00-14

CONTENTS
No. of page

10 STRUCTURE AND FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

20 TESTING AND ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1
30 DISASSEMBLY AND ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-1
40 MAINTENANCE STANDARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1

00-2

The affected pages are indicated by the use of the

following marks. It is requested that necessary actions be taken to these pages according to table
below.

Mark

Indication

Page to be newly

Page to be replaced

Replace

Page to be delete

Discard

Action required
Add

Pages having no marks are those previously revised

or made additions.

LIST OF REVISED PAGES

Mark

Page

00-1
00-2
00-2-1
00-2-2
00-3
00-4
00-5
00-6
00-7
00-8
00-9
00-10
00-11
00-12
00-13
10-1
10-2
10-3
10-4
10-5
10-6
10-7
10-8
10-9
10-10
10-11
10-12
10-13
10-14
10-15
10-16
10-17
10-18
10-19
10-20
10-21
10-22
10-23
10-24
10-25

Time of
Mark
revision

Page

10-26
10-27
10-28
10-29
10-30
10-31
10-32
10-33
10-34
10-35
10-36
10-37
10-38
10-39
10-40
10-41
10-42
10-43
10-44
10-45
10-46
10-47
10-48
10-49
10-50
10-51
10-52
10-53
10-54
10-55
10-56
10-57
10-58
10-59
10-60
10-61
10-62
10-63
10-64
10-65
10-66

Time of
Mark
revision

Page

10-67
10-68
10-69
10-70
10-71
10-72
10-73
10-74
10-75
10-76
10-77
10-78
10-79
20-1
20-2
20-3
20-4
20-5
20-6
20-7
20-8
20-9
20-10
20-11
20-12
20-13
20-14
20-15
20-16
20-17
20-18
20-19
20-20
20-21
20-22
20-23
20-24
20-25
20-26
20-27

Time of
Mark
revision

Page

20-28
20-29
20-30
20-31
20-32
20-33
20-34
20-35
20-36
20-37
20-38
20-39
20-40
20-41
20-42
20-43
20-44
20-45
20-46
20-47
20-48
20-49
20-50
20-51
20-52
20-53
20-54
20-55
20-56
20-57
20-58
20-59
20-60
20-61
20-62
20-63
20-64
20-65
20-66
20-67
20-68

Time of
Mark
revision

Time of
revision

Page

30-1
30-2
30-3
30-4
30-5
30-6
30-7
30-8
30-9
30-10
30-11
30-12
30-13
30-14
30-15
30-16
30-17
30-18
30-19
30-20
30-21
30-22
30-23
30-24
30-25
30-26
30-27
30-28
30-29
30-30
30-31
30-32
30-33
30-34
30-35
30-36
30-37
30-38
30-39
30-40
30-41

00-2-1

Mark

Page

30-42
30-43
30-44
30-45
30-46
30-47
30-48
30-49
30-50
30-51
30-52
30-53
30-54
30-55
30-56
30-57
30-58
30-59
30-60
30-61
30-62
30-63
30-64
30-65
30-66
30-67
30-68
30-69
30-70
30-71
30-72
30-73
30-74
30-75
30-76
30-77
30-78
30-79
30-80
30-81
30-82
30-83
30-84
30-85
30-86
30-87
30-88
30-89
30-90
30-91
30-92
30-93
30-94
30-95
30-96
30-97

00-2-2

Time of
Mark
revision

Page

Time of
Mark
revision

30-98
30-99
30-100
30-101
30-102
30-103
30-104
30-105
30-106
30-107
30-108
30-109
30-110
30-111
30-112
30-113
30-114
30-115
30-116
30-117
30-118
30-119
30-120
30-121
30-122
30-123
30-124
30-125
30-126
30-127
30-128
30-129
30-130
30-131
30-132
30-133
30-134
30-135
30-136
30-137
30-138
30-139
30-140
30-141
30-142
30-143
30-144
30-145
30-146
30-147
30-148
30-149
30-150
30-151
30-152
30-153

Page

Time of
Mark
revision

30-154
30-155
30-156
30-157
30-158
30-159
30-160
30-161
30-162
30-163
30-164
30-165
30-166
30-167
30-168
30-169
30-170
30-171
30-172
30-173
30-174
30-175
30-176
30-177
30-178
30-179
30-180
30-181
30-182
30-183
30-184
30-185
30-186
30-187
30-188
30-189
30-190
30-191
30-192
30-193
30-194
30-195
30-196
30-197
30-198
30-199
30-200
30-201
30-202
30-203
30-204
30-205
30-206
30-207
30-208
30-209

Page

Time of
Mark
revision

30-210
30-211
30-212
30-213
30-214
30-215
30-216
30-217
30-218
30-219
30-220
30-221
30-222
30-223
30-224
30-225
30-226
30-227
30-228
30-229
30-230
30-231
30-232
30-233
30-234
30-235
30-236
30-237
30-238
30-239
30-240
30-241
30-242
30-243
30-244
30-245
30-246
30-247
30-248
30-249
30-250
30-251
30-252
30-253
30-254
30-255
30-256
30-257
30-258
30-259
30-260
30-261
30-262
30-263
30-264
30-265

Page

Time of
revision

30-266
30-267
30-268
30-269
40-1
40-2
40-3
40-4
40-5
40-6
40-7
40-8
40-9
40-10
40-11
40-12
40-13
40-14
40-15
40-16
40-17
40-18
40-19
40-20
40-21
40-22
40-23
40-24
40-25
40-26
40-27
40-28
40-29
40-30
40-31
40-32
40-33
40-34
40-35
40-36
40-37
40-38
40-39
40-40
40-41
40-42
40-43

IMPORTANT SAFETY NOTICE

Proper service and repair is extremely important for the safe operation of your machine.
The service and repair techniques recommended by FKI 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
FKI 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.

Read all the Operation and Maintenance Manual carefully BEFORE operating the machine.

7. Before adding or making any repairs, park the machine on hard, level ground, and block the wheels
to prevent the machine from moving.

1. Before carrying out any greasing or repairs, read

all the precautions written on the decals which
are suck on the machine.

8. Before starting work, lower ourigger, bucket or

any other work equipment to the ground. If this
is not possible, use blocks to prevent the work
equipment from falling down. In addition, be sure
to lock all the control levers and hang warning
sign on them.

2. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work
clothes, or clothes with buttons missing.
. Always wear safety glasses when hitting parts
with a hammer.
. Always wear safety glasses when grinding
parts with a grinder, etc.
3. If welding repairs are needed, always have a trained, experienced welder carry out the work.
When carrying out welding work, always wear
welding gloves, apron, glasses, cap and other clothes suited for welding work.
4. When carrying out any operation with two or more
workers, always agree on the operating procedure
before starting. Always inform your fellow workers
before starting any step of the operation. Before
starting work, hang UNDER REPAIR signs on
the controls in the operator's compartment.
5. Keep all tools in good condition and learn the correct way to use them.
6. Decide a place in the repair workshop to keep
tools and removed parts. Always keep the tools
and parts in their correct places. Always keep
the work area clean and make sure that there is
no dirt or oil on the floor.
Smoke only in the areas provided for smoking.
Never smoke while working.

9. When disassembling or assembling, support the

machine with blocks, jacks or stands before starting work.
10. Remove all mud and oil from the steps or other
places used to get on and off the machine. Always
use the handrails, ladders or steps when getting
on or off the machine.
Never jump on or off the machine.
If it is impossible to use the handrails, ladders or
steps, use a stand to provide safe footing.

PRECAUTIONS DURING WORK

11. When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them
slowly to prevent the oil from spurting out.
Before disconnecting or removing components of
the hydraulic circuit and engine cooling circuit,
first remove the pressure completely from the circuit.
12. The water and oil in the circuits are not hot when
the engine in stopped, so be careful not to get
burned.
Wait for the oil water to cool before carrying out
any work on the cooling water circuits.

00-3

13. Before starting work, remove the leads from the

battery. Always remove the lead from the negative
( ) terminal first.
14. When raising heavy components, use a hoist or
crane. Check that the wire rope, chains and hooks
are free from damage.
Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct
places.
Use a hoist or crane and operate slowly to prevent
the component from hitting any other part.
Do not work with any part still raised by the hoist
or crane.
15. When removing covers which are under internal
pressure or under pressure from a spring, always
leave two bolts in position on opposite sides.
Slowly release the pressure, then slowly loosen
the bolts to remove.
16. When removing components, be careful not to
break or damage the wiring.
Damage wiring may cause electrical fires.
17. When removing piping, stop the fuel or oil from
spilling out. If any fuel or oil drips on to the floor,
wipe it up immediately.
Fuel or oil on the floor can cause you to slip, or
can 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.
19. Be sure to assemble all parts again in their original places. Replace any damage parts with new
parts.
. When installing hoses and wires, be sure that
they will not be damaged by conctat with other
parts when the machine is being operated.
20. When installing high pressure hoses, make sure
that they are not twisted. Damaged tubes are dangerous, so be extremely careful when installing
tubes for high pressure circuits. Also, check that
connecting parts are correctly tightened.
21. When assembling or installing parts, always use
specified tightening torques.
When installing the parts which vibrate violently or
rotate at high speed, be particulary careful to
check that they are correctly installed.
22. When aligning two holes, never insert your fingers
or hand.
23. When measuring hydraulic pressure, check that
the measuring tool is correctly assembled before
taking any measurement.

00-4

24. Take sure when removing or installing tracks of in

particular rubber tracks. When removing the
track, the track separates suddenly, so never let
anyone stand at either end of the wheel.

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
workshop.
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, dissassembling 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.

NOTICE
The specifications contained in this shop manual are subject to change at any time and without any
notice.
Contact your FKI distributor for the latest information.

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. These various volumes are designed to avoid
duplicating the same information.

In order to make the shop manual greatly chelpful,

important points about safety and quality are marked
with the following symbols.

DISTRIBUTION AND UPDATING

Any additions, amendments or other changes will
be sent to FKI distributors.
Get the most up-to-date information before you start
any work.

Symbol

Item

Special safety precautions are necessary when performing the

work.
Safety

FILING METHOD
1. See the page number on the bottom of the page.
File the pages in correct order.
2. Following examples show you how to read the page number.

Item number (10. Structure and

Function)
Consecutive page number for each
item.
3. Additional pages: additional pages are indicated
by a hyphen (-) and number after the page number.
Fle as in the example.
Example:
10-4
10-4-1
] Added pages
10-4-2
10-5

REVISED EDITION MARK

(1 2 3 ....)
When a manual is revised, an edition mark is recorded on the bottom outside corner of the pages.

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

00-6

Extra special safety precautions

are necessary when performing
the work because it is under internal pressure.

Caution

Special technical precautions or

other precautions for preserving
standards are necessary when
performing the work.

Weight

Weight of parts or systems.

Caution necessary when selecting
hoisting wire, or when working posture is important, etc.

Example
10 - 3

Remarks

Parts that require special attention

Tightening for the tightening torque during astorque
sembly.
Coat

Parts to be coated with adhesives

and lubricants etc.

Oil, water

Places where oil, water or fuel

must be added, and their quantity.

Drain

Places where oil or water must be

drained, and quantity to be drained.

HOISTING INSTRUCTIONS

HOISTING INSTRUCTIONS

Heavy parts (25 kg or more) must be lifted

with a hoist etc. In the Disassembly and Assembly section, every part weighing 25 kg or
more is clearly indicated with the symbol

ing, and a serious accident can result.

Hooks have maximum strenght at the middle
portion.

1. If a part cannot be smoothly removed from the

machine by hoisting, the following checks should
be made:
. Check for removal of all bolts fastening the part
to the relative parts.
. Check for any part causing interference with
the part to be removed.
2. Wire ropes
1) Use adequate ropes depending on the weight
of parts to be hoisted, referring to the table below:
WIRE ROPES
(Standard S or Z twist ropes
without galvanizing)
Rope diameter (mm)

Allowable load (tons)

10

1.0

11.2

1.4

12.5

1.6

14

2.2

16

2.8

18

3.6

20

4.4

22.4

5.6

30

10.0

40

18.0

50

28.0

60

40.0

3) Do not sling a heavy load with one rope alone,

but sling with two or more ropes symmetrically
wound on to the load.
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 load, which can cause dangerous accidents.

4) Do not sling a heavy load with ropes forming a

wide hanging angle from the hook.
When hoisting a load with two or more ropes,
the force subjected to each rope will increase
with the hanging angles.
The table below shows the variation of allowable load (kg) when hoisting is made with two ropes, each of which is allowed to sling up to
1000 kg vertically, at various handing angles.
When two ropes sling a load vertically, up to
2000 kg of total weight can be suspended.
This weight becomes 1000 kg when two ropes
make a 120 hanging angle.
On the other hand, two ropes are subjected to
an excessive force as large as 4000 kg if they
sling a 2000 kg load at a lifting angle of 150.

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 hoist-

00-7

STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE

The following charts give the stardard tightening torques of bolts and nuts. Exceptions are given in sections of Disassembly and Assembly.

1. STANDARD TIGHTENING TORQUE OF BOLTS AND NUT

Thread diameter
of bolts
(mm)

Pitch of
bolts
(mm)

Width across flat

(mm)

kgm

Nm

kgm

Nm

10

0.96w0.1

9.5w1

1.3w0.15

13.5w1.5

1.25

13

2.3w0.2

23w2

3.2w0.3

32.2w3.5

10

1.5

17

4.6w0.5

45w4.9

6.5w0.6

63w6.5

12

1.75

19

10

7.8w0.8

77w8

14

22

12

12.5w1

16

24

14

18

2.5

27

20

2.5

22

11w1

108w11

122w13

17.5w2

172w18

19.5w2

191w21

27w3

268w29

14

27w3

262w28

37w4

366w36

30

17

38w4

372w40

53w6

524w57

2.5

32

17

52w6

511w57

73w8

719w80

24

36

19

66w7

644w70

92w10

905w98

27

41

19

96w10

945w100

135w15

1329w140

30

3.5

46

22

131w14

1287w140

184w20

1810w190

33

3.5

50

24

177w20

1740w200

250w27

2455w270

36

55

27

230w25

2250w250

320w35

3150w350

39

60

295w33

2900w330

410w45

4050w450

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):

00-8

1 Nm = 0.102 kgm

STANDARD TIGHTENING TORQUE

2. TIGHTENING TORQUE FOR NUTS OF FLARED

Use these torques for nut part of flared.
Thread diameter
of nut part
(mm)

Width across flats

of nut part
(mm)

TIGHTENING TORQUE
kgm

Nm

1/2" - 20
9/16" - 18
3/4" - 16
7/8" - 14
1.1/16" - 12
1.5/16" - 12
1.5/8" - 12
22
33

17
17
22
27
32
38
50
27
41

2.6w0.5
4w0.5
6.7w2
8w2
9.7w3
17w3
20w5
8w2
20w5

25.5w4.9
39.2w4.9
65.7w19.6
78.5w19.6
95.15w29.4
166.7w29.4
196.2w49
78.5w19.6
196.2w49

COATING MATERIALS
The recommended coating materials prescribed in FKI Shop Manuals are listed below:
Nomenclature

Adhesives

Code
ASL800010

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

ASL800020

Used to apply resin, rubber, metallic and non-mettalic parts when a fast, strong
seal is needed.

Loctite 222

Used for low resistance locking of screws, check nuts and adjustment nuts.

Loctite 242

To prevent the loosening of bolts, nuts and plugs and the leakage of oil. Used for
medium resistance locking of screws and nuts of every type, and for locking keys
and bearings.

Loctite 262
Loctite 270

Used for high resistant of threaded parts that can be removed with normal tools.

Loctite 542

Used for sealing the union threads for hydraulic tubes.

Loctite 573
Loctite 601
Loctite 675
ASL800060

Used for high resistant locking and for sealing threaded parts, bolts and stud bolts.
Used for sealing rather exact plane surfaces when the option of possible future
dismantling is required.
Used for high resistant locking of mechanical components that can be removed
only after heating
Used to lock cylindrical couplings and for the permanent locking of threaded parts,
and also to lock shafts to bearings, gears, pulleys, pins, bushings, etc.
Used by itself to seal grease fittings, tapered screw fittings and tapered screw fittings in hydraulic circuits of less than 50 mm in diameter.

Loctite 518

Used by itself on mounting flat surface

(Clearance between surfaces within 0.2 mm)
Used by itself on mounting flat surface
(Clearance between surfaces within 0.5 mm)

Antifriction compound
(Lubricant inclunding
Molybdenum disulfide)

ASL800040

Applied to bearings and taper shaft to facilitate press-fitting and to prevent sticking, burning or rusting.

Grease
(Lithium grease)

ASL800050

Applied to bearings, sliding parts and oil seals for lubrication, rust prevention and
facilitation of assembling work.

Gasket sealant

Vaseline

Loctite 510

Used for protecting battery electrode terminals from corrosion.

00-9

ELECTRIC WIRE CODE

ELECTRIC

ELECTRIC WIRE CODE

In the wiring diagrams various colors 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
Nominal
number

Number
strands

Copper wire
of strands
(mm)

Cross section
(mm2)

Cable O.D.
(mm)

Current rating
(A)

CLASSIFICATION BY COLOUR AND CODE

Primary

Auxiliary

Code
Colour
Code
Colour
Code
Colour
Code
Colour
Code
Colour
Code
Colour
Code
Colour
Code
Colour
Code
Colour
Code
Colour
Code
Colour
Code
Colour

COMPOSITION OF THE COLOURS

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

00-10

Applicable circuit

WEIGHT TABLE
This weight table is a guide for use when transporting or handling components.
Unit: kg

Machine model

WB91R-2

WB93R-2

From serial no.

91F20001

93F20001

Engine assembly - Muffler - Exhaust pipe

400

410

Radiator - exchanger

37

37

Hydraulic tank (without hydraulic oil)

Fuel tank (without fuel)

300

300

Cab (without seat)

595

595

Seat

34

34

Engine - gear-box - pump group

730

740

Piston pump

38

38

Transmission

230

230

Convertor

Front axle

316

316

Rear axle

511

511

Front wheel
Rear wheel

65
163

65
163

2-spool control valve

24

24

3-spool control valve

30

30

Work equipment

Boom

323

323

Arm

213

213

Long arm

245

245

Boom swing bracket

133

133

Backframe

6-spool control valve

47

47

7-spool control valve

53

53

8-spool control valve

59

59

Jig arm

392

392

Outriggers

Boom cylinder

65

78

Arm cylinder

69

69

Bucket cylinder

49

49

Outrigger cylinder

Swing cylinder

30

30

Front counterweight
Engine hood

Backhoe
Work equipment

00-11

TABLE OF OIL AND COOLANT QUANTITIES

KIND OF
FLUID

RESERVOIR

CAPACITY ( < )

AMBIENT TEMPERATURE
20

10

10

20

30C

Specified

Refill

8.6

8.6

150

92

6.5

6.5

15

15

3.5

3.5

FKI 921

19

16

FKI 921

0.8

0.8

130

WATER+
ANTI-FREEZE

18

WATER

18

18

FKI 907 10W

Crankcase sump

FKI 907 20W-20

OIL
. API CD

FKI 907 SAE 30

FKI 907 SAE 40

Hydraulic circuit

OIL

FKI 909 10W-30

. API CD

Front axle
. differential
. final red. gear
(each)
Rear axle:

OIL

FKI 918

. UTTO FLUID

. differential
. final red. gear
(each)
Hydraulic
transmission
Braking system

OIL
.

GM DEXRONt II D
(DEXRONt is a registered trademark of General
Motors Corporation)
]

Fuel tank

Engine coolant
system

DIESEL OIL

ASTM D975 N. 2

PERMANENT
LIQUID

FKI 931

FKI
FKI
FKI
FKI
FKI

907
909
918
921
921

ASTM D975 N. 1

OLDEN TURBO UNIGRADO

MULTISERVICE 4
SPECIAL TRANSMISSION FLUID 68/F-100
ANDROS FLUID II D
ANTIFROST PRONTO (25 C)

00-12

ASTM: America Society of Testing and Materials

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

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

Engine oil change interval

from 0.5 to 1.0%

1/2 of regular interval

over 1.0%

1/4 of regular interval

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

00-13

00-14

STRUCTURE AND FUNCTION

Power train . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 2
Transmission . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 4
Drive shafts . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 9
Control valve block.. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 11
Front axle . . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 12
Differential .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 12
Final reduction-Joint .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 13
Steering cylinder . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 14
Rear axle . . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 15
Differential .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 15
Final Reduction.. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 16
Brakes . . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 17
Differential locking . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 18

Hydraulic pump. . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 20
Hydraulic steering system . .. . . . .. . . . . .. . . . . .. . . . .. . . . 41
Hydraulic circuit . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 43
Shovel control valve. . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 44
Backhoe control valve . . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 50
Solenoid valve . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 71
Safety valve.. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 72
Brake pump .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 74
Shovel cylinders . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 75
Backhoe cylinders. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 76

10-1

POWER TRAIN

2
3

6
RKZ01060

DESCRIPTION
. The driving power for the engine (1) is transmitted
through the flywheel to the converter (2).
The converter (2) uses hydraulic oil to convert the
torque transmitted by the engine (1) into driving
power. The converter (2) transmits motion to the
drive shaft of the transmission (3) and to the drive
shaft of the hydraulic pump (4).
. The transmission (3) has two hydraulically-activated clutches that can be selected by an electrically-controlled gear selector. It also has manual
gear selection (four forward gears and four reverse
gears).

10-2

. The driving power is transmitted from the transmission flanges (3) to the front (5) and rear (6) axles
through the Cardan drive shafts (7 and 8).
. The driving power transmitted to the front (5) and
rear (6) axles is reduced by the differentials and
then transmitted to the planetary gear through the
differential shafts.

Gears

Front axle
4.280

2nd gear

2.372

3rd gear

1.236

th

4 gear

Differential

Transmission

1st gear

Rear axle

Planetary

2.385

6.000

0.662

Total

Transmission

61.238

5.350

33.939

2.965

17.685

1.544

9.472

0.827

Differential

Planetary

Total
91.362

2.846

6.000

50.633
26.367
14.123

Z=37

Z=15

4
Z=75

Z=13

9
8
3

2
7
10

1
Z=13

Z=15
Z=....

Z=31

Z=75
RKZ01030

1.
2.
3.
4.

Diesel engine
Convertor
Transmission
Hydraulic pump

5.
6.
7.
8.

Front axle
Rear axle
Front Cardan drive shaft
Rear Cardan drive shaft

9. Rear wheels
10. Front wheels

10-3

TRANSMISSION

Diagram of the power train

7
Z=38

Z=28

Z=33
Z=24
Z=45

Z=27

Z=29
Z=49
Z=36

5
3
Z=27
Z=12

Z=29

Z=19

Z=43

RKZ01040

1.
2.
3.
4.
5.

Engine
Convertor
Forward clutch
Transmission
Reverse clutch

10-4

6.
7.
8.
9.

Hydraulic pump
Rear flange
4-WD engagement device
Front flange

3
a
th
34 marcia
gear

4
43ard
marcia
gear

11astmarcia
gear

a
2
2ndmarcia
gear

4,5

5,7

Hydraulic Convertor-Transmission Circuit Diagram

4
0,75

1,3

3,5

3,5

2
3
8
15
13
12

10

11
1
14

RKZ00860

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

Convertor pressurization valve

Convertor
Engine
Oil cooler
Forward clutch
Reverse clutch
Max. pressure valve: calib. 23 bar
Spin-on filter (15 Nm)

9.
10.
11.
12.
13.
14.
15.

Pump
Suction filter (250 Nm)
4-WD engagement device
Check valve
Pressure control
4-WD engagement solenoid
Control valve group

10-5

TRANSMISSION
Views

E
F

A
E

D
5

B
RKZ00970

a.
b.
c.
d.

From the oil cooler

To the oil cooler
To the solenoid valve group ST1 (Port P)
From the solenoid valve group ST1 (Port T)

1. Gear lever
2. Convertor

10-6

3.
4.
5.
6.
7.
8.

Filter
Oil temperature sensor
Suction filter
EV.... Reverse gears command solenoid
EV.... Forward gears command solenoid
EV.... 4-WD command solenoid

17

16

10
15

14

12

13

11

Sezione A
-A
Section
A
A

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

Hydraulic pump drive shaft

Propeller shaft
Reverse gears command clutch
Forward gears command clutch
Reverse gears idler shaft
Drive shaft
Flange
3rd gear driven gear
4th gear driven gear

10.
11.
12.
13.
14.
15.
16.
17.

RKZ00980

4-WD drive gear

1st gear driven gear
4-WD driven gear
4-WD engagement device
Front output shaft
Flange
2nd gear driven gear
Rear output shaft

10-7

C
1

10
10

Sezione C - C
Section C C

Sezione B - B
Section B B

12

13

14

15

16

11

Sezione D
D - D
Section
D

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

Gear-shift piston
Spring
Spring
Ball
3rd and 4th gear selecting fork
1st and 2nd gear selector piston
3rd and 4th gear selector piston
1st and 2nd gear selecting fork

10-8

Sezione E - E
Section E E

9.
10.
11.
12.
13.
14.
15.
16.

3rd and 4th gear selecting fork

1st and 2nd gear selecting fork
Suction filter (250 Nm)
Spin-on filter (15 Nm)
Valve
Spring
Ball
Spring

RKZ00990

DRIVE SHAFTS
Drive shaft for forward and reverse movement

2
a b c

6
5
4
a. Port commanding reverse clutch
b. Port commanding forward clutch
c. Lubrication port

1. Reverse gear clutch (Z=29)

2. Forward gear clutch (Z=29)
3. Reverse clutch piston

RKZ00950

4. Forward clutch piston

5. Thrust ring
6. Driven shaft

Driven gear shaft

8
1. Driven gear for 1st gear (Z=49)
3. 4-WD drive gear (Z=44)
4. Driven gear for 4th gear (Z=24)

8
5.
6.
7.
8.

RKZ01010

Driven gear for 3rd gear (Z=33)

Rear output shaft
Thrust ring
Synchronizer

10-9

4-WD driven shaft

2
1

a. 4-WD disengagement command port

1. Front output shaft
2. 4-WD driven gear (Z=36)
3. Thrust ring

10-10

4. Cylinder
5. Spring
6. Disc

RKZ01020

CONTROL VALVE BLOCK

2
1

10
11

14

15

12

13

Sezione F - F

Section F F

1.
2.
3.
4.
5.

Ball
Spring
Piston
Spring
Spring

6.
7.
8.
9.
10.

Spring-guide pin
Valve
Spring
Valve
Rod

12
RKZ01000

11.
12.
13.
14.
15.

Spring
Spool return spring
Spool
Forward gear command solenoid
Reverse gear command solenoid

10-11

FRONT AXLE
Differential

1
4
5

17

7
16
15
8

14

9
13
10

12
11

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

Planetary gear
Ring bevel gear (Z=31)
Bevel gear
Lock nut
Half-axle
Pin
Differential housing
Spacer
Bearing

10-12

RKZ00580

10.
11.
12.
13.
14.
15.
16.
17.

Seal
Flange
Cover
Lock nut
Bearing
Bevel pinion (Z=13)
Pin
Oil drain plug

Final reduction-Joint

7
3
1

5
4

6
10

11

24

23

13

22

17

12

14
18
21

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.

20

Planetary carrier
Planetary (Z =...)
Ring gear (Z=75)
Ring gear carrier
Wheel hub
Seal
Pin
Shim
Protection
Bushing
Seal
Axle body

16

15

19

RKZ00610

13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.

Bearing
Joint
Pin
Protection
Seal
Bearing
Snap ring
Steady pin
Stud bolt
Plug
Sun gear (Z=15)
Snap ring

10-13

Steering cylinder

A
A

5
4
Sezione A - A
Section A A

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

Steady pin
Oil refilling plug
Oil drain plug
Nut
Adjustment screw
Nut

10-14

Sezione B - B
Section B B

6
Particolare C

Detail C

Port a - From the steering unit (Port L)

Port b - From the steering unit (Port R)

RKZ00590

REAR AXLE
Differential

6
7

16

15

8
9

14

10
13

11

12

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

Bearing
Planetary gear
Bevel gear
Ring bevel gear (Z=37)
Differential housing
Lock nut
Half-axle
Pin

RKZ00570

9.
10.
11.
12.
13.
14.
15.
16.

Bearing
Nut
Seal
Flange
Cover
Spacer
Bevel pinion (Z=13)
Differential housing

10-15

Final Reduction

3
4
5
6

18

17

16
10

15
19
14
13

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

Planetary gear carrier

Stud bolt
Wheel hub
Planetary gears (Z=...)
Ring bevel gear carrier
Bearing
Seal
Joint
Half-axle

10-16

12

11

RKZ00600

10.
11.
12.
13.
14.
15.
16.
17.
18.

Planetary gear (Z=15)

Oil drain plug
Snap ring
Ring gear (Z=75)
Oil refilling plug
Steady pin
Cover
Pin
Snap ring

Brakes

8
9

10

4
5

11

6
7
Particolare
Detail B B

Sezione A
A- A
A
Section

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

Retainer ring
Bushing
Parking brake control rod
Bleeder valve
Parking brake lever
Parking brake control cam

RKZ00620

7.
8.
9.
10.
11.

Brake disk
External flange
Service brake piston
Pressure disk
Center reaction plate

10-17

Differential locking

8
a
7
6

a. From the solenoid valve block ST1 (Port2)

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

Sleeve
Pin
Control rod
Spacer
Fork
Piston
Cover
Snap ring

10-18

RKZ00630

10-19

HYDRAULIC PUMP

b
A

D
c
B

D
A
e

d
RKZ00400

1. Delivery variation group

2. Working mode selection solenoid ......
3. Delivery control valve

a.
b.
c.
d.
e.

10-20

Port L1 - To the intake flange (Spool Port)

Port B - To the shovel control valve (Port P)
Port X2 - From the shovel control valve
(Port LS)
Port L - To the hydraulic oil tank
Port S - To the hydraulic oil tank

2
1

Sezione A - A
Section A A

12
1.
2.
3.
4.
5.
6.

Seal
Bearing
Central spring
Bearing
Control rod
Swash plate

11

Sezione B
B
-B
Section
B

7.
8.
9.
10.
11.
12.

10

RKZ00380

Positioning piston
Spring
Cylinder block
Positioning piston
Piston
Guide shoe

10-21

Sezione C - C

Section C C

15

10

14

12

13

11

Sezione D
D - D
D
Section

POWER GOVERNOR
1. Spring
2. Piston rod
3. Bushing
4. Initial adjustment spring
5. Spring
6. Pressure cut calibration screw
7. Initial adjustment calibration screw
PC
8.
9.
10.

VALVE
Spool
Spring (internal)
Spring (external)

10-22

LS VALVE
11. External spring
12. Internal spring
13. Throttles ( ....)
14. Throttles ( ....)
15. Spool

RKZ00640

FUNCTION
. The rotation and torque transmitted to the pump
shaft is converted into hydraulic energy and pressurized oil is delivered according to the load requirements.
. The amount of oil delivered can be modified by
changing the angle of the swash plate.

RKZ01120

STRUCTURE
. The cylinder block (6) is supported and connected
to the shaft (1) by the spline a and the shaft (1) is
supported by the front and rear bearings.

. The pistons (5) perform their relative movements in

an axial direction, inside cylindrical chambers fashioned in the cylinder block (6).

. The tip of the piston (6) is ball-shaped. The shoe (4)

is caulked to it to form one unit in such a way that
the piston (5) and the shoe (4) together form a spherical bearing.

. The oil is brought up to pressure in the chambers of

the cylinder block (6) by the rotatory movement of
the block itself. The areas of pressure and suction
are determined by the swash plate (7).
The surface of the swash plate is so designed that
the oil pressure always remains within acceptable
limits.
The oil in each chamber is drawn in and discharged
through holes in the valve plate (7).

. The swash plate (3) has a flat surface A and the

shoe (4) remains pressed against this surface while
sliding in a circular movement.
The swash plate brings highly pressurized oil onto
the cylindrical surface B fashioned in the pump
body (2), which means that the swash plate (3)
slides on a hydrostatically-supported bearing.

10-23

OPERATION
1. Pump operation
1 - The cylinder block (7) rotates together with the
shaft (1) and the shoe (4) slides on the flat surface A. The swash plate (3) moves along the
cylindrical surface B. The angle a formed
between the center line of the shaft (1) and
the center line X of the swash plate (3)
changes, thus modifying the axial position of
the pistons in relation to the cylinder block.
The angle a is known as the swash plate angle.
2 - When the center line X of the swash plate (3)
maintains the angle a in relation to the center line of the shaft (1), and hence also of the
cylinder 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 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 intake of oil.
(The figure indicates the state of the pump
when the intake of chamber D and the delivery
of chamber C have been completed).
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
a=0), the difference between the volumes
C and D within the cylinder block (6) becomes
0 and the pump does not take in or deliver any
oil. (In practice the swash plate angle a
never becomes=0)
4 - In other words, pump delivery is directly proportional to the swash plate angle a.

10-24

X
C

RKZ01100

=0
X

C
RKZ01110

2. Control of Delivery
. As the swash plate angle a grows larger, the
difference between volumes C and D increases,
and the delivery Q also increases.
The swash plate angle is modified by servo-pistons (8) and (9).
. The servo-piston (8) moves in a reciprocating
linear motion (
) caused by pressure signals
from the PC and LS valves.
The linear movement is transmitted to the
swash plate (3), which is supported by the cylindrical surface of the cradle (7). The swash
plate therefore has a semi-circular reciprocating
movement ( ).
. The surfaces of the servo-pistons receiving the
pressures PP and LS are dissimilar. The delivery pressure PP of the main pump is always
passed into the smaller (upper) pressure chamber, whereas the pressure PEN coming from the
LS valve is passed into the larger (lower) pressure chamber.
The movement of the servo-piston is governed
by the relationship between pressures PP and
PEN, as well by the proportions between the surfaces (larger and smaller) of the servo-piston.

C
RKZ01130

10-25

2. PC VALVE, LS VALVE SERVO-PISTON

Control valve

Distributore

3
To
the actuator
All'utilizzo

7
SERVO-PISTON
1. Spring
2. Servo-piston
3. Servo-piston
LS VALVE
4. Piston
5. Spring

10-26

6
PC VALVE
6. Servo-piston
7. Spring

RKZ01140

LS VALVE
FUNCTION
. The LS valve controls the pump delivery according
to the stroke of the control valve level, i.e., in function of the delivery demands made by the actuators.
. The LS valve detects the actuator's delivery needs
by means of the differential pressure DPLS 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 DPLS are, respectively, the pump
pressure, the Load Sensing pressure, and the difference in pressure between these two values).
. In other words, the LS valve detects the pressure
difference DPLS generated by the passage of the
oil flow through the surface freed by the control
valve spool, and controls the pump delivery Q so
as to keep the pressure drop constant.
. It can therefore be assumed that the pump delivery
is proportional to the demands made known by the
control valve.

10-27

OPERATION
1. When the control valve is in a NEUTRAL position.

b
T

PP

PLS

To
the actuator
All'utilizzo

Distributore
Control
valve
Min

Max

PP

. The pressure PLS of the LS coming from the control

valve outlet passes into chamber a of the spring of
the LS valve. The pressure PP of the pump passes
into chamber b of the opposite side.
. The piston rod movement (4) is determined by the
combination of the force generated by the pressure
PLS, the force of the spring (6) and the force generated on the side opposite the piston rod by the
pressure PP.
. Before the engine is started the servo-piston (3) is
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 NEUTRAL position when the engine is started, the
pressure PLS of the LS will remain at 0 bar (0 bar)
because no oil is flowing through the control valve.

10-28

RKZ01150

At the same time the pump pressure PP increases

and is maintained at a value of about 21 bar (21.3
kg/cm2).
. For this reason the piston (4) is thrust to the right
(
) and a passage is formed between the delivery
lines c and d. This opening enables the pump pressure PP to enter chamber X of the servo-piston (3).
. Although the pump pressure PP is always passed
into chamber Y of the servo-piston (2), since the
force exerted by that pressure on piston (3) exceeds the force exerted on piston (2), the servo-piston (1) moves to the right (
), i.e. towards the side
of the minimum angle of the swash plate.

2. When a control valve lever is activated

b
PP

PLS

To
the actuator
All'utilizzo

Control
valve
Distributore

Min

Max

PP

. When the control valve lever is moved out of its

NEUTRAL position, the opening f is determined, allowing an LS signal to be generated.
. Until the DPLS generates a force less than the force
exerted by the spring (6) on the spool (4), the system will remain stable.
When the opening f is such as to provoke a reduction in DPLS, 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.

RKZ01160

. Equilibrium is re-established in the system when

the pressure DPLS generates on the spool (4) the
difference in force exerted by the spring (6), and
the passage between delivery lines c and d is reopened.

10-29

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

b
PP

PLS

To
the actuator
All'utilizzo

Distributore
Control
valve
Min

Max

PP

RKZ01160

. When the control lever is moved to full stroke, in

other words, when the spool opening reaches its
maximum, the difference between the pump pressure PP and the LS pressure PLS becomes smaller
(differential pressure DPLS).

. The pressurized oil present in the chamber X of the

servo-cylinder (3) flows through the lines d and e
and reaches the pump drainage chamber, so that
the pressure in chamber X of the servo-cylinder
(1) becomes equal to the drainage pressure.

. The LS pressure PLS introduced into the chamber a

of the LS valve becomes about the same as the
pump pressure PP and the piston (4) is moved to
the left (
) by the combined forces generated
by the pressure PLS and the spring (6).
The piston movement closes the delivery line c and
forms a passage between lines d and e.

. The servo-piston (3) is thus moved to the right (

)
by swash plate movement due to the pressure PP in
the chamber Y of the servo-cylinder (2).
In other words, it is drawn in the direction of the increase in angle of the swash plate.

10-30

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

b
PP

PLS

To the actuator
All'utilizzo

Distributore
Control valve
Min

Max

PP

. When the control valve lever moves in very small

increments towards the NEUTRAL position, i.e.
when the control valve opening f diminishes, the
differential pressure DPLS between the pump pressure PP and the LS pressure PLS increases.
. If the differential pressure DPLS generates on the
spool (4) a difference in force that exceeds the
force exerted by the spring (6), the spool moves
to the right (
) and a passage is formed between
the delivery lines c and d. The pressure PP is introduced into the chamber X and the swash plate
moves towards its minimum angle.
. When the control valve lever performs small movements towards the position of maximum opening,

Y
RKZ01170

i.e. when the opening f of the control valve increases, the differential pressure DPLS diminishes.
. If the differential pressure DPLS generates on the
spool (4) a force difference that does not exceed
the force exerted by the spring (6), the spool (4)
moves to the left (
) and a passage is formed between the delivery lines d and e.
The chamber X loses pressure and the servo-piston
provokes a movement of the swash plate towards
maximum displacement.
. Equilibrium is re-established in the system when
the pressure DPLS generates on the spool (4) the
difference in force exerted by the spring (6), and
hence the passage between delivery lines c and
d is also re-opened.

10-31

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

4
b

PP

PLS

All'utilizzo
To the actuator

Distributore
Control
valve

PEN

Hold
Fermo

A1

PP

3
PP

1
A2

. Let A1 be the surface of the servo-piston (3), A2 the

surface of the servo-piston (2), PEN the pressure
acting on the piston (1) and PP the pressure acting
on the piston side (2).
. When pump delivery reaches the quantity demanded by the control valve, the pump pressure
PP in chamber b of the LS valve is in equilibrium
with the combined forces of the LS pressure PLS
in chamber a, and the force exerted by the spring
(6).
Once equilibrium has been reached the piston (4)
stops in the central position.
. In this condition the passage from chamber c to
chamber d remains only slightly open in order to
maintain pressure in chamber d.

10-32

RKZ01180

A flow of oil is introduced into the servo-cylinder (3)

at a pressure that balances the force generated by
the pump pressure PP in the cylinder (2)
(PEN x A1=PP x A2).
. The stability of the equilibrium is guaranteed by a
flow stabilized by the throttle g.
. The force of the spring (6) is regulated so that the
piston (4) is in equilibrium when
PP PLS=DPLS=18 bar (18.4 kg/cm2).
. In practice, the pump flow is made proportional to
the section of the opening of the control valve,
which maintains the differential pressure
DPLS=18 bar (18.4 kg/cm2).

PC VALVE
. The PC valve performs an approximate power
check, and ensures that the hydraulic horse-power
absorbed by the pump does not exceed the horsepower delivered by the endothermal engine.
This is achieved by limiting the pump delivery Q in
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 increases simultaneously, the PC valve reduces the
pump delivery Q. When the delivery pressure PP
decreases, the PC valve increases the pump flow.

Portata amount
pompa Q
Pump discharge
Q

FUNCTION

Pump discharge pressure PP

Pressione pompa PP
RKP01180

. The relationships between the pump delivery pressure PP and the delivery Q are shown in the diagram.

10-33

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

PPC

d
3

4
PPC

PP

LS

PEN

To
the actuator
All'utilizzo

Control
valve
Distributore

1
PP
Min

Max

RKZ01190

. When a higher delivery is required, the LS valve receives a signal from the control valve to bring the
pump up to maximum displacement.
When the swash plate moves it also moves the
bushing (2) joined to it (by the pin (1)), which releases the spring (3). As the pressure of the actuators increases, pressure also increases in the delivery line c. When the calibrated setting of the spring
(3) is reached, the piston rod (4) is thrust to the left
(
) and the passage between chamber b and the
pump drainage chamber a is opened.
. The opening of the passage between the chambers

10-34

b and a generates a flow of oil and hence, due to

the calibrated hole (6), a DP is generated between
chambers f and g at the sides opposite the spool
(5). (DP=PP PPC)
. When the value of PP exceeds the value of the
spring loading (7) the spool (5) moves to the right
(
), opening the passage between the delivery
lines d and e and sending the pump pressure PP
towards the servo-cylinder (8).
. The pressure PP introduced into chamber X of the
cylinder (8) pushes it towards the minimum angle
of the swash plate (
).

2. When equilibrium has been reached

PPC

e
d
a

4
PPC

PP

LS

PEN

10

To
the actuator
All'utilizzo

Control
valve
Distributore

PP
Hold
Fermo

A1

A2

. When the piston (8) is pushed to the left (

) the
bushing (2) is also moved.
The oil flow between the chambers b and a is reduced and the PPC pressure tends to approach
the PP pressure value.
The DP decreases and the spool (5) is pushed to
the left (
) by the force of the spring (7).
. Equilibrium is reached when the force generated by
the PP pressure, the force generated by the PPC
pressure, and the force of the spring (7) are all balanced. (The force generated by PP=the force generated by the PPC+ the spring force (7)).

RKZ01200

. In this condition the passage from chamber d to

chamber e remains only slightly open in order to
maintain pressure in chamber e. A flow of oil is introduced into the cylinder (8) at a pressure that balances the force generated by the pump pressure
PP acting on the cylinder (9). (PEN x A1=PP x A2)
. The stability of this equilibrium is generated by a
continuous stabilized flow from the throttle (10).

10-35

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

5
c

PPC

e
d
a

4
PPC

PP

LS

PEN

To
the actuator
All'utilizzo

Control
valve
Distributore

PP
Hold
Fermo

9
. When the load on the actuators diminishes and the
pump delivery pressure PP drops, the PPC. pressure also drops.
. The reduction in the PPC causes the spool (4) to
move and the passage between chambers b, d
and a is closed.
The PPC pressure and the PP pressure of the pump
are equalised due to the interruption of the oil flow
through the calibrated hole (6) and hence the DP
becomes zero (DP=PP PPC=0).
. The spring (7) pushes the spool (5) to the left (
),
closing the passage between the chambers d and e
and opening the passage between chambers e and g.

10-36

RKZ01210

. The pressurized oil present in chamber X of the

servo-cylinder (8) passes through chambers e and
g and reaches the pump drainage chamber, so that
the pressure in chamber X of the servo-cylinder (7)
becomes equal to the drainage pressure.
. Therefore the servo-piston (7) is caused to move by
the PP pressure in chamber Y of the servo-cylinder
(9), i.e. in the direction of the increase in the angle
of the swash plate.

4. The function of the spring

11

4
PP

PLS

LS

To
the actuator
All'utilizzo

Control
valve
Distributore

RKZ01220

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

valve changes in proportion to the angle of inclination of the pump swash plate.

. When the piston (8) moves to the left (

) the
spring (3) is compressed.
If the piston (8) moves even further to the left (
),
the spring (11) comes into action to increase the
loading.
In other words, the overall loading of the springs is
varied by the piston (8), which either compresses or
releases them.
. The pump absorption torque curve, which indicates
the relationship between the pump delivery pressure PP and the delivery Q, is a broken line (as illustrated in the diagram).

Spring
(3)+spring
) + molla ((11)
Molla (3
11)
Portata amount
pompa Q
Pump discharge
Q

. The compression of the spring (3) varies with the

movements of the servo-piston (8).

(3)
Molla(3)
Spring

Pump discharge pressure PP

Pressione pompa PP
RKZ01240

10-37

. 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 increases, the delivery Q decreases, and as the pressure PP diminishes the pump delivery Q increases.

10-38

FUNCTION
. Calibration of the pump absorption torque is normally performed for the working mode E.
When the solenoid valve of the working mode is
commutated the absorbed power of the pump is increased, as indicated by the working mode curve.

Portataamount
pompaQQ
Pump discharge

WORKING MODE SOLENOID VALVE

Working mode P
Working mode E

Pump discharge
pressure
Pressione
pompaPPPP
RKZ01250

OPERATION
1. WORKING MODE E (Economy)

P1
2

a
5

RKZ01230

. During normal operation (Working mode E), the PC

valve intervenes when a DP1 is generated equal to
the loading on the spring (4).

. The DP1 is generated by the calibrated hole (3) in

the spool of the PC valve (2) when, at a determined
pump delivery pressure P1, the valve (1) puts the
delivery line a into discharge, thus generating a
flow F1 in the delivery line a.

10-39

2. WORKING MODE P (Power)

P2
2

RKZ01320

. When the solenoid valve (6) is commutated (Working Mode P) the pressurized oil coming from the
pump changes its route and passes through the
throttle (5), which has a larger diameter than the calibrated hole (3).
. Because the throttle (5) has a larger diameter, the
DP2 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 displacement and hence the delivery (See PC VALVE: 3.
When the load on the actuators decreases third
paragraph).

10-40

. The increase in flow causes an increment of the

DP2 which, when the loading value of the spring
is reached, allows the spool to shift to the right
(
).
. The pump starts to work in normal fashion once
again, and all the valves recommence normal functioning.

HYDRAULIC STEERING SYSTEM

240 bar

240 bar

DLS

175
bar

RKZ00830

a.
b.
c.
d.
e.

Port LS - From the shovel control valve

(Port DLS)
Port T - To the hydraulic oil tank
Port L - To the steering cylinder (Port a)
Port R - To the steering cylinder (Port b)
Port P - From the shovel control valve (Port D)

TECHNICAL DATA
Steering unit type: LAGCSDS160P
Displacement:
160 cc/kgm
OPERATION
. The steering unit is composed of a control valve
and a rotating oil dispenser, and is of the hydrostatic type.
. When the steering wheel is turned, the control
valve sends oil from the pump P2 (by means of
the rotating oil dispenser) to one of the sides of
the steering cylinder.
The rotating dispenser ensures that the volume of
oil supplied to the cylinder is proportionate to the
angle of rotation of the steering wheel.
. In the event of malfunction, the oil dispenser will
function automatically as a hand-pump, thus guaranteeing emergency steering.

10-41

10-42

HYDRAULIC CIRCUIT
Arm

R.H. outrigger

Boom swing

L.H. outrigger

Bucket

Boom

B6

B7

Jig arm

l/mn

Hammer

T1
T

M LS1

P2

B1

A1

B2

A2

B3

A3

B4

A4

B5

A5

A6

A7

B8

A8

21
bar

200 -50
bar

LS

160
bar

230
bar

230
bar

230
bar

230
bar

230
bar

300
bar

T2

240
bar

240
bar

DLS

X1

175
bar

X2

Arm
T

Additional
equipment

Bucket

LS

B1

DLS

A1

B2

A2

B3

A2

A3

b
b

B
P

5 bar

B
170
bar

A
230
bar

B
230
bar

230
bar

5 bar

L1

RKZ02870

10-43

SHOVEL CONTROL VALVE

2-Spool

A
c

d
e
f

h
D
1

3
4
5
6
B
Sezione A - A
Section A A

Sezione B
Section
B - B
B
RKZ01080

a.
b.
c.
d.
e.
f.
g.
h.

Port D - To the hydraulic steering unit (Port P)

Port A2 - To the bucket cylinders (Head side)
Port A1 - To the shovel-raising cylinders
(Base side)
Port LS - To the pump (Port X2)
Port T - To the hydraulic oil tank
Port P - From the pump (Port B)
Port B1 - To the shovel-raising cylinders
(Head side)
Port B2 - To the bucket cylinders (Base side)

10-44

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

Plug
Plug
Ball
Spring
Priority valve piston rod
Priority valve spring

2
6

5
E

Sezione C
C - C
Section
C

Sezione D
D
-D
Section
D

Sezione E
Section
E -EE

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

RKZ00660

Plug
Raising command spool
Spool return spring
Compensator
Antishock/anticavitation valve
Bucket dump command spool
Spring
Check valve

10-45

3-spool control valve

E
D
a

b c

A
d

e
f
g

i
D

3
4
5
6
B

Sezione A - A
Section A A

a.
b.
c.
d.

Port
Port
Port
Port

D
A3
A2
A1

e.
f.
g.
h.

Port
Port
Port
Port

LS
T
P
B1

i.
l.

Port B2 Port B3 -

10-46

To the hydraulic steering unit (Port P)

To the auxiliary equipment (Left side)
To the bucket cylinders (Head side)
To the shovel-raising cylinders
(Base side)
To the pump (Port X2)
To the hydraulic oil tank
From the pump (Port B)
To the shovel-raising cylinders
(Head side)
To the bucket cylinders (Base side)
To the auxiliary equipment
(Right side)

Sezione B - B
Section B B

1.
2.
3.
4.
5.
6.
7.

Plug
Plug
Ball
Spring
Priority valve piston rod
Priority valve spring
Plug

RKZ01070

5
F

10

Sezione D - D
Section D D

Sezione C - C

Section C C

11
8

12
13
12

13

Sezione F - F
Section F F

F
Sezione E - E
Section E E

1.
2.
3.
4.
5.
6.
7.

Plug
Raising command spool
Spool return spring
Spring
Ball
Ball
Compensator

RKZ00690

8.
9.
10.
11.
12.
13.

Antishock/anticavitation valve
Bucket dump command spool
Spool return spring
Optional equipment command spool
Spring
Check valve

10-47

3-spool control valve (with return to dig)

E
D
b

A
d

f
g

i
C
E

3
4
5
6
B

Sezione A - A
Section A A

a.
b.
c.
d.

Port
Port
Port
Port

D
A3
A2
A1

e.
f.
g.
h.

Port
Port
Port
Port

LS
T
P
B1

i.
l.

Port B2 Port B3 -

10-48

To the hydraulic steering unit (Port P)

To the auxiliary equipment (Left side)
To the bucket cylinders (Head side)
To the shovel-raising cylinders
(Base side)
To the pump (Port X2)
To the hydraulic oil tank
From the pump (Port B)
To the shovel-raising cylinders
(Head side)
To the bucket cylinders (Base side)
To the auxiliary equipment
(Right side)

Sezione B - B
Section B B

1.
2.
3.
4.
5.
6.
7.

Plug
Plug
Ball
Spring
Priority valve piston rod
Priority valve spring
Plug

RKZ01090

8
9

7
10

3
7
4
1

11

F
6

Sezione C
C - C
Section
C

12

Sezione D - D
Section D D

13

14

13

14

Sezione F - F
Section F F

Sezione E - E
Section E E

1.
2.
3.
4.
5.
6.
7.

Plug
Raising command spool
Spool return spring
Spring
Ball
Ball
Compensator

RKZ00940

8.
9.
10.
11.
12.
13.
14.

Antishock/anticavitation valve
Bucket dump command spool
Spool return spring
Coil
Optional equipment command spool
Spring
Check valve

10-49

BACKHOE CONTROL VALVE

6-spool

H
c

D
e

D
f

C
g

B
h

l
B

A
i

s
r

q
H

p
F

o
E

A
G

3
4

Sezione A
A
-A
Section
A

3
G
Sezione B - B
Section B B

a.
b.
c.
d.

Port
Port
Port
Port

e.

Port B3 -

f.

Port B4 -

g.
h.
i.

Port B5 Port B6 Port C -

10-50

P
T
B1
B2

From the pump (Port B)

To the hydraulic oil tank
To the arm cylinder (Base side)
To the arm LH swing cylinder
(Base side)
To the RH outrigger cylinder
(Base side)
To the LH outrigger cylinder
(Base side)
To the bucket cylinder (Base side)
To the boom cylinder (Head side)
To the backhoe backframe lock
cylinders

5
RKZ00230

l. Port A6 - To the boom cylinder (Base side)

m. Port A5 - To the bucket cylinder (Head side)
n. Port A4 - To the LH outrigger cylinder
(Head side)
o. Port A3 - To the RH outrigger cylinder
(Head side)
p. Port A2 - To the RH boom swing cylinder
(Base side)
q. Port A1 - To the arm cylinder (Head side)
r. Port T1 - To the hydraulic oil tank
s. Port LS - To the pump (Port X2)

G
3

G
7

10

11

6
6

Sezione C - C
Section C C

Sezione D - D
Section D D

G
Sezione E - E
Section E E

G
9

12

13

14

13

14

Sezione G - G

Section G G
RKZ00760

Sezione F - F
Section F F

1.
2.
3.
4.
5.
6.
7.

Ball
Backhoe backframe lock solenoid valve
Antishock/anticavitation valve
Boom command spool
Spool return spring
Compensator
Bucket command spool

8.
9.
10.
11.
12.
13.
14.

Anticavitation valve
Plug
Outrigger command spool
Boom swing command spool
Arm command spool
Spring
Check valve

10-51

4
Sezione H
H
-H
Section
H

1. Valve
2. Spring
3. Plug

10-52

5
SezioneLL-LL
Section

4. Pressure cut-out valve

5. Unloading valve

RKZ00790

10-53

7-spool control valve

For jig arm

A
a

b
RKZ00240

For side digging boom

For hammer

RKZ00250

C
e

C
RKZ00260

a.
b.
c.

Port B7 - To the jig arm cylinder (Base side)

Port A7 - To the jig arm cylinder (Head side)
Port B7 - To the side digging boom cylinder
(Base side)

10-54

d.
e.

Port A7 - To the side digging boom cylinder

(Head side)
Port B7 - To the hydraulic hammer (Left side)

Sezione A - A
Section A A

Sezione B
B - B
B
Section

6
Sezione C - C

Section C C

1.
2.
3.
4.

Anticavitation valve
Jig arm command spool
Spool return spring
Plug

5.
6.
7.
8.

RKZ00960

Compensator
Anti-shock/anticavitation valve
Side digging boom command spool
Hammer command spool

10-55

8-spool control valve

For hammer and jig arm

RKZ00270

For side digging boom and jig arm

a.
b.
c.
d.
e.

Port
Port
Port
Port

To the hydraulic hammer (L.H. side)

To the jig arm cylinder (Base side)
To the jig arm cylinder (Head side)
To the side digging boom cylinder
(Base side)
Port A7 - To the side digging boom cylinder
(Head side)

10-56

B7
B8
A8
B7

RKZ00280

CLSS
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 TCC valve and the LS valve.

Attrezzature
di lavoro
Attachment

PLS

Distributore
Control
valve

Valvola
TCC
TCC Valve

LS Valve
Valvola
LS

PP

Pistone di
Piston
controllo

Pistone di
Piston
controllo
RKZ01710

10-57

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 DPLS between the delivery pressure PP of the pump and the pressure PLS at the outlet of the control valve
towards the actuator is maintained at a constant value. (DPLS=pump delivery pressure PP pressure PLS of delivery to the actuator).
. If the differential pressure DPLS becomes lower than the set pressure of the LS valve, the angle of the swash
plate increases (delivery increasing).
If the differential pressure DPLS increases, the angle of the swash plate decreases.
H For details about this movement, see the description of the HYDRAULIC PUMP.

Attrezzatura
di lavoro
Attachment

Control valve
Distributore

Mandata
Pump pompa
delivery
Pistone
Piston di
posizionamento
Pistone di
posizionamento
Piston

PUMP
POMPA

TCC Valve
TCC
Valvola

Alta
High
pressure
pressione
LS Valve
Valvola
LS

Alta
High
pressure
pressione

RKZ01720

10-58

2. Pressure compensation control

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

Carico
Load

Load
Carico

Actuator

Actuator
Utilizzo

Utilizzo

Pressure
compensation
Compensatore
valve

Pressure
compensation

Compensatore
valve

S1

S2

PUMP
POMPA

RKZ01730

10-59

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
minimum angle position) is sent to the control valve.
In these conditions, the pump delivery pressure PP is regulated to 21 bar (21.4 kg/cm2) by the spring (2) inside
the valve.
(LS signal with pressure PLS=0 bar (0 kg/cm2))

PP

PLS

RKZ01740

OPERATION
When the control valve is in NEUTRAL position.
. On the two surfaces of the shuttle (1), the pump
pressure PP acts on the right-hand side, while the
LS signal with pressure PLS acts on the left-hand
side.
. Because no LS signal is generated with a pressure
PLS, when the control valve is in NEUTRAL position, only the pump delivery pressure PP regulated
by the compression of the spring (2), acts on the
shuttle (1).
. While the pump delivery pressure PP increases until it compensates for the loading on the spring (2)
(21 bar (21.4 kg/cm2)), the shuttle (1) moves to
the left (
) and the PP circuit is put into communication with the tank circuit T.

10-60

. This system ensures that the pump delivery pressure PP stays regulated at 21 bar (21.4 kg/cm2).

2. If, during the precision regulations of the control valve, the request for oil flow to the actuators in equal or less
than the delivery values given by the minimum angle of the swash plate, the pump delivery pressure PP is regulated by the pressure PLS+21 bar (21.4 kg/cm2).
Because the unloading valve opens when the differential pressure between the pump delivery pressure PP and
the PLS LS pressure becomes equivalent to the loading of the spring (2) (21 bar (21.4 kg/cm2)), the differential LS
pressure DPLS del LS becomes 21 bar (21.4 kg/cm2).

PP

PLS

RKZ01750

OPERATION
Final control of control valve
. When final control are performed with the control
valve, a pressure PLS is generated that pressurizing
the spring chamber, acts on the left-hand extremity
of the valve (1).
The actuator pressure is introduced into the LS circuit and then into the spring chamber.
As a result, the pump pressure PP tends to increase.

. The pump delivery pressure PP is regulated by the

combination of the pressure provided by the spring
(21 bar (21.4 kg/cm2)) and by the LS pressure PLS,
i.e. when the pressure differential DPLS reaches the
value of 21 bar (21.4 kg/cm2).

. When the differential pressure between the pump

delivery pressure PP and the LS pressure PLS has
the same value as the loading on the spring (2)
(21 bar (21.4 kg/cm2)), the shuttle (1) moves to
the left (
) and the pump circuit PP puts itself into
communication with the tank circuit T.
Consequently the exceeding pump delivery Q, relative to the actuator request, is sent to the tank circuit.

10-61

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.

PP

PLS

RKZ01760

OPERATION
When the control valve is in use
. When the control valve shuttle is operated to execute a bigger stroke, the opening section of spool
becomes bigger and consequently the controlled
delivery.
Because the control valve passage is large, the difference between the LS pressure PLS and the pump
delivery pressure PP is reduced up to 16 bar (16.3
kg/cm2) (LS pump valve setting).
. Because the differential pressure between the
pump delivery pressure PP and the LS pressure
PLS is not equal to the pressure given by the spring
loading (2) (21 bar (21.4 kg/cm2)), the shuttle (1) is
pushed to the right (
) of the spring (2).

10-62

. The result is that the connection between the pump

delivery circuit PP and the tank circuit T is excluded
and the entire pump delivery Q is sent to the actuators.

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.

To the
pump
Alla
pompa

PP

d
1
RKZ01780

OPERATION
. When the shuttle (1) is activated, the pump
pressure PP starts to flow into the actuator circuit A through the duct b.
. At the same time the compensator (2) moves
upwards ( ) so that the flow controlled by spool
(1) can flow towards the actuator A.
Check valve (4) do not allow any flow up to when
pressure in chamber c is higher than pressure
in chamber b.
Pressure downstream spool (1) flows in the PLS
circuit downstream the compensator valve
throught the orifice d.

. The system stabilizes when a pressure difference of 16 bar (16.3 kg/cm2) is generated
across the shuttle (1) between pump pressure
PP and PLS pressure.

. The PLS circuit of the LS is thus in communication with the tank circuit T by means of the LS
decompression valve (3). (See the description
of the LS decompression valve).

10-63

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 right is requesting higher pressure).

B
PB

PA

PLS

2
b

PBV

d
a
PAV

3
PP

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
(1) reaches the same value requested by actuator
B, no oil passes.
. When the pressure requested by actuator B is exceeded, movement can commence. This creates
a flow that adding to the one controlled by spool
(3) reduces the pressure upstream of spool (1)
and (3) and therefore the DP between PLS and PP.
. The pump compares the delivery pressures PP and
PLS and senses that the difference DP<16 bar
(16.3 kg/cm2). This variation in DP causes an increase in oil flow increasing the swash plate angle.
(For the detail see Hydraulic pump).

10-64

. Until the pump does not realize a DP of 16 bar (16.3

kg/cm2), i.e. until the increase in oil flow compensates the requirements of the two actuators, the
pump will continue to increase delivery.
. DP of 16 bar (16.3 kg/cm2) will stabilize as soon as it
is restored to.
. The compensator (2) is moved upwards by the oil
flow and stops when the aperture between the
chambers a and b reduces the passage sufficiently
to reduce the pressure in chamber a to be sent to
the actuator.

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

B
PB

PA

PLS

2
b

PBV

d
a
PAV

3
PP

RKZ02320

. If the actuator B needs to work at a higher pressure

(PB>PA), the pressure PB will start to increase.
. Since pressure PB is increasing, the compensator
(2) moves upwards to restore the DP between the
chambers a and b, and therefore the DP does not
vary upstream or downstream from the shuttle (1).
. When pressure PB exceeds pressure PA, the compensator (2) is fully open and the pressure PB is introduced into the LS circuit.
. The increase in pressure in the LS circuit obliges
the pump to increase delivery until the DP is restored to 16 bar (16.3 kg/cm2).

. Because the pressure PLS which is equal to the

pressure PB acts on the upper side of the compensator (4), and since the pressure PAV is lower, the
compensator (4) is pushed downwards.
. The compensator stops when the aperture between
the chambers c and d generates a reduction of the
passage sufficient to reduce the pressure to be
sent to the actuator, and to increase the pressure
PAV until the DP is restored to the 16 bar (16.3 kg/
cm2) necessary for equilibrium.

. Simultaneously the increase in pressure upstream

from the shuttle (3) generates an increase in DP upstream and downstream from the shuttle.
(PAV<PLS<PP)

10-65

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

B
PB

PA

PLS

2
b

PBV

d
a
PAV

3
PP

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 DP between 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
DP and increases the oil flow until the DP is restored
to DP of 16 bar (16.3 kg/cm2) between the two sides
of the shuttle (1) and the compensator (4) changes
position in order to restore the DP upstream and
downstream from the shuttle (3).

10-66

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.

1
PBV

PCV

PAV

2
RKZ02340

OPERATION
. When, during the simultaneous operation of more
than one actuator, one of them needs a higher
pressure and the characteristics of the pump are
exceeded, the pump guarantees a delivery limited
by its calibration curve.
. At this point less oil than requested is distributed to
all the actuators.
. Because the sections of the apertures remain unchanged, the pressure upstream and downstream
from the shuttles drops. Since the position of the
compensator (4) is determined by the pressure of
the LS signal, by the pressure PBV downstream
from the shuttle (3) and by the flow of oil needed
for the movement, the compensator is pushed
downwards by the higher pressure in the upper
chamber until the pressure PBV downstream from
the shuttle becomes equal to the pressure PAV
downstream from the shuttle (1). This equalizes
the pressure DP of the shuttle (1).

. Thus the flow of each actuator is reduced by a percentage equal to the reduction or absence of pump
delivery.
. In other words, when the request for performance is
excessive, the system can nevertheless guarantee
proportionality and graduality for the movements in
any load conditions.
. If an increase in delivery is requested, rather than
an increase in pressure, and the characteristics of
the pump are exceeded, the system will function
in the same way as described for the above case.

10-67

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.

Q ( / min)

1,3

0,8
0

20

RKZ02350

250

P (bar)
RKZ02360

OPERATION
. When the LS pressure reaches chamber a of the
valve, it generates a force that opposes the force
of the spring (2).
. Until the force generated by the LS pressure exceeds the force of the spring (2) (LS pressure low)
the shuttle (1) remains at rest and oil flows
through the calibrated orifice a in the tank circuit.
. When the force generated by the LS pressure exceeds the force of the spring (2), the shuttle is
pushed upwards ( ) and the passages c are
closed.
Oil continues to flow into the chamber d until the
force generated by the pressure contained in
chamber d, together with the force of the spring
(2), exceeds the force generated by the LS pressure.

10-68

. The shuttle is pushed downwards (

c is opened.

) and passage

. The system is in equilibrium (i.e. the shuttle is at

rest), when the quantity of oil allowed to flow into
the tank circuit is equivalent to the quantity that
generates a pressure difference DP such that
(PLSxS)=[(PLS1xS)+F] where:
PLS= LS pressure
PLS1= LS pressure contained in chamber d
S= section of the shuttle
F= force of the spring.

8. PRESSURE CUT-OFF VALVE

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

1
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 between the chamber a and the tank circuit.

10-69

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.

LS

DLS

ToAgli
the actuator
utilizzi
RKZ02370

10-70

SOLENOID VALVE
Solenoid valve block ST1
Differential locking - backhoe boom locking

d
a
b

RKZ00650

1.
2.
a.
b.
c.
d.

Solenoid.... - Backhoe boom locking

Solenoid.... - Differential locking
Port
Port
Port
Port

T12P-

To the transmission
Boom-locking cylinder
To the rear axle
From the transmission

10-71

SAFETY VALVE

A
b

Shovel raise
a. Port Y - to the raising cylinders (Head side)
b. Port A - From the shovel control valve (Port A1)
c. Port X - To the raising cylinders (Base side)
d. Port B - From the shovel control valve (Port B1)
Bucket Dump
a. Port Y - To the dump cylinders (Head side)
b. Port A - From the shovel control valve (Port B2)
c. Port X - To the dump cylinders (Base side)
d. Port B - From the shovel control valve (Port A2)
Boom
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)

10-72

RKZ00850

Arm
a. Port Y - To the arm cylinder (Head side)
b. Port A - From the backhoe control valve
(Port B1)
c. Port X - To the arm cylinder (Base side)
d. Port B - From the backhoe control valve
(Port A1)
CHARACTERISTICS
Safety valve calibration
Shovel dump:
Boom:
Arm:

230 bar
350 bar
230 bar

H The drawing represents the boom safety valve

7
15

14

13

12

11

10

Sezione A - A
Section A A

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

Plug
Check valve spring
Check valve
Check valve spring
Check valve
Plug
Protection
Over-ride screw (Safety)

9.
10.
11.
12.
13.
14.
15.

RKZ01050

Spool
Safety valve spring
Safety valve
Spool
Spring
Housing
Plug

10-73

BRAKE PUMP

7
8
17

16

15 14 13 12 11

10

9
RKZ00930

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

Pump body
Main piston
Seal
Differential piston
Spring
Pump spring
Spring
Check valve
Ball
Seal
Pin
Seal
Seal
Seal
Ball
Spring
Seal

10-74

CHARACTERISTICS:
Stroke:
Displacement:
Max. pressure:

36 mm
15 28 cc
150 bar

SHOVEL CYLINDERS
RAISING CYLINDER

7
8

RKZ00310

DUMPING CYLINDER

7
8

RKZ00300

1. Bushing, base side

2. Cylinder
3. Nut

4. Piston seal
5. Piston
6. Piston rod

7. Cylinder
8. Bushing, head side

CHARACTERISTICS
Cylinder

Raising

Dumping

Piston rod diameter

50

50

Internal cylinder diameter

85

85

Piston stroke

730

755

Max. cylinder length

1880

2145

Min. cylinder length

1150

1390

Key size for piston

safety nut

55

55

10-75

BACKHOE CYLINDERS
BOOM

7
9

8
1

11
1.
2.
3.
4.

5.
6.
7.
8.

Head bushing, piston rod side

Piston rod
Cylinder head
Cylinder

Piston
Piston ring
Guide ring
Cushion plunger

10

RKZ00200

9. Bottom bushing
10. Dowel bolt
11. Ball-bearings (9)

ARM

3
1

10

RKZ00220

1.
2.
3.
4.

Head bushing
Piston rod
Cylinder head
Cylinder

5.
6.
7.
8.

Bushing
Piston ring
Guide ring
Piston

9. Nut
10. Bottom bushing

BUCKET

RKZ00290

1. Head bushing
2. Piston rod
3. Cylinder head

10-76

4. Cylinder
5. Piston
6. Piston ring

7. Guide ring
8. Nut
9. Bottom bushing

OUTRIGGERS

RKZ00410

7. Piston
8. Nut

4. Spacer
5. Piston ring
6. Guide ring

1. Piston rod
2. Cylinder head
3. Cylinder

BOOM SWING

5
1

6
7

12

11 10

9 8
RKZ00360

1.
2.
3.
4.

Retaining ring
Throttling ring
Piston rod
Cylinder

5.
6.
7.
8.

Swing bushing
Cylinder head
Head bushing
Piston

9.
10.
11.
12.

Guide ring
Piston ring
Spacer
Cushion plunger

ARM (for side digging boom)

2
3

11
1.
2.
3.
4.

Head bushing
Cylinder head
Throttling ring
Piston ring

10
5.
6.
7.
8.

Guide ring
Nut
Bearing
Piston

RKZ00210

9. Piston
10. Piston rod
11. Cylinder

10-77

SIDE DIGGING BOOM

8 9

11
1.
2.
3.
4.

5.
6.
7.
8.

Head bushing
Piston rod
Ring nut
Gasket

10

RKZ00390

Cylinder head
Cylinder
Piston ring
Ring

9. Nut
10. Bottom bushing
11. Spacer

JIG ARM

5 6

RKZ00320

1. Piston rod
2 Cylinder head
3. Cylinder

10-78

4. Piston
5. Piston ring
6. Guide ring

7. Nut

CHARACTERISTICS
Arm
Cylinder

Boom

Standard

With side
digging boom

Bucket

Piston rod diameter

55

60

60

60

Internal Cylinder diameter

115

110

110

95

Piston stroke

849

920

910

765

Max. cylinder length

2049

2175

2170

1850

Min. cylinder length

1200

1255

1260

1085

Key size for piston

safety nut

65

55

55

55

Outriggers

Boom swing

Side digging boom

Jig arm

Piston rod diameter

40

50

45

40

Internal Cylinder diameter

80

100

85

70

Piston stroke

635

230

365

1140

Max. cylinder length

1690

319

830

2590

Min. cylinder length

1055

89

565

1450

Key size for piston

safety nut

46

46

46

CHARACTERISTICS
Cylinder

10-79

10-80

TESTING AND ADJUSTMENTS

Normal or standard technical data . . . . .. . . . . .. . . . .. . . 2

Special tools . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 30
Measuring engine speed . . . . .. . . . . .. . . . .. . . . . .. . . . .. . 31
Adjusting valve clearance . . . .. . . . . .. . . . .. . . . . .. . . . .. . 32
Measuring compression pressure .. . . . .. . . . . .. . . . .. . 33
Testing and adjusting fuel injection timing . .. . . . .. . 34
Checking and tightening the fan - belt .. . . . . .. . . . .. . 36
Measuring accelerator pedal operating
travel and accelerator lever . .. . . . . .. . . . .. . . . . .. . . . .. . 37
Adjusting brake pedal travel, brake alignment,
microswitches .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 39
Air bleeding - releasing residual pressure . . .. . . . .. . 40
Checking and setting pressure in the attachments
hydraulic circuit . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 43

Testing and adjusting of load sensing signal

(LS valve) . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 49
Checking unloading valve functionality . . . .. . . . .. . . . 50
Testing pump delivery . . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 51
Testing priority valve operation .. . . . . .. . . . . .. . . . .. . . . 53
Testing and setting steering control
system pressure . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 54
Testing brake system .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 55
Control of the engine speed under load . . . . . . . .. . . . 57
Testing pressures in the power train group. . . . .. . . . 59
Testing the correct functioning of the
power train clutches. . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 61
Adjusting the sensor for return to dig device . . . . . . . 62
Analysis of causes hydraulic drift . . . . .. . . . . .. . . . .. . . . 63

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 undergoing 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).

20-1

NORMAL OR STANDARD TECHNICAL DATA

. FOR ENGINE

Check item

Machine model

WB91R-2

Engine

4D106-1FA

Test conditions

Unit

Standard
value

Permissible
value

rpm
rpm
rpm

2375w50
1050w50
2200

2375 2425
1000 1100

Engine speed

High idling
Low idling
Set speed

Exhaust gas
colour

Sudden acceleration
At high idling speed

Bosch
index

0.9
0.5

1.2
0.8

Valve clearance

Intake valve (20C)

Exhaust valve (20C)

mm
mm

0.20w0.05
0.20w0.05

Max. 0.25
Max. 0.25

Compression
pressure
(SAE30 oil)

Oil temperature 69 72C

(Engine speed)

kg/cm2
rpm

35w1
250

28w1
250

Blow - by
pressure
(oil SAE30)

Water temperature in operating range

At high idling speed

mm H2O

Engine oil
pressure

Max. idling (in cold state)

At set speed
At low idling

kg/cm2
kg/cm2
kg/cm2

Max. 6
4.5
1

Max. 6
45
Min. 1

Oil temperature

Entire speed range

120

Max. 120

Fuel injection
timing

B.T.D.C.

degrees

12.5

11.5 13.5

Fan belt
tension

Deflection when pressed with finge force

of approx. 10 kg

mm

10

10 15

20-2

. FOR ENGINE
WB93R-2
S4D106-1FA
Standard
value

Permissible
value

2375w50
1050w50
2200

2375 2425
1000 1100

0.9
0.5

1.5
1.0

0.3w0.5
0.3w0.5

Max. 0.35
Max. 0.35

35w1
250

28w1
250

Max. 6
4.5
1

Max. 6
45
Min. 1

120

Max. 120

12.5

11.5 13.5

10

10 15

20-3

. FOR MACHINE
Machine model
Classification

Check item

Engine speed

.
.

.
Accelerator fuel

.
.

Hydraulic oil temperature:

45 55 C.
Converter oil temperature:
80 C
Engine oil temperature
cooling circuit:
in the limits.

Permissible
value

Max.

2375w50

2325 2425

Min.

1050w50

1000 1100

Max.

1900w50

1850 1950

Min.

1050w50

1000 1100

Unit

rpm

Hydraulic oil temperature:

45 55 C.
Converter oil temperature:
80 C
Engine oil temperature
cooling circuit:
in the limits.

All controls
(front bucket and
backhoe)

Control valve

Standard
value

Test conditions
.

Accelerator pedal

WB91R-2

For front shovel arm

command only
(with floating arm)

Front bucket control

lever

Front bucket control

lever

Travel of levers and pedals

.
.

20-4

Engine stopped
At the centre
of knob lever
Valve reading
at the end of
working stroke
Attachments
on the ground

41.5 8

41.5 8

mm

Front bucket tilt lever

control

Neutral

Raise
Lower

80

60 110

Neutral

Dump
Curled

115

90 140

Neutral

Raise
Lower

100

80 120

Arm backhoe control

lever

Neutral

Opening
Closing

100

80 120

Bucket backhoe
control lever

Neutral

Opening
Closing

100

80 120

Boom swing backhoe

control lever

Neutral

Right
Left

100

80 120

Outriggers control
lever

Neutral

Up
Down

50

35 65

Fuel control lever

Min.

Max.

70

50 90

Jig arm control

pedal

Neutral

Out
In

15
30

10 20
20 40

Hammer and side digging

boom control pedal

Neutral

Right
Left

15
30

10 20
20 40

mm

. FOR MACHINE
WB93R-2
Standard
value

Permissible
value

2375w50

2325 2425

1050w50

1000 1100

1900w50

1850 1950

1050w50

<

1000 1100

<

41.5 8

41.5 8

80

60 110

115

90 140

100

80 120

100

80 120

100

80 120

100

80 120

50

35 65

70

50 90

15
30

10 20
20 40

15
30

10 20
20 40

20-5

. FOR MACHINE
Machine model

Force for levers and pedals operation

Travel of levers and

pedals

Classification

20-6

WB91R-2
Unit

Standard
value

Permissible
value

Max.

mm

80

60 100

Right
Left

rev.

Max. 2.5

2.2 2.5

Front bucket tilt lever

control

2.5

23

Front bucket control

lever

2.5

23

Boom control
lever

1.5

12

1.5

12

1.5

12

1.5

12

2.5 3.5

12

10 14

4
8

34
6 10

Hammer and side digging

boom control pedal

6 10

Accelerator pedal

24

Brake pedal

30

Max. 60

Check item

Test conditions
.

Accelerator pedal

.
.

Wheel swing

Arm control
lever

.
.
.

Bucket control lever

Boom swing
control lever

Engine
stopped
Min.
At the centre
of knob lever
Valve reading
at the end of
working stroke Right
Attachments
Left
on the ground

Engine speed: max.

Oil temperature: 45 55C
Tool connection at the centre of knob
(for levers)
Tool connection on edge
(for pedals)

kg

Outriggers control
lever
Fuel control
lever
Jig arm control
pedal

In
Out

. FOR MACHINE
WB93R-2
Standard
value

Permissible
value

80

60 100

Max. 2.5

2.2 2.5

2.5

23

2.5

23

1.5

12

1.5

12

1.5

12

1.5

12

2.5 3.5

12

10 14

4
8

34
6 10

6 10

24

30

Max. 60

20-7

. FOR MACHINE
Machine model

Pressures of secondary valves circuits

Main valve
pressure

Classification

20-8

WB91R-2
Standard
value

Permissible
value

185

185w7

185

185w7

240

240w7

Front bucket
(curled) ]

230

230w7

Front bucket (dump)

170

170w7

Boom (raising) ]

300

300w7

230

230w7

230

230w7

240

240w7

230

230w7

Side digging boom

(right-left)

270

270w7

Hammer (delivery)

160

160w7

Steering unit

175

175w7

Check item
2-3-Spool control valve
6-7-8-Spool control valve
Steering unit (safety)

Boom (lowering)
Arm (Closing)
Boom swing
Bucket (curled)

Test conditions
.
.

Engine speed: max.

Oil temperature: 45 55C

Check on test bench

.
.
.

Engine speed: max.

Oil temperature: 45 55C
Check one circuit at the time

Check on test bench

Unit

bar

bar

. FOR MACHINE
WB93R-2
Standard
value

Permissible
value

185

185w7

185

185w7

240

240w7

230

230w7

170

170w7

300

300w7

230

230w7

230

230w7

240

240w7

230

230w7

270

270w7

160

160w7

175

175w7

20-9

. FOR MACHINE
Machine model

Engine speed (with load)

Converter

Classification

Check item

Test conditions

WB91R-2
Unit

Standard
value

Permissible
value

With converter

.
.
.
.
.

Engine speed (without load): 2375w50

Hydraulic oil temperature: 45 55C
Converter oil temperature: 80C
Machine in 4th gear
Working brakes applied

2100w50

2050 2150

With converter and

hydraulic circuit

.
.
.
.
.
.
.

Engine speed: 2375w50

Hydraulic oil temperature: 45 55C
Converter oil temperature: 80C
Machine in 4th gear
Working brakes applied
Front bucket curled stop
Steering stop

2000w50

1950 2050

With converter
(TBG version)

.
.
.
.
.

Engine speed: 2375w50

Hydraulic oil temperature: 45 55 C
Converter oil temperature: 80 C
Machine in 3rd gear
Working brakes applied

2125w50

2075 2175

With converter and

hydraulic circuit
(TBG version)

.
.
.
.
.
.

Engine speed (without load): 2375w50

Hydraulic oil temperature: 45 55 C
Converter oil temperature: 80 C
Machine in 3rd gear
Working brakes applied
Front bucket curled stop

2100w50

2050 2150

20-10

rpm

. FOR MACHINE
WB93R-2
Standard
value

Permissible
value

2275w50

2225 2525

2200w50

2150 2250

2200w50

2150 2250

2200w50

2150 2250

20-11

. FOR MACHINE
Machine model
Classification

Check item

WB91R-2

Test conditions

Unit

Standard
value

Permissible
value

250

400

30

45

15

25

300

450

35

50

15

25

10

15

Measuring posture

Hydraulic drift working equipment

Front bucket

Complete working
equipment
(Tip lowering of
bucket teeth)

~10

RKZ00530

Cylinders
(cylinder in)

Bucket cylinder
(cylinder in)

mm
.
.
.
.
.
.
.

Backhoe

Complete working
equipment
(Tip lowering of
bucket teeth)

Measuring posture

Boom cylinders
(cylinder out)

1m
RKZ00420

mm
.
Arm cylinder
(cylinder out)

Bucket cylinder
(Cylinder in)

20-12

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)
Engine stopped
Oil temperature: 45 55C
Check measures as soon as engine
stops.
Check changes every 5 min. and the total
change in 15 min.

.
.
.
.
.
.

In this position check the extension of

each cylinder and the leakage with normal load on the bucket.
On level ground.
Bucket : normal load (450 kg)
Engine stopped
Oil temperature: 45 55C
Check measures as soon as engine
stops.
Check changes every 5 min. and the total
change in 15 min.

. FOR MACHINE
WB93R-2
Standard
value

Permissible
value

250

400

30

45

15

25

300

450

35

50

15

25

10

15

20-13

. FOR MACHINE
Machine model
Classification

Check item

WB91R-2

Test conditions

Unit

RKZ02670

Boom swing
.
.

.
.
Backhoe

Hydraulic drift working equipment

Oil temperature: 45 55 C
Backhoe balanced on the guides bucket
in transport condition.
Arm and bucket cylinder in. Put the bucket link pin at 1 meter from ground and
swing at end of boom stroke in one of
the two direction.
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.
Make the test for each swing direction.

Outriggers
Max
RKZ00490

.
.
.
.
.
.

20-14

Oil temperature: 45 55C

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.

Standard
value

Permissible
value

15

25

15

25

mm

. FOR MACHINE
WB93R-2
Standard
value

Permissible
value

15

25

15

25

20-15

. FOR MACHINE
Machine model
Classification

Permissible
value

Boom

2.0
(each cylinder)

Max. 8.0

Bucket

1.6
(each cylinder)

Max. 6.0

Boom

3.3

Max. 13.5

3.0

Max. 12.0

2.4

Max. 9.5

3.2

Max. 13.0

Outriggers

3.3

Max. 13.5

Side digging

2.0

Max. 8.0

Jig arm

1.6

Max. 6.0

Front bucket

Arm
Bucket
Backhoe

Cylinder leaking

Standard
value

Check item

20-16

WB91R-2

Boom swing

Test conditions

.
.
.
H
H

Engine: Max. speed

Oil temperature: 45 55C
Leaking check: on the cylinder opposite
side to the pressure one.
Check 1 cylinder at a time.
For tilt front bucket, front bucket and for
swing, check the two cylinders separately.

Unit

mm

. FOR MACHINE
WB93R-2
Standard
value

Permissible
value

2.0
(each cylinder)

Max. 8.0

1.6
(each cylinder)

Max. 6.0

3.3

Max. 13.5

3.0

Max. 12.0

2.4

Max. 9.5

3.2

Max. 13.0

3.3

Max. 13.5

2.0

Max. 8.0

1.6

Max. 6.0

20-17

. FOR MACHINE

Standard
value

Permissible
value

Raised

3.9

3.3 4.5

Lowered

2.6

2.2 3.0

Curled

2.6

2.2 3.0

Dump

3.5

3.0 4.0

Raised

2.6

2.2 3.0

Lowered

1.9

1.6 2.2

Closing

4.5

3.9 5.1

Opening

Check item

3.6

3.1 4.1

Curled

Classification

WB91R-2

3.1

2.7 3.5

Dump

Machine model

2.6

2.2 3.0

Test conditions

Unit

Measuring posture
Tilt lever front
bucket

Front bucket

Bucket on level ground

Cylinders extended out .

.

RKZ00500

Engine speed: Max.

Oil temperature: 45 55C

Measuring posture
Arm
Cylinder in

RKZ00510

Cylinder out

.
.

Engine speed: Max.

Oil temperature: 45 55C

Measuring posture
Work equipment speed

Boom
Teeth bucket on level
ground

sec.
RKZ00430

Cylinder in

.
.
.

Engine speed: Max.

Oil temperature: 45 55C
Backhoe balanced

Measuring posture

Backhoe

Arm
Cylinder in

Cylinder out

.
.
.

RKZ00440

Engine speed: Max.

Oil temperature: 45 55C
Backhoe balanced

Measuring posture
Bucket
Cylinder in

RKZ00450

Cylinder out

20-18

.
.
.

Engine speed: Max.

Oil temperature: 45 55C
Backhoe balanced

. FOR MACHINE
WB93R-2
Standard
value

Permissible
value

3.9

3.3 4.5

2.6

2.2 3.0

2.6

2.2 3.0

3.5

3.0 4.0

2.6

2.2 3.0

1.9

1.6 2.2

4.5

3.9 5.1

3.6

3.1 4.1

3.1

2.7 3.5

2.6

2.2 3.0

20-19

. FOR MACHINE

Check item

Standard
value

Permissible
value

4.5

3.9 5.1

4.5

3.9 5.1

Lifting

Classification

WB91R-2

1.8 2.2

Lowering

Machine model

1.8 2.2

Test conditions

Unit

Right

Measuring posture
Boom swing

.
.
.

Backhoe

Work equipment speed

Right end travel

RKZ02570

Engine speed: Max.

Oil temperature: 45 55C
Arm vertical

Left

Left end travel

sec.

Measuring posture

Outriggers
All extended
RKZ00520

All raised

20-20

.
.
.
.
.
.

Engine speed: Max.

Oil temperature: 45 55C
Backhoe balanced
Dowel joint locking: applied
Rear wheels raised
Outriggers at maximum extension

. FOR MACHINE
WB93R-2
Standard
value

Permissible
value

4.5

3.9 5.1

4.5

3.9 5.1

1.8 2.2

1.8 2.2

20-21

. FOR MACHINE
Machine model
Classification

Check item

WB91R-2

Test conditions

Unit

Standard
value

Permissible
value

Max. 2

Max. 2

Max. 2

Measuring posture

Tilt lever front

bucket
RKZ00500

.
.
.

Engine speed: Min.

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

Time lags

Work equipment

Measuring posture

Boom

sec.
RKZ00460

.
.
.

Engine speed: Min.

Oil temperature: 45 55C
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

.
.
.

20-22

RKZ00470

Engine speed: Min.

Oil temperature: 45 55C
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.

. FOR MACHINE
WB93R-2
Standard
value

Permissible
value

Max. 2

Max. 2

Max. 2

20-23

. FOR MACHINE
Machine model
Classification

Check item

WB91R-2

Test conditions

Unit

Standard
value

Permissible
value

Max. 2

Max. 2

Measuring posture

Bucket

RKZ00480

Time lags

Work equipment

.
.
.

Engine speed: Min.

Oil temperature: 45 55C
Put arm in horizontal position. Tilt back
bucket cylinder an then extend it.
Check the time passing between bucket
stop at dead centre and the restart movement.

sec.

Measuring posture

Outriggers
.
.
.
.
H

20-24

RKZ00520

Engine speed: Min.

Oil temperature: 45 55C
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.

. FOR MACHINE
WB93R-2
Standard
value

Permissible
value

Max. 2

Max. 2

20-25

Machine model

Piston pump P1 delivery.

Working mode: Economy.
Pump speed: 2200 rpm
Hydraulic oil temperature: 45 55C.

P(bar)
(kg/cm2)

Classifi- .
cation
.
.
.

WB91R-2

294
(300)

245
(250)

221 bar
....... /min

223,5
(228)

196
(200)
221 bar
....... /min

Pumps characteristics

Max. delivery
Portata
massima
(teorica)
(theoretical)
147
(150)
........ bar
....... /min

98
(100)

Delivery
Portata minima
ammessa
(lower
limit)
........ bar
....... /min

49
(50)

50

100

151,6
150

163
Q (/min)
RKZ02590

H When measuring deliveries with the pump mounted on the machine, it becomes difficult to use the
accelerator to set the number of engine rpm corresponding to the test speed prescribed for the pump.
Measure the delivery with the engine set to .... rpm, and perform a proportional calculation to find the
delivery value required for the test.

20-26

Machine model

Piston pump P1 delivery.

Working mode: Power
Pump speed: 2200 rpm
Hydraulic oil temperature: 45 55C.

P(bar)
(kg/cm2)

Classifi- .
cation
.
.
.

WB91R-2

294
(300)

221 bar
....... /min

245
(250)

216,6
(221)

........ bar
....... /min

196
(200)

........ bar
....... /min

147
(150)

98
(100)

Max.
delivery
Portata
minima
ammessa
(theoretical)
49
(50)
Portata massima
Delivery
(teorica)
(lower limit)

Pumps characteristics

221 bar
....... /min

50

151,6
150

100

163
Q (/min)
RKZ02600

H When measuring deliveries with the pump mounted on the machine, it becomes difficult to use the
accelerator to set the number of engine rpm corresponding to the test speed prescribed for the pump.
Measure the delivery with the engine set to .....rpm, and perform a proportional calculation to find the
delivery value required for the test.

20-27

Machine model

WB93R-2

Piston pump P1 delivery.

Working mode: Economy.
Pump speed: 2200 rpm
Hydraulic oil temperature: 45 55C.

P(bar)
(kg/cm2)

Classifi- .
cation
.
.
.

294
(300)

221 bar
....... /min

245
(250)
223,5
(228)

Max. delivery
Portata
massima
(theoretical)
(teorica)

196
(200)

Pumps characteristics

221 bar
....... /min

........ bar
....... /min

147
(150)

Delivery
Portata
minima
(lower limit)
ammessa
98
(100)

........ bar
....... /min

49
(50)

50

100

151,6
150

163
Q (/min)
RKZ02610

H When measuring deliveries with the pump mounted on the machine, it becomes difficult to use the
accelerator to set the number of engine rpm corresponding to the test speed prescribed for the pump.
Measure the delivery with the engine set to .....rpm, and perform a proportional calculation to find the
delivery value required for the test.

20-28

Machine model

WB93R-2

Piston pump P1 delivery.

Working mode: Power
Pump speed: 2200 rpm
Hydraulic oil temperature: 45 55C.

P(bar)
(kg/cm2)

Classifi- .
cation
.
.
.

294
(300)

245
(250)

........ bar
....... /min

216,6
(221)
196
(200)

Pumps characteristics

221 bar
....... /min

147
(150)

........ bar
....... /min

98
(100)

Max. delivery
Portata
minima
(theoretical)
ammessa
49
(50)
Portata massima
Delivery
(teorica)
(lower limit)

50

100

151,6
150

163
Q (/min)
RKZ02620

H When measuring deliveries with the pump mounted on the machine, it becomes difficult to use the
accelerator to set the number of engine rpm corresponding to the test speed prescribed for the pump.
Measure the delivery with the engine set to .....rpm, and perform a proportional calculation to find the
delivery value required for the test.

20-29

TESTING AND ADJUSTMENTS

SPECIAL TOOLS

SPECIAL TOOLS
Measurement check point

Symbol

Valve clearance

Compression pressure

Engine speed

Oil and water temperature

E
Hydraulic pressure

F
G
Braking group

Hand brake

20-30

Q.ty

Note

Feeler gauge

Compression gauge

Adapter

Multiscale tachometer

20 - 4000 rpm

Stroboscopic tachometer

6 - 30000 rpm

Digital thermometer

50 - 1200 C

Pressure gauge

Full scale 60 bar

Pressure gauge

Full scale 250 bar

Pressure gauge

Full scale 400 bar

Pressure gauge

Full scale 600 bar

Servocontrol kit
Differential pressure
gauge

Digital pressure gauge

0 ......

Flow-meter

Delivery: ...... ......

Pipe fitting kit

Tank cap

Tool to check
leaktightness of brakes

Union kit

Spring dynamometer

Code
Commercially
available

Commercially
available

Commercially
available

Name

0-60 kg/cm2

Pump air bleeding

Full scale 20 kg

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.

H Check speed when following condition are reached:

. Engine water cooling temperature: 68 80C.
. Hydraulic oil temperature: 45 55C.
1 - Remove the air filter (1) and release the heating lines
from the hose-clamp (2).

2 - Install and connect C1 tachometer.

H If using C2 stroboscopic tachometer, mark a light
notch on, engine pulley for an easier reading.
3 - Start engine and check:
. Low idling speed without load (accelerator pedal
released in minimum position).
. High idling speed without load (accelerator pedal
at the travel end).
H Low idling speed: 1050w50 rpm
H High idling speed: 2375w50 rpm
H 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 ACCELERATOR LEVER ADJUSTING).

RKZA5290

C1

RKZA5300

20-31

TESTING AND ADJUSTMENTS

ADJUSTING VALVE CLEARANCE

ADJUSTING VALVE CLEARANCE

H Engine: in cold state.
H Adjust clearance between valves and rocker levers as
follows:

Unit: mm

Engine
At cold
engine

Intake-exhaust

4D106-1FA

0.20w0.05

S4D106-1FA

0.30w0.05

2
3

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

H Normal rotation sense: counterclockwise from flywheel
H The cylinder N 1 is on the opposite fan side.
.

RKZA5310

Adjusting procedure

1 - Remove air cleaner (1), intake manifold (2) and

valves cover (3).

2 - Rotate crankshaft in normal direction as long as

cylinder piston to be checked is at compression
Top Dead Center (PMS).
H In this position intake and exhaust valves are
closed.
3 - Loose lock nut (4) and unscrew tappet (5) of about
1 turn.
H Check that valve insert (6) is laying flat on
valve stem and that it is not worn askew.
1 - If valve inserts (6) are damaged, replaced
them with new ones.
2 - Make sure that inserts feet and lay flat on
valve stem.

YES
SI

RKZ01910

NO
NO

4 - Connect A1 feeler gauge between insert and rocker lever to adjust; rotate the tappet (5) until touching A1 feeler gauge.
Tight tappet (5) with lock nut (4).
Nut: 14.7 19.6 Nm
H After tightening the lock nut, check the clearance again.

A1

5 - Adjust with same procedures second cylinder

valve and repeat same operation for the other cylinders, according to the firing order.
.

RKZ01920

Cover valves installation

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

9
8

2 - Install valves cover (3), fit O-Rings (8) and lock

nuts (9).
Cover lock nut: 25w3 Nm

7
RKZ01930

20-32

TESTING AND ADJUSTMENTS

MEASURING COMPRESSION PRESSURE

MEASURING COMPRESSION PRESSURE

.
.

When measuring the compression pressure be

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

H Test condition:
. Engine: at operating temperature
. Hydraulic oil: 55 60 C.
. Battery: at full charge
. Valve clearance:
adjusted (see ADJUSTING VALVE)

RKZA5320

1 - Disconnect high pressure pipe (1).

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.

RKZA5330

5 - Install B2 adapter and connect B1 pressure gauge

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

7 - After measuring, install the nozzle holder assembly

(2), connect high pressure pipe, feedback pipe and
connector (3).
Nozzle holder collar bolts: 9.8 11.8 Nm
High pressure union: 19.6 24.5 Nm

B2

RKZA5340

Pressione
di compressione
Compression
pressure
(kg/cm2)

6 - Crank engine with starting motor and measure compression pressure.

H Measure the compression pressure at the point
where the pressure gauge indicator remains steady.
H When measuring the compression pressure,
check also engine speed with C2 stroboscopic
tachometer; if speed is not within the specified
range, refer to diagram.
H Compression value:
Normal: 35w1 kg/cm2 a 250 rpm
Minimum permissible: 28w1 kg/cm2 a 250 rpm
H Difference between cylinders: 2 3 kg/cm2

B1

40
35
30
25
20
200

250

300

350

400

Enginemotore
speed
(rpm)
Velocit
(giri/min)
RKZ01940

20-33

TESTING AND ADJUSTMENTS

TESTING AND ADJUSTING FUEL INJECTION TIMING

TESTING AND ADJUSTING FUEL INJECTION TIMING

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

N. 1 Cylinder
Cilindro
N 1

1 - Rotate crankshaft using engine pulley and put N. 1cylinder piston at top dead centre (PMS).

Flywheel
Volano
RKZ01960

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

pulley (1) positioned on zero of the scale (5)
and by closing of both cylinder N. 1 valves.
H 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.
H After recognition of PMS, rotate the crankshaft in
counterclockwise direction (from pulley side view)
of about 20.

1
RKZA5350

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

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

N1

RKZA0071

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

increase.

Raccordo

N. 1N1
Union

Level
Livello

RKZ01970

20-34

TESTING AND ADJUSTMENTS

TESTING AND ADJUSTING FUEL INJECTION TIMING

5 - Check notch (4) position on crankshaft pulley (1) compared with scale (5); reading value corresponds to angle of fuel injection timing.
H Standard fuel injection timing:
4D106-1FA: 12.5w1
S4D106-1FA: 12.5w1

NOTE. Repeat checking more than once.

1
6 - If injection timing is not on standard value, rotate injection pump (6) toward external or toward engine
after loosening pump nuts (7) (quantity 4) and pump
lock nuts (8) fixing the bracket (9) to injection pump.
. To RETARD injection, rotate pump (6) toward external.
. To ADVANCE injection, rotate pump (6) toward
cylinders block.
7 - Tight the pump lock nuts (7) at cylinder block and
pump lock nut (8) at bracket (9).
Nuts: 34.2 44.1 Nm
Bracket lock nut: 44.1 53.9 Nm

RKZA5360

6
7
8
Pumppompa
side
Lato

9
RKZA5370

Carter
side
Lato carter
Testing
advance
Controllo
anticipo
injector
d'iniezione

8 - Connect fuel delivery pipe (2) to pump

Delivery pipe union: 19.6 24.5 Nm

20-35

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) and pulley (3) operating water pump; check
the deflection.
With a pressure of 10 kg, deflection should be of
10 15 mm; if this value is not reached, tension
fan belt.
H With new belt, deflection must be of 7 9 mm.

RKZA5700

2 . Fan belt tension

1 - Loosen mounting bolt (4) of the alternator (2) and

mounting bolt (5) of adjustment plate.
2 - Rotate the alternator (2) to give correct tension to
fan belt (1) and tighten mounting bolts (4) and (5).
3 - Check fan belt (1) tension.
H If belt has been replaced, check tension again
after about 20 operating hours.

Bolts (4): 44.1 53.9 Nm

Bolts (5): 22.5 28.4 Nm

RKZA5690

Puleggia
pompa
Water
pump
acqua
pulley
10 15mm
mm
1015

Alternator
Alternatore

Crankshaft
Puleggia
pulley
albero
motore
RKZ01980

20-36

TESTING AND ADJUSTMENTS

MEASURING ACCELERATOR PEDAL OPERATING

TRAVEL AND ACCELERATOR LEVER

MEASURING ACCELERATOR PEDAL OPERATING

TRAVEL AND ACCELERATOR LEVER
H Work condition:
. Machine: in safety conditions.
. Engine stopped and at working temperature
. Low and high idling speed: within permissible value.
H 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.

RKZA5380

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

low idling speed adjusting screw (4).

3
RKZA5390

3 - Adjust nut (5) and lock nut (6) of accelerator pedal

cables and hand accelerator at a distance of
0.2 0.3 mm from lever (7).
4 - Push accelerator pedal until accelerator lever (3)
contacts 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).

9
10
RKZA5410

20-37

TESTING AND ADJUSTMENTS

MEASURING ACCELERATOR PEDAL OPERATING

TRAVEL AND ACCELERATOR LEVER

2. Accelerator lever travel adjusting

1 - Remove knob (1), accelerator lever (2) and lateral

cover (3).

RKZA5420

2 - Temporally, re-assembly accelerator lever (2);

loosen nut (4) and tight the end lever travel bolt
(5) of some turns.

3 - Start engine and bring it to the defined idling

speed for accelerator lever.
H Check using the stroboscopic tachometer C2.
H Engine idling speed: 1900w50 rpm
4 - Loosen end lever travel bolt (5) up to it is in contact with lever (2) and looked with nut (4).
5 - Bring engine at low idling and check accelerator
lever idling speed again pushing lever at end
stroke.

20-38

RKZA5430

TESTING AND ADJUSTMENTS

ADJUSTING BRAKE PEDAL TRAVEL,

BRAKE ALIGNMENT, MICROSWITCHES

ADJUSTING BRAKE PEDAL TRAVEL, BRAKE ALIGNMENT,

MICROSWITCHES
H Working condition:
. Engine stopped
. Machine with attachments on ground level

1 - Remove the rubber cover pedal (1).

2
RKZA5440

2 - Check that pedal (2) is near to the stopper (3) and the
pedals lower sides (2) are at standard measure from
cab level.
If necessary, adjust height acting on the stopper (3).
H Pedals lower sides height: 171 mm.
H Check that pin (4) can freely run and lock the two
pedals (2) together.

3 - Loosen nuts (5) locking the adjusting rod (6) and tighten them inside forks (7).

4 - Lock pedals (2) with pin (4); push pedals up to an

height of 154.4 mm.

5 - Mantening this position, loosen adjusting rods (6) until they touch the brake pump piston seat.
6 - Stop in this position with nut (5).
H After tightened nuts (5), check that the adjusting
rod (6) touch the brake pump piston seat simultaneously and at an height of 154.4 mm.

154.4
mm
154,4 mm

160 mm
160
mm

8 - Mantening this position, adjust microswitches (9) up

to they touch the pedal levers (2).

170.5
mm
170,5 mm

7 - Loosen microswitches (for 4 wheel brake) locking

nuts (8).
Push pedals (2) up to an height of 160 mm.

9 - Stop microswitches (9) in this position with nuts (8).

Nut: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nm

RKZ01990

RKZ01950

20-39

RICERCA GUASTI

AIR BLEEDING - RELEASING RESIDUAL PRESSURE

AIR BLEEDING - RELEASING RESIDUAL PRESSURE

1. Air bleeding from pump
H Air bleeding from pump (that means the filling of
pump body) is necessary:
1 - When removing pump.
2 - When removing or replacing connection hoses
between 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 plug G1.

RKZA5450

2 - Remove plug (1) of breather pipe (2).

3 - Connect plug G1 to low pressure air compressed
connection.
4 - Introduce slowly and intermittently air compressed
in the hydraulic tank until when flows out oil without air bubbles.
H 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.
7 - Start engine and run it for few minutes before
bleeding air from the whole system.

2. Air bleeding from cylinders

H When hydraulic cylinders or pipe fitting have been
removed, it is necessary to bleed air before to use
again the machine.
H Operate on a movement at a time starting from
main cylinders (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.
H 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 hydraulic pump reaches its maximum pressure.
4 - Repeat above operation (starting from point 2) for
all cylinders.

20-40

RKZA8090

RICERCA GUASTI

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.
H 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.
H Avoid to increase the engine speed before
completing all air bleeding procedures and
after the pressurization of oil tank.
H After air bleeding procedures, operate engine
at low Idling speed for about 10 minutes before starting 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
completely cylinders and main circuit remain pressure.
3 - Loosen slowly oil filler tank to remove remain
pressure.

6. Air bleeding from braking circuit

H Above operation is to be carried out every time
maintenance is made on braking circuit to remove
or replace a component, or when air entered into
the circuit.
H Machine must be stopped with attachments on level ground.

1 - Make sure that oil in brake system tank (1) is at

maximum level.
2 - Remove pedal lock pin.
RKZA5460

20-41

RICERCA GUASTI

AIR BLEEDING - RELEASING RESIDUAL PRESSURE

3 - Remove safety plugs and applied to bleeding

screws (2) a vinyl hose (3) to catch oil.
4 - Push one brake pedal to bottom and, keeping it
pushed, loosen bleeding screw (2) of one of two
braking units until the pedal reaches end of its
stroke.
5 - Keeping pedal at the end stroke, tighten bleeding
screw (2).
6 - Release braking unit pedal during air bleeding,
wait for few seconds and repeat above operations
until from bleeding screw, oil flows out without air
bubbles.
7 - Repeat same operations for the other braking unit.
H Check frequently the oil level in the tank and
carry out filling every time level approaches
to minimum.
H After air bleeding apply on screws (2) safety
plugs.

20-42

2
RKZA5470

CHECKING AND SETTING PRESSURE IN

THE ATTACHMENTS HYDRAULIC CIRCUIT

TESTING AND ADJUSTMENTS

CHECKING AND SETTING PRESSURE IN THE ATTACHMENTS

HYDRAULIC CIRCUIT
1. Introduction
.

On the machine configuration, one or two spool.

Mechanical control valves have been installed
with following function:
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 overpressure by a main relief valve (or general and
named Pressure cut off valve) with fixed setting.

STEERING
UNIT
IDROGUIDA

FRONT
SHOVEL
DISTRIBUTORE
CONTROL
VALVE
PALA
ANTERIORE
(2-3
SPOOLS)
(2-3
ELEMENTI)

POWER
TRAIN
TRASMISSIONE
DIESEL
DIESEL

P1
P1

VALVOLA
MAIN
RELIEF
GENERALE
VALVE

.
.

Control valves are feeded by P1 pump total delivery.

P1 pump delivery is checked by a priority valve
(internal to the control valve N. 1) when steering
unit is used.
Control valves include spools controlling:

BACKHOE
DISTRIBUTORE
CONTROL VALVE
RETROESCAVATORE
(6-7-8ELEMENTI)
SPOOLS)
(6-7-8

RKZ02490

2-SPOOL CONTROL VALVE

Control

Port

Front bucket (curled - dump)

A1-B1

Front bucket (lifting - lowering)

A2-B2

A
1

RKZ02040

20-43

CHECKING AND SETTING PRESSURE IN

THE ATTACHMENTS HYDRAULIC CIRCUIT

TESTING AND ADJUSTMENTS

3-SPOOL CONTROL VALVE

Control

Port

Optional attachment

A1-B1

Front bucket (curled - dump)

A2-B2

Front bucket (lifting - lowering)

A
1

A3-B3

RKZ02060

6-SPOOL CONTROL VALVE

Control

Port

Arm (opening - closing)

A1-B1

Boom swing (left - right)

A2-B2

R.H. outrigger (up - down)

A3-B3

L.H. outrigger (up - down)

A4-B4

Bucket cylinder (dump - curled)

A5-B5

Boom cylinder (lifting - lowering)

A6-B6

B
1

RKZ02070

7-SPOOL CONTROL VALVE

(For jig arm)
Control

Port
A7-B7

Jig arm (in - out)

B
7

RKZ02080

7-SPOOL CONTROL VALVE

(For hammer - side digging boom)
Control

Port

Hammer (R.H. side - L.H. side)

A7-B7

Side digging boom (left - right)

A7-B7

B
7

RKZ02090

20-44

CHECKING AND SETTING PRESSURE IN

THE ATTACHMENTS HYDRAULIC CIRCUIT

TESTING AND ADJUSTMENTS

8-SPOOL CONTROL VALVE

(For hammer and jig arm)
Control

Port

Hammer (R.H. side - L.H. side)

A7-B7

Jig arm (in - out)

A8-B8

B
7

RKZ02050

2. Testing and setting general valves

(Pressure cut off valve)
H Test condition:
. Engine: at operating temperature
. Hydraulic oil: 45 55 C
. Working brakes applied

E3
1

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

pressure adapter (1) of the front shovel control
valve (2).
2 - Start the engine, bring the hand accelerator lever
up to 1050 rpm and check the nominal pressure of
the main relief valve (pressure cut-off valve) by forcing the front bucket to rise to the end of its stroke.
H Nominal pressure: WB91R-2: 185w7 bar
WB93R-2: 200w7 bar
H If the main relief valve pressure do not correspond to the nominal values, they must be
re-set (See SETTING THE MAIN RELIEF
VALVES AND THE REDUCING VALVES).

2
RKZA5480

3. Testing and setting secondary valves

H Test condition:
. Engine: at operating temperature.
. Hydraulic oil: 55 60 C.
. Parking brake: applied.
H The pressure readings are to be operated from
the same check point.
1 - Connect the pressure gauge E3 (400 bar) to
the pressure adapter (3) of the backhoe control valve (4).
2 - Start the engine and bring the hand accelerator lever up to 1050 rpm.

E3
1

2
RKZA5480

20-45

CHECKING AND SETTING PRESSURE IN

THE ATTACHMENTS HYDRAULIC CIRCUIT

TESTING AND ADJUSTMENTS

3 - Set the main relief valve (pressure cut-off

valve) to a value 30 bar higher than the maximum pressure to be tested.
4 - Check the single movements pressure.
The secondary valve of backhoe boom lifting, must be checked and settled on
test bench only.
Setting 2-spool control valve secondary valves
Cylinder and movement

Unit: bar

Port

Setting WB91R-2

Setting WB93R-2

Front
bucket

Lifting

A1

Lowering

B1

Front
bucket

Curled

A2

230w7

230w7

Dump ]

B2

170w7

170w7

Port

Setting WB91R-2

Setting WB93R-2

] This setting can be carried without modifing the general valve pressure.
Setting 3-spool control valve secondary valves
Cylinder and movement

Unit: bar

Front
bucket

Lifting

A1

Lowering

B1

Front
bucket

Curled

A2

230w7

230w7

Dump ]

B2

170w7

170w7

A3

230w7

230w7

B3

230w7

230w7

Port

Setting WB91R-2

Setting WB93R-2

Closing

A1

230w7

230w7

Opening

B1

Left

A2

240w7

240w7

Right

B2

240w7

240w7

Up

A3

Down

B3

Up

A4

Down

B4

Dump

A5

Curled

B5

230w7

230w7

Lifting ]

A6

300w7

300w7

Lowering

B6

230w7

230w7

Optional
attachment

] This setting can be carried without modifing the general valve pressure.
Setting 6-spool control valve secondary valves
Cylinder and movement
Arm
Boom swing
Right outrigger
Left outrigger
Bucket
cylinder
Boom
cylinder

] The setting must be carried on test bench only.

20-46

Unit: bar

CHECKING AND SETTING PRESSURE IN

THE ATTACHMENTS HYDRAULIC CIRCUIT

TESTING AND ADJUSTMENTS

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

Hammer
7

Hammer
Jig arm
Hammer

8
Jig arm

Port

Setting WB91R-2

Setting WB93R-2

R.H. side

A7

165w7

165w7

L.H. side ]

B7

Right

A7

270w7

270w7

Left

B7

270w7

270w7

In

A7

Out

B7

R.H. side

A7

165w7

L.H. side ]

B7

In

A8

Out

B8

] This setting can be carried without modifing the general valve pressure.
H 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.
From serial number N 91F20001 to N 91F20022
N 93F20001 to N 93F20285

4. Main and secondary valves setting

.

General valves (Pressure cut off valve (1))

For setting, prepare machine as per pressure
testing.

1 - Loosen lock nut (2).

2 - Force to the end of its stroke the lever commanding
whichever movement is being used for the tests.
3 - Adjust pressure with adjusting screw (2).
. To INCREASE pressure, rotate in CLOCKWISE direction.
. To DECREASE pressure, rotate in COUNTERCLOCKWISE direction.
4 - Lock position with nut (2).
Lock nut: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nm

RKZA5490

From serial number N 91F20023 and up

N 93F20286 and up

3
RKZ02241
RKZA8100

20-47

TESTING AND ADJUSTMENTS

CHECKING AND SETTING PRESSURE IN

THE ATTACHMENTS HYDRAULIC CIRCUIT

Secondary valves
For setting, prepare machine as per pressure
testing.
H This setting is valid for all the secondary valve
and has to be carried forcing the movement to
be checked at its end of stroke.

2
1
3

1 - Loosen lock nut (1).

2 - Adjust pressure with adjusting screw (2).
. To INCREASE pressure, rotate in CLOCKWISE direction.
. To DECREASE pressure, rotate in COUNTERCLOCKWISE direction.
3 - Lock position with nut (1).
Lock nut: 10w1 Nm.
When terminated the setting, Apply safety
plug (3) to avoid not authorised tamperings.
4 - Set the general valve pressure to the standard value.

RKZ02010

20-48

TESTING AND ADJUSTING OF

LOAD SENSING SIGNAL (LS VALVE)

TESTING AND ADJUSTMENTS

TESTING AND ADJUSTING OF LOAD SENSING SIGNAL

(LS VALVE)
H Testing conditions.
. Engine: stopped but at working temperature.
. Hydraulic oil: 45 55C.
. Machine: front equipment on the ground and
parking brake applied.
1 - Disconnect hose(1) from the load sensing line. Install
an thee (2) and reconnect hose (1).

E3

2 - Connect to thee (2) a pressure port and gauge E3

(400 bar).
RKZA5500

3 - Connect to rear control valve pressure port a pressure gauge E3 (400 bar).
4 - Start the engine and bring it to 1050 rpm; check that
with no movements the load sensing pressure is zero
(PLS=0).

E3
1

5 - Raise boom up to end of stroke; force the movement

and read the pressure on both gauges.
6 - Calculate the differential pressure (iP) substracting
the reading from the two gauges (Control valve pressure Pump pressure).
H Normal iP: 15 16 bar
H If the iP value is not inside the limits, carry out
the Load sensing valve (3) setting.

2
RKZA5480

1. Adjusting of the Load Sensing valve

1 - Remove nut (4).
2 - Loosen nut (5).

3 - Adjust pressure using adjusting screw (6).

. To INCREASE pressure, rotate in CLOCKWISE direction.
. To DECREASE pressure, rotate in COUNTERCLOCKWISE direction.
4 - Lock the position with nut (5).
Lock nut: 21 Nm

RKZA5710

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

Nut: 21 Nm

RKZ02270

20-49

TESTING AND ADJUSTMENTS

CHECKING UNLOADING VALVE FUNCTIONALITY

CHECKING UNLOADING VALVE FUNCTIONALITY

H Test condition:
. Engine: stopped but at working temperature.
. Low idling: in the permissible limit.
. Hydraulic oil: 45 55C.
. Machine: in safety condition, parking brake applied.

E1

1 - Connect gauge E1 (60 bar) to rear control valve

pressure port.
2 - Start the engine at low idling and without any
movement check pressure.
H Normal pressure: 21w1 bar.
H Reading an higher pressure means that there
are any dirts which do not allow free movements of the spool or a seizure.

RKZA5510

From serial number N 91F20001 to N 91F20022

N 93F20001 to N 93F20285

3 - Stop the engine and release residual pressure.

4 - Remove valve (1) and clean it.

H Check the exact quantity of thickness (2)
mounted.
5 - Reassembly valve (1) inserting all the thickness
and check again the pressure.
Valve: 20 Nm
H If in spite of cleaning pressure is not inside the
limits, replacement of valve is need.

RKZA5491

From serial number N 91F20023 and up

N 93F20286 and up

RKZA8101

1
RKZ02251

20-50

TESTING AND ADJUSTMENTS

TESTING PUMP DELIVERY

TESTING PUMP DELIVERY

H Test condition:
. Engine: stopped but at working temperature.
. Hydraulic oil: 45 55C.
. General valve (Pressure cut off valve) and secondary valve: within normal limits.
. Machine: front equipment on the ground, boom
and arm fully extended and bucket fully curled
and on the ground.
. Parking brake: applied.

F1

1. Flow-meter connection
1 - Release residual pressure.

RKZA5520

2 - Disconnect bucket bottom side hose (1) and head

side (2).
H Plug holes to avoid impurity inlet.
3 - Connect cylinder bottom side hose (1) to the flowmeter F1 inlet port and connect the cylinder head
side hose to the outlet port.
4 - Use a tachometer C2 to control that pump delivery
is within the rpm limits during the test.
H If using a multiscale tachometer C1 mounted
on fuel delivery pipe, check that it is mounted
far from the pipes retainer.
H Pumps diagrams are refereed to constant idling for all the use range.
H When measuring the deliveries with the pump
mounted on the machine it becomes difficult
to use the accelerator to set the engine idling.
Make delivery measurements with the engine
running at a speed close to the test speed and
then make a proportional calculation.

C1

RKZA5300

Example:
MEASUREMENT
Engine speed: 2144 rpm
Delivery:
153.97 ,/min
PROPORTIONAL DELIVERY AT 2200 rpm
153197 x 2200 = 158 ,/min

2144

2. Measurement
1 - Start the engine and bring it up to 2200 rpm.

F1

2 - Move the bucket curling lever up to end of stroke

and, with the lever in this condition, adjust the delivery pressure with the flowmeter F1 knob (3).

PRESSURE

DELIVERY
RKZA5530

20-51

3 - Check the effective delivery flow and the engine

idling speed at each pressure increment, performing different reading each 20 bar pressure increasing, extending the readings to all the working range (up to the maximum value set by the
general valve).
H Perform more than once the reading to have a
media of the values.
H Those tests check the Economy mode curve.
H After checked the pump characteristic curve is
possible to carry out the check of the point of
pump initial regulation, that means the point
where the pump starts reducing the delivery
to preserve the pressure required.
To obtain the exact position of this diagram
point, perform the pressure-delivery-engine
speed tests each 10 bar a zone close to the
point found in the preceding test.

TESTING PUMP DELIVERY

bar

TESTING AND ADJUSTMENTS

Power
Power

Economy
Economy

4 - Release pressure to the minimum value using the

flowmeter F1 knob (3) and insert the Power mode
(Speed control push-button).
5 - Repeat phase 3 procedure to check Power mode
curve (Power mode).
6 - Release the Speed control push-button, reduce
pressure and stop the engine.
7 - Check the flow - pressure against the value shown
on TECHNICAL SPECIFICATION.
H If the measured value is lower of more the 7%
than the permissible, it is necessary to overhaul of the pump.
8 - Release the residual pressure.
9 - Restore the bucket hoses connection to the cylinder.

20-52

Initial
regulation
Inizio
regolazione

0
0

/min
RKZ02260

TESTING AND ADJUSTMENTS

TESTING PRIORITY VALVE OPERATION

TESTING PRIORITY VALVE OPERATION

H Test condition:
. Engine: operating temperature
. Hydraulic oil: 55 60 C
. Parking brakes: applied

E2

1. Testing Load Sensing signal

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

steering wheel (21 bar).
4 - Start a slight steering and check that pressure increases.

5 - Continue the steering up to end of stroke and

check that, forcing the steering wheel, pressure
increases till normal value.
H Normal pressure: 175w7 bar.
H If the pressure does not reach the normal value, re-set the pressure of the steering unit.
H 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, check the priority valve (2).

RKZA5550

2. Testing priority valve operation

1 - Remove priority valve plug (3), spring (4) and rod
(5).
H Check and make notes on the direction of assembly.

2 - Dismantle the plug (6) and remove the ball (7) of

the inside valve and the spring (8).

3 - Check that the hole (9) and the nozzle (10) are perfectly clean.
4 - Replace the spring (8), the ball (7) and the plug
(6).
Plug: Loctite 542
Plug: 20 Nm
H Do not allow any Loctite to enter the hole (9).
H Remove all excess Loctite from the rod (5).
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).
Plug: 100 Nm

10
3

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

20-53

TESTING AND SETTING STEERING

CONTROL SYSTEM PRESSURE

TESTING AND ADJUSTMENTS

TESTING AND SETTING STEERING CONTROL SYSTEM PRESSURE

H Test condition:
. Engine: operating temperature
. Hydraulic oil: 55 60 C

E2

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 of 1500w50 rpm
and carry out a total steering.
3 - Forcing the steering wheel at the end of stroke, check
pressure.
H Normal pressure: 175w7 bar

RKZA5540

4 - Check for the other steering direction too.

Setting

6 5

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 direction.
. To DECREASE pressure rotate in COUNTERCLOCKWISE direction.
4 - Stop engine, lock the adjusting screw (6) position
tightening screw (5).
5 - Reassemble plug (4) checking that gasket (7) is on its
seat.
Plug: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nm

20-54

3
RKZA5560

4 7

TESTING AND ADJUSTMENTS

TESTING BRAKE SYSTEM

TESTING BRAKE SYSTEM

H 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.

The system testing provides in two stages:

1 - Testing circuit and brake pump tightness.

2 - Leaktightness test of the braking group.

If both the tests give a positive result, the leaks
must be sought in the pipelines of the braking
system.

RKZA5570

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).
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 bring the circuit up to a pressure of approximately 120 bar.
H Do not exceed maximum permissible value
that is of 150w5 bar.
5 - Keep the pedal pushed for at least 2 minutes and
check that pedal pressure and position remain
steady.
H If the position of the pedal must be changed to
maintain pressure, the pressure loss is due to
leakages inside the pump.
This can be confirmed by checking the oil. If
there are leakages, it will show signs of mixing.

RKZA5580

E2

6 - Repeat test for the other brake pump.

RKZA5590

2. Testing braking group leaktightness

1 - Disconnect the delivery tube (5) of the braking
group being tested.
2 - Connect the tool H1 between the delivery line (5)
and the braking group.
H Check that the pressure adapter (6) is inserted
between the braking group and the exclusion
valve (7).
3 - Connect a pressure gauge E2 (250 bar) to the pressure adapter of the tool H1 and open the cock (7).

5
E2
7
H1
6
RKZA5600

20-55

TESTING AND ADJUSTMENTS

4 - Operate brake pump to feed pressure into the circuit

to maximum pressure of 150w5 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.
H 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 obtained 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
CIRCUIT).

20-56

TESTING BRAKE SYSTEM

TESTING AND ADJUSTMENTS

CONTROL OF THE ENGINE SPEED UNDER LOAD

CONTROL OF THE ENGINE SPEED UNDER LOAD

H Test conditions:
. Engine: stopped but at working temperature.
. Hydraulic oil: 45 55C.
. Power train oil: up to working temperature.
. Brake pedals: connected by a cotter-pin.
. Machine: on solid and level ground with the
equipment raised and safety devices engaged.
Two tests must be performed:
1 - Speed test with the torque converter under stress.
2 - Speed test with the torque converter and the hydraulic system under stress.
H 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):

RKZA8110

C1

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 AXLE).

RKZA5300

1. Preparing the machine

1 - Prepare the rev. counter C1 to measure the engine rpm.
H If mounting an electronic pressure transducer
rev. counter on a diesel delivery line to the injection nozzles, make sure that it is placed far
away from the clamp.
H If using a stroboscopic tachometer C2, make a
clearly visible notch on the engine pulley to facilitate the reading.
Make sure that the brake pedals are fastened
together by the cotter pin (1).

2. Testing with the torque converter under stress

1
RKZA5441

1 - Start the motor at MIN. Engage the highest FORWARD gear and brake hard.
2 - Keeping the machine on the brake, accelerate the
engine gradually up to high idling and measure
the speed reached.
H Normal speed: WB91R-2: 2100w50 rpm
WB93R-2: 2275w50 rpm
TBG version: WB91R-2: 2125w50 rpm
WB93R-2: 2200w50 rpm
3 - Release the accelerator pedal and move on to the
next test.

20-57

TESTING AND ADJUSTMENTS

3. Testing the torque converter and hydraulic system under stress

1 - Start the motor at MIN. Engage the highest FORWARD gear and brake hard.
2 - Keeping the machine on the brake, engage the
upper FORWARD gear, accelerate the engine gradually and at the same time act on the front bucket
closed (curled) command control valve lever.
3 - Once the maximum engine speed and the maximum pressure of the bucket circuit have been
reached, measure the speed reached by the engine.
H Normal speed: WB91R-2: 2000w50 rpm
WB93R-2: 2200w50 rpm
TGB version: WB91R-2: 2100w50 rpm
WB93R-2: 2200w50 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 conditions of the engine compression, the timing, the injection pump, and the valve clearances.

20-58

CONTROL OF THE ENGINE SPEED UNDER LOAD

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 identifying malfunctions.
Specifically, the tests involve:
1 - Converter oil pressure.
2 - Clutch engagement pressures for both directions of
travel.
H Test conditions:
. Engine: stopped.
. Brake pedals: connected by a cotter pin.
. Machine: on solid and level ground with the equipment raised and safety devices engaged.

RKZA8110

1. Preparing the machine

1 - Prepare the rev. counter C1 to measure the engine rpm.
H If mounting an electronic pressure transducer
rev. counter on a diesel delivery line to the injection nozzles, make sure that it is placed far
away from the line-clamp.
H If using a stroboscopic tachometer C2, make a
clearly visible notch on the engine pulley to facilitate the reading.

C1

Make sure that the brake pedals are fastened

together by the cotter pin (1).

RKZA5300

2. Converter oil pressure

1 - Remove the plug (P22) 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 80w5 C.
3 - With the engine at MIN, check the pressure on the
pressure gauge E6.
H Normal pressure: 0.9 bar

4 - Gradually increase the rev speed to MAX. Take a

new reading from the pressure gauge E6.
5 - Bring the engine back to MIN and compare the
pressure with the normal value.
H Normal pressure: 9 bar
H If the maximum pressure value drops to below
the permissible lower limit, the power train
pump needs an overhaul.

RKZA5441

P19

P22

P18
RKZ02110

20-59

TESTING AND ADJUSTMENTS

TESTING PRESSURES IN THE POWER TRAIN GROUP

3. Clutch engagement pressure

1 - Remove the cab floor.
2 - Remove the plug (P19) 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 80w5 C.
4 - Bring the engine up to MIN (idling) and check the
pressure on the pressure gauge E6.
H Normal pressure: max 0.4 bar
5 - Gradually increase the rev speed up to MAX. Take
a new reading from the pressure gauge E6.
6 - Bring the engine back to MIN and compare the
pressure with the normal value.
H Normal pressure: 11 13 bar
7 - Remove the pressure adapter and replace the
plug (P19).
Cap: 23 Nm
8 - Repeat the same test for the FORWARD gear,
reading the pressure from the orifice protected
by the plug (P18).
. If the pressures are different for the two travel
directions, there is a loss of pressure on the
clutch piston with lower pressure.

20-60

E6
P19

P18
RKZA5610

TESTING AND ADJUSTMENTS

TESTING THE CORRECT FUNCTIONING

OF THE POWER TRAIN CLUTCHES

TESTING THE CORRECT FUNCTIONING OF THE

POWER TRAIN CLUTCHES
H Test conditions:
. Engine: stopped.
. Brake pedals: connected by a cotter pin.
. Machine: on solid and level ground with the
equipment raised and safety devices engaged.
H 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 to measure the engine rpm.
H If mounting an electronic pressure transducer rev.
counter on a diesel delivery line to the injection
nozzles, make sure that it is placed far away from
the line-clamp.
H If using a stroboscopic tachometer C2, make a
clearly visible notch on the engine pulley to facilitate the reading.
Make sure that the brake pedals are fastened together by the cotter pin (1).

RKZA8110

C1

During the following tests, during the engine acceleration 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
engine.
b - Check the wear on the brake disks and change them
before completing the tests (See: 30. DISMANTLING AND ASSEMBLY - REAR AXLE).

RKZA5300

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 80w5 C.
2 - With the engine in idling condition, accelerate to
MAX and check that in this condition the revs remain within permissible limits. (See TESTING
ENGINE SPEED).
3 - Brake hard and bring the engine up to MAX.

1
RKZA5441

4 - Maintaining the braking action and the acceleration, engage 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.
H If the revs are high than the permissible limits,
the clutches are worn, and must be replaced.

20-61

TESTING AND ADJUSTMENTS

ADJUSTING THE SENSOR FOR RETURN TO DIG DEVICE

ADJUSTING THE SENSOR FOR RETURN TO DIG DEVICE

H Adjustment conditions:
. Machine: on solid and level ground.
. Engine: stopped.
. Hydraulic oil: 45 55C
. Parking brake: engaged.
1 - Rest the bucket on the ground, making sure that the
bottom is perfectly parallel to the surface.
2 - Stop the engine and remove the sensor guard (1).
3 - Check that there is a distance 3 4 mm between the
sensor (2) and the rod (3)
H If necessary loosen the nuts (4) and adjust the distance, until the indicated measurement is obtained, and secure that position.
Sensor nut: . . . . . . . . . . . . . . . . . . . . . . . . . . . Nm

RKZA8120

4 - Loosen the locking nuts (5) and (6) of the position-indicating rod (3) and shift the rod towards the front of
the machine until it has passed beyond the sensor
axis (2).
5 - Start the engine at MIN., tighten the rear nut (6) and
at the same time unscrew the front nut (5) until the
sensor (2) is engaged.
H When the rod engages the sensor, the pilot light
(7) comes on.
6 - Secure the position of the rod (2) by tightening the
nuts (5) and (6) behind the bracket (8).
Nuts: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nm
7 - Perform several tests by raising the bucket and simulating some dumping manoeuvres. If the bucket is
able to rest flat on the ground, replace the sensor
guard (1).

RKZA5620

3
4
3
4 mm
mm

2
2

4
7
RKZA5630

RKZA5640

20-62

TESTING AND ADJUSTMENTS

ANALYSIS OF CAUSES HYDRAULIC DRIFT

ANALYSIS OF CAUSES HYDRAULIC DRIFT

H If working attachments have a hydraulic drift, it is necessary to check if reason is due to cylinders gaskets
or to control valve.
H All testing conditions:
. Engine: at operating temperature
. Hydraulic oil: 45 55C
. Removal and installation of pipes only after remain pressure removal.
(See REMOVAL OF REMAIN PRESSURE
FROM CIRCUIT).

Blocks
Blocchi

FRONT EQUIPMENT

RKZA1830

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

pressure.

3 - Disconnect pipes (1) and (2) from lift cylinders (3)

and plug them.
4 - Plug cylinders, base side, and apply a temporary
pipe, 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.

RKZA5650

6 - Stop the engine and check bucket link position for

5 minutes.
. If bucket link has no lowering movement, drift
is due to control valve.
To check each cylinders, proceed as follow:
7 - Carry out with bucket a dump movement to let
teeth lean on ground in vertical position.

15

8 - Remove from one of cylinders the plug as installed on 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.

RKZA1840

10 - Stop the engine and check the bucket position for

5 minutes.
. 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 other cylinder.

20-63

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
kg
1500

RKZ02130

2 - Disconnect pipes (1) and (2) from dump cylinder

(3) and plug them to avoid impurity inlet.
3 - Plug dump cylinder hole, base side, and apply a
temporary pipe on head side to catch possible
oil leakage.

2
1
RKZA5660

4 - Start the engine and raise the bucket up to the

alignment of the bucket hinge and shovel arm
hinge.

1500
kg
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.
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.

20-64

RKZ02630

TESTING AND ADJUSTMENTS

ANALYSIS OF CAUSES HYDRAULIC DRIFT

BACKHOE
H 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
pressure.
RKZ02140

3 - Disconnect hoses (1) and (2) that feed cylinder (5).

4 - Plug the two hoses to avoid impurity inlet.

5 - Plug the cylinder head side.

6 - Apply a temporary pipe on pipe (3) base side to
catch possible oil leakage.

2
1
RKZA1341

7 - Start the engine and extend completely the arm.

8 - Stop the engine and check the boom position for 5
minutes.
. If boom has a lowering movement, drift is due
to cylinder gaskets.
. If boom has no lowering movement, drift is
due to control valve.

RKZ02520

2. Arm testing
1 - Set the machine with arm fully extended and with
bucket teeth on ground.
2 - Stop the engine and remove the remain hydraulic
pressure.

RKZ02530

20-65

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.
H 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
minutes.
. If arm has a lowering movement, drift is due to
cylinder gaskets.
. If arm has no movement, drift is due to control
valve.

RKZ02540

3. Bucket testing
1 - Set the machine with vertical arm and horizontal
bucket leaned at level ground on the side.
Put in the bucket a weight of 450 kg or fill it with
earth.
450
kg
450 kg

RKZ02550

2 - Stop the engine and remove the remain hydraulic

pressures.

3 - Disconnect bucket cylinders (3) pipes (1) and (2)

and plug them to avoid impurity inlet.

4 - Plug bucket cylinder hole on base side and fit a

temporary pipe on head side to catch possible
oil leakage.

3
RKZA5670

20-66

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 minutes.
. If bucket has an opening movement, drift is
due to cylinder gaskets.
. If bucket has no movement, drift is due to control valve.

RKZ02560

4. Outriggers testing
1 - Set machine with vertical arm and with bucket
leaned at ground on the side.
2 - Put blocks of about 20 cm under the outriggers.
3 - Without forcing them, lower the outriggers onto
the trestles.

20 cm

RKZ02200

4 - Stop the engine and release residual hydraulic

pressures.

5 - Remove clamp (1) and disconnect from cylinders

(4) the pipes (2) and (3).
6 - Plug cylinders pipes (2) base side and apply on
head sides temporary pipes to catch possible oil
leakage.
7 - Start the engine, use force on the boom to raise
the machine, and remove the trestles supporting
the outriggers.

RKZA1251

8 - Lower the machine and stop the engine.

9 - Check the outriggers position for 5 minutes.
. If one or both outriggers have a lowering
movement, drift is due to single or both cylinders.
. If there is no lowering, drift is due to control
valve.

RKZ02210

20-67

00-14

REMOVAL AND INSTALLATION

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

PRECAUTIONS TO BE TAKEN WHILE
WORKING . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 4
SPECIAL TOOLS . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 5
STARTING MOTOR
Removal. . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 9
Installation .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 9
ALTERNATOR
Removal. . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 10
Installation .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 10
INJECTION PUMP
Removal. . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 11
Installation .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 14
INJECTION NOZZLES
Removal. . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 15
Installation .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 15
THERMOSTAT
Removal. . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 16
Installation .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 16
COOLING LIQUID PUMP
Removal. . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 17
Installation .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 18
TURBOCOMPRESSOR
Removal. . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 19
Installation .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 20
CYLINDER HEAD
Removal. . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 21
Installation .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 24
FRONT COUNTERWEIGHT
Removal. . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 25
Installation .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 25
RADIATOR-OIL COOLER UNIT
Removal. . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 26
Installation .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 28
RADIATOR OIL COOLER GROUP
Removal. . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 29
Installation .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 29
TRANSMISSION OIL COOLER
Removal. . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 30
Installation .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 30
MUFFLER
Removal. . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 31
Installation .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 31

EXHAUST PIPE
Removal .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 31
Installation. . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 31
ENGINE HOOD
Removal .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 32
Installation. . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 32
CAB
Removal .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 33
Installation. . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 36
CAB HEATING GROUP
Removal .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 37
Installation. . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 37
FUEL TANK
Removal .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 38
Installation. . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 38
HYDRAULIC OIL TANK
Removal .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 39
Installation. . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 39
ENGINE-GEARBOX-PUMP GROUP
Removal .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 40
Installation. . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 44
PISTON PUMP
Removal .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 46
Installation. . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 47
TRANSMISSION
Removal .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 48
Installation. . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 51
Overhauling the transmission . . . . .. . . . . .. . . . .. . . . 52
CONVERTOR
Removal .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . 133
Installation. . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . 133
REMOVAL OF THE TRANSMISSION-REVERSE,
DIRECTION INDICATOR AND HEADLIGHT
DIPPER BEAM CONTROL GROUP
Removal .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . 134
Installation. . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . 134
STEERING UNIT
Removal .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . 135
Installation. . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . 135
WORKING BRAKE PUMP GROUP
Removal .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . 136
Installation. . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . 136

30-1

FRONT WORKING EQUIPMENT CONTROL VALVE

Removal . . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 137
Installation. . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 137
FRONT AXLE
Removal . . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 138
Installation. . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 139
Disassembly. .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 140
Assembly . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 158
REAR AXLE
Removal . . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 180
Installation. . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 181
Disassembly of rear axle final drive. . . .. . . . .. . . 182
Assembly of rear axle final drive . . . . . . .. . . . .. . . 188
Disassembly. .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 194
Assembly . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 215
FRONT BUCKET BOOM-RAISING CYLINDER
Removal . . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 239
Installation. . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 239
FRONT BUCKET TILT CYLINDERS
Removal . . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 240
Installation. . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 240
FRONT BUCKET
Removal . . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 241
Installation. . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 241
FRONT WORKING EQUIPMENT
Removal . . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 242
Installation. . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 243
BACKHOE CONTROL VALVE
Removal . . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 244
Installation. . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 245
BACKHOE BOOM CYLINDER
Removal . . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 246
Installation. . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 246
BACKHOE ARM CYLINDER
Removal . . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 247
Installation. . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 247
BACKHOE BUCKET CYLINDER
Removal . . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 248
Installation. . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 248
OUTRIGGER CYLINDERS
Removal . . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 249
Installation. . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 250

30-2

BACKHOE SWING CYLINDERS

Removal . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . 251
Installation . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . 251
BACKHOE BACKFRAME LOCK CYLINDER
Removal . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . 252
Installation . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . 252
CYLINDERS
(Front bucket raise and tilt, boom, arm, bucket, outriggers and telescopic arm)
Disassembly . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . 253
Assembly . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . 255
BOOM SWING CYLINDER
Disassembly . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . 259
Assembly . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . 260
BACKHOE BACKFRAME LOCK CYLINDER
Disassembly . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . 262
Assembly . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . 262
BOOM SAFETY CYLINDER
Removal . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . 263
Installation . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . 263
BACKHOE WORKING EQUIPMENT
Removal . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . 264
Installation . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . 264
BACKHOE BUCKET
Removal . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . 265
Installation . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . 265
ARM
Removal . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . 266
Installation . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . 266
BACKHOE BOOM
Removal . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . 267
Installation . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . 267
BACKHOE SWING BRACKET
Removal . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . 268
Installation . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . 268
BACKHOE BACKFRAME
Removal . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . 269
Installation . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . 269

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
. 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.
H : . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Technique or important point to remember when removing XXXX (1)
2 - ~ ~ ~ (2): . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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.

: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Technique to be used for installation.
H : . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Technique or important point to remember when removing ~ ~ ~ (2).

Addition of water or oil: . . . . . . . . . . . . . . . . . . . . . . Step in removal procedure.

H : . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Point to remember when adding water or oil.

2.

To the precautions to be taken during the removal or installation of the groups, must be added the specific
PRECAUTIONS TO BE TAKEN 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
procedures, 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
represent the values of TIGHTENING TORQUES, WEIGHT OF PARTS OR GROUPS, QUANTITIES
OF OIL OR LIQUIDS TO BE INTRODUCED, SCREW LOCKING MATERIAL, SEALANTS AND LUBRICATION, LUBRICATING GREASE.
NOTE
If no symbol is indicated, the values to be used are those given in the introductory sections of this manual.

30-3

REMOVAL AND INSTALLATION

PRECAUTIONS TO BE TAKEN WHILE WORKING

PRECAUTIONS TO BE TAKEN WHILE WORKING

H 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 installation 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.

.
.
.

30-4

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.
H For details, see 20. TESTING AND ADJUSTMENTS.
After having re-assembled cylinder joints or cylinders, or work equipment articulations, lubricate thoroughly.

REMOVAL AND INSTALLATION

SPECIAL TOOLS

SPECIAL TOOLS
Nature of work

Symbol
1

Disassembly and assembly

cylinders

Code

Description

Q.ty

Notes

Attachment

Cylinders disassembly assembly

Plunger 40

Plunger 45

Plunger 50

Plunger 75

Bushing 45

Notched wrench for

cylinders 70

Notched wrench for

cylinders 80

Notched wrench for

cylinders 85

Notched wrench for

cylinders 95

Notched wrench for

cylinders 115-120

Notched wrench for

cylinders 110

Notched wrench for

side digging boom cylinders

Head disassemblyassembly

Notched wrench

Disassembly ring nut

side digging boom
cylinder

Notched wrench

Boom swing head

disassembly-assembly

Socket wrench (6-point 46)

Socket wrench (6-point 55)

Socket wrench (6-point 65)

Plunger 40

Plunger 50

Plunger 55

10

Plunger 60

Expander 70

Expander 80

Expander 85

Expander 95

Expander 100

Expander 110

Expander 115

Bushing for rod 40

Bushing for rod 45

Bushing for rod 50

Bushing for rod 55

Bushing for rod 60

Assembly cylinder and

rod bushings
Cylinder and rod locking
on ATR200620
Blocking swing cylinders
on ATR200620

Head disassemblyassembly

Pistons removalinstallation

Dust seal assembly

Piston gaskets assembly

Head assembly on rod

30-5

REMOVAL AND INSTALLATION

Nature of work

Disassembly and assembly

cylinders

Symbol

11

Disassembly and assembly

piston pump

Disassembly and assembly

transmission

Assembly transmission

Disassembly and assembly

clutches - transmission

Disassembly and assembly

front axle

30-6

SPECIAL TOOLS

Code

Description

Q.ty

Bushing for piston 70

Bushing for piston 80

Bushing for piston 85

Bushing for piston 95

Bushing for piston 100

Bushing for piston 110

Bushing for piston 115

Tool

Tool

Set of spacers

Commercially Feeler gauge

available

Notes

Piston-cylinder assembly

Pump bracket
Transmission support
Clutch backlash control

Clamp

Upper flange

Tie-rod

Wrench

Adjustment differential
lock nuts

Socket wrench

Removal-installation
pinion lock nut

Socket wrench

Removal-installation
pinion

Plunger

Mounting pinion
bearing ring

Gauge block

Gauge tube

Lock nut

Plunger

Mounting pinion bearing

Guide ring

Mounting pinion
output cover

10

Plunger

Mounting pinion
bearing ring

11

Plunger

Mounting bronze
bushing

12

Plunger

Mounting seal rings

13

Plunger

Mounting bushing for

upper and lower joint

Securing drive shaft

Removal-installation
clutch spring

Measuring pinion shims

REMOVAL AND INSTALLATION

Nature of work

Disassembly and assembly

front axle

Disassembly and assembly

rear axle

Symbol

Code

Description

Q.ty

Notes

14

Plunger

Mounting lower joint

bushing

15

Plunger

Mounting final drive

bearing ring

16

Plunger

Mounting final drive seal

17

Plunger

Insertion ring bevel

gear bushing

Plunger

Mounting hub seal

Handle

Plunger

Mounting axle shaft seal

Plunger

Mounting axle shaft seal

Push-rod

Insertion pilot bosses

Wrench

Adjustment lock nuts for

differential register

Socket wrench

Removal-mounting
pinion lock nut

Socket wrench

Removal-mounting
pinion

Plunger

Mounting slack
adjuster bushing

10

Tool

Mounting pinion
bearing ring

11

Lock nut

12

Flange

13

Gauge block

14

Plunger

Mounting pinion bearing

Checking pre-loading
pinion bearings

15

Assembly transmission

SPECIAL TOOLS

Commercially Dynamometer
available

Measurement of bevel
pinion shims

16

Plunger

Mounting differential
bushing

17

Plunger

Mounting differential
bearings

18

Bushing

Checking tooth
clearance

19

Bushing

Mounting seal on
pinion side

Kit

Removal - mounting
input shaft

Plunger

Mounting seal

30-7

REMOVAL AND INSTALLATION

30-8

REMOVAL AND INSTALLATION

STARTING MOTOR

REMOVAL OF THE STARTING MOTOR

Fully raise the front working equipment and engage
the safety stop.

1 - Stop the engine and engage the parking brake.

2 - Raise the engine hood (1) and disconnect the clamp
(2) from accumulator (3) negative terminal ().

3
RKZA0010

3 - Disconnect the electric wiring (4).

4 - Loosen the two screws (5) and remove the starting
motor (6).

4
5

6
RKZA0020

INSTALLATION OF THE
STARTING MOTOR
.

To install, reverse the removal procedure.

Starting motor mounting screws:
78.4 98 Nm (8 10 kgm)

30-9

REMOVAL AND INSTALLATION

ALTERNATOR

REMOVAL OF THE ALTERNATOR

Fully raise the front working equipment and engage
the safety stop.

1 - Stop the engine and engage the parking brake.

2 - Raise the engine hood (1) and disconnect the clamp
(2) from accumulator (3) negative terminal ().

3
RKZA0010

3 - Disconnect the cable (4), the connector (5) and the

cotter pin (6).

4
6

RKZA0030

4 - Loosen the screws (7), (8) and (9) to leave the alternator (10) free to rotate.

4 - Release the belt (11) from the pulley and remove the
alternator (10).

11
8
RKZA0040

INSTALLATION OF THE
ALTERNATOR
.

To install, reverse the removal procedure.

10

9
H Adjust the fan-belt tension. (For details, see 20. TESTING AND ADJUSTMENTS Fan-belt tension.)

11
RKZA0050

30-10

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.
Raise the engine hood and disconnect the cable
from accumulator negative terminal ().

H Plug all tubes that have been removed or disconnected to prevent entry of impurities.
1 - Remove the engine coolant liquid container (1).

RKZA0060

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

from the injection pump (2).

5
4

3 - Disconnect the high-pressure pipes (5).

RKZA0070

4 - Disconnect the fuel feed hose (7) and delivery tube (9)
from the feed pump (6).

5 - Disconnect the tube (9) from the oil level dip-stick and
remove it.

7
9

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

30-11

REMOVAL AND INSTALLATION

INJECTION PUMP

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

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

13
2

RKZA0100

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

lubrication tube.
10 - Disconnect the lubrication tube (15).

15

14
RKZA0110

11 - Remove the cover (16) that gives access to the distribution gear and the oil filler plug (17).

17
16

RKZA0120

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

19

18

20

RKZA0130

30-12

REMOVAL AND INSTALLATION

13 - Remove the driving gear (20) of the pump (2).

H Before removing the pump driving gear, mark its
position with respect to the idling gear.
H For removal use a puller (X1). The puller screws
(X2) screw directly into the gear (20).
H Take great care not to damage the pump shaft
thread.
H During removal, be careful not to let the wrench
drop into the housing.

INJECTION PUMP

X2

23
21

20

X1
X2
RKZ00030

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

22
2
RKZA0081

30-13

REMOVAL AND INSTALLATION

INJECTION PUMP

INSTALLATION OF THE INJECTION PUMP

.

To install, reverse the removal procedure.

Fuel feed hoses: 24.5 34.3 Nm (2.5 3.5 kgm)
High pressure hoses:
24.5 34.3 Nm (2.5 3.5 kgm)
Stiffening bolt screw, pump side:
44.1 53.9 Nm (4.5 5.5 kgm)
Stiffening bolt screw, pump side:
22..5 8.4 Nm (2.3 2.9 kgm)
H Put in a new safety cotter pin.
Lubrication tube, pump side: . . . . . . . . . . . . . Nm
Lubrication tube, pump side: . . . . . . . . . . . . . Nm
Cover gasket: ASL800070
Cover bolts for ignition gear system:
18 Nm (1.84 kgm)

H Align the marks between the gears before installing the pump and mounting the nut.
Gear-locking nut:
83.3 93.1 Nm (8.5 9.5 kgm)

Ingranaggio pompa

Injection
pump
d'iniezione
(20) gear (20)

Reference
Riferimento

Idling gear folle

Ingranaggio
RKZ00130

Pump-locking nu:
35.2 43.1 Nm (34.4 42.2 kgm)
1 - Check fuel injection timing.
(For details, see 20. TESTING AND ADJUSTMENTS)

30-14

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.
Raise the engine hood and disconnect the cable
from accumulator negative terminal ().

1
2

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

2 - Remove the air-filter (2), the supporting bracket (3)
and the intake sleeve (4).

RKZA0150

3 - Remove and place to one side the bulldog clip (5) that
secures the cab heating pipes.

4 - Loosen the clip (7) and remove the high-pressure

pipes (8).

7
8
3
5

6
RKZA0160

5 - Disconnect the fuel flow-back pipes (9).

6 - Take out the nuts (10) that secure the collar (11) and
take out the injector (12), the seating (13) and the protection piece (14).

8
10
9
11
RKZA0170

INSTALLATION OF THE
INJECTION NOZZLES
.

11

To install, reverse the removal procedure.

10
High-pressure pipe:
24.5 34.3 Nm (2.5 3.5 kgm)
Hose-clamp screws: 9.8 11.8 Nm (1 1.2 kgm)

12

14
13

Collar lock nuts: 9.8 11.8 Nm (1 1.2 kgm)

RKZ00140

30-15

REMOVAL AND INSTALLATION

THERMOSTAT

REMOVAL OF THE THERMOSTAT

Fully raise the front working equipment and engage
the safety stop. Also make the backhoe safe.
Raise the engine hood and disconnect the cable
from accumulator negative terminal ().

2
1

H Drain the engine coolant liquid.

Coolant liquid: 18

1 - Disconnect the cable (1) of the clogged filter indicator

(2) and remove the entire suction filter (3).

RKZA0180

2 - Disconnect the radiator connection sleeve (5) from

the thermostat cover (4).
4 - Take out the screws and remove the thermostat cover
(4).
4 - Remove the gasket (6), the thermostat (7) and the
ring seal (8).

Put in new seals.

RKZA0190

INSTALLATION OF THE
THERMOSTAT
.

To install, reverse the removal procedure.

1 - Refill the coolant liquid tank.

Coolant liquid: 18

2 - Start the engine at low idling to circulate the coolant

liquid 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.
H Check that there are no leaks.
Cover screws: 22 27.8 Nm

30-16

6
7
8

RKZ00150

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.
Raise the engine hood and disconnect the cable
from accumulator negative terminal ().

H Drain the engine coolant liquid.

Coolant liquid: 18

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

RKZA0060

2 - Disconnect the cable (2) of the clogged air-filter sensor and remove the air filter (3).
3 - Remove the alternator and its support (4) (For details,
see REMOVAL OF THE ALTERNATOR).

6
4
RKZA0181

4 - Disconnect the cab heating pipes (5).

5 - Disconnect the temperature sensor cables (6) and (7).

RKZA0191

6 - Remove the radiator/oil-cooler group. (For details, see

REMOVAL OF THE RADIATOR - OIL COOLERS).
7 - Remove the fan (8), the spacer (9) and the pulley (10).

9
10

RKZA1610

30-17

REMOVAL AND INSTALLATION

COOLING LIQUID PUMP

8 - Remove the four screws (11) and then the complete

pump (12).
Replace all seals with new ones.

11

12
RKZA0200

INSTALLATION OF THE COOLANT

LIQUID PUMP
.

To install, reverse the removal procedure.

Locking screws for alternator support:

22.5 28.4 Nm (2.3 2.9 kgm)
Locking screws for pulley and fan:
44.1 53.9 Nm (4.5 5.5 kgm)
Pump screws: 22.5 28.4 Nm (2.3 2.9 kgm)
1 - Refill the coolant liquid circuit.
Coolant liquid: 18

2 - Start the engine at low idling to circulate the coolant

liquid 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.
H Check that there are no leaks.

30-18

REMOVAL AND INSTALLATION

TURBOCOMPRESSOR

REMOVAL OF THE TURBOCOMPRESSOR

Fully raise the front working equipment and engage
the safety stop. Also make the backhoe safe.
Raise the engine hood and disconnect the cable
from accumulator negative terminal ().
1 - Disconnect the clogged air-filter indication cable (1)
and remove the entire suction filter (3).

2
3

2 - Remove the muffler.

(For details, see REMOVAL OF THE MUFFLER).

RKZA0151

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.

6
5
5

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).

9
7

RKZA0230

30-19

REMOVAL AND INSTALLATION

TURBOCOMPRESSOR

6 - Take out the screws (10) that join the turbocompressor to the coupling sleeve, and remove the coupling
sleeve (11).

10

7 - Take out the screws (12) and remove the bracket (13).

13
12
RKZA1620

8 - Take out the nuts (14), and the washers (15) and lift
off the turbocompressor (16).
H 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.

Tube retaining screws: 22.5 28.4 Nm

Flange screws: 8 9 Nm

Coupling joint screws: 22.5 28.4 Nm

Bracket screws: 22.5 28.4 Nm

1 - Start the engine and check that there are no leaks in
the turbocompressor lubrication tubes.

30-20

REMOVAL AND INSTALLATION

CYLINDER HEAD

REMOVAL OF THE CYLINDER HEAD

Fully raise the front working equipment and engage
the safety stop. Also make the backhoe safe.
Raise the engine hood and disconnect the cable
from accumulator negative terminal ().

H Drain the engine coolant liquid.

Coolant liquid: 18

1 - Remove the container (1).

RKZA0060

2 - Disconnect the cable (2) of the clogged air-filter sensor and remove the entire suction filter (4) and its support (5).
For WB93R-2 only
H Remove the turbocompressor. (For details, see
REMOVE THE TURBOCOMPRESSOR).

RKZA0182

3 - Disconnect the cable (6) of the cold-start equipment.

4 - Remove the suction manifold (7) and the cold-start
equipment (8).
5 - Remove the diesel fuel filter (9) and place it to one
side.

7
9
6

6 - Disconnect the clips that secure the heating pipes

and diesel fuel pipes.

10
RKZA0161

7 - Disconnect the breather tube (11) from the engine

head.

11

RKZA0221

30-21

REMOVAL AND INSTALLATION

CYLINDER HEAD

8 - Remove the muffler (12).

(For details, see REMOVAL OF THE MUFFLER).

12

9 - Remove the muffler support bracket (13).

13
RKZA0250

10 - Disconnect the cables (14) from the temperature sensors (15).

11 - Disconnect the heating pipes (16).

15

12 - Remove the radiator connection pipes (17).

13 - Remove the coolant liquid pump. (For details, see
REMOVAL OF THE COOLANT LIQUID PUMP).

17

14

17

16

RKZA0192

14 - Disconnect the fuel return hose (18) from the injector

nozzles and remove the nozzles. (For details, see
REMOVAL OF THE INJECTOR NOZZLES).

18

19

15 - Remove the cover of the tappets (19).

RKZA0171

16 - Remove the valve rocker-arm shaft (20).

H Loosen the nuts and unscrew the tappets by 2-3
turns.

23

20
22

17 - Take out the rocker-arm control rods (21).

21
RKZ00160

30-22

REMOVAL AND INSTALLATION

CYLINDER HEAD

18 - Take out the screws (22) and remove the entire cylinder head (23). Follow the indicated sequence for loosening the screws.
H Sequence to be followed: see drawing.

BOLT LOOSENING ORDER

18

1
3

11
5

12

4
2

10

17
13

14

16

Loosen the cylinder head retaining screws in two

stages.

15

RKZ00170

30-23

REMOVAL AND INSTALLATION

CYLINDER HEAD

INSTALLATION OF THE CYLINDER HEAD

.

To install, reverse the removal procedure.

H Fill up the cooling circuit.

Coolant liquid: 18 ,
H Check carefully that there are no leaks.
Support screws: 35.2 Nm (3.6 kgm)
Bracket screws: 45 55 Nm
Screws for intake line: Loctite 262
Screws for intake line: 45 55 Nm
High-pressure pipe fittings:
24.5 34.3 Nm (2.5 3.5 kgm)
Collar lock nuts: 9.8 11.8 Nm (1 1.2 kgm)
H 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: 25w3 Nm
H Check that the tappets are firmly engaged in their
rods and that the valve collars are correctly assembled.
Rods - tappets: Engine oil
H Start tightening the rocker-arm shaft from the center towards the outside.
Screws and nuts for the rocker-arm shaft:
22.5 28.4 Nm (2.3 2.9 kgm)
H Adjust the valve clearances (For details, see 20.
TESTING AND ADJUSTMENTS).
H Assemble a new gasket..
Bolt and cylinder block threadings: Engine oil.
H Tighten the screws, manually at first, and then in
two stages, following the sequence indicated.
Cylinder head bolts.
First tightening: 88.3 98.1 Nm (9 10 kgm)
Final tightening: 181.4 191.2 Nm
(18.5 19.5 kgm)
1 - Start the engine at low idling to circulate the coolant
liquid through all circuits.
2 - Accelerate gradually up to 1700 rpm. After about one
minute, stop the engine and check or top up the level
in the container.

BOLTS TIGHTENING ORDER

12

16
14

2
6

13

3
10

18

15

9
4

17
11

RKZ00180

30-24

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 tightening torque, and thus to facilitate the subsequent
dismantling procedure.
2 - Insert the prongs of a fork-lift truck into the ventilation
slits, and force them gently upwards to compensate
for the weight of the counterweight (2).

3
1

3 - Remove the screws (1) and the washers (3).

4 - Remove the Front counterweight (2).

1 3
RKZA1840

Counterweight: 300 kg

2
RKZA1850

INSTALLATION OF THE FRONT COUNTERWEIGHT

.

To install, reverse the removal procedure.

Screws: 300w30 Nm

30-25

REMOVAL AND INSTALLATION

RADIATOR-OIL COOLER UNIT

REMOVAL OF THE RADIATOR-OIL COOLER UNIT

Fully raise the front working equipment and engage
the safety stop. Also make the backhoe safe.
Raise the engine hood and disconnect the cable
from accumulator negative terminal ().

1 - Disconnect the gas cylinder (1) and cable for maximum opening engine hood. Accompany the hood until it is completely open.
H Place some soft material between the engine
hood and the front closing mechanism.
Completely eliminate all residual pressures in all circuits. (For details, see 20. TESTING AND ADJUSTMENTS).
H Drain the cooling liquid.
Coolant liquid: 18

1
RKZA0260

2 - Disconnect the cable from accumulator positive terminal (+) and remove the accumulator (2).

3 - Disconnect the cable (3) and remove the acoustic

alarm (4).

4 - Remove the air filter suction line (5).

17

RKZA0270

5 - Remove the container (6).

6 - Disconnect the engine coolant circuit hoses (8) and

(9) from the radiator (7).

7 - Remove the brackets (17).

17
9
RKZA0061

8 - Slowly loosen the hoses (10) and (11) to drain the hydraulic oil from the oil cooler (12). When the oil is fully
drained, complete disconnection of the hoses, and
plug them to prevent entry of impurities.
Hydraulic oil: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ,

12

11

11

10

RKZA0280

30-26

REMOVAL AND INSTALLATION

RADIATOR-OIL COOLER UNIT

9 - Slowly loosen the hoses (13) to drain the oil from the
transmission oil cooler (14). When the oil is fully
drained, complete disconnection of the hoses, and
plug them to prevent entry of impurities.
Transmission oil:. . . . . . . . . . . . . . . . . . . . . . . . . . . .

15
14

,
11

13

RKZA0290

10 - Disconnect the conveyor (15) from the radiator (7) and

move it towards the engine.
11 - Take out the nuts (16) of the lower anti-vibration units
and remove the entire radiator - oil cooler group (18).

18

Radiator - oil cooler group: 37 kg

16
RKZA0281

30-27

REMOVAL AND INSTALLATION

RADIATOR-OIL COOLER UNIT

INSTALLATION OF THE RADIATOR OIL COOLER GROUP

.

To install, reverse the removal procedure.

Refill the coolant liquid circuit.

Coolant liquid: 18

H First connect the positive pole (+).

.

Ensure that the level of hydraulic oil in the tank is at

maximum.

Ensure that the level of transmission oil is at maximum.

Anti-vibration unit nuts:. . . . . . . . . . . . . . . . . . . Nm
1 - Start the engine at low idling to circulate all the fluids
and to fill up the oil coolers.
2 - Accelerate gradually up to 1700 rpm. After about one
minute, stop the engine and top up all levels.
H Check carefully that there are no leaks.

30-28

REMOVAL AND INSTALLATION

HYDRAULIC OIL COOLER

REMOVAL OF HYDRAULIC OIL COOLER

Fully raise the front working equipment and engage
the safety stop. Also make the backhoe safe.
Raise the engine hood and disconnect the cable
from accumulator negative terminal ().

1 - Disconnect the gas cylinder (1) and cable for maximum opening engine hood. Accompany the hood until it is completely open.
H Place some soft material between the engine
hood and the front closing mechanism.
Completely release residual pressures from all circuits.
(For details, see 20. TESTS AND ADJUSTMENTS).

1
RKZA0260

2 - Disconnect the cable from accumulator positive terminal (+) and remove the accumulator (2).

3 - Disconnect the cable (3) and remove the warning

horn (4).

RKZA0300

4 - Slowly loosen the hoses (4) and (5) to drain the hydraulic oil from the cooler (6). When all the oil has
been drained, disconnect the hoses completely and
plug them to prevent entry of impurities.
Hydraulic oil:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 - Remove the screws (7) and remove the oil cooler (8).

INSTALLATION OF THE
HYDRAULIC OIL COOLER
.

7
RKZA0282

To install, reverse the removal procedure.

H First connect the positive pole (+).

.

Make sure that the level of the hydraulic oil in the tank
is at maximum.
1 - Start the engine at low idling in order to circulate the
oil and fill up the cooler.
2 - Accelerate gradually up to 1700 rpm. After about one
minute stop the engine and top up the level of oil in
the tank.

30-29

REMOVAL AND INSTALLATION

TRANSMISSION OIL COOLER

REMOVAL OF THE TRANSMISSION OIL COOLER

Fully raise the front working equipment and engage
the safety stop. Also make the backhoe safe.
1 - Remove the radiator - oil cooler group. (For details,
see REMOVAL OF THE RADIATOR - OIL COOLER
GROUP).

6
6

2 - Remove bracket (1) and rubber sheet (2).

RKZA0310

3 - Loosen the retaining clip (3) of the coupling (4) on the

radiator (5).
4 - Take out the nuts(6) and remove the oil cooler (7).

5
7
3

4
RKZA0320

INSTALLATION OF THE
TRANSMISSION OIL COOLER
.

To install, reverse the removal procedure.

Make sure that the levels of the transmission oil, the

hydraulic oil and the engine cooling liquid are all at
maximum.
1 - Start the engine at low idling to let the fluids circulate,
and fill up the oil coolers.
2 - Gradually accelerate up to 1700 rpm. After about one
minute, stop the engine and top up the levels.

30-30

REMOVAL AND INSTALLATION

MUFFLER - EXHAUST PIPE

REMOVAL OF THE MUFFLER

Fully raise the front working equipment and engage
the safety stop. Also make the backhoe safe.
1 - Take out the retaining screws (1) of the flexible outlet
hose (2).

2 - Take out the two screws (3), the screws (4) and remove the muffler (5).

INSTALLATION OF THE MUFFLER

To install, reverse the removal procedure.
H Put in a new sealant.

RKZA0330

Muffle: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nm

3
RKZA0251

REMOVAL OF THE
EXHAUST PIPE
1 - Loosen the clip (6) and disconnect the flexible hose
(2).

2 - Take out two of the three lower screws (7) of the connecting flange (8).
H Loosen the third screw and leave it in place for
safety.

3 - Take out the nut (9) and the washer of the upper antivibration unit (10).

RKZA0340

4 - Take out the last screw (7) and remove the exhaust
pipe (11).

INSTALLATION OF THE
EXHAUST PIPE
.

To install, reverse the removal procedure.

10

9
11

RKZA0350

30-31

REMOVAL AND INSTALLATION

ENGINE HOOD

REMOVAL OF THE ENGINE HOOD

Lower the working equipment completely until it is
resting on the ground and stop the engine.
Raise the engine hood and disconnect the cable
from accumulator negative terminal ().

2
4

1 - Disconnect the gas cylinder (1) and cable for maximum opening engine hood.
2 - Mark the position of the bracket (3) on the hood (2).
3 - Take out the screws (4) and remove the engine hood
(2).

Engine hood:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . kg

RKZA0360

H If the hood is removed to aid extraction of the engine-transmission group, remove bracket (3) after
remove front counterweight (5), the safety pin (6)
and the washer too.
(See REMOVAL OF FRONT COUNTERWEIGHT).

5
RKZA0592

6
6

RKZA0370

INSTALLATION OF THE
ENGINE HOOD
To install, reverse the removal procedure.
H Check that the hood (2) closes perfectly, and re-attach
the screws (7).

RKZA0380

30-32

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 wrench.
Raise the engine hood and disconnect the cable
from accumulator negative terminal ().

2
1

Release all residual pressure in all circuits. (For details, see 20. TESTING AND ADJUSTMENTS).
1 - Disconnect the pedal accelerator and hand accelerator cables (1) from the injection pump. Disengage the
sheathings from the support (2).

RKZA0091

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

axle (3).

3 - Disconnect the braking circuit pipes (5) and the differential lock tube (6) from the rear axle.
H Mark the positions of the pipes to prevent exchange of positions when reconnecting.
H Plug the pipes and pipe-fittings to prevent entry of
impurities.

5
6
RKZA0390

4 - Disconnect the steering cylinder pipes (7) from the

rear axle.
H Mark the positions of the pipes to prevent exchanging positions when reconnecting.
H Plug the pipes and pipe-fittings to prevent entry of
impurities.

RKZA0400

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

from the steering unit.
H Mark the positions of the pipes to prevent exchanging positions when reconnecting.
H Plug the pipes and pipe-fittings to prevent entry of
impurities.

9
10
RKZA0410

30-33

REMOVAL AND INSTALLATION

CAB

6 - Disconnect the connectors (11) and (12), the grounding plait (13), and the grounding cable (14).
7 - Disconnect the connectors (15), (16) and (17) from the
gearbox.

12
11

13

15

16

17

14

RKZA0420

8 - Disconnect the connector (18) of the auxiliary controls

set into the bucket control lever.
9 - Disconnect the converter disengagement connector
(19) set into the gear lever.
10 - Disconnect the connector (20) of the differential disengagement and backhoe boom disengagement solenoids.
11 - Disconnect the power increment solenoid connector
(21) installed on the piston pump.

20

21

18
19
RKZA0430

12 - Disconnect the connectors (22) of the rear acoustic

alarm, the connector (23) of the rear lights and finally
the connector (24) of the solenoid of the backhoe control valve.

23

24

22

RKZA0440

13 - Lift off the lower left-hand guard of the cab and disconnect the connector (25) of the fuel level indicator
and the connector of the self-supply pump, if any.
14 - Also lift off the lower right-hand guard.

25
RKZA0450

30-34

REMOVAL AND INSTALLATION

15 - Remove the grip (2) of the hand accelerator and then

the inspection cover (27). Push the protective sleeve
(28) of the gearbox lever down into the side cover
(29).

CAB

29
28

26

27
RKZA0460

16 - Remove the grips (30) of the outrigger control levers

and the grip (31) of the lever-locking device. Lift off
the cover (32) of the control levers.
17 - Take off the self-locking nuts (33) and the four screws
that secure the cab.

30

33

31
32

RKZA0470

18 - Take off the protective plugs and screw two eyebolts

A into the holes supplied for hoisting purposes.
Attach the cab (34) to the hoisting tackle and apply a
slight tension.
19 - Slowly raise the cab, directing its movement in such
way that the gear lever slides out.
H Make sure that all the electrical leads and the accelerator cables are free.
Cab: 629 kg

34

RKZA0480

30-35

REMOVAL AND INSTALLATION

INSTALLATION OF THE CAB

.

To install, reverse the removal procedure.

H Check and adjust the stroke of the hand and pedal accelerators. (For details, see 20. TESTING AND ADJUSTMENTS).
H Adjust the stroke of the parking brake lever. (For details, see 20. TESTING AND ADJUSTMENTS).
H Bleed the air from the braking circuit. (For details, see
20. TESTING AND ADJUSTMENTS).
H Bleed the air from the steering circuit. (For details, see
20. TESTING AND ADJUSTMENTS).
Cab retaining screws: 196w9.8 Nm

30-36

CAB

REMOVAL AND INSTALLATION

CAB HEATING GROUP

REMOVAL OF THE CAB HEATING GROUP

Lower the working equipment completely until it
rests on the ground, and stop the engine.
Raise the engine hood and disconnect the cable
from accumulator negative terminal ().
H Drain the engine cooling liquid.
Coolant liquid: 18

1 - Disconnect the flexible hose (1) of the heating water

cock.

RKZA1630

2 - Disconnect the connector of the power-supply cabling

(2).
3 - Loosen the clips and disconnect the pipes (4) from
the fan-cooler (3).

4 - Loosen the four screws (5) and detach the fan-cooling

group complete with radiator (6) and fan (7) from the
cab.
H Lower the group in order to disconnect the internal pipes.

2
4

RKZA0490

5 - Disconnect the tubes (8) that connect with the engine.

6 - Remove the four screws (9) and remove the radiatorfan group, (6) and (7).

9
8

RKZA0500

INSTALLATION OF THE CAB

HEATING GROUP
.

To install, reverse the removal procedure.

1 - Refill the cooling liquid.
Coolant liquid: 18

RKZA0510

30-37

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.
Raise the engine hood and disconnect the cable
from accumulator negative terminal ().

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.
Fuel: max. 130 ,

RKZA0520

3 - Disconnect the connector (4) of the level indicator (5)

and the connector (6) of the self-supply pump, if fitted.
4 - Disconnect the fuel suction and flow-back hoses (7)
and (7) and the pipe of the self-supply pump, if fitted.
H Plug the pipes to prevent entry of impurities.
H Mark the pipes to avoid exchanging them during
installation.

5
RKZA0530

5 - Support the fuel tank (3) with hoisting tackle and remove the four retaining screws (9).

6 - Remove the fuel tank (3).

Fuel tank: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . kg

RKZA0540

INSTALLATION OF THE
FUEL TANK
.

To install, reverse the removal procedure.

1 - Refill the fuel tank.
Fuel: max. 130 ,
2 - Bleed the air from the fuel circuit.
3 - Start the engine.

30-38

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.
Eliminate completely any residual pressures from all
circuits. (For details, see 20. TESTING AND ADJUSTMENTS).
H Drain the hydraulic oil.

Hydraulic oil:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ,
1 - Take off the lower right-hand guard (1) of the cab and
the plug (2).

2
RKZA0550

2 - Disconnect the pipes (4), (5) and (6) from tank (3).
H Plug the pipes to prevent entry of impurities.

3
RKZA0560

3 - Support the tank (3) with hoisting tackle and remove

the four retaining screws (7).
4 - Remove the tank (3).
Oil for the tan: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . kg

INSTALLATION OF THE
HYDRAULIC OIL TANK
.

To install, reverse the removal procedure.

RKZA0570

Tank retaining screw: 120 Nm

1 - Refill the tank.
Hydraulic oil:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ,

2 - Refill the pump (For details, see 20. TESTING AND

ADJUSTMENTS).
3 - Start the engine to let the oil circulate through all the
hydraulic systems and check for leaks.

3 - Bleed the air from the hydraulic systems. (For details,

see 20. TESTING AND ADJUSTMENTS).
4 - Stop the engine, check the oil level in the tank, and
top it up if necessary.

RKZA0580

30-39

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.
Raise the engine hood and disconnect the cable
from accumulator negative terminal ().

Release all residual pressure in all circuits.

(For details, see 20. TESTING AND ADJUSTMENTS).
H Drain the hydraulic oil.

Hydraulic oil: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ,
H Drain the engine cooling liquid.
Coolant liquid: 18

RKZA0590

H Drain the oil from the gearbox.

Gearbox oil: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ,
1 - Remove the front working equipment. (For details,
see REMOVAL OF THE FRONT WORKING EQUIPMENT).
2 - Take off the accumulator the engine hood. (For details, see REMOVAL OF THE ENGINE HOOD).
3 - Take out the screws (1) and remove the front counterweight (2). (For details, see REMOVAL OF THE
FRONT COUNTERWEIGHT).

3
5
4

RKZA0600

4 - Remove the radiator-oil cooler group. (For details,

see REMOVAL OF THE RADIATOR-OIL COOLER
GROUP).
5 - Raise the protective sleeve (3), disconnect the connector (4) and remove the gear lever (5).
6 - Disconnect the rear cardan shaft (7) from the gearbox
(6).

6
RKZA0610

7 - Remove the front cardan shaft (8).

RKZA0401

30-40

REMOVAL AND INSTALLATION

8 - Disconnect the suction hose (10), the delivery pipe

(11) and the Load Sensing signal (12) from the pump
(9).
Disconnect also the power increment solenoid connector.
H Plug the pipes to prevent entry of impurities.

ENGINE-GEARBOX-PUMP GROUP

10
11

12

9
RKZA0620

9 - Disconnect the drainage pipe (13).

H Plug the pipes to prevent entry of impurities.
H Mark the mounting direction if removal of check
valve (14) is perfomed.

14
13
10
RKZA0630

10 - Disconnect from the gearbox (15) the connectors (16)

of the oil temperature sensor solenoid (17), the
grounding plait (18), the oil cooling circuit pipes and
the control lines (19), and the clips (20).
H Plug the pipes to prevent entry of impurities.

20

18

16
17

15

19
RKZA0640

11 - Disconnect the coolant liquid temperature sensors

(21) and (22) from the engine.
12 - Disconnect the cab heating pipes (23) from the coolant pump.

21

22

23

RKZA0650

30-41

REMOVAL AND INSTALLATION

ENGINE-GEARBOX-PUMP GROUP

13 - Disconnect the connector (24) of the oil pressure sensor and the connector (25) of the solenoid that stops
the engine.

24
25

RKZA0660

14 - Disconnect the cable (26) of the cold-start equipment,

the cab heating-pipe support clip (27), and the fuel
tank flow-back hose (28).

26
28
27

RKZA0162

15 - Disconnect the cables (29) of the pedal and hand accelerators. Disengage the support sheathing (30).

30
29

RKZA0092

16 - Disconnect the fuel lines (32) from the separator (31)

and plug them.

32

17 - Remove the separator.

31

RKZA0670

30-42

REMOVAL AND INSTALLATION

ENGINE-GEARBOX-PUMP GROUP

18 - Disconnect the cables (33) from the starting motor

(34) and the cables (35) from the alternator (36).

33

35

36

34

RKZA0680

19 - Remove the plate (37) and push it towards the back of

the machine.

37

RKZA0381

20 - Disconnect the flexible return hose (39) from the muffler (38).

39
38

RKZA0690

21 - Attach the entire group to some hoisting tackle using

the engine bracket (40) and the muffler support (41).
Apply a slight tension to the hoisting chains.

40

41

RKZA0700

30-43

REMOVAL AND INSTALLATION

H The chains should have a total length of about 800

mm and a difference between the arms of 53 mm.
H The shortest length should be attached to the bracket
(40).
H When under tension the cables should be about
200 mm apart at the height of the muffler.

ENGINE-GEARBOX-PUMP GROUP

-- 53 mm

200 mm

RKZA1640

22 - Loosen and remove the nuts (42) of the anti-vibration

supports (43) of the engine and gearbox, and take out
the screws (44).
23 - Raise the entire group until the chassis supports are
disengaged, and than accompany the group in order
to slide it away from the front part of the chassis.

44
43

43

Engine-gearbox-pump group:
WB91R-2: 730 kg
WB93R-2: 740 kg

42
42
44
RKZA0710

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: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ,
2 - Fill the gearbox up to its maximum level.
Gearbox oil: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ,
3 - Refill the coolant liquid.
Coolant liquid: 18 ,

H First connect the positive pole clamp (+).

Screws for front counterweight: 300w30 Nm
Screws on gearbox side: 70 Nm
Nuts on axle side: 70 Nm

30-44

REMOVAL AND INSTALLATION

ENGINE-GEARBOX-PUMP GROUP

H Fill up the pump casing and the pump, to bring the

tank up to pressure.
For the method see 20. TESTING AND ADJUSTMENTS.
H Bleed the air from the fuel lines.
Nuts from the anti-vibration supports
196w19.6 Nm
4 - Start the engine to circulate the oil and coolant liquid.
Check that there are no leaks.
5 - Bleed the air from the working equipment circuits.
(For details, see 20. TESTING AND ADJUSTMENTS).
6 - Stop the engine, check the levels and, if necessary,
top them up.

30-45

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.
Cut off the supply of electricity by turning the accumulator-disconnecting switch in a counter-clockwise
direction, and remove the handle.
Release residual pressure fully in all circuits. (For
details, see 20. TESTING AND ADJUSTMENTS).
H Drain the hydraulic oil.

1
2
3

Quantity of oil: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ,
1 - Disconnect the suction hose (2), the delivery pipe (3)
and the Load Sensing signal line (4) from the pump
(1).
Disconnect also the power increment solenoid connector.

4
RKZA0621

2 - Disconnect the drainage pipe (5).

H Plug the pipes to prevent entry of impurities.
H Mark the mounting direction if removal of check
valve (6) is perfomed.

9
5

RKZA0631

3 - Disconnect the solenoid connector (7).

4 - Take out the rear cardan shaft (8).

10
8
RKZA0720

5 - Attach the pump (1) to the tool B1 mounted on a pit

jack.
H For attachment purposes, use the pump body filling pipe (9).

B1
RKZA0730

30-46

REMOVAL AND INSTALLATION

PISTON PUMP

6 - Take out the two screws (10) and remove the pump
(1) complete with its O-ring (11).

Pump: 38 kg

11
1

B1
RKZA0740

INSTALLATION OF THE
PISTON PUMP
.

To install, reverse the removal procedure.

1 - Fill the tank with hydraulic oil up to maximum level.

Hydraulic oil:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ,
H Fill the pump body and the pump, bringing the
tank up to pressure.
For the method, see 20. TESTING AND ADJUSTMENTS.
Screws for suction flange: 100 Nm
Screws for delivery flange: 60 Nm
Screws on gearbox side: 70 Nm
Nut on axle side: 70 Nm
Pump retaining screws: Loctite 262
Pump retaining screws: 220 Nm
2 - Start the engine to circulate the oil in all hydraulic circuits.
3 - Stop the engine, check the oil level in the tank and, if
necessary, top it up.

30-47

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.
Raise the engine hood and disconnect the cable
from accumulator negative terminal ().
Release all residual pressure in all circuits. (For details, see 20. TESTING AND ADJUSTMENTS).
H Drain the hydraulic oil.
Hydraulic oil:: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ,
H Drain the oil from the gearbox.
Gearbox oil: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ,
1 - Remove the piston pump. (For details, see REMOVAL OF THE PISTON PUMP).
2 - Raise the protective sleeve (1), disconnect the connector (2) of the transmission disengagement and remove the gear lever (3).

3
2

RKZA0601

3 - Disconnect the pipe (4) that fills the gearbox with oil.

4 - Take out the front cardan shaft (5).

RKZA0750

5 - Take off the cover (6) of the flywheel oil-sump and

take out the six retaining screws (7) of the converter
coupling flange (8).

6
8

RKZA0760

30-48

REMOVAL AND INSTALLATION

6 - Disconnect the connectors (9) of the solenoids and

the temperature sensor (10).

TRANSMISSION

9
11

7 - Disconnect the four tubes (11) for oil circulation and

controls.

10
11
RKZA0770

8 - Remove the plate (12) and push it towards the back of

the machine.

12

RKZA0382

9 - Attach the engine-gearbox group to the hoisting

tackle using the engine bracket (13) and the muffler
support (14). Apply tension to the hoisting chains.

13

14

RKZA0701

10 - Loosen and remove the nuts (15), and screws (16)

and the anti-vibration nuts (17).

17

11 - Remove the gearbox supports (18).

17

15 16
18
16 15

RKZA0780

30-49

REMOVAL AND INSTALLATION

TRANSMISSION

12 - Attach in the place of the supports (18), the tool C1

mounted on a pit jack A which can be lowered by
approx. 60 cm.
H Secure the tool C1 with the spacers and screws
B M12x40.

20

C1

A
RKZA0790

13 - Loosen and remove the twelve screws (19) that hold

the engine and gearbox together.

19

20

RKZA0800

14 - Remove the entire gearbox, (20) by shifting it towards

the back of the machine in order to disengage the
convertor. Lower it slowly and turn the group in a
clockwise direction to disengage it from the chassis
in order to extract it.
Transmission: 230 kg

20
C1
RKZA0810

30-50

REMOVAL AND INSTALLATION

TRANSMISSION

INSTALLATION OF THE TRANSMISSION

.

To install, reverse the removal procedure.

Hydraulic oil:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ,
Gearbox oil:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ,
H Fill the pump body and the pump in order to pressurise the tank.
For the method, see 20. TESTING AND ADJUSTMENTS.
Screws for securing lever: 120 Nm
Screws: Loctite 262
Screws on gearbox side: 70 Nm
Nuts on axle side: 70 Nm
Flange screws: Loctite 262
Flange screws: . . . . . . . . . . . . . . . . . . . . . . . . . . . Nm
Anti-vibration nuts: 196w19.6 Nm
Support screws: Loctite 262
Support screws: 90 Nm
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.

30-51

REMOVAL AND INSTALLATION

TRANSMISSION

OVERHAULING THE TRANSMISSION

1. Dismantling the external group

12

2
21

13

22

14

23

16
18

20

6
20

15
17
19

25

27

26
11

24
10

30

27

29

28

RKZ02380

1 - Attach the transmission group to some equipment

that allows the group to rotate.

RKZA5730

2 - Take out the screws (1) and remove the distributor (2).

30-52

RKZA5740

REMOVAL AND INSTALLATION

TRANSMISSION

3 - Remove the gasket (4).

H A new gasket must be fitted every time it is dismantled.

RKZA5750

4 - Remove the three screws (5) that fasten the plate (6).

6
RKZA5760

5 - Remove the plate (6).

RKZA5770

6 - Remove the gasket (7).

H A new gasket must be fitted every time it is dismantled.

RKZA5780

30-53

REMOVAL AND INSTALLATION

TRANSMISSION

7 - Remove the screws (8) that secure the cover (9) and
take of the filter (10) complete with the O-ring (11).

8
10

11
RKZA5790

8 - Take out the screws (12) and remove the solenoid

valve (13).

12

13
RKZA5800

9 - Remove the gasket (14).

H A new gasket must be fitted every time it is dismantled.
10 - Remove the filter (15).

15
14

RKZA5810

11 - Remove the filter attachment fitting (16).

12 - Remove the valve spool (17).

16

17

RKZA5820

30-54

REMOVAL AND INSTALLATION

TRANSMISSION

13 - Take out the spring (18).

14 - Use a puller for blind holes to extract the priority valve
(19).
The priority valve is calibrated in the factory and
should not be modified. If it appears to be damaged, replace it with a new one.

19

18

RKZA5830

Only if necessary
15 - Remove the two caps (20).
H The caps should only be removed if there are leakages.
Caps: Loctite 262
Caps: 40 Nm

20
20

RKZA5840

16 - Loosen and take out the screws (21) that secure the
shifter group (22).

22

17 - Remove the group (22) and the O-ring (23).

23
21

RKZA5850

18 - Mount two screws in the holes in the flange (24) and,

holding the flange steady, remove the central screw
(25).

24
25

RKZA5860

30-55

REMOVAL AND INSTALLATION

TRANSMISSION

19 - Remove the washer (26).

20 - Remove the O-ring (27) and the flange (24).
H The O-ring (27) must be replaced every time it is
dismantled.

24

26

27
25

RKZA5870

21 - Mount two screws in the flange (28) holes and, holding the flange steady, remove the central screw (29).

29

28
RKZA5880

22 - Remove the washer (30).

23 - Remove the flange (28).
24 - Remove the internal O-ring (27).
H The O-ring (27) must be replaced every time it is
dismantled.

30

28

27

RKZA5890

30-56

REMOVAL AND INSTALLATION

TRANSMISSION

2. Assembly of the external groups

1 - Insert O-ring (27) in the flange and mount flange on
the shaft (75).

28

30

2 - Mount the washer (30).

RKZA8270

3 - Screw the screws (29) home by hand.

4 - Mount two screws in the flange (28).
5 - Holding the flange steady, tighten the screw (29).
Screw: 139 Nm

29

28
RKZA5880

6 - Mount the flange (24) of the secondary shaft.

7 - Mount the O-ring (27).
8 - Mount the washer (26) and the screw (25). Screw the
screw (25) home by hand.

27

26

24

25

RKZA8280

9 - Mount two screws in the flange (24).

10 - Holding the flange steady, tighten the screw (25).
Screw: 139 Nm

25

24

RKZA8290

30-57

REMOVAL AND INSTALLATION

TRANSMISSION

11 - Mount the O-ring (23) in the rear housing.

O-ring: ASL800050
12 - Lubricate the levers and the shifter levers' end (22).
Shifter and levers: ASL800040
13 - Mount the shifter group (22) and the screws (21).

22
23
22
21
RKZA8300

14 - Secure the shifter group (22).

Screws: 23 Nm

22

RKZA8310

15 - Mount the priority valve (19).

16 - Mount the spring (18).

19

18

RKZA8320

17 - Mount the spool (17).

18 - Mount and tighten the fitting (16).
Fitting: 50 Nm

17

16

RKZA8330

30-58

REMOVAL AND INSTALLATION

19 - Lubricate the gasket and mount the filter (15).

Filter: See the manufacturer's instructions.
20 - Mount the gasket (14).

TRANSMISSION

15

14

RKZA8340

21 - Mount the solenoid valve (13) and secure it with the

screws (12).
Screws: 23 Nm

12

13
RKZA5800

22 - Mount the gasket (7).

RKZA5780

23 - Mount the plate (6).

RKZA5770

30-59

REMOVAL AND INSTALLATION

TRANSMISSION

24 - Attach the plate (6) with the screws (5), using the alternating crosswise method.
Screws: 23 Nm

6
RKZA5760

25 - Place the gasket (4) of the distributor (2) in position.

RKZA8350

26 - Place the distributor (2) in position and secure it with

the screws (1).
H Tighten the screws starting in the centre and moving towards the outside, using the alternating
crosswise method.
Screws: 23 Nm

2
1

RKZA8360

27 - Insert the filter (10) complete with O-ring (11).

28 - Mount the cover (9) and secure it with the screws (8).
Screws: 23 Nm

8
9

10

11
RKZA8370

30-60

REMOVAL AND INSTALLATION

TRANSMISSION

3. Dismantling the transmission

34

38

39
35

46 47

48

40 41 36
43

33

51 44

49
50

42
45

40 37
54
52
31

60

32

56
57

59
58

RKZ02750

1 - Loosen and take out the screws (31) that secure the
rear housing (32).

31

32

RKZA5900

2 - Loosen and take out the screws (33).

33

RKZA5910

30-61

REMOVAL AND INSTALLATION

TRANSMISSION

3 - Use a lever inserted into the opposing cavities to disconnect the cover (34) of the transmission housing.

34

RKZA5920

4 - Remove the cover (34) complete with the hydraulic

pump drive shaft (35).

34
35

RKZA5930

5 - Remove the snap ring (36) that secures the shaft (35).
6 - Use a plastic mallet to extract the shaft (35)from the
bearing (37).

35
36

37

RKZA5940

7 - Extract the bearing (37) from the cover (34).

8 - Turn the cover (34) upside down and take out the seal
ring (38).
H A new seal ring must be substituted.

37

38

RKZA5950

30-62

REMOVAL AND INSTALLATION

TRANSMISSION

9 - Remove the sealing rings (39) from the shaft (35).

H The two extremities must be unhooked in order to
remove it.

39
39
RKZA5960

10 - With a punch, remove the pins (40) that fasten the differential lock rings (41) and (42) of the shifter rods.

41
40

42

RKZA5970

11 - Remove the differential lock rings (41) and (42).

41

42
RKZA5980

12 - Remove the screws (43) that secure the plate (44).

43

44

RKZA5990

30-63

REMOVAL AND INSTALLATION

TRANSMISSION

13 - Remove the plate (44).

14 - Use a magnet to remove the two balls (45) from the
hole between the two shifter rods.

44

45

RKZA6000

15 - Remove the cap (46).

46

RKZA6010

16 - Use a magnet to extract the spring (47) and the ball

(48).
H Repeat phases 15 and 16 for the other cap.

48

47

RKZA6020

17 - Remove the bearing-retaining snap ring (52) of the

secondary shaft (53).

52

53

RKZA6030

30-64

REMOVAL AND INSTALLATION

TRANSMISSION

18 - Remove the bearing-retaining snap ring (54) of the

main shaft (55).

54

55
RKZA6040

19 - Turn the transmission upside down and remove the

three screws (56).

56

RKZA6050

20 - Remove the screws (57) and remove the cover (58).

57

58
RKZA6060

21 - Remove the O-ring (59) and the seal ring (60) from the
cover.

60

59
RKZA6070

30-65

REMOVAL AND INSTALLATION

TRANSMISSION

32

77

76

74
3
68
71

73
69

63
62
75
66

67

67

64
72
61

70

RKZ02760

22 - Loosen and remove the retaining screws (61) of the

pump (62).

61

62

RKZA6080

23 - Using two levers opposite to each other, raise the

pump (62) smoothly.

62

RKZA6090

30-66

REMOVAL AND INSTALLATION

TRANSMISSION

24 - Take out the pump (62) complete with its seal ring
(63).

62
63

RKZA6100

25 - Slightly raise the input shaft (66) and remove the

bearing-retaining snap ring (65).

65

64

RKZA6110

26 - Attach some hoisting tackle to the front flange (3) of

the transmission and apply a slight tension.
Using two levers opposite to each other, separate the
flange (3) from the transmission housing.

RKZA6120

27 - Slowly raise the front flange (3), keeping it horizontal.

H If necessary, assist the raising operation with a lever and also by knocking on the shaft of the front
drive with a plastic mallet.

RKZA6130

30-67

REMOVAL AND INSTALLATION

TRANSMISSION

28 - Remove the differential lock ring (66) complete with

the sealing rings (67).

66

RKZA6140

29 - Remove the two sealing rings (67) from the differential lock ring.
H They can be removed by unhooking the two extremities.
H New sealing rings (67) must be substituted each
time they are dismantled.

67

67
RKZA6150

30 - Remove the bearing (68) of the main shaft and the

bearing (69) of the secondary shaft.
31 - Remove the bearing (70) from the seating of the front
flange (3).

69

68

70
3

RKZA6160

32 - Remove the fittings (71) and take out the pipe (72)
complete with the copper washers (73).

71

71
72

RKZA6170

30-68

REMOVAL AND INSTALLATION

TRANSMISSION

33 - Remove the O-rings (74) that form a seal between the

front housing (3) and the transmission housing (32).

74
74

32
RKZA6180

34 - Remove the shaft (75) of the 4-wheel drive.

75

RKZA6190

35 - Remove the input shaft (76) and the reverse shaft

(77).

76

77

RKZA6200

30-69

REMOVAL AND INSTALLATION

TRANSMISSION

86

85

87

80
79

32

81

89
84
83
78

82

88
89
RKZ02770

36 - Turn the transmission upside down. Connect it to

some hoisting tackle suitable for the upper gears.

RKZA6210

37 - Raise the secondary shaft (78) with the hoisting

tackle and at the same time raise the main shaft by
hand.
H The forks and the shifters for 1st/2nd and 3rd/4th
gears are also raised at the same time.
If any parts remain stuck, they can be separated
by tapping them with a plastic mallet.

78

79

RKZA6220

30-70

REMOVAL AND INSTALLATION

TRANSMISSION

38 - Raise the secondary shaft (78) until the shifter fork

(80) and (81) can be moved. Then remove the shaft.

78

RKZA6230

39 - Remove the shifter fork (81) for the 1st/2nd gears.

81

RKZA6240

40 - Remove the shifter fork (80) for the 3rd/4th gears.

H Make a note that this fork fits in the upper hole of
the transmission housing.

80

RKZA6250

41 - Remove from the transmission housing (32) the 4wheel drive clutch gear (82).

82

RKZA6260

30-71

REMOVAL AND INSTALLATION

TRANSMISSION

42 - Remove the bearing ring (83) and the bearing (84).

83

84

RKZA6270

43 - Remove the caps (85) for the pressure adapters, the

vent plug (86) and the temperature sensor (87).

85
86

32

87

RKZA6280

Only if necessary
44 - Remove the fittings (89) and the pipe (90) of the 4wheel drive clutch.

89
90

89

RKZA6290

4. Assembly of transmission
Only if it has been removed:
1 - Mount the clutch pipe (90) and lock it in place with the
fittings (89).
Fittings: 40 Nm

89
90

89

RKZA6290

30-72

REMOVAL AND INSTALLATION

2 - Mount on the housing (32) the temperature sensor

(87), the vent plug (86) and the caps for the pressure
adapters (85).

TRANSMISSION

85
86

32

87

RKZA6280

3 - Mount the bearing (84) and the bearing ring (83).

84

83

RKZA8380

4 - Install the gear (82).

H The side with the raised areas must face towards
the inside of the transmission.

82

RKZA6260

5 - Connect a hoisting tackle to the upper gear of the

secondary shaft (78) and position it above its seating.
Engage the forks (80) and (81) in the synchronizer
rings.
H The forks for the 3rd and 4th gears must be placed
in the upper hole.

80

78

81

RKZA8390

30-73

REMOVAL AND INSTALLATION

TRANSMISSION

6 - Lower the entire group, centering the individual

pieces in their respective seatings. At the same time,
slide in the main shaft (79), taking great care with the
mating of the gears.

78

79

RKZA6220

7 - Rotate the housing (32) by 90 and install the snap

ring (54) on the bearing of the main shaft (79).
H After mounting the snap ring, push the main shaft
home.

54

79
32
RKZA6041

8 - Install the snap ring (52) on the bearing of the secondary shaft (78).
H After mounting the snap ring, push the secondary
shaft home.

52

78
RKZA6031

9 - Mount the balls (48) and the springs (47) in the housing (32).

48

47

RKZA8400

30-74

REMOVAL AND INSTALLATION

TRANSMISSION

10 - Mount the caps (49) complete with the copper

washers and tighten them.
Caps: 80 Nm

49

RKZA6011

11 - Insert the two balls (45) into the hole between the shifter rods (80) and (81).
12 - Position the plate (44).

80
45

44

81
RKZA8410

13 - Secure the plate (44) with the screws (43).

Screws: Loctite 542
Screws: 50 Nm

43

RKZA5991

14 - Mount the differential lock rings (41) and (42) on the

shifter rods (80) and (81).

41

42
RKZA5980

30-75

REMOVAL AND INSTALLATION

TRANSMISSION

15 - Insert the pins (40).

H Deaden the blows on the shaft by using a hammer
in the place of an anvil.

40

RKZA8420

16 - At the same time install the input shaft (76) and the
reverse shaft (77).

76

77

RKZA6200

17 - Install the drive shaft for the 4th gear (75).

H Make sure that the shaft (75) has engaged with
the gears (82), the bearing ring (83) and the bearing (84).

75

RKZA6190

18 - If it has been removed, install the pipe (72) on the

front housing (3). Secure it with the fittings (71) and
the copper washers (73).
Fittings: 40 Nm

71 73

71 73
72

RKZA6171

30-76

REMOVAL AND INSTALLATION

19 - Decrease the sealing surface of the housing (32) and

coat it evenly with a sealant.
Housing: Loctite 510
H Do not allow any of the sealant to penetrate anywhere where oil flows or into the seatings of the
O-rings (74).

TRANSMISSION

32

RKZA8430

20 - Position the three O-rings (74).

74
74

RKZA6181

21 - Lubricate the bearings (69) and (68) and mount them

on the main and secondary shafts.

69

68

RKZA8440

22 - Install the front housing (3) on the rear housing (32).

H Make sure that all the bearings have settled correctly into their seatings in the front housing (3).
23 - Push the two housings home.

32
RKZA8450

30-77

REMOVAL AND INSTALLATION

TRANSMISSION

24 - Screw in all the screws by (31) by hand.

25 - Tighten the screws using the alternating crosswise
method.
Screws: 50 Nm

31

RKZA5901

26 - Screw in the screws (56) by hand.

27 - Tighten the screws using the alternating crosswise
method, starting from the centre.
Screws: 50 Nm

56

RKZA6050

28 - Mount the new sealing rings (67) on the differential

lock ring (66).
H Hook up the extremities and position them 180
apart.

66

67
RKZA6151

29 - Lubricate the differential lock ring (66) and mount it

on the 4-wheel drive shaft (75).

66

30 - Mount the bearing (70) on the shaft (75).

70

75
RKZA8460

30-78

REMOVAL AND INSTALLATION

TRANSMISSION

31 - Lubricate the seal ring (60) and, using the tool H2, install it in the cover (58).
H Pay careful attention to the direction of assembly.

60

H2
58
60
RKZA8470

32 - Mount the O-ring (59) on the cover (58).

33 - Lubricate the seal rings (59) and (60) and mount the
group on the housing (3).

58

58

59

RKZA8480

34 - Mount the screws (57) and tighten them.

Screws: 23 Nm

57

RKZA8490

35 - Pull the shaft (76) towards the front of the transmission and mount the snap ring (64) on the bearing.

64
76

RKZA8500

30-79

REMOVAL AND INSTALLATION

TRANSMISSION

36 - Lubricate the O-ring (63) of the pump (62) and, using

a guiding stud bolt "A", install the pump.

62
RKZA8510

37 - Take out the guiding stud bolt "A" and secure the
pump with the screws (69).
Screws: 23 Nm

61

RKZA6081

38 - Use a plunger to mount the seal ring (38) in the cover

(34).
H Pay careful attention to the direction of assembly.

34

38

RKZA8520

39 - Mount the sealing ring (39) on the shaft (35).

H The ring is secured by hooking up the two extremities "B".

35
B
36

RKZA8530

30-80

REMOVAL AND INSTALLATION

TRANSMISSION

40 - Use a press and a plunger to mount the bearing (37)

on the shaft (35).
41 - Mount the snap ring (36).

36
35
37

RKZA8540

42 - Lubricate the sealing rings and mount the complete

shaft (35) in the housing (34).

35

34

RKZA8550

43 - Coat the surface of the housing (32) with sealant.

Housing: Loctite 518
H Spread the sealant evenly all over the coupling
surface.

34

32

44 - Mount the housing (34) on the transmission and push

it home.

RKZA5931

45 - Mount the screws (33) and secure the housing (34).

Screws: 50 Nm

33

34
RKZA5911

30-81

REMOVAL AND INSTALLATION

TRANSMISSION

5. Dismantling the input shaft

104
102
103

99

105
106

107

101

97
93

107

100

91
121

94

96

108

92

95

108
109
110

110

115

109

111

106

111

107

115

113

98

107

116

121
118

112

120
108

114

101

108
117

105
119

103
102
104

RKZ02740

1 - Attach the tool H1 onto the reverse clutch side of the

shaft group.
Secure the tool in a vise, as illustrated.

H1

RKZA6300

30-82

REMOVAL AND INSTALLATION

TRANSMISSION

2 - Remove the seal ring (91).

91

RKZA6310

3 - Remove the snap ring (92) that holds the bearing (93)
in place.

92

93

RKZA6320

4 - Use a separator applied beneath the gear (94) and a

puller, to force the bearing (93) out of the seating of
the shaft (95).
Shaft seating: ASL800040
H Use a protective cap on the head of the shaft.

95

93

94

5 - Remove the bearing (93).

RKZA6330

6 - Remove the spacer (96).

7 - Remove the bearing ring (97).

97

96

RKZA6340

30-83

REMOVAL AND INSTALLATION

TRANSMISSION

8 - Remove the gear (94).

94

RKZA6350

9 - Remove the spring pin (98).

98

RKZA6360

10 - Remove the roller bearings (99).

11 - Remove the bearing ring (100).

99

100

RKZA6370

12 - Tap the outer ring (101) lightly in order to obtain some

clearance between the ring and the snap ring (102).

101

RKZA6380

30-84

REMOVAL AND INSTALLATION

TRANSMISSION

13 - Remove the snap ring (102).

102

RKZA6390

14 - Use two levers to remove the outer ring (101).

101

RKZA6400

15 - Remove the spring pin (115).

115

RKZA6410

16 - Install the upper part of the tool H1 and the three

threaded tie-rods complete with nuts, used to fasten
the component parts of the tool between them.

H1

RKZA6420

30-85

REMOVAL AND INSTALLATION

TRANSMISSION

17 - Gradually and evenly tighten the nuts in order to compress the spring (103) and to gain access to the snap
ring (104).

RKZA6430

18 - Remove the snap ring (104).

104

RKZA6440

19 - Gradually and evenly loosen the nuts and the tie-rods

on the tool H1 until the thrust of the spring (103) has
been eliminated.
Remove the upper part of the tool H1 and the tie-rods.

H1

RKZA6450

20 - Remove the spring retainer plate (105) and the spring

(103).

105

103

RKZA6460

30-86

REMOVAL AND INSTALLATION

21 - Remove the clutch pack (106).

H Make a note of the assembly sequence of the
disks.
H Make a mark on the assembly side of the clutch
pack.
H If the friction disks (108) have a thickness of less
than 1.65 mm, they must be replaced.

TRANSMISSION

106

RKZA6470

22 - Remove the piston (109).

H Take great care not to damage the surfaces and
edges of the piston.

109

RKZA6480

23 - Remove the seal ring (110).

110
RKZA6490

24 - Apply the tool H1 to the other side of the shaft group

(forward gear clutch in the upper position).
Secure the tool in a vise as indicated.

H1

RKZA6500

30-87

REMOVAL AND INSTALLATION

TRANSMISSION

25 - Remove the seal rings (111).

111
111

RKZA6510

26 - Repeat also for this side the operations performed

from phase 3 to phase 9 for the removal of the snap
ring (112), the bearing (113), the bearing ring (114)
the spring pin (115) and the gear (116).

113
112

114

RKZA6520

27 - Take out the 1st roller bearing (117) and the spacer
(118).

117

118

RKZA6540

28 - Remove the second roller bearing (119) and the bearing ring (120).

119

120

RKZA6550

30-88

REMOVAL AND INSTALLATION

TRANSMISSION

29 - Repeat the phases from 12 to 23 to complete the dismantling of the input shaft.

116
115

RKZA6530

30 - Remove the seal rings (121) from the pistons (109).

H New seal rings must be installed each time they
are dismantled.

109

121
RKZA6560

31 - Check carefully for splines in the shaft, the rotating

parts, and in the bearings and the gears.
If there are obvious signs of wear, pitting or scoring,
change the components.
H All seal rings should be changed for new, even if
they appear to be in good condition.

30-89

REMOVAL AND INSTALLATION

TRANSMISSION

6. Assembly of the input shaft

Unless otherwise specified, the pieces being re-assembled should be lubricated with transmission oil.

109

1 - Lubricate the seal rings (121) and mount them on the

pistons (109).

121
RKZA6560

2 - Mount the seal ring (110) to the rear of the input shaft.

110

RKZA6570

3 - Lubricate the seating of the shaft (95) and the complete piston (109). Mount the piston.

95

109

RKZA6580

4 - Mount the spring (103) and the spring retainer plate

(105).
H The collar of the spring retainer plate must center
the spring.

105
103

RKZA6590

30-90

REMOVAL AND INSTALLATION

5 - Mount the upper part of the tool H1 and fasten the two
parts together with tie-rods.
Tighten them equally and evenly as much as necessary to be able to install the snap ring (104).

TRANSMISSION

H1

104
RKZA6600

6 - Mount the spring pin (115).

7 - Lubricate and mount the bearing ring (120).
H The chamfer on the bearing ring must face upwards and the bearing ring must be engaged on
the spring pin.

115
120

8 - Remove the tool H1.

RKZA6610

9 - Lubricate and install the first roller bearing (119), the

spacer (118) and the second bearing (117).

117
118
119

RKZA6620

10 - Mount the thrust bearing ring (101) on the gear (116).

H The flat part must face upwards.

101

116

RKZA6630

30-91

REMOVAL AND INSTALLATION

TRANSMISSION

11 - Mount in sequence a steel disk (107) and a friction

disk (108) until the clutch pack is complete.
H Immerse the clutch disks in oil before assembling
them.

107

108
RKZA6640

12 - Align the tongues of the steel disks (108) and turn the
gear-clutch group upside down.
Using two screwdrivers as a support, position the
clutch group in its seating.

RKZA6650

13 - With a hammer and a punch, tap lightly all around the

circumference of the thrust bearing ring (101), until
the seating of the snap ring (102) becomes visible.

101

RKZA6660

14 - Mount the snap ring (102).

102

RKZA6670

30-92

REMOVAL AND INSTALLATION

TRANSMISSION

15 - Use two screwdrivers to raise the thrust bearing ring

(101) until the snap ring is completely engaged (102).
H Check the functioning and the leaktightness of
the piston by pressurizing the group with compressed air at 5 6 bar to settle the clutch in position.

RKZA6680

16 - Mount the spring pin (115).

17 - Lubricate the bearing ring (114) and mount it on the
shaft.
H The lubrication holes must face towards the gear.
H Make sure that the spring pin is engaged in the
seating of the bearing ring (114).

114
115

RKZA6690

18 - With an appropriate plunger, mount the bearing (113)

behind the bearing ring (114).
19 - Mount the snap ring (112).

112
113

RKZA6700

20 - Lubricate the seal rings (111) and mount them on the

shaft.
H Position the notches on the seal rings 120 apart.

111
111

RKZA6710

30-93

REMOVAL AND INSTALLATION

TRANSMISSION

21 - Turn the input shaft upside down and repeat the

phases from 1 to 15 in order to mount the rear clutch.
H For the rear clutch, phase 9 does not envisage installation of the spacer (118).

RKZA6720

22 - Install the spring pin (98).

23 - Lubricate the bearing ring (100) and mount it on the
shaft (95).
H Make sure that the lubrication slots face downwards and that the spring pin is engaged in the
seating of the bearing ring (100).
24 - Mount the spacer (96).
25 - Use a plunger to mount the bearing (93) behind the
spacer.
H The seating for the snap ring groove must face
upwards.

RKZA6730

26 - Mount the snap ring (92).

27 - Lubricate the seal ring (91) and mount it on the shaft.

91

RKZA6310

28 - Check the clearance of each clutch group using a

thickness calliper "C" inserted between the thrust
bearing ring and the first steel disk.
H Clearance limits: 2.3 4.3 mm
If the clearance does not fall within these tolerances, it
is very probable that the group has been incorrectly
assembled.

RKZA6740

30-94

REMOVAL AND INSTALLATION

TRANSMISSION

29 - Checking clutch function.

3
2

RKZ02660

1
2
3
4

Clutch duct FORWARD gear

Clutch duct REVERSE gear
FORWARD gear
Clutch pack FORWARD gear

5 - Clutch pack REVERSE gear

6 - REVERSE gear
7 - Drive input shaft

Slowly insert compressed air up to about 6 bar into the

clutch duct (1) for the forward gear.
Listen for the piston movement that should block the
clutch.
In this condition, the forward gear (3) should be
blocked while the reverse gear should be able to rotate freely on the input shaft (7).
. Repeat the test for the passage (2). In this condition
the forward gear (3) should rotate freely on the input
shaft (7) while the reverse gear (6) should be blocked.
H If the conditions described are not found, dismantle
the group and look for the causes of the malfunction.
.

30-95

REMOVAL AND INSTALLATION

TRANSMISSION

7. Dismantling the secondary shaft

156
151
150

149
146
142
69

147

132

131

145
148
124

143

141
163

152

162

155

123

144

153

158
159

161

164

154

122 125
126

136
137

160

133 127

138

157
134

148

135

139
140
129
130
128
RKZ02830

1 - Position the secondary shaft group (78) on plastic

blocks, as illustrated.
H Do not use wooden blocks.
2 - Position a separator beneath the gear (122) with the
conical edge facing downwards.
H Do not force the separator against the synchronizer assembly.

122

78

RKZA6750

30-96

REMOVAL AND INSTALLATION

TRANSMISSION

3 - Position a puller and force the bearing (123) until is

can be detached from the seating of the shaft (124).
Shaft seating: ASL800040
H Use a protective cap on the head of the shaft.

124
123

RKZA6760

4 - Remove the bearing (123) and the bearing ring (125).

123

125

RKZA6770

5 - Remove the gear (122) of the 3rd speed.

6 - Remove the synchronizer ring (126) of the 3rd and 4th
synchronizer assembly in order to reach the snap ring
(127).

122

126

RKZA6780

7 - Remove the snap ring (127).

8 - Remove the synchronizer assembly (128) and put it to
one side.

128
127

RKZA6790

30-97

REMOVAL AND INSTALLATION

TRANSMISSION

9 - Remove the snap ring (129).

130

10 - Remove the 4th speed gear (130).

129

RKZA6800

11 - Remove the snap ring (131).

12 - Remove the gear (132) of the 4-wheel drive gear.

131

132

RKZA6810

13 - Remove the bronze ring (133).

133

RKZA6820

14 - Arrange the sleeve (134) on some plastic blocks inside a container. Using a plunger, extract the hub
(135), the balls (136), the springs (138) and the blocks
(137).

136
135
137 138
136

138

137

134

138 137
136

RKZA6830

30-98

REMOVAL AND INSTALLATION

TRANSMISSION

15 - Remove the 2nd bronze ring (136) from the synchronizer ring (140).

139

140
RKZA6840

16 - Turn the group upside down so that the 2nd speed

gear faces upwards.
17 - Remove the snap ring (141).

141

RKZA6850

18 - Position a separator beneath the gear (142) with the

conical edge facing downwards.
H Do not force the separator against the synchronizer assembly.

69

19 - Position a puller and force the ring into the bearing

(69) until it can be detached from the seating of the
shaft (124).
Shaft seating: ASL800040
H Use a protective cap on the head of the shaft.

124
RKZA6860

20 - Remove the ring inside the bearing (69) and the bearing ring (143).

69

143

RKZA6870

30-99

REMOVAL AND INSTALLATION

TRANSMISSION

21 - Remove the pin (144).

22 - Remove the 2nd speed gear (142).

142

144

RKZA6880

23 - Remove the spacer (145).

146

24 - Remove the synchronizer ring (146) from the 1st and

2nd speed synchronizer assembly in order to reach
the snap ring (147).

145

RKZA6890

25 - Remove the snap ring (147).

26 - Remove the synchroniser assembly (148).

147

148

RKZA6900

27 - Remove the steel ring (149) and the bronze ring (150)
from the synchronizer assembly.

149
150

RKZA6910

30-100

REMOVAL AND INSTALLATION

TRANSMISSION

28 - Remove the tapered friction ring (151).

151

RKZA6920

29 - Turn the synchronizer assembly upside down and remove the other synchronizer ring (152).
30 - Remove the steel rings (153) and bronze rings (154).
Remove also the tapered friction ring (155). For details, see phases 27 and 28.

153

RKZA6930

31 - Place the sleeve (156) on some plastic blocks inside a

container. Using a plunger, extract the hub (157), the
balls (158), the springs (160) and the blocks (159).

156

160

157

159

158

RKZA6940

32 - Remove the spacer (161).

162

33 - Remove the snap ring (162).

161

RKZA6950

30-101

REMOVAL AND INSTALLATION

TRANSMISSION

34 - Remove the 1st speed gear (163).

35 - Remove the last snap ring (164).

163

164

RKZA6960

36 - Check that all component parts have been dismantled and, if there is any damage to the gears,
the inner or outer tooth bases, or to the bearings
(123), replace them with new ones.

37 - Check the clearance of the synchronizer assemblies

at three different points, 120 apart.
For this test use the thickness calliper.
H Minimum clearance permissible: 1.3 mm
If the clearance is less than this, put in new synchronizer assemblies.

1,3 MIN

38 - Carefully check the secondary shaft, especially

where bearing inner races will be installed. No wear
or scoring (even if only localised) can be allowed.
Check the springs of the synchronization assembly.
Cracks, heat distortion, or wear mean that the piece
must be changed.

30-102

RKZ02850

REMOVAL AND INSTALLATION

TRANSMISSION

8. Re-assembly of the secondary shaft

H If not otherwise indicated, lubricate the pieces with
transmission oil.

164

163

1 - Mount the snap ring (164) on the secondary shaft

(124)
2 - Mount the 1st speed gear (163).

RKZA6970

3 - Mount the snap ring (162).

4 - Mount the spacer (161).

162

161

RKZA6980

5 - Position the hub (157) on the sleeve (158).

Mount the springs (160), the blocks (159) and the
balls (158) into the hub (157).

159
157
160

156

158
RKZA6990

6 - Use a screwdriver or a plunger to push the balls (158)

into the blocks (159).
Press on the hub to engage the balls in the sleeve
(156) until they are engaged in the central seating
of the sleeve (156).

156
RKZA7000

30-103

REMOVAL AND INSTALLATION

TRANSMISSION

7 - Install the tapered friction ring (155) on the synchronizer assembly.

155

RKZA6921

8 - Install the bronze ring (154) and the steel ring (153).

153
154

RKZA6911

9 - Install the synchronizer ring (152).

H The flat surface of the teeth should face upwards.

152

RKZA6931

10 - Turn the group upside down and install the tapered

friction ring (151) on the synchronizer assembly.

151

RKZA6920

30-104

REMOVAL AND INSTALLATION

TRANSMISSION

11 - Install the bronze ring (150) and the steel ring (149).

149
150

RKZA6910

12 - Mount the synchronizer assembly (148) on the shaft

(124).
H The side with the seating for the snap ring must
face downwards.

148

124

RKZA7010

13 - Mount the snap ring (147).

147

RKZA7020

14 - Mount the upper synchronizer ring (146).

H The flat surface of the teeth must face upwards.
15 - Install the spacer (145) and the gear (142) of the 2nd
speed.

146

142

145

RKZA7030

30-105

REMOVAL AND INSTALLATION

TRANSMISSION

16 - Mount the pin (144).

17 - Lubricate the bearing ring (143) and mount it.
H The lubrication slots should face downwards and
the pin should be engaged in the cavity.

143

144

RKZA7040

18 - Using a plunger, mount the inner bearing ring of the

bearing (69) and knock it home on the bearing ring
(143).
H The wide base of the bearing ring (69) should face
downwards.
19 - Mount the snap ring (141).

141

69

RKZA7050

20 - Turn the group upside down and install the gear (132)
for the 4-wheel drive.
21 - Mount the snap ring (131).
H The ring (131) must be mounted in the lowest
seating and behind the gear (132).

132

131

RKZA7060

22 - Mount the gear (130) of the 4th speed.

23 - Mount the snap ring (129).

130

129

RKZA7070

30-106

REMOVAL AND INSTALLATION

TRANSMISSION

24 - Mount the bronze ring (139) on the synchronizer ring

(140).

139

140
RKZA6840

25 - Position the sleeve (134) and the hub (135).

Mount the springs (138) the blocks (137) and the balls
(136) in the hub (135).

137
135
134
138

136
RKZA7080

26 - Use a screwdriver or a plunger to push the balls (136)

into the blocks (137).
Press on the hub to engage the balls in the sleeve
(134) until they are engaged in the central seating
of the sleeve (134).

133
RKZA7090

27 - Mount the 2nd bronze ring (133).

133
RKZA7100

30-107

REMOVAL AND INSTALLATION

TRANSMISSION

28 - Install the synchronizer assembly (128) for the 3rd and

4th speeds.
H The side with the seating for the snap ring (129)
should face downwards.

129

128

RKZA7110

29 - Mount the snap ring (127).

30 - Mount the synchronizer ring (126).

127

126

RKZA7120

31 - Mount the gear (122) of the 3rd speed.

122

32 - Mount the bearing ring (125).

H Make sure that the lubrication slots are facing
downwards.
33 - Use a plunger to mount the bearing (123).
H Check that the snap ring groove on the outside of
the bearing is facing upwards.

RKZA7130

125

123

RKZA7140

30-108

REMOVAL AND INSTALLATION

TRANSMISSION

9. Dismantling the main shaft

165
168

169
167

166

68
170

RKZ02780

H Mark the gears and the main shaft to avoid exchanging the component parts.
1 - Position the group with the bearing upwards and remove the snap ring (165).

165
166

2 - Position a separator beneath the gear (166) with the

conical edge facing downwards.
Position a puller and force the bearing (167) until it
can be detached from the seating.
H Use a protective cap on the head of the shaft.

167

RKZA7150

3 - Remove the bearing (167).

4 - Remove the bearing ring (168).

167

168

RKZA7160

30-109

REMOVAL AND INSTALLATION

TRANSMISSION

5 - Remove the gear (166).

6 - Turn the group upside down and, with a plastic mallet, slide the gear (169) off the shaft (170).

166
170
169

RKZA7170

7 - Position a separator beneath the inner bearing ring of

the bearing (63).
Position a puller and force the bearing ring (68) until it
can be extracted from the shaft (170).
H Use a protective cap on the head of the shaft.
H Make a note of the direction of assembly.

RKZA7180

30-110

REMOVAL AND INSTALLATION

TRANSMISSION

10. Re-assembly of the main shaft

H Put in new bearings.
1 - Using a plunger, mount the inner bearing ring for the
bearing (68) on the shaft (170).
H Check the direction of assembly.

69

169

2 - Turn the shaft (170) upside down and, using a plastic

mallet, mount the gear (169).

170
RKZA7190

3 - Mount the gear (166).

4 - Lubricate the bearing ring (168) and mount it.
H The lubrication slots must face downwards.

166

168

RKZA7200

5 - Use a plunger to mount the bearing (167).

H The snap ring groove on the outside of the bearing must be facing upwards.
6 - Mount the snap ring (165).

165
167

RKZA7210

30-111

REMOVAL AND INSTALLATION

TRANSMISSION

11. Dismantling the reverse shaft

171

172

173

RKZ02790

1 - Position a separator beneath the bearing (171) with

the conical edge facing downwards.
Position a puller and force the bearing (171) until it
can be detached from its seating.
H Use a protective cap on the head of the shaft
(172).
2 - Turn the group upside down and repeat the same operations for the bearing (173).

172

RKZA7220

12. Re-assembling the reverse shaft

1 - Assemble the group by reversing the dismantling sequence.
H Use a plunger to install the bearings.

RKZA7230

30-112

REMOVAL AND INSTALLATION

TRANSMISSION

13. Dismantling the shifter group, shafts and forks

175

177
178
179

174
176

RKZ02710

H Make accurate notes of the sequence of assembly of

the shafts and forks.
H The forks and shifter rods must be replaced with new
ones every time the synchronizer assembly is changed.

177

174

176

1 - Dismantling is simply a question of extracting the

pins (175) and (178) between the shafts (174) and
(177) and the forks (176) and (179).

179
RKZA7240

14. Re-assembly of the shifter group, shafts

and forks
1 - To re-assemble, reverse the dismantling procedure.

30-113

REMOVAL AND INSTALLATION

15.

TRANSMISSION

Dismantling the drive shaft for the 4th speed

184
183
185

66
70

182

84

82

67
67
83
180
187
186

181
H A plug (181) sealed with Loctite 542 is mounted in the
central hole of the shaft (180). Do not remove this
plug unless it is absolutely necessary.
1 - Press the spring retainer (182) until the snap ring
(183) can be released.
Release the pressure slowly.

RKZ02730

181
180
182

RKZA7250

2 - Remove the snap ring (183).

3 - Remove the spring retainer (182) and spring (184).
4 - Remove the sleeve (185).

183
182

182
184

185
RKZA7260

30-114

REMOVAL AND INSTALLATION

TRANSMISSION

5 - Remove the O-rings (186) and (187) from the shaft

(180).

187

186

RKZA7270

6 - Check the thickness "X" of the lugs on the sleeve of

the clutch command of the 4th speed (82).
Minimum "X" permissible: 3.52 mm
H If the projections are worn, also check the 4-wheel
drive clutch gear. (See Dismantling the housing).

82

X
RKZ02840

16. Re-assembly of the 4th speed drive shaft

1 - To re-assemble, reverse the dismantling procedure.
H Lubricate the O-rings (186) and (187) with transmission oil.
H Check that the spring retainer (182) is mounted with
the seating for the snap ring (183) facing upwards.

30-115

REMOVAL AND INSTALLATION

TRANSMISSION

17. Dismantling the shifter housing

189
188

194

190
195

190

23
193
192
191
RKZ02800

1 - Undo the retaining clamps (188) and remove the protection (189).

189
188
RKZA7280

2 - Remove the two pins (190).

3 - Remove the snap ring (191).

190

191
RKZA7290

30-116

REMOVAL AND INSTALLATION

TRANSMISSION

4 - Remove the bushing (182).

5 - Remove the spring (193).

193

192

RKZA7300

6 - Remove the shift lever (194).

194
RKZA7310

18. Re-assembling the shifter housing

1 - Lubricate the ball of the shift lever (194) and mount
the lever in its seating (195).

195

194
RKZA7311

2 - Align the shift lever (7) with its seating (195). The flat
surface "A" of the lever must be parallel to the side
"B" of the housing and the grooves "C" must match
with the holes "D" in the housing.

195
194
RKZA7320

30-117

REMOVAL AND INSTALLATION

TRANSMISSION

3 - Mount the spring (193).

4 - Mount the bushing (192).

192

193

RKZA7330

5 - Push the snap ring (191) with the push-rod until it is

engaged in the seating of the lever (194).
6 - Install the pins (190).
7 - Mount the protection (189) and secure it with the
clamp (188).

194
190

RKZA7340

30-118

REMOVAL AND INSTALLATION

TRANSMISSION

19. Dismantling the 4th speed solenoid valve

196
198
12

199

197

201
14

200

RKZ02810

1 - Take out the lock nut (196).

196

RKZA7350

2 - Remove the solenoid coil (197).

197

RKZA7360

30-119

REMOVAL AND INSTALLATION

TRANSMISSION

3 - Remove the O-ring seal (198) and the valve rod (199).

198

199
RKZA7370

4 - Remove the check valve (200).

H Do not dismantle the check valve. If it gives problems, put in a completely new group.

200
RKZA7380

30-120

REMOVAL AND INSTALLATION

TRANSMISSION

20. Re-assembly of the 4th speed solenoid valve

H Put in new O-rings and lubricate them with transmission oil.

201

1 - Install the check valve (200) in the body (201).

200
RKZA7381

2 - Mount the complete valve rod (199).

Rod: 22 Nm
3 - Mount the O-ring (198).

198
199
RKZA7390

4 - Mount the solenoid coil (197).

197

RKZA7360

5 - Mount the lock nut (196).

Lock nut: 8 Nm

196

RKZA7350

30-121

REMOVAL AND INSTALLATION

TRANSMISSION

21. Dismantling the distributor

210
202
206

204

205

209
207

211

203

214

213

208
216

222

212
221

223
215

235
225

217
218

227

219

229

220

232

233

224

234

226
228

231

237

236

230
RKZ02820

1 - Remove the retaining nut (202) of the coils (203) and

(204).

204
203

RKZA7400

30-122

REMOVAL AND INSTALLATION

TRANSMISSION

2 - Remove the copper washers (205).

3 - Remove the outer coil (205).

203

205
RKZA7410

4 - Remove the O-ring (206) from the outer coil (203).

5 - Remove the intermediate O-ring (207).

207

206

RKZA7420

6 - Remove the intermediate O-ring (204).

7 - Remove the O-ring (208) from the internal coil.

204

208
RKZA7430

8 - Remove the last O-ring (209).

9 - Do not dismantle the rear check device of the coil
connector (210). This check device must only be dismantled when substituting a coil.

210

209
RKZA7440

30-123

REMOVAL AND INSTALLATION

TRANSMISSION

10 - Loosen the complete valve group (211).

211
RKZA7450

11 - Remove the valve group (211) complete with spool

(212).

212

211

RKZA7460

12 - Take out the screws (213) and remove the cover

(214).

214

213
RKZA7470

13 - Extract the outer modulation piston (215) from the

cover (214).

214

215
RKZA7480

30-124

REMOVAL AND INSTALLATION

TRANSMISSION

14 - Remove in sequence the spring (216), the spring

(217), the spring (218) and the pin (219).
H Replace the springs.

217
216
219
218
RKZA7490

15 - Remove the first gasket (220).

H Throw the gasket away.
16 - Remove the plate (221).

220

221
RKZA7500

17 - Remove the ball (222) and the spring (223).

18 - Remove the second gasket (224).
H Throw the gasket away.

222

223

224
RKZA7510

19 - Remove the inner modulation piston (225).

20 - Remove the snap ring (226).

226

225
RKZA7520

30-125

REMOVAL AND INSTALLATION

TRANSMISSION

21 - Remove the flow regulator (227).

22 - Remove the spring (228).
H Put in a new spring.

227

228

RKZA7530

23 - Remove the flow regulator piston (229).

24 - Remove the cap (230).

229

230
RKZA7540

Only if necessary

231

25 - Remove the snap ring (231).

RKZA7550

26 - Remove the cap (232) of the spool that selects the direction of movement.
27 - Remove the spring (233).

232

233
RKZA7560

30-126

REMOVAL AND INSTALLATION

TRANSMISSION

28 - Remove the spacer (234).

234

RKZA7570

Only if necessary
29 - Remove the four caps (235) and (236).
H Beneath each cap there is a copper washer that
must be substituted each time it is dismantled.

235
236

RKZA7580

30-127

REMOVAL AND INSTALLATION

TRANSMISSION

22. Re-assembly of the distributor

237

1 - Install the spacer (234) in the distributor body (237).

H The chamfer on the central hole must face towards the inside of the distributor.
2 - Mount the spring (233).

233

234

RKZA7590

3 - Mount the cap (232).

H Substitute the O-ring.
4 - Mount the cap (230).
H Substitute the O-ring.

232

230
RKZA7600

5 - Lubricate the regulating piston (229) with transmission oil and mount it in the body of the distributor
(237).
H The perforated surface must face towards the inside of the distributor.

228
237

6 - Mount the spring (228).

229
RKZA7610

7 - Mount the flow regulator (227).

8 - Mount the snap ring (226) and push it home in the
seating with a plunger.
H Make sure that the snap ring is completely inserted into its seating.

227

226

RKZA7620

30-128

REMOVAL AND INSTALLATION

TRANSMISSION

9 - Lubricate the innermodulation piston (225) with transmission oil and mount it so that the extremity with the
smallest diameter hole faces towards the inside of the
distributor.

223

10 - Mount the spring (223).

225
RKZA7630

11 - Mount the first gasket (224).

12 - Mount the ball (222).

224

222

RKZA7640

13 - Position the plate (221).

14 - Position the second gasket (220).

221

220

RKZA7650

15 - Mount concentrically the pin (219), the small spring

(218), then the medium spring (217) inserted into
the spring with the largest diameter (216).
H The springs must be new.

219
216

217

218
RKZA7660

30-129

REMOVAL AND INSTALLATION

TRANSMISSION

16 - Insert the pin and spring group into the distributor

(237).
H The pin (219) must face towards the inside of the
distributor.

219
237

RKZA7670

17 - Lubricate the outermodulation piston (215) and

mount it in the cover (214).
H The closed extremity of the piston (215) must face
towards the cover (214).

214
215

RKZA7680

18 - Mount the cover (214) and secure it with the screws

(213).
Screws: 11 Nm
H Tighten using the alternating crosswise method.

214

213
RKZA7470

19 - Mount a new O-ring on the solenoid plunger (211).

H Lubricate the O-ring with transmission oil.

211

RKZA7690

30-130

REMOVAL AND INSTALLATION

TRANSMISSION

20 - Lubricate the spool (212), insert it in the solenoid

plunger (211), and mount the group.
H Check carefully that the extremity of the spool is
engaged in the spring mounted in phase 2.

212

211

RKZA7460

21 - Tighten the solenoid plunger (211).

Solenoid plunger: 23 Nm

211
RKZA7700

22 - Mount the O-rings (208) and (209) on both sides of the

internal coil and lubricate them with transmission oil.

209

208
RKZA7710

23 - Mount the complete internal coil (204) on the solenoid

plunger (211).

204

211
RKZA7720

30-131

REMOVAL AND INSTALLATION

TRANSMISSION

24 - Mount the O-rings (207) and (206) on both sides of the

external coil and lubricate them with transmission oil.

207

206
RKZA7730

25 - Mount the complete external coil (203) on the solenoid plunger (211).

203

211

RKZA7740

26 - Mount the copper washer (205).

205
RKZA7750

27 - Mount the nut (202) and tighten it, keeping the two
coils aligned.
Nut: 7 10 Nm

202

RKZA7401

30-132

REMOVAL AND INSTALLATION

CONVERTOR

REMOVAL OF THE CONVERTOR

Lower the working equipment completely until it
rests on the ground and stop the engine.
Raise the engine hood and disconnect the cable
from accumulator negative terminal ().
Release all residual pressure in all circuits. (For details, see 20. TESTING AND ADJUSTMENTS).
H Drain the hydraulic oil.

Hydraulic oil:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ,
H Drain the oil from the gearbox.
Gearbox oil:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ,
1 - Remove the piston pump. (For details, see REMOVAL OF THE PISTON PUMP).

RKZA0820

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).
H If necessary, use two levers applied in opposed
positions.
H Take great care not to damage the centering hub
of the gearbox.

INSTALLATION OF THE
CONVERTOR
To install, reverse the removal procedure.
H 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:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ,
H Fill the pump body and the pump, bringing the
tank up to pressure.
For the method, see 20. TESTING AND ADJUSTMENTS.
2 - Refill the gearbox.
Gearbox oil:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ,
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.

30-133

REMOVAL AND INSTALLATION

TRANSMISSION-REVERSE, DIRECTION INDICATOR

AND 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.
Raise the engine hood and disconnect the cable
from accumulator negative terminal ().

1 - Raise the protective sleeve (1) and disconnect the

connectors (2) and (3).

1
RKZA0830

2 - Take out the two screws (4) that hold the switching
groups (5) and (6).
3 - Remove the right-hand half-clamp (7) (4 screws).

5
4
6
RKZA0840

4 - Take off the central cap (8) of the steering wheel.

5 - Remove the retaining nut (9) and its washer. Remove
the steering wheel (10).
6 - Take out the switching groups (5) and (6) complete
with their protective sleeve (1).

INSTALLATION OF THE
TRANSMISSION-REVERSE,
DIRECTION INDICATOR AND
HEADLIGHT DIPPER BEAM
CONTROL GROUP
.

To install, reverse the removal procedure.

7
11

RKZA0850

H Check that the reference pin (11) enters fully into the
steering column and that the transmission-reverse
gear control unit is perfectly attached to the steering
column.
Steering column retaining nut: 40 Nm

30-134

10

10
RKZA0860

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. (For details, see 20. TESTING AND ADJUSTMENTS).

Raise the engine hood and disconnect the cable

from accumulator negative terminal ().
1 - Disconnect the five pipes (2) from the steering unit (1)
and plug them to prevent entry of impurities.
H Mark the positions to prevent exchanges during
re-connection.

RKZA0870

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

wheel.

3
RKZA0880

3 - Raise the protective sleeve (4) and disconnect the

connectors (5) and (6).
4 - Disconnect the connector (7) and the relay (8).

5 - Loosen the steering column retaining screws (9) and

the steering unit (1).
6 - Take out the screws (11) and remove the plate (12)
that supports the steering column and the steering
unit.
7 - Take out the screws (9) and remove the steering unit
(1).

INSTALLATION OF THE
STEERING UNIT
.

To install, reverse the removal procedure.

H Bleed the air from the Load Sensing circuit. (For details, see 20. TESTING AND ADJUSTMENTS).
H Start the engine and perform several complete steering manoeuvres in both directions, to bleed the air out
of the steering system.

4
RKZA0831

10
9

12

11
RKZA0890

30-135

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.
Raise the engine hood and disconnect the cable
from accumulator negative terminal ().
1 - Remove the cap (1) of the oil tank (2) and draw out the
oil contained inside it.

1
2
6

2 - Remove the oil tank (2).

3 - Remove the clip (3) that holds the delivery lines (4).
4 - Remove the delivery lines (4) from the pumps (5).

5
RKZA0900

5 - Take out the four screws (6) and remove the pump
group (5).
H If only one pump is to be removed, also disconnect the pressure- equalizing pipe (7).

INSTALLATION OF THE
WORKING BRAKE PUMP GROUP
.

To install, reverse the removal procedure.

H Bleed the air from the braking circuit. (For details, see
20. TESTING AND ADJUSTMENTS).
H Make sure that the push-rods (8) center the seating of
the pistons.
H After installation, check the idle stroke and parallelism
of the brake pedals and, if necessary, adjust the coupling microswitches for 4-wheel brake control. (For details, see 20. TESTING AND ADJUSTMENTS).
Pipe fitting: 20 Nm

9
RKZA0910

30-136

REMOVAL AND INSTALLATION

FRONT 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. (For details, see 20. TESTING AND ADJUSTMENTS).
1 - Remove the grip (1) of the hand accelerator and disengage the protective sleeves (2), (3) and (4).

1
2

2 - Take out the screws (5) and remove the guard (6).

3
5

RKZA0461

3 - Disconnect the spool control tie-rods (8) from the control valve (7).

8
7

RKZA0920

4 - Disconnect from the control valve all pipes and lines

for the actuators (9), pump delivery (10), drainage
(11), Load Sensing (12) and plug them.
H Mark the pipes to avoid exchanging positions during reconnection.

10
7

5 - Take out the four control valve retaining screws.

11

6 - Remove the control valve (7).

12
RKZA0930

INSTALLATION OF THE FRONT

WORKING EQUIPMENT CONTROL
VALVE
.

To install, reverse the removal procedure.

1 - Start the engine to circulate the oil, and check that
there are no leaks.
2 - Bleed the air from all circuits. (For details, see 20.
TESTING AND ADJUSTMENTS).
3 - Stop the engine and check the oil level in the tank.

30-137

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. Also make the backhoe safe.

1
RKZA0940

4 - Engage the parking brake.

5 - Stop the engine and eliminate residual pressure from
all circuits. (See 20. TESTING AND ADJUSTMENTS).

Raise the engine hood and disconnect the cable

from accumulator negative terminal ().

6 - Take off the front wheels (1).

Wheel: 65 kg
7 - Remove the front guard (2). (For details, see REMOVAL OF FRONT GUARD).

3
RKZA0591

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

9 - Disconnect the lines (5) from the steering cylinder
and plug them to prevent entry of impurities

10 - Disconnect the lubrication tube (6) for the axle oscillation pin (7).

6
4

3
RKZA0402

11 - Position a jack B and some blocks C beneath the

axle. Raise the jack until the blocks can be forced under the axle arms (3).
H It should be possible to lower the jack 10 cm in order to disengage the axle from the fulcrum supports.

3
C

B
RKZA1670

30-138

REMOVAL AND INSTALLATION

FRONT AXLE

12 - Take out the nut and remove the retaining screw (7)
of the axle oscillation pin (7).
13 - Screw an eyebolt into the central hole of the axle oscillation pin (7). Extract the axle oscillation pin.

7
8

RKZA0950

14 - Lower the jack until the axle is disengaged.

15 - Extract the entire axle (3).
Front axle: 316 kg

INSTALLATION OF THE
FRONT AXLE
.

To install, reverse the removal procedure.

Nuts for front wheels: 350w9.8 Nm
Front closing screws: 300w30 Nm
Screws on gearbox side: 70 Nm
Self-locking nuts on axle side: 70 Nm

H Bleed the air from the Load Sensing circuit. (For details, see 20. TESTING AND ADJUSTMENTS.
Axle oscillation pin - bushings: ASL800050
1 - Check the oil level in the tank and start the engine.
2 - Perform a few complete steering manoeuvres in both
directions to bleed the air from the steering circuit.

30-139

REMOVAL AND INSTALLATION

FRONT AXLE

DISASSEMBLY OF FRONT AXLE

1. Final Drive

1 - Remove the screws (1) that secure the planetary carrier (2).

RKZA2460

2 - Use a puller to remove the shoulder studs (3).

3
RKZA2470

3 - Use a plastic mallet to separate the complete planetary carrier (2) from the axle and remove it.

RKZA2480

4 - Remove the snap ring (4).

RKZA2490

30-140

REMOVAL AND INSTALLATION

FRONT AXLE

5 - Remove the pinion (5) and the spacer (6).

RKZA2500

6 - Remove the screws (7) that secure the complete ring

bevel gear group (8).

RKZA2510

7 - Screw two M10 screws into the threaded holes of the

planetary carrier (8). Act on these two screws alternately until the entire bevel ring gear group (8) has
been extracted, complete with the centering bushings.

RKZA2520

8 - Use a puller to remove the hub (9) and outer bearing

(10) from the swivel housing.

9
10

RKZA2530

30-141

REMOVAL AND INSTALLATION

FRONT AXLE

9 - Use two levers to remove the inner bearing (11).

H Take great care not to damage the bearing.

11

RKZA2540

10 - Remove the snap ring (12) that secures the planetary

carrier. Remove the planetary carrier (13).

12
13

RKZA2550

11 - Remove the snap rings (14) and lift out the planetary
gear retainer (15).

14

15
14

RKZA2560

12 - Remove the complete planetary gears (16) together

with the lower retainer (17) and the roller bearings
(18).

18
16

17
RKZA2570

30-142

REMOVAL AND INSTALLATION

FRONT AXLE

Only where necessary

13 - Remove the outer retainers (10) and (11) and the seal
ring (19) from the wheel hub (9).

9
19

RKZA2580

16
14

18
17

4
1

19

15
6

11

2
10
12
3
8
9

13

RKZ02000

30-143

REMOVAL AND INSTALLATION

FRONT AXLE

2. Removal of the swivel housing

H Remove the final drive. (For details, see previous
paragraph).

11

1 - Remove the inner bearing (11).

H Take great care not to damage the bearing.

RKZA2540

2 - Loosen the nut (20) on the ball joint (21), but do not
remove it.
Use a puller to detach the joint (21) from the swivel
housing (22).

21

20

22

RKZA2590

3 - Remove the nut (20) and detach the ball joint (21)
from the swivel housing (22).

21
22

RKZA2600

4 - Remove the screws (23) that secure the upper (24)

and lower (25) knuckle pins.

23

24

RKZA2610

30-144

REMOVAL AND INSTALLATION

FRONT AXLE

5 - Use two levers to remove first the upper knuckle pin

(24) and then the lower knuckle pin (25).

24

RKZA2620

6 - Remove the Belleville washer (26), the upper ball joint

washer (27) and the Belleville washer (28) of the lower
ball joint.

24
26
27
28

25
RKZ02880

7 - Remove the swivel housing (22) and extract the axle

shaft (29).

22

29

RKZA2630

8 - Use a puller to remove the upper bushing (30) and

the spherical seating of the lower bushing (31).

30

RKZA2640

30-145

REMOVAL AND INSTALLATION

FRONT AXLE

9 - Use a puller to remove the seal ring (33) and the

bushing (34) from the axle body (32).

34

32

33

RKZA2650

10 - Use a puller to remove the seal ring (35) from the swivel housing (22).

35

RKZA2660

11 - Place the swivel housing (22) beneath a press and extract the bushing (36).

22

RKZA2670

Only where necessary

12 - Using an extremely sharp chisel, partially remove the
spherical bushing (37) from the lower knuckle pin
(25).
Complete the extraction of the bushing (37) using a
separator and a press.

37
25
37

RKZA3610

30-146

REMOVAL AND INSTALLATION

FRONT AXLE

26
27
30

21
29

23

32

35

24

31
37
28

22
34
33

36
20
25
23
RKZ02020

3. Dismantling the universal joint

1 - Remove the four snap rings (38).

38
29

RKZA2680

2 - Position the joint (29) on a V-shaped block beneath

a press.
With the appropriate plunger, press the lower bearing
cover (39) down until it rests on the V-shaped block.

29

39
RKZA2690

30-147

REMOVAL AND INSTALLATION

3 - Place the bearing cover (39) in a vise and use a copper mallet to extract the joint (29) from the bearing
cover.

FRONT AXLE

29

RKZA2700

4 - Reposition the joint (29) upside down on the Vshaped block and press the second bearing cover
(39).

39
RKZA2710

5 - Remove the fork (40) or (41) complete with cross-journal (42).

Remove the second bearing cover from the joint following the same procedure described under point 3
above.

42

RKZA2720

6 - Position the fork complete with cross-journal (42) beneath the press and remove in sequence the first
bearing cover, the cross-journal and the second bearing cover.
H Follow the procedures described in points 2 and
3.

42

RKZA2730

30-148

REMOVAL AND INSTALLATION

FRONT AXLE

4. Removal and dismantling of the differential

group
H Perform the same operations for both final drive
groups.

21

20

22

1 - Loosen the nut (20) of the ball joint (21) but do not
take it out.
Use a puller to extract the joint (21) from the swivel
housing (22).

RKZA2590

2 - Put a sling round the final drive group (43) as shown,

and attach it to a hoisting tackle.
Remove the screws (23) of the knuckle pins (24) and
(25). Remove the nut (20) and detach the ball joint
(21) from the swivel housing (22).

43
25
23

RKZA2740

3 - Remove the upper (24) and lower (25) knuckle pins together with their Belleville washers and shims.
H Make a note of the assembly sequence and the
arrangement.

25
RKZA2750

4 - Remove the final drive group (43) complete with the

axle shaft (29).

43
29

RKZA2760

30-149

REMOVAL AND INSTALLATION

FRONT AXLE

5 - Loosen and remove the RH tie-rod (44).

44

RKZA2770

6 - Loosen and remove the screws (45) that secure the

steering cylinder (46).
Use a plastic mallet to remove the cylinder (46).

46

45

RKZA2780

7 - Loosen and remove the screws (47) that secure the

differential group (48).

48

47

RKZA2790

8 - Put a sling around the differential group (48) and lift it

off with the help of a lever.
Place the differential group on a work-bench for repairs.

48

RKZA2800

30-150

REMOVAL AND INSTALLATION

FRONT AXLE

9 - Hold the bevel pinion (49) steady and measure the

clearance of the ring bevel gear with a centesimal
comparator.
H Make a note of the value measured.

49
RKZA2810

10 - Make a mark on the bearing support (50) on the ring

bevel gear side and remove the screws (51) and the
lock nut retainers (52).

51
52

54

50
RKZA2820

11 - Loosen the screws (53) that secure the bearing covers (50) and (54).

53

54

RKZA2830

12 - Use the tool F1 to loosen the clearance adjustment

lock nuts (55).

55

F1

RKZA2840

30-151

REMOVAL AND INSTALLATION

FRONT AXLE

13 - Take out the screws (53) and remove the bearing covers (50) and (54).

53

50

54

RKZA2850

14 - Remove the differential (56) complete with adjustment lock nuts (55) and the bearings (57). Remove
the outer rings from the bearings.

56

57

57

55

55

RKZA2860

15 - Loosen and remove the screws (58) that secure the

ring bevel gear (59).

57
59

58

RKZA2870

16 - Remove the ring bevel gear (59).

59

RKZA2880

30-152

REMOVAL AND INSTALLATION

FRONT AXLE

17 - Separate the two half boxes of the differential.

H Mark the two half boxes for re-assembly.

RKZA2890

18 - Take out the thrush washer (60) and the differential

gear (61).

60

61

RKZA2900

19 - Take out the planetary gear group (62) complete with

pin (63) and shims (64).

63

64

62

RKZA2910

20 - Take out the second differential gear (65).

65

RKZA2920

30-153

REMOVAL AND INSTALLATION

FRONT AXLE

21 - Take out the thrush washer (66).

66

RKZA2930

22 - Use a separator and a press to remove the bearings

(57) from the half boxes.

44

46
45
21

23
24
22

53
50

55
57

59
29

56
60

64

20

54

53

58
65

43

62

49

47

30-154

48

25

51

61

52

23

63
55
64

66
56

RKZ02030

57

REMOVAL AND INSTALLATION

FRONT AXLE

5. Removal of the bevel pinion

1 - Remove the cover (67).

67

RKZA2940

2 - Use a narrow-bladed chisel to remove the lock nut

(68) caulking from the bevel pinion well.
H Take great care not to damage the pinion threading.

68

RKZA2950

3 - Use tools F2 and F3 to remove the lock nut (68).

F3
F2

RKZA2960

4 - Remove the tabbed washer (69) of the lock nut (68).

69

RKZA2970

30-155

REMOVAL AND INSTALLATION

FRONT AXLE

5 - Use a soft mallet to extract the bevel pinion from the

outer bearing (70).

70

RKZA2980

6 - Remove from the pinion (71) the washer (72), the

spacer (73) and the second washer (74).
The spacer (73) cannot be used again, and must
be replaced by a new one every time it is dismantled.

71

72

73
74
RKZA2990

7 - Place the pinion (71) beneath a press and use a separator to remove the inner bearing (75).

71
75

RKZA3000

8 - Remove the shim (76) from the pinion (71).

71
76

RKZA3010

30-156

REMOVAL AND INSTALLATION

FRONT AXLE

Only if the bearings need replacing

9 - Remove the differential support (77), and the outer
bearing-rings (70) and (75).

77

RKZA3020

10 - Remove the seal ring (78) and the O-ring (79) from the
cover (67).

79

67

78

RKZA3030

30-157

REMOVAL AND INSTALLATION

FRONT AXLE

ASSEMBLY OF FRONT AXLE

1. Re-assembly of the bevel pinion

F4

1 - Using the tool F4, insert the outer retainers of the pinion bearings (70) and (75).

75
RKZA3040

2 - Mount into the differential support (77) the bearings

(70) and (75), the gauge block F5, with the lock nut
(68), the gauge tube F6, and the lock nuts F7.
In order to pre-load the bearings (70) and (75) tighten
the lock nut (68) until the pinion becomes hard to turn.

77
F7

F7

F6

68

F5
RKZ01790

3 - Mount the bearing covers (50) and (54) and tighten

the screws (53) uniformly until the lock nuts F7 are
held fast.

53

50
54
F7

RKZ01800

4 - Use a deep calliper to take the measurement B between the gauge tube F6, and the surface inside the
gauge F5.
H Write down the B measurement.

F5
RKZ01810

30-158

REMOVAL AND INSTALLATION

FRONT AXLE

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

the pinion (71).
Calculate the thickness S to be installed beneath
the pinion, using the formula:

S=BN

H S is the thickness of the shim (76).

71
RKZA3050

6 - Dismantle the special tools and remove the bearings

(70) and (75) from the differential support (77).

77
75

F7
RKZ01791

7 - Mount the shim (76) onto the pinion (71) and press
the inner bearing (75) using the tool F8.
H The chamfer on the inner diameter of the shim
must face the toothing.

F8
75
71
76

RKZA3060

8 - Mount onto the pinion the first washer (74), the new
spacer (73) and the second washer (72).

71

72

73
74
RKZA2990

30-159

REMOVAL AND INSTALLATION

FRONT AXLE

9 - Lubricate the bearings with gear oil. Mount the pinion

group (71) into the differential support (77) and position the outer bearing (70).

77

70

71
RKZA3070

10 - Mount the tabbed washer (69) and the lock nut (68).

69

68
RKZA3080

11 - Use the tools F2 and F3 to tighten the lock nut (68) a

little at a time until the clearance is eliminated and the
bearings are slightly pre-loaded.
H Rotate the gauge tube by a few turns between
one lock nut tightening increment and the next.

F3
F2
RKZ01820

12 - Wind a wire line round the pinion (71), 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 rotation. Do not take into consideration the thrust
force.

71

P
RKZ01830

30-160

REMOVAL AND INSTALLATION

FRONT AXLE

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

nut (68) taking dynamometric measurements at intervals until the indicated force P has been obtained.
H If the maximum permissible value is exceeded, a
new spacer must be fitted and all the bearing preloading operations must be repeated.

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

caulk the lip of the lock nut (68) to correspond to
the well of the pinion (71).

P=(9,2413,7) daN
(1 daN=10N)

71

68
RKZA3090

15 - Mount the seal ring (78) and the O-ring (79) in the cover (67).

78
79
67
RKZA3100

16 - Lubricate the O-ring (79) and the seal ring (78) and
use the tool F9 to mount the cover (67).

F9

67
RKZA3110

30-161

REMOVAL AND INSTALLATION

FRONT AXLE

2. Re-assembling and mounting the differential

1 - Using the tool F10, mount the bearings (57) on the
two half boxes.
H All the components parts of the differential must
be lubricated with oil beforehand.
H Thoroughly decrease the threaded holes in the
half box.

F10

57

RKZA3120

2 - Mount the thrust washer (66) and the planetary gear

(65) in the half box with the threaded holes.

66

65
RKZA3130

3 - Mount the bevel gears (81) and the spherical shim

washers (64) on the pinion (80).

81
80

81

64
64
4 - Mount the pin (63) and the complete bevel gear group
in the half box (82).

RKZA3140

63

82
RKZA2911

30-162

REMOVAL AND INSTALLATION

FRONT AXLE

5 - Coat the threaded holes of the half box (82) with Loctite.
Holes: Loctite 270

82

RKZA3150

6 - Mount the second differential gear (61).

61

RKZA3160

7 - Mount the thrust washer (60) in the other half box.

60

83

RKZA3170

8 - Assemble the two half boxes (82) and (83).

H Respect the markings.

83

82
RKZA2891

30-163

REMOVAL AND INSTALLATION

9 - Make sure that the surfaces are perfectly clean and

mount the toothed ring gear (59).

FRONT AXLE

59

RKZA2880

10 - Place the group beneath a press to stop it rotating.

Place the screws (58) in the holes and tighten them
employing the crosswise alternate method.

56

Screws: 95 Nm

RKZA3180

11 - Position the assembled differential group in the differential support (77).

H The toothed ring gear should face the markings
on the support.
H Lubricate the bearings with gear oil.

77

RKZA3190

12 - Mount the outer retainers (57).

57

RKZA3200

30-164

REMOVAL AND INSTALLATION

13 - Mount the bearing covers (50) and (54).

H Respect the markings made while dismantling.
Mount the screws (53).

FRONT AXLE

53

54

50

RKZA3210

14 - Tighten the screws (53) as much as is necessary to

hold in position and catch the outer bearing lock nuts.

53

RKZA3220

15 - Screw down the adjustment lock nuts (55) and tighten them, taking care to leave some clearance between the pinion and the ring bevel gear. Use the tool
F1 to tighten the lock nuts (55).

55
F1

RKZA3230

16 - Position a centesimal comparator and measure the

clearance at four points at 90.
H If differences are found, adjust the clearance
where the measurement is lower.
H Clearance limit: 0.17 0.23 mm
H If neither the pinion nor the ring bevel gear have
been substituted, the clearance should be the
same as that measured when dismantling.

RKZA2811

30-165

REMOVAL AND INSTALLATION

FRONT AXLE

17 - To increase the clearance, loosen the lock nut on the

ring bevel gear side by one notch and tighten the opposite lock nut by one notch. To decrease the clearance, reverse these actions.
H Before measuring the clearance, knock lightly on
the bearing covers with a mallet to ensure that
they are securely positioned.

RKZA3240

18 - When the clearance between pinion and ring bevel

gear is correct, tighten the screws (53) of the bearing
covers (50) and (54) until the adjustment lock nuts
(55) are locked.
H Final tightening should be performed after the following checks.

53

54

55

50
RKZA3250

19 - Using the same method employed to check the pinion

rotation torque, check the force T required to rotate
the entire group.
H Force required:

T=(P+3.9) (P+5.9) daN

(P=the force found for the pinion)

H The force should be that of continual rotation. Do
not take the thrust force into consideration.

T
RKZ01831

20 - If the force is not within permissible limits:

a - Tighten both the lock nuts to the same extent to
increase the force T.
b - Loosen both the lock nuts to the same extent to
decrease the force T.
The clearance between the ring bevel gear and
the pinion must remain within permissible limits.

30-166

REMOVAL AND INSTALLATION

FRONT AXLE

21 - Check the centering of the contact area using the following 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.
When moving the ring bevel gear away from the
pinion, the lock nuts must be turned to an equal
extent in the opposite direction.

RKZ01840

RKZ01850

22 - Give the screws (53) a final tightening.

Screws: 266 Nm

53

RKZA3251

23 - Mount the lock nut retainers (52) and secure them

with the screws (51).
Screws: 13 Nm

51

52

RKZA3260

30-167

REMOVAL AND INSTALLATION

FRONT AXLE

24 - Coat the supporting surface and install the differential

group (48).
Surface: Loctite 510

48

RKZA3270

25 - Secure the group (48) with the screws (47).

Screws: 169 Nm
H Tighten the screws employing the crosswise alternate method.

48

47

RKZA2790

26 - Mount the steering cylinder (46).

46

RKZA3280

27 - Secure the cylinder (46) with the screws (45).

Screws: 120 Nm

46

45

RKZA3290

30-168

REMOVAL AND INSTALLATION

28 - Connect and tighten the RH tie-rod (44).

Tie-rod: 300 Nm

FRONT AXLE

44

RKZA3300

29 - Install the final drive group (43) complete with the axle
shaft (29).
H Take great care not to damage the seal ring inside
the axle body.
H The assistance of a second person may be required to rotate the pinion.

43
29

RKZA2760

30 - Mount the knuckle pins (24) and (25), the shim (27),
the Belleville washers (26) and (28) and the self-locking screws (23).
H For details, see 4. Installation of the swivel housing.

25
23

RKZA3310

31 - Connect the ball joint (21) to the swivel housing (22)

and mount the nut (20).

22

21

RKZA3320

30-169

REMOVAL AND INSTALLATION

FRONT AXLE

32 - Secure the knuckle pins with the screws (23).

Screws: 190 Nm

20
23

RKZA3330

33 - Secure the ball joint (21) with the nut (20).

Nut: 220 Nm

21

RKZA3340

3. Assembling the universal joint

1 - Press a bearing cover (39) into a fork (41).
H Press until the cover protrudes through the fork by
6 mm.

41

39

RKZA3350

2 - Turn the fork (41) upside down, position the crossjournal (42) by centering the bearing cover assembled during phase 1.
Position the second bearing cover (39) and press it
into the fork.
H Press until the cover protrudes through the fork by
9 mm.

41

39

42

RKZA3360

30-170

REMOVAL AND INSTALLATION

3 - Raise the cross-journal (42) and, keeping it engaged

in the two bearing covers (39), press the covers into
the fork (41).

FRONT AXLE

39
41
42

39
RKZA3370

4 - Using the appropriate plunger, press the bearing covers (39) into the fork (41) in order to mount the snap
rings (38).
Mount the snap rings.

38

39
41
5 - Use a V-shaped block to support the joint (84) and
press a bearing cover until it is flush with the outer
diameter of the joint (84).

RKZA3380

84

RKZA3390

6 - Turn the joint (84) upside down and position the

cross-journal (42) by centering the bearing cover
mounted during phase 5.
Position the second bearing cover and press it into
the joint until it protrudes by 6 mm.

84
42

RKZA3400

30-171

REMOVAL AND INSTALLATION

FRONT AXLE

7 - Raise the cross-journal (42) and, holding it steady in

the two bearing covers (39), press the covers into
the joint.

39
42

RKZA3410

8 - Using the appropriate plunger, press the bearing covers (39) into the joint (84) in order to mount the snap
rings (38).
Mount the snap rings.

39

84

38

RKZA3420

4. Installation of the swivel housing

1 - Use the tool F11 to mount the bushings (34) and (36)
in the axle body (32) and in the swivel housing (22).
Insert it to protrude 8 mm beyond the edge of the hole
of the axle body and 4 mm beyond the edge of the
hole of the swivel housing.
Use the tool F12 to mount the seal rings (33) and (35)
of the axle body (32) and of the swivel housing (22).
H Check the direction of assembly of the seal rings.

F11

32

RKZA3430

2 - Use the tool F13 to push the upper bushing (30)

home in the axle body.
With the tools F13 and F14, insert the lower bushing
(37).

F13

30

RKZA3440

30-172

REMOVAL AND INSTALLATION

FRONT AXLE

3 - Install the axle shaft (29).

H Take great care not to damage the seal ring (33).

29

RKZA3450

4 - Install the swivel housing (22).

H Take great care not to damage the seal ring (35).

22

RKZA3620

5 - Mount the shim (27), the Belleville washer (26), the

upper knuckle pin (24) and the self-locking screws
(23).

23

24

RKZA3460

6 - Tighten the screws (23) to secure the knuckle pin

(24).
Screws: 190 Nm

23

24

RKZA3470

30-173

REMOVAL AND INSTALLATION

FRONT AXLE

7 - Install the lower knuckle pin (25), the Belleville

washer (28) and the self-locking screws (23).
H If the spherical swivel housing has been removed,
use a press to mount the new swivel housing before installing the knuckle pin (25).

25

RKZA3480

8 - Tighten the screws (23) to secure the knuckle pin

(24).
Screws: 190 Nm

25

23
RKZA3490

9 - Engage the ball joint (21) and tighten the nut (20) to
hold it in place.
Nut: 220 Nm

21

RKZA3500

30-174

REMOVAL AND INSTALLATION

FRONT AXLE

5. Assembly of the final drive

1 - If the retainers (10) and (11) have been removed, use
the tool F15 to install them in the hub (9).
H Check the orientation.

F15

RKZA3510

2 - Use the tool F16 to install the new seal (19).

H The words OIL SIDE should face towards the inside of the hub.
H Take care not to damage the seal (19).

19

RKZA3520

3 - Coat ASL800050 grease on one side of the bevel

gears (16) and inside the hole, and install the retainer
(17).

17

16
RKZA3530

4 - Turn the bevel gears upside down (16) and insert

eighteen roller bearings (18) into each gear.

18

16
RKZA3540

30-175

REMOVAL AND INSTALLATION

FRONT AXLE

5 - Mount the gears (16) complete with roller bearings

(18) and ring (17) on the shafts of the planetary carriers.
H The retainer should touch the planetary carriers
(2).

18
16

17
RKZA2570

6 - Mount the retainer of the planetary carriers (15) and

hold it in position with snap rings (14).

14

15
14

RKZA2560

7 - Mount the ring bevel gear carrier (13) in the gear and
hold it in position with a snap ring (12).

12
13

RKZA3550

8 - Heat the internal bearing (11) to approx. 120 C and

mount it in the swivel housing (22).
H Do not heat beyond 149 C.

11

22
RKZA3560

30-176

REMOVAL AND INSTALLATION

FRONT AXLE

9 - Lubricate the bearing (11) with oil and mount the hub
(9).

RKZA3570

10 - Heat the external bearing (10) to approx. 120 C and

mount it on the swivel housing (22).
H Do not heat beyond 149 C.

10

RKZA3580

11 - Mount the complete ring bevel gear (8), aligning the

holes with the bushings (85).
Use the tool F17 to push the bushings (85) home.
H Insert the bushings a little at a time, employing
the crosswise alternate method.

85

RKZA3590

12 - Insert the screws (7) and tighten them as much as

possible, employing the crosswise alternate method.
Screws: 230 Nm

RKZA2510

30-177

REMOVAL AND INSTALLATION

FRONT AXLE

13 - Mount the spacer (6) and the pinion (5) on the shaft.

RKZA2500

14 - Mount the snap ring (4).

RKZA2490

15 - Thoroughly decrease the coupling surfaces and coat

the hub surfaces with liquid sealant.
Hub: Loctite 510
Mount the complete planetary carrier (2).

RKZA3600

16 - Mount the screws (1) that secure the planetary carrier.

Screws: 80 Nm

RKZA2461

30-178

REMOVAL AND INSTALLATION

FRONT AXLE

17 - Mount the shoulder studs (3) and tighten them.

Shoulder studs: Loctite 542
Shoulder studs: 70 Nm

3
RKZA2470

30-179

REMOVAL AND INSTALLATION

REAR AXLE

REMOVAL OF THE REAR AXLE

1 - Lower the backhoe outriggers (1) and force them
downwards in order to raise the rear wheels (2) by approx. .... cm.
2 - Prepare a safety stand A, approx. 65 cm high, beneath the backhoe chassis. Pull up the outriggers until the machine is resting on the stand A.
3 - Stop the engine and take off the rear wheels (2).

Wheel: 163 kg

1
A
RKZA0960

4 - Start engine, remove the stand "A" and set two

stands "B" 50 cm high under the frame.
Pull up the outriggers until the machine is resting on
the stands "B".

B
RKZA1651

5 - For safety's sake, rest the backhoe bucket with its

back on the ground, keeping the arm vertical. Also
rest the front bucket on the ground.
5 - Stop the engine and completely release residual pressures from all the circuits. (For details, see 20.TESTING AND ADJUSTMENTS).

RKZA0970

7 - Disconnect the working brake hoses (3) and the differential lock tube (4) from the axle.

H Plug the pipes to prevent entry of impurities.

8 - Disconnect the parking brake command cable (5).
9 - Disconnect the cardan shaft (6) from the rear axle.

6
4
RKZA0391

30-180

REMOVAL AND INSTALLATION

REAR AXLE

10 - Partially loosen the self-locking nuts (8) in order to

eliminate the tightening torque and thus facilitate
subsequent dismantling.

7
10

H Loosen the nuts in criss-cross sequence.

9
8
RKZA0980

11 - Place a jack C and some blocks beneath the axle

(7). Raise the jack until the blocks can be forced under the arms of the axle.
H Leave free the nuts (8) and plates (9) that secure
the axle.
H It should be possible to lower the jack by approx.
20 cm.

12 - Remove the self-locking nuts (8), the plates (9) and

the screws (10).
12 - Lower the jack until the axle (7) is disengaged from
the chassis.

C
RKZA1650

13 - Extract the entire axle (7).

INSTALLATION OF THE
REAR AXLE
.

To install, reverse the removal procedure.

Wheel nuts: 500w9.8 Nm
H Bleed the air from the braking circuits.
(See 20. TESTING AND ADJUSTMENTS).
H Adjust the stroke of the parking brake lever.
(See 20. TESTING AND ADJUSTMENTS).
Self-locking nuts on axle side: 70 Nm
Screws on gearbox side: 70 Nm
Self-locking nuts for securing axle: 570 Nm
H Tighten in two stages, using the criss-cross method.
1 - Check the level in the tank and start the engine.

30-181

REMOVAL AND INSTALLATION

REAR AXLE FINAL DRIVE

DISASSEMBLY OF REAR AXLE FINAL DRIVE

The seal rings must be replaced by new ones each
time they are dismantled.

14
13
15
25

23

22

11
21
23

12

20

20

18

24

19

9
10

5
1

16

17
1 - Apply a stud bolt puller and remove the two shoulder
studs (1) that secure the planetary carrier (2).

RKZ01640

1
2

RKZA3630

2 - Remove the two screws (3) that secure the planetary

carrier (2).

2
3

RKZA3640

30-182

REMOVAL AND INSTALLATION

REAR AXLE FINAL DRIVE

3 - Remove the planetary carrier (2) and the half-axles

(4).

RKZA3650

4 - Loosen and take out the eight screws (5).

RKZA3660

5 - Screw into two threaded holes in the planetary carrier

(6) the two screws (5) removed in the preceding
phase.
Tighten the screws alternately in order to extract the
ring bevel gear group (6) from the bushings (7).
H If extraction proves difficult, use four screws (5).

RKZA3670

6 - Remove the complete planetary group (6).

RKZA3680

30-183

REMOVAL AND INSTALLATION

REAR AXLE FINAL DRIVE

7 - Remove the outer snap ring (9).

RKZA3690

8 - Remove the planetary carrier (8) and the inner snap

ring (9).

RKZA3700

9 - Using a plunger with appropriate guide, extract the

bushings (7) from the planetary carrier.

7
8

RKZA3710

10 - Use a plastic mallet to strike some blows all round the

circumference of the wheel hub (11) in order to loosen
the outer bearing (12).

11

12

RKZA3720

30-184

REMOVAL AND INSTALLATION

REAR AXLE FINAL DRIVE

11 - Remove the outer bearing (12).

12

RKZA3730

12 - Remove the wheel hub (11).

11

RKZA3740

13 - Remove the inner bearing (13).

H If necessary use a puller.

13

13

RKZA3750

14 - Use a puller to remove the seal ring (14).

14

RKZA3760

30-185

REMOVAL AND INSTALLATION

REAR AXLE FINAL DRIVE

15 - Use a puller to remove the bronze bushing (15).

15

RKZA3770

16 - Remove the screws (16) and then the cover (17) from
the planetary carrier (2).

2
17

16

RKZ01860

17 - Place the planetary carrier (2) beneath a press and,

using an appropriate plunger, remove the shaft (18),
complete with O-ring (19).

18

19
RKZA3780

18 - Beneath the planetary carrier (2) place a container in

which to catch the roller bearings (20) and the retainer (21). Take out the bevel gear (22) and the upper
and lower shims (23).
H Repeat these last two operations for all the planetary gears.

23
22

RKZA3790

30-186

REMOVAL AND INSTALLATION

REAR AXLE FINAL DRIVE

19 - Only if substitution is necessary.

Remove the shim (24).

24

RKZA3800

20 - Use a puller to remove the seal ring (25) from the

wheel hub (11).

11

RKZA3810

21 - If the bearings (12) and (13) need replacing, remove

the outer rings from the wheel hub (11).

11

RKZA3820

NOTE.
1 - Thoroughly clean all parts with a light solvent.
2 - Throw away all seals and O-rings.
3 - Carefully check bearings, bushings, gears and
half-axles. If any pitting, scratching, flattened
areas, general wear and tear or any other damage
is found, replace the parts.

30-187

REMOVAL AND INSTALLATION

REAR AXLE FINAL DRIVE

ASSEMBLY OF REAR AXLE FINAL DRIVE

1 - Mount the outer rings of the bearings (12) and (13) in
the wheel hub (11).
(Use a universal tool for bearing rings, or any other
suitable tool).
H Check the orientation.

11

RKZA3830

2 - Use tools G1 and G2 to mount the seal ring (25) in the

wheel hub (11).
H The side on which is written OIL SIDE should
face towards the inside of the wheel hub.
H The seal ring (25) must rest on the shoulder. Any
further pressure might damage the ring.

G2
G1
11
RKZA3840

3 - Only if the shim has been moved

Press the shim (24) into the seating of the planetary
carrier (2).

24

RKZA3800

4 - Coat the hole and the shim part of the gears (22) with
a layer of ASL800050 grease and place a shim (23) in
position.
H Make sure that the shim (23) has adhered to the
gear (22).

23
22

RKZA3850

30-188

REMOVAL AND INSTALLATION

REAR AXLE FINAL DRIVE

5 - Turn the planetary gear (22) upside down and mount

the first set of roller bearings (20) in the hole.
Mount the bearing ring (21), coat the upper part and
the shim surface with ASL800050.
Mount the second set of roller bearings (20) and the
shim (23).
H Make sure that the roller bearings have adhered
to the hole.

20
23
22

RKZA5260

6 - Place the planetary gear group (22) in the planetary

carrier (2), using the pin (18) to align the holes.
H Make sure that the shim holes (23) are correctly
aligned.

22

RKZA5270

7 - Mount the new O-ring (19) on the pin (18).

Lubricate the pin (18) and the O-ring (19) with oil and
mount them in the planetary carrier (2), centering the
pinion group (22) and the shims (23).
Press the pin completely home.

18

19

RKZA5720

8 - Mount the cover (17) on the planetary carrier (2) and

secure it with the screws (16).
Screw: 23 Nm
Cover: Loctite 518

2
17

16

RKZ01860

30-189

REMOVAL AND INSTALLATION

9 - Lubricate the bronze bushing (15) with oil and use the
tool G3 to mount the bushing in the arm.
H Insert it to the point where the tool makes contact
with the shoulder.

REAR AXLE FINAL DRIVE

15

G3
RKZA3860

10 - Lubricate the ring (14) with oil and use the tool G4 to
mount the ring in the arm.
H Check the orientation.
H Insert it to the point where the tool makes contact
with the arm.

14

G4
RKZA3870

11 - Lubricate the inside of the bearing (13) with oil and

use a punch and hammer to knock it home on the
shoulder of the arm.
H Strike light blows round the entire circumference.

13

RKZA3880

12 - With a solution of 50% white spirit and 50% water,

clean the sealing edge of the ring seal (25) of the
hub (11) and the sealing area of the axle in order to
remove all traces of lubricant.
H Mount the hub.

11

Do not oil the sealing area of the ring (25).

RKZA3740

30-190

REMOVAL AND INSTALLATION

REAR AXLE FINAL DRIVE

13 - Lubricate with oil the inside of the bearing (12) and

mount it on the arm.
Use a punch and hammer to knock the bearing home.
H Strike lightly over the entire circumference.

12

RKZA3890

14 - Use the tool G5 to mount the pilot bosses (7) in the

ring bevel gear carrier disc (8).

G5

RKZA3900

15 - Mount the inner snap ring (9) in the ring bevel gear
(10).

10
RKZA3910

16 - Install the ring bevel gear carrier disc (8) and the outer snap ring (9).

9
RKZA3920

30-191

REMOVAL AND INSTALLATION

REAR AXLE FINAL DRIVE

17 - Install the complete ring bevel gear group (6) and use
the screws (5) to hold it in position.
Tighten the screws, employing the alternating crosswise method, until the ring bevel gear carrier rests
on the arm.
Carry out the final tightening.
Screws: 230 Nm

5
RKZA3930

18 - Install the axle shafts (4) by engaging them in the inner joint.
H Take great care not to damage the seal ring (14).

4
RKZA3940

19 - Apply an unbroken trace of sealant around the hub

flange (11) inside the line of stud bolts and threaded
holes.
Flange: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

RKZA3950

20 - Install the complete planetary carrier group (2) on the

hub (11).
H Rotate the group (11) in both directions to facilitate the engagement of the gears.

11

RKZA3651

30-192

REMOVAL AND INSTALLATION

REAR AXLE FINAL DRIVE

21 - Mount the two screws (3) and secure the planetary

carrier (2).
Screws: 80 Nm

22 - Partially insert the shoulder studs (1). Screw in and

lock two nuts M22x15, and fully tighten the studs (1).
Stud bolts: 70 Nm
Stud bolts: Loctite . . . . . . . . . . . . . . . . . . . . . . . . . . .

3
2
RKZA3960

30-193

REMOVAL AND INSTALLATION

REAR AXLE

DISASSEMBLY OF REAR AXLE

1. Removal of the axle arms
Seal rings must be changed each time they are dismantled.

30
29
29
32

30

27
26

36
31

28

33

36

35

32
34
RKZ01650

1 - Loosen and remove the breather-pipe assembly.

Make a reference mark on the hexagonal-head screw
of the pipe (26) to correspond to the grooving.
H Detach the vent plug (27) from the pipe (26) only if
it needs replacing.

27

26

RKZA3970

2 - Attach the complete arm group to some hoisting

tackle.

RKZA3980

30-194

REMOVAL AND INSTALLATION

3 - Make a mark on the central body (28), the brake cylinders (29) and the seatings of the brake disks (30), to
prevent exchanges during re-assembly.

REAR AXLE

30

29

28

29
30

RKZA3990

4 - Loosen and remove the screws (31), with the exception of the top screw.
Slowly loosen the remaining top screw, adjust the
hoisting cable to balance the axle arm (32) and take
out the last screw (31).

31

32

RKZA4000

5 - Keep the axle arm (32) level and separate it from the
brake group (30).

30

32

RKZA4010

6 - Remove the joint (33) complete with snap ring (35)

and extract the half axle (34) from the central body
(28).
H Throw away the O-ring seal (36).

34
RKZA4020

30-195

REMOVAL AND INSTALLATION

REAR AXLE

2. Removal of the brake cylinder and disk seatings

44

47
48

45
46

39

37
38
40

38
40
49

41
42

29
RKZ01660

1 - Remove the outer reaction plate (37).

37

RKZA4030

2 - Remove the clutch plate (38).

38

RKZA4040

30-196

REMOVAL AND INSTALLATION

REAR AXLE

3 - Remove the sleeve (39) and the remaining clutch

group (intermediate reaction plate (40) and the clutch
plate (41).
H The internal reaction plate (42) remains in its seating on the cylinder (43).
H Continue dismantling the 2nd brake disc (38) and
the 2nd reaction plate (40), following the previously-described procedures.

41
39

RKZA4050

4 - Remove the oil-recirculation pipe (44), complete with

O-ring (45).

45

44

45

RKZ01870

5 -Push two supporting pins "A" into the two upper holes
and remove the screws (46).

46
43

RKZA4060

6 - Remove the seatings (47) of the clutch plates.

47

RKZA4070

30-197

REMOVAL AND INSTALLATION

REAR AXLE

7 - Remove the O-ring (48) and the braking cylinder

group (29) complete with O-ring (49).

29

RKZA4080

3. Braking cylinder

56
57
59
66
60

48
42

54
52

61
53
55

58

69

51

62
64

63

65
50
81

78

79

77

76

75

80
82
68
83

73

74

67
72

71

70

29

49

RKZ01700

1 - Loosen and remove the screws (50) and remove the

flange (51).

50
51

RKZA4090

30-198

REMOVAL AND INSTALLATION

REAR AXLE

2 - Remove the complete internal reaction plate (42).

H The isolator ring (52) and the piston could fall and
be damaged.

42

RKZA4100

3 - Remove the isolator ring (52).

52

RKZA4110

4 - Screw three screws "B" into the holes in the piston

(53) and, using a screwdriver as a lever, remove the
piston (53).

53
B

RKZA4120

5 - Remove the external O-ring (54) and the internal O-ring

(55) from the piston (53).

53
55
54

RKZA4130

30-199

REMOVAL AND INSTALLATION

REAR AXLE

6 - Remove the screw (56) and the washer (57).

56
57

RKZA4140

7 - Mark the position between the shaft (58) and the lever
(59).
Use a mallet to raise the lever (59) until a rotation is
obtained that cancels out the action of the spring (60).

60

59

RKZA4150

8 - Remove the lever (59), and spring (60) and the spacer
(61).

60
61

RKZA4160

9 - Remove the retaining screws (62) of the support (63).

62

63

RKZA4170

30-200

REMOVAL AND INSTALLATION

REAR AXLE

10 - Remove the support (63) complete with adjustment

screws (64) and nut (65) and the O-ring seal (66).

63

66

RKZA4180

11 - Use a lever to raise the cam (67) to cancel out the action of the spring (68). Apply a pair of self-locking
pliers to hold the shaft (58) in position.
H Take care not to damage the shaft (58).

58

67

RKZA4190

12 - Mark on the cam (67) its position in relation to the

screw (69).
Remove the screw (69).

67
69

RKZA4200

13 - Remove the shaft (58), the cam (67) and the spring
(68).

68

67

RKZA4210

30-201

REMOVAL AND INSTALLATION

14 - On the shaft (58) trace a alignment sign between the

cam (67) and the screw hole (69).

REAR AXLE

58
67

RKZA4220

15 - Loosen the screws (70) to release the action of the

piston return springs.

70

RKZA4230

16 - Remove the screws (70), then remove the spring retainers (71), the centering bushings (72), the internal
springs (73) and external springs (74).

74

73

71

70

RKZA4240

17 - Loosen and remove the screws (75), the washers (76)

and the centering bushings (77).

77

76

75

RKZA4250

30-202

REMOVAL AND INSTALLATION

REAR AXLE

18 - Remove the flange (78).

78

RKZA4260

19 - Remove from the cylinder the slack adjuster bushings

(79).
H Be very careful because the bushings (79) are
compressed.

79
RKZA4270

20 - Remove the air bleeder screw (80).

80

RKZA4280

H The following operations are only to be carried out if

the differential bearings and pinion or the bevel gear
pair need to be replaced.

82

21 - Loosen and take out the screw (81) and remove the
stop (82) of the adjustment lock nut (83).

81

83
RKZA4290

30-203

REMOVAL AND INSTALLATION

REAR AXLE

22 - Use the tool G6 to remove the adjustment lock nut

(83).

83

G6

RKZA4300

23 - Use a plunger to remove the outer ring (104) of the

differential bearing.

104

RKZA4310

30-204

REMOVAL AND INSTALLATION

REAR AXLE

4. Dismantling the differential locking group

84
85
99
94

95

97

96
98

93

91
97

90

92
87

89

88
86

RKZ01690

H Remove the axle arms and the braking groups. (For

details, see 2. Removal of brake cylinders).
1 - Loosen and take out the screws (84) and the remove
the complete cylinder (85).

84

85
RKZA4320

2 - Slowly and alternately loosen the screws (86) until the

action of the spring (87) has been cancelled.
Take out the screws (86), the cover (88) complete with
the O-ring (89) and the spring (87).

88

86

87
RKZA4330

30-205

REMOVAL AND INSTALLATION

REAR AXLE

3 - Move the complete differential in such a way as to detach it from the fork (91).
Extract the differential from the ring bevel gear side.

91
RKZA4340

4 - Remove the complete fork group (90) from the central

housing.

90

RKZA4350

5 - Compress the spring (93) and remove the snap ring

(94) and the spacer (95). Take out the spacer (92).

92

93

94

95
RKZA4360

6 - Remove the spring (93) and slide the shaft (96), complete with snap ring (97) out of the fork (91).

91

93

97

96

91

RKZA4370

30-206

REMOVAL AND INSTALLATION

REAR AXLE

7 - Remove from the cylinder (85) the O-ring (97) and the
piston (98) complete with O-rings (99).
Take out the O-rings (99).

85

85

99
98

97

RKZA4380

5. Dismantling the differential

112

111

109
111

112

113

112

114
115
106
110

104

116
111

101
100

102
112

103

104

102
107
108
102
103

102

105
RKZ01670

1 - Push the differential lock ring (100) downwards and

remove the snap ring (101).

101
100

RKZA4390

30-207

REMOVAL AND INSTALLATION

REAR AXLE

2 - Remove the lock ring (100), the pegs (102) and the
springs (103) from the differential.

102

103

100

RKZA4400

3 - Use a puller to remove the bearings (104) from the differential.

104

RKZA4410

4 - Remove the screws (105) that secure the ring bevel

gear (106).

105
106

RKZA4420

5 - Turn the differential upside down and remove the ring

bevel gear (106).
H Use a plastic mallet to strike blows all round the
circumference.

106

RKZA4430

30-208

REMOVAL AND INSTALLATION

REAR AXLE

6 - Remove the differential half box (107) on the locking

side.
H The differential half boxes are both marked to facilitate re-assembly.

107

RKZA4440

7 - Remove the thrust washer (108) and the differential

gear (109).

108
109

RKZA4450

8 - Remove the shafts (110) that form the cross journal,

the bevel gears (111) and the spherical thrust
washers (112).

110

112
RKZA4460

9 - Remove the second differential gear (113) and its

shim (114).

113
114
RKZA4470

30-209

REMOVAL AND INSTALLATION

REAR AXLE

10 - Take the cross journal shafts (110) to pieces by removing the bevel gears (111) and the thrust washers
(112).

111

110

112

RKZA4480

11 - Only if necessary
Extract the bushing (116) from the half box (115) on
the ring bevel gear side.

116
115

RKZA4490

30-210

REMOVAL AND INSTALLATION

REAR AXLE

6. Dismantling the bevel pinion

123
122
120
119
118
117
28

124
125
124

121
127
126
RKZ01680

1 - Use a chisel to move the cover (117).

117

RKZA4500

2 - Use two levers on opposite sides to extract the cover

(117) complete with O-ring (118) and the seal ring
(119) from the central housing (28).

28
117

RKZA4510

30-211

REMOVAL AND INSTALLATION

REAR AXLE

3 - Use a chisel to raise the caulked area of the lock nut

(120) from the pinion grooving (121).

120
121
RKZA4520

4 - Use the tools G7 and G8, to loosen the lock nut (120)
of the pinion (121).

G7
G8

RKZA4530

5 - Take out the lock nut (120) and the special washer
(122).

122

RKZA4540

6 - Use a puller as demonstrated in the figure to push the

pinion (121) into the central housing (28).

28

121

RKZA4550

30-212

REMOVAL AND INSTALLATION

REAR AXLE

7 - Remove the outer bearing (123).

123
RKZA4560

8 - Remove the pinion (121) complete with washers

(124), spacer (125), inner bearing (126) and thrust
washer (127).
H Throw away the spacer (125), which should be replaced every time it is dismantled.

124

126

125 124

RKZA4570

9 - Take the outer bearing rings (123) and (126) out of the
central housing (28).

28

RKZA4580

10 - Apply a separator "C" and, using a press, extract the

bearing (126) and the shim (127) from the pinion
(121).

121

126

RKZA4590

30-213

REMOVAL AND INSTALLATION

REAR AXLE

11 - Use a puller to take the seal ring (119) out of the cover
(117).

117
119

RKZA4600

12 - Take the O-ring (118) out of the cover (117).

117

118
RKZA4610

30-214

REMOVAL AND INSTALLATION

REAR AXLE

ASSEMBLY OF THE REAR AXLE

1. Braking cylinder
1 - Mount into the cylinder (29) the outer bearing ring
(104) of the differential.
H The ring (104) should lie just beneath the edge of
the hole.

29

104

RKZA4620

2 - Use the tool G6 to screw in the lock nut (83).

H Do not lock the lock nut at this point.

83

G6

RKZA4300

3 - Mount the air vent plug (80) in the cylinder (29).

Plug: 8 12 Nm

29

80

RKZA4281

4 - Use the tool G9 to mount the bushings (79) up to the

edge of the hole.

79

G9

RKZA4630

30-215

REMOVAL AND INSTALLATION

REAR AXLE

5 - Mount the isolator ring (52) onto the inner reaction

plate (42).

52
42

RKZA4640

6 - Mount the outer O-ring (54) and the inner O-ring (55)
onto the piston (53).
Lubricate the O-rings with ASL800050

53
55
54

RKZA4130

7 - Position the group formed by the inner reaction plate

(42) and the isolator ring (52) on the piston (53).

52
42

53

RKZA4650

8 - Insert the flange (78) into the cylinder (29).

Place the brake seating (47) on the cylinder (29), taking care that the marks coincide.
In order to maintain the alignment, provisionally insert
the two retaining screws of the brake seating into the
cylinder.

78

47
29

RKZA4660

30-216

REMOVAL AND INSTALLATION

REAR AXLE

9 - Install the piston group (53) complete with the reaction plate (42) in the brake seating and push it into
the cylinder (29).
H If necessary use a rubber mallet to strike blows all
round the circumference, in order to insert the piston into the cylinder.
H Align the grooves in the reaction plate with the
grooves in the brake seating.

42

RKZA4670

10 - Remove the brake seating (47) and the screws.

47

RKZA4680

11 - Install the flange (51) and hold it steady with two

screws (50) mounted opposite to each other, and secured provisionally.

50
51

RKZA4690

12 - Mount into the cylinder (29) the spring (68), the cam
(67) and the shaft (58), aligning the reference marks
made during the dismantling phase.
H Check that the thrust surface of the cam (67)
faces towards the contact surface of the flange
(51).

58

29

68
67

RKZA4700

30-217

REMOVAL AND INSTALLATION

REAR AXLE

13 - Raise the cam (67) with a lever, insert a shim "D" and
install the screw (69).
Screw: 10 Nm
H Remove the shim "D".

69

67
RKZA4710

14 - Install the flange (51) with the screws (50), tightened

provisionally.
H The screws (50) will be locked in place finally after
adjustment of the differential bearings.

50
51

RKZA4720

15 - Lubricate the O-ring (66) with oil and push it into its
seating. Mount the support (63) and secure it with
the screws (62).
H Do not tighten the screws at this point.

66

62

63

RKZA4730

16 - Mount the spacer (61) and position the spring (60).

61

60

RKZA4740

30-218

REMOVAL AND INSTALLATION

REAR AXLE

17 - Position the lever (59), aligning the reference marks

made during the dismantling phase.
H Do not hook up the spring (60).

59

RKZA4750

18 - Mount new O-ring seals, (48) and (49), on both sides

of the brake cylinder.

48
49

RKZA4760

30-219

REMOVAL AND INSTALLATION

REAR AXLE

2. Installation of the pinion

1 - Place the outer bearing ring (123) of the pinion in the
central section (28).
H Carefully check the orientation of the bearing ring.

123

28
RKZA4770

2 - Position the tool G10 from the front of the central

housing.

G10

RKZA4780

3 - Assemble the tool G10 by inserting the inner bearing

ring (126) of the pinion.
H Carefully check the orientation of the bearing ring.

126

G10

RKZA4790

4 - Keep the central rod of the tool G10, locked in position and screw in the nut until the bearing ring is completely inserted.
Remove the tool G10.

G10

RKZA5240

30-220

REMOVAL AND INSTALLATION

5 - Install the bearings (123) and (126) and the special

tools G11, G12, G13 which are needed to measure
the depth of the pinion.

REAR AXLE

G12

G13
G11

RKZA4800

G12

G13

RKZA4810

6 - Use a thickness gauge to measure the space "X" between the gauge block G12 and the pinion depth
gauge G13.
Insert the value "X" into the formula shown in the diagram on the next page.

G13

G12

RKZA4820

7 - Measure the height "V" marked on the pinion and insert it into the formula shown in the diagram on the
next page.

117

RKZA4830

30-221

REMOVAL AND INSTALLATION

REAR AXLE

2
3

RKZ01890

S=Shim measurement
1 - Tool G11

4 - Clearance measured

2 - Tool G12
3 - Tool G13

5 - Bearing group

A=Tool measurement (constant)

B=Tool measurement (constant)
X=Clearance measured
V=Value of pinion reading

8 - Select the shim "S" (127) from amongst the various

shims available.
H Range of shims: 2.5 3.4 mm with an increment
of 0.1 mm.
H The shim "S" (127) should be mounted between
the pinion (121) and the inner bearing (126).

S (127)

9 - Take away the special tools.

S (127)
RKZ01900

10 - Position the pinion (121) on the bed of a press and

mount the shim (127) and the bearing (126).
H Pay attention to the orientation of the bearing.

126

11 - Use the tool G14 to press the bearing (126) onto the
back of the shim (127).

G14

127
121

126

RKZA4840

30-222

REMOVAL AND INSTALLATION

REAR AXLE

12 - Lubricate the inner bearing (126) with gear oil, then

mount the first washer (124), the new spacer (125)
and finally the second washer (124) onto the pinion
(121).
Insert the group into the central housing (28).

124
124 125

126

121

28
RKZA4571

13 - Lubricate the outer bearing (123) with gear oil and

press it onto the pinion (121).

121

123
RKZA4561

14 - Mount the special washer (122) and the lock nut (120)
onto the pinion (121).

122

120

121

121
RKZA4850

15 - Use the tools G7 and G8 to tighten the lock nut (120)

until the bearing group is tightly assembled.

G7
G8

RKZA4860

30-223

REMOVAL AND INSTALLATION

REAR AXLE

16 - Measure the preloading "P" of the bearings with a dynamometer and a line wound round the pinion (121).
H Preloading P: 9.2 13.8 daN
(1 daN=10 N)
17 - Gradually adjust by tightening the lock nut (120) with
small rotation increments.
H The reloading must be controlled without seal
rings.

RKZA4870

18 - Caulk the lip of the lock nut (120) into the pinion
groove (121).

120

121
RKZA4880

3. Re-assembly of the differential

1 - If the bushing (116) has been moved, insert it into the
half box (115) on the ring bevel gear side.
For insertion, use the tool G16.

116

G16

115

RKZA4890

2 - Lubricate the thrust washers (112), the differential

gears (111) and the cross-journal shafts (110).
Install the groups.

111

110

112

RKZA4480

30-224

REMOVAL AND INSTALLATION

REAR AXLE

3 - Lubricate the inside surface of the half box (115) with

grease and install the shim (114) and the differential
gear (113).
Surface: ASL800050

113

114

115
RKZA4900

4 - Install the shafts (110) that form the cross-journal

complete with the bevel gears (111) and the shims
(112).

110

112
RKZA4460

5 - Position the differential gear (109) and the thrust

washer (108).
H The protruding parts of the thrust washer should
be oriented for insertion into the wells of the differential half case.

108
109

RKZA4450

6 - Mount the half box (107) on the locking side, taking

care to respect the alignment marks.

107

RKZA4440

30-225

REMOVAL AND INSTALLATION

REAR AXLE

7 - Turn the group upside down and check that both the
surface of the half box and the reference pin of the
ring bevel gear are perfectly clean.

107

RKZA4910

8 - The pinion (121) and the ring bevel gear (106) belong
to one single set and have been marked.
H Make sure that the number marked on the pinion
corresponds to the number marked on the ring
bevel gear.

43

121
RKZA4831

9 - Coat the coupling surface of the differential box (107)

with adhesive and mount the ring bevel gear (106),
centering it on the reference pin.
Adhesive: Loctite 638

106
43

107
RKZA4920

10 - Fix the entire differential group with screws (105) and

tighten them using the alternating crosswise method.
Screws: 155 Nm
Screws: Loctite 270

105

RKZA4930

30-226

REMOVAL AND INSTALLATION

REAR AXLE

11 - Use the tool G17, to mount the bearings (104).

G17

G17
104

104

RKZA4940

12 - Mount the springs (103) and the pegs (102) into the
differential box (107).

103

107

102

RKZA4950

13 - Position the differential-locking ring (100) and, pressing on the pegs (102), push it home.

100

102
RKZA4960

14 - Install the snap ring (101).

101
100

RKZA4390

30-227

REMOVAL AND INSTALLATION

REAR AXLE

4. Installation of the differential lock

85

1 - Mount new O-rings (99) onto the piston (98).

Lubricate the seals and insert the complete piston
into the cylinder (85).
Mount a new O-ring (97) onto the cylinder.

85

99
98

97
RKZA5250

2 - Mount the shaft (96) complete with snap ring (97) into
the fork (91).

96

97

91

RKZA4970

3 - Install the spring (93) onto the shaft (96).

Compress the spring (93) and install the spacer (95).

93
95

RKZA4980

4 - Install the snap ring (94) and release the spring (93).
Mount the spacer (92) on the shaft (96).

92

94

96

RKZA4990

30-228

REMOVAL AND INSTALLATION

REAR AXLE

5 - Install the fork group (90) in the central housing.

90

RKZA4350

6 - Install the complete differential group, moving it so as

to engage the fork (90) in the differential lock ring.

91
RKZA4340

7 - Install the spring (87) in the central housing and

mount the cover (88) complete with O-ring (89).
Fasten the cover with the screws (86), employing the
alternating crosswise method.
Screws: 23 Nm

88

86

87
RKZA4330

8 - Lubricate the seals (97) of the cylinder (85) and mount

the cylinder in the central housing.
Fasten the group with the screws (84), employing the
alternating crosswise method.
Screws: 23 Nm

84

85
RKZA4320

30-229

REMOVAL AND INSTALLATION

REAR AXLE

5. Completing the assembly of the axle

1 - Install two guide pins "A" in the central housing. Lubricate the O-ring seals (48) and (49) of the brake cylinder group (29).
Install the group on the central housing.
H Check that the markings correspond.

RKZA5010

2 - Install the brake disk seating (47) on the guides "A".

H Check that the markings correspond.

47

RKZA5020

3 - Use the axle shaft (34) to raise the differential group

into position for centering some bearings in the outer
bearing ring of the brake cylinder.
Push the brake cylinder and the brake disc seating
against the central housing.

34
RKZA5030

4 - Use the axle shaft to hold the group in position and

completely insert the two screws (46).
H Do not lock the screws at this point.

46

46
RKZA5040

30-230

REMOVAL AND INSTALLATION

REAR AXLE

5 - Lubricate the O-ring seals (45) and insert the oil re-circulation pipe (44).
H Make sure that the pipe (44) has been pushed
completely home in the central housing.

45

44

45

RKZ01870

6 - Give a final tightening to the screws (46) that secure

the cylinder (29) and the brake disk seating (47).
Screws: 120 Nm
H Repeat the assembly operations for the brake cylinder (29) and the brake disk seating (47) also on
the other side.

46

46

RKZA4061

7 - Remove the flange (51) in order to reach the lock nuts

(83) that adjust the differential.

51
83

RKZA5050

8 - Mount the tool G18 on the pinion (121).

121

G18

RKZA5060

30-231

REMOVAL AND INSTALLATION

REAR AXLE

9 - Attach a centesimal comparator perpendicular to the

notch "W" cut into the gauge block. Pre-load the comparator by about 4 mm.
10 - Rotate the pinion by hand in both directions to check
the clearance between the differential pinion teeth.
H Clearance allowed between the teeth:
0.2 0.28 mm

RKZA5070

11 - If the clearance between the teeth does not fall within

the permissible values, proceed as follows:
1 - Clearance above the limit
a - Unscrew the adjustment lock nut (1) by one
notch.
b - Screw in the lock nut (2) by one notch.
2 - Clearance below limit
a - Unscrew the adjustment lock nut (2) by one
notch.
b - Screw in the lock nut (1) by one notch.
H Repeat these operations until the clearance fall
within permissible limits.
H Use the tool G6 to turn the lock nuts.

106

RKZ01880

30-232

REMOVAL AND INSTALLATION

REAR AXLE

12 - Once the clearance between the teeth has been determined, check that the total pre-loading "T" of the
bearings falls within permissible limits.
H Pre-loading: T=(P+3.23)/(P+4.84) daN
(1 daN=10 N)
H P=pre-loading of the pinion bearings.
This check is performed in the same was as the
check on the pre-loading P of the pinion bearings.

RKZA4870

13 - If the pre-loading does not fall within permissible limits, proceed as follows:
1 - Pre-loading above the limit
a - Unscrew the lock nuts (1) and (2) by one notch.

106

2 - Pre-loading below the limit

a - Screw in the lock nuts (1) and (2) by one notch.
H Repeat these operations until the pre-loading falls
within permissible limits.
H Use the tool G6 to turn the lock nuts.

RKZ01880

14 - Lubricate the seal ring (119) with oil and, using the
tool G16, insert it into the cover (117).
Also mount the O-ring (118).

119
118

117
RKZA5080

30-233

REMOVAL AND INSTALLATION

REAR AXLE

15 - Lubricate the O-ring (118) and, using the tool G19,

mount the complete cover (117) into the central housing.
Remove the tool G19.

117

G19
RKZA5090

16 - Mount the adjusting ring locks (82) and block them

with the screws (81).
Screws: 13 Nm

82
81

RKZA5100

17 - Place the flange (51) in its final position and secure it

with the screws (50) tightening them progressively.
Screws: 23 Nm

50

51
RKZA5110

H If new brake disks (41) and (38) are to be installed,

make sure that the disks have been soaked in oil.
At the very least the disks should be lubricated on
both sides.

41

18 - Install the first brake disk (41).

RKZA5120

30-234

REMOVAL AND INSTALLATION

REAR AXLE

19 - Install the intermediate reaction plate (40), making

sure that the teeth of the outer circumference are engaged in the slots in the seating (47).

40

47

RKZA5130

20 - Install the sleeve (39), engaging the toothing in the

brake disk (41).
H Engage the brake disk in the short grooved part of
the sleeve.

41
39

RKZA4050

21 - Install the second brake disk (38), aligning the holes

with those of the first disk.
H Continue the assembly with the second reaction
plate (40) and the third brake disk (38), following
the previous procedures.

38

RKZA4040

22 - Install the outer reaction plate (37), making sure that

the teeth of the outer circumference are engaged in
the slots of the seating (47).
H The marked face should be turned towards the
outside of the central housing.

22

RKZA5270

30-235

REMOVAL AND INSTALLATION

23 - If the joint (33) on the axle shaft (34) has been moved,
re-assemble it.
H Check that the coupling (35) is mounted inside the
joint (33).

REAR AXLE

33
34

RKZA5140

24 - Install the shaft (34) in the axle arm (32).

H Make sure that the joint is engaged on the axle
shaft (4) of the final drive.
Lubricate the O-ring (36) and mount it on the
flange of the axle arm (32).

36

32

34

RKZA5150

25 - Raise the complete axle arm (32) horizontally and engage the axle shaft (34) with the brake group (30).
H If necessary rotate the bevel pinion to engage the
shaft (34).

30

32

RKZA5160

26 - Push the axle body (32) against the central housing.

Mount the screws (31) and employ the alternating
crosswise method to tighten them.
Screws: 130 Nm
H Repeat these assembly operations for the other
axle body.

31

32

RKZA4000

30-236

REMOVAL AND INSTALLATION

REAR AXLE

6. Final re-assembly

80

1 - Loosen the air breather plugs (80).

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 remove the pump.

RKZA5170

6 - Tighten the two levers (59) of the parking brake by applying 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.
H If necessary, raise the levers and engage them on
the grooves of the shaft in a different position,
making marks to indicate the new position.
H Check that each lever makes a return stroke of
at least 3 mm (center distance measurement
306 316 mm).

RKZA5280

8 - Raise the levers (59) and the springs (60). Hook up

the springs and pre-load them by rotating the levers
inside the supports (63).
H Make sure that the shaft rotates with the levers.

59

60
63
RKZA5180

9 - Use a mallet to push the levers (59) home on the shaft

(58).
10 - Install the retaining washer (57) and the screw (56).
Screw: 35 Nm

59

58

57

RKZA5190

30-237

REMOVAL AND INSTALLATION

REAR AXLE

11 - Move the supports (63) until the adjustment screws

(64) are perpendicular to the levers (59). Lock them
in position with the screws (62).

63
64
62
59

RKZA5200

12 - Adjust the return stroke of the levers from the braking

position to 3 mm, and lock the adjustment screws (64)
with the nuts (65).

64

65

RKZA5210

13 - Install the breather pipe (26) and tighten it until the reference mark made during the dismantling phase is in
the correct position.
Breather pipe: 10 Nm

26

RKZA5220

14 - If the plug (128) has been removed to drain the oil, replace it in the central housing.
Plug: 80 Nm
15 - Fill the axle up with oil and replace the cap (129).
Plug: 80 Nm

129
128

RKZA5230

30-238

REMOVAL AND INSTALLATION

FRONT BUCKET BOOM-RAISING CYLINDER

REMOVAL OF THE FRONT BUCKET BOOM-RAISING CYLINDER

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).

2 - Put a sling round the cylinder (3) and insert some

blocks A between the boom (4) and the fulcrum lever spacer (5).
3 - Take off the snap-ring and the internal retaining
spacer for the piston attachment pin (6).
4 - Take out the pin (6) in order to free the piston head
(7), but leave the fulcrum lever engaged (5).

RKZA0990

5 - Start the engine to retract the piston (7).

H Bind the piston head with wire to secure the fully retracted position and stop the engine.

A
5

Release all residual pressure in all circuits. (For details, see 20. TESTING AND ADJUSTMENTS).

4
6

6 - Disconnect the tubes (8) and (9) and plug them to prevent entry of impurities.

7 - Remove the snap-ring (10) and the spacer (11).

8 - Remove the cylinder (3).

RKZA1000

INSTALLATION OF FRONT
BUCKET BOOM-RAISING
CYLINDER
.

To install, reverse the removal procedure.

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
RKZA1450

Internal bushing: ASL800050

11

1 - Start the engine and bleed the air from the cylinders.
(For details, see 20. TESTING AND ADJUSTMENTS).
H After bleeding the air, check the oil level in the tank.

3
10
RKZA1010

30-239

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).
H For the right-hand cylinder only
Remove the bucket position indicator (3).
2 - Place a sling round the cylinder (4) and insert a block
A between the spacer (5) of the piston fulcrum lever
(7) and the lever (8).

3 - Take off the snap-ring and the internal retaining

spacer for the piston attachment pin (8).

RKZA1020

4 - Take out the pin (8).

5 - Start the engine to retract the piston (9).

6
H Bind the piston head with wire to secure the fully retracted position and stop the engine.
Release all residual pressure in all circuits. (For details, see 20. TESTING AND ADJUSTMENTS).

6 - Disconnect the tubes (10) and (11) and plug them to

prevent entry of impurities.

7 - Remove the snap-ring (12) and the spacer (13).

RKZA1030

8 - Remove the cylinder (4).

INSTALLATION OF THE FRONT

BUCKET TILT CYLINDERS
.

To install, reverse the removal procedure.

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.

Internal bushing: ASL800050

1 - Start the engine and bleed the air from the cylinders.
(For details, see 20. TESTING AND ADJUSTMENTS).
H After bleeding the air, check the oil level in the tank.

11
8

10
RKZA1040

12

13
RKZA1050

30-240

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.

RKZA1060

2 - Take out the screws (1) and remove the pins (2) of the
lever (3).
Rest the lever (3) on the boom.

1
3

2
RKZA1460

3 - Take out the screws (4) and remove the pins (5) of the
bucket fulcrum.

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.

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.

Internal bushing: ASL800050

30-241

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 ADJUSTMENTS).
1 - Remove the tilt cylinders. (See REMOVAL OF FRONT
BUCKET TILT CYLINDERS).

RKZA1060

2 - Disconnect the cylinders (2) from the boom and rest

them on wooden blocks A placed on the front axle.

2
RKZA1070

3 - 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.

RKZA1090

4 - 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.

3
1

RKZA1080

30-242

REMOVAL AND INSTALLATION

5 - Using a puller, take out the axle oscillation pins (5) of

the boom (1).
6 - Start the engine and put the machine into reverse
gear travel until the boom is disengaged.
H 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.

FRONT WORKING EQUIPMENT

7 - Place two stands in position and lower the boom until

it is resting on them.

RKZA1480

INSTALLATION OF THE FRONT WORKING EQUIPMENT

.

To install, reverse the removal procedure, if necessary using the front towing hook.
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.

Internal bushing: ASL800050

.

Start the engine and bleed the air from the cylinders.
(For details, see 20. TESTING AND ADJUSTMENTS).

H After bleeding the air, check the oil level in the tank.

30-243

REMOVAL AND INSTALLATION

BACKHOE CONTROL VALVE

REMOVAL OF THE BACKHOE CONTROL VALVE

1 - Swing the backhoe completely to the right of the machine, 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
backhoe plate and stop the engine.
Release all residual pressure in all circuits. (For details, see 20. TESTING AND ADJUSTMENTS).
RKZA1680

4 - Take out the lower window (1) of the cab and completely raise the upper window.

RKZA1100

5 - Remove the grips (2) of the control levers of the outriggers and the grip (3) of the lever-locking device.

6 - Raise the protective sleeves (4) of the control levers,

take out the screws (5) and remove the cover (6).

5
3

6
RKZA1110

H If any optional devices have been fitted, unhook

the spool command tie-rods (7) and remove the
pedals (8) and the supports (9).

7
RKZA1120

30-244

REMOVAL AND INSTALLATION

7 - Disconnect the connector (10) of the solenoid (11) of

the control valve (12).

BACKHOE CONTROL VALVE

12

13

8 - Disconnect the lever command tie-rods from the control valve.

9 - Disconnect from the control valve the pipes (14) (delivery, return, Load Sensing and actuators). Plug
them to prevent entry of impurities.
H Mark the pipes to prevent exchanging positions
during re-connection.

14

10 - Attach the control valve (12) to some hoisting tackle

and apply a slight tension to the cables.

11

10

RKZA1130

11 - Remove the four screws (15) and then the entire control valve.
Control valve: 6-spool 47 kg
7-spool 53 kg
8-spool 59 kg

15
15

RKZA1140

INSTALLATION OF THE
BACKHOE CONTROL VALVE
To install, reverse the removal procedure.
H Bleed the air from Load Sensing circuits and from the
hydraulic circuits of all the actuators. (For details, see
20. TESTING AND ADJUSTMENTS).

30-245

REMOVAL AND INSTALLATION

BACKHOE BOOM CYLINDER

REMOVAL OF BACKHOE BOOM CYLINDER

1- 1Remove the lubrication nipple and the extension (1).

Extend the arm (2) completely and fully open the

bucket (3).
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.

3 - Place a sling around the cylinder (4).

RKZA1150

4 - Take out the screws (5) and remove the pin (6).

10

5 - Start the engine and retract the piston.

H Secure the position of total retraction by binding
the piston head rod with wire.
6 - Stop the engine and release any residual hydraulic
pressures. (For details, see 20. TESTING AND ADJUSTMENTS).

2
3

7 - Disconnect the pipes (7) and (8) and plug them to prevent entry of impurities.
8 - Take out the screw (9) and remove the pin (10).

RKZA0140

9 - Remove the cylinder (4).

Cylinder: WB91R-2 65 kg
WB93R-2 78 kg

INSTALLATION OF THE
BACKHOE BOOM CYLINDER
.

To install, reverse the removal procedure.

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.

RKZA1170

Internal bushing: ASL800050

1 - Start the engine and bleed the air from the cylinders.
(For details, see 20. TESTING AND ADJUSTMENTS).
H After bleeding the air, check the oil level in the
tank.

7
RKZA1180

30-246

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.
1 - Stop the engine and release the pressures in the cylinder by moving the control lever several times.

1
2

2 - Place a sling around the cylinder (4).

3 - Take out the screws (5) and remove the pin (6).

A
B
RKZA1160

4 - Start the engine and retract the piston (7).

H 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
pressures. (For details, see 20. TESTING AND ADJUSTMENTS).

6 - Disconnect the pipes (8) and (9) and plug them to prevent entry of impurities.
7 - Take out the snap-ring (10) and remove the pin (11).

8 - Remove the cylinder (4).

RKZA1190

Cylinder: 69 kg

8
4

INSTALLATION OF THE
BACKHOE ARM CYLINDER
.

To install, reverse the removal procedure.

RKZA1200

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.

11

Internal bushing: ASL800050

1 - Start the engine and bleed the air from the cylinders.
(For details, see 20. TESTING AND ADJUSTMENTS).
H After bleeding the air, check the oil level in the tank.

10
RKZA1210

30-247

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.
1 - Stop the engine and release the pressures in the cylinder (4) by moving the control lever several times.

2 - Place a sling around the cylinder (4).

3 - Take out the lock-nut (5) and the washer and remove
the pin (6).

A
B
RKZA1161

4 - Start the engine and retract the piston (7).

H 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
pressures. (For details, see 20. TESTING AND ADJUSTMENTS).

6 - Disconnect the bracket (8) and the pipes (9) and (10),
and plug them to prevent entry of impurities.
7 - Take out the snap-ring (11) and remove the pin (12).

7
5

8 - Remove the cylinder (4).

RKZA1220

Cylinder: 49 kg

INSTALLATION OF THE
BACKHOE BUCKET CYLINDER
.

10
11

To install, reverse the removal procedure.

4
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.

12

RKZA1230

Internal bushing: ASL800050

Pin-retaining lock-nut: . . . . . . . . . . . . . . . . . . . . Nm
1 - Start the engine and bleed the air from the cylinders.
(For details, see 20. TESTING AND ADJUSTMENTS).
H After bleeding the air, check the oil level in the tank.

30-248

REMOVAL AND INSTALLATION

OUTRIGGER CYLINDERS

REMOVAL OF THE OUTRIGGER CYLINDERS

Position the backhoe with the equipment centered,
the arm vertical and the back of the bucket resting
on the ground.
1 - Extend the outriggers (1) of about 15 cm, stop the engine and release the cylinders pressures.

1
RKZA0971

2 - Place a lifting platform "A" beneath outrigger (2).

Raise this until it is forced up against the outrigger.

1
2
A

RKZA1240

3 - Remove the clamp (3).

4 - Disconnect from cylinder (5) the pipe (4) and plug

them to avoid impurity entry.
Plug also the union to avoid the movement of piston.
5 - Remove screw (6) and extract the pin (7) until the cylinder (5) is free.

4
3
7

6
RKZA1250

6 - Raise the lifting platform "A" to disengage the cylinder head (5) from frame.
Place a sling round the cylinder (5) and apply slight
tension to the cables.

5
7

RKZA1260

30-249

REMOVAL AND INSTALLATION

OUTRIGGER CYLINDERS

7 - Take out the screw (9) and remove the pin (10).

8
8 - Remove the cylinder (5).

RKZA1270

INSTALLATION OF THE
OUTRIGGER CYLINDERS
.

To install, reverse the removal procedure.

Do not insert fingers into the holes to check alignment.

Internal bushing: ASL800050

1 - Start the engine and bleed the air from the cylinders.
(For details, see 20. TESTING AND ADJUSTMENTS).
H After bleeding the air, check the oil level in the tank.

30-250

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
moving the control levers several times.
2 - Take out the screws (1) and remove vertically the upper
support (2) of the cylinder fulcrum.
3 - Disconnect the four tubes (4) from the cylinders (3)
and plug them to prevent entry of impurities.
4 - Take out the screws (5) and remove the pins (6).

RKZA0970

5 - Rotate the cylinders to disengage the piston heads

from the swing bracket (7) and remove the cylinders
(3).

Cylinder: 30 kg

INSTALLATION OF THE
BACKHOE SWING CYLINDERS

1
3
RKZA1280

1 - Mount the cylinders (3) and the upper cylinder fulcrum support (6). Secure the support with the four
screws (1).

6
Support screw: Loctite 262
Support screw: 100w10 kgm

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.

5
7
RKZA1290

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.

Internal bushing: ASL800050

4 - Start the engine and bleed the air from the cylinders.
(For details, see 20. TESTING AND ADJUSTMENTS).
H After bleeding the air, check the oil level in the tank.

30-251

REMOVAL AND INSTALLATION

BACKHOE BACKFRAME LOCK CYLINDER

REMOVAL OF BACKHOE BACKFRAME LOCK CYLINDER

H Set the backhoe with the centered attachments with
the arm in vertical position and the bucket leaned
on the back at level ground.
1 - Unlock the backframe (1).
2 - Stop the engine and release the residual hydraulic
pressures. (For details, see 20. TESTING AND ADJUSTMENT).
3 - Disconnect from cylinder (2) the pipes (3) and (4) and
plug them to avoid impurity entry.
4 - Remove screws (5) and cylinders (2).

RKZA0970

4
1

RKZA1300

INSTALLATION OF BACKHOE
BACKFRAME LOCK CYLINDER
.

To install, reverse the removal procedure.

Locking screw: Loctite 262

Locking screw: 41w4 kgm

Cylinder seat: ASL800050

1 - Start the engine, lock and unlock the backframe several times to make the circuit feeling.

30-252

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. Engage the cylinder head in the tools A2 appropriate to the diameter of the hole.

A2
A2
A1

1
RKZA1540

For the arm cylinder with side-digging boom first extract the snap-rings (2) and the ball-and-socket joint
(3).

5
1

RKZA1530

2 - Using the specially-made wrench A4 unscrew the cylinder head (4) and extract it from the cylinder (1).
For the side-digging boom cylinder, first remove
the lock-nut (5) that secures the piston-rod seal.

3 - Raise the cylinder (1) and attach the piston head to

the mobile group of the tool.
4 - Extract the piston-rod group (6) from the cylinder (1).
5 - Remove the cylinder (1) and the piston-rod group (6).

A1
4

RKZA1560

30-253

REMOVAL AND INSTALLATION

CYLINDERS

6 - Secure the piston-rod group (6) on the tool A1.

7 - For the side digging boom cylinder: remove the
snap-spin (10).
8 - For the piston rod of the boom cylinder: remove the
screw (7).
9 - Use the appropriate socket wrench A7 on the piston
hexagon (11) and unscrew the piston.
H Measurement of the socket wrench:
For raising the front bucket:
55 mm
For tilting the front bucket:
55 mm
Boom:
65 mm
Arm:
55 mm
Bucket:
55 mm
Outriggers:
46 mm
Telescopic arm:
46 mm
Side digging boom:
46 mm

7
9

1 BRACCIO

BOOM

8
RKZ00020

SIDEPISTONE
DIGGING
BOOM PISTON
DEPORTABILE

10

10 - For the piston rod of the boom cylinder: Take out

the ball bearings (8) and the cushion plunger (9).
11 - Dismantle all the groups by removing all the seals,
the dust-seals, the guide rings, and the fulcrum bushings.
The seals, the dust seals and the guide rings
cannot be used again.
Carefully check the pistons (11). If both safetycaulked areas show wear, the pistons must be
replaced.

11

2ARM
BRACCIO

11

RAISING
SOLLEVAMENTO
ROVESCIAMENTO
TILTING

30-254

11

RKZ00010

REMOVAL AND INSTALLATION

CYLINDERS

ASSEMBLY OF CYLINDERS

(Front bucket raise and tilt, boom, arm, bucket, outriggers and jig arm)
H Take great care not to damage the seals and the sliding surfaces.
H Prepare each individual component before the final
assembly.

16

15

1. ASSEMBLY OF THE CYLINDER HEAD

1.1 Only for the cylinders for front bucket raise
and tilt, boom, arm, bucket, outriggers, jig arm
1 - Mount the gasket (12) in the cylinder head.
2 - Mount the gasket (13) in the cylinder head.
H Make sure that the lips are turned towards the inside of the cylinder.

14

13

12
RKZ00040

3 - Mount the guard ring (14) using the tool A8.

22

21

20

4 - Mount the O-ring (15) and the anti-extrusion ring (16)

on the outside of the cylinder head.

1.2 Cylinder for side digging boom

1 - Insert the gasket (17) in the cylinder head, and let it

beat on seat bottom, then insert the anti-extrusion
ring (18).
H Check carefully the assembly orientation.
2 - Mount the guard ring (19) in the lock-nut (5).

19

18

17

23
RKZ00050

3 - Tighten the lock nut (5) until leaning lightly on anti-extrusion ring (18).
4 - Assemble on head the O-ring (20), the anti-extrusion
(21), the O-ring (22) and the ring (23).

25

2. RE-ASSEMBLING THE PISTON

26

2.1 Only for the cylinders for front bucket raise

and tilt, boom, arm, bucket, outriggers, jig arm

24

26

27
11

1 - Use the tool A9 with the appropriate diameter, mount

the ring (24) the external ring (25) and the anti-extrusion rings (26) onto the piston (11).
2 - Prepare the guide ring (27).
H There are two guide rings (27) for the boom piston.

RKZ00090

3 - For the boom piston only: insert the O-ring (28) into
the internal seating.

27
28
A9

RKZA1580

30-255

REMOVAL AND INSTALLATION

CYLINDERS

2.1 Side digging boom cylinder

H This mounting should be performed directly on piston.

33 31 30 31 34

1 - Mount central ring (29), rubber ring (30) and anti-extrusion ring (31).

35

32

36

2 - Mount on piston first washer (32), guide ring (33), central ring assembly (29), second guide ring (34) and
second washer (35).

10

3 - Tighten nut (36) and lock the piston group after locking rod head under the press. (See 3. RE-ASSEMBLING THE PISTON-ROD GROUP).

29
RKZ00060

4 - Insert the snap ring (10).

3. RE-ASSEMBLING THE PISTON-ROD GROUP

1 - Only for the cylinders for front bucket raise and
tilt, boom, arm, bucket and side digging boom:
using a press and tools A2 with the appropriate diameter, insert the bushing (37) into the piston head (6).

6
37
A1

A2

RKZA1500

2 - Mount the bushing A10 of the correct diameter onto

the tip of the piston rod (6).

3 - Slightly lubricate the cylinder head seals (4) and slide

the group onto the piston rod (6).
Seals: ASL800050

A10

RKZA1510

4 - For the cylinders of the outriggers only: mount the

spacer (38) with the O-ring (39).
H Check carefully the assembly orientation.
For the arm cylinder only: insert the spacer (40).

39 38

A10

STABILIZZATORI
OUTRIGGERS

40
ARM
2 BRACCIO

RKZ00070

30-256

REMOVAL AND INSTALLATION

CYLINDERS

5 - Remove from the tip of the piston rod (6) the bushing
A10 and mount the piston (11) and the nut (36).
H Grease the piston threading.
Piston locking nut: Loctite 262
Piston locking nut:
Front bucket raise:
Front bucket tilt:
Arm:
Bucket:
Outriggers:
Telescopic arm:

290w29
290w29
290w29
290w29
155w15
155w15

11
7

kgm
kgm
kgm
kgm
kgm
kgm

6 - For the boom cylinder: mount the cushion plunger

(9), slide the eleven ball-bearings (8) into the hole,
and mount the dowel bolt (7).

RKZ00021

11

Dowel bolt: Loctite 262

Dowel bolt: 23w2 Nm

7 - Screw the complete piston (11) onto the piston rod,

and secure it with the dynamometric wrench.
Piston: 120 125 kgm
8 - Caulk the piston (11) to correspond to the slot in the
piston rod (6) not previously used.

RKZA1550

4. RE-ASSEMBLING THE CYLINDERS

A2

1 - Mount onto the apparatus A1 the tools A2 with the

appropriate diameter.
2 - For the boom, arm, bucket and side digging boom
cylinders only:
Position the bushing (41) and mount it in the cylinder
head (1).
H There are two bushings for the arm cylinder, with
a spacer between them.
H Leave the cylinder in position for subsequent assembly.
3 - Lubricate the threading and the first part of the cylinder (1).
Cylinder: ASL800050

A2

A1

41
RKZA1541

A11

4 - Mount the two halves of the tool A11 with the appropriate diameter at the mouth of the cylinder (1).

RKZA1520

30-257

REMOVAL AND INSTALLATION

CYLINDERS

5 - Mount the piston rod group (6) on the apparatus A1

and raise the mobile part to the end of its stroke.
6 - Place the cylinder (1) in a vertical position and guide
the piston into the tool A11.

7 - Lower the apparatus that supports the piston rod (6)

in order to center the piston in the tool A11.

A1
4

8 - 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.

A11

Insert the piston slowly in order to calibrate the guide

rings (27) without overheating them.
9 - Take the cylinder out of the tool A11 and then lower
the apparatus A1 further in order to bring the cylinder
head (4) and the piston rod head closer to the cylinder.

10 - Bring the cylinder (1) into position for screwing in the

cylinder head (4).
11 - Insert the cylinder head into the cylinder and screw it
in by hand for several turns.
12 - Use the right special wrench A4, A5, A6 to screw the
cylinder head (4) home.

RKZA1561

Cylinder head: 95 100 kgm

13 - For the side digging boom cylinders only: tighten
the lock-nut (5).
Lock-nut: 50 kgm

RKZ00080

30-258

REMOVAL AND INSTALLATION

BOOM SWING CYLINDER

DISASSEMBLY OF BOOM SWING CYLINDER

9
1

4
7

8
RKZ00100

1 - Place the cylinder (1) on the apparatus A1. Engage

the axle oscillation pins in the tools A3.
2 - Using the specially-designed wrench A6, unscrew the
cylinder head (2) and extract it completely from the
cylinder (1).
3 - Remove the safety dowel bolt (10).
4 - Raise the cylinder (1) and attach the piston head to
the mobile group of the apparatus 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
areas 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).
H 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.

30-259

REMOVAL AND INSTALLATION

BOOM SWING CYLINDER

ASSEMBLY OF BOOM SWING CYLINDER

H Take great care not to damage the seals and the sliding surfaces.
H Prepare each individual component before the final
assembly.

13

14

10

11

15

1. Assembly of the cylinder head

1 - Mount the gasket (10) and the gasket (11) in the cylinder head.
H Make sure that the lips are turned towards the inside of the cylinder.

12
RKZ00110

2 - Mount the scraper ring (12).

3 - Mount the O-ring (13), the anti-extrusion ring (14) and
lastly the O-ring (15) of the front seal.

19 18 17 18 19
2. Re-assembling the piston
1 - Use the tool A9 with the appropriate diameter, mount
the rubber ring (16) and the seal ring (17) onto the piston. Remove the tool A9 and mount the anti-extrusion
rings (18).

16
A9

20

2 - Prepare the guide rings (19).

3 - Mount the O-ring (20) in the internal seating of the piston.

RKZA1600

3. Re-assembling the piston-rod group

1 - Using a press and tools A2 with the appropriate diameter, insert the bushing (21) into the piston head (4).

2 - Insert the ring (8) into the piston rod (4).

H 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).

A2

A10

4 - Mount the bushing A10 of appropriate diameter on

the tip of the piston rod (4).

RKZA1590

5 - Lightly lubricate the cylinder head gaskets (2) and

slide the group onto the piston rod (4).
Gaskets: ASL800050

6 - Lubricate the O-ring seals (22) and screw the piston

(5) onto the piston rod (4) by hand for several turns.
O-ring seal: ASL800050
7 - Position the group on the tool A1 and tighten the piston with the round prong wrench A7.

22

7
6

Piston: 95 100 kgm

8
RKZ00120

30-260

REMOVAL AND INSTALLATION

BOOM SWING CYLINDER

4. Re-assembling cylinders
1 - Mount on the apparatus A1 the tool A3 and engage
the cylinder axle oscillation pins (1).
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 appropriate diameter at the mouth of the cylinder (1).
4 - Mount the piston rod group on the apparatus A1 and
raise the mobile part up to the end of its stroke.
5 - Place the cylinder (1) in a vertical position.
6 - Lower the mobile part of the apparatus in order to
center the piston (5) in the tool A11.
7 - Wind the first guide ring (19) round the piston and insert part of the piston into the tool A11. Wind the second guide ring (19) and fully insert the piston.
Insert the piston slowly in order to calibrate the guide
rings (19) without overheating them.
8 - Insert the cylinder head (2) and screw it in by hand for
several turns.
9 - Use the special wrench A6 to screw the cylinder head
(4) home.
Cylinder head: 95 100 kgm
10 - Screw the brake cylinder (3) into the cylinder (1).
Brake cylinder: Loctite 270
Brake cylinder: 8 2 kgm
11 - Remove the cylinder from the equipment.
12 - Using and press and the appropriate tool A3 mount
the swing bushings (9).

30-261

REMOVAL AND INSTALLATION

BACKHOE BACKFRAME LOCK CYLINDER

DISASSEMBLY OF BACKHOE BACKFRAME LOCK CYLINDER

1 - Plug one of the two cylinder (1) ports.
2 - Connect to the other port compressed air (max. 3
bar).

3 - Slowly insert pressure up to piston (2) comes out.

H Retain piston and protect from oil using gloves
and a protection.
4 - Remove gasket (3).
The gasket has be replaced.
RKZ00190

ASSEMBLY OF BACKHOE
BACKFRAME LOCK CYLINDER
1 - Use the tool A9 with the appropriate diameter, mount
the seal ring (3) onto the piston (2).
H Make sure that the lips are turned towards the inside of the cylinder.
2 - Put the piston (2) onto cylinder (1).
Cylinder: ASL800050
3 - Apply an elastic band for piston ring and using a
press insert the piston.

30-262

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.
1 - Make sure that the safety stop (1) is raised.
2 - Stop the engine and release the residual hydraulic
pressures.
3 - Disconnect the tube (2) that feeds the cylinder (3).
Plug the tube to prevent entry of impurities.
4 - Take out the cotter pins, remove the pins (4) and (5)
and the cylinder (3).
RKZA0970

4
5

2
RKZA1310

INSTALLATION OF THE BOOM

SAFETY CYLINDER
.

To install, reverse the removal procedure.

Pin seatings: ASL800050

H Install new cotter pins.

1 - Start the engine and perform several lock and release
manoeuvres to fill up and bleed air from the unit.

30-263

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 - Stop the engine and release the residual hydraulic
pressures. (For details, see 20. TESTING AND ADJUSTMENTS).

2 - Remove the boom cylinder. (For details, see REMOVAL OF BOOM CYLINDER).
3 - Take out the bracket (1) mounted inside the boom.
Disconnect the tubes (2) from the arm cylinders and
the bucket. Plug all tubes to prevent entry of impurities.
H Mark the tubes to prevent exchanging positions
during re-connection.

RKZA1320

4 - Put a sling round the equipment (3) and apply slight

tension to the cables.
5 - Take out the snap-rings and remove the pin (4).

6 - Remove the working equipment (3).

Working equipment: . . . . . . . . . . . . . . . . . . . . . . . kg

4
RKZA1330

INSTALLATION OF THE BACKHOE

WORKING EQUIPMENT
.

To install, reverse the removal procedure.

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.

RKZA1340

Internal bushing: ASL800050

H Pass the tubes of the cylinders inside the brackets (5).

1 - Start the engine and bleed the air from the cylinders.
(For details, see 20. TESTING AND ADJUSTMENTS).
H After bleeding the air, check the oil level in the tank.

30-264

REMOVAL AND INSTALLATION

BACKHOE BUCKET

REMOVAL OF THE BACKHOE BUCKET

Place the bucket on a level surface, resting on its
back.

1 - Take out the safety pin (1) and remove the connecting
pin (2) between bucket (3) and tie-rods (4).

4
2

5
2 - Take out the safety pin (5) and remove the pin (6) that
attaches the bucket to the arm.

INSTALLATION OF THE
BACKHOE BUCKET
.

RKZA1350

To install, reverse the removal procedure.

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.

Internal bushing: ASL800050

30-265

REMOVAL AND INSTALLATION

ARM

REMOVAL OF THE ARM

1 - Remove the bucket. (For details, see REMOVAL OF
BUCKET).
2 - Remove the bucket cylinder and the lever (1). (For details, see REMOVAL OF THE BUCKET CYLINDER).
3 - Take off the lock-nut (2), and the washers, and remove the pin (3) and the lever (4).

4 - Start the engine, bring the arm into a vertical position

and lower it to the ground.

5 - Stop the engine and release residual pressures from

the cylinder.

RKZA1360

6 - Put a sling around the arm cylinder (5), remove the

screws (6) and remove the pin (7).
7 - Start the engine and retract the piston completely (8).
H Secure the fully retracted position by binding the
piston head with wire.

8 - Rest the cylinder (5) on a block A.

9 - Stop the engine.
10 - Attach the arm (9) to the hoisting tackle and apply a
slight tension to the cable.
11 - Take out the screws and remove the pin (10).
RKZA1201

12 - Remove the arm (9).

Arm: 213 kg

INSTALLATION OF THE ARM

.

To install, reverse the removal procedure.

When aligning the positions between the hole and

the pin, do not insert fingers into the holes to check
alignment.

RKZA1370

Internal bushing: ASL800050

Pin-retaining lock nut: . . . . . . . . . . . . . . . . . . . . Nm

9
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.

10
A

RKZA1380

30-266

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 CYLINDER).
3 - Start the engine and rest the boom on the ground.

4 - Remove the boom cylinder. (For details, see REMOVAL OF THE BOOM CYLINDER).
5 - Take out the bracket (1) and disconnect the tubes (2)
from the arm cylinders and the bucket. Plug all tubes
to prevent entry of impurities.
H Mark the tubes to prevent exchanging positions
during re-connection.

RKZA1320

6 - Put a sling round the boom (3).

7 - Take out the snap-rings and remove the pin (4).

3
8 - Remove the boom (3).
Boom: 323 kg

INSTALLATION OF THE
BACKHOE BOOM
.

RKZA1390

To install, reverse the removal procedure.

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
Internal bushing: ASL800050
H Pass the cylinder tubes inside the brackets (5).

RKZA1340

1 - Start the engine and bleed the air from the cylinders.
(For details, see 20. TESTING AND ADJUSTMENTS).
H After bleeding the air, check the oil level in the tank.

30-267

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 - Take out the screws (1) and remove the pins (2) that
connect the swing cylinders (3).

3 - Disconnect the tube (4) of the boom safety cylinder (5)

and remove the retaining clip (6). Plug the tube to prevent entry of impurities.

3
1

4 - Take out the four screws (7) and remove the boom
safety group (8).
5 - Put a sling round the swing bracket (9).

RKZA7760

6 - Take out the screws (10) and (11) and remove the
swing bracket axle oscillation pins (12) and (13).

7 - Remove the swing bracket (9) and the relative shim

adjustments to given clearance.

Bracket: 133 kg

4
6
RKZA1400

INSTALLATION OF THE
BACKHOE SWING BRACKET
.

To install, reverse the removal procedure.

12

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.

10

13
11

RKZA1410

Internal bushing: ASL800050

Safety group screws: 27w3 kgm

H Insert the shims.

1 - Start the engine and bleed the air from the cylinders.
(For details, see 20. TESTING AND ADJUSTMENTS).
H After bleeding the air, check the oil level in the tank.
RKZA1420

30-268

REMOVAL AND INSTALLATION

BACKHOE BACKFRAME

REMOVAL OF BACKHOE BACKFRAME

1 - Remove the equipment. (For detail see REMOVAL
OF BACKHOE WORKING EQUIPMENT).

5 6

2 - Remove the swing cylinders. (For detail see REMOVAL OF SWING CYLINDER).

3 - Remove the swing bracket. (For detail see REMOVAL OF SWING BRACKET).
4 - Disconnect from union (1) the feeding pipes (2) of
backhoe backframe and plug them to avoid impurity
entry.
5 - Loose nuts (4) and remove washers (5) and four
screw (6).
Loose partially lateral nuts (4) to remove backframe
(3) from frame (8).

RKZA1430

6 - Put a sling round the backframe (3) and apply slight

tension to the cables.

4 5

7 - Remove external nuts (4), washers (5) and screws (6).

8 - Remove the sliding piece (7) and then lower the backframe and remove it.
Backframe: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . kg

3
RKZA1440

INSTALLATION OF
BACKHOE BACKFRAME
.

To install, reverse the removal procedure.

Nut: Loctite 262

Nut: 100w10 kgm
1 - Start the engine and bleed the air from the cylinders.
(For details, see 20. TESTING AND ADJUSTMENTS).
H After bleeding the air, check the oil level in the tank.

RKZA1660

30-269

REMOVAL AND INSTALLATION

30-270

STANDARD MAINTENANCE

Transmission . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 3
Front axle . . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 8
Differential .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 8
Planetary - Joint . . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 9
Steering unit cylinder . . . . .. . . . . .. . . . .. . . . . .. . . . .. . 10
Rear axle . . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 11
Differential .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 11
Planetary . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 12
Brake .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 13
Differential lock .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 14
Hydraulic pump . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 16
2-spool control valve . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 18

3-spool control valve . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 20

3-spool control valve
(With return to dig) . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 22
6-spool control valve . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 24
7-spool control valve . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 27
8-spool control valve . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 29
Brake pump .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 31
Shovel cylinder . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 32
Backhoe cylinder .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 34
Front working equipment . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 38
Swing bracket . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 40
Backhoe working equipment . . . .. . . . . .. . . . . .. . . . .. . . . 42

40-1

40-2

TRANSMISSION

A
G

23 Nm
23 Nm

C
H

H
B

23 Nm
23 Nm

23 Nm

RKZ00971

40-3

50w2.5 Nm
50w2.5 Nm

23w1 Nm

40w4 Nm

139w7 Nm
Loctite 518

30w1.5 Nm
with Loctite 542

23w1 Nm
Loctite 510
Sezione A - A

Section A - A

40-4

RKZ00981

10w0.5 Nm

80w4 Nm

23w1 Nm

50w2.5 Nm
with Loctite 542

Sezione
Section B
B -- B
B

23w1 Nm

30w1.5 Nm
Sezione C
C --CC
Section

26 30 Nm
RKZ01260

40-5

9 11 Nm

7 10 Nm

21.5 24.5 Nm

Sezione D - D
Section D - D

5 8 Nm

22w1 Nm

Sezione E - E
Section E - E

40-6

23w1 Nm

RKZ01270

40w2 Nm

100w10 Nm
with Loctite 270

23w1 Nm

50w2.5 Nm
Sezione G - G

Sezione F - F
Section F - F

Section G - G

Loctite 638

RKZ01280

Sezione H - H

Section H - H

40-7

FRONT AXLE
Differential

95w5 Nm
with Loctite 270

13 Nm
266w13 Nm

60w3 Nm
Loctite 510
169w8.5 Nm
Loctite 270

Loctite 242

2
. . . . . . . . . Nm

3
4

57w3 Nm

RKZ00810

Unit: mm

Check item

Axle clearance

Backlash of crown wheel

and pinion

Pinion preload
(without seal ring)

Pinion-crown wheel preload

(without seal ring)

40-8

Criteria
Standard clearance

0.17 0.23

Remedy
Clearance limit

Adjust
9.2 13.7 daN

Planetary - Joint

190w9.5 Nm
80 Nm

8 Nm

230w11.5 Nm
8 Nm

70 Nm
with Loctite 270

70 Nm
with Loctite 542

RKZ00820

Unit: mm

Check item

Criteria

Remedy

Hub rotation torque

Adjust

Drive shaft axle clearance

Replace

40-9

Steering unit cylinder

120w6 Nm

B
B

300w15 Nm

350w9.8 Nm

500

A
A
250w12.5 Nm

1984
+

1984 +02

........

220w11 Nm

150w7.5 Nm

Sezione A - A

Sezione
B
Section B
B -- B

Section A - A

Particolare
Detail C C

RKZ00840

Unit: mm

Check item

Clearance between
bushing and pin

Criteria
Standard
size
50

40-10

Tolerance
Shaft

Hole

Remedy
Standard
clearance

Clearance
limit

Replace
bushing
and pin

REAR AXLE
Differential

13 Nm

130w6.5 Nm
230w11.5 Nm

155w7.8 Nm
with Loctite 270
25w1.25 Nm
with Loctite 638

Loctite 638

80w4 Nm

1
. . . . . . . . . Nm

120w6 Nm

2
Loctite 542

70w3.5 Nm

3
4

RKZ00870

Unit: mm

Check item

Axle clearance

Backlash of crown wheel

and pinion

Pinion preload
(without seal ring)

Pinion-crown wheel preload

(without seal ring)

Criteria
Standard clearance

Remedy
Clearance limit

Adjust
9.2 13.8 daN

40-11

Planetary - Joint

70w3.5 Nm
with Loctite 542
500w9.8 Nm

70 Nm
with Loctite 270

230w11.5 Nm

35w1.75 Nm

Loctite 518

60w3 Nm

80 Nm

Loctite 518

RKZ00880

Unit: mm

Check item

Hub rotation torque

Drive shaft axle clearance

40-12

Criteria

Remedy
Adjust

Brakes

1
10w0.5 Nm

10 Nm

8v12 Nm

35w1.75 Nm

15 Nm
10w0.5 Nm
with Loctite 270
Sezione A - A
Section A - A

A
A

10w0.5 Nm

RKZ00890

Unit: mm

Check item

Criteria
Standard size

Brake disc return spring

Disc thickness

Free
installed

Installed
length

Remedy
Repair limit

Installed
load

Standard thickness

Free
installed

Installed
load

Min. thickness

Replace if
damaged or
deformed

Replace

40-13

Differential lock

23 Nm

23 Nm
RKZ00900

40-14

40-15

HYDRAULIC PUMP
1

A
3

Particolare
Detail A A

RKZ01290

Unit: mm

N
1

Check item
Ball-bearing loading

Backlash between piston

and cylinder

Backlash between piston

and shoe

Criteria

Drive shaft diameter

Spring

40-16

Remedy

0 0.05
Standard
size

Tolerance
Shaft

Hole

Standard value

Standard
size

Adjust
Standard
clearance

Clearance
limit

Max. value

Tolerance
Shaft

Hole

Standard
clearance

Clearance
limit

. . . . . . . . . Nm

. . . . . . . . . Nm

. . . . . . . . . Nm

Sezione C
Section
C -- C
C

. . . . . . . . . Nm

. . . . . . . . . Nm

. . . . . . . . . Nm

. . . . . . . . . Nm

. . . . . . . . . Nm

. . . . . . . . . Nm

Sezione D
D -- D
D
Section

RKZ00641

Unit: mm

Check item

Criteria
Standard size

Spring

Power regulation spring

(external)

Power regulation spring

(internal)

PC valve spring (external)

PC valve spring (internal)

LS valve spring (external)

LS valve spring (internal)

Free
installed
x e

Installed
length

Remedy
Repair limit

Installed
load

Free
installed

Installed
load

40-17

2-SPOOL CONTROL VALVE

. . . . . . . . . Nm

. . . . . . . . . Nm

. . . . . . . . . Nm

25 Nm

20 Nm

20 Nm
with Loctite 542

8 Nm
with Loctite 542

25 Nm
with Loctite 542

B
25 Nm
Sezione A - A
Section A - A

Sezione
B
Section B
B -- B

RKZ01081

Unit: mm

Check item

Criteria
Standard size

Check valve spring

Priority valve spring

40-18

Free
installed
x e

Installed
length

Remedy
Repair limit

Installed
load

Free
installed

Installed
load

10w1 Nm

10w1 Nm

10w1 Nm

E
70w7 Nm

70w7 Nm

. . . . . . . . . Nm
. . . . . . . . . Nm

10w1 Nm

10w1 Nm

Sezione C - C
Section C - C
Sezione D
D --D
D
Section

30w3 Nm

RKZ00661

Sezione E - E

Section E - E

Unit: mm

Check item

Criteria
Standard size

Spool return spring

Free
installed
x e

Installed
length

Remedy
Repair limit

Installed
load

Free
installed

Installed
load

Check valve spring

40-19

3-SPOOL CONTROL VALVE

E
D

. . . . . . . . . Nm

. . . . . . . . . Nm

. . . . . . . . . Nm

E
25 Nm

20 Nm

20 Nm
with Loctite 542

8 Nm
with Loctite 542

25 Nm
with Loctite 542

2
B

100 Nm

Sezione A
A
Section
A -- A

Sezione B
B
Section
B -- B

RKZ01071

Unit: mm

Check item

Criteria
Standard size

Spool return spring

Check valve spring

40-20

Free
installed
x e

Installed
length

Remedy
Repair limit

Installed
load

Free
installed

Installed
load

70w7 Nm

10w1 Nm

10w1 Nm

70w7 Nm

. . . . . . . . . Nm

70w7 Nm

1
. . . . . Nm

70w7 Nm

F
. . . . . . .Nm

Sezione
Section CC--C
C

3
10w1 Nm

10w1 Nm

Sezione D
D -- D
D
Section

70w7 Nm
30w3 Nm

4
4

. . . . . . . . . Nm

70w7 Nm

Sezione
SectionFF--FF

F
Sezione E
E -- E
E
Section

RKZ01300

Unit: mm

Check item

Criteria
Standard size

Spool return spring

Spool locking spring

Spool return spring

Check valve spring

Free
installed
x e

Installed
length

Remedy
Repair limit

Installed
load

Free
installed

Installed
load

40-21

3-SPOOL CONTROL VALVE

With return to dig
E
D

. . . . . . . . . Nm

. . . . . . . . . Nm
. . . . . . . . . Nm

25 Nm

20 Nm

D
20 Nm
with Loctite 542

8 Nm
with Loctite 542

100 Nm

Sezione A
A
Section
A -- A

Sezione
B
Section B
B -- B

RKZ01091

Unit: mm

Check item

Criteria
Standard size

Spool return spring

Spool locking spring

Spool return spring

Check valve spring

40-22

Free
installed
x e

Installed
length

Remedy
Repair limit

Installed
load

Free
installed

Installed
load

10w1 Nm

10w1 Nm

10w1 Nm

70w7 Nm

70w7 Nm

. . . . . . . . . Nm

. . . . . Nm

1
2

70w7 Nm

70w7 Nm

. . . . . . . . . Nm

. . . . . . . . . Nm Sezione
Section CC-- C
C

. . . . . . . . . Nm

Sezione D - D

Section D - D

70w7 Nm

30w3 Nm
. . . . . . . . . Nm

70w7 Nm
Sezione F - F

Section F - F

F
Sezione E - E
RKZ00941

Section E - E

Unit: mm

Check item

Criteria
Standard size

Spool return spring

Spool locking spring

Spool return spring

Spool return spring

Check valve spring

Free
installed
x e

Installed
length

Remedy
Repair limit

Installed
load

Free
installed

Installed
load

40-23

6-SPOOL CONTROL VALVE

. . . . . . . . . Nm

H
E

10w1 Nm

G
70 Nm

70w7 Nm

45 Nm

20 Nm
with Loctite 542

. . . . . . . . . Nm
70 Nm

70w7 Nm
Sezione A - A

Section A - A

10w1 Nm

G
Sezione B - B
Section B - B

RKZ00231

Unit: mm

Check item

Criteria
Standard size

Spool return spring

40-24

Free
installed
x e

Installed
length

Remedy
Repair limit

Installed
load

Free
installed

Installed
load

10w1 Nm

70w7 Nm

10w1 Nm

10w1 Nm
70w7 Nm

. . . . . . . . . Nm

70w7 Nm

70w7 Nm

Sezione D - D
Section
D-D

Sezione
C
Section C
C -- C

10w1 Nm

10w1 Nm

10w1 Nm

70w7 Nm

2
30w3 Nm

10w1 Nm
70w7 Nm

Sezione F
F
Section
F -- F

RKZ01310

Sezione
Section EE -- E
E

Unit: mm

Check item

Criteria
Standard size

Spool return spring

Check valve spring

Free
installed
x e

Installed
length

Remedy
Repair limit

Installed
load

Free
installed

Installed
load

40-25

25 Nm
10 Nm

1
20 Nm

Sezione G - G
Section
G-G

20 Nm
Sezione H
H --H
H
Section

RKZ00791

Unit: mm

Check item

Criteria
Standard size

Unloading valve spring

40-26

Free
installed
x e

Installed
length

Remedy
Repair limit

Installed
load

Free
installed

Installed
load

7-SPOOL CONTROL VALVE

For jig arm

A
RKZ00241

For side digging boom

RKZ00251

For hammer

C
RKZ00261

40-27

10w1 Nm

10w1 Nm

70w7 Nm

70w7 Nm

. . . . . . . . . Nm

. . . . . . . . . Nm
70w7 Nm
10w1 Nm

10w1 Nm

70w7 Nm

Sezione A - A
Section A - A

10w1 Nm

1
Sezione
Section BB -- B
B

10w1 Nm
70w7 Nm

. . . . . . . . . Nm

. . . . . . . . . Nm

70w7 Nm

10w1 Nm

Sezione C - C
Section C - C

RKZ00961

Unit: mm

Check item

Criteria
Standard size

Spool return spring

40-28

Free
installed
x e

Installed
length

Remedy
Repair limit

Installed
load

Free
installed

Installed
load

8-SPOOL CONTROL VALVE

For hammer and jig arm

RKZ00271

For side digging boom and jig arm

RKZ00281

40-29

10w1 Nm

10w1 Nm

70w7 Nm

70w7 Nm

. . . . . . . . . Nm

. . . . . . . . . Nm

70w7 Nm
10w1 Nm

10w1 Nm

70w7 Nm

Sezione A - A
Section A - A

10w1 Nm

1
Sezione B
B -- B
B
Section

10w1 Nm
70w7 Nm

. . . . . . . . . Nm
. . . . . . . . . Nm

70w7 Nm

10w1 Nm

Sezione C - C

Section C - C

RKZ00961

Unit: mm

Check item

Criteria
Standard size

Spool return spring

40-30

Free
installed
x e

Installed
length

Remedy
Repair limit

Installed
load

Free
installed

Installed
load

BRAKE PUMP

4
RKZ00931

Unit: mm

Check item

Criteria
Standard size

Ball valve spring

Free
installed

Installed
length

Remedy
Repair limit

Installed
load

Free
installed

Tolerance
load
w8 N

Spring

Pump spring

Spring

Replace if
damaged or
deformed

40-31

SHOVEL CYLINDER
DUMP CYLINDER

RKZ00780

RAISE CYLINDER

RKZ00770

Unit: mm

Check item

Criteria
Cylinder

Tolerance between
piston rod and
cylinder head
Raise

Standard
size
50

Dump

50

Tolerance between Raise

bushing and piston
rod mounting pin
Dump

45

Tolerance
between bushing
and cylinder
mounting pin

Raise

50

Dump

50

40-32

45

Remedy

Tolerance
Shaft

Hole

Standard Clearance
clearance
limit

40-33

BACKHOE CYLINDER
BOOM

1
2

RKZ00750

ARM

RKZ00740

BUCKET

RKZ00730

40-34

BOOM SWING

RKZ00720

Unit: mm

Check item

Criteria
Cylinder

Clearance between
piston head and
cylinder head

Tolerance between
bushing and piston
head mounting pin

Tolerance
between bushing
and cylinder
mounting pin

Standard
size

Boom

55

Arm

60

Bucket

60

Boom swing

50

Boom

45

Arm

45

Bucket

45

Boom swing

50

Boom

45

Arm

45

Bucket

45

Remedy

Tolerance
Shaft

Hole

Standard Clearance
clearance
limit

Replace

Replace
pin and
spring

40-35

OUTRIGGER

RKZ00710

JIG ARM

RKZ00700

SIDE DIGGING BOOM

RKZ00680

40-36

ARM (for side digging boom)

RKZ00670

Unit: mm

Check item

Criteria
Cylinder

Clearance between
Outrigger
piston rod and
cylinder head
Arm for side
digging boom
Jig arm

Clearance between
Side digging
piston rod and
boom
bushing

Side digging
Tolerance between boom
bushing and piston
rod mounting pin
Arm for side
digging boom

Tolerance
between bushing
and cylinder
mounting pin

Clearance between
Arm for side
bearing and bearing
digging boom
seat

Side digging
boom

Standard
size

Remedy

Tolerance
Shaft

Hole

Standard
clearance

Clearance
limit

40
60
40
45
Replace
40
45

40

75

40-37

FRONT WORKING EQUIPMENT

E
C
E

C
D
D

B
B
A
A

Sezione A - A
Section A - A

Sezione B - B
Section B - B

Sezione C - C
Section C - C

5
4

Sezione D - D
Section D - D

40-38

Sezione E - E
Section E - E

RKZ02270

Unit: mm

Check item

Clearance between bushing

and bucket mounting pin

Criteria
Standard
size

Tolerance

Remedy
Standard
clearance

Shaft

Hole

45

0.050
0.089

+0.080
+0.240

0.130 0.329

Clearance between bushing

and link mounting pin

45

0.050
0.089

+0.080
+0.240

0.130 0.329

Clearance between bushing

and tilt lever mounting pin

45

0.050
0.089

+0.080
+0.119

0.130 0.208

Clearance between bushing

and link mounting pin

45

0.050
0.089

+0.080
+0.119

0.130 0.208

Clearance between bushing

and boom mounting pin

50

0.038
0.093

+0.080
+0.240

0.118 0.323

Clearance
limit

Replace

40-39

SWING BRACKET

B
A

1
3
4

Sezione B - B

Section B - B

5
1

6
Sezione A - A
Section A - A

Sezione C - C

Section C - C
RKZ02720

40-40

Unit: mm

Check item

Clearance between rotating

bushing and boom swing
cylinder bushing

Criteria
Tolerance

Standard
size

Shaft

Hole

Remedy
Standard
clearance

55

0.060
0.106

+ 0.090
0.120 0.196
+ 0.060

Clearance between bushing

and (lower) swing bracket
rotating pin

65

0.060
0.106

+ 0.190
0.250 0.370
+ 0.264

Clearance between bushing

and (upper) swing bracket
rotating pin

65

Clearance between bushing

and mounting pin

0.060
0.106

Standard size

+ 0.190
0.250 0.370
+ 0.264

Clearance
limit

Replace
bushing
and pin

Limit size

4.75 0.1

Central shim thickness

4.75 0.1

Lower shim thickness

4.75 0.1

40-41

BACKHOE WORKING EQUIPMENT

B
B

D
D

3
2

1
4

Sezione A - A
Section A - A

Sezione B - B
Section B - B

Sezione C - C

Section C - C

40-42

Sezione D - D
Section D - D

RKZ02900

Unit: mm

Check item

Clearance between link

bushings and bucket
mounting pin

Criteria
Standard
size

Tolerance

Remedy
Standard
clearance

Shaft

Hole

40

0.050
0.089

0.080
0.240

0.130 0.329

40

0.050
0.089

0.080
0.240

0.130 0.329

0.080
0.240

0.130 0.329

Clearance between arm

bushings and bucket
mounting pin

Clearance between arm

bushings and lever
mounting pin

45

0.050
0.089

Clearance between bushings

and tilt lever mounting pin

45

0.050
0.089

0.080
0.240

0.130 0.329

Clearance between bushings

and arm mounting pin

50

0.050
0.089

0.080
0.119

0.130 0.208

Clearance between
bushings and boom
mounting pin

50

0.038
0.083

0.080
0.119

0.118 0.202

Clearance
limit

Replace
spring and
pin

40-43

40-44