WEBM003301

September 2002 2002

40-28 PC15R-8
 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

WB150AWS-2 00-1
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following marks. It is requested that necessary ac- Mark Indication Action required
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low. ❍ Page to be newly Add

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Pages having no marks are those previously revised or

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LIST OF REVISED PAGES

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00-2-2 WB150AWS-2
➀
 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 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 Ko-
matsu 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 consider safety, and take necessary steps to face.

SAFETY
GENERAL PRECAUTIONS PREPARATIONS FOR WORK
Mistakes in operation extremely dangerous. 7. Before adding or making any repairs, park the ma-
Read all the Operation and Maintenance Manual care- chine on hard, level ground, and block the 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.

WB150AWS-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 WB150AWS-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 distributor for the latest information.

WB150AWS-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 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

(➀ ➁ ➂ ....)
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 PA-
GES between the title page and SAFETY page.

00-6 WB150AWS-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.

WB150AWS-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 WB150AWS-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

WB150AWS-2 00-9
 COATING MATERIALS

COATING MATERIALS
The recommended coating materials prescribed in Komatsu 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 WB150AWS-2
 ELECTRIC WIRE CODE

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

WB150AWS-2 00-11
 WEIGHT TABLE

WEIGHT TABLE
This weight table is a guide for use when transporting or handling components.
Unit: kg
Machine model WB150AWS-2
From serial number 150F80001-
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 530
Rear axle 540
Front wheel 163
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 telescopic 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
Telescopic arm 392
Outriggers 57
Boom cylinder 78
Arm cylinder 69
Bucket cylinder 49
Outriggers cylinder 42
Swing cylinder 30
Bucket 156

00-12 WB150AWS-2
 TABLE OF OIL AND COOLANT QUANTITIES

TABLE OF OIL AND COOLANT QUANTITIES

AMBIENT TEMPERATURE CAPACITY (ᐉ)

RESERVOIR KIND OF
FLUID -- 30 -- 20 -- 10 0 10 20 30 40 50°C
Specified Refill

SAE 5W-30

SAE 10W

SAE 20W-20
OIL
Crankcase sump SAE 30 7.9 7.9
• API CD
SAE 40

SAE 10W-30

SAE 15W-40

SAE 5W ✻

OIL SAE 10W

Hydraulic circuit 150 92
• API CD SAE 30

SAE 10W-30

Hydraulic circuit
with biodegradable 150 92
oil

Front axle
10.5 10.5
• Differential

• Final reduction gear

1.3 1.3
(each.)
See Note 1
Rear axle:
9 9
• Differential

• Final reduction gear

1.3 1.3
(each.)

Hydraulic OLIO
24.5 21.5
transmission GM DEXRON® II D
(DEXRON® is a
registered
Braking General Motors 0.8 0.8
system Corporation)

✽ ✽
Fuel tank DIESEL OIL 130 –
ASTM D975 N.2

WATER +
14 –
ANTI-FREEZE

Engine cooling
WATER 14 –
system

PERMANENT
14 –
LIQUID

✽ ✽ ASTM D975 N. 1
✽ OPTION FOR VERY COLD AREAS

WB150AWS-2 00-13
 TABLE OF OIL AND COOLANT QUANTITIES

NOTE 1
For axle oil, use only recommended oil as follows.
SHELL: DONAX TD
CALTEX: RPM TRACTOR HYDRAULIC FLUID
CHEVRON: TRACTOR HYDRAULIC FLUID
TEXACO: TEXTRAN TDH OIL
MOBIL: MOBILFLUID 422 or 424

IMPORTANT:
(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.
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.

ASTM: American Society of Testing and Materials

SAE: Society of Automotive Engineers
API: American Petroleum Institute

00-14 WB150AWS-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
the right) to return to the original value. This gives 550 mm = 21.65 in.

From millimeters to inches B

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

C
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
A
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717

70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110

80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504

90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898

WB150AWS-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 WB150AWS-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

WB150AWS-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 WB150AWS-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

WB150AWS-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 WB150AWS-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

WB150AWS-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 va-
lues 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 WB150AWS-2
GROUP 10
40-28 PC15R-8
 STRUCTURE AND FUNCTION

Power train ................................................................ 2 Backhoe control valve ..............................................52

Transmission ............................................................. 4 CLSS ........................................................................59
Drive shafts................................................................ 8 Solenoid valve ..........................................................73
Control valve block .................................................. 10 Safety valve..............................................................75
Front axle................................................................. 12 Brake pump ..............................................................77
Rear axle ................................................................. 15 Shovel cylinder .........................................................78
Steering system (4WS)............................................ 19 Backhoe cylinder ......................................................81
Hydraulic pump........................................................ 24 Air-conditioning unit..................................................82
Steering unit ............................................................ 45 How the air-conditioning unit functions.....................83
Hydraulic circuit ....................................................... 47 Electrical diagram.....................................................85
Shovel control valve ................................................ 48 Electrical diagram.....................................................87

WB150AWS-2 10-1
STRUCTURE AND FUNCTION POWER TRAIN

POWER TRAIN

1 2
3 4

7
5 8 6
RKZ04450

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 WB150AWS-2
STRUCTURE AND FUNCTION POWER TRAIN

Gears Transmission Differential Planetary Total

1st gear 4.374 83.273
2nd gear 2.436 46.377
2.75 6.923
3rd gear 1.232 23.455
4th gear 0.651 12.394

3
8

1 10

5
RKZ04460

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

WB150AWS-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 WB150AWS-2
STRUCTURE AND FUNCTION 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

WB150AWS-2 10-5
STRUCTURE AND FUNCTION TRANSMISSION

TRANSMISSION

1 b 2 c 3
7
a

A
X

4 A

d
B

9 5 12

11

B
6 10
View
Vista X
X
RKZ04250
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 WB150AWS-2
STRUCTURE AND FUNCTION TRANSMISSION

2 3

10
6
9 8 7
RKZ04270
Section
SezioneAA--A
A

1. Hydraulic pump drive shaft 6. Flange

2. Propeller shaft 7. Rear output shaft
3. Reverse gears idler shaft 8. Front output shaft
4. Drive shaft 9. 4WD engagement device
5. Driven shaft 10. Flange

WB150AWS-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 WB150AWS-2
STRUCTURE AND FUNCTION DRIVE SHAFTS

Driven gear shaft

5
2
4
1
3 c
a b

9
8 7 6
RKZ04280

a. Port commanding 4th gear 4. Drive gear for 4WD (Z=51)

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

Output shaft and 4WD

3
2

1 a

6 4
5 RKZ04290

a. 4WD disengagement command port 4. Rear output shaft

1. Front output shaft 5. Piston (No. 3)
2. 4WD disengagement command piston 6. Spring
3. 4WD driven gear (Z=41)

WB150AWS-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 IND 4ª 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 WB150AWS-2
PAGE INTENTIONALLY
LEFT BLANK
STRUCTURE AND FUNCTION FRONT AXLE

FRONT AXLE
Differentia

2 3

1
1

15 4

16 14 7

13 8

12 9

11 10

RKZ04260

1. Planetary gear 9. Bearing

2. Ring bevel gear (Z=31) 10. Seal
3. Bevel gear 11. Flange
4. Lock nut 12. Lock nut
5. Half-axle 13. Bearing
6. Pin 14. Bevel pinion (Z=13)
7. Differential housing 15. Pin
8. Spacer 16. Oil drain plug

10-12 WB150AWS-2
STRUCTURE AND FUNCTION FRONT AXLE

Final reduction - join

21 4 5
7
6 8
3 9

2 10

11

13
22 14
12
14
20 19 18 17 16

RKZ04300

1. Planetary carrier 12. Axle body

2. Planetary 13. Bearing
3. Ring gear 14. Joint
4. Ring gear carrier 15. Pin
5. Wheel hub 16. Protection
6. Seal 17. Seal
7. Pin 18. Bearing
8. Shim 19. Snap ring
9. Protection 20. Steady pin
10. Bushing 21. Stud bolt
11. Seal 22. Plug

WB150AWS-2 10-13
STRUCTURE AND FUNCTION FRONT AXLE

Steering cylinder

A 2 3

b 1 a
A B

A
B

7
8

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

RKZ04380

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
8. Bushing

10-14 WB150AWS-2
STRUCTURE AND FUNCTION REAR AXLE

REAR AXLE
Differential

1 2 4 3 5 6

7 7

15 8 16 17

14 9

13 10

12 11

RKZ04400

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
7. Half-axle 15. Differential housing
8. Pin

WB150AWS-2 10-15
STRUCTURE AND FUNCTION REAR AXLE

Final reduction

21 4 5
6 8 9 7
3

2 10

11

13
22 14
14 12
20 19 18 17 16

RKZ04410

1. Planetary gear carrier 12. Axle body

2. Planetary 13. Bearing
3. Ring gear 14. Articulation
4. Ring bevel gear carrier 15. Pin
5. Wheel hub 16. Protection
6. Seal 17. Seal
7. Pin 18. Bearing
8. Shim 19. Snap ring
9. Protection 20. Steady pin
10. Bushing 21. Stud bolt
11. Seal 22. Plug

10-16 WB150AWS-2
STRUCTURE AND FUNCTION REAR AXLE

Brakes

3 9 1 A

6 12 8 10 11 7

4 5

Detail A
Particolare A

RKZ04420

1. Spring 7. Brake disk

2. Bushing 8. Bushing
3. Parking brake control rod 9. Work brake command piston
4. Bleeder valve 10. Pressure disk
5. Parking brake lever 11. Intermediate disk
6. Parking brake control cam 12. Spacer

WB150AWS-2 10-17
STRUCTURE AND FUNCTION REAR AXLE

Steering cylinder

A e e

A
A
d c

2 3
4
Section
Sezione A
A- A Detail A A
Particolare

RKZ04440

1. Steering cylinder
2. Nut
3. Adjustment screw
4. Nut

c Port - From the solenoid valve block ST2 (Port A)

d Port - From the solenoid valve block ST2 (Port B)
e Port - From brake pump

10-18 WB150AWS-2
STRUCTURE AND FUNCTION STEERING SYSTEM (4WS)

STEERING SYSTEM (4WS)

4 5
3

2
10
9 T P
a d
6
A D

DLS 7 1
B C

Y2 Y4 c
b
L R
P B

T A
Y1 Y3

RKZ04480
1. Engine DESCRIPTION
2. Pump (P2) • The steering system is completely hydraulic. The oil
3. Tank required, supplied by the pump (2) driven by the mo-
4 Priority valve tor (1), is sent to the priority valve (4) which functions
5. Control valve by Load Sensing, and sends the necessary quantity
6. Steering unit of oil to the steering system (6), even when other
oleodynamic components supplied by the same cir-
7. Steering wheel
cuit are in operation. The oil passes from this group
8. ST2 Solenoid valve group: (6) into the steering cylinders (9) and (10).“The so-
- Y1: Rear steering cut out lenoid valve group (8) can switch the oil flow to pro-
- Y2: Front/rear steering vide three types of steering:
- Y3: Phase coincidence steering 1 - 2-wheels steering
- Y4: Crab steering Steering condition in which the rear axle is ex-
9. Front axle steering cylinder cluded.
10. Rear axle steering cylinder 2 - 2-wheels steering and 2 wheels counters-
teering
11. Front axle cylinder piston
Steering condition in which rear steering is ac-
10. Rear axle cylinder piston tivated and the direction of the rear wheels is
contrary to that of the front wheels.
3 - 4-wheels steering in the same direction
Steering condition in which rear axle steering is
activated and the direction of the rear wheels
agrees with that of the front wheels.
• The hydraulic power supplied by the pump (2) is
transferred to cylinders (9) and (10) and trans-
formed into mechanical steering power.

WB150AWS-2 10-19
STRUCTURE AND FUNCTION STEERING SYSTEM (4WS)

OPERATION
1 - Steering with front wheels, only.

b 9 a b 9 a

B A B A

g L T g L T
e e
6 3 6 3
R P R P
4 4
f
5 5
7 f 7
Y1 Y2 2 Y1 Y2 2

Y3 Y4 Y3 Y4

RKZ04490 RKZ04500

STEERING TO THE RIGHT STEERING TO THE LEFT

Turning the steering wheel (7) clockwise causes rotation Turning the steering wheel (7) anti-clockwise causes ro-
of the steering metering group (6) and prepares the con- tation of the steering metering group (6) and prepares
trol valve (port R) to send oil through line e directly into the control valve (port L) to send oil through line g to so-
chamber b of the cylinder (9); the pressurized oil moves lenoid valve group and thence through line f, into cham-
the piston which then steers the wheels. ber a of the cylinder (9); the pressurized oil moves the
The oil in chamber a of cylinder (9) is impelled into line f piston which then steers the wheels.
to solenoid valve group and thence into line g which is The oil in chamber b of cylinder (9) is impelled into line e
coupled to the control valve of the steering group (6) which is coupled to the control valve of the steering
(port L); from the control valve the oil passes out of Port group (5) (port R); from the control valve the oil passes
T and drains into the tank (3). out of Port T and drains into the tank (3).

10-20 WB150AWS-2
STRUCTURE AND FUNCTION STEERING SYSTEM (4WS)

2 - Steering with 2 wheels steering and 2 wheels countersteering.

b 9 a b 9 a

B A B A

g L T g L T
e e
6 3 6 3
R P R P

4 4

f
5 f
5
7 7
Y1 Y2 2 Y1 Y2 2

Y3 Y4 Y3 Y4
h h

i i

C D C D

c 10 d c 10 d

RKZ04510 RKZ04520

STEERING TO THE RIGHT STEERING TO THE LEFT

Turning the steering wheel (7) clockwise causes rotation Turning the steering wheel (7) anti-clockwise causes ro-
of the steering metering group (6) and prepares the con- tation of the steering metering group (6) and prepares
trol valve (port R) to send oil through line e directly to the control valve (port L) to send oil (through line g) to so-
chamber b of cylinder (9). lenoid valve group and thence through line i into cham-
The pressurized oil moves the piston of cylinder (9) ber c of cylinder (10).
which in turn steers the wheels while simultaneously im- The pressurized oil moves the piston of the cylinder (10)
pelling the oil in chamber a (at the same pressure as that steers the wheels and at the same time impels the oil
chamber b, through lines f - h into chamber d of cylinder in chamber d (at the same pressure as chamber c),
(10). through lines h and f into chamber a of cylinder (9).
The oil in chamber c of cylinder (9) is impelled through The oil in chamber b of cylinder (9) is impelled through
lines i and g to the control valve of the steering group line e to the control valve of the steering group (port R),
(port L) from which it passes (port T) to drain into the tank from which it passes (port T) to drain into the tank (3).
(3).

WB150AWS-2 10-21
STRUCTURE AND FUNCTION STEERING SYSTEM (4WS)

3 - Steering with 4 wheels steering in the same direction.

b 9 a b 9 a

B A B A

g L T g L T
e e
6 3 6 3
R P R P

4 4

f
5 f
5
7 7
Y1 Y2 2 Y1 Y2 2

Y3 Y4 Y3 Y4
h h

i i

C D C D

c 10 d c 10 d

RKZ04530 RKZ04540

STEERING TO THE RIGHT STEERING TO THE LEFT

Turning the steering wheel (7) clockwise causes rotation Turning the steering wheel (7) anti-clockwise causes ro-
of the steering metering group (6) and prepares the con- tation of the steering metering group (6) and prepares
trol valve (port R) to send oil through line e into chamber the control valve (port L) to send oil (through line g) to so-
b of cylinder (9).“The pressurized oil moves the piston of lenoid valve group and then through line h into chamber
cylinder (9) which in turn steers the wheels while simul- d of cylinder (10).
taneously impelling the oil in chamber a (at the same The pressurized oil moves the piston of the cylinder (10)
pressure as chamber b) through lines f and i into cham- that steers the wheels while simultaneously impelling
ber c of cylinder (10). the oil in chamber c (at the same pressure as chamber d)
The oil in chamber d of cylinder (10) is impelled through through lines i and f into chamber a of the cylinder (9).
lines h and g to the control valve of the steering group (5) The oil in chamber b of cylinder (9) is sent through line e
(port L) from which it passes (port T) to drain into the tank to the control valve of the steering group (port R) from
(3). which the oil passes (port T) to drain into the tank (3).

10-22 WB150AWS-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 L - To the hydraulic oil tank

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

10-24 WB150AWS-2
STRUCTURE AND FUNCTION HYDRAULIC PUMP

C C 3 4

2
1

Section
Sezione A
A -- A
A

7 8 9
6

12 11 Section
Sezione 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

WB150AWS-2 10-25
STRUCTURE AND FUNCTION HYDRAULIC PUMP

1 2 3 4 5

7 6
Section
SezioneCC -- C
C

8 9 10

15 14 13 12 11
Section
SezioneDD-- D
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)

10-26 WB150AWS-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 • The pistons (5) perform their relative movements in
to the shaft (1) by the spline a and the shaft (1) is an axial direction, inside cylindrical chambers fash-
supported 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 The surface of the swash plate is so designed that
shoe (4) remains pressed against this surface while the oil pressure always remains within acceptable
sliding 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.

WB150AWS-2 10-27
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-
1 3 A 4 5 6 D
face A. The swash plate (3) moves along the
cylindrical surface B. The angle = formed be-
tween 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 = is known as the swash plate angle.

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

maintains the angle = in relation to the center


line of the shaft (1), and hence also of the cylin- X
der 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 and D B C
RKZ01100
which provokes intake and discharge of the oil
in quantities equal to the difference between
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).

=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 ==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
practice the swash plate angle = never be-
comes=0)

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

portional to the swash plate angle =.
C
RKZ01110

10-28 WB150AWS-2
STRUCTURE AND FUNCTION HYDRAULIC PUMP

2. Control of Delivery
1 - As the swash plate angle = grows larger, the
difference between volumes C and D increas- 2 3 9 D
es, and the delivery Q also increases.
The swash plate angle is modified by servo-pi-
stons (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

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 8 C
chamber, whereas the pressure PEN coming RKZ01130
from the LS valve is passed into the larger (low-
er) 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-pi-
ston.

WB150AWS-2 10-29
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

10-30 WB150AWS-2
STRUCTURE AND FUNCTION POMPA IDRAULICA

LS VALVE
FUNCTION
• The LS valve controls the pump delivery according
to the stroke of the control valve level, i.e., in func-
tion 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
difference ,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.

WB150AWS-2 10-31
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 30 bar.

10-32 WB150AWS-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 RKZ01161
2

• 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.

WB150AWS-2 10-33
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 RKZ01161
2

• 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.

10-34 WB150AWS-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 • Equilibrium is re-established in the system when the
delivery lines c and d. The pressure PP is intro- pressure ,PLS generates on the spool (4) the dif-
duced into the chamber X and the swash plate ference in force exerted by the spring (6), and hence
moves towards 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.

WB150AWS-2 10-35
STRUCTURE AND FUNCTION HYDRAULIC PUMP

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

PP T PLS
c
g e a 6
d

To the actuator

Control valve
PEN
Hold

PP
A1

M 3 X
PP 1
A2

Y RKZ01181
2

• 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 pi-
combined forces of the LS pressure PLS in cham- ston (4) is in equilibrium when
ber a, and the force exerted by the spring (6). PP – PLS = ,PLS =21 bar.
Once equilibrium has been reached the piston (4)
stops in the central position. In practice, the pump flow is made proportional to
• In this condition the passage from chamber c to the section of the opening of the control valve, which
chamber d remains only slightly open in order to maintains the differential pressure
maintain pressure in chamber d. ,PLS = 21 bar.

10-36 WB150AWS-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
decreases, 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.

WB150AWS-2 10-37
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- • The opening of the passage between the chambers
ceives a signal from the control valve to bring the b and a generates a flow of oil and hence, due to the
pump up to maximum displacement. calibrated hole (6), a , P is generated between
When the swash plate moves it also moves the chambers f and g at the sides opposite the spool (5).
bushing (2) joined to it (by the pin (1)), which re- (,P =PP – PPC)
leases the spring (3). • When the value of PP exceeds the value of the
• As the pressure of the actuators increases, pres- spring loading (7) the spool (5) moves to the right
sure also increases in the delivery line c. When the ( ) opening the passage between the delivery
calibrated setting of the spring (3) is reached, the pi- lines d and e and sending the pump pressure PP to-
ston rod (4) is thrust to the left ( ) and the pas- wards the servo-cylinder (8).
sage between chamber b and the pump drainage • The pressure PP introduced into chamber X of the
chamber a is opened. cylinder (8) pushes it towards the minimum angle of
the swash plate ( ).

10-38 WB150AWS-2
STRUCTURE AND FUNCTION HYDRAULIC PUMP

2. When equilibrium has been reached

5 g 6 7
f ∆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)).

WB150AWS-2 10-39
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 and opening the passage between chambers e and
pump delivery pressure PP drops, the PPC. pres- g.
sure also drops. • The pressurized oil present in chamber X of the ser-
• The reduction in the PPC causes the spool (4) to vo-cylinder (8) passes through chambers e and g
move and the passage between chambers b, d and and reaches the pump drainage chamber, so that
a is closed. the pressure in chamber X of the servo-cylinder (7)
The PPC pressure and the PP pressure of the pump becomes equal to the drainage pressure.
are equalised due to the interruption of the oil flow
Therefore the servo-piston (7) is caused to move by
through the calibrated hole (6) and hence the ,P
the PP pressure in chamber Y of the servo-cylinder
becomes zero (,P = PP – PPC=0).
(9), i.e. in the direction of the increase in the angle of
• The spring (7) pushes the spool (5) to the left ( ) the swash plate.
closing the passage between the chambers d and e

10-40 WB150AWS-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.
• The compression of the spring (3) varies with the Spring (3) + spring (11)
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.
Pump discharge pressure PP
The pump absorption torque curve, which indicates
RKZ01241
the relationship between the pump delivery pres-
sure PP and the delivery Q, is a broken line (as il-
lustrated in the diagram).

WB150AWS-2 10-41
STRUCTURE AND FUNCTION HYDRAULIC PUMP

•The position in which the piston (8) stops, i.e. the pump
absorption torque, is determined by the position 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.

10-42 WB150AWS-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.
Working mode P
When the solenoid valve of the working mode is
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.

WB150AWS-2 10-43
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).

10-44 WB150AWS-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 rotat-
ing oil dispenser) to one of the sides of the steering
cylinder.
The rotating dispenser ensures that the volume of
oil supplied to the cylinder is proportionate to the an-
gle 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.

WB150AWS-2 10-45
PAGE INTENTIONALLY
LEFT BLANK
STRUCTURE AND FUNCTION HYDRAULIC CIRCUIT

HYDRAULIC CIRCUIT
Breaker Arm Boom swing L.H. outrigger R.H. outrigger Bucket Boom Telescopic arm

T1 P2 M LS1 B1 A1 B2 A2 B3 A3 B4 A4 B5 A5 B6 A6 B7 A7 B8 A8

T P

24 bar b b b b b b b b

220±7 bar

T LS

a a a a a a a a

A T A T T B A T T B T B A T
T B
A T
165 bar 240 bar 185 bar 185 bar 240 bar 240 bar 350 bar

T2

L D

240 bar 240 bar

Rear axle

DLS
D C

175 bar
Additional
Arm Bucket equipment
T P

Y3 B P
Y2
Solenoid valve
group ST2
Y4
Y1
A T

LS D B1 A1 B2 A2 B3 A3

DLS b
X1 b
A2 b
X2

P Front axle

5 bar A B
12V
DC Z
a a a
200 bar

T
T B A T T B A T

170 bar 230 bar 230 bar 230 bar

5 bar

S L1 L

RKZ06850

WB150AWS-2 10-47
STRUCTURE AND FUNCTION SHOVEL CONTROL VALVE

SHOVEL CONTROL VALVE

2 SPOOL

D C A
b c d
a
e

h g
C A

D
1 B 2

6
B
i Section
Sezione A
A -- A
A
Section
Sezione B
B -- B
B
RKZ00351

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)

10-48 WB150AWS-2
STRUCTURE AND FUNCTION SHOVEL CONTROL VALVE

E
1 E
8

9
2

7
3 10
7
4
1 8 11
5

E
6 E
Section
Sezione C
C -- C
C

Section
Sezione D
D -- D
D

12
13

12
13

Section EE --EE
Sezione
RKZ01360

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. Spring
6. Ball 13. Check valve
7. Compensator

WB150AWS-2 10-49
STRUCTURE AND FUNCTION SHOVEL CONTROL VALVE

3 SPOOL
E

D C A
a b c d e
f

l i h
C A

E D
1 B
2

6
B 7
m Section
Sezione A -- A
A Section
Sezione B
B -- B
B
RKZ00341

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 WB150AWS-2
STRUCTURE AND FUNCTION SHOVEL CONTROL VALVE

F
1 F
8

9
2

7
3 10
7
4
1 8 11
5

F F
Section
Sezione C
C -- C
C
6 F

8
12 Section
Sezione D
D -- D
D

13
14

13
14
7

8 F Section
Sezione FF - F

Section E -- EE
Sezione 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

WB150AWS-2 10-51
STRUCTURE AND FUNCTION BACKHOE CONTROL VALVE

BACKHOE CONTROL VALVE

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

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

Section 2 4
Sezione A
A -- A
A
G
Section
Sezione B
B -- B
B
RKZ01370

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

10-52 WB150AWS-2
STRUCTURE AND FUNCTION BACKHOE CONTROL VALVE

G G G
2 2
6 8 9 10

5
5 5

8 2
7 G 4 4
G 4 G
Section
Sezione C
C -- C
C Section
Sezione D
D -- D
D Section
Sezione E - E

G
8
11

12 13

12 13

Section
Sezione G
G -- G
G
2 G 4
RKZ01380
Section
Sezione F
F -- F
F
1. Ball 8. Plug
2. Antishock/anticavitation valve 9. Outrigger command spool
3. Boom command spool 10. Boom swing command spool
4. Spool return spring 11. Arm command spool
5. Compensator 12. Spring
6. Bucket command spool 13. Check valve
7. Anticavitation valve

WB150AWS-2 10-53
STRUCTURE AND FUNCTION BACKHOE CONTROL VALVE

3 2

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

1. Valve 4. Pressure cut-out valve

2. Spring 5. Unloading valve
3. Plug

10-54 WB150AWS-2
PAGE INTENTIONALLY
LEFT BLANK
STRUCTURE AND FUNCTION BACKHOE CONTROL VALVE

7 SPOOL
For telescopic arm

A
a

b
A RKZ01390

For hammer

c B
RKZ01400

a. Port B7 - To the telescopic arm cylinder (Base side)

b. Port A7 - To the telescopic arm cylinder (Head side)
c. Port A7 - To the hydraulic hammer (Left side)

10-56 WB150AWS-2
STRUCTURE AND FUNCTION BACKHOE CONTROL VALVE

1 2

4 3
Section A -- AA
Sezione A

6
7

4
3
Section
Sezione B
B -- B
B
RKZ01420

1. Anticavitation valve 5. Compensator

2. Telescopic arm command spool 6. Anti-shock/anticavitation valve
3. Spool return spring 7. Hammer command spool
4. Plug

WB150AWS-2 10-57
STRUCTURE AND FUNCTION BACKHOE CONTROL VALVE

8 SPOOL
For hammer and telescopic arm

c b RKZ01410

a. Port B8 - To the telescopic arm cylinder (Base side)

b. Port A8 - To the telescopic arm cylinder (Head side)
c. Port A7 - To the hydraulic hammer (L.H. side)

10-58 WB150AWS-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

WB150AWS-2 10-59
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

10-60 WB150AWS-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

WB150AWS-2 10-61
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 30 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 pressure
• On the two surfaces of the shuttle (1), the pump pres- PP stays regulated at 30 bar.
sure PP acts on the right-hand side, while the LS sig-
nal 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 provid-
ed 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 30 bar, the shuttle (1) moves to the
left ( ) and the PP circuit is put into communication
with the tank circuit T.

10-62 WB150AWS-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+24 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) (24 bar), the differential LS pressure ,PLS del
LS becomes 24 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, rela-
valve, a pressure PLS is generated that pressurizing tive to the actuator request, is sent to the tank circuit.
the spring chamber, acts on the left-hand extremity of • The pump delivery pressure PP is regulated by the
the valve (1). combination of the pressure provided by the spring
The actuator pressure is introduced into the LS circuit (24 bar) and by the LS pressure PLS, i.e. when the
and then into the spring chamber. pressure differential ,PLS reaches the value of 24
As a result, the pump pressure PP tends to increase. bar.
• When the differential pressure between the pump de-
livery pressure PP and the LS pressure PLS has the
same value as the loading on the spring (2) (24 bar),
the shuttle (1) moves to the left ( ) and the pump
circuit PP puts itself into communication with the tank
circuit T.

WB150AWS-2 10-63
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 execute • The result is that the connection between the pump
a bigger stroke, the opening section of spool becomes delivery circuit PP and the tank circuit T is excluded
bigger and consequently the controlled delivery. and the entire pump delivery Q is sent to the actuators
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 21 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)
(24 bar), the shuttle (1) is pushed to the right ( ) of
the spring (2).

10-64 WB150AWS-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 the with the tank circuit T by means of the LS decom-
duct b. pression valve (3).
• At the same time the compensator (2) moves up- (See the description of the LS decompression valve).
wards ( ) so that the flow controlled by spool (1) can • The system stabilizes when a pressure difference of
flow towards the actuator A. 21 bar is generated across the shuttle (1) between
(Check valve (4) do not allow any flow up to when pump pressure PP and PLS pressure.
pressure in chamber c is higher than pressure in
chamber b).
Pressure downstream spool (1) flows in the PLS cir-
cuit downstream the compensator valve throught the
orifice d.

WB150AWS-2 10-65
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 ing the swash plate angle.
(1) reaches the same value requested by actuator B, (For the detail see «Hydraulic pump»).
no oil passes. • Until the pump does not realize a ,P of 21 bar, i.e. un-
• When the pressure requested by actuator B is ex- til the increase in oil flow compensates the require-
ceeded, movement can commence. This creates a ments of the two actuators, the pump will continue to
flow that adding to the one controlled by spool (3) re- increase delivery.
duces the pressure upstream of spool (1) and (3) and • ,P of 21 bar will stabilize as soon as it is restored to.
therefore the ,P between PLS and PP. • The compensator (2) is moved upwards by the oil flow
• The pump compares the delivery pressures PP and and stops when the aperture between the chambers a
PLS and senses that the difference ,P<21 bar. This and b reduces the passage sufficiently to reduce the
variation in ,P causes an increase in oil flow increas- pressure in chamber b to be sent to the actuator

10-66 WB150AWS-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 (2) stream and downstream from the shuttle.
moves upwards to restore the ,P between the cham- (PAV<PLS<PP)
bers a and b, and therefore the ,P does not vary up- • Because the pressure PLS which is equal to the pres-
stream or downstream from the shuttle (1). sure PB acts on the upper side of the compensator
• When pressure PB exceeds pressure PA, the com- (4), and since the pressure PAV is lower, the com-
pensator (2) is fully open and the pressure PB is in- pensator (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 to
21 bar. the actuator, and to increase the pressure PAV until
the ,P is restored to the 21 bar necessary for equi-
librium.

WB150AWS-2 10-67
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 21 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).

10-68 WB150AWS-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 sure PBV downstream from the shuttle becomes

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

WB150AWS-2 10-69
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 c
valve, it generates a force that opposes the force of is opened.
the spring (2). • The system is in equilibrium (i.e. the shuttle is at rest),
• Until the force generated by the LS pressure exceeds when the quantity of oil allowed to flow into the tank
the force of the spring (2) (LS pressure low) the shuttle circuit is equivalent to the quantity that generates a
(1) remains «at rest» and oil flows through the cali- pressure difference ,P such that
brated 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 pushed PLS1=LS pressure contained in chamber d
upwards ( ) and the passages c are closed. S=section of the shuttle
Oil continues to flow into the chamber d until the force F=force of the spring
generated by the pressure contained in chamber d,
together with the force of the spring (2), exceeds the
force generated by the LS pressure.

10-70 WB150AWS-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.

b 1
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.

WB150AWS-2 10-71
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

10-72 WB150AWS-2
STRUCTURE AND FUNCTION SOLENOID VALVE

SOLENOID VALVE
Solenoid valve group ST1 - Backhoe boom locking.

a c

RKZ04640

1. EV4 - Backhoe boom locking

a. Port 3 - To the transmission
b. Port 2 - From the transmission
c. Port 1 - Boom-locking cylinder

WB150AWS-2 10-73
STRUCTURE AND FUNCTION SOLENOID VALVE

Solenoid valve group ST2 - Steering

2 3

a b

T A

P B

c 5 d

1 4
RKP03670

Measured at V=41 mm2/s e t=50°C Measured at V=41 mm2/s e t=50°C

5 3 6 9
10 10
Differential pressure ⌬p (bar)

Differential pressure ⌬p (bar)

8 8

6 6

4 4

2 2

0 0
0 20 40 60 80 0 20 40 60 80
Amount Q (ᐍ / min) Amount Q (ᐍ / min)

RKP04501 RKP04511

1. Y1 Rear steering cut out

2. Y2 Front/rear steering
Y1 Y3
c
3. Y3 Phase coincidence steering
rear
cylinder
4. Y4 Crab steering d
5. Blocks connection Y2 Y4

a. T Port - To front steering cylinder (b Port) Direction of travel

RKZ04571

b. A Port - To rear steering cylinder (c Port)

c. P Port - From steering unit (Port r)
d. B Port - To rear steering cylinder (d Port)

10-74 WB150AWS-2
STRUCTURE AND FUNCTION SAFETY VALVE

SAFETY VALVE

a b

A RKZ00850

Shovel raise Arm

a. Port Y - to the raising cylinders (Head side) a. Port Y - To the arm cylinder (Head side)
b. Port A - From the shovel control valve (Port A1) b. Port A - From the backhoe control valve
c. Port X - To the raising cylinders (Base side) (Port B1)
d. Port B - From the shovel control valve (Port B1) c. Port X - To the arm cylinder (Base side)
d. Port B - From the backhoe control valve
Bucket Dump (Port A1)
a. Port Y - To the dump cylinders (Head side)
b. Port A - From the shovel control valve (Port B2) CHARACTERISTICS
Safety valve calibration
c. Port X - To the dump cylinders (Base side)
Shovel dump: 230 bar
d. Port B - From the shovel control valve (Port A2) Boom: 350 bar
Boom Arm: 230 bar
a. Port Y - To the boom cylinder (Head side)
b. Port A - From the backhoe control valve
(Port A6)
c. Port X - To the boom cylinder (Base side)
d. Port B - From the backhoe control valve
(Port B6)

WB150AWS-2 10-75
STRUCTURE AND FUNCTION SAFETY VALVE

★ The drawing shows boom safety valve

2 3 4 5

6
1

15

14 13 12 11 10 9

Section
Sezione A
A -- A
A RKZ01050

1. Plug 9. Spool
2. Check valve spring 10. Safety valve spring
3. Check valve 11. Safety valve
4. Check valve spring 12. Spool
5. Check valve 13. Spring
6. Plug 14. Housing
7. Protection 15. Plug
8. Over-ride screw (Safety)

10-76 WB150AWS-2
STRUCTURE AND FUNCTION BRAKE PUMP

BRAKE PUMP

1 2 3 4 5 6

7
17 16 15 14 13 12 11 10 8
RKZ00932

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

WB150AWS-2 10-77
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 4. Piston seal 7. Cylinder

2. Cylinder 5. Piston 8. Bushing, head side
3. Nut 6. Piston rod

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

10-78 WB150AWS-2
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

WB150AWS-2 10-79
STRUCTURE AND FUNCTION BACKHOE CYLINDERS

OUTRIGGERSI
3 4 5 6 10 8 9
1 2

7 11
RKZ01440

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

TELESCOPIC 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

10-80 WB150AWS-2
STRUCTURE AND FUNCTION BACKHOE CYLINDERS

CHARACTERISTICS
Arm
Cylinder Boom With Bucket
Standard telescopic arm
Piston rod diameter 60 60 60 60
Internal cylinder diameter 125 115 110 95
Piston stroke 849 920 920 765
Max. cylinder length 2050 1255 1255 1085
Min. cylinder length 1040 2175 2175 1850
Key size for piston safety nut 65 55 55 55

CHARACTERISTICS
Cylinder Outriggers Boom swing Telescopic arm
Piston rod diameter 55 50 40
Internal cylinder diameter 110 115 70
Piston stroke 515 231.5 1140
Max. cylinder length 1365 318 2590
Min. cylinder length 850 86.5 1450
Key size for piston safety nut 65 65 46

WB150AWS-2 10-81
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
and ambient temperature at 25–30°C:
3. Drying-filter tank
Normal pressure: 15 –17 bar
4. Safety pressure
Low pressure: 1.6 –1.8 bar
5. Expansion valve
Safety pressures:
6. Evaporator
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: 970±15 g

10-82 WB150AWS-2
STRUCTURE AND FUNCTION AIR-CONDITIONING UNIT

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 eva-
compressor where it is subjected to compression and an porator.
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 co-
temperature of approximately – 8°C. olant 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.

WB150AWS-2 10-83
PAGE INTENTIONALLY
LEFT BLANK
STRUCTURE AND FUNCTION ELECTRICAL DIAGRAM

ELECTRICAL DIAGRAM

MOTORINO TERGI
X46

S
WIPER MOTOR
WINDSHIELD
N1
4
V1
3
R1
2
G1
1

R/N1
R-N1

N1
N1

V-N1

V-N1
N1

N1
N1

N1

N1

N1

N1

N1
R-N1 M-V1 R/N1

N1
G-R1

H18 N1
A-N1 L1.5 B-R1.5 A-N1

G1
R/N1

R/N1

R/N1

R/N1

R/N1

R/N1

R/N1

R/N1

R/N1

R1

N1

R1

N1
R/N1

R/N1
A2.5 G2.5 A-N1 A-R1 A-R1 L-G1.5 R/N1

H21

H20
H32

H17
H19
.
HA2

H30
MOTORINO TERGI ANT

H38
P1 P3 P4

H13

H22

H24
H10

H12

H14

H23

H25
H11

H36

H37
FRONT WINDSHIELD

H9

H1

H3

H5

H7
H2

H4

H6
A-R1 R1 ACC BR R2 C

57

59c
1 9 2 8 5 10 1 9 2 6 7 9 1 9 1 9 1 9

57

59c
1
WIPER MOTOR 1 0 1 0
R1
OFF ACC - - - 1 0 2 0 1 0 1 0 1 0
M
ST

S
rpm
S
q S
t°
KUE 312612137 +
i
+
i
+
i

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

R
10
9

M-N1
Z-N1

A-V1
G-R1

G-R1
G/N1

V-B1

A/V1

V-B1

A-G1
Z/B1
R-V1
V-N1

B/N1

A-B1
S1

B1

S1

V1

R/N1

H/N1

R/N1

L/N1
N1

A1
G1

G1

M-N1

M-N1
B/R1

A/N1
G1.5
S4L S5L

A/R1
L/N1

R6
B-R1
S3L

R-N1.5
L/B1
S3A S4A S1L S2L

N1

R1
S6

B-R1

N1
G-N1
5 4 3 2 1

B-R1
B-R1
B-G1
B-G1

N1
RIGHT

7
0A003917

X24
5
L-B1

6
6 5 4 3 2 1 2 1

X47
A-R1

XS
3
-

Z/N1
R/N1
A-N1

G-N1
G1
N1
S2A

N1
0
X33 R1

1
2
7
L-G1.5 G-N1
6
A-R1 B-V1
5
A/R1 V1
4
N1 A-N1 G1 -
10
3
9

B-G1 V-N1
2

Q
B-G1 V-N1
S1A NOT CONNECT

1 LEFT
Z-N1

N1
N1

N1
N1

N1

N1
N1
N1
N1
N1
N1
N1
N1
KUE 312612126

B-V1
R-N1
N1
S37
7

A-R1
0A003015

M-N1
M-N1
G2.5
5

A2.5
A2.5

R-N1.5

B-R1.5

G-R1

A-B1
R6

M-V1

A-G1

M1
A-N1

B-R1

R-V1

R/N1

H/N1
B/N1

N1
Z/N1

V-B1
L/N1

Z/B1
L/B1
L1.5
1

A1
G1
R1
R1
N1
N1
G1
N1

V1

S1
SIAC 444.409935 SIAC 444.407.656
4 3 2 1 21 20 19 18 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

Z-N1

X15

X17

X31
X26
Z-B1

V-N2.5
V2.5
R/N1 M4 MOTORINO
X18

S-G1
RISCALDAMENTO

C-L1
S10

G/N1
G/N1
R-V1
G2.5

A-R1
A2.5
A2.5

R6

N2.5
C-L1

A-B1
JUMPER
X29

G1
B/N1
M-V1
R-G1

G-R1
R1
R1
N1
N1

A1
Z/N1

V-B1

A-G1
L/N1
A-N1

R/N1

H/N1

Z/B1
V1

S1
L/B1

G1
L1.5
R-N1.5

N1
B-R1.5

A1.5

B1.5
N0.5

V2.5
R-V1 R-V1

B1

P
L0.5
(ONLY WITHOUT

N1
B1

N1
5

N1
M-V1 M-V1
K05 AIR COND.) N1

M1
L-B1
4
L-B1
86 87
M/N1
2 0A003603
3
86 87a 87 X39 S27 K04 NON MONTATO
2 3 4 1

V2.5
V2.5
A1 A1 1 2

A-B1
2
1 A-B1 L0.5
C
Y6 NOT CONNECTED
0
3
HEATING MOTOR Y3 15/1 30/3 L/6
0 1
15/1 30/3 L/6
0 1
15/1 30/3 L/6

N0.5 S3 NON MONTATO

B 85 30
M1 NOT CONNECTED
85 30 A + 1 2 1 4 3 2 1
KUE 312612133
49/4 30B/2 R/7 49/4 30b/2 R/7 49/4 30b/2 R/7

L-N4
R/N1

R/N1
H-G1.5
S4

N0.5
1
X45

N1
X25

S-G1

S-G1
X20
B-N1

C-N1
B-N1
S2 S1

V/N1

V/N1
N1
KUE 312612112

R1.5
2
C-N1

N1
3 I

K06
Z1.5 A-R1 15 15 I
4
H-R1 0A002211
F8 N1

N2.5
B1.5
V-N2.5
A1.5
85 87

V-N2.5
53M

V2.5
5 53M
B-N1 T
C-L1
XD2 KC 15A 31 T
31
86 30
X19

R1.5

L4
A1 A1
9
SM2 KUE 312608066

O
A-B1 A-B1
8
V-B1 B/V1 C-L1
7
H1
6 C-N1
M-V1 M-V1
5
R-V1 R-G1
4
SM3 SM1
G/N1
3
2
G/N1 X28 M-B1

MANIPOLATORE
G/N1 G/N1
1 12 C/B1
11

JOYSTICK
M-V1 10
SM4
54D

G-V1 9
N1 N1
L

8
C-L1
54S

7 M/N1
C-N1 6
M-B1
SM5
31
49

5
M/N1 4
C/B1 3
LIGHTS SWITCH

C-B1 2
C-B1
57/58

30

1 N1 M-N1 1
DEVIO LUCI

A/B1
2
SM6

N
C1
56b

3
4 V1.5 G-V1
G-V1.5 M-N1
CENTRALINA FLASHER

5
56a

6 A-G1
7 L1 1 B-R1
H-N1.5 B/R1 C-N1
FLASHER UNIT

8 2
9 R-N1.5 3 A-N1
A1 Y1

1
4
L1
XD1 5
6
7 N1
8 L/N1

2
9 R-G1
10 A/N1 N1
11 A-G1
12 A-B1 V/N1
A/B1
13
EV4
SX
DX

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

H-N1.5

R-N1.5
B-R1.5
X40

H-R1

A-G1
M-N1

M-N1
A-V1
R-G1

G-R1

G-N1

M-B1

M/N1
G-R1
A/V1

G1.5
R-N1

Z-B1

G-V1

C-L1
Z-N1

A-R1

A-N1

R/N1
B-N1

R-V1

R-V1
H/N1

A-R1

R/N1

B-R1
V-N1

L/B1

H-L1
V1.5

V-B1

Z/N1
Z1.5

Z/B1

R1.5

L/N1

A2.5
A2.5

N1
L1.5
X27

A-V1
R-N1.5
C1
N1

G1
G1
S1

B1

S1

V1

G-N1
R1

H-L1

A-N1
G1

M
N1

X32
N1 6
N1

X2

X9

X5
X8
V/N1 V/N1
MONITOR 4WS 5

H15
H1 C/B1

HA4
4

S15 XC1 HA3 C/B1 C/B1

R-N1.5
3
EV2

B/N1
B/V1
C-B1 C-B1

N1.5
N1
L0.5

N2.5

N2.5
N2.5
2

N1.5
1 2 3 4 5 6 7 8 9 10 11

N1
N1
N1

N1

N1

N1
N1

N1
N1
N1

N1
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 M-N1 1
M-N1
+15
D21

X21

X30
ALIMENTAZIONE AL KIT N1

N1.5

N1.5
N1

N1

N1
AUTORADIO CONDIZ. C-B1

B-R1
A-V1
G2.5

1
2
1 2 3

R1
CHECK SERVICE TO CONDITIONING EV1

L4
R6
D14 RADIO

B/N1
B/V1
N1

R-N1.5
N1.5
D20 POWER SUPPLY KIT
4 3 2 1
N1

N2.5

N1.5
N1

N1
N1

N1

N1
X14

X12
1 2 3

K9 KUE CAO142658 CA142658 M5 M-N1

R31

L
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
EV3

A-V1
S24

G2.5
B-R1.5
R1.5
+

L4
R4
+15 M
XM1

XM2

+15

D5 K4
R C
86 87a 87 L11 L17 L18 L20

R19 L19
R22 L22
R12 L12

R13 L13
L14

F3A
K7 R5 F N1

R3
KUE 312612103
R27

UP
0A000571
M-N1
A-B1

L-G1

A-V1
M-B1
M-V1

G-R1

Z-N1
V-B1
H-R1

A-G1

Z-B1

C-N1

S-G1

G-V1

R-N1
B-R1
B-N1
A-R1

R/N1

N1.5

R1.5

L-B1
S-N1

R-V1
V-N1

S1

V1
M1

G1
N1

F3C

D19
D18
86 87a 87
S19

F5A
85 30

R17

R20
R18
R11

F6A
F2B

F5B
N
F2C

F5C

F4A

F3B
F6C
KUE 312612068

R14
CARRARO
7.5A
1/4W 7.5A
D8 1/4W 1/4W
DOWN
85 30
0A001543 7.5A 1/4W 15A 1/4W 15A 1/4W 15A 1/4W
R AUT

R4
L27

10A 1/4W 7.5A 1/4W 10A 1/4W

L5 10A 1/4W 15A 1/4W

L3

A-N1.5
D17

D15
D16

H/N1
1/4W
D22 +30 +15 +15 +15 +15 +30 +15 +15 +15

S1
0A002248

V1
X49
L4

V-B1
A B C D E F G H J K L M N P R S T U V WX Y Z a b c d e f g h i 1 2 3 4 5 6 7 8 9
J18

Y7

RXD
R32

TXD

I
J31

J29
HA1

RXD
TXD
J05
J06
J07
J08
J16
J03
J29
J23
J24
J22
J20
J19
J21
J17
J18

J04
J25
J28

J29
J14
J09
J12
J10
J32
J26
J31
J13
J14
J11
X4 KUE 312612115 S22 S23 S21
A-G1
1
X7 p p t
V-B1 J16
2 1
V-N1 J29
3 2
J12 J17 t
4 3
R1.5 J03

N1.5
5 4

N1

N1

N1

N1
N1.5 J31
A-V1
6
7
5
6
J28 Y8
B-N1
Z-N1
8 L23 7
J25
J24
9 8
G1 J17
10 9
S1
11
J21
J05
D13 F7A R23
S30 Y9
7.5A 1/4W
p
S7

H
H33

J19
+15
+30 X16
N1 N1
Y10
F4B

B
R15

J06 A-V1 A-V1

A
+30

K5 S31
10A 1/4W p
D6 86 87a 87

N1.5
+15 +30

N1
N1
N1
N1

N1
N1
J20
D3 +30
K8
L15

S8
H34

K6

F7C

F2A

F1B
F1C
85 30
Y11 XAD

R10
R25

L7

L8
R6
86 87a 87
H-R1 86 87a 87 Z-B1
1 l
A-B1 Z/B1
2
G-R1 D7 D9 1/4W 7.5A 1/4W 10A 1/4W 3A 3A J07
-
F1A

85 30
R28

R8
R7
85 30
R2 S32

D12
4
J22
C-N1
K2

L25

L10
5
S-N1
C1 D2 X13
R29
F4C

6 1/4W 1/4W p
R9

15A 1/4W L4 L4

G
G-V1 86 87a 87
R24 L24
Y12
R21 L21

L6
7 l
N1 1/4W
8 -

J04

J29

J31

J14

J13
L28

R16

D11
9 15A 1/4W 1/4W
H35

S9

D10
22µF 85 30
XT2 KT2
M-N1

M-B1
S-G1

L-G1
A-R1

L9

10
L-B1

R1
F6B

F7B

11 1/4W
M-V1
Z-B1
R-N1
R/N1

R-V1

B-R1

S36 N1
L29

S34 S35 X11

M1

12
L2 1 53S
V1

R1
R1
N1
X51

J23 R4 R4 G/N1
13
P4
L16 +30 R4 J08
p t
R4 1
R4 R-V1
2
3
15
7.5 1/4W 10A 1/4W
01170894 Y13 G2.5 G2.5 M1
X52 1 2 3 4 5 6 7
S33 2 4 53M
X6

3 31
1 2 3 4 5 6 7 8 9 10 11 12 KUE 312612118 p
XE

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
KUE 312612108
X1
X3
J10
J09
J32
J26
J21
J11

CA114180
R/N1
A-G1
L-B1

N1.5
S-N1

Z-N1.5

B-N1
V-B1

Z/N1
Z-B1

B-R1
H/N1

N1.5
S1

V1

R-N1.5
A-N1.5

Y1(S)

G/N1

F
Z/B1
N1 K01
86 87
X10
DESCRIPTION

V1
A-N1.5 A-N1.5
Y2(S) H/N1
1
2
H/N1 85 30
S1 S1
3

G2.5
B-N1
V1 V1
4
R-N1.5 R-N1.5
5
N1 V-B1 V-B1
6
Z/N1 Z/N1
7
B-R1 B-R1
8
R-V1 Z-B1 Z-B1
9
M-V1 M-V1
Y3(S) 10
MODIFICATION

B-N1 B-N1

N1
11
R-V1 R-V1
12
A-V1 A-V1
13 R30

E
N1

M-V1
C-L1
********** =COD. CARRARO
Z-N1.5
A-G1

H-N1
S-N1
N1

R-N1

X43
A-B1
N1.5

N1.5

L-B1
Y4(S) 1 2

A1
X23

N1
M-V1
Z-B1

M10
B-R1

M1
R1

R1

N1

X37

X36

X22
S16 S18 S17
RP1 p
N1

N1

N1
S28 S29

M10

B1.5
1 2

R10
L4
R4
R4
******* =COD. CIAM

M-V1
1 2 1 2 l -

KUE 312612102 KUE 312612112

N1.5

N1.5

N1.5

N1.5

N1.5
N2.5

N2.5
B-R1

B-R1

K02
N1

N1
N1

N1
N1
N1

POMPETTA 60A 80A 30A 80A 86 87

OPZIONAL LAVAVETRO
0A001542

FUG1

FUG2

FUG3

FUG4
OPTIONAL H29 H28 0A002211 85 30
=COD. SIAC

M10
WINSHIELD WASHER *******

N1
CHECK

PUMP

D
Z-B1
B-R1
R50
XT1 KT1
SUBST.MICRO

G2.5

Z/N1
R10

R10
N1 53S
NO

1
B-R1
S13 - l G1
2
3
53M
B/R1
NAME DESCRIPTION NAME DESCRIPTION NAME DESCRIPTION NAME DESCRIPTION NAME DESCRIPTION NAME DESCRIPTION NAME DESCRIPTION NAME DESCRIPTION 31

XA
4
SI

15

EV1 OPENED GRAB SOLENOID VALVE

FUG4 GENERATOR FUSE 80A H36 REAR RIGHT STOP LIGHT AND SIDE LIGHT M1 STARTER MOTOR S1A 4 WD SWITCH ON FRONT DASHBOARD (ONLY SHUTTLE) S8 ROUND STEERING BUTTON X14 FRONT LINE-CROSS LINE 4 WAY CONNECTOR X4 MONITOR 11 WAY CONNECTOR

N1.5
N1

N1

N1
G2

R50
DIS.

50
EV2 CLOSED GRAB SOLENOID VALVE G1 BATTERY H37 REAR LEFT STOP LIGHT AND SIDE LIGHT M2 WASHER PUMP S1L REAR WORKING LIGHT SWITCH ON LAT. DASHBOARD S9 CRAB STEERING BUTTON X15 START KEY 4 WAY CONNECTOR X40 FLASHER UNIT 13 WAY CONNECTOR M1 30 D+

B/R1

B1.5
M 30 G W

EV3 DIFFERENTIAL LOCK SOLENOID VALVE G2 GENERATOR H38 COURTESY LIGHT M3 WINDSHIELD WIPER MOTOR S2 REAR 1^ BOOM UNLOCK SWITCH SM1 KICK DOWN X16 CONDITIONER CLUTCH 2 WAY CONNECTOR 3
G1 K03 86 87
EV4 REAR 1^ BOOM UNLOCK SOLENOID VALVE H1 PREHEATING WARNING LIGHT H4 ENGINE OIL PRESSURE WARNING LIGHT M4 BLOWER MOTOR S21 ENGINE WATER HIGH TEMPERATURE SWITCH SM2 CONTROL-SQUARE BUTTON X17 LATERAL DASHBOARD 21 WAY CONNECTOR U
DATE

F1A LOW BEAM FUSE 15A H10 CONVERTER OIL HIGH TEMPERATURE WARNING LIGHT H5 AIR FILTER WARNING LIGHT M5 FUEL PUMP S22 AIR FILTER BLOCKED SWITCH SM3 CLOSED GRAB BUTTON X18 FRONT CABLE 5 WAY CONNECTOR X43 NOT CONNECTED 2 WAY CONN. 12Vcc
31

C
85 30
F1B RIGHT TRAFFIC LIGHT FUSE 3A H11 4WD WARNING LIGHT H6 HYDRAULIC OIL FILTER WARNING LIGHT M8 WINDSHIELD WIPER MOTOR S23 ENGINE OIL LOW PRESSURE SWITCH SM4 CONVERTER DETACHMENT BUTTON X19 FRONT DASHBOARD 9 WAY CONNECTOR X45 POWER ECONOMY UNIT CONNECTOR

B1.5
G1
F1C LEFT TRAFFIC LIGHT 3A H12 FUEL RESERVE WARNING LIGHT H7 OPTIONAL WARNING LAMP H3 ENGINE WATER HIGH TEMPERATURE WARNING LIGHT S24 FUEL GAUGE SM5 OPENED GRAB BUTTON X2 LIGHTS SWITCH AND GEAR SHIFT LINE 9 WAY CONNECTOR X46 WINDSHIELD WIPER 4 WAY CONNECTOR

N50
INDEX MOD.

F2A ROTATING LAMP FUSE 10A H13 KOMATSU LOGO LIGHT H8 OPTIONAL WARNING LAMP M1 STARTER MOTOR S27 NPN SENSOR SM6 DIFFERENTIAL LOCK BUTTON X20 BLOWER MOTOR 4 WAY CONNECTOR X47 12 VOLT CURRENT INTAKE BEACON LIGHT

H9 M2
XAM
F2B RADIO CABIN LAMP FUSE 7.5A H14 KOMATSU LOGO LIGHT ENGINE WATER HIGH TEMPERATURE WARNING LAMP WASHER PUMP S28 FRONT AXLE PROXIMITY SWITCH Y1(S) 4WS SOLENOID VALVE X21 FUEL LEVEL INDICATOR 3 WAY CONNECTOR X49 EGM PROGRAMMING CONNECTOR
N1.5 1
N1.5 Y0
R-N1.5 R-N1.5
F2C WARNING FUSE 10A H15 CIGARETTE LIGHTER LAMP (OPTIONAL) HA1 HORN M3 WINDSHIELD WIPER MOTOR S29 REAR AXLE PROXIMITY SWITCH Y2(S) 2WS SOLENOID VALVE X22 WINDSHIELD WASHER PUMP 2 WAY CONNECTOR X5 CABIN COMMAND 11 WAY CONNECTOR B1.5
2
B1.5
3
F3A STARTING FUSE 7.5A H16 CABIN LAMP HA2 BUZZER M4 BLOWER MOTOR S30 1º SPEED PRESSURE SWITCH Y3(S) ROUND STEERING SOLENOID VALVE X23 OPTIONAL 2 WAY CONNECTOR X51 4WS WIRING 12 WAY CONNECTOR

F3B SWITCH+WARNING LIGHT+RETURN TO DIG FUSE 10A H17 FRONT WORKING LAMP HA3 REAR HORN M5 FUEL PUMP S31 2º SPEED PRESSURE SWITCH Y4(S) CRAB STEERING SOLENOID VALVE X24 WINDSHIELD WIPER 4 WAY CONNECTOR X52 STEERING BUTTON 13 WAY CONNECTOR

F3C OPTIONAL VALVE FUSE 7.5A H18 FRONT WORKING LAMP HA4 BUZZER M8 WINDSHIELD WIPER MOTOR S32 3º SPEED PRESSURE SWITCH Y0 FUEL SHUT OFF SOLENOID VALVE X25 POWERED BLOWER MOTOR 2 WAY CONNECTOR X6 NOT CONNECTED 9 WAY CONNECTOR

F4A 4WD VALVE-WINDSHIELD WIPER/WASHER FUSE 7.5A H19 BEACON LAMP K01 STARTER RELAY P1 RPM INSTRUMENT S33 4º SPEED PRESSURE SWITCH Y1 ECONOMY POWER SOLENOID VALVE X26 REAR LINE 8 WAY CONNECTOR X7 EGM INTERFACE 9 WAY CONNECTOR

F4B FORWARD-REVERSE SPEED FUSE 10A H2 GENERATOR WARNING LIGHT K02 PREHEATING RELAY P2 HOUR COUNTER S34 GENERAL GEAR OIL PRESSURE SWITCH Y3 PLATE UNLOCK SOLENOID VALVE (ONLY EUROPE VERS.) X27 VALVES LINE 6 WAY CONNECTOR X8 LATERAL DASHBOARD 17 WAY CONNECTOR

B
TOOL DESCRIPTION

F4C HIGH BEAM FUSE 15A H20 REAR WORKING LIGHT K03 FUEL SHUT OFF RELAY P3 FUEL LEVEL INDICATOR S35 GEAR OIL TEMPERATURE SWITCH Y6 RETURN TO DIG MAGNETIC X28 JOYSTICK 12 WAY CONNECTOR X9 FRONT DASHBOARD 17 WAY CONNECTOR

F5A BLOWER MOTOR SWITCH 15A H21 REAR WORKING LIGHT K04 3º SPEED BLOWER RELAY ( ONLY A/C VERSION) P4 WATER TEMPERATURE INSTRUMENT S36 RPM SENSOR Y7 FOWARD SOLENOID VALVE X29 CONVERT DETACHMENT BUTTON 2 WAY CONNECTOR XA GENERATOR 2WAY CONNECTOR

F5B REAR WORKING LIGHT SWITCH FUSE 15A H22 INDICATORS WARNING LIGHT K05 RETURN TO DIG RELAY R30 HEATING START S37 REAR DOOR SWITCH Y8 BACKWARD SOLENOID VALVE X3 FRONT LINE 11 WAY CONNECTOR XAD DIODE 2 WAY CONNECTOR

F5C FRONT WORKING LIGHT SWITCH FUSE 15A H23 HIGH BEAM WARNING LIGHT K06 POWER ECONOMY UNIT R31 FUEL LEVEL SENDER S2A WINSHIELD WIPER-WASHER SWITCH ON FRONT DASHBOARD Y9 3º SPEED SOLENOID VALVE X30 FUEL PUMP 2 WAY CONNECTOR XAM FUEL SHUT OFF VALVE 3 WAY CONNECTOR

F6A WINDSHIELD WIPER-WASHER SWITCH FUSE 15A H24 LOW LEVEL BRAKE OIL WARNING LIGHT KC LOAD FAN HEATER RELAY R32 WATER TEMPERATURE SENDER S2L WINDSHIELD WIPER-WASHER SWITCH ON LAT. DASHBOARD Y10 1º SPEED SOLENOID VALVE X31 CABIN 5 WAY CONNECTOR XM1 MONITOR 20 WAY CONNECTOR

F6B LIGHTS SWITCH POWER FUSE 7.5A H25 DIFFERENTIAL LOCK WARNING LIGHT K2 REVERSE SPEED RELAY RP1 REAR AXLE POTENTIOMETER S3 PLATE UNLOCK SWITCH (ONLY EUROPE VERS.) Y11 2º SPEED SOLENOID VALVE X32 RADIO POWER 2 WAY CONNECTOR XM2 MONITOR 18 WAY CONNECTOR

F6C WARNING POWER FUSE 10A H28 RIGHT FRONT INDICATOR K4 GEAR NEUTRAL POSITION RELAY S1 ECONOMY POWER PUSH BUTTON S3A FRONT WORKING LIGHT SWITCH ON FRONT DASHBOARD Y12 4º SPEED SOLENOID VALVE X33 WINDSHIELD WIPER AND BEACON 7 WAY CONNECTOR XD1 LIGHTS SWITCH 9 WAY CONNECTOR

F7A MONITOR POWER FUSE 7.5A H29 LEFT FRONT INDICATOR K5 LOW BEAM RELAY S10 HAMMER BUTTON S3L BEACON SWITCH ON LAT. DASHBOARD Y13 4WD SOLENOID VALVE X36 RIGHT FRONT INDICATOR WAY CONNECTOR XD2 NOT CONNECTED 5 WAY CONNECTOR

F7B HORN FUSE 10A H3 ENGINE WATER HIGH TEMPERATURE WARNING LIGHT K6 MAIN BEAM RELAY S13 BATTERY STOP SWITCH S4 BLOWER MOTOR SWITCH XC1 CIGARETTE LIGHTER (OPTIONAL) X37 LEFT FRONT INDICATOR WAY CONNECTOR XE EGM INTERFACE 7 WAY CONNECTOR

F7C FUEL SHUT OFF FUSE 7.5A H30 REAR LEFT INDICATOR K7 EGM POWER SUPPLY S15 HAND BRAKE SWITCH S4A WARNING SWITCH ON FRONT DASHBOARD X1 FRONT LINE(ENGINE) 11 WAY CONNECTOR XS MULTIFUNCTION INSTRUMENT 6 WAY CONNECTOR

A
F8 HEATER FAN FUSE 15A H32 REAR RIGHT INDICATOR K8 HORN RELAY S16 BRAKE OIL LOW LEVEL SWITCH S4L HORN SWITCH ON LAT. DASHBOARD X10 FRONT LINE-ENGINE LINE 13 WAY CONNECTOR X39 PROXIMITY 3 WAY CONNECTOR XT1 FUEL SHUT OFF TIMER 4 WAY CONNECTOR
TOOL NUM.

FUG1 GENERAL FUSE 60A H33 2WS LAMP K9 FLASHER UNIT S17 PEDAL SWITCH S5L OPTIONAL SWITCH ON LAT. DASHBOARD X11 POWER 3 WAY CONNECTOR XT2 PREHEATING TIMER 4 WAY CONNECTOR

FUG2 PREHEATING FUSE 80A H34 ROUND LAMP KT1 FUEL SHUT OFF TIMER S18 PEDAL SWITCH S6 STARTING SWITCH X12 FRONT LINE-CROSS LINE 3 WAY CONNECTOR

FUG3 FUEL SHUT OFF POWER FUSE 30A H35 CRAB LAMP KT2 PREHEATING TIMER S19 STOP LIGHT SWITCH S7 2WS STEERING BUTTON X13 FRONT LINE-ENGINE LINE 2 WAY CONNECTOR

23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

WB150AWS-2 10-85
PAGE INTENTIONALLY
LEFT BLANK
STRUCTURE AND FUNCTION ELECTRICAL DIAGRAM (AIR CONDITIONING)

ELECTRICAL DIAGRAM (AIR CONDITIONING)

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

87
1 9
86
1 0
K04
0 86 87a 87

5 10
CONNECT WITH PRESETTING SOCKET
INSIDE LATERAL DASHBOARD 85 30
9 5 10 1
85
X58 X56 X57 X56
30

G-V1

N1
X54 3° FAN SPEED RELAY
H-G1 CONNECT TO "S4" POSITION "1"
(BLOWER MOTOR SPEED SWITCH )

N1 GROUND CONNECTION (BLACK)

(FROM OPTIONAL LAMP SWITCH CONN.)

V1 X53 INTERFACE WITH EXTANT WIRE A-V1

K10 (INSIDE LATERAL DASHBOARD )
WIRING COLOURS
86 87a 87
C1

85 30 A LIGHTBLUE
X16
85 30 86 87 CONNECT WITH PRESETTING A B WHITE
X55 CONNECTOR NEAR GENERATOR X16
X55 X55 X55 B
C ORANGE

N1 V-N1 G YELLOW

G-V1 G-V1 H GREY

COMPRESSOR
A B L BLUE
ELECTROMAGNETIC
X59 X59 CLUTCH
M BROWN

V-N1 N BLACK

G-V1 R RED

S PINK

2 1 2 1
V GREEN

X62 X62 X61 X60 Z VIOLET

X33
S40 S10 X20
p 4 EXAMPLE:
t X20
CONNECT WITH PREVIOUS 3
HEATER MOTOR CONNECTOR X20 G/V ->YELLOW/GREEN (TRANSVERSE MARKED)
2
X20
1 BLACK YELLOW GREEN
M4
M

G-V ->YELLOW-GREEN(LONGITUDINAL COLOURS)

NAME DESCRIPTION NAME DESCRIPTION

YELLOW GREEN
K04 3° FAN SPEED RELAY X56 A/C SWITCH SWF CONNECTOR

K10 COMPRESSOR ELECTROMAGNETIC CLUTCH CONTROL RELAY X57 AMP 1 WAY CONNECTOR HEATER/CONDITIONING

M4 FAN MOTOR
MOTOR UNIT
X58 AMP 1 WAY CONNECTOR

R33 SPEED RESISTOR X59 2 WAY CONNECTOR

RKZ07450
S10 NO FROST THERMOSTAT X60 NO FROST THERMOSTAT 1 WAY CONNECTOR

S39 A/C SWITCH X61 NO FROST THERMOSTAT 1 WAY CONNECTOR

S40 A/C SAFETY SYSTEM PRESSURE SWITCH X62 SAFETY PRESSURE SWITCH AMP MINITIMER 4 WAY CONNECTOR

X53 AMP 1 WAY CONNECTOR X16 COMPRESSOR ELECTROMAGNETIC CLUTCH 2 WAY CONNECTOR

X54 FEMALE FASTON X20 HEATER/CONDITIONING MOTOR UNIT AMP 4 WAY CONNECTOR

X55 MINI-RELAY CONNECTOR C1 COMPRESSOR ELECTROMAGNETIC CLUTCH

WB150AWS-2 10-87
PAGE INTENTIONALLY
LEFT BLANK
GROUP 20
40-28 PC15R-8
 TESTING AND ADJUSTMENTS

Normal or standard technical data............................. 2 Testing and adjusting of unloading valve .................35
Special tools ............................................................ 14 Checking unloading valve functionality ....................36
Measuring engine speed ......................................... 15 Testing priority valve operation ................................37
Adjusting valve clearance ........................................ 16 Testing and setting steering
Measuring compression pressure ........................... 17 control system pressure ...........................................38
Testing and adjusting fuel injection timing............... 18 Testing brake system ...............................................39
Checking and tightening the fan - belt ..................... 20 Control of the engine speed under load ...................41
Checking and tightening the compressor fan - belt . 21 Testing pressures in the power train group ..............43
Measuring accelerator pedal operating Testing the correct functioning of the power train
travel and accelerator lever ..................................... 22 clutches ....................................................................45
Adjusting brake pedal travel, brake alignment, Adjusting the sensor for Return to Dig device .........46
microswitches .......................................................... 24 Analysis of causes hydraulic drift ............................47
Air bleeding - releasing residual pressure ............... 25 Testing the air-conditioning unit ..............................52
Checking and setting pressure in the attachments Emptying the air-conditioning unit ............................54
hydraulic circuit ........................................................ 28 Troubleshooting........................................................55
Testing and adjusting of load sensing signal
(LS valve) ................................................................ 34

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).

WB150AWS-2 20-1
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA

NORMAL OR STANDARD TECHNICAL DATA

FOR ENGINE

Machine model WB150AWS-2

Engine S4D106-1FA
Standard Permissible
Check item Test condition Unit
value value
High idling rpm 2375±50 2325–2425
Engine speed Low idling rpm 1050±50 1000–1100
Set speed rpm 2200 --
Exhaust gas Sudden acceleration Bosch 0.9 1.5
colour At high idling speed index 0.5 1.0
Intake valve (20°C) mm 0.30±0.05 Max. 0.35
Valve clearance
Exhaust valve (20°C) mm 0.30±0.05 Max. 0.35
Compression
Oil temperature 69 – 72°C bar 34.3±1 27.5±1
pressure
(Engine speed) rpm 250 250
(SAE30 oil)
Blow - by
Water temperature in operating range -- --
pressure mm H2O
At high idling speed -- --
(oil SAE30)
Max. idling (in cold state) bar Max. 5.8 Max. 5.8
Engine oil
At set speed bar 4.4 3.9–4.9
pressure
At low idling bar 1 Min. 1
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 WB150AWS-2
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA

FOR MACHINE

Machine model WB150AWS-2

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

• Hydraulic oil temperature:

45 – 55 °C Max. 2375±50 2325–2425
• Converter oil temperature:
Accelerator pedal 80 °C
• Engine oil temperature
Engine speed

cooling circuit: Min. 1050±50 1000–1100

in the limits
rpm
• Hydraulic oil temperature:
45 – 55 °C Max. 1950±50 1900–2000
• Converter oil temperature:
Accelerator lever 80 °C
• Engine oil temperature
cooling circuit: Min. 1050±50 1000–1100
in the limits

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 5 -- -- -- --
(with floating arm) RKZ02580

Front bucket tilt lever Raise

Neutral 50 60–110
control Lower
Front bucket control Dump
Neutral 115 90–140
lever Curled
Boom backhoe control Raise
Neutral 100 80–120
lever Lower
Travel of levers and pedals

Arm backhoe control Opening

• Engine stopped Neutral 100 80–120
lever Closing
• At the centre
Bucket backhoe control of knob lever Opening
• Valve reading Neutral 100 80–120
lever Closing mm
at the end of
Boom swing working stroke Right
Neutral 100 80–120
backhoe control lever • Attachments Left
on the ground
Outriggers control Up
Neutral 50 30–65
lever Down
Fuel control lever Min. Max. 70 50–90
Telescopic arm Out 15 10–20
Neutral
control pedal In 30 20–40
Right 15 10–20
Breaker control pedal Neutral
Left 30 20–40

WB150AWS-2 20-3
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA

FOR MACHINE

Machine model WB150AWS-2

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

• Engine stopped
Accelerator pedal • At the centre Min. Max. mm 80 60–100
of knob lever
pedals

• Valve reading
at the end of
working stroke Right Left
Wheel swing • Attachments rev. Max. 2.5 2.2–2.5
on the ground Left Right

Front bucket tilt lever

2.5 2–3
control
Front bucket control
2.5 2–3
lever
Boom control
1.5 1–2
lever
Force for levers and pedals operation

Arm control
1.5 1–2
lever
Bucket control lever • Engine speed: max. 1.5 1–2
Boom swing • Oil temperature: 45 –55 °C
• Tool connection at the 1.5 1–2
control lever centre of knob kg
Outriggers control (for levers)
• Tool connection on edge 3 2.5–3.5
lever
(for pedals)
Fuel control
12 10–14
lever

Telescopic arm control In 4 3–4

pedal Out 8 6–10
Breaker
8 6–10
boom control pedal
Accelerator pedal 3 2–4
Brake pedal 30 Max. 60

20-4 WB150AWS-2
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA

FOR MACHINE

Machine model WB150AWS-2

Classifi- Standard Permissible
cation
Check item Test condition Unit
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 220 220±7

• Engine speed: 1500±50 rpm

Steering unit 175 175±7
• Oil temperature: 45 – 55 °C

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

Front bucket
175 175±7
(dump)
Attachment
235 235±7
(3rd spool) ✽ • Engine speed: 1050±50 rpm
Boom • Oil temperature: 45 – 55 °C
• Check one circuit at the time 355 355±7
(raising) ✽ bar
Boom (lowering) ✽Check on bench test 245 245±7
(do not check on the machine)
Arm (Closing) 245 245±7
Boom swing 190 190±7
Bucket (curled) 245 245±7
Breaker (delivery) 170 170±7
Steering unit ✽ 240 240±7

WB150AWS-2 20-5
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA

FOR MACHINE

Machine model WB150AWS-2

Classifi- Standard Permissible
cation
Check item Test condition Unit
value value
Engine speed (with load) - Converter

• Engine speed (without load): 2375±50

• Hydraulic oil temperature: 45 – 55 °C
With converter • Converter oil temperature: 80°C 2275–50 2225–2325
• Machine in 4th gear
• Working brakes applied

rpm
• Engine speed (without load): 2375±50
• Hydraulic oil temperature: 45 – 55 °C
• Converter oil temperature: 80°C
With converter and
• Machine in 4th gear 2000±50 1950–2050
hydraulic circuit • Working brakes applied
• Front bucket curled stop
• Steering at the end of stroke

20-6 WB150AWS-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 telescopic arm) closed.
FOR MACHINE

Machine model WB150AWS-2

Classifi- Standard Permissible
cation
Check item Test condition Unit
value value
Measuring posture
Complete working
equipment
250 400
(Tip lowering of
bucket teeth)
~10°
Front bucket

RKZ06790

Cylinders
mm 30 45
(cylinder in)
• In this position check in feedback of each cylinder
and the leakage with applied load on the tip of
bucket teeth.
• Ground level.
• Bucket: normal load (1500 kg)
Hydraulic drift working equipment

• Engine stopped
Bucket cylinder • Oil temperature: 45 – 55°C
• Check measures as soon as engine 15 25
(cylinder in)
stops.
• Check changes every 5 min. and the total change
in 15 min

Measuring posture
Complete working
equipment
300 450
(Tip lowering of
bucket teeth)

Boom cylinders
35 50
(cylinder out)
1m
Backhoe

RKZ06870 mm
• In this position check the extension of each cylin-
Arm cylinder der and the leakage with normal load on the buck-
15 25
(cylinder out) et.
• On level ground.
• Bucket: normal load (450 kg)
• Engine stopped
• Oil temperature: 45 – 55°C
Bucket cylinder • Check measures as soon as engine stops.
• Check changes every 5 min. and the total change 10 15
(Cylinder in)
in 15 min.

WB150AWS-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 telescopic arm) closed.

FOR MACHINE

Machine model WB150AWS-2

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

RKZ06800
Boom swing 15 25

• Oil temperature: 45 – 55 °C
• 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
cylinder feed back opposite to the boom every 5
min. for a total of 15 minutes.
Backhoe

• Make the test for each swing direction

mm

Measuring posture

Outriggers RKZ02690 20 30

• 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 WB150AWS-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 telescopic arm) closed.

FOR MACHINE

Machine model WB150AWS-2

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

2.0
Front bucket

Boom Max. 8.0

(each cylinder)

1.6
Bucket Max. 6.0
(each cylinder)

Boom 3.5 Max. 15.0

• Engine: Max. speed

Cylinder leaking

Arm • Oil temperature: 45--55°C 3.2 Max. 13.0

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

check the two cylinders separately.

Boom swing 3.2 Max. 13.0

Outrigger 3.3 Max. 13.5

Telescopic arm 1.6 Max. 6.0

WB150AWS-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 telescopic arm) closed.

FOR MACHINE

Machine model WB150AWS-2

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

Raised
bucket 3.6 3.1–4.1

Cylinders
extended out

Lowered
RKZ06810
Bucket on 2.5 2.1–2.9
• Engine speed: Max.
level ground • Oil temperature: 45 – 55°C
Loader

• Speed up
Measuring posture

Curled
Bucket 2.5 2.1–2.9

Cylinder out
Dump

RKZ06820
Cylinder in 3.2 2.7–3.7
Work equipment speed

• Engine speed: Max.

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

Measuring posture sec.

Raised ✽

Boom 2.3 1.9–2.7

Cylinder in
Lowered

Teeth bucket on level RKZ01580

ground 0 1.6 1.2–2.0

• Engine speed: 1700 + 50 rpm
• Oil temperature: 45 – 55°C
Backhoe

• Power mode

Measuring posture
Opening

3.4 2.9–3.9
Arm

Cylinder in
Closing ✽

RKZ01590
Cylinder out
4.3 3.8–4.8
0
• Engine speed: 1700 + 50 rpm
• Oil temperature: 45 – 55°C
• Power mode

✽ From starting up to slowing down of cylinder

20-10 WB150AWS-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 telescopic arm) closed.

FOR MACHINE

Machine model WB150AWS-2

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

Dump
Bucket 2.1 1.7–2.5

Cylinder in

RKZ01600

Curled
Cylinder out 0 2.9 2.5–3.3
• Engine speed: 1700 + 50 rpm
• Oil temperature: 45 – 55°C
• Power mode
Work equipment speed

Measuring posture
Backhoe

sec.

Right
3.5 3.1–3.9

Boom swing

Left end travel

Right end travel RKZ06830

Left

0
• Engine speed: 1700 + 50 rpm 3.5 3.1–3.9
• Oil temperature: 45 – 55°C
• Arm horizontal
• Power mode
• From starting up to slowing down of cylinder

NOTE. The engine speed (1700 +0 50 rpm) has to be checked with the procedure described at paragraph
«MEASURING ENGINE SPEED» in this section.

WB150AWS-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 telescopic arm) closed.

FOR MACHINE

Machine model WB150AWS-2

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

Tilt lever front

0 Max. 2
bucket
RKZ06810

• 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 RKZ01610 sec. 0 Max. 2

• 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 0 Max. 2
RKZ01621

• 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 WB150AWS-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 telescopic arm) closed.

FOR MACHINE

Machine model WB150AWS-2

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

Bucket 0 Max. 2
RKZ01630

• Engine speed: Min.

• Oil temperature: 45 – 55°C
• Put arm in horizontal position. Tilt back bucket
cylinder an then extend it.
Check the time passing between bucket stop at
Work equipment

dead centre and the restart movement.

Time lags

Measuring posture sec.

Outriggers 0 Max. 2

RKZ02700

• 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.

WB150AWS-2 20-13
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
Hydraulic pressure E available
Commercially
4 Pressure gauge 1 Full scale 600 bar
available
5 Servocontrol kit
ATR800200 Differential digital 1 0 – 1000 bar
6 pressure gauge
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

20-14 WB150AWS-2
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. C1
★ Check speed when following condition are reached:
• Engine water cooling temperature: 68 – 80 °C.
• Hydraulic oil temperature: 45 – 55 °C.

1 - Install and connect C1 tachometer.

★ If using C2 stroboscopic tachometer, mark a light
notch on, engine pulley for an easier reading.

2 - Start engine and check:

• Low idling speed without load (accelerator pedal RKZA5380

and accelerator lever released in «minimum» po-

sition).
• High idling speed without load (accelerator pedal at
the end of stroke).
★ Low idling speed: 1050±50 rpm
★ High idling speed: 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-
ATOR LEVER ADJUSTING»).

WB150AWS-2 20-15
TESTING AND ADJUSTMENTS ADJUSTING VALVE CLEARANCE

ADJUSTING VALVE CLEARANCE

★ Engine: in cold state.
★ Adjust clearance between valves and rocker levers as
follows: 2
Unit: mm 1
At cold Engine Intake-exhaust
engine S4D106-1FA 0.30±0.05

3
★ 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.

RKZB5020

• Adjusting procedure
1 - Remove air cleaner (1), muffler (2) and valves cov-
er (3). 5
2 - Rotate crankshaft in normal direction as long as
4
cylinder piston to be checked is at compression
Top Dead Center (PMS).
★ In this position intake and exhaust valves are
closed.
3 - Loose lock nut (4) and unscrew tappet (5) of about
6
YES
SI NO
1 turn.
★ Check that valve insert (6) is laying flat on valve
stem and that it is not worn askew.
• If valve inserts (6) are damaged, replaced them RKZ01913
7
with new ones.
• Make sure that inserts feet and lay flat on valve
stem.
4 - Connect A1 feeler gauge between insert and rock- 5
er lever to adjust; rotate the tappet (5) until touching
4
A1 feeler gauge. A1
Tight tappet (5) with lock nut (4).
Nut: 14.7 – 19.6 Nm
★ After tightening the lock nut, check the clearance
again.
5 - Adjust with same procedures second cylinder
valve and repeat same operation for the other cyl-
inders, according to the firing order. RKZ01922

• Cover valves installation

1 - Check condition of cover valves (3), gasket (7), O- 3 9
Rings (8) and lock nuts (9); clean carefully contact
surface on cylinder head. 8
2 - Install valves cover (3), fit O-Rings (8) and lock nuts
(9).

Cover lock nut: 25±3 Nm

7
RKZ01932

20-16 WB150AWS-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 2
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: 1
• Engine: at operating temperature
• Hydraulic oil: 55 – 60°C.
• Battery: at full charge
RKZA5320

• Valve clearance:
adjusted (see «ADJUSTING VALVE»)

1 - Disconnect high pressure pipe (1). 4

2 - Remove nozzle holder assembly (2) of cylinder to be
checked.

3 - Disconnect connector (3) of fuel cut-off solenoid valve

(4).

4 - Crank engine with starting motor. 3

RKZA5330

5 - Install B2 adapter and connect B1 pressure gauge.

★ Check that seal is installed in the adapter and that it B1
is not damaged.

6 - Crank engine with starting motor and measure com-

pression pressure.
★ Measure the compression pressure at the point
where the pressure gauge indicator remains B2
steady.
★ When measuring the compression pressure,
check also engine speed with C2 stroboscopic ta-
chometer; if speed is not within the specified range,
refer to diagram. RKZA5340

★ Compression value:
Normal: 34.3±1 bar at 250 rpm
Minimum permissible: 27.5±1 bar at 250 rpm
★ Difference between cylinders: 2 – 2.9 bar
Compression pressure (bar)

39.2
7 - After measuring, install the nozzle holder assembly (2),
connect high pressure pipe, feedback pipe and con- 34.3

nector (3). 29.4

Nozzle holder collar bolts: 9.8 – 11.8 Nm 24.5

High pressure union: 19.6 – 24.5 Nm 19.6

200 250 300 350 400

Engine speed (rpm)
RKZ01943

WB150AWS-2 20-17
TESTING AND ADJUSTMENTS TESTING AND ADJUSTING FUEL INJECTION TIMING

TESTING AND ADJUSTING FUEL INJECTION TIMING

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

1 - Rotate crankshaft using engine pulley and put N.

1cylinder piston at top dead centre (PMS).
1

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.
5
★ After recognition of PMS, rotate the crankshaft in coun-
terclockwise direction (from pulley side view) of about
20°.

1
RKZA5350

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

jection pump.

3 - Rotate crankshaft slowly in clockwise direction from 2

pulley side view, checking fuel level into the N. 1 delivery
of injection pump.

Nº1

RKZA0071

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

crease. Level
Nº 1
Uni on

RKZ01971

20-18 WB150AWS-2
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
RKZA5360

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

tion pump (6) toward external or toward engine after 6
loosening pump nuts (7) (quantity 4) and pump lock nuts
(8) fixing the bracket (9) to injection pump. 7
• To RETARD injection, rotate pump (6) toward ex-
ternal.
• To ADVANCE injection, rotate pump (6) toward cyl- 8
inders block.
Pump side
7 - Tight the pump lock nuts (7) at cylinder block and pump
lock nut (8) at bracket (9).
Carter side
9 Testing advance
Nuts: 34.2 – 44.1 Nm RKZA5371 injector

Bracket lock nut: 44.1 – 53.9 Nm

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

Delivery pipe union: 19.6 – 24.5 Nm

WB150AWS-2 20-19
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 (3) of the alternator (2) and 4
mounting bolt (4) of adjustment plate. 2
2 - Rotate the alternator (2) to give correct tension to fan
belt (1) and tighten mounting bolts (3) and (4).

3 - Check fan belt (1) tension.

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

7-10 mm

3
2

RKZO6750

20-20 WB150AWS-2
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 2
mm; if this value is not reached, tension fan belt. 3
★ With new belt, deflection must be of 4 – 6 mm.

RKZO6760

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

WB150AWS-2 20-21
 MEASURING ACCELERATOR PEDAL OPERATING
TESTING AND ADJUSTMENTS TRAVEL AND ACCELERATOR LEVER

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). 4 8

3
RKZA5390

3 - Adjust nut (5) and lock nut (6) of accelerator pedal ca-
bles and hand accelerator at a distance of 0.2 – 0.3 mm
from lever (7).

4 - Push accelerator pedal until accelerator lever (3) con-

tacts the high idling adjusting screw (8). 7

5 6

RKZA5400

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).

1

10
9

RKZA9340

20-22 WB150AWS-2
 MEASURING ACCELERATOR PEDAL OPERATING
TESTING AND ADJUSTMENTS TRAVEL AND ACCELERATOR LEVER

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: 2000±50 rpm
4 - Loosen end lever travel bolt (3) up to it is in contact with
lever (4) and looked with nut (2). 2

5 - Bring engine at low idling and check accelerator lever

idling speed again pushing lever at end stroke.
RKZA9360

WB150AWS-2 20-23
 ADJUSTING BRAKE PEDAL TRAVEL,
TESTING AND ADJUSTMENTS BRAKE ALIGNMENT, MICROSWITCHES

ADJUSTING BRAKE PEDAL TRAVEL, BRAKE ALIGNMENT,

MICROSWITCHES
★ 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. 6
Microswitches adjustment 7
5 - Loosen microswitches (7) locking nuts (6).

6 - Adjust microswitches (7) paying attention to guarantee 1 mm

(0.0394 in.)
(at pedals in neutral position) a minimum clearance 1
(about 1 mm) between microswitches body and the
pedal.

Checking adjustment
7 - Verify measure like shown in figure. A = 313 ± 3 mm
“A” measure: at pedal in neutral position B = 302 mm
“B” measure: at master cylinder rod touching the pump C = 292 mm

“C” measure: at pedal touching the microswitch.

RKZ03671

5 4 RKZ01951

20-24 WB150AWS-2
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.
★ 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.

WB150AWS-2 20-25
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.
1 - Make sure that oil in brake system tank (1) is at maxi- MIN.
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. 3
5 - Keeping pedal at the end stroke, tighten bleeding screw
(2).

2 RKZA9050

20-26 WB150AWS-2
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

RKZ03680

WB150AWS-2 20-27
 CHECKING AND SETTING PRESSURE IN
TESTING AND ADJUSTMENTS THE ATTACHMENTS HYDRAULIC CIRCUIT

CHECKING AND SETTING PRESSURE IN THE ATTACHMENTS

HYDRAULIC CIRCUIT
1. Introduction
STEERING UNIT
• The machine is equipped with two control valves having
following functions:
Control valve No. 1 (2-3-spools):
for front work attachments control.
Control valve No. 2 (6-7-8-spools):
for rear work attachments control.
• The two control valves are protected against overpres-
sure by a main relief valve (or general and named Pres-
sure cut off valve) with adjustable setting. MAIN RELIEF
VALVE
FRONT SHOVEL
CONTROL VALVE
(2-3 SPOOL)

POWER TRAIN

DIESEL

P1

MAIN RELIEF
VALVE

BACKHOE
• Control valves are feeded by P1 pump total delivery. CONTROL VALVE
(6-7-8 SPOOL)
• P1 pump delivery is controlled by a priority valve (inter-
nal to the control valve N. 1) when steering unit is used.
• Control valves include spools with following functions:
RKZ06730

2-SPOOL CONTROL VALVE

Control Port

Loader arm (lifting - lowering) A1 - B1 A

Front bucket (curled - dump) A2 - B2 2 1
B

RKZ07460

20-28 WB150AWS-2
 CHECKING AND SETTING PRESSURE IN
TESTING AND ADJUSTMENTS THE ATTACHMENTS HYDRAULIC CIRCUIT

3-SPOOL CONTROL VALVE

Control Port

Loader arm (lifting - lowering) A1 - B1

Front bucket (curled - dump) A2 - B2

A
Optional attachment A3 - B3 3 2 1
B

RKZ06740

6-SPOOL CONTROL VALVE

Control Port

Arm (closing - opening) A1 - B1

Boom swing (left - right) A2 - B2

B
R.H. outrigger (up - down) A3 - B3 1 2 3 4 5 6
L.H. outrigger (up - down) A4 - B4
A

Bucket (dump - curled) A5 - B5

Boom (lifting - lowering) A6 - B6

RKZ02070

7-SPOOL CONTROL VALVE

(For telescopic arm)
Control Port

Telescopic arm (in - out) A7 - B7

B
7
A

RKZ02080

7-SPOOL CONTROL VALVE

(For breaker)
Control Port

Breaker (L.H. side) A7

B
7

RKZ02090

WB150AWS-2 20-29
 CHECKING AND SETTING PRESSURE IN
TESTING AND ADJUSTMENTS THE ATTACHMENTS HYDRAULIC CIRCUIT

8-SPOOL CONTROL VALVE

(For breaker and telescopic arm)
Control Port

Breaker (L.H. side) A7

B B
Telescopic arm (in - out) A8 - B8
7 8
A

2. Testing and setting general valves

(Pressure cut off valve) RKZ02050

2.1 Front shovel control valve (2-3 spools)

1 - Connect the pressure gauge E3 (400 bar) to the
pressure adapter (1) of the front shovel control val-
ve (2). 2 E3

2 - Start the engine, bring the hand accelerator lever

up to max. speed and check the nominal pressure
of the main relief valve (pressure cut-off valve) by
forcing the front bucket to raise to the end of its stro-
ke.
★ Nominal pressure: 200±7 bar
2.2 Backhoe control valve (6-7-8 spools) 1
RKZA8190

1 - Connect the pressure gauge E3 (400 bar) to the pres-

sure adapter (3) of the backhoe control valve (4).

2 - Start the engine, bring the hand accelerator lever

up to max. speed and check the nominal pressure E3
of the main relief valve (pressure cut-off valve) whi- 3
le forcing the bucket into maximum curl position (or
forcing the raising movement of the boom to the
end of its stroke).
★ Nominal pressure: 220±7 bar
★ If the main relief valve pressures do not correspond
to the nominal values, they must be re-set (See
«SETTING THE MAIN RELIEF VALVES AND THE
REDUCING VALVES»). 4
RKZA5481

3. Testing and setting secondary valves

★ Test condition:
• Engine: at operating temperature
• Hydraulic oil: 55–60 °C
2
• Parking brake: applied
★ The pressure readings are to be operated from the che-
ck points of the two control valve.

1 - Connect the pressure gauge E3 (400 bar) to the pres- 1

sure adapter of the control valve on which the move-
ment to be tested depends.

2 - Start the engine and bring the hand accelerator lever up

to 1050 rpm.
RKZA8200

20-30 WB150AWS-2
 CHECKING AND SETTING PRESSURE IN
TESTING AND ADJUSTMENTS THE ATTACHMENTS HYDRAULIC CIRCUIT

3 - Set the main relief valve (pressure cut-off valve) (1) or

(2) of the control valve concerned to a value 30 bar hi-
gher than the maximum pressure to be tested.

The secondary valve of backhoe boom lifting, must

be checked and setted on bench test only.

Setting 2-spool control valve secondary valves

Unit: bar
Cylinder and movement Port Setting
Lifting A1 --
Loader arm
Lowering B1 --
Curled A2
Front bucket
Dump ✽ B2
✽ This setting can be carried without modifing the general valve pressure.

Setting 3-spool control valve secondary valves

Unit: bar
Cylinder and movement Port Setting
Lifting A1 --
Loader arm
Lowering B1 --
Curled A2
Front bucket
Dump ✽ B2
A3
Optional attachment
B3
✽ This setting can be carried without modifing the general valve pressure.

Setting 6-spool control valve secondary valves

Unit: bar
Cylinder and movement Port Setting
Closing A1
Arm
Opening B1 --
Left A2
Boom swing
Right B2
Up A3 --
Left outrigger
Down B3 --
Up A4 --
Right outrigger
Down B4 --
Dump A5 --
Bucket
Curled B5
Lifting ✽ A6
Boom
Lowering B6
✽ The setting must be carried on bench test only.

WB150AWS-2 20-31
 CHECKING AND SETTING PRESSURE IN
TESTING AND ADJUSTMENTS THE ATTACHMENTS HYDRAULIC CIRCUIT

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
No. of spools Cylinder and movement Port Setting
Left ✽ A7
Breaker
Right B7 --
7
In A7 --
Telescopic arm
Out B7 --
Left ✽ A7 –
Breaker
Right B7 --
8
In A8 --
Telescopic 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.

4. Main and secondary valves setting

• General valves (1) e (2)

For setting, prepare machine as per pressure te-

sting.
1 - Loosen lock nut (3).

2 - Force to the end of its stroke the lever commanding 1

whichever movement is being used for the tests.

3 - Adjust pressure with adjusting screw (4).

• To INCREASE pressure, rotate in CLOCKWISE di-
rection.
RKZA8210
• To DECREASE pressure, rotate in COUNTER-
CLOCKWISE direction.

4 - Lock position with nut (2).

3 2

4
RKZ02240

RKZA8220

20-32 WB150AWS-2
 CHECKING AND SETTING PRESSURE IN
TESTING AND ADJUSTMENTS THE ATTACHMENTS HYDRAULIC CIRCUIT

• 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

WB150AWS-2 20-33
 TESTING AND ADJUSTING OF
TESTING AND ADJUSTMENTS 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

1 - Disconnect hose (1) from the Load Sensing line. Install 3

an tee and reconnect hose (1).

2 - Remove plug (2) and install a pressure adapter (M8x1).

2
3 - Connect the pressure gauge E5 to adapter. RKZB5640

4 - Start the engine and bring it to 1050±50 rpm and, with-

out any movement (lever in neutral position), read the
,P pressure.
Normal value: 24±1 bar 3
1
★ If the ,P value is not inside the limits, adjusting the
Unloading valve. E5
(For details see «TESTING AND ADJUSTING OF
UNLOADING VALVE»).

5 - Raise boom up to end of stroke and read the the ,P

pressure.
Normal value: 21±1.5 bar
2
★ If the ,P value is not inside the limits, carry out the
Load Sensing valve (3) setting. RKZ07391

1. Adjusting of the Load Sensing valve

4 6 5
1 - Remove nut (4).

2 - Loosen nut (5).

3 - Adjust pressure using adjusting screw (6).

• To INCREASE pressure, rotate in CLOCKWISE di-
rection.
7
• To DECREASE pressure, rotate in COUNTER-
CLOCKWISE direction.

4 - Lock the position with nut (5). RKZ074440

Lock nut: 21 Nm

5 - Check gasket (7) and mount nut (4).

Nut: 21 Nm

20-34 WB150AWS-2
TESTING AND ADJUSTMENTS CHECKING UNLOADING VALVE FUNCTIONALITY

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: 24±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 val-
ve.
• One shim of 1 mm increase pressure ,P of 3 bar.

Plug: 100 Nm

4 5 6 7
RKZ07420

WB150AWS-2 20-35
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).

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.

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

20-36 WB150AWS-2
TESTING AND ADJUSTMENTS TESTING PRIORITY VALVE OPERATION

TESTING PRIORITY VALVE OPERATION

★ Test condition:
• Engine: operating temperature. E2
• Hydraulic oil: 55 – 60 °C. 1
• Parking brakes: applied.

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 stee-
ring wheel (21 bar).

4 - Start a slight steering and check that pressure increas-

es. 2
5 - Continue the steering up to end of stroke and check that,
forcing the steering wheel, pressure increases till nor-
mal value.
★ Normal pressure: 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 RKZA5550

the priority valve (2).

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

WB150AWS-2 20-37
TESTING AND ADJUSTMENTS TESTING AND SETTING STEERING CONTROL SYSTEM PRESSURE

TESTING AND SETTING STEERING CONTROL SYSTEM PRESSURE

★ Test condition:
• Engine: operating temperature E2
• Hydraulic oil: 55 – 60 °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: 175±7 bar
4 - Check for the other steering direction too.
6 5 4 7
Setting
If pressure is not within permissible value, carry out setting
acting on upper valve (3) of the steering unit.

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- 3
rection. RKZA9430

• To DECREASE pressure rotate in COUNTER-

CLOCKWISE direction.

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.

20-38 WB150AWS-2
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

1 - Disconnect the delivery tube (5) of the braking group be-
5
ing tested.
E2
2 - Connect the tool “B” between the delivery line (5) and
7
the braking group.
★ Check that the pressure adapter (6) is inserted be-
tween the braking group and the exclusion valve B
(7).

3 - Connect a pressure gauge E2 (250 bar) to the pressure 6

adapter of the tool “B” and open the cock (7).
RKZA9191

WB150AWS-2 20-39
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»).

20-40 WB150AWS-2
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.

RKZ06840
2 - Speed test with the torque converter and the hydraulic
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. C1
★ If mounting an electronic pressure transducer rev.
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-

gether by the cotter pin (1). RKZA5380

RKZB0021

WB150AWS-2 20-41
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: 2275±50 rpm

3 - Release the accelerator pedal and move on to the next

test.

3. Testing the torque converter and hydraulic sys-

tem 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: 2000±50 rpm

• 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.

20-42 WB150AWS-2
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.
RKZ06840
• Machine: on solid and level ground with the equip-
ment raised and safety devices engaged.

1. Preparing the machine

1 - Prepare the rev. counter C1 to measure the engine rpm. C1
★ If mounting an electronic pressure transducer rev.
counter on a diesel delivery line to the injection noz-
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). RKZA5380

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

WB150AWS-2 20-43
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 pi-
ston with lower pressure.

20-44 WB150AWS-2
 TESTING THE CORRECT FUNCTIONING OF
TESTING AND ADJUSTMENTS THE POWER TRAIN CLUTCHES

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. RKZ06840
counter on a diesel delivery line to the injection noz-
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- C1
tate the reading.
Make sure that the brake pedals are fastened together
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
RKZA5380
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.

WB150AWS-2 20-45
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.

RKZA9080

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).

20-46 WB150AWS-2
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. Blocks

4 - Plug cylinders, base side, and apply a temporary pipe, RKZA9091

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°.

6 - Stop the engine and check bucket link position for 5 min-
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 1

on ground in vertical position.
2
8 - Remove from one of cylinders the plug as installed on RKZA9180

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.

11 - Repeat operation from stage 8 to stage 10 to check the 15°

other cylinder.

RKZA9100

WB150AWS-2 20-47
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

RKZ04350

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. RKZ04360

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.

20-48 WB150AWS-2
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.
RKZ02140

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
cylinder gaskets.
• If boom has no lowering movement, drift is due to
control valve.

RKZ02150

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.

RKZ02160

WB150AWS-2 20-49
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 cylin-
der gaskets.
• If arm has no movement, drift is due to control
valve.

RKZ02170

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

RKZ02180

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

20-50 WB150AWS-2
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.

RKZ02190

4. Outriggers testing
1 - Set machine with vertical arm and with bucket leaned at
ground on the side.

2 - Place trestles "A" of a suitable height beneath the out-

riggers, and bring the cylinder eyes to a horizontal po-
sition.

3 - Without forcing them, lower the outriggers onto the tres-

tles.

A
RKZA8240

4 - Stop the engine and release residual hydraulic pres-

sures.

5 - Disconnect the tubes (1) and (2) from the cylinders (3)
1 2
and plug them to prevent entry of impurities.

6 - Plug cylinders pipes (2) base side and apply on head

sides temporary pipes to catch possible oil leakage. 3

7 - Start the engine, use force on the boom to raise the ma-
chine, and remove the trestles supporting the outrig-
gers.

RKZA8250

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.

RKZA8260

WB150AWS-2 20-51
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. RKZ06840

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.

20-52 WB150AWS-2
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

WB150AWS-2 20-53
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. 1
2 - Disconnect the group to be substituted or reconditioned
immediately after switching off the maintenance station. 2
Plug the removed or disconnected connection
tubes tightly and with a minimum of delay.
3 - Carefully check the quantity of anti-freeze oil recovered
and contained in the disassembled parts, since the
same quantity must be replaced when the air-condi-
tioning unit is refilled.
RKZA8570

20-54 WB150AWS-2
 TROUBLESHOOTING

Front axle troubleshooting ....................................... 56

Rear axle troubleshooting........................................ 61
Transmission troubleshooting.................................. 66
Checking and inspection of
the electronic control unit......................................... 69

WB150AWS-2 20-55
TROUBLESHOOTING FRONT AXLE

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
Broken 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 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
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

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
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.

20-56 WB150AWS-2
TROUBLESHOOTING FRONT AXLE

Uneven wear of tyre

CAUSES REMEDY
Incorrect installation Correct installation
Replace the differential in case it does not survive any one of the
Defective axle
test phases
Remove excessive weight and redistribute load, following 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
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
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
Replace the tyre or adjust pressure to have same radius on both
Different rotation radius of the tyres
tyre

WB150AWS-2 20-57
TROUBLESHOOTING FRONT AXLE

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

20-58 WB150AWS-2
TROUBLESHOOTING FRONT AXLE

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

WB150AWS-2 20-59
TROUBLESHOOTING FRONT AXLE

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

20-60 WB150AWS-2
TROUBLESHOOTING REAR AXLE

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
Broken 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 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
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

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
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.

WB150AWS-2 20-61
TROUBLESHOOTING REAR AXLE

Uneven wear of tyre

CAUSES REMEDY
Incorrect installation Correct installation
Replace the differential in case it does not survive any one of the
Defective axle
test phases
Remove excessive weight and redistribute load, following 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
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
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
Replace the tyre or adjust pressure to have same radius on both
Different rotation radius of the tyres
tyre

20-62 WB150AWS-2
TROUBLESHOOTING REAR AXLE

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

WB150AWS-2 20-63
TROUBLESHOOTING REAR AXLE

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

20-64 WB150AWS-2
TROUBLESHOOTING REAR AXLE

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

WB150AWS-2 20-65
TROUBLESHOOTING TRANSMISSION

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

20-66 WB150AWS-2
TROUBLESHOOTING TRANSMISSION

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

WB150AWS-2 20-67
TROUBLESHOOTING TRANSMISSION

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

20-68 WB150AWS-2
TROUBLESHOOTING TRANSMISSION

CHECKING AND INSPECTION OF THE ELETRONIC 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

WB150AWS-2 20-69
TROUBLESHOOTING TRANSMISSION

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

20-70 WB150AWS-2
GROUP 30
40-28 PC15R-8
 REMOVAL AND INSTALLATION

HOW TO READ THE MANUAL................................. 3 CAB

PRECAUTIONS TO BE TAKEN WHILE WORKING . 4 Removal ...................................................................37
SPECIAL TOOLS ...................................................... 5 Installation ................................................................40
STARTING MOTOR HEAT AND AIR-CONDITIONING GROUP
Removal and installation ........................................... 9 Removal ...................................................................41
ALTERNATOR Installation ................................................................42
Removal .................................................................. 10 FUEL TANK
Installation ............................................................... 11 Removal and installation ..........................................43
AIR-CONDITIONING UNIT COMPRESSOR HYDRAULIC OIL TANK
Removal .................................................................. 12 Removal and installation ..........................................44
Installation ............................................................... 13 ENGINE-GEARBOX-PUMP GROUP
INJECTION PUMP Removal ...................................................................45
Removal .................................................................. 14 Installation ................................................................50
Installation ............................................................... 17 PISTON PUMP
INJECTION NOZZLES Removal ...................................................................51
Removal and installation ......................................... 18 Installation ................................................................52
THERMOSTAT TRANSMISSION
Removal and installation ......................................... 19 Removal ...................................................................53
COOLING LIQUID PUMP Installation ................................................................56
Removal .................................................................. 20 Disassembly and assembly......................................57
Installation ............................................................... 21 CONVERTOR
TURBOCOMPRESSOR Removal and installation ........................................155
Removal .................................................................. 22 TRANSMISSION-REVERSE, DIRECTION
Installation ............................................................... 23 INDICATOR AND HEADLIGHT DIPPER BEAM
CYLINDER HEAD CONTROL GROUP
Removal .................................................................. 24 Removal and installation ........................................156
Installation ............................................................... 26 STEERING UNIT
FRONT COUNTERWEIGHT Removal and installation ........................................157
Removal and installation ......................................... 28 WORKING BRAKE PUMP GROUP
RADIATOR – OIL COOLER GROUP Removal and installation ........................................158
Removal .................................................................. 29 FRONT WORKING EQUIPMENT CONTROL VALVE
Installation ............................................................... 31 Removal and installation ........................................159
CONDENSER FRONT AND BACKOHE CONTROL VALVE
Removal and installation ......................................... 32 Disassembly and assembly................................ 159-1
MUFFLER FRONT AXLE
Removal and installation ......................................... 33 Removal .................................................................160
EXHAUST PIPE Installation ..............................................................161
Removal and installation ......................................... 34 Disassembly ...........................................................162
Assembly................................................................174
ENGINE HOOD
Removal .................................................................. 35
Installation ............................................................... 36

WB150AWS-2 30-1
➀
REAR AXLE CYLINDERS
Removal ................................................................ 191 (Front bucket raise and tilt, boom, arm, bucket,
Installation ............................................................. 192 outriggers and telescopic arm)
Disassembly .......................................................... 193 Disassembly...........................................................249
Assembly............................................................... 212 Assembly............................................................... 251
STEERING SOLENOID VALVE GROUP BOOM SWING CYLINDER
Removal and installation ....................................... 235 Disassembly...........................................................254
FRONT BUCKET BOOM-RAISING CYLINDER Assembly................................................................255
Removal and installation ....................................... 236 BOOM SAFETY CYLINDER
FRONT BUCKET TILT CYLINDERS Removal and installation ........................................257
Removal and installation ....................................... 237 BACKHOE WORKING EQUIPMENT
FRONT BUCKET Removal and installation ........................................258
Removal and installation ....................................... 238 BACKHOE BUCKET
FRONT WORKING EQUIPMENT Removal and installation ........................................259
Removal ................................................................ 239 ARM
Installation ............................................................. 240 Removal and installation ........................................260
BACKHOE CONTROL VALVE TELESCOPIC ARM
Removal ................................................................ 241 Removal and installation ........................................261
Installation ............................................................. 242 2nd ARM
BACKHOE BOOM CYLINDER Removal and installation ........................................262
Removal and installation ....................................... 243 2nd ARM GUIDES
BACKHOE ARM CYLINDER Removal and installation ........................................263
Removal and installation ....................................... 244 BACKHOE BOOM
TELESCOPIC ARM CYLINDER Removal and installation ........................................264
Removal and installation ....................................... 245 BACKHOE SWING BRACKET
BACKHOE BUCKET CYLINDER Removal and installation ........................................265
Removal and installation ....................................... 246 BACKHOE OUTRIGGERS
OUTRIGGER CYLINDERS Removal .................................................................266
Removal and installation ....................................... 247 Installation ..............................................................267
BACKHOE SWING CYLINDERS
Removal and installation ....................................... 248

30-2 WB150AWS-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.

WB150AWS-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
adhesive to cover the threading in a uniform manner.
• When applying a liquid sealant, clean the surface involved, remove residual oil and grease, check that there are
no dents or dirt, then apply the liquid sealant in a uniform manner.
• Clean all the parts, remove dirt, rust, burrs, or dents.
• Apply a film of engine oil over all the moving parts.
• Apply a film of anti-friction grease (ASL800040) over all surfaces assembled with pressure, to avoid sticking
• After having mounted the snap-rings, check that they are firmly positioned in their seatings.
• When installing electrical system jacks, remove any oil, dust or water that may have penetrated into them, then
connect them firmly.
• If using eyebolts, check that they are not distorted, screw them in fully, and then align the eye with the 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 WB150AWS-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

Hydraulic Plunger Ø 40 2
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
Disassembly and cylinders Ø115-120
A
assembly cylinder Notched wrench for
1
cylinders Ø110
Notched wrench for
5 1
cylinders
Boom swing head
6 ATR200300 Notched wrench 1
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

Hydraulic Plunger Ø40 1

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

WB150AWS-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 CA715027 Plunger 1 Driver for bush
For differential housing
2 CA715265 Wrench 1
lock nut
3 CA119099 Wrench 1 For pinion lock nut
4 CA715022 Wrench 1 Pinion shaft lock
5 CA119225 Plunger 1 Pinion shaft lock wrench
6 CA715064 Plunger 1 Mounting outer ring
7 CA119202 False pinion 1
Measurament shim for
8 CA119228 False differential holder 1
pinion
9 CA119182 Ring nut 1
10 CA715167 Plunger 1 Pinion bearing cone
Disassembly and
C 11 CA715116 Kit 1 Preload measurament
assembly front axle
Mounting differential
12 CA715028 Plunger 1
holder bearing
13 CA119056 Plunger 1 For pinion oil seal
14 CA715039 Plunger 1 Mounting joint bushing
15 CA119146 Plunger 1 For mounting bushing
16 CA715397 Plunger 1 For mounting ring
17 CA715036 Plunger 1 For swivel bush
18 CA715037 Plunger 1 For wheel hub oil seal
19 CA715042 Plunger 1 For ball joint
20 CA715026 Plunger 1 Bearing drive
21 CA119086 Plunger 1 For hub ring
Disassembly-assembly
1 CA715027 Plunger 1
crown bushing
Disassembly and For differential housing
D 2 CA715265 Wrench 1
assembly rear axle lock nut
3 CA119099 Wrench 1 For pinion lock nut
4 CA715022 Wrench 1 Pinion shaft lock

30-6 WB150AWS-2
REMOVAL AND INSTALLATION SPECIAL TOOLS

Nature of work Symbol Code Description Q.ty Notes

For bearing cups assembly
5 CA715380 Kit 1
in the central housing
6 CA715128 False pinion 1
7 CA119198 False differential box 1
8 CA715167 Plunger 1 Pinion bearing cone
9 CA715116 Kit 1 Preload measurament
10 CA715028 Plunger 1
11 CA715391 Plunger 1
12 CA119033 Interchangeable handle 1
13 CA715056 Kit 1 Mounting piston on flange
Disassembly and 14 CA715055 Kit 1 Measurament backlash
D
assembly rear axle
15 CA715039 King pin bush driver 1
16 CA119146 Plunger per bronzina 1
17 CA715397 Plunger anello di tenuta 1
18 CA715036 Driver for bush 1
19 CA715037 Driver for oil seal 1
20 CA715042 Plunger 1 For king pin bush
21 CA715026 Plunger 1
22 CA119086 Plunger 1 For oil seal
23 CA715392 Mask 1 For potentiometer
24 CA715156 Driver for oil seal 1
1 CA715404 Extractor 1 Remove oil pump
2 CA715409 Plunger 1 Mounting oil pump seal ring
Removal-installation flange
3 CA715411 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
E
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

WB150AWS-2 30-7
PAGE INTENTIONALLY
LEFT BLANK
REMOVAL AND INSTALLATION STARTING MOTOR

REMOVAL OF STARTING MOTOR

Fully raise the front working equipment and engage the
safety stop.
2
1 - Stop the engine and engage the parking brake.
Cut off the supply of electricity by turning the accumu- 1
lator-disconnecting switch (1) in a counter-clockwise di-
rection and remove the handle (2).

RKZA1690

2 - Disconnect the electric wiring (3).

3 - Loosen the two screws (4) and remove the starting mo- 4
tor (5). 1
4
3

RKZA1700

INSTALLATION OF THE
STARTING MOTOR
• To install, reverse the removal procedure.

1
Starting motor mounting screws: 78.4–98 Nm

WB150AWS-2 30-9
REMOVAL AND INSTALLATION ALTERNATOR

REMOVAL OF THE ALTERNATOR

Fully raise the front working equipment and engage the
safety stop.
2
1 - Stop the engine and engage the parking brake.
Cut off the supply of electricity by turning the accumu- 1
lator-disconnecting switch (1) in a counter-clockwise di-
rection and remove the handle (2).

RKZA1690

2 - Disconnect the cable (3), the connector (4) and the cot-
ter pin (5).

RKZB5032

3 - Loosen the screws (6), (7) and (8) to leave the alternator
(9) free to rotate.
6

7
9

RKZB5091

4 - Release the belt (10) from the pulley and remove the al-
8
ternator (9). 1
9

10

RKZB5102

30-10 WB150AWS-2
REMOVAL AND INSTALLATION ALTERNATOR

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»).

WB150AWS-2 30-11
REMOVAL AND INSTALLATION AIR-CONDITIONING UNIT COMPRESSOR

REMOVAL OF THE AIR-CONDITIONING UNIT COMPRESSOR

(Only for machines equipped with an air-conditioning unit)
Cut off the supply of electricity by turning the accumu-
lator-disconnecting switch in a counter-clockwise direc-
tion and remove the handle.
1
1 - Remove lateral guard (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 WB150AWS-2
REMOVAL AND INSTALLATION AIR-CONDITIONING UNIT COMPRESSOR

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: 970±15 g

WB150AWS-2 30-13
REMOVAL AND INSTALLATION INJECTION PUMP

REMOVAL OF THE INJECTION PUMP

Fully raise the front working equipment and engage the
safety stop. Also make the backhoe safe.
1
Cut off the supply of electricity by turning the accumu-
lator-disconnecting switch in a counter-clockwise direc-
tion and remove the handle.

★ Plug all tubes that have been removed or disconnected

to prevent entry of impurities.

1 - Remove the engine coolant liquid container (1).

RKZB5410

2 - Disconnect the fuel supply (3) and flow-back (4) hoses

from the injection pump (2). 1
5
3 - Disconnect the high-pressure pipes (5). 2
4

2
3
RKZA0070

4 - Disconnect the fuel feed hose (7) and delivery tube (8)
from the feed pump (6)
7
1
5 - Disconnect the tube (9) from the oil level dip-stick and 9 8
remove it.
3
6 - Remove the support-bracket (10) of the pump.
6

10
RKZA0080

7 - Disconnect the accelerator control cable support (12)

from the lever (11).

11

12

RKZA0090

30-14 WB150AWS-2
REMOVAL AND INSTALLATION INJECTION PUMP

8 - Disconnect the engine-stopping solenoid (13) from the

injection pump (2). Lift out the entire group. 4
13

RKZA0100

9 - Remove the retaining clip (14) of the injection pump lu-

brication tube.

10 - Disconnect the lubrication tube (15).

15

14

RKZA0110

11 - Remove the cover (16) that gives access to the distri-

bution gear and the oil filler plug (17). 5 17

16

RKZA0120

12 - Loosen and lift off the retaining nut (18) and safety
washer (19) of the pump driving gear (20). 6 19
★ Take great care not to drop the safety washer (19)
into the pump casing.

18
20

RKZA0130

WB150AWS-2 30-15
REMOVAL AND INSTALLATION INJECTION PUMP

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

14 - Take out the four nuts (22) and remove the injection
pump (2) with its O-ring seal (23). 7

22

RKZA0081

30-16 WB150AWS-2
REMOVAL AND INSTALLATION INJECTION PUMP

INSTALLATION OF THE INJECTION PUMP

• To install, reverse the removal procedure.

1
Fuel feed hoses: 24.5–34.3 Nm

2
High pressure hoses: 24.5–34.3 Nm

3
Bolt screw, pump side: 44.1–53.9 Nm

Bolt screw, engine side: 22.5–8.4 Nm

4
★ Put in a new safety cotter pin.

5
Cover gasket: ASL800070

Cover bolts for ignition gear system: 18 Nm

6
★ Align the marks between the gears before installing
the pump and mounting the nut. Injection pump
gear (20)
Gear-locking nut: 83.3–93.1 Nm

7
Pump-locking nut: 35.2–43.1 Nm
Reference
1 - Check fuel injection timing.
(For details, see «20. TESTING AND ADJUST-
MENTS»).
Idling gear

RKZ00131

WB150AWS-2 30-17
REMOVAL AND INSTALLATION INJECTION NOZZLES

REMOVAL OF THE INJECTION NOZZLES

Fully raise the front working equipment and engage the
safety stop. Also make the backhoe safe. 2
4
Cut off the supply of electricity by turning the accumu-
lator-disconnecting switch in a counter-clockwise direc- 1
tion and remove the handle.

1 - Disconnect the sensor (1) for a clogged air-filter.

3
2 - Remove the air-filter (2), the supporting bracket (3) and
the intake sleeve (4). 1
3 - Remove the muffler.
(For details, see «REMOVAL OF THE MUFFLER»). RKZB5021

4 - Remove the intake duct (5). 2

5 - Loosen the clip (6) and remove the high-pressure pipes 5
(7).
3
6
6 - Disconnect the fuel flow-back pipes (8).
7

RKZA9970

7 - Take out the nuts (9) that secure the collar (10) and take
out the injector (11), the seating (12 and the protection 10
piece (13).
4
9

INSTALLATION OF THE
INJECTION NOZZLES 11 13
• To install, reverse the removal procedure.
12
1
RKZ00141

Bracket screw: Loctite 262

2
Duct screw: 45–55Nm

Bracket screw: Loctite 262

3
High-pressure pipes: 24.5–4.3 Nm
Hose-clamp screws: 9.8–11.8 Nm

4
Collar lock nuts: 9.8–11.8 Nm

30-18 WB150AWS-2
REMOVAL AND INSTALLATION THERMOSTAT

REMOVAL OF THE THERMOSTAT

Fully raise the front working equipment and engage the
safety stop.
Also make the backhoe safe.

Cut off the supply of electricity by turning the accumu- 2

lator-disconnecting switch in a counter-clockwise direc-
tion and remove the handle. 4
3
★ Drain the engine coolant liquid.
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

thermostat cover (5).

4 - Take out the screws and remove the thermostat cover

(5).

RKZB5130

5 - Remove the gasket (7), the thermostat (8) and the ring
seal (9).
5
Put in new seals.

8
INSTALLATION OF THE 9
THERMOSTAT
• To install, reverse the removal procedure.
RKZ00151

1
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

WB150AWS-2 30-19
REMOVAL AND INSTALLATION 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.
1
Cut off the supply of electricity by turning the accumu-
lator-disconnecting switch in a counter-clockwise direc-
tion and remove the handle.

★ Drain the engine coolant liquid.

Coolant liquid: 18

1 - Remove the engine coolant liquid container (1).

RKZB5410

2 - Remove the fan guard (2).

3 - Disconnect the cable (3) of the clogged filter indicator

and remove the air filter (4).
4

RKZB5023

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

30-20 WB150AWS-2
REMOVAL AND INSTALLATION COOLING LIQUID PUMP

6 - Disconnect the cab heating pipes (7).

7 - Disconnect the temperature sensor cables (8) and (9). 8

8 - Remove the radiator/oil-cooler group.
(For details, see «REMOVAL OF THE RADIATOR - OIL
COOLERS»).

9 - Remove the fan (10), the spacer (11) and the pulley
(12).
7
2
10 - Remove the four screws (13) and then the complete RKZB5370

pump (14).

3
Replace all seals with new ones.

INSTALLATION OF THE COOLANT

LIQUID PUMP
• To install, reverse the removal procedure.

1
Locking screws for alternator support:
22.5–28.4 Nm
RKZB5400

★ Apply tension to the alternator belt.

(For details, see «20. TESTING AND ADJUST-
MENTS»).
13
2
Locking screws for pulley and fan:
44.1–53.9 Nm

3
Pump screws: 22.5–28.4 Nm

4 14
Locking screw for compressor: 64 Nm
RKZB5140

★ Apply tension to the compressor belt.

(For details, see «TESTING AND APPLYING TEN-
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.

WB150AWS-2 30-21
REMOVAL AND INSTALLATION TURBOCOMPRESSOR

REMOVAL OF THE TURBOCOMPRESSOR

Fully raise the front working equipment and engage the
safety stop.
Also make the backhoe safe.
3
Cut off the supply of electricity by turning the accumu-
lator-disconnecting switch in a counter-clockwise direc-
tion and remove the handle. 2
1 - Disconnect the clogged air-filter indication (2) cable (1)
and remove the entire suction filter (3).
1
2 - Remove the muffler
(For details, see «REMOVAL OF THE MUFFLER»).
RKZB5024

3 - Disconnect the turbocompressor delivery coupling

sleeve (4) from the suction manifold. 16

RKZA0210

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

30-22 WB150AWS-2
REMOVAL AND INSTALLATION TURBOCOMPRESSOR

6 - Take out the screws (10) that join the turbocompressor

tothecouplingsleeve,andremovethecouplingsleeve(11). 10
2
7 - Take out the screws (12) and remove the bracket (13).
11
3

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.

WB150AWS-2 30-23
REMOVAL AND INSTALLATION CYLINDER HEAD

REMOVAL OF THE CYLINDER HEAD

Fully raise the front working equipment and engage the
safety stop.
1
Also make the backhoe safe
Cut off the supply of electricity by turning the accumu-
lator-disconnecting switch in a counter-clockwise direc-
tion and remove the handle.

★ Drain the engine coolant liquid.

Coolant liquid: 18

1
RKZB5410
1 - Remove the container (1).

2 - Disconnect the cable (2) of the clogged air-filter sensor

(3) and remove the entire suction filter (4) and its sup-
port.
2 4
★ Remove the turbocompressor.
(For details, see «REMOVE THE TURBOCOMPRES- 3
SOR»).

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

30-24 WB150AWS-2
REMOVAL AND INSTALLATION CYLINDER HEAD

5 - Disconnect the cable (9) of the cold-start equipment.

13
6 - Remove the suction manifold (10) and the cold-start
equipment (11). 5
7 - Remove the diesel fuel filter (12) and place it to one side. 10 11
8 - Disconnect the clips (13) that secure the heating pipes.
9

12

RKZB5150

9 - Disconnect the breather tube (14) from the engine

head.

14

RKZA0222

10 - Remove the muffler (15).

(For details, see «REMOVAL OF THE MUFFLER»).
15
11 - Remove the muffler support bracket (16).
6
16

RKZB5160

12 - Disconnect the cables (17) from the temperature sen-

sors (18).

13 - Disconnect the heating pipes (19). 17

14 - Remove the radiator connection pipes (20).

15 - Remove the coolant liquid pump. (For details, see «RE- 18 20

MOVAL OF THE COOLANT LIQUID PUMP»).
19
20

RKZB5132

WB150AWS-2 30-25
REMOVAL AND INSTALLATION CYLINDER HEAD

16 - Disconnect the fuel return hose (21) from the injector

nozzles and remove the nozzles. 22
(For details, see «REMOVAL OF THE INJECTOR 21
NOZZLES»).
6 7
17 - Remove the cover of the tappets (22). 8

RKZA0173

18 - Remove the valve rocker-arm shaft (23).

★ Loosen the nuts and unscrew the tappets by 2-3
26 23
turns

19 - Take out the rocker-arm control rods (24).

25

24

RKZ00161

20 - Take out the screws (25) and remove the entire cylinder
head (26). Follow the indicated sequence for loosening BOLT LOOSENING ORDER
the screws.
10

★ Sequence to be followed: see drawing. 7 16 14 6

1 9 18 12 4

Loosen the cylinder head retaining screws in two

3 11 17 10 2
stages. 5 13 15 8

RKZ00171

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.

30-26 WB150AWS-2
REMOVAL AND INSTALLATION CYLINDER HEAD

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
Bracket screws: 45–55 Nm
Screws for intake line: Loctite 262
Screws for intake line: 45–55 Nm
6
High-pressure pipe fittings: 24.5–34.3 Nm
7
Collar lock nuts: 9.8–11.8 Nm
8
★ 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: 25±3 Nm
9
★ 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:
22.5–28.4 Nm
★ Adjust the valve clearances. (For details, see «20.
TESTING AND ADJUSTMENTS»).
10
★ Assemble a new gasket.
Bolt and cylinder block threadings: Engine oil.
★ Tighten the screws, manually at first, and then in two
stages, following the sequence indicated. BOLTS TIGHTENING ORDER

Cylinder head bolts:

First tightening: 88.3–98.1 Nm
12 3 5 13
Final tightening: 181.4–191.2 Nm 18 10 1 7 15

1 - Start the engine at low idling to circulate the coolant liq- 16 8 2 9 17

uid through all circuits. 14 6 4 11

2 - Accelerate gradually up to 1700 rpm. After about one

minute, stop the engine and check or top up the level in
the container. RKZ00181

WB150AWS-2 30-27
REMOVAL AND INSTALLATION 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.
1
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).
2 1 3
3 - Remove the screws (1) and the washers (3). RKZA9220

4 - Remove the Front counterweight (2).

Counterweight: 300 kg

INSTALLATION OF THE
FRONT COUNTERWEIGHT
• To install, reverse the removal procedure.

1
Screws: 300±30 Nm

30-28 WB150AWS-2
REMOVAL AND INSTALLATION RADIATOR GROUP

REMOVAL OF THE RADIATOR GROUP

Fully raise the front working equipment and engage the
safety stop.
Also make the backhoe safe.
Cut off the supply of electricity by turning the accumu-
lator-disconnecting switch in a counter-clockwise direc-
tion and remove the handle.

1 - Disconnect the safety gas cylinders (1) for opening the 1

engine hood. Remove the engine hood.
(For details, see «REMOVAL OF ENGINE HOOD»).

RKZB5170

Completely eliminate all residual pressures in all cir-

cuits. (For details, see «20. TESTING AND ADJUST-
MENTS»).
★ Drain the cooling liquid.
Cooling liquid: 18
2
1 5
3
2 - Disconnect the cable (2) from the acoustic alarm (3).

3 - Loosen bracket (4) screw (5). 3

4
RKZB5180

4 - Only for machines equipped with an air-condition-

ing unit 7
Drain the air conditioning unit, and disconnect the tubes
(6), (7). (For details, see «20. TESTING AND ADJUST-
MENTS»). 6
2

RKZB5190

5 - Disconnect the engine hoses (8) and (9) from the radi-
8
ator (9).

RKZA1743

WB150AWS-2 30-29
REMOVAL AND INSTALLATION RADIATOR GROUP

6 - Slowly loosen the hoses (10) and (11) to drain the hy-
draulic oil from the radiator (12). When the oil is fully 12
drained, complete disconnection of the hoses, and plug 11
them to prevent entry of impurities. 4

10

RKZB5200

7 - Loosen radiator (12) nut (13).

13

RKZB5420

8 - Disconnect the hoses (14) and plug them to prevent en-

try of impurities. 5
9 - Take out the nuts (13) of the lower anti-vibration units
and remove the entire radiator group (12).

14

RKZB5210

30-30 WB150AWS-2
REMOVAL AND INSTALLATION 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): 970±15 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.

WB150AWS-2 30-31
REMOVAL AND INSTALLATION CONDENSER

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): 970±15 g

Quantity of oil: see the amount recovered.

30-32 WB150AWS-2
REMOVAL AND INSTALLATION MUFFLER

REMOVAL OF THE MUFFLER

Fully raise the front working equipment and engage the
safety stop.
Also make the backhoe safe.
1 - Loosen the retaining clip (1) of the hose (2) and discon-
nect it from frame. 1

2
RKZB5340

2 - Take out screws (3).

RKZA9931

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.

WB150AWS-2 30-33
REMOVAL AND INSTALLATION EXHAUST PIPE

REMOVAL OF THE EXHAUST PIPE

1 - Loosen the clip (1) and disconnect the flexible hose (2).

2
RKZB5340

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.

30-34 WB150AWS-2
REMOVAL AND INSTALLATION 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-
nition key.

1 - Open the engine hood (1) take out the safety pins (2) 1
and disconnect the hood from the gas cylinders (3).

RKZA9530

2 - Raise the hood (1) to a vertical position and attach it to

some hoisting tackle.
★ To attach it, use the hole in the opening cavity.

RKZB5240

3 - Take out the two screws (4) and remove the hood (1).

Engine hood: 27 kg 1

4
RKZA7871

WB150AWS-2 30-35
REMOVAL AND INSTALLATION ENGINE HOOD

INSTALLATION OF THE ENGINE HOOD

• To install, reverse the removal procedure.

★ Check that the hood (1) closes perfectly, and re-attach

the screws (5).
5

RKZA9540

30-36 WB150AWS-2
REMOVAL AND INSTALLATION 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.
Cut off the supply of electricity by turning the accumu-
lator-disconnecting switch in a counter-clockwise direc-
tion and remove the handle.
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 she- 2
athings from the support (2). 2

RKZA0091

2 - Disconnect the parking brake cable (4) from the rear

axle (3) and pipe (5). 5 5
3
3 - Disconnect the braking circuit pipes (6) from the rear ax-
le.
★ Mark the positions of the pipes to prevent exchange
of positions when reconnecting. 4
★ Plug the pipes and pipe-fittings to prevent entry of
impurities.
4
6 3 RKZA9291

4 - Disconnect the steering cylinder pipe (7) from the rear

axle.
5
★ Plug the pipe and pipe-fitting to prevent entry of im- 7
purities.

RKZA9130

WB150AWS-2 30-37
REMOVAL AND INSTALLATION CAB

5 - Disconnect the pipes (8, 9 and 10) of the R-L-T ports

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 the connectors (11) and (12) and the

grounding cable (13). 16
7 - Disconnect the connectors (14), (15) and (16) from the
gearbox. 12 17
8 - Disconnect from grounding stud two connectors (17).

14

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 backhoe boom dis- 20 21

engagement solenoids.

12 - Disconnect the power increment solenoid connector 18

(21) installed on the piston pump.
19
RKZA0430

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.

14 - Disconnect the control steering connector.

23

22 24
RKZA0440

30-38 WB150AWS-2
REMOVAL AND INSTALLATION CAB

15 - Disconnect the heating unit tubes (25) and (26).

(For details, see «REMOVAL OF THE CAB HEATING 25
GROUP»).
28
16 - Only for machines equipped with an air-condition-
ing unit.
Disconnect the tubes (27), (28) connecting the expan-
sion valve (29). 29
★ Immediately plug the tubes and the orifices tightly 26
to prevent moisture from entering into the air-con-
ditioning circuit. 27

RKZB5250

17 - Lift off the lower left-hand guard of the cab and discon-
nect the connector (30) of the fuel level indicator and the
connector of the self-supply pump, if any.
30
18 - Also lift off the lower right-hand guard.

RKZA1924

19 - Remove the floor-mat (31) and remove the lateral cover

(32).
★ Push the protective sleeve (33) of the gearbox lever
down into the side cover.
32

33
31

RKZB0033

20 - Remove the grips (34) of the outrigger control levers

and lift off the cover (35) of the control levers.
34
21 - Remove the self-locking nuts (36) and the four screws
that secure the cab. 6

36
35

RKZA9601

WB150AWS-2 30-39
REMOVAL AND INSTALLATION CAB

22 - Disconnect the hoses (37) and (38) from control valve

(39).
39
37

38
RKZA9993

23 - Remove the protective plugs and screw two eyebolts

“A” into the holes supplied for hoisting purposes.
Attach the cab (40) to the hoisting tackle and apply a
slight tension.

24 - Slowly raise the cab, directing its movement in such way

that the gear lever slides out. A
★ Make sure that all the electrical leads and the ac-
celerator cables are free.
Cab: circa 630 kg
40
INSTALLATION OF THE CAB
• To install, reverse the removal procedure.

1
★ Drain and refill the air-conditioning unit

Quantity of fluid (R134a): 970±15 g

Quantity of oil: see the amount recovered.

2
★ Check and adjust the stroke of the hand and pedal ac-
celerators. (For details, see «20. TESTING AND AD-
JUSTMENTS»).

3
★ Adjust the stroke of the parking brake lever. (For details, RKZA0483

see «20. TESTING AND ADJUSTMENTS»).

4
★ Bleed the air from the braking circuit.
(For details, see «20. TESTING AND ADJUST-
MENTS»).

5
★ Bleed the air from the steering circuit. (For details, see
«20. TESTING AND ADJUSTMENTS»).

6
Cab retaining screws: 169±9.8 Nm

30-40 WB150AWS-2
REMOVAL AND INSTALLATION 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 (3).

RKZB5270

4 - Disconnect the connector (5) from the pressure switch

(4). 13 9
10
5 - Disconnect the delivery pipe (7) and the return pipe (8) 11
from the expansion valve (6).
12
★ Immediately plug the tubes and the orifices tightly
to prevent moisture from entering into the air-con-
ditioning circuit.
★ Re-use the O-ring.

RKZB5280

6 - Disconnect the pipes (10) from the fan-cooler (9).

7 - Disconnect the tubes (11) and (12) that connect with the
engine. 8
7 6
8 - Remove the four nuts (13) and remove the group (9).

4
5
RKZB5251

WB150AWS-2 30-41
REMOVAL AND INSTALLATION HEAT 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): 970±15 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.

30-42 WB150AWS-2
REMOVAL AND INSTALLATION 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

WB150AWS-2 30-43
REMOVAL AND INSTALLATION 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

30-44 WB150AWS-2
REMOVAL AND INSTALLATION 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.
Cut off the supply of electricity by turning the accumu-
lator-disconnecting switch in a counter-clockwise direc-
tion and remove the handle.
2
Release all residual pressure in all circuits. 1
(For details, see «20. TESTING AND ADJUST-
MENTS»).

★ Drain the hydraulic oil.

1
Hydraulic oil: 92
RKZA9140

★ Drain the engine cooling liquid.

Coolant liquid: 18

★ Drain the oil from the gearbox. 3

Gearbox oil: 16

4
1 - Only for machines equipped with an air-condition-
ing unit.
Drain the air conditioning unit.
(For details, see «20. TESTING AND ADJUST-
MENTS»).

2 - Remove the front working equipment. RKZB0050

(For details, see «REMOVAL OF THE FRONT WORK-

ING EQUIPMENT»).

3 - Take off the engine hood.

(For details, see «REMOVAL OF THE ENGINE HO- 1
OD»).

4 - Take out the screws (1) and remove the front counter-
weight (2). (For details, see «REMOVAL OF THE
FRONT COUNTERWEIGHT»).
1 8
5 - Remove the radiator-oil cooler group.
(For details, see «REMOVAL OF THE RADIATOR-OIL 7
COOLER GROUP»). RKZB5310

6 - Lift the protection (3), disconnect connector (4).

2
7 - Disconnect rear cardan shaft (5) from transmission (6).
2
8 - Remove front cardan shaft (7). 3

RKZA9320

WB150AWS-2 30-45
REMOVAL AND INSTALLATION 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-
tor. 9

4
★ Plug the pipes to prevent entry of impurities.

11 10

RKZB5320

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

RKZA8880

12 - Disconnect from thermostat (19) and from speed sen-

sor (20) the sensors (18) connectors. 18

19

18
18

20
RKZO4370

30-46 WB150AWS-2
REMOVAL AND INSTALLATION 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

RKZB5300

17 - Disconnect the cables (29) of the pedal and hand ac-

celerators. Disengage the support sheathing (30).
30

29

RKZA0092

WB150AWS-2 30-47
REMOVAL AND INSTALLATION 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 connectors (40) and (41).
40

RKZB5054

22 - Remove the plate (42) and push it towards the back of

the machine.

42

RKZA9690

30-48 WB150AWS-2
REMOVAL AND INSTALLATION ENGINE-GEARBOX-PUMP GROUP

23 - Loosen the clamp (43) and disconnect the flexible re-

turn hose (44).

43

44
RKZB5341

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

RKZB5350

★ The chains should have a total length of about 800 mm

and a difference between the arms of 53 mm.
200 mm
★ The shortest length should be attached to the bracket -- 53 mm
(45).

★ When under tension the cables should be about 200

mm apart at the height of the muffler.

RKZA1641

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
26 - Raise the entire group until the chassis supports are dis-
engaged, and than accompany the group in order to 48 48
slide it away from the front part of the chassis.
47
Engine-gearbox-pump group: 740 kg
47
49
RKZA0712

WB150AWS-2 30-49
REMOVAL AND INSTALLATION 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): 970±15 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.

30-50 WB150AWS-2
REMOVAL AND INSTALLATION 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»).
Cut off the supply of electricity by turning the accumu-
lator-disconnecting switch in a counter-clockwise direc-
tion and remove the handle.

★ Drain the hydraulic oil. 3 2

Quantity of oil: 92
RKZB5321

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.

7
RKZB5311

6 - Take out the two screws (8) and remove the pump (1)
complete with its O-ring (9). 3 1
Pump: 40 kg

RKZA9720

WB150AWS-2 30-51
REMOVAL AND INSTALLATION 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.

30-52 WB150AWS-2
REMOVAL AND INSTALLATION TRANSMISSION

REMOVAL OF THE TRANSMISSION

Lower the working equipment completely until it rests on
the ground, and stop the engine.
Make the backhoe safe.

Cut off the supply of electricity by turning the accumu-

lator-disconnecting switch in a counter-clockwise direc-
tion and remove the handle.

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
1 - Remove the piston pump. (For details, see «REMOVAL
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 - Take out the front cardan shaft (4). 6 3 4

RKZA2071

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). 5
7

7 6

RKZA0761

WB150AWS-2 30-53
REMOVAL AND INSTALLATION 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

RKZA8881

7 - Disconnect the connectors from sensors (11), from

thermostat (12) and from speed sensor (13). 11

12

11 11

13
RKZO4371

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

30-54 WB150AWS-2
REMOVAL AND INSTALLATION TRANSMISSION

10 - Loosen and remove the nuts (17), and screws (18) and
the anti-vibration nuts (19). 8
19
11 - Remove the gearbox supports (20). 9

17 18
17 18
20

RKZB5360

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

A
B
RKZA9201

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

WB150AWS-2 30-55
REMOVAL AND INSTALLATION 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.

30-56 WB150AWS-2
REMOVAL AND INSTALLATION 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

WB150AWS-2 30-57
REMOVAL AND INSTALLATION 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

30-58 WB150AWS-2
REMOVAL AND INSTALLATION 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

WB150AWS-2 30-59
REMOVAL AND INSTALLATION 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

30-60 WB150AWS-2
REMOVAL AND INSTALLATION 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

WB150AWS-2 30-61
REMOVAL AND INSTALLATION 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

30-62 WB150AWS-2
REMOVAL AND INSTALLATION 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 E1

★ Take a care to not damage the oil pump seal. 2
E1

4
RKZB1630

WB150AWS-2 30-63
REMOVAL AND INSTALLATION 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 E2.

E2 4

RKZB1650

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

30-64 WB150AWS-2
REMOVAL AND INSTALLATION 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

WB150AWS-2 30-65
REMOVAL AND INSTALLATION 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

30-66 WB150AWS-2
REMOVAL AND INSTALLATION 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

WB150AWS-2 30-67
REMOVAL AND INSTALLATION TRANSMISSION

6 - Remove 1st speed antishock valve (7).

RKZB1740

7 - Remove 3rd 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

30-68 WB150AWS-2
REMOVAL AND INSTALLATION 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

WB150AWS-2 30-69
REMOVAL AND INSTALLATION 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

30-70 WB150AWS-2
REMOVAL AND INSTALLATION TRANSMISSION

19 - Remove 2nd speed antishock valve (22) and lower fit-

ting (23).

22

23

RKZB1870

20 - Untighten 4th 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

WB150AWS-2 30-71
REMOVAL AND INSTALLATION 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

30-72 WB150AWS-2
REMOVAL AND INSTALLATION 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

WB150AWS-2 30-73
REMOVAL AND INSTALLATION 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

30-74 WB150AWS-2
REMOVAL AND INSTALLATION 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

WB150AWS-2 30-75
REMOVAL AND INSTALLATION TRANSMISSION

16 - Assemble seal (14) and its sensor cover (13).

13

14

RKZB2000

17 - Assemble screws (12).

Screw: 23 Nm

12

RKZB2010

30-76 WB150AWS-2
REMOVAL AND INSTALLATION 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

WB150AWS-2 30-77
REMOVAL AND INSTALLATION 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

30-78 WB150AWS-2
REMOVAL AND INSTALLATION 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

WB150AWS-2 30-79
REMOVAL AND INSTALLATION 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

30-80 WB150AWS-2
REMOVAL AND INSTALLATION TRANSMISSION

11. Disassembly transmission housing

A
15
14 11
17
16
35 12
13
36
B
32
22 18
19
20 E
1 C
21

A 24
25
26
8 23 27
6 28 30
5 29
30
34
3 9
2
7 33
10
RKZ06480
E 4

1 - Drain oil from transmission hydraulic circuit.

1
2 - Remove bearing retaining ring (1).

RKZB2090

WB150AWS-2 30-81
REMOVAL AND INSTALLATION TRANSMISSION

3 - Remove flange retaining screw (2), washer (3) and O-

ring (4). Use tool E3 to avoid flange rotation.

2 3 4

RKZB2100

4 - Remove flange (5).

RKZB2110

5 - Remove screws (6), cover (7) and O-ring (8).

7 8

RKZB2120

6 - Remove bearing (9).

RKZB2130

30-82 WB150AWS-2
REMOVAL AND INSTALLATION TRANSMISSION

7 - Remove oil seal (10). Use tool E4.

E4 10

RKZB2140

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

WB150AWS-2 30-83
REMOVAL AND INSTALLATION TRANSMISSION

11 - Remove retaining ring (15).

15

RKZB2180

12 - Remove retaining ring (16).

16

RKZB2190

13 - Extract bearing (17) with tool E5.

E5

17
RKZB2200

14 - Remove screws (18) and cover (19).

18

19

RKZB2210

30-84 WB150AWS-2
REMOVAL AND INSTALLATION TRANSMISSION

15 - Remove retaining ring (20).

20

RKZB2220

16 - Remove screws (21) and cover (22).

21

22

RKZB2230

17 - Remove retaining ring (23).

23

RKZB2240

18 - Remove flange retaining screw (24), washer (25) and O-

ring (26). Use tool E3.

24 25 26

RKZB2250

WB150AWS-2 30-85
REMOVAL AND INSTALLATION TRANSMISSION

19 - Remove flange (27).

27

RKZB2260

20 - Remove screws (28) and cover (29).

29 28
RKZB2270

21 - Tap with a rubber hammer from the opposite side until

removing bearing (30) retaining ring, from the contact 30
with the housing. Then extract with a normal extractor.

RKZ06621

22 - Remove oil seal (31). Use tool E4.

E4 31

RKZB2280

30-86 WB150AWS-2
REMOVAL AND INSTALLATION TRANSMISSION

23 - Remove screws (32).

32

RKZB2290

24 - Remove screws (33).

33 RKZB2300

25 - Insert a lever in the special slot “A” and remove the cover
(34) and (36).

36

34
RKZB2310

26 - Lift the front half-housing (34). Use tool E6.

E6
34

RKZB2320

WB150AWS-2 30-87
REMOVAL AND INSTALLATION TRANSMISSION

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 E6, locate front half-housing (34) on rear half-

housing (36).
E6

34

36

RKZB2350

4 - Assemble screws (32).

Screw: 50 Nm

32

RKZB2290

30-88 WB150AWS-2
REMOVAL AND INSTALLATION TRANSMISSION

5 - Assemble screws (33).

Screw: 50 Nm 33

RKZB2360

6 - Assemble bearing retaining ring (1).

1
RKZB2370

7 - Assemble bearing (9). Use tool E7.

RKZB2380

8 - Assemble seal ring (10) on cover (7).

10
E4

RKZB2390

WB150AWS-2 30-89
REMOVAL AND INSTALLATION TRANSMISSION

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

RKZB2420

12 - Assemble screw (2). Use tool E3 to avoid flange rota-

tion.

Screw: 50 Nm

RKZB2430

30-90 WB150AWS-2
REMOVAL AND INSTALLATION TRANSMISSION

13 - Assemble bearing (30). Use tool E8.

30 E8

RKZB2440

14 - Apply a thin film of Loctite 510.

RKZB2450

15 - Assemble seal ring (31) on cover (29). Use tool E4.

E4 31

29

RKZB2460

16 - Assemble cover (29) and tighten with screw (28).

Screw: 139 Nm

29 28 RKZB2470

WB150AWS-2 30-91
REMOVAL AND INSTALLATION TRANSMISSION

17 - Assemble flange (27), O-ring (26) and washer (25).

27

26

25
RKZB2480

18 - Assemble screw (24). Use tool E4 to avoid flange ro-

tation.

Screw: 139 Nm

24

RKZB2490

19 - Assemble retaining ring (23).

23
RKZB2500

20 - Apply a thin film of Loctite 510.

RKZB2510

30-92 WB150AWS-2
REMOVAL AND INSTALLATION TRANSMISSION

21 - Assemble cover (22) and tighten screws (21).

21
Screw: 50 Nm
22

RKZB2520

22 - Assemble retaining ring (20).

20

RKZB2530

23 - Apply a thin film of Loctite 510.

RKZB2540

24 - Assemble cover (19) and tighten screws (18).

Screw: 50 Nm

19
18

RKZB2550

WB150AWS-2 30-93
REMOVAL AND INSTALLATION TRANSMISSION

25 - Assemble bearing (17) on transmission shaft PTO (14).

14
17

RKZB2560

26 - Assemble retaining ring (16).

16

RKZB2570

27 - Assemble retaining ring (15).

15

RKZB2580

28 - Insert transmission shaft PTO (14) to the stroke.

14

RKZB2590

30-94 WB150AWS-2
REMOVAL AND INSTALLATION TRANSMISSION

29 - Assemble O-ring (13) and apply a thin film of grease on

the flange inner diameter (12).

13

12

RKZB2600

30 - Assemble screws (11).

Screw: 50 Nm

11

RKZB2610

WB150AWS-2 30-95
REMOVAL AND INSTALLATION 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

30-96 WB150AWS-2
REMOVAL AND INSTALLATION 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

WB150AWS-2 30-97
REMOVAL AND INSTALLATION 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

30-98 WB150AWS-2
REMOVAL AND INSTALLATION 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 E9 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

WB150AWS-2 30-99
REMOVAL AND INSTALLATION 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

30-100 WB150AWS-2
REMOVAL AND INSTALLATION 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

WB150AWS-2 30-101
REMOVAL AND INSTALLATION 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

30-102 WB150AWS-2
REMOVAL AND INSTALLATION 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 E9 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

WB150AWS-2 30-103
REMOVAL AND INSTALLATION 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

30-104 WB150AWS-2
REMOVAL AND INSTALLATION 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

WB150AWS-2 30-105
REMOVAL AND INSTALLATION 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 E9 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

30-106 WB150AWS-2
REMOVAL AND INSTALLATION 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

WB150AWS-2 30-107
REMOVAL AND INSTALLATION TRANSMISSION

12 - Assemble washer (23), bearing (22) and insert retaining

ring (21). Use tool E8.

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

30-108 WB150AWS-2
REMOVAL AND INSTALLATION 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 E9 and a hydraulic

press.
14

13

15 RKZB3290

19 - Assemble spring pin (12).

12

RKZB3300

20 - Insert washer (9) and roller retainers (8).

RKZB4820

WB150AWS-2 30-109
REMOVAL AND INSTALLATION 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

30-110 WB150AWS-2
REMOVAL AND INSTALLATION TRANSMISSION

25 - Assemble washer (5), spacer (4) and bearing (3). Use

tool E8.

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 E10.

E10 41

RKZB3370

WB150AWS-2 30-111
REMOVAL AND INSTALLATION TRANSMISSION

29 - Assemble D shaft bearing (42). Use tool E10.

E10
42

RKZB3380

30 - Reposition shaft assembly D.

RKZB4840

31 - Reposition shaft assembly A.

RKZB4960

30-112 WB150AWS-2
REMOVAL AND INSTALLATION TRANSMISSION

15. Disassembly shaft B

16
16

14
12
13
11 15
10 15
7 B
9 15

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
E11. E11

RKZB3400

WB150AWS-2 30-113
REMOVAL AND INSTALLATION 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

30-114 WB150AWS-2
REMOVAL AND INSTALLATION 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

WB150AWS-2 30-115
REMOVAL AND INSTALLATION 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

30-116 WB150AWS-2
REMOVAL AND INSTALLATION 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 E9 and a hydraulic press.

19

20
RKZB3540

17 - Remove spring retaining cover (18) and spring (20).

18

20

RKZB3550

WB150AWS-2 30-117
REMOVAL AND INSTALLATION 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

30-118 WB150AWS-2
REMOVAL AND INSTALLATION TRANSMISSION

16. Assembly shaft B

E10 26
1 - Assemble bearing (26). Use tool E10.

RKZB3610

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

WB150AWS-2 30-119
REMOVAL AND INSTALLATION 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 E9 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

30-120 WB150AWS-2
REMOVAL AND INSTALLATION 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

WB150AWS-2 30-121
REMOVAL AND INSTALLATION TRANSMISSION

14 - Assemble washer (7), spacer (6) and gear (5).

6
5

RKZB3720

15 - Assemble bearing (4). Use tool E7.

E7 4

RKZB3730

16 - Insert spacer (3) and assemble retaining ring (1).

1

RKZB3740

17 - Insert rotary seal (2).

2

RKZB3750

30-122 WB150AWS-2
REMOVAL AND INSTALLATION 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 E11. E11

RKZB3770

WB150AWS-2 30-123
REMOVAL AND INSTALLATION 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 E11.
E11

RKZB3400

30-124 WB150AWS-2
REMOVAL AND INSTALLATION 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

WB150AWS-2 30-125
REMOVAL AND INSTALLATION 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

30-126 WB150AWS-2
REMOVAL AND INSTALLATION 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 E9 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 - Remove washer (21), the seal ring (22) and the shims
(23) requested for assembly.
21

22

23

RKZB3900

WB150AWS-2 30-127
REMOVAL AND INSTALLATION TRANSMISSION

15 - Widen and remove rotary seal (24).

24

RKZB3910

16 - By means of an extractor remove 1st speed gear (25)

and bearing (26).

26

25

RKZB3920

17 - Slightly lower stop washer (27).

27

RKZB3930

19 - Remove retaining ring (28).

28

RKZB3940

30-128 WB150AWS-2
REMOVAL AND INSTALLATION TRANSMISSION

20 - Remove stop washer (27) by means of two screwdriv-

ers.
27

RKZB3950

21 - Remove disc pack (29) and counterdiscs (30).

29
30

RKZB3960

22 - Remove Belleville washer (31).

31

RKZB3970

23 - Lower spring retaining cover (34) to allow retaining ring

removal (32). Use tool E9 and a hydraulic press.

32
34

RKZB3980

WB150AWS-2 30-129
REMOVAL AND INSTALLATION TRANSMISSION

24 - Remove retaining ring (32), spring retaining cover (33)

and spring (34). 32

33

34

RKZB3990

25 - Remove clutch piston (35) by blowing in compressed air

through the delivery hole. Remove rotary seal (36). 35 36

RKZB4000

26 - Remove retaining ring (37).

37

RKZB4860

27 - Remove roller retainer (38), bushings (39) and spacer

(40).
38

39 40

38

39
RKZB4870

30-130 WB150AWS-2
REMOVAL AND INSTALLATION TRANSMISSION

28 - Remove gear (41).

41

RKZB4010

29 - Remove gear (42).

42

RKZB4020

30 - Remove roller retainers (43).

43

RKZB4030

31 - Slightly lower stop washer (44).

44

RKZB4040

WB150AWS-2 30-131
REMOVAL AND INSTALLATION TRANSMISSION

32 - Remove retaining ring (45).

45

RKZB4050

33 - Remove stop washer (44) by means of two screwdriv-

ers.

44

RKZB4060

34 - Remove Belleville washer (46), discs (47), counterdiscs

(48) and washer (49).

46

47 48
RKZB4070

35 - Remove spring ring (50).

50

RKZB4080

30-132 WB150AWS-2
REMOVAL AND INSTALLATION TRANSMISSION

36 - Lower spring retaining cover (53). Use tool E9 and a hy-

draulic press.

53

RKZB4090

37 - Remove retaining ring (51), spring retaining cover (52)

and spring (53).
51

52

53

RKZB4950

38 - 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

WB150AWS-2 30-133
REMOVAL AND INSTALLATION TRANSMISSION

2 - Apply a thin film of grease on the outer edge and in the in-
ner part of clutch piston (54).

54

RKZB4120

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 E9 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

30-134 WB150AWS-2
REMOVAL AND INSTALLATION TRANSMISSION

6 - Assemble spring pin (50).

50

RKZB4160

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

WB150AWS-2 30-135
REMOVAL AND INSTALLATION TRANSMISSION

11 - Assemble retaining ring (45).

45

RKZB4890

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

30-136 WB150AWS-2
REMOVAL AND INSTALLATION TRANSMISSION

15 - Apply a thin film of grease on the outer edge and in the in-
ner part of clutch piston (35). 35

RKZB4220

16 - Insert clutch piston (35), spring (34) and spring retaining

cover (33). 33

34
35

RKZB4230

17 - Lower spring retaining cover (34) and assemble retai-

ning ring (32). Use tool E9 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

WB150AWS-2 30-137
REMOVAL AND INSTALLATION TRANSMISSION

19 - Insert stop washer (27), disc pack (29), counterdiscs

(30) and Belleville washer (31) on main shaft (56) mak- 56
30
ing sure they are all aligned.

29 31

27
RKZB4260

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

30-138 WB150AWS-2
REMOVAL AND INSTALLATION TRANSMISSION

23 - Assemble bearing (26). Use tool E8.

26
E8

RKZB4300

24 - Insert retaining ring (21) to measure dimension X.

Calculate the shim S with this formula: 21
22
S=X–(S1+S2)

S1 = retaining ring (21)

S2 = washer thickness (22)

S1
X

S2
S

RKZB4310

25 - Insert and close rotary seal (20) on clutch piston (19).

19

20

RKZB4320

26 - Apply a thin film of grease on the outer edge and in the in-
ner part of clutch piston (19).

19

RKZB4330

WB150AWS-2 30-139
REMOVAL AND INSTALLATION TRANSMISSION

27 - Insert clutch piston, spring (18) and spring retaining cov-

er (16).
16
18

RKZB4340

28 - Lower spring retaining cover (18) and insert retaining

ring (17). Use tool E9 and a hydraulic press.

17

18
RKZB4350

29 - Assemble spring pin (14).

14

RKZB4360

30 - Apply a thin film of grease under washer (15) to avoid its

falling when overturning the shaft.

15

RKZB4370

30-140 WB150AWS-2
REMOVAL AND INSTALLATION TRANSMISSION

31 - Insert stop washer, Belleville washer, discs (12) and

counterdiscs (13) on gear (6).
12

11
13

6
9

RKZB4910

32 - Insert roller retainers (7).

RKZB4380

33 - Insert gear (6) with the disc pack on the main shaft.
6

RKZB4390

34 - Locate the pack assembly by means of two screwdriv-

ers.

RKZB4400

WB150AWS-2 30-141
REMOVAL AND INSTALLATION TRANSMISSION

34 - Lift gear (6) for retaining ring assembly.

RKZB4410

35 - Assemble retaining ring (10) and gear.

10

RKZB4420

36 - Assemble pin (8).

8
RKZB4920

37 - Assemble phonic wheel (5).

RKZB4430

30-142 WB150AWS-2
REMOVAL AND INSTALLATION TRANSMISSION

38 - Assemble bearing (4). Use tool E7.

E7
4

RKZB4440

39 - Insert washer (3) and retaining ring (2).

2

RKZB4450

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 E11. E11

RKZB4470

WB150AWS-2 30-143
REMOVAL AND INSTALLATION TRANSMISSION

42 - Check for proper operation by blowing in compressed air into the special hole, about 6 bar.

30-144 WB150AWS-2
REMOVAL AND INSTALLATION 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
E11. E11

RKZB3400

WB150AWS-2 30-145
REMOVAL AND INSTALLATION TRANSMISSION

2 - Widen and remove rotary seals (1).

RKZB4480

3 - Lower Belleville washers (2) and remove retaining ring

(3). Use tool E9 and a hydraulic press.
★ Take care not to damage the Belleville washers.

3
E9

2
RKZB4490

4 - Remove washers (4) and spacers (5).

4
3

RKZB4500

5 - Remove spacer (6) and Belleville washers (2).

6 2

RKZB4510

30-146 WB150AWS-2
REMOVAL AND INSTALLATION TRANSMISSION

6 - Remove clutch piston (7) from its seat. To remove the pi-
ston 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

WB150AWS-2 30-147
REMOVAL AND INSTALLATION 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

30-148 WB150AWS-2
REMOVAL AND INSTALLATION 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

WB150AWS-2 30-149
REMOVAL AND INSTALLATION 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 E12.

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

30-150 WB150AWS-2
REMOVAL AND INSTALLATION TRANSMISSION

4 - Position the pins (10) on clutch piston (7) in correspond-

ence with the holes on output shaft and insert clutch pi-
ston.

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

WB150AWS-2 30-151
REMOVAL AND INSTALLATION 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

30-152 WB150AWS-2
REMOVAL AND INSTALLATION 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 E9 and a hydraulic press.

3
E9

2
RKZB4490

14 - Insert a pressure of about 10 bar with an oil pump to

check the seal of ring (8) and (9). Use tool E13. 9

E13

8
RKZ06520

15 - Insert rotary seals (1).

RKZB4750

WB150AWS-2 30-153
REMOVAL AND INSTALLATION TRANSMISSION

16 - Assemble bearing (23). Use tool E14.

E14

23

RKZB4760

17 - Insert spacer (22).

22

RKZB4770

18 - Using tool E11, lift the three shafts B-C-E at the same
time and insert the unit into the half-housing.

RKZB4780

30-154 WB150AWS-2
REMOVAL AND INSTALLATION CONVERTOR

REMOVAL OF THE CONVERTOR

Lower the working equipment completely until it rests on
1
the ground and stop the engine. 2
Cut off the supply of electricity by turning the accumu-
lator-disconnecting switch in a counter-clockwise direc-
tion and remove the handle.
Release all residual pressure in all circuits.
(For details, see «20. TESTING AND ADJUST-
MENTS»).
★ Drain the hydraulic oil.
Hydraulic oil: 92

RKZA8730

★ Drain the oil from the gearbox.

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.

WB150AWS-2 30-155
 TRANSMISSION-REVERSE, DIRECTION INDICATOR AND
REMOVAL AND INSTALLATION HEADLIGHT DIPPER BEAM CONTROL GROUP

REMOVAL OF THE TRANSMISSION-REVERSE, DIRECTION

INDICATOR AND HEADLIGHT DIPPER BEAM CONTROL GROUP
Lower the working equipment completely until it rests on
the ground, and stop the engine. 1
Cut off the supply of electricity by turning the accumu-
lator-disconnecting switch in a counter-clockwise direc-
tion and remove the handle.

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

30-156 WB150AWS-2
REMOVAL AND INSTALLATION STEERING UNIT

REMOVAL OF THE STEERING UNIT

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. 2 1
(For details, see «20. TESTING AND ADJUST-
MENTS»).
Cut off the supply of electricity by turning the accumu-
lator-disconnecting switch in a counter-clockwise direc-
tion and remove the handle.

1 - Disconnect the five pipes (2) from the steering unit (1)
and plug them to prevent entry of impurities. 1 RKZA0870

★ Mark the positions to prevent exchanges during re-

connection.

2 - Remove the central guard (3) beneath the steering whe-

el.

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
11
★ Bleed the air from the Load Sensing circuit.
(For details, see «20. TESTING AND ADJUST-
MENTS»).
9 8
★ Start the engine and perform several complete steering 10
manoeuvres in both directions, to bleed the air out of the
steering system.

RKZA9791

WB150AWS-2 30-157
REMOVAL AND INSTALLATION 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
Cut off the supply of electricity by turning the accumu-
lator-disconnecting switch in a counter-clockwise direc-
2 7
tion and remove the handle.
5
1 - Remove the cap (1) of the oil tank (2) and draw out the oil
3
contained inside it. 7

2 - Disconnect the connectors (3). 4

6
3 - Remove the oil tank (2).
8
RKZA9800
4 - Remove the clip (4) that holds the delivery lines (5).

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
the pistons. 9 10
RKZA0911
★ After installation, check the idle stroke and parallelism
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

30-158 WB150AWS-2
REMOVAL AND INSTALLATION WORKING EQUIPMENT CONTROL VALVE

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 1
(For details, see «20. TESTING AND ADJUST-
MENTS»).

1 - Remove the grip (1) of the hand accelerator and disen- 2

gage the protective sleeves (2), (3).

RKZB0070

2 - Take out the screws (4) and remove the guard (5).

3
5

RKZB0030

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

WB150AWS-2 30-159
REMOVAL AND INSTALLATION FRONT AND BACKHOE CONTROL VALVE

DISASSEMBLY AND ASSEMBLY FRONT AND BACKHOE CONTROL

VALVE (from serial number 150F80048-)
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

30-159-1 WB150AWS-2
➀
REMOVAL AND INSTALLATION FRONT AND BACKHOE CONTROL VALVE

• 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

WB150AWS-2 30-159-2
➀
REMOVAL AND INSTALLATION FRONT AND BACKHOE CONTROL VALVE

• 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

30-159-3 WB150AWS-2
➀
REMOVAL AND INSTALLATION FRONT AND BACKHOE CONTROL VALVE

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.

WB150AWS-2 30-159-4
➀
REMOVAL AND INSTALLATION FRONT AND BACKHOE CONTROL VALVE

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

30-159-5 WB150AWS-2
➀
REMOVAL AND INSTALLATION FRONT AND BACKHOE CONTROL VALVE

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

WB150AWS-2 30-159-6
➀
REMOVAL AND INSTALLATION FRONT AND BACKHOE CONTROL VALVE

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

30-159-7 WB150AWS-2
➀
REMOVAL AND INSTALLATION FRONT AND BACKHOE CONTROL VALVE

• 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

WB150AWS-2 30-159-8
➀
REMOVAL AND INSTALLATION FRONT AND BACKHOE CONTROL VALVE

★ 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

30-159-9 WB150AWS-2
➀
REMOVAL AND INSTALLATION FRONT AND BACKHOE CONTROL VALVE

• 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

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

• 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

WB150AWS-2 30-159-10
➀
REMOVAL AND INSTALLATION FRONT AND BACKHOE CONTROL VALVE

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

• Visually check the condition of parts and replace the as-

sembly if necessary.

RKZB6180
RKZB6190

30-159-11 WB150AWS-2
➀
REMOVAL AND INSTALLATION FRONT AND BACKHOE CONTROL VALVE

★ 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

• 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.

WB150AWS-2 30-159-12
➀
REMOVAL AND INSTALLATION FRONT AND BACKHOE CONTROL VALVE

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

30-159-13 WB150AWS-2
➀
REMOVAL AND INSTALLATION FRONT AND BACKHOE CONTROL VALVE

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

WB150AWS-2 30-159-14
➀
REMOVAL AND INSTALLATION 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.

RKZA9150

4 - Engage the parking brake.

5 - Stop the engine and eliminate residual pressure from all

circuits. (See «20. TESTING AND ADJUSTMENTS»).

Cut off the supply of electricity by turning the accumu-

lator-disconnecting switch in a counter-clockwise direc-
tion and remove the handle. 3

6 - Take off the front wheels (1). 1

Wheel: 163 kg
7 - Remove the front counterweight (2). 1 2
(For details, see «REMOVAL OF FRONT COUNTER- RKZA9160

WEIGHT»).
2
8 - Remove the front guard.

9 - Disconnect the cardan shaft (4) from the axle (3).

3

3
4

10 - Disconnect the lines (5) from the steering cylinder and RKZA9270

plug them to prevent entry of impurities. 4

11 - Disconnect the lubrication tube (6) for the axle oscilla-
tion pin (7).
6
12 - Disconnect cable (8). 5
6
5
13 - Position a jack “B” and some blocks “C” beneath the ax- 8
le. Raise the jack until the blocks can be forced under
the axle arms (3).
★ It should be possible to lower the jack 10 cm in order
to disengage the axle from the fulcrum supports.
14 - Take out the nut and remove the retaining screw (8).
3
5
7
RKZA9280

30-160 WB150AWS-2
REMOVAL AND INSTALLATION FRONT AXLE

15 - Lower the jack until the axle is disengaged.

16 - Extract the entire axle (3).

Front axle: 530 kg

8
INSTALLATION OF THE
FRONT AXLE 8
• To install, reverse the removal procedure.
RKZA9250

1
Nuts for front wheels: 800 Nm

2
Front counterweight screw: 300±30 Nm

3
Screws on gearbox side: 73.5 Nm

4
★ Bleed the air from the Load Sensing circuit.
(For details, see «20. TESTING AND ADJUST-
MENTS»).

5
Screw: 568 Nm

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.

WB150AWS-2 30-161
REMOVAL AND INSTALLATION FRONT AXLE

DISASSEMBLY OF FRONT AXLE

1. Trunnions disassembly
1 - Remove the circlip (1) and the input flange (2). Collect
the O-ring (3) and the washer (4).

4 2

3
RKZ05200

2 - Remove front (5) and rear trunnions (6).

It is necessary to use a chisel to remove the bushing (7)
and the snap ring (8) if worn out.
NOTE. Destructive operation for the components.

8
7
5

6 RKZ05490

3 - Loosen the screw (9) and pull the bushing (10) out of the
rear support (6).

10

6
9

RKZ05500

4 - Check and replace as necessary the bushings (11) of

rear trunnion (6).
11

6
RKZ05510

30-162 WB150AWS-2
REMOVAL AND INSTALLATION FRONT AXLE

5 - Check and replace as necessary the bushings (12) of

front trunnion (5). 12

5
RKZ05520

6 - Loosen the screw (13) and take the bushing (14) out of
the front support (5).
Remove the O-ring (15). 13

15

5
14
RKZ05530

2. Steering cylinder group disassembly

3 1
1 - Remove the inductive magnetic steering sensor (2) and
the relative support bracket (3) by loose the fastening
screws (1).

RKZ05540

2 - Loose the guide rod (5) locknut (4) of some turns till it is
over the base of the threaded pin. Beat on the nut (4) 6 5
with a hammer in order to disjoint the guide rod (5) from
the swivel housing (6).
★ Nut (4) must be replaced every disassembly.

RKZB0080

WB150AWS-2 30-163
REMOVAL AND INSTALLATION FRONT AXLE

3 - Remove the guide rod link (5) and the washer (7). Un-
screw the fastening screw (8) of the cylinder and take 7
5
the cylinder (9) out of its housing.
8

5 RKZ05550

4 - Detach the cylinder head (10) from the cylinder case

(11) and remove of the rod (12).

11

12
10

RKZ05560

5 - Remove of the cylinder head (10) from the rod, making

sure not to lose any of the sealing (13) and O-rings both 13
from the cylinder head and the rod.
11
13

13 12

10
RKZ05570

3. Epicyclic reduction gear disassembly

1 - Unscrew and remove the two fastening screws (1) of the
planetary carrier (2) with a wrench. 1
2

RKZB0110

30-164 WB150AWS-2
REMOVAL AND INSTALLATION FRONT AXLE

2 - Remove the planetary carrier (2) from the wheel hub (3).
Position the planetary carrier on a table and check its
wear conditions. Remove the O-ring (4) and check its 4
conditions.

RKZB0120

3 - To replace the epicyclic gears, if necessary, remove the

screw (5) and relevant washers (6) and (7). 5
★ Leave the pin (8) in its seat. 6

8 7

RKZ05210

4 - Remove the epicyclic gear (9) and the washer (10).

9
5 - Remove the rollers (11) from gear (9).
10 9

11

RKZ05220

6 - If the pins (12) of the pinion gears are in poor condition,

replace the entire planetary train with pre-fitted pins. 12

RKZ05230

WB150AWS-2 30-165
REMOVAL AND INSTALLATION FRONT AXLE

4. Wheel hub group disassembly

Before disassembling the splined sleeve, it is advisable
2
to secure it with a belt or a rope on a hoist or any other
supporting device, in order to avoid its accidental fall
that could damage either the operator or the wheel hub
group.

1 - Remove the Seeger ring (1) from the U-Joint shaft (2) 1
using suitable pliers.

RKZB0130

2 - Remove and collect the axle shaft (2) washers (3) and
(4).
2 4
3
1

RKZB1260

3 - Unscrew and remove the fastening screws (5) from the

hub-lock ring gear (6). 6

RKZB0140

4 - To remove the hub-lock ring gear (6) from its housing,

screw at least two of the just removed screws (5) in the
threaded extraction holes “A”.
6
A

RKZB0150

30-166 WB150AWS-2
REMOVAL AND INSTALLATION FRONT AXLE

5 - Remove the steel stop ring (7) and disjoint the hub-lock
ring gear (6) from the epicyclic ring gear (8).
★ Check the wear conditions of the components. 9
6 - Only if necessary, remove the centering bushes (9) of
the hub lock ring gear with a hammer and the special
tool C1.
7

6
8
RKZB0180

7 - Remove the hub (10) with inner ring (11), using levers
and a hammer to facilitate the operation.

10

11
RKZB0170

8 - Position on a flat surface the hub and take the seal ring
(12) out with a lever. 13
★ Seal ring must be replaced every disassembly.
9- Using a extractor and soft hammer, remove external
washer (11) and (13) on both sides of the hub (10).

10 - Using a extractor, remove inner washer (13) from the

swivel housing. 12

11 10
RKZ05590

11 - Unscrew and remove the fastening screws (15) from the

upper (16) and lower (17) king pin.
15

14
16

17
RKZB0190

WB150AWS-2 30-167
REMOVAL AND INSTALLATION FRONT AXLE

12 - Secure the swivel housing (14) with a belt or a rope to a

hoist or any other supporting device. Remove the king 14
pins (16) and (17). 16

17

RKZB0200

13 - Remove the Belleville washers (18) and the shims (19)

and (20).

18
19

20

RKZB0220

14 - Position the swivel housing (14) on a flat surface and

take the oil seal ring (21) out with a lever.
★ Seal ring must be replaced every disassembly. 14

21

RKZB0230

15 - Turn the swivel housing (14) and take the bushing (22)
out, using a suitable special tool and a hammer.

22

RKZB0240

30-168 WB150AWS-2
REMOVAL AND INSTALLATION FRONT AXLE

5. Axle beam group disassembly

1 - Remove the U-Joint (1) from the axle beam.

RKZB0251

2 - Take the seal ring (2) out of the axle beam with a lever.
★ Seal ring must be replaced every disassembly.
In order to replace bushing (3) inside the axle beam, it is 3
need to be cut and destroyed with a chisel.

RKZB0260

3 - Take the upper (4) and lower (5) bushing out of the king
pin housing with a suitable extractor.

RKZB0270

4 - Take the bushing (6) out of the king pins (7) with a suit-
able extractor. 6

RKZ05250

WB150AWS-2 30-169
REMOVAL AND INSTALLATION FRONT AXLE

6. Differential support group disassembly

1 - Loosen and remove screws (1) on the differential sup-
port (2). Remove the differential (2).
2
Secure the differential support with a belt or a rope
to a hoist.

2 -Remove the seal ring (3).

★ Seal ring must be replaced every disassembly.
3

1
RKZ05260

3 - Loosen and remove the screws (4) to remove the ring

nut retainers (5).
4

RKZ05280

4 - Mark halfbridles and the differential carrier with perma-

nent reference marks to avoid inverting them when re-
assembling the unit. Mark the area between the ring 6
6
nuts and the differential carrier as well.

RKZ05290

5 - Unscrew the adjuster ring nuts using tool C2 and a

7
wrench.

7
C2

RKZ05300

30-170 WB150AWS-2
REMOVAL AND INSTALLATION FRONT AXLE

6 - Loosen and remove the screws (8) and remove the half-
collar (6). 8

RKZ05310

7 - Take out the differential case (9).

★ Take care not to loose the cups (10) bearing. 10
★ Check that the bushes (11) remains in their hou- 9
sings.
10
11

RKZ05320

7. Differential group disassembly

1 - Remove the differential and put it in a clamp.

2 - Unscrew and remove all the fastening screw (1) of the

bevel gear crown.
2
3 - Remove bevel gear crown (2).

RKZB0570

4 - Disassemble the differential box in two half boxes com-

plete with the relative components.
★ Mark the half boxes.

RKZB0580

WB150AWS-2 30-171
REMOVAL AND INSTALLATION FRONT AXLE

5 - Disassemble all the components. Check the operating

and wear conditions of the components. Take the bear-
ing out differential half box, using two levers or a three- 3
hold extractor.

4 RKZ05580

8. Pinion group disassembly

1 - Fit the differential carrier (1) on a vise. C3 1
2 - Undo the lock nut (2) using special tools C3 and C4. 2
★ Lock nut must be replaced every disassembly.

C4
RKZ05330

3 - Remove the nut (2) and the lock nut retaining washer
(3).

3
2

RKZ05340

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 (6) and the inner
cone of the tapered roller bearing (7). 7
★ The collapsible must be replaced every disassem- 5
bly.

4 RKZ05350

30-172 WB150AWS-2
REMOVAL AND INSTALLATION FRONT AXLE

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) and (8) using a drift and a hammer. 8

RKZ05360

7 - To remove the inner cone of the tapered roller bearing

(8) of the pinion (4), use a standard extractor.
Set aside the bearing cone (8) and the underlying shim
(9).
8

RKZ05370

8 - Check all pinion components for wear.

5
5 4

8
6
7 RKZ05990

WB150AWS-2 30-173
REMOVAL AND INSTALLATION FRONT AXLE

ASSEMBLY OF FRONT AXLE

1. Re-assembly of the bevel pinion
1 - Using the tool C5 and C6, insert the outer retainers of
the pinion bearings (1) and (2). 1

RKZ05380

2 - Mount into the differential support (3) the bearings (1)

and (2), the gauge block C7, with the lock nut (4), the
gauge tube C8, and the lock nuts C9. 3
In order to pre-load the bearings (1) and (2) tighten the
lock nut (4) until the pinion becomes hard to turn. C9
C9

C8 C7
4
RKZ01792

3 - Mount the bearing covers (5) and tighten the screws (6)
uniformly until the lock nuts C9 are held fast. 6 5

C9

RKZ01801

4 - Use a deep calliper to take the measurement “X” be-

tween the gauge tube C8, and the surface inside the
gauge C7.
★ Write down the “X” measurement.

C7

RKZ01811

30-174 WB150AWS-2
REMOVAL AND INSTALLATION FRONT AXLE

5 - Make a note of the value “N” marked on the head of the

pinion.
Calculate the thickness “S” to be installed beneath the
pinion, using the formula:

S=X--N
★ “S” is the thickness of the shim.

RKZB1530

6 - Dismantle the special tools and remove the bearings (1)

and (2) from the differential support (3).
3

RKZ01793

7 - Mount the shim (8) onto the pinion (7) and press the in-
ner bearing (1) using the tool C10.
★ The chamfer on the inner diameter of the shim must
face the toothing.
1

RKZ05440

8 - Mount onto the pinion the first washer (9), the new spac-
er (10) and the second washer (9). 9

10

RKZ05450

WB150AWS-2 30-175
REMOVAL AND INSTALLATION FRONT AXLE

9 - Lubricate the bearings with gear oil. Using puller C10,

mount the pinion group (7) into the differential support
(3) and position the outer bearing (2).

10 - Mount the washer (11) and the lock nut (4). 2

11 7
4

RKZ05460

11 - Use the tools C4 and C3 to tighten the lock nut (4) a little
at a time until the clearance is eliminated and the bear-
ings are slightly pre-loaded.
★ Rotate the gauge tube by a few turns between one
lock nut tightening increment and the next.

C3

C4
RKZ05470

12 - Wind a wire line C11 round the pinion (7), 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.

C11

P
RKZ05480

13 - Using the tools mentioned in point 11, tighten the lock

nut (4) taking dynamometric measurements at intervals
until the indicated force “P” has been obtained.
★ If the maximum permissible value is exceeded, a
new spacer must be fitted and all the bearing pre-
loading operations must be repeated. P= (9.2–13.7) daN
(1 daN = 10 N)

30-176 WB150AWS-2
REMOVAL AND INSTALLATION FRONT AXLE

14 - Once the correct pre-loading has been achieved, caulk

the lip of the lock nut (4) to correspond to the well of the
pinion (7).

4
7

RKZB1270

2. Differential group assembly

1 - Assemble the cones of the new taper roller bearing (1)
on the half boxes (2), using the special tool C12 and a C12
hammer. 1

RKZB0720

2 - Position a half box on a workbench and assemble all its

inner components (sun gears, planetary gears, thrust
rings, pins and counterdiscs). Join the two half boxes, 2
aligning the reference marks made upon them.

2 RKZ05581

3 - Joint the two half boxes (2), aligning the reference

marks. 3
4 - Position the ring bevel gear (3) and then fix the whole by
tightening the screws. 4
Screw: 155 Nm
Screw: Loctite 270

RKZB1290

WB150AWS-2 30-177
REMOVAL AND INSTALLATION FRONT AXLE

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 inverse the outer cups.
★ Crown must be faced to the marked support.

RKZ05600

2 - Place the differential group and the two halfbridles (3)

and bolts (4) in their seat. Check the right position of the 4
half collars with the previously-traced reference marks.
Position and tighten slightly the halfbridles bolts (5).
3 3

RKZ05610

3 - Assemble and tighten the two adjustment lock nuts (5)

5
in the differential support with tool C2, 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 lock nuts; align the pre- 5
viously-traced reference marks. C2

RKZ05301

4 - Position a magnetic-base dial gauge on the differential

carrier, so that the feeler stylus touches the surface 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: 0.20 – 0.30 mm

RKZ05620

30-178 WB150AWS-2
REMOVAL AND INSTALLATION FRONT AXLE

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).

RKZ05650

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+3.4) < T < (P+5.1) daN
P= the force found for the pinion

★ The force should be that of continual rotation. Do

not take the thrust force into consideration. C11
8 - If the force is not within permissible limits: T
a - Tighten both the lock nuts to the same extent to in- RKZ05481

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.

WB150AWS-2 30-179
REMOVAL AND INSTALLATION FRONT AXLE

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
pinion.

RKZ01840

RKZ01850

10 - Tighten the bolts (4).

Screw: 413 Nm 4

RKZ05270

11 - Once you have completed adjustment operations, fit

the adjuster nut (6) retainers screws (7). 7
Screw: 13 Nm 6

RKZ05690

30-180 WB150AWS-2
REMOVAL AND INSTALLATION FRONT AXLE

12 - Fit a new ring (8) on the differential support using the

tool C13 and a hammer.

RKZ05700

13 - Spread a film of Loctite 510 on the contact surface be-

tween the axle beam and the differential carrier (2).
14 - Tighten retaining screws (9) for lock group (1).

Screw: 169 Nm 1
★ Use a criss-cross method.

9
RKZ05710

4. Axle beam group assembly

1 - Assemble the upper king pin bush (1) and (2) on the axle
beam with the special tool C14 and a hammer.
2
★ To make the assembly easier, it is suggest to cool C15
the cup of the ball bearing at a temperature less
than –100°C.

RKZB0990

2 - Assemble the bush (3) on the axle beam with the special
tool C15 and a hammer.
Fill 3/4 of the seal ring cavity with grease. 3 4
3 - Assemble the seal ring (4) on the beam with the special
tool C16 and a hammer.

C15 C16

RKZB1000

WB150AWS-2 30-181
REMOVAL AND INSTALLATION FRONT AXLE

4 - Lubricate the bush (3) and the seal ring (4) lips. Insert
the U-Joint (5) inside the axle beam.
★ Be careful not to damage the seal ring.

RKZB0250

5. Wheel hub group assembly

1 - Force the bush (1) in the swivel housing (2) with the spe-
cial tool C17 and a hammer or a press. Fill 3/4 to the gas-
ket (3) cavity with grease.
C18 C17
Assemble the ring (3) on the swivel housing (2) with the 1 3
special tool C18 and a hammer.

RKZB1010

2 - Mount shim (4) and grease well the king pin housing
with specific grease. 4
5
3 - Position the Belleville washers and shim (5) on the king
pin housings.

RKZB1400

4 - Position the lower pin (1) on a workbench and mount the

2
washer (2) of the taper roller bearings with the special
tool C19 under a press.

RKZ05720

30-182 WB150AWS-2
REMOVAL AND INSTALLATION FRONT AXLE

5 - Secure the swivel housing group (3) with a rope and as-
semble it the axle beam. 3
★ Take care not to damage the seal ring.
4
6 - Mount the lower (5) and upper (4) pin and tighten screw
(6).
6
Screw: 300 Nm
★ Make sure that the Belleville washers remain in
their position.
5

RKZB1410

7 - In the case the bearings (7) and (8) 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
8
C = 23.070 – 23.172
7 C A C

RKZ05740

8 - Position the wheel hub (9) on a workbench and using

the tool C20 and a press, force the two cups of the taper 8 10
roller bearings (7) and (8) in position. 7
Using the tool C21 mount the seal (10) in the wheel hub
(9).

C20 C21

C20 9

RKZB1420

9 - Assemble the cone of the taper roller bearing (8) on the 9

3
swivel housing (3).

10 - Assemble the wheel hub (3) on the swivel housing (9) 8

and force the other cone of the taper roller bearing (7) in
positions.

RKZB1430

WB150AWS-2 30-183
REMOVAL AND INSTALLATION FRONT AXLE

11 - Position the wheel carrier (11) on a workbench and

force the bushes (12) to the carrier surface level with the
special tool C1. 12
NOTE. At least two bushes (diametrically-opposed)
should be set slightly higher than the carrier sur-
face level to be used as dowel pins.

11
RKZB1090

12 - Preassemble the wheel carrier group (13), epicyclic ring

gear (14), with the special lock ring (15). 14

13

15

RKZ05730

13 - Assemble the wheel carrier group (13) on the wheel hub

(9) using the two projecting bushes (12) as dowel pins. 9 13

12

RKZB1100

14 - Force all the hub dowel bushes completely with the spe-
cial tool C1 and a hammer. 13
Assemble the wheel carrier fastening screws (16) and 16
tighten to the requested torque.

Screw: 220 Nm

RKZB1440

30-184 WB150AWS-2
REMOVAL AND INSTALLATION FRONT AXLE

15 - Insert the rings (17) and the shim (18) into the axle shaft
of the U-Joint and lock with the seeger ring (19).
17
18
19

RKZB1261

6. Epicyclic reduction gear assembly

1 - Place the planetary carrier on a work bench and fit the 1
epicyclic gears (1) and respective washers (2) on the
dowels already fitted.
2

RKZ05750

2 - Insert all the rolls (3) into the epicyclic gears (4), then
place the two thrust washers (5) and (6).
6
★ The first washer (6) must be aligned with the dowel 4
5
pin.

3 RKZ05760

3 - Fit and tighten the epicyclic gears (4) fixing bolts (7),
tightening to the prescribed torque.
4
7
Screw: 79 Nm

RKZ05770

WB150AWS-2 30-185
REMOVAL AND INSTALLATION FRONT AXLE

4 - Assemble a new O-ring (8) on the wheel hub (9). As-

semble the epicyclic reduction gear (10) on the wheel 8 10
hub (9). Screw in the fastening screws and tighten.

Screw: 25 Nm

RKZB1140

7. Steering cylinder group assembly

1
1 - Fit new seal rings (1) to the cylinder head (2), to the
cylinder body (3), to the cylinder rod (4). 3
1

1
4

2
RKZ05571

2 - Mount the cylinder head (2) with gasket on the cylinder

rod (4) and slide into cylinder body (3).

4
2
3

RKZ05780

3 - Fit the tie rods (4) to the ends of the cylinder rod (5) and
tighten
6
Tie-rod: 300 Nm
★ Position and lock the measurement washer on the
4
left side. 5
4 - Install the steering cylinder on the axle central body,
with guide rods already assembled on the stem. As-
semble and tighten the steering cylinder fastening
screws (6) with dynamometric wrench

Screw: 460 Nm RKZ05790

30-186 WB150AWS-2
REMOVAL AND INSTALLATION FRONT AXLE

5 - Unloose nut (7) and screw in or out the guide rod (5) so
that the ball joint call be inserted into the swivel housing
(8).
7 8
5

RKZB1160

6 - Tighten nut (8).

Nut: 260 Nm

RKZB1170

7 - Assemble the sensor (10) and the relative support (11)

to the axle and fix the fastening (12) screws with a dy- 11 12
namometric wrench

Screw: 460 Nm

10

RKZ05541

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

WB150AWS-2 30-187
REMOVAL AND INSTALLATION FRONT AXLE

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 - 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
(M --0 5).
Example:
M distance measured: 2145 mm
Correct toe-in:
• rear side: 2147 mm
• front side: 2143 mm

RKZB1210

4 - After adjusting, screw in the lock nuts (1) of the guide

rods. 1
Lock nut: 250 Nm

RKZB1220

5 - Check the steering sensor position with the wheel hubs

perpendicular to axle. If necessary, adjust the steering M -0 5
sensor position.

6 - Check that the distance between disc and sensor is

0.5–0.75 mm.

M
RKZ05810

30-188 WB150AWS-2
REMOVAL AND INSTALLATION FRONT AXLE

9. Steering angle adjustment

A
1 - Use the same bars “A” assembled for the toe-in adjust-
ment and a long bar perfectly leaned 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 65° less the prescribed angle

and position in on the long bar.
Move a wheel side till it form, with the two bars, the angle
fixed by the goniometer.

RKZB1240

3 - Adjust the steering mechanical retainer, screwing in or

out the screws (1), locking them with a locknut (2) to the
requested torque. 2 1
Nut: 150 Nm
★ Repeat the same operation for the other side.

RKZB1250

10. Trunnions assembly

7
1 - Insert the bushes (3), (4) and the bush retaining bolts
3
(5), (6), then torque. Place the front (1) and rear (2) sup-
4
port on a workbench.

Screw: 200 Nm
2 - Insert a new O-ring (7) in the rear support.

6
5
2 1 RKZ05820

WB150AWS-2 30-189
REMOVAL AND INSTALLATION FRONT AXLE

3 - If necessary, spread a film of Loctite 542 on the contact

surface and fit the centralizing bushes with a driver. 8 9

2 1
RKZ05830

4 - Fit the rear (1) and front (2) supports to the axel.
★ Take care not to damage the O-ring (15).

2 RKZ05840

5 - Fit the shim (10) together with a new O-ring (11) and the
pinion shaft flange (12). Secure the assembled parts
with the circlip (13).

10
12
13

11
RKZ05850

30-190 WB150AWS-2
REMOVAL AND INSTALLATION 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 2
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).

Wheels: 163 kg
1 A
1
RKZA2130

3 - 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.

4 - Stop the engine and completely release residual pres-

sures from all the circuits.
(For details, see «20.TESTING AND ADJUST-
MENTS»).

RKZA2140

5 - Mark and disconnect the pipes (3) from steering cylin-

der. 3
★ Plug the pipes to prevent entry of impurities.
6 - Disconnect the working brake hoses (4).
2
★ Plug the pipes to prevent entry of impurities.
5
7 - Disconnect the parking brake command cable (5) and
free collar. 3 6

8 - Disconnect the cardan shaft (6) from the rear axle.

4 4 RKZA9290

9 - Disconnect the steering cylinder sensor connector.

10 - Partially loosen the screws (7) in order to eliminate the

tightening torque and thus facilitate subsequent dis-
mantling.
5
★ Loosen the screws in criss-cross sequence.

7
RKZA9240

WB150AWS-2 30-191
REMOVAL AND INSTALLATION REAR AXLE

11 - Place a jack “C” and some blocks beneath the axle (8).
Raise the jack until the blocks can be forced under the
8
arms of the axle.
★ Leave free the screws (7) and plates (9) that secure
the axle.
★ It should be possible to lower the jack by approx. 20 7
cm.
9
12 - Remove the screws (7) and the plates (9).

13 - Lower the jack until the axle (8) is disengaged from the
chassis.
C
14 - Extract the entire axle (8). RKZB5450

Rear axle: 540 kg

INSTALLATION OF THE
REAR AXLE
• To install, reverse the removal procedure.

1
Wheel nuts: 800 Nm

2
★ Adjust the stroke of the parking brake lever.
(See «20. TESTING AND ADJUSTMENTS»).

3
★ Bleed the air from the braking circuits.
(See «20. TESTING AND ADJUSTMENTS»).

4
Screw: 73.5 Nm

5
Screw: 980 Nm

Screw: Loctite 243

★ Tighten in two stages, using the criss-cross method.

1 - Check the 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.

30-192 WB150AWS-2
REMOVAL AND INSTALLATION REAR AXLE

DISASSEMBLY OF REAR AXLE

1. Flange and oil pipe disassembly
1 - Take the Seeger ring (1) out and remove off the input
flange (2). Collect the O-ring (3) and the washer (4).
4
2 3

RKZ05050

2 - Remove the oil pipe (7), unscrewing the fastening nut

(5) and screw (5). 6
5
Collect the related washers (8).
8
7

RKZ06010

2. Steering cylinder group disassembly

1
1 - Remove the inductive magnetic steering sensor (2), un-
screwing the sensor bracket (3) locking screws (1). 3

RKZ06020

2 - Loose the guide rod (5) locknut (4) of some turns till it is
on a level with the threaded pin. 6 5
Beat on the nut (4) with a hammer in order to disjoint the
guide rod (5) from the swivel housing (6).
★ Nut (4) must be replaced every disassembly.

RKZB0080

WB150AWS-2 30-193
REMOVAL AND INSTALLATION REAR AXLE

3 - Disassembly the steering cylinder (10), removing the

7
fastening screws (7) and (8) and the related bush (9). 9
8

10

RKZ06030

4 - Remove the joint clamps (11) from the potentiometer

connector cable and the guide rod (12) with washer 11
(13).

12

13

12 RKZ06040

5 - Detach the cylinder head (14) from the cylinder case

(15) and remove off the rod (16).

15

14 16

RKZB0090

6 - Remove off the cylinder head (14) from the rod (16),
making sure not to lose any of the sealing (17) and O- 17
rings both from the cylinder head and the rod.
17
16
15 14

17 RKZ06050

30-194 WB150AWS-2
REMOVAL AND INSTALLATION REAR AXLE

3. Epicyclic reduction gear disassembly

1 - Unscrew and remove the two fastening screws (1) of the
planetary carrier (2) with a wrench. 1
2

RKZB0110

2 - Remove the planetary carrier (2) from the wheel hub (3).

2
RKZB4960

3 - To replace the epicyclic gears, if necessary, remove the

screw (4) and relevant washers (5) and (6). 4
★ Leave the pin (7) in its seat. 5

7 6

RKZ05211

4 - Remove the epicyclic gear (8) and the washer (9).

8
5 - Remove the rollers (10) from gear (8).
9 8

10

RKZ05221

WB150AWS-2 30-195
REMOVAL AND INSTALLATION REAR AXLE

6 - If the pins (11) of the pinion gears are in poor condition,

replace the entire planetary train with pre-fitted pins. 11

RKZ05231

4. Wheel hub group disassembly

Before disassembling the splined sleeve, it is advisable
2
to secure it with a belt or a rope on a hoist or any other
supporting device, in order to avoid its accidental fall
that could damage either the operator or the wheel hub
group.

1 - Remove the Seeger ring (1) from the U-Joint shaft (2) 1
using suitable pliers.

RKZB0130

2 - Remove and collect the axle shaft (2) washers (3) and
(4). 2
4

RKZ06070

3 - Unscrew and remove the fastening screws (5) from the

hub-lock ring gear (6). 6

RKZB0140

30-196 WB150AWS-2
REMOVAL AND INSTALLATION REAR AXLE

4 - To remove the hub-lock ring gear (6) from its housing,

screw at least two of the just removed screws (5) in the
threaded extraction holes “A”.
6
A

RKZB0150

5 - Remove the steel stop ring (7) and disjoint the hub-lock
ring gear (6) from the epicyclic ring gear (8).
★ Check the wear conditions of the components. 9
6 - Only if necessary, remove the centering bushes (9) of
the hub lock ring gear with a hammer and the special
tool D1.
7

6
8
RKZB0180

7 - Remove the hub (10) with inner ring (11), using levers
and a hammer to facilitate the operation.

10

11
RKZB0170

8 - Position on a flat surface the hub and take the seal ring
(12) out with a lever. 13
★ Seal ring must be replaced every disassembly.
9- Using a extractor and soft hammer, remove external 14
washer (11) and (13) on both sides of the hub (10).

10 - Using a extractor, remove inner washer (13) from the 12

swivel housing.

11 - Remove O-ring (14).

10
11 RKZ06360

WB150AWS-2 30-197
REMOVAL AND INSTALLATION REAR AXLE

12 - Unscrew and remove the fastening screws (15) from the

15
upper (16) and lower (17) king pin.
★ Only is necessary, remove the cable (17) from 16
cover (16).

17

RKZ06090

13 - Loosen potentiometer (19) screws (18) and washer.

Extract the potentiometer (19) from pin (20).
18
NOTA. Take care not to damaged the potentiometer.
19
.

20

RKZ06100

14 - Remove the Seeger (21) from joint pin seat.

Extract the potentiometer pin (20) and remove the O- 21
ring (22).
Verify the condition of all components.
20

22

RKZ06110

15 - Loosen the screw (23) of upper (24) and lower (25) joint
pin. 23

24

25
RKZB0191

30-198 WB150AWS-2
REMOVAL AND INSTALLATION REAR AXLE

16 - Secure the swivel housing (26) with a belt or a rope to a

hoist or any other supporting device. Remove the king 26
pins (24) and (25). 24

25

RKZB0201

17 - Remove the Belleville washers (27) and the shims (28)

and (29).

27
28

29

RKZB0221

18 - Position the swivel housing (26) on a flat surface and

take the oil seal ring (30) out with a lever.
★ Seal ring must be replaced every disassembly. 26

30

RKZB0231

19 - Turn the swivel housing (26) and take the bushing (31)
out, using a suitable special tool and a hammer.

31

RKZB0241

WB150AWS-2 30-199
REMOVAL AND INSTALLATION REAR AXLE

5. Axle beam group disassembly

1 - Remove the U-Joint (1) from the axle beam.

RKZB0251

2 - Take the seal ring (2) out of the axle beam with a lever.
★ Seal ring must be replaced every disassembly.
In order to replace bushing (3) inside the axle beam, it is 3
need to be cut and destroyed with a chisel.

RKZB0260

3 - Take the upper (4) and lower (5) bushing out of the king
pin housing with a suitable extractor.

RKZB0270

4 - Take the bushing (6) out of the king pins (7) with a suit-
able extractor. 6

RKZ05250

30-200 WB150AWS-2
REMOVAL AND INSTALLATION REAR AXLE

6. Axle beam trumpets and brake groups

disassembly
1 - 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.

RKZB0280

2 - 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 (1) to disassemble the

axle beam trumped.

RKZB0290

4 - Separate the axle beam trumpet (2) from body (3).

3 5 4
Remove the O-ring (4).
★ Take care that once the axle beam trumped has
2
been removed, the brake disks are free.

RKZB0940

WB150AWS-2 30-201
REMOVAL AND INSTALLATION REAR AXLE

5 - Remove the first brake counter disk (5).

RKZB0310

6 - Remove the other disks (6) and counter disks (7) as far
as the brake splined sleeve (8), being careful how the
different parts are positioned.
7 6

RKZB1310

7 - Remove the brake splined sleeve (8), recording the in-

dent position compared to the brake group.

RKZB1320

8 - Remove the last counter disk (9).

RKZB0320

30-202 WB150AWS-2
REMOVAL AND INSTALLATION REAR AXLE

9 -Secure the brake flange (10) to a hoist with ropes or

safety belts. Unscrew the upper fastening screw (11) to 11
remove the differential supporting flange from the cen-
tral body.

10

RKZB0330

10 -Unscrew the lower stud bolt (12). Remove the differen-

tial supporting flange (10) from the central body.
★ This operation frees the differential box, that must
be kept to avoid its fall. 10

12

RKZB0340

11 -Remove the O-ring (13) and (14) from its housing and
from oil pipe hole and check its conditions.

13 14
RKZB4970

7. Brake control group disassembly

1 - Unloose the locknut (1) and unscrew the adjusting
screw on the supporting bracket (2).
1
2

RKZB4980

WB150AWS-2 30-203
REMOVAL AND INSTALLATION REAR AXLE

2 -Unscrew and remove the lever (4) fastening screw (3)

and washer (5).
3

RKZB0400

3 -Put an alignment mark on the lever (4) and shaft splines

(6)

6
4

RKZB1330

4 -Loosen the lever (4) to release the tension on the spring

(7).

4
7

RKZB1340

5 -Remove the lever (4) and spring (7).

4
7

RKZB1350

30-204 WB150AWS-2
REMOVAL AND INSTALLATION REAR AXLE

6 - Remove the washer (8) and the spacer (9).

8
9

RKZB4990

7 - Remove the screws (10) and remove bracket (2).

10
RKZB0420

8 - Make an alignment mark on the cam (11) near the set-

screw (12).

11

12

RKZB5010

9 - Free the cam unscrewing the setscrew (12).

12

RKZB0440

WB150AWS-2 30-205
REMOVAL AND INSTALLATION REAR AXLE

10 - Unscrew the shaft setscrew (13), being careful the steel

ball (14) does not get lost.

13

RKZB0450

11 - Collect the steel ball (14).

14

RKZB0460

12 - Remove the O-ring (15), taking the shaft (16) out.

15

16

RKZB0470

13 - Remove the shaft (16) and collect the cam (11).

16

11

RKZB0480

30-206 WB150AWS-2
REMOVAL AND INSTALLATION REAR AXLE

14 -Unscrew the upper self-adjust screws (17) and take the

springs (18) and the bushes (19) out.
17 18 19

RKZB0490

15 - Unscrew the lower self-adjust screws (20) and take the

bushes (21) and the spacers (22) out.

20 21 22

RKZB0500

16 - Remove the valve (23) from brake flange (24).

23 24

RKZB0510

17 -Take the piston out. If necessary, blow in air through the

brake bleeder vent to eject the piston, using the mini-
mum pressure. Possible swift ejection of the piston.

25

RKZB1380

WB150AWS-2 30-207
REMOVAL AND INSTALLATION REAR AXLE

18 -Remove the O-rings (26) and (27) from the piston (25)
and check their conditions.
25
26

27
RKZB0520

19 -Unscrew the fastening screw (28) of the ring nut (29) re-
tainer.

28
29

RKZB0530

20 -Unscrew the ring nut (30) with suitable D2 special tool.

30

D2

RKZB0550

21 -Remove the ring nut (31).

31

RKZB0560

30-208 WB150AWS-2
REMOVAL AND INSTALLATION REAR AXLE

8. Differential group disassembly

1 - Remove the differential and put it in a clamp.

2 - Unscrew and remove all the fastening screw (1) of the

bevel gear crown.
2
3 - Remove bevel gear crown (2).

RKZB0570

4 -Disassemble the differential box in two half boxes (3)

complete with the relative components.
★ Mark the half boxes.

RKZB0580

5 -Disassemble all the components. Check the operating

and wear conditions of the components. 4
Take the bearing (4) out differential half box, using two
levers or a three-hold extractor.

3 3

RKZ06140

9. Pinion group disassembly

1 - Remove the seal ring (1) from the central housing (2)
with a puller. 2
★ Seal ring must be replaced every disassembly.

RKZ05160

WB150AWS-2 30-209
REMOVAL AND INSTALLATION REAR AXLE

2 - Position the central body on a steady plane, before dis-

assembling it.

3 - In order to avoid serious damages to the bevel pinion

thread, unscrew the ring nut (3) with the special tool D3 3
and code D4.
D4

D3
RKZB0600

4 - Once the ring nut washer (4) has been removed, take
the pinion (5) out of its housing, by beating with a ham-
4
mer made of soft material on the splined end.

RKZB0610

5 - Once the bevel pinion has been removed, collect the

washers (6), the elastic spacer (7) and the cones of the
taper roller bearing (8).
★ When the elastic spacer (7) is removed, it should be 8
6
replaced by a new one.

RKZB0620

6 - Take the bearing (9) cone out of the bevel pinion (5) end,
using a suitable extractor. Remove the adjusting shim
(10) placed under the bearing and check its wear con-
ditions.

9
10 RKZB0630

30-210 WB150AWS-2
REMOVAL AND INSTALLATION REAR AXLE

7 - Take the cups of the taper roller bearing (8) and (10) out
of the central body (2), using a chisel and a hammer.

RKZB0640

WB150AWS-2 30-211
REMOVAL AND INSTALLATION REAR AXLE

ASSEMBLY OF REAR AXLE

1. Pinion group assembly
1 - Force the cups of the taper roller bearings on their hou-
sings (1) using the special tool D5.
D5

RKZB0650

2 - Insert the false pinion with D6, together with its bearings
(2) and (3) and its ring nut (4), in the just mounted hou-
sings for the bearings. Tighten without exceeding, till D6
the backlash is eliminated.

2 3 4

RKZB0660

3 -Assemble the two brake flanges (5) and fix them with
their screws (6) (screw it at least two ones diametrically- 6
opposed for each flange).
5

RKZB0670

4 - Insert the false differential box with D7 into the central

body to measure the distance. Check that the false box 5
is inserted in both brake flanges housings (5).

D7

RKZB0680

30-212 WB150AWS-2
REMOVAL AND INSTALLATION REAR AXLE

5 -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

6 -Make a note of the value “N” marked on the head of the

pinion.
Calculate the thickness “S” to be installed beneath the
pinion, using the formula:

S=X--N
★ “S” is the thickness of the shim.

RKZB1530

7 -Remove the false pinion D6, the bearings (2), (3) and
the ring nut (4) from the central body (1).
Disassemble the false differential box D7 from the flang- D6
es (5) and then unscrew the screws to remove the flang- 3
es. D7

4
2 RKZ05100

8 -Insert the suitable shim (8) (chosen before) on the pin-

ion shaft (7) with chamfer against the gear. Force the D8 2
bearing (2) into the pinion shaft (7) and with D8 special
tool under a press, making sure that it is well set. Insert
the shims and the new elastic spacer into the shaft. 8

RKZB0690

WB150AWS-2 30-213
REMOVAL AND INSTALLATION REAR AXLE

9 - Insert the bevel pinion unit (7) into the central body
housing (1) and the second bearing cone (3) into the 1
pinion end. In order force the bearing into position use
the special tool D8 and a hammer.

RKZB0700

10 - Mount the special washer (8) and the lock nut (4) onto
the pinion (7).
Use the tools D3 and D4 to tighten the lock nut (7).

8 4

D3
D4
RKZB0601

11 -Measure the preloading "P" of the bearings (2), (3) with

a dynamometer and a line wound round the tool D9.
Gradually adjust by tightening the lock nut (4) with small
rotation increments.
Caulk the lip of the lock nut (4) into the pinion groove
(121).
★ Preloading P= 9.2–13.8 daN

D9
RKZB0710

30-214 WB150AWS-2
REMOVAL AND INSTALLATION REAR AXLE

2. Differential group assembly

1 - Assemble the cones of the new taper roller bearing (1)
on the half boxes (2), using the special tool D10 and a D10
hammer. 1

RKZB0721

2 -Position a half box on a workbench and assemble all its

inner components (sun gears, planetary gears, thrust 1
rings, pins and counterdiscs). Join the two half boxes,
aligning the reference marks made upon them.

2 2

RKZ06141

3 - Joint the two half boxes (2), aligning the reference

marks.
3
4 - Position the ring bevel gear (3) and then fix the whole by
tightening the screws.
4
Screw: 155 Nm
Screw: Loctite 270

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
tools D11 and D12.
D12
1
D11

RKZB0730

WB150AWS-2 30-215
REMOVAL AND INSTALLATION REAR AXLE

2 - Push the washers (2) into the self-adjust housings till

they are aligned with the piston (3) supporting inner sur-
face. Assemble the O-rings (4) and (5) on the piston and
lubricate the facing surface piston/flange with a light lay-
2 3
er of grease.

2 5

2 4
RKZB0740

3 - Insert the piston (3) into the brake flange (6) and position
the special tool D13 or a flat disk on the piston (3) and
with a lever anchored to an eyebolt, exert a pressure just
enough to insert the piston (3) into the brake flange (6).

D13
6

RKZB0750

4 - Mount the spacers (7), washers (8), screws (9) the

springs (10) and (11), spacers (12), washers (13) and 10
screws (14). 12
Screws (9) and (14): 10 Nm 14

11
13

7
8
9 RKZ06150

5 - Insert a new O-ring (16) in its relative housing (oil pipe

hole) on the central body (15).
★ Before assembling, lubricate the O-ring.

15

16

RKZ06160

30-216 WB150AWS-2
REMOVAL AND INSTALLATION REAR AXLE

6 - Insert a new O-ring (17) on the brake flange (3).

★ Sustain the differential box with a bar, positioning 17
first the brake flange on the side of the ring bevel
gear.
★ Respect the correct position of the ring bevel gear,
that could be assembled inverted.
3

RKZ05190

7 - Assemble and tighten the upper fastening screw (18)

18
and the lower fastening stud bolt (19) of the brake flange
(3) with dynamometric wrench to the requested torque.

Screw: 80 Nm
Stud: 120 Nm

19

RKZB1390

8 - Assemble the second brake flange (3) on the opposite

bevel gear side. Insert and screw the adjusting ring nuts
(20) of the pinion-ring, using the wrench with code D2 till
the bearing backlash is eliminated.
Then measure the pinion-ring gear backlash. 20
3
★ Tighten the ring nuts step by step without exceed-
ing.
9 - Assemble the special tool D14 on the pinion end.
Move the pinion end alternatively and note the pinion
gear backlash, measured with a comparator “A”, so that D2
the feeler is in contact and at 90° with the bracket sur-
face on the special tool in correspondence with the ref-
erence mark.
Check if the measured backlash value is within the re- RKZB0760

quest range.
★ Backlash: 0.20 – 0.30 mm
Carry out the adjustment by operating on the two ring
nuts with the tool D2.
Adjust the ring nuts remembering that:
- If the measured backlash is less than the given tol-
erance range, screw the ring nut from the side opposite A
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 D14
measure.
RKZB0770

WB150AWS-2 30-217
REMOVAL AND INSTALLATION REAR AXLE

10 - 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 operations till
the indicated conditions are reached.

RKZ05110

11 - 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 tool D9 inserted on the pinion spline.

★ Force required:
(P+2.59) < T < (P+3.88) daN D9
P= the force found for the pinion

★ The force should be that of continual rotation. Do

not take the thrust force into consideration. B

12 - If the force is not within permissible limits:

RKZ05120

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.

30-218 WB150AWS-2
REMOVAL AND INSTALLATION REAR AXLE

13 -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

14 -Insert the ring nut retainer turning the ring nut (20)
slightly in order to align it to the retainer.
Screw in and tighten the screw (21) of the ring nut (20)
retainer. 20
Screw: 13 Nm 21

RKZB0780

WB150AWS-2 30-219
REMOVAL AND INSTALLATION REAR AXLE

4. Control brake group assembly

1 - Insert the cam (2) and the shaft (3), on the side you are 3
operating, on the brake flange (1). They can be recog-
nized by the reference marks previously put.

4
2
RKZB0790

2 - When the shaft is inserted into the cam (2), align the ref-
erence mark with the cam setscrew (4) hole.
Screw in the cam setscrew (4). 2
Screw (4): 10 Nm

RKZB0820

3 - Insert the steel ball (5) that sets the shaft and the relative
screw (6). 6
Screw: 25 Nm
Screw: Loctite 270

RKZB0830

4 - Insert a new O-ring (7) on the shaft (3).

7
3

RKZB0840

30-220 WB150AWS-2
REMOVAL AND INSTALLATION REAR AXLE

5 - Position the supporting bracket (8). Insert the fastening

screws (9).
9

8
RKZB0850

6 - Insert the washer (10), the spacer (11) and the spring
(12) on the shaft end (3).
12

10
11

RKZB0870

7 - Insert the brake control lever (13), respecting the ref-

erence marks put during disassembly.
13

RKZB0880

5. Axle beam group and brake group assembly

★ During the assembly, take care not to move parking
brake command levers. 1

1 - Insert the first shaped brake counterdiscs (1), respect-

ing the indicated position compared to the cam position.

RKZB0890

WB150AWS-2 30-221
REMOVAL AND INSTALLATION REAR AXLE

★ Before install new disc, lubricate the both surfaces of

the disc with oil.

2 - Mount one brake disc (2), coupling (3), one counter- 4

discs (4) then reassemble all components following the
sequence shows in the figure.
★ Take care that the coupling should be inserted po-
sitioned with the shortest line against the differen- 1
tial.
★ Align the holes on the brake disc.
3
2
RKZ06170

3 - Insert a new O-ring (5) into the axle beam trumpet (6).
5
Assemble the axle beam trumpet on the flange, being 6
careful to the fastening holes’alignment.

RKZB0300

4 - Screw in and tighten the fastening screws (7) of the axle

beam trumped (6) with a dynamometric wrench to the
requested torque.

Screw: 320 Nm
Nut: 190 Nm

6
RKZ06180

30-222 WB150AWS-2
REMOVAL AND INSTALLATION REAR AXLE

6. Adjusting parking brake control levers

1
1- Loosen the air breather plugs (1).

2 - Connect a hand-pump, supplied with braking circuit oil

and a pressure gauge, to a braking group.

3 - Pump the oil in, and tighten the breather plug when oil
comes out without any trace of air.

4 - Bring the pressure up to 40 bar to settle the braking

group.

5 - Repeat these operations for the other group and re- RKAB5171
move the pump.

6 - Tighten the two levers (2) of the parking brake by ap-

plying a force of 5 kg on each lever, and checking that
the center distance between the holes is 300–310 mm
with the levers inclined symmetrically.
★ If necessary, raise the levers and engage them on
the grooves of the shaft in a different position, mak-
ing marks to indicate the new position.
★ Check that each lever makes a return stroke of at
least 3 mm (center distance measurement 306–
316 mm).
2 300
310 mm 2
RKZ06190

7 - Raise the levers (2) and the springs (3). Hook up the
springs and pre-load them by rotating the levers inside
the supports (4).
★ Make sure that the shaft rotates with the levers. 6

8 - Use a mallet to push the levers (2) home on the shaft (4). 2
5
9 - Install the retaining washer (5) and the screw (6).
3
Screw: 35 Nm
4

RKZB0950

10 - Assemble the adjusting screws (7) on the brackets and

screw in them, till they are in contact with the levers.

RKZB0970

WB150AWS-2 30-223
REMOVAL AND INSTALLATION REAR AXLE

11 - Screw in the two screws (7) of the same measure to be

within the foreseen range for the levers (2) in rest po-
sition: 310 –315 mm (about 3 mm between lever and
bracket will remain).

Nut: 190 Nm

310
315 mm
2 2
RKZ06200

12 - If the screw (7) is not perpendicular to the side surface of

the lever (2), adjust its position by moving the support-
ing bracket. 90°
Screw: 25 Nm

7
2

RKZ06210

7. Axle beam group assembly

1 - Assemble the upper king pin bush (1) and (2) on the axle
beam with the special tool D15 and a hammer.
2
★ To make the assembly easier, it is suggest to cool D15
the cup of the ball bearing at a temperature less
than –100°C.

RKZB0991

2 -Assemble the bush (3) on the axle beam with the special
tool D16 and a hammer.
Fill 3/4 of the seal ring cavity with grease. 3 4
3 - Assemble the seal ring (4) on the beam with the special
tool D17 and a hammer.

D16 D17

RKZB1001

30-224 WB150AWS-2
REMOVAL AND INSTALLATION REAR AXLE

4 - Lubricate the bush (3) and the seal ring (4) lips. Insert
the U-Joint (5) inside the axle beam.
★ Be careful not to damage the seal ring.

RKZB0250

8. Wheel hub group assembly

1 - Force the bush (1) in the swivel housing (2) with the spe-
cial tool D18 and a hammer or a press. Fill 3/4 to the gas-
ket (3) cavity with grease.
D18 D19
Assemble the ring (3) on the swivel housing (2) with the
special tool D19 and a hammer.
1 3

RKZB1011

2 - Mount shim (4) and grease well the king pin housing
with specific grease. 4
5
3 - Position the Belleville washers and shim (5) on the king
pin housings.

RKZB1400

4 - Position the lower pin (1) on a workbench and mount the 2

washer (2) of the taper roller bearings with the special
tool D20 under a press.

RKZ05720

WB150AWS-2 30-225
REMOVAL AND INSTALLATION REAR AXLE

5 - Secure the swivel housing group (3) with a rope and as-
semble it the axle beam. 3
★ Take care not to damage the seal ring.
4
6 - Mount the lower (5) and upper (4) pin and tighten screw
(6).
6
Screw: 300 Nm
★ Make sure that the Belleville washers remain in
their position.
5

RKZB1410

7 - In the case the bearings (7) and (8) 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
8
C = 23.070 – 23.172
7 C A C

RKZ05740

8 - Position the wheel hub (9) on a workbench and using

the tool D21 and a press, force the two cups of the taper 8 10
roller bearings (7) and (8) in position. 7
Using the tool D22 mount the seal (10) in the wheel hub
(9).
Mount O-Ring.
D21 D22

D21 9

RKZB1421

9 - Assemble the cone of the taper roller bearing (8) on the

3 9
swivel housing (3).

10 - Assemble the wheel hub (3) on the swivel housing (9) 8

and force the other cone of the taper roller bearing (7) in
positions.

RKZB1430

30-226 WB150AWS-2
REMOVAL AND INSTALLATION REAR AXLE

11 - Position the wheel carrier (11) on a workbench and

force the bushes (12) to the carrier surface level with the
special tool D1. 12

NOTE. At least two bushes (diametrically-opposed)

should be set slightly higher than the carrier sur-
face level to be used as dowel pins.

11
RKZB1090

12 - Preassemble the wheel carrier group (13), epicyclic ring

gear (14), with the special lock ring (15). 14

13

15

RKZ05730

13 - Assemble the wheel carrier group (13) on the wheel hub

(9) using the two projecting bushes (12) as dowel pins. 9 13

12

RKZB1100

14 - Force all the hub dowel bushes completely with the spe-
cial tool D1 and a hammer. 13
Assemble the wheel carrier fastening screws (16) and 16
tighten to the requested torque.

Screw: 230 Nm

RKZB1440

WB150AWS-2 30-227
REMOVAL AND INSTALLATION REAR AXLE

15 - Insert the rings (17) and the shim (18) into the axle shaft
of the U-Joint. 17

18

RKZ06000

9. Epicyclic reduction gear assembly

1 - Place the planetary carrier on a work bench and fit the 1
epicyclic gears (1) and respective washers (2) on the
dowels already fitted.
2

RKZ05750

2 - Insert all the rolls (3) into the epicyclic gears (4), then
place the two thrust washers (5) and (6). 6
★ The first washer (6) must be aligned with the dowel 4
5
pin.

3 RKZ05760

3 - Fit and tighten the epicyclic gears (4) fixing bolts (7),
tightening to the prescribed torque.
4
7
Screw: 79 Nm

RKZ05770

30-228 WB150AWS-2
REMOVAL AND INSTALLATION REAR AXLE

4 - Assemble the epicyclic reduction gear (8) on the wheel

8
hub (9). Screw in the fastening screws and tighten.

Screw: 25 Nm

9 RKZB5000

10. Steering cylinder group assembly

1
1 - Fit new seal ring (1) to the cylinder head, to the cylinder
body (2), to the cylinder rod (3).
1
3
2

RKZ06051

2 - Mount the cylinder head (4) with gasket on the cylinder

rod (3) and slide into cylinder body (2).

4 3

RKZB0091

3 - Instal the steering cylinder (5) on the central on the body

7
inserting the dowel bush (6) and the screws (7) and (8) 6
in their housings.
8
Screw (7): 220 Nm
Screw (8): 660 Nm
Screw (7) e (8): Loctite 270 5

RKZ06031

WB150AWS-2 30-229
REMOVAL AND INSTALLATION REAR AXLE

4 - Mount on the cylinder rod the guide rod (9) and tighten
them. 11
★ Mount the washer (10) in the left side of cylinder
rod.
12
Guide rod: 3 Nm

13

12 RKZ06040

5 - Insert the ball joint into its own housing (12) on the cap.
Assemble and tighten the lock nut (11).

11 12
9

RKZB1161

6 - Tighten the nut (13).

Nut: 260 Nm

13
RKZB1171

7 - Assemble the inductive magnetic steering sensor (14)

by mean of appropriate bracket (15) and tighten screw 16
(16).
15
Screw: 23 Nm

Screw: Loctite 542

14

RKZ06021

30-230 WB150AWS-2
REMOVAL AND INSTALLATION REAR AXLE

11. 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 - 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
M±3.
Example:
M distance measured: 2145 mm
Correct toe-in:
rear side: 2147 mm
front side: 2143 mm

RKZB1210

4 - After adjusting, screw in the lock nuts (1) of the guide

rods. 1
Lock nut: 250 Nm

RKZB1220

WB150AWS-2 30-231
REMOVAL AND INSTALLATION REAR AXLE

5 - Check the steering sensor position with the wheel hubs

perpendicular to axle. If necessary, adjust the steering M +- 3
sensor position.

0,5
0,75 mm
6 - Check that the distance between disc and sensor is
0.5–0.75 mm.

M
RKZ06260

12. Steering angle adjustment

A
1 - Use the same bars “A” assembled for the toe-in adjust-
ment and a long bar perfectly leaned 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 65° less the prescribed angle

and position in on the long bar.
Move a wheel side till it form, with the two bars, the angle
fixed by the goniometer.

RKZB1240

3 - Adjust the steering mechanical retainer, screwing in or

out the screws (1), locking them with a locknut (2) to the
requested torque. 2 1
Nut: 150 Nm
★ Repeat the same operation for the other side.

RKZB1250

30-232 WB150AWS-2
REMOVAL AND INSTALLATION REAR AXLE

13. Potentiometer assembly

1 - Before assembly the potentiometer, it is necessary to =
verify the correct wheel alignment with the vehicle’s div-
ing direction.

RKZ06270

2 - To insert the potentiometer’s control pin (1) on the king

pin, use the special tool D23 to orientate it respecting
the angle pointed out in figure. Insert a little bar in the

Avanti/forward
special tools and push until the contact with the plane on 1 D23
control pin (1) is reached.

45°

RKZ06280

3 - Assemble a new O-ring (2) into its seat in the central

hole of the king pin. Insert the potentiometer’s control 3
pin (1) on the king pin, respecting the procedure de-
Avanti/forward

scribed above. 1 D23

Respect the angle pointed out in figure. Lock the control
2
pin (1) with the Seeger ring (3). 45°

RKZ06290

4 - Assemble the potentiometer (4) and fasten it with the

relative screws (5).
5
Screw: 3 Nm
6

RKZ06101

WB150AWS-2 30-233
REMOVAL AND INSTALLATION REAR AXLE

5 - Screw the potentiometer connector kit (6) in the cover

(7). Assemble the cover (7), positioning the connector
8
towards the pinion side of the axle. Insert the relative 7
screws (8), tightening them to the prescribed torque
with a torque wrench.

Screw: 23 Nm
6

RKZ06091

6 - Fit the potentiometer kit cable (6) to the steering cylinder

guide rod by means of two clamps (9) as shown in fig-
ure.

6 RKZ06300

14. Oil pipe and flange assembly

6
1 - Assemble the oil pipe (1) with union (3) and bolts (2). 5
8
Screw: 23 Nm
7
Screw: Loctite 496

Union: 60 Nm 6

RKZ06010

2 - Assemble the seal ring (4) in the central body with a spe-
cial tool D24 and a hammer. Insert the washer (5) into
the splined pinion end, a new O-ring (6) and the flange
(7). Block the whole with a Seeger lock ring (8). 4
7 6

5
RKZ05170

30-234 WB150AWS-2
REMOVAL AND INSTALLATION STEERING SOLENOID VALVE GROUP

REMOVAL OF STEERING SOLENOID VALVE GROUP

Lower all working equipment and stop engine.
Cut off the supply of electricity by turning the accumu- 2 3 4 5
lator-disconnecting switch in a counter-clockwise direc-
tion and remove the handle.

1 - Disconnect the solenoids (Y1), (Y2), (Y3), (Y4) from the Y3

valve body (1). 1 Y1
★ Ensure that the wiring harness is clearly labelled, if Y2 Y4 1
in doubt mark the corresponding position of the so- 6
lenoids.

2 - Disconnect the pipes (2) - (3) - (4) - (5) from the valve
body (1). RKZA9300

★ Mark the pipes for correct re-assembly.

★ Cap the pipe ends to prevent impurities entering.
Front cylinder
3 - Remove the screws (6) that fasten the valve body (1) to
the support bracket (7).
Y1 Y3
c
Rear cylinder
INSTALLATION OF THE d
STEERING SOLENOID Y2 Y4
VALVE GROUP Steering unit

• Installation is the reverse of the removal procedure.

Direction of travel
RKZ04550
1
★ Check the mounting position carefully.

1 - Start engine.

2 - Steer the vehicle in both directions to remove any air in

the steering system.

3 - Stop the engine and check the oil level in the tank.

WB150AWS-2 30-235
REMOVAL AND INSTALLATION 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.

30-236 WB150AWS-2
REMOVAL AND INSTALLATION 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
prevent entry of impurities. 13
8 - Remove the snap-ring (15) and the spacer (16). 10
9 - Remove the cylinder (5).

Cylinder: 45 kg

INSTALLATION OF THE FRONT 14

12
9
BUCKET TILT CYLINDERS
• To install, reverse the removal procedure. 11 RKZA2200

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

WB150AWS-2 30-237
REMOVAL AND INSTALLATION 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.

RKZA9080

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

30-238 WB150AWS-2
REMOVAL AND INSTALLATION 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»).

RKZA9080

2 - Disconnect the cylinders (2) from the boom (1) and rest
them on wooden blocks “A” placed on the front axle.
1 2
1

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
to the cables. 1

RKZA9210

WB150AWS-2 30-239
REMOVAL AND INSTALLATION 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 EQUIPMENT
• 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.

30-240 WB150AWS-2
REMOVAL AND INSTALLATION BACKHOE CONTROL VALVE

REMOVAL OF THE BACKHOE CONTROL VALVE

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.

(For details, see «20. TESTING AND ADJUST-
MENTS»).
RKZA8040

4 - Take out the lower window (1) of the cab and completely
raise the upper window.
1

RKZA2230

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

WB150AWS-2 30-241
REMOVAL AND INSTALLATION BACKHOE CONTROL VALVE

7 - Disconnect the lever command tie-rods (11) from the

control valve.
11
8 - Disconnect from the control valve the pipes (12) (deliv-
ery, return, Load Sensing and actuators). Plug them to
prevent entry of impurities. 10
★ Mark the pipes to prevent exchanging positions
during re-connection.
12
9 - Attach the control valve (10) to some hoisting tackle and 12
apply a slight tension to the cables.

RKZA2252

10 - Remove the four screws (13) and then the entire control
valve.
Control valve:6-spool 47 kg
7-spool 53 kg
8-spool 59 kg

13 13

RKZA2261

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).

30-242 WB150AWS-2
REMOVAL AND INSTALLATION 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.
9
6 - Stop the engine and release any residual hydraulic
pressures. (For details, see «20. TESTING AND AD- 2
JUSTMENTS»). 1

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 RKZA2270

9 - Remove the cylinder (4).

Cylinder: 78 kg

INSTALLATION OF THE 5
6
BACKHOE BOOM 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. RKZA2280

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

WB150AWS-2 30-243
REMOVAL AND INSTALLATION 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.
Rest the bucket teeth on the ground.
3
1 - Stop the engine and release the pressures in the cylin- 1
2
der 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).
1 2
A
B
RKZA2290

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

30-244 WB150AWS-2
REMOVAL AND INSTALLATION TELESCOPIC ARM CYLINDER

REMOVAL OF THE TELESCOPIC 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 telescopic arm (2) until it rests on a block “B”, 1
and let 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
TELESCOPIC 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.

WB150AWS-2 30-245
REMOVAL AND INSTALLATION 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.
Rest the bucket teeth on the ground.
4 1 3
1 - Stop the engine and release the pressures in the cylin-
der (4) by moving the control lever several times. 2
2 - Place a sling around the cylinder (4).
3 - Take out the lock-nut (5) and the washer and remove
the pin (6).
1 2 3
A
B
RKZA2291
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 telescopic arm: loosen nut (12) and remove pin
(13). 6
8 - Remove the cylinder (4). RKZA2300

Cylinder: 49 kg

9
INSTALLATION OF THE 8
BACKHOE BUCKET CYLINDER 10
• To install, reverse the removal procedure.

1
When aligning the positions between the hole and the 4
pin, turn the engine over at low idling speed. 11
Do not insert fingers into the holes to check alignment.
RKZA9851

2
For telescopic arm
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»).
13
★ After bleeding the air, check the oil level in the tank.

12
RKZA9950

30-246 WB150AWS-2
REMOVAL AND INSTALLATION OUTRIGGER CYLINDERS

REMOVAL OF THE OUTRIGGER CYLINDERS

Rest the back of the bucket on the ground, keeping the
arm vertical.

1 - Lower the outriggers to the ground and stop the engine.

2 - Put a sling round the cylinder (1) and apply a slight ten-
sion to the cables.
★ Leave the pipes free.
3 - Loosen and remove the nut (2) and the screw (3).
Draw out the pin (4) until the piston head is disengaged.
1 2
RKZA2140

4 - Start the engine and retract the piston (5).

★ Secure the position of total retraction of the piston 3
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- 2
MENTS»).
1 5
6 - Disconnect the pipes (6) and (7) and plug them to pre-
vent entry of impurities.

7 - Take out the nut (8) and the screw (9) and remove the 4
pin (10). 1 2
RKZA2320

8 - Remove the cylinder (1).

Cylinder: 56 kg
7
6
9
INSTALLATION OF THE
OUTRIGGER CYLINDERS
• To install, reverse removal procedure.

1 10
8
When aligning the positions between the hole and the
pin, turn the engine over at low idling speed.Do not in-
sert fingers into the holes to check alignment. RKZA2330

2
Internal bushing: ASL800050

1 - Start the engine and bleed the air from the cylinders.
(For details, see «20. TESTING AND ADJUSTMEN-
TS»).

★ After bleeding the air, check the oil level in the tank.

WB150AWS-2 30-247
REMOVAL AND INSTALLATION 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 mo-

ving the control levers several times.

2 - Take the retaining screws (1) out of the clamp (2).

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 vertically the upper
support (6) of the cylinder fulcrum. 1 3 RKZA2140

5 - Take out the screws (7) and remove the pins (8).
2 3
6 - Rotate the cylinders to disengage the piston heads from 2 1
the swing bracket (9) and remove the cylinders (3).
3
4
Cylinder: 32.5 kg

INSTALLATION OF THE 5
BACKHOE SWING CYLINDERS 3
RKZA2340
1 - Mount the cylinders (3) and the upper cylinder fulcrum
support (6). Secure the support with the four screws (1).

1
Support screws: Loctite 262
6
Support screws: 100±10 daNm

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 (8). Secure the 1st pin with the screw
(7).Perform the same operation for the other pin.
3
2
RKZA2350

When aligning the positions between the hole and the

pin, turn the engine over at low idling speed.
Do not insert fingers into the holes to check alignment.

3
Internal bushing: ASL800050 8

4 - Start the engine and bleed the air from the cylinders. 7
(For details, see «20. TESTING AND ADJUSTMEN-
TS»).

★ After bleeding the air, check the oil level in the tank. 3

9
RKZA2360

30-248 WB150AWS-2
REMOVAL AND INSTALLATION CYLINDERS

DISASSEMBLY OF CYLINDERS
(Front bucket raise and tilt, boom, arm, bucket, outriggers and telescopic arm)
1 - Place the cylinder (1) on the tool A1.

A2
A2

A1

1
RKZA1540

2 - Using the specially-made wrench A4, A5, A6 unscrew

the cylinder head (4) and extract it from the cylinder (1).
1
3 - Extract the piston-rod group (6) from the cylinder (1) 4
4 - Remove the cylinder (1) and the piston-rod group (6).

RKPB1460

5 - Secure the piston-rod group (6) on the tool A1.

7
6 - For the piston rod of the boom cylinder: remove the
screw (7). BOOM OUT
RIGGER 9
7 - Use the appropriate socket wrench A7 on the piston
hexagon (11) and unscrew the piston.
★ Measurement of the socket wrench:
For raising the front bucket.: 55 mm
For tilting the front bucket.: 55 mm
Boom: 65 mm 8
Arm: 55 mm
Bucket: 55 mm RKZ00022
Outriggers: 65 mm
Telescopic arm: 46 mm

WB150AWS-2 30-249
REMOVAL AND INSTALLATION CYLINDERS

8 - 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.
ARM
The seals, the dust seals and the guide rings can- 2° BRACCIO
not be used again.

Carefully check the pistons (11). If both safety-

caulked areas show wear, the pistons must be re-
placed.
6
11

SOLLEVAMENTO
RAISING-TILTING
ROVESCIAMENTO

6
11

RKZ00011

30-250 WB150AWS-2
REMOVAL AND INSTALLATION CYLINDERS

ASSEMBLY OF CYLINDERS
(Front bucket raise and tilt, boom, arm, bucket, outriggers and telescopic 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 - Mount the gasket (12) in the cylinder head.

2 - Mount the gasket (13) in the cylinder head.

★ Make sure that the lips are turned towards the in-
side of the cylinder. 14 13 12
RKZ00040

3 - Mount the guard ring (14) using the tool A8.

4 - Mount the O-ring (15) and the anti-extrusion ring (16) on

the outside of the cylinder head.

2. Re-assembling the piston 25 26 27

1 - Use the tool A9 with the appropriate diameter, mount 26 11
the ring (24) the external seal (25) and the anti-extrusion
rings (26) onto the piston (11). 24

RKZ00090

2 - Prepare the guide ring (27).

★ There are two guide rings (27) for the boom piston.
27
3 - For the boom piston only: insert the O-ring (28) into the
internal seating. 28

A9

RKZA1580

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

RKPB1491

WB150AWS-2 30-251
REMOVAL AND INSTALLATION CYLINDERS

3. Re-assembling the piston-rod group

1 - Only for the cylinders for front bucket raise and tilt,
boom, arm and bucket: using a press and tools A2 with 6
the appropriate diameter, insert the bushing (37) into
the piston head (6).
37

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

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
Telescopic arm: 1520±152 Nm RKZ00021

30-252 WB150AWS-2
REMOVAL AND INSTALLATION CYLINDERS

6 - For the boom and outriggers cylinder: mount the

cushion plunger (9), slide the eleven ball-bearings (8)
into the hole, and mount the dowel bolt (7). 6 11
Dowel bolt: Loctite 262
36

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 pi-

RKZA1552
ston rod (6) not previously used.

4. Re-assembling the cylinders

1 - For the boom, arm and bucket cylinders only:
Position the bushing (41) and mount it in the cylinder
head (1) using tool A2 of the correct diameter.
★ There are two bushings for the arm cylinder, with a 41
spacer between them.
1
★ Leave the cylinder in position for subsequent as-
sembly.
A2
2 - Lubricate the threading and the first part of the cylinder
(1).
Cylinder: ASL800050 RKZ06320

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 (6) and the cylinder (1) on 1 A11
the apparatus A1.

5 - Guide the piston and center it in the tool A11.

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. RKZA1520

7 - Take the cylinder out of the tool A11 and bring the cylin-
der head (4) and the piston rod head closer to the cylin-
der.
1 A11
8 - Bring the cylinder (1) into position for screwing in the A1 4 6
cylinder 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
RKPB1480

WB150AWS-2 30-253
REMOVAL AND INSTALLATION 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
cylinder (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.

30-254 WB150AWS-2
REMOVAL AND INSTALLATION 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 pi-
ston. 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 pi- A9
ston. 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

RKPB1490

WB150AWS-2 30-255
REMOVAL AND INSTALLATION 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 rin-
gs (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).

30-256 WB150AWS-2
REMOVAL AND INSTALLATION 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.

RKZA2140

1 - Make sure that the safety stop (1) is raised.

2 - Stop the engine and release the residual hydraulic pres- 1

sures.

3 - Take out the cotter pins (2) and remove the pin (3).
1 2
2
3

RKZA9860

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).
5
1
6

RKZA9890

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.

WB150AWS-2 30-257
REMOVAL AND INSTALLATION 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 «REMO-
VAL OF BOOM CYLINDER»).
3 - Take out the bracket (2) mounted inside the boom. Di-
sconnect 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 BACKHOE

WORKING EQUIPMENT
• To install, reverse the removal procedure.

1 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.
4
2 RKZA2390

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

30-258 WB150AWS-2
REMOVAL AND INSTALLATION 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 BACKHOE

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

WB150AWS-2 30-259
REMOVAL AND INSTALLATION 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
CYLINDER»). 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 pi-
ston 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

30-260 WB150AWS-2
REMOVAL AND INSTALLATION TELESCOPIC ARM

REMOVAL OF COMPLETE TELESCOPIC 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 telescopic arm hoses (5) and (6), the

bucket cylinder 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»).

Telescopic arm cylinder: 392 kg 9 8

5
RKZA7970

INSTALLATION OF THE
COMPLETE TELESCOPIC 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.

WB150AWS-2 30-261
REMOVAL AND INSTALLATION 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
1 2
CYLINDER»).
3
3 - Remove the 2nd arm cylinder.
(For details, see «REMOVAL OF THE 2nd ARM CYLIN-
DER»).
★ 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.

30-262 WB150AWS-2
REMOVAL AND INSTALLATION 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 telescopic arm (1)

aligned with respect to the 2nd arm (2). (For details, see
«20. TESTS AND ADJUSTMENTS»).

RKZA8030

WB150AWS-2 30-263
REMOVAL AND INSTALLATION 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).

1 2 3
8 - Remove the boom (3). 3
Boom: 323 kg 4

RKZB1520

INSTALLATION OF THE BACKHOE

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.

30-264 WB150AWS-2
REMOVAL AND INSTALLATION 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
3 - Remove boom safety cylinder (4).
(For details, see «REMOVAL OF BOOM SAFETY
CYLINDER»).
1

RKZA2410

4 - Remove snap ring (5), pin (6) and link (7). 3

5 - Put a sling round the swing bracket (8).
4
6 - Take out the screws (9) and (10) and remove the swing
bracket axle oscillation pins (11) and (12).
5 7
1 2
7 - Remove the swing bracket (8) and the relative shim (13)
adjustments to given clearance. 6
4
Bracket: 133 kg
RKZB1512

INSTALLATION OF THE
BACKHOE SWING BRACKET 10
• To install, reverse the removal procedure. 12
9
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. 13
11
2
Internal bushing: ASL800050
RKZA2430

3
Pin: ASL800050

4
14
★ 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. 14

14
RKZ01330

WB150AWS-2 30-265
REMOVAL AND INSTALLATION BACKHOE OUTRIGGERS

REMOVAL OF THE BACKHOE OUTRIGGERS

Position the backhoe with the equipment centered, with
the arm vertical, and the back of the bucket on the
ground.

1 - Rest the supports on the ground and stop the engine.

RKZA2140

2 - Put a sling round the cylinder (1) and apply a slight ten-
sion to the cable. 3
★ Leave the tubes free.
3 - Loosen and remove the nut (2) and the screw (3). Slide
off the pin (4). 1 2 2

4 - Start the engine to retract the piston. 1 5

4
RKZA2320

5 - Raise the cylinder (1) and secure it in vertical position

with a clip “A”.

RKZB5440

6 - Put a sling round the support (5) and apply a slight ten-
sion to the cable.

7 - Loosen and take out the nut (6) and the screw (7). Slide
out the pin (8). 1 2 8

6
RKZA8070

30-266 WB150AWS-2
REMOVAL AND INSTALLATION BACKHOE OUTRIGGERS

8 - Raise the support (5) until it is in a horizontal posi-

tion.Loosen and take out the nut (9) and the screw (10).
Slide out the pin (11) and take off the support (5).
1 2 10
9 - Repeat the same operations on the other side.

11
INSTALLATION OF THE
BACKHOE OUTRIGGERS 9
• To install, reverse the removal procedure. 5
RKZB5430

1
When aligning the positions between the hole and the
pin, turn the engine over at low idling speed.Do not in-
sert fingers into the holes to check alignment.

2
Internal bushing: ASL800050

WB150AWS-2 30-267
GROUP 40
40-28 PC15R-8
 STANDARD MAINTENANCE

Transmission ............................................................. 2 8-Spool control valve................................................23

Front axle................................................................... 5 Brake pump ..............................................................24
Rear axle ................................................................... 8 Shovel cylinders .......................................................25
Hydraulic pump........................................................ 12 Backhoe cylinders ....................................................26
2-Spool control valve ............................................... 14 Front working equipment..........................................30
3-Spool control valve ............................................... 16 Swing bracket...........................................................32
6-Spool control valve ............................................... 18 Backhoe working equipment ....................................34
7-Spool control valve ............................................... 21

WB150AWS-2 40-1
STANDARD MAINTENANCE TRANSMISSION

TRANSMISSION

C
B A
C L

D D

F F

E
A

........... Nm

23±1 Nm H H

RKZ04251

40-2 WB150AWS-2
STANDARD MAINTENANCE TRANSMISSION

50±2.5 Nm

23±1 Nm

50±2.5 Nm
23±1 Nm

50±2.5 Nm

Loctite 510

50±2.5 Nm

139±7 Nm

139±7 Nm

Loctite 510

Loctite 510
Section A
Sezione A --AA RKZ04271

WB150AWS-2 40-3
STANDARD MAINTENANCE TRANSMISSION

50±2.5 Nm
25±1 Nm

23±1 Nm

Section B - B Section
SezioneCC-- C
C
Sezione B - B

25±1 Nm

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 G -- G
Sezione 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 WB150AWS-2
STANDARD MAINTENANCE FRONT AXLE

FRONT AXLE
Differential

155 Nm
with Loctite 270

13 Nm

413 Nm

Loctite 510

60 Nm
1

169 Nm

2 3
4 RKZ04261

Unit: mm

N° Check item Criteria Remedy

Standard clearance Clearance limit

1 Axle clearance
– –
Backlash of crown wheel
2 and pinion 0.20–0.30 –
Adjust
Pinion preload “P”
3 (without seal ring) 92–137 Nm

Pinion-crown wheel preload

4 (without seal ring) (P+34)–(P+51)N

WB150AWS-2 40-5
STANDARD MAINTENANCE FRONT AXLE

Planetary - joint

70 Nm
with Loctite 270
300 Nm
1
8 Nm

79 Nm

25 Nm 200 Nm

60 Nm 8 Nm
RKZ04301

Unit: mm

N° Check item Criteria Remedy

1 Hub rotation torque ---- Adjust

2 Drive shaft axle clearance ---- Replace

40-6 WB150AWS-2
STANDARD MAINTENANCE FRONT AXLE

Steering unit cylinder

2145 +-20

300 Nm 460 Nm
Y= 50 mm (standard wheel)
A 250 Nm B 56 mm (optional wheel)

A y
B

X= 62 mm (standard wheel)
56 mm (optional wheel)
800 Nm
200 Nm

150 Nm
260 Nm
Section
Sezione A
A -- A
A Section
Sezione B
B -- B
B Detail A
Particolare A
RKZ04381

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
– – – – –

WB150AWS-2 40-7
STANDARD MAINTENANCE REAR AXLE

REAR AXLE
Differential
155 Nm
with Loctite 270

1
2
23 Nm
with Loctite 542
320 Nm 80 Nm
3
4
220 Nm
with Loctite 270

120 Nm 190 Nm

Section
Sezione ZZ -- Z
Z
Z 60 Nm

Z RKZ04401

Unit: mm

N° Check item Criteria Remedy

Standard clearance Clearance limit

1 Axle clearance
– –
Backlash of crown wheel
2 and pinion 0.20–0.30 –
Adjust
Pinion preload “P”
3 92–138 Nm
(without seal ring)
Pinion-crown wheel preload “T”
4 (without seal ring) (P+25.9)<T<(P+38.8)N

40-8 WB150AWS-2
STANDARD MAINTENANCE REAR AXLE

Planetary

70 Nm 23 Nm
with Loctite 270 3 Nm

79 Nm

230 Nm
60 Nm

25 Nm
300 Nm
8 Nm
RKZ04411

Unit: mm

N° Check item Criteria Remedy

1 Hub rotation torque ---- Adjust

2 Drive shaft axle clearance ---- Replace

WB150AWS-2 40-9
STANDARD MAINTENANCE REAR AXLE

Brakes

190 Nm
1 A

2 10 Nm

300mm (Min.) 35 Nm
310mm (Max.)
25 Nm
50 N with Loctite 270

Detail A
Particolare A

RKZ04421

Unit: mm

N° Check item Criteria Remedy

Standard size Repair limit

Installed Replace if
Free Installed Installed Free load
1 Brake disc return spring installed length load installed damaged or
on screw deformed

– – – – –
Standard thickness Min. thickness
2 Disc thickness Replace
4.83 4.53

40-10 WB150AWS-2
STANDARD MAINTENANCE REAR AXLE

Differential lock

A
2145 +-20

Y= 50 mm (standard wheel)
56 mm (optional wheel)
y

A x
X= 62 mm (standard wheel)
A 250 Nm 56 mm (optional wheel)
300 Nm 800 Nm

150 Nm
260 Nm con Loctite 270
Section A -–AA
Sezione A Detail A
Particolare A
RKZ04441

WB150AWS-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 Shaft Hole clearance limit
2 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 Installed Free Installed
5 Spring length load installed load
x Øe
---- 88.7 276±12 N

40-12 WB150AWS-2
STANDARD MAINTENANCE HYDRAULIC PUMP

1 2 3

60 Nm 21 Nm
.25 Nm
Section
SezioneCC- -CC

5 35 Nm 21 Nm
12 Nm 4

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 (external) 125.4±10 N

Power regulation spring

3 (internal) 180.2±12.5

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

WB150AWS-2 40-13
STANDARD MAINTENANCE 2-SPOOL CONTROL VALVE

2-SPOOL CONTROL VALVE

D C A

27±2 Nm

............ Nm

............ Nm

C A

D
25 Nm B 20 Nm
20 Nm
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 RKZ01450

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 WB150AWS-2
STANDARD MAINTENANCE 2-SPOOL CONTROL VALVE

10±1 Nm 10±1 Nm E 10±1 Nm

E
70±7 Nm 70±7 Nm

............ Nm

............ Nm 1 3

2
70±7 Nm
70±7 Nm

............ Nm E 10±1 Nm ............ Nm

F
E
Section
Sezione C
C -- C
C

Section
SezioneDD-- D
D

30±3 Nm
4

Section
Sezione E
E -- E
E
RKZ01460

Unit: mm

N° Check item Criteria Remedy

Standard size Repair limit
Free
Installed Installed Free Installed
1 Spool return spring installed x length installed load
load
Øe

2 Spool locking spring

3 Spool return spring
4 Check valve spring

WB150AWS-2 40-15
STANDARD MAINTENANCE 3-SPOOL CONTROL VALVE

3-SPOOL CONTROL VALVE

D C A

27±2 Nm

............ Nm

............ Nm

C A
27±2 Nm

20 Nm
E D
25 Nm B
20 Nm
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 RKZ01470

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 WB150AWS-2
STANDARD MAINTENANCE 3-SPOOL CONTROL VALVE

10±1 Nm 10±1 Nm F 10±1 Nm

F
70±7 Nm 70±7 Nm

............ Nm

........ Nm 1 3

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

4
30±3 Nm

............ Nm 4

70±7 Nm

Section
Sezione F
F -- F
F

F
Section
Sezione E
E -- 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

WB150AWS-2 40-17
STANDARD MAINTENANCE 6-SPOOL CONTROL VALVE

6-SPOOL CONTROL VALVE

G E B D D C B A
H
27±2 Nm

H
G E B D D C B A

10±1 Nm
G
70±7 Nm
70 Nm

20 Nm
with Loctite 542

............ Nm

70 Nm
Section A - A 70±7 Nm
1 G 10±1 Nm
Section
Sezione B
B -- B
B
RKZ01480

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

40-18 WB150AWS-2
STANDARD MAINTENANCE 6-SPOOL CONTROL VALVE

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
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 -- FF
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

WB150AWS-2 40-19
STANDARD MAINTENANCE 6-SPOOL CONTROL VALVE

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

40-20 WB150AWS-2
STANDARD MAINTENANCE 7-SPOOL CONTROL VALVE

7-SPOOL CONTROL VALVE

For telescopic arm

A RKZ01490

For hammer

B
RKZ01500

WB150AWS-2 40-21
STANDARD MAINTENANCE 7-SPOOL CONTROL VALVE

10±1 Nm

70±7 Nm

............ Nm
70±7 Nm

10±1 Nm
10±1 Nm 1
Section
SezioneAA-- A
A

10±1 Nm

70±7 Nm

............ Nm

............ Nm

70±7 Nm
10±1 Nm
1
Section
Sezione B
B -- B
B RKZ01510

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

40-22 WB150AWS-2
STANDARD MAINTENANCE 8-SPOOL CONTROL VALVE

8-SPOOL CONTROL VALVE

For hammer and telescopic arm

B A

B A RKZ01520

10±1 Nm
10±1 Nm

70±7 Nm 70±7 Nm

............ Nm

............ Nm
............ Nm

70±7 Nm
10±1 Nm 70±7 Nm 10±1 Nm
10±1 Nm 1 1
Section A -- AA
Sezione A Section
Sezione B - B
RKZ01530
70±7 Nm

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

WB150AWS-2 40-23
STANDARD MAINTENANCE BRAKE PUMP

BRAKE PUMP

1 2 3

4
RKZ00931

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

40-24 WB150AWS-2
STANDARD MAINTENANCE SHOVEL CYLINDERS

SHOVEL CYLINDERS
DUMP CYLINDER

2845±284 Nm 932 Nm

3 1 2

RKZ00781

RAISE CYLINDER

2845±284 Nm 961 Nm

3 1 2

RKZ00771

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

WB150AWS-2 40-25
STANDARD MAINTENANCE BACKHOE CYLINDERS

BACKHOE CYLINDERS
BOOM
932 – 980 Nm 932 – 980 Nm

1 3
2

RKZ00751

ARM
932 – 980 Nm 2845±284 Nm

1 3
2

RKZ00741
BUCKET
932 – 980 Nm 2845±284 Nm

2 1 3

RKZ00731

BOOM SWING
932 – 980 Nm

1
2

78 +0 20 Nm
with Loctite 542

RKZ00721

40-26 WB150AWS-2
STANDARD MAINTENANCE BACKHOE CYLINDERS

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
-- 0.060 + 0.030
Clearance between
1 Arm with
60 -- 0.030 + 0.076 0.06 0.136 Replace
piston head and telescopic arm -- 0.060 + 0.030
cylinder head

Bucket 60 -- 0.030 + 0.076 0.06 0.136

-- 0.060 + 0.030

+ 0.025 + 0.064
Boom swing 50 + 0.050 + 0.025 0.05 0.114

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 45
-- 0.050 + 0.24
0.13 0.329
-- 0.089 + 0.08
Replace
Boom swing 50
-- 0.050 + 0.119
0.13 0.208 pin and
-- 0.089 + 0.080
bushing

Boom 50 -- 0.050 + 0.24 0.13 0.329

-- 0.089 + 0.08
Tolerance between -- 0.050 + 0.24
3 bushing and cylinder Arm 45 -- 0.089 + 0.08 0.13 0.329
mounting pin

Bucket 45
-- 0.050 + 0.24
0.13 0.329
-- 0.089 + 0.08

WB150AWS-2 40-27
STANDARD MAINTENANCE BACKHOE CYLINDERS

OUTRIGGER

932 – 980 Nm 1520±152 Nm

1
2 3

RKZ01431

TELESCOPIC ARM

932 – 980 Nm 785 Nm

RKZ00701

Unit: mm

Criteria

N° Check
item
Cylinder Tolerance Remedy
Standard Standard Clearance
size clearance limit
Shaft Hole

Outrigger 55 -- 0.030 + 0.076 0.06 0.136

Clearance between -- 0.060 + 0.030
1 piston rod and
cylinder head – 0.025 + 0.064
Telescopic arm 40 0.05 0.114
– 0.050 + 0.025

Tolerance between Replace

2 bushing and piston rod Outrigger 45
-- 0.050 + 0.24
0.13 0.329
mounting pin -- 0.089 + 0.08

Tolerance between -- 0.050 + 0.24

3 bushing and cylinder Outrigger 45 0.13 0.329
mounting pin
-- 0.089 + 0.08

40-28 WB150AWS-2
PAGE INTENTIONALLY
LEFT BLANK
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
RKZ04390

40-30 WB150AWS-2
STANDARD MAINTENANCE FRONT WORKING EQUIPMENT

Unit: mm

Criteria

N° Check item Tolerance

Clearance
Remedy
Standard Standard
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

WB150AWS-2 40-31
STANDARD MAINTENANCE SWING BRACKET

SWING BRACKET

B
A

A C

1
3
4

Section
Sezione B - B
B
2

1 6
Section AA--AA
Sezione

Section
Sezione C
C -- C
C

RKZ02280

40-32 WB150AWS-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 0.250–0.370 bushing
rotating pin -- 0.106 + 0.264
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

WB150AWS-2 40-33
STANDARD MAINTENANCE BACKHOE WORKING EQUIPMENT

BACKHOE WORKING EQUIPMENT

C
C

F F
B

B A
A
D
D
E E

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
Sezione C
C -- C
C
RKZ02290

40-34 WB150AWS-2
STANDARD MAINTENANCE BACKHOE WORKING EQUIPMENT

Section Section
SezioneFF -- F
F
Sezione E
E -- E
E
RKZ02300

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 -- 0.089 --- 0.240 0.130–0.329
mounting pin

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

7
Clearance between bushings
45
-- 0.050 --- 0.080 0.130–0.208
and outrigger mounting pin -- 0.089 --- 0.119

WB150AWS-2 40-35
40-28 PC15R-8