing the torque converter and hydraulic

system under stress
1 - Start the motor at MIN. Engage the highest FORWARD
gear and brake hard.

2 - Keeping the machine on the brake, engage the upper

FORWARD gear, accelerate the engine gradually and
at the same time act on the front bucket closed (curled)
command control valve lever, steer and maintain the
steering at the end of stroke.

3 - Once the maximum engine speed and the maximum

pressure of the bucket circuit have been reached,
measure the speed reached by the engine.
★ Speed: 2050±100 giri/min

• If the revs of the engine are higher than the permissible

limit, in both tests, check the pressure of delivery to the
converter and the clutch pressures. (See «TESTING
PRESSURES OF THE POWER TRAIN GROUP»).
• If the revs of the engine are lower than the permissible
limit, check the condition of the air filter, and the condi-
tions of the engine compression, the timing, the injec-
tion pump, and the valve clearances.

WB97R-2 20-59
TESTING AND ADJUSTMENTS TESTING PRESSURES IN THE POWER TRAIN GROUP

TESTING PRESSURES IN THE POWER TRAIN GROUP

The power train group can be used to perform pressure tests
on the internal hydraulic circuit. These are useful for iden-
tifying malfunctions.
Specifically, the tests involve:
1 - Converter oil pressure.
2 - Clutch engagement pressures for both directions of
travel.

★ Test conditions:
• Engine: stopped.
• Brake pedals: connected by a cotter pin.
• Machine: on solid and level ground with the equip- RKZA8580

ment raised and safety devices engaged.

1. Preparing the machine

1 - Prepare the rev. counter C1 to measure the engine rpm.
★ If mounting an electronic pressure transducer rev.
counter on a diesel delivery line to the injection noz- C1
zles, make sure that it is placed far away from the
line-clamp.
★ If using a stroboscopic tachometer C2, make a
clearly visible notch on the engine pulley to facili-
tate the reading.

Make sure that the brake pedals are fastened to-

gether by the cotter pin (1). RKZB6230

2. Converter oil pressure

1 - Remove the plug (P28) and connect the pressure
gauge E6.

2 - Start the engine and heat the engine and all the fluids up
to working temperature. In particular make sure that the
power train oil reaches a temperature of 80±5 °C.

3 - With the engine at MIN, check the pressure on the pres-

sure gauge E6.
★ Normal pressure: Min. 1 bar - Max 4.5 bar 1
4 - Gradually increase the rev speed to 2200 rpm.
Take a new reading from the pressure gauge E6. RKZB0021

★ Normal pressure: Min. 6 bar - Max 11 bar

5 - Bring the engine back to MIN and compare the pressure
with the normal value. P20 P28
★ Normal pressure: Min. 1 bar - Max 4.5 bar
★ If the maximum pressure value drops to below the
permissible lower limit, the power train pump needs
an overhaul.

P19
RKZ06340

20-60 WB97R-2
TESTING AND ADJUSTMENTS TESTING PRESSURES IN THE POWER TRAIN GROUP

3. Clutch engagement pressure

1 - Remove the cab floor.

2 - Remove the plug (P20) and connect the pressure

gauge E6.

3 - Start the engine and heat the engine and all the fluids up
to working temperature. In particular make sure that the
power train oil reaches a temperature of 80±5 °C. E6
4 - Bring the engine up to MIN. (idling), actuated the brake
pedals, insert the 4th REVERSE gear and check the P20
pressure on the pressure gauge E6. P19 RKZA8590

★ Normal pressure: max 13.5 – 15.5 bar

5 - Gradually increase the rev speed up to 2200 rpm.
Take a new reading from the pressure gauge E6.
★ Normal pressure: max 14.5 – 16.5 bar
6 - Bring the engine back to MIN and compare the pressure
with the normal value.
★ Normal pressure: 13.5 – 15.5 bar
7 - Remove the pressure adapter and replace the plug
(P20).

Cap: 23 Nm

8 - Repeat the same test for the 4th FORWARD gear, read-
ing the pressure from the orifice protected by the plug
(P19).
• If the pressures are different for the two travel di-
rections, there is a loss of pressure on the clutch
piston with lower pressure.

WB97R-2 20-61
TESTING AND ADJUSTMENTS TESTING THE CORRECT FUNCTIONING OF THE POWER TRAIN

TESTING THE CORRECT FUNCTIONING OF THE POWER TRAIN

CLUTCHES
★ Test conditions:
• Engine: stopped.
• Brake pedals: connected by a cotter pin.
• Machine: on solid and level ground with the equip-
ment raised and safety devices engaged.
★ This test must be performed after having checked
the pressures of the power train group.

1. Preparation of the machine

1 - Prepare a rev. counter C1 to measure the engine rpm.
★ If mounting an electronic pressure transducer rev.
counter on a diesel delivery line to the injection noz- RKZA8580

zles, make sure that it is placed far away from the

line-clamp.
★ If using a stroboscopic tachometer C2, make a
clearly visible notch on the engine pulley to facili-
tate the reading.
Make sure that the brake pedals are fastened together C1
by the cotter pin (1).
During the following tests, during the engine accelera-
tion phase with the gear engaged, the condition of the
brake disks can also be checked
If, while force is being exerted on the brake pedals, the
machine starts to travel (even slowly):
a - Release the accelerator immediately and stop the
RKZB6230
engine.
b - Check the wear on the brake disks and change
them before completing the tests.
(See: «30. DISMANTLING AND ASSEMBLY -
REAR AXLE»).

2. Testing
1 - Start the engine and heat the engine and all the fluids up
to working temperature. In particular make sure that the
power train oil reaches a temperature of 80±5 °C.
2 - With the engine in idling condition, accelerate to MAX.
and check that in this condition the revs remain within 1
permissible limits. (See «TESTING ENGINE SPEED»).
3 - Brake hard and bring the engine up to MAX. RKZB0021

4 - Maintaining the braking action and the acceleration, en-

gage the FORWARD gear and check that the engine
speed decreases until it is once again within permissible
limits (See «TESTING THE ENGINE SPEED UNDER
STRESS»).
5 - Repeat this test in REVERSE gear.
★ If the revs are high than the permissible limits, the
clutches are worn, and must be replaced.

20-62 WB97R-2
TESTING AND ADJUSTMENTS ADJUSTING THE SENSOR FOR RETURN TO DIG DEVICE

ADJUSTING THE SENSOR FOR RETURN TO DIG DEVICE

★ Adjustment conditions:
• Machine: on solid and level ground.
• Engine: stopped.
• Hydraulic oil: 45 – 55 °C
• Parking brake: engaged.

1 - Rest the bucket on the ground, making sure that the bot-
tom is perfectly parallel to the surface.

RKZA9440

2 - Stop the engine and remove the sensor guard (1).

RKZB5060

3 - Check that there is a distance 3–4 mm between the sen-

sor (2) and the rod (3).
4 2
If necessary loosen the nuts (4) and adjust the distance, 3
until the indicated measurement is obtained, and se- 3
4 mm
cure that position.

4 - Loosen the screw (5) and move the bracket (6) towards
the rear, until the sensor is completely free of the rod (3). 7
5 - Start the engine and allow to idle. 6
5
Adjust the position of the bracket (6) until the sensor (2)
is engaged.
★ When the rod contacts the sensor, the warning RKZA9460

lamp (7) will be activated.

6 - Lock bracket (6) position.

7 - Perform several tests by raising the bucket and simu-

lating some dumping manoeuvres. If the bucket is able
to rest flat on the ground, replace the sensor guard (1).

WB97R-2 20-63
TESTING AND ADJUSTMENTS ANALYSIS OF CAUSES HYDRAULIC DRIFT

ANALYSIS OF CAUSES HYDRAULIC DRIFT

★ If working attachments have a hydraulic drift, it is nec-
essary to check if reason is due to cylinders gaskets or
to control valve.
★ All testing conditions:
• Engine: at operating temperature
• Hydraulic oil: 45 – 55 °C
• Removal and installation of pipes only after remain
pressure removal.
(See «REMOVAL OF REMAIN PRESSURE
FROM CIRCUIT»)

FRONT EQUIPMENT
1. Testing of front bucket lifting
1 - Put the machine with bucket teeth on blocks of about 10
cm and in vertical position compared to ground.

2 - Stop the engine and remove the remain hydraulic pres-

sure.

3 - Disconnect pipes (1) and (2) from lift cylinders (3) and
plug them. Block

4 - Plug cylinders, base side, and apply a temporary pipe, RKZA8131

head side, to catch possible oil leakage.

5 - Start the engine and retract the bucket until to bring the
teeth in tilt position of about 15°. 1
6 - Stop the engine and check bucket link position for 5 min- 2
utes. 3
• If bucket link has no lowering movement, drift is due
to control valve.

To check each cylinders, proceed as follow:

7 - Carry out with bucket a dump movement to let teeth lean

on ground in vertical position.

8 - Remove from one of cylinders the plug as installed on RKZA5650

base side at stage 4.

9 - Start the engine and retract the bucket until to bring

teeth in tilt position of about 15° towards upper.

10 - Stop the engine and check the bucket position for 5 min-
utes.
• If bucket link has a lowering movement, drift is due
to gaskets of plugged cylinder. 3
11 - Repeat operation from stage 8 to stage 10 to check the
1
other cylinder.
1 3
2
RKZA1840

20-64 WB97R-2
TESTING AND ADJUSTMENTS ANALYSIS OF CAUSES HYDRAULIC DRIFT

2. Testing of front bucket dumping

1 - Put the machine with bucket on level ground and teeth
tilted of about 15°.
Put in the bucket a weight of 1500 kg.

1500 kg

RKZ02130

2 - Disconnect pipes (1) and (2) from dump cylinder (3) and
plug them to avoid impurity inlet.

3 - Plug dump cylinder hole, base side, and apply a tem- 3

porary pipe on head side to catch possible oil leakage.

2
1

RKZB5080

4 - Start the engine and raise the bucket up to the alignment

of the bucket hinge and shovel arm hinge. 1500 kg

5 - Stop the engine and check bucket teeth position for 5

minutes.
• If bucket has no swing movement, drift is due to
control valve.

To test the individual cylinders, proceed as follows:

6 - Lower the bucket to the ground.

7 - Remove from one of the cylinders the plug fitted on the

cylinder bottom side in Phase 3. RKZ02630

8 - Start the engine and raise the bucket as indicated in

phase 4.

9 - Stop the engine and check the position of the bucket

teeth for 5 minutes.
• If the bucket teeth turn, the drift is due to the gasket
seals of the plugged cylinder.

10 - Repeat the operations from phase 6 to phase 9 in order

to test the other cylinder.

WB97R-2 20-65
TESTING AND ADJUSTMENTS ANALYSIS OF CAUSES HYDRAULIC DRIFT

BACKHOE
★ Test condition:
• Backhoe aligned
• Lifted outriggers

1. Boom testing
1 - Set the machine with arm in vertical position and with
bucket on level ground leaned on the side.

2 - Stop the engine and remove the remain hydraulic pres-

sure.
RKZ02510

3 - Disconnect hoses (1) and (2) that feed cylinder (3).

4 - Plug the two hoses to avoid impurity inlet. 3

5 - Plug the cylinder head side.

6 - Apply a temporary pipe on pipe (3) base side to catch

possible oil leakage.

1
RKZA1341

7 - Start the engine and extend completely the arm.

8 - Stop the engine and check the boom position for 5 min-
utes.
• If boom has a lowering movement, drift is due to cyl-
inder gaskets.
• If boom has no lowering movement, drift is due to
control valve.

RKZ02520

2. Arm testing
1 - Set the machine with arm fully extended and with bucket
teeth on ground.

2 - Stop the engine and remove the remain hydraulic pres-

sure.

RKZ02530

20-66 WB97R-2
TESTING AND ADJUSTMENTS ANALYSIS OF CAUSES HYDRAULIC DRIFT

3 - Disconnect pipes (1) and (2) pipes from arm cylinder (3)
and plug them to avoid impurity inlet. 1
3 2
★ If safety valve is fitted, provide to removal.
4 - Plug arm cylinder hole on head side and fit a temporary
pipe on base side to catch possible oil leakage.

RKZA5680

5 - Start the engine and raise the boom.

6 - Stop the engine and check the arm position for 5 min-
utes.
• If arm has a lowering movement, drift is due to cyl-
inder gaskets.
• If arm has no movement, drift is due to control
valve.

RKZ02540

3. Bucket testing
1 - Set the machine with vertical arm and horizontal bucket
leaned at level ground on the side.
Put in the bucket a weight of 450 kg or fill it with earth.

450 kg

RKZ02550

2 - Stop the engine and remove the remain hydraulic pres-

sures.

3 - Disconnect bucket cylinders (3) pipes (1) and (2) and

plug them to avoid impurity inlet
2
4 - Plug bucket cylinder hole on base side and fit a tempo- 1
rary pipe on head side to catch possible oil leakage.

3
RKZA9850

WB97R-2 20-67
TESTING AND ADJUSTMENTS ANALYSIS OF CAUSES HYDRAULIC DRIFT

5 - Start the engine and raise the boom.

6 - Stop the engine and check the bucket position for 5 min-
utes.
• If bucket has an opening movement, drift is due to
cylinder gaskets.
• If bucket has no movement, drift is due to control
valve.

RKZ02560

4. Outriggers testing
1 - Set machine with vertical arm and with bucket leaned at
ground on the side.

2 - Put blocks of about 20 cm under the outriggers.

3 - Without forcing them, lower the outriggers onto the tres-

tles.

20 cm

RKZ02200

4 - Stop the engine and release residual hydraulic pres-

sures. 2 3

5 - Remove clamp (1) and disconnect from cylinders (4) the

pipes (2) and (3).

6 - Plug cylinders pipes (2) base side and apply on head

sides temporary pipes to catch possible oil leakage. 1
4
7 - Start the engine, use force on the boom to raise the ma-
chine, and remove the trestles supporting the outrig-
gers.

RKZA1251

8 - Lower the machine and stop the engine.

9 - Check the outriggers position for 5 minutes.

• If one or both outriggers have a lowering move-
ment, drift is due to single or both cylinders.
• If there is no lowering, drift is due to control valve.

RKZ02210

20-68 WB97R-2
TESTING AND ADJUSTMENTS TESTING THE AIR-CONDITIONING UNIT

TESTING THE AIR-CONDITIONING UNIT

★ Test conditions:
• Machine on level ground with the working equip-
ment raised and in safety conditions
• Parking brake engaged

1. Testing the working temperature

1 - Connect the maintenance station to the high pressure
valve (H.P.) and the low pressure valve (L.P.)

2 - Start the engine and bring it up to a speed of 1500 rpm.

3 - Switch on the A/C unit using the switch in the cab.

RKZA8580

4 - Select an intermediate ventilation speed inside the cab.

5 - Use the thermometer/hygrometer M2 to check that the

temperature inside the cab is equal to or lower than the
ambient temperature.
★ If the temperature of the cab is higher than the am-
bient temperature, open the doors and widows and
wait until the cab temperature stabilizes at the out-
side value.

6 - Close the doors and windows and let the A/C unit op-
erate in these conditions for 5 - 10 minutes.

7 - Use the thermometer M2 to check the temperature of

the air at the central outlets.
★ Position the probe as close as possible to the air
outlets.

8 - Compare the average value of the measured temper-

atures using the following table

Ambient
20 25 30 35
temperature (°C)
Outgoing air
6 -- 8 8 -- 10 8 -- 12 9 -- 14
temperature (°C)

9 - If the average value of the temperature measured does

not fall within the values given in the table, it will be nec-
essary to thoroughly check the unit.

WB97R-2 20-69
TESTING AND ADJUSTMENTS TESTING THE AIR-CONDITIONING UNIT

2. Checking the unit

Check the unit after the point 1., 2., 3., 4. and 6. of the prec-
edent paragraph.
A diagnosis of faults in the unit is based on the working pres-
sures.
When the pressures do not fall within the values given in the
following table, the causes must be sought by checking the
high-pressure (H.P.) and low pressure (L.P.) pressure gaug-
es.
Unit with R134a.
Outside
L.P. (kg/cm²) H.P. (kg/cm²)
Temperature (°C)
Min. Max Min. Max
20 1.2 2.5 6.0 9.0
25 1.0 2.5 7.5 10.5
30 1.1 2.4 9.5 13.0
35 1.3 2.4 12.0 15.5
40 1.5 1.8 18.0 18.8
45 1.8 1.9 21.5 22.0

The following conditions may be found:

Conditions Causes - Faults

• Electromagnetic pulley that slips or does not engage correctly
L.P. high - H.P. normal or low • Expansion valve blocked in open position
• Compressor damaged
• Expansion valve blocked in closed position or obstructed
• Filter saturated with moisture
L.P. low - A.P. high or normal
• Obstruction in the L.P. line or in the H.P. line between the filter and the evap-
oratorL.P.
• Infiltration of hot air into the evaporator group, the pipes or the cab
L.P.normal - H.P. normal • Hot air circulating in the heating group
• Formation of ice on the evaporator
• Normal condition with very high ambient temperature (higher than 43°C)
• Excess coolant(30 – 35% more)
• Overheating of condenser
L.P. high - H.P. high
• Air present in the unit
• Obstruction in the H.P. line between the compressor and the condenser-fil-
ter tube, behind the measurement point of the H.P
• Normal condition with very low temperature (lower than 5°C)
• Lack of coolant (70 - 75% less) (probable leakages)
L.P. normal or low - H.P. low • Obstruction in the H.P. line between the compressor and the condenser-fil-
ter tube, before the measurement point of the H.P.
• Compressor damaged
• Compressor belt missing
L.P. roughly equal to H.P. • Electromagnetic pulley that slips or does not engage
• Compressor damaged

20-70 WB97R-2
TESTING AND ADJUSTMENTS EMPTYING THE AIR-CONDITIONING UNIT

EMPTYING THE AIR-CONDITIONING UNIT

1 - Connect the maintenance station M1 to the service
valves (1) and (2) and follow the specific maintenance
station instructions relative to the drainage of the unit.
17
2 - Disconnect the group to be substituted or reconditioned
immediately after switching off the maintenance station.
Plug the removed or disconnected connection
tubes tightly and with a minimum of delay.
3 - Carefully check the quantity of anti-freeze oil recovered 1
and contained in the disassembled parts, since the 2
same quantity must be replaced when the air-condi-
tioning unit is refilled.
RKZB5050

WB97R-2 20-71
PAGE INTENTIONALLY
LEFT BLANK
 TROUBLESHOOTING

FRONT AXLE TROUBLESHOOTING .......................74

REAR AXLE TROUBLESHOOTING..........................79
TRANSMISSION TROUBLESHOOTING......................84
CHECKING AND INSPECTION OF THE ELECTRONIC
CONTROL UNIT ...........................................................87

WB97R-2 20-73
TROUBLESHOOTING FRONT AXLE 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 in-
Overloading/ incorrect weight distribution
structions related to the vehicle
Replace the tyre or adjust pressure to have same radius on both
Different rotation radius of the tyres
tyre
Bent halfshaft Replace halfshaft

Steering is difficult; vehicle goes straight while its turning.

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
Replace the tyre or adjust pressure to have same radius on both
Different rotation radius of the tyres
tyre
Broken halfshaft Replace halfshaft

No differential action; jamming while steering.

CAUSES REMEDY
Incorrect installation Correct installation
Replace the differential in case it does not survive any one of the
Defective axle
test phases
Broken halfshaft Replace halfshaft
Bent halfshaft Replace halfshaft

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 in-
Overloading/ incorrect weight distribution
structions related to the vehicle
Replace the tyre or adjust pressure to have same radius on both
Different rotation radius of the tyres
tyre
Bent or broken halfshaft Replace halfshaft
Incorrect wheel adjustment Verify group integrity and wheel side bearings.
Contamination in the axle box or incorrect assembly Look for foreign particles. Check assembly of the various parts of
of parts the axle.

20-74 WB97R-2
TROUBLESHOOTING FRONT AXLE TROUBLESHOOTING

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 in-
Overloading/ incorrect weight distribution
structions related to the vehicle
Replace the tyre or adjust pressure to have same radius on both
Different rotation radius of the tyres
tyre
Bent or broken halfshaft Replace halfshaft
Blocked halfshaft:
• Abnormal functioning of the differential or breakage/ • Verify assembly and all components
blockage of command device.
• Vehicles with wide steering angle may proceed with • Reduce the steering angle to minimum and decelerate when the
kicks, have steering difficulty or cause pneumatic vehicle begins to kick.
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
Bent or broken halfshaft Replace halfshaft
Check the condition of ring gear, pinion gear, bearings etc. Replace
Spoiled or worn out axle parts
when ever necessary.
Contamination in the axle box or incorrect assembly Look for foreign particles. Check assembly of the various parts of
of parts the axle.
Incorrect adjustment of bevel gearset: Parts of the
transmission worn out. Replace or adjust as required.
(transmission gears, U joints, etc.)

Vibration during forward drive, intermittent 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 in-
Overloading/ incorrect weight distribution
structions related to the vehicle
Bent halfshaft Replace halfshaft
Replace the tyre or adjust pressure to have same radius on both
Different rotation radius of the tyres
tyre

WB97R-2 20-75
TROUBLESHOOTING FRONT AXLE TROUBLESHOOTING

Noise while driving

CAUSES REMEDY
Excessive backlash between pinion and ring gear Adjust
Worn out pinion and gear ring Replace
Worn out pinion bearings Replace
Pinion bearings loosened Adjust
Excessive axial pinion backlash Adjust
Worn out differential bearings Replace
Differential bearings loosened Adjust
Ring gear out of roundness Replace
Low lubricant level Oil level
Poor or wrong lubricant Replace
Bent halfshaft Replace

Noise while driving in neutral

CAUSES REMEDY
Noise coming from axle are usually heard when vehicle
Replace or adjust (see above)
moves in neutral gear but are not loud.
Incorrect backlash between pinion and ring (sound
heard while decelerating disappears while increasing Replace
the speed)
Pinion or input flange worn out Adjust

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

Noise while steering

CAUSES REMEDY
Worn out differential gears Replace
Worn out differential box or spider Replace
Differential thrust washers worn out Replace
Half shaft spline worn out Replace

20-76 WB97R-2
TROUBLESHOOTING FRONT AXLE TROUBLESHOOTING

Ring gear tooth broken at the outer side

CAUSES REMEDY
Excessive gear load compared to the one foreseen Replace bevel gear set
Incorrect gear adjustment (excessive backlash) Follow carefully the recommended operations for the adjustment of
Pinion nut loosened bevel gear set free backlash

Ring gear tooth broken side

CAUSES REMEDY
Load bump
Replace bevel gear set
Incorrect gear adjustment (insufficient backlash)
Adjust bevel gear set freebacklash
Pinion nut loosened

Pinion or ring gear teeth or worn

CAUSES REMEDY
Insufficient lubrication; contaminated oil; Replace bevel gear set
incorrect lubrication or depleted additives Follow carefully the recommended operations for the adjustment of
bevel gear set freeplay
Worn out pinion bearings Use correct lubricants, fill up to the right levels and replace accord-
ing to the recommended program.

Overheated ring and pinion teeth

CAUSES REMEDY
Prolong ed functioning at high temperatures Replace bevel gear set.
Insufficient lubrication; contaminated oil; Use proper lubrication, fill up to right level and replace at recom-
incorrect lubrication mended program.

Pinion teeth pitting

CAUSES REMEDY
Excessive use Replace bevel gear set.
Use correct lubrication, fill up to the right level and substitute at rec-
Insufficient lubrication ommended intervals

Axle beam body bent

CAUSES REMEDY
Vehicle over loaded
Vehicle's accident Replace axle beam body
Load bump

Worn out or pitted bearings

CAUSES REMEDY
Insufficient lubrication; contaminated oil
Excessive use Replace bearings.
Use correct lubrication fill up, to the right level and replace at rec-
Normal wear out ommended intervals
Pinion nut loosened

WB97R-2 20-77
TROUBLESHOOTING FRONT AXLE TROUBLESHOOTING

Oil leakage form gaskets and seals

CAUSES REMEDY
Prolonged functioning at high temperature of the oil
Oil gasket assembled incorrectly Replace the gasket or seal and matching surface if damaged
Seal lip damaged Use correct lubrication and replace at recommended intervals

Contaminated oil

Excessive wearing out of input flange spline

CAUSES REMEDY
Exhaustive use
Replace the flange
Pinion nut loosened Check that the pinion spline is not excessively worn out
Replace bevel gear set if required
Pinion axle backlash

Fatigue failure of pinion teeth

CAUSES REMEDY
Exhaustive use
Replace bevel gear set
Continuous overload

Pinion and ring teeth breakage

CAUSES REMEDY
Crash load of differential components Check and/or replace other differential components

Side gear spline worn out

CAUSES REMEDY
Replace differential gear group.
Excessive use
Replace halfshaft if required

Thrust washer surface worn out or scratched

CAUSES REMEDY
Use correct lubrication and fill up to right level.
Insufficient lubrication; contaminated oil; Replace at intervals recommended.
incorrect lubrication Replace all scratched washers and those with 0.1mm thickness
lower than the new ones

Inner diameter of tapered roller bearing worn out

CAUSES REMEDY
Excessive use axial pinion Replace bearing.
Check pinion axial backlash.
Excessive pinion axial backlash
Use proper lubrication, fill up to right level and replace at recom-
Insufficient lubrication; contaminated oil mended intervals.

Bent or broken halfshaft or halfshaft broken at wheel side

CAUSES REMEDY
Vehicle intensively operated or overloaded
Replace.
Wheel support loosened
Check that wheel support is not worn out or wrongly adjusted.
Beam body bent

20-78 WB97R-2
TROUBLESHOOTING REAR AXLE TROUBLESHOOTING

REAR 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 in-
Overloading/ incorrect weight distribution
structions related to the vehicle
Replace the tyre or adjust pressure to have same radius on both
Different rotation radius of the tyres
tyre
Bent halfshaft Replace halfshaft

Steering is difficult; vehicle goes straight while its turning.

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
Replace the tyre or adjust pressure to have same radius on both
Different rotation radius of the tyres
tyre
Broken halfshaft Replace halfshaft

No differential action; jamming while steering.

CAUSES REMEDY
Incorrect installation Correct installation
Replace the differential in case it does not survive any one of the
Defective axle
test phases
Broken halfshaft Replace halfshaft
Bent halfshaft Replace halfshaft

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 in-
Overloading/ incorrect weight distribution
structions related to the vehicle
Replace the tyre or adjust pressure to have same radius on both
Different rotation radius of the tyres
tyre
Bent or broken halfshaft Replace halfshaft
Incorrect wheel adjustment Verify group integrity and wheel side bearings.
Contamination in the axle box or incorrect assembly Look for foreign particles. Check assembly of the various parts of
of parts the axle.

WB97R-2 20-79
TROUBLESHOOTING REAR AXLE TROUBLESHOOTING

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 in-
Overloading/ incorrect weight distribution
structions related to the vehicle
Replace the tyre or adjust pressure to have same radius on both
Different rotation radius of the tyres
tyre
Bent or broken halfshaft Replace halfshaft
Blocked halfshaft:
• Abnormal functioning of the differential or breakage/ • Verify assembly and all components
blockage of command device.
• Vehicles with wide steering angle may proceed with • Reduce the steering angle to minimum and decelerate when the
kicks, have steering difficulty or cause pneumatic vehicle begins to kick.
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
Bent or broken halfshaft Replace halfshaft
Check the condition of ring gear, pinion gear, bearings etc. Replace
Spoiled or worn out axle parts
when ever necessary.
Contamination in the axle box or incorrect assembly Look for foreign particles. Check assembly of the various parts of
of parts the axle.
Incorrect adjustment of bevel gearset: Parts of the
transmission worn out. Replace or adjust as required.
(transmission gears, U joints, etc.)

Vibration during forward drive, intermittent 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 in-
Overloading/ incorrect weight distribution
structions related to the vehicle
Bent halfshaft Replace halfshaft
Replace the tyre or adjust pressure to have same radius on both
Different rotation radius of the tyres
tyre

20-80 WB97R-2
TROUBLESHOOTING REAR AXLE TROUBLESHOOTING

Noise while driving

CAUSES REMEDY
Excessive backlash between pinion and ring gear Adjust
Worn out pinion and gear ring Replace
Worn out pinion bearings Replace
Pinion bearings loosened Adjust
Excessive axial pinion backlash Adjust
Worn out differential bearings Replace
Differential bearings loosened Adjust
Ring gear out of roundness Replace
Low lubricant level Oil level
Poor or wrong lubricant Replace
Bent halfshaft Replace

Noise while driving in neutral

CAUSES REMEDY
Noise coming from axle are usually heard when vehicle
Replace or adjust (see above)
moves in neutral gear but are not loud.
Incorrect backlash between pinion and ring (sound
heard while decelerating disappears while increasing Replace
the speed)
Pinion or input flange worn out Adjust

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

Noise while steering

CAUSES REMEDY
Worn out differential gears Replace
Worn out differential box or spider Replace
Differential thrust washers worn out Replace
Half shaft spline worn out Replace

WB97R-2 20-81
TROUBLESHOOTING REAR AXLE TROUBLESHOOTING

Ring gear tooth broken at the outer side

CAUSES REMEDY
Excessive gear load compared to the one foreseen Replace bevel gear set
Incorrect gear adjustment (excessive backlash) Follow carefully the recommended operations for the adjustment of
Pinion nut loosened bevel gear set free backlash

Ring gear tooth broken side

CAUSES REMEDY
Load bump
Replace bevel gear set
Incorrect gear adjustment (insufficient backlash)
Adjust bevel gear set freebacklash
Pinion nut loosened

Pinion or ring gear teeth or worn

CAUSES REMEDY
Insufficient lubrication; contaminated oil; Replace bevel gear set
incorrect lubrication or depleted additives Follow carefully the recommended operations for the adjustment of
bevel gear set freeplay
Worn out pinion bearings Use correct lubricants, fill up to the right levels and replace accord-
ing to the recommended program.

Overheated ring and pinion teeth

CAUSES REMEDY
Prolong ed functioning at high temperatures Replace bevel gear set.
Insufficient lubrication; contaminated oil; Use proper lubrication, fill up to right level and replace at recom-
incorrect lubrication mended program.

Pinion teeth pitting

CAUSES REMEDY
Excessive use Replace bevel gear set.
Use correct lubrication, fill up to the right level and substitute at rec-
Insufficient lubrication ommended intervals

Axle beam body bent

CAUSES REMEDY
Vehicle over loaded
Vehicle's accident Replace axle beam body
Load bump

Worn out or pitted bearings

CAUSES REMEDY
Insufficient lubrication; contaminated oil
Excessive use Replace bearings.
Use correct lubrication fill up, to the right level and replace at rec-
Normal wear out ommended intervals
Pinion nut loosened

20-82 WB97R-2
TROUBLESHOOTING REAR AXLE TROUBLESHOOTING

Oil leakage form gaskets and seals

CAUSES REMEDY
Prolonged functioning at high temperature of the oil
Oil gasket assembled incorrectly Replace the gasket or seal and matching surface if damaged
Seal lip damaged Use correct lubrication and replace at recommended intervals

Contaminated oil

Excessive wearing out of input flange spline

CAUSES REMEDY
Exhaustive use
Replace the flange
Pinion nut loosened Check that the pinion spline is not excessively worn out
Replace bevel gear set if required
Pinion axle backlash

Fatigue failure of pinion teeth

CAUSES REMEDY
Exhaustive use
Replace bevel gear set
Continuous overload

Pinion and ring teeth breakage

CAUSES REMEDY
Crash load of differential components Check and/or replace other differential components

Side gear spline worn out

CAUSES REMEDY
Replace differential gear group.
Excessive use
Replace halfshaft if required

Thrust washer surface worn out or scratched

CAUSES REMEDY
Use correct lubrication and fill up to right level.
Insufficient lubrication; contaminated oil; Replace at intervals recommended.
incorrect lubrication Replace all scratched washers and those with 0.1mm thickness
lower than the new ones

Inner diameter of tapered roller bearing worn out

CAUSES REMEDY
Excessive use axial pinion Replace bearing.
Check pinion axial backlash.
Excessive pinion axial backlash
Use proper lubrication, fill up to right level and replace at recom-
Insufficient lubrication; contaminated oil mended intervals.

Bent or broken halfshaft or halfshaft broken at wheel side

CAUSES REMEDY
Vehicle intensively operated or overloaded
Replace.
Wheel support loosened
Check that wheel support is not worn out or wrongly adjusted.
Beam body bent

WB97R-2 20-83
TROUBLESHOOTING TRANSMISSION 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 electrical wiring Clean
Break in electric cable Replace
Damaged solenoids Replace
Damaged sensors Replace
Short circuits or false contacts Check/replace fuses
Irregular functioning of electronic gear
Replace EGM
management (EGM)
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 0°C Wait for oil to reach working temperature (stall test)
Damaged rotary seals Replace
Blocked reverser lever Repair
Worn clutch unit Replace/Repair clutch unit
No drive transmission
Check/Repair/Replace
(broken gears, shafts, bearings, etc.)

Vehicle has reduced power transmission

CAUSES REMEDY
Incorrect oil temperature Wait for oil to reach working temperature (stall test)
Transmission oil overheating Restore acceptable temperature values
Incorrect operating pressure Check hydraulic circuit and replace (oil pump, filters, control valve)
Damaged converter Replace
Incorrect oil level Top up
Worn clutch unit Replace/Repair
4WD clutch failure Repair/Replace 4WD shaft group
Overheating solenoids Replace
Damaged transmission and vehicle wiring connections Repair/Replace
Damaged EGM logic Replace EGM
Damaged sensors Replace

20-84 WB97R-2
TROUBLESHOOTING TRANSMISSION TROUBLESHOOTING

Overheating
CAUSES REMEDY
Damaged hydraulic cooling system Repair
Dirty heat exchanger Clean
Parking brake inadvertently activated Release
Excessive dirt on axle wheel hubs Clean
Seizing (broken gears, shafts, bearings, etc.) Check/Repair/Replace
Braking force outside transmission:
Check/Repair axle
irregular axle operation
Clutch plate drag Repair/Replace
Damaged converter Replace
Damaged oil thermostat Replace
Incorrect oil level Top up
Worn oil pump Replace

Wheels rotate when vehicle is raised

CAUSES REMEDY
Clutch plate drag Repair/Replace
Low oil temperature (high oil viscosity) Wait for oil to reach working temperature (stall test)
Incorrect oil specifications Replace oil and filters
Damaged control valve Replace
Faulty reverser locking Repair/Replace

Noise
CAUSES REMEDY
Damaged converter Replace
Damaged oil pump Replace
Aeration/Cavitation Check oil level / Check oil specifications
Seizing (broken gears, shafts, bearings, etc.) Check/Repair/Replace
Worn clutch plates Replace

Irregular 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"
Faulty EGM operation Replace EGM
Damaged hydraulic system Repair/Replace

WB97R-2 20-85
TROUBLESHOOTING TRANSMISSION TROUBLESHOOTING

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
Irregular EGM operation Replace EGM
No 4WD power transmission
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
Faulty EGM operation Replace EGM

Gear shift won’t engage

CAUSES REMEDY
Damaged clutch unit Repair/Replace
Damaged hydraulic system Repair/Replace
Damaged control valve Replace
Damaged pressure sensors Check/Replace
Electrical system fault Repair/Replace
Irregular EGM operation Replace EGM

20-86 WB97R-2
TROUBLESHOOTING CHECKING AND INSPECTION OF THE ELECTRONIC CONTROL

CHECKING AND INSPECTION OF THE ELECTRONIC CONTROL UNIT

1. FAILURE
Condition in both autotest and operating mode
• Red alarm LED (1) permanently on 1
• No. 3 long beeps (1 sec)
• Numerical message on display (2) 2
• Rest state for all solenoid valves

RKZ06540

1.1 Numerical error

Numerical error code

Error code description Cause of alarm
on display

Alarm from general pressure sensor alarm Insufficient pressure in system

Insufficient electrical power.

General alarm
Electronic card defective

2. ANOMALY
Condition in autotest mode:
• Red alarm LED (1) flashing 1
• No. 3 long beeps (1 sec)
• Numerical message on display (2) 2
Flashing numerical message on display (15) in place of gear
selected

RKZ06540

2.1 Numerical error

Numerical error code

Error code description Cause of alarm
on display

Alarm from oil thermostat Overheating

Alarm from 1st gear pressure sensor Insufficient pressure on 1st gear clutch

WB97R-2 20-87
TROUBLESHOOTING CHECKING AND INSPECTION OF THE ELECTRONIC CONTROL

Numerical error code

Error code description Cause of alarm
on display

Alarm from 2nd gear pressure sensor Insufficient pressure on 2nd gear clutch

Alarm from 3rd gear pressure sensor Insufficient pressure on 3rd gear clutch

Alarm from 4th gear pressure sensor Insufficient pressure on 4th gear clutch

Alarm from 1st gear solenoid valve 1st gear solenoid valve failure

Alarm from 2nd gear solenoid valve 2nd gear solenoid valve failure

Alarm from 3rd gear solenoid valve 3rd gear solenoid valve failure

Alarm from 4th gear solenoid valve 4th gear solenoid valve failure

Alarm from FORWARD FORWARD control solenoid valve

control solenoid valve failure

Alarm from REVERSE control solenoid valve REVERSE control solenoid valve failure

Alarm from 4WD control solenoid valve 4WD control solenoid valve failure

20-88 WB97R-2
 REMOVAL AND INSTALLATION

HOW TO READ THE MANUAL ......................................3 INSTALLATION OF THE HEATING AND AIR-CONDI-
PRECAUTIONS TO BE TAKEN WHILE WORKING ......4 TIONING GROUP ........................................................ 46
SPECIAL TOOLS............................................................5 REMOVAL OF THE FUEL TANK ................................. 47
INSTALLATION OF THE FUEL TANK ........................ 47
REMOVAL OF STARTING MOTOR ...............................9
INSTALLATION OF THE STARTING MOTOR ..............9 REMOVAL OF HYDRAULIC OIL TANK....................... 48
INSTALLATION OF THE HYDRAULIC OIL TANK ...... 48
REMOVAL OF THE ALTERNATOR .............................10
INSTALLATION OF THE ALTERNATOR ....................11 REMOVAL OF THE ENGINE-GEARBOX-PUMP
GROUP ........................................................................ 49
REMOVAL OF THE AIR-CONDITIONING UNIT
INSTALLATION OF THE ENGINE GEARBOX-PUMP
COMPRESSOR ............................................................12
GROUP ........................................................................ 54
INSTALLATION OF THE AIR-CONDITIONING UNIT
COMPRESSOR ...........................................................13 REMOVAL OF THE PISTON PUMP ............................ 55
INSTALLATION OF THE PISTON PUMP .................... 56
REMOVAL OF THE INJECTION PUMP .......................14
INSTALLATION OF THE INJECTION PUMP ..............16 REMOVAL OF THE TRANSMISSION ......................... 57
INSTALLATION OF THE TRANSMISSION ................. 60
REMOVAL OF THE VALVE COVER ............................17
DISASSEMBLY AND ASSEMBLY OF
INSTALLATION OF THE VALVE COVER ....................19
TRANSMISSION .......................................................... 61
REMOVAL OF THE INJECTION NOZZLES.................20
REMOVAL OF THE CONVERTOR............................ 159
INSTALLATION OF THE INJECTION NOZZLES.........21
INSTALLATION OF THE CONVERTOR ................... 159
REMOVAL OF THE THERMOSTAT.............................22
REMOVAL OF THE TRANSMISSION-REVERSE,
INSTALLATION OF THE THERMOSTAT ....................22
DIRECTION INDICATOR AND HEADLIGHT DIPPER
REMOVAL OF THE COOLING LIQUID PUMP ............23 BEAM CONTROL GROUP (standard version)........... 160
INSTALLATION OF THE COOLANT LIQUID PUMP ...24 INSTALLATION OF THE TRANSMISSION REVERSE,
REMOVAL OF THE TURBOCOMPRESSOR...............25 DIRECTION INDICATOR AND HEADLIGHT DIPPER
INSTALLATION OF THE TURBOCOMPRESSOR ......26 BEAM CONTROL GROUP ....................................... 160
REMOVAL OF THE CYLINDER HEAD ........................27 REMOVAL OF THE TRANSMISSION-REVERSE,
INSTALLATION OF THE CYLINDER HEAD ...............30 DIRECTION INDICATOR AND HEADLIGHT DIPPER
BEAM CONTROL GROUP (EGM version) ................ 161
REMOVAL OF THE FRONT COUNTERWEIGHT........32
INSTALLATION OF THE TRANSMISSION REVERSE,
INSTALLATION OF THE FRONT COUNTERWEIGHT ... 32
DIRECTION INDICATOR AND HEADLIGHT DIPPER
REMOVAL OF THE RADIATOR UNIT .........................33 BEAM CONTROL GROUP ....................................... 161
INSTALLATION OF THE RADIATOR GROUP.............35
REMOVAL OF THE STEERING UNIT ....................... 162
REMOVAL OF THE CONDENSER ..............................36 INSTALLATION OF THE STEERING UNIT .............. 162
INSTALLATION OF THE CONDENSER .....................36
REMOVAL OF THE WORKING BRAKE
REMOVAL OF THE MUFFLER ....................................37 PUMP GROUP ........................................................... 163
INSTALLATION OF THE MUFFLER ...........................37 INSTALLATION OF THE WORKING BRAKE
REMOVAL OF THE EXHAUST PIPE ...........................38 PUMP GROUP .......................................................... 163
INSTALLATION OF THE EXHAUST PIPE ..................38 REMOVAL OF THE FRONT WORKING EQUIPMENT
REMOVAL OF THE ENGINE HOOD............................39 CONTROL VALVE ..................................................... 164
INSTALLATION OF THE ENGINE HOOD ...................39 INSTALLATION OF THE FRONT
WORKING EQUIPMENT CONTROL VALVE ........... 164
REMOVAL OF THE CAB ..............................................40
INSTALLATION OF THE CAB .....................................44 DISASSEMBLY AND ASSEMBLY FRONT AND
BACKHOE CONTROL VALVE................................... 165
REMOVAL OF THE HEAT AND
AIR-CONDITIONING GROUP ......................................45 REMOVAL OF THE FRONT AXLE ............................ 181
INSTALLATION OF THE FRONT AXLE ................... 182

WB97R-2 30-1
DISASSEMBLY OF FRONT AXLE............................. 183 INSTALLATION OF THE BACKHOE BUCKET
ASSEMBLY OF FRONT AXLE................................... 192 CYLINDER .................................................................267
REMOVAL OF THE REAR AXLE............................... 208 REMOVAL OF THE OUTRIGGER CYLINDERS........268
INSTALLATION OF THE REAR AXLE ...................... 209 INSTALLATION OF THE OUTRIGGER
DISASSEMBLY OF REAR AXLE ............................... 210 CYLINDERS ..............................................................269
ASSEMBLY OF REAR AXLE ..................................... 225 REMOVAL OF THE BACKHOE SWING CYLINDERS270
REMOVAL OF THE FRONT BUCKET INSTALLATION OF THE BACKHOE SWING
BOOM-RAISING CYLINDER ..................................... 244 CYLINDERS ..............................................................270
INSTALLATION OF FRONT BUCKET REMOVAL OF BACKHOE BACKFRAME
BOOM-RAISING CYLINDER .................................... 244 LOCK CYLINDER .......................................................271
REMOVAL OF THE FRONT BUCKET TILT INSTALLATION OF BACKHOE BACKFRAME
CYLINDERS ............................................................... 245 LOCK CYLINDER ......................................................271
INSTALLATION OF THE FRONT BUCKET TILT DISASSEMBLY OF CYLINDERS
CYLINDERS .............................................................. 245 (Front bucket raise and tilt, boom, arm, bucket, outriggers
REMOVAL OF THE FRONT BUCKET....................... 246 and jig arm) .................................................................272
INSTALLATION OF THE FRONT BUCKET .............. 246 ASSEMBLY OF CYLINDERS
REMOVAL OF THE FRONT WORKING (Front bucket raise and tilt, boom, arm, bucket, outriggers
EQUIPMENT .............................................................. 247 and jig arm) .................................................................274
INSTALLATION OF THE FRONT WORKING DISASSEMBLY OF BOOM SWING CYLINDER ........278
EQUIPMENTI ............................................................ 248 ASSEMBLY OF BOOM SWING CYLINDER ..............279
REMOVAL OF THE BACKHOE CONTROL VALVE DISASSEMBLY OF BACKHOE BACKFRAME LOCK
(standard version)....................................................... 249 CYLINDER..................................................................281
INSTALLATION OF THE BACKHOE ASSEMBLY OF BACKHOE BACKFRAME LOCK
CONTROL VALVE .................................................... 250 CYLINDER .................................................................281
REMOVAL OF THE BACKHOE CONTROL VALVE REMOVAL OF THE BOOM SAFETY CYLINDER ......282
(version with servocontrol).......................................... 251 INSTALLATION OF THE BOOM SAFETY
INSTALLATION OF THE BACKHOE CYLINDER .................................................................282
CONTROL VALVE ..................................................... 253 REMOVAL OF THE BACKHOE WORKING
REMOVAL OF THE PPC VALVES CONTROLLING THE EQUIPMENT...............................................................283
BACKHOE CONTROL VALVES (OPTIONAL) ........... 254 INSTALLATION OF THE BACKHOE WORKING
INSTALLATION OF THE PPC VALVES ................... 255 EQUIPMENT ..............................................................283
REPLACING THE PPC VALVE SUPPORT REMOVAL OF THE BACKHOE BUCKET ..................284
RELEASE CABLES.................................................... 256 INSTALLATION OF THE BACKHOE BUCKET .........284
REMOVAL OF THE PPC VALVE SUPPORT REMOVAL OF THE ARM ...........................................285
RETURN GAS SPRING ............................................. 259 INSTALLATION OF THE ARM ..................................285
INSTALLATION OF THE PPC VALVE SUPPORT REMOVAL OF COMPLETE JIG ARM ........................286
RETURN GAS SPRING ............................................ 260 INSTALLATION OF THE COMPLETE JIG ARM .......286
REMOVAL OF THE SOLENOID VALVE ASSEMBLY REMOVAL OF 2nd ARM ............................................287
CONTROLLING THE HAMMER AND JIG ARM/HAMMER INSTALLATION OF 2nd ARM ...................................287
AND SIDE DIGGING BOOM ...................................... 261
INSTALLATION OF THE SOLENOID VALVE ASSEMBLY REMOVAL OF 2nd ARM GUIDES..............................288
CONTROLLING THE HAMMER AND JIG ARM/HAMMER INSTALLATION OF 2nd ARM GUIDE .......................288
AND SIDE DIGGING BOOM ..................................... 261 REMOVAL OF THE BACKHOE BOOM......................289
REMOVAL OF THE SERVOCONTROL FEED VALVE INSTALLATION OF THE BACKHOE BOOM .............289
(OPTIONAL) ............................................................... 262 REMOVAL OF THE BACKHOE SWING BRACKET ..290
INSTALLATION OF THE SERVOCONTROL FEED INSTALLATION OF THE BACKHOE
VALVE (OPTIONAL) .................................................. 263 SWING BRACKET .....................................................290
REMOVAL OF BACKHOE BOOM CYLINDER .......... 264 REMOVAL OF BACKHOE BACKFRAME ..................291
INSTALLATION OF THE BACKHOE INSTALLATION OF BACKHOE BACKFRAME .........291
BOOM CYLINDER .................................................... 264
REMOVAL OF THE BACKHOE ARM CYLINDER ..... 265
INSTALLATION OF THE BACKHOE ARM
CYLINDER ................................................................ 265
REMOVAL OF THE JIG ARM CYLINDER ................. 266
INSTALLATION OF THE JIG ARM CYLINDER ........ 266
REMOVAL OF THE BACKHOE BUCKET
CYLINDER ................................................................. 267

30-2 WB97R-2
REMOVAL AND INSTALLATION HOW TO READ THE MANUAL

HOW TO READ THE MANUAL

1. Removal and Installation of the groups
(1) The procedures and information needed to carry out the work of removing or Installing units or groups are given
in the removal procedure. The sequence of operations is not repeated in the installation procedure.

(2) Information needed for installation is marked with the symbol 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 GROUP ● ● ● : .......................................................Title of operation

: ............................................................................................Safety precautions to be followed when carrying

out the operation.
1 - Remove XXXX (1): ..............................................................Step in removal procedure.
★:.........................................................................................Technique or important point to remember when
removing XXXX (1)
2 - ▲ ▲ ▲ (2):................................................................... 1 This sign means that information is given
for the installation procedure
3 - Remove ■ ■ ■ (3):
...........
: ......................................................................Recovery of oil or water, and the quantity to be
recovered.

INSTALLATION GROUP ● ● ● : ...............................................Title of operation

• To install, reverse removal procedure.

1 : .........................................................................................Technique to be used for installation

★:.........................................................................................Technique or important point to remember when
removing ▲ ▲ ▲ (2)

• Addition of water or oil: ........................................................Step in removal procedure

★:.........................................................................................Point to remember when adding water or oil.

2. To the precautions to be taken during the removal or installation of the groups, must be added the specific «PRE-
CAUTIONS TO BE TAKEN DURING THE OPERATIONS».
Always make sure that these precautions are taken.

3. List of special tools

(1) For details of the descriptions, codes and quantities of each tool (A1; A2 etc.) mentioned in the operational pro-
cedures, see the list «SPECIAL TOOLS» supplied in this section.

4. List of the tightening torques and weights, and the quantities oil, liquids or grease needed to fill tanks and
containers

(1) In the operating procedures, you will find the symbols , , , ; In the following order, these rep-
resent the values of «TIGHTENING TORQUES», «WEIGHT OF PARTS OR GROUPS», «QUANTITIES OF
OIL OR LIQUIDS TO BE INTRODUCED», «SCREW LOCKING MATERIAL, SEALANTS AND LUBRICA-
TION», «LUBRICATING GREASE».

NOTE
If no symbol is indicated, the values to be used are those given in the introductory sections of this manual.

WB97R-2 30-3
REMOVAL AND INSTALLATION PRECAUTIONS TO BE TAKEN WHILE WORKING

PRECAUTIONS TO BE TAKEN WHILE WORKING

★ When dismantling or installing a part, always take the following general precautions.

1. Precautions for removal operations

• If not otherwise indicated, lower the work equipment until it rests on the ground.
• If the coolant liquid contains an anti-freeze substance, follow the instructions given for drainage.
• After having removed flanges and tubes, insert plugs to prevent impurities from entering.
• Before removing a cylinder, fully retract the piston and tie it with wire.
• Use a sufficiently large container to collect the oil.
• Before removing a part from the machine, check the alignment reference marks which show the correct in-
stallation position. If necessary add further marks to avoid incorrect installation.
• While dismantling the connectors, always grasp them firmly to avoid undue strain on the wiring.
• If necessary, attach markers to the wires and tubes to avoid muddling them up during installation.
• Check the number and height of the adjustments to a given clearance and store them in a safe place.
• When raising the machine or some parts of it, use adequate equipment for the weight of the part concerned.
• When using screws or eyebolts to remove items of the machinery, screw them alternately, and as deeply as
they will go.
• Before removing a piece, clean the surrounding area and, after removal, cover the area to prevent dirt or dust
from gaining entrance.

2. Precautions to be taken during installation

• Tighten nuts and screws with the specified tightening torques.
• Install the flexible hoses, taking care not to entangle or twist them.
• Bend the cotter pins and stops in such a way as to secure them.
• When coating the threads with adhesives, clean the piece to remove oil and grease, then apply just enough ad-
hesive to cover the threading in a uniform manner.
• When applying a liquid sealant, clean the surface involved, remove residual oil and grease, check that there are
no dents or dirt, then apply the liquid sealant in a uniform manner.
• Clean all the parts, remove dirt, rust, burrs, or dents.
• Apply a film of engine oil over all the moving parts.
• Apply a film of anti-friction grease (ASL800040) over all surfaces assembled with pressure, to avoid sticking
• After having mounted the snap-rings, check that they are firmly positioned in their seatings.
• When installing electrical system jacks, remove any oil, dust or water that may have penetrated into them, then
connect them firmly.
• If using eyebolts, check that they are not distorted, screw them in fully, and then align the eye with the hoisting
hook.
• Mount the flanges in a uniform manner, and tighten the screws in criss-cross sequence, to avoid excessive pull
on one side only.

3. Precautions to be taken on completion of removal and installation operations.

• If the coolant liquid has been drained away, close the drainage plug and add new liquid up to normal level. Start
the engine to circulate the liquid throughout the cooling system and then top up the level once more.
• When the hydraulic equipment has been dismantled, add engine oil to the indicated level. Start up the engine
to circulate the oil in the hydraulic circuits, and then top up to the indicated level.
• If hoses or hydraulic equipment, such as hydraulic cylinders, pumps, motors, solenoid valves and valves, are
removed for repairs or substitution, bleed air from the hydraulic circuits after having re-assembled the machine.
★ For details, see «20. TESTING AND ADJUSTMENTS».
• After having re-assembled cylinder joints or cylinders, or work equipment articulations, lubricate thoroughly.

30-4 WB97R-2
REMOVAL AND INSTALLATION SPECIAL TOOLS

SPECIAL TOOLS
Nature of work Symbol Code Description Q.ty Notes
ATR200620
Cylinder disassembly -
1 See Attachment 1
assembly
960119000
Plunger Ø 40 2
Hydraulic
press Plunger Ø45 2 Assembly cylinder
2
Commercially Plunger Ø50 2 and rod bushings
available
Plunger Ø75 2
See
Bushing 1
960117005 To calibrate piston
3
See gasket
Bushing support 1
960117006
Notched wrench for
1
cylinders Ø70
Notched wrench for
1
cylinders Ø80
Notched wrench for
1
cylinders Ø85
4
Commercially Notched wrench for Disassembly-assembly
1
available cylinders Ø95 head cylinder
Notched wrench for
1
cylinders Ø115-120
Disassembly and Notched wrench for
A 1
assembly cylinder cylinders Ø110
Notched wrench for
5 1
boom cylinders
Disassembly ring nut
boom cylinder
6 ATR200300 Notched wrench 1
Boom swing head
disassembly-assembly
Socket wrench (6-point 46) 1
Commercially Removal - installation of
7 Socket wrench (6-point 55) 1
available piston
Socket wrench (6-point 65) 1
Plunger Ø40 1
Hydraulic
press Plunger Ø50 1
8 Dust seal assembly
Commercially Plunger Ø55 1
available
Plunger Ø60 1
Expander Ø70 1
Expander Ø80 1
See Expander Ø85 1
960117002
9 Expander Ø95 1 Piston gaskets assembly
960117003
960030002 Expander Ø100 1
Expander Ø110 1
Expander Ø115 1

WB97R-2 30-5
REMOVAL AND INSTALLATION SPECIAL TOOLS

Nature of work Symbol Code Description Q.ty Notes

Bushing for rod Ø40 1
Bushing for rod Ø45 1
See
10 Bushing for rod Ø50 1 Head assembly on rod
960117001
Bushing for rod Ø55 1
Bushing for rod Ø60 1

Disassembly and Bushing for rod Ø70 1

A
assembly cylinder Bushing for rod Ø80 1
Bushing for rod Ø85 1
See
11 Bushing for rod Ø95 1 Piston-cylinder assembly
960117004
Bushing for rod Ø100 1
Bushing for rod Ø110 1
Bushing for rod Ø115 1
Commercially Draining and refilling
Air conditioning unit B 1 Maintenance station 1
available the unit
1 CA715404 Extractor 1 Remove oil pump
2 CA715409 Plunger 1 Mounting oil pump seal ring
Removal-installation flange
3 CA715407 Wrench 1
screw
Removal-installation
4 CA715405 Plunger 1
ring
5 CA715412 Plunger 1 Disassembly bearing
Removal-installation
6 CA715406 Hook 1
front holder
Disassembly and 7 CA715179 Plunger 1 Mounting bearing
C
assembly transmission
8 CA715004 Plunger 1 Mounting bearing
Disassembly-assembly
9 CA715410 Plunger 1
clutch
10 CA715377 Plunger 1 Mounting bearing
Removal-installation
11 CA715408 Extractor 1
shaft
12 CA715148 Plunger 1 Mounting bearing
13 CA715414 Equipment for test 1 For tightness test
14 CA715376 Plunger 1 Mounting bearing

30-6 WB97R-2
REMOVAL AND INSTALLATION SPECIAL TOOLS

1 CA715027 Plunger 1
2 CA119030 Wrench 1
3 CA119099 Wrench 1
4 CA715022 Wrench 1
5 CA119225 Plunger 1
6 CA715023 False pinion 1
Measurament shim for
7 CA119206 False differential holder 1
pinion
8 CA119182 Ring nut 1
9 CA715021 Plunger 1
10 CA119230 Plunger 1
Disassembly and
D 11 CA715087 Plunger 1
assembly front axle
12 CA715163 Plunger 1
13 CA715164 Plunger 1
14 CA715034 Plunger 1
15 CA119055 Plunger 1
16 CA715396 Plunger 1
17 CA119043 Plunger 1
18 CA715087 Plunger 1
19 CA715035 Plunger 1
20 CA715026 Plunger 1
21 CA119143 Plunger 1
1 CA715027 Plunger 1
2 CA715265 Wrench 1
3 CA119099 Wrench 1
4 CA715022 Wrench 1
5 CA715380 Kit 1
6 CA715128 False pinion 1
7 CA715388 False differential box 1
8 CA715167 Plunger 1

Disassembly and 9 CA715028 Plunger 1

E
assembly rear axle 10 CA715391 Plunger 1
11 CA119033 Interchangeable handle 1
12 CA715056 Kit 1
13 CA715055 Kit 1
14 CA715466 Plunger 1
15 CA119187 Plunger 1
16 CA715467 Plunger 1
17 CA715026 Plunger 1
18 CA119143 Plunger 1

WB97R-2 30-7
PAGE INTENTIONALLY
LEFT BLANK
REMOVAL AND INSTALLATION REMOVAL OF STARTING MOTOR

REMOVAL OF STARTING MOTOR

Fully raise the front working equipment and engage the
safety stop.
2 1
1 - Stop the engine and engage the parking brake.

2 - Remove guard (1) from tank (2).

RKZA9480

3 - Loosen the rods (3), move battery (4) outwards and lift
the protection (5).
Disconnect the clamp (6) from battery (4) negative ter-
minal (–). 4 3
6

RKZA9490

4 - Disconnect the electric wiring (7).

5 - Loosen the two screws (8) and remove the starting mo-
tor (9). 8 7
1

RKZA0022

INSTALLATION OF THE
STARTING MOTOR
• To install, reverse the removal procedure.

1
Starting motor mounting screws: 78.4–98 Nm

WB97R-2 30-9
REMOVAL AND INSTALLATION REMOVAL OF THE ALTERNATOR

REMOVAL OF THE ALTERNATOR

Fully raise the front working equipment and engage the
safety stop.
2 1
1 - Stop the engine and engage the parking brake.

2 - Remove guard (1) from tank (2).

RKZA9480

3 - Loosen the rods (3), move battery (4) outwards and lift
the protection (5).
Disconnect the clamp (4) from battery (6) negative ter-
minal (–). 4 3
6

RKZA9490

4 - Disconnect the cable (7), the connector (8) and the cot-
ter pin (9).

RKZB5031

5 - Loosen the screws (10), (11) and (12) to leave the al-
ternator (13) free to rotate.
10

11
13

RKZB5090

30-10 WB97R-2
REMOVAL AND INSTALLATION REMOVAL OF THE ALTERNATOR

6 - Release the belt (14) from the pulley and remove the al-
ternator (13). 12
1
13

14

RKZB5100

INSTALLATION OF THE
ALTERNATOR
• To install, reverse the removal procedure.

1
★ Adjust the fan-belt tension.
(For details, see «20. TESTING AND ADJUSTMENTS -
Fan-belt tension»).

WB97R-2 30-11
REMOVAL AND INSTALLATION REMOVAL OF THE AIR-CONDITIONING UNIT COMPRESSOR (Only

REMOVAL OF THE AIR-CONDITIONING UNIT COMPRESSOR

(Only for machines equipped with an air-conditioning unit)
Disconnect the cable from battery negative terminal (–).

1 - Remove lateral guard (1).

1

RKZB5110

2 - Connect the outlets (2) and (3) to the maintenance sta-

tion for air-conditioning units B1 and drain the cooling
fluid.

3 - Disconnect the connector (4). 2

RKZB5051

4 - Loosen the screw (5) and remove the belt (6) that drives
the compressor (7). 1

RKZB5041

5 - Loosen and remove the screw (8) that holds the bracket
(9) that supports the delivery and suction lines (10), 7
(11).
2 11
★ Be careful to avoid damaging the seals. 8

9
10
RKZA8600

30-12 WB97R-2
REMOVAL AND INSTALLATION REMOVAL OF THE AIR-CONDITIONING UNIT COMPRESSOR (Only

6 - Remove the front screws (12), the rear nuts (13) and lift
out the compressor (7) complete with its support (14). 7
3

14

12 13

RKZB5120

INSTALLATION OF THE
AIR-CONDITIONING UNIT
COMPRESSOR
• To install, reverse the removal procedure.

1
Belt-tightening screw: 123 Nm
★ Apply tension to the compressor belt.
(For details, see «TESTING AND APPLYING TEN-
SION TO THE COMPRESSOR BELT»).

2
★ Tighten until the flanges rest on the compressor.

3
Compressor retaining screws: 32 Nm

1 - Connect the unit to the maintenance station B1 and refill

it.

Quantity of fluid: 2250 ±150 g

WB97R-2 30-13
REMOVAL AND INSTALLATION REMOVAL OF THE INJECTION PUMP

REMOVAL OF THE INJECTION PUMP

Fully raise the front working equipment and engage the
safety stop. Also make the backhoe safe.
Raise the engine hood and disconnect the cable from
battery negative terminal (–).
1
★ Plug all tubes that have been removed or disconnected
to prevent entry of impurities.

1 - Remove the engine coolant liquid container (1).

RKZB6480

2 - Disconnect the fuel supply (3) and flow-back (4) hoses

from the injection pump (2).

3 - Disconnect the high-pressure pipes (5) 1 5

RKZB6490

4 - Disconnect the tube (6) from the oil level dip-stick and
remove it. 9
8
5 - Disconnect the hoses (7) and (8) from the feed pump 7
(9).

6 - Disconnect the connector (10).

10

RKZB6500

7 - Disconnect the accelerator control cable support (12)

from the lever (11). 11

12
RKZB6441

30-14 WB97R-2
REMOVAL AND INSTALLATION REMOVAL OF THE INJECTION PUMP

8 - Remove the retaining clip (13) of the injection pump lu-

brication tube.
9 - Disconnect the lubrication tube (14) and remove it.
10 - Remove bracket (15). 2 14

13

12
RKZB6510

11 - Remove the cover (16) that gives access to the distri-

bution gear and the oil filler plug (17). 17
3

16

RKZA0120

12 - Loosen and lift off the retaining nut (18) and safety
washer (19) of the pump driving gear (20).
19
4
★ Take great care not to drop the safety washer (19)
into the pump casing.

18
20

RKZA0130

13 - Remove the driving gear (20) of the pump (2).

★ Before removing the pump driving gear, mark its X2
position with respect to the idling gear. 23
★ For removal use a puller (X1). The puller screws
(X2) screw directly into the gear (20). 21
Take great care not to damage the pump shaft
thread
★ During removal, be careful not to let the wrench
(21) drop into the housing.
20 X1

X2
RKZ00030

WB97R-2 30-15
REMOVAL AND INSTALLATION REMOVAL OF THE INJECTION PUMP

14 - Take out the four nuts (22) and remove the injection
pump (2) with its O-ring seal (23). 5

21

RKZB6421

INSTALLATION OF
THE INJECTION PUMP
• To install, reverse the removal procedure.

1
Fuel feed hoses: 24.5–34.3 Nm

2
Bolt screw, pump side: 44.1–53.9 Nm

Bolt screw, engine side: 22.5–8.4 Nm

3
Cover gasket: ASL800070

Cover bolts for ignition gear system: 18 Nm

4
★ Align the marks between the gears before installing
the pump and mounting the nut.
Gear-locking nut:
113÷123 Nm (without lubrication)
Injection pump
5 gear (20)

Pump-locking nut: 35.2–43.1 Nm

1 - Check fuel injection timing.

(For details, see «20. TESTING AND ADJUST-
MENTS»). Reference

Idling gear

RKZ00131

30-16 WB97R-2
REMOVAL AND INSTALLATION REMOVAL OF THE VALVE COVER

REMOVAL OF THE VALVE COVER

1 - Remove the air filter (1) and the muffler (2).

2
1

RKZB5027

2 - Loosen the muffler support screws (3) and remove the air
intake duct (4) and cold-start aid (5).
★ Cap the turbocompressor and intake holes to prevent
contamination. 3
★ Inspect the seals for signs of damage.
1

4
5
RKZB6240

3 - Disconnect the injector fuel feed pipes (6)

2

RKZB6251

4 - Remove clamp (7) and loosen clamp (8).

3

RKZB6520

WB97R-2 30-17
REMOVAL AND INSTALLATION REMOVAL OF THE VALVE COVER

5 - Loosen the fittings (9) of the fuel feed pipes (6) on the pump
(10). 2

10
RKZB6261

6 - Rotate the pipes (6) until they become disengaged from the
valve cover (11).
7 - Remove the feed-through fittings (12) and their seals.
12 11

RKZB6271

8 - Loosen and remove the screws (12) retaining the valve

cover (11).
★ Inspect the grommets. 4
12
11

RKZB6281

9 - Remove the valve cover (11).

★ Inspect the seal. Replace the seal if it is damaged or
cracked. 11

RKZB6291

30-18 WB97R-2
REMOVAL AND INSTALLATION INSTALLATION OF THE VALVE COVER

INSTALLATION OF THE VALVE COVER

• To install, reverse the removal procedure.

1
Screw: 45÷55 Nm
Screw: Loctite 262

2
Union: 19,6÷24,5 Nm

3
Screw: 7,8÷9,8 Nm

4
Nut: 16,7÷22,5 Nm

WB97R-2 30-19
REMOVAL AND INSTALLATION REMOVAL OF THE INJECTION NOZZLES

REMOVAL OF THE INJECTION NOZZLES

The removal procedure should be performed on all the cyl-
inders even if one nozzle only is damaged. 2
Fully raise the front working equipment and engage the 4
safety stop. Also make the backhoe safe. 1

Raise the engine hood and disconnect the cable from

battery negative terminal (–).
3
1 - Disconnect the sensor (1) for a clogged air-filter.

2 - Remove the air-filter (2), the supporting bracket (3) and

the intake sleeve (4).
RKZB5021

3 - Remove the muffler.

(For details, see «REMOVAL OF THE MUFFLER»).

4 - Remove the intake duct (5) and the cold-start aid (6).
5
1
★ Cap the turbocompressor and intake holes to prevent
contamination.
★ Inspect the seals for signs of damage.

6
RKZB6241

5 - Remove clamp (7) and loosen clamp (8).

6 - Remove the valve cover (for details see «REMOVAL OF

THE VALVE COVER»).
8

RKZB6520

7 - Loosen and remove the fittings (9) retaining the fuel re-
covery pipe (10), and the seals. 2
8 - Loosen the fitting (11) and rotate the pipe (12) outward.
11
2

12

10
9
RKZB6321

30-20 WB97R-2
REMOVAL AND INSTALLATION INSTALLATION OF THE INJECTION NOZZLES

9 - Loosen and remove the screw (13) retaining the injection

nozzle clamp (14). 3
13
14

RKZB6331

10 - Turn the bracket (14) over and pull out the injection nozzle
(15).
★ Use care not allow dirt inside the injection nozzle and 14
the injector nozzle seat.
15

RKZB6341

INSTALLATION OF THE
INJECTION NOZZLES
• To install, reverse the removal procedure.

1
Clamp screws: 9.8–11.8 Nm

2
Union: 7,8÷9,8 Nm

3
Bracket screw: 22,6÷28,4 Nm

WB97R-2 30-21
REMOVAL AND INSTALLATION REMOVAL OF THE THERMOSTAT

REMOVAL OF THE THERMOSTAT

Fully raise the front working equipment and engage the
safety stop.
Also make the backhoe safe.

Raise the engine hood and disconnect the cable from 2

battery negative terminal (–).
4
★ Drain the engine coolant liquid.
3
1
Coolant liquid: 18
1
1 - Disconnect the cable (1) of the clogged filter indicator
(2) and remove the entire suction filter (3). RKZB5022

2 - Remove the fan guard (4).

3 - Disconnect the radiator connection sleeve (6) from the

5
thermostat cover (5).

4 - Take out the screws and remove the thermostat cover

(5). 6

RKZB6530

5 - Remove the gasket (7), the thermostat (8) and the ring
seal (9).
5
Put in new seals.

7
INSTALLATION OF THE 8
THERMOSTAT
• To install, reverse the removal procedure. 9

1
RKZ00151
1 - Refill the coolant liquid tank.

Coolant liquid: 18

2 - Start the engine at low idling to circulate the coolant liq-

uid through all circuits.

3 - Accelerate gradually up to 1700 rpm. After about one

minute, stop the engine and check or top up the level in
the container.

★ Check that there are no leaks.

Cover screws: 22–27.8 Nm

30-22 WB97R-2
REMOVAL AND INSTALLATION REMOVAL OF THE COOLING LIQUID PUMP

REMOVAL OF THE COOLING LIQUID PUMP

Fully raise the front working equipment and engage the
safety stop. Also make the backhoe safe.
Disconnect the cable from battery negative terminal (–).
1
★ Drain the engine coolant liquid.
Coolant liquid: 18

1 - Remove the engine coolant liquid container (1).

RKZB6480

2 - Remove the fan guard (2).

3 - Disconnect the cable (3) of the clogged filter indicator 4

and remove the air filter (4).
3

RKZB6540

4 - Remove the alternator and its support (5).

(For details, see «REMOVAL OF THE ALTERNA-
5
TOR»).
1

RKZB5101

5 - Only for machines equipped with a compressor

Remove the air-conditioning unit compressor (6) and its
supports. Put the compressor to one side.
(For details, see «REMOVAL OF THE AIR-CONDI-
TIONING UNIT COMPRESSOR»). 4

RKZB5052

WB97R-2 30-23
REMOVAL AND INSTALLATION REMOVAL OF THE COOLING LIQUID PUMP

6 - Disconnect the cab heating pipes (7).

7 - Remove the radiator/oil-cooler group.

(For details, see «REMOVAL OF THE RADIATOR - OIL
COOLERS»).

8 - Rimuovere la ventola (8), il distanziale (9) e la puleggia

(10). 2
9 - Remove the four screws (11) and then the complete
pump (12).
7
3
Replace all seals with new ones. RKZB6550

INSTALLATION OF THE
COOLANT LIQUID PUMP
• To install, reverse the removal procedure.

1
Locking screws for alternator support: 8
22.5–28.4 Nm
10
9
★ Apply tension to the alternator belt.
(For details, see «20. TESTING AND ADJUST- RKZB6990

MENTS»).

2
Locking screws for pulley and fan: 11
44.1–53.9 Nm

3
Pump screws: 22.5–28.4 Nm

4
Locking screw for compressor: 64 Nm 12
★ Apply tension to the compressor belt.
(For details, see «TESTING AND APPLYING TEN- RKZB5140

SION TO THE COMPRESSOR BELT»).

1 - Refill the coolant liquid circuit.

Coolant liquid: 18

2 - Start the engine at low idling to circulate the coolant liq-
uid through all circuits.
3 - Accelerate gradually up to 1700 rpm. After about one
minute, stop the engine and check or top up the level in
the container.
★ Check that there are no leaks.

30-24 WB97R-2
REMOVAL AND INSTALLATION REMOVAL OF THE TURBOCOMPRESSOR

REMOVAL OF THE TURBOCOMPRESSOR

Fully raise the front working equipment and engage the
safety stop.
Also make the backhoe safe.
3
Raise the engine hood and disconnect the cable from
battery negative terminal (–).
2
1 - Disconnect the clogged air-filter indication (2) cable (1)
and remove the entire suction filter (3).

2 - Remove the muffler 1

(For details, see «REMOVAL OF THE MUFFLER»).

RKZB5024

3 - Disconnect the turbocompressor delivery coupling

sleeve (4) from the suction manifold. 16

RKZB7000

4 - Take the screws out of the clips (5) and disconnect the
tube (6) that delivers the turbocompressor lubrication
oil.

RKZA0220

5 - Take out the tube-retaining screws (7) and the two

screws (8) that secure the flange of the lubrication oil
drainage tube (9).
1

8 9

RKZA0230

WB97R-2 30-25
REMOVAL AND INSTALLATION REMOVAL OF THE TURBOCOMPRESSOR

6 - Take out the screws (10) that join the turbocompressor

to the coupling sleeve, and remove the coupling sleeve 10
(11).

2
7 - Take out the screws (12) and remove the bracket (13). 11

13
12
RKZA1621

8 - Take out the nuts (14), and the washers (15) and lift off
the turbocompressor (16).
★ Carefully check the state of all the sealing gaskets.
Replace them if there is any sign of damage. 16
14 15

RKZA0240

INSTALLATION OF THE
TURBOCOMPRESSOR
• To install, reverse the removal procedure.

1
Tube retaining screws: 22.5–28.4 Nm

Flange screws: 8–9 Nm

2
Coupling joint screws: 22.5–28.4 Nm

3
Bracket screws: 22.5–28.4 Nm

1 - Start the engine and check that there are no leaks in the
turbocompressor lubrication tubes.

30-26 WB97R-2
REMOVAL AND INSTALLATION REMOVAL OF THE CYLINDER HEAD

REMOVAL OF THE CYLINDER HEAD

Fully raise the front working equipment and engage the
safety stop.
Also make the backhoe safe.
Raise the engine hood and disconnect the cable from
1
battery negative terminal (–).

★ Drain the engine coolant liquid.

Coolant liquid: 18

1
1 - Remove the engine coolant liquid container (1).
RKZB6480

2 - Disconnect the cable (2) of the clogged air-filter sensor

(3) and remove the entire suction filter (4) and its sup-
port. 2
★ Remove the turbocompressor. 4
(For details, see «REMOVE THE TURBOCOMPRES-
SOR»). 3

RKZB5025

3 - Only for machines equipped with an air-condition-

ing unit
6
Remove the alternator (5), the compressor (6) and the
supporting bracket (7).
(For details, see «REMOVAL OF THE ALTERNATOR»
and «REMOVAL OF THE AIR-CONDITIONING
UNIT»).
3
5 7

RKZB5053

4 - Remove the support (8). 4

RKZB5042

WB97R-2 30-27
REMOVAL AND INSTALLATION REMOVAL OF THE CYLINDER HEAD

5 - Disconnect the cable (9) of the cold-start equipment

6 - Remove the cover of the tappets.

9
★ Replace the gasket. 5

RKZB6570

7 - Remove the fuel filter (10) and move it to one side.

★ Mark the hoses so as not to mix them up when reas- 11
sembling.

8 - Disconnect the clips (11) that secure the heating pipes.

10
RKZB6560

9 - Disconnect the breather tube (12) from the engine

head.

10 - Loosen the screws (13) and remove the muffler support

(14).

12
13
14

RKZA0223

11 - Disconnect the cables (15) and (17) from the temper-

ature sensors (16) and (18). 15

16

18

17
RKZB6590

30-28 WB97R-2
REMOVAL AND INSTALLATION REMOVAL OF THE CYLINDER HEAD

12 - Disconnect the heating pipes (19).

13 - Remove the radiator connection pipes (20).

14 - Remove the coolant liquid pump. (For details, see «RE-

MOVAL OF THE COOLANT LIQUID PUMP»).

19
20
RKZB6551

15 - Remove the injection nozzles (21).

(For detail see «REMOVAL OF THE INJECTION NOZ-
ZLES»).
★ Protect the injection nozzle hole and threads to pre- 21
vent contamination.

RKZB6342

16 - Loosen the tappets of the rocker arms (4 pcs.) by 2-3 turns.

17 - Loosen and remove the screws (22) and remove the rocker
arm shaft (23).
22
6

23

RKZ08180

18 - Loosen and remove the screws (24) and remove the whole
cylinder head (25). 24
25

RKZ08190

WB97R-2 30-29
REMOVAL AND INSTALLATION REMOVAL OF THE CYLINDER HEAD

19 - Follow the indicated sequence for loosening the

screws.
BOLT LOOSENING ORDER
Loosen the cylinder head retaining screws in two
stages. 7
7 16 14 6
1 9 18 12 4

3 11 17 10 2
5 13 15 8

RKZ00170

INSTALLATION OF THE
CYLINDER HEAD
• To install, reverse the removal procedure.
1
★ Fill up the cooling circuit.

Coolant liquid: 18

★ Check carefully that there are no leaks.

2
Support screws: 35.2 Nm
3
Frontal screw (M8): 32 Nm
Lateral screws (M10): 64 Nm

4
Frontal screws (M10): 64 Nm
Lateral screw (M8): 32 Nm
5
★ Check the condition of the seals of the tappet cover and
the O-rings of the fastening nuts. Thoroughly clean the
contact surfaces on the cylinder heads.
Cover fastening nuts: 16,7÷22,5 Nm
6
★ Check that the tappets are firmly engaged in their rods
and that the valve collars are correctly assembled.
Rods - tappets: Engine oil
Start tightening the rocker-arm shaft from the center to-
wards the outside
Screws and nuts for the rocker-arm shaft:
18÷22,7 Nm
★ Adjust the valve clearances. (For details, see «20.
TESTING AND ADJUSTMENTS»).

30-30 WB97R-2
REMOVAL AND INSTALLATION REMOVAL OF THE CYLINDER HEAD

7
★ Assemble a new gasket.
BOLT TIGHTENING ORDER
Bolt and cylinder block threadings: Engine oil.
★ Tighten the screws, manually at first, and then in two
12 3 5 13
stages, following the sequence indicated. 18 10 1 7 15

Cylinder head bolts:

16 8 2 9 17
First tightening: 88.3–98.1 Nm 14 6 4 11
Final tightening: 181.4–191.2 Nm

1 - Start the engine at low idling to circulate the coolant liq-

uid through all circuits. RKZ00180

2 - Accelerate gradually up to 1700 rpm. After about one

minute, stop the engine and check or top up the level in
the container.

WB97R-2 30-31
REMOVAL AND INSTALLATION REMOVAL OF THE FRONT COUNTERWEIGHT

REMOVAL OF THE FRONT COUNTERWEIGHT

Fully raise the front working equipment and engage the
safety stop.
Also make the backhoe safe.

1 - Partially loosen the screws (1) to eliminate the tighten-

ing torque, and thus to facilitate the subsequent dis-
mantling procedure.
3
1
1

1 3
2
RKZA1840

2 - Insert the prongs of a fork-lift truck into the ventilation

slits, and force them gently upwards to compensate for
the weight of the counterweight (2).

3 - Remove the screws (1) and the washers (3).

4 - Remove the Front counterweight (2).

Counterweight: 300 kg

2
RKZA1850

INSTALLATION OF THE
FRONT COUNTERWEIGHT
• To install, reverse the removal procedure.

1
Screws: 300±30 Nm

30-32 WB97R-2
REMOVAL AND INSTALLATION REMOVAL OF THE RADIATOR UNIT

REMOVAL OF THE RADIATOR UNIT

Fully raise the front working equipment and engage the
safety stop.
Also make the backhoe safe.
Raise the engine hood and disconnect the cable from
battery negative terminal (–).

1 - Disconnect the safety gas cylinders (1) for opening the 1

engine hood. Remove the engine hood.
(For details, see «REMOVAL OF ENGINE HOOD»).

RKZB6620

2 - Remove screws (2) and remove the front frame (3).

RKZB6610

Completely eliminate all residual pressures in all cir-

cuits. (For details, see «20. TESTING AND ADJUST-
MENTS»).
★ Drain the cooling liquid.
Cooling liquid: 18
4
1 7
5
3 - Disconnect the cable (4) from the acoustic alarm (5).

4 - Loosen bracket (5) screw (6). 2

6 RKZB5181

5 - Only for machines equipped with an air-condition-

ing unit 9
Drain the air conditioning unit, and disconnect the tubes
(8), (9). (For details, see «20. TESTING AND ADJUST-
MENTS»). 8
3

RKZB5192

WB97R-2 30-33
REMOVAL AND INSTALLATION REMOVAL OF THE RADIATOR UNIT

6 - Disconnect the engine hoses (10) and (11) .

10

11
RKZB7010

7 - Slowly loosen the hoses (12) and (13) to drain the hy-
draulic oil from the radiator (14). When the oil is fully
12
drained, complete disconnection of the hoses, and plug
them to prevent entry of impurities. 4
13

14

RKZB5201

8 - Loosen radiator (14) nut (15) and remove them.

15

RKZB5421

9 - Disconnect the hoses (16) and plug them to prevent en-

try of impurities.
5
10 - Take out the nuts (15) of the lower anti-vibration units
and remove the entire radiator group.

16

RKZB5212

30-34 WB97R-2
REMOVAL AND INSTALLATION INSTALLATION OF THE RADIATOR GROUP

INSTALLATION OF THE RADIATOR GROUP

• To install, reverse the removal procedure.

1
★ Refill the coolant liquid circuit.

Coolant liquid: 18

2
★ Refill the air-conditioning unit.

Quantity of fluid (R134a): 2250 ±150 g

Quantity of oil: See the amount recovered.

3
★ Align the radiator with the fan and make sure that the fan
is inserted in the inner of conveyor for 2/3 of the blade
width.

4
★ Ensure that the level of hydraulic oil in the tank is at max-
imum.

5
★ Ensure that the level of transmission oil is at maximum.

1 - Start the engine at low idling to circulate all the fluids and
to fill up the ststems.

2 - Accelerate gradually up to 1700 rpm. After about one

minute, stop the engine and top up all levels.
★ Check carefully that there are no leaks.

WB97R-2 30-35
REMOVAL AND INSTALLATION REMOVAL OF THE CONDENSER (Only for machines equipped with

REMOVAL OF THE CONDENSER

(Only for machines equipped with an air-conditioning unit)
Completely raise the front working equipment and en-
gage the parking brake.
Also place the backhoe in its secure position. 1

1 - Drain the air-conditioning unit.

6
(For details, see «20. TESTING AND ADJUST-
MENTS»).

2 - Disconnect the cable (1) and remove the klaxon (2). 5

2

RKZB5230

3 - Disconnect the tubes (3) and (4)

★ Immediately plug the tubes and the condenser
tightly to prevent moisture from entering into the air- 4
conditioning circuit.

4 - Loosen the upper retaining screw (5) of the condenser 3

(6), leaving it in position for reasons of safety.

RKZB5191

5 - Loosen the screws (7) and remove the locknuts.

6 - Remove the screws (5) and (7) and take out the con-
denser.

RKZB5220

INSTALLATION OF THE
CONDENSER
• To install, reverse the removal procedure.

1 - Refill the air-conditioning unit.

Quantity of fluid (R134a): 2250 ±150 g

Quantity of oil: see the amount recovered.

30-36 WB97R-2
REMOVAL AND INSTALLATION REMOVAL OF THE MUFFLER

REMOVAL OF THE MUFFLER

Fully raise the front working equipment and engage the
safety stop.
Also make the backhoe safe.
2
1 - Loosen the retaining clip (1) of the hose (2) and discon-
nect it from frame.
1

RKZB6630

2 - Take out screws (3).

RKZB7020

3 - Take out the four screws (4) and remove the complete
muffler (5).

4
5

RKZA9941

INSTALLATION OF THE MUFFLER

• To install, reverse the removal procedure.

★ Put in a new sealant.

WB97R-2 30-37
REMOVAL AND INSTALLATION REMOVAL OF THE EXHAUST PIPE

REMOVAL OF THE EXHAUST PIPE

1 - Loosen the clip (1) and disconnect the flexible hose (2).

RKZB6630

2 - Take out two of the three lower screws (3) of the con-
necting flange (4).
★ Loosen the third screw and leave it in place for safe-
ty.

RKZA0341

3 - Take out the nut (5) and the washer of the upper anti-vi-
bration unit (6).

4 - Take out the last screw (3) and remove the exhaust pipe
6 5
(7).

RKZA0351

INSTALLATION OF THE
EXHAUST PIPE
• To install, reverse the removal procedure.

30-38 WB97R-2
REMOVAL AND INSTALLATION REMOVAL OF THE ENGINE HOOD

REMOVAL OF THE ENGINE HOOD

Lower the working equipment completely until it is rest-
ing on the ground. Stop the engine and remove the ig- 2
nition key.

1 - Loosen and remove the screws (2) and washers and re-
move the front grille (1). 1

RKZB6640

2 - Fully raise the engine hood (3), remove the safety pins (4)
and disconnect the gas spring (5) from the chassis.

RKZB6650

3 - Remove the snap rings (6) and washers (7).

3
4 Pull out the fulcrum pins (8) while holding the engine hood
(3). 6
Remove the hood (3).

8
7

RKZB7030

INSTALLATION OF THE ENGINE

HOOD
• To install, reverse the removal procedure.

★ Check the lock engagement .

WB97R-2 30-39
REMOVAL AND INSTALLATION REMOVAL OF THE CAB

REMOVAL OF THE CAB

Lower the working equipment completely until it rests on
the ground and stop the engine and remove the ignition
key.
Disconnect the cable from battery negative terminal (–).
Release all residual pressure in all circuits.

★ Only for machines equipped with an air-condition-

ing unit
Drain the air conditioning unit.
(For details, see «20. TESTING AND ADJUST-
MENTS»).
1

1 - Disconnect the pedal accelerator and hand accelerator

cables (1) from the injection pump. Disengage the
sheathings from the support (2). 2

2
1

RKZB6431

2 - Disconnect the braking circuit pipes (4) and the differ-

ential lock tube (5) from the rear axle (3). 4
3
★ Plug the pipes and pipe-fittings to prevent entry of
impurities. 6 3

RKZA9550

3 - Disconnect the steering cylinder pipes (6) from the rear

axle.
★ Mark the positions of the pipes to prevent exchang- 6
ing positions when reconnecting. 6
★ Plug the pipes and pipe-fittings to prevent entry of
impurities. 3
4

RKZA9562

30-40 WB97R-2
REMOVAL AND INSTALLATION REMOVAL OF THE CAB

4 - Disconnect the steering cylinder pipes (7) from the front

axle.
5
★ Mark the positions of the pipes to prevent exchang-
ing positions when reconnecting.
★ Plug the pipes and pipe-fittings to prevent entry of
impurities.
7

RKZA9570

5 - Disconnect the pipes of the L-T-P ports (8, 9 and 10)

from the steering unit.
★ Mark the positions of the pipes to prevent exchang-
ing positions when reconnecting. 8
★ Plug the pipes and pipe-fittings to prevent entry of
impurities.
9

10

RKZA9580

6 - Disconnect from gearbox the connectors (11) and (12)

and the grounding cable (13). 16
7 - Disconnect the five connectors (14) of sensor, the con-
trol speed connector (15). 12 17
Only for machine with EGM.
Disconnect the solenoid connector (16) from the trans-
mission. 14

8 - Disconnect from grounding stud two connectors (17). 13

15 14
11 RKZA8760

9 - Disconnect the connector (18) of the auxiliary controls

set into the bucket control lever.

10 - Disconnect the converter disengagement connector

(19) set into the gear lever.

11 - Disconnect the connector (20) of the differential disen- 20 21

gagement and backhoe boom disengagement sole-
noids. 18
12 - Disconnect the power increment solenoid connector
(21) installed on the piston pump. 19
RKZA0430

WB97R-2 30-41
REMOVAL AND INSTALLATION REMOVAL OF THE CAB

13 - Disconnect the connectors (22) of the rear acoustic

alarm, the connector (23) of the rear lights and finally the
connector (24) of the solenoid of the backhoe control
valve.

23

22 24
RKZA0440

14 - Disconnect the heating unit tubes (25) and (26).

(For details, see «REMOVAL OF THE CAB HEATING
GROUP»). 25 29
15 - Only for machines equipped with an air-condition-
ing unit.
Disconnect the tubes (27), (28) connecting the unit to
the drying filter (29) and the expansion valve (30).
★ Immediately plug the tubes and the orifices tightly 26 28
to prevent moisture from entering into the air-con-
ditioning circuit.
27 30
RKZA8710

16 - Lift off the lower left-hand guard of the cab and discon-
nect the connector (31) of the fuel level indicator and the
connector of the self-supply pump, if any.
31
17 - Also lift off the lower right-hand guard.

RKZA1922

18 - Remove the floor-mat (32) and remove the lateral cover

(33).
★ Push the protective sleeve (34) of the gearbox lever
down into the side cover (33).
33

34
32

RKZB0031

30-42 WB97R-2
REMOVAL AND INSTALLATION REMOVAL OF THE CAB

19 - Lever-controlled backhoe control valve only.

Remove the knobs (35) from the outrigger control levers
and remove the control lever hood (36). 35

37
36

RKZA9600

20 - Servocontrolled backhoe control valve only.

Remove the platform (37). 37

RKZB6660

21 - Servocontrolled backhoe control valve only.

Disconnect the control valve hoses (39) from the junction
blocks (38). 6
IMPORTANT
Ensure that both the hoses and their connection positions
are clearly marked.
★ Cap the hoses and holes to prevent contamination.

38 38

39 RKZB6670

22 - Loosen and remove the self-locking nuts (40) and remove

the screws (4 screws) that secure the cab. 7 40

RKZB6663

WB97R-2 30-43
REMOVAL AND INSTALLATION REMOVAL OF THE CAB

23 - Disconnect from the control valve (43) the hoses (41)

and (42).

24 - Remove the protective plugs and screw two eyebolts 43

“A” into the holes supplied for hoisting purposes.
Attach the cab (44) to the hoisting tackle and apply a 41
slight tension.

25 - Slowly raise the cab, directing its movement in such way

that the gear lever slides out.
★ Make sure that all the electrical leads and the ac-
celerator cables are free. 42
RKZA9994
Cab: approx. 630 kg

INSTALLATION OF THE CAB

• To install, reverse the removal procedure.

1
★ Drain and refill the air-conditioning unit A

Quantity of fluid (R134a): 2250 ±150 g

Quantity of oil: see the amount recovered.

2
44
★ Check and adjust the stroke of the hand and pedal ac-
celerators. (For details, see «20. TESTING AND AD-
JUSTMENTS»).

★ Adjust the stroke of the parking brake lever. (For details,

see «20. TESTING AND ADJUSTMENTS»).

★ Bleed the air from the braking circuit.

(For details, see «20. TESTING AND ADJUST-
MENTS»).

5
RKZA0484

★ Bleed the air from the steering circuit. (For details, see
«20. TESTING AND ADJUSTMENTS»).

6
Cab retaining screws: 169±9.8 Nm

30-44 WB97R-2
REMOVAL AND INSTALLATION REMOVAL OF THE HEAT AND AIR-CONDITIONING GROUP

REMOVAL OF THE HEAT AND AIR-CONDITIONING GROUP

NOTE If no air-conditioning unit is included, perform
only those operations relating to the heating
unit.
Lower the working equipment completely until it rests on
the ground, and stop the engine.
Cut off the supply of electricity by turning the accumu-
lator-disconnecting switch in a counter-clockwise direc- 1
tion, and remove the handle.

★ Drain the engine cooling liquid.

Coolant liquid: 18
RKZB5260

1 - Drain the air-conditioning unit.

(For details, see «20. TESTING AND ADJUST-
MENTS»). 3
2 - Disconnect the flexible hose (1) of the heating water
cock.

3 - Disconnect the connector of the power-supply cabling

2
(2) and the clamp.

RKZB5270

4 - Disconnect the connector (5) from the pressure switch

(4).

5 - Disconnect the delivery pipe (7) and the return pipe (8) 8
from the expansion valve (6). 7 6
★ Immediately plug the tubes and the orifices tightly
to prevent moisture from entering into the air-con-
ditioning circuit.
★ Re-use the O-ring.

4
5
RKZB5251

6 - Disconnect the pipes (10) from the fan-cooler (9). 13 9

10
7 - Disconnect the tubes (11) and (12) that connect with the 11
engine.
12
8 - Remove the four nuts (13) and remove the group (9).

RKZB5280

WB97R-2 30-45
REMOVAL AND INSTALLATION INSTALLATION OF THE HEATING AND AIR-CONDITIONING GROUP

INSTALLATION OF THE HEATING AND AIR-CONDITIONING GROUP

• To install, reverse the removal procedure.

1 - Refill the cooling liquid.

Coolant liquid: 18

2 - Drain and refill the air-conditioning unit.

Quantity of fluid (R134a): 2250 ±150 g

Quantity of oil: See the amount recovered.

3 - Start the engine and use a leak detector to check the

leaktightness of the air-conditioning unit.

30-46 WB97R-2
REMOVAL AND INSTALLATION REMOVAL OF THE FUEL TANK

REMOVAL OF THE FUEL TANK

Lower the working equipment completely until it rests on
the ground and stop the engine. 2 3 1
1 - Remove the lower left-hand guard (1) of the cab.

2 - Take the cap (2) off the filling inlet of the fuel tank (3) and
remove also the bottom plug in order to drain the fuel. 6
Fuel: max. 130

5
3 - Remove the nut (4) in order to free the clips (5).

4
RKZA9610

4 - Remove the guard (6), loosen the rods (7) until the bat-
tery (8) is free (8) from the bracket (9).
Disconnect the clamps (10) and (11) and remove the 11
battery (8). 9
8 10
First remove the clamp of the negative battery ter-
minal (8) (–).
7
5 - Disconnect the connector (12) of the level indicator (13)
and the connector (14) of the self-supply pump, if fitted.

6 - Disconnect the fuel suction and flow-back hoses (15)

and (16) and the pipe of the self-supply pump, if fitted.
★ Plug the pipes to prevent entry of impurities. RKZA9491

★ Mark the pipes to avoid exchanging them during in-

stallation.

7 - Remove the screws (17) and the guard (18). 18

8 - Support the fuel tank (3) with hoisting tackle and remove 15 16 14 12
the four retaining screws (19). 1
17
9 - Remove the fuel tank (3).

Fuel tank: 73 kg

13
INSTALLATION OF THE RKZA1923

FUEL TANK
• To install, reverse the removal procedure.

1
Retaining screws for fuel tank: 120 Nm

1 - Refill the fuel tank.

19

Fuel: max. 130

2 - Bleed the air from the fuel circuit.

3 - Start the engine.

RKZA1952

WB97R-2 30-47
REMOVAL AND INSTALLATION REMOVAL OF HYDRAULIC OIL TANK

REMOVAL OF HYDRAULIC OIL TANK

Lower the working equipment completely until it rests on
the ground and stop the engine. 1
2
Eliminate completely any residual pressures from all
circuits.
(For details, see «20. TESTING AND ADJUST-
MENTS»).

1 - Take off the lower right-hand guard (1) of the cab.

2 - Remove the guard (2).

12
3 - Remove the oil drainage cap (3).
★ Drain the hydraulic oil. RKZA9620

Hydraulic oil: 92

4 - Disconnect the lower suction (5) and drainage (6) hoses

from the tank (1).
★ Plug the hoses to prevent entry of impurities.
3
5 - Disconnect the upper pipes (7), (8) and (9), remove the
check valve (10) and the T-piece (11).
★ Make a note of the assembly sequence.
6 - Support the tank (4) with hoisting tackle and remove the
four retaining screws (12). 4
1
7 - Remove the tank (4).
RKZA9630
Oil for the tank: 77 kg

INSTALLATION OF THE 5
HYDRAULIC OIL TANK
• To install, reverse the removal procedure.

1
Tank retaining screws: 120 Nm

1 - Refill the tank.

6
Hydraulic oil: 92

RKZA9640
2 - Refill the pump (For details, see «20. TESTING AND
ADJUSTMENTS»).

3 - Start the engine to let the oil circulate through all the hy-
draulic systems and check for leaks. 7
10
4 - Bleed the air from the hydraulic systems.
(For details, see «20. TESTING AND ADJUST-
MENTS»).
11
5 - Stop the engine, check the oil level in the tank, and top it 8
up if necessary.
9
RKZA1991

30-48 WB97R-2
REMOVAL AND INSTALLATION REMOVAL OF THE ENGINE-GEARBOX-PUMP GROUP

REMOVAL OF THE ENGINE-GEARBOX-PUMP GROUP

Lower the working equipment completely until it rests on
the ground, and stop the engine.
Disconnect the cable from battery negative terminal (–).
1
Release all residual pressure in all circuits.
(For details, see «20. TESTING AND ADJUST-
MENTS»).

★ Drain the hydraulic oil.

Hydraulic oil: 92

2 1
★ Drain the engine cooling liquid. RKZA2000

Coolant liquid: 18

★ Drain the oil from the gearbox.

Gearbox oil: 16
3
1 - Only for machines equipped with an air-condition-
4
ing unit.
Drain the air conditioning unit.
(For details, see «20. TESTING AND ADJUST-
MENTS»).

2 - Remove the front working equipment.

(For details, see «REMOVAL OF THE FRONT WORK-
ING EQUIPMENT»). RKZB0050

3 - Take off the engine hood.

(For details, see «REMOVAL OF THE ENGINE
HOOD»).

4 - Take out the screws (1) and remove the front counter-
weight (2). (For details, see «REMOVAL OF THE
FRONT COUNTERWEIGHT»).
1 7

5 - Remove the radiator-oil cooler group.

(For details, see «REMOVAL OF THE RADIATOR-OIL 6
COOLER GROUP»).

6 - Lift the protection (3), disconnect connector (4). RKZA9660

2
7 - Disconnect rear cardan shaft (7) from transmission (6).
3
8 - Remove front cardan shaft (8). 3

RKZA9571

WB97R-2 30-49
REMOVAL AND INSTALLATION REMOVAL OF THE ENGINE-GEARBOX-PUMP GROUP

9 - Disconnect the suction hose (10) and the drainage pipe

(11) from the pump (9).
Disconnect also the power increment solenoid connec-
9
tor.

4
★ Plug the pipes to prevent entry of impurities.

10

11
RKZA9670

10 - Disconnect the Load Sensing signal pipe (12) and the

delivery pipe (13) from valve (14).
★ Plug the pipes to prevent entry of impurities.
14

13

12

RKZA9411

11 - Disconnect from the transmission (15) the solenoid

valve (16) connectors and the oil cooling circuit pipes 16 16
(17).
★ Plug the pipes to prevent entry of impurities.

15

17

RKZB0040

12 - Disconnect from thermostat (19) and, only for EGN ver-

sion, from speed sensor (20) the sensors (18) connec- 18
tors.

19

18
18

20
RKZO3270

30-50 WB97R-2
REMOVAL AND INSTALLATION REMOVAL OF THE ENGINE-GEARBOX-PUMP GROUP

13 - Disconnect from the engine the sensor (21) and (22)

22
14 - Disconnect the cab heating pipes (23) from the coolant 21
pump.

23

RKZB5290

15 - Disconnect the connector (24) of the oil pressure sensor

and the connector (25) of the solenoid that stops the en-
gine.

24

25

RKZA0660

16 - Disconnect the cable (26) of the cold-start equipment,

the cab heating-pipe support clip (27), and the fuel tank
flow-back hose (28). 5 26
27

28

RKZB6680

17 - Disconnect the cables (29) of the pedal and hand ac-

celerators. Disengage the support sheathing (30).

30

29

RKZB6690

WB97R-2 30-51
REMOVAL AND INSTALLATION REMOVAL OF THE ENGINE-GEARBOX-PUMP GROUP

18 - Disconnect the fuel lines (32) from the separator (31)

and plug them. 32

19 - Remove the separator.

31

RKZA0670

20 - Disconnect the cables (33) from the starting motor (34)

and the cables (35) from the alternator (36).
33 35

34 36

RKZB5330

21 - Only for machines equipped with an air-condition-

ing unit.
41 39
Save the coolant R134a and disconnect the delivery
tubes (38) and suction tubes (39) from the compressor
(37).
★ Immediately plug the tubes and orifices tightly to
prevent moisture from entering into the air-condi-
tioning circuit.
37 38
★ Disconnect the air-conditioning unit connectors
(40) and (41). 40

RKZB5054

22 - Remove the plate (42) and push it towards the back of

the machine.

42

RKZA9690

30-52 WB97R-2
REMOVAL AND INSTALLATION REMOVAL OF THE ENGINE-GEARBOX-PUMP GROUP

23 - Loosen the clamp (43) and disconnect the flexible re-

turn hose (44).

44

43

RKZB6631

24 - Attach the entire group to some hoisting tackle using the

engine bracket (45) and the muffler support (46). Apply
a slight tension to the hoisting chains.

45 46

RKZA0702

★ The chains should have a total length of about 800 mm

and a difference between the arms of 53 mm.

★ The shortest length should be attached to the bracket

(45).

★ When under tension the cables should be about 200

mm apart at the height of the muffler. 45 46

RKZB5350

25 - Loosen and remove the nuts (47) of the anti-vibration

supports (48) of the engine and gearbox, and take out
the screws (49).
6
49 48
26 - Raise the entire group until the chassis supports are dis- 48
engaged, and than accompany the group in order to
47
slide it away from the front part of the chassis.

Engine-gearbox-pump group: 740 kg

47 49

RKZA9700

WB97R-2 30-53
REMOVAL AND INSTALLATION INSTALLATION OF THE ENGINE GEARBOX-PUMP GROUP

INSTALLATION OF THE ENGINE GEARBOX-PUMP GROUP

• To install, reverse the removal procedure.
1 - Fill the hydraulic oil tank up to its maximum level.
Hydraulic oil: 92

2 - Fill the gearbox up to its maximum level.

Gearbox oil: 16

3 - Refill the coolant liquid.

Coolant liquid: 18

4 - Drain and refill the air-conditioning unit.

Quantity of fluid (R134a): 2250 ±150 g

Quantity of oil: see the amount recovered.

1
Screws for front counterweight: 300±30 Nm

2
Screws on gearbox side: 70 Nm

Screws on gearbox side: Loctite 262

3
Nut on axle side: 70 Nm

4
★ Fill up the pump casing and the pump, to bring the tank
up to pressure.
For the method see «20. TESTING AND ADJUST-
MENTS».

5
★ Bleed the air from the fuel lines.

6
Nuts from the anti-vibration supports:
196±19.6 Nm

4 - Start the engine to circulate the oil and coolant liquid.

Check that there are no leaks.

5 - Use a leak detector to check the leaktightness of the de-

livery and return pipes of the air-conditioning unit com-
pressor.

6 - Bleed the air from the working equipment circuits.

(For details, see «20. TESTING AND ADJUST-
MENTS»).

7 - Stop the engine, check the levels and, if necessary, top

them up.

30-54 WB97R-2
REMOVAL AND INSTALLATION REMOVAL OF THE PISTON PUMP

REMOVAL OF THE PISTON PUMP

Lower the working equipment completely until it rests on
the ground, and stop the engine.
Release residual pressure fully in all circuits. 1
(For details, see «20. TESTING AND ADJUST-
MENTS»).
Disconnect the cable from battery negative terminal (–).

★ Drain the hydraulic oil. 2

Quantity of oil: 92

3
RKZA9671

1 - Disconnect the suction hose (2) and the drainage pipe

(3) from piston pump (1). 1 6
2 - Disconnect the delivery pipe (4) and the Load Sensing
signal line (5).
★ Plug the pipes to prevent entry of impurities.
3 - Disconnect the solenoid connector (6) 4

RKZB0010

4 - Take out the rear cardan shaft (7).

2 3
1
5 - Attach under pump (1) a pit jack and a suitable support.
8

RKZA9710

6 - Take out the two screws (8) and remove the pump (1)
complete with its O-ring (9). 3 1
Pump: 40 kg

RKZA9720

WB97R-2 30-55
REMOVAL AND INSTALLATION INSTALLATION OF THE PISTON PUMP

INSTALLATION OF THE PISTON PUMP

• To install, reverse the removal procedure.

1 - Fill the tank with hydraulic oil up to maximum level.

Hydraulic oil: 92

★ Fill the pump body and the pump, bringing the tank
up to pressure.
For the method, see «20. TESTING AND ADJUST-
MENTS».

1
Screws for suction flange: 100 Nm

Screws for delivery flange: 60 Nm

2
Screws on gearbox side: Loctite 262

Screws on gearbox side: 70 Nm

Nut on axle side: 70 Nm

3
Pump retaining screws: Loctite 262

Pump retaining screws: 220 Nm

2 - Start the engine to circulate the oil in all hydraulic cir-

cuits.

3 - Stop the engine, check the oil level in the tank and, if
necessary, top it up.

30-56 WB97R-2
REMOVAL AND INSTALLATION REMOVAL OF THE TRANSMISSION

REMOVAL OF THE TRANSMISSION

Lower the working equipment completely until it rests on
the ground, and stop the engine.
Make the backhoe safe.

Raise the engine hood and disconnect the cable from

battery negative terminal (–).

Release all residual pressure in all circuits.

(For details, see «20. TESTING AND ADJUST-
MENTS»).

★ Drain the hydraulic oil. 1

Hydraulic oil: 92

★ Drain the oil from the gearbox. 2

Gearbox oil: 16

1 - Remove the piston pump. (For details, see «REMOVAL 1
OF THE PISTON PUMP»). 3
2
2 - Raise the lever (1) protective sleeve, disconnect the
connector (2) of the transmission disengagement.
4

RKZB0051

3 - Disconnect the pipe (3) that fills the gearbox with oil.
5
4
4 - Take out the front cardan shaft (4). 6
3

RKZA9731

5 - Take off the cover (5) of the flywheel oil-sump and take
out the six retaining screws (6) of the converter coupling
flange (7). 7 5

7 6

RKZA9741

WB97R-2 30-57
REMOVAL AND INSTALLATION REMOVAL OF THE TRANSMISSION

6 - Disconnect the connectors (9) of the solenoids and the

tubes (10) for oil circulation and controls from transmis- 9 9
sion (8).
★ Plug the pipes to prevent entry of impurities.

10

RKZB0041

7 - Disconnect the connectors from sensors (11), from

thermostat (12) and; only for EGM version, from speed 11
sensor (13).

12

11
11

13
RKZO3271

8 - Remove the plate (14) and push it towards the back of

the machine.

14

RKZA9692

9 - Attach the engine-gearbox group to the hoisting tackle

using the engine bracket (15) and the muffler support
(16). Apply tension to the hoisting chains.

15 16

RKZB5351

30-58 WB97R-2
REMOVAL AND INSTALLATION REMOVAL OF THE TRANSMISSION

10 - Loosen and remove the nuts (17), and screws (18) and
the anti-vibration nuts (19). 8
11 - Remove the gearbox supports (20). 9
19
19

17 18
18 17
20
RKZA9761

12 - Attach in the place of the supports (20) a support with

spacer “A” and mounted it on a pit jack “B” which can be
lowered by approx. 60 cm.
★ Secure the support with the screws “C”. C
C

A
B
RKZA9771

13 - Loosen and remove the twelve screws (21) that hold the
engine and gearbox together. 10
14 - Remove the entire gearbox, by shifting it towards the
back of the machine in order to disengage the conver- 21
tor. Lower it slowly and turn the group in a clockwise di-
rection to disengage it from the chassis in order to
extract it.

Transmission: 230 kg

RKZA8770

WB97R-2 30-59
REMOVAL AND INSTALLATION INSTALLATION OF THE TRANSMISSION

INSTALLATION OF THE TRANSMISSION

• To install, reverse the removal procedure.
1

Hydraulic oil: 92

Gearbox oil: 16

3
★ Fill the pump body and the pump in order to pressurise
the tank.
For the method, see «20. TESTING AND ADJUST-
MENTS».
4
Screws for securing lever: 120 Nm
5
Screws: Loctite 262
6
Screws on gearbox side: 70 Nm
7
Flange screws: Loctite 262
Flange screws: 70 Nm
8
Anti-vibration nuts: 196±19.6 Nm
9
Support screws: Loctite 262
Support screws: 90 Nm

10
Engine-gearbox screws: Loctite 262
Engine-gearbox screws: 90 Nm

1 - Start the engine to circulate the oil. Check that there are
no leaks.

2 - Bleed the air from the working equipment circuits. (For

details, see «20. TESTING AND ADJUSTMENTS»).

3 - Stop the engine, check the levels and, if necessary, top

them up.

30-60 WB97R-2
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY OF TRANSMISSION

DISASSEMBLY AND ASSEMBLY OF TRANSMISSION

1. Disassembly converter

2
1

RKZ06380

1- Drain oil from transmission hydraulic circuit and remove

torque converter (1). 1

RKZB1540

2 - Remove fastening screws (2) of bellhousing (3).

3
RKZ06390

WB97R-2 30-61
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY OF TRANSMISSION

3 - Remove bellhousing (3).

3
RKZ06400

4 - Remove seal (4)

4
RKZ06410

2. Assembly converter
1 - Locate seal (4) on bellhousing (3).

3
RKZ06420

2 - Fit bellhousing (3) to transmission.

3
RKZ06400

30-62 WB97R-2
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY OF TRANSMISSION

3 -Insert bellhousing (3) fastening screws (2).

Screw: 170 Nm

3
RKZ06390

4 - Fit converter (1).

Turn the torque converter until engaging the relative 1
splined shafts.

RKZB1540

WB97R-2 30-63
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY OF TRANSMISSION

3. Disassembly plugs and filters

2
3

4 1
RKZ06430

1 - Drain oil from transmission hydraulic circuit and remove

oil drain plugs (1). Clean the magnet.

RKZB1550

2 - Remove oil filling/drain plug (2).

RKZB1560

30-64 WB97R-2
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY OF TRANSMISSION

3 - With a filter wrench remove filter (3).

RKZB1570

4 - Remove plug (4) and clean the magnet.

RKZB1580

5 - Remove filter (5).

★ Filter must be replaced every disassembly.

4
RKZB1590

4. Assembly plugs and filters

1 - Assemble filter (5). 5

RKZB1600

WB97R-2 30-65
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY OF TRANSMISSION

2 - Assemble plug (4).

Plug: 80 Nm

RKZB1580

3 - Apply a thin film of grease on filter (3) seal and assem-

ble. Tighten by hand.
3

RKZB1610

4 - Assemble oil drain plugs (1).

Plug: 25 Nm

RKZB1550

30-66 WB97R-2
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY OF TRANSMISSION

5. Disassembly oil pump

4
RKZ06440

1 - Drain oil from transmission hydraulic circuit. Remove

screws (1).
★ Mark pump position before remove the screw.

RKZB1620

2 -Remove the oil pump (2) by means of tool C1

★ Take a care to not damage the oil pump seal. 2
C1

4
RKZB1631

WB97R-2 30-67
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY OF TRANSMISSION

3 -Remove O-ring (3) and seal ring (4).

RKZB1640

6. Assembly oil pump

1 - Assemble seal ring (4) on oil pump (2). Use tool C2.

C2 4

RKZB1651

2 - Fit O-ring (3).

RKZB1660

3 - Before oil pump assembly, check that oil passage holes

between pump (2) and half-case or the visual marks co- 2
incide.

RKZB1670

30-68 WB97R-2
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY OF TRANSMISSION

4 - Apply a thin film of grease on the coupling seat with the

front half-case.

5 - Assemble the oil pump (2). 2

RKZB1680

6 - Fit screws (1).

★ Make sure that the marks on oil pump and bell-
housing are aligned.
Screw: 23 Nm
1

RKZB1620

WB97R-2 30-69
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY OF TRANSMISSION

7. Disassembly pipes and sensors

11
3 10

4
1
8 9

24 17 20
7

2 5
27
6
21

16
15 22
25 18
26 23
12 28
14
13 19 RKZ06450

1 - Drain oil from transmission hydraulic circuit, disconnect

all electrical connections and untighten 3rd speed pipe
upper fitting (1).

RKZB1690

30-70 WB97R-2
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY OF TRANSMISSION

2 - Untighten 3rd speed pipe lower fitting and remove pipe

(2).

RKZB1700

3 - Remove 3rd speed antishock valve (6).

RKZB1730

4 - Untighten 1st speed pipe upper fitting (3).

3

RKZB1710

5 - Untighten the 1st speed pipe (4) and lower fitting (5).
4

RKZB1720

WB97R-2 30-71
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY OF TRANSMISSION

6 - Remove 1st speed antishock valve (7).

RKZB1740

7 - Remove 4st speed pressure sensor 2 bar (8).

RKZB1750

8 - Remove 1st speed pressure sensor 2 bar (9).

9
RKZB1760

9 - Remove pressure sensor 11 bar (10).

10

RKZB1770

30-72 WB97R-2
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY OF TRANSMISSION

10 - Remove oil temperature sensor (11).

11

RKZB1780

11 - Remove screws (12) of sensor cover.

12

RKZB1790

12 - Remove sensor cover (13) and relative seal (14).

14 13
RKZB1800

13 - Remove sensor/inductor (15) and O-ring (16).

15

16

RKZB1810

WB97R-2 30-73
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY OF TRANSMISSION

14 - Untighten FWD delivery pipe (18) and upper fitting (17).

17

18

RKZB1820

15 - Untighten FWD delivery pipe (18) and lower fitting (19).

18
19

RKZB1830

16 - Untighten upper fitting (20) and 2nd speed delivery pipe

(21).
20

21

RKZB1840

17 - Untighten lower fitting, 2nd speed pipe (21) and upper fit-
ting (20).

18 - Remove pipe (21) and fitting (20). 21

RKZB1850

30-74 WB97R-2
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY OF TRANSMISSION

19 - Remove 2nd speed antishock valve (22) and lower fit-

ting (23).

22

23

RKZB1870

20 - Untighten 3rd speed pipe upper fitting (24).

24

RKZ06450

21 - Untighten 4th speed pipe (26) lower fitting (25) and re-
move pipe.

25
26

RKZB1860

22 - Remove 2nd speed pressure sensor 2 bar (27).

27

RKZB1880

WB97R-2 30-75
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY OF TRANSMISSION

24 - Remove 4th speed pressure sensor 2 bar (28).

28

RKZB1890

8. Assembly pipes and sensors

1 - Assemble 1st speed antishock valve (7).
★ Make sure that arrow is directed towards clutch.
Valve: 50 Nm

RKZB1900

2 - Assemble lower fitting (23) and 2nd speed antishock

valve (22).
★ Make sure that arrow is directed towards clutch.
Valve: 40 Nm

22

23

RKZB1910

3 - Assemble 3rd speed antishock valve (6).

★ Make sure that arrow is directed towards clutch.
Valve: 25 Nm

RKZB1920

30-76 WB97R-2
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY OF TRANSMISSION

4 - Assemble 2nd speed pipe (21) and tighten fitting (20).

Pipe: 26–30 Nm
Fitting: 40 Nm 20

21

RKZB1930

5 - Assemble 1st speed pipe (4) and tighten fitting (3).

Pipe: 26–30 Nm
3
Fitting: 40 Nm
4

RKZB1940

6 - Assemble 3rd speed pipe (2) and tighten fitting

Pipe: 26–30 Nm
Fitting: 40 Nm

RKZB1950

7 - Assemble FWD delivery pipe (18) and tighten fittings.

18
Pipe: 26–30 Nm
Fitting: 40 Nm

RKZB1960

WB97R-2 30-77
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY OF TRANSMISSION

8 - Assemble 4th speed pipe (26) and tighten fittings.

Pipe: 26–30 Nm
Fitting: 40 Nm

26

RKZB1970

9 - Assemble oil temperature sensor (11).

Sensor: 23 Nm

11

RKZB1780

10 - Assemble pressure sensor 2 bar (8), 3rd speed.

Sensor: 25 Nm
8

RKZB1750

11 - Assemble pressure sensor 2 bar (9), 1st speed.

Sensor: 25 Nm

RKZB1980

30-78 WB97R-2
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY OF TRANSMISSION

12 - Assemble pressure sensor 11 bar (10).

Sensor: 25 Nm 10

RKZB1770

13 - Assemble pressure sensor (28) 2 bar 4th speed.

28
Sensor: 25 Nm

RKZB1890

14 - Assemble pressure sensor (27) 2 bar 2nd speed.

Sensor: 25 Nm

27

RKZB1880

15 - Assemble O-ring (16) and sensor (15) by centering it on

its reference pin.

15

16

RKZB1990

WB97R-2 30-79
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY OF TRANSMISSION

16 - Assemble seal (14) and its sensor cover (13).

13

14

RKZB2000

17 - Assemble screws (12).

Screw: 23 Nm

12

RKZB2010

30-80 WB97R-2
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY OF TRANSMISSION

9. Disassembly hydraulic control valve

6
4
8
5
1 7

RKZ06470

1 - Drain oil from transmission hydraulic circuit.

2 - Disconnect all electrical connections.

3 - Untighten all the fitting of the delivery pipes connected

with the control valve.

RKZB1841

WB97R-2 30-81
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY OF TRANSMISSION

4 - Unscrew screw (1) fixing the control valve on transmis-

sion.
1

RKZB2020

5 - Lift control valve (2) and remove seal (3).

RKZB2030

6 - Untighten the solenoid valve retaining nut (4).

7 - Remove O-ring (5), solenoid valve (6) and O-ring (7).

4 5 6 7

RKZB2040

8 - Untighten solenoid valve inductor (8).

RKZB2050

30-82 WB97R-2
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY OF TRANSMISSION

10. Assembly hydraulic control valve

1 - Assemble solenoid valve inductor (8).

RKZB2050

2 - Assemble O-ring (7), solenoid valve (6), O-ring (5) and

then tighten nut (4) by hand.

4 5 6 7

RKZB2040

3 - Assemble seal (3) on transmission.

RKZB2060

4 - Assemble control valve (2).

2

RKZB2070

WB97R-2 30-83
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY OF TRANSMISSION

5 - Assemble screws (1) and tighten them in a cross se-

quence.

RKZB2080

6 - Assemble all the fittings of the delivery pipes connected

with the control valve.

RKZB1941

30-84 WB97R-2
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY OF TRANSMISSION

11. Disassembly transmission housing

A
15
14
17 11
35 16
12
36
32 13
19
B
20 18

1 27
31
25
A 26
E
9
7 8 28
6 29
5 30
21
4 34 23 22
2 37
10
33
E 3 RKZ0660

1 - Drain oil from transmission hydraulic circuit.

1
2 - Remove bearing retaining ring (1).

RKZB2090

WB97R-2 30-85
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY OF TRANSMISSION

3 - Remove flange retaining screw (2), washer (3) and O-

ring (4). Use tool C3. to avoid flange rotation.
2 3 4

RKZB2620

4 - Remove flange (5).

RKZB2630

5 - Remove screws (6), cover (7) and O-ring (8).

7 8

RKZB2120

6 - Remove bearing (9).

RKZB2130

30-86 WB97R-2
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY OF TRANSMISSION

7 - Remove oil seal (10). Use tool C4.

C4 10

RKZB2141

8 - Remove screws (11).

11

RKZB2150

9 - Remove flange (12) and O-ring (13).

13 12

RKZB2160

10 - Remove transmission shaft PTO (14); by pushing lightly

on the opposite side.

14

RKZB2170

WB97R-2 30-87
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY OF TRANSMISSION

11 - Remove retaining ring (15).

15

RKZB2180

12 - Remove retaining ring (16).

16

RKZB2190

13 - Extract bearing (17) with tool C5.

C5

17
RKZB2201

14 - Remove screws (18) and cover (19).

19

18

RKZB2640

30-88 WB97R-2
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY OF TRANSMISSION

15 - Remove retaining ring (20).

20

RKZB2220

16 - Remove screws (21) and cover (22).

21
22

RKZB2650

17 - Remove retaining ring (23).

23

RKZ06610

18 - Remove flange retaining screw (24), washer (25) and O-

ring (26). Use tool C3.

24 25 26

RKZB2660

WB97R-2 30-89
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY OF TRANSMISSION

19 - Remove flange (27).

27

RKZB2670

20 - Remove screws (28) and cover (29).

29

28

RKZB4790

21 - Remove retaining ring (30).

30

RKZB2680

22 - Remove oil seal (31). Use tool C4.

C4 31

RKZB2281

30-90 WB97R-2
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY OF TRANSMISSION

23 - Tap with a rubber hammer from the opposite side until

removing bearing retaining ring (36) from the contact 36
with the housing.
Then extract with a normal extractor.

RKZ06620

24 - Remove screws (32).

32

RKZB2290

25 - Remove screws (33).

33 RKZB2300

26 - Insert a lever in the special slot “A” and remove the cover
(34) and (36).

36

34
RKZB2310

WB97R-2 30-91
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY OF TRANSMISSION

27 - Lift the front half-housing (34). Use tool C6.

C6
34

RKZB2321

12. Assembly transmission housing

1 - Replace O-ring (35). 35

RKZB2330

2 - Apply a thin film of Loctite 510 on the rear half-housing

(36).

36

RKZB2340

3 - Using tool C6, locate front half-housing (34) on rear half-

housing (36).
C6

34

36

RKZB2351

30-92 WB97R-2
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY OF TRANSMISSION

4 - Assemble screws (32).

Screw: 50 Nm

32

RKZB2290

5 - Assemble screws (33).

Screw: 50 Nm 33

RKZB2360

6 - Assemble bearing retaining ring (1).

1
RKZB2370

7 - Assemble bearing (9). Use tool C7.

RKZB2380

WB97R-2 30-93
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY OF TRANSMISSION

8 - Assemble seal ring (10) on cover (7).

10
C4

RKZB2391

9 - Assemble O-ring (8) and cover (7).

7

RKZB2400

10 - Assemble screws (6).

Screw: 50 Nm

RKZB2410

11 - Assemble flange (5), O-ring (4) and washer (3).

3
RKZB2690

30-94 WB97R-2
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY OF TRANSMISSION

12 - Assemble screw (2). Use tool C3 to avoid flange rota-

tion.

Screw: 50 Nm

RKZB2430

13 - Assemble bearing (30).

30

RKZB2680

14 - Apply a thin film of Loctite 510.

RKZB2720

15 - Assemble seal ring (31) on cover (29). Use tool C4.

C4 31

29

RKZB2462

WB97R-2 30-95
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY OF TRANSMISSION

16 - Assemble cover (29) and tighten with screw (28).

Screw: 139 Nm

29 28 RKZB2470

17 - Assemble flange (27), O-ring (26) and washer (25).

27

26
25
RKZB2740

18 - Assemble screw (24). Use tool C3 to avoid flange ro-

tation.

Screw: 139 Nm

24

RKZB2750

19 - Using tool C8, assemble bearing (36).

36 C8

RKZB2442

30-96 WB97R-2
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY OF TRANSMISSION

20 - Assemble retaining ring (23).

23

RKZ06610

21 - Apply a thin film of Loctite 510.

RKZB2720

22 - Assemble cover (22) and tighten screws (21).

Screw: 50 Nm

22
21

RKZB2770

23 - Assemble retaining ring (20).

20

RKZB2530

WB97R-2 30-97
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY OF TRANSMISSION

24 - Apply a thin film of Loctite 510.

RKZB2540

25 - Assemble cover (19) and tighten screws (18).

19
Screw: 50 Nm

18

RKZB2800

26 - Assemble bearing (17) on transmission shaft PTO (14).

14
17

RKZB2560

27 - Assemble retaining ring (16).

16

RKZB2570

30-98 WB97R-2
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY OF TRANSMISSION

28 - Assemble retaining ring (15).

15

RKZB2580

29 - Insert transmission shaft PTO (14) to the stroke.

14

RKZB2590

30 - Assemble O-ring (13) and apply a thin film of grease on

the flange inner diameter (12).

13

12

RKZB2600

31 - Assemble screws (11).

Screw: 50 Nm

11

RKZB2610

WB97R-2 30-99
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY OF TRANSMISSION

13. Disassembly shaft A

42 16
D 16
16
41 10
11
32
9 31
17 33
8 17
7
17
5
3 4
2 36
1
37
40
A
24 A
30
27
6 12
38
20 27 21
22
19 23
34 26
15 18 34
14 13 25
34
26
39
29
28
35
35
RKZ06500 35

1 - Grasp with pliers shaft assembly A and shaft assembly

D and lift.

D
A

RKZB2810

30-100 WB97R-2
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY OF TRANSMISSION

2 - Widen and remove rotary seal (1).

RKZB2820

3 - Remove retaining ring (2).

3 2
RKZB2830

4 - By means of an extractor remove bearing (3).

RKZB2840

5 - Remove spacer (4) and washer (5).

4

RKZB2850

WB97R-2 30-101
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY OF TRANSMISSION

6 - Remove spring pin (6).

RKZB2860

7 - Remove gear (7).

RKZB2870

8 - Remove roller retainers (8) and washer (9).

9
RKZB2880

9 - Lower stop washer (11) to allow retaining ring (10) re-

moval. Use a drift and a hammer.

11
10

RKZB2890

30-102 WB97R-2
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY OF TRANSMISSION

10 - Remove retaining ring (10) and stop washer (11).

11

10

RKZB2900

11 - Lower spring retaining cover (15). Remove spring pin

(12). Use tool C9 and a hydraulic press.

12
RKZB2910

12 - Remove retaining ring (14).

14
RKZB2920

13 - Remove spring retaining cover (13) and spring (15).

13
15

RKZB2930

WB97R-2 30-103
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY OF TRANSMISSION

14 - Remove disc pack (16) and counterdiscs (17).

17
16

RKZB2940

15 - Remove clutch piston (18) by blowing in compressed air

through the delivery hole.

18

RKZB2950

16 - Widen and remove rotary seal (19).

19
RKZB2960

17 - Widen and remove rotary seal (20).

20 RKZB2970

30-104 WB97R-2
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY OF TRANSMISSION

18 - Widen and remove rotary seals (38).

38

RKZB2980

19 - Remove retaining ring (21).

21

RKZB3000

20 - Remove bearing (22) by means of an extractor.

22

RKZB3010

21 - Remove bearing (23)

22

23

RKZB3020

WB97R-2 30-105
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY OF TRANSMISSION

22 - Remove spring pin (24).

24

RKZB3030

23 - Remove gear (25).

25

RKZB3040

24 - Remove roller retainers (26), spacer (27) and washer

(39).

27

26 39

RKZB3050

25 - Lower stop washer (28) to allow retaining ring (29) re-

moval. Use a drift and a hammer.

29
28

RKZB2891

30-106 WB97R-2
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY OF TRANSMISSION

26 - Remove retaining ring (29) and stop washer (28).

29

28

RKZB3060

27 - Lower spring retaining cover (33). Remove spring pin

(30). Use tool C9 and a hydraulic press.

30
RKZB3070

28 - Remove retaining ring (32).

32
RKZB3080

29 - Remove spring retaining cover (31) and spring (33).

31

33

RKZB3090

WB97R-2 30-107
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY OF TRANSMISSION

30 - Remove disc pack (34) and counterdiscs (35).

35
34

RKZB3100

31 - Remove clutch piston (36) by blowing in compressed air

through the delivery hole. 36

RKZB3110

32 - Remove rotary seal (37).

37
RKZB3120

33 - Widen and remove rotary seal (40).

40 RKZB4800

30-108 WB97R-2
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY OF TRANSMISSION

34 - Remove shaft D axle bearing (41) by means of an ex-

tractor.

41
RKZB3130

35 - Remove shaft D axle bearing (42) by means of an ex-

tractor.

42
RKZB3140

14. Assembly shaft A

1 - Insert rotary seal (40).

40

RKZB3150

2 - Insert rotary seal (37) on clutch piston (36).

36

37
RKZB3160

WB97R-2 30-109
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY OF TRANSMISSION

3 - Apply a thin film of grease on the outer edge and in the in-
ner part of clutch piston (36).

36

RKZB3170

4 - Insert spring (33), spring retaining cover (31).

5 - Lower the spring retaining cover (33). Insert retaining

ring (32). Use tool C9 and a hydraulic press.

31
32

33

RKZB3180

6 - Assemble spring pin (30), align the hole with the cover
notch (31).

31 30

RKZB3190

7 - Insert washer (39), roller retainers (26) and spacer (27).

26

27

26

39

RKZB3200

30-110 WB97R-2
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY OF TRANSMISSION

8 - Assemble disc pack (34), counterdiscs (35) and stop

washer (28) on gear (25).

35

34

28

25
RKZB3210

9 - Insert the assembly by means of two screwdrivers.

RKZB3220

10 - Lift gear (25) to allow retaining ring (29) assembly.

25

29

RKZB3230

11 - Assemble spring pin (24).

24

RKZB3240

WB97R-2 30-111
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY OF TRANSMISSION

12 - Assemble washer (23), bearing (22) and insert retaining

ring (21). Use tool C8.

21

22

23
RKZB3250

13 - Insert and close rotary seal (38).

38

38

RKZB3260

14 - Insert rotating seal ring (20).

20

RKZB3270

15 - Insert rotary seal (19) on clutch piston (18).

19

18

RKZB4810

30-112 WB97R-2
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY OF TRANSMISSION

16 - Apply a thin film of grease on the outer edge and in the in-
ner part of clutch piston (18) and insert.

18

RKZB3280

17 - Insert spring (15) and spring retaining cover (13) and lov-
er the spring retaining cover.

18 - Insert retaining ring (14). Use tool C9 and a hydraulic

press.
14

13

15 RKZB3290

19 - Assemble spring pin (12).

12

RKZB3300

20 - Insert washer (9) and roller retainers (8).

RKZB4820

WB97R-2 30-113
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY OF TRANSMISSION

21 - Assemble disc pack (16), counterdiscs (17) and stop

washer (10) on gear (7).
17

16

10

RKZB3310

22 - Insert the assembly by means of two screwdrivers.

RKZB3320

23 - Lift gear (7) to allow retaining ring (11) assembly.

7

11

RKZB3330

24 - Assemble spring pin (6).

RKZB3340

30-114 WB97R-2
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY OF TRANSMISSION

25 - Assemble washer (5), spacer (4) and bearing (3). Use

tool C8.

RKZB3350

26 - Insert retaining ring (2). Insert and close rotary seal (1).

RKZB3350

27 - Check for proper operation by blowing in compressed air

into the special hole, about 6 bar.

RKZB3360

28 - Assemble D shaft bearing (41). Use tool C100.

C10 41

RKZB3371

WB97R-2 30-115
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY OF TRANSMISSION

29 - Assemble D shaft bearing (42). Use tool C10.

C10
42

RKZB3381

30 - Reposition shaft assembly D.

RKZB4840

31 - Reposition shaft assembly A.

RKZB4960

30-116 WB97R-2
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY OF TRANSMISSION

15. Disassembly shaft B

16
16

14
12
13
11 15
10 15
7
9 15 B

5 6
24
4 25
3 1 26
2

B
17
18 8
23

22
21
RKZ06490 19 20

1 - Lift the three shafts B-C-E, at the same time. Use tool
C11. C11

RKZB3401

WB97R-2 30-117
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY OF TRANSMISSION

2 - Widen and remove rotary seals (1).

RKZB3390

3 - Remove retaining ring (2).

RKZB3410

4 - Remove spacer (3).

RKZB3420

5 - By means of an extractor remove bearing (4).

RKZB3430

30-118 WB97R-2
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY OF TRANSMISSION

6 - Remove gear (5).

4

RKZB3440

7 - Remove spacer (6) and washer (7).

RKZB3450

8 - Remove spring pin (8).

RKZB3460

9 - Remove gear (9).

RKZB3470

WB97R-2 30-119
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY OF TRANSMISSION

10 - Remove roller retainers (10) and washer (11).

10

11
RKZB3480

11 - Slightly press stop washer (12).

12

RKZB3490

12 - Remove retaining ring (13).

13

RKZB3500

13 - Remove stop washer (12) by means of two screwdriv-

ers.
12

RKZB3510

30-120 WB97R-2
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY OF TRANSMISSION

14 - Remove Belleville washer (14), disc pack (15) and

counterdiscs (16).

16

15

14

RKZB3520

15 - Remove spring pin (17).

17

RKZB3530

16 - Lower spring retaining cover (20). Remove retaining

ring (19). Use tool C9 and a hydraulic press.

19

20
RKZB3540

17 - Remove spring retaining cover (18) and spring (20).

18

20

RKZB3550

WB97R-2 30-121
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY OF TRANSMISSION

18 - Remove clutch piston (21) by blowing in compressed air

through the delivery. 22
19 - Remove the rotary seal (22).

21

RKZB3560

20 - Widen and remove rotary seal (23).

23

RKZB3570

21 - Remove retaining ring (24) and washer (25).

24

25

RKZB3590

22 - Remove bearing (26) by means of an extractor.

RKZB3600

30-122 WB97R-2
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY OF TRANSMISSION

16. Assembly shaft B

C10 26
1 - Assemble bearing (26). Use tool C10.

RKZB3611

2 - Insert washer (25) and assemble retaining ring (24).

24

25

RKZB3620

3 - Insert and close rotary seal (23).

23

RKZB3630

4 - Insert rotary seal (22) on clutch piston (21).

21

22

RKZB3640

WB97R-2 30-123
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY OF TRANSMISSION

5 - Apply a thin film of grease on the outer edge and in the in-
ner part of clutch piston (21). 21

RKZB3650

6 - Insert clutch piston (21), spring (20) and spring retaining

cover (18).

7 - Lower spring retaining cover (20) and insert retaining

ring (19). Use tool C9 and a hydraulic press.
19

18 20
RKZB3660

8 - Assemble spring pin (17).

17

RKZB4850

9 - Insert washer (11) and roller retainers (10).

10

11

RKZB3670

30-124 WB97R-2
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY OF TRANSMISSION

10 - Assemble disc pack (15), counterdiscs (16), Belleville

washer (14) and stop washer (12) on gear (9). 15 16

14

12

RKZB3680

11 - Insert the assembly by means of two screwdrivers.

RKZB3690

12 - Assemble retaining ring (13).

13

RKZB3700

13 - Assemble spring pin (8).

RKZB3710

WB97R-2 30-125
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY OF TRANSMISSION

14 - Assemble washer (7), spacer (6) and gear (5).

6
5

RKZB3720

15 - Assemble bearing (4). Use tool C7.

C7 4

RKZB3731

16 - Insert spacer (3) and assemble retaining ring (1).

1

RKZB3740

17 - Insert rotary seal (2).

2

RKZB3750

30-126 WB97R-2
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY OF TRANSMISSION

18 - Check for proper operation by blowing in compressed air

into the special hole, about 6 bar.

RKZB3360

19 - Lift the three shafts B-C-E at the same time and insert
into the rear half-housing. Use tool C11. C11

RKZB3771

WB97R-2 30-127
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY OF TRANSMISSION

17. Disassembly shaft C

13
13
13
49
C 51
5
2 3 4 53
55
12
12
12
12 52
11
30
10 9 54
56 30
6 30
7 50
14 31
1 8
20 29
19 29
18 C
16 29
15 17
27 38 39
40
28 39
48 41 24
48 42 38
43
25
45
44 21
46 22
37
47 23
47 36 26
35
34
33
RKZ06510 32

1 - Lift the three shaft B-C-E at the same time. Use tool C11.
C11

RKZB3401

30-128 WB97R-2
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY OF TRANSMISSION

2 - Widen and remove rotary seals (1).

RKZB3780

3 - Remove retaining ring (2).

RKZB3790

4 - Remove washer (3).

RKZB3800

5 - By means of an extractor remove bearing (4), phonic

wheel (5) and gear (6).

4
5

RKZB3810

WB97R-2 30-129
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY OF TRANSMISSION

6 - Remove roller retainers (7) and pin (8).

7
8

7
RKZB3820

7 - Slightly press stop washer (9).

RKZB3830

8 - Remove retaining ring (10).

10

RKZB3840

9 - Remove the pack including stop washer (9), Belleville

washer (11), discs (12) and counterdiscs (13). 9
11

12

13
RKZB3850

30-130 WB97R-2
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY OF TRANSMISSION

10 - Remove washer (15) and spring pin (14).

15
14

RKZB3860

11 - Lower spring retaining cover (18) and remove retaining

ring (17). Use tool C9 and a hydraulic press.

17

18

RKZB3870

12 - Remove spring retaining cover (16), spring (18).

16
13 - Remove clutch piston (19) by blowing in compressed air
through the delivery hole. Remove the rotary seal (20). 18

19

20
RKZB3880

14 - Widen and remove rotary seal (24).

24

RKZB3910

WB97R-2 30-131
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY OF TRANSMISSION

15 - By means of an extractor remove 1st speed gear (25)

and bearing (26).

26

25

RKZB3920

16 - Slightly lower stop washer (27).

27

RKZB3930

17 - Remove retaining ring (28).

28

RKZB3940

18 - Remove stop washer (27) by means of two screwdriv-

ers. 27

RKZB3950

30-132 WB97R-2
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY OF TRANSMISSION

19 - Remove disc pack (29) and counterdiscs (30).

29
30

RKZB3960

20 - Remove Belleville washer (31).

31

RKZB3970

21 - Lower spring retaining cover (34) to allow retaining ring

removal (32). Use tool C9 and a hydraulic press.

32
34

RKZB3980

23 - Remove retaining ring (32), spring retaining cover (33)

32
and spring (34).

33

34

RKZB3990

WB97R-2 30-133
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY OF TRANSMISSION

24 - Remove clutch piston (35) by blowing in compressed air

through the delivery hole. Remove rotary seal (36). 35 36

RKZB4000

25 - Remove retaining ring (37).

37

RKZB4860

26 - Remove roller retainer (38), bushings (39) and spacer

(40).
38

39 40

38

39
RKZB4870

27 - Remove gear (41).

41

RKZB4010

30-134 WB97R-2
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY OF TRANSMISSION

28 - Remove gear (42).

42

RKZB4020

29 - Remove roller retainers (43).

43

RKZB4030

30 - Slightly lower stop washer (44).

44

RKZB4040

31 - Remove retaining ring (45).

45

RKZB4050

WB97R-2 30-135
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY OF TRANSMISSION

32 - Remove stop washer (44) by means of two screwdriv-

ers.

44

RKZB4060

33 - Remove Belleville washer (46), discs (47), counterdiscs

(48) and washer (49).

46

47 48
RKZB4070

34 - Remove spring ring (50).

50

RKZB4080

35 - Lower spring retaining cover (53). Use tool C9 and a hy-

draulic press.

53

RKZB4090

30-136 WB97R-2
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY OF TRANSMISSION

36 - Remove retaining ring (51), spring retaining cover (52)

and spring (53).
51

52

53

RKZB4950

37 - Remove clutch piston (54) by blowing in compressed air

through the delivery hole. Remove rotary seal (55). 55

54

RKZB4100

18. Assembly shaft C

1 - Insert rotary seal (55) on clutch piston (54).

55

54

RKZB4110

2 - Apply a thin film of grease on the outer edge and in the in-
ner part of clutch piston (54).

54

RKZB4120

WB97R-2 30-137
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY OF TRANSMISSION

3 - Insert clutch piston (54), spring (53) and spring retaining

cover (52).

52
53

54

RKZB4130

4 - Lower spring retaining cover (53) and insert retaining

ring (51). Use tool C9 and a hydraulic press.

51

53

RKZB4140

5 - Insert stop washer (44), Belleville washer (46), discs

(47) and counterdiscs (48) on gear (42).
48
47

46

42
44
RKZB4150

6 - Assemble spring pin (50).

50

RKZB4160

30-138 WB97R-2
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY OF TRANSMISSION

7 - Apply a thin film of grease under washer (49) to avoid its

falling when overturning the shaft.

49

RKZB4170

8 - Align discs (47), counterdiscs (48) and stop washer (44).

9 - Insert the preassembled main shaft (56).

56

47 48

44 RKZB4180

10 - Insert roller retainers (43).

43

43

RKZB4190

11 - Assemble retaining ring (45).

45

RKZB4890

WB97R-2 30-139
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY OF TRANSMISSION

12 - Lift retaining ring (45) with a screwdriver to insert into its

seat.

45

RKZB4200

13 - Insert and close rotary seal (37) on gear (25).

25 37

RKZB4900

14 - Insert and close rotary seal (36) on clutch piston (35).

35 36

RKZB4210

15 - Apply a thin film of grease on the outer edge and in the in-
ner part of clutch piston (35). 35

RKZB4220

30-140 WB97R-2
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY OF TRANSMISSION

16 - Insert clutch piston (35), spring (34) and spring retaining

cover (33). 33

34
35

RKZB4230

17 - Lower spring retaining cover (34) and assemble retain-

ing ring (32). Use tool C9 and a hydraulic press. 32

34

RKZB4240

18 - Insert gear (41), roller retainers (38), bushings (39) and

spacer (40) on main shaft. 38

39

40 39

38
41

RKZB4250

19 - Insert stop washer (27), disc pack (29), counterdiscs 56

(30) and Belleville washer (31) on main shaft (56) mak- 30
ing sure they are all aligned.

29 31

27
RKZB4260

WB97R-2 30-141
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY OF TRANSMISSION

20 - Insert gear assembly (25) on main shaft (56).

25

56

RKZB4270

21 - Assemble retaining ring (28) making sure it is correctly

seated.
28

RKZB4280

22 - Insert and close rotary seals (24).

24

RKZB4290

23 - Assemble bearing (26). Use tool C8.

26
C8

RKZB4301

30-142 WB97R-2
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY OF TRANSMISSION

24 - Insert and close rotary seal (20) on clutch piston (19).

19

20

RKZB4320

25 - Apply a thin film of grease on the outer edge and in the in-
ner part of clutch piston (19).

19

RKZB4330

26 - Insert clutch piston, spring (18) and spring retaining cov-

er (16).
16
18

RKZB4340

27 - Lower spring retaining cover (18) and insert retaining

ring (17). Use tool C9 and a hydraulic press.

17

18
RKZB4350

WB97R-2 30-143
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY OF TRANSMISSION

28 - Assemble spring pin (14).

14

RKZB4360

29 - Apply a thin film of grease under washer (15) to avoid its

falling when overturning the shaft.

15

RKZB4370

30 - Insert stop washer, Belleville washer, discs (12) and

counterdiscs (13) on gear (6).
12

11
13

6
9

RKZB4910

31 - Insert roller retainers (7).

RKZB4380

30-144 WB97R-2
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY OF TRANSMISSION

32 - Insert gear (6) with the disc pack on the main shaft.
6

RKZB4390

33 - Locate the pack assembly by means of two screwdriv-

ers.

RKZB4400

34 - Lift gear (6) for retaining ring assembly.

RKZB4410

35 - Assemble retaining ring (10) and gear.

10

RKZB4420

WB97R-2 30-145
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY OF TRANSMISSION

36 - Assemble pin (8).

8
RKZB4920

37 - Assemble phonic wheel (5).

RKZB4430

38 - Assemble bearing (4). Use tool C7.

C7
4

RKZB4441

39 - Insert washer (3) and retaining ring (2).

2

RKZB4450

30-146 WB97R-2
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY OF TRANSMISSION

40 - Insert rotary seals (1).

RKZB4460

41 - Lift the three shafts B-C-E at the same time and insert the
unit into the half-housing. Use tool C11. C11

RKZB4471

42 - Check for proper operation by blowing in compressed air

into the special hole, about 6 bar.

RKZB3760

WB97R-2 30-147
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY OF TRANSMISSION

19. Disassembly shaft E

2
16
2 15

17
6
4
5 17
4
3 17

13
E 19 18 E

18

9 1 18
7 21
22

23
11 20
10

12
8 14 RKZ06530

1 - Lift the three shafts B-C-E at the same time. Use tool
C11. C11

RKZB3401

30-148 WB97R-2
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY OF TRANSMISSION

2 - Widen and remove rotary seals (1).

RKZB4480

3 - Lower Belleville washers (2) and remove retaining ring

(3). Use tool C9 and a hydraulic press.
★ Take care not to damage the Belleville washers.

3
C9

2
RKZB4491

4 - Remove washers (4) and spacers (5).

4
3

RKZB4500

5 - Remove spacer (6) and Belleville washers (2).

6 2

RKZB4510

WB97R-2 30-149
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY OF TRANSMISSION

6 - Remove clutch piston (7) from its seat. To remove the

piston blow compressed air into output shaft. 19

RKZB4520

7 - By means of an extractor remove clutch piston (7).

RKZB4530

8 - Remove O-rings, inner (8) and outer (9).

9

8
RKZB4540

9 - Remove the three pins (10) and the relative O-rings (11).

10
10

11

10
RKZB4930

30-150 WB97R-2
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY OF TRANSMISSION

10 - Remove retaining ring (12).

12

RKZB4550

11 - Remove bearing (14) by means of an extractor.

14

RKZB4560

12 - Slightly press stop washer (15).

15

RKZB4570

13 - Remove retaining ring (16).

16

RKZB4580

WB97R-2 30-151
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY OF TRANSMISSION

14 - Remove stop washer (15).

15

RKZB4590

15 - Remove disc pack (17), counterdiscs (18) and brake ac-

tuating disc (13). 17
18

13

RKZB4600

16 - Remove spacer (22).

22

RKZB4610

17 - Remove bearing (23) by means of two levers.

23

RKZB4620

30-152 WB97R-2
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY OF TRANSMISSION

18 - Remove all bearing (23) parts.

23

RKZB4630

20. Assembly shaft E

1 - Assemble bearing (14) and the relative retaining ring 12
(12). Use tool C12.

14

RKZB4640

2 - Insert inner (8) and outer (9) O-rings on clutch piston (7).

9
RKZB4650

3 - Insert O-rings (11) on the relative pins (10).

10

11

RKZB4660

WB97R-2 30-153
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY OF TRANSMISSION

4 - Position the pins (10) on clutch piston (7) in correspond-

ence with the holes on output shaft and insert clutch pis-
ton.

7
RKZB4670

5 - Insert stop ring (15), disc pack (17), counterdiscs (18)

and brake actuator (13) on gear (20). 15
18

17

20

13

RKZB4940

6 - Assemble shaft (19) on gear (20).

19

20
RKZB4680

7 - Insert shaft (19) by using a rubber hammer.

19

RKZB4690

30-154 WB97R-2
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY OF TRANSMISSION

8 - Assemble retaining ring (16) after lifting gear (20).

16 20

RKZB4700

9 - Make sure that the disc pack, the counterdiscs and the
piston are correctly seated.

RKZB4710

10 - Preassemble spacer (6), washers (4) and retaining ring

(3). 3

RKZB4720

11 - Insert retaining ring (3) to measure dimension X.

Calculate the shim S with this formula:

S=X–(S1+S2)

S1 = retaining ring (3)

S1

S2 = washer thickness (4)

3
X

S2
S
5

RKZB4730

WB97R-2 30-155
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY OF TRANSMISSION

12 - Insert Belleville washers (2), spacer (6), washers (4) and

shims (5).
4

2
5

RKZB4740

13 - Lower Belleville washers (2) and assemble retaining

ring (3). Use tool C9 and a hydraulic press.

3
C9

2
RKZB4491

14 - Insert a pressure of about 10 bar with an oil pump to

check the seal of ring (8) and (9). Use tool C13. 9

C13

8
RKZ06521

15 - Insert rotary seals (1).

RKZB4750

30-156 WB97R-2
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY OF TRANSMISSION

16 - Assemble bearing (23). Use tool C14.

C14

23

RKZB4761

17 - Insert spacer (22).

22

RKZB4770

18 - Using tool C11, lift the three shafts B-C-E at the same
time and insert the unit into the half-housing.

RKZB4780

WB97R-2 30-157
PAGE INTENTIONALLY
LEFT BLANK
REMOVAL AND INSTALLATION REMOVAL OF THE CONVERTOR

REMOVAL OF THE CONVERTOR

Lower the working equipment completely until it rests on
1
the ground and stop the engine. 2
Raise the engine hood and disconnect the cable from
battery negative terminal (–).
Release all residual pressure in all circuits.
(For details, see «20. TESTING AND ADJUST-
MENTS»).
★ Drain the hydraulic oil.
Hydraulic oil: 92

★ Drain the oil from the gearbox. RKZA8730

Gearbox oil: 16

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

OF THE PISTON PUMP»). 1
2 - Remove the gearbox.
(For details, see «REMOVAL OF THE GEARBOX»).

3 - Slide the convertor (1) away from the gearbox shafts

(2), (primary and secondary).
★ If necessary, use two levers applied in opposed po-
sitions.
★ Take great care not to damage the centering hub of
the gearbox.

INSTALLATION OF THE
CONVERTOR
• To install, reverse the removal procedure.
★ Engage the two shafts (primary and secondary) by
slowly rotating the body of the convertor.
1 - Refill the tank with hydraulic oil up to maximum level.

Hydraulic oil: 92

1
★ Fill the pump body and the pump, bringing the tank
up to pressure.
For the method, see «20. TESTING AND ADJUST-
MENTS».

2 - Refill the gearbox.

Gearbox oil: 16

3 - Start the engine to circulate the oil in all circuits. Check
that there are no leaks.
4 - Bleed the air from the working equipment circuits. (For
details, see «20. TESTING AND ADJUSTMENTS»)
5 - Stop the engine, check the levels and, if necessary, top
them up.

WB97R-2 30-159
REMOVAL AND INSTALLATION REMOVAL OF THE TRANSMISSION-REVERSE, DIRECTION

REMOVAL OF THE TRANSMISSION-REVERSE, DIRECTION

INDICATOR AND HEADLIGHT DIPPER BEAM CONTROL GROUP
(standard version)
Lower the working equipment completely until it rests on
the ground, and stop the engine. 2
Raise the cable from battery negative terminal (–).

1 - Remove screws (1) and guard (2).

RKZB6700

2 - Lower the bellows boot (3) and disconnect the connectors

(4), (5).

RKZB6710

3 - Remove the screws (6), the self-locking nuts and the gear-
shift control assembly (7) and direction indicator and head- 8
light dipper beam control assembly (8). 7
★ The control assemblies have fixed orientation and po-
sition, defined by a location pin.

RKZB6720

INSTALLATION OF THE
TRANSMISSION REVERSE,
DIRECTION INDICATOR AND
HEADLIGHT DIPPER BEAM
CONTROL GROUP
8
• To install, reverse the removal procedure.
2

RKZA8690

30-160 WB97R-2
REMOVAL AND INSTALLATION REMOVAL OF THE TRANSMISSION-REVERSE, DIRECTION

REMOVAL OF THE TRANSMISSION-REVERSE, DIRECTION

INDICATOR AND HEADLIGHT DIPPER BEAM CONTROL GROUP
(EGM version)
1
Lower the working equipment completely until it rests on
the ground, and stop the engine.

Raise the cable from battery negative terminal (–).

1 - Remove four nut (1) and divide the transmission-re-

verse (2) from direction and headlight dipper beam con-
trol group (3). 2

RKZA8660

2 - Remove two screw (4) and guard (5).

3
4

5
RKZA8670

3 - Raise the protective sleeve (6) and disconnect the con-

nector (7); remove the direction and headlight dipper 6
beam control group. 7

RKZA8680

4 - Rotate in counterclockwise direction the ring (8) and

disconnect the control group (2).

INSTALLATION OF THE
TRANSMISSION REVERSE,
DIRECTION INDICATOR AND 8
HEADLIGHT DIPPER BEAM 2
CONTROL GROUP
• To install, reverse the removal procedure.
RKZA8690

WB97R-2 30-161
REMOVAL AND INSTALLATION REMOVAL OF THE STEERING UNIT

REMOVAL OF THE STEERING UNIT

The model with EGM is illustrated here. For the standard
model, see also «REMOVAL OF THE TRANSMISSION-
REVERSE, DIRECTION INDICATOR AND HEADLIGHT
DIPPER BEAM CONTROL GROUP». 1
2
Lower the working equipment completely until it rests on
the ground and stop the engine and remove the ignition
wrench.
Release all residual pressure in all circuits.
(For details, see «20. TESTING AND ADJUST-
MENTS»).
Raise the engine hood and disconnect the cable from RKZA0870

battery negative terminal (–).

1 - Disconnect the five pipes (2) from the steering unit (1)
and plug them to prevent entry of impurities. 1
★ Mark the positions to prevent exchanges during re-
connection.

2 - Remove the central guard (3) beneath the steering

4
wheel.

3 5

RKZA8700

3 - Remove the guard (4) raise the protective sleeve (5)

and disconnect the connectors (6) and (7).

4 - Disconnect the connector (8) and the relay (9).

7
5 - Loosen the steering column (11) retaining screws (10)
and the steering unit (1).

6 - Remove screw (10) and remove the steering unit (1).

6
INSTALLATION OF THE
STEERING UNIT RKZA8890

• To install, reverse the removal procedure.

1
★ Bleed the air from the Load Sensing circuit. 11
(For details, see «20. TESTING AND ADJUST-
MENTS»). 8
9
★ Start the engine and perform several complete steering 10
manoeuvres in both directions, to bleed the air out of the
steering system.

RKZA9791

30-162 WB97R-2
REMOVAL AND INSTALLATION REMOVAL OF THE WORKING BRAKE PUMP GROUP

REMOVAL OF THE WORKING BRAKE PUMP GROUP

Lower the working equipment completely until it rests on
the ground, and stop the engine.
1
Raise the engine hood and disconnect the cable from
battery negative terminal (–).
2 7
1 - Remove the cap (1) of the oil tank (2) and draw out the 5
oil contained inside it. 3
7
2 - Disconnect the connectors (3).
4
3 - Remove the oil tank (2). 6
4 - Remove the clip (4) that holds the delivery lines (5). 8
RKZA9800

5 - Remove the delivery lines (5) from the pumps (6).

1
6 - Take out the four screws (7) and remove the pump
group (6).
2
★ If only one pump is to be removed, also disconnect
the pressure- equalizing pipe (8).
3

INSTALLATION OF THE
WORKING BRAKE PUMP GROUP
• To install, reverse the removal procedure.

1
★ Bleed the air from the braking circuit.
(For details, see «20. TESTING AND ADJUST-
MENTS»).

2
★ Make sure that the push-rods (9) center the seating of
9
the pistons.

★ After installation, check the idle stroke and parallelism

RKZB6730
of the brake pedals and, if necessary, adjust the cou-
pling microswitches for 4-wheel brake control. (For de-
tails, see «20. TESTING AND ADJUSTMENTS»).

3
Pipe fitting: 20 Nm

WB97R-2 30-163
REMOVAL AND INSTALLATION REMOVAL OF THE FRONT WORKING EQUIPMENT CONTROL

REMOVAL OF THE FRONT WORKING EQUIPMENT CONTROL

VALVE
Lower the working equipment completely until it rests on
the ground and stop the engine and remove the ignition
wrench.
Release all residual pressure in all circuits.
3
(For details, see «20. TESTING AND ADJUST-
MENTS»).

1 - Remove the mat (1) and disengage the protective

sleeves (2), (3).

RKZB0071

2 - Take out the screws (4) and remove the guard (5).

3
5

1 4

RKZB0032

3 - Disconnect the spool control tie-rods (7) from the con-

trol valve (6). 7
4 - Disconnect from the control valve all pipes and lines for
the actuators (8), pump delivery (9), drainage (10), Load 6
Sensing (11) and steering unit delivery (13), and plug
them.
★ Mark the pipes to avoid exchanging positions dur-
ing reconnection.

5 - Take out the four control valve retaining screws.

6 - Remove the control valve (6).

RKZA8780

INSTALLATION OF THE FRONT

WORKING EQUIPMENT
6 9
CONTROL VALVE 11
• To install, reverse removal procedure.

1 - Start the engine to circulate the oil, and check that there 12
are no leaks.
8
2 - Bleed the air from all circuits.
10
(For details, see «20. TESTING AND ADJUST-
MENTS»).
11
3 - Stop the engine and check the oil level in the tank. RKZA9992

30-164 WB97R-2
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY FRONT AND BACKHOE CONTROL

DISASSEMBLY AND ASSEMBLY FRONT AND BACKHOE CONTROL

VALVE
INLET AND OUTLET ELEMENTS REPAIR
PROCEDURES
1. LS pressure relief valve replacement
• On the inlet element, unscrew the LS pressure relief
valve (17 mm wrench).
★ Reassembly: torque: 45 ± 4 Nm

RKZB5850

2. Flow regulator replacement

• On the inlet element, unscrew the flow regulator (22 mm
wrench).
★ Reassembly:
install the flow regulator on the inlet element,
torque: 20 ± 2 Nm

RKZB5860

2.1 Flow regulator filter replacement

• Using pliers, extract the filter from the end of the flow
regulator.
★ Be careful not to damage the seal and the end of the
flow regulator.

RKZ07530

3. Flow divider replacement

• On the inlet element, unscrew the plug (12 mm socket
wrench).
★ Reassembly:
- Replace the plug O-ring
- torque: 100 ± 10 Nm

RKZB5870

WB97R-2 30-165
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY FRONT AND BACKHOE CONTROL

• Remove the shim, the stop, the spring and the piston as-
sembly.

RKZB5880

★ Replace defective parts.

★ Reassemble parts in reverse order.

RKZ07540

4. Removal of the flushing valve for “closed center“

• On the inlet element, unscrew the flushing valve plug
(12 mm socket wrench).
★ Reassembly:
- replace the plug O-ring.
- torque: 100 ± 10 Nm

RKZB5900

30-166 WB97R-2
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY FRONT AND BACKHOE CONTROL

• Remove:
- shim
- spring
- piston.
★ Reassemble parts in reverse order.

RKZB5890

5. “Closed center” removal

• On the inlet element, unscrew the plug from the “closed
center“ (12 mm allen wrench).
★ Reassembly:
- replace the plug O-ring
- torque: 100 ± 10 Nm

RKZB5920

• Remove the piston.

★ Reassemble parts in reverse order.

RKZB5910

6. Solenoid valve, "clamps" and shuttle valve

removal (installed on backhoe loader)

6.1 Solenoid replacement

• On the outlet element, unscrew the knurled knob from
the solenoid.
Pull the solenoid off the stem of the 2-ways valve.
★ Reassembly: replace the 2 seals of the solenoid.

RKZB5930

WB97R-2 30-167
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY FRONT AND BACKHOE CONTROL

6.2 2-ways valve replacement

• Unscrew the 2-ways valve (24 mm wrench)
★ Reassembly: torque: 45 ± 4 Nm
6.3 Shuttle valve or selector removal
• On the outlet element, unscrew the upper seat (4 mm
socket wrench).
★ Reassembly: torque: 20 ± 2 N.m.
• Remove the ball.
• Unscrew the lower seat.
★ Reassembly: torque: 20 ± 2 N.m.
• Replace shuttle valve parts. RKZ07570

★ Apply Loctite 542 pneumatic/hydraulic sealant

• Reassemble parts in reverse order.

30-168 WB97R-2
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY FRONT AND BACKHOE CONTROL

DISTRIBUTION ELEMENT REPAIR PROCEDURE

1. Secondary pressure relief valve replacement

• On the distribution element in question, unscrew the
secondary pressure relief valve (24 mm open end span-
ner).
★ Reassembly:
- set the pressure relief valve to the specified value.
- install the secondary pressure relief valve on the
distribution element (torque: 70 ± 7 Nm)
- fit a new appropriate locking cover.

RKZB5940

2. Spool stroke measurement

• Move the control lever of the element in question in all
possible positions, and measure the corresponding
spool stroke values at the tongue.

RKZ07580

3. Removal of spool with spring return and lip seal

3.1 Tongue side

• Remove:
- mounting screws (L=12 mm) (screwdriver Torx Tx30)
- the boot and its plate
- plate.
★ Reassembly:
- replace the lip seal
- torque: 10 ± 1 Nm

RKZB5950

CAUTION
• Position the metallic part of the lip seal on the
outside.
• The lip seal must be fitted on the end of the
spool so that it is not damaged on the spool
grooves and its tightness property does not de-
teriorate.
Slide the lip seal perpendicularly onto the
spool.
(For detail see «8. PRECAUTION WHEN RE-
PLACING THE SPOOL LIP SEAL»).
RKZB5960

WB97R-2 30-169
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY FRONT AND BACKHOE CONTROL

3.2 Cover side

• Remove the mounting screws (L=16 mm) and the cover
(screwdriver Torx Tx30).
★ Reassembly:
- replace the lip seal
- torque: 10 ± 1 Nm

RKZB5970

CAUTION
• Position the metallic part of the lip seal on the
outside.
• The lip seal must be fitted on the end of the
spool so that it is not damaged on the spool
grooves and its tightness property does not de-
teriorate.
Slide the lip seal perpendicularly onto the
spool. (For detail see «8. PRECAUTION WHEN
REPLACING THE SPOOL LIP SEAL»).
• Remove the spool from the working section.
★ Reassemble parts in reverse order. RKZB5980

3.3 Return system removal for lip seal replacement

CAUTION
• In order to avoid breaking the clamp, place it ap-
proximately 15 mm from the end of the spool
(never in the centre).
• Beforehand, heat the spool to 200° C in an oven or, fail-
ing that, with a heat gun.

Wear thick protective gloves when handling the hot

spool.
• Remove the adapter (5 mm socket wrench).
• Remove 2 spring retainers ,spring, plate and lip seal. RKZ07590

★ Reassembly:
- Fit the lip seal and reassemble the return system
parts in reverse order after greasing the spring
- torque: 10 ± 1 Nm
CAUTION
• Position the metallic part of the lip seal on the
outside.
• The lip seal must be fitted on the end of the
spool so that it is not damaged on the spool
grooves and its tightness property does not de-
teriorate. Slide the lip seal perpendicularly onto
the spool. (For detail see «8. PRECAUTION
WHEN REPLACING THE SPOOL LIP SEAL»).
RKZB5990

30-170 WB97R-2
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY FRONT AND BACKHOE CONTROL

3.4 Tongue replacement (if necessary)

• Beforehand, heat the spool to 200° C in an oven or, fail-
ing that, with a heat gun.

Wear thick protective gloves when handling the hot

spool.
Do not use a welding torch to heat the tongue as
spool deformation may result.
• Loosen the tongue with an open end wrench (8 mm
wrench).
★ Reassembly: torque: 10 ± 1 Nm
RKZB6000

4. Removal of mechanical detent system

(pull function only) with lip seal

4.1 Tongue side

• For detail see paragraph 3.1.

4.2 Cover side

• Remove the 2 mounting screws and the cover
(screwdriver Torx Tx30).
• Remove the spool from the working section.

★ Reassembly:
- replace the O-ring on the spacer RKZB6010

- replace the spool lip seals on the space side and

tongue side.
- torque:10 ± 1 Nm
CAUTION
• Position the metallic part of the lip seal on the
outside.
• The lip seal must be fitted on the end of the
spool so that it is not damaged on the spool
grooves and its tightness property does not de-
teriorate.
Slide the lip seal perpendicularly onto the
spool.
(For detail see «8. PRECAUTION WHEN RE- RKZB6020

PLACING THE SPOOL LIP SEAL»).

• Use the spool clamp (DSI.-No: 236 647 19) and a vice to
secure the spool.

CAUTION
• In order to avoid breaking the clamp, place it ap-
proximately 15 mm from the end of the spool
(never in the centre).

RKZ07600

WB97R-2 30-171
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY FRONT AND BACKHOE CONTROL

• Using a metal rod (min. lenght= 80 mm Ø6), push the

central ball while extracting the detent bush.
★ Mark the arientation of the detent bush for the re-
assembly.
• Remove the balls and the spring.

RKZB6030

★ Reassembly:
- introduce the spring into the adapter
- place the 3 balls into the radial holes of the adapter and
hold them with a small amount of grease
- position the central ball against with the spring
- slip the detent bush onto a metal rod
- using the rod, press the central ball into the adapter,
then slide the detent bush onto the adapter, making
sure that the 3 balls are still in place,
NOTE: the orientation of the detent bush must be re-
spected.
• Remove the metal rod, assembly is complete. RKZB6040

5. Removal of electrical detent system (spool

pushed) with lip seal on tongue side

5.1 Spool removal for seal replacement

Tongue side
• For detail see paragraph 3.1.

Control side
• Remove the 2 mounting screws
(screwdriver Torx Tx30)
★ Reassembly
- torque: 10 ±1 Nm RKZB6050

• Remove the detent system.

• Remove the spool from the distribution element.

RKZB6060

30-172 WB97R-2
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY FRONT AND BACKHOE CONTROL

★ Reassembly:
- replace the detent system O-ring
- replace the spool lip seal on tongue side.
CAUTION
• Position the metallic part of the lip seal on the
outside.
• The lip seal must be fitted on the end of the
spool so that it is not damaged on the spool
grooves and its tightness property does not de-
teriorate. Slide the lip seal perpendicularly onto
the spool. (For detail see «8. PRECAUTION
WHEN REPLACING THE SPOOL LIP SEAL»). RKZB6070

Solenoid replacement
NOTE: this operation can be performed independent-
ly of the solenoid replacement operation.
• Unscrew the solenoid from the housing (10 mm Allen
wrench).

RKZB6080

• Install a new solenoid.

★ Reassembly: torque: 20 ±2 Nm

RKZB6090

6. Electrical controlled spool removal

6.1 Solenoid control replacement

• Remove the 2 mounting screws and the solenoid con-
trol (5 mm socket wrench).
★ Reassembly: torque: 10 ± 1 Nm

RKZB6100

WB97R-2 30-173
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY FRONT AND BACKHOE CONTROL

• Unscrew the mounting plate from the solenoid control.

★ Reassembly
Replace the O-rings on the solenoid control and
mounting plate.
• Repeat the operation on the other side of the distribution
element.

★ Reassemble parts in reverse order.

RKZB6110

6.2 Remove control valve cover (for servocontrol

control valve).
• Remove the four screws.
★ Reassembly:
replace the O-ring.
Screw torque: 10 ±2 Nm
★ Reassemble parts in reverse order.

RKZ08170

7. Control block Disassembly / Assembly

7.1 Preliminary operations

• Remove the 3 nuts (13 mm ring wrench)
★ Reassembly: torque: 35 ± 3 Nm

RKZB6120

• Remove the outlet element.

RKZB6130

30-174 WB97R-2
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY FRONT AND BACKHOE CONTROL

• Separate the working sections from the inlet element.

• Replace the O-rings located between the working sec-
tions, the inlet element and the outlet element.
• If the inlet element is to be replaced, remove the tie rods.
★ Reassemble parts in reverse order, and make sure
that the tie rods are tightened to the specified
torque.
• Check the cleanliness of the element faces prior to re-
assembly.

RKZB6140

7.2 Individual pressure compensator removal

• Unscrew the compensator plug (8 mm socket wrench).

RKZB6150

• Remove the compensator piston.

• Clean the piston’s nozzle with compressed air.
• Check the condition of the bore in the distribution ele-
ment body.

★ Reassembly:
- replace the plug O-ring.
- torque: 60 ± 6 N.m.

RKZB6160

7.3 Check valve removal

• Unscrew the check valve plug (5 mm allen wrench).

RKZB6170

WB97R-2 30-175
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY FRONT AND BACKHOE CONTROL

• Visually check the condition of parts and replace the as-

sembly if necessary.

RKZB6180
RKZB6190

★ Reassembly:
- replace the plug O-ring.
- torque: 30 ± 3 Nm

RKZB6190

8. Precaution when replacing the spool lip seal

The lip seals are not interchangeable with the other
spool seals (O-ring + wiper ring).
• Place the spool in the working section.

RKZB6200

30-176 WB97R-2
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY FRONT AND BACKHOE CONTROL

• Slide the lip seal perpendicularly onto the spool, posi-

tioning the metallic part of the lip seal on the outside.

NOTE: the lip seal must be fitted on the end of the

spool so that it is not damaged on the spool
grooves and its tightness property does not
deteriorate.

RKZB6210

WB97R-2 30-177
REMOVAL AND INSTALLATION TROUBLESHOOTING

TROUBLESHOOTING
Before starting any procedures of trouble shooting or removing the control block, inspect the global machine's hy-
draulic system to eliminate all possible malfunctions not related to the sx 14 control block.

Abnormal operation of the actuators connected to the control block

Malfunction Probable cause Additional checks Remedy

1 - LS pressure relief valve Replace LS pressure relief
defective Take a pressure measure- valve
Lack of strength at all
ment
actuators 2 - LS pressure relief valve out (see block specifications) Make necessary adjustments
of adjustment
1 - Secondary pressure relief Reset to original pressure
valve out of adjustment (refer to block specifications)
Lack of force on one actuator
only 2 - Secondary pressure relief
Replace secondary pressure
valve blocked "open"
relief valve
(return to tank)
Manual control:
If stroke is incorrect: replace
measure spool stroke
housing + spool assembly
1 - Spool stroke incorrect Direct electrical control:
If resistance is incorrect:
- check solenoid resistance
replace solenoid
(R : 2,5 Ω at 25 °C)
Movement performance slow
2 - Hydraulic operator
adjustable stopnut out of Make necessary adjustments
adjustment
3 - Individual compensator Replace housing + pressure
pressure blocked compensator assembly
1 - Load hold check valve Replace housing + valve
failure assembly
Lack of load hold 2 - Excessive clearance
Replace housing + spool
between the housing
assembly
and the spool
1 - Adjustment piston sliding
Replace control sub-system
1 - Flow divider adjustment freely
Steering abnormally hard
problem Replace housing + control
2 - Adjustment piston blocked
system assembly
Steering response time Filter of the check piston’s flow
Replace the filter
abnormally long divider is clogged
1 - Solenoid on the outlet Check solenoid resistance If resistance is incorrect
element defective (R : 7,6 Ω at 20 °C) replace the solenoid
Clamp operation malfunction 2 - Shuttle valve malfunction
Replace shuttle valve
on the outlet element
3 - 2-way valve defective Replace 2-way valve
1 - Blockage of the individual Remove and clean individual
compensator orifice compensator
Simultaneous movement Replace the housing +
2 - Individual pressure
malfunction pressure compensator
compensator blocked
assembly
3 - LS line leakage Replace LS flow regulator

30-178 WB97R-2
REMOVAL AND INSTALLATION TROUBLESHOOTING

Abnormal machine operation

Malfunction Probable cause Additional checks Remedy

Engine remains under load 1- Flow regulator blocked Replace flow regulator
after spools are returned
to neutral 2- Flow regulator filter clogged Replace the filter

Abnormal control block operation

Malfunction Probable cause Additional checks Remedy

1- Mechanism defective Replace mechanical detent

Detent malfunction Check solenoid resistance

If resistance is incorrect:
2- Solenoid defective (for electrical detent)
Replace solenoid
(R: 16,5 Ω at 20 °C)
Loosen and tighten
Control block assembly tie to 25 ± 2 Nm
Increase of force on controls rods too tight Remove control block
or spool return defective fixation points
Spool seals obsolete Replace spool seals

Visual defects

Malfunction Probable cause Additional checks Remedy

Replace spool seals
Spool leaking oil Spool seals defective Check the rubber boot
condition
Remove pressure relief
Oil leakage at pressure relief
Seals defective valve or plug and
valves and plugs
replace seals
Oil leakage between Seals between elements Remove working sections and
elements defective replace joints
1 - Seal between housing and
Replace seal
Oil leaking from hydraulic body defective
operator housing 2 - Seal of adjustable stop nut
Replace seal
defective
Tongue control boot damaged Replace boot

WB97R-2 30-179
PAGE INTENTIONALLY
LEFT BLANK
REMOVAL AND INSTALLATION REMOVAL OF THE FRONT AXLE

REMOVAL OF THE FRONT AXLE

1 - Start the engine and force the front bucket downwards
in order to raise the machine and the front wheels.

2 - Place two stands “A” and some blocks beneath the

chassis.

3 - Slowly lower the machine onto the blocks, checking that

the wheels remain at least 5 cm above the ground.
Fully raise the front working equipment and engage the
safety stop. A
Also make the backhoe safe.
1
RKZA0940

4 - Engage the parking brake.

5 - Stop the engine and eliminate residual pressure from all

circuits. (See «20. TESTING AND ADJUSTMENTS»).

Disconnect the cable from battery negative terminal (–). 2

6 - Take off the front wheels (1). 1

Wheel: 65 kg

7 - Remove the front guard (2).

(For details, see «REMOVAL OF FRONT GUARD»).
1 3
2 RKZB6740

8 - Disconnect the cardan shaft (4) from the axle (3).

5
3
9 - Disconnect the lines (5) from the steering cylinder and
plug them to prevent entry of impurities. 4 5
6
10 - Disconnect the lubrication tube (6) for the axle oscilla-
tion pin (7).

3
RKZA9572

11 - Position a jack “B” and some blocks “C” beneath the ax-
le. Raise the jack until the blocks can be forced under
the axle arms (3). 3
★ It should be possible to lower the jack 10 cm in order
to disengage the axle from the fulcrum supports. C

B
RKZA1670

WB97R-2 30-181
REMOVAL AND INSTALLATION REMOVAL OF THE FRONT AXLE

12 - Take out the nut and remove the retaining screw (8) of
the axle oscillation pin (7).

13 - Screw an eyebolt into the central hole of the axle oscil- 8

lation pin (7). Extract the axle oscillation pin. 5
14 - Lower the jack until the axle is disengaged.

15 - Extract the entire axle (3).

Front axle: 316 kg 7

RKZA2120

INSTALLATION OF THE
FRONT AXLE
• To install, reverse the removal procedure.

1
Nuts for front wheels: 350±9.8 Nm

2
Front closing screws: 300±30 Nm

3
Screws on gearbox side: 70 Nm

Self-locking nuts on axle side: 70 Nm

4
★ Bleed the air from the Load Sensing circuit.
(For details, see «20. TESTING AND ADJUST-
MENTS»).

5
Axle oscillation pin - bushings: ASL800050

1 - Check the oil level in the tank and start the engine.

2 - Perform a few complete steering manoeuvres in both di-

rections to bleed the air from the steering circuit.

30-182 WB97R-2
REMOVAL AND INSTALLATION DISASSEMBLY OF FRONT AXLE

DISASSEMBLY OF FRONT AXLE

1. Steering cylinder group disassembly
3 2
1 - Unloose the guide rod (2) locknut (1) of some turns till it
is over the end of the threaded pin.
Beat on the nut (1) with a hammer in order to disjoin the
guide rod (2) from the swivel housing (3).
★ Don’t beat on the end of the threaded pin.
★ This is a destructive operation for the nut.
3 1

RKZB5580

2 - Remove the guide rod link (4) by unloosing the nut (5)
with a suitable wrench, then check its conditions. 4

3 - Unscrew the fastening screws (6) of the cylinder, then 7

take the cylinder (7) out of its housing and, if necessary,
use a rubber hammer.
6
5
★ Remove only that parts that need to be overhauled
and/or replaced. 4

5
RKZ07110

4 - Detach the cylinder head (8) from the cylinder case (10).
Remove off the cylinder head and the rod (9) from the 10
cylinder case.

5 - Remove all the sealings and O-Rings (11), both from 9

the cylinder head and the rod.
8
11

RKZ07120

2. Epicyclic reduction gear disassembly

2
Before draining the oil, position the wheel hub (1) 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 wheel hub upside-down
till the hole is in the lowest point.
Drain the oil completely.

RKZB0101

WB97R-2 30-183
REMOVAL AND INSTALLATION DISASSEMBLY OF FRONT AXLE

1 - Unscrew and remove both fastening screws (3) and the

2 stud bolts (4) of the planetary carrier with a standard
wrench. 3
★ Don’t ruin the thread of the two stud bolts.
2 - Remove the planetary carrier from the wheel hub.
Position the planetary carrier on a workbench and
check its wear conditions.

4
RKZ07130

2.1 Replacements of the planetary gears

(if necessary) 9

1 - Remove the snap ring (5). 8

5
2 - Remove the thrust washer (6).

3 - Take the planetary gears (7) out of the pins (8).

7
6
4 - Collect the needle bearings (9), checking their condi- 10
tions.

5 - Remove the thrust washers (10).

RKZ07140

★ With new planetary gears is advisable to assembly new

roller bearings.

3. Wheel hub group disassembly 2

Before disassembling the wheel hub, it is advisable to

1
secure it with a belt or a rope on a hoist or any other sup-
porting device, in order to avoid its accidental fall that
could damage either the operator or the wheel hub
group.
1
1 - Remove the steel lock ring (1) from the axle shaft (2) by
using a suitable plier.
2
2 - Remove and collect the lock ring, the sleeve (3) and the 4
spacer (4) from the axle shaft. 3 RKZB0131

3 - Unscrew and remove the fastening screws (5) from the 6

wheel carrier (6) group.
5

RKZB0140

30-184 WB97R-2
REMOVAL AND INSTALLATION DISASSEMBLY OF FRONT AXLE

4 - In order to remove the wheel carrier group (6) from its

housing, screw (5) at least two of the just removed
screws in the threaded extraction holes “A”.
6
A

RKZB0150

5 - Extract and remove the wheel carrier (6) together with

the epicyclic ring gear (8).

6 - Remove the steel lock ring (7) and disjoin the wheel car- 9
rier (6) from the epicyclic ring gear (8).
★ Check the wear conditions of the components.
7 - Only if necessary, remove the centering bushes (9) of
the hub lock ring gear with a hammer and the special
tool D1.
6
7
8
RKZB5590

8 - Remove the hub (10), using levers and a hammer to fa-

cilitate the operation.
★ Collect the bearing cone (11).

10

11
RKZB0170

9 - Position on a flat surface the hub and take the seal ring
out (12) with a lever. 13
★ This is a destructive operation for the seal ring.
10 - Take the bearing cups out (11) and (13), on both sides of
the hub, using a hammer and a suitable tool to be beat-
en.
12
11 - Remove the bearing cone (13) from the swivel housing
end, using a suitable extractor.
10
11
RKZ07150

WB97R-2 30-185
REMOVAL AND INSTALLATION DISASSEMBLY OF FRONT AXLE

12 - Unscrew and remove the fastening screws (14) from the

upper (15) and lower (16) king pin.
14

Before removing the king pins, secure the swivel

housing with a belt or a rope to a hoist or any other
supporting device.
15
13 - Remove the king pins (15) and (16).

16

RKZB5620

14 - Remove the swivel housing (17) from the axle beam

and from the short shaft (18) of the U-Joint.

18
17

RKZB0211

15 - Position the swivel housing (17) on a flat surface and

take the seal ring (19) out with a lever.
★ This is a destructive operation for the seal ring. 17
16 - Turn the swivel housing (17) and take the bush (20) out,
19 20
using a driver and a hammer.

RKZB5630

4. Axle beam group disassembly

1 - Remove the U-Joint (1) from the axle beam.

RKZ07160

30-186 WB97R-2
REMOVAL AND INSTALLATION DISASSEMBLY OF FRONT AXLE

2 - Take the seal ring (2) out of the axle beam with a lever.
★ This is a destructive operation for the seal ring. 9 4

3 - Remove the cup springs (4) and (8) from the king pin 5
housings in the axle beam. 3
4 - Remove thickiness (9) from the upper part of axle beam. 2

5 - Remove the bush (3) from the beam with a suitable ex-
tractor.
★ Examine the bush before the removal and replace it 6
only if the wear conditions require this.
2 8
RKZ07170

6 - Take the upper (5) and lower (6) bushes out of the king
pin housings (7) and out of king pin with a suitable ex-
tractor. 7

RKZ07400

7 - Remove the seal rings (10) from the pivot with a suitable
tool. 10
★ Destructive operation for the seal rings.
If necessary, replace the bushings with a standard
three-gripping point extractor or a suitable driver and a
hammer.

RKZB5500

5. Differential support group disassembly

1 - Remove the fastening screw (1) and the nut (2) from the
flange (3).
Using a small chisel, detach the oil seal cover just 2
enough to fit a lever. 1
2 - Remove the oil seal cover from the central beam as-
sembly, using two levers.

RKZ07180

WB97R-2 30-187
REMOVAL AND INSTALLATION DISASSEMBLY OF FRONT AXLE

3 - Remove the seal ring (4) from the oil seal cover, using a
suitable tool.

RKZB5480

4 - Put the O-ring (5) from the oil seal cover in a safe place.

RKZB5490

5 - Loosen and remove the screws on the differential sup-

port (6).
Remove the differential carrier (6).

Support the differential carrier with a rope or other

appropriate means.

RKZ07190

6 - Loosen and remove the screws (7) to remove the two

ring nut retainers (8). 7

RKZ05281

30-188 WB97R-2
REMOVAL AND INSTALLATION DISASSEMBLY OF FRONT AXLE

7 - Before removing bolts, mark halfbridles (9) and the dif-

ferential carrier with permanent reference marks to
avoid inverting them when re-assembling the unit. Mark 9
9
the area between the ring buts and the differential car-
rier as well.

RKZ05291

8 - Unscrew the adjuster ring nuts (10) using tool D2 and a

wrench. 10

10
D2

RKZ05302

9 - Loosen and remove the 4 screws (11) and remove the 2

half-collar (9). 11

RKZ05311

10 - Take out the differential case (12). 13

★ Take care not to loose the cups bearing (13) that
are removed together with the differential case
12
(12).
13
★ Not mismatch the cups of the bearings (13) if they
are not to be replaced. 14
★ Check that the bushes (14) remains in their hous-
ings.

RKZ05321

WB97R-2 30-189
REMOVAL AND INSTALLATION DISASSEMBLY OF FRONT AXLE

6. Pinion group disassembly

1
1 - Fit the differential carrier (1) in a vise.

2 - Unscrew the lock nut using special tools D3 and D4. D4

★ This operation will irretrievably damage the ring
nut.

D3
RKZ05330

3 - Remove the ring nut (2) and collect its retaining washer
(3).

3
2

RKZ07200

4 - Tap the shaft with a soft hammer to remove the bevel

pinion (4). 6
★ Take care not to drop the pinion.
5 - Collect the washers (5), the collapsible spacer (6) and
the inner cone of the tapered roller bearing (7). 7
5

4 RKZ05350

6 - Place the differential carrier on a flat surface as shown in

the figure and remove the outer cups of the taper roller
bearing (7) using a driver and a hammer.

RKZ05360

30-190 WB97R-2
REMOVAL AND INSTALLATION DISASSEMBLY OF FRONT AXLE

7 - To remove the inner cone of the tapered roller bearing

(7) of the pinion (4), use a standard extractor.

8 - Collect the bearing cone and the underlying shim (8).

RKZ05370

9 - Check all pinion components for wear.

The ring nut and the snap spacer must be replaced
when reassembling the unit.

RKZ07370

7. Differential group disassembly

1 - Collect the differential (1) and put it in a clamp.

2 - Unscrew all the fastening screws (2) of the bevel gear

crown (3).
★ This will make both differential half boxes free, so 3
take care not to drop the internal components.

3 - Remove the bevel gear crown. 2

1
RKZB0570

4 - Disassemble the differential box in two half boxes (3)

complete with the relevant components. 4
5 - Recover the components from both half boxes.

6 - Check the operating and wear conditions of the com-

ponents.
4 5
7 - Take the bearing (5) out of the differential half box (4),
using two levers or a three-hold extractor.

5 RKZ07210

WB97R-2 30-191
REMOVAL AND INSTALLATION ASSEMBLY OF FRONT AXLE

ASSEMBLY OF FRONT AXLE

1. Pinion group assembly
1 - Place the differential support (3) on a workbench.
1
2 - Fit the outer cups of the new bearings (1) and (2) using
the special tool D5 and a hammer. 3

RKZ05380

3 - In order to measure the distance, use the kit consisting

of the special tools called “false pinion” D6 and “false dif-
ferential box” D7 e D8. 3

4 - Insert the false pinion with D6, together with its bearings
and its ring nut (4), in the just mounted housings for the D8
D8
bearings.
Tighten without exceeding, till the backlash is eliminat-
ed.

D7 D6
4
RKZ07230

5 - Install special tools D7 and D8 to the differential group

supports and screw in the half collar bolts (5) and (6).
6 5
D7
5

D8

RKZ07240

6 - Use a deep gauge to take the measurement “X”.

★ Write down the “X” measurement.

RKZ07250

30-192 WB97R-2
REMOVAL AND INSTALLATION ASSEMBLY OF FRONT AXLE

7 - Make a note of the value “V” marked on the head of the

pinion.
Calculate the thickness “S” to be installed beneath the V
pinion, using the formula:

S=X--V
107.00
“S” is the thickness of the shim. 00

RKZ05080

9 - Mount the shim (8) onto the pinion (7) and press the in-
ner bearing (1) using the tool D9. 9
★ The chamfer on the inner diameter of the shim must 10
face the toothing. 1

10 - Mount onto the pinion the first washer (9), the new spac- 9
er (10) and the second washer (9).
8

7 7

RKZ07430

11 - Insert the bevel pinion unit (7) into the differential sup-
port housing (3) (from the internal axle side) and the 2
3
second bearing cone (2) into the pinion end, from the
opposite side.
★ In order to force the second bearing into position,
use the special tool D9 and a hammer.

7
RKZ05351

12 - Insert a ring nut washer (11) and screw a new lock ring
nut (4) on the pinion end.

11
4

RKZ07260

WB97R-2 30-193
REMOVAL AND INSTALLATION ASSEMBLY OF FRONT AXLE

13 - Screw the ring nut in, using the wrench for ring nut D3
and for pinion retainer D4.
★ The torque setting is given by the preloading meas-
urement on bearings. Tighten the ring nut gradu-
ally. D3
★ If the tightening is excessive, the elastic spacer
must be replaced and the procedure repeated.
When you check the preloading, it is advisable to
beat slightly both pinion ends with a soft hammer,
so as to help setting the bearings.
D4
RKZ05332

14 - Wind a wire line round the pinion, uniformly and without

overlapping. Connect it to a dynamometer and check
the force “P” required to rotate the shaft.
The force should be that needed for continual ro-
tation.
Do not take into consideration the thrust force.
15 - Using the tools mentioned in point 13, tighten the lock
nut (4) taking dynamometric measurements at intervals
until the indicated force “P” has been obtained.
P= (9.2–13.7) daN P
If the maximum permissible value is exceeded, a new RKZ07270
spacer must be fitted and all the bearing pre-loading op-
erations must be repeated.

2. Differential group assembly

1 - Assemble the cones of the new taper roller bearings (1) 2
on the half boxes (2), using the special tool D10 and a
hammer. 2

1
RKZ07221

2 - After occurate cleaning and after checking both the op-

eration conditions and the components wear, it is pos-
sible to assemble the differential parts.

RKZ07380

30-194 WB97R-2
REMOVAL AND INSTALLATION ASSEMBLY OF FRONT AXLE

3 - Position a half box on a workbench and assemble all its

inner components (sun gears, planetary gears, thrust 2
washers pin and differential lock counterdiscs) as illus-
trated in the figure.
Join the two half boxes (2).

RKZ07211

4 - Position the ring bevel gear (3) and then fix the whole by
tightening the screws (4).
3
Screw: 95 Nm
Screw: Loctite 270 4

RKZB1290

3. Differential carrier group assembly

1 - Position the complete differential box (1), with the outer
1
cups (2) of the tapered roller bearings already assem-
bled, on the differential carrier. 2

Take care not to invert the outer races of the ta-

pered roller bearings and check you are working on
the right side of the bevel crown assembly.

RKZ05600

2 - Place the differential group and the two halfbridles (3)

4
and bolts in their seat.
Check the right position of the halfbridles with the pre-
viously-traced reference marks. 3
Position and tighten slightly the halfbridles bolts (4). 3

RKZ07290

WB97R-2 30-195
REMOVAL AND INSTALLATION ASSEMBLY OF FRONT AXLE

3 - Assemble and tighten the two adjustment ring nuts (5) in

5
the differential support with tool D2, so as to pre-load the
differential bearings slightly. Knock lightly with a soft
hammer in order to properly set the bearings in position.
★ Take care not to reverse the ring nuts; align the pre-
viously-traced reference marks. 5
D2

RKZ05303

4 - Position a magnetic-base dial gauge “A” on the differ-

ential carrier, so that the feeler stylus touches the sur-
face of one tooth of the crown gear with a 90° angle. A
Lock the pinion and move the crown gear alternatively
and note the pinion-ring gear backlash, measured with
the comparator.
Repeat the operation on 2 or more points (teeth), rotat-
ing the crown gear, so that to obtain an average value.

Permissible backlash: 0.18 – 0.25 mm

RKZ05620

5 - If the measured backlash is lesser than the given tol-

erance range, screw the ring nut from the side opposite
to the ring gear and unscrew the opposite one of the
same measure.
If the measured backlash is higher than the given tol-
erance range, screw the ring nut from the side of the ring
gear and unscrew the opposite one of the same meas-
ure.
★ Before measuring the clearance, knock lightly on
the bearing covers with a mallet to ensure that they
are securely positioned.
RKZ05640

6 - Tighten screw (4).

4

RKZ05630

30-196 WB97R-2
REMOVAL AND INSTALLATION ASSEMBLY OF FRONT AXLE

7 - Using the same method employed to check the pinion

rotation torque, check the force “T” required to rotate the
entire group.
★ Force required:
(P+3.9) < T < (P+5.9) daN
P= the force found for the pinion
★ The force should be that of continual rotation. Do
not take the thrust force into consideration.
8 - If the force is not within permissible limits:
a - Tighten both the lock nuts to the same extent to in- T
crease the force “T”.
RKZ07300
b - Loosen both the lock nuts to the same extent to de-
crease the force “T”.
The clearance between the ring bevel gear and the
pinion must remain within permissible limits.

9 - Check the centering of the contact area using the fol-

lowing procedure:
a - Coat both surfaces of the teeth of the ring bevel
gear with a marking substance.
b - Rotate the pinion.
If the contact area is excessive near to the edge of the
teeth, the ring bevel gear must be brought closer to the
pinion.If the contact area is excessive on the side of the
teeth, the ring bevel gear must be moved away from the
RKZ01840
pinion.

RKZ01850

10 - Tighten the bolts (4).

Screw: 266 Nm
4

RKZ07310

WB97R-2 30-197
REMOVAL AND INSTALLATION ASSEMBLY OF FRONT AXLE

11 - Once you have completed adjustment operations, fit

the adjuster nut (6) retainers screws (7). 7
Screw: 13 Nm 6

RKZ05690

12 - Fit the seal ring (8) in the bevel pinion cover (9) with spe-
cial tool D11. D11

RKZB5560

13 - Fit new O-ring (10) onto the bevel pinion cover (9).

10
9

RKZB5570

14 - Assemble the bevel pinion cover (9) with a suitable

beater.
★ Do not damage the O-ring (10).

RKZ07320

30-198 WB97R-2
REMOVAL AND INSTALLATION ASSEMBLY OF FRONT AXLE

15 - Before matching two surfaces make sure they are per-

fectly clean. Degrease and clean with the appropriate
cleaner. Spread a film of Loctite 510 on the contact sur-
face between the axle beam and the differential carrier.
Position the differential carrier (11) on the axle housing.
Re-place and tighten retaining screws (12) to the pre-
scribed torque with a torque wrench. 12

Screw: 169 Nm

11

RKZ07191

16 - Insert the flange (13) on the pinion end.

Fit the flange fastening screws (14) with the relative nuts
on the flange (13).
Tighten screws and nuts with dynamometric wrench to 13
the requested torque.

Screw: 56 Nm

14
RKZ07330

4. Axle beam group assembly 1 2

1 - Assemble two new bushings (1) respectively (assemble
the longer bushing from the bevel pinion side) and two
new seal rings (2) in the central unit pivot by using spe-
cial tools D12 and D13.

D12 D13

RKZB5470

2 - Assemble the upper king pin bush (3) and (4) on the axle
beam with the special tool D14 and a hammer. 3 D14
★ To make the assembly easier, it is suggest to cool 3
the cup of the ball bearing at a temperature less
than –100°C.

D14

4
4
RKZB5650

WB97R-2 30-199
REMOVAL AND INSTALLATION ASSEMBLY OF FRONT AXLE

3 - Assemble the bush (5) on the axle beam with the special
tool D15 and a hammer.
5 6
4 - Assemble the seal ring (6) on the beam with the special
tool D16 and a hammer.
Fill ¾ of the seal ring cavity with grease.

D15 D16

RKZB1002

5 - Lubricate the bush (5) and the seal ring lip (6).
Insert the U-Joint (7) inside the axle beam.
★ Be careful not to damage the seal.

RKZB0252

5. Wheel hub group assembly

1 - Force the bush (1) into the swivel housing (2) with the
special tool D17 and a hammer or a press. D18 D17
2 - Assemble the seal ring (3) on the swivel housing (2) with 1 3
the special tool D18 and a hammer.
Fill ¾ of the seal ring cavity with grease.
2

RKZB1012

3 - Position the lower king pin (4) on a workbench and as-

semble the cone of the spherical joint (5) with the special 6
5
tool D19 under a press. Put the shim under the Belleville
washer on the upper part.
Grease well the king pin housings with specific grease.

4 - Position the Belleville washers (6) on the king pin hous- 4

ings.

6
RKZB5660

30-200 WB97R-2
REMOVAL AND INSTALLATION ASSEMBLY OF FRONT AXLE

5 - Secure the swivel housing (7) group with a rope.

Lubricate the seal ring lip and protect the splined end of 7
the axle shaft by winding it with thin adhesive tape to
8
avoid damage to the seal ring. After assembly, remove
completely the adhesive tape. Assemble the swivel
housing on the axle beam.
10
6 - Assemble the two king pins, the upper (9) and the lower
(8), and tighten the retaining screws (10).

Screw: 190 Nm 9
★ Make sure that the Belleville washers remain in
their position. RKZB1411

7 - Position the wheel hub (11) on a workbench and force

both cups of the taper roller bearings (12) e (13) in po- 13 14
sition with the special tool D20 under a press or with a 12
hammer.

8 - Insert the seal ring (14) into the wheel hub (11) with the
special tool D21 and a hammer.
D20 D21

D20 11

RKZB1423

9 - Assemble the cone of the taper roller bearing (13) on the

swivel housing end (7). 7 11

10 - Assemble the wheel hub (11) on the swivel housing (7) 13

and fit the other cone of the taper roller bearing (12) in
position.

12

RKZB1432

11 - Position the wheel carrier (15) on a workbench and

force the bushes (16) to the carrier surface level with the
special tool D1. 16
At least two bushes (diametrically-opposed) should be
set slightly higher than the carrier surface level to be
used as dowel pins.

15
RKZB1092

WB97R-2 30-201
REMOVAL AND INSTALLATION ASSEMBLY OF FRONT AXLE

12 - Preassemble the wheel carrier-epicyclic ring gear

group (17) and (18) with the special locking ring (19) 18
shown in figure.

17

19

RKZ05732

13 - Assemble the wheel carrier group (20) on the wheel hub

using the two projecting bushes (16) as dowel pins and
screw the relative screws in order to put in contact the 20
ring bevel gear with the wheel hub.

16

RKZB1102

14 - Force all the hub dowel bushes completely with the spe-
cial tool D1 and a hammer. 20
Assemble the wheel carrier (20) fastening screws (21) 21
and tighten.

Screw: 230 Nm

RKZB1442

15 - In the case the bearings (22) and (23) are substituted,

verify that the measure “A”, “B” and “C” are in the limits.

A = 17.950 – 18.000
B = 64.275 – 64.325 23
C = 23.070 – 23.172 22
C A C

RKZ05742

30-202 WB97R-2
REMOVAL AND INSTALLATION ASSEMBLY OF FRONT AXLE

16 - Slide the spacer (24) onto the axle shaft of the double
joint, fit the sleeve (25) and assemble the lock ring (26)
by inserting it at the end of the splined hub and pushing
it into its housing. 26

25
26

24 RKZB0132

6. Epicyclic reduction gear assembly

2
1 - Position the planetary carrier on a workbench.

2 - Insert the planetary gear (1) the rolls (2), the upper trust
3
washers (3), the snap rings (4) and the plate (5) in the
planetary carrier pins.
1
5
4

RKZ07142

3 - Assemble the epicyclic reduction gear on the wheel

hub.
Apply Loctite 542 on hub side thread of the 2 special 6
stud bolts.

4 - Screw in the fastening screws (6) and the 2 stud bolts (7)
and tighten with dynamometric wrench.

Screw: 80 Nm

Stud: 70 Nm

7
RKZ07131

7. Steering cylinders group assembly

1 - Assemble new seal rings (1) on the cylinder head (2), on 4
the piston (3) and on the cylinder body (4).

2
RKZ07340

WB97R-2 30-203
REMOVAL AND INSTALLATION ASSEMBLY OF FRONT AXLE

2 - Slide pre-assembled rod into the cylinder body (4).

RKZB0092

3 - Fit the guide rods (5) to the ends of the cylinder rod and
tighten with dynamometric wrench.

Guide rod: 300 Nm

5 5
4 - Install the steering cylinder on the central body, with
guide rods (5) already assembled on the stem. 6
5 - Install the spacer flange.

6 - Assemble and tighten the steering cylinder fastening

screws (6) with dynamometric wrench.

Guide rod: 120 Nm

RKZB5460

7 - Align the swivel housings with the axle (parallel wheel

hub).
Screw the guide rod (5) so that the ball joint can be in-
serted into the swivel housing arm. 7 5
★ It is important to unscrew the locking nut (7) to carry
out this operation.

RKZB1162

8 - Insert the ball joint (8) (into its own housing on the swivel
housing.
Assemble and tighten the lock nut (9) with dynamomet- 8
ric wrench.

Lock nut: 220 Nm

9 - Screw in the lock nut (7) of the guide rod (5) only when
the toe-in adjustment has been carried out.

RKZB1172

30-204 WB97R-2
REMOVAL AND INSTALLATION ASSEMBLY OF FRONT AXLE

8. Toe-in adjustment
1 - Put two equal one-meter-long linear bars “A” on the A
wheel sides and lock them with two nuts on the wheel
hub stud bolt.
★ The two bars should be fixed on their middle so that
they are perpendicular to the supporting surface
and parallel to the pinion shaft axis.
Align the two bars.

50 cm 50 cm

RKZB1190

2 - Measure the distance in mm “M” between the bar ends

with a tapeline.
Keep the minimum value, swinging the measurement
point. M

RKZB1200

3 - Check that the difference of the measurements be-

tween the wheel hubs diameters ends is within the re-
quested tolerance range.
The nominal toe-in (A) value is referred to the external
A -0 2
diameter of the wheel hubs flange,therefore the meas-
ured toe-in value (M) at the bars ends must be related to
the ratio between lenght of the bar anf flange diameter.
nominal toe-in = A --0 2
measured toe-in = M --0 5

M -0 5

M
RKZ07350

WB97R-2 30-205
REMOVAL AND INSTALLATION ASSEMBLY OF FRONT AXLE

4 - If toe-in is incorrect, operate with two wrenches on the

guide rods screwing in and out the two joint tie rods
equally till the toe-in is within the requested tolerance.

RKZB1210

5 - After adjusting, screw in the lock nuts of the guide rods.

Lock nut: 250 Nm

RKZB1221

9. Steering angle adjustment

A
1 - Use the same bars “A” assembled for the toe-in adjust-
ment and a long bar perfectly leant over the machined
part of the central body (pinion side), so that the two bars
form an acute angle at the maximum steering.

RKZB1230

2 - Adjust a goniometer to the angle of 50° and position it on

the long bar.
Move a wheel side till it forms, with the two bars, the an-
gle fixed by the goniometer.

RKZB1240

30-206 WB97R-2
REMOVAL AND INSTALLATION ASSEMBLY OF FRONT AXLE

3 - Adjust the steering mechanical retainer, screwing in or

out the special screws (1) on the bar body, locking them
with a locknut (2). 2 1
Lock nut: 150 Nm

Steer completely towards the other side and repeat the

same operations.

RKZB1250

WB97R-2 30-207
REMOVAL AND INSTALLATION REMOVAL OF THE REAR AXLE

REMOVAL OF THE REAR AXLE

1 - Lower the backhoe outriggers (1) and force them down-
wards in order to raise the rear wheels (2) by approx. 5
cm.

2 - Prepare a safety stand “A”, approx. 65 cm high, beneath

the backhoe chassis. Pull up the outriggers until the ma-
chine is resting on the stand “A”.

3 - Stop the engine and take off the rear wheels (2).
2
1 1
Wheel: 163 kg
1 A
RKZA0960

4 - Start the engine, remove the previously positioned “A”

stand (point 2) and place two “B” stands (height 50 cm) un-
der the chassis.
Retract the outriggers until the machine bottoms on stands
“B”, then move the chassis back to its horizontal position.

RKZA9820

5 - For safety’s sake, rest the backhoe bucket with its back
on the ground, keeping the arm vertical. Also rest the
front bucket on the ground.

6 - Stop the engine and completely release residual pres-

sures from all the circuits.
(For details, see «20.TESTING AND ADJUST-
MENTS»).

RKZA0970

7 - Disconnect the parking brake cable (4) and the differ-

ential lock tube (5) from the rear axle (3). 2 4
★ Plug the pipes to prevent entry of impurities.
8 - Disconnect the cardan shaft (6) from the rear axle. 6 3

RKZA9550

30-208 WB97R-2
REMOVAL AND INSTALLATION REMOVAL OF THE REAR AXLE

9 - Disconnect the working brake hoses (7) and remove

screws (8). 3
10 - Partially loosen the self-locking nuts (9) in order to elim- 7
7
inate the tightening torque and thus facilitate subse-
quent dismantling. 4
★ Loosen the nuts in criss-cross sequence.
11 - Place a jack “C” and some blocks beneath the axle (3).
Raise the jack until the blocks can be forced under the 8
arms of the axle.
★ Leave free the nuts (9) and plates (10) that secure
the axle. RKZA9561

★ It should be possible to lower the jack by approx. 20

cm.

12 - Remove the self-locking nuts (9), the plates (10) and the
screws (11).
11
13 - Lower the jack until the axle (3) is disengaged from the
chassis.
10
14 - Extract the entire axle (3). 9 9

INSTALLATION OF THE
REAR AXLE RKZA9810

• To install, reverse the removal procedure.

1
Wheel nuts: 500±9.8 Nm
3
2
★ Adjust the stroke of the parking brake lever.
(See «20. TESTING AND ADJUSTMENTS»).

3
★ Bleed the air from the braking circuits. C
(See «20. TESTING AND ADJUSTMENTS»).
RKZA9821
4
Self-locking nuts for securing axle: 570 Nm

★ Tighten in two stages, using the criss-cross method.

1 - Check the level in the tank and start the engine.

WB97R-2 30-209
REMOVAL AND INSTALLATION DISASSEMBLY OF REAR AXLE

DISASSEMBLY OF REAR AXLE

1. Epicyclic reduction gear disassembly
Before draining the oil, position the hub with the plug on
the upper part and loosen it of some turns in order to 1
2
eliminate any possible inner pressure, and then remove
it completely.
Turn the hub upside-down till the hole is in the lowest
point.
Drain the oil completely.

1 - Unscrew and remove the two fastening screws (1) of the

planetary carrier (2) with a wrench.
RKZB0110

2 - Remove the planetary carrier (2) from the wheel hub (3).
Position the planetary carrier on a table and check its
wear conditions. 4
3 - Remove the O-ring (4) and check its conditions.
3

RKZB0121

4 - To replace the epicyclic gears (5), if necessary, remove

the screw (6) and relevant washers (7) and (8).
6
★ Treat the pin (9) with care. 7

9 8

RKZ05212

5 - Remove the epicyclic gear (5) from its seat, taking care
11 14
not to lose the two units of rollers (10) and thrust washer
(11) and (12) inside it. 5
★ If the pins (13) of the pinion gears are in poor con-
dition, replace the entire planetary train with pre-fit-
ted pins. 12
★ If the halfshaft stop (14) is worn, replace the entire
planetary carrier.

10
13
RKZ07460

30-210 WB97R-2
REMOVAL AND INSTALLATION DISASSEMBLY OF REAR AXLE

2. Wheel hub group disassembly

2
Before disassembling the wheel hub, it is advisable to
secure it with a belt or a rope on a hoist or any other sup-
porting device, in order to avoid its accidental fall that
could damage either the operator or the wheel hub
group.
1
1 - Remove the short half-shaft.
Unscrew and remove the fastening screws (1) from the
wheel the hub-lock ring gear (2).

RKZB5601

2 - To remove the hub-lock ring gear (2) from its housing,

screw at least two of the just removed screws (1) in the
threaded extraction holes “A”. 2
A

RKZB0151

3 - Extract and remove the hub-lock ring gear (2) together

with the epicyclic ring gear (3).
3

2
RKZB0161

4 - Remove the steel stop ring (4) and disjoin the hub-lock
ring gear (2) from the epicyclic ring gear (3).

5 - Only if necessary, remove the centering bushes (5) of 9

the hub lock ring gear with a hammer and the special
tool E1.

6
7
8
RKZB0181

WB97R-2 30-211
REMOVAL AND INSTALLATION DISASSEMBLY OF REAR AXLE

6 - Remove the hub (6), using levers and a hammer to fa-

cilitate the operation.
★ Collect the bearing (7) cone.

7
RKZB0171

7 - Position on a flat surface the hub and take the seal ring
out (8) with a lever.
★ This is a destructive operation for the seal ring.
8 - Take the bearing cups out (9) and (10), on both sides of
the hub, using a hammer and a suitable tool to be beat-
en.
9 8
Remove the bearing (10) cone from the swivel housing 10
end, using a suitable extractor.

RKZ06880

3. Axle beam trumpets and brake groups

disassembly
Drain oil from the axle, removing the breathers first, for
to release the axle inner pression, then loosen the plug
very carefully. 2
1 - Extract from the axle beam trumpet the seal ring (1) out 1
with a lever.
★ This is a destructive operation for the seal ring.
2 - In order to replace it inside the axle beam trumpet, the
bushing (2) to be cut and destroyed with a chisel.
RKZ06890
★ Do not ruin the bushing seat

3 - Put alignment marks on the axle beam body and on the

differential supporting flanges, in order to identify the
right side and the left side with certainty.

RKZB0281

30-212 WB97R-2
REMOVAL AND INSTALLATION DISASSEMBLY OF REAR AXLE

4 - Position the axle on supports fitted to hold either the

central body or the two beam trumpets, even after their
disjunction, or secure the three disjointed groups to a
lifting device with ropes or belts.

RKZB1300

3 - Unscrew the fastening screws (3) to disassemble the

axle beam trumpet.

RKZB0291

4 - Spread apart the axle beam trumpet.

4
★ Once the axle beam trumpet has been removed,
the brake disks are free.

5 - Remove the O-ring (4) from its seat and the oil passage
hole and check the conditions.
Remove the long axle shaft (5) and the sleeve. Remove
the snap ring from the sleeve.

5
RKZB0941

6 - Remove the first brake counter disck (6).

RKZB0311

WB97R-2 30-213
REMOVAL AND INSTALLATION DISASSEMBLY OF REAR AXLE

7 - Remove the other disks (7) and counter disks (8) as far
as the brake splined sleevem, being careful how the dif-
ferent parts are positioned.
8 7

RKZB1311

8 - Remove the brake splined sleeve (9), recording the in-

dent position compared to the brake group.
★ The brake splined sleeve should be reassembled
in the same position as the one before disassem- 9
bling.

RKZB1321

9 - Remove the last counter disk (10).

10

RKZB0321

10 - Secure the brake flange to a hoist with ropes or safety

belts.
Unscrew the lower screw (11).
Remove the differential supporting flange (12) from the 12
central body, together with the bevel gear backlash-ad-
justing ring nut and the brake control unit.
★ This operation frees the differential box, that must 11
be kept to avoid its fall.

RKZB0341

30-214 WB97R-2
REMOVAL AND INSTALLATION DISASSEMBLY OF REAR AXLE

11 - Remove the O-ring (13) from its housing and check its
conditions.

13

RKZB0351

12 - Remove the O-Ring (14) from the two oil pipe holes and
check its conditions.

14
RKZB0361

13 - Remove the oil blow-by tube (15) from the central body.

14 - Remove the O-Rings (16) and check their conditions

16
15

16
RKZ06900

4. Brake control group disassembly

1 - Remove the brake group and position it on a workbench
or fix it in a clamp.
1
2 - Unloose the locknut (1) and unscrew the adjusting 2
screw on the supporting bracket (2).
Remove the adjusting screw.

RKZB4980

WB97R-2 30-215
REMOVAL AND INSTALLATION DISASSEMBLY OF REAR AXLE

3 - Unscrew and remove the lever fastening screw (3) at

the shaft end (4).
3

RKZB0401

4 - Remove the washer (5).

RKZB0411

5 - Put an alignment mark on the lever (4) and shaft (6)

splines for use during installation and to distinguish be-
tween right and left control (for example: you can put two
marks on the right and only one on the left).

6
4

RKZB1330

6 - Loosen the lever (4) to release the tension on the spring

(7).

4
7

RKZB1340

30-216 WB97R-2
REMOVAL AND INSTALLATION DISASSEMBLY OF REAR AXLE

7 - Remove the lever (4).

4
7

RKZB1351

8 - Remove the spring (7).

8
9 - Remove the washer (8) and the spacer (9).
9

RKZB4990

10 - Remove the two bracket (2) fastening screws (10).

10
RKZB0420

11 - Remove the bracket (2).

RKZB0431

WB97R-2 30-217
REMOVAL AND INSTALLATION DISASSEMBLY OF REAR AXLE

12 - Make an alignment mark on the cam (11) near the set-

screw (12) align with the top of the roll pin, for use during
assembly.
★ Distinguish between right operation side and left 11
one.

12

RKZB5010

13 - Free the cam unscrewing the setscrew (12).

12

RKZB0440

14 - Unscrew the shaft setscrew (13), being careful the steel

ball (14) does not get lost.

13

RKZB0450

15 - Collect the steel ball (14).

14

RKZB0460

30-218 WB97R-2
REMOVAL AND INSTALLATION DISASSEMBLY OF REAR AXLE

16 - Remove the O-Ring (15), taking the shaft (16) out.

15

16

RKZB0470

17 - Remove the shaft (16) and collect the cam (11).

16

11

RKZB0480

18 - Unscrew the upper screws (17) of kit brake mechanism

return and take the springs (18) and the bushes out (19).
17 18 19

RKZB0490

19 - Unscrew the lower self-adjust kit screws (20) and take

the bushes (21) and the spacers (22) out.

20 21 22

RKZB0500

WB97R-2 30-219
REMOVAL AND INSTALLATION DISASSEMBLY OF REAR AXLE

20 - Unloose the brake flange (24) bleed (23).

23 24

RKZB0510

21 - Take the piston out (25).

If necessary, blow in air through the brake bleeder vent
to eject the piston, using the minimum pressure.
★ Possible swift ejection of the piston.

25

RKZB1380

22 - Remove the O-Rings (26) and (27) from the piston (25)
and check their conditions.
25
26

27
RKZB0520

23 - Unscrew the fastening screw (28) of the ring nut retainer

(29).

28
29

RKZB0530

30-220 WB97R-2
REMOVAL AND INSTALLATION DISASSEMBLY OF REAR AXLE

24 - Remove the ring nut retainer (30).

30

RKZB0541

25 - Unscrew the ring nut (32) with suitable E2 special tool.

Remove the ring nut.
31

E2

RKZB0551

26 - Remove the bearing cup (31) with a hammer and a suit-

able tool.

32

RKZB0561

5. Differential group disassembly

1 - Collect the differential and put it in a clamp.
Unscrew all the fastening screws (1) of the bevel gear
crown (2).
★ This will make both differential half boxes free, so
take care not to drop the internal components. 3

1
RKZB0570

WB97R-2 30-221
REMOVAL AND INSTALLATION DISASSEMBLY OF REAR AXLE

2 - Disassemble the differential box in two half boxes (3)

complete with the relative components. 3
★ Mark the two half boxes (3) before disjoining them,
in order to reassemble them in the same position as
the one before disassembling.

3 - Disassemble all the components and check the oper- 4

ating and wear conditions of the components.
4
★ Take the bearing (4) out of the differential half box,
using two levers or a three-hold extractor.

RKZ06910

6. Pinion group disassembly

1 - Remove the snap ring (1) and slide the input flange (2).
★ Collect the O-ring (3) and the shim (4). 3
2

RKZ06920

2 - Remove the seal ring (5) from the central housing with a
puller.
★ This is a destructive operation for the seal ring.
3 - Position the central body on a steady plane, before dis-
assembling it.

RKZ06930

4 - Unscrew the ring nut (6) with the special tools E3 and
E4.

E4

E3
RKZB0602

30-222 WB97R-2
REMOVAL AND INSTALLATION DISASSEMBLY OF REAR AXLE

5 - Once the ring nut washer (7) has been removed, take
the pinion (8) out of its housing, by beating with a ham-
7
mer made of soft material on the splined end.

RKZB0611

6 - Collect the washers (9), the elastic spacer (10) and the
cones of the taper roller bearing (11).
★ When the elastic spacer is removed, it should be re-
placed by a new one. 11
9

10

RKZB0621

8 - Take the bearing (12) cone out of the bevel pinion (8)
end, using a suitable extractor.

9 - Remove the adjusting shim (13) placed under the bear-

ing and check its wear conditions.

12
13
RKZB0631

10 - In order to remove the differential lock device unscrew

the cylinder support screws (14), then remove off it col- 15
lecting the O-Rings and the piston (15). 17
Remove the Seeger ring (16), holding the bush (17) that 18
is pushed outside by the spring (19), remove off the
bush and the spring from the shaft (18). 14
Remove the cover (20) paying attention to the spring
16 21
(21) that could still be under load.
20
Remove off the shaft (18) by collecting the O-Ring, the
spring, the spacer and the snap ring.

RKZ06940

WB97R-2 30-223
REMOVAL AND INSTALLATION DISASSEMBLY OF REAR AXLE

11 - Extract differential lock fork (22) from the central body.

★ Check the integrity of all components disassem-
bled.

22

RKZ06950

12 - Take the cups of the taper roller bearing out of the cen-
tral body (23), using a chisel and a hammer.

23

RKZB0641

30-224 WB97R-2
REMOVAL AND INSTALLATION ASSEMBLY OF REAR AXLE

ASSEMBLY OF REAR AXLE

1. Pinion group assembly
1 - Position the central body (1) on a workbench.

2 - Insert the cups of the taper roller bearings on their hous-

ings using the special tools included on the kit E5
E5

RKZB0651

3 - In order to measure the distance, the kit composed of

the special tools E5 and E6, respectively called “false
pinion” and “false differential box”, is used. E6
4 - Insert the false pinion with E5, together with its bearings
(2) and (3) and its ring nut (4), in the just mounted hous-
ings for the bearings.
Tighten without exceeding, till the backlash is eliminat-
ed.
2 3 4

RKZB0661

5 - Check the correct positioning of the right and left flang-

es, using the reference marks on them and on the cen- 6
tral body.
Assemble the two brake flanges (5) and fix them with 5
their screws (6) M14X120.

Screw: 79 Nm
★ Screw in at least two ones diametrically-opposed
for each flange).

RKZB0670

6 - Insert the false differential box with E6 into the central

body to measure the distance. 5
Check that the false box is inserted in both brake flang-
es’ housings (5).

E7

RKZB0681

WB97R-2 30-225
REMOVAL AND INSTALLATION ASSEMBLY OF REAR AXLE

7 - Carry out the measurement “A” with a depth gauge

through the suitable false pinion hole and calculate the
measure “X”.
B= 100 mm
C= 50 mm

C
X
(A+C) - B= X

A
B
RKZ05070

8 - Make a note of the value “V” marked on the head of the

pinion.
Calculate the thickness “S” to be installed beneath the
pinion, using the formula: V
S=X--V
★ “S” is the thickness of the shim. 107.00
00

RKZ05420

9 - Remove the false pinion, the bearings (2) and (3) and
the ring nut (4) from the central body (1). 1
Disassemble the false differential box from the flanges
(5) and then unscrew the screws to remove the flanges. 3
E7

4
2 RKZ05101

10 - Mount the shim (8) onto the pinion (7) and press the in-
ner bearing (2) using the tool E8.
★ Use always a new elastic spacer. E8 2

RKZB0691

30-226 WB97R-2
REMOVAL AND INSTALLATION ASSEMBLY OF REAR AXLE

11 - Insert the bevel pinion unit (7) into the central body
housing (1) and the second bearing (3) cone into the 1
pinion end.
In order to force the bearing into position use the special
tool E8 and a hammer.
3

RKZB0700

12 - Insert into the pinion shaft (7) a new ring nut washer (9)
and the ring nut (4) retainer.

13 - Screw the ring nut in, using the wrench for ring nut E3
and for pinion retainer E4.
★ The torque setting is given by the preloading meas-
urement on bearings. 9 4
★ Tighten the ring nut step by step.
★ If it is tightened too much, the elastic spacer should
be replaced and the procedure repeated. E3
E4
RKZB0603

14 - Carry out the preloading measurement P of the pinion

taper roller bearings, using a dynamometer whose cord
is wound on the 34.87 mm diameter of the pinion spline.
★ The adjustment is carried out by increasing the ring
nut torque setting gradually, being careful not to ex-
ceed.
★ All preloadings should be measured without the
seal ring.

15 - Once you got the requested preloading value, caulk the

ring nut, using a hammer and a chisel.

P=9.2–13.8 daN RKZB0711

WB97R-2 30-227
REMOVAL AND INSTALLATION ASSEMBLY OF REAR AXLE

2. Differential group assembly

1 - Assemble the cones of the new taper roller bearings (1)
on the half boxes (2), using the special tool E9 and a E9
hammer. 1

RKZB0722

2 - Position a half box (2) on a workbench and assemble all

its inner components (sun gears, planetary gears, 2
thrust washers, pins, discs and counterdiscs) as per fig-
ure.
Join the two half boxes (2), aligning the reference marks
made upon them. 2
1
1

RKZ06911

3 - Position the ring bevel gear (3), apply Loctite 270 on the
thread and then fix the whole by tightening the screws
3
(4).
Screw: 155 Nm
4

RKZB1290

3. Brake flange and differential housing assembly

1 - Position the flange on a flat surface and force the cup of
the taper roller bearing (1) in position, using the special
tool E10, interchangeable handle E11 and a hammer
E11
1
E10

RKZB0731

30-228 WB97R-2
REMOVAL AND INSTALLATION ASSEMBLY OF REAR AXLE

2 - Collect the brake piston (3).

Push the elastic pin (2) into the self-adjust kit housing till
they are leveled with the piston supporting inner sur-
face.
2 3
Assemble the O-rings (4) and (5) on the piston and lu-
bricate the faying surface piston flange with a light layer
of grease.

2 5

2 4
RKZB0740

3 - Apply a slight coat of grease on the piston surfaces and

especially on the O-rings already inserted, insert the
piston (3) into the brake flange (6) and position the spe-
cial tool E12 or a disk on the piston and with a lever an-
chored to an eyebolt, exert a pressure just enough to
insert the piston into the brake flange.
3

E12
6

RKZB0751

4 - Take the components of the self-adjst kit and fit them on

the piston (3) as shown in the figure.
Screw the securing screws (7) of the two kits and tighten
them.

Screw: 10 Nm

3
7 RKZ06960

5 - Insert the new O-rings in their relative housings (oil pipe

hole) on the central body. Before assembling, lubricate 8
the O-rings (8).
9
Insert two new O-rings (9) in the oil pipe hole housings
(10). 10
Grease the O-rings.

6 - Insert the oil blow-by tube.

Insert the differential locking fork (10) in the central
body, respecting the showed position.
★ Do not invert the fork assembly position.
9
8
RKZ06970

WB97R-2 30-229
REMOVAL AND INSTALLATION ASSEMBLY OF REAR AXLE

7 - Insert a new O-ring (11) on the flange. Lubricate the O-

ring. Assemble the left flange on the central body. 11
8 - Tighten the securing screw of the brake cylinder with a
torque-wrench.

Screw: 79 Nm
★ Check that the reference marks made in the dis-
assembly between flange and central body coin-
cide.

RKZ06980

9 - Before the adjustment of the ring bevel gear bearings

preloading, prefasten the brake cylinders with two ad-
ditive screws M14X120.
Tighten at 79 Nm.
Once adjustment is made, remove them.
★ Respect the correct assemble side of the differen-
tial box with its relative components.

10 - Overturn and position the flange central body on a flat

surface.
Insert the differential box.

RKZB5520

★ The differential locking device elements have to be as-

sembled by respecting the relative position pointed out
in the figure.

RKZ06941

11 - Once the snap ring (13) has been introduced into the
shaft (12) till about 20 mm from the flatted end, introduce
14
the shaft into its housing in the central body, on the gear
side, slipping it into the fork (14).
★ Do not put the snap ring in the housing. 12

13

RKZ06990

30-230 WB97R-2
REMOVAL AND INSTALLATION ASSEMBLY OF REAR AXLE

12 - Insert the spring (20) and the bush (21) into the shaft
(12), operating into the central body on the opposite 22
21
side of the gear, then assemble the snap ring (22) in its
housing. 20

12

RKZ07000

13 - Insert the piston (24) in the cylinder (27), with new O-

Ring (23) and (25) Assemble a new O-Ring (26) in the
cylinder support (27), and then insert the support, with
the piston, in the central body, fastening it with relative
screws (28), tightened with dynamometric wrench. 28
Screw: 27.6 Nm
★ Before the assembly lubricate properly the seal
rings and the faying surfaces. 27
26
25
24
23 RKZ07010

14 - Push the seeger lock ring (13) in its housing in the dif-
ferential locking device of the shaft (12), by operating in 14
the central body on the bevel gear side. Then let the
seeger ring sliding along the shaft with a pipe or a suit-
12
able tool. Insert the spacer (15) and the spring (16) into 15
the shaft. Assemble a new lubricate O-Ring (17) upon
16
the cap (18). Assemble the cap (18) upon the central 17
body at the flatted end of the shaft, tightening the rela- 18
tive screws (19). 13 19
Screw: 27.6 Nm

RKZ07020

15 - Assemble the right brake flange. Tighten the securing

screw of the brake flange with a torque-wrench.

Screw: 79 Nm

Once the correct assembly side of the differential box it

has been checked, assemble the second brake flange
on the opposite bevel gear side. Insert and screw the
adjusting ring nuts of the pinion-ring, using the wrench
with E2 till the bearing backlash is eliminated. Then
measure the pinion-ring gear backlash.

RKZB5530

WB97R-2 30-231
REMOVAL AND INSTALLATION ASSEMBLY OF REAR AXLE

16 - Assemble the special tool E13 on the pinion end.

Move the pinion end alternatively and note the pinion
gear backlash, measured with a comparator “A”, so that
the feeler is in contact and at 90° with the bracket sur-
face on the special tool in correspondence with the ref-
erence mark. A
Check if the measured backlash value is within the re-
quest range.
★ Backlash: 0.18 – 0.23 mm
Carry out the adjustment by operating on the two ring E13
nuts with the tool E2.
Adjust the ring nuts remembering that: RKZB0771

- If the measured backlash is less than the given tol-

erance range, screw the ring nut from the side opposite
to the ring gear and unscrew the opposite one of the
same measure;
- If the measured backlash is higher than the given
tolerance range, screw the ring nut from the side of the
ring gear and unscrew the opposite one of the same
measure.

17 - Once you have carried out the adjusting of the pinion-

ring gear backlash, check also that there is a minimum
preloading on the differential box bearings.
Repeat the whole sequence of the above mentioned op-
erations till the indicated conditions are reached. RKZ05111

18 - Once the pinion gear backlash has been established,

measure the total preloading “T” of the bearings (pinion-
ring gear system), using a dynamometer whose cord
“B” is wound on the diamater 34.87 mm of the pinion
spline shaft.

★ Force required:
(P+3.73) < T < (P+5.55) daN
P= the force found for the pinion

★ The force should be that of continual rotation. Do

not take the thrust force into consideration. B
19 - If the force is not within permissible limits:
RKZ05121
a - Tighten both the lock nuts to the same extent to in-
crease the force “T”.

b - Loosen both the lock nuts to the same extent to de-

crease the force “T”.

The clearance between the ring bevel gear and the

pinion must remain within permissible limits.

30-232 WB97R-2
REMOVAL AND INSTALLATION ASSEMBLY OF REAR AXLE

20 - Check the centering of the contact area using the fol-

lowing procedure:
a - Coat both surfaces of the teeth of the ring bevel
gear with a marking substance.
b - Rotate the pinion.
If the contact area is excessive near to the edge of the
teeth, the ring bevel gear must be brought closer to the
pinion.If the contact area is excessive on the side of the
teeth, the ring bevel gear must be moved away from the
pinion.

RKZ01840

RKZ01850

21 - Insert the ring nut retainer (29) turning the ring nut slight-
ly in order to align it to the retainer.
Screw in and tighten the screw (30) of the ring nut re-
tainer with a dynamometric wrench. 29
Screw: 13 Nm
30

RKZB0781

22 - The seal ring into the central housing using seal driver
E14.

E14
RKZ07030

WB97R-2 30-233
REMOVAL AND INSTALLATION ASSEMBLY OF REAR AXLE

23 - Coat the seal lip and O-ring with oil and insert on the pin-
ion shaft the shim together with a new O-ring and input
flange.
Secure the assembled parts with snap ring (4).

4
RKZ07040

4. Brake control group asselmbly

3
1 - Insert the cam (2) and the shaft (3), on the side you are
operating, on the brake flange (1). They can be recog-
nized by the reference marks previously put.
1

2
RKZB0791

2 - When the shaft is inserted into the cam, align the ref-
erence mark with the cam setscrew (4) hole.

RKZB0801

3 - Insert the cam setscrew (4).

2

RKZB0811

30-234 WB97R-2
REMOVAL AND INSTALLATION ASSEMBLY OF REAR AXLE

4 - Screw in the cam setscrew (4) with dynamometric

wrench.

Screw: 10 Nm
2

RKZB0820

5 - Insert the steel ball (5) that sets the shaft and the relative
screw (4).

RKZB0461

6 - Put on the shaft setscrew (6) thread a slight layer of SI-

LASTIC. 6
Screw in and tighten the shaft setscrew (6) with dy-
namometric wrench.

Screw: 25 Nm

RKZB0831

7 - Insert a new O-Ring (7) on the shaft (3).

7
3

RKZB0840

WB97R-2 30-235
REMOVAL AND INSTALLATION ASSEMBLY OF REAR AXLE

8 - Position the supporting bracket (8).

Insert the fastening screws (9).
9

8
RKZB0850

9 - Screw in and tighten the bracket fastening screws (9)

with dynamometric wrench.

Screw: 35 Nm
9

RKZB0861

10 - Insert the spacer (11) the washer (10) and the spring
(12) on the shaft end.
12

10
11

RKZB0870

11 - Insert the brake control lever (13), respecting the ref-

erence marks put during disassembly.
13

RKZB0880

30-236 WB97R-2
REMOVAL AND INSTALLATION ASSEMBLY OF REAR AXLE

5. Brake and axle beam groups assembly

1 - Insert the first shaped brake counterdisc (1), respecting 1
the indicated position compared to the cam position.

RKZB0890

2 - Check that the friction discs and the counterdiscs do not

present any sign of burning; if yes, replace them. Fur-
thermore check friction disc wear and if necessary re- 4
place them.
★ Friction disc thickness: min. 4.03 mm
1
3 - Reassemble all the components of the brake group
(discs (2), counterdiscs (4) and coupling (3)) inside the
flange as per the sequence in the figure.
★ The coupling should be inserted after the first disc
and positioned with the shortest spline against the 2
differential.
3
★ If new brake discs are installed, before assembling, RKZ07050

they should be dipped in the suitable oil.

★ The discs and counterdisc unit are free.
4 - Insert the long half-shaft (5) into the axle central body 6
(6).
Position the seeger ring (7) on the inner seat of sleeve
(8).
Insert the sleeve on the long half-shaft. 5
★ The sleeve must be inserted with the inner seeger
ring resting against on the long half-shaft 7

8
RKZ07060

5 - Before assembly, check the reference marks carried

out during disassembly for the correct positioning of the
axle beam trumpets.

RKZB5610

WB97R-2 30-237
REMOVAL AND INSTALLATION ASSEMBLY OF REAR AXLE

6 - Drive the bushing (9) in the seat on the axle beam trum-
pet by means of the special tool E15.

RKZ07070

7 - Assemble a new O-ring into the axle beam trumpet and

into the two oil blow-by holes. Lubricate the O-rings.
Assemble the axle beam trumpet on the flange, being
careful to the fastening holes’ alignment.
★ Support the groups properly as already pointed out
for disassembly phase.

8 - Screw in and tighten the fastening screws (10) of the

axle beam trupet with a dynamometric wrench.

Screw: 176 Nm
10
★ Assemble the brehater adapter with the nocht
aligned to half-shaft. RKZ07080

9 - Lubricate with care the lip of the new seal ring.

Insert the new seal ring (11) in the seat on the axle beam
trumpet by means of the special tool E16.

11

RKZ07090

10 - Insert the short half-shaft (12) on the axle beam trum-

pet.

12

RKZ07100

30-238 WB97R-2
REMOVAL AND INSTALLATION ASSEMBLY OF REAR AXLE

11 - Set the brake group, putting the system under pressure.

It is advisable to use compressed air at high pressure
blown through the breather.
★ The braking system (piston, discs, self-adjust kit
and kit brake mechanism return) should be set, be-
fore moving the brake control levers.

12 - Operate the control levers, setting them on braking po-

sition (locked levers).
★ The lever return springs should not be inserted.
⫼310.5 mm
301⫼
13 - Measure the distance between the middle of the con-
nection holes at the ends of the control levers and check RKZ06201

that it is within the foreseen range:

301–310.5 mm
• If the value is not within the foreseen range, correct
13
the lever position: take them out of the shaft and re-
insert them shifted of one spline so that the error 14
can be compensated.

Repeat the checking operation and the further adjust-

ment till the requested conditions are reached.

14 - Release the brake control levers, screw in the fastening

screws (13) and the relative washers (14).

RKZB0921

15 - Tighten the fastening screw (13) of the control lever with

dynamometric wrench.

Screw: 35 Nm
13

RKZB0951

16 - Hitch the return spring (15) to the brake control lever

(16).
Repeat all the described operations also for the other 16
brake group.
15

RKZB0961

WB97R-2 30-239
REMOVAL AND INSTALLATION ASSEMBLY OF REAR AXLE

17 - Check that, in rest position, the measure between the

middle of the connection holes at the lever ends is high-
er than the minimum value 320 mm.

⫼329.5 mm
320⫼

RKZ06191

18 - Assemble the adjusting screws (17) on the brackets and

screw in them, till they are in contact with the levers.

17

RKZB0971

19 - Screw in the two screws of the same measure to be

within the foreseen range for the levers in rest position:
320–329.5 mm (about 3 mm between lever and bracket
will remain).

⫼329.5 mm
320⫼

RKZ06191

20 - If the screw (17) is not perpendicular to the side surface

of the lever (16), adjust its position by moving the sup-
porting bracket. 90°

16 17

RKZ06211

30-240 WB97R-2
REMOVAL AND INSTALLATION ASSEMBLY OF REAR AXLE

6. Wheel hub group assembly

3 4
1 - Position the wheel hub (1) on a workbench and force the 2
two cups of the taper roller bearings (2) and (3) in po-
sition with the special tool E17 under a press or with a
hammer.

2 - Insert the seal ring (4) into the wheel hub with the special E17 E18
tool E18 and a hammer.

E17 1
RKZB1422

3 - Assemble the cone of the taper roller bearing (3) on the

beam trumpet (5) end. 5 1

4 - Assemble the wheel hub (1) on the beam trumpet (5) 3

and force the other cone of the taper roller bearing (2) in
position.

RKZB1431

5 - Position the wheel carrier (6) on a workbench and force

the bushes (7) to the carrier surface level with the spe-
cial tool E1. 7
At least two bushes (diametrically-opposed) should be
set slightly higher than the carrier surface level to be
used as dowel pins.

6
RKZB1091

6 - Preassemble the wheel carrier group (8), epicyclic ring

gear (9), with the special snap ring (10) shown in the fig- 9
ure.

10

RKZ05731

WB97R-2 30-241
REMOVAL AND INSTALLATION ASSEMBLY OF REAR AXLE

7 - Assemble the wheel carrier group (8) on the wheel hub

(1) using the two projecting bushes (7) as dowel pins. 1 8

RKZB1101

8 - Force all the hub dowel bushes completely with the spe-
cial tool E1 and a hammer. 8
Assemble the wheel carrier fastening screws (11) and 11
tighten.

Screw: 230 Nm

RKZB1441

9 - In the case the bearings (2) and (3) are substituted, ver-
ify that the measure “A”, “B” and “C” are in the limits.

A = 17.950 – 18.000
B = 64.275 – 64.325
C = 23.070 – 23.172 3
2 C A C

RKZ05741

7. Epicyclic reduction gear assembly

1
1 - Place the planetary carrier on a work bench and fit the
epicyclic gears (1) and respective washers (2) on the
dowels already fitted. 2

RKZ05750

30-242 WB97R-2
REMOVAL AND INSTALLATION ASSEMBLY OF REAR AXLE

2 - Insert all the rollers (3) into the epicyclic gears (4), then
place the two thrust washers (5) and (6).
★ The first washer must be aligned with the dowel pin. 4
5

3 RKZ05760

3 - Fit and tighten the epicyclic gears (4) fixing bolts (7),
tightening.
4
Screw: 79 Nm
7

RKZ05770

4 - Insert a new O-ring on the centering diameter of wheel

hub.

5 - Fit the planetary carrier to the wheel hub (8). Insert and 8
9
tighten the fixing bolts (9) to the prescribed torque.

Screw: 25 Nm

RKZB0111

WB97R-2 30-243
REMOVAL AND INSTALLATION REMOVAL OF THE FRONT BUCKET BOOM-RAISING CYLINDER

REMOVAL OF THE FRONT BUCKET BOOM-RAISING CYLINDER

Lower completely the working equipment until it rests on
the ground and stop the engine.

1 - Put a sling round the cylinder (1) and insert some blocks A
“A” between the boom (2) and the fulcrum lever spacer 2
(3). 3
2 - Take off the snap-ring and the internal retaining spacer
for the piston attachment pin (4). 4
3 - Take out the pin (4) in order to free the piston head (5), 1
but leave the fulcrum lever engaged (3).
5
4 - Start the engine to retract the piston (1). RKZA2160

★ Bind the piston head with wire to secure the fully re-
tracted position and stop the engine.
1 2
Release all residual pressure in all circuits.
(For details, see «20. TESTING AND ADJUST-
MENTS»). 1
Cut off the supply of electricity by turning the battery-dis-
connecting switch in a counter-clockwise direction, and
remove the handle.
7
5 - Disconnect the tubes (6) and (7) and plug them to pre-
6
vent entry of impurities.
RKZA1951

6 - Remove the snap-ring (8) and the spacer (9).

7 - Remove the cylinder (1).

9
Cylinder: 40 kg 1 8

INSTALLATION OF FRONT
BUCKET BOOM-RAISING
CYLINDER
• To install, reverse the removal procedure.
RKZA2170

1
When aligning the positions between the hole and the
pin, turn the engine over at low idling speed.
Do not insert fingers into the holes to check alignment.

2
Internal bushing: ASL800050

1 - Start the engine and bleed the air from the cylinders.
(For details, see «20. TESTING AND ADJUST-
MENTS»).

★ After bleeding the air, check the oil level in the tank.

30-244 WB97R-2
REMOVAL AND INSTALLATION REMOVAL OF THE FRONT BUCKET TILT CYLINDERS

REMOVAL OF THE FRONT BUCKET TILT CYLINDERS

Lower the working equipment completely until it rests on
the ground and stop the engine.

1 - Loosen the clips (1) and remove the tube protection (2). 3
4
★ For the right-hand cylinder only
Disconnect the sensor (3) and remove the bucket po-
sition indicator (4).
2 - Place a sling round the cylinder (5) and insert a block “A”
between the spacer (6) of the piston fulcrum lever (7)
and the link (8).
3 - Take off the snap-ring and the internal retaining spacer
for the piston attachment pin (9). RKZB5061

4 - Take out the pin (9).

5 - Start the engine to retract the piston (10).
1 2
★ Bind the piston head with wire to secure the fully re-
tracted position and stop the engine.
7
Release all residual pressure in all circuits.
(For details, see «20. TESTING AND ADJUST-
5
MENTS»). A
Cut off the supply of electricity by turning the battery-dis- 8
connecting switch in a counter-clockwise direction, and 6
remove the handle.
RKZA2190

6 - Take out the screw (11) and remove the clamp (12).
7 - Disconnect the tubes (13) and (14) and plug them to
10 13 12
prevent entry of impurities.
8 - Remove the snap-ring (15) and the spacer (16).
9 - Remove the cylinder (5).

Cylinder: 45 kg
14 11
9
INSTALLATION OF THE FRONT
BUCKET TILT CYLINDERS
• To install, reverse the removal procedure.
RKZB6750

1
When aligning the positions between the hole and the
pin, turn the engine over at low idling speed.
Do not insert fingers into the holes to check alignment. 16
2
Internal bushing: ASL800050
12
1 - Start the engine and bleed the air from the cylinders.
(For details, see «20. TESTING AND ADJUST-
MENTS»). 15

★ After bleeding the air, check the oil level in the tank. 11

RKZA2210

WB97R-2 30-245
REMOVAL AND INSTALLATION REMOVAL OF THE FRONT BUCKET

REMOVAL OF THE FRONT BUCKET

Lower the bucket to the ground, resting on its back, but
without forcing it downwards.

1 - Stop the engine and release residual pressures.

RKZB6760

2 - Take out the screws (1) and remove the pins (2) of the
lever (3).
Rest the lever (3) on the boom.
1 2

2
RKZA1460

3 - Take out the screws (4) and remove the pins (5) of the
bucket fulcrum.
1 2 4
4 - Start the engine and put the machine into reverse gear
in order to disengage the boom (6).

5
RKZA1470

INSTALLATION OF THE
FRONT BUCKET
• To install, reverse the removal procedure.

1
When aligning the positions between the hole and the
pin, turn the engine over at low idling speed.
Do not insert fingers into the holes to check alignment.

2
Internal bushing: ASL800050

30-246 WB97R-2
REMOVAL AND INSTALLATION REMOVAL OF THE FRONT WORKING EQUIPMENT

REMOVAL OF THE FRONT WORKING EQUIPMENT

Lower the working equipment completely until it rests on
the ground stop the engine and remove the ignition
wrench.

Release all residual pressure in all circuits.

(For details, see «20. TESTING AND ADJUST-
MENTS»).

1 - Remove the tilt cylinders. (See «REMOVAL OF FRONT

BUCKET TILT CYLINDERS»).

RKZB6760

2 - Disconnect the cylinders (2) from the boom (1) and rest
them on wooden blocks «A» placed on the front axle.

1 2

2
A
RKZA2220

3 - Open the front hood (3) and take out the screws (4) that
lock the axle oscillation pins of the boom (1).
Close the front hood.

4 4

RKZA1090

4 - Put a sling round the boom (1) as shown in the figure,

and attach it to the hoisting tackle. Apply a slight tension 1
to the cables.

RKZB6761

WB97R-2 30-247
REMOVAL AND INSTALLATION REMOVAL OF THE FRONT WORKING EQUIPMENT

5 - Using a puller, take out the axle oscillation pins (5) of the
boom (1). 1 2
6 - Start the engine and put the machine into reverse gear
5
travel until the boom is disengaged.
1
★ If the working equipment is to be detached to aid the
removal of the engine-gearbox-pump group, and
the machine cannot travel automatically, it can be
towed using the towing hooks of the backhoe.

7 - Place two stands in position and lower the boom until it

is resting on them.

Work equipment: 960 kg RKZA7920

INSTALLATION OF THE FRONT

WORKING EQUIPMENTI
• To install, reverse the removal procedure, if necessary
using the front towing hook.

1
When aligning the positions between the hole and the
pin, turn the engine over at low idling speed.
Do not insert fingers into the holes to check alignment.

2
Internal bushing: ASL800050
• Start the engine and bleed the air from the cylinders.
(For details, see «20. TESTING AND ADJUST-
MENTS»).

★ After bleeding the air, check the oil level in the tank.

30-248 WB97R-2
REMOVAL AND INSTALLATION REMOVAL OF THE BACKHOE CONTROL VALVE (standard version)

REMOVAL OF THE BACKHOE CONTROL VALVE

(standard version)
1 - Swing the backhoe completely to the right of the ma-
chine, and rotate the boom to approx. 45° to the right.

2 - Lower the outriggers to the ground, open the bucket and

rest the arm on a block “A” keeping it perpendicular to
the ground.

3 - Rest the bucket teeth on the ground, release the back-

hoe plate and stop the engine.

Release all residual pressure in all circuits. A

(For details, see «20. TESTING AND ADJUST-
MENTS»).
RKZA1681

4 - Take out the lower window (1) of the cab and completely
raise the upper window.

RKZA1100

5 - Remove the grips (2) of the control levers of the outrig-

gers.
2
6 - Raise the protective sleeves (3) of the control levers,
take out the screws (4) and remove the cover (5).

3 3
4
5
RKZA9830

★ If any optional devices have been fitted, unhook the

spool command tie-rods (6) and remove the pedals (7)
and the supports (8). 8
7

RKZA9840

WB97R-2 30-249
REMOVAL AND INSTALLATION REMOVAL OF THE BACKHOE CONTROL VALVE (standard version)

7 - Disconnect the connector (10) of the solenoid (11) of the

control valve (12).
13
8 - Disconnect the lever command tie-rods (13) from the
control valve.
12 11
9 - Disconnect from the control valve the pipes (14) (deliv-
ery, return, Load Sensing and actuators). Plug them to
prevent entry of impurities. 10
★ Mark the pipes to prevent exchanging positions 14
during re-connection.

10 - Attach the control valve (12) to some hoisting tackle and

RKZA2251
apply a slight tension to the cables.

11 - Remove the four screws (15) and then the entire control
valve.

Control valve:6-spool 47 kg
7-spool 53 kg
8-spool 59 kg

15 15

RKZA2260

INSTALLATION OF THE
BACKHOE CONTROL VALVE
• To install, reverse the removal procedure.

★ Bleed the air from Load Sensing circuits and from the
hydraulic circuits of all the actuators.
(For details, see «20. TESTING AND ADJUST-
MENTS).

30-250 WB97R-2
REMOVAL AND INSTALLATION REMOVAL OF THE BACKHOE CONTROL VALVE (version with

REMOVAL OF THE BACKHOE CONTROL VALVE

(version with servocontrol)
1 - Swing the backhoe completely to the right of the ma-
chine, and rotate the boom to approx. 45° to the right.

2 - Lower the outriggers to the ground, open the bucket and

rest the arm on a block “A” keeping it perpendicular to
the ground.

3 - Rest the bucket teeth on the ground, release the back-

hoe plate and stop the engine.

Release all residual pressure in all circuits. A

(For details, see «20. TESTING AND ADJUST-
MENTS»).
RKZA1681

4 - Take out the lower window (1) of the cab and completely
raise the upper window.

RKZA1100

5 - Remove the rear mat (2).

RKZB6770

6 - Remove the screws (3) and remove the platform (4).

4

3
RKZB6661

WB97R-2 30-251
REMOVAL AND INSTALLATION REMOVAL OF THE BACKHOE CONTROL VALVE (version with

7 - Disconnect the upper servocontrol hoses (6) from the con-

6 6
trol valve (5).
★ Ensure that all hoses are marked and note down
bends and routing pattern.
★ Cap the hoses and the holes to prevent contamina-
tion.
★ Lay the hoses inside the cab to gain access to the feed
and exhaust hoses.

RKZB6780

8 - Disconnect the lower servocontrol hoses (7) from the con-

trol valve (5).
★ Check that all the hoses are marked and note down
the bends and routing patterns.
★ Cap the hoses and holes to prevent contamination.
★ Lay down the hoses in the cab to gain access to the
feed and exhaust hoses.

7 7

RKZB6790

9 - Disconnect the solenoid valve connector (8) of the control

valve (5).

10- Disconnect the hoses (9) (feed, exhaust, Load Sensing

and functions) from the control valve (5). 8
★ Cap the hoses to prevent contamination.
★ Mark the hoses so as not to mix them up when re-as-
sembling.

11 - Attach the control valve to a hoist and slightly tension the

rods.
9
12 - Remove the fastening screws and then the entire control RKZB6800
valve (5).

Control valve: 6 elements: 47 kg

7 elements: 53 kg
8 elements: 59 kg

30-252 WB97R-2
REMOVAL AND INSTALLATION INSTALLATION OF THE BACKHOE CONTROL VALVE

INSTALLATION OF THE BACKHOE CONTROL VALVE

• To install, reverse the removal procedure.
• For servo-control hose connection and routing, refer to the di-
agram and illustrations below.

SERVO-CONTROL CONNECTION DIAGRAM

RKZB7050

RKZB7060

WB97R-2 30-253
REMOVAL AND INSTALLATION REMOVAL OF THE PPC VALVES CONTROLLING THE BACKHOE

REMOVAL OF THE PPC VALVES CONTROLLING THE BACKHOE

CONTROL VALVES (OPTIONAL)
The following removal procedure applies to both
PPC valves.
1 - Lower the outriggers to the ground: fold the bucket and rest
the arm on an “A” block, keeping it at right angles with the
ground.
2 - Release the backhoe plate and stop the engine.
Eliminate residual pressure in all circuits.
(For a detail see «20. TESTING AND ADJUSTMENTS»).
3 - Remove the cab lower window and fully raise the upper
A
window.

RKZA1681

4 - Fully raise the boot (1).

5 - Loosen and remove the screws (2) retaining the PPC valve 2
(3) and armrest (4).

3
5 RKZB6810

6 - Raise the armrest from the rear side and remove the screw
(5) retaining the rear guard (6). 8
7
7 - Cut the retaining clamp and lower the lower boot (7). 5
8 - Loosen and remove the screw (8) and remove the rear
guard (6).

RKZB6820

9 - Disconnect the connector (9).

10 - Ensure that the hoses are marked (10), then disconnect

the hoses from the PPC valve. 1
★ Mark the hoses, if necessary.
9
★ Cap the hoses to prevent contamination.

10
RKZB6830

30-254 WB97R-2
REMOVAL AND INSTALLATION REMOVAL OF THE PPC VALVES CONTROLLING THE BACKHOE

11 - Remove the PPC valve (11).

11

RKZB6840

INSTALLATION OF THE PPC

VALVES
• To install, reverse the removal procedure.
1
★ Carefully inspect the hoses for the proper position
when connecting them.
(For more information, see «10. STRUCTURE AND
FUNCTION»).

WB97R-2 30-255
REMOVAL AND INSTALLATION REPLACING THE PPC VALVE SUPPORT RELEASE CABLES

REPLACING THE PPC VALVE SUPPORT RELEASE CABLES

1. Removal procedure
1 - Lower the outriggers and the equipment to the ground.
Stop the engine.

RKZA1680

2 - Remove the rear mat (1).

RKZB6771

3 - Pull out the screws (2) and remove the platform (3).
3

2
RKZB6662

4 - Fully raise the boot (4).

5 - Loosen and remove the screws (5) retaining the PPC valve 4
and the armrest (6).

RKZB6811

30-256 WB97R-2
REMOVAL AND INSTALLATION REPLACING THE PPC VALVE SUPPORT RELEASE CABLES

6 - Raise the armrest from the rear side and remove the screw
(7) retaining the rear guard (8). 10
9
7 - Cut the retaining clamp and release the lower boot (9).
7
8 - Loosen and remove the screw (10) and remove the rear
guard (8).

RKZB6821

9 - Loosen and remove the screws (11) and raise the boot (12)
and the retaining edge (13). 12
★ Raise until the lower fulcrum and locking assembly be-
come fully disengaged.

13 11

RKZB6850

10 -Remove the retaining screws (14) from the lock-actuating

lever assembly (15).

11 -Remove the entire lever assembly (15). 15

14
RKZB6860

12 -Loosen the nut (16) and disengage the sheath (18) from
the support (17).

13 -Disconnect the cable (20) from the lower locking lever (19).

17 20

18

19
16
RKZB6870

WB97R-2 30-257
REMOVAL AND INSTALLATION REPLACING THE PPC VALVE SUPPORT RELEASE CABLES

14 -Loosen the nut (21) and unscrew the tensioner (22); dis-
engage the control cable (20) from the release control lever
(15).

21
15

22

20
RKZB6970

2. Installation and adjustment procedure

• To install, reverse the removal procedure.

1 - Using the tensioner (22), adjust cable tension to obtain safe

locking and friction-free unlocking of the column.

2 - Lock the nut while holding the tensioner into position (21).

21
22

RKZB7070

30-258 WB97R-2
REMOVAL AND INSTALLATION REMOVAL OF THE PPC VALVE SUPPORT RETURN GAS SPRING

REMOVAL OF THE PPC VALVE SUPPORT RETURN GAS SPRING

1 - Lower the outriggers and the equipment to the ground.
Stop the engine.

RKZA1680

2 - Remove the rear mat (1).

RKZB6771

3 - Pull out the screws (2) and remove the platform (3).
3

2
RKZB6662

4 - Fully loosen the stop knob (4) of the PPC valve support (5)
you are working on.

9
RKZB6800

WB97R-2 30-259
REMOVAL AND INSTALLATION REMOVAL OF THE PPC VALVE SUPPORT RETURN GAS SPRING

5 - Fully raise the boot (6).

6 - Loosen and remove the screws (7) that retain the PPC 6
valve and armrest (8).

RKZB6812

7- Raise the armrest from the rear side and remove the screw
(9) retaining the rear guard (10). 12
11
8 - Cut the retaining clamp to disengage the lower enclosing
9
boot (11).

9 - Loosen and remove the screw (12) and remove the rear
guard (10).

10

RKZB6822

10 -Loosen and remove the screws (13) and raise the boot (14)
and the retaining edge (15). 14
★ Raise until the gas spring (16) becomes fully disen-
gaged.

15 13

RKZB6851

11- Loosen the nut (17) and remove the snap ring (18) and
washer (19). 16 18
12- Disconnect the gas spring (16) and remove it.

17

INSTALLATION OF THE PPC

VALVE SUPPORT RETURN GAS
19
SPRING
• To install, reverse the removal procedure.
RKZB7080

30-260 WB97R-2
REMOVAL AND INSTALLATION REMOVAL OF THE SOLENOID VALVE ASSEMBLY CONTROLLING

REMOVAL OF THE SOLENOID VALVE ASSEMBLY CONTROLLING THE

HAMMER AND JIG ARM/HAMMER AND SIDE DIGGING BOOM
1 - Move the backhoe to the right hand side.
Lower the outriggers and the equipment to the ground; stop
the engine.

2 - Eliminate residual pressure in all circuits.

(For detail see «20. TESTING AND ADJUSTMENTS»).

3- Release the wire harness from the clamps.

Disconnect the connectors (2) (3 pcs.) from the solenoid
valves (1). 2
★ Ensure that the connectors are marked to avoid mix-
ing them up during installation.

1
2
RKZB6880

4- Disconnect the lower hoses (4) (2 pcs.) and the rear hoses
(5) (3 pcs.) from the valve (3). 3
★ Mark the position of the hoses to avoid mixing them up
during installation.

RKZB6890

5- Loosen and remove the screws (6) and remove the valve
(3).
3

INSTALLATION OF THE SOLE-

NOID VALVE ASSEMBLY CON-
TROLLING THE HAMMER AND JIG 6

ARM/HAMMER AND SIDE DIG-

GING BOOM
• To install, reverse the removal procedure. RKZB6900

WB97R-2 30-261
REMOVAL AND INSTALLATION REMOVAL OF THE SERVOCONTROL FEED VALVE (OPTIONAL)

REMOVAL OF THE SERVOCONTROL FEED VALVE

(OPTIONAL)
1 - Position the machine over a pit, lower the outriggers and
the equipment to the ground.
Stop the engine.

Release all residual pressure in all circuits.

(For detail see «20. TESTING AND ADJUSTMENTS»).

2 - Mark connectors (1) (5 pcs.) and disconnect them from the

solenoid valves. 1
★ Gather the connectors together and place them in a
clean area. 1

RKZB6910

3 - Mark the hoses (2) with the abbreviations for the connec-
tions and then disconnect them from the valve (3).
★ Immediately plug the hoses to prevent contamination. 2

3
2

RKZB6920

4 - Loosen the screws (4) and remove the entire valve.

3 4
RKZB6930

30-262 WB97R-2
REMOVAL AND INSTALLATION INSTALLATION OF THE SERVOCONTROL FEED VALVE (OPTIONAL)

INSTALLATION OF THE SERVOCONTROL FEED VALVE (OPTIONAL)

• To install, reverse the removal procedure.

1 - Start the engine and repeat as many backhoe movements

as possible several times to bleed air from the circuits.

If the valve is replaced or removed, perform the op-

erating pressure calibration procedure.
(For detail description «20. TESTING AND ADJUST-
MENTS»).

WB97R-2 30-263
REMOVAL AND INSTALLATION REMOVAL OF BACKHOE BOOM CYLINDER

REMOVAL OF BACKHOE BOOM CYLINDER

1 - Remove the lubrication nipple and the extension.

Extend the arm (2) completely and fully open the bucket
(3).
1 5
Manoeuvre the front equipment until the bucket teeth
are resting on the ground, the arm on a block “A” about
10 cm high, and the joint between the arm and the boom
on a stand “B”, about 70 cm high.

2 - Stop the engine and release residual pressures.

6
3 - Place a sling around the cylinder (4).

4 - Take out the screws (5) and remove the pin (6). RKZA1150

1 2
5 - Start the engine and retract the piston. 10
★ Secure the position of total retraction by binding the
piston head rod with wire.

6 - Stop the engine and release any residual hydraulic

2 9
pressures. (For details, see «20. TESTING AND AD-
JUSTMENTS»). 3

7 - Disconnect the pipes (7) and (8) and plug them to pre-
vent entry of impurities.

8 - Take out the screw (9) and remove the pin (10). B
1 2 A RKZA0140

9 - Remove the cylinder (4).

Cylinder: 78 kg

5
INSTALLATION OF THE
BACKHOE BOOM CYLINDER
• To install, reverse the removal procedure.
6
1
When aligning the positions between the hole and the
pin, turn the engine over at low idling speed. RKZA1170

Do not insert fingers into the holes to check alignment.

2
4
Internal bushing: ASL800050

1 - Start the engine and bleed the air from the cylinders.
(For details, see «20. TESTING AND ADJUST-
MENTS»).

★ After bleeding the air, check the oil level in the tank.

7
8
RKZA1180

30-264 WB97R-2
REMOVAL AND INSTALLATION REMOVAL OF THE BACKHOE ARM CYLINDER

REMOVAL OF THE BACKHOE ARM CYLINDER

Extend the arm (1) completely and fully open the bucket
(2). Lower the arm (3) until the joint between the arm and
the boom is resting on a stand “A” about 90 cm high, and
tip of the arm on a block “B” about 10 cm high. 3
Rest the bucket teeth on the ground. 1
1 - Stop the engine and release the pressures in the cyl-
2
inder by moving the control lever several times.

2 - Place a sling around the cylinder (4).

3 - Take out the screws (5) and remove the pin (6). A
1 2 B
RKZA1160

4 - Start the engine and retract the piston (7).

★ Secure the position of total retraction of the piston
(7) by binding the piston head rod with wire.

5 - Stop the engine and release the residual hydraulic pres- 5

sures. (For details, see «20. TESTING AND ADJUST-
MENTS»).

6 - Disconnect the pipes (8) and (9) and plug them to pre-
vent entry of impurities.

7 - Take out the snap-ring (10) and remove the pin (11). 6
1 2 4
8 - Remove the cylinder (4). RKZA1190

Cylinder: 69 kg

8
7
4 9
INSTALLATION OF THE
BACKHOE ARM CYLINDER
• To install, reverse the removal procedure.

1
When aligning the positions between the hole and the
pin, turn the engine over at low idling speed. RKZA1200

Do not insert fingers into the holes to check alignment.

2
Internal bushing: ASL800050 11 4
1 - Start the engine and bleed the air from the cylinders.
(For details, see «20. TESTING AND ADJUST-
MENTS»).

★ After bleeding the air, check the oil level in the tank.

10
RKZA1210

WB97R-2 30-265
REMOVAL AND INSTALLATION REMOVAL OF THE JIG ARM CYLINDER

REMOVAL OF THE JIG ARM CYLINDER

Open the arm (1) completely and lower it until it rests on
a trestle “A” that is roughly 40 cm high.
Extend the jig arm (2) until it rests on a block “B”, and let 1
the bucket teeth rest on the ground. 4
1 - Stop the engine and release the cylinder (3) pressures,
by moving the command pedal several times.
2
2 - Put a sling around the cylinder (3).

3 - Take off the snap ring and remove the pin (4).
A
1 2
B
4 - Start the engine to retract the piston. RKZA7930

★ Secure the fully retracted position of the piston by

binding it with wire.

5 - Stop the engine and release the residual hydraulic pres-

sures.
5
(For details see «20. TESTS AND ADJUSTMENTS»).

6 - Take out the safety pin (5).

7 - Disconnect the hoses (6), (7), (8) and (9), and plug them
to prevent entry of impurities.

8 - Remove the clamp (10). 3

9 - Remove the screws (11) and the pin (12). 1 2

RKZA7940

10 - Remove the cylinder (3).

INSTALLATION OF THE 11 10
JIG ARM CYLINDER 6
• To install, reverse the removal procedure.
8
1 12
When aligning positions between hole and pin, let the
engine turn over at low idling.
Do not insert fingers into the holes to check on align-
ment. 9 7
RKZA7950

2
Internal bushings: ASL800050

1 - Start the engine and bleed the air from the cylinders.
(For details, see «20. TESTS AND ADJUSTMENTS»).

★ After bleeding the air, check the oil level in the tank.

30-266 WB97R-2
REMOVAL AND INSTALLATION REMOVAL OF THE BACKHOE BUCKET CYLINDER

REMOVAL OF THE BACKHOE BUCKET CYLINDER

Extend the arm (1) completely and fully open the bucket
(2). Lower the boom (3) until the arm is resting on a
stand “A” about 90 cm high, and tip of the arm on a block
“B” about 10 cm high. 3
Rest the bucket teeth on the ground. 1
4
1 - Stop the engine and release the pressures in the cyl- 2
inder (4) by moving the control lever several times.
2 - Place a sling around the cylinder (4).
3 - Take out the lock-nut (5) and the washer and remove
the pin (6). A
1 2 3 B
RKZA1161
4 - Start the engine and retract the piston (7).
★ Secure the position of total retraction of the piston
by binding the piston head rod with wire
5 - Stop the engine and release the residual hydraulic pres-
sures. (For details, see «20. TESTING AND ADJUST- 4
MENTS»).
6 - Disconnect the pipes (8) and (9), and plug them to pre-
vent entry of impurities.
7
7 - Take out the snap-ring (10) and remove the pin (11).
1 2 5
★ For jig arm: loosen nut (12) and remove pin (13).
8 - Remove the cylinder (4). 6 RKZA1220

Cylinder: 49 kg

INSTALLATION OF THE 9
BACKHOE BUCKET CYLINDER 8
• To install, reverse the removal procedure. 10

1
When aligning the positions between the hole and the
pin, turn the engine over at low idling speed. 4
Do not insert fingers into the holes to check alignment. 11
2 RKZA9851

Internal bushing: ASL800050

3
★ Tighten the locknut completely, then release it half a
turn.
1 - Start the engine and bleed the air from the cylinders.
(For details, see «20. TESTING AND ADJUST-
MENTS»).
★ After bleeding the air, check the oil level in the tank. 13

12
RKZA9950

WB97R-2 30-267
REMOVAL AND INSTALLATION REMOVAL OF THE OUTRIGGER CYLINDERS

REMOVAL OF THE OUTRIGGER CYLINDERS

Position the backhoe with the equipment centered, the
arm vertical and the back of the bucket resting on the
ground.

1 - Extend the outriggers (1) of about 15 cm, stop the en-

gine and release the cylinders pressures.

1
RKZA0971

2 - Place a lifting platform “A” beneath outrigger (2) of cyl-

inder to be remove.
Raise this until it is forced up against the outrigger. 1

RKZA1240

3 - Remove the retainer pipes clamp (3).

4
5
4 - Disconnect from cylinder (5) the pipes (4) and plug them
to avoid impurity entry.
Plug also the union to avoid the movement of piston.
4
5 - Remove screw (6) and extract the pin (7) until the cyl-
inder (5) is free. 1 2
3

7
6
RKZA1250

6 - Raise the lifting platform “A” to disengage the cylinder

head (5) from frame
Place a sling round the cylinder (5) and apply slight ten-
sion to the cables. 5

RKZA1260

30-268 WB97R-2
REMOVAL AND INSTALLATION REMOVAL OF THE OUTRIGGER CYLINDERS

7 - Take out the screw (8) and remove the pin (9).
1 2
8
8 - Remove the cylinder (5).

Cylinder: 42 kg

RKZA1270

INSTALLATION OF THE
OUTRIGGER CYLINDERS
• To install, reverse the removal procedure.

1
Do not insert fingers into the holes to check alignment.

2
Internal bushing: ASL800050

1 - Start the engine and bleed the air from the cylinders.
(For details, see «20. TESTING AND ADJUST-
MENTS»).

★ After bleeding the air, check the oil level in the tank.

WB97R-2 30-269
REMOVAL AND INSTALLATION REMOVAL OF THE BACKHOE SWING CYLINDERS

REMOVAL OF THE BACKHOE SWING CYLINDERS

Position the backhoe with the equipment centered, the
arm vertical and the back of the bucket resting on the
ground.

1 - Stop the engine and release cylinder pressures by mov-

ing the control levers several times.

2 - Take out the screws (1) and remove vertically the upper
support (2) of the cylinder fulcrum. 1 3
3 - Disconnect the four tubes (4) from the cylinders (3) and
plug them to prevent entry of impurities.

4 - Take out the screws (5) and remove the pins (6). RKZA0970

2 3
5 - Rotate the cylinders to disengage the piston heads from
the swing bracket (7) and remove the cylinders (3).

Cylinder: 30 kg 1

INSTALLATION OF THE 2
BACKHOE SWING CYLINDERS
1
1 - Mount the cylinders (3) and the upper cylinder fulcrum
support (2). Secure the support with the four screws (1).
3
RKZA1280

1
Support screws: Loctite 262
Support screws: 981±98 Nm 4
6
2 - Connect the four tubes (4) to the cylinders.

3 - Start the engine and swing the boom in order to center

one of two pins (6). Secure the 1st pin with the screw.
Perform the same operation for the other pin. 3

2 5
When aligning the positions between the hole and the
pin, turn the engine over at low idling speed. 7
Do not insert fingers into the holes to check alignment. RKZA1290

3
Internal bushing: ASL800050

4 - Bleed the air from the cylinders. (For details, see «20.
TESTING AND ADJUSTMENTS»).

★ After bleeding the air, check the oil level in the tank.

30-270 WB97R-2
REMOVAL AND INSTALLATION REMOVAL OF BACKHOE BACKFRAME LOCK CYLINDER

REMOVAL OF BACKHOE BACKFRAME LOCK CYLINDER

★ Set the backhoe with the centered attachments with the
arm in vertical position and the bucket leaned on the
back at level ground.

RKZA0970

1 - Unlock the backframe (1).

2 - Stop the engine and release the residual hydraulic pres- 3 2

sures. (For details, see «20. TESTING AND ADJUST-
MENT»).

3 - Disconnect from cylinder (2) the pipes (3) and (4) and
plug them to avoid impurity entry.
4
4 - Remove screws (5) and cylinders (2).
1 5
1 2

RKZA1300

INSTALLATION OF BACKHOE
BACKFRAME LOCK CYLINDER
• To install, reverse the removal procedure.

1
Locking screw: Loctite 262

Locking screw: 420±40 Nm

2
Cylinder seat: ASL800050

1 - Start the engine, lock and unlock the backframe several

times to make the circuit feeling.

WB97R-2 30-271
REMOVAL AND INSTALLATION DISASSEMBLY OF CYLINDERS (Front bucket raise and tilt, boom,

DISASSEMBLY OF CYLINDERS
(Front bucket raise and tilt, boom, arm, bucket, outriggers and jig arm)
1 - Place the cylinder (1) on the tool A1.

A2
A2

A1

1
RKZA1540

For the arm cylinder with side-digging boom first extract

the snap-rings (2) and the ball-and-socket joint (3).

3 2

RKZ06310

2 - Using the specially-made wrench A4, A5, A6 unscrew

the cylinder head (4) and extract it from the cylinder (1).
1
For the side-digging boom cylinder, first remove 4
the lock-nut (5) that secures the piston-rod seal.

3 - Extract the piston-rod group (6) from the cylinder (1)

4 - Remove the cylinder (1) and the piston-rod group (6).

RKZB1460

30-272 WB97R-2
REMOVAL AND INSTALLATION DISASSEMBLY OF CYLINDERS (Front bucket raise and tilt, boom,

5 - Secure the piston-rod group (6) on the tool A1.

7
6 - For the side digging boom cylinder: remove the
snap-spin (10). BOOM OUT
RIGGER 9
7 - For the piston rod of the boom cylinder: remove the
screw (7).

8 - Use the appropriate socket wrench A7 on the piston

hexagon (11) and unscrew the piston.
★ Measurement of the socket wrench: 8
For raising the front bucket.: 55 mm
For tilting the front bucket.: 55 mm
RKZ00022
Boom: 65 mm
Arm: 55 mm
Bucket: 55 mm
Outriggers: 46 mm
Jig arm: 46 mm
Side digging boom: 46 mm
SIDE DIGGING 10
BOOM PISTON

9 - For the piston rod of the boom cylinder: Take out the
ball bearings (8) and the cushion plunger (9).

10 - Dismantle all the groups by removing all the seals, the

dust-seals, the guide rings, and the fulcrum bushings. 6
11
The seals, the dust seals and the guide rings can-
not be used again. ARM

Carefully check the pistons (11). If both safety-

caulked areas show wear, the pistons must be re-
placed.

6
11
RAISING
TILTING

6
11 RKZ00012

WB97R-2 30-273
REMOVAL AND INSTALLATION ASSEMBLY OF CYLINDERS (Front bucket raise and tilt, boom, arm,

ASSEMBLY OF CYLINDERS
(Front bucket raise and tilt, boom, arm, bucket, outriggers and jig arm)
★ Take great care not to damage the seals and the sliding
surfaces.
16 15
★ Prepare each individual component before the final as-
sembly.

1. Assembly of the cylinder head

1.1 Only for the cylinders for front bucket raise and tilt,
boom, arm, bucket, outriggers, jig arm

1 - Mount the gasket (12) in the cylinder head.

14 13 12
2 - Mount the gasket (13) in the cylinder head. RKZ00040

★ Make sure that the lips are turned towards the in-
side of the cylinder.

3 - Mount the guard ring (14) using the tool A8. 22 21 20

4 - Mount the O-ring (15) and the anti-extrusion ring (16) on
the outside of the cylinder head.
5
1.2 Cylinder for side digging boom
1 - Insert the gasket (17) in the cylinder head, and let it beat
on seat bottom, then insert the anti-extrusion ring (18).
★ Check carefully the assembly orientation.
2 - Mount the guard ring (19) in the lock-nut (5). 19 18 17 23
RKZ00050

3 - Tighten the lock nut (5) until leaning lightly on anti-ex-

trusion ring (18).

4 - Assemble on head the O-ring (20), the anti-extrusion

(21), the O-ring (22) and the ring (23).
25 26 27
26 11
24

RKZ00090

2. Re-assembling the piston

2.1 Only for the cylinders for front bucket raise and tilt, 27
boom, arm, bucket, outriggers, jig arm
28
1 - Use the tool A9 with the appropriate diameter, mount
the ring (24) the external seal (25) and the anti-extrusion
rings (26) onto the piston (11). A9
2 - Prepare the guide ring (27).
★ There are two guide rings (27) for the boom piston.
3 - For the boom piston only: insert the O-ring (28) into the
internal seating. RKZA1580

30-274 WB97R-2
REMOVAL AND INSTALLATION ASSEMBLY OF CYLINDERS (Front bucket raise and tilt, boom, arm,

4 - Gauge the diameter of the seal (25) of the piston (11)

mounting the group under a press and use the tools A3
for the piston diameter.
11

A3

RKZB1491

2.1 Side digging boom cylinder

★ This mounting should be performed directly on piston. 33 31 30 31 34

1 - Mount central ring (29), rubber ring (30) and anti-extru- 32 35
sion ring (31). 36
2 - Mount on piston first washer (32), guide ring (33), cen-
10
tral ring assembly (29), second guide ring (34) and sec-
ond washer (35).

3 - Tighten nut (36) and lock the piston group after locking
rod head under the press. (See «3. RE-ASSEMBLING 29
THE PISTON-ROD GROUP»). RKZ00060

4 - Insert the snap ring (10).

3. Re-assembling the piston-rod group

6
1 - Only for the cylinders for front bucket raise and tilt,
boom, arm, bucket and side digging boom: using a
37
press and tools A2 with the appropriate diameter, insert
the bushing (37) into the piston head (6).

A1
A2

RKZA1500

2 - Mount the bushing A10 of the correct diameter onto the

tip of the piston rod (6).
6 6
A10 4
3 - Slightly lubricate the cylinder head seals (4) and slide
the group onto the piston rod (6).

Seals: ASL800050

RKZA1510

WB97R-2 30-275
REMOVAL AND INSTALLATION ASSEMBLY OF CYLINDERS (Front bucket raise and tilt, boom, arm,

4 - For the cylinders of the outriggers only: mount

the spacer (38) with the O-ring (39). 39 38 6 A10
★ Check carefully the assembly orientation.
For the arm cylinder only: insert the spacer (40). OUTRIGGERS

40
ARM

RKZ00071

5 - Remove from the tip of the piston rod (6) the bushing
A10 and mount the piston (11) and the nut (36). 11
★ Grease the piston threading. 6 7
9
Piston locking nut: Loctite 262

Piston locking nut:

Front bucket raise: 2845±284 Nm
Front bucket tilt: 2845±284 Nm
Arm: 2845±284 Nm
Bucket: 2845±284 Nm
8
Outriggers: 1520±152 Nm
Jig arm: 1520±152 Nm RKZ00021

6 - For the boom cylinder: mount the cushion plunger (9),

slide the eleven ball-bearings (8) into the hole, and
mount the dowel bolt (7).
Dowel bolt: Loctite 262
6 11

Dowel bolt: 23±2 Nm

7 - Screw the complete piston (11) onto the piston rod (6),
and secure it with the dynamometric wrench.

Piston: 2697–3924 Nm

8 - Caulk the piston (11) to correspond to the slot in the pis-

ton rod (6) not previously used. RKZB1470

4. Re-assembling the cylinders

1 - For the boom, arm, bucket and side digging boom
cylinders only:
Position the bushing (41) and mount it in the cylinder
41
head (1) using tool A2 of the correct diameter.
★ There are two bushings for the arm cylinder, with a 1
spacer between them.
★ Leave the cylinder in position for subsequent as- A2
sembly.

RKZ06320

30-276 WB97R-2
REMOVAL AND INSTALLATION ASSEMBLY OF CYLINDERS (Front bucket raise and tilt, boom, arm,

2 - Lubricate the threading and the first part of the cylinder

(1).
1 A11
Cylinder: ASL800050

3 - Mount the two halves of the tool A11 with the appropri-
ate diameter at the mouth of the cylinder (1).

RKZA1520

4 - Mount the piston rod group (6) and the cylinder (1) on
the apparatus A1.
1 A11
5 - Guide the piston and center it in the tool A11. A1 4 6
6 - Mount the first guide ring (27) onto the piston and insert
part of the piston into the tool A11.
For the boom cylinder only: mount the second guide
ring (27) and fully insert the piston.

Insert the piston slowly in order to calibrate the

guide rings (27) without overheating them.

7 - Take the cylinder out of the tool A11 and bring the cyl- RKZB1480

inder head (4) and the piston rod head closer to the cyl-
inder.

8 - Bring the cylinder (1) into position for screwing in the cyl-
inder head (4).

9 - Insert the cylinder head into the cylinder and screw it in

by hand for several turns.

10 - Use the right special wrench A4, A5, A6 to screw the

cylinder head (4) home.

Cylinder head: 932–980 Nm

11 - For the side digging boom cylinders only: tighten the

lock-nut (5).

Lock-nut: 490 Nm

RKZ00080

WB97R-2 30-277
REMOVAL AND INSTALLATION DISASSEMBLY OF BOOM SWING CYLINDER

DISASSEMBLY OF BOOM SWING CYLINDER

9
5 1

2
6

4
7 8
RKZ00100

1 - Place the cylinder (1) on the apparatus A1. Engage the

fulcrum pins in the suitable support.

2 - Using the specially-designed wrench A6, unscrew the

cylinder head (2) and extract it completely from the cyl-
inder (1).

3 - Remove brake cylinder (3).

4 - Attach the piston head to the mobile group of the ap-

paratus A1.

5 - Extract the piston rod group (4) from the cylinder.

6 - Remove the cylinder and the piston rod group.

7 - Secure the complete piston rod (4) to the apparatus A1.

8 - Raise the part caulked for safety purposes and unscrew

the piston using the tool A7.
Check the piston (5) carefully. If both safety-caulked ar-
eas have been used, the piston must be replaced.

9 - Remove the snap-ring (6) from the piston and extract

the ring (7) and the spacer ring (8).
★ Make a note of the order of assembly of the ring (7).
10 - Using a puller remove the swing bushings (9) from the
cylinder axle oscillation pins.

11 - Dismantle the groups by removing all the seals, the

guard rings, the guide rings and the piston fulcrum
bushing.

The seals, guard rings and guide rings must not be

used again.

30-278 WB97R-2
REMOVAL AND INSTALLATION ASSEMBLY OF BOOM SWING CYLINDER

ASSEMBLY OF BOOM SWING CYLINDER

★ Take great care not to damage the seals and the sliding
surfaces. 13 14 2 15
★ Prepare each individual component before the final as-
sembly.

1. Assembly of the cylinder head

1 - Mount the gasket (10) and the gasket (11) in the cylinder
head (2).
★ Make sure that the gasket lips (11) are turned to-
wards the inside of the cylinder.

2 - Mount the scraper ring (12).

10 11 12
RKZ00110

3 - Mount the O-ring (13), the anti-extrusion ring (14) and

lastly the O-ring (15) of the front seal.

2. Re-assembling the piston

1 - Use the tool A9 with the appropriate diameter, mount

19 18 17 18 19
the rubber ring (16) and the seal ring (17) onto the pis-
ton. Remove the tool A9 and mount the anti-extrusion
rings (18).

2 - Prepare the guide rings (19). 16

3 - Mount the O-ring (20) in the internal seating of the pis- A9
ton. 20

RKZA1600

4 - Gauge the diameter of the seal (16) of the piston mount-

ing the group under a press and use the tools A3 for the
piston diameter.

A3

RKZB1490

WB97R-2 30-279
REMOVAL AND INSTALLATION ASSEMBLY OF BOOM SWING CYLINDER

3. Re-assembling the piston rod group

1 - Using a press and tools A2 with the appropriate diam-
eter, insert the bushing (21) into the piston head (4). 3
A10
2 - Insert the ring (8) into the piston rod (4).
★ Check carefully the direction of assembly of the ring (8).
21
3 - Insert the spacer ring (7) and secure the group with the
snap-ring (6).
4 - Mount the bushing A10 of appropriate diameter on the A2
tip of the piston rod (4).
5 - Lightly lubricate the cylinder head gaskets (2) and slide
the group onto the piston rod (4). RKZA1590

Gaskets: ASL800050
6 - Lubricate the O-ring seals (22) and screw the piston (5)
onto the piston rod (4) by hand for several turns. 5 22 4
O-ring seal: ASL800050
7 - Position the group on the tool A1 and tighten the piston
with the round prong wrench A7. 7
Piston: 932–980 Nm
6
4. Re-assembling cylinders
1 - Place the cylinder (1) on the apparatus A1. Engage the
fulcrum pins in the suitable support. 8
RKZ00120
2 - Lubricate the threading and the first part of the cylinder
(1).
Cylinder: ASL800050
3 - Mount the two halves of the tool A11 with the appropri-
ate diameter at the mouth of the cylinder (1).
4 - Mount the piston rod group on the apparatus A1.
5 - Center the piston (5) in the tool A11.
6 - Wind the first guide ring (19) round the piston and insert
part of the piston into the tool A11. Wind the second
guide ring (19) and fully insert the piston.
Insert the piston slowly in order to calibrate the guide
rings (19) without overheating them.
7 - Insert the cylinder head (2) and screw it in by hand for
several turns.
8 - Use the special wrench A6 to screw the cylinder head
home.
Cylinder head: 932–980 Nm
9 - Screw the brake cylinder (3) into the cylinder (1).
Brake cylinder: Loctite 270
Brake cylinder: 804 Nm
10 - Remove the cylinder from the equipment A1.
11 - Using a press and the appropriate tool A2, mount the
swing bushings (9).

30-280 WB97R-2
REMOVAL AND INSTALLATION DISASSEMBLY OF BACKHOE BACKFRAME LOCK CYLINDER

DISASSEMBLY OF BACKHOE BACKFRAME LOCK CYLINDER

1 - Plug one of the two cylinder (1) ports.

2 - Connect to the other port compressed air (max. 3 bar). 3 2

1
3 - Slowly insert pressure up to piston (2) comes out.
★ Retain piston and protect from oil using gloves and
a protection.

4 - Remove gasket (3).

The gasket has be replaced.

RKZ00190

ASSEMBLY OF BACKHOE
BACKFRAME LOCK CYLINDER
1 - Use the tool with the appropriate diameter, mount the
seal ring (3) onto the piston (2).
★ Make sure that the lips are turned towards the in-
side of the cylinder.

2 - Put the piston (2) onto cylinder (1).

Internal Cylinder: ASL800050

3 - Apply an elastic band, tighten gasket (3) and using a

press insert the piston at the end of stroke.

WB97R-2 30-281
REMOVAL AND INSTALLATION REMOVAL OF THE BOOM SAFETY CYLINDER

REMOVAL OF THE BOOM SAFETY CYLINDER

Center the backhoe with the arm vertical and the back of
the bucket on the ground.

RKZA0970

1 - Make sure that the safety stop (1) is raised.

2 - Stop the engine and release the residual hydraulic pres-

sures. 1
3 - Take out the cotter pins (2) and remove the pin (3).
1 2

2 3

RKZB6940

4 - Disconnect the tube (4) that feeds the cylinder (5). Plug
the tube to prevent entry of impurities.

5 - Take out the snap ring (6) and remove the cylinder (5). 6
1
5

RKZB6950

INSTALLATION OF THE BOOM

SAFETY CYLINDER
• To install, reverse the removal procedure.

1
Pin seatings: ASL800050

2
★ Install new cotter pins.

1 - Start the engine and perform several lock and release

manoeuvres to fill up and bleed air from the unit.

30-282 WB97R-2
REMOVAL AND INSTALLATION REMOVAL OF THE BACKHOE WORKING EQUIPMENT

REMOVAL OF THE BACKHOE WORKING EQUIPMENT

Fully extend the arm and open the bucket completely.
Lower the equipment until it is resting on the ground.
1
1 - Stop the engine and release the residual hydraulic pres-
sures. (For details, see «20. TESTING AND ADJUST- 2
MENTS»).
2 - Remove the boom cylinder. (For details, see «REMOV-
AL OF BOOM CYLINDER»).
3 - Take out the bracket (2) mounted inside the boom. Dis-
connect the tubes (1) from the arm cylinders.
★ Plug all tubes to prevent entry of impurities.
★ Mark the tubes to prevent exchanging positions
during re-connection. RKZA9900

4 - Remove bracket (3).

★ Mark the tubes to prevent exchanging positions
during re-connection.
5 - Put a sling round the equipment (4) and apply slight ten-
sion to the cables. 3
6 - Take out the snap-rings and remove the pin (5).
1 2
7 - Remove the working equipment (4).
3
Standard work equipment: 850 kg
★ While remove the equipment, extract the control RKZA9870

hoses and take care to not stress them.

INSTALLATION OF THE BACK-

HOE
WORKING EQUIPMENT
• To install, reverse the removal procedure. 4

1
When aligning the positions between the hole and the
pin, turn the engine over at low idling speed. 5
Do not insert fingers into the holes to check alignment.
RKZA1331

2
Internal bushing: ASL800050

3
★ Pass the tubes of the cylinders inside the brackets (6).

1 - Start the engine and bleed the air from the cylinders.
(For details, see «20. TESTING AND ADJUST-
MENTS»).
6
★ After bleeding the air, check the oil level in the tank.

RKZA1342

WB97R-2 30-283
REMOVAL AND INSTALLATION REMOVAL OF THE BACKHOE BUCKET

REMOVAL OF THE BACKHOE BUCKET

Place the bucket on a level surface, resting on its back.
7
1 - Take out the safety pin (1) and remove the connecting 4
pin (2) between bucket (3) and tie-rods (4).
6
1 2 2
2 - Take out the safety pin (5) and remove the pin (6) that at- 5
taches the bucket to the arm (7).
1 2 1
3

RKZA1350

INSTALLATION OF THE BACK-

HOE BUCKET
• To install, reverse the removal procedure.

1
When aligning the positions between the hole and the
pin, turn the engine over at low idling speed.
Do not insert fingers into the holes to check alignment.

2
Internal bushing: ASL800050

30-284 WB97R-2
REMOVAL AND INSTALLATION REMOVAL OF THE ARM

REMOVAL OF THE ARM

1 - Remove the bucket.
(For details, see «REMOVAL OF BUCKET»).
4

2 - Remove the bucket cylinder and the lever (1).

(For details, see «REMOVAL OF THE BUCKET CYL-
INDER»). 1
3
3 - Take off the lock-nut (2), and the washer, and remove
the pin (3) and the levers (4). 1 2
4 - Start the engine, bring the arm into a vertical position 2
and lower it to the ground.

5 - Stop the engine and release residual pressures from RKZA1360

the cylinder.

6 - Put a sling around the arm cylinder (5), remove the

screws (6) and remove the pin (7). 2 3
7 - Start the engine and retract the piston completely (8).
8 5
★ Secure the fully retracted position by binding the
piston head with wire.

8 - Rest the cylinder (5) on a block “A”.

9 - Stop the engine.

10 - Attach the arm (9) to the hoisting tackle and apply a

slight tension to the cable.
RKZA1201

11 - Take out the screws and remove the pin (10).

1 2 6
7
12 - Remove the arm (9).

Arm: 213 kg

INSTALLATION OF THE ARM

• To install, reverse the removal procedure.

1
RKZA1370
When aligning the positions between the hole and the
pin, do not insert fingers into the holes to check align-
ment.

2
Internal bushing: ASL800050
9
10
★ Tighten the locknut completely, then release it half a
turn. A

3
When aligning the positions between the hole and the
pin, turn the engine over at low idling speed
Do not insert fingers into the holes to check alignment.
RKZA1380

WB97R-2 30-285
REMOVAL AND INSTALLATION REMOVAL OF COMPLETE JIG ARM

REMOVAL OF COMPLETE JIG ARM

1 - Remove the bucket.
(For details, see «REMOVAL OF BUCKET»).
4

2 - Remove the bucket cylinder and the link (1).

(For details, see REMOVAL OF BUCKET CYLIN-
DER»). 1
3
3 - Take out the lock nut (2) and the washer, and remove
the pin (3) and the cylinder link (4). 1 2
2

RKZA1360

4 - Disconnect the jig arm hoses (5) and (6), the bucket cyl-
inder hoses (7) and (8), and the hoses of the auxiliary
equipment (9) and (10).
★ Mark the hoses to avoid exchanging them during
11
INSTALLATION. 6
5 - Remove the clamp (11).

6 - Proceed with the removal as for the arm. 10

7
(See «REMOVAL OF THE ARM»).

Jig arm cylinder: 392 kg 9 8

5
RKZA7970

INSTALLATION OF THE
COMPLETE JIG ARM
• To install reverse the removal procedure.

1
When aligning positions between hole and pin, do not
insert fingers into the holes to check on alignment.

2
Internal bushings: ASL800050

★ Tighten the locknut completely, then release it half a

turn.

30-286 WB97R-2
REMOVAL AND INSTALLATION REMOVAL OF 2nd ARM

REMOVAL OF 2nd ARM

1 - Remove the bucket (1).
(For details, see «REMOVAL OF BUCKET»).

2 - Remove the bucket cylinder (2) and the link (3).

(For details, see «REMOVAL OF THE BUCKET CYL-
1 2
INDER»).
3
3 - Remove the 2nd arm cylinder.
(For details, see «REMOVAL OF THE 2nd ARM CYL-
INDER»).
★ For safety, tightly plug all the disconnected hoses.
7
RKZA7980

4 - Take out the lock nut (4), and the washer and remove
the pin (5) and the links (6). 1 2 3 6
5 - Connect the 2nd arm (7) to some hoisting tackle.
★ Use the bucket pin hole and the safety pin holes.
5
6 - Start the engine and, maintaining constant tension on 3
the section of cable or chain connected to the bucket
coupling, slowly raise the boom until both sections of ca-
4
ble or chain are under slight tension.

7 - Stop the engine and loosen by several turns the gib ad-
justment screws.
RKZA7990
★ Loosen the screws on both sides.

8 - Slide out the 2nd arm (7).

2nd arm: 160 kg

INSTALLATION OF 2nd ARM

• To install, reverse the removal procedure.

1
RKZA8000

When aligning the positions between hole and pin, do

not insert fingers into the holes to check on alignment.

2
Internal bushings: ASL800050

3
★ Tighten the locknut completely, then release it half a
turn.

WB97R-2 30-287
REMOVAL AND INSTALLATION REMOVAL OF 2nd ARM GUIDES

REMOVAL OF 2nd ARM GUIDES

1 - Remove the bucket (1).
(For details, see «REMOVAL OF BUCKET»). 2
1
2 - Partially extend the 2nd arm (1).

3 - Rest the arm (2) on a trestle “A” about 80 cm (3.5 ft.)

high.

RKZA8010

4 - Loosen and remove the screws (3), the spring washers

and remove the upper guides (4). 1
5 - Connect the 2nd arm (1) to some hoisting tackle.
★ Use the bucket pin hole and the safety pin holes.
6 - Slowly raise the 2nd arm (1) until it rests on the sup- 3
porting surfaces of the upper guides.

5 6

RKZA8020

7 - Loosen the nuts (5) and remove the adjustment dowel

bolts (6). 3

8 - Raise the lower guides (7) and slide them out. 1

4

6
7
RKZ02390

INSTALLATION OF 2nd ARM

2
GUIDE 1
• To install, reverse the removal procedure.

1
Guides and 2nd arm guides: ASL800040

1 - Adjust the clearances, keeping the jig arm (1) aligned

with respect to the 2nd arm (2). (For details, see «20.
TESTS AND ADJUSTMENTS»).

RKZA8030

30-288 WB97R-2
REMOVAL AND INSTALLATION REMOVAL OF THE BACKHOE BOOM

REMOVAL OF THE BACKHOE BOOM

1 - Remove the arm.
(For details, see «REMOVAL OF THE ARM»).

2 - Remove the arm cylinder.

(For details, see «REMOVAL OF THE ARM CYLIN-
1
DER»).

3 - Start the engine and rest the boom on the ground. 2

4 - Remove the boom cylinder.

(For details, see «REMOVAL OF THE BOOM CYLIN-
DER»).

5 - Take out the bracket (1) and disconnect the tubes (2) RKZA9871

from the arm cylinders and the bucket. Plug all tubes to
prevent entry of impurities.
★ Mark the tubes to prevent exchanging positions
during re-connection.

6 - Put a sling round the boom (3).

7 - Take out the snap-rings and remove the pin (4).

3
1 2
8 - Remove the boom (3). 3 4
Boom: 323 kg

RKZA9880

INSTALLATION OF THE BACK-

HOE BOOM
• To install, reverse the removal procedure.

1
When aligning the positions between the hole and the
pin, turn the engine over at low idling speed.
Do not insert fingers into the holes to check alignment.
5

2
Internal bushing: ASL800050
RKZA1340

3
★ Pass the cylinder tubes inside the brackets (5).

1 - Start the engine and bleed the air from the cylinders.
(For details, see «20. TESTING AND ADJUST-
MENTS»).

★ After bleeding the air, check the oil level in the tank.

WB97R-2 30-289
REMOVAL AND INSTALLATION REMOVAL OF THE BACKHOE SWING BRACKET

REMOVAL OF THE BACKHOE SWING BRACKET

1 - Remove the working equipment.
(For details, see «REMOVAL OF THE WORKING
EQUIPMENT»). 2
2 - Take out the screws (1) and remove the pins (2) that
connect the swing cylinders (3). 1 2
3 - Remove boom safety cylinder (4). 3
(For details, see «REMOVAL OF BOOM SAFETY CYL-
INDER»). 1

RKZA7760

4 - Remove snap ring (5), pin (6) and link (7). 3

5 - Put a sling round the swing bracket (8). 8
5
6 - Take out the screws (9) and (10) and remove the swing
bracket axle oscillation pins (11) and (12). 7
1 2 4
7 - Remove the swing bracket (8) and the relative shim ad-
justments to given clearance.
4 6
Bracket: 133 kg
RKZB6951

INSTALLATION OF THE
BACKHOE SWING BRACKET 10
12
• To install, reverse the removal procedure. 9
1
When aligning the positions between the hole and the
pin, turn the engine over at low idling speed.
13
Do not insert fingers into the holes to check alignment.
11
2
Internal bushing: ASL800050
RKZA1410

3
Pin: ASL800050

4
13
★ Insert the shims.

1 - Start the engine and bleed the air from the cylinders.
(For details, see «20. TESTING AND ADJUST-
MENTS»).

★ After bleeding the air, check the oil level in the tank. 13

13
RKZ01330

30-290 WB97R-2
REMOVAL AND INSTALLATION REMOVAL OF BACKHOE BACKFRAME

REMOVAL OF BACKHOE BACKFRAME

1 - Remove the equipment.
(For details, see «REMOVAL OF BACKHOE WORK- 5 6
ING EQUIPMENT»).

2 - Remove the swing cylinders. 1 2

(For detail see «REMOVAL OF SWING CYLINDER»).

3 - Remove the swing bracket.

(For detail see «REMOVAL OF SWING BRACKET»).

4 - Disconnect from union (1) the feeding pipes (2) of back-

hoe backframe and plug them to avoid impurity entry.

RKZA1430

5 - Loose nuts (4) and remove washers (5) and four screw
(6).
7 4 5
Loose partially lateral nuts (4) to remove backframe (3) 8
from frame (8). 1
6 - Put a sling round the backframe (3) and apply slight ten-
sion to the cables.

7 - Remove external nuts (4), washers (5) and screws (6).

1
3
RKZA1440

8 - Remove the sliding piece (7) and then lower the back
frame (3) and remove it.

Backframe: 237 kg
3

INSTALLATION OF
BACKHOE BACKFRAME
• To install, reverse the removal procedure.

1
RKZA1660
Nuts: Loctite 262

Nuts: 980±98 Nm

1 - Start the engine and bleed the air from the cylinders.
(For details, see «20. TESTING AND ADJUST-
MENTS»).

★ After bleeding the air, check the oil level in the tank.

WB97R-2 30-291
PAGE INTENTIONALLY
LEFT BLANK
 STANDARD MAINTENANCE

TRANSMISSION ....................................................... 2 8-SPOOL CONTROL VALVE

FRONT AXLE ............................................................ 5 (WITH SERVOCONTROL).......................................32
REAR AXLE .............................................................. 8 BRAKE PUMP..........................................................34
HYDRAULIC PUMP ................................................ 12 SHOVEL CYLINDERS .............................................35
2-SPOOL CONTROL VALVE .................................. 14 BACKHOE CYLINDERS ..........................................36
3-SPOOL CONTROL VALVE .................................. 16 FRONT WORKING EQUIPMENT ............................40
3-SPOOL CONTROL VALVE (With Return to Dig) . 18 SWING BRACKET ...................................................42
6-SPOOL CONTROL VALVE (STANDARD)........... 20 BACKHOE WORKING EQUIPMENT.......................44
7-SPOOL CONTROL VALVE (STANDARD)........... 23
8-SPOOL CONTROL VALVE (STANDARD)........... 25
6-SPOOL CONTROL VALVE
(WITH SERVOCONTROL) ...................................... 27
7-SPOOL CONTROL VALVE
(WITH SERVOCONTROL) ...................................... 30

WB97R-2 40-1
STANDARD MAINTENANCE TRANSMISSION

TRANSMISSION

C
B A
C L

D D

F F

E
A

........... Nm

23±1 Nm H H

RKZ03043

40-2 WB97R-2
STANDARD MAINTENANCE TRANSMISSION

50±2.5 Nm

23±1 Nm

50±2.5 Nm
23±1 Nm

50±2.5 Nm

Loctite 510

139±7 Nm

50±2.5 Nm

139±7 Nm

Loctite 510

Loctite 510
RKZ03053
Section A-A
Sezione A - A

WB97R-2 40-3
STANDARD MAINTENANCE TRANSMISSION

50±2.5 Nm 25±1 Nm

23±1 Nm

Section C - C
Sezione C - C
Section B-B
Sezione B - B

25±1 Nm ✽ For EGM version (optional)

25±1 Nm Section D - D
Sezione D - D

80±4 Nm
Section
Sezione E
E -- E
E
RZ03110

23±1 Nm

80±4 Nm

Section
Sezione G
G -- G
G
Section
Sezione F
F -- F
F

26–30 Nm

50±2.5 Nm

25±1 Nm
Section 26–30 Nm
Sezione H
H -- H
H

40±2 Nm
Detail L
Particolare L
RZ03120

40-4 WB97R-2
STANDARD MAINTENANCE FRONT AXLE

FRONT AXLE
Differential

95±5 Nm
with Loctite 270 13 Nm

266±13 Nm
1

60±3 Nm

Loctite 510
169±8.5 Nm
Loctite 638
Loctite 270
2
92 – 137 Nm

3
56 Nm 4

RKZ00811

Unit: mm

N° Check item Criteria Remedy

Standard clearance Clearance limit

1 Axle clearance
---- ----
Backlash of crown wheel
2 and pinion 0.17 – 0.23 0.23
Adjust
Pinion preload
3 92 – 137 Nm
(without seal ring)
Pinion-crown wheel preload
4 (without seal ring) 95.9 – 142.9

WB97R-2 40-5
STANDARD MAINTENANCE FRONT AXLE

Planetary - Joint

Loctite 510 190±9.5 Nm

80 Nm 1
8 Nm

230±11.5 Nm

70 Nm 8 Nm
with Loctite 270

70 Nm
with Loctite 270
RKZ00821

Unit: mm

N° Check item Criteria Remedy

1 Hub rotation torque ---- Adjust

2 Drive shaft axle clearance ---- Replace

40-6 WB97R-2
STANDARD MAINTENANCE FRONT AXLE

Steering unit cylinder

120±6 Nm
B

350±9.8 Nm
C
300±15 Nm

A
500

A
250±12.5 Nm

+
1984 +02

220±11 Nm 150±7.5 Nm
Section
Sezione A
A -- A
A Section
Sezione B
B -- B
B Detail C
Particolare C
RKZ00842

Unit: mm

N° Check item Criteria Remedy

Tolerance
Standard Standard Clearance
size clearance limit Replace
Clearance between Shaft Hole
1 bushing and pin bushing
and pin
50 ---- 50.19+0 0.04 ---- ----

WB97R-2 40-7
STANDARD MAINTENANCE REAR AXLE

REAR AXLE
Differential

13 Nm
155 Nm
with Loctite 270

79 Nm 1
176 Nm
2
Loctite 542

3
4

RKZ04971

Unit: mm

N° Check item Criteria Remedy

Standard clearance Clearance limit

1 Axle clearance
---- ----
Backlash of crown wheel
2 and pinion 0.17 – 0.23 0.23
Adjust
Pinion preload
3 (without seal ring)
92 – 138 Nm

Pinion-crown wheel preload

4 95.23 – 141.84 Nm
(without seal ring)

40-8 WB97R-2
STANDARD MAINTENANCE REAR AXLE

Planetary

500 Nm 70 Nm
with Loctite 270

79 Nm

230 Nm

60 Nm

25 Nm

RKZ04981

Unit: mm

N° Check item Criteria Remedy

1 Hub rotation torque ---- Adjust

2 Drive shaft axle clearance ---- Replace

WB97R-2 40-9
STANDARD MAINTENANCE REAR AXLE

Brakes

A
10 Nm

1
35 Nm 3
8 – 12 Nm

10 Nm
25 Nm
15 Nm
2

Detail B B
Particolare

10 Nm
Section A -- AA
Sezione A RKZ04991

Unit: mm

N° Check item Criteria Remedy

Standard size Repair limit

Installed
Free Installed Installed Free load
1 Brake disc return spring installed length load installed Replace if
on screw damaged or
deformed
27 13 127 Nm 21 10 Nm
2 Disc return spring 35 19 369 Nm 21 10 Nm
Standard thickness Min. thickness
3 Disc thickness Replace
5 --0 0.15 3.3

40-10 WB97R-2
STANDARD MAINTENANCE REAR AXLE

Differential lock

27 Nm 27 Nm

RKZ05001

WB97R-2 40-11
STANDARD MAINTENANCE HYDRAULIC PUMP

HYDRAULIC PUMP

1 5 2

A
3

Detail A A
Particolare RKZ01290

Unit: mm

N° Check item Criteria Remedy

1 Ball-bearing loading 0 – 0.05 Adjust

Tolerance
Standard Standard Clearance
Backlash between piston size clearance limit
2 Shaft Hole
and cylinder
20 ---- 0.065
Backlash between piston
3 and shoe 0.15

Standard value Max. value

4 Drive shaft diameter
34.91
Standard size Repair limit

Free
Installed Installed Free Installed
5 Spring installed length load load
installed
x Øe
---- 88.7 276±12 N

40-12 WB97R-2
STANDARD MAINTENANCE HYDRAULIC PUMP

1 2 3

60 Nm 21 Nm
.25 Nm
Section
SezioneCC- -CC

12 Nm 4 5 35 Nm 21 Nm

12 Nm
6 7 35 Nm 21 Nm

Section
Sezione D
D -- D
D RKZ00643

Unit: mm

N° Check item Criteria Remedy

Standard size Repair limit
Free
Installed Installed Free Installed
1 Spring installed length load installed load
x Øe
---- ---- ---- ---- ----
Power regulation spring
2 125.4±10 N
(external)
Power regulation spring
3 180.2±12.5
(internal)
4 PC valve spring (external) 40.2±2.8
5 PC valve spring (internal) 81.7±14.5
6 LS valve spring (external) 81.7±14.5
7 LS valve spring (internal) 40.2±2.8

WB97R-2 40-13
STANDARD MAINTENANCE 2-SPOOL CONTROL VALVE

2-SPOOL CONTROL VALVE

D C A
27±2 Nm
............ Nm

............ Nm

D C A

25 Nm 20 Nm
20 Nm
B with Loctite 542

8 Nm
with Loctite 542 1

25 Nm
with Loctite 542
2
B

25 Nm
Section
Sezione A
A -- A Section
A Sezione B
B -- B
B RKZ01081

Unit: mm

N° Check item Criteria Remedy

Standard size Repair limit
Free
Installed Installed Free Installed
1 Check valve spring installed x installed load
length load
Øe

2 Priority valve spring

40-14 WB97R-2
STANDARD MAINTENANCE 2-SPOOL CONTROL VALVE

10±1 Nm 10±1 Nm 10±1 Nm

E
E 70±7 Nm
70±7 Nm

............ Nm

............ Nm

E
1 10±1 Nm 1 10±1 Nm
E
Section
Sezione C
C -- C
C
Section
Sezione D
D -- D
D

30±3 Nm 2

Section
Sezione E
E -- E
E RKZ00661

Unit: mm

N° Check item Criteria Remedy

Standard size Repair limit
Free
Installed Installed Free Installed
1 Spool return spring installed x length load installed load
Øe

2 Check valve spring

WB97R-2 40-15
STANDARD MAINTENANCE 3-SPOOL CONTROL VALVE

3-SPOOL CONTROL VALVE

D C A
............ Nm 27±2 Nm

............ Nm

D C A
E
25 Nm 20 Nm
20 Nm with Loctite 542
B

8 Nm
with Loctite 542
1
25 Nm
with Loctite 542

2
B 100 Nm
Section
Sezione A
A -- A
A Section
SezioneBB -- B
B RKZ01071

Unit: mm

N° Check item Criteria Remedy

Standard size Repair limit
Free
Installed Installed Free Installed
1 Spool return spring installed x length load Installed load
Øe

2 Check valve spring

40-16 WB97R-2
STANDARD MAINTENANCE 3-SPOOL CONTROL VALVE

70±7 Nm 10±1 Nm
F F 10±1 Nm
70±7 Nm

............ Nm

1 70±7 Nm
............ Nm
2
F
70±7 Nm

F
F 10±1 Nm
............ Nm Section C -- CC
Sezione C 3
Section
Sezione D
D -- D
D
10±1 Nm

70±7 Nm

30±3 Nm 4

4
............ Nm

70±7 Nm Section
SezioneFF--FF

F
Section E -- EE
Sezione E RKZ01300
Unit: mm
N° Check item Criteria Remedy
Standard size Repair limit
Free
Installed Installed Free Installed
1 Spool return spring installed x length load installed load
Øe

2 Spool locking spring

3 Spool return spring
4 Check valve spring

WB97R-2 40-17
STANDARD MAINTENANCE 3-SPOOL CONTROL VALVE (With Return to Dig)

3-SPOOL CONTROL VALVE (With Return to Dig)

D C A

27±2 Nm

............ Nm

............ Nm

C A

E D
25 Nm 20 Nm
20 Nm
B with Loctite 542

8 Nm
with Loctite 542
1
25 Nm
with Loctite 542

2
B
100 Nm
Section
Sezione A
A -- A
A Section
Sezione B
B -- B
B RKZ01091

Unit: mm

N° Check item Criteria Remedy

Standard size Repair limit
Free
Installed Installed Free Installed
1 Check valve spring installed x length load installed load
Øe

2 Spool return spring

40-18 WB97R-2
STANDARD MAINTENANCE 3-SPOOL CONTROL VALVE (With Return to Dig)

10±1 Nm 10±1 Nm F 10±1 Nm

F
70±7 Nm 70±7 Nm

............ Nm

1 3
............ Nm

2
70±7 Nm
70±7 Nm
F
F
............ Nm
............ Nm Section
Sezione C
C -- C
C
F
10±1 Nm

Section
Sezione D
D -- D
D
70±7 Nm

30±3 Nm
4

............ Nm 4

70±7 Nm
Section
Sezione FF -- F
F

F
Section
SezioneEE -- E
E
RKZ00941

Unit: mm
N° Check item Criteria Remedy
Standard size Repair limit
Free
Installed Installed Free Installed
1 Spool return spring installed x length load installed load
Øe

2 Spool locking spring

3 Spool return spring
4 Check valve spring

WB97R-2 40-19
STANDARD MAINTENANCE 6-SPOOL CONTROL VALVE (STANDARD)

6-SPOOL CONTROL VALVE (STANDARD)

G E B D D C B A
H 27±2 Nm

H
G E B D D C B A

G 10±1 Nm
70±7 Nm
70 Nm 45 Nm

20 Nm
with Loctite 542

............ Nm

70 Nm
Section
Sezione A
A -- A
A 70±7 Nm
10±1 Nm
1 G
Section
Sezione B
B -- B
B RKZ00231

Unit: mm

N° Check item Criteria Remedy

Standard size Repair limit
Free
Installed Installed Free Installed
1 Spool return spring installed x length load installed load
Øe

40-20 WB97R-2
STANDARD MAINTENANCE 6-SPOOL CONTROL VALVE (STANDARD)

F 10±1 Nm 10±1 Nm F 10±1 Nm

70±7 Nm
70±7 Nm

............ Nm

70±7 Nm 70±7 Nm
F 1
1 10±1 Nm
F
Section
Sezione D
D -- D
D
Section
Sezione C
C -- C
C

10±1 Nm F 10±1 Nm

70±7 Nm

2
30±3 Nm

10±1 Nm Section
Sezione FF -- F
F
70±7 Nm F 1
Section
Sezione E
E -- E
E
RKZ01310

Unit: mm

N° Check item Criteria Remedy

Standard size Repair limit
Free
Installed Installed Free Installed
1 Spool return spring installed length load installed load
x Øe

2 Check valve spring

WB97R-2 40-21
STANDARD MAINTENANCE 6-SPOOL CONTROL VALVE (STANDARD)

25 Nm

10 Nm

20 Nm 20 Nm
Section
Sezione G
G -- G
G
Section
SezioneHH -- H
H RKZ00791

Unit: mm

N° Check item Criteria Remedy

Standard size Repair limit
Free
Installed Installed Free Installed
1 Unloading valve spring installed x length load installed load
Øe

40-22 WB97R-2
STANDARD MAINTENANCE 7-SPOOL CONTROL VALVE (STANDARD)

7-SPOOL CONTROL VALVE (STANDARD)

For jig arm
A

A
RKZ00241

For side digging boom

B RKZ00251

For hammer
C

C
RKZ00261

WB97R-2 40-23
STANDARD MAINTENANCE 7-SPOOL CONTROL VALVE (STANDARD)

10±1 Nm 10±1 Nm

70±7 Nm 70±7 Nm

............ Nm ............ Nm

70±7 Nm
10±1 Nm
1 70±7 Nm 10±1 Nm
10±1 Nm 1
Section
Sezione A
A -- A
A Section
Sezione B
B -- B
B

10±1 Nm

70±7 Nm

............ Nm

............ Nm

70±7 Nm 10±1 Nm
1
Section
Sezione C
C -- C
C RKZ00961

Unit: mm

N° Check item Criteria Remedy

Standard size Repair limit
Free
Installed Installed Free Installed
1 Spool return spring installed x length load installed load
Øe

40-24 WB97R-2
STANDARD MAINTENANCE 8-SPOOL CONTROL VALVE (STANDARD)

8-SPOOL CONTROL VALVE (STANDARD)

For hammer and jig arm

C A

C A
RKZ00272

For side digging boom and jig arm

B A

B A RKZ00282

WB97R-2 40-25
STANDARD MAINTENANCE 8-SPOOL CONTROL VALVE (STANDARD)

10±1 Nm 10±1 Nm

70±7 Nm 70±7 Nm

............ Nm ............ Nm

70±7 Nm
10±1 Nm
1 70±7 Nm 10±1 Nm
10±1 Nm 1
Section
Sezione A
A -- A
A Section
Sezione B
B -- B
B

10±1 Nm

70±7 Nm

............ Nm

............ Nm

70±7 Nm 10±1 Nm
1
Section
Sezione C
C -- C
C RKZ00961

Unit: mm

N° Check item Criteria Remedy

Standard size Repair limit
Free
Installed Installed Free Installed
1 Spool return spring installed x length load installed load
Øe

40-26 WB97R-2
STANDARD MAINTENANCE 6-SPOOL CONTROL VALVE (WITH SERVOCONTROL)

6-SPOOL CONTROL VALVE (WITH SERVOCONTROL)

G E B D D C B A
H
27±2 Nm

H
G E B D D C B A

RKZ07701

G
1
45 Nm 10 Nm
70 Nm 70±7 Nm

20 Nm
con Loctite 542

............ Nm

70 Nm
Section 70±7 Nm
Sezione A
A -- A
A
1
G
RKZ08000
Section
Sezione B
B -- B
B
Unit: mm

N° Check item Criteria Remedy

Standard size Repair limit
Free
Installed Installed Free Installed
1 Spool return spring installed x length load installed load
Øe

WB97R-2 40-27
STANDARD MAINTENANCE 6-SPOOL CONTROL VALVE (WITH SERVOCONTROL)

F 10 Nm F
70±7 Nm
1
70±7 Nm 10 Nm

............ Nm

70±7 Nm 70±7 Nm

10±1 Nm 1
1 F F
Section
Sezione D
D -- D
D
Section C
Sezione C -- C
C

1
70±7 Nm 10 Nm

2
............ Nm
30±3 Nm

70±7 Nm
1 Section
SezioneFF -- FF

Section RKZ01310
Sezione E
E -- E
E

Unit: mm

N° Check item Criteria Remedy

Standard size Repair limit
Free
Installed Installed Free Installed
1 Spool return spring installed length load installed load
x Øe

2 Check valve spring

40-28 WB97R-2
STANDARD MAINTENANCE 6-SPOOL CONTROL VALVE (WITH SERVOCONTROL)

25 Nm

10 Nm

20 Nm 20 Nm
Section
Sezione G
G -- G
G
Section
SezioneHH -- H
H RKZ00791

Unit: mm

N° Check item Criteria Remedy

Standard size Repair limit
Free
Installed Installed Free Installed
1 Unloading valve spring installed x length load installed load
Øe

WB97R-2 40-29
STANDARD MAINTENANCE 7-SPOOL CONTROL VALVE (WITH SERVOCONTROL)

7-SPOOL CONTROL VALVE (WITH SERVOCONTROL)

For jig arm
A

A RKZ07781

For side digging boom

B

B RKZ07731

For hammer
C

C RKZ07741

40-30 WB97R-2
STANDARD MAINTENANCE 7-SPOOL CONTROL VALVE (WITH SERVOCONTROL)

G
1
1 70±7 Nm 10 Nm
10 Nm
70±7 Nm

............ Nm

......... Nm

70±7 Nm
70±7 Nm 1

1 G
Section
Sezione A
A -- A
A Section
Sezione B
B -- B
B

1
70±7 Nm 10 Nm

............ Nm

70±7 Nm
1
Section
SezioneCC--CC
RKZ08020

Unit: mm

N° Check item Criteria Remedy

Standard size Repair limit
Free
Installed Installed Free Installed
1 Spool return spring installed x length load installed load
Øe

WB97R-2 40-31
STANDARD MAINTENANCE 8-SPOOL CONTROL VALVE (WITH SERVOCONTROL)

8-SPOOL CONTROL VALVE (WITH SERVOCONTROL)

For hammer and jig arm

C A

C A RKZ07751

For side digging boom and jig arm

B A

B A RKZ07761

40-32 WB97R-2
STANDARD MAINTENANCE 8-SPOOL CONTROL VALVE (WITH SERVOCONTROL)

10±1 Nm 10±1 Nm

70±7 Nm 70±7 Nm

............ Nm ............ Nm

70±7 Nm
10±1 Nm
1 70±7 Nm 10±1 Nm
10±1 Nm 1
Section
Sezione A
A -- A
A Section
Sezione B
B -- B
B

10±1 Nm

70±7 Nm

............ Nm

............ Nm

70±7 Nm 10±1 Nm
1
SectionCC--CC
Sezione RKZ00961

Unit: mm

N° Check item Criteria Remedy

Standard size Repair limit
Free
Installed Installed Free Installed
1 Spool return spring installed x length load installed load
Øe

WB97R-2 40-33
STANDARD MAINTENANCE BRAKE PUMP

BRAKE PUMP

1 2 3

RKZ07861

Unit: mm

N° Check item Criteria Remedy

Standard size Repair limit

Free
Installed Installed Free Installed
1 Ball valve spring installed x length load installed load
Øe Replace if
damaged or
25 13 20 N 18–22 N deformed

2 Spring 21 13 7.3 N 7.3–7.8 N

3 Pump spring 91 60 72 N 65–79 N

4 Spring 14 7.3 4N 36–44 N

40-34 WB97R-2
STANDARD MAINTENANCE SHOVEL CYLINDERS

SHOVEL CYLINDERS
DUMP CYLINDER

2845±284 Nm 932 Nm

3 1 2

RKZ00780

RAISE CYLINDER

2845±284 Nm 961 Nm

3 1 2

RKZ00770

Unit: mm

Criteria

N° Check
item Cylinder Standard Tolerance Minimum Clearance Remedy
size clearance limit
Shaft Hole

Raise 50
-- 0.025 + 0.064 0.05 0.114
Tolerance between -- 0.050 + 0.025
1 piston rod and Replace
cylinder head
Dump 50
-- 0.025 + 0.064
0.05 0.114
-- 0.050 + 0.025

Raise 45
-- 0.050 + 0.24 0.13 0.329
Tolerance between -- 0.089 + 0.08
2 bushing and piston
rod mounting pin
Dump 45
-- 0.050 + 0.24 0.13 0.329
-- 0.089 + 0.08 Replace
pin and
Raise 50
-- 0.038 + 0.24
0.118 0.323 bushing
Tolerance between -- 0.083 + 0.08
3 bushing and cylinder
mounting pin
Dump 50 -- 0.038 + 0.24
0.118 0.323
-- 0.083 + 0.08

WB97R-2 40-35
STANDARD MAINTENANCE BACKHOE CYLINDERS

BACKHOE CYLINDERS
BOOM

932 – 980 Nm

1 3
2

RKZ00750

ARM

932 – 980 Nm 2845±284 Nm

1 3
2

RKZ00740

BUCKET

932 – 980 Nm 2845±284 Nm

2 1 3

RKZ00730

40-36 WB97R-2
STANDARD MAINTENANCE BACKHOE CYLINDERS

BOO M SWING

932 – 980 Nm

1
2

78 +0 20 Nm
with Loctite 542

RKZ00720

Unit: mm

Criteria

N° Check
item Cylinder Tolerance Remedy
Standard Minimum Clearance
size clearance limit
Shaft Hole

Boom 60
-- 0.030 + 0.076
0.06 0.136
-- 0.060 + 0.030

Arm 60
-- 0.030 + 0.076 0.06 0.136
Clearance between -- 0.060 + 0.030
1 piston head and
cylinder head Bucket 60
-- 0.030 + 0.076
0.06 0.136 Replace
-- 0.060 + 0.030

+ 0.025 + 0.064
Boom swing 50 0.05 0.114
+ 0.050 + 0.025

Boom 50
-- 0.050 + 0.24
0.13 0.329
-- 0.089 + 0.08

Arm 45
-- 0.050 + 0.24
0.13 0.329
Tolerance between -- 0.089 + 0.08
2 bushing and piston head
mounting pin
Bucket 50 -- 0.050 + 0.24
0.13 0.329
-- 0.089 + 0.08

Boom swing 50
-- 0.050 + 0.119
0.13 0.208
-- 0.089 + 0.080 Replace
pin and
Boom 50
-- 0.050 + 0.24
0.13 0.329
bushing
-- 0.089 + 0.08
Tolerance between
3 bushing and cylinder Arm 45
-- 0.050 + 0.24
0.13 0.329
mounting pin
-- 0.089 + 0.08

Bucket 45
-- 0.050 + 0.24
0.13 0.329
-- 0.089 + 0.08

WB97R-2 40-37
STANDARD MAINTENANCE BACKHOE CYLINDERS

OUTRIGGERI

1520±152 Nm
932 – 980 Nm

RKZ00710

JIG ARM

1520±152 Nm
932 – 980 Nm

RKZ00700

SIDE DIGGING BOOM

932 – 980 Nm 785 Nm

3 2 4

RKZ00680

40-38 WB97R-2
STANDARD MAINTENANCE BACKHOE CYLINDERS

ARM (FOR SIDE DIGGING BOOM)

932 – 980 Nm 1520±152 Nm

3 1 5

RKZ00671

Unit: mm

Criteria

N° Check
item Cylinder Tolerance Remedy
Standard Standard Clearance
size clearance limit
Shaft Hole

Outrigger 40
-- 0.025 + 0.064
0.050 0.114
-- 0.050 + 0.025
Clearance between Arm for side -- 0.030 + 0.076
1 piston rod and 60 0.060 0.136
cylinder head
digging boom -- 0.060 + 0.030

Jig arm 40
-- 0.025 + 0.064
0.114 0.050
-- 0.050 + 0.025

Clearance between
2 Side digging
45 -- 0.009 + 0.380
0.049 0.405
piston rod and boom -- 0.025 + 0.040
bushing
Replace
Side digging
40
-- 0.050 + 0.119
0.130 0.208
Tolerance between boom -- 0.089 + 0.080
3 bushing and piston rod
mounting pin Arm for side -- 0.050 + 0.119
45 0.130 0.208
digging boom -- 0.089 + 0.080

Tolerance between Side digging -- 0.050 + 0.119

4 bushing and cylinder 40 0.130 0.208
mounting pin
boom -- 0.089 + 0.080

Clearance between
Arm for side 0 0
5 bearing and
digging boom 75
-- 0.013 -- 0.035 ---- 0.013
bearing seat

WB97R-2 40-39
STANDARD MAINTENANCE FRONT WORKING EQUIPMENT

FRONT WORKING EQUIPMENT

E
C
C E

D
B
B
A

1 2 3

Section
SezioneAA -- A
A Section
Sezione B
B -- B

Section
SezioneCC--CC

5
4

Section
Sezione D
D -- D
D
Section
SezioneEE--EE
RKZ02270

40-40 WB97R-2
STANDARD MAINTENANCE FRONT WORKING EQUIPMENT

Unit: mm

Criteria

N° Check item Tolerance Remedy

Standard Standard Clearance
size clearance limit
Shaft Hole

Clearance between bushing -- 0.050 + 0.080

1 45 0.130–0.329
and bucket mounting pin -- 0.089 + 0.240

2 Clearance between bushing

45 -- 0.050 + 0.080 0.130–0.329
and link mounting pin -- 0.089 + 0.240

3 Clearance between bushing

45
-- 0.050 + 0.080
0.130–0.208 Replace
and tilt lever mounting pin -- 0.089 + 0.119

4 Clearance between bushing

45
-- 0.050 + 0.119
0.130–0.208
and link mounting pin -- 0.089 + 0.080

5 Clearance between bushing

50
-- 0.038 + 0.080
0.118–0.323
and boom mounting pin -- 0.093 + 0.240

WB97R-2 40-41
STANDARD MAINTENANCE SWING BRACKET

SWING BRACKET

A C
1
3
4

Section
Sezione B
B -- B
B

1 6
Section
Sezione A
A -- A
A

Section
SezioneCC-- C
C
RKZ02720

40-42 WB97R-2
STANDARD MAINTENANCE SWING BRACKET

Unit: mm

Criteria

N° Check item Tolerance

Standard
Remedy
Standard Clearance
size clearance limit
Shaft Hole

Clearance between rotating -- 0.060 + 0.090

1 bushing and boom swing 55 -- 0.106 + 0.060
0.120–0.196
cylinder bushing

Clearance between bushing -- 0.060 + 0.190

2 and (lower) swing bracket 65 0.250–0.370
rotating pin -- 0.106 + 0.264

Clearance between bushing -- 0.060 + 0.190 Replace

3 and (upper) swing bracket 65
-- 0.106 + 0.264
0.250–0.370 bushing
rotating pin and pin
Standard size Limit size
4 Upper shim thickness
4.75 --0 0.1

5 Central shim thickness 4.75 --0 0.1

6 Lower shim thickness 4.75 --0 0.1

WB97R-2 40-43
STANDARD MAINTENANCE BACKHOE WORKING EQUIPMENT

BACKHOE WORKING EQUIPMENT

C
C

B A
A
D

3
2

1
4

Section
Sezione A
A -- A
A
Section
Sezione B
B -- B
B

5 6 6

Section
Sezione D
D -- D
D
Section C -- CC
Sezione C RKZ02900

40-44 WB97R-2
STANDARD MAINTENANCE BACKHOE WORKING EQUIPMENT

Unit: mm

Criteria

N° Check item Tolerance Remedy

Standard Standard Clearance
size clearance limit
Shaft Hole

Clearance between link -- 0.050 --- 0.080

1 bushings and bucket 40 0.130–0.329
mounting pin -- 0.089 --- 0.240

Clearance between arm

2 bushings and bucket 40 -- 0.050 --- 0.080 0.130–0.329
-- 0.089 --- 0.240
mounting pin

Clearance between arm -- 0.050 --- 0.080

3 bushings and lever 45 0.130–0.329 Replace
mounting pin -- 0.089 --- 0.240

4 Clearance between bushings

45 -- 0.050 --- 0.080 0.130–0.329
and tilt lever mounting pin -- 0.089 --- 0.240

5 Clearance between bushings

50
-- 0.050 --- 0.080 0.130–0.208
and arm mounting pin -- 0.089 --- 0.119

6
Clearance between bushings
50
-- 0.038 --- 0.080 0.118–0.202
and boom mounting pin -- 0.083 --- 0.119

WB97R-2 40-45
© 2004 KOMATSU UTILITY EUROPE S.p.A.
All Rights Reserved
Printed in Europe