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 ac- Mark Indication Action required
tions be taken to these pages according to table
below.
C Page to be newly Add

c Page to be replaced Replace

( ) Page to be delete Discard

Pages having no marks are those previously revised

or made additions.

LIST OF REVISED PAGES

Time of Time of Time of Time of Time of

Mark Page Mark Page Mark Page Mark Page Mark Page
revision revision revision revision revision

00-1 10-26 20-4 20-44 30-27

00-2 10-27 20-5 20-45 30-28
00-2-1 10-28 20-6 20-46 30-29
00-2-2 10-29 20-7 20-47 30-30
00-3 10-30 20-8 20-48 30-31
00-4 10-31 20-9 20-49 30-32
00-5 10-32 20-10 20-50 30-33
00-6 10-33 20-11 20-51 30-34
00-7 10-34 20-12 20-52 30-35
00-8 10-35 20-13 20-53 30-36
00-9 10-36 20-14 20-54 30-37
00-10 10-37 20-15 20-55 30-38
00-11 10-38 20-16 20-56 30-39
00-12 10-39 20-17 30-40
10-40 20-18 30-1 30-41
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10-2 10-42 20-20 30-3 30-43
10-3 10-43 20-21 30-4 30-44
10-4 10-44 20-22 30-5 30-45
10-5 10-45 20-23 30-6 30-46
10-6 10-46 20-24 30-7 30-47
10-7 10-47 20-25 30-8 30-48
10-8 10-48 20-26 30-9 30-49
10-9 10-49 20-27 30-10 30-50
10-10 10-50 20-28 30-11 30-51
10-11 10-51 20-29 30-12 30-52
10-12 10-52 20-30 30-13 30-53
10-13 10-53 20-31 30-14 30-54
10-14 10-54 20-32 30-15 30-55
10-15 10-55 20-33 30-16 30-56
10-16 10-56 20-34 30-17 30-57
10-17 10-57 20-35 30-18 30-58
10-18 10-59 20-36 30-19 30-59
10-19 10-61 20-37 30-20 30-60
10-20 10-63 20-38 30-21 30-61
10-21 10-65 20-39 30-22 30-62
10-22 20-40 30-23 30-63
10-23 20-1 20-41 30-24 30-64
10-24 20-2 20-42 30-25 30-65
10-25 20-3 20-43 30-26 30-66

00-2-1
 Time of Time of Time of Time of Time of
Mark Page Mark Page Mark Page Mark Page Mark Page
revision revision revision revision revision

30-67 30-123 40-15

30-68 30-124 40-16
30-69 30-125 40-17
30-70 30-126 40-18
30-71 30-127 40-19
30-72 30-128 40-20
30-73 30-129 40-21
30-74 30-130 40-22
30-75 30-131 40-23
30-76 30-132 40-24
30-77 30-133 40-25
30-78 30-134 40-26
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30-81 30-137 40-29
30-82 30-138 40-30
30-83 30-139 40-31
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30-85 30-141 40-33
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30-87 30-143 40-35
30-88 30-144
30-89 30-145
30-90 30-146
30-91 30-147
30-92 30-148
30-93 30-149
30-94 30-150
30-95 30-151
30-96 30-152
30-97 30-153
30-98 30-154
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30-100 30-156
30-101 30-157
30-102 30-158
30-103 30-159
30-104 30-160
30-105 30-161
30-106 30-162
30-107 30-163
30-108 30-164
30-109
30-110 40-1
30-111 40-3
30-112 40-4
30-113 40-5
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30-119 40-11
30-120 40-12
30-121 40-13
30-122 40-14

00-2-2
 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 ma-
nual. The cautions accompanying these symbols should always be carefully followed. If any danger ari-
ses or may possibly arise, first consider safety, and take necessary steps to face.

SICUREZZE
GENERAL PRECAUTIONS PREPARATIONS FOR WORK
Mistakes in operation extremely dangerous. 7. Before adding or making any repairs, park the ma-
Read all the Operation and Maintenance Manual care- chine on hard, level ground, and block the wheels
fully BEFORE operating the machine. to prevent the machine from moving.
1. Before carrying out any greasing or repairs, read 8. Before starting work, lower ourigger, bucket or
all the precautions written on the decals which any other work equipment to the ground. If this
are suck on the machine. is not possible, use blocks to prevent the work
2. When carrying out any operation, always wear sa- equipment from falling down. In addition, be sure
fety shoes and helmet. Do not wear loose work to lock all the control levers and hang warning
clothes, or clothes with buttons missing. sign on them.
. Always wear safety glasses when hitting parts 9. When disassembling or assembling, support the
with a hammer. machine with blocks, jacks or stands before star-
. Always wear safety glasses when grinding ting work.
parts with a grinder, etc.
10. Remove all mud and oil from the steps or other
3. If welding repairs are needed, always have a trai- places used to get on and off the machine. Always
ned, experienced welder carry out the work. use the handrails, ladders or steps when getting
When carrying out welding work, always wear on or off the machine.
welding gloves, apron, glasses, cap and other clo- Never jump on or off the machine.
thes suited for welding work. If it is impossible to use the handrails, ladders or
steps, use a stand to provide safe footing.
4. When carrying out any operation with two or more
workers, always agree on the operating procedure
before starting. Always inform your fellow workers PRECAUTIONS DURING WORK
before starting any step of the operation. Before 11. When removing the oil filler cap, drain plug or hy-
starting work, hang UNDER REPAIR signs on draulic pressure measuring plugs, loosen them
the controls in the operator's compartment. slowly to prevent the oil from spurting out.
5. Keep all tools in good condition and learn the cor- Before disconnecting or removing components of
rect way to use them. the hydraulic circuit and engine cooling circuit,
first remove the pressure completely from the cir-
6. Decide a place in the repair workshop to keep cuit.
tools and removed parts. Always keep the tools
and parts in their correct places. Always keep 12. The water and oil in the circuits are not hot when
the work area clean and make sure that there is the engine in stopped, so be careful not to get
no dirt or oil on the floor. burned.
Smoke only in the areas provided for smoking. Wait for the oil water to cool before carrying out
Never smoke while working. any work on the cooling water circuits.

00-3
13. Before starting work, remove the leads from the 24. Take sure when removing or installing tracks of in
battery. Always remove the lead from the negative particular rubber tracks. When removing the
( ± ) terminal first. track, the track separates suddenly, so never let
anyone stand at either end of the wheel.
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 ca-
pacity. 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 gaso-
line when washing electrical parts.
19. Be sure to assemble all parts again in their origi-
nal 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 dan-
gerous, 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
 FOREWORD

This shop manual has been prepared as an aid to improve the quality of repairs by giving the operator an ac-
curate 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 understan-
ding 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 re- In order to make the shop manual greatly chelpful,
pairs. These various volumes are designed to avoid important points about safety and quality are marked
duplicating the same information. with the following symbols.

Symbol Item Remarks

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

Example Weight of parts or systems.

10 - 3 Caution necessary when selecting
Weight hoisting wire, or when working po-
sture is important, etc.
Item number (10. Structure and
Function) Parts that require special attention
Tightening for the tightening torque during as-
torque
Consecutive page number for each sembly.
item.
Parts to be coated with adhesives
Coat and lubricants etc.
3. Additional pages: additional pages are indicated
by a hyphen (-) and number after the page num- Places where oil, water or fuel
Oil, water must be added, and their quantity.
ber.
Fle as in the example.
Places where oil or water must be
Example:
Drain drained, and quantity to be drai-
10-4
ned.
10-4-1
10-4-2
] Added pages
10-5

REVISED EDITION MARK

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

REVISIONS
Revised pages are shown on the LIST OF REVI-
SED PAGES between the title page and SAFETY pa-
ge.

00-6
HOISTING INSTRUCTIONS

HOISTING INSTRUCTIONS

ing, and a serious accident can result.

Heavy parts (25 kg or more) must be lifted Hooks have maximum strenght at the middle
with a hoist etc. In the Disassembly and As- portion.
sembly section, every part weighing 25 kg or
more is clearly indicated with the symbol

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. 3) Do not sling a heavy load with one rope alone,
but sling with two or more ropes symmetrically
wound on to the load.
2. Wire ropes Slinging with one rope may cause turning of
1) Use adequate ropes depending on the weight the load during hoisting, untwisting of the ro-
of parts to be hoisted, referring to the table be- pe, or slipping of the rope from its original
low: winding position on the load, which can cau-
se dangerous accidents.

WIRE ROPES
(Standard «S» or «Z» twist ropes
without galvanizing)
4) Do not sling a heavy load with ropes forming a
Rope diameter (mm) Allowable load (tons) wide hanging angle from the hook.
When hoisting a load with two or more ropes,
10 1.0 the force subjected to each rope will increase
with the hanging angles.
11.2 1.4 The table below shows the variation of allowa-
ble load (kg) when hoisting is made with two ro-
12.5 1.6 pes, each of which is allowed to sling up to
1000 kg vertically, at various handing angles.
14 2.2 When two ropes sling a load vertically, up to
16 2.8 2000 kg of total weight can be suspended.
This weight becomes 1000 kg when two ropes
18 3.6 make a 120ë hanging angle.
On the other hand, two ropes are subjected to
20 4.4 an excessive force as large as 4000 kg if they
sling a 2000 kg load at a lifting angle of 150ë.
22.4 5.6
30 10.0
40 18.0
50 28.0
60 40.0

The allowable load value is estimated to be

one-sixth or one-seventh of the breaking
strength of the rope used.

2) Sling wire ropes from the middle portion of the

hook. Slinging near the edge of the hook may
cause the rope to slip off the hook during 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 «Di-
sassembly and Assembly».

1. STANDARD TIGHTENING TORQUE OF BOLTS AND NUT

Width across flat

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

6 1 10 5 0.96w0.1 9.5w1 1.3w0.15 13.5w1.5

8 1.25 13 6 2.3w0.2 23w2 3.2w0.3 32.2w3.5

10 1.5 17 8 4.6w0.5 45w4.9 6.5w0.6 63w6.5

12 1.75 19 10 7.8w0.8 77w8 11w1 108w11

14 2 22 12 12.5w1 122w13 17.5w2 172w18

16 2 24 14 19.5w2 191w21 27w3 268w29

18 2.5 27 14 27w3 262w28 37w4 366w36

20 2.5 30 17 38w4 372w40 53w6 524w57

22 2.5 32 17 52w6 511w57 73w8 719w80

24 3 36 19 66w7 644w70 92w10 905w98

27 3 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 4 55 27 230w25 2250w250 320w35 3150w350

39 4 60 Ð 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): 1 Nm = 0.102 kgm

00-8
STANDARD TIGHTENING TORQUE

2. TIGHTENING TORQUE FOR NUTS OF FLARED

Use these torques for nut part of flared.

Thread diameter Width across flats TIGHTENING TORQUE

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

1/2" - 20 17 2.6w0.5 25.5w4.9

9/16" - 18 17 4w0.5 39.2w4.9
3/4" - 16 22 6.7w2 65.7w19.6
7/8" - 14 27 8w2 78.5w19.6
1.1/16" - 12 32 9.7w3 95.15w29.4
1.5/16" - 12 38 17w3 166.7w29.4
1.5/8" - 12 50 20w5 196.2w49
22 27 8w2 78.5w19.6
33 41 20w5 196.2w49

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

Nomenclature Code Applications

ASL800010 Used to apply rubber pads, rubber gaskets and cork plugs.
Used to apply resin, rubber, metallic and non-mettalic parts when a fast, strong
ASL800020 seal is needed.
Loctite 222 Used for low resistance locking of screws, check nuts and adjustment nuts.
To prevent the loosening of bolts, nuts and plugs and the leakage of oil. Used for
Loctite 242 medium resistance locking of screws and nuts of every type, and for locking keys
and bearings.
Loctite 262 Used for high resistant of threaded parts that can be removed with normal tools.
Adhesives Used for high resistant locking and for sealing threaded parts, bolts and stud
Loctite 270 bolts.
Loctite 542 Used for sealing the union threads for hydraulic tubes.
Used for sealing rather exact plane surfaces when the option of possible future
Loctite 573 dismantling is required.
Used for high resistant locking of mechanical components that can be removed
Loctite 601 only after heating
Used to lock cylindrical couplings and for the permanent locking of threaded parts,
Loctite 675 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 fit-
ASL800060 tings in hydraulic circuits of less than 50 mm in diameter.
Used by itself on mounting flat surface
Gasket sealant Loctite 510 (Clearance between surfaces within 0.2 mm)
Used by itself on mounting flat surface
Loctite 518 (Clearance between surfaces within 0.5 mm)
Antifriction compound
Applied to bearings and taper shaft to facilitate press-fitting and to prevent stic-
(Lubricant inclunding ASL800040 king, burning or rusting.
Molybdenum disulfide)
Grease Applied to bearings, sliding parts and oil seals for lubrication, rust prevention and
(Lithium grease) ASL800050 facilitation of assembling work.
Vaseline ± Used for protecting battery electrode terminals from corrosion.

00-9
ELECTRIC WIRE CODE

ELECTRIC ELECTRIC WIRE CODE

n 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
Copper wire
Nominal Cable O.D. Current rating
Number ù of strands Cross section Applicable circuit
number (mm) (A)
strands (mm) (mm2)
0.35 11 0.20 0.35 1.55 3.5 Proximity sensor
0.5 16 0.20 0.50 2.40 6 Instruments
0.8 11 0.30 0.78 2.80 8 Instruments, transmitter
1 14 0.30 0.99 2.80 11 Light switch - signal etc.
1.5 21 0.30 1.48 3.35 14 Working beam - solenoid valve etc.
2,5 35 0.30 2.47 3.80 20 Control panel - Ignition switch etc.
4 56 0.30 3.95 4.60 28 Alternator - preheating etc.
6 84 0.30 5.93 5.20 37 Starter motor fuses
50 399 0.40 50.11 14 160 Ground - starter motor

CLASSIFICATION BY COLOUR AND CODE

Primary Auxiliary
Code A A-B A/B A-G A/G A-N A/N A-R A/R A-V A/V
Colour Light blue Light blue-White Light blue-Yellow Light blue-Black Light blue-Red Light blue-Green
Code B B-G B/G B-L B/L B-N B/N B-R B/R ÐÐ ÐÐ
Colour White White-Yellow White-Blue White-Black White-Red ÐÐ
Code C C-B C/B C-N C/N C-V C/V ÐÐ ÐÐ ÐÐ ÐÐ
Colour Orange Orange-White Orange-Black Orange-Green ÐÐ ÐÐ
Code G G-N G/N G-R G/R G-V G/V ÐÐ ÐÐ ÐÐ ÐÐ
Colour Yellow Yellow-Black Yellow-Red Yellow-Green ÐÐ ÐÐ
Code H H-G H/G H-N H/N H-R H/R ÐÐ ÐÐ ÐÐ ÐÐ
Colour Grey Grey-Yellow Grey-Black Grey-Red ÐÐ ÐÐ
Code L L-G L/G L-N L/N L-R L/R ÐÐ ÐÐ ÐÐ ÐÐ
Colour Blue Blue-Yellow Blue-Black Blue-Red ÐÐ ÐÐ
Code M M-B M/B M-N M/N ÐÐ ÐÐ ÐÐ ÐÐ ÐÐ ÐÐ
Colour Brown Brown-White Brown-Black ÐÐ ÐÐ ÐÐ
Code N ÐÐ ÐÐ ÐÐ ÐÐ ÐÐ ÐÐ ÐÐ ÐÐ ÐÐ ÐÐ
Colour Black ÐÐ ÐÐ ÐÐ ÐÐ ÐÐ
Code R R-N R/N R-V R/V ÐÐ ÐÐ ÐÐ ÐÐ ÐÐ ÐÐ
Colour Red Red-Black Red-Green ÐÐ ÐÐ ÐÐ
Code S S-G S/G S-N S/N ÐÐ ÐÐ ÐÐ ÐÐ ÐÐ ÐÐ
Colour Pink Pink-Yellow Pink-Black ÐÐ ÐÐ ÐÐ
Code V V-B V/B V-N V/N V-R V/R ÐÐ ÐÐ ÐÐ ÐÐ
Colour Green Green-White Green-Black Green-Red ÐÐ ÐÐ
Code Z Z-B Z/B Z-G Z/G Z-N Z/N ÐÐ ÐÐ ÐÐ ÐÐ
Colour Violet Violet-White Violet-Yellow Violet-Black ÐÐ ÐÐ

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

Machine model WB70A-1

From serial no. F10001
Engine assembly
Radiator - exchanger
Hydraulic tank (without hydraulic oil)
Fuel tank (without fuel)
Rear frame
Front frame
Joint
Counterweight
Loader arm
Loader bucket
Tie-rod
Tilti lever
Cab
Seat
Engine hood
Piston pump
Hydraulic motor
Transmission
Control valve
Control valve support
Front axle
Rear axle
Wheel, assy.

Backhoe
From serial no.
Backhoe, assy. (without bucket)
Boom
Arm
Jig arm
Boom swing bracket
Backframe
Backhoe frame
Side digging boom
6-spool control valve
7-spool control valve
8-spool control valve
Control valve support

00-11
 TABLE OF OIL AND COOLANT QUANTITIES
KIND OF AMBIENT TEMPERATURE CAPACITY ( < )
RESERVOIR
FLUID ±20 ±10 0 10 20 30ëC Specified Refill

SAE 10W
OIL
SAE 20W-20
. API CD-SG
Crankcase sump 10 10
. MIL-L-2104 E SAE 30
. CCMC D2-G2
SAE 40

Only loader:
Hydrostatic 100
OIL
transmssion and SAE 15W/30 65
. ATF DEXRON With
hydraulic circuit backhoe:
133
OIL
Braking system 0.5 0.5
. ATF DEXRON
Front axle 4 4
. differential
. final red. gear (each) 0.9 0.9
OIL
. Reduction gear 1.7 1.7
. UTTO FLUID
Rear axle: 5.2 5.2
. differential
. final red. gear (each) 0.9 0.9

Fuel tank DIESEL OIL * ASTM D975 N. 2

70 ÐÐ

WATER+
15 ÐÐ
ANTI-FREEZE

Engine coolant
WATER 15 ÐÐ
system
PERMANENT
15 ÐÐ
LIQUID

ASTM: America Society of Testing and Materials * ASTM D975 N. 1

SAE: Society of Automotive Engineers

API: American Petroleum Institute
MIL: USA Military Specification
CCMC: Common Market Constructors Committe

NOTE: (2) When starting the engine is weathers temperature

below 0ëC, be sure to use engine oil SAE 10W,
(1) When fuel sulphur content is less than 0.5%, SAE 20W-20, even if weather temperature goes
change oil in the oil pan ebery periodic maintenan- up to 10ëC day time.
ce hours described in operation and maintenance
manual. Change oil according to the following ta- (3) Use classification CD as engine oil, if use classifi-
ble if fuel sulphur content is above 0.5%. cation CC, reduce the engine oil change interval to
half.
Fuel sulphur content Engine oil change interval (4) Use original products, which have characteristics
specifically formulated and approved for the engi-
0.5 to 1.0% 1/2 of regular interval
ne, the hydraulic circuit of equipment and for re-
Above 1.0% 1/4 of regular interval ductions.

00-12
01

10

20

30

40

90
01

10

20

30

40

90
 STRUCTURE AND FUNCTION

P.T.O. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 2 8-spool control valve . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 40

Power train . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 3 Valves . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 41
Transmission . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 4 Gear pump . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 43
Axles . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 6 Outrigger safety valves . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 44
Hydrostatic transmission . . . . .. . . . . .. . . . .. . . . . .. . . . .. . 12 Brake pump .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 45
Hydrostatic transmission operation. . . . .. . . . . .. . . . .. . 13 Front equipment cylinder . . . . . . . .. . . . . .. . . . . .. . . . .. . . . 46
Hydrostatic transmission pump . . . .. . . . .. . . . . .. . . . .. . 14 Front work equipment.. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 48
Inching valve . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 22 Loader control lever . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 49
Travel motor . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 23 Backhoe cylinder .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 50
Steering system . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 28 Backhoe work equipment. . .. . . . .. . . . . .. . . . . .. . . . .. . . . 54
Steering system pump. . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 29 Backhoe control lever .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 55
Steering unit . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 30 Solenoid valve . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 56
Priority valve. . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 31 Electrical diagram (1/5) . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 57
Frames knuckle and joint . . . .. . . . . .. . . . .. . . . . .. . . . .. . 32 Electrical diagram (2/5) . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 59
Hydraulic circuit diagram . . . . .. . . . . .. . . . .. . . . . .. . . . .. . 33 Electrical diagram (3/5) . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 61
3-spool control valve . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 35 Electrical diagram (4/5) . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 63
6-spool control valve . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 36 Electrical diagram (5/5) . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 65
7-spool control valve . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 38

10-1
P.T.O.

5
D0400764

1 - Flywheel housing
2 - Screw
3 - Hub
4 - Damper (No. 4)
5 - Disc

10-2
POWER TRAIN

REDUCTION RATIO

Reduction gear
Differential Planetary Total axle Total
(Transmission)
High speed 1.093 18.47
3.22 5.25 16.915
Low speed 4.06 68.6

Front
Fronteofmacchina
machine

6 Z=29 Z=9
Z=51

Z=12

Z=19
4
Z=73
Z=18
8
Z=43 Z=47

2
3 5
1

9
Z=29 Z=9

Z=19

Z=12

Z=51
7

D0400766

1. Engine (Diesel) 6. Front axle

2. Hydraulic pump 7. Rear axle
3. Travel motor 8. Front wheels
4. Transmission 9. Rear wheels
5. Drive shaft

10-3
TRANSMISSION

B
B

1
3 A

6 7

14 9

10
a b 12 13 11
Section
Sezione B
B -- B
B

a. A Port - From ST1 solenoid valve group D0400749

(A3 Port)
b. B Port - From ST1 solenoid valve group
(A4 Port)

1. Flange 8. Selecting fork

2. Filler and level oil plug 9. Speed sensor
3. Oil drain plug 10. Safety switch
4. Neutral manual control 11. Selector shaft
5. Low speed selector piston 12. Spring
6. High speed selector piston 13. Ball
7. Selector gear 14. Piston

10-4
 1 2 3 4 5

8 9

19

18

17

16

15

14 12 13 11 10
Section
Sezione A
A -- A
A
D0400755

1. Flange 11. Protection

2. Breather 12. Oil drain plug
3. High speed drive gear (Z=43) 13. High speed driven gear (Z=47)
4. Rear housing 14. Cover
5. Low speed drive gear (Z=18) 15. Bearing
6. Bearing 16. Flange
7. Low speed driven gear (Z=73) 17. Output shaft
8. Roller bearing 18. Nut
9. Bearing 19. Bearing
10. Front housing

10-5
AXLES

FRONT DIFFERENTIAL

1 2 3 4 5 1

5 8 7 6

9 10 11 12

14 13 D0400752

1. Drive shaft 9. Oil filler plug

2. Central housing 10. Snap ring
3. Dowel pin 11. Cover
4. Ring bevel gear 12. Differential housing
5. Bearing 13. Bevel gear
6. Differential gear 14. Differential housing cover
7. Pin
8. Oil drain plug Amount of oil: 4 ,

10-6
REAR DIFFERENTIAL
1 2 3 1 4 5

8 7 6

9 10 11 9

12 17 12

18 13
14
17

16 15 D0400753

1. Differential gear 11. Pin

2. Bevel gear 12. Oil filler plug
3. Ring bevel gear 13. Seal
4. Ring nut 14. Flange
5. Drive shaft 15. Nut
6. Differential housing 16. Pinion
7. Oil drain plug 17. Bearing
8. Differential housing cover 18. Spacer
9. Bearing Amount of oil: 5.2 ,
10. Dowel pin

10-7
PLANETARY

1 2 3 4 5 6 7

10

11

15

14 13 12

D0400756

1. Seal 10. Planetary carrier

2. Bearing 11. Plug
3. Hub 12. Ring gear carrier
4. Screw 13. Nut
5. Bearing 14. Stud bolt
6. Ring gear 15. Seal
7. Bevel gear
8. Bevel gear pin Amount of oil: 0.9 ,
9. Thrust washer

10-8
DIFFERENTIAL LOCKING
(H Only for rear axle)

1 2 3 4 5
A

a Section A - A
Sezione A - A

D0400757
8 7

a. B Port - From ST1 solenoid valve group

(A1 Port)

1. Nut
2. Cylinder
3. Spring
4. Piston
5. Ring nut
6. Bleading screw
7. Sleeve
8. Fork

10-9
PARKING AND WORKING BRAKE
(H Only for rear axle)

1 2 3 4 5 6

10 9 a 8

11 10 7

D0400758

a. From brake pump

1. Brake bleeding screw 7. Brake disk

2. Adjusting screw 8. Brake lever
3. Nut 9. Pressure disk
4. Push-rod 10. Pressure lever
5. Disk release spring 11. Brake piston
6. Adjusting screw

10-10
10-11
HYDROSTATIC TRANSMISSION

TRANSMISSION COMPONENTS
Machine travel is obtained via a closed circuit hydro-
static transmission including:
1- Reversible and variable displacement axial piston
hydraulic pump direct-coupled on diesel engine.
2 - Variable displacement axial piston hydraulic mo-
tor direct-coupled on transmission.
They are connected by hoses (A - B).

2
7 4 8 1

3
B
11 5
7
6
Hydraulic pump
Pompa idraulica
A
12

10
14

13
Hydraulicidraulico
Motore motor
D0400783

On «closed circuit» system have been installed also

following devices:

On hydraulic pump
a - Electrodistributor (5) to select hydraulic motor ro- On hydraulic motor
tation direction. g - Automatic displacement control device according
b - Pressure cut-off valve (6). to working pressure (10).
c - By-pass valve (7). h - Additional piloting (11).
d - Control valve (8). i - Recognition device for travel direction (12).
e - Inching valve (9). l - Oil exchange valve (13).
f - Main relief valve (4).

10-12
HYDROSTATIC TRANSMISSION OPERATION

. Pump shaft (1), (which drags cylinder barrel) is ro- . This is the «closed circuit» principle which, theoreti-
tates by the engine. cally, utilises once again the same oil quantity.
. Moving the positioning piston (2) the swash plate is NOTE - Moving the positioning piston in the other di-
shifted from neutral position; an angle is fixed be- rection, it will create the reversal direction of engine
tween pistons and swash plate (on which pistons rotation.
are constrained); this angle will create a volume dif- . Oil leakages between moving parts, cause, during
ference in one side smaller and in the other side machine's life, the emptying of closed circuit; this
bigger. In this way it is created an oil pressure de- trouble is solved applying a gear pump (3) named
livery area (hydraulic power) through hydraulic mo- boosting pump, which sucks oil from the hydraulic
tor (pipe A on diagram) and a suction area from hy- tank and introducing it into the closed circuit keep-
draulic motor (pipe B on diagram). ing inside constant pressure, checked by a fixed
. The oil sent from pump to motor (pipe A), pressing setting main relief valve (4).
on pistons, will move pistons and consequently the . Part of pressurised oil of the boosting circuit is used
output shaft (14), transforming «hydraulic power» for positioning piston (2) operation which allows the
into «mechanical power». stepless variable inclination of the swash plate and
. The oil transferring power is returned through pipe therefore the hydraulic motor speed.
(B) to hydraulic pump's suction port to be reused. . All the system is protected from pressure peaks
(and therefore from overloads) by safety valves (7).

7 8 B
PUMP
POMPA MOTOR
6 MOTORE

14
1

Swash
3
Piatto Cylinder
Blocco
plate
oscillante barrel
cilindri 7 4
10 13
12
11
A

2 5
D0400773

10-13
HYDROSTATIC TRANSMISSION PUMP

2 1
a

A A
a
b

d e
3

5 f 7 D0400694

a. B Port - To travel motor (A Port) 1. EV6 REVERSE gear selection

b. A Port - To travel motor (B Port) 2. Initial adjusting valve
c. S Port - From hydraulic oil tank 3. Main relief valve
d. T2 Port - To hydraulic oil tank 4. EV7 FORWARD gear selection
e. T1 Port - To travel motor (T1 Port) 5. Cut pressure valve
f. PS Port - To INCH device (A Port) 6. Boosting valve
g. G Port - To ST1 solenoid valve group (P Port) 7. Positioning cylinder

SPECIFICATIONS
Max displacement: 40 cc/rpm
Max absorptance at 2000 rpm: 54 kW (80 ,/min)
Max pressure: 450 bar Max.
Max flow rate: 160 ,/min Max.

10-14
 3 4 5 6 A
2

7
1

10 B

B Section A - A
Sezione A - A

11
Detail A A
Particolare
13
12

14

16
Section B - B 15 D0400701
Sezione B - B

1. Feed pump gear 9. Valve plate

2. Feed pump body 10. Feed pump shaft
3. Rotating cylinder 11. Positioning cylinder external spring
4. Central spring 12. Positioning cylinder internal spring
5. Piston 13. Nut
6. Swash plate 14. Piston centering adjusting screw
7. Motor shaft 15. Positioning cylinder cover
8. Spring 16. Positioning piston

10-15
1 - BOOSTING CIRCUIT

Description
The boosting circuit apart to complete the oil scattered
by leakages of the closed circuit, supplies the piloting
pressure needed to move the positioning piston (2)
which checks the oil flow pressure variations through
the motor.
The constant pressure is obtained by means a fixed Pipe B
setting main relief valve (4). Ramo B

8
1 4

1 7
To motor
Al motore

Pipe A
Ramo A

D0400774

Valvola di max
Mainpressione
relief valve (4)
(4)
Operation From
dalla pump (3)
pompa (3)

. When the engine is started, through the main shaft

(1) of variable axial piston pump, it rotates the gear
Exhaust
Scarico
pump (3).
. Flow rate of gear pump gets through initial adjust-
ing valve (8) and then across the check valves (7)
pressurises the complete hydrostatic circuit until
the pressure value checked by the main boosting
relief valve (4).
. Exceeding flow rate is sent directly to exhaust.
AlTo pipeBB
ramo

Settingdi
Spessore shim
taratura D0400714

10-16
2 - INITIAL ADJUSTING VALVE AND DISPLACEMENT CHANGE ACCORDING TO ENGINE SPEED

Function
. The function of this valve is to supply to positioning
piston a piloting proportional pressure to engine re-
volutions.

P1 P2

7 B 5

6 3
8
A

1 - External fixed part

2 - Internal sliding part
3 - Contrast spring
4 - Gauged diaphragm
5 - Adjusting screw
6 - Gear pump
7 - Solenoid valve
8 - Positioning piston a

2
b

4 D0400712

P1

∆p
Operation
P2
1 - Flow rate of gear pump (6), acrossing lengthwise
the valve leaves out through exhaust port a. The
crossover of diaphragm (4) by the flow rate, gen- P3
erates (Dp)a pressure drop created by the pump
(6). The pressure P1 exhisting before diaphragm ∆ p = f (Q)
(4) (which is upper to the internal pressure P2 into
the valve), acts on surface of the sliding part (2) Q = f (n)
opposed by spring (3).
D0400849
P1 - Pressure before the diaphragm
P2 - Pressure after diaphragm
P3 - Piloting pressure

10-17
 P1 P2

7 B 5

6 3
8
A

1 - External fixed part

2 - Internal sliding part
3 - Contrast spring
4 - Gauged diaphragm
5 - Adjusting screw
6 - Gear pump
7 - Solenoid valve
8 - Positioning piston a

2
b

4 D0400712
The movement of the sliding part (2) on fixed part the pressure difference on sliding part (2), is not
(1), opens the port b allowing an oil flow having a sufficient to compress the spring (3) and therefore
checked pressure (and therefore fixed), to reach any gallery will be opened between the fixed part
the solenoid valve (7) and later the positioning pis- (1) and the sliding part (2). Acting on adjusting
ton (8). screw (5), it is possible to fix the idle engine to per-
The principle that the pressure acting on position- mit the hydraulic pump regulation and, conse-
ing cylinder is proportional to the Diesel engine re- quently the motion of the machine.
volutions, derives from the following considera- 3 - If during the work the Diesel engine idle speed de-
tions: creases, this causes the following decrease:
a - The quantity of pressurised oil which reaches . hydraulic pump delivery;
the solenoid valve (7) depends from the flow
section between the fixed part (1) and the slid- . pressure difference between the two sides of
ing part (2) of the valve. diaphragm (4);
b - The flow section depends from the force gen- . the force acting on sliding part (2);
erated on sliding part (2) surface, by the pres- . pressure P3 acting on positioning piston (8)
sure difference generated by the oil volume which, pushed by the springs, returns towards
acrossing the diaphragm (4). (Dp=f(Q)) the centre of cylinder.
c - The oil volume sent from gear pump (6) to initi- Therefore it is obtained a displacement decrease
al regulation valve is directly proportional to which will stop only when the balance is resetted
the Diesel engine revolutions. (Q=f(n)) between torque supplied by Diesel engine and
2 - If the Diesel engine revolutions is low, the pump the torque absorbed by the hydrostatic transmis-
delivery is also low and the force generated by sion.

10-18
3 - POSITIONING CYLINDER

6
B

A
a 2

1
7
b
4

5
8

9 10 11
3 D0400775

Function Operation
. Positioning cylinder (1) is the actuator that moves . The selector of machine's travel direction, ener-
the swash plate to address the pump's oil flow into gises a magnet (in the example the magnet (3)
pipe A or B and therefore to fix the travel direction which movable core moves the distribution piston
of machine. (5), allowing the oil passage coming from initial ad-
. The oil flow direction is fixed by the excitation of the justing valve (6) towards the positioning cylinder
magnets (2) ± (3) of solenoid valve (4) by means of (1).
selector of machine's travel direction. . When the idle speed of Diesel engine increases,
the pressure coming from the oil gallery a by
means of initial adjusting valve (6), increases in
proportional manner and acting on surface b of pis-
ton (7) causing a movement bared by the centering
springs (8).
. The movement of piston (7) causes a movement of
swash plate (9) of pump which, increasing the an-
gle, moves the pistons (10) inside the cylinder bar-
rel (11), creating the suction and the delivery zones.

10-19
4 - PRESSURE CUT VALVE

4 3
B

2
a

6 A
1
D0400715

a Operation
. The valve includes a slider (2) which intercepts the
5 piloting pressure coming from initial adjusting valve
(1) and going to positioning cylinder (3). The slider
(2) is moved by the higher pressure of closed circuit
b in contrast with the adjusting spring (4). The pres-
sure exhisting in the pressure line of closed circuit
(line A on the drawing) selects the oil passage
through flow selection valve (5) and, pressing on
plunger (6) and therefore on slider (2), engages
the spring (4). When the setting value is reached,
the slider (2) lifts itself putting in communication
the chamber a of piloting pressure, with relief
chamber b; the effect of piloting pressure drops,
causing a positioning piston backing and therefore
Function a swash plate repositioning, until a balance condi-
. The valve limits the maximum relief pressure of hy- tion is reached to allow the minimum flow rate hold-
drostatic transmission before the intervention of ing, necessary to setting pressure value (stand-by
safety valves, cutting the piloting pressure and can- condition).
celling partially the pump oil flow. The valve, acting . The pressure cut valve must be adjusted to operate
on piloting circuit, permits to limit the maximum at a lower pressure compared with the safety
pressure supplied by the initial adjusting regulation valves setting; the adjustment is obtained with the
valve (1) limiting the direct flow to positioning pis- screw (7) which acts directly on contrast spring (4).
ton, avoiding the intervention of safety valves and
therefore without any oil leakage and oil overheat-
ing.

10-20
5 - SAFETY VALVES

The safety valves are used to protect the hydro- Low pressure
Bassa pressione
static circuit from pressure peaks which exceed
the maximum permissible value for hydraulic
pump.
1
The valves are dual cartridge movable type, separat-
ing the low pressure line from the other high pressure High
line and both are fitted on delivery line. Alta
pressure
When the restrictor (1) is opened, exceeding pressure pressione 3
is sent directly from high pressure line into low pres-
sure line. 2
The safety valves must operate only in special case
and only for a short time period because the oil leak-
age following the opening of the valve (1), produces 4
heat and therefore the oil overheating inside the
closed circuit.
The safety valves setting must be done on test bench
and is obtained adjusting the restrictor (1) into the seat
(2) of the contrast spring (3).
The position is fixed by the screw (4).

D0400713

10-21
INCHING VALVE

1
A

3
4
5
Section
SezioneAA--A
A
b A

D0400767

a. A Port - From hydrostatic transmission pump INCH VALVE

(PS Port) The function of this valve is to send to relief all or part
b. B Port - To ST1 solenoid valve (T Port) of piloting flow acting on positioning piston, to limit the
displacement and therefore the machine speed inde-
pendently from Diesel engine revolutions.
1. Valve body The engine power not utilised for the swing function
remains at disposal for the work equipments.
2. Control lever
3. Spool
4. O-Ring
5. O-Ring

10-22
TRAVEL MOTOR

3
2

c
X b

View
Vista X
X
D0400695
4 d

a. A Port - From hydrostatic transmission pump 1. EV8 Additional piloting device

(B Port) 2. Automatic variable displacement device
b. T1 Port - From hydrostatic transmission pump 3. EV9 Detection of travel direction device
(T1 Port) 4. Oil exchange valve
c. B Port - From hydrostatic transmission pump
(A Port)
d. T Port - To oil radiator (C1 Port)

10-23
 A

12
11 17
10
8
6 13
3 2 1

9 13

18

19

B
B
A
7 4 5
14 Section A - A
Sezione A - A

16 15 16
Section
Sezione B
B -- B
B D0400776

1 - Output shaft 11 - Adjustment piston

2 - Front bearing 12 - Automatic start adjusting regulator
3 - Rear bearing 13 - One way valves
4 - Cylinder block 14 - Orifice
5 - Pistons 15 - Flow selector
6 - Swash plate 16 - Centering spring
7 - Minimum displacement lock 17 - Spool
8 - Maximum displacement lock 18 - Check valve
9 - Positioning piston 19 - Orifice
10 - Measuring piston spring

10-24
1 - AUTOMATIC VARIABLE DISPLACEMENT DEVICE

e
h

k g
12

m
a a
c

f d
D0400777

Function . The forces difference acting on positioning piston c

allow the movement of cylinder block g on which it
. This device is used to change automatically the dis-
is mechanically blocked until a balance condition is
placement according to operation pressure. The in-
reached between forces acting on both surfaces of
crease of displacement involves a reduction of
positioning piston c or, until to reach the maximum
crankshaft revolutions and an increase of output
displacement. The maximum displacement is ob-
torque.
tained by mechanical lock h.
Operation . When into the delivery gallery the pressure de-
creases, the balance of forces acting on positioning
. Oil coming from pump, after crossover the check piston c, is cutted; the measuring piston b, moves
valves a and the recognition of travel direction opening the gallery m which puts in relief the pres-
valve (12), reaches the piston b, and the smaller sure exhisting into the chamber f.
surface of positioning piston c pushing it towards
the minimum flow rate displacement through an ad- . The positioning piston c gradually returns towards
justing screw d. the minimum displacement position; the movement
is stopped when a new balance is reached between
. When the pressure inside the circuit increases, the the forces acting on positioning piston c.
adjustment piston b, acting in contrast with spring e
moves, allowing to oil to go through the gallery k
into the chamber f and to act on bigger surface of
positioning piston c.

10-25
2 - ADDITIONAL PILOTING

B
5
9

m 7

D0400778

Function
The movement of positioning piston (2) continues
. This device allows to cut the automatic variable dis-
up to maximum displacement, fixed by the me-
placement and to take the engine to maximum dis-
chanical block (7).
placement.
. When the magnet is no more energised the adjust-
Operation ing piston (5) moves opening the gallery m which
sends in relief the pressure exhisting into the cham-
. When the magnet B is energised, the actuator (9) ber f. The positioning piston (2) gradually returns
pushes on adjusting piston (5) which switches al- towards the minimum displacement position; the
lowing the oil passage through the gallery k, into movement is stopped when a new balance is
the chamber f of the bigger surface of positioning reached between the forces acting on adjusting pis-
piston (2). ton (5) and on positioning piston (2). From this mo-
. The pressure difference moves the positioning pis- ment the change of displacement becomes auto-
ton (2) which is mechanically connected to cylinder matic.
barrel of motor; the piston moves the cylinder barrel
increasing the displacement.

10-26
3 - RECOGNITION OF TRAVEL DIRECTION DEVICE

Function
. This device secures that the pressure acting on ad-
justing piston (5) is the one coming from the high
pressure gallery corresponding to travel direction
of machine; preselected by the selector putted
near the steering wheel. This avoids that the inver-
sion of pressures between the circuit branches
caused by the negative loads (as example during 2 5
the sloping travel) cause sudden and not wanted
displacement changes.
1
Operation 3
. The magnet (1) device, acts on spool (2) which in-
tercepts the pressure coming from branches A
and B of closed circuit through the check valve a.
. When the magnet (1) is in rest position, the spool is B A
held in position by the spring (3). The spool allows
the passage of pressure of branch A and prevents
the passage of pressure of branch B.
. When the magnet (1) is energised, the spool closes
A
B
the passage of pressure coming from branch A and
allows the passage of pressure of branch B.

4 - OIL EXCHANGE VALVE D0400779

Function
. The valve takes the oil from low pressure branch of
closed circuit to send it inside the motor housing to
join the oil leakage sent to relief. The oil quantity
leaving from the circuit is restored by means of
boosting circuit which supplies oil strained and hav-
ing a lower temperature.

Operation
. When machine is stopped, with pump in neutral po-
sition, the hydraulic motor is stopped and both
branches of transmission are feed by boosting
2 1 3 4 5
pressure. The same pressure acts also on both flow
regulator (1) sides which remains in neutral posi-
tion. When Diesel engine is stopped the regulator
is held in neutral position by springs (2) and (3).
. When into branch transmission (A) the operation
pressure increases, the flow selector (1) moves
and the opposite branch transmission oil (B), pas-
sing through the diaphragm (4), is putted into the
motor housing after the opening of valve (5). A B
. The same operation principle is valid also for the
opposite branch.

D0400780

10-27
STEERING SYSTEM

6
6

4 5

1 2 D0400781

DESCRIPTION
. Steering is completely hydraulic.
The necessary oil, supplied by the pump (1) oper-
ated by the engine (2), is sent by the «Load Sen-
sing» priority valve (3).
The priority valve must sent the necessary oil quan-
tity to the steering unit (4) even when the other hy-
draulic components are serviced by the same cir-
cuit. From the steering unit, operated by the steer-
ing wheel (5), oil is sent into the steering cylinders
(6) connected to front frame (7) and to joint (8).

10-28
STEERING SYSTEM PUMP

1 2

3
8

b 4
a
7

5
6

D0400698

a. P Port - To priority valve (P Port) SPECIFICATIONS:

b. S Port - From hydraulic tank Theoretical displacement: 14.4 cc/rev
Delivery at 2000 rpm: 28.8 ,/min
1. Drive gear Rated pressure: 260 bar
2. Snap ring Max. pressure: 320 bar
3. Oil seal
4. Bushing
5. Side plate
6. Driven gear
7. Pump body
8. Front flange

10-29
STEERING UNIT

a e b

D0400020

c d

a. L Port - To R.H. steering cylinder (Bottom side) SPECIFICATIONS

b. R Port - To L.H. steering cylinder (Bottom side) Steering unit type: OSPC200LS
c. T Port - To hydraulic tank Rated discharge: 20 ,/min
d. P Port - From priority valve (CF Port)
e. LS Port - From priority valve (LS Port) OPERATION
. The steering unit consists of a control valve and a
rotating oil dispenser and functions hydrostatically.
. When the steering wheel is moved, the control
valve sends oil from pump P2 (through the rotating
oil dispenser) to one or other of the chambers of the
steering cylinder. The rotating oil dispenser en-
sures that the amount of oil supplied to the cylinder
is proportional to the rotation angle of the steering
wheel.
. In the steering unit pump malfunctions the oil dis-
penser functions automatically like a hand-pump
to ensure emergency steering.

10-30
PRIORITY VALVE

d c

D0400036

a. P Port - From pump P2 (P Port) OPERATION

b. LS Port - To steering unit (LS Port) . The oil from pump is distributed through the priority
c. CF Port - To steering unit (P Port) valve to the steering unit (CF Port) and to the other
d. EF Port - To 3 spool control-valve hydraulic components (EF Port).
(T2 Port) . Distribution is determined by the position of the
priority valve slider in function of:
SPECIFICATIONS a - the Load Sensing signal coming from the steer-
Type: OLS 40 ing unit (LS Port);
b - the pump oil delivery;
c - the pressure in the steering system;
d - the pressure in the connected hydraulic circuit.
. The slider position is such as to ensure that deliv-
ery to the steering unit always corresponds to the
actual requirements.

10-31
FRAMES KNUCKLE AND JOINT

7
5
B

1 2 3
Detail A A
Particolare A C

2
4
3

Particolare
Detail B B 6
5

5 5
8 2

4
Detail C C
Particolare
D0400768

1 - Joint
2 - Spacer
3 - Bushing
4 - Joint flange
5 - Bushing
6 - Fitting
7 - Spacer
8 - Spacer

10-32
3-SPOOL CONTROL VALVE

b 1 c A B C d e

i h A B C g f

2 3 2 6 7

5 5 5

2 4 2 4 4
Section
Sezione A
A -- A
A Section
SezioneBB -- B
B SectionCC- -CC
Sezione D0400690

a. T2 Port - From priority valve (EF Port) and from 1. Main relief valve
backhoe control valve (P Port) 2. Safety-suction valve
b. P Port - From pump P3 (P Port) 3. Spool (Optional attachments)
c. B1 Port - To auxiliary attachments (L.H. side) 4. Spool return spring
d. B2 Port - To dump cylinder (Bottom side) 5. Check valve
e. B3 Port - To lift cylinder (Bottom side) 6. Spool (Bucket)
f. A3 Port - To lift cylinder (Head side) 7. Spool (Lift arm)
g. A2 Port - To dump cylinder (Head side)
h. A1 Port - To auxiliary attachments (R.H. side)
i. T Port - To hydraulic oil tank
l. T1 Port - From oil radiator (C2 Port)

10-35
6-SPOOL CONTROL VALVE

a b c d e f g h
A B C C D E

A B C C D E

q p o n m l i

D0400696

a. T1 Port -
To backframe locking cock (A Port) l. B6 Port - . Parallel control-valve:
b. A1 Port -
To arm cylinder (Head side) - To boom cylinder (Head side)
c. A2 Port -
To bucket cylinder (Bottom side) . Series control-valve:
d. A3 Port -
To R.H. outrigger safety valve (V1 Port) - To boom cylinder (Bottom side)
e. A4 Port -
To L.H. outrigger safety valve (V1 Port) m. B5 Port - To L.H. boom swing cylinder
(Head side)
f. A5 Port -
To R.H. boom swing cylinder
(Head side) n. B4 Port - To L.H. outrigger safety valve (V2 Port)
g. A6 Port - . Parallel control-valve: o. B3 Port - To R.H. outrigger safety valve (V2 Port)
- To boom cylinder (Bottom side) p. B2 Port - To bucket cylinder (Head side)
. Series control-valve: q. B1 Port - To arm cylinder (Bottom side)
- To boom cylinder (Head side)
h. Port T - To hydraulic oil tank
i. P Port - From priority valve (EF Port), from
3-spool control valve (T2 Port) and to
backframe locking cock (C Port)

10-36
 1 2 6 4 7

3 3 3

5 4 5 4 5
Section Section C - C
Sezione A
A -- A
A Section
Sezione B
B -- B
B Sezione C - C

8 4 9 4 9 4

3 3 3

5 4 5 Section E - E 4 5 Section E - E
4
Section D-D
Sezione D - D Sezione E - E Sezione E - E
Series tipo
Distributore Parallel tipo
Distributore
control valve
serie Control valve
parallelo
D0400717

1. Spool (Arm) 6. Spool (Bucket)

2. Suction valve 7. Spool (Outrigger)
3. Check valve 8. Spool (Boom swing)
4. Safety-suction valve 9. Spool (Boom)
5. Spool return spring

10-37
7-SPOOL CONTROL VALVE

ForPer
sidedeportabile
digging boom
A
a

b
A
PerFor jig arm
telescopico
B
c

d
B
For hammer
Per martello
C D

e
C D
D0400693

a. A7 Port - To side digging boom cylinder d. B7 Port - To jig arm cylinder (Head side)
(Bottom side) e. B7 Port - To hydraulic breaker
b. B7 Port - To side digging boom cylinder
(Head side)
c. A7 Port - To jig arm cylinder (Bottom side)

10-38
 1 2 5 6

3 3

4 2 4 6
Section A - A Section B - B
Sezione A - A Sezione B - B

7 8 9 2

3 3

4 2 4 2
Section C - C Section D - D
Sezione C - C Sezione D - D
D0400718

1. Spool (Side digging boom)

2. Safety-suction valve
3. Check valve
4. Spool return spring
5. Spool (Jig arm)
6. Plug
7. Spool (Hydraulic breaker)
8. Check valve
9. Spool (Bucket)

10-39
8-SPOOL CONTROL VALVE

A B
a b

d c
A B

1 2 5

3 3

4 2
4
Section A - A Section B - B
Sezione A - A Sezione B - B
D0400697

a. Port A7 - To side digging boom cylinder 1. Spool (Side digging boom)

(Bottom side) 2. Safety-suction valve
b. Port A8 - To jig arm cylinder (Bottom side) 3. Check valve
c. Port B8 - To jig arm cylinder (Head side) 4. Spool return spring
d. Port B7 - To side digging boom cylinder 5. Spool (Jig arm)
(Head side)

10-40
VALVES

MAIN RELIEF VALVE

1. Suction valve
2. Safety valve
3. Spring
1 2 3 4 4. Spring

SETTINGS
3-spool control valve: 200 bar
6-spool control valve: 190 bar
7-spool control valve: 190 bar
8-spool control valve: 190 bar

D0400703

SAFETY-SUCTION VALVE
1. Suction valve
2. Safety valve
3. Spring
1 2 3 4 4. Spring

SETTINGS
. 3-Spool control valve:
- Bucket cylinder bottom side: 270 bar
- Bucket cylinder head side: 195 bar
- Auxiliary attachments L.H. side: 170 bar
- Auxiliary attachments R.H. side: 170 bar

. 6-Spool control valve:

D0400703 - Boom cylinder head side: 270 bar
- Boom cylinder bottom side: 210 bar
- Arm cylinder bottom side: 210 bar
- Bucket cylinder bottom side: 210 bar
- R.H. boom swing cylinder head side: 160 bar
- L.H. boom swing cylinder bottom side: 160 bar

. 7-Spool control valve for side digging boom:

- Side digging boom cylinder bottom side: 270 bar
- Side digging boom cylinder head side: 270 bar

. 7-Spool control valve for hammer:

- Hammer delivery: 160 bar

. 8-Spool control valve:

- Side digging boom cylinder bottom side: 270 bar
- Side digging boom cylinder head side: 270 bar

10-41
SUCTION VALVE
1. Dowel
2. Ball
3. Body valve
1 2 3

. 6-Spool control valve:

- Arm cylinder head side
- Bucket cylinder head side

D0400720

CHECK VALVE
1. Check valve
2. Spring
3. Body valve
1 2 3

D0400708

10-42
GEAR PUMP

2 3
1

a b

View Z View X
Vista Z Vista X

D0400704

a. S Port - From hydraulic tank SPECIFICATIONS:

b. P Port - To 3-Spool control valve (P Port) Theoretical displacement: 26.5 cc/rev
Delivery at 2000 rpm: 53 ,/min
1. Input shaft Rated pressure: 210 bar
2. Pump body Max. pressure: 250 bar
3. Cover

10-43
OUTRIGGER SAFETY VALVES

a b

c d

D0400060

a. V2 Port - R.H. outrigger:

from 6-spool control valve (A3 Port)
L.H. outrigger:
⌬p (bar)

from 6-spool control valve (A4 Port) 16

pressure

b. V1 Port - R.H. outrigger: 14

from 6-spool control valve (B3 Port)

di pressione

12
10
L.H. outrigger: 2
Differential

8 ➔C
from 6-spool control valve (B4 Port) 6
V2
V2
2➔
c. C2 Port - To outrigger cylinder (Bottom side)
Differenza

4 C

d. C1 Port - To outrigger cylinder (Head side) 2

0
0 6 12 18 24 30
Delivery Q (,Q/min)
Portata (l / min)

D0400061

10-44
BRAKE PUMP

1 2 5 6 7 8

17 16 15 14 13 12 11 10 9
D0400699

1. Pump body SPECIFICATIONS:

2. Main piston Stroke: 36 mm
3. Oil brake tank Displacement: 15 cc
4. Union Max. pressure: 150 bar
5. Oil seal
6. Piston
7. Detaching valve spring
8. Pump spring
9. Plug
10. Seal
11. Pin
12. Seal
13. Seal
14. Seal
15. Ball
16. Spring
17. Seal

10-45
FRONT EQUIPMENT CYLINDER

LIFT CYLINDER

1 2 3 4 5 6 7 8

D0400685

1. Head bushing 4. Cylinder 7. Piston nut

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

DUMP CYLINDER

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

D0400687
13

1. Head bushing 6. Guide ring 11. Dowel pin

2. Piston rod 7. Cylinder 12. Bottom bushing
3. Ring nut 8. Thrust ring 13. Nut
4. Cylinder head 9. Piston ring
5. Oil seal 10. Thrust ring

STEERING CYLINDER

1 2 3 4 5 6 7 8

D0400683

1. Head bushing 4. Cylinder 7. Nut

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

10-46
KNUCKLE LOCKING CYLINDER

1 2 3 4 5

D0400682

1. Piston rod 3. Oil seal 5. Cylinder

2. Snap ring 4. Cylinder head

SPECIFICATIONS

Knuckle
Cylinder Lift Dump Steering
locking

Piston rod size 40 50 25 18

Bove 70 95 50 30

Stroke 650 380 310 40

Max. stroke 1600 1400 910 Ð

Min. stroke 950 1020 600 Ð

Width across flats of piston nut 41 50 30 Ð

10-47
FRONT WORK EQUIPMENT

5
4

3
1
7

D0400769

1 - Bucket
2 - Bucket link
3 - Tilt lever
4 - Lift arm
5 - R.H. lift cylinder
6 - Bucket cylinder
7 - L.H. lift cylinder

10-48
LOADER CONTROL LEVER

3
2

1
4

D0400771

CONTROL LEVER POSITION 1 - Optional work equipment control lever

1 Lift arm lowers 2 - Work equipment control lever
2 Lift arm raises 3 - Loader locking lever
3 Bucket dump
4 Bucket curl

10-49
BACKHOE CYLINDER

BOOM CYLINDER

1 2 3 4 5 6 7 8 9

11 10 D0400688

1. Head bushing 5. Piston 9. Bottom bushing

2. Piston rod 6. Piston ring 10. Bottom cushion pluger
3. Cylinder head 7. Guide ring 11. Ball (No. 9)
4. Cylinder 8. Screw

ARM AND BUCKET CYLINDER

1 2 3 4 5 6 7 8

D0400689

1. Head bushing 4. Cylinder 7. Guide ring

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

OUTRIGGER CYLINDER

1 2 3 4 5 6 7

D0400684

1. Piston rod 4. Spacer 7. Piston

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

10-50
BOOM SWING
H The drawing shows R.H. boom swing cylinder

1 2 3 4 5
A
6
13
12

11
10 7
Section
Sezione A
A -- AA
A
D0400680
9 8 5

1. Guide ring 6. Head bushing 11. Pin

2. Piston ring 7. Throttling 12. Retaining ring
3. Cylinder 8. Spring 13. Piston
4. Cylinder head 9. Spring guide
5. Swing bushing 10. Circlip

BACKFRAME LOCKING

2 3 4 5 6

D0400686

1. Rod 3. Piston 5. Sliding pad

2. Cylinder 4. Locking pad 6. Nut

10-51
ARM CYLINDER (FOR SIDE DIGGING BOOM CYLINDER)

1 2 3 4 5 6 7 8 9

D0400679

1. Head bushing 4. Cylinder 7. Guide ring

2. Piston rod 5. Piston 8. Bearing
3. Cylinder head 6. Piston ring 9. Snap ring

SIDE DIGGING BOOM CYLINDER

1 2 3 4 5 6 7 8 9 10

D0400681

1. Head bushing 5. Oil seal 9. Dowel pin

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

JIG ARM CYLINDER

1 2 3 4 5 6

D0400691

1. Piston rod 3. Cylinder 5. Guide ring

2. Cylinder head 4. Piston 6. Piston ring

10-52
SPECIFICATIONS

Arm
Boom
Cylinder Boom With standard With side Bucket
swing
boom digging boom

Piston rod size 50 50 50 45 45

Bore 95 95 95 85 95

Stroke 895 670 670 650 208

Max. stroke 2090 1645 1665 1600 292

Min. stroke 1195 975 995 950 84

Width across flats

65 65 65 65 50
of piston nut

SPECIFICATIONS

Backframe Side digging

Cylinders Outrigger Jig arm
locking boom

Piston rod size 35 33 40 35

Bore 60 92 80 60

Stroke 635 4 220 720

Max. stroke 1605 Ð 740 1690

Min. stroke 970 Ð 520 970

Width across flats

46 Ð 46 46
of piston nut

10-53
BACKHOE WORK EQUIPMENT

4 6

7
8

9
3

14

2
13
10
12 11

D0400770

1 - Bucket 8 - Boom swing R.H. cylinder

2 - Arm 9 - Outrigger L.H. cylinder
3 - Bucket cylinder 10 - Backframe locking cylinder
4 - Arm cylinder 11 - Boom swing L.H. cylinder
5 - R.H. outrigger cylinder 12 - Boom swing bracket
6 - Backhoe frame 13 - Boom
7 - Backframe 14 - Boom cylinder

10-54
BACKHOE CONTROL LEVER

1
4

3 5
2 8

7 6
1
10 3
12
9
11
2
4
6

CONTROL LEVER POSITION

1 Arm out
2 Arm in
3 Bucket dump D0400772
4 Bucket curl
5 Boom lower
6 Boom raise
7 Boom R.H. swing 1 - R.H. work equipment control lever
8 Boom L.H. swing 2 - R.H. outrigger control lever
9 R.H. outrigger lower 3 - L.H. work equipment control lever
10 R.H. outrigger raise 4 - L.H. outrigger control lever
11 L.H. outrigger lower 5 - Backframe locking lever
12 L.H. outrigger raise 6 - Backhoe locking lever

10-55
SOLENOID VALVE

SOLENOID VALVE BLOCK ST1 (FOR KNUCKLE LOCKING, AXLE LOCKING, FAST-LOW SPEED CONTROL)

1 2 3 4

a b

g f e d c

D0400738

a. P Port - From pump P1 (G Port) CONNECTOR

b. B2 Port - To bounce locking cylinder 1. EV4 Bounce locking
(Bottom side) 2. EV3 Differential locking
c. A4 Port - To transmission (B Port) 3. EV2 Low speed
d. A3 Port - To transmission (A Port) 4. EV1 High speed
e. A1 Port - To rear differential (B Port)
f. A2 Port - To bounce locking cylinder (Head side)
g. T Port - To hydraulic oil tank and from inching
valve (B Port)

10-56
01

10

20

30

40

90
 TESTING AND ADJUSTMENTS

Normal or standard technical data . . . . .. . . . . .. . . . .. . . 2 Testing and adjusting hydrostatic transmission . . . . 35

Tool list. . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 16 Testing and adjusting travel maximum speed
Measuring engine speed . . . . .. . . . . .. . . . .. . . . . .. . . . .. . 17 (universal joint) . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 41
Adjusting valve clearance . . . .. . . . . .. . . . .. . . . . .. . . . .. . 18 Testing travel motor leakage . . . .. . . . . .. . . . . .. . . . .. . . . 42
Measuring compression pressure .. . . . .. . . . . .. . . . .. . 19 Adjusting transmission sensor . .. . . . . .. . . . . .. . . . .. . . . 43
Testing and adjusting fuel injection timing . .. . . . .. . 20 Testing priority valve operation .. . . . . .. . . . . .. . . . .. . . . 44
Checking and tightening the fan - belt .. . . . . .. . . . .. . 21 Testing and setting steering control
Measuring accelerator pedal operating force system pressure . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 45
and accelerator lever . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 22 Testing steering cylinder leakage. . . . .. . . . . .. . . . .. . . . 46
Adjusting inch pedal travel . . . . . . . . .. . . . .. . . . . .. . . . .. . 23 Testing brake system .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 47
Adjusting brake pedal travel . . . . . . .. . . . .. . . . . .. . . . .. . 24 Adjusting parking brake lever . . .. . . . . .. . . . . .. . . . .. . . . 49
Testing frame articulation clearance . . .. . . . . .. . . . .. . 25 Checking wear in the brake disks . . . .. . . . . .. . . . .. . . . 50
Air bleeding - releasing residual pressure . . .. . . . .. . 26 Analysis of causes hydraulic drifts. . . .. . . . . .. . . . .. . . . 51
Checking and setting pressure in the Adjusting of cylinder draft of backframe locking . . . 56
attachments hydraulic circuit.. . . . . .. . . . .. . . . . .. . . . .. . 30

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
Machine model WB70A-1

Engine 4D98E-1FA

Check item Test conditions Unit Standard Permissible

value value

High idling rpm 2700w50 Ð

Engine speed Low idling rpm 900w50 Ð
Set speed rpm Ð Ð

Exhaust gas Sudden acceleration Index 0.9 1.1

colour At high idling speed Bosch 0.5 0.6

Intake valve (20ëC) mm 0.20 Ð

Valve clearance
Exhaust valve (20ëC) mm 0.20 Ð

Compression Oil temperature 69 ± 72ëC kg/cm2 35w1 28w1

pressure
(SAE30 oil) (Engine speed) rpm 250 250

Blow - by Water temperature in operating range Ð Ð

pressure mm H2O
(SAE30 oil) At high idling speed Ð Ð

Max idling (in cold state) kg/cm2 Max. 6 Ð

Engine oil At set speed kg/cm2 3±4 Ð
pressure
At low idling kg/cm2 Min. 0.6 Ð

Oil temperature Entire speed range ëC 90ë Max. 120

Fuel injection B.T.D.C. degrees 10 ± 12 Ð

timing

Fan - belt Deflection when pressed with finge force mm 10 ± 15 Ð

tension of approx. 10 kg

20-2
. FOR MACHINE

Machine model WB70A-1

Classi- Check item Test conditions Unit Standard Permissible

fication value value

. Hydraulic oil temperature: 55 ± 65 ëC.

. Engine oil temperature cooling circuit:
With piston pump in the limits 2620w50 Min. 2550
at max. pressure.
. Raised machine and working brakes
applied in 2nd gear
Engine speed

. Hydraulic oil temperature: 55 ± 65 ëC.

. Engine oil temperature cooling circuit:
With piston pump in the limits rpm
and steering pump 2600w50 Min. 2500
at max. pressure . Raised machine and working
brakes applied in 2nd gear
and total steering

. Hydraulic oil temperature: 55 ± 65 ëC.

With equipment . Engine oil temperature cooling circuit:
pump at 2550w50 Min. 2450
max. pressure in the limits
. Front bucket curled

, a b , a b
艎
Control valve

a b
All controls
(front bucket mm
and backhoe) 42 6.4 6.4 Ð Ð Ð

D0401125

Front bucket tilt . Engine stop- Raise

lever control ped Neutral Lower 100 75 ± 125
. At the centre
Front bucket control of knob lever Dump
lever Neutral Curled 100 75 ± 125
. Valve reading
at the end of
Additional working stroke
attachments R.H. side
. Attachments Neutral L.H. side 100 75 ± 125
control lever on the ground

Boom control Neutral Raise 80 60 ± 100

lever Lower
Travel of levers and pedals

Arm control Neutral Opening 80 60 ± 100

lever Closing

Bucket control Neutral Opening 80 60 ± 100

lever Curled mm
Boom swing control Neutral Right 80 60 ± 100
lever Left

Outriggers control lever Neutral Up 50 37 ± 63

Down

Fuel control lever Min. Max. 220 200 ± 240

Jig arm control Neutral Out 25 20 ± 30

pedal In

Side digging boom Neutral Right 25 20 ± 30

control pedal Left

Hammer control Neutral Ð 25 20 ± 30

pedal Max.

20-3
. FOR MACHINE

Machine model WB70A-1

Classi- Check item Test conditions Unit Standard Permissible

fication value Value

Accelerator pedal Min. Max. 70 52 ± 88

Travel of levers and pedals

. Engine mm
Inch control pedal stopped 0 Applied 100 75 ± 125
. At the centre
Backhoe locking of lever knob
lever Lock Unlock Degrees 90 Ð
. Reading of
value at the
end of working Right Left
Wheel swing stroke left right Rpm 3.5 2.8 ± 4.2
. Attachments
Parking brake on ground
lever Released Stopped Clicks 7 10

Front bucket tilt lever 2.5 1.8 ± 3.2

control

Front bucket control 2.5 1.8 ± 3.2

lever

Additional
attachments 2.5 1.8 ± 3.2
control lever

Boom control 2 1.5 ± 2.5

lever

Arm control
Force for levers and pedals operation

lever 2 1.5 ± 2.5

Bucket control lever 2 1.5 ± 2.5

. Engine speed : Max.
Boom swing control lever . Oil temperature: 55 ± 65ëC 2 1.5 ± 2.5
. Tool connection at the centre of knob kg
Outriggers control (for levers)
lever . Tool connection on edge 5 3.75 ± 6.25
(for pedals)
Fuel control lever 3 2.5 ± 3.5

Jig arm control 6 5±7

pedal

Side digging boom 6 5±7

control pedal

Hammer control 6 5±7

pedal

Accelerator pedal 8 6 ± 10

Brake pedal 8 6 ± 10

Inch control pedal 8 6 ± 10

20-4
. FOR MACHINE

Machine model WB70A-1

Classi- Check item Test conditions Unit Standard Permissible

fication value value

3-Spool control valve . Engine speed: Max. 200w5 190 ± 210

. Oil temperature: 55 ± 65ëC
Main valve
pressure

6-7-8-Spool control valve . Check one circuit at the time 190w5 180 ± 200
bar
Steering unit 160w5 150 ± 170
. Check on test bench
Hydrostatic circuit 450w5 440 ± 460

Front bucket 270w5 260 ± 280

(curled) ]

Front bucket (dump) 195w5 185 ± 205

Pressures of secondary valves circuits

Additional
attachments 170w5 160 ± 180
(right - left)

Boom (raising) ] 270w5 260 ± 280

. Engine speed: max.
Boom (lowering) . Oil temperature: 55 ± 65ëC 210w5 200 ± 220
. Check one circuit at a time bar
Arm (in) 210w5 200 ± 220
] Check on the test bench
Bucket (curled) 210w5 200 ± 220

Side digging boom 270w5 260 ± 280

(right - left)

Hammer (delivery) 160w5 150 ± 170

Steering unit 230w5 220 ± 240

Cut pressure valve 440w5 430 ± 450

20-5
. FOR MACHINE

Machine model WB70A-1

Classi- Check item Test conditions Unit Standard Permissible

fication value value

Measuring posture

Normal
2750w100 Min. 2600
(1975w75) (1875)

Travel motor
swing speed (1) rpm
(no-load)
Blocks
Blocchi D0401008

For TUV approval

. Engine speed: 2200 rpm Min. 1450
1520w50
. Oil temperature: 55 ± 65ëC (Min. 1100)
(1175w50)
. Machine with raised wheels
. Oscillating locking dowel applied
. Check speed of the transmission
shaft with 2nd gear

Measuring posture
Normal

4.7w0.3 Max. 5.2

Travel

Travel speed (2) sec.

For TUV approval

D0401007
. Road circulation configuration
. Engine speed max.
. Oil temperature 55 ± 65ëC
. On level ground 10w0.5 Max. 11
. 2nd gear
. Move for at least 20 meters and
check the necessary time to cover
50 meters.

Measuring posture

Leakage from Blocks

Blocchi D0401008
,/min Ð Ð
travel motor

. Engine speed: 2000 rpm

. Oil temperature:: 55 ± 65ëC
. Machine with raised wheels
. Oscillating locking dowel applied
. Working brakes applied
. 2nd gear
. After 30 seconds start the check for the
following minute.

20-6
. FOR MACHINE

Machine model WB70A-1

Classi- Check item Test conditions Unit Standard Permissible

fication value value
Measuring posture

Complete working
equipment
Max. 250 Max. 300
(Tip lowering of
bucket teeth ) ~10°
Front bucket

D0401010

Cylinders mm Max. 40 Max. 50

(cylinder in)

. In this position check in feedback of each

cylinder and the leakage with applied
load on the tip of bucket teeth.
. Ground level.
. Bucket: normal load (1250 kg)
Bucket cylinder . Engine stopped
Hydraulic drift working equipment

. Oil temperature: 55 ± 65ëC Max. 15 Max. 20

(cylinder in)
. Check measures as soon as engine
stops.
. Check changes every 5 min. and the total
change in 15 min.

Measuring posture
Complete working
equipment
Max. 300 Max. 400
(Tip lowering of
bucket teeth)

Boom cylinders
Max. 35 Max. 45
(cylinder out)
1m
Backhoe

D0401025 mm

Arm cylinder
Max. 12 Max. 16
(cylinder out)
. In this position check the extension of
each cylinder and the leakage with nor-
mal load on the bucket.
. On level ground.
. Bucket : normal load (220 kg)
. Engine stopped
Bucket cylinder . Oil temperature: 55 ± 65ëC
. Check measures as soon as engine Max. 10 Max. 14
(cylinder in)
stops.
. Check changes every 5 min. and the total
change in 15 min.

20-7
. FOR MACHINE

Machine model WB70A-1

Classi- Check item Test conditions Unit Standard Permissible

fication value value

D0401011

Boom swing Max. 15 Max. 20

(each side)
. Oil temperature: 55 ± 65ëC
. Backhoe balanced on the guides, bucket
in transport condition.
. Arm and bucket cylinder in. Put the buc-
ket 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 15ë and
Hydraulic drift working equipment

apply the parking brake.

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

H Make the test for each swing direction.

mm

D0401012
Outriggers Max. 20 Max. 30

. Oil temperature: 55 ± 65ëC

. By pass the safety valves.
. Balanced backhoe.
. Boom and arm cylinders in, bucket cylin-
der out
. Outriggers at maximum extension.
. Engine stopped.
. Check the frame lowering for each side
every 5 min. for a total of 15 minutes

20-8
. FOR MACHINE

Machine model WB70A-1

Classi- Check item Test conditions Unit Standard Permissible

fication value value

Boom Ð Ð
Front bucket

Bucket Ð Ð

Steering Ð Ð

Boom Ð Ð
. Engine: Max. speed
Cylinder leaking

. Oil temperature: 55 ± 65ëC

Arm . Leaking check: on the cylinder opposite Ð Ð
side to the pressure one
mm
H Check 1 cylinder at a time.
Bucket H For tilt front bucket, for steering and for Ð Ð
Backhoe

swing: check the two cylinders separate-

ly.
Boom swing Ð Ð

Outriggers Ð Ð

Side digging boom Ð Ð

Jig arm Ð Ð

20-9
. FOR MACHINE

Machine model WB70A-1

Classi- Check item Test conditions Unit Standard Permissible

fication value value

Measuring posture
Tilt lever front

Raised
bucket
4.5 5.0
Bucket on level ground

Lowered
D0401013 3.0 3.5
Cylinders extended out .
Front bucket

Engine speed: Max.

. Oil temperature: 55 ± 65ëC

Measuring posture
Front bucket

Curled
1.8 2.0
Cylinder out

Dump
D0401014
2.1 2.5
Cylinder in . Engine speed: Max.
. Oil temperature: 55 ± 65ëC

Measuring posture
Boom
Raised
Work equipment speed

2.9 3.3
Teeth bucket on level
ground

sec.
Lowered

D0401015

. Engine speed: Max. 2.3 2.6

Cylinder in
. Oil temperature: 55 ± 65ëC
. Backhoe balanced

Measuring posture
Arm
Closing

4.5 5.0

Cylinder in
Backhoe

Opening

D0401016
. Engine speed: Max. 3.5 4.0
Cylinder out
. Oil temperature: 55 ± 65ëC
. Backhoe balanced

Measuring posture
Bucket
Curled

3.5 4.0

Cylinder in

D0401017
Dump

. Engine speed: Max. 2.9 3.3

Cylinder out
. Oil temperature: 55 ± 65ëC
. Backhoe balanced

20-10
. FOR MACHINE

Machine model WB70A-1

Classi- Check item Test conditions Unit Standard Permissible

fication value value

Measuring posture

Right
Boom swing 3.5 4.0

Left end travel

D0401021
Right end travel

Left
Work equipment speed

. Engine speed: Max. 3.5 4.0

. Oil temperature: 55 ± 65ëC
. Backhoe balanced
Backhoe

. Arm vertical
sec.
Measuring posture

Lifting
Outriggers 25 40

All extended

D0401022
. Engine speed: Max.
Lowering

All raised . Oil temperature: 55 ± 65ëC

. Backhoe balanced 6 10
. Dowel joint locking: applied
. Front bucket on level ground
. Rear wheels raised

20-11
. FOR MACHINE

Machine model WB70A-1

Classi- Check item Test conditions Unit Standard Permissible

fication value value

Measuring posture

Tilt lever front 2.5 Max. 3.0

bucket

D0401018

. Engine speed: Min.

. Oil temperature: 55 ± 65ëC
. Check the time necessary to lift bucket
from level ground.

Measuring posture
Work equipment

Time lags

Boom sec. 1.75 Max. 2.2

D0401019

. Engine speed: Min.

. Oil temperature: 55 ± 65ëC
. With attachments fully extended, lower
the boom and check the necessary time
from the beginning of machine lifting until
bucket is on level ground.

Measuring posture

45°

Arm 0.2 Max. 0.5

D0401020

. Engine speed: Min.

. Oil temperature: 55 ± 65ëC
. Put boom at 45ë, open completely the
arm with curled bucket. Extend arm cylin-
der and check the time passing between
arm stop at dead centre and the restart
movement.

20-12
. FOR MACHINE

Machine model WB70A-1

Classi- Check item Test conditions Unit Standard Permissible

fication value value

Measuring posture

Bucket D0401023
0 Max. 0.2

. Engine speed: Min.

. Oil temperature: 55 ± 65ëC
. Put arm in horizontal position. Tilt back
bucket cylinder an then extend it.
Check the time passing between bucket
Work equipment

stop at dead centre and the restart move-

Time lags

ment.

Measuring posture sec.

Outriggers 0 Max. 0.2

D0401024

. Engine speed: Min.

. Oil temperature: 55 ± 65ëC
. 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.
H Check each outrigger at a time.

20-13
. FOR MACHINE

Machine model WB70A-1

Classi- Check item Test conditions Unit Standard Permissible

fication value value

50 bar
P3 gear pump . Engine: 2000 rpm
(26.5 cc/rev) . Oil temperature: 55 ± 65ëC
100 bar Ð Ð
. Measure the flow rate at
(R=1:1.2) 50 - 100 - 200 bar
200 bar
Pumps

50 bar
. Engine: 2000 rpm ,/min
P2 gear pump . Oil temperature: 55 ± 65ëC
100 bar Ð Ð
(14.2 cc/rev) . Measure the flow rate at
50 - 100 - 160 bar
160 bar

. Engine: 2000 rpm

P1 piston pump . Oil temperature: 55 ± 65ëC See following diagram
. Check the speed/pressure ratio

20-14
 Machine model WB70A-1

Classifi- . Setting : 5 hours

cation . Diaphragm: ù 4.6

500 50

Max. delivery
Portata massima
(theorical)
(teorica)
400 40
Pumps characteristics

(bar)
Boosting di
Pressione

pressure (bar)
(bar) (bar)

pressure

di sovralimentazione
sovralimentazione
30
pressure

300
di mandata

25

Boosting
Delivery

200 20
Delivery lower
Portata minima

Pressione
Pressione

limit
ammessa

100 10

0 0
700 800 1000 1200 1400 1600 1800 2000 2200 2400 2600 2800 rpm
giri/min
1850 D0401143

20-15
SPECIAL TOOLS
Measurement check point Symbol Code Name Q.ty Remarks

Valve clearance A 1 Commercially Feeler gauge 1 Ð

available

1 ATR800090 Compression gauge 1 0-70 kg/cm2

Compression pressure B
2 ATR800130 Adapter 1 Ð

1 ATR800070 Multiscale tachometer 1 20 - 4000 rpm

Engine speed C
2 ATR800060 Stroboscopic tachometer 1 6 - 30000 rpm

Oil and water temperature D 1 Commercially Digital thermometer 1 ± 50 - 1200 ëC

available

1 ATR800010 Pressure gauge 2 Full scale 600 bar

2 ATR800140 Pressure gauge 1 Full scale 400 bar

Hydraulic pressure E 3 ATR800150 Pressure gauge 1 Full scale 250 bar
and flow rates
4 ATR800160 Pressure gauge 1 Full scale 100 bar

5 ATR800170 Pressure gauge 3 Full scale 60 bar

Pump adjusting F 1 ATR201270 Connection between 1 Ð

piston position chambers

Disc brake thickness G 1 ATR500930 Feeler gauge 1 4.5/4.3 (T23 CK)

Brake performance H 1 ATR201280 Tool for circuit selection 1 Ð

20-16
TESTING AND ADJUSTMENT 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: 69.5 ± 72.5 ëC. C1
. Hydraulic oil temperature: 55 ± 60 ëC.
1 - Install and connect C1 tachometer.
H If using C2 stroboscopic tachometer, mark a light
notch on, engine pulley for an easier reading.
2 - Start engine and check:
. Low idling speed without load (accelerator pedal F0401180

released and hand accelerator lever (1) in «mini-

mum» position).
. High idling speed without load (accelerator pedal
at the travel end or hand accelerator pedal (1) at
MAX
end travel). MIN.
H Low idling speed: 900w50 rpm
1 1
H High idling speed: 2700w50 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 « AC-
CELERATOR LEVER ADJUSTING»).
F0401181

20-17
TESTING AND ADJUSTMENT ADJUSTING VALVE CLEARANCE

ADJUSTING VALVE CLEARANCE

H Adjust clearance between valves and rocker levers as 1

follows:
Unit: mm

Intake valve Exhaust valve

At cold
engine
0.20 0.20

H Firing order: 1-3-4-2-1.....

H Normal rotation sense: counterclockwise from flyw-
heel

. Adjusting procedure F0401182

1 - Remove valves cover (1).

2 - Rotate crankshaft in normal direction as long as
cylinder piston to be checked is at compression 3
Top Dead Center. (PMS).
2
H In this position intake and exhaust valves are clo-
sed.
3 - Loose lock nut (2) and unscrew tappet (3) of about
1 turn.
4
H Check that valve insert (4) is laying flat on val-
ve stem and that it is not worn askew.
SI
YES NO
NO

1 - If valve inserts (4) are damaged, replaced

them with new ones.
2 - Make sure that inserts feet and lay flat on D0400882 4
valve stem.
4 - Connect A1 feeler gauge between insert and roc-
ker lever to adjust; rotate the tappet (3) until tou-
ching A1 feeler gauge. 3 2
Tight tappet (3) with lock nut (2).
H After tightening the lock nut, check the clea- A1
rance again.
5 - Adjust with same procedures second cylinder val-
ve and repeat same operation for the other cylin-
ders, according to the firing order.

D0400893

. Cover valves installation

1 7
1 - Check condition of cover valves (1), gasket (5), O-
Rings (6) and lock nuts (7); clean carefully contact 6
surface on cylinder head.
2 - Install valves cover (1), fit O-Rings (6) and lock
nuts (7).
Cover lock nut: 25w3 Nm

5
D0400891

20-18
TESTING AND ADJUSTMENT MEASURING COMPRESSION PRESSURE

MEASURING COMPRESSION PRESSURE

. When measuring the compression pressure be

careful not to get caught in cooling fan, in the al-
ternator belt or in other rotating parts.
. Check all cylinders.
2
H Test condition:
. Engine: at operating temperature 1
. Hydraulic oil: 55 ± 60 ëC
. Battery: at full charge
. Valve clearance:
adjusted (see «ADJUSTING VALVE»)
1 - Disconnect high pressure pipe (1).
F0401183

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.

F0401184

5 - Install B2 adapter and connect B1 pressure gauge

H Check that seal is installed in the adapter and that B1
it is not damaged.
6 - Crank engine with starting motor and measure com-
pression pressure.
H Measure the compression pressure at the point
B2
where the pressure gauge indicator remains stea-
dy.
H When measuring the compression pressure,
check also engine speed with C2 stroboscopic ta-
chometer; if speed is not within the specified ran-
ge, refer to diagram. F0401185

H Compression value:
Normal: 35w1 kg/cm2 at 250 rpm
Minimum permissible: 28w1 kg/cm2 at 250 rpm
H Difference between cylinders: 2 ± 3 kg/cm2
pressure
Pressione di compressione

40
7 - After measuring, install the nozzle holder assembly
(2), connect high pressure pipe, feedback pipe and 35
Compression

connector (3). 30
Nozzle holder collar bolts: 6.9 ± 8.8 Nm 25
High pressure union: 19.6 ± 24.5 Nm
20
(kg/cm ) 2)
(kg/cm
2

200 250 300 350 400

Engine speed
Velocità motore (rpm)
(giri/min)
D0400881

20-19
TESTING AND ADJUSTMENT TESTING AND ADJUSTING FUEL INJECTION TIMING

TESTING AND ADJUSTING FUEL INJECTION TIMING

H Check fuel injection timing of N.1 cylinder by 2

means of N.1 delivery valve of injection pump.
H Cylinders are numbered 1-2-3-4 starting from
6
flywheel side.
Nº1
1 - Rotate crankshaft using engine pulley and put N. 1cy- 3
linder piston at top dead centre (PMS). 7
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 8 9
the scale (5) but cylinders N. 1 valves are not clo-
sed, rotate the crankshaft of 1 turn. F0401186

H After recognition of PMS, rotate the crankshaft in

counterclockwise direction (from pulley side view)
of about 90ë.
N. 1 Cylinder
Cilindro n°1
2 - Disconnect all cylinder delivery pipes (2) from injec-
tion pump.
3 - Move externally the stop engine lever (3) and fix posi-
tion with a temporary string.
4 - Rotate crankshaft slowly in clockwise direction from
pulley side view, checking fuel level into the N. 1 de-
livery of injection pump.
Stop pulley (1) rotation as soon as fuel level starts to
increase. Flywheel
Volano
D0400892
5 - Check notch (4) position on crankshaft pulley (1) com-
pared with scale (5); reading value corresponds to an-
gle of fuel injection timing.
H Standard fuel injection timing: ±10*12ë
6 - If injection timing is not on standard value, rotate in-
jection pump (6) toward external or toward engine af-
ter loosening pump nuts (7) (quantity 4) and pump
lock nuts (8) fixing the bracket (9) to injection pump. 5 4 4 5
. To RETARD injection, rotate pump (6) toward ex- 1
ternal.
. 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). F0401513

Nuts: 34.2 ± 44.1 Nm

Bracket lock nut: 44.1 ± 53.9 Nm
8 - Connect fuel delivery pipes (2) to pump. Raccordo Level
Livello
Delivery pipes unions: 19.6 ± 24.5 Nm N. 1 Union
N°1
9 - Release the stop engine lever (3) and carry out air
bleeding.

D0401031

20-20
TESTING AND ADJUSTMENT CHECKING AND TIGHTENING THE FAN - BELT

CHECKING AND TIGHTENING THE FAN - BELT

1. Tension check
1 - Push fan belt (1) at midway point between alterna-
tor (2) and pulley (3) operating water pump; check 2
the deflection.
With a pressure of 10 kg (98 Nm), deflection 3
should be of 10 ± 15 mm; if this value is not rea-
ched, tension fan belt.
H With new belt, deflection must be of 7 ± 9 mm 1

F0401187

2 . Fan belt tension

1 - Loosen mounting bolt (4) of the alternator (2) and
mounting bolt (5) of adjustment plate. 5

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 af-
ter about 20 operating hours.
Alternator mounting bolts on timing cover:
44.1 ± 53.9 Nm 4
Bracket clamping bolts: 22.5 ± 28.4 Nm F0401188

Water pump
Puleggia pompa
pulley
acqua

10
10
15 mmmm
± 15

Alternator
Alternatore

Crankshaft
Puleggia
pulley
albero motore
D0400883

20-21
 MEASURING ACCELERATOR PEDAL OPERATING
TESTING AND ADJUSTMENT FORCE AND ACCELERATOR LEVER

MEASURING ACCELERATOR PEDAL OPERATING

FORCE AND ACCELERATOR LEVER
H Work condition:
. Engine stopped
. Low and high idling speed: within permissible va- 1
lue.
1 - Remove lower cover (1) and approach to rods con-
nected to accelerator lever.
2 - Make sure that accelerator pedal is fully raised.

F0401189

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

idling speed adjusting screw (3).
3 7

F0401191

4 - Adjust nut (4) and lock nut (5) of accelerator pedal ca-
bles and hand accelerator at a distance of 0.2±0.3 4 5
mm from lever (6).
5 - Push accelerator pedal until accelerator lever (2) con-
6
tacts the high idling adjusting screw (7).

4 5

F0401190

6 - Adjust the end travel stopper (8) of accelerator pedal

(9) in this position and lock it with nut (10).
7 - Release the accelerator pedal.
8 - Operate hand accelerator lever and check that acce- 9
lerator lever (2) contacts the high idling adjusting
screw (7).
8

10

F0401192

20-22
TESTING AND ADJUSTMENT ADJUSTING INCH PEDAL TRAVEL

ADJUSTING INCH PEDAL TRAVEL

1 - Loosen nut (1) and tight the end pedal travel bolt (2) 6 2
of some turns.
H Make sure that the inch valve control lever (3)
(inch) returns at its total locking position.
H To check the return in position of inch control le- 1
ver (3), disconnect rod (4) and check that the di-
stance between lever and pedal is within a play
of 0.1 ± 0.2 mm measured between valve lever
and lever stopper.
H At the end of adjusting reconnect the rod (4), and
adjust the fork (7). 4
F0401193

2 - Push control pedal (5) slowly until it reaches the end.

H The end travel is given when the lever contacts
the holder (6).
00.,1
1
±
3 - Keeping the pedal position (5), adjust end travel bolt 00.,2
2m
(2) near to pedal stopper. mm
m
4 - Release pedal, loosen end pedal travel bolt (2) of
other 45ë and lock in position with nut (1).

5 3

7 4
D0401033

4 7

F0401194

20-23
TESTING AND ADJUSTMENT ADJUSTING BRAKE PEDAL TRAVEL

ADJUSTING BRAKE PEDAL TRAVEL

H Working condition:
. Engine stopped 5
. Machine with attachments on ground level
1 - Remove the rubber cover pedal (1).
4

F0401195

2 - Check that pedal (2) is near to the stopper (3) and that
pedal (2) central tip is at standard measure from cab
level.
If necessary , adjust height acting on the stopper (3).
H Pedal height: 140w2 mm

mmmm
1100
mm

88 ±

140  2mm
140w2

D0401005

3 - Loosen nut (4) locking the adjusting rod (5).

4 - Tighten or loosen the rod (5) to adjust the peda travel 5 3
(2).
H Pedal travel: 8 ± 10 mm
5 - Stop in this position with nut (4).

4
D0401006

20-24
TESTING AND ADJUSTMENT TESTING FRAME ARTICULATION CLEARANCE

TESTING FRAME ARTICULATION CLEARANCE

H Test condition:
. Sturdy and levelled ground
. Aligned frames (as for linear shifting)
. Braked machine with counterweight or backhoe 2000 kg
. Front bucket with load of 2000 kg
1 - Put the front bucket as shown in the illustration and
stop the engine. 45°
2 - Mark on front frame a «X» at a 250w2 mm upper the
longitudinal axis of machine's joint pin.
~100 mm
D0401028

3 - Apply a magnetic dial (1).

H The base axis and feeler tip must be exactly on X
the sign. 1
4 - Preload the dial gauge (1) of about 4 mm and set to
«zero» above measure.

mm
250 2 mm
250w2
PIN PERNO
ASSE AXIS

a
F0401198

5 - Start the engine and force the bucket into level groun-
duntil the front wheels are raised of about 50 mm.
6 - Note the dial gauge deviation (1) in such condition
(measuring change «a»). 1
When machine is raised, be careful not to put
hands or feet under the wheels.

7 - Return the machine in test starting position and

check that the dial gauge returns to «zero».
8 - Repeat testing several times and calculate the read X
value average.
F0401197

50 mm

D0401027

20-25
TESTING AND ADJUSTMENT AIR BLEEDING - RELEASING RESIDUAL PRESSURE

AIR BLEEDING - RELEASING RESIDUAL PRESSURE

1. Air bleeding from hydrostatic circuit

H Circuit air bleeding is necessary when:
1 - When removing piston pump or hydraulic motor for
overhaul or replacement.
2 - When removing or replacing connection hoses bet-
ween piston pump and hydraulic motor.
3 - When removing connection hoses to tank or to oil
cooler and therefore air is entered into hydrostatic
transmission piping. 1

F0401184

The air bleeding is obtained as follows:

1 - Carry out tank oil filling.
2 - Disconnect engine stop connector (1).
3 - Take out the hydraulic motor plug (2). 2
4 - Crank the engine with the starter engine until from
plug hole (2) flows out oil without air bubbles.
5 - Stop the engine and install again the plug.
6 - Check and, if necessary, refill tank oil at correct level.
7 - Connect stop engine connector (1) and start engine at
low idling speed for some minutes before moving the F0401196

machine.

2. Air bleeding from Load Sensing circuit

H When removing priority valve or steering unit, it is ne-
cessary that at machine starting to bleed air from
2
Load Sensing circuit as follows:
1 - Remove the cover (1). 1

2 - Release steering wheel with lever (2) and bring

the steering column in vertical position.
3 - Start the engine and keep it at low idling.
4 - Loosen pipe union (3) coming out from steering
unit (4). F0401199

5 - Start to make a slow steering and continue until

when from pipe union (3) flows out oil without air
bubbles.
4
6 - Stop the steering and tighten the pipe union (3).
H After air bleeding and before moving, carry
out a total steering in both directions.

F0401200

20-26
TESTING AND ADJUSTMENT AIR BLEEDING - RELEASING RESIDUAL PRESSURE

3. Air bleeding from cylinders

H When hydraulic cylinders or pipe fitting have been re-
moved, 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 sy-
stem.
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 re-
peat operation of point 2; return the engine at low
idling speed and make a complete travel of piston un-
til the hydraulic pump reaches its maximum pressure.
4 - Repeat above operation (starting from point 2) for all
cylinders.

4. Air bleeding from oil tank

1 - Put the machine in oil level check position and remo-
ve the tank plug.
H If necessary add oil until reaching the correct le-
vel.
2 - After stopping the engine wait for some minutes, until
air bubbles on oil surface are fully disappeared.
3 - When air bleeding is completed, repeat the hydrosta-
tic circuit bleeding (see paragraph 1).

5. 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 com-
pleting 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 star-
ting to work.

20-27
TESTING AND ADJUSTMENT AIR BLEEDING - RELEASING RESIDUAL PRESSURE

6. Releasing residual pressure from the

circuits
1 - Put work attachments on level ground, stop the engi-
ne and remove tank plug.
2 - Move all control levers in all directions to release
completely cylinders and main circuit remain pressu-
re.
3 - Loosen slowly oil filler tank to remove remain pressu-
re.

7. Air bleeding from braking circuit

H Above operation is to be carried out every time main-
tenance is made on braking circuit to remove or repla- 1
MAX
ce a component, or when air entered into the circuit.
H Machine must be stopped with attachments on level MIN.
ground.
1 - Make sure that oil in brake system tank (1) is at maxi-
mum level.

F0401201

2 - Remove safety plugs and applied to bleeding screws

(2) a vinyl hose (3) to catch oil.
3 - Push 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.
2
4 - Keeping pedal at the end stroke, tighten bleeding
screw (2).
5 - 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. 3
6 - Repeat same operations for the other braking unit. F0401202

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.

20-28
TESTING AND ADJUSTMENT AIR BLEEDING - RELEASING RESIDUAL PRESSURE

8. Air bleeding from differential

locking circuit
H Above operation is to be carried out every time main-
tenance is made on the circuit to remove or replace a
component or if rear axle is removed. 1
H Machine must be stopped with attachments on level
ground and parking brake applied.
1 - Start engine and keep it at low idling speed.
2 - Remove safety plug and apply to bleeding screw
(1) a vinyl hose (2) to catch oil. 2
3 - Apply differential locking, loosen bleeding screw F0401203

(1) until oil flows out without air bubbles.

4 - Tighten the bleeding screw (1).
H After air bleeding, apply on the screw the safety
plug.

20-29
 CHECKING AND SETTING PRESSURE IN THE
TESTING AND ADJUSTMENT ATTACHMENTS HYDRAULIC CIRCUIT

CHECKING AND SETTING PRESSURE IN THE ATTACHMENTS

HYDRAULIC CIRCUIT
1. Introduction
. According to machine configuration, one or two
spool. Mechanical control valves have been in-
stalled with following function:
Control valve No. 1 (3-spools): for front work at-
tachments control.
Control valve No. 2 (6-7-8-spools): for rear work at-
tachments control.
. Each control valve is protected against overpres-
sure by a main relief valve (or general) with fixed
setting.

DIESEL
DIESEL PRIORITY
VALVOLA
P2
P2 MAIN RELIEF VALVE
PRIORITARIA BACKHOE
DISTRIBUTORE
VALVOLA
VALVE CONTROL VALVE
RETROSCAVATORE
P3
P3 GENERALE
(6-7-8-SPOOLS)
(6-7-8 ELEMENTI)

P1
P1

3-SPOOL
DISTRIBUTORE
CONTROL VALVE
PALA ANTERIORE MAIN RELIEF
VALVOLA
(3 ELEMENTI) VALVE
GENERALE

. Control valves are feeded by: D0400872

Front bucket control valve: by P1 pump delivery.

Backhoe control valve: by P1 pump delivery and
by P2 pump total delivery when steering is not ac-
tuated.
. P2 pump delivery is checked by a priority valve
when steering unit is used.
. Control valves include spools controlling:

3-SPOOL CONTROL VALVE

Control Port
PORTS SIDE VIEW
Optional attachment B1 - A1

Front bucket (curled - dump) B2 - A2

Front bucket (lifting - lowering) B3 - A3

A
1 2 3
B

D0400871

20-30
 CHECKING AND SETTING PRESSURE IN THE
TESTING AND ADJUSTMENT ATTACHMENTS HYDRAULIC CIRCUIT

6-SPOOL CONTROL VALVE «Parallel» version

PORTS SIDE VIEW
In brackets ( ) are shown «series» version uses.

Control Port

Arm (opening - closing) A1 - B1

A
Bucket (curled - dump) A2 - B2 1 2 3 4 5 6
B
R.H. outrigger (down - up) A3 - B3

L.H. outrigger (down - up) A4 - B4

Boom swing (right - left) A5 - B5

D0400868

Boom (lowering - lifting) A6 - B6

(B6 - A6)

PORTS SIDE VIEW

(For the other ports, see «6-spool control valve»)

7-SPOOL CONTROL VALVE

Single application for side digging boom or jig arm.
A
Control Port 7
Side digging boom (right - left) or
B
B7 - A7
jig arm (out - in)
66-SPOOLS
ELEMENTI

D0400869
8-SPOOL CONTROL VALVE «series» version
Combined application with side digging boom or jig
arm.
PORTS SIDE VIEW
(For the other ports, see «6-spool control valve»)
Control Port

Side digging boom (right - left) B7 - A7

Jig arm (out - in) A8 - B8 A

7 8
B

6 6-SPOOLS
ELEMENTI

D0400870
2. Testing and setting general valves
H Test condition:
. Engine: at operating temperature
. Engine idle speed min. and max.: within per- E1
missible value
. Hydraulic oil: 55 ± 60 ëC
. Parking brake: applied 1 2
1 - Connect gauge E1 (600 bar) to pressure port (1) of
the 3-spool control valve (2).

F0401204

20-31
 CHECKING AND SETTING PRESSURE IN THE
TESTING AND ADJUSTMENT ATTACHMENTS HYDRAULIC CIRCUIT

2 - Start the engine, bring it to high idling speed and

check in sequence the setting pressure of main
relief valve of bucket and backhoe control valves
using following movements:
Unit: bar

Control valve Movement to be Setting

carried out pressure

3-spool Bucket lifting 200 5

(cylinder end stroke)

6-7-8-spool Boom lifting 190 5

(cylinder end stroke)

. If valve setting pressure do not correspond to the

indicated ones, provide to set them (see «SET-
TING MAIN AND SECONDARY VALVES»).

3. Testing and setting secondary valves

H Test condition:
E1
. Engine: at operating temperature
. Engine idle speed : within permissible value
. Hydraulic oil: 55 ± 60 ëC 2
1
. Parking brake: applied
1 - Connect gauge E1 (600 bar) to pressure port (1) of
the 3-spool control valve (2).
2 - Start the engine and put the accelerator lever in
MAX. position.
3 - Set general valves of the two control valves at an
F0401204

upper value of 30 bar compared with maximum

pressure to be checked.
4 - Acting a movement at a time, bring the piston at
end of stroke; check on gauge E1 the maximum
pressure of secondary valve corresponding to car-
ried out movement.
The secondary valves, to make front bucket cur-
ling and backhoe boom lifting, must be checked
and settled on test bench only.

20-32
 CHECKING AND SETTING PRESSURE IN THE
TESTING AND ADJUSTMENT ATTACHMENTS HYDRAULIC CIRCUIT

Setting 3-spool control valve secondary valves

Unit: bar
E1
Cylinder and movement Port Setting

Optional B1 170 5
attachment A1 170 5 1 2

Front Curled B2 270 5

bucket Lowered 195
A2 5

Lifting B3 200 5
Front
bucket Lowering A3 200 5
F0401204

Setting 6-spool control valve secondary valves Unit: bar

Port
Cylinder and movement Setting
«Series» version «Parallel» version
Lifting B6 A6 210 5
Boom
Lowering A6 B6 270 5

Right A5 160 5
Boom swing
Left B5 160 5

Up A4 190 5
Left outrigger
Down B4 190 5

Up A3 190 5
Right outrigger
Down B3 190 5

Curled A2 210 5
Bucket
Dump B2 190 5

Opening A1 190 5
Arm
Closing B1 210 5

Setting 7-8-spool control valve secondary valves (for other setting, refer to 6-spool control valve) Unit: bar
No. of Cylinder and movement Port Setting
spools
Side Right B7 270 5
digging
boom Left A7 270 5

7 Out B7 190 5
Jig arm
In A7 190 5

Hammer B7 160 5

Side Right B7 270 5

digging
boom Left A7 270 5
8
Out A8 190 5
Jig arm
In B8 190 5

. If valve setting pressure do not correspond to indicated ones, provide to set them (see «MAIN AND SECON-
DARY VALVE SETTING»).
5 - Restore general valve setting.

20-33
 CHECKING AND SETTING PRESSURE IN THE
TESTING AND ADJUSTMENT ATTACHMENTS HYDRAULIC CIRCUIT

4. Main and secondary valves setting

For setting, prepare machine as per pressure te-
sting.

1 - Loosen lock nut (1). 2

2 - Adjust pressure with adjusting screw (2). 1
. To INCREASE pressure, rotate in CLOCKWI-
SE direction.
. To DECREASE pressure, rotate in COUN-
TERCLOCKWISE direction.
3 - Lock position with nut (1).
Lock nut: 20 ± 24 Nm

D0400873

20-34
 TESTING AND ADJUSTING
TESTING AND ADJUSTMENT HYDROSTATIC TRANSMISSION

TESTING AND ADJUSTING HYDROSTATIC TRANSMISSION

H All testing condition:

. Engine: at operating temperature
. Engine idle speed MIN. and MAX: within permis-
sible value
. Hydraulic oil: 55 ± 65 ëC
. Machine: on blocks in safety condition with
wheels raised of about 10 cm.
. Swinging frame lock pin: applied.

1. Adjustment piston pump centering

The adjustment piston centering occurs in two pha- 10 cm
F0401205
ses:
a - Approach adjustment.
b - Delicate final adjustment. E1 E1
1 - Remove from adjusting unit the plugs (X1 and X2)
and assemble tool F1 to connect the two cylinder MA
chambers.
X1

2 - Remove plugs (MA - MB) and connect two gauges

E1 (600 bar). F1
3 - Make sure machine is in neutral and parking bra-
ke is applied. MB
4 - Start the engine, connect 2nd speed and bring en-
gine at high idling speed. X2 D0400952

5 - Loosen nut (1) and rotate slowly adjusting rod (2)

until levelling pressure shown by the two gauges.
Above adjusting is compulsorily rough because
readings are the some approaching to starting
of instruments indication (5/20 bar).

6 - Lock rod (2) temporary in this position and stop

1
the engine.
7 - Replace gauges E1 (600 bar) with gauges E5 (60
bar).
8 - Start the engine again, bring it to high idling 2
speed and proceed to pressure levelling shown
by the two gauges. D0400961

9 - Lock definitively adjustment rod (2) with nut (1).

Nut: 20 Nm
H Mark positions between adjustment rod (2),
nut (1) and governor body with a paint sealing.
10 - Disconnect tool F1, gauges E5 and reassemble
SEAL
SIGILLO
plugs.
Governor plug: 20 Nm
Using plug: 30 Nm

F0401206

20-35
 TESTING AND ADJUSTING
TESTING AND ADJUSTMENT HYDROSTATIC TRANSMISSION

2. Testing and setting boosting pressure

Testing E5
1 - Disconnect delivery pipe for secondary circuit and 1
connect a gauge E5 (60 bar).
H Plug pipe to avoid impurity inlet.
2 - Make sure machine is in neutral.
3 - Start the engine at high idling speed and check boo-
sting pressure value.
G
H Boosting pressure: 27 bar
D0400944

Setting
If pressure is lower than permissible value:
1 - Stop the engine.
1
2 - Remove valve (1) and put a shim (2) under the spring
(3).
3 - Reassemble the valve (1).
Valve: 70 Nm
4 - Start the engine and accelerate gradually until high
idling speed; check that boosting pressure is in line
as shown in «Technical specification».
H The minimum permissible value boosting pressure is
of 20 bar; above condition can be relieved with tran- F0401207

smission subjected to maximum stress (2nd speed ap-

plied, braked wheels, engine at 2000 rpm).
If pressure is below 20 bar, it is necessary the pumpo-
verhaul. 2 1

3 D0400874

3. Testing and adjusting pump setting starting

point (machine starting)
Testing
1 - Start the engine and bring it at low idling speed.
2 - Apply forward speed and check that wheels are stop-
ped.
3 - Increase engine idle speed until 1000 100 rpm; check
that wheels start to move slowly.
H If one of above test is negative it is necessary to set
start adjusting valve.

20-36
 TESTING AND ADJUSTING
TESTING AND ADJUSTMENT HYDROSTATIC TRANSMISSION

Setting
1 - Stop the engine, apply parking brake and remove sa- 1
fety valve (2) of plug (1). 2

F0401207

2 - Remove port B plug (MB) and connect a gauge E1

(600 bar).
E1
3 - Start the engine and bring it at low idling speed.
4 - Apply 2nd speed and bring the engine speed to 2
1000 50 rpm.

MB
D0400910
5 - Loosen nut (3) and adjust the valve setting pressure
with screw (4).
H Valve setting: 50 5 bar
. To INCREASE pressure, rotate in COUNTER-
CLOCKWISE direction.
. To DECREASE pressure, rotate in CLOCKWISE
direction.
4
6 - Lock the position with nut (3).
Nut: 22 Nm 3
7 - Decrease engine speed until low idling.
8 - Bring the travel gearshift lever in neutral and release
the parking brake.
9 - Apply 1st slow speed.
10 - Increase engine speed until 1000 100 rpm; check
that the wheels start a slow swing.
11 - Return engine at low idling speed an check that
wheels are stopped.
12 - Stop the engine, remove gauge and reassemble port
B plug (MB).
Plug: 30 Nm
13 - Apply safety plug (1) to avoid not authorised tampe-
rings.

D0400875

20-37
 TESTING AND ADJUSTING
TESTING AND ADJUSTMENT HYDROSTATIC TRANSMISSION

4. Testing and setting of valve pressure cut (1)

1 - Remove port plugs (MA - MB) and connect two gau-
ges E1 (600 bar).
2 - Start the engine and select 2nd forward speed.
3 - Brake firmly the wheels using brake pedal and, kee-
ping the brake pedal pushed accelerate gradually un- 1
til reaching high idling speed.
2

F0401208

4 - Check on gauge (MB) that pressure reaches normal

value.
H Cutting pressure: 440 10 bar E1 E1
H If pressure is not within tolerance limit, set valve
pressure cut (1). MA

MB
Setting
1 - Remove safety plug (2). D0400898

2 - Loosen nut (3).

3 - Adjust pressure by adjusting screw (4).
. To INCREASE pressure, rotate in CLOCKWISE 2
direction. 4
. To DECREASE pressure, rotate in COUNTER-
3
CLOCKWISE direction.
4 - Lock the position with nut (3).
Nut: 22 Nm 1
5 - Return engine at low idling speed, apply reverse
speed and check also the second port.
6 - Apply safety plug (2) against not authorised tampe-
rings.
H If in spite of valve cut pressure adjusting, pressure
does not reach normal value in both ports:
1 - Check boosting pressure setting (see paragraph 2).
2 - Check pump setting starting point adjustment
(see paragraph 3).
3 - Remove the port safety valve where failure is relie-
ved and proceed to overhaul at bench or to repla-
cement.

D0400876

20-38
 TESTING AND ADJUSTING
TESTING AND ADJUSTMENT HYDROSTATIC TRANSMISSION

5 . Testing and setting of pump end adjusting pres-

sure
Testing 1
1 - Remove port plugs (MA - MB) and connect two gau-
ges E1 (600 bar).
2 - Remove pilot pressure plugs (X1-X2) and boosting
pressure plug G; connect three gauges E5 (60 bar).
3 - Check boosting pressure setting with machine in neu-
tral (see paragraph 2).
4 - Check pump adjusting starting point setting (see pa-
ragraph 3). F0401209

5 - Check valve cut pressure setting (see paragraph 4).

6 - Apply 2nd forward speed and brake the wheels pus- E1 E5 E1
hing the brake pedal. X2
E5
7 - Accelerate the engine gradually up to 2000 rpm and
check that pump reaches maximum of end adjusting
pressure. MA
H End adjusting pressure: 400 5 bar E5
(See also pump characteristic curve as shown in
«technical specification»). G
If pressure value is not within the tolerance limit, it is ne-
cessary to adjust timing angle position of the swash plate. MB
X1 D0400899
Setting
1 - Remove safety plug (1).
2 - Check cam (2) reference notch position.
H Normal position is oriented at 5 o'clock.
90ë max.
3 - Loosen lock nut (3) and rotate cam (2). 90° max.
3
. To INCREASE end adjustment pressure, rotate in
COUNTERCLOCKWISE direction.
Reference
Riferimento
. To DECREASE end adjustment pressure, rotate
in CLOCKWISE direction.
3Ore
hours
3
H Rotate cam slowly and for few degrees only compared
to normal position (5 hours). 90ë
2 90° max.
max.
H Stop rotation as soon as projected pressure is rea-
ched. D0400877

H The cam maximum rotation is of w90ë compared to

horizontal (3 hours).
4 - Lock the position with nut (3).
Nut: 29.5 Nm
5 - Apply safety plug (1) against not authorised tampe-
rings.
H If with above adjustment, pressure of 400 bar is
not reached, it means that there is strong leakage
within the pump and so it is necessary a general
overhaul.

20-39
 TESTING AND ADJUSTING
TESTING AND ADJUSTMENT HYDROSTATIC TRANSMISSION

6. Testing and setting of hydraulic motor starting

adjustment pressure
G
Testing
1 - Remove plugs (G-M1) and connect two gauges E1
(600 bar).
2 - Start the engine, apply 2nd forward speed and brake
the wheels using the brake pedal.
3 - Accelerate slowly and check if gauge connected to M1
governor (M1) starts moving when operation pressure
(G) gauge marks the setting pressure.
H Setting pressure: 200 10 bar F0401210

E1 G

E1

M1 D0400878

Setting
1 - Remove safety plug (1).
2 - Loosen nut (2).
3 - Set operating point by screw (3).
H Operating point: 200 10 bar
2 3
. To INCREASE pressure, rotate in CLOCKWISE
direction.
. To DECREASE pressure, rotate in COUNTER-
CLOCKWISE direction.
F0401211

4 - When operating point is adjusted, rotate screw (3) of

90ë in counterclockwise direction to get high pressu- 1
re safety factor.
5 - Lock screw (3) position with nut (2).
3
Lock nut: 10 Nm
6 - Reassemble plugs (G-M1). 2
Plugs: 30 Nm
7 - Apply safety plug (1) against not authorised tampe-
rings.

D0400879

20-40
 TESTING AND ADJUSTING TRAVEL
TESTING AND ADJUSTMENT MAXIMUM SPEED (UNIVERSAL JOINT)

TESTING AND ADJUSTING TRAVEL MAXIMUM SPEED

(UNIVERSAL JOINT)
H Test condition:
. Engine: at operating temperature
. Hydraulic oil: 55 ± 60 ëC
. Machine: in safety condition with raised wheels
and swinging frame dowel applied

Testing
H Apply on drive shaft a light notch (1) to ease tachome-
ter C2 reading.
1 - Start the engine and apply 2nd forward speed.
10 cm
2 - Bring engine to idle speed of 2200 rpm tested by in- F0401205

strument C1.
3 - Check with tachometer C2 drive shaft revolving
speed.
Unit: rpm

Standard speed: 2750w50

Speed for TUV homologation: 1460w50

C2
F0401212

Adjusting
1 - Remove safety plug (2).
2 - Loosen nut (3).
3 - Adjust speed by means of minimum displacement ad-
justing screw (4).
. To INCREASE speed, rotate in COUNTER-
CLOCKWISE direction.
. To DECREASE speed, rotate in CLOCKWISE di-
rection.
2
4 - Lock the position with nut (3).
Lock nut: 69 Nm
F0401213

5 - Apply a new safety plug (2) against not authorised

tamperings.

3
4
D0400880

20-41
TESTING AND ADJUSTMENT TESTING TRAVEL MOTOR LEAKAGE

TESTING TRAVEL MOTOR LEAKAGE

Before carrying out testing, check brake efficiency.

H Test condition:
. Engine: at operating temperature
. Hydraulic oil: 55 ± 60 ëC
. Machine: in safety condition with raised wheels
2
1 - Disconnect drain hose (1) from engine lower side (2)
and plug it; plug engine too.
2 - Disconnect upper drain hose (3) and plug it.
1
3 - Apply to upper union a temporary hose to catch oil.
F0401214

4 - Start the engine, apply 2nd forward speed and brake

the wheels using the brake pedal.
5 - Accelerate engine slowly up to 2000 rpm.
6 - Keep the accelerator pedal position for 30 sec. and
then measure engine drain for the following minute.
7 - Check if leakages are normal.
(See «NORMAL OR STANDARD TECHNICAL DATA»).
8 - Stop the machine and reset the hydraulic connec-
tions.

20-42
TESTING AND ADJUSTMENT ADJUSTING TRANSMISSION SENSOR

ADJUSTING TRANSMISSION SENSOR

When disassembling or replacing transmission sensor, to 0

get final position, proceed as follow: 0,5 +0.2
0.5 0,2
1 2 3
1 - Tighten seal (2) on sensor (1) and tighten manually, 4
into transmission housing, (3) sensor (1) until resting
on gear (4).
H Check carefully seal (2) condition.
2 - Unscrew sensor (1) until getting a space of 0.5 ± 0.2
mm (about 0.5 ± 0.6 turns) between sensor and gear
(4).
3 - Lock sensor with nut (5). 5
Lock nut: 22w2 Nm D0400444

4 - Connect electrical wiring and fit the rubber boot (6).

Position boot (6) with wiring outlet tilted towards
ground to avoid backwater or moisture.

F0401215

20-43
TESTING AND ADJUSTMENT TESTING PRIORITY VALVE OPERATION

TESTING PRIORITY VALVE OPERATION

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

1. Testing Load Sensing signal

1 - Connect gauge E3 (250 bar) to priority valve (2)
pressure port (1).
E3
2 - Start the engine and bring it to idle speed of 2000
rpm.
F0401216
3 - Check on gauge E3 pressure value with stopped
steering wheel.
4 - Start a slight steering and check that pressure in-
creases.
5 - Continue the steering up to end of stroke and
check that, forcing the steering wheel, pressure 2
increases till normal value.
H Normal pressure: 160w5 bar
H If turning the steering wheel the pressure shown 1
by gauge does not change and stress on steering
wheel necessary to carry out steering is high,
check the priority valve (2).

F0401217

2. Testing priority valve operation

1 - Remove priority valve (2).
(See «30. REMOVAL AND INSTALLATION»). 3
4
2 - Remove inlet plug «PP» (3) and check (pushing
with a rod) that spool (4) moves freely for all pos-
sible travel.
3 - Check that inner nozzle (5) of spool is free.
4 - Reassemble priority valve (2).
5
5 - Start the engine and bleed Load Sensing circuit.
(See «AIR BLEEDING OF LOAD SENSING CIR-
CUIT»). 2
6 - Carry out some steerings and, if failure remain, D0400960
overhaul or replace orbit-roll valve.

20-44
 TESTING AND SETTING STEERING
TESTING AND ADJUSTMENT CONTROL SYSTEM PRESSURE

TESTING AND SETTING STEERING CONTROL SYSTEM PRESSURE

H Test condition:
. Engine: operating temperature E3
. Hydraulic oil: 55 ± 60 ëC 1

Testing
1 - Connect gauge E3 (250 bar) to priority valve (2) pres-
sure port (1).
2 - Start the engine, bring it to high idling speed and car-
ry out a total steering. 2
3 - Forcing the steering wheel at the end of stroke, check
pressure. F0401216

H Normal pressure: 160w5 bar

4 - Check for the other steering direction too.
5
Setting
If pressure is not within permissible value, carry out set- 7
ting acting on upper valve (3) of orbit-roll valve (4).
1 - Remove plug (5). 4
2 - Insert a wrench of 4 mm and adjust maximum pressu-
re with screw (6). 3
. To INCREASE pressure rotate in CLOCKWISE di-
rection. 4
. To DECREASE pressure rotate in COUNTER- F0401514

CLOCKWISE direction.
3 - Stop the engine and reassemble plug (5) checking
that gasket (7) is on its seat.
Plug: 50 ± 10 Nm

20-45
TESTING AND ADJUSTMENT TESTING STEERING CYLINDER LEAKAGE

TESTING STEERING CYLINDER LEAKAGE

H Test condition:
. Engine: operating temperature
. Hydraulic oil: 55 ± 60 ëC
. Parking brakes: applied
3 1
. Steering maximum pressure: within permissible
value
1 - Start the engine and carry out a total steering in one
of the two direction.
2 - Stop the engine.
3 - Disconnect from cylinder (1) the feeding pipe (2) with
rod side completely out (3); plug the pipe.
F0401218

4 - Connect to cylinder (1) a temporary tube to catch pos-

sible leakages.
5 - Start the engine and bring it to high idling speed.
2
6 - Force steering wheel to end of stroke and keep this
position for 30 seconds; measure possible leakages
for the following minute. 1 4
7 - Release the steering wheel, bring the engine to low
idling speed and then stop it.
8 - Check if leakage is normal (see «NORMAL OR STAN-
DARD TECHNICAL DATA»).
9 - Reset hydraulic connection, carry out several total
steerings in both directions to bleed air from circuit.
F0401219

10 - Carry out the test also for second cylinder (4).

20-46
TESTING AND ADJUSTMENT TESTING BRAKE SYSTEM

TESTING BRAKE SYSTEM

H Test condition:
. Engine: stopped
1
. Machine: on solid ground and on flat surface

The system testing provides in two stages:

1 - Testing circuit and brake pump tightness.
2 - Determining of defective brake unit.

1. Testing circuit and brake pump tightness 2

1 - Remove windshield washer tank.
F0401220

2 - Disconnect brake unit feed hose (1) and plug it.

H Plug also T-union (2) to avoid impurity inlet.
3 - Remove pressure switch (3) and connect an air gau- 4
ge E3 (250 bar).
4 - Operate the brake pedal to feed pressure into the cir-
cuit until about 120 bar.
H Do not exceed maximum permissible value that is
of 150w10 bar. 5

5 - Keep the pedal pushed for at least 2 minutes and 3

check that pedal pressure and position remain stea-
dy.
H If it must be changed pedal position to keep pres-
sure, check visually circuit possible leaks. F0401221

H If there are no leaks in the circuit, the pressure

leak is due to pump inner leakage.
To be sure, remove cap (4) of tank (5) and check if
oil, in case of leakages has rabblings. 4

E3

F0401222

2. Determining of defective brake unit

1 - Disconnect brake pump delivery hose (1). 4 4
1
2 - Release T-union (2) and elbow (3) from eye bolt (4);
remove complete brake pressure unit.

3 2

F0401223

20-47
TESTING AND ADJUSTMENT TESTING BRAKE SYSTEM

3 - Connect tool H1 between brake pump hose (1) and

eye union (5) of one of the two brake units. 1
4 - Connect to tool H1 pressure port a gauge E3 (250
bar) and open the exclusion valve (6).
E3
5 - Operate brake pump to feed pressure into the circuit
6
to maximum pressure of 150w10 bar.
6 - Keeping pressure, close valve (6) to keep in pressure
the brake unit to test.
7 - Release the brake pedal and check for 2 minutes the
H1
pressure indicated by gauge E3.
F0401224

H If pressure value has a negative change, it means that

at least one of steering piston is defective.
H If pressure value keeps steady, defect concerns the
other steering unit. 5
1 - A further confirmation about leak of one or more
steering pistons, can be also shown by oil level
increase in the axle central housing.
2 - If there are level increases, and therefore oil mi-
xing due to steering piston leaks, replace all
seals among axle section and replace lubricant
completely.
8 - Repeat, as confirmation, test for the other brake unit 1
using the same procedure.
F0401225

9 - Reset brake circuit with disassembled parts.

After testing and possible repairs, bleed air from bra-
ke units (see «AIR BLEEDING OF BRAKE CIRCUIT»).

20-48
TESTING AND ADJUSTMENT ADJUSTING PARKING BRAKE LEVER

ADJUSTING PARKING BRAKE LEVER

H Adjusting condition:
2
. Engine: stoppped
. Machine: on solid ground and on plate surface, in
safety condition.
1 - Loosen lock nut (1) and unscrew of some turns.
2 - Screw on tie rod (2) the nut (3) until getting parking
brake lever travel of 7-10 clicks.
3 - Block the position with lock nut (1).

F0401226

2 1

F0401227

20-49
TESTING AND ADJUSTMENT CHECKING WEAR IN THE BRAKE DISKS

CHECKING WEAR IN THE BRAKE DISKS

H Test condition:
. Engine: stopped
. Machine: on solid ground and on plate surface, in
safety condition
H Before carrying out measuring, adjust parking brake
lever travel.
1 - Pull the parking brake lever completely.
2 - Remove filling plugs (1) and, using tool G1, check the
two brake units thickness «S». 1
H Minimum thickness «S»: 4.5 mm
1 - If thickness «S» of one of the two axle brake units
F0401228

is equal or lower than the permissible minimum,

replace disk on both brake unit.
2 - After brake disk replacement, bleed air from bra-
ke units.
(See «BRAKE CIRCUIT AIR BLEEDING»).

BRAKE DISC CLEARANCE

ADJUSTMENT
H Setting condition:
. Engine: stopped
G1
. Machine: on solid ground and on plate surface, in
D0400461
safety condition
F0401229

H Before carrying out the adjustment, make sure

that brake disk are not worn (see «CHECKING
WEAR IN THE BRAKE DISKS»).
1 - Loosen lock nuts (1) of adjusting screws (2) (No. 3).
1
2 - Rotate in counterclockwise direction the adjusting
screws (2) to block brake disks.
3 - Rotate in clockwise direction the adjusting screws of
180ë (half turn) to give to discs the correct adjusting
clearance.
H Adjusting clearance: 0.5 mm
4 - Keeping the adjusting screws (2) in position, lock the
nuts (1). F0401230

F0401231

20-50
TESTING AND ADJUSTMENT ANALYSIS OF CAUSES HYDRAULIC DRIFTS

ANALYSIS OF CAUSES HYDRAULIC DRIFTS

H If working attachments have a hydraulic drift, it is ne-

cessary to check if reason is due to cylinders gaskets
or to control valve.
H All testing conditions:
. Engine: at operating temperature
. Hydraulic oil: 55 ± 60 ëC
. Removal and installation of pipes only after re-
main pressure removal.
(See «REMOVAL OF REMAIN PRESSURE
FROM CIRCUIT»).
10 cm
BLOCKS
BLOCCHI
F0401232

FRONT EQUIPMENT
1. Testing of front bucket lifting
1 - Put the machine with bucket teeth on blocks of about 2
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.
1
4 - Plug cylinders, base side, and apply a temporary pi-
pe, head side, to catch possible oil leakage.
3
5 - Start the engine and retract the bucket until to bring
the teeth in tilt position of about 15ë. F0401233

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.
8 - Remove from one of cylinders the plug as installed on 15°
base side at stage 4.
9 - Start the engine and retract the bucket until to bring
teeth in tilt position of about 15ë towards upper.
10 - Stop the engine and check the bucket position for 5 F0401234

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.

20-51
TESTING AND ADJUSTMENT ANALYSIS OF CAUSES HYDRAULIC DRIFTS

2. Testing of front bucket dumping

1 - Put the machine with bucket on level ground and
teeth tilted of about 15ë.
Put in the bucket a weight of 200 kg. 200 kg

15°

D0400884

2 - Disconnect pipes (1) and (2) from dump cylinder (3)

and plug them to avoid impurity inlet.
2
3 - Plug dump cylinder hole, base side, and apply a tem- 1
porary pipe on head side to catch possible oil leaka-
ge.

F0401235

4 - Start the engine and raise the bucket of about 50 cm.

5 - Stop the engine and check bucket teeth position for 5 200 kg
minutes.
. If bucket has a swing movement, drift is due to cy-
linder gaskets.
. If bucket has no movement, drift is due to control
valve.

50 cm

D0400885

20-52
TESTING AND ADJUSTMENT ANALYSIS OF CAUSES HYDRAULIC DRIFTS

BACKHOE
H Test condition:
. Backhoe aligned
. Lifted stabilisers

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.
D0400886

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

4 - Plug the two hoses to avoid impurity inlet.
5 - Plug the pipe (3) feeding cylinder head side.
1
6 - Apply a temporary pipe on pipe (4) base side to catch
possible oil leakage. 2

F0401236

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.

D0400890

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.

D0400894

20-53
TESTING AND ADJUSTMENT ANALYSIS OF CAUSES HYDRAULIC DRIFTS

3 - Disconnect pipes (1) and (2) pipes from arm cylinder

(3) and plug them to avoid impurity inlet. 1 3 2
H If safety valve is fitted, provide to removal.
4 - Plug arm cylinder hole on head side and fit a tempo-
rary pipe on base side to catch possible oil leakage.

F0401237

5 - Start the engine and raise the boom.

6 - Stop the engine and check the arm position for 5 mi-
nutes.
. If arm has a lowering movement, drift is due to cy-
linder gaskets.
. If arm has no movement, drift is due to control val-
ve.

D0400895

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

D0400896

2 - Stop the engine and remove the remain hydraulic

pressures.
3 - Disconnect bucket cylinders (3) pipes (1) and (2) and 1 2
plug them to avoid impurity inlet.
4 - Plug bucket cylinder hole on base side and fit a tem-
porary pipe on head side to catch possible oil leaka-
ge.
3

F0401238

20-54
TESTING AND ADJUSTMENT ANALYSIS OF CAUSES HYDRAULIC DRIFTS

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.

D0400897

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 - Lean the outriggers on blocks without forcing them.

20 cm

D0401026

4 - Stop the engine and disconnect safety valves (2) from

cylinders (1); plug valves holes to avoid impurity inlet. 2
3
5 - Plug cylinders pipes (3) base side and apply on head
1
sides temporary pipes (4) to catch possible oil leaka-
ge.
6 - Start the engine, force with boom to lift machine and
remove outriggers face blocks.
4

F0401239

7 - Lower the machine and stop the engine.

8 - Check the outriggers position for 5 minutes.
. If one or both outriggers have a lowering move-
ment, drift is due to single or both cylinders.
. If there is no lowering, drift is due to safety valves.

D0401029

20-55
 ADJUSTING OF CYLINDER DRAFT OF
TESTING AND ADJUSTMENT BACKFRAME LOCKING

ADJUSTING OF CYLINDER DRAFT OF BACKFRAME LOCKING

H Test condition:
. Engine at low idling
. Machine: On flat surface
. Parking brake: applied
1 - Set the machine with backhoe arm in vertical position
and with bucket on ground leaned on the side.

D0401030

2 - Release backframe (1).

3 - Tighten pins (2) to bottom and then loosen them of 1
turn to fix standard clearance of 2 mm.
4 - Lock backframe (1).
2

F0401240

20-56
01

10

20

30

40

90
 DISASSEMBLY AND ASSEMBLY

HOW TO READ THE MANUAL. . . .. . . . .. . . . . .. . . . .. . . 3 PISTON PUMP AND STEERING PUMP

PRECAUTIONS TO BE TAKEN WHILE Removal and installation. . . . .. . . . . .. . . . . .. . . . .. . . . 34
WORKING . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 4 Disassembly . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 35
SPECIAL TOOLS Assembly . . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 41
(For machine). .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 5 ENGINE-PUMP COUPLING JOINT
SPECIAL TOOLS Removal and installation. . . . .. . . . . .. . . . . .. . . . .. . . . 47
(For backhoe). .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 7 TRAVEL MOTOR
STARTER MOTOR Removal and installation. . . . .. . . . . .. . . . . .. . . . .. . . . 48
Removal and installation .. . . . . .. . . . .. . . . . .. . . . .. . . 9 Disassembly . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 49
ALTERNATOR Assembly . . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 53
Removal and installation .. . . . . .. . . . .. . . . . .. . . . .. . 10 STEERING PUMP
INJECTION PUMP Removal and installation. . . . .. . . . . .. . . . . .. . . . .. . . . 58
Removal. . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 11 STEERING GEAR PUMP
Installation .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 13 Disassembly . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 59
NOZZLE HOLDER Assembly . . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 61
Removal and installation .. . . . . .. . . . .. . . . . .. . . . .. . 15 WORK EQUIPMENT PUMP
CYLINDER HEAD Removal and installation. . . . .. . . . . .. . . . . .. . . . .. . . . 63
Removal. . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 16 BRAKE PUMP
Installation .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 17 Removal and installation. . . . .. . . . . .. . . . . .. . . . .. . . . 64
RADIATOR - OIL COOLER UNIT TRANSMISSION-REVERSE, DIRECTION
Removal. . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 18 INDICATOR AND HEADLIGHT DIPPER BEAM
Installation .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 19 CONTROL GROUP
MUFFLER Removal and installation. . . . .. . . . . .. . . . . .. . . . .. . . . 65
Removal and installation .. . . . . .. . . . .. . . . . .. . . . .. . 20 STEERING UNIT
EXHAUST PIPE Removal and installation. . . . .. . . . . .. . . . . .. . . . .. . . . 66
Removal and installation .. . . . . .. . . . .. . . . . .. . . . .. . 20 Disassembly . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 67
SEAT AND ENGINE HOOD Assembly . . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 73
Removal and installation .. . . . . .. . . . .. . . . . .. . . . .. . 21 PRIORITY VALVE
SIDE COVER Removal and installation. . . . .. . . . . .. . . . . .. . . . .. . . . 83
Removal and installation .. . . . . .. . . . .. . . . . .. . . . .. . 22 Disassembly and assembly. .. . . . . .. . . . . .. . . . .. . . . 84
HEATING RADIATOR FRONT EQUIPMENT CONTROL VALVE
Removal and installation .. . . . . .. . . . .. . . . . .. . . . .. . 23 Removal and installation. . . . .. . . . . .. . . . . .. . . . .. . . . 85
CAB FRONT AXLE
Removal. . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 24 Removal .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 86
Installation .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 27 Installation. . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 87
FUEL TANK REAR AXLE
Removal and installation .. . . . . .. . . . .. . . . . .. . . . .. . 28 Removal .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 88
Installation. . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 89
HYDRAULIC OIL TANK
Removal and installation .. . . . . .. . . . .. . . . . .. . . . .. . 29 AXLES
Disassembly . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 90
ENGINE - PUMP GROUP
Assembly . . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 98
Removal. . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 30
Installation .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 33

30-1
TRANSMISSION BACKHOE BOOM CYLINDER
Disassembly. .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 106 Removal and installation . .. . . . . .. . . . .. . . . . .. . . . . 144
Assembly . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 114 BACKHOE ARM CYLINDER
FRAMES JOINT PIN Removal and installation . .. . . . . .. . . . .. . . . . .. . . . . 145
Removal . . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 124 BACKHOE BUCKET CYLINDER
Installation. . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 125 Removal and installation . .. . . . . .. . . . .. . . . . .. . . . . 146
FRAMES JOINT BACKHOE SWING CYLINDERS
Removal and installation . . . . .. . . . .. . . . . .. . . . .. . . 126 Removal and installation . .. . . . . .. . . . .. . . . . .. . . . . 147
FRONT BUCKET LIFT ARM CYLINDERS OUTRIGGER CYLINDERS
Removal and installation . . . . .. . . . .. . . . . .. . . . .. . . 127 Removal and installation . .. . . . . .. . . . .. . . . . .. . . . . 148
FRONT BUCKET DUMPING CYLINDERS BACKHOE BACKFRAME LOCK CYLINDERS
Removal and installation . . . . .. . . . .. . . . . .. . . . .. . . 128 Removal and installation . .. . . . . .. . . . .. . . . . .. . . . . 149
STEERING CYLINDERS BACKHOE CYLINDERS
Removal and installation . . . . .. . . . .. . . . . .. . . . .. . . 129 (boom, arm, bucket, outrigger, jig arm)
FRAME OSCILLATING LOCK CYLINDER Disassembly . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . 150
Removal and installation . . . . .. . . . .. . . . . .. . . . .. . . 130 Assembly . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . 152
MACHINE CYLINDERS BOOM SWING CYLINDER
Disassembly. .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 131 Disassembly . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . 156
Assembly . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 133 Assembly . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . 157
FRAME OSCILLATING LOCK CYLINDER BACKHOE EQUIPMENT
Disassembly and assembly . .. . . . .. . . . . .. . . . .. . . 137 Removal and installation . .. . . . . .. . . . .. . . . . .. . . . . 159
FRONT BUCKET BACKHOE BUCKET
Removal and installation . . . . .. . . . .. . . . . .. . . . .. . . 138 Removal and installation . .. . . . . .. . . . .. . . . . .. . . . . 160
TILT LEVER AND BUCKET LINK ARM
Removal and installation . . . . .. . . . .. . . . . .. . . . .. . . 139 Removal and installation . .. . . . . .. . . . .. . . . . .. . . . . 161
ARM AND FRONT BUCKET LIFT BACKHOE BOOM
Removal and installation . . . . .. . . . .. . . . . .. . . . .. . . 140 Removal and installation . .. . . . . .. . . . .. . . . . .. . . . . 162
BACKHOE CONTROL VALVE BRACKET
Removal . . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 141 Removal and installation . .. . . . . .. . . . .. . . . . .. . . . . 163
Installation. . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 143 BACKFRAME
Removal and installation . .. . . . . .. . . . .. . . . . .. . . . . 164

30-2
DISASSEMBLY AND ASSEMBLY 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 re-
moving 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 re-
covered.

INSTALLATION GROUP *** : . . . . . . . . . . . . . . . . . . . . . Title of operation.

. To install, reverse removal procedure.
: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Technique to be used for installation.
H : . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Technique or important point to remember when re-
moving ~ ~ ~ (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 LUBRICA-
TION», «LUBRICATING GREASE».
NOTE
If no symbol is indicated, the values to be used are those given in the introductory sections of this manual.

30-3
 PRECAUTIONS TO BE
DISASSEMBLY AND ASSEMBLY 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 in-
stallation position. If necessary add further marks to avoid incorrect installation.
. While dismantling the connectors, always grasp them firmly to avoid undue strain on the wiring.
. If necessary, attach markers to the wires and tubes to avoid muddling them up during installation.
. Check the number and height of the adjustments to a given clearance and store them in a safe place.
. When raising the machine or some parts of it, use adequate equipment for the weight of the part concerned.
. When using screws or eyebolts to remove items of the machinery, screw them alternately, and as deeply as
they will go.
. Before removing a piece, clean the surrounding area and, after removal, cover the area to prevent dirt or
dust from gaining entrance.
2. Precautions to be taken during installation
. Tighten nuts and screws with the specified tightening torques.
. Install the flexible hoses, taking care not to entangle or twist them.
. Bend the cotter pins and stops in such a way as to secure them.
. When coating the threads with adhesives, clean the piece to remove oil and grease, then apply just enough
adhesive to cover the threading in a uniform manner.
. When applying a liquid sealant, clean the surface involved, remove residual oil and grease, check that there
are no dents or dirt, then apply the liquid sealant in a uniform manner.
. Clean all the parts, remove dirt, rust, burrs, or dents.
. Apply a film of engine oil over all the moving parts.
. Apply a film of anti-friction grease (ASL800040) over all surfaces assembled with pressure, to avoid sticking.
. After having mounted the snap-rings, check that they are firmly positioned in their seatings.
. When installing electrical system jacks, remove any oil, dust or water that may have penetrated into them,
then connect them firmly.
. If using eyebolts, check that they are not distorted, screw them in fully, and then align the eye with the hoist-
ing hook.
. Mount the flanges in a uniform manner, and tighten the screws in criss-cross sequence, to avoid excessive
pull on one side only.
3. Precautions to be taken on completion of removal and installation operations.
. If the coolant liquid has been drained away, close the drainage plug and add new liquid up to normal level.
Start the engine to circulate the liquid throughout the cooling system and then top up the level once more.
. When the hydraulic equipment has been dismantled, add engine oil to the indicated level. Start up the en-
gine 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.

30-4
DISASSEMBLY AND ASSEMBLY SPECIAL TOOLS (For machine)

SPECIAL TOOLS
For machine
Nature of work Symbol Code Description Q.ty Notes

Installation of fuel tank

A 1 ATR201290 Tool 1 Tanks lifting
Installation of hydraulic tank

1 ATR501260 Plunger 1 Check ring disassembly

Disassembly and assembly
piston pump B 2 ATR501270 Tool 1 Control shaft assembly

3 ATR501280 Tool 1 Seal assembly

1 ATR501290 Tool 1 Rotating unit assembly

For central pin clearance

Assembly travel motor C 2 ATR501300 Tool 1 checking

3 ATR501310 Tool 1 Gasket, spacer, circlip

assembly

Guide
1 ATR501090 Plunger 1 Spool seal assembly

Assembly of steering unit D Fork

2 ATR501100 Fork 1 Control shaft check

3 ATR501110 Plunger 1 Dust seal assembly

1 ATR501320 Tool 1 Pinion lock

Disassembly and assembly E
transmission
2 ATR501330 Tool 1 Locking-unlocking pinion nut

1 T09 Tool 1 Disassembly and assembly

2 T11 Tool 1 rear axle bevel pinion

3 T06 Tool 1 Thrust bearing assembly in

rear axle pinion bracket

4 T13 Tool 1 Bevel pinion adjusting and

Disassembly and assembly 5 T23 Tool 1 seal assembly in rear axle
axles F

6 T05 Wrench 1 Bevel gear torque adjusting

7 T03 Tool 1 Seal hub assembling

8 T02 Tool 1 Arm seal assembly

9 T04 Tool 1 Bearing assembly

1 ATR200620 Attachment 1 Cylinders disassembly -

assembly
Disassembly and assembly G ATR200740 Plunger ù 30 2
cylinders Cylinder bushings head and
2 ATR200750 Plunger ù 35 2 rod assembly.
Cylinder and rod locking on
ATR200760 Plunger ù 40 2 ATR200620

30-5
DISASSEMBLY AND ASSEMBLY SPECIAL TOOLS (For machine)

SPECIAL TOOLS
(For machine)
Nature of work Symbol Code Description Q.ty Notes

Ð Cylinder wrench ù 50 1
3 Ð Cylinder wrench ù 70 1 Head disassembly and
assembly
Ð Cylinder wrench ù95 1

4 Ð Cylinder wrench ù 95 1 Removal-installation rod

gasket nut

Ð Plunger ù 50 1
5 Pistons gaskets assembly
Disassembly and assembly G Ð Plunger ù 70 1
cylinders
Ð Bushing for rod ù 25 1
6 Ð Bushing for rod ù 40 1 Head on rod assembly
Ð Bushing for rod ù 50 1
Ð Bushing for rod ù 50 1
7 Ð Bushing for rod ù 70 1 Piston-cylinder assembly
Ð Bushing for rod ù 95 1

30-6
DISASSEMBLY AND ASSEMBLY SPECIAL TOOLS (For backhoe)

SPECIAL TOOLS
(For backhoe)
Nature of work Symbol Code Description Q.ty Notes

Disassembly of backhoe H 1 ATR201300 Tool 1 Backframe lifting

1 ATR200620 Attachment 1 Cylinders disassembly -

assembly

Ð Plunger ù 35 2
Assembly cylinder and rod
Ð Plunger ù 40 2 bushings
2
Ð Plunger ù 45 2 Cylinder and rod locking on
ATR200620
Ð Plunger ù 68 1

Ð Notched wrench for 1

cylinders ù 60
Notched wrench for
Ð cylinders ù 80 1

3 Ð Notched wrench for 1 Head disassembly-assembly

cylinders ù 85

Ð Notched wrench for 1

cylinders ù 95
Ð Notched wrench 1

Ð Socket wrench 1
(6-point 46)
4 Ð Socket wrench 1 Pistons removal-installation
(6-point 65)
Disassembly and assembly L
cylinders Ð Notched wrench 1
Ð Plunger ù 35 1
5 Ð Plunger ù 45 1 Dust seal assembly
Ð Plunger ù 50 1
Ð Plunger ù 60 1
Ð Plunger ù 80 1
6 Piston gaskets assembly
Ð Plunger ù 85 1
Ð Plunger ù 95 1
Ð Bushing for rod ù 35 1
Ð Bushing for rod ù 40 1
7 Head assembly on rod
Ð Bushing for rod ù 45 1
Ð Bushing for rod ù 50 1
Ð Bushing for piston ù 60 1
Ð Bushing for piston ù 80 1
8 Piston-cylinder assembly
Ð Bushing for piston ù 85 1
Ð Bushing for piston ù 95 1

30-7
30-8
DISASSEMBLY AND ASSEMBLY STARTER MOTOR

REMOVAL OF STARTER MOTOR

Disconnect the cable from accumulator negative
terminal (±).

1 - Raise the engine hood (1).

1

F0401241

2 - Disconnect the electrical wirings (2).

3 - Loosen screws (3) and remove starting motor (4). 3
2

3
F0401242

INSTALLATION OF STARTER
MOTOR
. To install, reverse the removal procedure.
Mounting bolt: 78.4 ± 98 Nm

30-9
DISASSEMBLY AND ASSEMBLY ALTERNATOR

REMOVAL OF ALTERNATOR
Disconnect the cable from accumulator negative
terminal (±).

1 - Raise the engine hood (1). 1

F0401243

2 - Disconnect wire (2) and connector (3).

4
3 - Loosen screws (4) (5) and (6) to let alternator (7) ro-
tate.
4 - Take out the belt (8) from pulley and remove alterna-
7
tor (7). 3

5
F0401188

INSTALLATION OF ALTERNATOR 6
. To install, reverse the removal procedure. 7
8

H Adjust fan belt tension (For details, see «20. TESTING

AND ADJUSTMENTS - Fan belt tension»).

F0401187

30-10
DISASSEMBLY AND ASSEMBLY INJECTION PUMP

REMOVAL OF INJECTION PUMP

Disconnect the cable from accumulator negative
terminal (±).
H Close the cock (1) of separator (2) to prevent fuel leak-
age.
H Plug removed or disconnected pipes to avoid impurity
entry. 1
2

F0401244

1 - Remove seat and engine hood. (For details, see «RE-

MOVAL OF SEAT AND ENGINE HOOD»).
3
2 - Remove frame rear cross-bar (3).

F0401245

3 - Disconnect and remove air-inlet pipe (4).

4 - Disconnect pipes (5) from fuel filter (6) and plug them
(No. 5 pipes). 5
H Mark the pipes to avoid exchanges during instal-
lation.
5 - Remove the fuel filter unit (6).

6
4

F0401246

6 - Disconnect from injection pump (7) fuel feeding pipes

(8) and return pipes (9).
7 - Disconnect high pressure pipes (10) from injection 10
pump.

7
9

F0401364

30-11
DISASSEMBLY AND ASSEMBLY INJECTION PUMP

8 - Remove engine oil level dipstick (11).

13
9 - Disconnect pipes (13) and (14) from fuel feed-pump 11
(12).
10 - Disconnect the engine stop solenoid (15) from injec- 12
tion pump (7) and remove the complete unit.
11 - Disconnect control cables connection from accelera-
tor lever (16).
15
16
14
F0401248

12 - Remove the bolt and bracket (17) of injection pump

lubricating pipe.
13 - Remove injection pump lubricating pipe (18).

17

18
F0401249

14 - Remove the inlet cover (19) to ignition gear system

and the filler oil plug (20).
20
19

F0401250

15 - Loosen and remove nut (21) and lock washer (22) of

pump driving gear (23).
H Be careful not to let lock washer drop in the hous-
ing. 23

22
21

F0401251

30-12
DISASSEMBLY AND ASSEMBLY INJECTION PUMP

16 - Remove pump (7) driving gear (23).

H Before removing pump driving gear, mark posi- X2
tion compared to idling gear.
16
H For removal, use a puller (X1) and tighten its
screws (X2) directly in the gear (23). 24
H Be careful not to damage pump shaft thread.
H During removal be careful not to let key drop in
the housing.
23 X1

X2 D0400967

17 - Remove nuts (24) (No. 4) and injection pump (7) with

relative OR rings.

2
24

F0401252

INSTALLATION OF INJECTION PUMP

. To install, reverse the removal procedure.

Feed and return pipes: 19.6 ± 24.5 Nm

High pressure pipes: 19.6 ± 24.5 Nm

H Replace safety cotter pin.

Lubrication pipe pump side: 9.8 ± 12.7 Nm

Lubrication pipe cylinders side: 12.7 ± 16.7 Nm
Stiffening bolt: 22.5 ± 28.4 Nm

Cover gasket: Loctite 518

Timing gear system cover bolts:17.6 ± 22.5 Nm

30-13
DISASSEMBLY AND ASSEMBLY INJECTION PUMP

Ingranaggio pompa
Injection pump gear
d'iniezione
H Align marks among gears before to install pump
and nut.
Gear lock nut: 83.3 ± 93.1 Nm

Reference
Riferimento

Idling gear folle

Ingranaggio
D0400888

Pump lock nuts: 34.3 ± 44.1 Nm

1 - Check fuel injection timing.
(For details, see «20. TESTING AND ADJUSTMENTS»).

30-14
DISASSEMBLY AND ASSEMBLY NOZZLE HOLDER

REMOVAL OF NOZZLE HOLDER

1 - Loosen clips (1) and (2) and remove high pressure

4
pipes (3) and fuel recovery pipes (4).
2

1 3

F0401253

2 - Remove collar (6) lock nut (5) and remove nozzle

holder (7), seat (8) and guard (9). 6

9
7
8
D0400887

INSTALLATION OF NOZZLE HOLDER

. To install, reverse the removal procedure.

High pressure pipe fittings: 19.6 p 24.5 Nm

Collar lock nuts: 6.9 p 8.8 Nm

30-15
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD

REMOVAL OF CYLINDER HEAD

Disconnect the cable from accumulator negative
terminal (±).
H Drain the coolant liquid.
Coolant liquid: 15 , 2
1 - Remove the seat.
(For details, see «REMOVAL OF SEAT AND ENGINE
HOOD»).
2 - Remove suction hose (1). 1
3 - Remove the fuel filter unit (2) and put it at engine
side.
F0401246

4 - Remove fan belt tension adjusting bracket (3).

18 7 8
5 - Disconnect coolant pipe (4) and heating pipe (5) from 4
cylinder head.
3
6 - Disconnect the coolant temperature sensor cables
(6).
7 - Disconnect the thermostat cable (7).
8 - Remove injectors. (for details, see «REMOVAL OF
NOZZLE HOLDER»).
6 6
9 - Remove the valve-tappets cover (8). 5
F0401254

10 - Remove the rocker shaft (9).

H Loosen lock nut and unscrew valve tappets of 2-3 9
turns.
11
11 - Remove the push rods (10).
12

10

D0401032

12 - Remove screw (11) and the cylinder head (12) follow-

ing the indicated order for bolts loosening. BOLT LOOSENING ORDER
H Bolts loosening order: see illustration
Loosen cylinder head bolts in two stages.
7 16 14 6
1 9 18 12 4

3 11 17 10 2
5 13 15 8

D0400972

30-16
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD

INSTALLATION OF CYLINDER HEAD

. To install, reverse the removal procedure.

1 - Fill the cooling circuit.

Coolant liquid: 15 ,
2 - Start engine to allow liquid circulation in all circuits;
stop the engine and check the level.

H Adjust fan belt tension (for details see «20. TEST-

ING AND ADJUSTMENTS»).

High pressure pipe fittings: 19.6 ± 24.5 Nm

Collar lock nuts: 6.9 ± 8.8 Nm

3 - Check the condition of valves cover gasket and of

lock nuts OR rings, clean carefully contact surface
on cylinders head.
Cover lock nuts: 25w3 Nm

H Check that tappets are firmly engaged in the rods

and that the valves collar are correctly as-
sembled.
H Start the rocker shaft tightening starting from the
center to external.
Rocker shaft bolts: 44.1 ± 53.9 Nm

H Adjust valves clearance.

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

H Assemble a new gasket. BOLTS TIGHTENING ORDER

H Lubricate with engine oil bolts thread and cylinder
bock.
H Tighten screws, first manually and after in two 12 5 13
3
stages, according to assigned order. 18 10 1 7 15
Cylinder head bolts.
1st Tightening: 49 ± 59 Nm 16 8 2 9 17
14 6 4 11
Final tightening: 103 ± 113 Nm

D0400973

30-17
DISASSEMBLY AND ASSEMBLY RADIATOR - OIL COOLER UNIT

REMOVAL OF RADIATOR - OIL COOLER UNIT

1 - Remove counterweight or backhoe from machine; re-

move cab lock guard too.
1
2 - Lower front bucket unit leaning on level ground and
stop the engine.
3 - Remove completely pressure from all circuits.
(For details, see «20. TESTING AND ADJUST-
MENTS»).
4 - Remove the seat and engine hood.
(For details, see «REMOVAL OF SEAT AND ENGINE
HOOD»).
5 - Remove cab cross-bar (1). F0401245

6 - Drain the engine cooling liquid loosening the plug (2)

and the breather (3).
Coolant liquid: 15 , 3

F0401255

7 - Loosen slowly the lower pipe (4) to drain oil contained

in the oil cooler.
Oil cooler oil: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 - Disconnect engine cooling pipes (5) (No. 2) and oil
5
cooler pipes (4) (No. 2); plug the pipes to avoid impur-
4
ity entry.
9 - Remove the bolts (6) of unit (No. 4)
10 - Remove clips (7) of heating pipes (8).
11 - Remove the complete radiator - oil cooler unit (9).

F0401256

6
8
7 7

F0401257 F0401258

30-18
DISASSEMBLY AND ASSEMBLY RADIATOR - OIL COOLER UNIT

INSTALLATION OF RADIATOR - OIL COOLER UNIT

. To install, reverse the removal procedure.

1 - Carry out the coolant filling.
H When level arrives to drain plug top level (3), tight-
en plug and continue to fill through auxiliary tank
(10).

Coolant: 15 ,
2 - Carry out oil tank filling up to maximum level. 10

Necessary hydraulic oil:. . . . . . . . . . . . . . . . . . . . . .

3 - Start the engine at idling to allow coolant circulation.
4 - Brake machine using the pedal brakes, engage the
F0401259

2nd forward gear and accelerate gradually the engine

until about 1700 rpm to carry out oil cooler filling and
check that there are no leaks.
5 - After about one minute stop the engine, check the
auxiliary tank level and, if necessary, restore it.
6 - Restore the tank oil level.

30-19
DISASSEMBLY AND ASSEMBLY MUFFLER

REMOVAL OF MUFFLER

1 - Loosen clip (1) and slide it on engine connection pipe

(2).
2 - Release engine connection pipe (2) and put it side-
wise.
3 - Loosen clip (3) and slide it on outlet pipe (4).
4 - Remove clips (5).
5 - Release muffler (6) from outlet pipe (4) and remove it.

INSTALLATION OF MUFFLER
. To install, reverse the removal procedure.
4

2 1
3
5
D0400956

REMOVAL OF EXHAUST PIPE

1 - Release clip (7) from cab.
2 - Loosen clip (8).
7

3 - Remove the exhaust pipe (9).

INSTALLATION OF EXHAUST PIPE

. To install, reverse the removal procedure.

F0401260

30-20
DISASSEMBLY AND ASSEMBLY SEAT AND ENGINE HOOD

REMOVAL OF SEAT AND ENGINE HOOD

Lower work attachment until leaning on level ground
and stop the engine.

2
Seat
1 - Remove seat mounting bolts (1) (No. 4).
2 - Remove the seat (2).
Seat: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

F0401241

Engine hood
1 - Open engine hood (3) and remove gas cylinder (4).
During the gas cylinder removal, keep engine hood 3
raised using safety stiffeners. 4

2 - Lower the engine hood (3).

F0401243

3 - Loosen and remove bolts (5) fixing the hinge (6).

4 - Remove engine hood (3).
6
Engine hood: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INSTALLATION OF SEAT AND

ENGINE HOOD
. To install, reverse the removal procedure.
5
F0401261

30-21
DISASSEMBLY AND ASSEMBLY SIDE COVER

REMOVAL OF SIDE COVER

Disconnect cable of accumulator negative terminal
(±). 1

1 - Remove the seat. 5

(For details see «REMOVAL OF SEAT»).
2 4
2 - Remove knob (1), rubber guard (2), stud (3) and front
bucket control cover (4).
3 - Remove parking brake guard (5). 3

F0401302

4 - Remove connection pin (6) between parking brake le-

ver (7) and cable (8). 7

5 - Remove hand accelerator unit (9).

6 - Loosen screws (10), remove cover and unthread ac- 6
celerator cable (11).
F0401262

7 - Remove cover (13) mounting bolts (12).

8 - Disarrange switches and warning lights unit (14) and 9 11
insert them inside the hole.
9 - Raise parking lever (7) and remove the cover assem-
bly (13).

INSTALLATION OF SIDE COVER

. To install, reverse the removal procedure. 10

F0401263

12
14 13

12
F0401264 F0401265

30-22
DISASSEMBLY AND ASSEMBLY HEATING RADIATOR

REMOVAL OF HEATING RADIATOR

Lower completely work attachments until leaning on
level ground and stop the engine. 1
Disconnect cable of accumulator negative terminal
(±).

Drain the coolant.

Coolant quantity: 15 ,
1 - Remove cab side cover.
(For details see «REMOVAL OF SIDE COVER»).
2 - Remove heating pipes retaining clips (1). F0401257

3 - Disconnect hoses (2) and (3) from engine and lower

the terminals to drain totally liquid from heating radia-
tor.

2 3

F0401254

4 - Remove the radiator opening cover (4).

5 - Take out the radiator (5). 4
H During extraction, couple connection hoses to en-
gine.

F0401266

INSTALLATION OF HEATING
RADIATOR
. To install, reverse the removal procedure. 5
1 - Carry out coolant filling.

Coolant: 15 ,
2 - Open heating cock and start the engine to allow cool-
ant circulation.
3 - Stop engine and restore the correct level.
F0401267

30-23
DISASSEMBLY AND ASSEMBLY CAB

REMOVAL OF CAB
Lower work attachments until leaning on level
ground and stop the engine.
1
Disconnect cable of accumulator negative terminal
(±). 2
Drain the coolant.

Coolant quantity: 15 ,
1 - Remove windshield washer (1) and cab front hood (2).

F0401268

2 - Disconnect intake hose (4) from filter (3).

3 - Disconnect brake line pipe (5).
5
H Plug pipes ends to avoid impurity entry.
3
4

F0401269

4 - Remove front bucket control hood (6).

5 - Remove parking brake guard (7).
7

F0401302

6 - Remove engine opening lock (8) and lower central

hood (9).

F0401270

30-24
DISASSEMBLY AND ASSEMBLY CAB

7 - Disconnect pipes (11) from steering unit (10).

H Mark pipes to avoid exchanges when they will be 11
reconnected.
H Plug pipes and connectors to avoid impurity entry.

10

F0401271

8 - Disconnect pipes (12) from inch valve (13).

H Plug pipes and connectors to avoid impurity entry. 13

12

F0401194

9 - Remove instrument panel (15) mounting bolts (14),

handle (16) and relative pin and front hood (18) 15
mounting bolts (17). 18

14
14

16 17
F0401272

10 - Remove instrument panel (15) and loosen central

upper bolts (19) and front hood (18) mounting side
19
bolts (20).

20

20

15

F0401273

30-25
DISASSEMBLY AND ASSEMBLY CAB

11 - Remove front cover from front cab and disconnect

lower electrical system connectors (21).

21

F0401274

12 - Disconnect from engine cables (22) and sheathings

(23) of pedal accelerator and hand accelerator. 23 22

F0401190

13 - Remove heating pipes retaining clips (24).

14 - Disconnect heating hoses (25) and (26) from the en-
gine and lower the terminals to drain totally heating
radiator fluid.
Coolant quantity: 15 ,
25
24

26
F0401275

15 - Remove cab mounting bolts (27) (No. 3 external and

No. 1 in heating fan space).

27 27

F0401276

30-26
DISASSEMBLY AND ASSEMBLY CAB

16 - Remove upper guard plugs and fit lifting eye-bolts

(28).
17 - Hook eye-bolts to lifting device and raise slowly cab
(29) for about 10 cm.
H Couple sheathings of pedal accelerator cables, of
hand accelerator and lower electrical connec-
tions. 28
29
18 - Remove the cab (29).
Cab: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

F0401277

INSTALLATION OF CAB
. To install, reverse the removal procedure.

H Bleed air from braking circuit.

(See «20. TESTING AND ADJUSTMENTS»).

H Bleed air from Load Sensing circuit.

(See «20. TESTING AND ADJUSTMENTS»).
1 - Carry out coolant filling.

Coolant: 15 ,
2 - Open heating cock and start the engine to allow cool-
ant circulation.
3 - Stop the engine and restore the level.

30-27
DISASSEMBLY AND ASSEMBLY FUEL TANK

REMOVAL OF FUEL TANK

Lower work attachment until leaning on level ground
and stop the engine.

Disconnect cable of accumulator negative terminal

(±).
H Drain the fuel. 1
2
Fuel maximum quantity: 70 ,
1 - Turn the cock (1) of separator (2).
2 - Disconnect intake and fuel return pipes (3) and (4)
from fuel tank.
H Mark pipes to avoid exchanges during installa- F0401244
tion.
H Plug pipes to avoid impurity entry.
3 - Disconnect connectors (5) from fuel level gauge (6)
and ground cable (7).
3
4 - Disconnect the hose (if fitted) from scavenge pump.
4
5 - Apply tool A1 to fuel tank (8) and connect the unit to a
lifting device.
6 - Remove bolts (9) (No. 4) and the fuel tank.
Tank:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

F0401278

7
6

F0401279

INSTALLATION OF FUEL TANK

8
. To install, reverse the removal procedure.
A1
1 - Fill up the fuel tank.

Maximum fuel capacity: 70 ,

2 - Bleed air from fuel circuit. 9
3 - Start the engine.

F0401280

30-28
DISASSEMBLY AND ASSEMBLY HYDRAULIC OIL TANK

REMOVAL OF HYDRAULIC OIL TANK

Lower work attachments until leaning on level
ground and stop the engine.

Release completely residual pressures from all cir-

cuits. (For details, see « 20. TESTING AND ADJUST- 2
MENTS»).
H Drain the hydraulic oil.
Oil quantity: 65 ,
1 - Disconnect from oil tank (1) the suction pipes (2) (low-
er), the return pipes (3) (upper) and, if fitted the return
pipes from backhoe (4). 1
H Plug pipes to avoid impurity entry. F0401281

2 - Apply tool A1 to oil tank (1) and connect it to a lifting

device.
3
Oil tank:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 - Remove bolts (5) (No. 4) and the oil tank.

F0401282

F0401247

INSTALLATION OF HYDRAULIC OIL

. To install, reverse the removal procedure.
1 - Fill up the oil tank. A1
Hydraulic oil: 65 ,
2 - Start the engine to allow oil circulation in all hydraulic 1
systems and check the seals.
3 - Bleed air from hydraulic systems.
(See «20. TESTING AND ADJUSTMENTS»).
4 - Stop the engine, check oil level in the tank and, if ne-
cessary, restore it.
F0401283

30-29
DISASSEMBLY AND ASSEMBLY ENGINE - PUMP GROUP

REMOVAL OF ENGINE - PUMP GROUP

Removal counterweight or backhoe.

Lower completely work front attachments until lean-

ing on level ground and stop the engine. 1
Disconnect cable from accumulator negative term-
inal (±).

Release completely residual pressure from all cir-

cuits. (For details, see «20. TESTING AND ADJUST-
MENTS»).
H Drain hydraulic oil.
Oil quantity: 65 , F0401189

H Drain engine coolant.

Coolant quantity: 15 ,
H Close the separator cock. 2
1 - Remove the seat and the engine hood.
(For details, see «REMOVAL OF SEAT AND ENGINE
HOOD»).
2 - Remove the lower guard (1).
3 - Remove the cab rear cross-bar (2).
4 - Remove the radiator - oil cooler unit.
(For details, see «REMOVAL OF OIL COOLER UNIT - F0401245
RADIATOR»); remove the engine connection hoses
(3).
5 - Disconnect the heating pipes (4) from engine and 18 3
plug them; disconnect temperature sensor cables (5).
6 - Disconnect air intake hose (18) from engine and re- 5
move it.
5

3
4

F0401254

7 - Remove exhaust pipe (6) between engine and muf-

fler.

D0400958

30-30
DISASSEMBLY AND ASSEMBLY ENGINE - PUMP GROUP

8 - Disconnect accelerator cables (8) from lever (7); dis-

connect engine ground cable (9). 8

F0401284

9 - Disconnect starting motor cables (10).

10 - Disconnect alternator cables (11).
10

11

F0401285

11 - Disconnect the engine stop solenoid (12) cable and

the engine oil pressure sensor (13).
13

12

F0401286

12 - Disconnect the main fuses bracket (14).

13 - Disconnect fuel return pipe (15) from fuel filter and
plug it. 15

14
F0401287

30-31
DISASSEMBLY AND ASSEMBLY ENGINE - PUMP GROUP

14 - Disconnect from fuel pump the feed pipe (16) and

plug it.
15 - Disconnect the hydraulic motor connection pipes
from hydrostatic transmission pump, the gear pump
pipes, the connection pipes to tank, to inch valve
and to solenoid unit (No. 7 pipes).
H Plug the pump pipes and connections to avoid im-
purity entry.
16 - Disconnect the travel selection magnets solenoids.
16
F0401248

17 - Hook the engine to a lifting device using lifting brack-

ets and put in tension the chains lightly.
Group weight: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

F0401548

18 - Remove the bracket engine bolts (17) (No. 4).

17

F0401288

19 - Raise slowly the unit and remove it through the rear

opening.

30-32
DISASSEMBLY AND ASSEMBLY ENGINE - PUMP GROUP

INSTALLATION OF ENGINE - PUMP GROUP

. To install, reverse the removal procedure.

H Bleed air from fuel pipes before starting the en-

gine.

H Bleed air from hydrostatic transmission circuit.

(SEE «20. TESTING AND ADJUSTMENTS»).

Engine bracket bolts: . . . . . . . . . . . . . . . . . . . . . . . .

Engine bracket bolts: . . . . . . . . . . . . . . . . . . . . . . . .
1 - Fill up the hydraulic tank until maximum level.

Necessary hydraulic oil: approx. 65 ,

2 - Fill up the cooling circuit until maximum level.
3 - Before starting the engine, bleed air from hydrostatic
circuit.
(See «20. TESTING AND ADJUSTMENTS»).
4 - Start the engine to allow oil and coolant circulation:
check that there are no leaks.
5 - Bleed the air from work attachments circuits.
(For details, see «20. TESTING AND ADJUST-
MENTS»).
6 - Stop the engine, check levels and, if necessary, re-
store them.

30-33
DISASSEMBLY AND ASSEMBLY PISTON PUMP AND STEERING PUMP

REMOVAL OF PISTON PUMP AND STEERING PUMP

Lower work attachments until leaning on level
ground and stop the engine.

Release completely residual pressures from all cir-

cuits. (For details, see « 20. TESTING AND ADJUST-
MENTS»).
H Drain the hydraulic oil.
Oil quantity: 65 , 2
1 - Remove the lower guard (1).
1
2 - Disconnect the cardan shaft (2) from rear axle and put
it sidewise.
F0401189

3 - Disconnect from hydrostatic transmission pump the

connection pipes to hydraulic motor, gear pump
pipes, connection pipes to tank, to inch valve and to
solenoid unit (No. 7 pipes).
3
H Plug all pipes to avoid impurity entry.
4 - Disconnect the travel selection magnets solenoids. 4
5 - Remove bolts (3) (No. 2) and the pump unit (4).

INSTALLATION OF PISTON PUMP

AND STEERING PUMP F0401289

. To install, reverse the removal procedure.

Universal joint lock nuts: . . . . . . . . . . . . . . . . . . . . .

Piston pump mounting bolts: . . . . . . . . . . . . . . . . .

Piston pump mounting bolts: . . . . . . . . . . . . . . . . .
1 - Fill up the hydraulic oil tank until maximum level.

Necessary hydraulic oil: approx. 65 ,

2 - Bleed air from hydrostatic and Load Sensing circuits.
(For details, see «20. TESTING AND ADJUSTMENTS»).
3 - Start the engine and move the machine towards and
backwards to check that there are no leaks.
4 - Stop the engine, check oil level in the tank and, if ne-
cessary, restore it.

30-34
DISASSEMBLY AND ASSEMBLY PISTON PUMP

DISASSEMBLY OF PISTON PUMP

1 - Loosen boosting pump (2) bolts (1) (No. 4).

Remove boosting pump (2).
H Before disassembling boosting pump (2), mark
2 1
position between pump and valve body (3).
3

D0400918

2 - Mark the adjusting screw (4) position.

Loosen screw (4) of 45ë in clockwise direction.
4

2
D0400919

3 - Loosen the bolts (5) (No. 4) and remove valves body

5
(3) using some levers.
H Be careful not to damage the machined surfaces. 3

D0400920

4 - Remove the valve plate (6) from valves body (3).

H Be careful to assembly position.
6

D0400921

30-35
DISASSEMBLY AND ASSEMBLY PISTON PUMP

5 - Using a lever, push rotating unit (7) and remove posi-

tion adjusting screw (8) of valve plate (6).
7

1
8

D0400940

6 - Take out the cylinder barrel (7), the swash plate (9),
plug (10) and pin (11).

7
9

11
10 D0400943

7 - Remove the circlip (12), seal (13) and circlip (14).

14
13
12

D0400941

8 - Take out shaft (15) with a soft hammer.

15
D0400945

30-36
DISASSEMBLY AND ASSEMBLY PISTON PUMP

9 - Remove thrust washers (16) and bearings (17).

16
16

D0400922

10 - Loosen bolts (18) and remove the travel selection unit

(19).

18

19

D0400923

11 - Loosen bolts (20) (No. 4) and remove the positioning

cylinder unit (21).

21
20

D0400924

12 - Loosen nut (22) and remove the cover (23).

23

22

D0400925

30-37
DISASSEMBLY AND ASSEMBLY PISTON PUMP

13 - Using a press and the push tool B1, remove the retai-
ner (24).
B1 24

D0400942

14 - Remove the half rings (25) (No. 2) and the circlip (26).

26

25

D0400950

15 - Remove in sequence disc (27), springs (28) and (29),

spacer (30) and disc (31).
Repeat operations of points 12, 13 and 14 for the 31
other side of the positioning cylinder. 30
29
28
27

D0400933

16 - Remove safety valves (32) (No. 2) of valves body.

32

32
D0400929

30-38
DISASSEMBLY AND ASSEMBLY PISTON PUMP

17 - Remove pressure cut valve (33) and take out from

33
valve body in following order, adjusting pin (34), 39
spring (35), adjusting pin (36), plunger (37), piston 34
(38), bushing (39), flow selection valve (40) and its 35 40
seat (41). 36 41
37
38

D0400932

18 - Remove the initial adjusting valve (42).

42

D0400930

19 - Remove plug (43) and take out from valves body max
boosting upper valve (44), seat (45) and spring (46).

46
45
44
43

D0400931

30-39
30-40
DISASSEMBLY AND ASSEMBLY PISTON PUMP

ASSEMBLY OF PISTON PUMP

1 - Install on positioning rod (47) in the following order 47

the disc (31), spacer (30), spring (29) and (28), and
disc (27). 31
30
29
28
27

D0400934

2 - Insert the unit into positioning cylinder (48) and using

a press and the push tool B1, fit half rings (25), retain- 24
ing ring (24) and circlip (26).
Repeat operations 1 and 2 for the other side of posi-
B1
tioning cylinder.
48
26

25

D0400946

3 - Install on positioning cylinder assembly (21), the cov-

er (23) and the nut (22). B
H Check that the dimension «B» is 16 mm.
21
23

22

D0400953

4 - Put positioning cylinder assembly (21) into pump body

(49) and tighten the bolts (20). 49
H Be careful to notch position at the centre of posi-
tioning cylinder.
H Lubricate on positioning piston.
21
Positioning piston: hydraulic oil
20

D0400954

30-41
DISASSEMBLY AND ASSEMBLY PISTON PUMP

5 - Install on swash plate (50) the bearings (17), lever 52

(51), the pin (52) and the connection wires (53) and
(54). 51
H Spread grease on the sliding surface to lock the
53
bearings.

50
17

54 D0400935

6 - Put into pump body (49) thrust washers (16) of bear-

ings (17).
Put the swash plate (55) into pump body (49).
H Make sure that swash plate is assembled cor- 16 55
rectly. 16
49 49

D0400926

7 - Fit the pin (11) and plug (10).

11 10

D0400927

8 - Install tool B2 into pump body (49).

B2

49

D0400957

30-42
DISASSEMBLY AND ASSEMBLY PISTON PUMP

9 - Assembly the shaft (15) into pump body (49). 14

Assembly circlip (14) into pump body (49).
15

49

D0400900

10 - Using tool B3 fit seal (13) into pump body.

Fit circlip (12).
B3
12
13

D0400906

11 - Fir into cylinder barrel (7) the piston (56) together with
plate (57).
57

56

D0400904

12 - Insert the cylinder barrel (58) into pump body (49).

49

58

D0400905

30-43
DISASSEMBLY AND ASSEMBLY PISTON PUMP

13 - Remove tool B2.

B2

D0400938

14 - With a lever lower cylinders unit and insert position

adjusting screw (8) of valve plate.
C
H Adjust screw (8) at measure «C».
Measure C: 24w0.75 mm
56
H Be careful not to damage the cylinder barrel work-
ing area.
8
8

D0400937

15 - Dowel valve plate (6) on cylinder barrel (7).

H Be careful to valve plate correct direction. 6

D0400936

16 - Fit into valve body (3) spring (46), seat (45), max
boosting upper valve (44) and plug (43). 3

46
45
44
43

D0400965

30-44
DISASSEMBLY AND ASSEMBLY PISTON PUMP

17 - Fit initial adjusting valve (42).

42

D0400930

18 - Fit into valve body the flow selection valve seat (41),
flow selection valve (40), bushing (39), piston (38), 33
39
plunger (37), adjusting pin (36), spring (35), adjusting 34
pin (34) and nut (33). 40
35
36 41
37
38

D0400932

19 - Fit the safety valves (32) (No. 2).

32

32
D0400929

20 - Fit valve body (3) on pump body and tighten bolts (5)
(No. 4). 3 5
H Align marks carried out before disassembly on
valve plate position adjusting screw.

D0400951

30-45
DISASSEMBLY AND ASSEMBLY PISTON PUMP

21 - Install the boosting pump (2).

H Align marks carried out before disassembly. 2

D0400901

22 - Install travel selection unit (19) and tighten bolts (18).

18

19

D0400902

30-46
DISASSEMBLY AND ASSEMBLY ENGINE-PUMP COUPLING JOINT

REMOVAL OF ENGINE-PUMP COUPLING JOINT

Lower completely work attachments until leaning on
level ground and stop the engine.
1
1 - Remove the piston pump.
(For details, see «REMOVAL OF PISTON PUMP»).

Half joint on pump

2
2 - Loosen dowel pin (1) fixing half joint (2) in more
stages and alternatively.
H Heat dowel pins to 85 ± 100 ëC.
3 - Remove pump half joint (2). 3
F0401290
H If necessary, use a puller.

Half joint on flywheel

4 - Remove bolts (3) and flywheel cover (4). 5
5 - Remove bolts (5) and drive flange (6).

6
F0401291

INSTALLATION OF ENGINE-PUMP
COUPLING JOINT
. To install, reverse the removal procedure.

Pump half joint mounting bolts: . . . . . . . . . . . . . .

Pump half joint mounting bolts: . . . . . . . . . . . . . .

Flywheel cover bolts: . . . . . . . . . . . . . . . . . . . . . . . .

Flywheel cover bolts: . . . . . . . . . . . . . . . . . . . . . . . .

Drive flange bolts: . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drive flange bolts: . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 - Bleed air from hydrostatic circuit.

(See «20. TESTING AND ADJUSTMENTS»).
2 - Start the engine to allow oil circulation in all systems
and check the seals.
3 - Bleed air from all hydraulic systems.
(See «20. TESTING AND ADJUSTMENTS»).
4 - Stop the engine and, if necessary, restore oil level in
the tank.

30-47
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR

REMOVAL OF TRAVEL MOTOR

Lower completely work attachments until leaning on
level ground and stop the engine. +
Release completely residual pressures from all cir-
cuits. (For details, see «20. TESTING AND ADJUST- --
MENTS»).
1 - Remove the accumulator (1).
H Disconnect first the cable from negative (±) term-
inal and then positive terminal (+).

1
F0401292

2 - Disconnect from motor (2) connection pipes (3) to

pump and drain pipes (4). 4
H Plug the pipes to avoid impurity entry.
3 - Disconnect travel direction (5) and additional piloting 3 7
(6) magnet solenoids.
H Mark the positions to avoid exchanges during in-
stallation.
4 - Remove bolts (7) and motor (2). 4
Motor: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
F0401214

INSTALLATION OF TRAVEL MOTOR

4
. To install, reverse the removal procedure.

3 3
H Before to start the engine, bleed the hydrostatic
circuit.
(For details, see «20. TESTING AND ADJUST-
MENTS»).

F0401294

Motor mounting bolts: . . . . . . . . . . . . . . . . . . . . . . . .

Motor mounting bolts: . . . . . . . . . . . . . . . . . . . . . . . .
1 - Fill up the tank until maximum level.
2 - Start the engine and move the machine towards and
backwards to check that there are no leaks.
3 - Stop the engine, check tank level and, if necessary, 5
restore it.
6

F0401295

30-48
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR

DISASSEMBLY OF TRAVEL MOTOR

1 - Remove circlip (1) and spacer (2).

1

D0400903

2 - Install two screws in gasket (3) holes and extract it

using pliers.

D0400948

3 - Remove oil exchange valve (4).

4

D0400916

4 - Remove recognition of travel direction device and

automatic displacement device (5), guide pin (6),
spring (7), bushing (8) and spring (9).

8
7
5 6
D0400917

30-49
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR

5 - Set the motor on a work bench, mark measure «A» of

minimum displacement adjusting screw (34) and re-
move it. A

34

D0400969

6 - Push positioning piston (10) until to bring the cylinder

barrel to position zero. 10
H Mark the measure «B» of maximum displacement
adjusting screw.

D0400968

7 - Mark position between motor case (11) and displace-

ment adjusting case (12), and after removed bolts 12 13
(13) (No. 8) remove the adjusting case.

11

D0400939

8 - Remove screw (14) and piston (15) complete with

gaskets. 15 16
Loosen locking screw (16) and positioning pin (17).
H For an easy removal, make a pin (17) and screw
(16) heating at about 120 ëC.

14
17
D0400970

30-50
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR

9 - Stop with threaded pin (18) a washer (19) and a nut

(20) the cylinder barrel in zero position. 20
Remove maximum displacement adjusting screw 19
(21).
18
H Threaded pin: M5x71

21

D0400907

10 - Using a puller, remove the complete swing unit (22).

22

D0400912

11 - Tighten the complete swing unit into a vice and re-

move nut (20), washer (19) and threaded pin (18). 20
Remove cylinder barrel (23).
H Use a vice provided with soft jaws.
19
18

23

D0400913

12 - Loosen mounting bolts (24) of valve plate (25).

24

25
D0400911

30-51
30-52
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR

ASSEMBLY OF TRAVEL MOTOR

1 - Tighten the swing unit (26) in a vice and install pis-

tons (27), valve plate (25) and screws (24).

24

27

26 25

D0400908

2 - Install cylinder block (23).

H Check that all components are oriented correctly
and in the right position.

D0400966

3 - Block cylinder block (23) in vertical position using the

threaded pin (18), and washer (19) and nut (20).
H Threaded pin: M5X71
23

D0400909

4 - Install tool C1 on swing unit (22).

22
C1

D0400975

30-53
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR

5 - Heat the motor case (11) at 80 ëC and insert complete

swing unit.

11

D0400971

6 - Lock cylinder barrel in zero position using maximum

displacement adjusting screw (21).
Loosen nut (20) used to lock cylinder barrel and re-
move washer (19) and threaded pin (18).
Install O-ring gasket (28).
28
21

D0400947

7 - Set valve plate (29) on cylinder barrel (23) and dowel

it with dowel pin of tool C2.

29

23
8 - Prepare tool C2 assembling the travel motor compo-
nents as shown in the illustration.
D0400949

452010 452269
083105

Posizioni
Useful
position
utili per
C2
for detail
particolari
452271
452271
083010

452269 452271
452021
D0400976
452014
D0400963

30-54
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR

9 - Assemble and set tool C2 on motor case (11).

Check and bring to zero dial gauge when knob has
been rotated in counterclockwise direction till end of C2
stroke.

11

D0400962

10 - Rotate the knob for 4 turns in clockwise direction and

make sure with a caliper that the dial gauge has a
clearance of 2 mm and that pointer is in zero position.
H This is the starting zero for checking.

D0400548

11 - Rotate the knob in clockwise direction till end of

stroke and check the central pin (30) clearance value
that corresponds to dial gauge indicated value.
H Pin clearance: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C2
H If central pin clearance is not within the tolerance,
replace springs guide plate (31).
30 31
11

D0400964

12 - Remove tool C2.

30-55
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR

13 - Assemble positioning piston (32) into the displace-

ment adjusting case (12). 32 16
Assemble the positioning pin (17) and locking bolt
(16).
H Use a new locking bolt.
H Tighten the bolt to recommended tightening tor-
que.

17
D0400977

14 - Assemble rings (33) into the piston (15).

Assemble complete piston on positioning piston (32)
and tighten the bolt (14).
33
H Assemble rings (33) with opposed notch. 15
14

D0400914

15 - Assemble displacement adjusting case (12) on pump

case (11) and tighten mounting bolts (13) (No. 8). 12 13
Restore the measures «A» and «B» of maximum (21)
and minimum (34) displacement adjusting bolts.
H Align marks made on pump case and on displace-
ment adjusting case before the disassembly.
11

D0400939

16 - Assemble the spring (9), bushing (8), spring (7), guide

pin (6) and the recognition travel direction device (5).

8
7
5 6
D0400917

30-56
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR

17 - Assemble the oil exchange valve (4).

4

D0400916

18 - Using tool C3, fit the gasket (3), spacer (2) and circlip
(1).

1 2
3

D0400978

30-57
DISASSEMBLY AND ASSEMBLY STEERING PUMP

REMOVAL OF STEERING PUMP

Lower completely the work attachments until leaning
on level ground and stop the engine.

Release completely residual pressure from all cir-

cuits. (For details, see «20. TESTING AND ADJUST-
MENTS»). 2
1 - Disconnect suction and delivery pipes (2) from pump
(1).
2 - Remove bolts (3), pump (1) and relative O-ring (4).
1 2
F0401378

INSTALLATION OF STEERING
PUMP
. To install, reverse the removal procedure.

Pump mounting bolts: . . . . . . . . . . . . . . . . . . . . . . . . 4

Pump mounting bolts: . . . . . . . . . . . . . . . . . . . . . . . .
3 D0400974

1 - Bleed the load sensing circuit.

(See «20. TESTING AND ADJUSTMENTS»).

30-58
DISASSEMBLY AND ASSEMBLY STEERING GEAR PUMP

DISASSEMBLY OF STEERING GEAR PUMP

H During disassembly, be careful not to damage ma-

chined surfaces.
2
1 - Set pump on a flat surface and lock it with two bolts
(1).
Suction
Aspirazione
2 - Mark with a line (A) the two pumps sections. 1
3 - Loosen bolts (2) and remove them with relative
washers.

F0401529

4 - Turn over the pump and, using a plastic hammer,

beat alternatively under the flange - cover (3) until re-
lease it from bushings (4).

3
4

F0401541

5 - Remove flange - cover (3) leaving gears (5) and thrust

washers into pump case (6).
3

6
F0401542

6 - Remove the upper thrust washer (7).

H Take note of assembly direction and orientation.
7

Delivery
Lato side
mandata

F0401543

30-59
DISASSEMBLY AND ASSEMBLY STEERING GEAR PUMP

7 - Remove the gears (5).

F0401544

8 - Remove the lower thrust washer (8).

H Take note of assembly direction and orientation. Delivery
Lato side
mandata

9 - Remove from all the units the gasket that must be re-
placed at each disassembly.

F0401532

30-60
DISASSEMBLY AND ASSEMBLY STEERING GEAR PUMP

ASSEMBLY OF STEERING GEAR PUMP

H Clean perfectly all parts and, before movable parts as-

sembly, lubricate them lightly. 2 3
1 - Assemble on flange - cover (1) the output shaft seal
(2).
H Use a press and a push tool. 3
H Grease the ring external surface.

Ring: ASL800050
H Check carefully seal assembly orientation. 2
1
2 - Assemble retainer (3). F0401533

3 - Assemble into the thrust bearing (4) the gasket (5)

checking that the extrusion profile seat is turned to-
wards outside.
5

4
F0401534

4 - Assemble the extrusion profile (6) into the gasket seat

(5).
6
H Make sure that profile is fully inserted.

5
F0401535

5 - Spread with grease gaskets side and assemble the

lower thrust bearing (4) into the pump case (7).
Delivery side
Lato mandata
H Check carefully exhaust orientation.

Thrust bearing: ASL800050

4

7
F0401532

30-61
DISASSEMBLY AND ASSEMBLY STEERING GEAR PUMP

6 - Assemble the gears (8).

9
7 - Assemble the upper thrust washer (9). 8

F0401545

8 - Assemble O-ring (10) into flange - cover (1) seat.

H To keep O-ring in its seat, lubricate the seat with
grease ASL800050. 10

F0401546

9 - Assemble flange - cover (1) on pump case (7).

H Lubricate the internal portion of flange - cover
seal. 1
Seal: ASL800050
H Hit flange - cover with a plastic hammer until let it
hit on pump case.
H Check that the contact surfaces are totally con-
nected.
7

F0401542

10 - Lock the group with bolts (11) and relative washers.

H Tighten the bolts following the locking cross meth-
od. 11
Bolts: 71.5 Nm
11 - Check drive shaft rotation to assure the gaskets cor-
rect position.

F0401537

30-62
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT PUMP

REMOVAL OF WORK EQUIPMENT PUMP

Lower completely the work attachment until leaning
on level ground an stop the engine. 2
Release completely the residual pressures from all
circuits. (For details, see «20. TESTING AND AD-
JUSTMENTS»).
1 - Disconnect the suction and delivery pipes (2) from 1
pump (1).
2 - Remove the bolts (3), pump (1) and relative O-ring (4).

3
F0401296

1
4

D0400889

INSTALLATION OF WORK
EQUIPMENT PUMP
. To install, reverse the removal procedure.

Pump mounting bolts:. . . . . . . . . . . . . . . . . . . . . . . .

Pump mounting bolts: . . . . . . . . . . . . . . . . . . . . . . .
1 - Bleed air from work equipment hydraulic circuit.
(See «20. TESTING AND ADJUSTMENTS»).

30-63
DISASSEMBLY AND ASSEMBLY BRAKE PUMP

REMOVAL OF BRAKE PUMP

Lower completely the work attachment until leaning
on level ground and stop the engine.

Disconnect the cable from accumulator negative

terminal (±).

1 - Remove the front hood (1). 1

F0401268

2 - Disconnect the connectors (2), windshield washer

hose (3) and remove windshield washer tank (4).
4

2
3

F0401297

3 - Disconnect from oil tank cover (5) the connectors (6)

for oil level warning lamp. 6
5
4 - Disconnect the pressure switch (8) from T-union (7).
7

5 - Remove the bolts (9) and the brake pump (10). 9

8
10
INSTALLATION OF BRAKE PUMP
F0401221
. To install, reverse the removal procedure.

H Carry out air bleeding from braking circuit.

(For details, see «20. TESTING AND ADJUSTMENTS»).

H Make sure that the strut hits piston seat center.

H After the installation, check the brake pedal idle
stroke. (For details, see»20. TESTING AND ADJUST-
MENTS»).

30-64
 TRANSMISSION-REVERSE, DIRECTION INDICATOR
DISASSEMBLY AND ASSEMBLY AND HEADLIGHT DIPPER BEAM CONTROL GROUP

REMOVAL OF TRANSMISSION-REVERSE, DIRECTION INDICATOR

AND HEADLIGHT DIPPER BEAM CONTROL GROUP
Lower completely the work attachment until leaning
on level ground and stop the engine.
1
Disconnect cable from accumulator negative term-
inal (±).

1 - Remove steering wheel central cap (1).

2 - Remove the retaining nut (2) and relative washer; re-
move the steering wheel (3). 2

3
F0401298

3 - Remove the connection bolts (4) (No. 4) of switches

units (5) and (6).

6
5

F0401299

4 - Remove the right half clamp (7).

5 - Open the door of gear case and disconnect the
switches connectors (8) and (9).
6 - Remove the switches units (5) and (6) complete with 11
guard cowling (10).

INSTALLATION
F0401300

. To install, reverse the removal procedure.

5

Steering wheel retaining nut:. . . . . . . . . . . . . . . . . 8

9
H Check that dowel (11) is fully connected into the
steering column and that transmission-reverse 10
gear control unit is perfectly sticking to the steer-
ing column. 6

F0401301

30-65
DISASSEMBLY AND ASSEMBLY STEERING UNIT

REMOVAL OF STEERING UNIT

Lower completely the work attachment until leaning
on level ground and stop the engine.

Disconnect cable from accumulator negative term-

inal (±).

Release completely the residual pressures from all 1

circuits. (For details, see «20. TESTING AND AD-
JUSTMENTS»).
1 - Remove the transmission-reverse, direction indicator
and head light dipper beam control group.
(For details, see «REMOVAL OF TRANSMISSION-
REVERSE, DIRECTION INDICATOR AND HEAD- F0401199

LIGHT DIPPER BEAM CONTROL GROUP»).

2 - Remove the central hood (1) under the steering
wheel.
3 - Disconnect the hoses (2) (No. 5) from steering unit
and plug them.
4
H Mark positions to avoid exchanges when they will
be reconnected.

F0401271

4 - Remove the bolts (3) and the steering unit (4).

F0401303

INSTALLATION OF STEERING UNIT

. To install, reverse the removal procedure.

H Bleed Load Sensing circuit.

(For details, see «20. TESTING AND ADJUSTMENTS»).
H Start the engine an carry out some complete steerings
to bleed air from steering system.

30-66
DISASSEMBLY AND ASSEMBLY STEERING UNIT

DISASSEMBLY OF STEERING UNIT

Steering unit casing disassembly
1 - Loosen and remove cover (2) mounting bolts (1) and 3
(3) (No. 6 bolts plus one special). 1

F0400533

2 - Remove the cover (2) and make it slide sidewise.

F0400534

3 - Raise the swing meetering unit (4) complete of O-

Rings (34). Remove also the spacer (5).
4

5
34

F0400535

4 - Remove the cardan shaft (6).

F0400536

30-67
DISASSEMBLY AND ASSEMBLY STEERING UNIT

5 - Remove the timing plate (7).

F0400537

6 - Remove the safety valve lock bushing (8).

F0400538

7 - Remove the O-ring (9).

F0400539

8 - Take out the check valve ball (10), and the anticavita-
tion valves pins (11) and balls (12).

11

10

12

F0400540

30-68
DISASSEMBLY AND ASSEMBLY STEERING UNIT

9 - Checking through the spool central hole, set horizon-

tally the spool-bushing connection dowel.
Push the complete unit (13) and the complete bearing 13
until extract them from steering unit case (14).

14

F0400541

10 - Remove from spool the outer ring (15), inner ring (16)
and roller-bearing (17); remove also the ring (33).
H Inner ring (16) (thin) sometimes can remain into
steering unit case (14); make sure that it will be re-
moved. 33

16

15 17

F0400542

11 - Remove the drive pin (18), the bushing (19) and the
spool (20).
H Use the cover mounting special bolt (3). 19
3

18

20

F0400543

12 - Unthread slowly the spool (20) from bushing (19).

20

19

F0400544

30-69
DISASSEMBLY AND ASSEMBLY STEERING UNIT

13 - Push in neutral position the springs (21) and take

them out from spool (20).
21

20

F0400545

14 - Remove dust seal (22) and compound seal (23) (O-

Ring + gasket).
23
22

F0400546

15 - Remove the anti-shock valves plugs (24).

24

F0400547

16 - Remove the gaskets (25).

25

F0400548

30-70
DISASSEMBLY AND ASSEMBLY STEERING UNIT

17 - Remove the setting screws (26) (6 mm hexagonal

wrench).

26

F0400549

18 - Take out the springs (27) and the two balls (28).
H Valve seats are blocked into the steering unit case
and it is impossible to remove them.

27

F0400550

19 - Check that disassembly is the one shown in the illus-

tration. 26
25
27

28 24

27 25
26
F0400551

Safety valve removal

20 - Remove the plug (29) and relative gasket (30) (8 mm
hexagonal wrench).

29

30

F0400552

30-71
DISASSEMBLY AND ASSEMBLY STEERING UNIT

Safety valve disassembly

21 - Remove the main relief valve (31) and relative gasket
(32).
31 32
22 - Check that the steering unit is fully disassembled.

REMARKS
Cleaning
H Clean all components with an aliphatic solvent (miner-
al resin or similar).

Inspection and replacement

F0400553
H Replace all gaskets and seals.
H Check all parts and replace those that could create
operating doubts.

30-72
DISASSEMBLY AND ASSEMBLY STEERING UNIT

ASSEMBLY OF STEERING UNIT

H Before assembly, lubricate all components with

hydraulic oil.
1 - When assembly the spool (20) and bushing (19), only
a
one of possible orientations is correct.
Assemble with the bushing (19) three holes (a) oppo- 20
site to spool (20) grooves (b). 19
Check that some of bushing holes are visible through
spool (b) grooves.
b

F0400554

2 - Put the two flat springs (21a) into the seat and set
them compared to spool diameter (20). Insert be-
tween the two flat springs (21a) the four curved
springs (21b) arranged in pairs and push until intro-
duce them completely.

21a
20
21b

F0400555

3 - Align the springs (21).

21

F0400556

4 - Insert the spool (20) in the bushing (19).

H Make sure that position between bushing and
spool is the one as described in assembly stage 1. 20

21 19

F0400557

30-73
DISASSEMBLY AND ASSEMBLY STEERING UNIT

5 - Push at the same time the springs (21) and spool (20)
until engaging the springs in bushing (19) seat.
21

20

19

F0400558

6 - Align the springs (21) between them and set com-

pared to bushing (19) diameter.
21

19

F0400559

7 - Install the ring (33) into the bushing (19) seat.

H The ring (33) must be free to rotate without inter-
fering with springs (21).
19

33

F0400560

8 - Insert the drive dowel (18).

18

F0400561

30-74
DISASSEMBLY AND ASSEMBLY STEERING UNIT

9 - Assemble the thrust bearing according to scheme

shown at point 10.

16

17

15

F0400562

10 - Scheme of bearing assembly.

15 - Outer ring 16
16 - Inner ring
17
17 - Needle bearing
19 - Bushing 15
20 - Spool

20

19
D0400464

11 - Arrange the steering unit case (14) with horizontal

hole. Insert into the bushing/spool unit hole the tool
D1 guide.
14

D1

F0400563

12 - Lubricate the seal (23a) and O-ring (23b) and assem-

ble them on tool D1 strut.

23a D1
23b

F0400564

30-75
DISASSEMBLY AND ASSEMBLY STEERING UNIT

13 - Assemble tool D1 and put it in the guide previously

inserted into the steering unit hole.

23
D1

F0400565

14 - Push the gasket (23) into the steering unit case (14)
seat favouring setting with light rotations.

14

F0400566

15 - Take out tool D1 and guide from steering unit case

(14) leaving the gasket strut in position.

14

F0400567

16 - Insert into the steering unit (14) hole the bushing/

spool unit (13).
Easy introduction is obtained making light rotations.
H Insert the unit keeping the drive dowel in horizon-
tal. 13

14

F0400568

30-76
DISASSEMBLY AND ASSEMBLY STEERING UNIT

17 - Push the unit (13) till his end of stroke to exit the strut
left in position in stage 15.

14

13

F0400569

18 - Rotate the steering unit case (14) until bringing cen-

tral hole in vertical position.
Insert the ball (10) of safety valve into the hole as
shown by the arrows.
10

14

F0400570

19 - Tighten the valve stop bushing (8) into the safety

valve hole.
H The retaining upper bushing side must be lower
than steering unit case (14) plane.
8

14

F0400571

Anti-cavitation valves assembly

20 - Insert the balls (12) into the two holes shown by ar-
rows.
12

F0400572

30-77
DISASSEMBLY AND ASSEMBLY STEERING UNIT

21 - Insert the dowels (11) in same holes.

11

F0400573

22 - Lubricate O-ring (9) and assemble it in the seat.

Mineral oil: viscosity about 500 cSt a 20ëC
9

F0400574

23 - Set the distribution valve plate (7) making holes corre-

spond with those of steering unit case (14).
7

14

F0400575

24 - Insert the cardan shaft (6) into the hole and engage it
with drive dowel; check that engagement with dowel
is parallel to connection surface of steering unit to
6
steering column.

F0400576

30-78
DISASSEMBLY AND ASSEMBLY STEERING UNIT

25 - Put cardan shaft in vertical position and keep the po-

sition using tool D2.

D2

F0400577

26 - Lubricate the two O-rings (34) and assemble them in

the two seats of ring gear metering unit (4).
Assemble the metering unit on cardan shaft (6).
Mineral oil: viscosity about 500 cSt a 20ëC 4 34

F0400578

Rotor setting
27 - Install the rotor (4a) on cardan shaft (6) so that the
bottom of a rotor tooth corresponds to cardan shaft
spline.
Rotate the external gear (4b) to align the locking 6
holes.

4a

F0400579

28 - Install the spacer (5).

4b

F0400580

30-79
DISASSEMBLY AND ASSEMBLY STEERING UNIT

29 - Assemble the cover (2).

30 - Insert the special bolt (3) complete with washer into

the hole shown in the illustration.

F0400582

31 - Insert the 6 bolts (1) complete with washer.

Tighten the bolts (1) in cross sequence with a tighten-
ing torque of 30w6 Nm.

F0400583

32 - Set the dust seal (22) into the steering unit case (14).

22

14

F0400584

30-80
DISASSEMBLY AND ASSEMBLY STEERING UNIT

33 - Press the dust seal (22) into the steering unit case
using tool D3 and a plastic hammer.
D3

22

F0400585

34 - Close the hydraulic connection holes with plastic

plugs to avoid impurity entry.
H Push plugs by hand without to use the hammer.

F0400586

Main relief valve assembly

35 - Assemble the gasket (32) on main relief valve (31)
and tighten the cartridge into the steering unit case
(14) using an hexagonal spanner of 12 mm. 31
Cartridge: 50w1 Nm
14

32

F0400587

36 - Tighten the plug (29) complete with gasket (30) using

an hexagonal spanner of 8 mm.
Plug: 50w1 Nm

29

30

F0400588

30-81
DISASSEMBLY AND ASSEMBLY STEERING UNIT

Anti-shock valve assembly

37 - Insert anti-shock valves balls (28) into the holes shown 28
by the arrows.

F0400589

38 - Insert into the holes the anti-shock valves spring (27).

27

F0400590

39 - Tighten into the holes the adjusting screws (26) of set-

ting pressure.
26

F0400591

40 - Assemble on locking plugs (24) the seals (25) and

tighten all into the two holes of anti-shock valves.
(6 mm hexagonal wrench). 24
Plugs: 30 Nm

25

F0400592

30-82
DISASSEMBLY AND ASSEMBLY PRIORITY VALVE

REMOVAL OF PRIORITY VALVE

Lower completely the work attachments until leaning
on level ground and stop the engine. 2

Release completely the residual pressure from all

circuits. (For details see, «20. TESTING AND AD- 3
JUSTMENTS»).
5
1 - Disconnect from priority valve (1) the pipes (2), (3)
and (4) and the union (5) complete with pressure out-
let.
H Plug all pipes to avoid impurity entry. 4
6
2 - Remove the bolt (6) and the valve (1).
F0401217

D0400915

INSTALLATION OF PRIORITY VALVE

. To install, reverse the removal procedure.
1 - Start the engine and bleed air from loading sensing
circuit.
(See, «20. TESTING AND ADJUSTMENTS»).

30-83
DISASSEMBLY AND ASSEMBLY PRIORITY VALVE

DISASSEMBLY OF PRIORITY VALVE

1 - Loosen the plug (1) (hole PP) and remove it with rela-
tive aluminium gasket.
2 - Loosen the plug (2) (hole LS).
2
3 - Remove the plug (2) complete with aluminium gasket
and spring (3).
4 - Using a nylon push tool take out the spool (4).
3

ASSEMBLY OF PRIORITY VALVE

H Before the assembly:
1 - Washer parts carefully with kerosene or similar
products.
2 - Make sure that spool neck is clean.
3 - Lubricate the parts before the assembly.
4 - Replace the aluminium gasket.
1 - Insert the spool (4) keeping it trued with nylon push 1 4
tool.
2 - Tighten in the hole PP, the plug (1) complete with alu-
minium gasket.
D0400522

3 - Tighten into the hole LS, the plug (2) complete with
aluminium gasket and spring (3).
4 - Tighten completely and in sequence, the plug (2) and
plug (1).
Plugs (1) and (2): 50w10 Nm

30-84
DISASSEMBLY AND ASSEMBLY FRONT EQUIPMENT CONTROL VALVE

REMOVAL OF FRONT EQUIPMENT CONTROL VALVE

Lower completely the work attachments until leaning
on level ground, stop the engine and remove the 1
starting key.

Release completely the residual pressure from all

circuits. (For details, see «20. TESTING AND AD- 2 4
JUSTMENTS»).
1 - Remove the knob (1), the rubber guard (2), the stud
(3) and the front control bucket hood (4). 3

F0401302

2 - Disconnect from control valve all pipes, of pump de-

livery and exhaust pipes.
H Mark pipes to avoid position exchange when they
will be reconnected. 5
3 - Disconnect the control rods (5) from spools.
6
4 - Remove the control valve mounting bolts (6) (No. 3).
5 - Remove the control valve (7). 7

F0401304

INSTALLATION OF FRONT
EQUIPMENT CONTROL VALVE
. To install, reverse the removal procedure.
1 - Start the engine to allow oil circulation 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.

30-85
DISASSEMBLY AND ASSEMBLY FRONT AXLE

REMOVAL OF FRONT AXLE

1 - Steer completely towards left, lean the front bucket

on level ground and stop the engine.
2 - Remove the cardan shaft (1).
3 - Start the engine and push the front bucket till end of
stroke to raise the machine and the front wheels.

F0401305

4 - Set under the machine a stand (A) and some blocks

(B).
5 - Lower machine slowly on blocks (B) checking that
wheels are raised from level ground.
6 - Stop the engine and eliminate the residual pressures B
from all circuits. (See, «20. TESTING AND ADJUST-
MENTS»).
Disconnect cable from accumulator negative term-
inal (±). C
A
F0401306

7 - Using dynamometric spanner E, remove the front

wheels (2).
Wheels: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2
F0401307

8 - Remove the travel hydraulic motor (3).

(See «REMOVAL OF TRAVEL MOTOR»).
4
9 - Disconnect the transmission sensors (4) and (5).
5
10 - Disconnect control pipes (6) from transmission and
plug them to avoid impurity entry; plug also the holes 3
on transmission. 6
H Mark pipes to avoid exchange when they will be
reconnected.

F0401215

30-86
DISASSEMBLY AND ASSEMBLY FRONT AXLE

11 - Put under the axle and transmission a jack (C) and

some blocks (D) as shown in the illustration; raise un-
til forcing side blocks under the axle arms and lean
central blocks under the transmission.
H Release the nuts and the axle mounting plates.
H The jack must complete a down stroke of about 15
cm.

D
F0401306

12 - Remove the lock nuts (7), the plates (8) and bolts (9).
H Loosen the nuts in two stages and following the
cross method.
13 - Let go down the jack (C) until releasing the axle (10)
from the frame. 9

14 - Take out the complete axle (10).

8

10
7
INSTALLATION OF FRONT AXLE
F0401308

. To install, reverse the removal procedure.

Cardan shaft lock nuts: . . . . . . . . . . . . . . . . . . . . . .

Wheel nuts: 245w20 Nm

Axle mounting lock nuts: . . . . . . . . . . . . . . . . . . . . .

H Tighten in two stages following the cross method.
1 - Check the level in the tank and start the engine.

30-87
DISASSEMBLY AND ASSEMBLY REAR AXLE

REMOVAL OF REAR AXLE

1 - Remove the counterweight or, if fitted, the backhoe.

2 - Using lower hooks of counterweight and backhoe,
raise the machine until to lift from level ground the
rear wheels of about 15cm.
3 - Set a stand (A) and some blocks (B) under the rear B
cross-bar.
4 - Lower machine slowly on blocks (B) checking that
wheels are raised from level ground. A
5 - Start the engine, lean on level ground the front bucket
and stop the engine. F0401309

Release completely the residual pressures from all

circuits. (For details, see»20. TESTING AND AD-
JUSTMENTS»).
6 - Using a dynamometric spanner E, remove the wheels
(1).
Wheels: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1
F0401310

7 - Disconnect the cardan shaft (3) from rear axle (2).

4 5
8 - Disconnect from axle the parking brake control cable
(4).
9 - Disconnect brake system pipe (5) and plug it to avoid
impurity entry; plug also the union remained on axle. 2

3
F0401223

10 - Disconnect the pipe (6) for differential locking and

plug it to avoid impurity entry; plug also the union re-
mained on axle.

F0401311

30-88
DISASSEMBLY AND ASSEMBLY REAR AXLE

11 - Settle under the axle (2) a jack (C) and some blocks
(D) as shown in the illustration; raise until forcing
the blocks under the axle. 2
H Release nuts (7) and axle mounting plates (8).
H The jack must make a down stroke of about 15 cm.

C
D
F0401309

12 - Remove the lock nuts (7), the plates (8) and the bolts
(9).
H Loosen the nuts in two stages and following the
cross method. 9
13 - Let go down the jack (C) until to release the axle (2)
from the frame.
8

14 - Take out the complete axle (2).

7
F0401312

INSTALLATION OF REAR AXLE

. To install, reverse the removal procedure.

Cardan shaft lock nuts: . . . . . . . . . . . . . . . . . . . . . .

Wheel nuts: 245w20 Nm

H Adjust the parking brake lever travel.

(See «20. TESTING AND ADJUSTMENTS»).

H Bleed the air from brake circuits.

(See «20. TESTING AND ADJUSTMENTS»).

H Bleed the air from differential locking circuit.

(See «20. TESTING AND ADJUSTMENTS»).

Axle mounting lock nuts: . . . . . . . . . . . . . . . . . . . . .

H Tighten in two stages following the cross locking
method.
1 - Check the level in the tank and start the engine.
2 - Bleed the brake and a differential locking circuits.
(See «20. TESTING AND ADJUSTMENTS»).

30-89
DISASSEMBLY AND ASSEMBLY AXLES

DISASSEMBLY OF AXLES
1. Final reduction gear
(For front and rear axle)
1 - Loosen the bolts (1) and remove the planet carrier (2). 2
1

F0401410

2 - Remove the circlip (3).

Using a press, remove pins (4); remove side gears (5)
complete with roller-bearings and thrust washers. 3

4
5
F0401411

3 - Remove the axle shaft (6) and loosen the bolts (7) (No. 8).

6
7

F0400595

4 - Using a puller, remove the ring gear (8) and wheel

hub (9).
H As contact face for puller, use ring gear mounting
bolts lightly tightened and a plate. 8 9

F0400596

30-90
DISASSEMBLY AND ASSEMBLY AXLES

5 - Remove the bearing (10) with a puller. Remove seal

(11). 11 10

F0400597

6 - Using a puller, remove from shaft the seal (12) and

ring (13).

12 13
F0401412

2. Brakes (only for rear axle)

14
1 - Loosen the nuts (14) (No. 16) of each side and remove 15
axle housing assembly (15).
Loosen the nuts (16) (No. 3) of each side.

16
F0401549

2 - Remove the adjusting bolts (17) (No. 3).

Remove the thrust plate (18). 18

17
F0401413

30-91
DISASSEMBLY AND ASSEMBLY AXLES

3 - Remove the clutch discs (19) and (20).

20
H If discs don't need to be replaced, remove the
complete set without changing the discs position. 19

F0401414

4 - Supply compressed air and take out the pistons (22)

from intermediate cover (21).

21

22

F0401415

5 - Remove the thrust ring (23) and O-ring (24) from pis-
tons (22). 24 23

D0400979

3. Differential locking
(Only for rear axle) 14 15 27 27
1 - Loosen the nuts (14) (No. 16) and remove the right
axle housing assembly (15).
Loosen the nut (25) and remove the fork (26) and cov-
er (27).

26
25

F0401416

30-92
DISASSEMBLY AND ASSEMBLY AXLES

2 - Remove the studs (28) (No. 2 horizontal and opposite)

and the intermediate cover (21). 28 21

F0401417

3 - Loosen the ring nut (29) and remove the spring (30).
Loosen the cylinder (31) complete with piston (32).
29
32

31
F0401418

4 - Remove the piston (32) and O-ring (33).

32 31

30 D0400980

30-93
DISASSEMBLY AND ASSEMBLY AXLES

4. Differential unit

36 48
45

40 41
39
42
46 48
45
47 41 43
38
44 36
43
48 45 45 39
40
48

37
D0400981

1 - Remove the axle housing assembly. (See «2. Brakes»).

Remove the studs (28) (No. 2 horizontal and opposite
for each side).
28

F0401419

2 - Only for rear axle

Remove the intermediate covers (21).
Remove differential unit assembly (35).
21 35
H Be careful not to damage the sealing areas of O-
rings.

F0401420

30-94
DISASSEMBLY AND ASSEMBLY AXLES

3 - Take out the bearing (36) and remove the bolts (37)
38
(No. 12).
Remove the cover (38), the pinion gears (39) and the
thrust washer (40).

36
37

F0401421

4 - Insert completely the dowels (41) (No. 3) in the shafts

(42) and (43). Remove shafts (42) and (43), spider 46
(44), sun gears (45), thrust washers (48) and second
pinion gear (39) complete with shim (40).
Loosen the bolts (46) and remove the ring bevel gear 42 43
(47).
H Replace the bolts (46) at each disassembly.

47

F0400613

30-95
DISASSEMBLY AND ASSEMBLY AXLES

5. Bevel pinion (Only for rear axle)

57
58 49
61

59
56
53
60
52
51
50
55
54

D0400982

1 - Remove the differential.

(See, «5. Differential unit»).
Loosen the bolts (49) (No. 8) and remove pinion car- 50
rier assembly (50).

49

50
F0401422

2 - Using tools F1 and F2 loosen the nut (51) and take

out O-ring (52), flange (53) complete with cover (54),
seal (55) and spacer (56). Remove bevel pinion (57) F2
complete with roller-bearing (58). 50
Remove the bearing (59) from pinion carrier.
Remove the thrust washer (60) and the spacer (61)
from the bevel pinion.
H If bevel pinion removal is difficult, use a soft ham-
mer. F1
57

F0401423

30-96
DISASSEMBLY AND ASSEMBLY AXLES

3 - Remove the bearing (58) from the bevel pinion (57).

Remove the thrust bearing (59) from pinion carrier
(50). 57

58

50

F0401424

30-97
DISASSEMBLY AND ASSEMBLY AXLES

ASSEMBLY OF AXLES
1. Bevel pinion carrier
(Only for rear axle)
F3
1 - Using tool F3 assemble thrust bearings (58) and (59)
on pinion carrier (50).
50

F3
F0401425

2 - Assemble bearings (58) and (59) into the pinion car-

rier.
Measure distance «A».
Measure «A» corresponds to distance between bevel
carrier face and external bearing (58) surface.

58

F0401426

3 - Using tool F3 measure distance «B».

B
F3

F3
F0401427

4 - Assemble bearings (58) and (59) and spacer (61) on

tool F3; measure distance «C».

F3 C
58
61
59
F3

F0401428

30-98
DISASSEMBLY AND ASSEMBLY AXLES

5 - Using a press assemble bearing (58) on bevel pinion

(57). 60
Assemble spacer (61), thrust washer (60) on bevel pi-
nion.
H Thrust washer measure: S1=B±C+X 61
H X=0.05 ± 0.07 mm 58

F0401429

6 - Assemble the bearing (59) into the bevel pinion (50)

and, using a press, assemble bevel pinion assembly 57
(57).
Assemble spacer (56).
Assemble the flange (53), O-ring (52) and using tool
F1, tighten the nut (51).
Nut: 260 ± 300 Nm
Check that bevel pinion rotation torque is within the
permissible value.
H Pinion rotation torque: 120 ± 170 Ncm
If the bevel pinion rotation torque is not within the per- F1
missible value, change the dimension of measure- F0401430

ment of thickness (60).

. The INCREASE of thickness of 0.02 mm will in-
crease the bevel pinion rotation torque of *10
Ncm.
F5
. The REDUCTION of thickness of 0.02 mm will de- 55
crease the bevel pinion rotation torque of *10 Ncm.
Loosen the nut (51), O-Ring (52), flange (53) and using
the tool F5, install the seal (55).
Fit finally the flange (53), O-Ring (52) and using the
tool F1 lock the nut (51).
Nut: Loctite 270
Nut: 260 ± 300 Nm
F0401431

2. Differential
1 - Insert into the differential case (35) the thrust washer 42
(40) and pinion gear (39).
33 mm

Insert the thrust washers (48) (No. 4), sun gears (45)
(No. 4) and spider (44).
Insert the shafts (42) and (43) and dowels (41).
H Check that shafts holes are aligned with dowels
holes.
H Insert the dowels until 33 mm depth.
43 43

F0401432

30-99
DISASSEMBLY AND ASSEMBLY AXLES

2 - Insert the pinion gear (39) and thrust washer (40) into
the differential case. 36
37
Assemble cover (38) on differential case and tighten
the bolts (37) (No. 12). 38
Using a press, assemble bearings (36) inner rings.
Bolt: Loctite 270
Bolts: 69v72 Nm

36

F0401433

3 - Insert the bevel gear ring (47) and tighten the bolts
(46) (No. 12).
Bolt: Loctite 270
Bolts: 73v76 Nm

46

47

F0401434

3. Measuring pinion carrier position shim (only for

rear axle)
1 - Measure distances «E» and «F».
H Determine measure «S2» of shim (62).
H S2=(98+A)±(E+F)

F F E
S2
D0400984

2 - Assemble complete pinion carrier (50) and spacer

(52).
Tighten the bolts (49).
Bolts: Loctite 270
Bolts: 69 ± 71 Nm

50 52 49
F0401435

30-100
DISASSEMBLY AND ASSEMBLY AXLES

4. Differential locking
(Only for rear axle)
34 34
1 - Assemble the cylinder (31) complete with O-rings (34)
into the right intermediate cover (21).
Cylinder: Loctite 242
Assemble the piston (32) complete with O-rings (33)
into the cylinder (31).

31 32
F0401436

2 - Check that measure «D» is correct.

Assemble the spring (30) and ring nut (29).
H Measure «D» corresponds to distance between 29
cylinder upper side (30) and axle housing surface.
H Measure «D»: 41.5 ± 42 mm
Ring nut: Loctite 242

30
F0401437

3 - Assemble cap (27), fork (26) and tight the nut (25).
Nut: Loctite 242
Nut: 90 ± 93 Nm

27
25

26
F0401438

5. Bevel gear torque adjustment

(Only for rear axle) 21
1 - Assemble intermediate cover (21) of opposite side to
gear and lock the studs (28) (No. 2 horizontal and op-
posite).
Remove from intermediate covers the safety plates
(63) and remove the ring nuts (64) using tool F6.
H Be careful not to damage the surface of O-ring.
H Clean very well the ring nuts. F6

F0401439

30-101
DISASSEMBLY AND ASSEMBLY AXLES

2 - Screw the ring nuts (64) and check the clearance be-
tween bevel pinion and bevel gear.
64
When reached the established clearance screw the
ring nut of opposite side to ring until increasing bevel
pinion rotation torque of 35v45 Ncm.
Caulk the safety plates (63).
Ring nuts: Loctite 222
H Clearance between pinion and gear: 0.15v0.18 mm
H If achieved clearance is LOWER than established
one, LOOSEN the ring nut of GEAR SIDE and
screw the ring nut of opposite side to gear of F0401440

same measure.
H If achieved clearance is UPPER than prescribed
one, LOOSEN the ring nut of GEAR OPPOSITE
SIDE and screw side gear nut of same measure.
H Be careful not to preload the differential taper roll-
er bearings.

F0401441

6. Final drive
1 - Using a press, assemble the thrust washers and in-
ner bearing (10) into the hub (9).
10 10
9

F0401442

2 - Using a press and tool F7, assemble seal (11) into the
hub (9).
F7
11

F0401443

30-102
DISASSEMBLY AND ASSEMBLY AXLES

3 - Using tool F8, assemble the seal (12) and ring (13)
into the axle housing (15).
F8
Seat the hub (9) on the axle housing (15).
13

12 15 9

15
F0401444

4 - Using tool F9 and a soft hammer, beat on outer bear-

ing (10).

F9

10

F0401445

5 - Assemble the gear (8), insert the centering bushing

(65) (No. 8) and tight the bolts (7) (No. 8). 8
Bolts: 76 ± 81 Nm 7

F0401446

6 - Check that hub rotation torque is within the permissi-

ble value.
H Hub rotation torque: 7 ± 20 Nm

F0401447

30-103
DISASSEMBLY AND ASSEMBLY AXLES

7 - Assemble on pinion gear (4) the bearings (65) and

spacer (67). 4
Insert the sun gear (5) and thrust washer (68) from 67
sun gear carrier (2) central hole and using a press in- 65
sert the pinion gear (4). 4
2
65

F0401448

8 - Insert the circlip (3).

H Check carefully the circlip correct introduction.
H Caulk the sun gear carrier in the area not inter- 3
ested by the circlip.

5
68

F0401449

9 - IIntroduce the drive shaft (6) and assemble the sun

gear carrier assembly (2).
Tighten the bolts (1). 6
Bolts: 86 ± 89 Nm
1
2

F0401450

7. Brakes
1 - Assemble O-rings (24) and thrust rings (23) on pis-
tons.
H Make sure that gasket (24) and anti thrust ring
23
(23) assemblies are correct.

24

F0401451

30-104
DISASSEMBLY AND ASSEMBLY AXLES

2 - Introduce pistons assembly (22) (No. 3 each side) into

the intermediate cover (21).
21
Raise the pressure into the brake circuit for about ten
minutes with compressed air at 0.5 ± 1 bar.
Repeat the test for the other side. 22

F0401452

3 - Introduce brake discs (19) and (20) into their seat.

H Make sure that lubricating holes are all aligned. 20
H Make sure that discs are assembled in the right 19
order.

F0401414

4 - Introduce thrust plate (18), the spring (69), the adjust-

ing bolts (17) complete with O-ring. 18
Tight the adjusting screws (17).

17
F0401413

5 - Assemble the axle housings (15) on differential case

14
and lock the nuts (14). 17
Adjust brake discs clearance, loosening the adjusting 15
bolts (17) of 1/2 turn.
Tight the lock nuts (16) (No. 3 each side).

16
F0401549

30-105
DISASSEMBLY AND ASSEMBLY TRANSMISSION

DISASSEMBLY OF TRANSMISSION

2 3 Particolare
View of cilindro
gear
1 comando marce
cylinder control
4
16 5 6 8
44 29
31
23
22
21 24 7
18
35
17 30
19 32
36
20
13 26

14
34
12 11
10 38
9 28
37
27
39
33
25

38
42

40 41
15

43 D0400959

1 - Remove the flange (1) complete with O-ring (2),

breather plug (3), seal (4) and thrust ring (5).
H Check and note the tickness of thrust ring (5). 3

F0401551

30-106
DISASSEMBLY AND ASSEMBLY TRANSMISSION

2 - Unscrew and take out the gear control shaft (6).

6
F0401453

3 - Remove the gear control cylinder assembly (7) and

guard plate (8).

7
8
F0401454

4 - Disassemble the gear control cylinder (7).

H Check carefully the O-rings position.
7
H Arrange the components in reassembly order.

F0401455

5 - Remove the gear position microswitch (9), washer

(10) and O-ring (11).

F0401456

30-107
DISASSEMBLY AND ASSEMBLY TRANSMISSION

6 - Remove the plug (12), spring (13) and ball (14) for
neutral position.
14 13 12

F0401457

7 - Assemble on bevel pinion (15) the lock tool E1.

15

E1

F0401458

8 - Remove the nut (16).

H To remove the nut (16) heat it at about 120 ëC.
17
H Make unit cold before continuing in disassembly.

16
F0401459

9 - Remove the ring (18) and the flange (17).

17
18
16

F0401493

30-108
DISASSEMBLY AND ASSEMBLY TRANSMISSION

10 - Remove the cover (19) complete with seal (20).

H Note that notch «X» must be turned upwards.
X 19

F0401460

11 - Take out the bearing (21) and possible thrust rings

(22). 21
H Check and note the thickness of thrust rings (22).

22

F0401461

12 - Remove the bolts (23) and lightly the cover (24) using
the flange mounting bolts (1).
23

24
F0401462

13 - Using some levers, force the cover (24) to divide it

from housing (25). 24

25

F0401463

30-109
DISASSEMBLY AND ASSEMBLY TRANSMISSION

14 - Remove the bolts of cut flow housings (26) and (27)

and remove the housing (27).

27
F0401464

15 - Take out from cover (24) at the same time, hub (28)
and fork (29) complete with pads (30) and transmis-
sion shaft (31).

28
29
24 30
F0401465

16 - Check the wear of pads (30) sliding hub (28) and dow-
el (32); if they are worn, replace them. 30 28

30

F0401466

17 - Remove at the same time the housing (26) and the

gear (33).

33 26
F0401467

30-110
DISASSEMBLY AND ASSEMBLY TRANSMISSION

18 - Remove the spacer (34).

34

F0401468

19 - Using two levers, remove the inlet shaft (35) complete

with bearing (36). 36

35

F0401469

20 - Take out from bevel pinion (15) the fixed hub (37) with
needle bearings (38), gear (39) and spacer (40). 37 40

39

38
F0401470

21 - Remove the tool E1.

E1

F0401471

30-111
DISASSEMBLY AND ASSEMBLY TRANSMISSION

22 - Remove bevel pinion (15) complete with bearing (41).

41
15

F0401472

23 - Using levers, remove the gear case (25) from axle

central case. 42
H Be careful not to damage the contact surfaces. 25
H Measure and note the spacers (42).

F0401473

24 - Take out the seal (43) and bearing (41) outer thrust
ring.

43
41

F0401474

25 - Using a press and a specific tool, remove the bearing

inner ring (41) from the pinion (15).

15
41

F0401475

30-112
DISASSEMBLY AND ASSEMBLY TRANSMISSION

26 - Take out bearing (36) from inlet pinion (35) (small

gear side). 36

35

F0401476

27 - Take out bearing (44) from inlet pinion (35) (big gear
side).
44
H Mark the bearing shielding side.

35

F0401477

30-113
DISASSEMBLY AND ASSEMBLY TRANSMISSION

ASSEMBLY OF TRANSMISSION
Removed gaskets and O-rings cannot be used
again.
H Check carefully that contact surfaces are not damaged.
H Remove from contact surfaces each sealing residual.

1 - Assemble the shielded bearing (44) on inlet shaft (35)

(big gear side).
H Check the bearing shielding orientation (44).

44

35

F0401478

2 - Assemble the bearing (36) on inlet shaft (35) (small

gear side).

36

35

F0401479

3 - Install the seal (43) into the housing (25).

H Check that the seal lip is turned toward housing
outside.

43
25

F0401480

30-114
DISASSEMBLY AND ASSEMBLY TRANSMISSION

4 - Assemble into the housing (25) and into the cover (24)
the thrust washers of taper bearing (41) and (21).

41
25

F0401481

5 - Assemble taper bearing inner ring (41) and rotate it to

carry out a settling.
Keeping ring stopped into its seat, measure the di-
mension «A» between bearing inner ring and surface
of axle case.
41

F0401482

6 - Mark the measure «A» taken on the housing.

F0401483

7 - Using a press, assemble on pinion (15) the bearing

(41) inner ring.

15
41

F0401484

30-115
DISASSEMBLY AND ASSEMBLY TRANSMISSION

8 - Determine the thrust rings thickness (42) to be used

with following method:
Thickness=S=(A±X)+B
where A=Measured dimension
X=Fixed dimension=21.0 mm A1
B=Deviation stamped on pinion
A1= Fit value
(should match the same mark stamped
on ring gear)

B
F0401915

9 - Apply the shims (42) on housing hub (25).

H Seal all contact surfaces with Loctite 510.
25

42

F0401485

10 - Assemble the housing (25) on axle case and lock it.

Mounting bolts: 45 ± 51 Nm

25

F0401486

11 - Assemble the pinion (15) and keep it locked with tool

E1. E1

F0401471

30-116
DISASSEMBLY AND ASSEMBLY TRANSMISSION

12 - Lubricate the spacer (40) and assemble it in the hous- 25

ing (25).
Spacer: ASL800050

40

F0401487

13 - Assemble on bevel pinion (15), gear (39), fixed hub

(37) with needle bearings (38). 37 40

39

38
F0401470

14 - Put into the cover (24) the input shaft (35) complete
with bearing. 35

24

F0401488

15 - Lubricate the spacer (34) and insert it into the cover.

Spacer: ASL800050

34

F0401468

30-117
DISASSEMBLY AND ASSEMBLY TRANSMISSION

16 - Introduce into the cover (24) the cut flow housing (26)
and at the same time the gear (33).

33 26
F0401467

17 - Reassemble the fork assembly (29) on sliding hub

(28); assemble the unit on fixed hub (37).
Assemble the cut flow housing (27).

27
29 28

27

F0401489

18 - Lock the cut flow housing mounting bolts.

Bolts: 25 ± 26 Nm

F0401490

19 - Put into the housing (25) the centering dowels.

Spread the surface of cover (24) with sealant. 24 25
Cover: Loctite 510

F0401491

30-118
DISASSEMBLY AND ASSEMBLY TRANSMISSION

20 - Assemble the cover (24) and lock the mounting bolts

following the cross locking method. 24
Bolts: 49 ± 51 Nm

F0401909

21 - Assemble on pinion (15), previously disassembled

shims (22) and bearing (21). 21
Alternatively if taper bearings are replaced, install the
test shims (fixed dimension) of 1.65 mm.

22

F0401461

22 - Mount the flange (17) temporarily, the spacer (18) and

nut (16).

17
18
16

F0401493

23 - Remove the pinion (15) locking tool E1.

E1

15
F0401494

30-119
DISASSEMBLY AND ASSEMBLY TRANSMISSION

24 - Apply tool E2 and lock temporarily the nut (16).

Nut: 260 ± 300 Nm
E2

F0401495

25 - Check that the bevel pinion (15) rotation torque is

within the standard values.
Pinion: 120 ± 170 Ncm
H If necessary, add or remove the shims until reach-
ing the standard torque.

15

F0401496

26 - Remove the nut (16), ring (18) and flange (17).

17
18
16

F0401493

27 - Insert into the cover (19) the seal (20) and lubricate
the lip. X
Spread the cover contact surface (19) with sealant.
Seal: ASL800050
Contact surface: Loctite 510
H Keep the notch «X» turned upwards.

19 20
F0401497

30-120
DISASSEMBLY AND ASSEMBLY TRANSMISSION

28 - Assemble the cover (19) on transmission and lock it

with the bolts.
Bolts: Loctite 510
Bolts: 49 ± 51 Nm

19

F0401498

29 - Assemble the flange (17), ring (18) and nut (16).

Nut: Loctite 270

16 18 17

F0401499

30 - Lock the nut (16).

Nut: 260 ± 300 Nm
E2

F0401495

31 - Assemble the thrust rings (5) into the flange (1).

Assemble temporarily the flange on transmission and 5
lock it.
Check clearance between bearing and flange and if
1
necessary change the thrust rings.
H Standard clearance: 0.25 ± 0.35 mm

F0401500

30-121
DISASSEMBLY AND ASSEMBLY TRANSMISSION

32 - Remove the flange (1), assemble the seal (4).

Spread with sealant the coupling surfaces and as-
semble the unit definitively.
Seal: ASL800050
Surfaces: Loctite 510
1
Bolts: 42 ± 52 Nm

F0401551

33 - Introduce the ball (14), the spring (13) and plug (12) of
neutral position.
Plug: 80 ± 100 Nm
14 13 12

F0401457

34 - Assemble the gear position micro switch (9) with gas-

ket (11) and washer (10).
Micro switch: 25 ± 30 Nm

F0401456

35 - Reassemble all parts of gear control cylinder follow-

ing disassembly opposite order, lubricating gaskets 7
lightly.
Gaskets: ASL800050

F0401455

30-122
DISASSEMBLY AND ASSEMBLY TRANSMISSION

36 - Assemble the guard plate (8) after spreading the sur-

face with sealant.
Surface: Loctite 510 8

F0401492

37 - Assemble the gear control cylinder (7) complete with

O-ring and lock it with relative bolts.
Bolts: 49 ± 51 Nm

7
8
F0401454

38 - Tighten the gear control shaft and lock it.

Shaft: Loctite 242
Shaft: 24 ± 26 Nm

6
F0401453

30-123
DISASSEMBLY AND ASSEMBLY FRAME JOINT PIN

REMOVAL OF FRAMES JOINT PIN

H This operation is to be carried out when replacing joint

bushings or when replacing joint rotation bushings. B
1 - Steer towards left, lean front bucket on two track roll-
er brackets, stop the engine and engage the parking
1
brake.
2 - Put under the rear frame two stands (A), each one
complete of two jacks (B).
3 - Raise the jacks until forcing them under the rear
frame (1).
A
F0401313

4 - Sling front frame (2) and tension the ropes lightly.

Ropes tension must support front frame without lift-
ing the rear frame.

F0401314

5 - Remove the bolts (3) and the steering cylinders pins

(4).
6 - Start the engine and retract completely the cylinders
(5).
3
7 - Stop the engine.
Release completely the residual pressure from all
4 5
circuits. (For details, see «20. TESTING AND AD-
JUSTMENTS»).

F0401315

Disconnect cable negative terminal (±) from accumu-

lator.

8 - Disconnect cardan shaft (6) from transmission.

9 - Disconnect from devices fixed to front frame, all pipes

and electric connections coming from rear frame (hy-
draulic motor, lifting and bucket dumping cylinders,
steering cylinders, drains solenoid valves, lights, etc.) 6

F0401305

30-124
DISASSEMBLY AND ASSEMBLY FRAME JOINT PIN

10 - Disconnect the ground cable (7).

11 - Remove the flange (9) mounting bolts (8); remove the 8
flange (9) and O-ring (10).
9
7

10

F0401316

12 - Remove the lock nuts (11) and pin mounting bolts.

13 - Remove the joint pin (12).

H If pin removal is difficult, operate on jacks or lift
front frame until finding the ideal alignment for
an easy removal of joint pin (12).
14 - Using a lever and the lifter, divide the front frame
from the rear one, removing it of about 50 cm.
11
12
F0401317

INSTALLATION OF FRAMES
JOINT PIN
. To install, reverse the removal procedure.
H Replace all O-rings installed to keep the lubricating
grease.

Cardan shaft nut: . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 - Before to use the machine, proceed to joint pin lubri-
cation.

H Bleed the travel and the hydraulic circuits.

Flange bolts:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lock nuts: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30-125
DISASSEMBLY AND ASSEMBLY FRAMES JOINT

REMOVAL OF FRAMES JOINT

1 - Remove the accumulator (1).

+
2 - Disconnect, from front frame side, all hydraulic hoses
(2) coming from the rear frame (travel hydraulic mo- --
tor, steering cylinders, transmission, bucket dumping
and lifting cylinders). Plug all hydraulic hoses and un-
ions or flanges to avoid impurity entry.

1
F0401292

3 - Disconnect, from front frame side, all electric connec-

tions (3) coming from the rear frame (light, horn, hy- 2
draulic motor solenoids, transmission sensors).
4 - Loosen the bolts (4) fixing the flange (5) and leave
them temporarily in their seat.
5 - Remove the frames joint pin. 3
(See «REMOVAL OF FRAMES JOINT PIN»).

F0401219

6 - Using a lever and the hydraulic jack, divide the front

frame from the rear frame removing it of about 50 cm.
H During the frames division, accompany hydraulic 4
pipes and electric wires.
7 - Support the frame joint, remove the mounting bolts of 5
flange (5) and remove the joint assembly.

INSTALLATION OF FRAMES JOINT F0401318

. To install, reverse the removal procedure.

H Replace all O-rings installed to retain the lubricating
grease.

Joint flange bolts: . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 - Bleed the air from hydraulic circuits. (See «20. TEST-
ING AND ADJUSTMENTS).
2 - Before to use the machine, proceed to joint and con-
nection pin lubrication.

30-126
DISASSEMBLY AND ASSEMBLY FRONT BUCKET LIFT ARM CYLINDERS

REMOVAL OF FRONT BUCKET LIFT ARM CYLINDERS

Dump completely the front bucket (1) and lower it un-
til leaning on level ground. 4

1 - Sling the cylinder (2).

2 - Stop the engine, release the cylinder pressure mov- 1
ing several times the control valve lever. 3
2
3 - Remove the bolt, pin (3) and the safety plate (4).
4 - Start the engine to retract the cylinder (5).

H Secure the total return position, fastening the rod F0401319

eye with iron wire.

5 - Stop the engine and release the residual hydraulic
pressures. (For details, see «20. TESTING AND AD-
JUSTMENTS»).
6 - Disconnect the hoses (6) and (7) and plug them to
avoid impurity entry. 4
7 - Remove the bolt and the pin (8). 2
8
8 - Remove the cylinder (2).
5
Cylinder: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 - Repeat the removal operations for the other cylinder.
F0401320

INSTALLATION OF FRONT
BUCKET LIFT ARM CYLINDERS
. To install, reverse the removal procedure.
7

When aligning positions between hole and pin, run 2

the engine at idling.
Do not introduce hand fingers in the holes to check F0401233

the alignment.

Bushings inside: ASL800050

1 - Start the engine and bleed air from cylinders.
(For details, see «20. TESTING AND ADJUSTMENTS»).
H After air bleeding, check the level in the tank.

30-127
DISASSEMBLY AND ASSEMBLY FRONT BUCKET DUMPING CYLINDER

REMOVAL OF FRONT BUCKET DUMPING CYLINDER

Lower the bucket (1) until level ground and make it
lean on the back.

1 - Sling the cylinder (2).

1
2 - Stop the engine, release the cylinder pressures mov-
ing several times the control lever.
3 - Remove the bolt (3) and bucket positioner (4).
4 - Remove the bolt and the pin (5).
5 - Start the engine to retract the cylinder (6).
H Secure total return position fastening the rod eye
with iron wire.
F0401321

6 - Stop the engine and release the residual hydraulic

pressures. (For details, see «20. TESTING AND AD-
JUSTMENTS») 6

7 - Disconnect the hoses (7) and plug them to avoid im-

purity entry.
8 - Remove the bolt and the pin (8).
4
9 - Remove the cylinder (2).
Cylinder: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3

F0401322

INSTALLATION OF FRONT
BUCKET DUMPING CYLINDER
7
. To install, reverse the removal procedure.

When aligning position between hole and pin, run

the engine at idling. 2
Do not introduce hand fingers in the holes to check
the alignment.

F0401323

Bushings inside: ASL800050

1 - Start the engine and bleed the air from cylinders.
(For detail, see «20. TESTING AND ADJUSTMENTS»).
H After the air bleeding, check oil level in the tank.

30-128
DISASSEMBLY AND ASSEMBLY STEERING CYLINDERS

REMOVAL OF STEERING CYLINDERS

Lower the bucket until level ground and lean it on the
back. +
1 - Stop the engine and release the residual hydraulic --
pressures.
2 - Remove the front cover and remove the accumulator
(1).
H Disconnect first the negative terminal (±) cable
and then the positive cable (+).
1
3 - Remove the accumulator bracket (2).
4 - Disconnect the hoses (3) from cylinders and plug F0401292

them to avoid impurity entry; plug also the cylinders

holes to avoid that pistons, dumping the removal,
can follow out.
5 - Disconnect lubricating pipes (4) of swing cylinders
connections base side. 3
6 - Apply supporting blocks «A» between piston (5) and 3
front frame (6).
7 - Remove the bolts and piston mounting pins (7). 7
8

8 - Remove the bolts and cylinder fulcrum pins (8).

2
F0401324

9 - Rotate the cylinders towards machine centre to re-

lease piston eye from frames joint (9); extract the cy-
linders (10).
H Be careful not to damage the piston rod.

INSTALLATION OF STEERING
CYLINDERS F0401325

. To install, reverse the removal procedure.

H Connect first the positive cable terminal (+) and

then the negative (±) one. 6
9
Bushings inside: ASL800050
7 5 10

When aligning positions between hole and pin, run

the engine at idling.
Do not put fingers in the holes to check the align-
ment. A
F0401315

30-129
DISASSEMBLY AND ASSEMBLY FRAME OSCILLATING LOCK CYLINDER

REMOVAL OF FRAME OSCILLATING LOCK CYLINDER

Lower the front bucket (1) until level ground leaning it
on the back.

1 - Make sure that the frames are unlocked.

1
2 - Stop the engine and release the residual hydraulic
pressures. (For details, see «20. TESTING AND AD-
JUSTMENTS»).
3 - Disconnect the hoses (2) and (3) and plug them to
avoid impurity entry.
H Mark the hoses to avoid exchanges when they will
be reassembled.
F0401321

4 - Remove the bolts (4) and the cylinder (5).

5
3

F0401326

INSTALLATION OF FRAME
OSCILLATING LOCK CYLINDER
. To install, reverse the removal procedure.
1 - Start the engine and carry out several times the lock-
ing and unlocking of frames oscillation to bleed the
air from the system.

30-130
DISASSEMBLY AND ASSEMBLY MACHINE CYLINDERS

DISASSEMBLY OF MACHINE CYLINDERS

1 - Settle the cylinder (1) on tool G1; engage cylinder eye

into the tools G2 usable for the bushing diameter. G2
G2
G1

1
F0400810

2 - Using appropriate spanner G3, unscrew the head (2)

and extract it from cylinder (1) completely.
3
For bucket control cylinder, remove first the rod gas-
ket ring nut (3) using the wrench G4.

1 2

F0401524

3 - Raise the cylinder (1) and hook the piston eye to at-
tachment G1 movable unit.
4 - Extract the rod unit (4) from cylinder (1).
5 - Remove the cylinder (1) and rod unit.
4
G1

F0400813

30-131
DISASSEMBLY AND ASSEMBLY MACHINE CYLINDERS

6 - Lock the rod assembly (4) on attachment G1.

4 6
7 - Only for bucket control cylinder: remove the dowel
pin (5). STEERING AND ARM
LIFTING CYLINDERS
8 - Apply on piston lock nut (6) the correct wrench and re-
move the nut.
4 6
H Spanner measure:
Unit: mm
BUCKET CONTROL
Cylinder Arm lifting Bucket Steering CYLINDER
control
Wrench 41 50 30 5
D0400985

9 - Disassembly all the units and remove all gaskets,

seals, and guide rings.

Gaskets, dust seal and guide rings cannot be used

again.

30-132
DISASSEMBLY AND ASSEMBLY MACHINE CYLINDERS

ASSEMBLY OF MACHINE CYLINDERS

H Be very careful not to damage gaskets and sliding

surfaces.
2 10 9
H Carry out preparation of single components before fi-
nal assembly.

1. HEAD ASSEMBLY
1.1 Arms lifting and steering cylinders
1 - Assemble the gasket (7) in the head (2). 8 7
ANTI-EXTRUSION
ANELLO
H Check that back up ring of seal is oriented to- RING
ANTIESTRUSIONE
wards outside of cylinder.
D0400986

2 - Assemble the dust seal (8) into the head (2).

3 - Assemble on head the O-ring (9) and anti-extrusion 2 10 9
ring (10).
H Check that anti-extrusion ring (10) is installed to-
wards outside of cylinder.

8 7
BACK UP RING
ANELLO DI
RINFORZO
D0400986

1.2 Bucket control cylinder

1 - Introduce the guide ring (11) into the head (2).
2 16 15

2 - Introduce the gasket (12) into the head, and make it

beat against the seat bottom, then install the gasket
seat (13).
H Check carefully the assembly orientation.
3 - Assemble into the ring nut (3) the dust seal (14).
4 - Tighten the ring nut (3) until leaning lightly on gasket
seat (13). 14 3 13 12 11
D0400988
5 - Assemble on head the O-ring (15) and the anti-extru-
sion ring (16).

30-133
DISASSEMBLY AND ASSEMBLY MACHINE CYLINDERS

2. PISTON ASSEMBLY
2.1 Steering and arm lifting cylinders 19 18 17 18 19
1 - Using tool G5 fitting to diameter, assemble the piston
seal. Assemble in sequence the rubber ring (17), the
back up ring (18) and the guide and anti-extrusion
rings (19).
2 - Assemble O-ring (20) into piston inside (22).
G5

22 20

F0401503

3. ROD UNIT ASSEMBLY

1 - Using a press and tool G2 fitting to diameter, install 4
bushing (21) into the rod eye (4).

21

G2

F0401521

2 - Assemble on rod end (4) the bushing G6 fitting to dia-

meter.
3 - Lubricate lightly the head gaskets (2) and install the 4 4 2
unit on rod (4).
G6

Gaskets: ASL800050

F0401522

4 - Remove the bushing G6 from rod end.

5 - Assemble the piston assembly (22). 22

F0401553

30-134
DISASSEMBLY AND ASSEMBLY MACHINE CYLINDERS

H Only for bucket cylinder control

a - Assemble the first retaining ring (23) of gasket 23 25 24 25 23
(24).
b - Assemble the anti-extrusion ring (25). 6
c - Assemble the gasket (24).
d - Assemble the second anti-extrusion ring (25).
e - Assemble the second retaining ring (23) of
gasket (24). 5
6 - Assemble the piston rod nut (6) and lock it with a di-
namometric wrench. D0400990

Nut: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Unit: kgm

Cylinder Arm lift Bucket Steering

control
Tightening 85 ± 90 100 ±105 60 ±65
torque

7 - Only for bucket cylinder control: insert the dowel

pin (5) which lock the nut position (6).

4. CYLINDER ASSEMBLY
1 - Assemble tools G2 on attachment G1.
G2
2 - Set the bushing (21) and assemble it into the cylinder
(1) eye. G2
H Leave the cylinder in this position for the next as- G1
sembly.

21
F0400810

3 - Lubricate the thread and the first portion of cylinder

(1).
Cylinder: ASL800050
1 G7
4 - Assemble the two half part of tool G7 fitting to dia-
meter at cylinder (1) entrance.

F0401523

30-135
DISASSEMBLY AND ASSEMBLY MACHINE CYLINDERS

5 - Assemble the piston rod unit (4) on attachment G1

and raise the movable portion until the end of stroke.
6 - Put the cylinder (1) in vertical position and guide the
piston into the tool G7. 4
7 - Lower the attachment supporting the piston rod (4) to
install the piston into the cylinder barrel.
G1
8 - Remove tool G7 from cylinder and then lower
furtherly the attachment G1 until approaching the
head (2) and piston rod eye to cylinder. 2
G7
9 - Bring the cylinder (1) into the head (2) screwing posi-
tion.
10 - Install the head into the cylinder and screw it manu-
ally for some turn.
11 - Apply the wrench G3 fitting to diameter and tighten
the head (2) completely. 1
Head:
Unit: kgm

Cylinder Arm lift Bucket Steering

control
Tightening 95 ±100 95 ±100 95 ±100
torque

F0400813

12 - Only for bucket cylinder control: lock the piston rod

seal ring nut (3) with wrench G4.
Ring nut: 50 kgm

30-136
DISASSEMBLY AND ASSEMBLY FRAME OSCILLATING LOCK CYLINDER

DISASSEMBLY OF FRAME OSCILLATING LOCK CYLINDER

7 4 6 2 3

1 8 5 D0400991

1 - Remove the circlip (1).

2 - Unthread from the cylinder (2) the piston (3) and the
ring nut (4).
3 - Remove all O-rings and the dust ring.
The O-rings and the dust ring cannot be used
again.

ASSEMBLY
1 - Assemble O-ring (5) on piston (3).
2 - Assemble in the ring nut (4) the O-ring (6) and the
dust ring (7).
3 - Assemble O-ring (8) on ring nut (4).
4 - Lubricate all gaskets and thread on piston rod (3) the
ring nut assembly (4).
Gaskets: ASL800050
5 - Thread the piston unit into the cylinder (2) and tight
the ring nut (4).
6 - Lock the ring nut position with circlip (1).

30-137
DISASSEMBLY AND ASSEMBLY FRONT BUCKET

REMOVAL OF FRONT BUCKET

Lower the bucket to level ground and lean it on the
back without forcing it.
4
1 - Stop the engine.
2 - Remove the bolts and the pins (1) of bucket support
(2).

3
F0401321

3 - Remove the bolts and the bucket hinge pins (3).

1 2
4 - Start the engine and move the machine in reverse to
release the lift arm (4).

1
F0401327

INSTALLATION OF FRONT BUCKET

. To install, reverse the removal procedure.

When aligning the positions between hole and pin

run the engine at idling.
Do not introduce hand fingers in the holes to check
the alignment.

Bushings inside: ASL800050

30-138
DISASSEMBLY AND ASSEMBLY TILT LEVER AND BUCKET LINK

REMOVAL OF TILT LEVER AND BUCKET LINK

Lower the front bucket to level ground and lean it on
the back without forcing it.
1
1 - Remove the front bucket (see «REMOVAL OF FRONT
BUCKET»).
2 - Loosen the bolt and remove the pin (1) and the bucket
link (2).
Bucket link: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2

F0401328

3 - Remove the bolt (3) and the bucket positioner (4).

4 - Sling the bucket dump cylinder (5).
5 - Remove the bolt and the pin (6).
6 - Lower the cylinder (5) completely. 4
7 - Sling the tilt lever (7).
6
8 - Remove the bolt and the pin (8).
3
9 - Remove the tilt lever (7).

Tilt lever: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F0401322

F0401323

INSTALLATION OF TILT LEVER

AND BUCKET LINK
. To install, reverse the removal procedure.

When aligning the positions between hole and pin,

run the engine at idling. 7
Do not introduce hand fingers in the holes to check
the alignment. 8

Bushing inside: ASL800050

F0401329

30-139
DISASSEMBLY AND ASSEMBLY FRONT BUCKET LIFT ARM

REMOVAL OF FRONT BUCKET LIFT ARM

1 - Remove the front bucket.

(See «REMOVAL OF FRONT BUCKET»). 1
2 - Remove the tilt lever and the bucket link.
(See «REMOVAL OF TILT LEVER AND BUCKET A
LINK»).
3 - Start the engine and raise the bucket lift arm (1); put a
stand (A) under the front cross bar and lean the arm
on it.
4 - Stop the engine and remove the arm lift cylinders.
(See «REMOVAL OF FRONT BUCKET LIFT CYLIN-
DERS»).
F0401330

5 - Sling the lift arm (1).

6 - Remove the bolts and the hinge pins (2).

2
7 - Remove the lift arm (1).
Lift arm:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

F0401331

INSTALLATION OF FRONT
BUCKET LIFT ARM
. To install, reverse the removal procedure.

When aligning the positions between hole and pin,

run the engine at idling.
Do not introduce hand fingers in the holes to check
the alignment.

Bushings inside: ASL800050

1 - Start the engine and bleed the air from cylinders.
(For details, see «20. TESTING AND ADJUSTMENTS»).
2 - Stop the engine and check oil level in the tank.

30-140
DISASSEMBLY AND ASSEMBLY BACKHOE CONTROL VALVE

REMOVAL OF BACKHOE CONTROL VALVE

1 - Set the backhoe centred with the machine.

2 - Rest the outriggers to level ground, crowd the bucket
completely and make it lean to the ground keeping
the arm perpendicular to ground.

90°

D0400989

3 - Set the blocks (A) high about 45 cm between backhoe

frame and the outriggers.
Set a block (B) high about 55 cm under the boom
swing bracket.
A
4 - Retract the outriggers slowly until to engage simulta-
neously the blocks (A) and (B).
5 - Stop the engine, release the residual pressures mov-
ing the control levers in all directions and disconnect
B
the backhoe delivery and exhaust pipes.
6 - Disconnect the delivery and exhaust pipes from the
unions fitted on machine; start the engine again F0401554

and send off the machine.

7 - Remove the quick attachment device guard (1).

F0401397

8 - Remove control levers locking knob (2), the rubber

guard (3) and the sliding plate lock lever knob (4).

4 3

F0401398

30-141
DISASSEMBLY AND ASSEMBLY BACKHOE CONTROL VALVE

9 - Remove the brackets control levers handgrips (5) and

the relative protection cowling (6).
5

F0401399

10 - Raise the control levers protection cowling (7) and re-

move the bolts (8) (No. 6) and the hood (9). 7

8
F0401400

11 - Disconnect from control valve, the control levers rods

(11). 10
10

F0401401

12 - Disconnect from control valve the pipes (10) and plug

them.
H Mark the positions to avoid exchanges during the
installation.

11

F0401402

30-142
DISASSEMBLY AND ASSEMBLY BACKHOE CONTROL VALVE

13 - Support the control valve (12) and remove the mount-

ing bolts (13) (No. 3).
14 - Remove the control valve (12). 12
Control valve: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13
F0401403

INSTALLATION OF BACKHOE
CONTROL VALVE
. To install, reverse the removal procedure.
H Bleed the air from hydraulic circuits.
(See» 20. TESTING AND ADJUSTMENTS»).

30-143
DISASSEMBLY AND ASSEMBLY BACKHOE BOOM CYLINDER

REMOVAL OF BACKHOE BOOM CYLINDER

Extended the arm (1) and open the bucket (2) com-
pletely.
Operate the front attachments to make lean on level
ground the bucket teeth, the arm on a block (A) high
about 10 cm and the joint between the boom and the 4
arm on a stand (B) high about 90 cm. 1 6
2
1 - Stop the engine and release the cylinder pressures
moving the control lever several times.
2 - Remove the grease nipple and the extension (3).
3 - Sling the cylinder (4).
A B
4 - Remove the bolt (5) and the pin (6).
F0401332

5 - Start the engine and retract the piston.

H Secure piston total return piston fastening the rod
eye with iron wire.
5
6 - Stop the engine and release the residual hydraulic 3
pressures. (For details, see «20. TESTING AND AD-
JUSTMENTS»).
7 - Disconnect the hoses (7) and (8) and plug them to
avoid impurity entry. 6
8 - Remove the circlip and the pin (9).
9 - Remove the cylinder (4).
Cylinder: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F0401333

INSTALLATION OF BACKHOE
BOOM CYLINDER 7
. To install, reverse the removal procedure.
9

When aligning positions between hole and pin, run

the engine at idling. 8
Do not introduce hand fingers in the holes the check
the alignment. F0401334

Bushings inside: ASL800050

4
1 - Start the engine and bleed the air from cylinders.
(For details, see «20. TESTING AND ADJUSTMENTS»).
H After air bleeding, check the oil level in the tank.

F0401335

30-144
DISASSEMBLY AND ASSEMBLY BACKHOE ARM CYLINDER

REMOVAL OF BACKHOE ARM CYLINDER

Extended the arm (1) and extend the bucket (2) com-
pletely; lower the boom (3) until leaning the joint be-
tween boom and arm on a stand (A) high about 90
cm and arm end on a block (B) high about 10 cm.
Rest the bucket teeth against the ground level. 4
3
1 - Stop the engine and release the cylinder pressures 2 1
moving control lever several times.
2 - Sling the cylinder (4).
3 - Remove the bolt (5) and the pin (6).
4 - Start the engine and retract the piston (7). B A
F0401332

H Secure the piston (7) total return position fasten-

ing the rod eye with iron wire.
5 - Stop the engine and release the residual hydraulic
pressures. (For details, see «20. TESTING AND AD-
JUSTMENTS»). 5
6
6 - Disconnect the hoses (8) and (9) and plug them to
avoid impurity entry.
7 - Remove the bolt and the pin (10).
8 - Remove the cylinder (4).
Cylinder: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

F0401336

INSTALLATION OF BACKHOE
BOOM CYLINDER
8 9
. To install, reverse the removal procedure.
4 10

When aligning the positions between hole and pin,

run the engine at idling.
Do not introduce hand fingers in the holes to check
the alignment.

F0401337

Bushings inside: ASL800050

1 - Start the engine and bleed the air from cylinders.
(For details, see «20. TESTING AND ADJUSTMENTS»).
H After the air bleeding, check the oil level in the tank.

30-145
DISASSEMBLY AND ASSEMBLY BACKHOE BUCKET CYLINDER

REMOVAL FO BACKHOE BUCKET CYLINDER

Extend the arm (1) and extend the bucket (2) comple-
tely; lower the boom (3) until leaning the arm on a
stand (A) high about 90 cm and the arm end on a
block (B) high about 10 cm.
Rest the bucket teeth against the level ground. 1
3
1 - Stop the engine, release the cylinder (4) pressures 2 4
moving the control lever several times.
2 - Sling the cylinder (4).
3 - Remove the ring nut (5), the washer and pin (6).

B A
F0401332

4 - Start the engine and retract the piston (7).

H Secure the piston (7) total return position fasten-
ing the rod eye with iron wire.
5 - Stop the engine and release the residual hydraulic
8
pressures. (For details, see «20. TESTING AND AD-
JUSTMENTS»).
6 - Disconnect the pipes (8) and (9) and plug them to
avoid impurity entry. 4 10
7 - Remove the bolt and the pin (10).
9
8 - Remove the cylinder (4).
Cylinder: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F0401338

INSTALLATION OF BACKHOE
BUCKET CYLINDER
5
. To install, reverse the removal procedure.

When aligning the positions between hole and pin,

run the engine at idling. 6
Do not introduce hand fingers in the holes to check
the alignment.
F0401339

Bushings inside: ASL800050

10
Pin ring nut:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1 - Start the engine and bleed the air from cylinders.
(For details, see «20. TESTING AND ADJUSTMENTS»). 7
H After the air bleeding, check the oil level in the tank.

F0401340

30-146
DISASSEMBLY AND ASSEMBLY BACKHOE SWING CYLINDERS

REMOVAL OF BACKHOE SWING CYLINDERS

Set the backhoe with the centred attachments, with
the arm in vertical position and the bucket leaned
on the back at level ground.

1 - Stop the engine and release the cylinders pressures

moving control lever several times.
2 - Remove the rear bolts (No. 4) and remove vertically
the upper bracket (1) of cylinders fulcrum.
3 - Disconnect the hoses (3) (No. 4) from cylinders (2)
and plug them to avoid impurity entry.
4 - Remove the bolts and the pins (4). F0401341

5 - Rotate the cylinders to release piston rod eyes from

turning backframe (5) and remove the cylinders (2).
Cylinder: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INSTALLATION OF BACKHOE 2
SWING CYLINDERS
F0401342

1 - Assemble the cylinders (2) and the upper bracket (1)

of cylinders fulcrum; lock the bracket with rear bolts
(No. 4).

Bracket mounting bolts: . . . . . . . . . . . . . . . . . . . . . .

2 - Connect the hoses (3) (No. 4) to cylinders.
3 - Start the engine and operate boom rotation to set one
of the two pins (4); lock the pins with relative bolts. 2
3

When aligning the positions between hole and pin,

run the engine at idling. F0401343

Do not introduce hand fingers in the holes to check

the alignment.
4
3
Bushings inside: ASL800050
4 - Bleed the air from cylinders. (For details, see «20,
TESTING AND ADJUSTING»).
H After the air bleeding, check the oil level in the tank. 2

F0401344

30-147
DISASSEMBLY AND ASSEMBLY OUTRIGGER CYLINDERS

REMOVAL OF OUTRIGGER CYLINDERS

Set the backhoe with the centred attachments, with
the arm in vertical position and the bucket leaned
on the back at level ground.

1 - Extend the stabilizers until leaning on level ground. 1

2 - Stop the engine and release cylinders pressures

moving control levers several times.
2
3 - Remove the bolts (1) and the pins (2).
4 - Start the engine and force on outriggers to raise the
cylinders of about 10 cm; thread into the pins holes
a cross-bar (A) for lifting; sling the cross-bar and ten- F0401345

sion lightly the ropes.

5 - Stop the engine and release cylinders pressures
moving control levers several times.
6 - Remove the bolts and pins (3) of supporting brackets
(4). 7
7 - Start the engine and make pistons return completely. 5
8 - Stop the engine and release residual hydraulic pres-
6
sures. (For details, see «20. TESTING AND ADJUST-
MENTS»).
A
9 - Disconnect the hoses (5) and (6) and plug them to
avoid impurity entry; seal also the unions of safety 8
valves (7). F0401346

H Mark the hoses to avoid exchange during installa-

tion.
10 - Remove the cylinders (8).
Cylinder: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3

INSTALLATION OF CYLINDERS
OUTRIGGER
. To install, reverse the removal procedure.
F0401347

When aligning the positions between hole and pin,

run the engine at idling.
Do not introduce hand fingers in the holes to check
the alignment.

1 - Start the engine and bleed the air from cylinders.

(For details, see «20. TESTING AND ADJUSTMENTS»).
H After the air bleeding, check the oil level in the tank.

30-148
DISASSEMBLY AND ASSEMBLY BACKHOE BACKFRAME LOCK CYLINDERS

REMOVAL OF BACKHOE BACKFRAME LOCK CYLINDERS

Set the backhoe with the centred attachments, with
the arm in vertical position and the bucket leaned
on the back at level ground.
3
1 - Unlock the backframe (1).
2 - Stop the engine and release the residual hydraulic 1
pressures. (For details, see»20. TESTING AND AD-
JUSTMENTS»).
3 - Unscrew and remove the upper cylinders (3) rods (2). 6
4 - Disconnect the T unions (4) from the upper cylinders
(3). F0401342

5 - Remove the upper cylinders (3).

6 - Disconnect the lower cylinders (6) feeding pipes (5),
plug all pipes to avoid impurity entry.
7 - Remove the lower cylinders (6) in the same way of
3
stage 3.

F0401348

5
F0401240

INSTALLATION OF BACKHOE
BACKFRAME LOCK CYLINDERS
. To install, reverse the removal procedure.
1 - Start the engine, lock and unlock the backframe sev-
eral times to make the circuit filling.
2 - Adjust each cylinder locking.
(For details see, «20. TESTING AND ADJUSTMENTS»).

30-149
 BACKHOE CYLINDERS
DISASSEMBLY AND ASSEMBLY (boom, arm, bucket, outrigger, jig arm)

DISASSEMBLY OF BACKHOE CYLINDERS

(boom, arm, bucket, outrigger, jig arm)
1 - Set the cylinder (1) on attachment L1; engage cylin-
der eye in the tool L2 fitting to hole diameter. L2
L2
L1

1
F0400810

For the arm cylinder for side digging boom; extract 3 2

before the circlips (2) and the ball joint (3).

5
4

F0401524

2 - Using the proper wrench L3, unscrew the head (4)

and extract it from cylinder (1).
For side digging boom cylinder, remove first the
piston rod seal ring nut (5).
6
3 - Raise the cylinder (1) and hook the piston eye to at-
tachment movable unit.
4 - Extract the piston rod unit (6) from cylinder (1). L1
5 - Remove the cylinder (1) and the piston rod unit (6).
4

7 9

D0400992

F0400813

30-150
 BACKHOE CYLINDERS
DISASSEMBLY AND ASSEMBLY (boom, arm, bucket, outrigger, jig arm)

6 - Lock the piston rod unit (6) on attachment L1.

7 - For side digging boom cylinder only: remove the 7 9
dowel pin (10).
8 - For boom cylinder piston rod only: remove the
screw (7).
9 - Apply on piston (11) hexagon the proper tube wrench
L4 and unscrew the piston.
H Tube wrench measure: boom: 65 mm 8
arm: 65 mm
bucket: 65 mm D0400992
outrigger: 46 mm
jig arm: 46 mm
side digging
boom: 46 mm
SIDE DIGGING 6
10 - For boom cylinder piston rod only: remove the balls BOOM PISTON
(8) and braking pin (9). 10
11 - Disassembly all units removing all gaskets, dust seals 6 11
and guide rings. 11
Gaskets, dust seals and guide rings cannot be
used again.
Check carefully the pistons (11); if both safety BACKHOE CYLINDERS
calking areas have been used, pistons must be PISTON
replaced. D0400993

30-151
 BACKHOE CYLINDERS
DISASSEMBLY AND ASSEMBLY (boom, arm, bucket, outrigger, jig arm)

ASSEMBLY OF BACKHOE CYLINDERS

(boom, arm, bucket, outrigger, jig arm)
H Be very careful not to damage the gaskets and the
sliding sur faces.
H Carry out the preparation of single components before 16 15
final assembly.

1. HEAD ASSEMBLY
1.1 Boom, arm, bucket, outrigger cylinders
1 - Assemble gasket (12) in the head.
2 - Assemble the gasket (13) into the head. 14 13 12
H Check that the lips are oriented towards cylinder D0400994
inside.
3 - Assemble the dust seal (14) using the tool L5.
4 - Assemble the O-ring (15) and the anti-extrusion ring
(16) on head outside. 22 21 20
1.2 Side digging boom cylinder 5
1 - Insert the gasket (17) into the head and let it beat on
seat bottom, then insert the anti-extrusion ring (18).
H Check carefully the assembly orientation.
2 - Assemble the dust seal (19) into the ring nut (5).
3 - Tighten the ring nut (5) until leaning lightly on anti-ex-
19 18 17
trusion ring (18). D0400995

4 - Assemble on head the O-ring (20), the anti-extrusion

ring (21) and the O-ring (22).
28 25 24 25 11
2. PISTON ASSEMBLY
2.1 Boom, arm, bucket, outrigger cylinder
1 - Using the tool L6 fitting to diameter, assemble on pis-
ton (11) O-ring (23) and then gasket (24).
2 - Prepare the two guide rings (25).
3 - Insert the O-ring (26) into the inner seat.
4 - For outrigger cylinders only: assemble O-ring (27)
into the spacer (28).
27 26 23 D0400996

L6

F0400818

30-152
 BACKHOE CYLINDERS
DISASSEMBLY AND ASSEMBLY (boom, arm, bucket, outrigger, jig arm)

2.2 Side digging boom cylinder

1 - Using the tool L6 fitting to diameter assemble the pis- 31 30 29 30 31
ton seal. Assemble in sequence the rubber ring (29),
the back up rings (30) the anti-extrusion and the
guide rings (31).

11

D0400997

3. PISTON ROD UNIT ASSEMBLY

1 - For boom, arm, bucket, cylinders only: using a
press and the tools L2 fitting to diameter, insert the 6
bushing (32) into the piston rod (6) eye.
32

L2
A

F0401521

2 - Assemble the bushing L7 fitting to diameter on piston

rod end (6).
6 6
3 - Lubricate lightly the head (4) gaskets and thread unit L7 4
on the piston rod (6).
Gaskets: ASL800050

F0401522

4 - For outrigger cylinders only: assemble the spacer

(28) complete with the O-ring (27).
H Check carefully the assembly direction. 27 28 6 L2

D0400998

30-153
 BACKHOE CYLINDERS
DISASSEMBLY AND ASSEMBLY (boom, arm, bucket, outrigger, jig arm)

5 - Remove the bushing L7 from piston rod (6) end.

6 - For boom cylinder only: assemble the braking pin
(9), thread the balls (8) (No. 9) in the hole and assem-
6 11 7 9
ble the screw (7).
10
Loctite:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Screw: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 - Tighten the piston assembly (11) on the piston rod (6)
and lock it with a dynamometric wrench. 8
Piston: 95 ± 100 kgm
D0400999
8 - Caulk the piston (11) on the piston rod (6) slot corre-
spondence not previously used.
9 - For side digging boom cylinder only: insert the
dowel pin (10).
11 6

F0401555

4. Cylinder assembly L2
1 - Assemble the tools L2 fitting to diameter on attach- L2
ment L1. 1
L1
2 - For boom, arm, bucket, and side digging boom cy-
linders only
Set the bushing (32) and assemble it into the cylinder
(1) eye.
H Leave the cylinder in position for the next assem-
bly.
32
F0400810

3 - Lubricate the thread and the first portion of cylinder 1 L8

(1).
Cylinder: ASL800050
4 - Assemble the two half of tools L8 fitting to diameter,
at cylinder (1) entry.

F0401523

30-154
 BACKHOE CYLINDERS
DISASSEMBLY AND ASSEMBLY (boom, arm, bucket, outrigger, jig arm)

5 - Assemble the piston rod unit (6) on attachment L1

and raise the movable side until end of stoke.
6 - Set the cylinder (1) in vertical position and drive the
piston into the tool L8. 6
7 - Lower the attachment supporting the piston rod (6) to
adjust the piston into the tool L8.
L1
8 - Wrap first guide ring (25) on piston and insert a part of
piston into the tool L8, wrap the second guide ring
(25) and insert the piston totally. 4
L8
Carry out the piston introduction slowly to calibrate
the guide ring (25) without to overheat them.
9 - Remove the tool L8 from cylinder and then lower
furtherly the attachment L1 until approaching head
(4) and rod eye to cylinder.
10 - Bring the cylinder (1) in the head (4) screw position.
1
11 - Insert the head into the cylinder and screw it manu-
ally for some turn.
12 - Apply the special wrench L3 and screw completely
the head (4).
Head: 95 ± 100 kgm

F0400813

13 - For side digging boom cylinder only: tighten the

ring nut (5).
Ring nut: 50 kgm

D0401000

30-155
DISASSEMBLY AND ASSEMBLY BOOM SWING CYLINDER

DISASSEMBLY OF BOOM SWING CYLINDER

12
5 1

4 2

6 7 10 8 9 12 11

D0401001
1 - Set the cylinder (1) on attachment L1; engage the
hinge pins into the tools L2.
2 - Using the proper wrench L3, unscrew the head (2)
and extract it completely from the cylinder (1).
3 - Raise the cylinder (1) and hook the piston eye to the
movable unit of attachment L1.
4 - Take out the piston rod unit (3) from cylinder.
5 - Remove the cylinder and the piston rod unit.
6 - Lock the piston rod assembly on attachment L1.
7 - Remove the circlip (4) and unscrew the piston (5)
using the tool L4.
8 - Remove the circlip (6), the lock ring (7) and remove
the spool (8), the spring (9) and the guide spring (10).
9 - Remove the throttle (11) from the cylinder.
10 - Using an extractor remove the swing bushings (12)
from the cylinder hinge pins.
11 - Disassembly the units removing all gaskets, dust
seals and guide rings.
Gaskets, dust seals and guide rings cannot be
used again.

30-156
DISASSEMBLY AND ASSEMBLY BOOM SWING CYLINDER

ASSEMBLY OF BOOM SWING CYLINDER

H Be very careful not to damage the gaskets and the

sliding surfaces. 16 17 2 18
H Carry out the preparation of single components before
final assembly.

1. Head assembly
1 - Assemble the gasket (13) and gasket (14) into the
head (2).
H Check that gaskets lips (14) are turned towards
cylinder inside. 13 14 15
2 - Assemble the scraper ring (15). D0401002

3 - Assemble the O-ring (16), the anti-extrusion ring (17)

and front seal O-ring (18) on head outside.

2. Piston assembly
21 20 21
1 - Using the tool L6 fitting to diameter, assemble the O-
ring (19) on piston, and afterwards gasket (20) outer
ring.
5 19
2 - Prepare the two guide rings (21).
L6
3 - Assemble the O-ring (22) into the piston inner seat.
22

F0401503

3. Piston rod unit assembly

1 - Using a press and tools L2 fitting to diameter, insert
3
the bushing (22) into the rod eye (3). L7
2 - Assemble the bushing L7 fitting to diameter on piston
rod end (3). 23
3 - Lubricate lightly the head inner gaskets and thread
the unit on piston rod (3).
L2
4 - Remove the bushing L7 from the piston rod (3) end.
5 - Lubricate the O-ring (22) and tighten manually by
hand for some turn the piston (5) on piston rod (3). F0401512

O-ring: ASL800050
6 - Set the unit on tool L1 and tighten the piston with
round prong wrench L4.
5 22 3
Piston: 95 ± 100 kgm
7 - Insert the spring (9), the guide spring (10), the spool 4
(8), the lock ring (7) and the circlip (6) into the piston
rod (3).
8 - Lock the piston (5) position installing the circlip (4).
6 8 10 9
7
D0401003

30-157
DISASSEMBLY AND ASSEMBLY BOOM SWING CYLINDER

4. Cylinder assembly
1 - Assemble on attachment L1 the tools L2 fitting to dia-
meter and engage the cylinder (1) hinge pins.
2 - Lubricate the thread and the first portion of cylinder
(1).
Cylinder: ASL800050
3 - Assemble the two half of tool L8 fitting to diameter, at
cylinder (1) entry.
4 - Assemble the piston rod unit on attachment L1 and
raise the movable side.
5 - Bring the cylinder (1) in vertical position.
6 - Lower the attachment movable side to adjust piston
(5) into the tool L8.
7 - Wrap on piston the first guide ring (21) and insert a
part of piston in the tool L8; wrap the second guide
ring (21) and insert the piston completely.
Carry out the piston introduction slowly to adjust the
guide rings (21) without to overheat them.
8 - Insert the head (2) and tighten it manually for some
turn.
9 - Apply the wrench L3 and lock the head completely.
Head: 95 ± 100 kgm
10 - Remove the cylinder from the attachment.
11 - Using a press and proper tool L2, assemble the swing
bushings (12).

30-158
DISASSEMBLY AND ASSEMBLY BACKHOE EQUIPMENT

REMOVAL OF BACKHOE EQUIPMENT

Extend completely the arm and dump the bucket;
lower the attachments until leaning on level ground.

1 - Stop the engine and release the residual hydraulic

pressures. (For details, see «20. TESTING AND AD-
JUSTMENTS»).
2 - Remove boom cylinder. (For details, see «20. TEST-
ING AND ADJUSTMENTS»). 1 2
3 - Remove inner bracket (1) to boom and disconnect the
cylinders hoses (2) of arm and bucket; plug all hoses
to avoid impurity entry.
H Mark the hoses to avoid exchanges when they will
F0401349

be reconnected.
4 - Sling the attachments (3) and tension lightly the
ropes.
5 - Remove the circlips and the pin (4).
6 - Remove the work attachments (3).

Work attachments: . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 4

F0401350

INSTALLATION OF BACKHOE
EQUIPMENT
. To install, reverse the removal procedure.

When aligning the positions between hole and pin,

run the engine at idling.
Do not introduce hand fingers in the holes to check
the alignment.

Bushings inside: ASL800050

1 - Start the engine and bleed the air from cylinders.
(For details, see «20. TESTING AND ADJUSTMENTS»).
H After the air bleeding, check the oil level in the tank.

30-159
DISASSEMBLY AND ASSEMBLY BACKHOE BUCKET

REMOVAL OF BACKHOE BUCKET

Set the bucket at level ground on a flat surface, and
lean it on the back. 7
4
1 - Remove the safety dowel (1) and remove the connec-
tion pin (2) between bucket (3) and links (4).
6
2
5
2 - Remove the safety dowel (5) and remove the pin (6)
connecting the bucket to arm (7). 1 3

F0400216

INSTALLATION OF BACKHOE BUCKET

. To install, reverse the removal procedure.

When aligning the positions between hole and pin,

run the engine at idling.
Do not introduce hand fingers in the holes to check
the alignment.

Bushings inside: ASL800050

30-160
DISASSEMBLY AND ASSEMBLY ARM

REMOVAL OF ARM

1 - Remove the bucket. (For details, see «REMOVAL OF

BUCKET CYLINDER»).
2 - Remove the bucket cylinder. (For details, see «RE-
MOVAL OF BUCKET CYLINDER»). 1
3
3 - Remove the ring nut (1), the washer and remove the
pin (2) and the links (3).
4 - Start the engine, bring the arm in vertical position and
lower it at level ground.
2
5 - Stop the engine and release the cylinder residual
pressures. F0401351

6 - Sling the arm cylinder (4), remove the bolt (5) and the
pin (6).
7 - Start the engine and retract the piston (7) completely.

4
H Secure the total return position fastening the pis- 7
ton rod eye with iron wire.
8 - Lean the cylinder (4) on a block (A).
9 - Stop the engine.
10 - Link the arm (8) to lifting device and tension the rope
lightly.
F0401337
11 - Remove the bolt and the pin (9).
12 - Remove the arm (8).
Arm: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5

INSTALLATION OF ARM
. To install, reverse the removal procedure.
F0401336

When aligning the positions between hole and pin,

do not introduce hand fingers in the holes to check
the alignment.

Bushings inside: ASL800050 8 9

A

When aligning the positions between hole and pin,

run the engine at idling.
Do not introduce hand fingers in the holes to check
the alignment.
F0401352

30-161
DISASSEMBLY AND ASSEMBLY BACKHOE BOOM

REMOVAL OF BACKHOE BOOM

1 - Remove the arm.

(For details, see «REMOVAL OF ARM»).
2 - Remove the arm cylinder.
(For details, see «REMOVAL OF ARM CYLINDER»).
3 - Start the engine and lean the boom at level ground.
4 - Remove the boom cylinder. (For details, see «RE- 1 2
MOVAL OF BOOM CYLINDER»).
5 - Remove the bracket (1) and disconnect the arm and
bucket cylinders hoses (2); plug all hoses to avoid im-
purity entry. F0401349

H Mark the hoses to avoid exchanges when they will

be reconnected.
6 - Sling the boom (3).
7 - Remove the circlips and remove the pin (4).

3
8 - Remove the boom (3).
Boom:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4
F0401353

INSTALLATION OF BACKHOE BOOM

. To install, reverse the removal procedure.

When aligning the positions between hole and pin,

run the engine at idling.
Do not introduce hand fingers in the holes to check
the alignment.

Bushings inside: ASL800050

1 - Start the engine and bleed the air from cylinders.
(For details, see «20. TESTING AND ADJUSTMENTS»).
H After the air bleeding, check the oil level in the tank.

30-162
DISASSEMBLY AND ASSEMBLY BRACKET

REMOVAL OF BRACKET

1 - Remove the work attachments. (For details, see «RE-

MOVAL OF WORK ATTACHMENTS»).
2 - Remove the bolts and the connecting pins (1) of 6
swing cylinders (2).
3
3 - Sling the bracket (3).
4 - Remove the circlip (4) and the boom blocking unit (5)
with the spacer (6). 1
5 - Remove the bolts and the bracket hinge pins (7).
2
6
F0401354

6 - Remove the bracket (3) and relative thrust rings (No.

3).

Support: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5
INSTALLATION OF BRACKET
4
. To install, reverse the removal procedure.
7

When aligning the positions between hole and pin, 6

run the engine at idling. F0401355

Do not introduce hand fingers in the holes to check

the alignment.

Bushings inside: ASL800050

3
H Insert the thrust rings.
1 - Start the engine and bleed the air from cylinder.
(For details, see «20. TESTING AND ADJUSTMENTS»).
H After the air bleeding, check the oil level in the tank.

F0401356

30-163
DISASSEMBLY AND ASSEMBLY BACKFRAME

REMOVAL OF BACKFRAME

1 - Remove the work attachments. (For details, see «RE-

MOVAL OF WORK ATTACHMENTS»).
2 - Remove the swing cylinders. (For details, see «RE- 1
MOVAL OF SWING CYLINDERS»).
2

3 - Remove the swing post. (For details, see «REMOVAL

OF BRACKET»).
4 - Disconnect the feeding pipe (1) of backframe lock pis-
tons and plug it to avoid impurity entry; plug also the
pipe (2) connection.
5 - Sling the backframe (3) with tool H1. F0401357

6 - Remove the backframe lock cylinders.

(For details, see «REMOVAL OF BACKFRAME LOCK
CYLINDERS»).
7 - Remove the backframe (3).
H1
3

INSTALLATION OF BACKFRAME
. To install, reverse the removal procedure.
1 - Start the engine and bleed the air from all cylinders.
(For details, see «20. TESTING AND ADJUSTMENTS»). F0401358

H After the air bleeding, check the oil level in the tank.

30-164
01

10

20

30

40

90
 MAINTENANCE STANDARD

P.T.O. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 3 3-spool control valve . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 18

Transmission . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 4 6-spool control valve . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 19
Axles . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 6 Brake pump .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 20
Front differential. . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 6 Outrigger safety valves . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 21
Rear differential . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 7 Steering and front work equipment cylinders. . .. . . . 22
Planetary . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 8 Backhoe cylinders. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 24
Differential locking . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 9 Frame knuckle and joint . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 28
Brakes. . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 10 Backhoe frame . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 29
Hydrostatic transmission pump . . . .. . . . .. . . . . .. . . . .. . 11 Front work equipment.. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 30
Travel motor . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 15 Backframe and bracket . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 32
Steering pump.. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 17 Backhoe work equipment. . .. . . . .. . . . . .. . . . . .. . . . .. . . . 34

40-1
40-2
P.T.O.

50
50Nm
Nm

50
50Nm
Nm

50 Nm 195 195
Nm Nm
50 Nm
with Loctite 262
con Loctite 262

90
90Nm
Nm

D0400782

50
50Nm
Nm

40-3
TRANSMISSION

A 25 Nm
25 Nm

50w2.5
50 Nm
2,5 Nm

50w2.5 Nm
50 2,5 Nm

50w2.5
50 2,5Nm
Nm
35 ± 50
35
50Nm
Nm

A 50w2.5 Nm
35 ± 50
35
Nm
50 Nm 50 2,5 Nm

24

24 ± 26
26 Nm
Nm

25 Nm
25Nm
Loctite 510
Loctite 510
80 ± 100 Nm
80
100 Nm 30Nm
30 Nm

Section
SezioneBB- -BB
D0400751

40-4
 25
25 Nm
Nm Loctite
Loctite 510
510

50w2.5
50 Nm
± 2,5 Nm

260 ±
300
260 300Nm
Nm
with Loctite270
con Loctite 270

2
23.8 ± 28.5
23,8
Nm
28,5 Nm

Loctite
Loctite510
510 Loctite
Loctite 510510

Section
SezioneAA -- A
A
D0400754

Unit: mm

No . Check item Criteria Remedy

Standard clearance Clearance limit

1 Bearing axial clearance
0.25 0.50 Adjust

2 Pinion rotation torque 100 ± 150 Ncm

40-5
AXLES

FRONT DIFFERENTIAL

73w76 Nm
49w52
49  52Nm
Nm 73  76 Nm
Loctite
Loctite 270
270 with Loctite
con Loctite 270
270
with Loctite
con Loctite 242
242

49w52
49  52Nm
Nm
with Loctite
con Loctite 272
272

D0400759

Unit: mm

No . Check item Criteria Remedy

Standard clearance Clearance limit

1 Bearing axial clearance Adjust
0 0.05

40-6
REAR DIFFERENTIAL

10
10Nm
Nm 69
69±
7272Nm
Nm 73
73±
7676Nm
Nm
with
conLoctite
Loctite222
222 with
con Loctite
Loctite 270
270 with Loctite 270
con Loctite 270 Loctite
Loctite222
222

2
69

69 ± 71
71 Nm
Nm
withLoctite
con Loctite270
270

260
260 ±
300
300NmNm
with Loctite 270
con Loctite 270
D0400760

Unit: mm

No . Check item Criteria Remedy

Standard clearance Clearance limit

1 Bearing axial clearance
0 0.05

Backlash of crow wheel Adjust

2 0.18 0.23
and pinion

Tightening torque of slew

3 100 ± 150 Ncm
pinion (w/o seal)

40-7
PLANETARY

86
86±
89 Nm
89Nm

7676
± 81 Nm

81 Nm

D0400761

Unit: mm

No . Check item Criteria Remedy

1 Hub rotation torque 7 ± 20 Nm Adjust

2 Drive shaft axial clearance 1±2 Replace

40-8
DIFFERENTIAL LOCKING

90

90 93 Nm
± 93 Nm
1 2 Loctite
Loctite 242242
con
withLoctite
Loctite242
242

Loctite 242
Loctite 242

D0400762

Unit: mm

No . Check item Criteria Remedy

1 Piston stroke 10

Standard size Repair limit

Replace if
Free Installated Installated Free Installated
2 Piston returning spring dannaged
length length load length load
or deformed
40.5 29 18.3w1 Ð Ð

40-9
BRAKES

10±

10 1111Nm
Nm 25 ±
28
25 28Nm
Nm 30
± 35
30 35 Nm
Nm
con
withLoctite
Loctite270
270

3 2
D0400763

Unit: mm

No . Check item Criteria Remedy

Standard size Repair limit

Replace if
Free Installated Installated Free Installated
1 Returning spring dannaged
length length load length load
or deformed
35 24.4 19.6w1 Ð Ð

Standard thickness Min. thickness

2 Disk thickness Replace
4.8 ± 4.9 4.3 ± 4.4

Standard clearance Max. clearance

3 Disk clearance Adjust
w0.5 1.5

40-10
HYDROSTATIC TRANSMISSION PUMP

PUMP BODY AND BOOSTING PUMP

2 3 4 X

8 6

Section
SezioneAA-- A
A Detail X X
Particolare
D0400851

Unit: mm

No . Check item Criteria Remedy

Gear boosting pump Standard value Repair limit

1
diameter Ð Ð

Backlash between drive shaft Standard backlash Max. backlash

2
and bushing Ð Ð
Backlash between piston
3 Ð Ð
and bushing
Tolerance Standard Max.
Backlash between pump Nominal size
4 Shaft Hole backlash backlash
shaft and bushing
Ð Ð Ð Ð Ð
Backlash between shoe
5 Ð Ð Ð Ð Ð
and piston
Backlash between oscillating
6 Ð Ð Ð Ð Ð
lever and swash plate pin
Standard value Max. value
7 Gear boosting pump width
Ð Ð
8 Rotating body length 89.6 0.2 Ð
9 Drive shaft diameter Ð Ð

40-11
POSITIONING CYLINDER

2 3 2 3
Section B
Sezione B -- BB
D0400856

Unit: mm

No . Check item Criteria Remedy

Tolerance
Standard Max.
Nominal size
Backlash between cylinder backlash backlash
1 Shaft Hole
and bushing
Ð Ð Ð Ð Ð

Standard size Repair limit

Positioning cylinder inner Free Installated Installated Free Installated

2
spring lenght length load length load

37.76 Ð Ð Ð Ð

Positioning cylinder outer

3 49.98 Ð Ð Ð Ð
spring

40-12
RELIEF AND BOOSTING VALVE

MAIN RELIEF
VALVOLA VALVE
DI MASSIMA VALVOLABOOSTING VALVE
DI SOVRALIMENTAZIONE

1
90w10
90  10Nm
Nm
70
70 Nm
Nm

Section
SezioneCC--CC Section D
Sezione D -- D
D

D0400854

Unit: mm

No . Check item Criteria Remedy

Standard size Repair limit

Free Installated Installated Free Installated

1 Spring
lenght length load length load

26 Ð Ð Ð Ð

2 Relief valve spring 44.94 Ð Ð Ð Ð

3 Boosting valve spring 27 Ð Ð Ð Ð

40-13
TRAVEL MOTOR

10 Nm
10 Nm

69 Nm
69 Nm
2
3
1

69 Nm D0400850
69 Nm

Unit: mm

No . Check item Criteria Remedy

Standard value Repair limit

Free Installated Installated Free Installated

1 Check valve spring
length length load length load

Ð Ð Ð Ð Ð

2 Piston spring Ð Ð Ð Ð Ð

3 Cylinder block central spring Ð Ð Ð Ð Ð

4 Scavenge circuit valve spring Ð Ð Ð Ð Ð

40-15
 1

...............
............... ...............
...............

2 2
Section B - B
Sezione B-B
...............
...............

...............
...............

...............
............... ...............
...............
D0400852
Section
SezioneAA- -AA

Unit: mm

No . Check item Criteria Remedy

Standard size Repair limit

Solenoid spool returning Free Installated Installated Free Installated

1 Replace if
spring length length load length load
dannaged
or deformed
Ð Ð Ð Ð Ð

2 Exchange valve spring Ð Ð Ð Ð Ð

40-16
STEERING PUMP (P2)

2 3

4
70
70Nm
Nm

2
1

D0400709

Unit: mm

No . Check item Criteria Remedy

Standard clearance Clearance limit

Axial clearance between gears
1
and bushings
+0.06 +0.01

Clearance between gear shaft

2 0.01 0.082
and bushing

Radial clearance between

3 0.07 0.11
gear and gear case
Replace
Standard value Repair limit
Wear of gear shaft surface
4
contacting with oil seal
18.00 17.98

Revolutions Delivery Revolutions Delivery

(rpm) (,/min) (rpm) (,/min)
5 Delivery (Flow rale)
1500 Ð Ð Ð

40-17
3-SPOOL CONTROL VALVE

A B C
20

± 24 8 ±
10
8 10Nm
Nm
20 24Nm
Nm

28 Nm
28 Nm
28
28Nm
Nm

20
20±

2424Nm
Nm 8
8 ±
10
10Nm
Nm
A B C

±

88 1010
NmNm 88±

1010Nm
Nm 8
Nm
8 ± 10 10 Nm
1 with
conLoctite
Loctite262
262 1 with
conLoctite
Loctite 262
262 1 withcon
Loctite 262
Loctite 262

Section
Sezione A
A -- A
A Section
Sezione B
B -- B
B Section C
Sezione C -- C
C

D0400710

Unit: mm

No . Check item Criteria Remedy

Standard sizee Repair limit

Replace if
Free Installated Installated Free Installated
1 Spool return spring dannaged
length length load length load
or deformed
54.43 24.65 105 N 52 100 N

40-18
6-SPOOL CONTROL VALVE

10
8 ±8 10 NmNm

A B C
20
20±

2424Nm
Nm
2020
± 24 NmNm

24

2828Nm
Nm

28
28Nm
Nm

A B C 20 ±
24
20 24Nm
Nm

88
± 10 Nm

10 Nm

1 8 8

± 1010Nm
Nm 1 88

± 10
10Nm
Nm 1 8 ±8

10 10
NmNm
with
conLoctite
Loctite262
262 with
con Loctite
Loctite 262
262 with Loctite
con 262
Loctite 262
Section A - A Section B - B Section C - C
Sezione A - A Sezione B - B Sezione C - C
D0400711

Unit: mm

No . Check item Criteria Remedy

Standard value Repair limit

Replace if
Free Installated Installated Free Installated
1 Spool return spring dannaged
length length load length load
or deformed
54.43 24.65 105 N 52 100 N

40-19
BRAKE PUMP

1 2 3 157 Nm
157 Nm

D0400853

Unit: mm

No . Check item Criteria Remedy

Standard value Repair limit

Free Installated Installated Free Installated

1 Spring
length length load length load
Replace if
dannaged
24 13.5 45 N 13.5 w8 N
or deformed
2 Spring 16 12.5 3N 12.5 w1.5 N

3 Pump spring 94 60 45 N 60 w6 N

40-20
OUTRIGGER SAFETY VALVES

83 Nm
83 Nm

33 Nm
33 Nm

D0400094

Unit: mm

No . Check item Criteria Remedy

Standard value Repair limit

Replace if
Free Installated Installated Free Installated
1 Setting spring dannaged
length length load length load
or deformed
16.5 11.12 2.464 kg 13.5 1.1 kg

40-21
STEERING AND FRONT WORK EQUIPMENT CYLINDERS

LIFT CYLINDER

930±

930 980
980Nm
Nm 784
882
± 882
784 NmNm

2 4 3

D0400721

DUMP CYLINDERx

490 Nm
490 Nm 930±
980
930 950Nm
Nm 980±

980 1029
1029Nm
Nm

2 1
3

D0400722

STEERING CYLINDER

930
980 Nm 588
637 Nm

930 ± 980 Nm 588 ± 637 Nm

2 4 3

D0400723

40-22
KNUCKLE LOCKING CYLINDER

D0400724

Unit: mm

No . Check item Criteria Remedy

Tolerance
Standard Standard Clearance
Clearance Cylinder
size clearance limit
1 between piston Shaft Hole
rod and guide ring
Dump Ð Ð Ð Ð Ð

Lift Ð Ð Ð Ð Ð
Clearance
between piston
2 Dump Ð Ð Ð Ð Ð
rod support shaft
and bushing
Steering Ð Ð Ð Ð Ð

Lift Ð Ð Ð Ð Ð
Clearance
between cylinder
3 Dump Ð Ð Ð Ð Ð
botton shaft and
bushing
Steering Ð Ð Ð Ð Ð

Lift Ð Ð Ð Ð Ð
Clearance
between piston
4 Steering Ð Ð Ð Ð Ð
rod and cylinder
head
Bounce locking Ð Ð Ð Ð Ð

40-23
BACKHOE CYLINDERS

BOOM CYLINDER

930
930±
980
980Nm
Nm 930

930 ± 980
980Nm
Nm

2 1 3

D0400725

ARM AND BUCKET CYLINDER

930930
980
± 980 NmNm 930±

930 980
980 NmNm

2 1 3

D0400726

BOOM SWING CYLINDER

930930
± 980 NmNm

980 .............
...............

A ...............
.............
2

A
4 1 D0400731

40-24
 Unit: mm

No . Check item Criteria Remedy

Tolerance
Standard Standard Clearance
Cylinder
size clearance limit
Shaft Hole
Clearance Boom Ð Ð Ð Ð Ð
between piston
1 Replace
rod and cylinder
head Arm Ð Ð Ð Ð Ð

Bucket Ð Ð Ð Ð Ð

Boom swing Ð Ð Ð Ð Ð

Boom Ð Ð Ð Ð Ð
Clearance Arm Ð Ð Ð Ð Ð
between piston
2
rod support shaft
and bushing Bucket Ð Ð Ð Ð Ð
Replace
Boom swing Ð Ð Ð Ð Ð pin and
bushing
Boom Ð Ð Ð Ð Ð
Clearance
between cylinder
3 Arm Ð Ð Ð Ð Ð
botton shaft and
bushing
Bucket Ð Ð Ð Ð Ð

Standard value Repair limit

Replace if
Free Installated Installated Free Installated
4 Piston spring Boom swing dannaged
length length load length load
or deformed
Ð Ð Ð Ð Ð

40-25
OUTRIGGER CYLINDER

930±

930 980 Nm
980 Nm 930±

930 980 Nm
980 Nm

D0400727

JIG ARM CYLINDER

930
930
980
± 980 NmNm 930
930
980
± 980 NmNm

D0400983

SIDE DIGGING BOOM CYLINDER

490
490Nm
Nm 930

930 ± 980
980Nm
Nm 930
930±

980
980Nm
Nm

3 1 4

D0400729

ARM CYLINDER SIDE DIGGING BOOM

930

930 ± 980
980Nm
Nm 930
930±
980
980Nm
Nm

3 1
5

D0400728

40-26
BACKFRAME LOCKING CYLINDER

D0400730

Unit: mm

No . Check item Criteria Remedy

Tolerance
Standard Standard Clearance
Cylinder
size clearance limit
Shaft Hole

Outrigger Ð Ð Ð Ð Ð
Clearance
between piston
1 Side digging
rod and cylinder Ð Ð Ð Ð Ð
head boom

Arm for side

Ð Ð Ð Ð Ð
digging boom

Jig arm Ð Ð Ð Ð Ð

Clearance
Backframe
2 between piston Ð Ð Ð Ð Ð Replace
locking
rod and piston

Side digging
Clearance Ð Ð Ð Ð Ð
boom
between piston
3
rod support shaft
and bushing Arm for side
Ð Ð Ð Ð Ð
digging boom

Clearance
between cylinder Side digging
4 Ð Ð Ð Ð Ð
botton shaft and boom
bushing

Clearance
Arm for side
5 between bearing Ð Ð Ð Ð Ð
digging boom
and bearing seat

Clearance between Standard clearance Clearance limit

Backframe
6 locking pad and Adjust
locking
back frame 2 Ð

40-27
FRAME KNUCKLE AND JOINT

...............
..................

Detail A A
Particolare A C

2
...............
..................

Detail C C
Particolare

D0400750

Unit: mm

No . Check item Criteria Remedy

Tolerance
Standard Standard Max.
size clearance tolerance
Clearance between hinge Shaft Hole
1
pin and bushing Replace
±0.060 +0.106 0.131± bushing
70 Ð and pin
±0.106 +0.071 0.212

Clearance between joint ±0.500 ±0.357 0.103

2 130 Ð
and bushing ±0.540 ±0.397 0.183

Standard clearance Clearance limit

3 Joint axial clearance
Ð Ð

Standard thickness Minimum thickness Rebuit

4 Spacer thickness
+0
11.5 ± 0.05 Ð

+0
5 Spacer thickness 5.5 ± 0.05 Ð

40-28
BACKHOE FRAME

1
A

A 4
3

D B

Section
SezioneAA -- A
A
D0400732
Unit: mm

No . Check item Criteria Remedy

Check Repair limit

Curvature Ð

1 Deformation of backhoe frame Horizontal torsion Ð

Vertical torsion Ð

Parallelism of giudes Ð

Standard size Size limit

2 Distance between guide centre
525w1 Ð Rebuit

3 Support tolerance Ð Ð

Check Standard size Size limit

A 80 Ð

4 Guide dimension B 125 Ð

C 10 Ð

D 45 Ð

40-29
FRONT WORK EQUIPMENT

E E

D
D

B
B C
C
A
A

1 2 3

Section
SezioneAA- -AA Section
SezioneB B- B
-B Section
Sezione CC -- C
C

4
5

Section
SezioneDD-- D
D Section
Sezione E
E -- E
E
D0400734

40-30
 Unit: mm

No . Check item Criteria Remedy

Tolerance
Standard Standard Max.
Clearance between pin and size clearance clearance
1 bushing at joint of lift arm and Shaft Hole
bucket
Ð Ð Ð Ð Ð

Clearance between pin and

2 bushing at boss ends of bucket Ð Ð Ð Ð Ð
link
Replace
Clearance between pin and
3 Ð Ð Ð Ð Ð
bushing at joint of tilt lever

Clearance between pin and

4 bushing at joint of tilt lever Ð Ð Ð Ð Ð
and lif arm

Clearance between pin and

5 bushing at joint of lift arm and Ð Ð Ð Ð Ð
frame

40-31
BACKFRAME AND BRACKET

1 2

Section
Sezione A
A -- A
A Section
Sezione B
B -- B
B D0400735

40-32
 4

Section
Sezione CC -- C
C
D0400736

Unit: mm

No . Check item Criteria Remedy

Clearance between rotating Tolerance

Standard Standard Max.
1 bushing and boom swing
size clearance tolerance
cylinder bushing Shaft Hole

Clearance between bushing ±0.05 +0.242 0.230

2 ù 45 1.2 Replace
and swing post rotating pin ±0.089 +0.180 0.331
bushing
and pin
Clearance between bushing ±0.05 +0.242 0.230
3 ù 45 1.2
and hinge pin ±0.089 +0.180 0.331

Clearance between bushing ±0.05 +0.242 0.170

4 ù 45 1.0
and hinge pin ±0.089 +0.180 0.253

Standard size Size limit

5 Shim thickness
4.75 10 Replace

6 Shim thickness 4.75 10

40-33
BACKHOE WORK EQUIPMENT

C
C

D B A A

1 2 3 4

Section
Sezione A
A -- A
A Section
SezioneBB-- B
B

6
5

Section
Sezione CC -- C
C
6
Section
Sezione D
D -- D
D D0400733

40-34
 Unit: mm

No . Check item Criteria Remedy

Tolerance
Standard Standard max.
Clearance between arm size clearance clearance
Shaft Hole
1 bushings and bucket
mounting pin
±0.05 +0.08 0.130
ù 40 1.2
±0.089 +0.24 0.329

Clearance between link

±0.05 +0.08 0.130
2 bushings and bucket ù 40 1.2
±0.089 +0.24 0.329
mounting pin
Replace
Clearance between bushings bushing
±0.05 +0.08 0.130
3 and the fulcrum lever ù 40 1.2 and pin
±0.089 +0.24 0.329
mounting pin

Clearance between link

±0.05 +0.08 0.130
4 bushings and the fulcrum ù 40 1.0
±0.089 +0.18 0.269
lever mounting pin

Clearance between arm ±0.05 +0.119 0.130

5 ù 45 1.0
mounting pin and bushings ±0.089 +0.080 0.208

Clearance between boom ±0.05 +0.119 0.130

6 ù 45 1.0
mounting pins and bushings ±0.089 +0.080 0.208

40-35
01

10

20

30

40

90
HYDRAULIC CIRCUIT DIAGRAM

3-spool control valve

P1

P T2
R.H. equipment port

200 kg/cm2
Lift cylinder
Raise

Lower

170 kg/cm2

170 kg/cm2

195 kg/cm2

270 kg/cm2
T T1

B1 A1 B2 A2 B3 A3
Dump cylinder

Curl

Dump 3 bar

Raise

Lower
Backframe locking cylinder
Lift cylinder
Suction filter 60 m
Backframe
L.H. equipment port locking cock
Hydraulic
65 ø tank C

Hydrostatic transmission strainer 10 m

LS T P
Steering unit
230 kg/cm2
6-spool control valve
(parallel type)
T
190 kg/cm2 Boom cylinder
Inching valve
Lower
Knuckle locking 3 bar
cylinder 160 kg/cm2 160 kg/cm2 Raise
P3 Pump:
Hydrostatic transmission theorical displacement A6
210 kg/cm2
L R P1 pump A4VG40 26.5 cc/rev
A FS S MH G X2 X1 T2 270 kg/cm2
L.H. boom swing
Travel motor A6VM55 P B6 cylinder
dx sx
B M1 T1 MA
160 kg/cm2 A5 Right
EV3 S sx dx
R.H. steering cylinder Left R.H. boom swing
B A 160 kg/cm2
Front axle

B5 cylinder
S
A4 Lower
L.H. outrigger
EV8 P cylinder
B4 Raise

MB Engine 4D98E-1FA: A3 Lower

51.1 kW at 2500 rpm R.H. outrigger
U A G T cylinder
B3 Raise
B Fa PS T1 R
EV7 EV6 2 A2 Curl
210 kg/cm
Bucket cylinder
B2 Dump

L.H. steering cylinder A1 In

210 kg/cm2
CF EF Arm cylinder
P2 Pump: B1 Out
theorical displacement
Priority 14.2 cc/rev
valve LS

P
T1

Rear axle
Differential
A4 A3 A1 A2 B2 locking

T
EV1 EV2 EV3 EV4
D0401092

10-33
 7-SPOOL CONTROL VALVE 7-SPOOL CONTROL VALVE
6-SPOOL CONTROL VALVE SERIES TYPE FOR SIDE DIGGING BOOM FOR HAMMER
T P T P T P
190 kg/cm2 190 kg/cm2 190 kg/cm2
Boom cylinder Boom cylinder
Boom cylinder
Lower Lower Lower
Raise Raise Raise

A6 210 kg/cm 2 A6 A6
270 kg/cm2 210 kg/cm2

210 kg/cm2 270 kg/cm2 L.H. boom swing cylinder 270 kg/cm2 L.H. boom swing cylinder
B6 L.H. boom swing cylinder B6 B6

160 kg/cm2 A Right

160 kg/cm2 A5 Right
160 kg/cm2
A5 Right
160 kg/cm2 Left Left
R.H. boom swing cylinder 160 kg/cm2
160 kg/cm2
Left B5 R.H. boom swing cylinder
B5 R.H. boom swing cylinder B5
A4 Lower Lower
A4
A4
L.H. outrigger cylinder L.H. outrigger cylinder
L.H. outrigger cylinder Raise
B4 B4 Raise
B4 Raise
A3 Lower Lower
A3
A3 Lower R.H. outrigger cylinder R.H. outrigger cylinder
R.H. outrigger cylinder Raise
B3 Raise
Raise B3
B3
210 kg/cm2 A2 Curl 210 kg/cm2 A2 Curl
A2 Curl
210 kg/cm2 Bucket cylinder Bucket cylinder
Bucket cylinder Dump
B2 Dump
Dump B2
B2
A1 In A1
A1 In
In
210 kg/cm2 Arm cylinder Arm cylinder
Arm cylinder 210 kg/cm2
210 kg/cm2 B1 Out B1 Out
B1 Out
A7 Left
A7
Side digging
Right boom cylinder Hammer
B7 B7
T1

T1 T1

7-SPOOL CONTROL VALVE 8-SPOOL CONTROL VALVE FOR

FOR JIG ARM JIG ARM AND SIDE DIGGING BOOM
T P
T P 190 kg/cm2
190 kg/cm2
Boom cylinder
Out
Lower Jig arm cylinder
Raise A8 In

210 kg/cm2 A6
B8
Lower
270 kg/cm2 L.H. boom swing cylinder Boom cylinder
B6
210 kg/cm2 A6 Raise
160 kg/cm2 A5 Right
270 kg/cm2 L.H. boom swing cylinder
160 kg/cm2 Left B6
B5 R.H. boom swing cylinder
160 kg/cm2 A5 Right
A4 Lower
160 kg/cm2 Left
L.H. outrigger cylinder B5 R.H. boom swing cylinder
B4 Raise
A4 Lower
A3 Lower L.H. outrigger cylinder
R.H. outrigger cylinder B4 Raise
B3 Raise
A3 Lower
210 kg/cm2 A2 Curl R.H. outrigger cylinder
Bucket cylinder B3
Raise
B2 Dump
210 kg/cm2 A2 Curl
A1
In Bucket cylinder
B2 Dump
210 kg/cm2 Arm cylinder
B1 Out
A1 In
A7 Out
210 kg/cm2
Arm cylinder
Jig arm cylinder B1 Out
B7 In
A7 Left
Side digging
arm cylinder
Right
B7

T1
D0401345

T1

10-34
ELECTRICAL DIAGRAM (1/5)

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

R1
2.14

R1
R1

N1

R1

R1
ST2
L5
T°

A2,5

B1,5
A2,5
ST1 i
+ S- G1 G1
L1 L3 L2 L4 ST1-H i R1 2.15

+ S-

V-B1

H-N1
R1 ACC. R2 BR C

N1
OF AC

M1

V1

L-G1
R S
1 2 3 4 5 6
L-V1

H-N1,5
2.2
B
C-B1

Z-B1
N1
Z-N1
G1
3.2

Z-B1
S1 M-B1
4.1

N1
2.14

Z-B1
Z-B1

M-B1
B1,5

L-V1
C-B1
H-N1
Z-N1
V-B1

L-G1
M1
V1
X3 X3 16 X3 17 X3 X3 X3 X7 X3 X7 X7 X3 11
X2 12
8 6 7 20 11 21 7 14

K2

F5C
3.2
K12
A3
86 87a 87 K1 86 87a 87
+30 3.5 D1
2.14
D21 D25 2.1
K6

D12
D24
85 30 85 30
2.1
D8
D26 86 87a 87
+30 +15
K8 3.2
86 87a 87 85 30 K2
R10

K10 D10 D19 +15 4.4 4

3.5
2.9
K11
85 30 5 3

F2A
D28 D29
1 2 Z1 D32
D18
F2A

F5B K11

F2C
2.9
D27

D23 OP. OP.

D31
+15
+15 2.1

12 1 3 7 14 17 4 16 15 9 2 11 8 6 10 5 13 17 10
X1 X1 X1 X1 X1 X1 X1 X1 X1 X1 X1 X1 X1 X1 X1 X1 X1 X6 X6

A-V1
M1

H1
H-N1

L-G1
S1

H-R1
R/N1

H-G1,5
M-N1,5
Z-N1
Z-B1

V1
V-B1
L-N1,5
R2,5
B-N1

G2,5

2.1

86 87 R1

KA

A-V1
85 30
Z-B1

R-N2,5 S8

L-N1,5

N2,5

N1
R2,5
G2,5 G-N1
FG1 FG2 SOL1

M-N1,5

H-G1,5
G-N1

R-N1

1 2 3 4 5

H-N1
V1
V-B1

H-R1
M1
N1

R/N1
R10

Z-B1

H1

N1
L-G1
S1

N1
N1
R6

N1
R35

R6

KE
86 87a 87 S3 X0 1 2 1 2 1 2
D+ 1 2 3 4 5 S2 S6 S7
+ S4
30
M 50
G1
B+
G W OP.
M4

85 30
B1 12Vcc
M1 3
R-N1 1A 1A 1A
R1
R4

C1

N1
U K15 EV6 EV7 EV8
- D
N35

N1

N1

COMPONENTS FUSES CONNECTOR

A3 - Buzzer K1 - Neutral machine relay M1 - Starter motor F2A - Neutral, forward travel, reverse high X1 - 17-ways connector dash-board red line
B1 - Battery K8 - Hydraulic neutral pilot lamp relay S1 - Starter switch speed solenoid valve X2 - 13-ways connector dash-board line
C1 - Pre-heater K10 - Starting from neutral approval S2 - Air filter clogging sensor F5B - Roof light (opt. radio), emergency light, X3 - 21-ways connector dash-board black
SOL1 - Stop motor K12 - Recognition relay S3 - Lubricating oil pressure sensor K3 coil relay line
EV6 - Forward travel solenoid valve L1 - Battery light S4 - Coolant temperature sensor F5C - 6 - way solenoid valve (optional), recogni- X6 - 21-ways connector front line
EV7 - Reverse high speed solenoid valve L2 - Pre-heater light S6 - Coolant high temperature sensor tion, ENPI solenoid valve (optional), floating X7 - 17-ways connector cabin line
EV8 - Travel solenoid valve return L3 - Oil pressure light S7 - Hydraulic oil filter clogging sensor axle solenoid Valve, manual breaker solenoid
KA - Starter relay L4 - Air filter clogging light S8 - SW ride ON valve (optional).
KE - Preheating cut out relay L5 - Hydraulic oil filter clogging light

10-57
10-58
ELECTRICAL DIAGRAM (2/5)

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
DE 1.15
N1
M-V1 LATO LUCI CLAXON
3.1 H-G1,5 4.12 PAG.3
S17 N1 1.15 3.1
G1
1 2
S25 1 5 7 4 6 XE S28

A-N1
1 6
X12 X11 X11 ST3

G1
A1
N.C. 2

S-N1

A-B1
A-N1
86 87a 87

R1
G1
A1

B1
1.15
4 1 5 R1

N1

C1

R1
K18 Q i G1

N1

N1
6 7 1 2 3 4 5 6
1 5 7 4 6 + S -
1.19 X5 X5 X5 X5 X5 30 S16

N1
85

R1
L-V1

B1
S12

N1
L-V1

L-V1

S-N1
R-V1
L6 L7

H-G1,5
H-R1

B-G1
L17 L18 R-V1
4.12
3.3 H-G1,5
L-R1 3.8
L-B1
C-B1

B-R1
3.12
N1 3.2
L-B1
3.12

M-N1
M-B1

C-N1

R-N1
B-N1
G-R1

A-G1
A-N1
H1

B1
C1
X3 9
X3 18 X4 4
X4 9
X4 3
X4 8
X4 5
X4 2
X4 1
X4 6
X4 7
X2 6
X7 13 X3 4
X7 12 X3 3
X3 12 X2 11 X7 3
X3 10
X3 5
X3 19 X2 13 X3 1
4.10
1.12
D33
1.8 1.2
D30 +30
1.19 D22 F5B
K1
K6 1.19 3.7
86 87a 87

D6
K1 K5
4.12 D11 86 87a 87 86 87a 87 86 87a 87
K13 86 87a 87 86 87a 87
85 30
D5 K4 D9 K9
D4

F6A
85 30 85 30 85 30 85 30 85 30

D3
K11
86 87a 87 D13
1.19 F4C K3
1.19
85 30
+15
K1 D15 D16

9 7 20 6 7 4 3 2 1 5 8 17 15 14 4 6 6 18 13 16 7 12 9 5 21 11
X6 X6 X6 X10 X10 X10 X10 X10 X10 X10 X6 X8 X8 X8 X8 X8 X6 X6 X8 X8 X8 X8 X8 X8 X6 X6
Z1

Z1

N1

R1

R-N1
B-N1

B-R1
A-V1

C1
C-L1

M-B1
C-N1
B-N1

B1
H2,5
M-N1

L-B1
M-B1

G-N1
S-G1

A-G1

A-G1

C-B1
Z-N1
1 2 3
R-N1 S11

C-N1

C-N1
3.2

I S -
EV11 EV12 EV13
S9

N1

N1

N1
Z1

N1
N1

N1

N1
B-N1

B-R1
A-V1
C-L1

N1
C1

N1
R1
N1

N1

2
1 2
X9 1 2
S10 1 2 1 2 1

1 2
1 2 3 4 5 6 7 8
K16
1 2 3 4 5 XM6

N1
CENTRALINA CAMBIO 1A 1A 1A 1A 1A

1A EV6 EV3 EV4 EV1 EV2

N1
EV9

N1
CONNECTOR
X2 - 13-ways connector dash-board line
X3 - 21-ways connector dash-board black line
COMPONENTS FUSIBILI X4 - 9-ways connector dash-board line
EV9 - Displacement change solenoid valve K4 - ENPI (optional) solenoid valve relay L18 - High light F4C - Transmission inhibition unit 1st and X5 - 7-ways connector indicator light line
EV6 - Hammer (optional) solenoid valve K5 - Bounce locking solenoid valve relay S9 - Axle sensor 2nd travel speed X6 - 21-ways connector front line
EV3 - Differential locking solenoid valve K6 - Feed switch relay S10 - Brake oil level sensor F5B - Roof light (opt. radio) emergency X7 - 17-ways connector cabin line
EV4 - Bounce locking solenoid valve K9 - 6-ways solenoid valve (optional) relay S11 - Fuel level sensor light, K3 coil releÁ X8 - 17-ways connector rear line, solenoid valve line
EV1 - Low speed solenoid valve K11 - Hammer solenoid valve relay S12 - Micro hand brake F6A - Horn, supply fuel pump, electric socket X9 - 5-ways connector rear line
EV2 - High speed solenoid valve K13 - Hor relay S16 - Push-button panel X10 - 7-ways connector transmission main box
EV11 - ENPI (optional) solenoid valve K16 - Ride inhibition unit S17 - Horn light side X11 - 9-ways connector indicator light
EV12 - ENPI (optional) solenoid valve K18 - Neutral mechanical relay S25 - Switch transmission side X12 - 13-ways connector upper line
EV13 - 6-ways solenoid valve (optional) L6 - Differential locking light S28 - Electric socket XE - Connector 4th fast speed cut out
K1 - Neutral mechanical relay L7 - Brake oil level light ST3 - Fuel level indicator XM6 -Connector fuel pump preset
K3 - Mechanical speed gear L17 - Low light

10-59
10-60
ELECTRICAL DIAGRAM (3/5)

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

R-V1
2.16
G1 2.8

2.9
R-N1 57/58 56b 56a 54s 54d 49
S15 2.18

M-V1 0 1 2
4.1 54s
L-R1
L19 30 L 31 54d L13 L14 L15 L12 A-B1 L-B1
1 14
S27
1 6 4 9 R1
15
R3
FOLLE MECCANICA G-N1

B-R1
4 7 5 8 9 6 3 30/2 15/4 R/6 L/7
0 1 7

A-N1

M2,5
5 8 10

A1

G1

V1

C1
H1
N1 8
L16 49/1 x12
X11
2
X11
5
X11
7
X11
8
X11
4
X11
9
X11
6 S14 49a/5 5
220

1.15
B-R1 A-B1
3 4
C-B1
5
2.20 R2
N1 A-B1

V-N1
G-N1

H-N1

B-R1
G-R1

G-N1

R-G1
L-N1

S-G1
R1
G1

A1
L1

11

2.7
B-R1 N1 2

X7 6
X7 15
X3 14 X2 1
X2 2
X2 8
X2 3
X2 9
X2 4
X2 7
X3 15 X2 10 X7 10 X2 5
X3 13
2.7
L-B1
H-N1

R-N1.5

2.16
R1
10 16
G-N1
A4 17
R4
R1
F6B

F3B

F3A

6
9 12
1.19

A-B1
1.7 13
K1 +15 D14 86 87a 87 86 87a 87 4 K17
86 87a 87 1.3 D7 5 3
85 30 85 30
K2 +30 Z3
F3C

F6C

K14 K7 1 2
85 30

1.19 4.2

K1

A-B1

R1

N1
OP. OP.

16 1 3 11 10 2 14 4 3 15 12 1 13 2 5 8 19
X6 X8 X8 X8 X8 X8 X6 X6 X6 X6 X6 X6 X6 X6 X6 X8 X6

S1

N1
A1

G-R1
R1

R1

A-B1

30/1 15/2 L/6

A1

G1
G-R1

A-B1
G1

B1,5

B1,5
M1,5

M1,5
0 1

30b/4 49/3 R/7

S26

2.8
S15
57/58 56b 56a 54s 54d 49
0 1 2
R-N1

54s

30 L 31 54d

N1.5 N1.5
S13
N1

N1

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

G-R1
L8 L9 L10 L11 L26
4 5 7 8 4 9 6 1 3

A-N1

M2,5
N1

G1

H1

C1

N1
A1

V1

B1

N1
COMPONENTS FUSES CONNECTORS
A4 - Buzzer L10 - Front L.H. beam L26 - Registration number light F3A - Displacement change solenoid valve X2 - 13-ways connector dash-board line
K1 - Neutral mechanical relay L11 - Front R.H. beam S13 - Brake switch F3B - Tail light R.H. and panel light X3 - 21-ways connector dash-board black line
K2 - Buzzer output L12 - Driving beam light S14 - Emergency warning switch F3C - R.H. and L.H. lower beam X6 - 21-ways connector front line
K7 - Driving beam relay L13 - Roof light S15 - Light switch F6B - L.H. parking light X7 - 17-ways connector cabin line
K14 - Lower beam relay L14 - Car radio switch S26 - Low-high selection switch (registration number beam opt.) X8 - 17-ways connector rear line
K17 - Ride approval unit L15 - Direction indicator light S27 - Mechanical neutral F6C - R.H. and L.H. driving beam X11 - 9-ways connector switch
L8 - Rear L.H. beam L16 - Parking light Z3 - Flashing light X12 - 13-ways connector upper line
L9 - Rear R.H. beam L19 - Neutral pilot lamp

10-61
10-62
ELECTRICAL DIAGRAM (4/5)

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
1.19
M-B1 X12
11
A-B1 A-B1
3.3

L-N1,5
R-N1

A-N1

B-N1
1 5 9
0 1 2 L-B1 X12

L-N1,5
L20 A1 7
A1 7 6 2 9 0 1 2
7 6 2 9
1

R-N1
0 2

A-N1
A-B1
M
10

C1
3
X12

A1

A-R1

H-R1
S19

N1

N1
L-B1 6 L-B1 S21 5 3 10

N1
S20

C1
1 5 9 5 3 10 1

B-N1
0 1 2 3 4 5 6
1 2 3 4

N1
1 10
S18 G1,5
X12 A2 X12
12 4
M M L-N1,5
X12
10
A-N1,5
13

M
M2
C1

N1

3 B-N1

C1

N1

N1
L-N1,5
R1,5

A-N1
2 X12
N1,5 L-N1,5 3 L-N1,5
C1
1
M4 M3
A-G1,5
M5
N1

X7 16
X12 9
X7 5
X7 4

1.7
+15
3.14

F1C
F4A

2.8 2.7
F4B

F1B

F1A

17 9 8 2 1
X7 X7 X7 X7 X7
G2,5
S-N1,5

G-N2,5

H-G1.5
2.11
M-B1

4 1
X12 X12
A-N1

G-N1,5
S-N1,5

A-N1

A-N1
5 9 5 9 G1,5
0 1 0 1 0 1 5 9

M S22

G1,5

G1,5
L21
G-N1,5

G-N1,5

S23 S24
1 10 1 10 1 10

L24 L25
G-N2,5
Z1,5

G2,5

N1

L22 L23
N1
N1

N1,5

N1,5
N1,5

N1,5

COMPONENTS M3 - Front wiper motor FUSES CONNECTORS

A2 - Rear horn M4 - Fan motor
F1A - Rear working beam X7 - 17-ways connector cabin line
L20 - Mechanical neutral pilot lamp M5 - Rear wiper motor
F1B - Front working beam X12 - 13-ways connector upper line
L21 - Rotary beam S18 - Rear horn switch
F1C - Front and rear wiper
L22 - L.H. front working beam S19 - Fan switch
F4A - Fan solenoid valve, rear horn
L23 - R.H. front working beam S20 - Front wiper switch
L24 - L.H. rear working beam S21 - Rear wiper switch
L25 - R.H. rear working beam S22 - Rotary beam switch
M2 - Windshield washer motor S23 - Front working beam switch
S24 - Rear working beam switch

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ELECTRICAL DIAGRAM (5/5)

COMPONENTS
A3 - Buzzer
A4 - Buzzer
21 20 19 18 17 16 15 14 13 12 9 8 7 6 K1 - Mechanical neutral pilot lamp
X3 X4 K2 - Buzzer output
A4 11 10 9 8 7 6 5 4 3 2 1 5 4 3 2 1 K3 - Mechanical speed gear
K4 - Solenoid valve and ENPI (optional) relay
K5 - Bounce locking solenoid valve relay
7 6 5 13 12 11 10 9 8

X10 X2
K6 - Feed switch relay
4 3 2 1 7 6 5 4 3 2 1
K7 - Driving beam relay
F1 F2 F3
+15 K8 - Hydraulic neutral pilot lamp relay
K9 - 6-ways solenoid valve relay
K10 - Starting from neutral approval
A B C A B C A B C
K11 - Hammer (optional) solenoid valve relay
F4 F5 F6 K12 - Recognition relay
+30
K13 - Horn relay
K14 - Lower beam relay
Z1 - Elettrostop timer
A B C A B C A B C Z3 - Flashing light
TIMER E/G STOP FLASHER UNITS
GND
Z1 Z3
FUSES
F1A - Rear working beam
F1B - Front working beam
F1C - Front and rear wiper
F2A - Mechanical neutral solenoid valve, forward and
D1 D3 D4 D5 D6 D7 Reverse speed
K1 K2 K3 K4 K5 K6 K7 F2B - Elettrostop hold and alternator (reg.)
F2C - Alarm buzzers, coils R9, R4, R5, R11, Indicator lights,
mechanical neutral pilot lamp, Push-button panel and
instruments.
D17
D8 D9 D10 D11 D12 D13 D14 F3A - Displacement change solenoid valve
K8 K9 K10 K11 K12 K13 K14 F3B - R.H. parking light and instrument light
F3C - R.H. and L.H. lower beam
F4A - Fan solenoid valve, rear horn
F4B - Rotary beam
D17 D18 D19 D20 D21 D22 D23 D24 D25 D26 D27 D28 D29 D30 D31 D32 D33 F4C - Transmission inhibition unit 1st and 2nd travel speed
D16 F5A - Feed timed elettrostop
F5B - Roof light (optional radio), emergency light, bobina releÁ
A3 17 16 15 14 13 12 11 10 21 20 19 18 17 16 15 14 13 12
K3
X1 X6
F5C - Elettrovalvole 6 vie (op.), riconoscimento, elettrovalvola
enpi (op.), elettrovalvola ponte oscillante, elettrovalvola
9 8 7 6 5 4 3 2 1 11 10 9 8 7 6 5 4 3 2 1
martello a mano (op.)
17 16 15 14 13 12 11 10 17 16 15 14 13 12 11 10 F6A - Horn, supply fuel tank, electric socket
X7 X8
F6B - L.H. parking light (registration number beam optional)
F6C - R.H. and L.H. driving beam
9 8 7 6 5 4 3 2 1 9 8 7 6 5 4 3 2 1

CONNECTORS
1 2 3 4 5 7 8 9 10 11
X1 - 17-ways connector dash-board red line
X2 - 13-ways connector dash-board line
X3 - 21-ways connector dash-board black line
X4 - 9-ways connector instrument panel line
X6 - 21-ways connector front line
X7 - 17-ways connector cabin line
X8 - 17-ways connector rear and solenoid valve line
X10 - 7-ways connector transmission command line

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