00-14

CONTENTS

No. of page

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

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

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

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

WB91R-2 WB93R-2 00-1

00-2 WB91R-2 WB93R-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 10-67 20-15 20-56

00-2 10-27 10-68 20-16 20-57
00-2-1 10-28 10-69 20-17 20-58
00-2-2 10-29 10-70 20-18 20-59
00-3 10-30 10-71 20-19 20-60
00-4 10-31 10-72 20-20 20-61
00-5 10-32 10-73 20-21 20-62
00-6 10-33 10-74 20-22 20-63
00-7 10-34 10-75 20-23 20-64
00-8 10-35 10-76 20-24 20-65
00-9 10-36 10-77 20-25 20-66
00-10 10-37 10-78 20-26 20-67
00-11 10-38 10-79 20-27 20-68
00-12 10-39 10-80 20-28 20-69
00-13 10-40 10-81 20-29 20-70
10-41 10-82 20-30
10-1 10-42 10-83 20-31 30-1
10-2 10-43 10-84 20-32 30-2
10-3 10-44 10-85 20-33 30-3
10-4 10-45 10-86 20-34 30-4
10-5 10-46 10-87 20-35 30-5
10-6 10-47 10-88 20-36 30-6
10-7 10-48 10-89 20-37 30-7
10-8 10-49 10-90 20-38 30-8
10-9 10-50 10-91 20-39 30-9
10-10 10-51 10-92 20-40 30-10
10-11 10-52 20-41 30-11
10-12 10-53 20-1 20-42 30-12
10-13 10-54 20-2 20-43 30-13
10-14 10-55 20-3 20-44 30-14
10-15 10-56 20-4 20-45 30-15
10-16 10-57 20-5 20-46 30-16
10-17 10-58 20-6 20-47 30-17
10-18 10-59 20-7 20-48 30-18
10-19 10-60 20-8 20-49 30-19
10-20 10-61 20-9 20-50 30-20
10-21 10-62 20-10 20-51 30-21
10-22 10-63 20-11 20-52 30-22
10-23 10-64 20-12 20-53 30-23
10-24 10-65 20-13 20-54 30-24
10-25 10-66 20-14 20-55 30-25

WB91R-2 WB93R-2 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

30-26 30-85 30-144 30-203 30-262

30-27 30-86 30-145 30-204 30-263
30-28 30-87 30-146 30-205 30-264
30-29 30-88 30-147 30-206 30-265
30-30 30-89 30-148 30-207 30-266
30-31 30-90 30-149 30-208 30-267
30-32 30-91 30-150 30-209 30-268
30-33 30-92 30-151 30-210 30-269
30-34 30-93 30-152 30-211 30-270
30-35 30-94 30-153 30-212 30-271
30-36 30-95 30-154 30-213 30-272
30-37 30-96 30-155 30-214 30-273
30-38 30-97 30-156 30-215 30-274
30-39 30-98 30-157 30-216 30-275
30-40 30-99 30-158 30-217
30-41 30-100 30-159 30-218 40-1
30-42 30-101 30-160 30-219 40-2
30-43 30-102 30-161 30-220 40-3
30-44 30-103 30-162 30-221 40-4
30-45 30-104 30-163 30-222 40-5
30-46 30-105 30-164 30-223 40-6
30-47 30-106 30-165 30-224 40-7
30-48 30-107 30-166 30-225 40-8
30-49 30-108 30-167 30-226 40-9
30-50 30-109 30-168 30-227 40-10
30-51 30-110 30-169 30-228 40-11
30-52 30-111 30-170 30-229 40-12
30-53 30-112 30-171 30-230 40-13
30-54 30-113 30-172 30-231 40-14
30-55 30-114 30-173 30-232 40-15
30-56 30-115 30-174 30-233 40-16
30-57 30-116 30-175 30-234 40-17
30-58 30-117 30-176 30-235 40-18
30-59 30-118 30-177 30-236 40-19
30-60 30-119 30-178 30-237 40-20
30-61 30-120 30-179 30-238 40-21
30-62 30-121 30-180 30-239 40-22
30-63 30-122 30-181 30-240 40-23
30-64 30-123 30-182 30-241 40-24
30-65 30-124 30-183 30-242 40-25
30-66 30-125 30-184 30-243 40-26
30-67 30-126 30-185 30-244 40-27
30-68 30-127 30-186 30-245 40-28
30-69 30-128 30-187 30-246 40-29
30-70 30-129 30-188 30-247 40-30
30-71 30-130 30-189 30-248 40-31
30-72 30-131 30-190 30-249 40-32
30-73 30-132 30-191 30-250 40-33
30-74 30-133 30-192 30-251 40-34
30-75 30-134 30-193 30-252 40-35
30-76 30-135 30-194 30-253 40-36
30-77 30-136 30-195 30-254 40-37
30-78 30-137 30-196 30-255 40-38
30-79 30-138 30-197 30-256 40-39
30-80 30-139 30-198 30-257 40-40
30-81 30-140 30-199 30-258 40-41
30-82 30-141 30-200 30-259 40-42
30-83 30-142 30-201 30-260 40-43
30-84 30-143 30-202 30-261 40-44

00-2-2 WB91R-2 WB93R-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.

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

WB91R-2 WB93R-2 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 contact 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 WB91R-2 WB93R-2

 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, disassembling or assembling
each component, as well as precautions to be taken for these operations.

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

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.

WB91R-2 WB93R-2 00-5

HOW TO READ THE SHOP MANUAL

HOW TO READ THE SHOP MANUAL

VOLUMES SYMBOLS
Shop manual are issued as a guide to carry out 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 WB91R-2 WB93R-2

HOISTING INSTRUCTIONS

HOISTING INSTRUCTIONS

ing, and a serious accident can result.

Heavy parts (25 kg or more) must be lifted Hooks have maximum strength 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-

WB91R-2 WB93R-2 00-7

STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE

The following charts give the standard tightening torques of bolts and nuts. Exceptions are given in sections of «Di-
sassembly and Assembly».

1. STANDARD TIGHTENING TORQUE OF BOLTS AND NUT

Width across flat

(mm)
Thread diameter Pitch of
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 WB91R-2 WB93R-2

STANDARD TIGHTENING TORQUE

2. TIGHTENING TORQUE FOR NUTS OF FLARED

Use these torques for nut part of flared.

Thread diameter Width across flats TIGHTENING TORQUE

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

1/2" - 20 17 2.6w0.5 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

Sealing
Superficie surface
di tenuta

Thread diameter Width across flats TIGHTENING TORQUE

of nut part of nut part
(mm) (mm) kgm Nm
9/16" - 18 17 2.3 ± 2.5 23 ± 25
11/16" - 16 22 3.4 ± 3.9 33 ± 38
13/16" - 16 24 5.2 ± 5.8 51 ± 57
1" - 14 30 8.2 ± 9.2 80 ± 90
1.3/16" - 12 36 12.2 ± 13.3 120 ± 130
1.7/16" - 12 41 15.3 ± 17.3 150 ± 170
1.11/16" - 12 50 18.4 ± 20.4 180 ± 200
2" - 12 57 20.4 ± 24.4 200 ± 240

WB91R-2 WB93R-2 00-9

 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-metallic parts when a fast, strong
ASL800020 seal is needed.

Loctite 222 Used for low resistance locking of screws, check nuts and adjustment nuts.

To prevent the loosening of bolts, nuts and plugs and the leakage of oil. Used for
Loctite 242 medium resistance locking of screws and nuts of every type, and for locking keys
and bearings.

Loctite 262 Used for high resistant of threaded parts that can be removed with normal tools.
Adhesives
Loctite 270 Used for high resistant locking and for sealing threaded parts, bolts and stud 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 including 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.

00-10 WB91R-2 WB93R-2

ELECTRIC WIRE CODE

ELECTRIC WIRE CODE ELECTRIC

n the wiring diagrams various colours and symbols are employed to indicate the thickness of wires.
This wire code table will help you understand WIRING DIAGRAMS.
Example: R -N 1.5 indicates a cable having a nominal number 1.5 and red coating with black stripe.
CLASSIFICATION BY THICKNESS
Copper wire
Nominal Cable O.D. Current rating
number Number ù of strands Cross section (mm) (A)
strands (mm) (mm2)
0.5 16 0.20 0.35 1.55 3.5
1 14 0.30 0.99 2.80 11
1.5 21 0.30 1.48 3.35 14
2.5 35 0.30 2.47 3.80 20
4 56 0.30 3.95 4.60 28
6 84 0.30 5.93 5.20 37
10 84 0.40 10.55 7.10 53
50 399 0.40 50.11 14 160

CLASSIFICATION BY COLOUR AND CODE

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

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.

WB91R-2 WB93R-2 00-11

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

Machine model WB93R-2 WB93R-2

From serial no. 91F20070 93F21638
Engine assembly - Muffler - Exhaust pipe 400 410
Radiator - exchanger 37 37
Hydraulic tank (without hydraulic oil) Ð Ð
Fuel tank (without fuel) Ð Ð
Front counterweight 300 300
Engine hood Ð Ð
Cab (without seat) 595 595
Seat 34 34
Engine - gear-box - pump group 730 740
Piston pump 38 38
Transmission 230 230
Convertor Ð Ð
Front axle 316 316
Rear axle 511 511
Front wheel 65 65
Rear wheel 163 163
2-spool control valve 24 24
3-spool control valve 30 30
Work equipment Ð Ð

Backhoe
Work equipment Ð Ð
Boom 323 323
Arm 213 213
Long arm 245 245
Boom swing bracket 133 133
Backframe Ð Ð
6-spool control valve 47 47
7-spool control valve 53 53
8-spool control valve 59 59
Jig arm 392 392
Outriggers Ð Ð
Boom cylinder 65 78
Arm cylinder 69 69
Bucket cylinder 49 49
Outrigger cylinder Ð Ð
Swing cylinder 30 30

00-12 WB91R-2 WB93R-2

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

FKI 907 10W

FKI 907 20W-20

OIL
Crankcase sump 8.6 8.6
. API CD FKI 907 SAE 30

FKI 907 SAE 40

OIL
Hydraulic circuit FKI 909 10W-30 150 92
. API CD
Front axle
6.5 6.5
. differential
. final red. gear
(each) 1 1
OIL
FKI 918
Rear axle: . UTTO FLUID
15 15
. differential
. final red. gear
(each) 3.5 3.5

Hydraulic OIL
transmission
FKI 921 19 16
. GM DEXRONt II D
(DEXRONt is a registe-
Braking system red trademark of General FKI 921 0.8 0.8
Motors Corporation)

]
Fuel tank DIESEL OIL 130 Ð
ASTM D975 N. 2
WATER+
18 Ð
ANTI-FREEZE

Engine coolant WATER 18 Ð

system
PERMANENT
18 Ð
LIQUID
FKI 931

] ASTM D975 N. 1

FKI 907 OLDEN TURBO UNIGRADO

FKI 909 MULTISERVICE 4
FKI 918 SPECIAL TRANSMISSION FLUID 68/F-100
FKI 921 ANDROS FLUID II D
FKI 921 ANTIFROST PRONTO (±25 ëC)

WB91R-2 WB93R-2 00-13

ASTM: America Society of Testing and Materials
SAE: Society of Automotive Engineers
API: American Petroleum Institute
MIL: USA Military Specification
CCMC: Common Market Constructors Committe

First filling quantity: total quantity of oil, including the oil for the components and pipes.
Oil change quantity: quantity of oil necessary to fill the system or unit during the normal inspection and mainte-
nance operations.

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

Sulphur content Engine oil change interval

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

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

00-14 WB91R-2 WB93R-2

 STRUCTURE AND FUNCTION

Power train . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 2 Solenoid valve . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 71

Transmission . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 4 Safety valve.. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 72
Drive shafts . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 9 Brake pump .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 74
Control valve block.. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 11 Shovel cylinders . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 75
Front axle . . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 12 Backhoe cylinders. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 76
Rear axle . . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 15 Air-conditioning unit . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 80
Hydraulic pump . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 20 How the air-conditioning unit functions. . . . .. . . . .. . . . 81
Hydraulic steering system. . . .. . . . . .. . . . .. . . . . .. . . . .. . 41 Electrical diagram (1/5) . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 83
Hydraulic circuit . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 43 Electrical diagram (2/5) . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 85
Shovel control valve . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 44 Electrical diagram (3/5) . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 87
Backhoe control valve . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 50 Electrical diagram (4/5) . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 89
CLSS . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 57 Electrical diagram (5/5) . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 91

WB91R-2 WB93R-2 10-1

POWER TRAIN

1 2
3 4

5 7 8
6
RKZ01060

DESCRIPTION
. The driving power for the engine (1) is transmitted . The driving power is transmitted from the transmis-
through the flywheel to the converter (2). sion flanges (3) to the front (5) and rear (6) axles
The converter (2) uses hydraulic oil to convert the through the Cardan drive shafts (7 and 8).
torque transmitted by the engine (1) into driving po- . The driving power transmitted to the front (5) and
wer. The converter (2) transmits motion to the drive rear (6) axles is reduced by the differentials and
shaft of the transmission (3) and to the drive shaft then transmitted to the planetary gear through the
of the hydraulic pump (4). differential shafts.
. The transmission (3) has two hydraulically-activa-
ted clutches that can be selected by an electrical-
ly-controlled gear selector. It also has manual gear
selection (four forward gears and four reverse
gears).

10-2 WB91R-2 WB93R-2

 Front axle Rear axle
Gears
Transmission Differential Planetary Total Transmission Differential Planetary Total
1st gear 4.280 61.238 5.350 91.362
2nd gear 2.372 33.939 2.965 50.633
2.385 6.000 2.846 6.000
3rd gear 1.236 17.685 1.544 26.367
th
4 gear 0.662 9.472 0.827 14.123

Z=37
6

Z=15

4
Z=13 Z=75

9
8
3

1 10

Z=13

Z=75

Z=15

5 Z=31 Z=75

RKZ01030

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

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

WB91R-2 WB93R-2 10-3

TRANSMISSION

Diagram of the power train

Z=38 Z=28 Z=33

Z=24

Z=45
Z=27 Z=29
Z=49
Z=36

4
8
5

Z=27

Z=29 Z=12 Z=43

9
Z=19

RKZ01040

1. Engine 6. Hydraulic pump

2. Convertor 7. Rear flange
3. Forward clutch 8. 4WD engagement device
4. Transmission 9. Front flange
5. Reverse clutch

10-4 WB91R-2 WB93R-2

Hydraulic Convertor-Transmission Circuit Diagram

2ndmarcia

34 marcia
11astmarcia

marcia
gear

gear

gear
gear
Ø4

Ø4

Ø3
Ø3

43ard

th
a

a
2
Ø2

Ø2
Ø 4,5
Ø 5,7
5 6

Ø 0,75

3
Ø 1,3

7
2
Ø 3,5
Ø 3,5

3
8

15
13
12 9 10
11

14

RKZ00860

1. Convertor pressurization valve 9. Pump

2. Convertor 10. Suction filter (250 mm)
3. Engine 11. 4WD engagement device
4. Oil cooler 12. Check valve
5. Forward clutch 13. Pressure control
6. Reverse clutch 14. 4WD engagement solenoid
7. Max. pressure valve: calib. 23 bar 15. Control valve group
8. Spin-on filter (15 Nm)

WB91R-2 WB93R-2 10-5

TRANSMISSION

Views

b 2
E c d
1 F F
3
a
4
A

D A
5

6 7

B B

RKZ00970
8

a. From the oil cooler 3. Filter

b. To the oil cooler 4. Oil temperature sensor
c. To the solenoid valve group ST1 (Port P) 5. Suction filter
d. From the solenoid valve group ST1 (Port T) 6. Y5 Reverse gears command solenoid
7. Y4 Forward gears command solenoid
1. Gear lever
8. Y2 4WD command solenoid
2. Convertor

10-6 WB91R-2 WB93R-2

 3 4 5

1 2

17

16 9 8 7

10

15 14 13 12 11
RKZ00980
Sezione A
Section A±-A
A

1. Hydraulic pump drive shaft 10. 4-WD drive gear

2. Propeller shaft 11. 1st gear driven gear
3. Reverse gears command clutch 12. 4WD driven gear
4. Forward gears command clutch 13. 4WD engagement device
5. Reverse gears idler shaft 14. Front output shaft
6. Drive shaft 15. Flange
7. Flange 16. 2nd gear driven gear
8. 3rd gear driven gear 17. Rear output shaft
9. 4th gear driven gear

WB91R-2 WB93R-2 10-7

 C

2 3 4 5 6 7 8 9
9

10
10 Sezione C - C
Section C ± C

Sezione B - B
Section B ± B

12 13 14 15 16

11

Sezione D
Section D ±- D
D
Sezione E - E
Section E ± E RKZ00990

1. Gear-shift piston 9. 3rd and 4th gear selecting fork

2. Spring 10. 1st and 2nd gear selecting fork
3. Spring 11. Suction filter (250 mm)
4. Ball 12. Spin-on filter (15 mm)
5. 3rd and 4th gear selecting fork 13. Valve
6. 1st and 2nd gear selector piston 14. Spring
7. 3rd and 4th gear selector piston 15. Ball
8. 1st and 2nd gear selecting fork 16. Spring

10-8 WB91R-2 WB93R-2

DRIVE SHAFTS

Drive shaft for forward and reverse movement

1
2

a b c

6
5

4 3 RKZ00950

a. Port commanding reverse clutch 1. Reverse gear clutch (Z=29) 4. Reverse clutch piston
b. Port commanding forward clutch 2. Forward gear clutch (Z=29) 5. Thrust ring
c. Lubrication port 3. Forward clutch piston 6. Driven shaft

Driven gear shaft

1 2 3 4 5 6

8 8 7 RKZ01010

1. Driven gear for 2st gear (Z=43) 5. Driven gear for 3rd gear (Z=33)
2. Driven gear for 1st gear (Z=49) 6. Rear output shaft
3. 4WD drive gear (Z=44) 7. Thrust ring
4. Driven gear for 4th gear (Z=24) 8. Synchronizer

WB91R-2 WB93R-2 10-9

4WD driven shaft

2
1 a

6 5 4 3 RKZ01020

a. 4WD disengagement command port 4. Cylinder

5. Spring
1. Front output shaft
6. Disc
2. 4WD driven gear (Z=36)
3. Thrust ring

10-10 WB91R-2 WB93R-2

CONTROL VALVE BLOCK

3 4 5 6 7 8 9

1 10

11

15 14 12 13 12
Sezione F - F
Section F ± F RKZ01000

1. Ball 6. Spring-guide pin 11. Spring

2. Spring 7. Valve 12. Spool return spring
3. Piston 8. Spring 13. Spool
4. Spring 9. Valve 14. Forward gear command solenoid
5. Spring 10. Rod 15. Reverse gear command solenoid

WB91R-2 WB93R-2 10-11

FRONT AXLE

Differential

1 2 3 1

4
5

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

11 RKZ00580

1. Planetary gear 10. Seal

2. Ring bevel gear (Z=31) 11. Flange
3. Bevel gear 12. Cover
4. Lock nut 13. Lock nut
5. Half-axle 14. Bearing
6. Pin 15. Bevel pinion (Z=13)
7. Differential housing 16. Pin
8. Spacer 17. Oil drain plug
9. Bearing

10-12 WB91R-2 WB93R-2

Final reduction-Joint

7
3 5 8 9
2 4 6
1
10 11

24

23

13
22 17 12
14
18 16
15
21 20 19 RKZ00610

1. Planetary carrier 13. Bearing

2. Planetary (Z =...) 14. Joint
3. Ring gear (Z=75) 15. Pin
4. Ring gear carrier 16. Protection
5. Wheel hub 17. Seal
6. Seal 18. Bearing
7. Pin 19. Snap ring
8. Shim 20. Steady pin
9. Protection 21. Stud bolt
10. Bushing 22. Plug
11. Seal 23. Sun gear (Z=15)
12. Axle body 24. Snap ring

WB91R-2 WB93R-2 10-13

Steering cylinder

B 1

C 2 3

A
A
a b

7 7

5
4 Sezione B - B 6
Sezione A - A Section B ± B Particolare C
Section A ± A Detail C RKZ00590

1. Steady pin Port a - From the steering unit (Port L)

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

10-14 WB91R-2 WB93R-2

REAR AXLE

Differential

1 2 3 4 5 6

7 7

16 15 8
9
14
10
13 11

12 RKZ00570

1. Bearing 9. Bearing
2. Planetary gear 10. Nut
3. Bevel gear 11. Seal
4. Ring bevel gear (Z=37) 12. Flange
5. Differential housing 13. Cover
6. Lock nut 14. Spacer
7. Half-axle 15. Bevel pinion (Z=13)
8. Pin 16. Differential housing

WB91R-2 WB93R-2 10-15

Final Reduction

2 3
4
5

1 6 7 8

18

17

16

10 9
15
19
14
13 12 11 RKZ00600

1. Planetary gear carrier 10. Planetary gear (Z=15)

2. Stud bolt 11. Oil drain plug
3. Wheel hub 12. Snap ring
4. Planetary gears (Z=...) 13. Ring gear (Z=75)
5. Ring bevel gear carrier 14. Oil refilling plug
6. Bearing 15. Steady pin
7. Seal 16. Cover
8. Joint 17. Pin
9. Half-axle 18. Snap ring
19. Bushing

10-16 WB91R-2 WB93R-2

Brakes

2
A
B 1
8
9
4 10
3
5
11

6
7
Particolare
Detail B B

Sezione A
Section A±- A
A RKZ00620

1. Retainer ring 7. Brake disk

2. Bushing 8. External flange
3. Parking brake control rod 9. Service brake piston
4. Bleeder valve 10. Pressure disk
5. Parking brake lever 11. Center reaction plate
6. Parking brake control cam

WB91R-2 WB93R-2 10-17

Differential locking

1 2

6 5 4 3 RKZ00630

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

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

10-18 WB91R-2 WB93R-2

WB91R-2 WB93R-2 10-19
HYDRAULIC PUMP

a b
A 2 3
D

c
B B

A
e d
RKZ00400

1. Delivery variation group a. Port L1 - To the intake flange (Spool Port)

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

10-20 WB91R-2 WB93R-2

 C C 3 4

2
1

Sezione A - A
Section A ± A

7 8 9
6

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

1. Seal 7. Positioning piston

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

WB91R-2 WB93R-2 10-21

 1 2 3 4 5

7 6
Sezione C - C
Section C ± C

8 9 10

15 14 13 12 11
Sezione D
D ±- D
D RKZ00640
Section

POWER GOVERNOR LS VALVE

1. Spring 11. External spring
2. Piston rod 12. Internal spring
3. Bushing 13. Throttles (ù ....)
4. Initial adjustment spring 14. Throttles (ù ....)
5. Spring 15. Spool
6. Pressure cut calibration screw
7. Initial adjustment calibration screw
PC VALVE
8. Spool
9. Spring (internal)
10. Spring (external)

10-22 WB91R-2 WB93R-2

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

1 2 3 4 5 6 7

B A a RKZ01120

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

WB91R-2 WB93R-2 10-23

OPERATION
1. Pump operation
1 - The cylinder block (7) rotates together with the 1 3 A 4 5 6 D
shaft (1) and the shoe (4) slides on the flat sur-
face «A». The swash plate (3) moves along the
cylindrical surface «B». The angle «a» formed
between the center line of the shaft (1) and
the center line X of the swash plate (3) chan-
ges, thus modifying the axial position of the pi-
stons in relation to the cylinder block.
The angle «a» is known as the swash plate an-
gle.


2 - When the center line X of the swash plate (3)
maintains the angle «a» in relation to the cen- X
ter line of the shaft (1), and hence also of the
cylinder block (6), the flat surface A acts as a
cam for the shoe (4). As the piston (5) rotates
and slides inside the cylinder block (6), it the- B C
refore creates a difference between the volu- RKZ01100
mes C and D which provokes intake and di-
scharge of the oil in quantities equal to the dif-
ference between the volumes (D ± C=delive-
ry).
In other words, as the cylinder block (6) rota- 3 6 D
tes, chamber D loses volume while the volume
of chamber C is increased, thus provoking an
intake of oil.
(The figure indicates the state of the pump
=0
when the intake of chamber D and the delivery
of chamber C have been completed).
3 - When the center line X of the swash plate (3)
and the center line of the cylinder block (6) X
are perfectly aligned (the swash plate angle
«a»=0), the difference between the volumes
C and D within the cylinder block (6) becomes
0 and the pump does not take in or deliver any
oil. (In practice the swash plate angle «a» ne-
ver becomes=0)
4 - In other words, pump delivery is directly pro- C
portional to the swash plate angle «a». RKZ01110

10-24 WB91R-2 WB93R-2

2. Control of Delivery
. As the swash plate angle «a» grows larger, the
difference between volumes C and D increases, 2 3 9 D
and the delivery Q also increases.
The swash plate angle is modified by servo-pi-
stons (8) and (9).
. The servo-piston (8) moves in a reciprocating li-
near motion ( ) caused by pressure signals
from the PC and LS valves.
The linear movement is transmitted to the
swash plate (3), which is supported by the cylin-
drical surface of the cradle (2). The swash plate
therefore has a semi-circular reciprocating mo-
vement ( ).


. The surfaces of the servo-pistons receiving the
pressures PP and LS are dissimilar. The delive-
ry pressure PP of the main pump is always pas-
sed into the smaller (upper) pressure chamber,
whereas the pressure PEN coming from the LS
valve is passed into the larger (lower) pressure
chamber. 8 C
RKZ01130
The movement of the servo-piston is governed
by the relationship between pressures PP and
PEN, as well by the proportions between the sur-
faces (larger and smaller) of the servo-piston.

WB91R-2 WB93R-2 10-25

2. PC VALVE, LS VALVE SERVO-PISTON

1 2

Control valve
Distributore

To the actuator
All'utilizzo

7 6 RKZ01140

SERVO-PISTON PC VALVE
1. Spring 6. Servo-piston
2. Servo-piston 7. Spring
3. Servo-piston
LS VALVE
4. Piston
5. Spring

10-26 WB91R-2 WB93R-2

LS VALVE
FUNCTION
. The LS valve controls the pump delivery according
to the stroke of the control valve level, i.e., in func-
tion of the delivery demands made by the actua-
tors.
. The LS valve detects the actuator's delivery needs
by means of the differential pressure DPLS existing
between the pump delivery pressure PP and the
pressure PLS coming from the control valve. This
reading permits control of the main pump delivery
Q.
(PP, PLS and DPLS are, respectively, the pump
pressure, the Load Sensing pressure, and the diffe-
rence in pressure between these two values).
. In other words, the LS valve detects the pressure
difference DPLS generated by the passage of the
oil flow through the surface freed by the control val-
ve spool, and controls the pump delivery Q so as to
keep the pressure drop constant.
. It can therefore be assumed that the pump delivery
is proportional to the demands made known by the
control valve.

WB91R-2 WB93R-2 10-27

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

PP T PLS
c d a 6

To the actuator
All'utilizzo

Control valve
Distributore

Min Max

PP

M 3 X

Y
2 RKZ01150

. The pressure PLS of the LS coming from the control At the same time the pump pressure PP increases
valve outlet passes into chamber a of the spring of and is maintained at a value of about 27 bar (27.5
the LS valve. The pressure PP of the pump passes kg/cm2).
into chamber b of the opposite side. . For this reason the piston (4) is thrust to the right
. The piston rod movement (4) is determined by the ( ) and a passage is formed between the delivery
combination of the force generated by the pressure lines c and d. This opening enables the pump pres-
PLS, the force of the spring (6) and the force gene- sure PP to enter chamber X of the servo-piston (3).
rated on the side opposite the piston rod by the . Although the pump pressure PP is always passed
pressure PP. into chamber Y of the servo-piston (2), since the for-
. Before the engine is started the servo-piston (3) is ce exerted by that pressure on piston (3) exceeds
pushed to the right by the spring (1) (corresponding the force exerted on piston (2), the servo-piston
to the maximum angle of the swash plate). (1) moves to the right ( ), i.e. towards the side
. If all the control valve spools are in their «NEU- of the minimum angle of the swash plate.
TRAL» position when the engine is started, the
pressure PLS of the LS will remain at 6w2 bar
(6.1w2 kg/cm2) because no oil is flowing through
the control valve.

10-28 WB91R-2 WB93R-2

2. When a control valve lever is activated

PP T PLS
c d e a 6

To the actuator
All'utilizzo

Control valve
Distributore f
Min Max

PP

M 3 X
1

Y RKZ01160
2

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

WB91R-2 WB93R-2 10-29

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

PP T PLS
c d e a 6

To the actuator
All'utilizzo

Control valve
Distributore f
Min Max

PP

M 3 X
1

Y RKZ01160
2

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

10-30 WB91R-2 WB93R-2

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

PP T PLS
c d e a 6

To the actuator
All'utilizzo

Distributore
Control valve f
Min Max

PP

M 3 X
1

Y
2 RKZ01170

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

WB91R-2 WB93R-2 10-31

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

PP T PLS
c
g e a 6
d

To the actuator
All'utilizzo

Control valve
Distributore
Hold PEN
Fermo

PP
A1

M 3 X
PP 1
A2

Y RKZ01180
2

at a pressure that balances the force generated by

. Let A1 be the surface of the servo-piston (3), A2 the the pump pressure PP in the cylinder (2)
surface of the servo-piston (2), PEN the pressure ac- (PEN x A1=PP x A2).
ting on the piston (1) and PP the pressure acting on
the piston side (2). . The stability of the equilibrium is guaranteed by a
. When pump delivery reaches the quantity deman- flow stabilized by the throttle g.
ded by the control valve, the pump pressure PP in . The force of the spring (6) is regulated so that the
chamber b of the LS valve is in equilibrium with piston (4) is in equilibrium when
the combined forces of the LS pressure PLS in PP ± PLS=DPLS=18 bar (18.4 kg/cm2).
chamber a, and the force exerted by the spring (6). . In practice, the pump flow is made proportional to
Once equilibrium has been reached the piston (4) the section of the opening of the control valve,
stops in the central position. which maintains the differential pressure
. In this condition the passage from chamber c to DPLS=18 bar (18.4 kg/cm2).
chamber d remains only slightly open in order to
maintain pressure in chamber d.
A flow of oil is introduced into the servo-cylinder (3)

10-32 WB91R-2 WB93R-2

PC VALVE
FUNCTION
. The PC valve performs an approximate power
check, and ensures that the hydraulic horse-power

Pump discharge amount Q

absorbed by the pump does not exceed the horse-
power delivered by the endothermal engine.
This is achieved by limiting the pump delivery Q in
function of the delivery pressure PP, even if the LS
valve requests an increase in delivery Q due to the
larger section freed by the control valve spool, in
the presence of high pressure pump delivery.
. In other words, when during operation the delivery
Q increases and the delivery pressure PP also in-
creases simultaneously, the PC valve reduces the
pump delivery Q. When the delivery pressure PP Pump discharge pressure PP
decreases, the PC valve increases the pump flow. RKP01181

. The relationships between the pump delivery pres-

sure PP and the delivery Q are shown in the dia-
gram.

WB91R-2 WB93R-2 10-33

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

f 5 g 6 7
∆p

PPC
e
c
d

3 a b 4

PPC PP PEN T LS

To the actuator
All'utilizzo

Control valve
Distributore
2 1
PP

Min Max

M 8 X

RKZ01190

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

10-34 WB91R-2 WB93R-2

2. When equilibrium has been reached

5 g 6 7
f ∆p

c PPC
e

a 2 b 4

PPC PP PEN LS

10

To the actuator
All'utilizzo

Control valve
Distributore
PP
Hold
Fermo
A1

M 8 X

A2

9 RKZ01200

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

WB91R-2 WB93R-2 10-35

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

5 6 7

c
PPC
e

a b 4

PPC PP PEN LS
g

To the actuator
All'utilizzo

Control valve
Distributore

PP
Hold
Fermo

M 8 X

9 Y RKZ01210

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

10-36 WB91R-2 WB93R-2

4. The function of the spring

3 11 4

PP PLS T LS

To the actuator
All'utilizzo

Control valve
Distributore

M 8

RKZ01220

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

valve changes in proportion to the angle of inclina-
tion of the pump swash plate.
Spring (3)+spring
Molla (3 ) + molla ((11)
11)
. The compression of the spring (3) varies with the
pompa QQ

movements of the servo-piston (8).

Portata amount

. When the piston (8) moves to the left ( ) the (3)

Molla(3)
Spring
spring (3) is compressed.
Pump discharge

If the piston (8) moves even further to the left ( ),

the spring (11) comes into action to increase the
loading.
In other words, the overall loading of the springs is
varied by the piston (8), which either compresses or
releases them.
. The pump absorption torque curve, which indicates Pump discharge pressure PP
Pressione pompa PP
the relationship between the pump delivery pressu- RKZ01240
re PP and the delivery Q, is a broken line (as illu-
strated in the diagram).

WB91R-2 WB93R-2 10-37

. The position in which the piston (8) stops, i.e. the
pump absorption torque, is determined by the posi-
tion in which the PPC pressure applied to the spool
(4) is balanced by the force exerted by the springs
(3) and (11).
. In practice, as the pump delivery pressure PP in-
creases, the delivery Q decreases, and as the pres-
sure PP diminishes the pump delivery Q increases.

10-38 WB91R-2 WB93R-2

WORKING MODE SOLENOID VALVE

pompaQQ
FUNCTION

Portataamount
Working mode P
. Calibration of the pump absorption torque is nor-
mally performed for the working mode E.

Pump discharge
Working mode E
When the solenoid valve of the working mode is
commutated the absorbed power of the pump is in-
creased, as indicated by the working mode curve.

Pump discharge pressure

Pressione pompaPPPP
RKZ01250

OPERATION
1. WORKING MODE E (Economy)

∆ P1

2 3 4

RKZ01230

. During normal operation (Working mode E), the PC . The DP1 is generated by the calibrated hole (3) in
valve intervenes when a DP1 is generated equal to the spool of the PC valve (2) when, at a determined
the loading on the spring (4). pump delivery pressure P1, the valve (1) puts the
delivery line a into discharge, thus generating a
flow F1 in the delivery line a.

WB91R-2 WB93R-2 10-39

2. WORKING MODE P (Power)

∆ P2

2 3 4

RKZ01320

. When the solenoid valve (6) is commutated (Wor- . The increase in flow causes an increment of the
king Mode P) the pressurized oil coming from the DP2 which, when the loading value of the spring
pump changes its route and passes through the is reached, allows the spool to shift to the right
throttle (5), which has a larger diameter than the ca- ( ).
librated hole (3). . The pump starts to work in normal fashion once
. Because the throttle (5) has a larger diameter, the again, and all the valves recommence normal func-
DP2 generated is less than is needed to overcome tioning.
the force generated by the spring (4). The spool
of the PC valve (2) is therefore pushed to the left
( ) by the force of the spring (4).
. This shift obliges the pump to increase displace-
ment and hence the delivery (See «PC VALVE: 3.
When the load on the actuators decreases» third
paragraph).

10-40 WB91R-2 WB93R-2

HYDRAULIC STEERING SYSTEM

a b d

e c

L D

240 bar 240 bar

DLS

175
bar

T P

RKZ00830

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

(Port DLS) Steering unit type: LAGCSDS160P
b. Port T - To the hydraulic oil tank Displacement: 160 cc/rev
c. Port L - To the steering cylinder (Port a)
d. Port R - To the steering cylinder (Port b) OPERATION
e. Port P - From the shovel control valve (Port D) . The steering unit is composed of a control valve
and a rotating oil dispenser, and is of the hydrosta-
tic type.
. When the steering wheel is turned, the control val-
ve sends oil from the pump P2 (by means of the ro-
tating oil dispenser) to one of the sides of the stee-
ring cylinder.
The rotating dispenser ensures that the volume of
oil supplied to the cylinder is proportionate to the
angle of rotation of the steering wheel.
. In the event of malfunction, the oil dispenser will
function automatically as a hand-pump, thus gua-
ranteeing emergency steering.

WB91R-2 WB93R-2 10-41

10-42 WB91R-2 WB93R-2
HYDRAULIC CIRCUIT
Hammer Arm Boom swing R.H. outrigger L.H. outrigger Bucket Boom Jig arm

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

T P

21
bar b b b b b b b b

200 -50
bar

T LS

a a a a a a a a

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

T2

L D

240 240
bar bar

DLS

175
X1 X2 bar
Additional
Arm Bucket equipment
T P

LS D B1 A1 B2 A2 B3 A3

DLS b
b
A2 b

B
P

5 bar

Z
a a a

T
T B A T T B A T
170 230 230 230
bar bar bar bar
5 bar

S L1 L

RKZ02870

WB91R-2 WB93R-2 10-43

SHOVEL CONTROL VALVE

2-Spool

D C A
a b c d
e

h g
D C A

1 2
B

6
B
Sezione A - A
Section A ± A Sezione B
Section B ±- B
B
RKZ01080

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

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

10-44 WB91R-2 WB93R-2

 E 5 E
1
2
6

4
4

3 5 3
E
E
Sezione C
Section C ±- C
C
Sezione D
Section D±-D
D

7 8

7
8

Sezione E
Section E -±EE RKZ00660

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

WB91R-2 WB93R-2 10-45

3-spool control valve

D C A
a b c d e
f

l i h
D C A
1 2 E
B

6
B
7
Sezione A - A Sezione B - B
Section A ± A Section B ± B RKZ01070

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

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

10-46 WB91R-2 WB93R-2

 1 F 8 F

2 9

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

11

8 14
15

14
15

8 13 Sezione F - F
Section F ± F

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

WB91R-2 WB93R-2 10-47

3-spool control valve (with return to dig)

D C A
b c d e
a
f

l i h
C A

2 E D
1
B

6
B 7
Sezione A - A
Section A ± A Sezione B - B
Section B ± B RKZ01090

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

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

10-48 WB91R-2 WB93R-2

 F
1 F
8

9
2

7
3 10
7
4
1 8 11
5

F F
Sezione C
C ±- C
6 F
Section C

8
12 Sezione D - D
Section D ± D

13
14

13
14
7

8 F Sezione F - F
Section F ± F

Sezione E - E
Section E ± E RKZ00940

1. Plug 8. Antishock/anticavitation valve

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

WB91R-2 WB93R-2 10-49

BACKHOE CONTROL VALVE

6-spool

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

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

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

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

10-50 WB91R-2 WB93R-2

 G G G
3 3
7 9 10 11

6
6 6

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

G
9
12

13 14

13 14

Sezione G - G
G 5 Section G ± G
3
RKZ00760
Sezione F - F
Section F ± F

1. Ball 8. Anticavitation valve

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

WB91R-2 WB93R-2 10-51

 1

3 2

4 5
Sezione H
Section H±-H
H SezioneLL±-LL
Section RKZ00790

1. Valve 4. Pressure cut-out valve

2. Spring 5. Unloading valve
3. Plug

10-52 WB91R-2 WB93R-2

WB91R-2 WB93R-2 10-53
7-spool control valve

For hammer A
a

b
A RKZ00240

For hammer and jig arm

B
c

d B RKZ00250

For side digging boom and jig arm

C
e

C
RKZ00260

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

10-54 WB91R-2 WB93R-2

 1 2 6 7

5 5

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

4 8

6 3
Sezione C - C
Section C ± C RKZ00960

1. Anticavitation valve 5. Compensator

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

WB91R-2 WB93R-2 10-55

8-spool control valve

a b

c RKZ00270

d b

e c RKZ00280

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

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

10-56 WB91R-2 WB93R-2

CLSS

1. DESCRIPTION
CHARACTERISTICS
The term CLSS means Closed Center Load Sensing System, which has the following characteristics:
a) High precision control that is independent of the load applied to the movement;
b) High precision control of digging action even during delicate manoeuvres;
c) Ability to perform complex operations, guaranteed by control of oil flow in function of the aperture surfaces of the
shuttles;
d) Energy savings guaranteed by control of pump delivery.
STRUCTURE
. The CLSS system includes the variable flow pump, the control valve and the working equipment.
. The pump includes the main pump, the PC valve and the LS valve.

Attachment
Attrezzature di lavoro

PLS
Control valve
Distributore

PC Valve
Valvola PC

LS Valve
Valvola LS

PP Pistone di
Piston
controllo

Pistone di
Piston
controllo
RKZ01710

WB91R-2 WB93R-2 10-57

2. OPERATING PRINCIPLES
1. Control of the angle of the pumping plate.
. The angle of the swash plate (and hence the pump delivery) is controlled in such a way that the differential pres-
sure DPLS between the delivery pressure PP of the pump and the pressure PLS at the outlet of the control valve
towards the actuator is maintained at a constant value. (DPLS=pump delivery pressure PP ± pressure PLS of de-
livery to the actuator).
. If the differential pressure DPLS becomes lower than the set pressure of the LS valve, the angle of the swash
plate increases (delivery increasing).
If the differential pressure DPLS increases, the angle of the swash plate decreases.
H For details about this movement, see the description of the «HYDRAULIC PUMP».

Attrezzatura di lavoro
Attachment

Control valve
Distributore

Pump pompa
Mandata delivery

Pistone
Piston di
posizionamento

Pistone di
posizionamento PUMP
POMPA
Piston

PC Valve
Valvola PC

High
Alta
pressure
pressione

LS Valve
Valvola LS

High
Alta
pressure
pressione

RKZ01720

10-58 WB91R-2 WB93R-2

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

Load
Carico Load
Carico

Actuator Actuator
Utilizzo Utilizzo

Pressure Pressure
compensation compensation
Compensatore
valve Compensatore
valve

⌬P S1 S2 ⌬P

PUMP
POMPA

RKZ01730

WB91R-2 WB93R-2 10-59

3. Unloading valve

FUNCTION
1. When the control valve is in «NEUTRAL» position, the flow Q of the pump (due to the swash plate being in the
minimum angle position) is sent to the control valve.
In these conditions, the pump delivery pressure PP is regulated to 27 bar (27.5 kg/cm2) by the spring (2) inside
the valve.
(PP=PLS + spring load with PLS=6.1 kg/cm2 (6 bar) )

2 1 PP

PLS T
RKZ01740

OPERATION
When the control valve is in «NEUTRAL» position.
. On the two surfaces of the shuttle (1), the pump . This system ensures that the pump delivery pressu-
pressure PP acts on the right-hand side, while the re PP stays regulated at 27 bar (27.5 kg/cm2).
LS signal with pressure PLS acts on the left-hand si-
de.
. Because a LS signal is generated with a pressure
PLS 6.1w2 kg/cm2, when the control valve is in
«NEUTRAL» position, the pump delivery pressure
PP is regulated by the combination of the pressure
provided by the spring and by the LS pressure PLS.
. While the pump delivery pressure PP increases un-
til it compensates for the loading on the spring (2)
and for the LS pressure 27 bar (27.5 kg/cm2), the
shuttle (1) moves to the left ( ) and the PP circuit
is put into communication with the tank circuit T.

10-60 WB91R-2 WB93R-2

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

2 1 PP

PLS T RKZ01750

OPERATION
Final control of control valve
. When final control are performed with the control . The pump delivery pressure PP is regulated by the
valve, a pressure PLS is generated that pressurizing combination of the pressure provided by the spring
the spring chamber, acts on the left-hand extremity (21 bar (21.4 kg/cm2)) and by the LS pressure PLS,
of the valve (1). i.e. when the pressure differential DPLS reaches the
The actuator pressure is introduced into the LS cir- value of 21 bar (21.4 kg/cm2).
cuit and then into the spring chamber.
As a result, the pump pressure PP tends to increa-
se.
. When the differential pressure between the pump
delivery pressure PP and the LS pressure PLS has
the same value as the loading on the spring (2)
(21 bar (21.4 kg/cm2)), the shuttle (1) moves to
the left ( ) and the pump circuit PP puts itself into
communication with the tank circuit T.
Consequently the exceeding pump delivery Q, rela-
tive to the actuator request, is sent to the tank cir-
cuit.

WB91R-2 WB93R-2 10-61

3. When the request for oil flow from the actuators exceeds the minimum delivery of the pump during use of the
control valve, the connection to the tank circuit is eliminated and the entire pump delivery Q is sent to the ac-
tuators.

2 1 PP

PLS T RKZ01760

OPERATION
When the control valve is in use
. When the control valve shuttle is operated to exe- . The result is that the connection between the pump
cute a bigger stroke, the opening section of spool delivery circuit PP and the tank circuit T is excluded
becomes bigger and consequently the controlled and the entire pump delivery Q is sent to the actua-
delivery. tors.
Because the control valve passage is large, the dif-
ference between the LS pressure PLS and the pump
delivery pressure PP is reduced up to 18 bar (18.3
kg/cm2) (LS pump valve setting).
. Because the differential pressure between the
pump delivery pressure PP and the LS pressure
PLS is not equal to the pressure given by the spring
loading (2) (21 bar (21.4 kg/cm2)), the shuttle (1) is
pushed to the right ( ) of the spring (2).

10-62 WB91R-2 WB93R-2

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

A
4 To the
Alla pump
pompa

PP
c d
1
RKZ01780

OPERATION
. When the shuttle (1) is activated, the pump . The system stabilizes when a pressure differen-
pressure PP starts to flow into the actuator cir- ce of 18 bar (18.3 kg/cm2) is generated across
cuit A through the duct b. the shuttle (1) between pump pressure PP and
. At the same time the compensator (2) moves PLS pressure.
upwards ( ) so that the flow controlled by spool
(1) can flow towards the actuator A.
Check valve (4) do not allow any flow up to when
pressure in chamber c is higher than pressure
in chamber b.
Pressure downstream spool (1) flows in the PLS
circuit downstream the compensator valve
throught the orifice d.
. The PLS circuit of the LS is thus in communica-
tion with the tank circuit T by means of the LS
decompression valve (3). (See the description
of the LS decompression valve).

WB91R-2 WB93R-2 10-63

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

A B
PB
PA
PLS

C
2

4 b

PBV
d
a
PAV

3
PP 1

RKZ02310
OPERATION
1. When activating an actuator at a pressure lower than the one already working.
(While operating actuator A starts operating actuator B)
. Until the pressure PBV downstream from the shuttle . Until the pump does not realize a DP of 18 bar (18.3
(1) reaches the same value requested by actuator kg/cm2), i.e. until the increase in oil flow compensa-
B, no oil passes. tes the requirements of the two actuators, the pump
. When the pressure requested by actuator B is ex- will continue to increase delivery.
ceeded, movement can commence. This creates . DP of 18 bar (18.3 kg/cm2) will stabilize as soon as it
a flow that adding to the one controlled by spool is restored to.
(3) reduces the pressure upstream of spool (1) . The compensator (2) is moved upwards by the oil
and (3) and therefore the DP between PLS and PP. flow and stops when the aperture between the
. The pump compares the delivery pressures PP and chambers a and b reduces the passage sufficiently
PLS and senses that the difference DP<18 bar to reduce the pressure in chamber b to be sent to
(18.3 kg/cm2). This variation in DP causes an in- the actuator.
crease in oil flow increasing the swash plate angle.
(For the detail see «Hydraulic pump»).

10-64 WB91R-2 WB93R-2

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

A B
PB
PA
PLS

C
2

4 b

PBV
d
a
PAV

3
PP 1

RKZ02320

. If the actuator B needs to work at a higher pressure . Simultaneously the increase in pressure upstream
(PB>PA), the pressure PB will start to increase. from the shuttle (3) generates an increase in DP up-
. Since pressure PB is increasing, the compensator stream and downstream from the shuttle.
(2) moves upwards to restore the DP between the (PAV<PLS<PP)
chambers a and b, and therefore the DP does not . Because the pressure PLS which is equal to the
vary upstream or downstream from the shuttle (1). pressure PB acts on the upper side of the compen-
. When pressure PB exceeds pressure PA, the com- sator (4), and since the pressure PAV is lower, the
pensator (2) is fully open and the pressure PB is in- compensator (4) is pushed downwards.
troduced into the LS circuit. . The compensator stops when the aperture between
. The increase in pressure in the LS circuit obliges the chambers c and d generates a reduction of the
the pump to increase delivery until the DP is resto- passage sufficient to reduce the pressure to be
red to 18 bar (18.3 kg/cm2). sent to the actuator, and to increase the pressure
PAV until the DP is restored to the 18 bar (18.3 kg/
cm2) necessary for equilibrium.

WB91R-2 WB93R-2 10-65

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

A B
PB
PA
PLS

C
2

4 b

PBV
d
a
PAV

3
PP 1

RKZ02330

. When an increased delivery is required by actuator

A, i.e. when the shuttle (3) is asked to execute a
bigger movement, the section of the aperture in-
creases.
. The increase in aperture provokes a drop in DP bet-
ween the two sides of the shuttles (2) and (3), be-
cause the flow, which has remained unchanged un-
til now, is divided between both the actuators.
. At the same time the pump senses the variation in
DP and increases the oil flow until the DP is restored
to DP of 18 bar (18.3 kg/cm2) between the two sides
of the shuttle (1) and the compensator (4) changes
position in order to restore the DP upstream and
downstream from the shuttle (3).

10-66 WB91R-2 WB93R-2

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

C B A

6 4 1

PCV PBV PAV

5 3 2

RKZ02340

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

WB91R-2 WB93R-2 10-67

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

2 d

Q (ᐍ / min)
1
1,3
c

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

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

10-68 WB91R-2 WB93R-2

8. PRESSURE CUT-OFF VALVE
DESCRIPTION
The function of the pressure cut-off valve is to regulate the maximum pressure of the Load Sensing signal and hen-
ce also the pressure of the pump.

b 1
1

RKZ01770

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

WB91R-2 WB93R-2 10-69

9. PRIORITY VALVE (ONLY FOR THE 2-3 SPOOL CONTROL VALVE)
FUNCTION
The function of the priority valve is to distribute oil to the steering unit and to the other hydraulic components. Di-
stribution is determined by the position of the valve of the priority valve in function of the LS signal, oil delivery from
the pump, the pressure of the steering unit and the pressure of the hydraulic circuit. The position of the valve is such
as to guarantee that delivery to the steering unit will always correspond to the actual need.

P LS

D DLS

ToAgli
the actuator
utilizzi
RKZ02370

10-70 WB91R-2 WB93R-2

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

d
a

b c

1 2

RKZ00650

1. EV4 - Backhoe boom locking

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

WB91R-2 WB93R-2 10-71

SAFETY VALVE

a b

A RKZ00850

Shovel raise Arm

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

10-72 WB91R-2 WB93R-2

H The drawing represents the boom safety valve

2 3 4 5

6
1

15

14 13 12 11 10 9

Sezione A - A RKZ01050
Section A ± A

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

WB91R-2 WB93R-2 10-73

BRAKE PUMP

1 2 3 4 5 6

8
17 16 15 14 13 12 11 10 9
RKZ00930

1. Pump body CHARACTERISTICS:

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

10-74 WB91R-2 WB93R-2

SHOVEL CYLINDERS

RAISING CYLINDER

2 3 4 5 6 7
1 8

RKZ00310

DUMPING CYLINDER

2 3 4 5 6 7
1 8

RKZ00300

1. Bushing, base side 4. Piston seal 7. Cylinder

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

CHARACTERISTICS

Cylinder Raising Dumping

Piston rod diameter 50 50

Internal cylinder diameter 85 85

Piston stroke 730 755

Max. cylinder length 1880 2145

Min. cylinder length 1150 1390

Key size for piston
55 55
safety nut

WB91R-2 WB93R-2 10-75

BACKHOE CYLINDERS

BOOM
2 3 4 5 6 7
8 9
1

11 10 RKZ00200

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

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

ARM
3 4 5 6 7 8 9
10
1 2

RKZ00220

1. Head bushing 5. Bushing 9. Nut

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

BUCKET
2 3 4 5 6 7 8 9
1

RKZ00290

1. Head bushing 4. Cylinder 7. Guide ring

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

10-76 WB91R-2 WB93R-2

OUTRIGGERS
1 2 3 4 5 6 7 8

RKZ00410

1. Piston rod 4. Spacer 7. Piston

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

BOOM SWING 5

1 2 3 4 6
7

12 11 10 9 8
RKZ00360

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

2. Throttling ring 6. Cylinder head 10. Piston ring
3. Piston rod 7. Head bushing 11. Spacer
4. Cylinder 8. Piston 12. Cushion plunger

ARM (for side digging boom)

2 4 5 6
3 7 8
1

11 10 9 RKZ00210

1. Head bushing 5. Guide ring 9. Piston

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

WB91R-2 WB93R-2 10-77

SIDE DIGGING BOOM

1 2 3 4 5 6 7 8 9 10

11 RKZ00390

1. Head bushing 5. Cylinder head 9. Nut

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

JIG ARM

1 2 3 4 5 6 7

RKZ00320

1. Piston rod 4. Piston 7. Nut

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

10-78 WB91R-2 WB93R-2

CHARACTERISTICS

Arm
Cylinder Boom Bucket
With side
Standard
digging boom

Piston rod diameter 55 60 60 60

Internal cylinder diameter 115 110 110 95

Piston stroke 849 920 910 765

Max. cylinder length 2049 2175 2170 1850

Min. cylinder length 1200 1255 1260 1085

Key size for piston
65 55 55 55
safety nut

CHARACTERISTICS

Cylinder Outriggers Boom swing Side digging boom Jig arm

Piston rod diameter 40 50 45 40

Internal cylinder diameter 80 100 85 70

Piston stroke 635 230 365 1140

Max. cylinder length 1690 319 830 2590

Min. cylinder length 1055 89 565 1450

Key size for piston
46 Ð 46 46
safety nut

WB91R-2 WB93R-2 10-79

AIR-CONDITIONING UNIT

2
Low pressure steam

Low pressure liquid/steam

High pressure steam

AIR AT AMBIENT TEMPERATURE High pressure liquid

1a

3 1

8
5

7
9
INTERIOR OF CAB
RKZ03130

1. Compressor TECHNICAL DATA

2. Condenser . Operating pressure in circuit with engine at 2500
3. Drying-filter tank rpm and ambient temperature at 25 ± 30ëC:
4. Safety pressure Normal pressure: 15 ± 17 bar
Low pressure: 1.6 ± 1.8 bar
5. Expansion valve
. Safety pressures:
6. Evaporator High pressure: 26 bar
7. Thermostatic clutch control sensor Low pressure: 2,5 bar
8. Air-circulation fan in cab . Coolant fluid: R134a
9. Air conveyor . Quantity of coolant: 1100 g (+50 / ± 30)

10-80 WB91R-2 WB93R-2

HOW THE AIR-CONDITIONING UNIT FUNCTIONS

The compressor (1) is driven directly by the engine On leaving the evaporator (6) the coolant is drawn on-
shaft by means of a belt, and made to rotat by a pulley ce more into the compressor (1) and a new cycle com-
fitted with an electromagnetically-engaged clutch (1a). mences.
A thermostatic sensor (7) controls the engagement The yielding of heat from the atmosphere in which the
and disengagement of the clutch. It disengages the evaporator is positioned leads to the condensation of
clutch when the evaporator reaches the lower tempe- the water suspended in the air, and hence to dehumi-
rature limit and engages the clutch when the evapora- dification. The condensate is deposited on the evapo-
tor reaches the upper temperature limit. rator fins where, if a temperature higher than 0ëC is
The coolant fluid (in gaseous phase) is drawn into the not maintained, it freezes and inhibits the functioning
compressor where it is subjected to compression and of the evaporator.
an intense heating process. In these conditions the The task of keeping the temperature of the evaporator
fluid is then sent into the condenser (2) where, due above 0ëC (and thus within the optimum limits for heat
to the heat extracted by ambient temperature air flo- exchange) is entrusted to a thermostatic sensor (7).
wing over fins, it reaches condensation temperature, The condensate that forms on the evaporator fins (6)
and passes into a high-pressure liquid state. also contains dust, pollens and particles suspended
Subsequently the coolant passes into the drying-filter in the air. Continual condensation therefore effectively
group (3) which performs three functions: it filters out purifies the air, and the droplets of condensate are di-
impurities, absorbs any moisture present in the circuit scharged to the exterior.
and, finally, also functions as a reserve tank. A fixed quantity of anti-freeze oil is also introduced into
The coolant in its liquid state is then transferred to the the circuit, with the function of lubricating all the me-
evaporator (6), first passing through an expansion val- chanical parts of the unit. A percentage of this oil cir-
ve (5). The task of this valve is the constant metering culates constantly throughout the unit in nebulized
of the quantity of fluid in order to maintain optimum form, lubricating the compressor (pistons and bea-
evaporation. rings) and the expansion valve.
In the evaporator the coolant fluid is subjected to ex- A pressure switch (4) has been inserted in the electri-
pansion, bringing it up to the critical evaporation point cal control circuit to protect the unit in the case of a
at a temperature of approximately ± 8ëC. lack of coolant fluid or if the quantity becomes insuffi-
The flow of air generated by centrifugal fan (8) which cient due to leakages. This switch will inhibit the enga-
passes through the evaporator (6) at ambient tempera- gement of the electromagnetic clutch and hence the
ture is considerably warmer than ± 8ëC. For this rea- functioning of the air-conditioning unit.
son it yields heat to the coolant fluid, bringing it up
to boiling point and complete evaporation.

WB91R-2 WB93R-2 10-81

10-82 WB91R-2 WB93R-2
ELECTRICAL DIAGRAM (1/5)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

R/N1
3.1

P1 P2 P3 P4
R1 ACC BR R2 C - - - -
R1
OFF ACC H1 H2 H3 H4 H5 H6 H7 H8 rpm h q t_

R/N1
ST
S i S i S i S i
+ + + +

M-V1
A2.5

N1.5

XS
S6 B

XS
5

X15

X15

X17

X17
X17

X17

X17

X17

X17

X17
R6 G2.5
XS 6
4 XS

X15

X15
3 4 13 11 12 1 4 6 5 2 1
X17
X17 X17 3
1 2 X17 X17

H/N1
14 9

G2.5

A2.5

A2.5

M-V1

R-V1

Z/B1

S1

V1
8
R6

A-G1

G1

R/N1
V-B1
Z/N1
10 2 9 6 8 5 7 3 11 12 8 5 3 7 2 1 9 11 10 4 6
X8 X8 X8 X8 X8 X8 X8 X8 X8 X8 X4 X4 X4 X4 X4 X4 X4 X4 X4 X4 X4
+15 D20
L4
2.13
1 +30
AL KIT 12
2.5
X12 COND. 8 X14 11 9 4 5
8
3.12
A-V1

X10 1 X10 X10 X19 X19 A-R1

R4

R4

2.19
L4

D19
2.2

D18
M-V1
R-V1
G2.5
2
X12 10

D17
X12 l KT2 KT1 D5 2.19

D16

D13
2

L13

L23
2
XAD X18 X18 7 5
RELE' K4 +15 +15 11
2.2
X11 X10 X10 NON MONTATO
A-V1

5 4
3
R25 F7C
L4

3.6

R-N1.5
M-V1
R-V1
R3 F3A

53M

53M
53S

53S
B-R1

1 l 13

31
15
4

15

31
1/4W 7.5A 4.18
X11 X13 X10 12 10
1/4W 7.5A
F3B R13 F7A R23

XT1
XT1
XT1
XT1
XT2
XT2
XT2
XT2
R4
XAD
L4

9
X10 X10 1/4W L25 1/4W 1/4W 4.12
1 4 2 3 1 2 3 4 7.5A 7.5A R6

R-V1
- 7
R4

R4

Z/N1
L3

M-V1
3.9 1/4W
G/N1
B-N1

Z/B1

B/R
L4

G
2
4.18
D10

M1
+15 +15
D12 L6
FUG1 FUG1 FUG1 FUG1 K01 K02 K03 13
D11
Z-B1

4.15
60A 80A 30A 70A 86 87 86 87 86 87

85 30 85 30 85 30
X1 X1 X1 X1 X1 X1 X1 X1 X1 X1 X1
11 6 9 5 7 2 4 1 3 8 10
G2.5

Z-B1

B-R1
M10

S1

V1

H/N1

V-B1

A-N1.5
B1.5 B-N1
R10

G2.5

A-V1

Z-N1

R-N1.5
B/V1
2.4
B1.5

B/V1
B/N1
R50
- l 3 2 A 1 2 3 4 2 6 1
XA
XA

S13 XAM XAM X16 X21 X21 X10 X10 X10 X10 X10
30 50 G2 R30 R31 R32 S22 HA1
D+
Y0 S24 S21 S23
M G
R50

30 W

M1 3 t p p
G1 U
t
31
12Vcc
XAM X16 X21
1 B 3

N1.5

N1.5
N1.5

N1

N1

N1

N1

N1

N1
N1

N1
N50

31
2.1

RKZ03170

COMPONENTS CONNECTORS FUSES

G1 - Battery K03 - Fuel shut off relay S22 - Air filter blocked switch X1 - 11-ways connector front line (engine) XA - 2-ways connector alternator F3A - Starting fuse 7.5A
G2 - Alternator KT1 - Fuel shut off timer S23 - Engine oil low pressure switch X4 - 11-ways connector monitor XAD - 2-ways connector diode F3B - Switch + warning light fuse 7.5A
H1 - Preheating warning light KT2 - Preheating timer S24 - Fuel gauge X8 - 17-ways connector lateral dashboard XAM - 3-ways connector shut off valve F7A - Monitor fuse 7.5A
H2 - Generator warning light M1 - Starter motor Y0 - Fuel shut off solenoid valve X10 - 13-ways connector front line - engine line XS - 6-ways connector instrument F7C - Fuel shut off fuse 7.5A
H3 - Engine water high temperature warning light P1 - RPM instrument X11 - 3-ways connector power XT1 - 4-ways connector timer stop engine FUG1 - General fuse 60A
H4 - Air filter warning lamp P2 - Hour counter X12 - 3-ways connector front line - cross line XT2 - 4-ways connector timer preheater
H5 - Hydraulic oil filter warning lamp P3 - Fuel level indicator X13 - 2-ways connector front line - engine line
H6 - Optional warning lamp P4 - Water temperature instrument X14 - 4-ways connector front line - cross line
H7 - Optional warning lamp R30 - Preheater X15 - 4-ways connector start key
H8 - Optional warning lamp R31 - Fuel level sender X16 - 2-ways connector conditioner clutch
HA1 - Horn R32 - Water temperature sender X17 - 21-ways connector lateral dashboard
K01 - Starting relay S21 - Engine water high X18 - 5-ways connector power box
K02 - Preheating relay temperature switch X19 - 9-ways connector front dashboard
X21 - 3-ways connector fuel level indicator

WB91R-2 WB93R-2 10-83

10-84 WB91R-2 WB93R-2
ELECTRICAL DIAGRAM (2/5)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

1
2 6 7 9 1 7 2 8 9 15/1 30/3 L/6 15/1 30/3 L/6
II
I 0 1 0 H9 H10 H11 H12 2 3 4 0 1 MANIPOLATORE S10 X29 0 1
0 1 2
3

3 5 1 5 6 1 49/4 30b/2 R/7 X28 X28 X28 X28 X28 X28 X28 X28 X28 X28 X28 X28 49/4 30b/2 R/7
S2A S1A S2 1 2 3 4 5 6 7 8 9 10 11 12 S1
+ 1
S4

V-B1
V-N1
S1
L-B1
A-R1
1.9
A1.5

M-N1

G-V1
M-B1
C-B1
V/N1

C/B1
R/N1 R/N1
X29

A-N1
2.19
2
N1
4.1

H-R1
4.15

L/B1 C-L1
3.9 3.1

X19
M- M-N1
4.5
X18

H-R1
M/N1
A-R1

Z-N1
C-L1

Z-B1

R1.5

B1.5
3 7 R/N1 R/N1
2.2 3.11

N1
X19

M-N1
10 11 10 7 4 6
4 8 15 16 5 1 9 1 8 3 7 13
X8 X9 X9 X9 X5 X5 X5 X9 X2 X2 X9 X9 X8 X5 X5 X5 X9
1
1.20 D14
10
1.20
1.20
11 20
3.7
V2.5 33
4.18

17
4.17
32
L14 +15
18
4.17 +15
3.1

K7 R5 K3 R26 F5A R17 K04

F4A R14 R27 F3C 87 1/4W 1/4W
D8 86 87a 87 1/4W 86 87a 15A 86 87
7.5A
1/4W 1/4W 7.5A
D4

85 30 8 30 85 30
L5 L26 L17
L27
+15

D21 31
4.17

40
3.1
D22
B/V1

12 16
1.20 4.6

15

X26
X26
4.6

X6
X3
3
X3
5
X3 X5 X3 X8 V2.5 L4 L4 1 1 9
4 1 7 13 1.2

V-N2.5
B/V1
1.15 Z-N1.5 X25 X25

H1
L-B1

S-N1

1 2

V-N2.5
4
A-G1

B-R1
G-N1

C-N1
6 2 3 1 5

Z-B1
H1
l 4 3 1 2 2 3 4
X27 X27 X27 X27 X27 X27
22 X24 X24 X23 X23 S18 X20 X20 X20
X14 X14

M-N1
C/B1

C/B1

V/N1
3 4

Y1 Y2
B-R1.5
53a
M2 M3 OPTIONAL S16 S15 M4 EV1 EV2 EV3 EV4 1 1
M
B-R1

R1.5

R1.5
M 53 M 53b
31b p

31 S17 S19 S20 2 2

N1

X24 R1
X22 1 1
4.7

- X20
B-R1

N2.5
R1
N1

N1
N1

N1

N1

N1

N1

N1

N1

N1

N1

N1
31 31
1.20 3.1

RKZ03190

COMPONENTS CONNECTORS FUSES

EV1 - Opened grab solenoid valve M4 - Blower motor X2 - 9-ways connector light switch and rear X25 - 2-ways connector powered blower motor F3C - Optional solenoid valve fuse 7.5A
EV2 - Closed grab solenoid valve S1 - Economy power switch shift line X26 - 8-ways connector rear line F4A - 4WD-windshield wiper fuse 7.5A
EV3 - Differential lock solenoid valve S10 - Hammer button X3 - 11-ways connector front line X27 - 6-ways connector solenoid valve line F5A - Blower motor switch fuse 15A
EV4 - Boom unlock solenoid valve S15 - Hand brake switch X5 - 11-ways connector cabin command X28 - 12-ways connector joystick
H10 - Engine water high temperature S16 - Brake oil low level switch X6 - 9-ways connector solenoid valves line X29 - 12-ways connector convert detachment
warning light S17 - Stop switch X8 - 17-ways connector lateral dashboard button
H11 - Engine oil high temperature S18 - Stop switch X9 - 17-ways connector front dashboard
warning light S19 - Stop light switch X14 - 4-ways connector front line - cross line
H12 - Fuel reserve warning light S2 - Boom unlock switch X18 - 5-ways connector power box
H9 - 4WD warning lamp S20 - Stop light switch X19 - 9-ways connector front dashboard
K04 - Powered blower relay S2A - Windshield wiper-washer X20 - 4-ways connector blower motor
K3 - 4WD relay switch on front dashboard X22 - 2-ways connector windshield washer
K7 - Switch relay Y1 - Economy power solenoid valve pump
M2 - Washer pump Y2 - 4WD solenoid valve X23 - 2-ways connector optional
M3 - Windshield wiper motor X24 - 4-ways connector windshield wiper

WB91R-2 WB93R-2 10-85

10-86 WB91R-2 WB93R-2
ELECTRICAL DIAGRAM (3/5)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

R/N1 R/N1
1.14 4.5
C-L1 L1.5 L-G1.5 A-R1
2.20

15/1 30/3 L/6 1 9 1 9 1 9 1 9

HA2 1 9 2 6 7 9

G/N1
0 1 1 0 1 0 1 0 1 0 1 0 II I
0
H13 H14

R/N1

A-N1
49/4 30b/2 R/7 5 10 5 10 5 10 5 10 5 10 3 5 10
S3 S4L S5L S1L S3L S3A S2L

G-R1
B-R1 G1.5

B-R1.5
B-G1

B-R1
A-N1
L/B1 A-R1

A/R1
1 2
X19 X19 6 3 4 5

X17 X17 Z1.5

4.15 X17 H-G1
4.15
X17 X17 2 1 X33 X33 X33 X33 X33 X33
18 16 17 10 19
R/N1
2.20
S-G1

L/B1

H-G1
Z1.5

L1.5

L/N1
2.2

A-N1

R-N1.5
G-V1 G-V1
4.9
15 5 14 9 16 12 1 7

X8 X2 X8 X2 X8 X9 X2 X9

G/N1

G/N1
19 7 8
4.19 1.16 1.20
+15

L20
F4B R15 L18 +30 +30 L19
10A 1/4W
F6A R20 R2 K1 R1
K2 86 87a 87 86 87a 87
1/4W 1/4W K05
15A 1/4W
D3 D1 F5B R18 F2A R10 F1C L7 F1B L8 F2B R11 F5C R19 86 87a 87
L15 85 30 85 30 15A 1/4W 10A 1/4W 3A 3A 7.5A 1/4W 15A 1/4W

J2 L2 L1 R7 85 30
+15
2.9
40
1 2 3
L10 1/4W 1/4W L11 R-V1

+15
+15
2.8
18 R8

3 20 12
P4 1.20 2.5 4.5

X5 X6 X6 X6 X6 X6 X6 X6 X6 X8 X5 X5 X3 X5
2 4 5 7 1 3 8 2 6 17 9 6 1 4

G1 G-R1 G1

B1
M1

R-V1

L-G1.5
N0.5
4.9 4.7 4.1

R-N1.5
H-R1

V-N1
H-L1

H-L1

G1

A/R1

B-G1

B-G1
A-N1

A-R1
R-V1

A C 1
4 3
X38 X38 X30 2
H19

R-V1
1
X31 X31

X31

X31
A
HA4 M5

X39
HA3 Y5 53a
Y3 Y4 S26 M X1 H15 1 2
H17 H18
Y6 M M8 53
M 53b

X32

X32
31b
t
H20 H21
31
ALIM. S27
AUTORADIO
X38 X38 X30 H16 X39 X39
B D 2 N1 B C
N1.5

N1.5
N1

N1

N1

N1

N1

N1

N1

N1

N1

N1

N1

N1
L.05

N1.5
L. CABINA
31 31
2.20 4.1

RKZ03160

COMPONENTS CONNECTORS FUSES

H13 - Dashboard light M5 - Fuel pump Y3 - Plate unlock solenoid valve X2 - 9-ways connector light switch and F1B - Right traffic light fuse 3A
H14 - Dashboard light M8 - Windshield wiper motor Y4 - Forward speed solenoid valve gear shift line F1C - Left traffic light fuse 3A
H15 - Cigarette lighter lamp S1L - Rear working light switch Y5 - Reverse speed solenoid valve X3 - 11-ways connector front line F2A - Rotary beam fuse 10A
H16 - Cabin lamp on lateral dashboard Y6 - Return to dig solenoid valve X17 - 21-ways connector lateral dashboard F2B - Radio and cabin lamp fuse 7.5A
H17 - Front working lamp S26 - Convertor oil max. temperature X19 - 9-ways connector front dashboard F4B - Forward-reverse speed fuse 10A
H18 - Front working lamp thermostat X30 - 2-ways connector fuel pump F5B - Rear working light switch fuse 15A
H19 - Beacon lamp S27 - Proximity return to dig X31 - 5-ways connector cabin F5C - Front working light switch fuse 15A
H20 - Rear working lamp S2L - Windshield wiper on X32 - 2-ways connector radio power F6A - Windshield wiper-washer switch fuse 15A
H21 - Rear working lamp lateral dashboard switch X33 - 7-ways connector lateral dashboard
HA2 - Buzzer S3 - Plate lock switch X38 - 4-ways connector forward-reverse speed
HA3 - Rear horn S3A - Front working light switch X39 - 3-ways connector proximity
HA4 - Buzzer on front dashboard
K05 - Return to dig relay S3L - Beacon switch on lateral dashboard
K1 - Forward speed relay S4L - Horn switch on lateral dashboard
K2 - Reverse speed relay S5L - Optional switch on lateral dashboard

WB91R-2 WB93R-2 10-87

10-88 WB91R-2 WB93R-2
ELECTRICAL DIAGRAM (4/5)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

A-N1 R/N1 R/N1 G-V1

3.20 3.14

N1
2.8 TRANSMISSION

G-V1
H22 H23 H24 H25 LIGHT
DEVIOSWITCH
LUCI DEVIO CAMBIO
SWITCH

N1
2 8 5 10
1 0

XD1 XD1 XD1 XD1 XD1 XD1 XD1 XD1 XD1 XD2 XD2 XD2 XD2
1 2 3 4 5 6 7 8 9 1 2 3 4 5
4 6 3 1 7
S4A

A/B1

C1

H-R1
B-N1
H-G1

Z1.5
M-N1
2.20

B/R1

A/N1

A/N1
B-R1
3.8 H-G1

3.5
Z1.5

H-R1
2.9
H-N1

B1

V1

X19
R-N1

A/V1

X18
X18
R1.5
X19

A-V1

R-N1
9
2 1 8
8 4 6 17 3 5 11 3 2 6 2 14 1 2 3 4 5 6 7 8 9
X2 X9 X9 X9 X2 X9 X9 X9 X9 X2 X2 X9 X7 X7 X7 X7 X7 X7 X7 X7 X7
16 13 15
+30 2.7 1.12 2.7

D15
31
K5 +30 9
2.9
1.20
86 87a 87 32
L12 K6 2.9

D6 L22 K9
D7 86 87a 87
K8 2.16
17
85 30 +
86 87a 87 1.20
4
F2C R12 F6C R22 85 30 C R D9 2
1.12
F1A R28 10A 1/4W 1/4W
10A F4C R29 85 30
2.16
33
15A 1/4W
R16 15A 1/4W 19
R9 L21 L24
3.5

+30 +15 1/4W

1/4W L28 L29
F6B R21 F7B R24
L16
L9 7.5 1/4W 10A 1/4W

P1 12
3.12 +15 +15

X3 X3 X3 X3 X3 X3 R1 R1
8 11 6 2 10 9 2.20
G-R1

G-R1 G1
A-B1
B1

M1
B1

A1
M1

3.12 3.10

A1
A-B1
G1 G1

A-B1
A-G1
3.13

R-G1
L1
A1
3 1 7 1 2 3 4 5 6 7 8 9 10 11 12 13
2 3 6 4 2 3 6 4 1 1 X26 4 2 8

X26

X26
X34

X34

X34

X34

X26

X26

X26
X40 X40 X40 X40 X40 X40 X40 X40 X40 X40 X40 X40 X40
X36

X37
X35

X35

X35

X35

G-R1
H26 H27 H30 H32

N1

N1
N1
56a

56b

56a

56b
57
R

57

N1
59c

59c
57

57
R
L

H28 H29 H31

31

31

31

31
X34 X35 X36 X37 X26 X26
1 1 2 2 5 6
CONTROFIGURA SOLO PER EUROPA
PER USA CENTRALINA FLASHER
N1

N1

N1
N1.5

N1.5
N1.5

N1.5

N1.5

31 31
3.20 /./

RKZ03180

COMPONENTS CONNECTORS FUSES

H22 - Indicators warning light X2 - 9-ways connector light switch and gear shift line F1A - Low beam fuse 15A
H23 - Main beam warning light X3 - 11-ways connector front line F2C - Warning fuse 10A
H24 - Low level brake oil warning light X7 - 9-ways connector F4C - Main beam fuse 15A
H25 - Differential lock warning light X9 - 17-ways connector front dashboard F6B - Light switch fuse 7.5A
H26 - Right front lamp X18 - 5-ways connector power box F6C - Warning power fuse 10A
H27 - Left front lamp X19 - 9-ways connector front dashboard F7B - Horn fuse 10A
H28 - Right front indicators lamp X26 - 8-ways connector rear line
H29 - Left front indicators lamp X34 - 6-ways connector right front light
H30 - Left rear lamp X35 - 6-ways connector left front light
H31 - Number plate lamp X36 - 2-ways connector right front indicator
H32 - Right rear lamp X37 - 2-ways connector left front indicator
K5 - Low beam relay X40 - 13-ways connector flasher unit
K6 - Main beam relay XD1 - 9-ways connector lights switch
K9 - Flasher unit XD2 - 5-ways connector transmission switch
S4A - warning switch on front dashboard

WB91R-2 WB93R-2 10-89

10-90 WB91R-2 WB93R-2
ELECTRICAL DIAGRAM (5/5)

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

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

XD1

XD1

XD1

XD1

XD1

XD1

XD1

XD1

XD1

XD2

XD2

XD2

XD2

XD2
57/58 49 54S 54D
MI N MA
DX 0
MI MA

SX

56a 56b 30 31 L
+

LIGHT SWITCH TRANSMISSION SWITCH

DEVIO CAMBIO
DEVIO LUCI

RKZ03200

CONNECTORS
XD1 - 9-ways connector lights switch
XD2 - 5-ways connector transmission switch

WB91R-2 WB93R-2 10-91

10-92 WB91R-2 WB93R-2
 TESTING AND ADJUSTMENTS

Normal or standard technical data . . . . .. . . . . .. . . . .. . . 2 Testing and adjusting of load sensing signal
Special tools . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 30 (LS valve) . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 50
Measuring engine speed . . . . .. . . . . .. . . . .. . . . . .. . . . .. . 31 Checking unloading valve functionality . . . .. . . . .. . . . 51
Adjusting valve clearance . . . .. . . . . .. . . . .. . . . . .. . . . .. . 32 Testing pump delivery . . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 52
Measuring compression pressure .. . . . .. . . . . .. . . . .. . 33 Testing priority valve operation .. . . . . .. . . . . .. . . . .. . . . 54
Testing and adjusting fuel injection timing . .. . . . .. . 34 Testing and setting steering control system
Checking and tightening the fan - belt .. . . . . .. . . . .. . 36 pressure . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 55
Checking and tightening the compressor Testing brake system .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 56
fan - belt .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 37 Control of the engine speed under load . . . . . . . .. . . . 58
Measuring accelerator pedal operating Testing pressures in the power train group. . . . .. . . . 60
travel and accelerator lever . .. . . . . .. . . . .. . . . . .. . . . .. . 38 Testing the correct functioning of the
Adjusting brake pedal travel, brake alignment, power train clutches. . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 62
microswitches .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 40 Adjusting the sensor for return to dig device . . . . . . . 63
Air bleeding - releasing residual pressure . . . . . . . .. . 41 Analysis of causes hydraulic drift . . . . .. . . . . .. . . . .. . . . 64
Checking and setting pressure in the attachments Testing the air-conditioning unit . . . . . .. . . . . .. . . . .. . . . 69
hydraulic circuit . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 44

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).

WB91R-2 WB93R-2 20-1

NORMAL OR STANDARD TECHNICAL DATA
. FOR ENGINE
Machine model WB91R-2

Engine 4D106-1FA

Check item Test conditions Unit Standard Permissible

value value

High idling rpm 2375w50 2375 ± 2425

Engine speed Low idling rpm 1050w50 1000 ± 1100
Set speed rpm 2200 Ð

Exhaust gas Sudden acceleration Bosch 0.9 1.2

colour At high idling speed index 0.5 0.8

Intake valve (20ëC) mm 0.30w0.05 Max. 0.35

Valve clearance
Exhaust valve (20ëC) mm 0.30w0.05 Max. 0.35

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
(oil SAE30) At high idling speed Ð Ð

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

Engine oil At set speed kg/cm2 4.5 4±5
pressure
At low idling kg/cm2 1 Min. 1

Oil temperature Entire speed range ëC 120ë Max. 120ë

Fuel injection B.T.D.C. degrees 12.5 11.5 ± 13.5

timing

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

tension of approx. 10 kg

20-2 WB91R-2 WB93R-2

. FOR ENGINE

WB93R-2

S4D106-1FA

Standard Permissible
value value

2375w50 2375 ± 2425

1050w50 1000 ± 1100
2200 Ð

0.9 1.5
0.5 1.0

0.3w0.5 Max. 0.35

0.3w0.5 Max. 0.35

35w1 28w1
250 250

Ð Ð
Ð Ð

Max. 6 Max. 6
4.5 4±5
1 Min. 1

120ë Max. 120ë

12.5 11.5 ± 13.5

10 10 ± 15

WB91R-2 WB93R-2 20-3

. FOR MACHINE

Machine model WB91R-2

Classifi- Check item Test conditions Unit Standard Permissible

cation value value

. Hydraulic oil temperature:

45 ± 55 ëC. Max. 2375w50 2325 ± 2425
. Converter oil temperature:
Accelerator pedal 80 ëC
. Engine oil temperature
Engine speed

cooling circuit: Min. 1050w50 1000 ± 1100

in the limits.
rpm
. Hydraulic oil temperature:
45 ± 55 ëC. Max. 1900w50 1850 ± 1950
. Converter oil temperature:
Accelerator fuel 80 ëC
. Engine oil temperature
cooling circuit: Min. 1050w50 1000 ± 1100
in the limits.

ᐉ , a b c , a b c
All controls
Control valve

(front bucket and a b c

backhoe) 41.5 8 8 Ð Ð Ð Ð Ð
mm

For front shovel arm

command only 41.5 8 8 5 Ð Ð Ð Ð
(with floating arm) RKZ02580

Front bucket tilt lever . Engine stopped Raise

control Neutral Lower 80 60 ± 110
. At the centre
of knob lever
Front bucket control . Valve reading Neutral Dump 115 90 ± 140
lever at the end of Curled
working stroke
Front bucket control . Attachments
Neutral Raise 100 80 ± 120
lever on the ground Lower

Arm backhoe control Opening

Travel of levers and pedals

lever Neutral Closing 100 80 ± 120

Bucket backhoe Neutral Opening 100 80 ± 120

control lever Closing
mm
Boom swing backhoe Neutral Right 100 80 ± 120
control lever Left

Outriggers control Neutral Up 50 35 ± 65

lever Down

Fuel control lever Min. Max. 70 50 ± 90

Jig arm control Out 15 10 ± 20

pedal Neutral In 30 20 ± 40

Hammer and side digging Right 15 10 ± 20

boom control pedal Neutral Left 30 20 ± 40

20-4 WB91R-2 WB93R-2

. FOR MACHINE

WB93R-2

Standard Permissible
value value

2375w50 2325 ± 2425

1050w50 1000 ± 1100

1900w50 1850 ± 1950

1050w50 1000 ± 1100

< a b c < a b c

41.5 8 8 Ð Ð Ð Ð Ð

41.5 8 8 5 Ð Ð Ð Ð

80 60 ± 110

115 90 ± 140

100 80 ± 120

100 80 ± 120

100 80 ± 120

100 80 ± 120

50 35 ± 65

70 50 ± 90

15 10 ± 20
30 20 ± 40

15 10 ± 20
30 20 ± 40

WB91R-2 WB93R-2 20-5

. FOR MACHINE

Machine model WB91R-2

Classifi- Check item Test conditions Unit Standard Permissible

cation value value

. Engine
Travel of levers and

Accelerator pedal stopped Min. Max. mm 80 60 ± 100

. At the centre
of knob lever
pedals

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

Front bucket tilt lever 2.5 2±3

control

Front bucket control 2.5 2±3

lever

Boom control 1.5 1±2

lever
. Engine speed: max.
Force for levers and pedals operation

Arm control . Oil temperature: 45 ± 55ëC 1.5 1±2

lever . Tool connection at the centre of knob
(for levers)
Bucket control lever . Tool connection on edge 1.5 1±2
(for pedals)
Boom swing 1.5 1±2
control lever
kg
Outriggers control 3 2.5 ± 3.5
lever

Fuel control 12 10 ± 14
lever

In 4 3±4
Jig arm control
pedal 8 6 ± 10
Out

Hammer and side digging 8 6 ± 10

boom control pedal

Accelerator pedal 3 2±4

Brake pedal 30 Max. 60

20-6 WB91R-2 WB93R-2

. FOR MACHINE

WB93R-2

Standard Permissible
value value

80 60 ± 100

Max. 2.5 2.2 ± 2.5

2.5 2±3

2.5 2±3

1.5 1±2

1.5 1±2

1.5 1±2

1.5 1±2

3 2.5 ± 3.5

12 10 ± 14

4 3±4
8 6 ± 10

8 6 ± 10

3 2±4

30 Max. 60

WB91R-2 WB93R-2 20-7

. FOR MACHINE

Machine model WB91R-2

Classifi- Check item Test conditions Unit Standard Permissible

cation value value
±1
2-3-Spool control valve . Engine speed: max. 221 221+6
Main valve
pressure

. Oil temperature: 45 ± 55ëC

±1
6-7-8-Spool control valve . Without steering bar 221 221+6

Steering unit (safety) . Check on test bench 240 240w7

Front bucket 230 230w7

(curled) ]
Pressures of secondary valves circuits

Front bucket (dump) 170 170w7

Boom (raising) ] 300 300w7

Boom (lowering) 230 230w7

. Engine speed: max.
Arm (Closing) . Oil temperature: 45 ± 55ëC 230 230w7
. Check one circuit at the time bar
Boom swing 240 240w7
] Check on test bench
Bucket (curled) 230 230w7

Side digging boom 270 270w7

(right-left)

Hammer (delivery) 160 160w7

Steering unit 175 175w7

20-8 WB91R-2 WB93R-2

. FOR MACHINE

WB93R-2

Standard Permissible
value value
±1
221 221+6

±1
221 221+6

240 240w7

230 230w7

170 170w7

300 300w7

230 230w7

230 230w7

240 240w7

230 230w7

270 270w7

160 160w7

175 175w7

WB91R-2 WB93R-2 20-9

. FOR MACHINE

Machine model WB91R-2

Classifi- Check item Test conditions Unit Standard Permissible

cation value value

. Engine speed (without load): 2375w50

. Hydraulic oil temperature: 45 ± 55ëC
With converter . Converter oil temperature: 80ëC 2100w50 2050 ± 2150
. Machine in 4th gear
. Working brakes applied

. Engine speed: 2375w50

. Hydraulic oil temperature: 45 ± 55ëC
Engine speed (with load)

. Converter oil temperature: 80ëC

With converter and . Machine in 4th gear 2000w50 1950 ± 2050
hydraulic circuit
. Working brakes applied
Converter

. Front bucket curled stop

. Steering stop rpm
. Engine speed: 2375w50
. Hydraulic oil temperature: 45 ± 55 ëC
With converter . Converter oil temperature: 80 ëC 2125w50 2075 ± 2175
(TBG version)
. Machine in 3rd gear
. Working brakes applied

. Engine speed (without load): 2375w50

. Hydraulic oil temperature: 45 ± 55 ëC
With converter and . Converter oil temperature: 80 ëC
hydraulic circuit 2100w50 2050 ± 2150
(TBG version) . Machine in 3rd gear
. Working brakes applied
. Front bucket curled stop

20-10 WB91R-2 WB93R-2

. FOR MACHINE

WB93R-2

Standard Permissible
value value

2275w50 2225 ± 2325

2200w50 2150 ± 2250

2200w50 2150 ± 2250

2200w50 2150 ± 2250

WB91R-2 WB93R-2 20-11

. FOR MACHINE

Machine model WB91R-2

Classifi- Check item Test conditions Unit Standard Permissible

cation value value

Measuring posture
Complete working
equipment
250 400
(Tip lowering of
bucket teeth) ~10°
Front bucket

RKZ00530

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

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

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

Boom cylinders 1m
35 50
(cylinder out)
Backhoe

RKZ00420

mm
. In this position check the extension of
Arm cylinder each cylinder and the leakage with nor-
mal load on the bucket. 15 25
(cylinder out) . On level ground.
. Bucket : normal load (450 kg)
. Engine stopped
. Oil temperature: 45 ± 55ëC
Bucket cylinder . Check measures as soon as engine
stops. 10 15
(Cylinder in) . Check changes every 5 min. and the total
change in 15 min.

20-12 WB91R-2 WB93R-2

. FOR MACHINE

WB93R-2

Standard Permissible
value value

250 400

30 45

15 25

300 450

35 50

15 25

10 15

WB91R-2 WB93R-2 20-13

. FOR MACHINE

Machine model WB91R-2

Classifi- Check item Test conditions Unit Standard Permissible

cation value value

RKZ02670
Boom swing 15 25

. Oil temperature: 45 ± 55 ëC
. 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.
Hydraulic drift working equipment

. Move the machine on a chute of 15ë and

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

H Make the test for each swing direction.

Outriggers 15 25

Max

. Oil temperature: 45 ± 55ëC RKZ00490

. Backhoe balanced.
. Boom and arm cylinders in,
bucket cylinder out
. Outriggers at maximum extension.
. Engine stopped.
. Check the frame lowering for each side
every 5 min. for a total of 15 minutes.

20-14 WB91R-2 WB93R-2

. FOR MACHINE

WB93R-2

Standard Permissible
value value

15 25

15 25

WB91R-2 WB93R-2 20-15

. FOR MACHINE

Machine model WB91R-2

Classifi- Check item Test conditions Unit Standard Permissible

cation value value
Front bucket

Boom 2.0 Max. 8.0

(each cylinder)

Bucket 1.6 Max. 6.0

(each cylinder)

Boom 3.3 Max. 13.5

. Engine: Max. speed

Cylinder leaking

Arm . Oil temperature: 45 ± 55ëC 3.0 Max. 12.0

. Leaking check: on the cylinder opposite
side to the pressure one.
Bucket mm 2.4 Max. 9.5
H Check 1 cylinder at a time.
Backhoe

H For tilt front bucket, front bucket and for

Boom swing swing, check the two cylinders separate- 3.2 Max. 13.0
ly.

Outriggers 3.3 Max. 13.5

Side digging 2.0 Max. 8.0

Jig arm 1.6 Max. 6.0

20-16 WB91R-2 WB93R-2

. FOR MACHINE

WB93R-2

Standard Permissible
value value

2.0 Max. 8.0

(each cylinder)

1.6 Max. 6.0

(each cylinder)

3.3 Max. 13.5

3.0 Max. 12.0

2.4 Max. 9.5

3.2 Max. 13.0

3.3 Max. 13.5

2.0 Max. 8.0

1.6 Max. 6.0

WB91R-2 WB93R-2 20-17

. FOR MACHINE

Machine model WB91R-2

Classifi- Check item Test conditions Unit Standard Permissible

cation value value

Measuring posture
Tilt lever front

Raised
bucket 3.9 3.3 ± 4.5

Bucket on level ground

Lowered
RKZ00500 2.6 2.2 ± 3.0
Cylinders extended out .
Front bucket

Engine speed: Max.

. Oil temperature: 45 ± 55ëC

Measuring posture
Bucket Curled
2.6 2.2 ± 3.0

Cylinder in
Dump

3.5 3.0 ± 4.0

RKZ00510

Cylinder out
. Engine speed: Max.
. Oil temperature: 45 ± 55ëC

Measuring posture
Boom
Work equipment speed

Raised

2.6 2.2 ± 3.0

Teeth bucket on level
ground
sec.
Lowered

RKZ00430

. Engine speed: Max. 1.9 1.6 ± 2.2

Cylinder in . Oil temperature: 45 ± 55ëC
. Backhoe balanced

Measuring posture
Closing

Arm
4.5 3.9 ± 5.1

Cylinder in
Backhoe

Opening

RKZ00440
. Engine speed: Max. 3.6 3.1 ± 4.1
Cylinder out
. Oil temperature: 45 ± 55ëC
. Backhoe balanced

Measuring posture
Curled

Bucket
3.1 2.7 ± 3.5

Cylinder in

RKZ00450
Dump

. Engine speed: Max. 2.6 2.2 ± 3.0

Cylinder out
. Oil temperature: 45 ± 55ëC
. Backhoe balanced

20-18 WB91R-2 WB93R-2

. FOR MACHINE

WB93R-2

Standard Permissible
value value

3.9 3.3 ± 4.5

2.6 2.2 ± 3.0

2.6 2.2 ± 3.0

3.5 3.0 ± 4.0

2.6 2.2 ± 3.0

1.9 1.6 ± 2.2

4.5 3.9 ± 5.1

3.6 3.1 ± 4.1

3.1 2.7 ± 3.5

2.6 2.2 ± 3.0

WB91R-2 WB93R-2 20-19

. FOR MACHINE

Machine model WB91R-2

Classifi- Check item Test conditions Unit Standard Permissible

cation value value

Measuring posture

Right
Boom swing 4.5 3.9 ± 5.1

Left end travel

Right end travel

4.5 3.9 ± 5.1

Left
RKZ02570
.
Work equipment speed

Engine speed: Max.

. Oil temperature: 45 ± 55ëC
. Arm vertical
Backhoe

Measuring posture sec.

2 1.8 ± 2.2
Lifting

Outriggers

All extended

. Engine speed: Max. RKZ00520

All raised . Oil temperature: 45 ± 55ëC
Lowering

. Backhoe balanced
2 1.8 ± 2.2
. Dowel joint locking: applied
. Rear wheels raised
. Outriggers at maximum extension

20-20 WB91R-2 WB93R-2

. FOR MACHINE

WB93R-2

Standard Permissible
value value

4.5 3.9 ± 5.1

4.5 3.9 ± 5.1

2 1.8 ± 2.2

2 1.8 ± 2.2

WB91R-2 WB93R-2 20-21

. FOR MACHINE

Machine model WB91R-2

Classifi- Check item Test conditions Unit Standard Permissible

cation value value

Measuring posture

Tilt lever front 0 Max. 2

bucket

RKZ00500

. Engine speed: Min.

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

Measuring posture
Work equipment

Time lags

Boom sec. 0 Max. 2

RKZ00460

. Engine speed: Min.

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

Measuring posture

45°

Arm 0 Max. 2

RKZ00470
. Engine speed: Min.
. Oil temperature: 45 ± 55ëC
. 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.

20-22 WB91R-2 WB93R-2

. FOR MACHINE

WB93R-2

Standard Permissible
value value

0 Max. 2

0 Max. 2

0 Max. 2

WB91R-2 WB93R-2 20-23

. FOR MACHINE

Machine model WB91R-2

Classifi- Check item Test conditions Unit Standard Permissible

cation value value

Measuring posture

Bucket 0 Max. 2
RKZ00480

. Engine speed: Min.

. Oil temperature: 45 ± 55ëC
. 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-

ment.
Time lags

Measuring posture sec.

Outriggers 0 Max. 2

RKZ00520
. Engine speed: Min.
. Oil temperature: 45 ± 55ëC
. 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.

20-24 WB91R-2 WB93R-2

. FOR MACHINE

WB93R-2

Standard Permissible
value value

0 Max. 2

0 Max. 2

WB91R-2 WB93R-2 20-25

 Machine model WB91R-2

Classifi- . Piston pump P1 delivery.

cation . Working mode: Economy.
. Pump speed: 2200 rpm
. Hydraulic oil temperature: 45 ± 55ëC.
(kg/cm2)
P(bar)

........ bar
....... ᐉ/min
320
(326,5)

280
(285,7)

........ bar
....... ᐉ/min
240
(244,9) Max. delivery
Portata massima
(theoretical)
(teorica)

200
(204)

Delivery
Portata minima
Pumps characteristics

160 ........ bar

(lower
ammessalimit) ....... ᐉ/min
(163,2)

120
(124,5)

80
(81,6)
....... bar
....... ᐉ/min

40
(40,8)

0 40 80 120 160 Q (ᐍ/min)

RKZ02590

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

20-26 WB91R-2 WB93R-2

 Machine model WB91R-2

Classifi- . Piston pump P1 delivery.

cation . Working mode: Power
. Pump speed: 2200 rpm
. Hydraulic oil temperature: 45 ± 55ëC.
(kg/cm2)
P(bar)

........ bar
....... ᐉ/min
320
(326,5)

280 ........ bar Max. delivery

Portata massima
(285,7) ....... ᐉ/min (theoretical)
(teorica)

240 ........ bar

(244,9) ....... ᐉ/min

PortataDelivery
minima
200 (lower limit)
ammessa
(204)

160
Pumps characteristics

(163,2)

....... bar
....... ᐉ/min
120
(124,5)

80
(81,6)

40
(40,8)

0 40 80 120 160 Q (ᐍ/min)

RKZ02600

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

WB91R-2 WB93R-2 20-27

 Machine model WB93R-2

Classifi- . Piston pump P1 delivery.

cation . Working mode: Economy.
. Pump speed: 2200 rpm
. Hydraulic oil temperature: 45 ± 55ëC.
(kg/cm2)
P(bar)

........ bar
320 ....... ᐉ/min
(326,5)

280
(285,7)

........ bar
....... ᐉ/min
240
(244,9)

Max. delivery
Portata massima
200 (theoretical)
(teorica)
(204)
........ bar
....... ᐉ/min
160
Delivery
Pumps characteristics

(163,2) Portata minima

(lower limit)
ammessa

120
(124,5)

....... bar
80 ....... ᐉ/min
(81,6)

40
(40,8)

0 40 80 120 160 Q (ᐍ/min)

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

20-28 WB91R-2 WB93R-2

 Machine model WB93R-2

Classifi- . Piston pump P1 delivery.

cation . Working mode: Power
. Pump speed: 2200 rpm
. Hydraulic oil temperature: 45 ± 55ëC.
(kg/cm2)
P(bar)

........ bar
....... ᐉ/min
320
(326,5)
Max. delivery
Portata massima
(theoretical)
(teorica)

280 ........ bar ........ bar

(285,7) ....... ᐉ/min ....... ᐉ/min

240
(244,9) Portata Delivery
minima
(lower limit)
ammessa

200
(204)

....... bar
160 ....... ᐉ/min
Pumps characteristics

(163,2)

120
(124,5)

80
(81,6)

40
(40,8)

0 40 80 120 160 Q (ᐍ/min)

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

WB91R-2 WB93R-2 20-29

TESTING AND ADJUSTMENTS SPECIAL TOOLS

SPECIAL TOOLS

Measurement check point Symbol Code Name Q.ty Note

Valve clearance A 1 Commercially Feeler gauge 1 Ð

available

1 Compression gauge 1 0-60 kg/cm2

Compression pressure B
2 Adapter 1 Ð

1 Multiscale tachometer 1 20 - 4000 rpm

Engine speed C
2 Stroboscopic tachometer 1 6 - 30000 rpm

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

available

1 Pressure gauge 2 Full scale 60 bar

2 Pressure gauge 1 Full scale 250 bar

3 Pressure gauge 1 Full scale 400 bar

E 4 Pressure gauge 1 Full scale 600 bar
Hydraulic pressure Servocontrol kit
5 Differential pressure 1 Ð
gauge

6 Digital pressure gauge 1 0 ± ......

1 Flow-meter 1 Delivery: ...... ± ......

F
2 Pipe fitting kit 1 Ð

G 1 Tank cap 1 Pump air bleeding

1 Tool to check 1 Ð
leaktightness of brakes
Braking group H
2 Union kit 1 Ð

Hand brake L 1 Commercially Spring dynamometer 1 Full scale 20 kg

available

1 Commercially Maintenance station 1 For Coolant R134a

available

Air-conditioning unit M 2 Commercially Thermometer-Hygrometer 1 Sampling every 15

available seconds

3 Commercially Leak detector 1 For coolant R134a

available

20-30 WB91R-2 WB93R-2

TESTING AND ADJUSTMENTS MEASURING ENGINE SPEED

MEASURING ENGINE SPEED

When checking engine speed, be careful not to

touch high temperature parts and not to get caught
in rotating parts.
1
H Check speed when following condition are reached:
. Engine water cooling temperature: 68 ± 80ëC.
. Hydraulic oil temperature: 45 ± 55ëC.
1 - Remove the air filter (1) and release the heating lines
from the hose-clamp (2).
2

2 - Install and connect C1 tachometer.

H If using C2 stroboscopic tachometer, mark a light
notch on, engine pulley for an easier reading. RKZA1763

3 - Start engine and check:

. Low idling speed without load (accelerator pedal
released in «minimum» position).
. High idling speed without load (accelerator pedal
at the travel end). C1
H Low idling speed: 1050w50 rpm
H High idling speed: 2375w50 rpm
H If low and high idling speed with engine without
load are not within permissible value, before
going on with other operations, check accelerator
pedal stoppers and wiring sheathings. (See «AC-
CELERATOR LEVER ADJUSTING»).
RKZA5300

WB91R-2 WB93R-2 20-31

TESTING AND ADJUSTMENTS ADJUSTING VALVE CLEARANCE

ADJUSTING VALVE CLEARANCE

H Engine: in cold state.

H Adjust clearance between valves and rocker levers as
follows:
Unit: mm 1

Engine Intake-exhaust
At cold 2
engine 4D106-1FA 0.30w0.05

S4D106-1FA 0.30w0.05
3
H Firing order: 1-3-4-2-1..... at 180ë step.
H Normal rotation sense: counterclockwise from flyw- RKZA5310

heel
H The cylinder Në 1 is on the opposite fan side.

. Adjusting procedure 5
1 - Remove air cleaner (1), intake manifold (2) and
valves cover (3).
4
2 - Rotate crankshaft in normal direction as long as
cylinder piston to be checked is at compression
Top Dead Center (PMS).
H In this position intake and exhaust valves are clo-
6
sed.
YES
SI NO
NO
3 - Loose lock nut (4) and unscrew tappet (5) of about
1 turn.
6
H Check that valve insert (6) is laying flat on val- RKZ01910

ve stem and that it is not worn askew.

1 - If valve inserts (6) are damaged, replaced
them with new ones.
2 - Make sure that inserts feet and lay flat on 5
valve stem. 4
4 - Connect A1 feeler gauge between insert and roc- A1
ker lever to adjust; rotate the tappet (5) until tou-
ching A1 feeler gauge.
Tight tappet (5) with lock nut (4).
Nut: 14.7 ± 19.6 Nm
H After tightening the lock nut, check the clea-
rance again.
5 - Adjust with same procedures second cylinder val- RKZ01920

ve and repeat same operation for the other cylin-

ders, according to the firing order.
. Cover valves installation
1 - Check condition of cover valves (3), gasket (7), O-
3
9
Rings (8) and lock nuts (9); clean carefully contact
surface on cylinder head. 8
2 - Install valves cover (3), fit O-Rings (8) and lock
nuts (9).
Cover lock nut: 25w3 Nm

7
RKZ01930

20-32 WB91R-2 WB93R-2

TESTING AND ADJUSTMENTS MEASURING COMPRESSION PRESSURE

MEASURING COMPRESSION PRESSURE

. When measuring the compression pressure be

careful not to get caught in cooling fan, in the al- 2
ternator belt or in other rotating parts.
. For this measurement the engine should be up to
working temperature. Take every precaution
against burns.
. Check all cylinders.

H Test condition: 1
. Engine: at operating temperature
. Hydraulic oil: 55 ± 60 ëC.
. Battery: at full charge RKZA5320

. Valve clearance:
adjusted (see «ADJUSTING VALVE»)
1 - Disconnect high pressure pipe (1). 4
2 - Remove nozzle holder assembly (2) of cylinder to be
checked.
3 - Disconnect connector (3) of fuel cut-off solenoid valve
(4).
4 - Crank engine with starting motor.
3

RKZA5330

5 - Install B2 adapter and connect B1 pressure gauge

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
where the pressure gauge indicator remains stea- B2
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. RKZA5340

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

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

connector (3).
Compression

30
Nozzle holder collar bolts: 9.8 ± 11.8 Nm
Pressione

25
High pressure union: 19.6 ± 24.5 Nm
20

200 250 300 350 400

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

WB91R-2 WB93R-2 20-33

TESTING AND ADJUSTMENTS TESTING AND ADJUSTING FUEL INJECTION TIMING

TESTING AND ADJUSTING FUEL INJECTION TIMING

H Check fuel injection timing of N.1 cylinder by

means of N.1 delivery valve of injection pump. N. 1 Cylinder
Cilindro Nº1
H Cylinders are numbered 1-2-3-4 starting from
flywheel side.
1 - Rotate crankshaft using engine pulley and put N. 1cy-
linder piston at top dead centre (PMS).
1

Flywheel
Volano
RKZ01960

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

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

1
RKZA5350

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

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

Nº1

RKZA0071

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

increase. Raccordo Level
Livello
N. 1Nº1
Union

RKZ01970

20-34 WB91R-2 WB93R-2

TESTING AND ADJUSTMENTS TESTING AND ADJUSTING FUEL INJECTION TIMING

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

pared with scale (5); reading value corresponds to an- 5
gle of fuel injection timing.
H Standard fuel injection timing:
4D106-1FA: 12.5ëw1ë
S4D106-1FA: 12.5ëw1ë
4
NOTE. Repeat checking more than once.

1
RKZA5360

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

jection pump (6) toward external or toward engine af- 6
ter loosening pump nuts (7) (quantity 4) and pump
lock nuts (8) fixing the bracket (9) to injection pump. 7
. To RETARD injection, rotate pump (6) toward ex-
ternal.
. To ADVANCE injection, rotate pump (6) toward 8
cylinders block.
Pumppompa
Lato side
7 - Tight the pump lock nuts (7) at cylinder block and
pump lock nut (8) at bracket (9).
Nuts: 34.2 ± 44.1 Nm Carter side
Lato carter
9 Testing
Controlloadvance
anticipo
Bracket lock nut: 44.1 ± 53.9 Nm RKZA5370 injector
d'iniezione

8 - Connect fuel delivery pipe (2) to pump

Delivery pipe union: 19.6 ± 24.5 Nm

WB91R-2 WB93R-2 20-35

TESTING AND ADJUSTMENTS CHECKING AND TIGHTENING THE FAN - BELT

CHECKING AND TIGHTENING THE FAN - BELT

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

RKZA5700

2 . Fan belt tension

1 - Loosen mounting bolt (4) of the alternator (2) and 5
mounting bolt (5) of adjustment plate.
2 - Rotate the alternator (2) to give correct tension to
fan belt (1) and tighten mounting bolts (4) and (5).
3 - Check fan belt (1) tension.
H If belt has been replaced, check tension again af-
ter about 20 operating hours.
Bolts (4): 44.1 ± 53.9 Nm 4
Bolts (5): 22.5 ± 28.4 Nm
RKZA5690

Water pump
Puleggia pompa
pulley
acqua

10 ± 15mm
10÷15 mm

Alternator
Alternatore

Crankshaft
Puleggia
pulley
albero motore
RKZ01980

20-36 WB91R-2 WB93R-2

 CHECKING AND TIGHTENING
TESTING AND ADJUSTMENTS THE COMPRESSOR FAN - BELT

CHECKING AND TIGHTENING THE COMPRESSOR FAN - BELT

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

RKZO3260

2 . Fan belt tension

1 - Loosen mounting bolt (4) of the eccentric (5). 1
2 - Apply tube on eccentric (5), give correct tension to
fan belt and lock with bolt (4).
5
3 - Check fan belt (1) tension
H If belt has been replaced, check tension again
after about 20 operating hours. 4
Bolt: 123 Nm

RKZA8560

WB91R-2 WB93R-2 20-37

 MEASURING ACCELERATOR PEDAL OPERATING
TESTING AND ADJUSTMENTS TRAVEL AND ACCELERATOR LEVER

MEASURING ACCELERATOR PEDAL OPERATING

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

1. Accelerator pedal travel adjusting

1 - Make sure that accelerator pedal (1) is fully raised
and accelerator lever (2) is at minimum stroke. RKZA5380

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

low idling speed adjusting screw (4).
4 8

3
RKZA5390

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

cables and hand accelerator at a distance of
0.2 ± 0.3 mm from lever (7).
4 - Push accelerator pedal until accelerator lever (3)
contacts the high idling adjusting screw (8). 7

5 6

RKZA5400

5 - Adjust the end travel stopper (9) of accelerator pe-

dal (1) in this position and lock it with nut (10).
6 - Release the accelerator pedal (1).
1

10

RKZA5410

20-38 WB91R-2 WB93R-2

 MEASURING ACCELERATOR PEDAL OPERATING
TESTING AND ADJUSTMENTS TRAVEL AND ACCELERATOR LEVER

2. Accelerator lever travel adjusting

1
1 - Remove knob (1), accelerator lever (2) and lateral 3
cover (3).

RKZA5420

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

sen nut (4) and tight the end lever travel bolt (5) of
some turns. 5
3 - Start engine and bring it to the defined idling 2
speed for accelerator lever.
H Check using the stroboscopic tachometer C2.
H Engine idling speed: 1900w50 rpm
4 - Loosen end lever travel bolt (5) up to it is in con- 4
tact with lever (2) and looked with nut (4).
5 - Bring engine at low idling and check accelerator
lever idling speed again pushing lever at end stro- RKZA5430

ke.

WB91R-2 WB93R-2 20-39

 ADJUSTING BRAKE PEDAL TRAVEL,
TESTING AND ADJUSTMENTS BRAKE ALIGNMENT, MICROSWITCHES

ADJUSTING BRAKE PEDAL TRAVEL, BRAKE ALIGNMENT,

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

4 2
RKZA5440

2 - Check that pedal (2) is near to the stopper (3) and the
pedals lower sides (2) are at standard measure from
cab level.
If necessary, adjust height acting on the stopper (3).
H Pedals lower sides height: 171 mm.
H Check that pin (4) can freely run and lock the two 3
pedals (2) together.
3 - Loosen nuts (5) locking the adjusting rod (6) and tigh-
ten them inside forks (7).
4 - Lock pedals (2) with pin (4); push pedals up to an 8
height of 154.4 mm.
9
5 - Mantening this position, loosen adjusting rods (6) un-
til they touch the brake pump piston seat.
6 - Stop in this position with nut (5).
2
H After tightened nuts (5), check that the adjusting
rod (6) touch the brake pump piston seat simulta-
neously and at an height of 154.4 mm.
7 - Loosen microswitches (for 4 wheel brake) locking
nuts (8).
mm
mm

154,4 mm

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

170,5 mm

mm
160 mm

154.4
170.5

160

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

to they touch the pedal levers (2).
9 - Stop microswitches (9) in this position with nuts (8). RKZ01990

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

6 5 7 RKZ01950

20-40 WB91R-2 WB93R-2

TESTING AND ADJUSTMENTS AIR BLEEDING - RELEASING RESIDUAL PRESSURE

AIR BLEEDING - RELEASING RESIDUAL PRESSURE

1. Air bleeding from pump
H Air bleeding from pump (that means the filling of
pump body) is necessary:
1 - When removing pump.
2 - When removing or replacing connection hoses
between pump and hydraulic tank.
3 - When replacing hydraulic oil and hydraulic
tank overhaul.
The air bleeding is obtained as follows:
1 - Carry out tank oil filling and close hydraulic tank G1
with plug G1.
RKZA5450

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

3 - Connect plug G1 to low pressure air compressed
connection.
4 - Introduce slowly and intermittently air compressed
in the hydraulic tank until when flows out oil wi- 1
thout air bubbles.
H Max. pressure in tank: 0.5 bar
5 - Mount plug (1) and lock it. 2
6 - Depressurize slowly hydraulic tank, check level
and, if necessary, refill tank oil at correct level.
7 - Start engine and run it for few minutes before
bleeding air from the whole system.
RKZA8090

2. Air bleeding from cylinders

H When hydraulic cylinders or pipe fitting have been
removed, it is necessary to bleed air before to use
again the machine.
H Operate on a movement at a time starting from
main cylinders (lifting).
1 - Start engine and run it at high idling speed for
about 5 min. to worm up oil and to pressurise hy-
draulic system.
2 - Return engine at low idling speed, extend and re-
tract the interested piston 4-5 times.
H Extend, lower and retract pistons until about
100 mm from their end of stroke.
3 - Bring again the engine at high idling speed and
repeat operation of point 2; return the engine at
low idling speed and make a complete travel of pi-
ston until the hydraulic pump reaches its maxi-
mum pressure.
4 - Repeat above operation (starting from point 2) for
all cylinders.

WB91R-2 WB93R-2 20-41

TESTING AND ADJUSTMENTS AIR BLEEDING - RELEASING RESIDUAL PRESSURE

3. Air bleeding from oil tank

1 - Put the machine in oil level check position and re-
move the tank plug.
H If necessary add oil until reaching the correct
level.
2 - After stopping the engine wait for some minutes,
until air bubbles on oil surface are fully disappea-
red.
3 - Install tank plug.

4. Hydraulic oil tank pressurization

1 - With engine at low idling speed extend slowly, up
to end of stroke, all cylinders.
2 - Stop the engine and remove tank plug.
3 - Check the condition of gasket and reassemble
plug.
H Avoid to increase the engine speed before
completing all air bleeding procedures and af-
ter the pressurization of oil tank.
H After air bleeding procedures, operate engine
at low Idling speed for about 10 minutes befo-
re starting to work.

5. Releasing residual pressure from the circuits

1 - Put work attachments on level ground, stop the
engine.
2 - Move all control levers in all directions to release
completely cylinders and main circuit remain pres-
sure.
3 - Loosen slowly oil filler tank to remove remain
pressure.

6. Air bleeding from braking circuit

H Above operation is to be carried out every time
maintenance is made on braking circuit to remove
or replace a component, or when air entered into
the circuit.
H Machine must be stopped with attachments on le-
vel ground. 1
1 - Make sure that oil in brake system tank (1) is at
maximum level.
2 - Remove pedal lock pin.

RKZA5460

20-42 WB91R-2 WB93R-2

TESTING AND ADJUSTMENTS AIR BLEEDING - RELEASING RESIDUAL PRESSURE

3 - Remove safety plugs and applied to bleeding

screws (2) a vinyl hose (3) to catch oil.
4 - Push one brake pedal to bottom and, keeping it
pushed, loosen bleeding screw (2) of one of two
braking units until the pedal reaches end of its
stroke.
5 - Keeping pedal at the end stroke, tighten bleeding
screw (2).
6 - Release braking unit pedal during air bleeding, 2
wait for few seconds and repeat above operations
until from bleeding screw, oil flows out without air
bubbles.
RKZA5470

7 - Repeat same operations for the other braking unit.

H Check frequently the oil level in the tank and
carry out filling every time level approaches
to minimum.
H After air bleeding apply on screws (2) safety
plugs.

7. Emptying the air-conditioning unit

1 - Connect the maintenance station M1 to the servi- 1
ce valves (1) and (2) and follow the specific main-
tenance station instructions relative to the draina-
ge of the unit. 2
2 - Disconnect the group to be substituted or recondi-
tioned immediately after switching off the mainte-
nance station. Plug the removed or disconnec-
ted connection tubes tightly and with a mini-
mum of delay.
3 - Carefully check the quantity of anti-freeze oil reco-
vered and contained in the disassembled parts, RKZA8570

since the same quantity must be replaced when

the air-conditioning unit is refilled.

WB91R-2 WB93R-2 20-43

 CHECKING AND SETTING PRESSURE IN
TESTING AND ADJUSTMENTS THE ATTACHMENTS HYDRAULIC CIRCUIT

CHECKING AND SETTING PRESSURE IN THE ATTACHMENTS

HYDRAULIC CIRCUIT
1. Introduction
. On the machine configuration, one or two spool. STEERING UNIT
Mechanical control valves have been installed IDROGUIDA
with following function:
Control valve No. 1 (2-3-spools):
for front work attachments control.
Control valve No. 2 (6-7-8-spools):
for rear work attachments control.
. The two control valves are protected against over-
pressure by a main relief valve (or general and na-
med Pressure cut off valve) with fixed setting.

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

POWER TRAIN
TRASMISSIONE

DIESEL
DIESEL

P1
P1

MAIN RELIEF
VALVOLA
VALVE
GENERALE

BACKHOE
CONTROL VALVE
DISTRIBUTORE
. Control valves are feeded by P1 pump total deli- (6-7-8 SPOOLS)
RETROESCAVATORE
(6-7-8 ELEMENTI)
very.
. P1 pump delivery is checked by a priority valve
(internal to the control valve N. 1) when steering
unit is used. RKZ02490

. Control valves include spools controlling:

2-SPOOL CONTROL VALVE

Control Port
Front bucket (curled - dump) A1-B1
Front bucket (lifting - lowering) A2-B2 A
1 2
B

RKZ02040

20-44 WB91R-2 WB93R-2

 CHECKING AND SETTING PRESSURE IN
TESTING AND ADJUSTMENTS THE ATTACHMENTS HYDRAULIC CIRCUIT

3-SPOOL CONTROL VALVE

Control Port
Optional attachment A1-B1
Front bucket (curled - dump) A2-B2 A
1 2 3
Front bucket (lifting - lowering) A3-B3
B

RKZ02060

6-SPOOL CONTROL VALVE

Control Port
Arm (opening - closing) A1-B1
Boom swing (left - right) A2-B2 B
R.H. outrigger (up - down) A3-B3 1 2 3 4 5 6
L.H. outrigger (up - down) A4-B4
A
Bucket cylinder (dump - curled) A5-B5
Boom cylinder (lifting - lowering) A6-B6
RKZ02070

7-SPOOL CONTROL VALVE

(For jig arm)
Control Port
Jig arm (in - out) A7-B7
B
7
A

RKZ02080

7-SPOOL CONTROL VALVE

(For hammer - side digging boom)
Control Port
Hammer (R.H. side - L.H. side) A7-B7
Side digging boom (left - right) A7-B7
B
7
A

RKZ02090

WB91R-2 WB93R-2 20-45

 CHECKING AND SETTING PRESSURE IN
TESTING AND ADJUSTMENTS THE ATTACHMENTS HYDRAULIC CIRCUIT

8-SPOOL CONTROL VALVE

(For hammer and jig arm)
Control Port
Hammer (R.H. side - L.H. side) A7-B7
Jig arm (in - out) A8-B8 B B
7 8
A A

RKZ02050

2. Testing and setting general valves

(Pressure cut off valve)
E3
H Test condition:
1
. Engine: at operating temperature
. Hydraulic oil: 45 ± 55 ëC
. Working brakes applied
1 - Connect the pressure gauge E3 (400 bar) to the
pressure adapter (1) of the front shovel control val-
ve (2).
2 - Start the engine, bring the hand accelerator lever
2
up to 1050 rpm and check the nominal pressure of RKZA5480

the main relief valve (pressure cut-off valve) by for-

cing the front bucket to rise to the end of its stroke.
±1
H Nominal pressure: 221+6

H If the main relief valve pressure do not corre-

spond to the nominal values, they must be
re-set (See «SETTING THE MAIN RELIEF
VALVES AND THE REDUCING VALVES»).

3. Testing and setting secondary valves

H Test condition:
. Engine: at operating temperature.
. Hydraulic oil: 55 ± 60 ëC. E3
. Parking brake: applied. 1
H The pressure readings are to be operated from
the same check point.
1 - Connect the pressure gauge E3 (400 bar) to
the pressure adapter (3) of the backhoe con-
trol valve (4).
2 - Start the engine and bring the hand accelera-
tor lever up to 1050 rpm.
2
RKZA5480

20-46 WB91R-2 WB93R-2

 CHECKING AND SETTING PRESSURE IN
TESTING AND ADJUSTMENTS THE ATTACHMENTS HYDRAULIC CIRCUIT

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

ve) to a value 30 bar higher than the maximum
pressure to be tested.
4 - Check the single movements pressure.
The secondary valve of backhoe boom lif-
ting, must be checked and settled on
test bench only.

Setting 2-spool control valve secondary valves

Unit: bar
Cylinder and movement Port Setting WB91R-2 Setting WB93R-2

Front Lifting A1 Ð Ð
bucket Lowering B1 Ð Ð

Front Curled A2 230w7 230w7

bucket Dump ] B2 170w7 170w7

] This setting can be carried without modifing the general valve pressure.

Setting 3-spool control valve secondary valves

Unit: bar
Cylinder and movement Port Setting WB91R-2 Setting WB93R-2

Front Lifting A1 Ð Ð
bucket Lowering B1 Ð Ð

Front Curled A2 230w7 230w7

bucket Dump ] B2 170w7 170w7

Optional A3 230w7 230w7

attachment B3 230w7 230w7

] This setting can be carried without modifing the general valve pressure.

Setting 6-spool control valve secondary valves

Unit: bar
Cylinder and movement Port Setting WB91R-2 Setting WB93R-2
Closing A1 230w7 230w7
Arm
Opening B1 Ð Ð
Left A2 240w7 240w7
Boom swing
Right B2 240w7 240w7
Up A3 Ð Ð
Right outrigger
Down B3 Ð Ð
Up A4 Ð Ð
Left outrigger
Down B4 Ð Ð

Bucket Dump A5 Ð Ð
cylinder Curled B5 230w7 230w7
Lifting ] A6 300w7 300w7
Boom
cylinder Lowering B6 230w7 230w7

] The setting must be carried on test bench only.

WB91R-2 WB93R-2 20-47

 CHECKING AND SETTING PRESSURE IN
TESTING AND ADJUSTMENTS THE ATTACHMENTS HYDRAULIC CIRCUIT

Nominal values of the reducing valves of the 7-8 element control valve
(for the other settings, please refer to the 6-element control valve).
Unit: bar
No. of spools Cylinder and movement Port Setting WB91R-2 Setting WB93R-2
R.H. side A7 165w7 165w7
Hammer
L.H. side ] B7 Ð Ð
Right A7 270w7 270w7
7 Hammer
Left B7 270w7 270w7
In A7 Ð Ð
Jig arm
Out B7 Ð Ð
R.H. side A7 165w7 Ð
Hammer
L.H. side ] B7 Ð Ð
8
In A8 Ð Ð
Jig arm Ð
Out B8 Ð

] This setting can be carried without modifing the general valve pressure.

H If valve setting pressure do not correspond to the

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

4 - Set the general valve pressure to the standard va-

lue.

4. Main and secondary valves setting

. General valves (Pressure cut off valve (1))
For setting, prepare machine as per pressure te- 1
sting.

1 - Loosen lock nut (2).

2 - Force to the end of its stroke the lever commanding
whichever movement is being used for the tests.
3 - Adjust pressure with adjusting screw (2).
. To INCREASE pressure, rotate in CLOCKWI-
SE direction.
RKZA8100
. To DECREASE pressure, rotate in COUN-
TERCLOCKWISE direction.
4 - Lock position with nut (2).
Lock nut: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nm
2

3
RKZ02241

20-48 WB91R-2 WB93R-2

 CHECKING AND SETTING PRESSURE IN
TESTING AND ADJUSTMENTS THE ATTACHMENTS HYDRAULIC CIRCUIT

. Secondary valves
For setting, prepare machine as per pressure te-
sting. 2
H This setting is valid for all the secondary valve 1
and has to be carried forcing the movement to
be checked at its end of stroke. 3
1 - Loosen lock nut (1).
2 - Adjust pressure with adjusting screw (2).
. To INCREASE pressure, rotate in CLOCKWI-
SE direction.
. To DECREASE pressure, rotate in COUN-
TERCLOCKWISE direction.
3 - Lock position with nut (1).
Lock nut: 10w1 Nm.
When terminated the setting, Apply safety
plug (3) to avoid not authorised tamperings.

4 - Set the general valve pressure to the standard va-

lue.

RKZ02010

WB91R-2 WB93R-2 20-49

 TESTING AND ADJUSTING OF
TESTING AND ADJUSTMENTS LOAD SENSING SIGNAL (LS VALVE)

TESTING AND ADJUSTING OF LOAD SENSING SIGNAL

(LS VALVE)
H Testing conditions.
. Engine: stopped but at working temperature.
1
. Hydraulic oil: 45 ± 55ëC.
. Machine: front equipment on the ground, parking E3
brake applied and boom and arm fully extended.
2
1 - Disconnect hose(1) from the Load Sensing line. In-
stall an thee (2) and reconnect hose (1).
2 - Connect to thee (2) a pressure port and gauge E3
(400 bar).

RKZA5501

3 - Connect to rear control valve pressure port a pressu-

re gauge E3 (400 bar).
E3
4 - Start the engine and bring it to 2000 rpm; check that
1
with no movements the Load Sensing pressure is
6w2 bar.
5 - Raise boom up to middle of stroke; force the move-
ment and read the pressure on both gauges.
6 - Calculate the differential pressure (iP) substracting
the reading from the two gauges (control valve P -
Load Sensing PLS).
H Normal DP: P ± PLS= 18w1 bar 2
RKZA5480
H If the iP value is not inside the limits, carry out
the Load sensing valve (3) setting.

1. Adjusting of the Load Sensing valve

1 - Remove nut (4).
2 - Loosen nut (5).
1 3
3 - Adjust pressure using adjusting screw (6).
. To INCREASE pressure, rotate in CLOCKWI-
SE direction.
. To DECREASE pressure, rotate in COUN-
TERCLOCKWISE direction.
4 - Lock the position with nut (5). RKZA5710

Lock nut: 21 Nm
5 - Check gasket (7) and mount nut (4).
Nut: 21 Nm
4 6 5

RKZ02270

20-50 WB91R-2 WB93R-2

TESTING AND ADJUSTMENTS CHECKING UNLOADING VALVE FUNCTIONALITY

CHECKING UNLOADING VALVE FUNCTIONALITY

H Test condition:
. Engine: stopped but at working temperature.
1
. Low idling: in the permissible limit.
. Hydraulic oil: 45 ± 55ëC. E1
. Machine: in safety condition, parking brake ap- 2
plied.
. Control valve lever at neutral position.
1 - Disconnect hose (1) from the Load Sensing line. In-
stall an thee (2) and reconnect hose (1).
2 - Connect to thee (2) a pressure port and gauge E1 (60
bar). RKZA8740

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

sure port (3).
E1
4 - Start the engine at low idling and without any move-
ment check pressure on both gauges. 3
H Normal pressure (P) control valve gauge
27w3 bar
H Normal pressure Load Sensing line gauge (PLS):
6w2 bar
(This value is due to the influence of the counter-
pressure present in the steering circuit).
H If any variations are found, they do not represent
a problem provided that the difference of 21w1 RKZA5511
bar between the two readings is respected.
5 - If the difference between the two readings is higher
than 21w1 bar, stop the engine and release residual
pressures.
6 - Thoroughly clean the valve (4) and re-install it.
Valve: 20 Nm
4
7 - If, in spite of cleaning the valve (4), the value of 21w1
bar still does not fall within the tolerance limits, install
a new valve.

RKZA8102

1
RKZ02251

WB91R-2 WB93R-2 20-51

TESTING AND ADJUSTMENTS TESTING PUMP DELIVERY

TESTING PUMP DELIVERY

H Test condition:
. Engine: stopped but at working temperature.
. Hydraulic oil: 45 ± 55ëC.
. General valve (Pressure cut off valve) and secon-
dary valve: within normal limits. 2
. Machine: front equipment on the ground, boom
1
and arm fully extended and bucket fully curled
and on the ground.
. Parking brake: applied.

1. Flow-meter connection F1
1 - Release residual pressure.
RKZA5520

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

side (2).
H Plug holes to avoid impurity inlet.
3 - Connect cylinder bottom side hose (1) to the flow- C1
meter F1 inlet port and connect the cylinder head
side hose to the outlet port.
4 - Use a tachometer C2 to control that pump delivery
is within the rpm limits during the test.
H If using a multiscale tachometer C1 mounted
on fuel delivery pipe, check that it is mounted
far from the pipes retainer.
H Pumps diagrams are refereed to constant
idling for all the use range.
RKZA5300

H When measuring the deliveries with the pump

mounted on the machine it becomes difficult
to use the accelerator to set the engine idling.
Make delivery measurements with the engine Example:
running at a speed close to the test speed and
then make a proportional calculation. MEASUREMENT
Engine speed: 2144 rpm
Delivery: 153.97 ,/min
PROPORTIONAL DELIVERY AT 2200 rpm
153197 x 2200 = 158 ,/min
ÐÐÐÐ
2144

2. Measurement
1 - Start the engine and bring it up to 2200 rpm. F1
2 - Move the bucket curling lever up to end of stroke 3
and, with the lever in this condition, adjust the de-
livery pressure with the flowmeter F1 knob (3).

PRESSURE
DELIVERY

RKZA5530

20-52 WB91R-2 WB93R-2

TESTING AND ADJUSTMENTS TESTING PUMP DELIVERY

3 - Check the effective delivery flow and the engine

idling speed at each pressure increment, perfor-
ming different reading each 20 bar pressure in-
creasing, extending the readings to all the wor-
king range (up to the maximum value set by the

bar
general valve).
H Perform more than once the reading to have a
media of the values.
H Those tests check the Economy mode curve.
H After checked the pump characteristic curve is
possible to carry out the check of the point of
Power
pump initial regulation, that means the point Power
where the pump starts reducing the delivery
to preserve the pressure required.
To obtain the exact position of this diagram
point, perform the pressure-delivery-engine
speed tests each 10 bar a zone close to the Economy
Economy

point found in the preceding test.

4 - Release pressure to the minimum value using the
flowmeter F1 knob (3) and insert the Power mode Initial regulation
Inizio regolazione
(«Speed control» push-button).
5 - Repeat phase 3 procedure to check Power mode
0
curve (Power mode). 0 ᐍ/min
6 - Release the «Speed control» push-button, reduce RKZ02260

pressure and stop the engine.

7 - Check the flow - pressure against the value shown
on «TECHNICAL SPECIFICATION».
H If the measured value is lower of more the 7%
than the permissible, it is necessary to over-
haul of the pump.
8 - Release the residual pressure.
9 - Restore the bucket hoses connection to the cylin-
der.

WB91R-2 WB93R-2 20-53

TESTING AND ADJUSTMENTS TESTING PRIORITY VALVE OPERATION

TESTING PRIORITY VALVE OPERATION

H Test condition:
. Engine: operating temperature E2
1
. Hydraulic oil: 55 ± 60 ëC
. Parking brakes: applied

1. Testing priority valve operation

1 - Connect a pressure gauge E2 (250 bar) to the
pressure adapter (1) of the backhoe control valve.
2 - Start the engine and bring it to idle speed of
1500 ± 50 rpm.
RKZA5540
3 - Check on gauge E2 pressure value with stopped
steering wheel (21 bar).

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

creases.
2
5 - Continue the steering up to end of stroke and
check that, forcing the steering wheel, pressure
increases till normal value.
H Normal pressure: 175w7 bar.
H If the pressure does not reach the normal va-
lue, re-set the pressure of the steering unit.
H If turning the steering wheel the pressure
shown by gauge does not change and stress
on steering wheel necessary to carry out stee-
ring is high, clean the priority valve (2). RKZA5550

2. Cleaning priority valve

1 - Remove priority valve plug (3), spring (4) and rod
(5).
H Check and make notes on the direction of as-
sembly. 6
2 - Dismantle the plug (6) and remove the ball (7) of
the inside valve and the spring (8). 8
3 - Check that the hole (9) and the nozzle (10) are per-
fectly clean. 7 9
4 - Replace the spring (8), the ball (7) and the plug
(6).
Plug: Loctite 542
Plug: 20 Nm
H Do not allow any Loctite to enter the hole (9). 5
4
H Remove all excess Loctite from the rod (5).
10
5 - Lubricate the rod (5) and mount it in its seating,
ensuring that it slides freely.
6 - Insert the spring (4) and mount the plug (3). 3
Plug: 100 Nm
7 - Start the motor, execute several steering manoeu-
vres and, if the fault is not corrected, replace the
complete steering column with a new one.
RKZ02220

20-54 WB91R-2 WB93R-2

 TESTING AND SETTING STEERING
TESTING AND ADJUSTMENTS CONTROL SYSTEM PRESSURE

TESTING AND SETTING STEERING CONTROL SYSTEM PRESSURE

H Test condition:
. Engine: operating temperature E2
1
. Hydraulic oil: 55 ± 60 ëC

Testing
1 - Connect a pressure gauge E2 (250 bar) to the pressu-
re adapter (1) of the backhoe control valve.
2 - Start the engine and bring it to idle speed of 1500w50 rpm
and carry out a total steering.
3 - Forcing the steering wheel at the end of stroke, check
pressure. RKZA5540

H Normal pressure: 175w7 bar

4 - Check for the other steering direction too.

Setting 6 5 4 7
If pressure is not within permissible value, carry out set-
ting acting on upper valve (3) of the steering unit.
1 - Remove plug (4).
2 - Insert a wrench of 4 mm and loosen screw (5).
3 - Adjust pressure with screw (6).
. To INCREASE pressure rotate in CLOCKWISE di-
rection. 3
. To DECREASE pressure rotate in COUNTER-
RKZA5560
CLOCKWISE direction.
4 - Stop engine, lock the adjusting screw (6) position
tightening screw (5).
5 - Reassemble plug (4) checking that gasket (7) is on its
seat.
Plug: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nm

WB91R-2 WB93R-2 20-55

TESTING AND ADJUSTMENTS TESTING BRAKE SYSTEM

TESTING BRAKE SYSTEM

H Test condition:
. Engine: stopped
. Machine: on solid and level ground, with equip-
ment raised and safety devices engaged.
. Brake pedals: independent, with the container le-
vel at maximum. 1
The system testing provides in two stages:
1 - Testing circuit and brake pump tightness.
3
2 - Leaktightness test of the braking group. 2
If both the tests give a positive result, the leaks RKZA5570

must be sought in the pipelines of the braking

system.

1. Testing circuit and brake pump tightness 4

1 - Disconnect the connecting pipe (2) of the equali-
zers from the brake pumps (1) of the circuit to
be tested.
2 - Securely plug the equalizer orifice (plug A).
2
3 - Remove the clamp (3) and disconnect the delivery
lines (4) from the pumps. Connect a pressure gau-
ge E2 (250 bar) to the pump (1) being tested.
4 - Move the brake pedal corresponding to the pump
A
and bring the circuit up to a pressure of approxi- RKZA5580

mately 120 bar.

H Do not exceed maximum permissible value
that is of 150w5 bar.
5 - Keep the pedal pushed for at least 2 minutes and
check that pedal pressure and position remain E2
steady.
H If the position of the pedal must be changed to
maintain pressure, the pressure loss is due to
leakages inside the pump.
This can be confirmed by checking the oil. If
there are leakages, it will show signs of mi- 1
xing.
6 - Repeat test for the other brake pump.
RKZA5590

2. Testing braking group leaktightness

1 - Disconnect the delivery tube (5) of the braking 5
group being tested.
2 - Connect the tool H1 between the delivery line (5) E2
and the braking group. 7
H Check that the pressure adapter (6) is inserted
between the braking group and the exclusion
valve (7). H1
3 - Connect a pressure gauge E2 (250 bar) to the pres-
sure adapter of the tool H1 and open the cock (7).
6
RKZA5600

20-56 WB91R-2 WB93R-2

TESTING AND ADJUSTMENTS TESTING BRAKE SYSTEM

4 - Operate brake pump to feed pressure into the circuit

to maximum pressure of 150w5 bar.
5 - Maintaining pressure, close the valve (7) to main-
tain pressure in the braking group being tested.
6 - Release the brake pedal and check for 2 minutes
the pressure indicated by gauge E2.
H If the pressure value shows a negative chan-
ge, it means that the braking piston seals
are defective.
Further confirmation of the leak can also be ob-
tained by an increase in the oil level in the axle,
which leads to a mixing of the oils. Change all
the sealing rings between the axle sections,
and carry out a complete lubrication oil change.

7 - Repeat the test for the other braking group, follo-

wing the same method.
8 - Re-assemble the braking circuit.
After testing and possible repairs, bleed air from
brake units (see «AIR BLEEDING OF BRAKE
CIRCUIT»).

WB91R-2 WB93R-2 20-57

TESTING AND ADJUSTMENTS CONTROL OF THE ENGINE SPEED UNDER LOAD

CONTROL OF THE ENGINE SPEED UNDER LOAD

H Test conditions:
. Engine: stopped but at working temperature.
. Hydraulic oil: 45 ± 55ëC.
. Power train oil: up to working temperature.
. Brake pedals: connected by a cotter-pin.
. Machine: on solid and level ground with the
equipment raised and safety devices engaged.

Two tests must be performed:

1 - Speed test with the torque converter under stress.
2 - Speed test with the torque converter and the hydrau- RKZA8580

lic system under stress.

H The tests must be performed after a no-load test
of the engine speed.
(For details, see «ENGINE SPEED TESTS»).
During the following tests, while accelerating the
engine with the gear engaged, the condition of C1
the brake disks can also be checked.
If, while force is being exerted on the brake pe-
dals, the machine starts to travel (even slowly):
a - Release the accelerator immediately and
stop the engine.
b - Check the wear on the brake disks and chan-
ge them before completing the tests (See:
«30. DISMANTLING AND ASSEMBLY -
REAR AXLE»). RKZA5300

1. Preparing the machine

1 - Prepare the rev. counter C1 to measure the engi-
ne rpm.
H If mounting an electronic pressure transducer
rev. counter on a diesel delivery line to the in-
jection nozzles, make sure that it is placed far
away from the clamp.
H If using a stroboscopic tachometer C2, make a
clearly visible notch on the engine pulley to fa-
cilitate the reading.
Make sure that the brake pedals are fastened 1
together by the cotter pin (1).
RKZA5441

2. Testing with the torque converter under stress

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

20-58 WB91R-2 WB93R-2

TESTING AND ADJUSTMENTS CONTROL OF THE ENGINE SPEED UNDER LOAD

3. Testing the torque converter and hydraulic sy-

stem under stress
1 - Start the motor at MIN. Engage the highest FOR-
WARD gear and brake hard.
2 - Keeping the machine on the brake, engage the
upper FORWARD gear, accelerate the engine gra-
dually and at the same time act on the front bucket
closed (curled) command control valve lever.
3 - Once the maximum engine speed and the maxi-
mum pressure of the bucket circuit have been rea-
ched, measure the speed reached by the engine.
H Normal speed: WB91R-2: 2000w50 rpm
WB93R-2: 2200w50 rpm
TBG version: WB91R-2: 2100w50 rpm
WB93R-2: 2200w50 rpm
. If the revs of the engine are higher than the per-
missible limit, in both tests, check the pressure
of delivery to the converter and the clutch pressu-
res. (See «TESTING PRESSURES OF THE PO-
WER TRAIN GROUP»).
. If the revs of the engine are lower than the permis-
sible limit, check the condition of the air filter, and
the conditions of the engine compression, the ti-
ming, the injection pump, and the valve clearan-
ces.

WB91R-2 WB93R-2 20-59

TESTING AND ADJUSTMENTS TESTING PRESSURES IN THE POWER TRAIN GROUP

TESTING PRESSURES IN THE POWER TRAIN GROUP

The power train group can be used to perform pressure

tests on the internal hydraulic circuit. These are useful
for identifying malfunctions.
Specifically, the tests involve:
1 - Converter oil pressure.
2 - Clutch engagement pressures for both directions of
travel.
H Test conditions:
. Engine: stopped.
. Brake pedals: connected by a cotter pin.
. Machine: on solid and level ground with the equip- RKZA8580

ment raised and safety devices engaged.

1. Preparing the machine

1 - Prepare the rev. counter C1 to measure the engi-
ne rpm. C1
H If mounting an electronic pressure transducer
rev. counter on a diesel delivery line to the in-
jection nozzles, make sure that it is placed far
away from the line-clamp.
H If using a stroboscopic tachometer C2, make a
clearly visible notch on the engine pulley to fa-
cilitate the reading.
Make sure that the brake pedals are fastened
together by the cotter pin (1). RKZA5300

2. Converter oil pressure

1 - Remove the plug (P22) and connect the pressure
gauge E6.
2 - Start the engine and heat the engine and all the
fluids up to working temperature. In particular ma-
ke sure that the power train oil reaches a tempera-
ture of 80w5 ëC.
3 - With the engine at MIN, check the pressure on the
pressure gauge E6.
H Normal pressure: 0.9 bar 1
4 - Gradually increase the rev speed to MAX. Take a RKZA5441
new reading from the pressure gauge E6.
5 - Bring the engine back to MIN and compare the
pressure with the normal value. P22
P19
H Normal pressure: 9 bar
H If the maximum pressure value drops to below
the permissible lower limit, the power train
pump needs an overhaul.

P18
RKZ02110

20-60 WB91R-2 WB93R-2

TESTING AND ADJUSTMENTS TESTING PRESSURES IN THE POWER TRAIN GROUP

3. Clutch engagement pressure

1 - Remove the cab floor.
2 - Remove the plug (P19) and connect the pressure
gauge E6.
3 - Start the engine and heat the engine and all the
fluids up to working temperature. In particular ma-
ke sure that the power train oil reaches a tempera-
ture of 80w5 ëC.
E6
4 - Bring the engine up to MIN (idling) and check the
pressure on the pressure gauge E6. P19 P18
H Normal pressure: max. 0.4 bar RKZA5610

5 - Gradually increase the rev speed up to MAX. Take

a new reading from the pressure gauge E6.
6 - Bring the engine back to MIN and compare the
pressure with the normal value.
H Normal pressure: 11 ± 13 bar
7 - Remove the pressure adapter and replace the
plug (P19).
Cap: 23 Nm
8 - Repeat the same test for the FORWARD gear,
reading the pressure from the orifice protected
by the plug (P18).
. If the pressures are different for the two travel
directions, there is a loss of pressure on the
clutch piston with lower pressure.

WB91R-2 WB93R-2 20-61

TESTING AND ADJUSTMENTS TESTING THE CORRECT FUNCTIONING
OF THE POWER TRAIN CLUTCHES

TESTING THE CORRECT FUNCTIONING OF THE

POWER TRAIN CLUTCHES
H Test conditions:
. Engine: stopped.
. Brake pedals: connected by a cotter pin.
. Machine: on solid and level ground with the
equipment raised and safety devices engaged.
H This test must be performed after having checked
the pressures of the power train group.

1. Preparation of the machine

1 - Prepare a rev. counter to measure the engine rpm.
H If mounting an electronic pressure transducer rev. RKZA8580

counter on a diesel delivery line to the injection

nozzles, make sure that it is placed far away from
the line-clamp.
H If using a stroboscopic tachometer C2, make a
clearly visible notch on the engine pulley to facili-
tate the reading. C1
Make sure that the brake pedals are fastened toge-
ther by the cotter pin (1).
During the following tests, during the engine accele-
ration phase with the gear engaged, the condition of
the brake disks can also be checked.
If, while force is being exerted on the brake pedals,
the machine starts to travel (even slowly):
a - Release the accelerator immediately and stop the
engine.
RKZA5300

b - Check the wear on the brake disks and change them

before completing the tests (See: «30. DISMAN-
TLING AND ASSEMBLY - REAR AXLE»).

2. Testing
1 - Start the engine and heat the engine and all the
fluids up to working temperature. In particular ma-
ke sure that the power train oil reaches a tempera-
ture of 80w5 ëC.
2 - With the engine in idling condition, accelerate to
MAX. and check that in this condition the revs re-
main within permissible limits. (See «TESTING 1
ENGINE SPEED»).
RKZA5441

3 - Brake hard and bring the engine up to MAX.

4 - Maintaining the braking action and the accelera-
tion, engage the FORWARD gear and check that
the engine speed decreases until it is once again
within permissible limits (See «TESTING THE EN-
GINE SPEED UNDER STRESS»).
5 - Repeat this test in REVERSE gear.
H If the revs are high than the permissible limits,
the clutches are worn, and must be replaced.

20-62 WB91R-2 WB93R-2

TESTING AND ADJUSTMENTS ADJUSTING THE SENSOR FOR RETURN TO DIG DEVICE

ADJUSTING THE SENSOR FOR RETURN TO DIG DEVICE

H Adjustment conditions:
. Machine: on solid and level ground.
. Engine: stopped.
. Hydraulic oil: 45 ± 55ëC
. Parking brake: engaged.
1 - Rest the bucket on the ground, making sure that the
bottom is perfectly parallel to the surface.
2 - Stop the engine and remove the sensor guard (1).
3 - Check that there is a distance 3 ± 4 mm between the
sensor (2) and the rod (3)
RKZA8120

H If necessary loosen the nuts (4) and adjust the di-

stance, until the indicated measurement is obtai-
ned, and secure that position.
Sensor nut:. . . . . . . . . . . . . . . . . . . . . . . . . . . . Nm
4 - Loosen the locking nuts (5) and (6) of the position-in-
dicating rod (3) and shift the rod towards the front of
the machine until it has passed beyond the sensor
axis (2).
5 - Start the engine at MIN., tighten the rear nut (6) and
at the same time unscrew the front nut (5) until the 1
sensor (2) is engaged.
H When the rod engages the sensor, the pilot light
(7) comes on.
RKZA5620
6 - Secure the position of the rod (2) by tightening the
nuts (5) and (6) behind the bracket (8).
Nuts: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nm
3 3
3± 4 mm
÷4 mm 3
7 - Perform several tests by raising the bucket and simu-
lating some dumping manoeuvres. If the bucket is
able to rest flat on the ground, replace the sensor
guard (1).
2

2 4
7
RKZA5630

3 6 5

RKZA5640

WB91R-2 WB93R-2 20-63

TESTING AND ADJUSTMENTS ANALYSIS OF CAUSES HYDRAULIC DRIFT

ANALYSIS OF CAUSES HYDRAULIC DRIFT

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: 45 ± 55ëC
. Removal and installation of pipes only after re-
main pressure removal.
(See «REMOVAL OF REMAIN PRESSURE
FROM CIRCUIT»). Blocks
Blocchi

FRONT EQUIPMENT RKZA1830

1. Testing of front bucket lifting

1 - Put the machine with bucket teeth on blocks of 1
about 10 cm and in vertical position compared to
ground. 2
3
2 - Stop the engine and remove the remain hydraulic
pressure.
3 - Disconnect pipes (1) and (2) from lift cylinders (3)
and plug them.
4 - Plug cylinders, base side, and apply a temporary
pipe, head side, to catch possible oil leakage.
5 - Start the engine and retract the bucket until to
bring the teeth in tilt position of about 15ë.
RKZA5650

6 - Stop the engine and check bucket link position for

5 minutes.
. If bucket link has no lowering movement, drift
is due to control valve.
To check each cylinders, proceed as follow:
7 - Carry out with bucket a dump movement to let
teeth lean on ground in vertical position. 15°

8 - Remove from one of cylinders the plug as instal-

led on base side at stage 4.
9 - Start the engine and retract the bucket until to
bring teeth in tilt position of about 15ë towards up-
per. RKZA1840

10 - Stop the engine and check the bucket position for

5 minutes.
. If bucket link has a lowering movement, drift is
due to gaskets of plugged cylinder.
11 - Repeat operation from stage 8 to stage 10 to
check the other cylinder.

20-64 WB91R-2 WB93R-2

TESTING AND ADJUSTMENTS ANALYSIS OF CAUSES HYDRAULIC DRIFT

2. Testing of front bucket dumping

1 - Put the machine with bucket on level ground and
teeth tilted of about 15ë.
Put in the bucket a weight of 1500 kg.

1500 kg
1500 kg

RKZ02130

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

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

2
1
RKZA5660

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

alignment of the bucket hinge and shovel arm hin- 1500 kg
1500 kg
ge.
5 - Stop the engine and check bucket teeth position
for 5 minutes.
. If bucket has no swing movement, drift is due
to control valve.
To test the individual cylinders, proceed as follows:
6 - Lower the bucket to the ground.
7 - Remove from one of the cylinders the plug fitted
on the cylinder bottom side in Phase 3. RKZ02630

8 - Start the engine and raise the bucket as indicated

in phase 4.
9 - Stop the engine and check the position of the buc-
ket teeth for 5 minutes.
. If the bucket teeth turn, the drift is due to the
gasket seals of the plugged cylinder.
10 - Repeat the operations from phase 6 to phase 9 in
order to test the other cylinder.

WB91R-2 WB93R-2 20-65

TESTING AND ADJUSTMENTS ANALYSIS OF CAUSES HYDRAULIC DRIFT

BACKHOE
H Test condition:
. Backhoe aligned
. Lifted outriggers

1. Boom testing
1 - Set the machine with arm in vertical position and
with bucket on level ground leaned on the side.
2 - Stop the engine and remove the remain hydraulic
pressure.
RKZ02510

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

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

1
RKZA1341

7 - Start the engine and extend completely the arm.

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

RKZ02520

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

RKZ02530

20-66 WB91R-2 WB93R-2

TESTING AND ADJUSTMENTS ANALYSIS OF CAUSES HYDRAULIC DRIFT

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

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

RKZA5680

5 - Start the engine and raise the boom.

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

RKZ02540

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

450 kg
450 kg

RKZ02550

2 - Stop the engine and remove the remain hydraulic

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

3
RKZA5670

WB91R-2 WB93R-2 20-67

TESTING AND ADJUSTMENTS ANALYSIS OF CAUSES HYDRAULIC DRIFT

5 - Start the engine and raise the boom.

6 - Stop the engine and check the bucket position for
5 minutes.
. If bucket has an opening movement, drift is
due to cylinder gaskets.
. If bucket has no movement, drift is due to con-
trol valve.

RKZ02560

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

20 cm

RKZ02200

4 - Stop the engine and release residual hydraulic

pressures.
2 3
5 - Remove clamp (1) and disconnect from cylinders
(4) the pipes (2) and (3).
6 - Plug cylinders pipes (2) base side and apply on
head sides temporary pipes to catch possible oil
leakage. 1
4
7 - Start the engine, use force on the boom to raise
the machine, and remove the trestles supporting
the outriggers.

RKZA1251

8 - Lower the machine and stop the engine.

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

RKZ02210

20-68 WB91R-2 WB93R-2

TESTING AND ADJUSTMENTS TESTING THE AIR-CONDITIONING UNIT

TESTING THE AIR-CONDITIONING UNIT

H Test conditions:
. Machine on level ground with the working equip-
ment raised and in safety conditions
. Parking brake engaged

1. Testing the working temperature

1 - Connect the maintenance station to the high pressure
valve (H.P.) and the low pressure valve (L.P.)
2 - Start the engine and bring it up to a speed of 1500
rpm.
3 - Switch on the A/C unit using the switch in the cab. RKZA8580

4 - Select an intermediate ventilation speed inside the

cab.
5 - Use the thermometer/hygrometer M2 to check that
the temperature inside the cab is equal to or lower
than the ambient temperature.
H If the temperature of the cab is higher than the
ambient temperature, open the doors and widows
and wait until the cab temperature stabilizes at
the outside value.
6 - Close the doors and windows and let the A/C unit
operate in these conditions for 5 - 10 minutes.
7 - Use the thermometer M2 to check the temperature of
the air at the central outlets.
H Position the probe as close as possible to the air
outlets.
8 - Compare the average value of the measured tempe-
ratures using the following table:
Ambient 20ë 25ë 30ë 35ë
temperature (ëC)

Outgoing air 6ë ± 8ë 8ë ± 10ë 8ë ± 12ë 9ë ± 14ë

temperature (ëC)

9 - If the average value of the temperature measured

does not fall within the values given in the table, it will
be necessary to thoroughly check the unit.

WB91R-2 WB93R-2 20-69

TESTING AND ADJUSTMENTS TESTING THE AIR-CONDITIONING UNIT

2. Checking the unit

A diagnosis of faults in the unit is based on the working
pressures.
When the pressures do not fall within the values given in
the following table, the causes must be sought by chec-
king the high-pressure (H.P.) and low pressure (L.P.) pres-
sure gauges.
Unit with R134a
Outside L.P. (kg/cm2) H.P. (kg/cm2)
Temperature (ëC)
Min. Max. Min. Max.
15.5 0.5 3.0 9.5 13.0
21 0.5 3.0 12.5 17.5
26.5 0.5 3.0 14.0 20.5
32 0.5 3.5 16.0 24.0
38.8 0.5 3.5 18.5 25.5
43.0 0.5 3.5 22.0 28.0

The following conditions may be found:

Conditions Causes - Faults
. Tubes inverted on the compressor
. Electromagnetic pulley that slips or does not engage correctly
L.P. high - L.P. normal or low
. Expansion valve blocked in open position
. Compressor damaged
. Expansion valve blocked in closed position or obstructed
L.P. low - H.P. high or normal . Filter saturated with moisture
. Obstruction in the L.P. line or in the H.P. line between the filter
and the evaporator
. Infiltration of hot air into the evaporator group, the pipes or the
cab
L.P. normal - H.P. normal . Hot air circulating in the heating group
. Formation of ice on the evaporator
. Normal condition with very high ambient temperature (higher
than 43ëC)
. Excess coolant (30 - 35% more)
L.P. high - H.P. high . Overheating of condenser
. Air present in the unit
. Obstruction in the H.P. line between the compressor and the
condenser-filter tube, behind the measurement point of the H.P.
. Normal condition with very low temperature (lower than 5ëC)
. Lack of coolant (70 - 75% less) (probable leakages)
L.P. normal or low - H.P. low . Obstruction in the H.P. line between the compressor and the
condenser-filter tube, before the measurement point of the H.P.
. Compressor damaged
. Compressor belt missing
L.P. roughly equal to H.P. . Electromagnetic pulley that slips or does not engage
. Compressor damaged

20-70 WB91R-2 WB93R-2

 REMOVAL AND INSTALLATION

HOW TO READ THE MANUAL. . . .. . . . .. . . . . .. . . . .. . . 3 TRANSMISSION OIL COOLER

PRECAUTIONS TO BE TAKEN Removal .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 33
WHILE WORKING .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 4 Installation. . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 33
SPECIAL TOOLS . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 5 MUFFLER
STARTING MOTOR Removal .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 34
Removal. . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 9 Installation. . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 34
Installation .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 9 EXHAUST PIPE
ALTERNATOR Removal .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 34
Removal. . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 10 Installation. . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 34
Installation .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 11 ENGINE HOOD
INJECTION PUMP Removal .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 35
Removal. . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 12 Installation. . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 36
Installation .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 15 CAB
INJECTION NOZZLES Removal .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 37
Removal. . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 16 Installation. . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 40
Installation .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 16 HEAT AND AIR-CONDITIONING GROUP
THERMOSTAT Removal .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 41
Removal. . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 17 Installation. . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 42
Installation .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 17 FUEL TANK
COOLING LIQUID PUMP Removal .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 43
Removal. . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 18 Installation. . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 43
Installation .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 19 HYDRAULIC OIL TANK
TURBOCOMPRESSOR Removal .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 44
Removal. . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 20 Installation. . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 44
Installation .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 21 ENGINE-GEARBOX-PUMP GROUP
CYLINDER HEAD Removal .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 45
Removal. . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 22 Installation. . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 50
Installation .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 25 PISTON PUMP
FRONT COUNTERWEIGHT Removal .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 51
Removal. . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 26 Installation. . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 52
Installation .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 26 TRANSMISSION
RADIATOR ± OIL COOLER GROUP Removal .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 53
Removal. . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 27 Installation. . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 56
Installation .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 29 TRANSMISSION
CONDENSER Overhauling . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 57
Removal. . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 30 CONVERTOR
Installation .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 30 Removal .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . 138
HYDRAULIC OIL COOLER Installation. . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . 138
Removal. . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 31
Installation .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 32

WB91R-2 WB93R-2 30-1

TRANSMISSION-REVERSE, DIRECTION BACKHOE BUCKET CYLINDER
INDICATOR AND HEADLIGHT DIPPER Removal . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . 253
BEAM CONTROL GROUP Installation . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . 253
Removal . . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 139 OUTRIGGER CYLINDERS
Installation. . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 139 Removal . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . 254
STEERING UNIT Installation . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . 255
Removal . . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 140 BACKHOE SWING CYLINDERS
Installation. . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 140 Removal . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . 256
WORKING BRAKE PUMP GROUP Installation . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . 256
Removal . . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 141 BACKHOE BACKFRAME LOCK CYLINDER
Installation. . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 141 Removal . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . 257
FRONT WORKING EQUIPMENT CONTROL VALVE Installation . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . 257
Removal . . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 142 CYLINDERS
Installation. . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 142 Disassembly . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . 258
FRONT AXLE Assembly . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . 260
Removal . . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 143 BOOM SWING CYLINDER
Installation. . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 144 Disassembly . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . 264
Disassembly. .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 145 Assembly . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . 265
Assembly . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 163 BACKHOE BACKFRAME LOCK CYLINDER
REAR AXLE Disassembly . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . 267
Removal . . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 185 Assembly . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . 267
Installation. . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 186 BOOM SAFETY CYLINDER
REAR AXLE FINAL DRIVE Removal . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . 268
Disassembly. .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 187 Installation . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . 268
Assembly . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 193 BACKHOE WORKING EQUIPMENT
REAR AXLE Removal . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . 269
Disassembly. .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 199 Installation . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . 269
Assembly . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 220 BACKHOE BUCKET
FRONT BUCKET BOOM-RAISING CYLINDER Removal . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . 270
Removal . . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 244 Installation . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . 270
Installation. . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 244 ARM
FRONT BUCKET TILT CYLINDERS Removal . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . 271
Removal . . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 245 Installation . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . 271
Installation. . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 245 BACKHOE BOOM
FRONT BUCKET Removal . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . 272
Removal . . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 246 Installation . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . 272
Installation. . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 246 BACKHOE SWING BRACKET
FRONT WORKING EQUIPMENT Removal . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . 273
Removal . . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 247 Installation . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . 273
Installation. . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 248 BACKHOE BACKFRAME
BACKHOE CONTROL VALVE Removal . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . 274
Removal . . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 249 Installation . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . 274
Installation. . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 250
BACKHOE BOOM CYLINDER
Removal . . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 251
Installation. . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 251
BACKHOE ARM CYLINDER
Removal . . . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 252
Installation. . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 252

30-2 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION HOW TO READ THE MANUAL

HOW TO READ THE MANUAL

1. Removal and Installation of the groups
(1) The procedures and information needed to carry out the work of removing or Installing units or groups are
given in the removal procedure. The sequence of operations is not repeated in the installation procedure.
(2) Information needed for installation is marked with the symbol . 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.

WB91R-2 WB93R-2 30-3

REMOVAL AND INSTALLATION PRECAUTIONS TO BE TAKEN WHILE WORKING

PRECAUTIONS TO BE TAKEN WHILE WORKING

H When dismantling or installing a part, always take the following general precautions.

1. Precautions for removal operations

. If not otherwise indicated, lower the work equipment until it rests on the ground.
. If the coolant liquid contains an anti-freeze substance, follow the instructions given for drainage.
. After having removed flanges and tubes, insert plugs to prevent impurities from entering.
. Before removing a cylinder, fully retract the piston and tie it with wire.
. Use a sufficiently large container to collect the oil.
. Before removing a part from the machine, check the alignment reference marks which show the correct 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 hoi-
sting 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 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION SPECIAL TOOLS

SPECIAL TOOLS

Nature of work Symbol Code Description Q.ty Notes

1 Attachment 1 Cylinders disassembly -

assembly
Plunger é 40 2
Assembly cylinder and
Plunger é 45 2 rod bushings
2 Cylinder and rod locking
Plunger é 50 2
on ATR200620
Plunger é 75 2

3 Bushing é 45 2 Blocking swing cylinders

on ATR200620
Notched wrench for 1
cylinders é 70
Notched wrench for 1
cylinders é 80
Notched wrench for 1
cylinders é 85 Head disassembly-
4 assembly
Notched wrench for 1
cylinders é 95
Notched wrench for 1
cylinders é 115-120
Notched wrench for 1
cylinders é 110

5 Notched wrench for 1 Head disassembly-

side digging boom cylinders assembly
Disassembly ring nut
Notched wrench 1 side digging boom
Disassembly and assembly 6 cylinder
cylinders A
Notched wrench 1 Boom swing head
disassembly-assembly
Socket wrench (6-point 46) 1
7 Socket wrench (6-point 55) 1 Pistons removal-
installation
Socket wrench (6-point 65) 1
Plunger é 40 1
Plunger é 50 1
8 Dust seal assembly
Plunger é 55 1
Plunger é 60 1
Expander é 70 1
Expander é 80 1
Expander é 85 1
9 Expander é 95 1 Piston gaskets assembly
Expander é 100 1
Expander é 110 1
Expander é 115 1
Bushing for rod é 40 1
Bushing for rod é 45 1
10 Bushing for rod é 50 1 Head assembly on rod
Bushing for rod é 55 1
Bushing for rod é 60 1

WB91R-2 WB93R-2 30-5

REMOVAL AND INSTALLATION SPECIAL TOOLS

Nature of work Symbol Code Description Q.ty Notes

Bushing for piston é 70 1
Bushing for piston é 80 1
Bushing for piston é 85 1
Disassembly and assembly
cylinders A 11 Bushing for piston é 95 1 Piston-cylinder assembly
Bushing for piston é 100 1
Bushing for piston é 110 1
Bushing for piston é 115 1
Disassembly and assembly B 1 Tool 1 Pump bracket
piston pump

Disassembly and assembly Tool 1

transmission C 1 Transmission support
Set of spacers 1

Assembly transmission D 1 Commercially Feeler gauge 1 Clutch backlash control

available
Clamp 1
Disassembly and assembly Securing drive shaft
clutches - transmission E 1 Upper flange 1 Removal-installation
clutch spring
Tie-rod 3

1 Wrench 1 Adjustment differential

lock nuts

2 Socket wrench 1 Removal-installation

pinion lock nut

3 Socket wrench 1 Removal-installation

pinion

4 Plunger 1 Mounting pinion

bearing ring

5 Gauge block 1

6 Gauge tube 1 Measuring pinion shims

Disassembly and assembly F 7 Lock nut 2
front axle
8 Plunger 1 Mounting pinion bearing

9 Guide ring 1 Mounting pinion

output cover

10 Plunger 1 Mounting pinion

bearing ring

11 Plunger 1 Mounting bronze

bushing

12 Plunger 1 Mounting seal rings

Mounting bushing for

13 Plunger 1 upper and lower joint

30-6 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION SPECIAL TOOLS

Nature of work Symbol Code Description Q.ty Notes

14 Plunger 1 Mounting lower joint

bushing

15 Plunger 1 Mounting final drive

Disassembly and assembly bearing ring
front axle F
16 Plunger 1 Mounting final drive seal

17 Plunger 1 Insertion ring bevel

gear bushing
1 Plunger 1 Mounting hub seal
2 Handle 1
3 Plunger 1 Mounting axle shaft seal
4 Plunger 1 Mounting axle shaft seal
5 Push-rod 1 Insertion pilot bosses

6 Wrench 1 Adjustment lock nuts for

differential register

7 Socket wrench 1 Removal-mounting

pinion lock nut

8 Socket wrench 1 Removal-mounting

pinion

9 Plunger 1 Mounting slack

adjuster bushing

Disassembly and assembly 10 Tool 1 Mounting pinion

rear axle G bearing ring
11 Lock nut 1
12 Flange 1 Measurement of bevel
pinion shims
13 Gauge block 1
14 Plunger 1 Mounting pinion bearing

15 Commercially Dynamometer 1 Checking pre-loading

available pinion bearings

16 Plunger 1 Mounting differential

bushing

17 Plunger 1 Mounting differential

bearings

18 Bushing 1 Checking tooth

clearance

19 Bushing 1 Mounting seal on

pinion side

1 Kit 1 Removal - mounting

Assembly transmission H input shaft
2 Plunger 1 Mounting seal

WB91R-2 WB93R-2 30-7

REMOVAL AND INSTALLATION

30-8 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION STARTING MOTOR

REMOVAL OF THE STARTING MOTOR

Fully raise the front working equipment and engage
the safety stop.
5
1 - Stop the engine and engage the parking brake. 4

2 - Remove guard (4) from tank (5).

RKZA1821

3 - Remove the cover (6).

Disconnect the clamp (2) from accumulator (3) nega-
tive terminal (±). 6

3
RKZA7792

4 - Disconnect the electric wiring (4).

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

INSTALLATION OF THE RKZA0020

STARTING MOTOR
. To install, reverse the removal procedure.

Starting motor mounting screws:

78.4 ± 98 Nm (8 ± 10 kgm)

WB91R-2 WB93R-2 30-9

REMOVAL AND INSTALLATION ALTERNATOR

REMOVAL OF THE ALTERNATOR

Fully raise the front working equipment and engage
the safety stop.
5
1 - Stop the engine and engage the parking brake. 4

2 - Remove guard (4) from tank (5).

RKZA1821

3 - Remove the cover (6).

6
Disconnect the clamp (2) from accumulator (3) nega-
tive terminal (±).

3
RKZA7792

4 - Disconnect the cable (7), the connector (8) and the

cotter pin (9).
7

9
8

RKZA0031

5 - Loosen the screws (10), (11) and (12) to leave the al-
ternator (13) free to rotate.
10

14
11

RKZA0041

30-10 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION ALTERNATOR

6 - Release the belt (14) from the pulley and remove the
alternator (13).

12 13

14

INSTALLATION OF THE
RKZA0051

ALTERNATOR
. To install, reverse the removal procedure.

H Adjust the fan-belt tension. (For details, see «20. TE-

STING AND ADJUSTMENTS ± Fan-belt tension».)

WB91R-2 WB93R-2 30-11

REMOVAL AND INSTALLATION INJECTION PUMP

REMOVAL OF THE INJECTION PUMP

Fully raise the front working equipment and engage
the safety stop. Also make the backhoe safe.
Raise the engine hood and disconnect the cable 1
from accumulator negative terminal (±).
H Plug all tubes that have been removed or disconnec-
ted to prevent entry of impurities.
1 - Remove the engine coolant liquid container (1).

RKZA8800

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

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

2
3
RKZA0070

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

9 8
5 - Disconnect the tube (9) from the oil level dip-stick and
remove it.
6 - Remove the support-bracket (10) of the pump.
6

10
RKZA0080

7 - Disconnect the accelerator control cable support (12)

from the lever (11).

11

12

RKZA0090

30-12 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION INJECTION PUMP

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

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

RKZA0100

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

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

15

14

RKZA0110

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

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

16

RKZA0120

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

18
20

RKZA0130

WB91R-2 WB93R-2 30-13

REMOVAL AND INSTALLATION INJECTION PUMP

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

H Before removing the pump driving gear, mark its X2
position with respect to the idling gear.
23
H For removal use a puller (X1). The puller screws
(X2) screw directly into the gear (20). 21
H Take great care not to damage the pump shaft
thread.
H During removal, be careful not to let the wrench
drop into the housing. 20 X1

X2
RKZ00030

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

22

RKZA0081

30-14 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION INJECTION PUMP

INSTALLATION OF THE INJECTION PUMP

. To install, reverse the removal procedure.

Fuel feed hoses: 24.5 ± 34.3 Nm (2.5 ± 3.5 kgm)

High pressure hoses:

24.5 ± 34.3 Nm (2.5 ± 3.5 kgm)

Stiffening bolt screw, pump side:

44.1 ± 53.9 Nm (4.5 ± 5.5 kgm)
Stiffening bolt screw, pump side:
22..5 ± 8.4 Nm (2.3 ± 2.9 kgm)

H Put in a new safety cotter pin.

Lubrication tube, pump side: . . . . . . . . . . . . . . Nm

Lubrication tube, pump side: . . . . . . . . . . . . . . Nm

Cover gasket: ASL800070

Cover bolts for ignition gear system:
18 Nm (1.84 kgm)

H Align the marks between the gears before instal- Ingranaggio pompa
ling the pump and mounting the nut. Injection pump
d'iniezione (20) gear (20)

Gear-locking nut:
83.3 ± 93.1 Nm (8.5 ± 9.5 kgm)

Reference
Riferimento

Idling gear folle

Ingranaggio

RKZ00130

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

WB91R-2 WB93R-2 30-15

REMOVAL AND INSTALLATION INJECTION NOZZLES

REMOVAL OF THE INJECTION NOZZLES

Fully raise the front working equipment and engage
the safety stop. Also make the backhoe safe.
Raise the engine hood and disconnect the cable
from accumulator negative terminal (±). 1
1 - Disconnect the sensor (1) for a clogged air-filter. 2
2 - Remove the air-filter (2), the supporting bracket (3)
and the intake sleeve (4).

RKZA0150

3 - Remove and place to one side the bulldog clip (5) that
secures the cab heating pipes. 4
4 - Loosen the clip (7) and remove the high-pressure pi-
pes (8). 7

8
3

5
6
RKZA0160

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

6 - Take out the nuts (10) that secure the collar (11) and
8
take out the injector (12), the seating (13) and the pro-
tection piece (14).
10

11

RKZA0170

INSTALLATION OF THE 11
INJECTION NOZZLES
. To install, reverse the removal procedure.
10
High-pressure pipe:
24.5 ± 34.3 Nm (2.5 ± 3.5 kgm)
Hose-clamp screws: 9.8 ± 11.8 Nm (1 ± 1.2 kgm) 14
12
13
Collar lock nuts: 9.8 ± 11.8 Nm (1 ± 1.2 kgm)
RKZ00140

30-16 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION THERMOSTAT

REMOVAL OF THE THERMOSTAT

Fully raise the front working equipment and engage
the safety stop. Also make the backhoe safe. 2
Raise the engine hood and disconnect the cable
from accumulator negative terminal (±). 1
H Drain the engine coolant liquid. 3
4
Coolant liquid: 18 ,
1 - Disconnect the cable (1) of the clogged filter indicator
(2) and remove the entire suction filter (3).

RKZA0180

2 - Disconnect the radiator connection sleeve (5) from

the thermostat cover (4).
4 - Take out the screws and remove the thermostat cover
(4).
4 - Remove the gasket (6), the thermostat (7) and the
5
ring seal (8).

Put in new seals.

RKZA0190

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

RKZ00150
1 - Refill the coolant liquid tank.

Coolant liquid: 18 ,
2 - Start the engine at low idling to circulate the coolant
liquid through all circuits.
3 - Accelerate gradually up to 1700 rpm. After about one
minute, stop the engine and check or top up the level
in the container.
H Check that there are no leaks.

Cover screws: 22 ± 27.8 Nm

WB91R-2 WB93R-2 30-17

REMOVAL AND INSTALLATION COOLING LIQUID PUMP

REMOVAL OF THE COOLING LIQUID PUMP

Fully raise the front working equipment and engage
the safety stop. Also make the backhoe safe.
Disconnect the cable from accumulator negative ter- 1
minal (±).
H Drain the engine coolant liquid.
Coolant liquid: 18 ,
1 - Remove the engine coolant liquid container (1).

RKZA8800

2 - Remove the fan guard (2).

3 - Disconnect the cable (3) of the clogged filter indicator
and remove the air filter (4).

2 4
3

RKZA1771

4 - Remove the alternator and its support (5) (For details,

see «REMOVAL OF THE ALTERNATOR»).
5

RKZA1800

5 - Only for machines equipped with a compressor

Remove the air-conditioning unit compressor (14) and
its supports. Put the compressor to one side.
(For details, see «REMOVAL OF THE AIR-CONDI-
TIONING UNIT COMPRESSOR»).

14

RKZA8572

30-18 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION COOLING LIQUID PUMP

6 - Disconnect the cab heating pipes (6).

8
7 - Disconnect the temperature sensor cables (7) and (8).
8 - Remove the radiator/oil-cooler group. (For details,
see «REMOVAL OF THE RADIATOR - OIL COO-
LERS»).
9 - Remove the fan (9), the spacer (10) and the pulley
(11). 6
10 - Remove the four screws (12) and then the complete
pump (13).
RKZA7770

Replace all seals with new ones.

10
11

INSTALLATION OF THE COOLANT

LIQUID PUMP
. To install, reverse the removal procedure.
RKZA1810

Locking screws for alternator support:

22.5 ± 28.4 Nm
H Apply tension to the alternator belt.
(For details, see «20. TESTING AND ADJUST-
12
MENTS»).

Locking screws for pulley and fan:

44.1 ± 53.9 Nm

Pump screws: 22.5 ± 28.4 Nm

13
Locking screw for compressor: 64 Nm RKZA2450

H Apply tension to the compressor belt.

(For details, see «TESTING AND APPLYING
TENSION TO THE COMPRESSOR BELT»).
1 - Refill the coolant liquid circuit.

Coolant liquid: 18 ,
2 - Start the engine at low idling to circulate the coolant
liquid through all circuits.
3 - Accelerate gradually up to 1700 rpm. After about one
minute, stop the engine and check or top up the level
in the container.
H Check that there are no leaks.

WB91R-2 WB93R-2 30-19

REMOVAL AND INSTALLATION TURBOCOMPRESSOR

REMOVAL OF THE TURBOCOMPRESSOR

Fully raise the front working equipment and engage
the safety stop. Also make the backhoe safe.
Raise the engine hood and disconnect the cable
from accumulator negative terminal (±).
2
1 - Disconnect the clogged air-filter indication cable (1)
and remove the entire suction filter (3). 3
2 - Remove the muffler.
(For details, see «REMOVAL OF THE MUFFLER»). 1

RKZA0151

3 - Disconnect the turbocompressor delivery coupling

sleeve (4) from the suction manifold. 16

RKZA0210

4 - Take the screws out of the clips (5) and disconnect

the tube (6) that delivers the turbocompressor lubrica-
tion oil.
6

RKZA0220

5 - Take out the tube-retaining screws (7) and the two

screws (8) that secure the flange of the lubrication
oil drainage tube (9).

8 9

RKZA0230

30-20 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION TURBOCOMPRESSOR

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

sor to the coupling sleeve, and remove the coupling 10
sleeve (11).
7 - Take out the screws (12) and remove the bracket (13).

13
12
RKZA1620

8 - Take out the nuts (14), and the washers (15) and lift
off the turbocompressor (16).
H Carefully check the state of all the sealing ga-
skets. Replace them if there is any sign of dama- 16
ge. 14 15

RKZA0240

INSTALLATION OF THE TURBOCOMPRESSOR

. To install, reverse the removal procedure.

Tube retaining screws: 22.5 ± 28.4 Nm

Flange screws: 8 ± 9 Nm

Coupling joint screws: 22.5 ± 28.4 Nm

Bracket screws: 22.5 ± 28.4 Nm

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

WB91R-2 WB93R-2 30-21

REMOVAL AND INSTALLATION CYLINDER HEAD

REMOVAL OF THE CYLINDER HEAD

Fully raise the front working equipment and engage
the safety stop. Also make the backhoe safe.
Raise the engine hood and disconnect the cable 1
from accumulator negative terminal (±).
H Drain the engine coolant liquid.
Coolant liquid: 18 ,

1 - Remove the container (1).

RKZA8800

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

sor and remove the entire suction filter (4) and its sup- 2 3
port (5).
Only for WB93R-2
H Remove the turbocompressor. (For details, see 4
«REMOVE THE TURBOCOMPRESSOR»). 5

RKZA0182

3 - Only for machines equipped with an air-conditio-

ning unit
Remove the alternator (24), the compressor (25) and
the supporting bracket (26).
(For details, see «REMOVAL OF THE ALTERNA-
TOR» and «REMOVAL OF THE AIR-CONDITIONING 26
25
UNIT»).

24
RKZA8573

4 - Remove the support (27).

27
RKZA8562

30-22 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION CYLINDER HEAD

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

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

RKZA7780

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

head.

11

RKZA0221

10 - Remove the muffler (12).

(For details, see «REMOVAL OF THE MUFFLER»). 12
11 - Remove the muffler support bracket (13).

13

RKZA0250

12 - Disconnect the cables (14) from the temperature sen-

sors (15).
15
13 - Disconnect the heating pipes (16).
14
14 - Remove the radiator connection pipes (17).
15 - Remove the coolant liquid pump. (For details, see
«REMOVAL OF THE COOLANT LIQUID PUMP»). 17

16

RKZA1782

WB91R-2 WB93R-2 30-23

REMOVAL AND INSTALLATION CYLINDER HEAD

16 - Disconnect the fuel return hose (18) from the injector 19

nozzles and remove the nozzles. (For details, see 18
«REMOVAL OF THE INJECTOR NOZZLES»).

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

RKZA0171

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

H Loosen the nuts and unscrew the tappets by 2-3
turns. 23 20
19 - Take out the rocker-arm control rods (21). 22

21

RKZ00160

20 - Take out the screws (22) and remove the entire cylin-
der head (23). Follow the indicated sequence for loo- BOLT LOOSENING ORDER
sening the screws.
H Sequence to be followed: see drawing.
Loosen the cylinder head retaining screws in two 7 16 14 6
stages. 1 9 18 12 4

3 11 17 10 2
5 13 15 8

RKZ00170

30-24 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION CYLINDER HEAD

INSTALLATION OF THE CYLINDER HEAD

. To install, reverse the removal procedure.

H Fill up the cooling circuit.

Coolant liquid: 18 ,
H Check carefully that there are no leaks.

Support screws: 35.2 Nm (3.6 kgm)

Frontal screw (M8): 32 Nm

Lateral screws (M10): 64 Nm

Frontal screws (M10): 64 Nm

Lateral screw (M8): 32 Nm

Bracket screws: 45 ± 55 Nm
Screws for intake line: Loctite 262
Screws for intake line: 45 ± 55 Nm

High-pressure pipe fittings:

24.5 ± 34.3 Nm (2.5 ± 3.5 kgm)

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

H Check the condition of the seals of the tappet cover

and the O-rings of the fastening nuts. Thoroughly
clean the contact surfaces on the cylinder heads.
Cover fastening nuts: 25w3 Nm

H Check that the tappets are firmly engaged in their rods

and that the valve collars are correctly assembled.
Rods - tappets: Engine oil
H Start tightening the rocker-arm shaft from the center
towards the outside.
Screws and nuts for the rocker-arm shaft:
22.5 ± 28.4 Nm (2.3 ± 2.9 kgm)
H Adjust the valve clearances (For details, see «20. TE-
STING AND ADJUSTMENTS»).

H Assemble a new gasket.

Bolt and cylinder block threadings: Engine oil.
H Tighten the screws, manually at first, and then in two BOLTS TIGHTENING ORDER
stages, following the sequence indicated.
Cylinder head bolts.
first tightening: 88.3 ± 98.1 Nm (9 ± 10 kgm) 12 3 5 13
Final tightening: 181.4 ± 191.2 Nm 18 10 1 7 15
(18.5 ± 19.5 kgm)
16 8 2 9 17
1 - Start the engine at low idling to circulate the coolant 14 6 4 11
liquid through all circuits.
2 - Accelerate gradually up to 1700 rpm. After about one
minute, stop the engine and check or top up the level
in the container. RKZ00180

WB91R-2 WB93R-2 30-25

REMOVAL AND INSTALLATION FRONT COUNTERWEIGHT

REMOVAL OF THE FRONT COUNTERWEIGHT

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

1 - Partially loosen the screws (1) to eliminate the tighte-

ning torque, and thus to facilitate the subsequent di-
smantling procedure.
2 - Insert the prongs of a fork-lift truck into the ventilation 3
slits, and force them gently upwards to compensate
for the weight of the counterweight (2). 1
3 - Remove the screws (1) and the washers (3). 1 3
4 - Remove the Front counterweight (2).
2
RKZA1840

Counterweight: 300 kg

2
RKZA1850

INSTALLATION OF THE FRONT COUNTERWEIGHT

. To install, reverse the removal procedure.

Screws: 300w30 Nm

30-26 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION RADIATOR-OIL COOLER UNIT

REMOVAL OF THE RADIATOR-OIL COOLER UNIT

Fully raise the front working equipment and engage
the safety stop. Also make the backhoe safe.
Disconnect the cable from accumulator negative ter-
minal (±).
2

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

the engine hood. Accompany the hood until it is com-
pletely open.
1
H Place some soft material between the engine
hood and the front closing mechanism.

Completely eliminate all residual pressures in all cir-

cuits. (For details, see «20. TESTING AND ADJUST- RKZA1860

MENTS»).
H Drain the cooling liquid.

Cooling liquid: 18 , 5
2 - Remove the fan guard (2).
3 - Disconnect the cable (3) and remove the acoustic
alarm (4).
7
4 - Remove the air filter suction line (5).
3

RKZA1870

5 - Only for machines equipped with an air-conditio-

ning unit
Drain the air conditioning unit, and disconnect the tu-
bes (19), (20). 20
(For details, see «20. TESTING AND ADJUST-
MENTS»). 19

RKZA8620

6 - Remove the container (6). 8

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

(9) from the radiator (7).
8 - Remove the brackets (10).
9

10

RKZA1741

WB91R-2 WB93R-2 30-27

REMOVAL AND INSTALLATION RADIATOR-OIL COOLER UNIT

9 - Slowly loosen the hoses (11) and (12) to drain the hy-
draulic oil from the oil cooler (13). When the oil is fully
drained, complete disconnection of the hoses, and
plug them to prevent entry of impurities.

Hydraulic oil: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ,

12 13

11
RKZA1880

10 - Slowly loosen the hoses (14) to drain the oil from the
transmission oil cooler (15). When the oil is fully drai-
ned, complete disconnection of the hoses, and plug
them to prevent entry of impurities.
15
Transmission oil: . . . . . . . . . . . . . . . . . . . . . . . . . . . . , 16

14

RKZA7820

11 - Disconnect the conveyor (17) from the radiator (7) and

move it towards the engine.

17

RKZA7830

12 - Take out the nuts (18) of the lower anti-vibration units

and remove the entire radiator - oil cooler group (7).

Radiator - oil cooler group: . . . . . . . . . . . . . . . . . kg

13 - Remove the rubber conveyor situated between chas-
sis and radiator.

7
18 18
RKZA7840

30-28 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION RADIATOR ± OIL COOLER GROUP

INSTALLATION OF THE RADIATOR ± OIL COOLER GROUP

. To install, reverse the removal procedure.

H First connect the positive pole (+).

. Refill the coolant liquid circuit.

Coolant liquid: 18 ,

H Refill the air-conditioning unit.

Quantity of fluid (R134a): 1100 g (+ 50 / ± 30 g)
Quantity of oil: See the amount recovered.

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

maximum.

. Ensure that the level of transmission oil is at maxi-

mum.

Anti-vibration unit nuts: . . . . . . . . . . . . . . . . . . . Nm

1 - Start the engine at low idling to circulate all the fluids

and to fill up the oil coolers.
2 - Accelerate gradually up to 1700 rpm. After about one
minute, stop the engine and top up all levels.
H Check carefully that there are no leaks.
3 - Stop the engine and replace the rubber conveyor.

WB91R-2 WB93R-2 30-29

REMOVAL AND INSTALLATION CONDENSER

REMOVAL OF THE CONDENSER (Only for machines equipped with an air-conditioning unit)
Completely raise the front working equipment and
engage the parking brake.
Also place the backhoe in its secure position. 1
6
1 - Drain the air-conditioning unit.
(For details, see «20. TESTING AND ADJUST-
MENTS»).
2 - Disconnect the cable (1) and remove the klaxon (2). 5

2
RKZA8630

3 - Disconnect the tubes (3) and (4).

H Immediately plug the tubes and the condenser
tightly to prevent moisture from entering into the
air-conditioning circuit. 4

4 - Loosen the upper retaining screw (5) of the conden- 3

ser (6), leaving it in position for reasons of safety.

RKZA8621

5 - Loosen the screws (7) and remove the locknuts.

6
6 - Remove the screws (5) and (7) and take out the con-
denser.

7 RKZA8640

INSTALLATION OF THE
CONDENSER
. To install, reverse the removal procedure.
1 - Refill the air-conditioning unit.

Quantity of fluid (R134a): 1100 g (+ 50 / ± 30 g)

Quantity of oil: See the amount recovered.

30-30 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION HYDRAULIC OIL COOLER

REMOVAL OF HYDRAULIC OIL COOLER

Fully raise the front working equipment and engage
the safety stop. Also make the backhoe safe.
Disconnect the cable from accumulator negative ter-
minal (±).

1 - Disconnect the safety gas cylinders (1) from the engi-

ne hood. Accompany the hood until it is completely
open.
1
H Place some soft material between the engine
hood and the front closing mechanism.

Completely release residual pressures from all cir-

cuits. RKZA1862

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

MENTS»).
2 - Disconnect the cable (2) and remove the acoustic
alarm (3).

7
8

2
3

RKZA1871

3 - Only for machines equipped with an air-conditio-

ning unit
Remove the condenser (11) without detaching the tu-
bes, and put it to one side.
11

RKZA8650

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

Hydraulic oil:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ,

RKZA1881

WB91R-2 WB93R-2 30-31

REMOVAL AND INSTALLATION HYDRAULIC OIL COOLER

5 - Remove the screws (7) that fasten the oil cooler (6) to
the radiator group (8).
6 - Take out the nuts and washers (9) and remove the ful- 7
crum screws and washers (10).
7 - Remove the rubber conveyor.

6
8
10 9
RKZA7841

INSTALLATION OF THE
HYDRAULIC OIL COOLER
. To install, reverse the removal procedure.

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

30-32 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION TRANSMISSION OIL COOLER

REMOVAL OF THE TRANSMISSION OIL COOLER

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

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

see «REMOVAL OF THE RADIATOR - OIL COOLER
GROUP»).
2 - Remove bracket (1) and rubber sheet (2). 3
5

1 2
RKZA0321

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

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

5
RKZA7850

INSTALLATION OF THE
TRANSMISSION OIL COOLER
. To install, reverse the removal procedure.

. Make sure that the levels of the transmission oil, the

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

WB91R-2 WB93R-2 30-33

REMOVAL AND INSTALLATION MUFFLER - EXHAUST PIPE

REMOVAL OF THE MUFFLER

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

1 - Take out the retaining screws (1) of the flexible outlet

hose (2). 6 2 1
2 - Take out the two screws (3), the screws (4) and remo-
ve the muffler (5).

INSTALLATION OF THE MUFFLER

. To install, reverse the removal procedure.
RKZA0330
H Put in a new sealant.

Muffle: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nm
5

RKZA0251

REMOVAL OF THE
EXHAUST PIPE
1 - Loosen the clip (6) and disconnect the flexible hose
(2).
8
2 - Take out two of the three lower screws (7) of the con-
necting flange (8).
H Loosen the third screw and leave it in place for sa-
fety. 7
3 - Take out the nut (9) and the washer of the upper anti-
vibration unit (10). RKZA0340

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

INSTALLATION OF THE 10 9
EXHAUST PIPE 11
. To install, reverse the removal procedure.

RKZA0350

30-34 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION ENGINE HOOD

REMOVAL OF THE ENGINE HOOD

Lower the working equipment completely until it is re-
sting on the ground. Stop the engine and remove the
ignition key.

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

3
RKZA7860

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

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

RKZA7880

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

4
RKZA7871

WB91R-2 WB93R-2 30-35

REMOVAL AND INSTALLATION ENGINE HOOD

INSTALLATION OF THE ENGINE HOOD

. To install, reverse the removal procedure.

H Check that the hood (1) closes perfectly, and re-attach
the screws (5).
5

RKZA1913

30-36 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION CAB

REMOVAL OF THE CAB

Lower the working equipment completely until it
rests on the ground and stop the engine and remove
the ignition key.
Disconnect the cable from accumulator negative ter-
minal (±).
Release all residual pressure in all circuits. (For de-
tails, see «20. TESTING AND ADJUSTMENTS»).
H Only for machines equipped with an air-conditio-
ning unit
Drain the air conditioning unit.
(For details, see «20. TESTING AND ADJUST-
MENTS»).

1 - Disconnect the pedal accelerator and hand accelera-

tor cables (1) from the injection pump. Disengage the
sheathings from the support (2). 2

RKZA0091

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

axle (3). 4
3 - Disconnect the braking circuit pipes (5) and the diffe-
rential lock tube (6) from the rear axle. 5
H Mark the positions of the pipes to prevent exchan- 3
ge of positions when reconnecting.
H Plug the pipes and pipe-fittings to prevent entry of
impurities. 5

6
RKZA0390

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

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

RKZA0400

WB91R-2 WB93R-2 30-37

REMOVAL AND INSTALLATION CAB

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

from the steering unit.
H Mark the positions of the pipes to prevent exchan-
ging positions when reconnecting. 8
H Plug the pipes and pipe-fittings to prevent entry of
impurities.

10
RKZA0410

6 - Disconnect the connectors (11) and (12) and the

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

14

13
15 14
11 RKZA8760

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

set into the bucket control lever.
10 - Disconnect the converter disengagement connector
(19) set into the gear lever.
11 - Disconnect the connector (20) of the differential di- 20 21
sengagement and backhoe boom disengagement so-
lenoids.
18
12 - Disconnect the power increment solenoid connector
(21) installed on the piston pump.
19
RKZA0430

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

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

23

22 24
RKZA0440

30-38 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION CAB

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

(For details, see «REMOVAL OF THE CAB HEATING
GROUP»). 25 29
15 - Only for machines equipped with an air-conditio-
ning unit.
Disconnect the tubes (27), (28) connecting the unit to
the drying filter (29) and the expansion valve (30).
H Immediately plug the tubes and the orifices tightly 26 28
to prevent moisture from entering into the air-con-
ditioning circuit.
27 30
RKZA8710

16 - Lift off the lower left-hand guard of the cab and di-
sconnect the connector (31) of the fuel level indicator
and the connector of the self-supply pump, if any.
31
17 - Also lift off the lower right-hand guard.

RKZA1922

18 - Remove the grip (32) of the hand accelerator and

then the inspection cover (33). Push the protective 35
sleeve (34) of the gearbox lever down into the side co-
ver (35). 34

32

33
RKZA0462

19 - Remove the grips (36) of the outrigger control levers

and the grip (37) of the lever-locking device. Lift off
the cover (38) of the control levers. 30
20 - Take off the self-locking nuts (39) and the four screws
that secure the cab.
33
31

32

RKZA0470

WB91R-2 WB93R-2 30-39

REMOVAL AND INSTALLATION CAB

21 - Take off the protective plugs and screw two eyebolts

«A» into the holes supplied for hoisting purposes.
Attach the cab (40) to the hoisting tackle and apply a
slight tension.
22 - Slowly raise the cab, directing its movement in such
way that the gear lever slides out. A
H Make sure that all the electrical leads and the ac-
celerator cables are free.
Cab: 630 kg 34

INSTALLATION OF THE CAB

. To install, reverse the removal procedure.

H Drain and refill the air-conditioning unit. RKZA0480

Quantity of fluid (R134a): 1100 g (+50 / ± 30 g)

Quantity of oil: See the amount recovered.

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

H Adjust the stroke of the parking brake lever. (For de-

tails, see «20. TESTING AND ADJUSTMENTS»).

H Bleed the air from the braking circuit. (For details, see
«20. TESTING AND ADJUSTMENTS»).

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

Cab retaining screws: 169w9.8 Nm

30-40 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION HEAT AND AIR-CONDITIONING GROUP

REMOVAL OF THE HEAT AND AIR-CONDITIONING GROUP

NOTE. If no air-conditioning unit is included, perform only

those operations relating to the heating unit. 1
Lower the working equipment completely until it
rests on the ground, and stop the engine.
Disconnect the cable from accumulator negative ter-
minal (±).
H Drain the engine cooling liquid. 6
Coolant liquid: 18 ,
1 - Drain the air-conditioning unit. 5
(For details, see «20. TESTING AND ADJUST-
MENTS»). RKZA8820

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

cock.
3 - Disconnect the connector of the power-supply cabling
(2) and the clamp.
2

10 9
RKZA8830

4 - Disconnect the pipes (4) from the fan-cooler (3).

5 - Disconnect the tubes (5) and (6) that connect with the
4
engine.
6 - Disconnect the connector (8) from the pressure
switch (7).
7 - Disconnect the delivery pipe(11) and the return pipe
(12) from the expansion valve (9) and the dryer filter 5
(10).
H Immediately plug the tubes and the orifices tightly 6 3
to prevent moisture from entering into the air-con-
ditioning circuit. RKZA8840

H Re-use the O-ring.

8 - Loosen the clip and remove the drying filter (10).
H Immediately plug the delivery tube (11) and the 8
13
expansion valve (9) tightly to prevent moisture
7
from entering into the air-conditioning circuit.
H Re-use the O-ring. 6
9 - Remove the four screws (13) and remove the group
(3). 9 10

11
12
RKZA8711

WB91R-2 WB93R-2 30-41

REMOVAL AND INSTALLATION HEATING AND AIR-CONDITIONING GROUP

INSTALLATION OF THE HEATING AND AIR-CONDITIONING GROUP

. To install, reverse the removal procedure.

1 - Refill the cooling liquid.

Coolant liquid: 18 ,
2 - Drain and refill the air-conditioning unit.

Quantity of fluid (R134a): 1100 g (+ 50 / ± 30 g)

Quantity of oil: See the amount recovered.
3 - Start the engine and use a leak detector to check
the leaktightness of the air-conditioning unit.

30-42 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION FUEL TANK

REMOVAL OF THE FUEL TANK

Lower the working equipment completely until it
rests on the ground and stop the engine. 3
2 1
Cut off the supply of electricity by turning the accu-
mulator-disconnecting switch in a counter-clockwise
direction, and remove the handle.

1 - Remove the lower left-hand guard (1) of the cab. 6

2 - Take the cap (2) off the filling inlet of the fuel tank (3)
and remove also the bottom plug in order to drain the 5
fuel.

Fuel: max. 130 , 4 RKZA1940

3 - Remove the nut (4) in order to free the clips (5).

4 - Take off the guard (6) and lift off the accumulator co-
ver (7).
Disconnect the clamps (8) and (9) and left out the ac- 7
cumulator (10). 9
First remove the negative clamp (±) and then the 8
positive clamp (+).

5 - Disconnect the connector (11) of the level indicator

(12) and the connector (13) of the self-supply pump,
if fitted.
10
6 - Disconnect the fuel suction and flow-back hoses (14)
and (15) and the pipe of the self-supply pump, if fitted. RKZA7791

H Plug the pipes to prevent entry of impurities.

H Mark the pipes to avoid exchanging them during
installation.
7 - Remove the screws (16) and the guard (17).
17
14 15 13 11
8 - Support the fuel tank (3) with hoisting tackle and re-
move the four retaining screws (18).
16
9 - Remove the fuel tank (3).
Fuel tank:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . kg

12

INSTALLATION OF THE
RKZA1921

FUEL TANK
. To install, reverse the removal procedure.

Retaining screws for fuel tank: 120 Nm

18
1 - Refill the fuel tank.

Fuel: max. 130 ,

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

RKZA1950

WB91R-2 WB93R-2 30-43

REMOVAL AND INSTALLATION HYDRAULIC OIL TANK

REMOVAL OF HYDRAULIC OIL TANK

Lower the working equipment completely until it
rests on the ground and stop the engine. 1
Eliminate completely any residual pressures from all
2
circuits.
(For details, see «20. TESTING AND ADJUST-
MENTS»).
1 - Take off the lower right-hand guard (1) of the cab. 3
14
2 - Remove the guard (2).
3 - Raise the guard (3) and remove the oil drainage cap
(4).
H Drain the hydraulic oil. RKZA1960

Hydraulic oil: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ,
4 - Disconnect the lower suction (6) and drainage (7) ho-
ses from the tank (5).
H Leave the check valve (8) on the tank.
H Plug the hoses to prevent entry of impurities.
3
4
5 - Disconnect the upper pipes (9), (10) and (11), remove
the check valve (12) and the T-piece (13).
H Make a note of the assembly sequence.
6 - Support the tank (5) with hoisting tackle and remove 5
the four retaining screws (14).
7 - Remove the tank (5).
RKZA1970

Oil for the tank: . . . . . . . . . . . . . . . . . . . . . . . . . . . . kg

7
INSTALLATION OF THE
HYDRAULIC OIL TANK
. To install, reverse the removal procedure.

7 8
Tank retaining screws: 120 Nm RKZA1980

1 - Refill the tank.

Hydraulic oil: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ,
2 - Refill the pump (For details, see «20. TESTING AND 9
ADJUSTMENTS»). 12

3 - Start the engine to let the oil circulate through all the
hydraulic systems and check for leaks.
13
3 - Bleed the air from the hydraulic systems. (For details,
10
see «20. TESTING AND ADJUSTMENTS»).
4 - Stop the engine, check the oil level in the tank, and 11
top it up if necessary.
RKZA1990

30-44 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION ENGINE-GEARBOX-PUMP GROUP

REMOVAL OF THE ENGINE-GEARBOX-PUMP GROUP

Lower the working equipment completely until it
rests on the ground, and stop the engine.
Disconnect the cable from accumulator negative ter-
minal (±). 1
Release all residual pressure in all circuits.
(For details, see «20. TESTING AND ADJUST-
MENTS»).
H Drain the hydraulic oil.

Hydraulic oil:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ,
H Drain the engine cooling liquid. 2 1
,
RKZA2000
Coolant liquid: 18
H Drain the oil from the gearbox.

Gearbox oil:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ,

1 - Only for machines equipped with an air-conditio- 5

ning unit.
Drain the air conditioning unit.
(For details, see «20. TESTING AND ADJUST-
MENTS»).
4
2 - Remove the front working equipment. (For details, 3
see «REMOVAL OF THE FRONT WORKING EQUIP-
MENT»).
3 - Take off the engine hood. (For details, see «REMO- RKZA2010

VAL OF THE ENGINE HOOD»).

4 - Take out the screws (1) and remove the front counter-
weight (2). (For details, see «REMOVAL OF THE
FRONT COUNTERWEIGHT»).
5 - Remove the radiator-oil cooler group. (For details,
see «REMOVAL OF THE RADIATOR-OIL COOLER
GROUP»). 7
6 - Lift the protection (3), disconnect connector (4) and
remove transmission lever (5).
7 - Disconnect rear cardan shaft (7) from transmission 6
(6).
RKZA0610

8 - Remove front cardan shaft (8).

RKZA0401

WB91R-2 WB93R-2 30-45

REMOVAL AND INSTALLATION ENGINE-GEARBOX-PUMP GROUP

9 - Disconnect the suction hose (10) and the drainage pi-

pe (11) from the pump (9). 9
Disconnect also the power increment solenoid con-
nector.
H Plug the pipes to prevent entry of impurities.
11

10
RKZA8872

10 - Disconnect the Load Sensing signal pipe (12) and the

delivery pipe (13) from valve (14).
H Plug the pipes to prevent entry of impurities.

14

12
13
RKZA8862

11 - Disconnect from the transmission (15) the connectors

(16) and the oil cooling circuit pipes and the control
lines (17).
H Plug the pipes to prevent entry of impurities. 20
18

16
15 19
17
RKZA0640

12 - Disconnect the coolant liquid temperature sensors

(21) and (22) from the engine.
21
13 - Disconnect the cab heating pipes (23) from the coo- 22
lant pump.

23

RKZA7890

30-46 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION ENGINE-GEARBOX-PUMP GROUP

14 - Disconnect the connector (24) of the oil pressure sen-

sor and the connector (25) of the solenoid that stops
the engine.

24

25

RKZA0660

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

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

28

26
RKZA1762

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

celerators. Disengage the support sheathing (30).
30

29

RKZA0092

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

and plug them. 32

18 - Remove the separator.

31

RKZA0670

WB91R-2 WB93R-2 30-47

REMOVAL AND INSTALLATION ENGINE-GEARBOX-PUMP GROUP

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

(34) and the cables (35) from the alternator (36).
33
35

36
34
RKZA0680

20 - Only for machines equipped with an air-conditio-

41 39
ning unit.
Save the coolant R134a and disconnect the delivery
tubes (38) and suction tubes (39) from the compres-
sor (37).
H Immediately plug the tubes and orifices tightly to
prevent moisture from entering into the air-condi- 37
tioning circuit.
38
H Disconnect the air-conditioning unit connectors
(40) and (41).
40
RKZA8575

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

the machine.

42

RKZA0383

22 - Disconnect the flexible return hose (44) from the muf-

fler (43).
44

43

RKZA0691

30-48 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION ENGINE-GEARBOX-PUMP GROUP

23 - Attach the entire group to some hoisting tackle using

the engine bracket (45) and the muffler support (46).
Apply a slight tension to the hoisting chains.

45 46

RKZA0702

H The chains should have a total length of about 800 -- 53 mm

mm and a difference between the arms of 53 mm. 200 mm
H The shortest length should be attached to the bracket
(45).
H When under tension the cables should be about 200
mm apart at the height of the muffler.

RKZA1640

24 - Loosen and remove the nuts (47) of the anti-vibration

supports (48) of the engine and gearbox, and take out
the screws (49).
49
25 - Raise the entire group until the chassis supports are
disengaged, and than accompany the group in order 48
48
to slide it away from the front part of the chassis.
Engine-gearbox-pump group: . . . . . . . . . . . . . . kg 47
47
49
RKZA0712

WB91R-2 WB93R-2 30-49

REMOVAL AND INSTALLATION ENGINE GEARBOX-PUMP GROUP

INSTALLATION OF THE ENGINE GEARBOX-PUMP GROUP

. To install, reverse the removal procedure.

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

Hydraulic oil: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ,
2 - Fill the gearbox up to its maximum level.

Gearbox oil: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ,

3 - Refill the coolant liquid.

Coolant liquid: 18 ,
4 - Drain and refill the air-conditioning unit.

Quantity of fluid (R134a): 1100 g (+50 / ± 30 g)

Quantity of oil: See the amount recovered.

Screws for front counterweight: 300w30 Nm

Screws on gearbox side: 70 Nm

Screws on gearbox side: Loctite 262

Nut on axle side 70 Nm

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

tank up to pressure.
For the method see «20. TESTING AND ADJUST-
MENTS».

H Bleed the air from the fuel lines.

Nuts from the anti-vibration supports:

196w19.6 Nm
4 - Start the engine to circulate the oil and coolant liquid.
Check that there are no leaks.
5 - Use a leak detector to check the leaktightness of the
delivery and return pipes of the air-conditioning unit
compressor.
6 - Bleed the air from the working equipment circuits.
(For details, see «20. TESTING AND ADJUST-
MENTS»).
7 - Stop the engine, check the levels and, if necessary,
top them up.

30-50 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION PISTON PUMP

REMOVAL OF THE PISTON PUMP

Lower the working equipment completely until it
rests on the ground, and stop the engine. 1
Cut off the supply of electricity by turning the accu-
mulator-disconnecting switch in a counter-clockwise
direction, and remove the handle.
Release residual pressure fully in all circuits. (For
6
details, see «20. TESTING AND ADJUSTMENTS»). 3
H Drain the hydraulic oil.
Quantity of oil: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ,
1 - Disconnect the suction hose (2) and the drainage pi- 2
pe (3) from piston pump (1). RKZA8871

2 - Disconnect the delivery pipe (4) and the Load Sen-

sing signal line (5).
H Plug the pipes to prevent entry of impurities.
3 - Disconnect the solenoid connector (6).

5
4
RKZA8861

4 - Take out the rear cardan shaft (7).

RKZA2040

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

jack.
H For attachment purposes, use the pump body fil-
ling pipe (8).

1
B1

RKZA2050

WB91R-2 WB93R-2 30-51

REMOVAL AND INSTALLATION PISTON PUMP

6 - Take out the two screws (9) and remove the pump (1)
9
complete with its O-ring (10).
Pump: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . kg
11
1

B1
RKZA0740

INSTALLATION OF THE
PISTON PUMP
. To install, reverse the removal procedure.
1 - Fill the tank with hydraulic oil up to maximum level.

Hydraulic oil: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ,

H Fill the pump body and the pump, bringing the

tank up to pressure.
For the method, see «20. TESTING AND ADJUST-
MENTS».
Screws for suction flange: 100 Nm
Screws for delivery flange: 60 Nm

Screws on gearbox side: Loctite 262

Screws on gearbox side: 70 Nm
Nut on axle side: 70 Nm

Pump retaining screws: Loctite 262

Pump retaining screws: 220 Nm

2 - Start the engine to circulate the oil in all hydraulic cir-

cuits.
3 - Stop the engine, check the oil level in the tank and, if
necessary, top it up.

30-52 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION TRANSMISSION

REMOVAL OF THE TRANSMISSION

Lower the working equipment completely until it
rests on the ground, and stop the engine. Make the
backhoe safe.
Raise the engine hood and disconnect the cable
from accumulator negative terminal (±).
Release all residual pressure in all circuits. (For de-
tails, see «20. TESTING AND ADJUSTMENTS»).
H Drain the hydraulic oil.

Hydraulic oil:: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ,
H Drain the oil from the gearbox.

Gearbox oil:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ,
1 - Remove the piston pump. (For details, see «REMO-
VAL OF THE PISTON PUMP»).
2 - Raise the protective sleeve (1), disconnect the con-
nector (2) of the transmission disengagement and re-
move the gear lever (3). 1
3
2

RKZA0601

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

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

RKZA0750

5 - Take off the cover (6) of the flywheel oil-sump and ta-
ke out the six retaining screws (7) of the converter
coupling flange (8). 6

8 7

RKZA0760

WB91R-2 WB93R-2 30-53

REMOVAL AND INSTALLATION TRANSMISSION

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

the temperature sensor (10). 9
7 - Disconnect the four tubes (11) for oil circulation and 11
controls.

10
11

RKZA0770

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

the machine.

12

RKZA0382

9 - Attach the engine-gearbox group to the hoisting tack-

le using the engine bracket (13) and the muffler sup-
port (14). Apply tension to the hoisting chains.

13 14

RKZA0701

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

and the anti-vibration nuts (17).
11 - Remove the gearbox supports (18). 17

17
15 16

18

16 15
RKZA0780

30-54 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION TRANSMISSION

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

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

20

C1 A
RKZA0790

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

the engine and gearbox together.

19
20

RKZA0800

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

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

20
C1

RKZA0810

WB91R-2 WB93R-2 30-55

REMOVAL AND INSTALLATION TRANSMISSION

INSTALLATION OF THE TRANSMISSION

. To install, reverse the removal procedure.

Hydraulic oil: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ,

Gearbox oil: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ,

H Fill the pump body and the pump in order to pressuri-

se the tank.
For the method, see «20. TESTING AND ADJUST-
MENTS».

Screws for securing lever: 120 Nm

Screws: Loctite 262

Screws on gearbox side: 70 Nm

Nuts on axle side: 70 Nm

Flange screws: Loctite 262

Flange screws: . . . . . . . . . . . . . . . . . . . . . . . . . . . Nm

Anti-vibration nuts: 196w19.6 Nm

Support screws: Loctite 262

Support screws: 90 Nm

Engine-gearbox screws: Loctite 262

Engine-gearbox screws: 90 Nm

1 - Start the engine to circulate the oil. Check that there

are no leaks.
2 - Bleed the air from the working equipment circuits.
(For details, see «20. TESTING AND ADJUST-
MENTS»).
3 - Stop the engine, check the levels and, if necessary,
top them up.

30-56 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION TRANSMISSION

OVERHAULING THE TRANSMISSION

1. Dismantling the external group
1 2
12 21
22
13 4
14
5 23
16
18 20 6
20
7
15
17 25
27
9 19

8
26
11 24
10

27
30
29 3
28 RKZ02380

1 - Attach the transmission group to some equipment

that allows the group to rotate.

RKZA5730

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

1 2

3
RKZA5740

WB91R-2 WB93R-2 30-57

REMOVAL AND INSTALLATION TRANSMISSION

3 - Remove the gasket (4).

H A new gasket must be fitted every time it is di-
smantled.
4

RKZA5750

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

6
RKZA5760

5 - Remove the plate (6).

RKZA5770

6 - Remove the gasket (7).

H A new gasket must be fitted every time it is di-
smantled.

RKZA5780

30-58 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION TRANSMISSION

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

11
RKZA5790

8 - Take out the screws (12) and remove the solenoid val-
ve (13). 12

13

RKZA5800

9 - Remove the gasket (14).

H A new gasket must be fitted every time it is di- 15
smantled.
14
10 - Remove the filter (15).

RKZA5810

11 - Remove the filter attachment fitting (16).

12 - Remove the valve spool (17).
17
16

RKZA5820

WB91R-2 WB93R-2 30-59

REMOVAL AND INSTALLATION TRANSMISSION

13 - Take out the spring (18).

14 - Use a puller for blind holes to extract the priority valve 19
(19). 18
The priority valve is calibrated in the factory and
should not be modified. If it appears to be dama-
ged, replace it with a new one.

RKZA5830

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

RKZA5840

16 - Loosen and take out the screws (21) that secure the
shifter group (22).
22
17 - Remove the group (22) and the O-ring (23).

23
21

RKZA5850

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

holding the flange steady, remove the central screw
24
(25).

25

RKZA5860

30-60 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION TRANSMISSION

19 - Remove the washer (26).

20 - Remove the O-ring (27) and the flange (24).
H The O-ring (27) must be replaced every time it is
dismantled. 24
26

27

25 RKZA5870

21 - Mount two screws in the flange (28) holes and, hol-

ding the flange steady, remove the central screw (29).

29

28
RKZA5880

22 - Remove the washer (30).

23 - Remove the flange (28). 28 27
30
24 - Remove the internal O-ring (27).
H The O-ring (27) must be replaced every time it is
dismantled.

RKZA5890

WB91R-2 WB93R-2 30-61

REMOVAL AND INSTALLATION TRANSMISSION

2. Assembly of the external groups

1 - Insert O-ring (27) in the flange and mount flange on
the shaft (75). 28
30
2 - Mount the washer (30).

RKZA8270

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

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

28
RKZA5880

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

7 - Mount the O-ring (27).
8 - Mount the washer (26) and the screw (25). Screw the
screw (25) home by hand. 27 26
24
25

RKZA8280

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

10 - Holding the flange steady, tighten the screw (25).
Screw: 139 Nm 25 24

RKZA8290

30-62 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION TRANSMISSION

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

O-ring: ASL800050
12 - Lubricate the levers and the shifter levers' end (22).
22
Shifter and levers: ASL800040
23
13 - Mount the shifter group (22) and the screws (21). 22

21

RKZA8300

14 - Secure the shifter group (22).

Screws: 23 Nm

22

RKZA8310

15 - Mount the priority valve (19).

16 - Mount the spring (18).
19 18

RKZA8320

17 - Mount the spool (17).

18 - Mount and tighten the fitting (16).
Fitting: 50 Nm
17
16

RKZA8330

WB91R-2 WB93R-2 30-63

REMOVAL AND INSTALLATION TRANSMISSION

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

Filter: See the manufacturer's instructions.
15
20 - Mount the gasket (14). 14

RKZA8340

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

screws (12). 12
Screws: 23 Nm

13

RKZA5800

22 - Mount the gasket (7).

RKZA5780

23 - Mount the plate (6).

RKZA5770

30-64 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION TRANSMISSION

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

6
RKZA5760

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

RKZA8350

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

the screws (1).
2
H Tighten the screws starting in the centre and mo-
ving towards the outside, using the alternating 1
crosswise method.
Screws: 23 Nm

RKZA8360

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

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

10 11
RKZA8370

WB91R-2 WB93R-2 30-65

REMOVAL AND INSTALLATION TRANSMISSION

3. Dismantling the transmission

34 38
39
35
46 47 40 41 36
48
43 33
49 51 44
50 42
45 40 37
54
52

31

60 32
56

57 59
58 RKZ02750

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

32

RKZA5900

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

33

RKZA5910

30-66 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION TRANSMISSION

3 - Use a lever inserted into the opposing cavities to di-

sconnect the cover (34) of the transmission housing. 34

RKZA5920

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

34
pump drive shaft (35).

35

RKZA5930

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

36 37

RKZA5940

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

8 - Turn the cover (34) upside down and take out the seal 37
ring (38).
H A new seal ring must be substituted.

38

RKZA5950

WB91R-2 WB93R-2 30-67

REMOVAL AND INSTALLATION TRANSMISSION

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

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

39
39
RKZA5960

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

41

40

42 RKZA5970

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

41

42
RKZA5980

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

43 44

RKZA5990

30-68 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION TRANSMISSION

13 - Remove the plate (44).

14 - Use a magnet to remove the two balls (45) from the
hole between the two shifter rods. 44 45

RKZA6000

15 - Remove the cap (46).

46

RKZA6010

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

(48).
H Repeat phases 15 and 16 for the other cap. 47 48

RKZA6020

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

secondary shaft (53).

52

53

RKZA6030

WB91R-2 WB93R-2 30-69

REMOVAL AND INSTALLATION TRANSMISSION

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

main shaft (55). 54

55

RKZA6040

19 - Turn the transmission upside down and remove the

three screws (56).

56

RKZA6050

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

57

58
RKZA6060

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

60

59

RKZA6070

30-70 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION TRANSMISSION

32

77
76
74
3

68
73
71 69
63
62
75
67
66
67
64
72
61 70 RKZ02760

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

pump (62).

61

62
RKZA6080

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

pump (62) smoothly.

62

RKZA6090

WB91R-2 WB93R-2 30-71

REMOVAL AND INSTALLATION TRANSMISSION

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

RKZA6100

25 - Slightly raise the input shaft (66) and remove the bea-
ring-retaining snap ring (65).

65 64

RKZA6110

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

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

RKZA6120

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

H If necessary, assist the raising operation with a le-
ver and also by knocking on the shaft of the front 3
drive with a plastic mallet.

RKZA6130

30-72 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION TRANSMISSION

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

the sealing rings (67).

66

RKZA6140

29 - Remove the two sealing rings (67) from the differen-

tial lock ring. 67
H They can be removed by unhooking the two extre-
mities.
H New sealing rings (67) must be substituted each
time they are dismantled.

67

RKZA6150

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

bearing (69) of the secondary shaft. 69 68
31 - Remove the bearing (70) from the seating of the front 70
flange (3). 3

RKZA6160

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

RKZA6170

WB91R-2 WB93R-2 30-73

REMOVAL AND INSTALLATION TRANSMISSION

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

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

74
74

32
RKZA6180

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

75

RKZA6190

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

(77).
76

77

RKZA6200

30-74 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION TRANSMISSION

86 85
80 87

79 32

81

89
84
83
78 82

88
89
RKZ02770

36 - Turn the transmission upside down. Connect it to so-

me hoisting tackle suitable for the upper gears.

RKZA6210

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

le and at the same time raise the main shaft by hand.
H The forks and the shifters for 1st/2nd and 3rd/4th
gears are also raised at the same time.
If any parts remain stuck, they can be separated 78 79
by tapping them with a plastic mallet.

RKZA6220

WB91R-2 WB93R-2 30-75

REMOVAL AND INSTALLATION TRANSMISSION

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

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

78

RKZA6230

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

81

RKZA6240

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

H Make a note that this fork fits in the upper hole of
the transmission housing. 80

RKZA6250

41 - Remove from the transmission housing (32) the 4-

wheel drive clutch gear (82).
82

RKZA6260

30-76 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION TRANSMISSION

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

83 84

RKZA6270

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

vent plug (86) and the temperature sensor (87). 85

32 86

87

RKZA6280

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

RKZA6290

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

RKZA6290

WB91R-2 WB93R-2 30-77

REMOVAL AND INSTALLATION TRANSMISSION

2 - Mount on the housing (32) the temperature sensor 85

(87), the vent plug (86) and the caps for the pressure
adapters (85). 32 86

87

RKZA6280

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

84 83

RKZA8380

4 - Install the gear (82).

H The side with the raised areas must face towards
the inside of the transmission. 82

RKZA6260

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

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

RKZA8390

30-78 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION TRANSMISSION

6 - Lower the entire group, centering the individual pie-

ces in their respective seatings. At the same time, sli-
de in the main shaft (79), taking great care with the
mating of the gears.
78 79

RKZA6220

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

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

79

32
RKZA6041

8 - Install the snap ring (52) on the bearing of the secon-

dary shaft (78).
H After mounting the snap ring, push the secondary
shaft home.
52

78

RKZA6031

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

48 47

RKZA8400

WB91R-2 WB93R-2 30-79

REMOVAL AND INSTALLATION TRANSMISSION

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

ers and tighten them.
Caps: 80 Nm
49

RKZA6011

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

81
RKZA8410

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

Screws: Loctite 542
Screws: 50 Nm
43

RKZA5991

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

shifter rods (80) and (81).
41

42
RKZA5980

30-80 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION TRANSMISSION

15 - Insert the pins (40).

H Deaden the blows on the shaft by using a hammer
in the place of an anvil.
40

RKZA8420

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

77

RKZA6200

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

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

75

RKZA6190

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

front housing (3). Secure it with the fittings (71) and 3 71 73
the copper washers (73).
71 73
Fittings: 40 Nm 72

RKZA6171

WB91R-2 WB93R-2 30-81

REMOVAL AND INSTALLATION TRANSMISSION

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

coat it evenly with a sealant.
Housing: Loctite 510 32
H Do not allow any of the sealant to penetrate anyw-
here where oil flows or into the seatings of the O-
rings (74).

RKZA8430

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

74
74

RKZA6181

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

on the main and secondary shafts.
69 68

RKZA8440

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

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

32
RKZA8450

30-82 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION TRANSMISSION

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

25 - Tighten the screws using the alternating crosswise
method. 31
Screws: 50 Nm

RKZA5901

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

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

56

RKZA6050

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

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

67

RKZA6151

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

on the 4-wheel drive shaft (75).
30 - Mount the bearing (70) on the shaft (75). 66
70

75
RKZA8460

WB91R-2 WB93R-2 30-83

REMOVAL AND INSTALLATION TRANSMISSION

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

H2

58
60
RKZA8470

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

33 - Lubricate the seal rings (59) and (60) and mount the
group on the housing (3). 58 59 58

RKZA8480

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

Screws: 23 Nm

57

RKZA8490

35 - Pull the shaft (76) towards the front of the transmis-

sion and mount the snap ring (64) on the bearing.
64
76

RKZA8500

30-84 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION TRANSMISSION

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

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

62

RKZA8510

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

61

RKZA6081

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

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

38

RKZA8520

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

H The ring is secured by hooking up the two extre-
mities "B". 35

36

RKZA8530

WB91R-2 WB93R-2 30-85

REMOVAL AND INSTALLATION TRANSMISSION

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

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

37

RKZA8540

42 - Lubricate the sealing rings and mount the complete

shaft (35) in the housing (34). 35

34

RKZA8550

43 - Coat the surface of the housing (32) with sealant. 32

34
Housing: Loctite 518
H Spread the sealant evenly all over the coupling
surface.
44 - Mount the housing (34) on the transmission and push
it home.

RKZA5931

45 - Mount the screws (33) and secure the housing (34).

Screws: 50 Nm 33

34

RKZA5911

30-86 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION TRANSMISSION

5. Dismantling the input shaft

104
102

103
99 105
106
97 101 107
93 100 107
91
94 121
96
108
92
95 108
109
110
110 115
109 111
106 111
107 115 113
107 98
116
121
118 112
120
108 101 114
108
105 117
103 119

102
104 RKZ02740

1 - Attach the tool H1 onto the reverse clutch side of the

shaft group.
Secure the tool in a vise, as illustrated.

H1

RKZA6300

WB91R-2 WB93R-2 30-87

REMOVAL AND INSTALLATION TRANSMISSION

2 - Remove the seal ring (91).

91

RKZA6310

3 - Remove the snap ring (92) that holds the bearing (93)
in place.

92
93

RKZA6320

4 - Use a separator applied beneath the gear (94) and a

puller, to force the bearing (93) out of the seating of
the shaft (95). 93
Shaft seating: ASL800040
94
95
H Use a protective cap on the head of the shaft.
5 - Remove the bearing (93).

RKZA6330

6 - Remove the spacer (96).

7 - Remove the bearing ring (97). 96
97

RKZA6340

30-88 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION TRANSMISSION

8 - Remove the gear (94).

94

RKZA6350

9 - Remove the spring pin (98).

98

RKZA6360

10 - Remove the roller bearings (99).

11 - Remove the bearing ring (100).
99
100

RKZA6370

12 - Tap the outer ring (101) lightly in order to obtain some

clearance between the ring and the snap ring (102).

101

RKZA6380

WB91R-2 WB93R-2 30-89

REMOVAL AND INSTALLATION TRANSMISSION

13 - Remove the snap ring (102).

102

RKZA6390

14 - Use two levers to remove the outer ring (101).

101

RKZA6400

15 - Remove the spring pin (115).

115

RKZA6410

16 - Install the upper part of the tool H1 and the three

threaded tie-rods complete with nuts, used to fasten
the component parts of the tool between them.

H1

RKZA6420

30-90 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION TRANSMISSION

17 - Gradually and evenly tighten the nuts in order to com-

press the spring (103) and to gain access to the snap
ring (104).

RKZA6430

18 - Remove the snap ring (104).

104

RKZA6440

19 - Gradually and evenly loosen the nuts and the tie-rods

on the tool H1 until the thrust of the spring (103) has
been eliminated.
Remove the upper part of the tool H1 and the tie-rods.

H1

RKZA6450

20 - Remove the spring retainer plate (105) and the spring

(103).
105 103

RKZA6460

WB91R-2 WB93R-2 30-91

REMOVAL AND INSTALLATION TRANSMISSION

21 - Remove the clutch pack (106).

H Make a note of the assembly sequence of the
disks.
H Make a mark on the assembly side of the clutch
pack.
H If the friction disks (108) have a thickness of less
than 1.65 mm, they must be replaced. 106

RKZA6470

22 - Remove the piston (109).

H Take great care not to damage the surfaces and
edges of the piston.
109

RKZA6480

23 - Remove the seal ring (110).

110
RKZA6490

24 - Apply the tool H1 to the other side of the shaft group

(forward gear clutch in the upper position).
Secure the tool in a vise as indicated.

H1

RKZA6500

30-92 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION TRANSMISSION

25 - Remove the seal rings (111).

111

111

RKZA6510

26 - Repeat also for this side the operations performed

from phase 3 to phase 9 for the removal of the snap 113
ring (112), the bearing (113), the bearing ring (114)
112
the spring pin (115) and the gear (116). 114

RKZA6520

27 - Take out the 1st roller bearing (117) and the spacer
(118).
117 118

RKZA6540

28 - Remove the second roller bearing (119) and the bea-

ring ring (120).

119
120

RKZA6550

WB91R-2 WB93R-2 30-93

REMOVAL AND INSTALLATION TRANSMISSION

29 - Repeat the phases from 12 to 23 to complete the di-

smantling of the input shaft.
116
115

RKZA6530

30 - Remove the seal rings (121) from the pistons (109).

H New seal rings must be installed each time they
are dismantled. 109

121
RKZA6560

31 - Check carefully for splines in the shaft, the rotating

parts, and in the bearings and the gears.
If there are obvious signs of wear, pitting or scoring,
change the components.
H All seal rings should be changed for new, even if
they appear to be in good condition.

30-94 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION TRANSMISSION

6. Assembly of the input shaft

Unless otherwise specified, the pieces being re-as-
sembled should be lubricated with transmission oil.
109
1 - Lubricate the seal rings (121) and mount them on the
pistons (109).

121
RKZA6560

2 - Mount the seal ring (110) to the rear of the input shaft.

110

RKZA6570

3 - Lubricate the seating of the shaft (95) and the com-

plete piston (109). Mount the piston.
95

109

RKZA6580

4 - Mount the spring (103) and the spring retainer plate

(105).
H The collar of the spring retainer plate must center
the spring.
105

103

RKZA6590

WB91R-2 WB93R-2 30-95

REMOVAL AND INSTALLATION TRANSMISSION

5 - Mount the upper part of the tool H1 and fasten the two
parts together with tie-rods.
Tighten them equally and evenly as much as neces-
sary to be able to install the snap ring (104). H1

104
RKZA6600

6 - Mount the spring pin (115).

7 - Lubricate and mount the bearing ring (120). 115
H The chamfer on the bearing ring must face up-
wards and the bearing ring must be engaged on 120
the spring pin.
8 - Remove the tool H1.

RKZA6610

9 - Lubricate and install the first roller bearing (119), the

spacer (118) and the second bearing (117).
117
118

119

RKZA6620

10 - Mount the thrust bearing ring (101) on the gear (116).

H The flat part must face upwards.

101

116

RKZA6630

30-96 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION TRANSMISSION

11 - Mount in sequence a steel disk (107) and a friction

disk (108) until the clutch pack is complete.
H Immerse the clutch disks in oil before assembling
them.

107
108
RKZA6640

12 - Align the tongues of the steel disks (108) and turn the
gear-clutch group upside down.
Using two screwdrivers as a support, position the
clutch group in its seating.

RKZA6650

13 - With a hammer and a punch, tap lightly all around the

circumference of the thrust bearing ring (101), until
the seating of the snap ring (102) becomes visible.

101

RKZA6660

14 - Mount the snap ring (102).

102

RKZA6670

WB91R-2 WB93R-2 30-97

REMOVAL AND INSTALLATION TRANSMISSION

15 - Use two screwdrivers to raise the thrust bearing ring

(101) until the snap ring is completely engaged (102).
H Check the functioning and the leaktightness of
the piston by pressurizing the group with com-
pressed air at 5 ± 6 bar to settle the clutch in posi-
tion.

RKZA6680

16 - Mount the spring pin (115).

17 - Lubricate the bearing ring (114) and mount it on the
shaft. 114
H The lubrication holes must face towards the gear.
115
H Make sure that the spring pin is engaged in the
seating of the bearing ring (114).

RKZA6690

18 - With an appropriate plunger, mount the bearing (113)

behind the bearing ring (114).
19 - Mount the snap ring (112). 112

113

RKZA6700

20 - Lubricate the seal rings (111) and mount them on the

shaft.
H Position the notches on the seal rings 120ë apart. 111

111

RKZA6710

30-98 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION TRANSMISSION

21 - Turn the input shaft upside down and repeat the pha-
ses from 1 to 15 in order to mount the rear clutch.
H For the rear clutch, phase 9 does not envisage in-
stallation of the spacer (118).

RKZA6720

22 - Install the spring pin (98).

23 - Lubricate the bearing ring (100) and mount it on the
shaft (95).
H Make sure that the lubrication slots face down-
wards and that the spring pin is engaged in the
seating of the bearing ring (100).
24 - Mount the spacer (96).
25 - Use a plunger to mount the bearing (93) behind the
spacer.
H The seating for the snap ring groove must face
upwards. RKZA6730

26 - Mount the snap ring (92).

27 - Lubricate the seal ring (91) and mount it on the shaft.

91

RKZA6310

28 - Check the clearance of each clutch group using a

thickness calliper "C" inserted between the thrust
bearing ring and the first steel disk.
H Clearance limits: 2.3 ± 4.3 mm
C
If the clearance does not fall within these tolerances, it
is very probable that the group has been incorrectly
assembled.

RKZA6740

WB91R-2 WB93R-2 30-99

REMOVAL AND INSTALLATION TRANSMISSION

29 - Checking clutch function.

6 5 4 3

7 2 1

RKZ02660

1 - Clutch duct FORWARD gear 5 - Clutch pack REVERSE gear

2 - Clutch duct REVERSE gear 6 - REVERSE gear
3 - FORWARD gear 7 - Drive input shaft
4 - Clutch pack FORWARD gear

. Slowly insert compressed air up to about 6 bar into the

clutch duct (1) for the forward gear.
Listen for the piston movement that should block the
clutch.
In this condition, the forward gear (3) should be bloc-
ked while the reverse gear should be able to rotate
freely on the input shaft (7).
. Repeat the test for the passage (2). In this condition
the forward gear (3) should rotate freely on the input
shaft (7) while the reverse gear (6) should be blocked.
H If the conditions described are not found, dismantle
the group and look for the causes of the malfunction.

30-100 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION TRANSMISSION

7. Dismantling the secondary shaft 156

151
150
149
146 147 131
132
145
142
148
143 124
69
141
163 164

162
161
152
153 144 123
158
154 122 125
159 155
136 126
160 137
133 127
157 138
135
134
148
139
140

129
130
128

RKZ02830

1 - Position the secondary shaft group (78) on plastic

blocks, as illustrated.
H Do not use wooden blocks.
122
2 - Position a separator beneath the gear (122) with the 78
conical edge facing downwards.
H Do not force the separator against the synchroni-
zer assembly.

RKZA6750

WB91R-2 WB93R-2 30-101

REMOVAL AND INSTALLATION TRANSMISSION

3 - Position a puller and force the bearing (123) until is

can be detached from the seating of the shaft (124).
124
Shaft seating: ASL800040
H Use a protective cap on the head of the shaft.
123

RKZA6760

4 - Remove the bearing (123) and the bearing ring (125).

123 125

RKZA6770

5 - Remove the gear (122) of the 3rd speed.

6 - Remove the synchronizer ring (126) of the 3rd and 4th
synchronizer assembly in order to reach the snap ring 122 126
(127).

RKZA6780

7 - Remove the snap ring (127).

8 - Remove the synchronizer assembly (128) and put it to 128
one side.
127

RKZA6790

30-102 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION TRANSMISSION

9 - Remove the snap ring (129).

10 - Remove the 4th speed gear (130). 130
129

RKZA6800

11 - Remove the snap ring (131).

12 - Remove the gear (132) of the 4-wheel drive gear. 131 132

RKZA6810

13 - Remove the bronze ring (133).

133

RKZA6820

14 - Arrange the sleeve (134) on some plastic blocks insi-

de a container. Using a plunger, extract the hub 136
(135), the balls (136), the springs (138) and the blocks 138 137 134
(137). 135

137 138 138 137

136 136

RKZA6830

WB91R-2 WB93R-2 30-103

REMOVAL AND INSTALLATION TRANSMISSION

15 - Remove the 2nd bronze ring (136) from the synchroni-

zer ring (140).

139

140
RKZA6840

16 - Turn the group upside down so that the 2nd speed

gear faces upwards.
17 - Remove the snap ring (141). 141

RKZA6850

18 - Position a separator beneath the gear (142) with the

conical edge facing downwards.
H Do not force the separator against the synchroni-
zer assembly.
19 - Position a puller and force the ring into the bearing 69
(69) until it can be detached from the seating of the
shaft (124).
Shaft seating: ASL800040
H Use a protective cap on the head of the shaft.
124
RKZA6860

20 - Remove the ring inside the bearing (69) and the bea-
ring ring (143).
69 143

RKZA6870

30-104 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION TRANSMISSION

21 - Remove the pin (144).

22 - Remove the 2nd speed gear (142). 142
144

RKZA6880

23 - Remove the spacer (145).

24 - Remove the synchronizer ring (146) from the 1st and 146
2nd speed synchronizer assembly in order to reach
the snap ring (147).

145

RKZA6890

25 - Remove the snap ring (147).

26 - Remove the synchroniser assembly (148). 147 148

RKZA6900

27 - Remove the steel ring (149) and the bronze ring (150)
from the synchronizer assembly.
149

150

RKZA6910

WB91R-2 WB93R-2 30-105

REMOVAL AND INSTALLATION TRANSMISSION

28 - Remove the tapered friction ring (151).

151

RKZA6920

29 - Turn the synchronizer assembly upside down and re-

move the other synchronizer ring (152).
30 - Remove the steel rings (153) and bronze rings (154).
Remove also the tapered friction ring (155). For de-
tails, see phases 27 and 28.

153

RKZA6930

31 - Place the sleeve (156) on some plastic blocks inside a

container. Using a plunger, extract the hub (157), the
156
balls (158), the springs (160) and the blocks (159). 160 157

158 159
RKZA6940

32 - Remove the spacer (161).

33 - Remove the snap ring (162). 162
161

RKZA6950

30-106 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION TRANSMISSION

34 - Remove the 1st speed gear (163).

35 - Remove the last snap ring (164).
164
163

RKZA6960

36 - Check that all component parts have been disman-

tled and, if there is any damage to the gears, the in-
ner or outer tooth bases, or to the bearings (123), re-
place them with new ones.

37 - Check the clearance of the synchronizer assemblies

at three different points, 120ë apart.
For this test use the thickness calliper.
H Minimum clearance permissible: 1.3 mm
If the clearance is less than this, put in new synchro-
nizer assemblies.

1,3 MIN

38 - Carefully check the secondary shaft, especially whe- RKZ02850

re bearing inner races will be installed. No wear or

scoring (even if only localised) can be allowed.
Check the springs of the synchronization assembly.
Cracks, heat distortion, or wear mean that the piece
must be changed.

WB91R-2 WB93R-2 30-107

REMOVAL AND INSTALLATION TRANSMISSION

8. Re-assembly of the secondary shaft

H If not otherwise indicated, lubricate the pieces with
164
transmission oil.
163
1 - Mount the snap ring (164) on the secondary shaft
(124)
2 - Mount the 1st speed gear (163).

RKZA6970

3 - Mount the snap ring (162).

4 - Mount the spacer (161). 162
161

RKZA6980

5 - Position the hub (157) on the sleeve (158).

Mount the springs (160), the blocks (159) and the 159
balls (158) into the hub (157).
157

160
156

158

RKZA6990

6 - Use a screwdriver or a plunger to push the balls (158)

into the blocks (159).
Press on the hub to engage the balls in the sleeve
(156) until they are engaged in the central seating
of the sleeve (156).

156
RKZA7000

30-108 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION TRANSMISSION

7 - Install the tapered friction ring (155) on the synchroni-

zer assembly.

155

RKZA6921

8 - Install the bronze ring (154) and the steel ring (153).

153

154

RKZA6911

9 - Install the synchronizer ring (152).

H The flat surface of the teeth should face upwards.

152

RKZA6931

10 - Turn the group upside down and install the tapered

friction ring (151) on the synchronizer assembly.

151

RKZA6920

WB91R-2 WB93R-2 30-109

REMOVAL AND INSTALLATION TRANSMISSION

11 - Install the bronze ring (150) and the steel ring (149).

149

150

RKZA6910

12 - Mount the synchronizer assembly (148) on the shaft

(124).
H The side with the seating for the snap ring must
face downwards.

148

124

RKZA7010

13 - Mount the snap ring (147).

147

RKZA7020

14 - Mount the upper synchronizer ring (146).

H The flat surface of the teeth must face upwards. 142
nd
146
15 - Install the spacer (145) and the gear (142) of the 2
speed.

145

RKZA7030

30-110 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION TRANSMISSION

16 - Mount the pin (144).

17 - Lubricate the bearing ring (143) and mount it.
144 143
H The lubrication slots should face downwards and
the pin should be engaged in the cavity.

RKZA7040

18 - Using a plunger, mount the inner bearing ring of the

bearing (69) and knock it home on the bearing ring
(143).
H The wide base of the bearing ring (69) should face
141
downwards.
69
19 - Mount the snap ring (141).

RKZA7050

20 - Turn the group upside down and install the gear (132)
for the 4-wheel drive.
132
21 - Mount the snap ring (131).
H The ring (131) must be mounted in the lowest sea-
ting and behind the gear (132).

131

RKZA7060

22 - Mount the gear (130) of the 4th speed.

23 - Mount the snap ring (129).

130

129

RKZA7070

WB91R-2 WB93R-2 30-111

REMOVAL AND INSTALLATION TRANSMISSION

24 - Mount the bronze ring (139) on the synchronizer ring

(140).

139

140
RKZA6840

25 - Position the sleeve (134) and the hub (135).

Mount the springs (138) the blocks (137) and the balls 137
(136) in the hub (135). 135

134
138

136

RKZA7080

26 - Use a screwdriver or a plunger to push the balls (136)

into the blocks (137).
Press on the hub to engage the balls in the sleeve
(134) until they are engaged in the central seating
of the sleeve (134).

133
RKZA7090

27 - Mount the 2nd bronze ring (133).

133

RKZA7100

30-112 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION TRANSMISSION

28 - Install the synchronizer assembly (128) for the 3rd and

129
4th speeds.
H The side with the seating for the snap ring (129)
should face downwards.

128

RKZA7110

29 - Mount the snap ring (127).

30 - Mount the synchronizer ring (126). 127 126

RKZA7120

31 - Mount the gear (122) of the 3rd speed.

122

32 - Mount the bearing ring (125). RKZA7130

H Make sure that the lubrication slots are facing

downwards.
33 - Use a plunger to mount the bearing (123).
125 123
H Check that the snap ring groove on the outside of
the bearing is facing upwards.

RKZA7140

WB91R-2 WB93R-2 30-113

REMOVAL AND INSTALLATION TRANSMISSION

9. Dismantling the main shaft

165

168

169

167

166

68

170

RKZ02780

H Mark the gears and the main shaft to avoid exchan-

ging the component parts.
165
1 - Position the group with the bearing upwards and re-
move the snap ring (165). 166
2 - Position a separator beneath the gear (166) with the 167
conical edge facing downwards.
Position a puller and force the bearing (167) until it
can be detached from the seating.
H Use a protective cap on the head of the shaft.

RKZA7150

3 - Remove the bearing (167).

4 - Remove the bearing ring (168). 167 168

RKZA7160

30-114 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION TRANSMISSION

5 - Remove the gear (166).

6 - Turn the group upside down and, with a plastic mal- 166
let, slide the gear (169) off the shaft (170). 170

169

RKZA7170

7 - Position a separator beneath the inner bearing ring of

the bearing (63).
Position a puller and force the bearing ring (68) until it
can be extracted from the shaft (170).
H Use a protective cap on the head of the shaft.
H Make a note of the direction of assembly.

RKZA7180

WB91R-2 WB93R-2 30-115

REMOVAL AND INSTALLATION TRANSMISSION

10. Re-assembly of the main shaft

H Put in new bearings.
1 - Using a plunger, mount the inner bearing ring for the
bearing (68) on the shaft (170).
H Check the direction of assembly. 69 169
2 - Turn the shaft (170) upside down and, using a plastic
mallet, mount the gear (169).

170

RKZA7190

3 - Mount the gear (166).

4 - Lubricate the bearing ring (168) and mount it. 168
166
H The lubrication slots must face downwards.

RKZA7200

5 - Use a plunger to mount the bearing (167).

H The snap ring groove on the outside of the bea-
ring must be facing upwards. 165

6 - Mount the snap ring (165). 167

RKZA7210

30-116 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION TRANSMISSION

11. Dismantling the reverse shaft

171

172

173

RKZ02790

1 - Position a separator beneath the bearing (171) with

the conical edge facing downwards.
Position a puller and force the bearing (171) until it
can be detached from its seating.
H Use a protective cap on the head of the shaft
(172).
2 - Turn the group upside down and repeat the same
operations for the bearing (173). 172

RKZA7220

12. Re-assembling the reverse shaft

1 - Assemble the group by reversing the dismantling se-
quence.
H Use a plunger to install the bearings.

RKZA7230

WB91R-2 WB93R-2 30-117

REMOVAL AND INSTALLATION TRANSMISSION

13. Dismantling the shifter group, shafts and forks

177 175
178
174
179
176

RKZ02710

H Make accurate notes of the sequence of assembly of

the shafts and forks. 176
H The forks and shifter rods must be replaced with new 174
177
ones every time the synchronizer assembly is chan-
ged.
1 - Dismantling is simply a question of extracting the
pins (175) and (178) between the shafts (174) and
(177) and the forks (176) and (179).

179
RKZA7240

14. Re-assembly of the shifter group, shafts

and forks
1 - To re-assemble, reverse the dismantling procedure.

30-118 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION TRANSMISSION

15. Dismantling the drive shaft for the 4th speed

184

183
185 84
66

70 82
182
67

67
83
180

187
186

181 RKZ02730

H A plug (181) sealed with Loctite 542 is mounted in the

central hole of the shaft (180). Do not remove this 181
plug unless it is absolutely necessary.
180
1 - Press the spring retainer (182) until the snap ring
(183) can be released.
Release the pressure slowly. 182

RKZA7250

2 - Remove the snap ring (183).

3 - Remove the spring retainer (182) and spring (184).
4 - Remove the sleeve (185). 183
182

182
184

185

RKZA7260

WB91R-2 WB93R-2 30-119

REMOVAL AND INSTALLATION TRANSMISSION

5 - Remove the O-rings (186) and (187) from the shaft

(180). 187
186

RKZA7270

6 - Check the thickness "X" of the lugs on the sleeve of

the clutch command of the 4th speed (82).
Minimum "X" permissible: 3.52 mm
82
H If the projections are worn, also check the 4-wheel
drive clutch gear. (See «Dismantling the hou-
sing»).

X X
RKZ02840

16. Re-assembly of the 4th speed drive shaft

1 - To re-assemble, reverse the dismantling procedure.
H Lubricate the O-rings (186) and (187) with transmis-
sion oil.
H Check that the spring retainer (182) is mounted with
the seating for the snap ring (183) facing upwards.

30-120 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION TRANSMISSION

17. Dismantling the shifter housing

189

188

194

190
190 195

23
193

192
191
RKZ02800

1 - Undo the retaining clamps (188) and remove the pro-

tection (189).

189
188
RKZA7280

2 - Remove the two pins (190).

3 - Remove the snap ring (191).

190

191

RKZA7290

WB91R-2 WB93R-2 30-121

REMOVAL AND INSTALLATION TRANSMISSION

4 - Remove the bushing (182).

5 - Remove the spring (193). 193
192

RKZA7300

6 - Remove the shift lever (194).

194

RKZA7310

18. Re-assembling the shifter housing

1 - Lubricate the ball of the shift lever (194) and mount 195
the lever in its seating (195).

194

RKZA7311

2 - Align the shift lever (7) with its seating (195). The flat
surface "A" of the lever must be parallel to the side
"B" of the housing and the grooves "C" must match
with the holes "D" in the housing.

195

194
RKZA7320

30-122 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION TRANSMISSION

3 - Mount the spring (193).

4 - Mount the bushing (192).

193 192
RKZA7330

5 - Push the snap ring (191) with the push-rod until it is

engaged in the seating of the lever (194).
6 - Install the pins (190). 194
7 - Mount the protection (189) and secure it with the 190
clamp (188).

RKZA7340

WB91R-2 WB93R-2 30-123

REMOVAL AND INSTALLATION TRANSMISSION

19. Dismantling the 4th speed solenoid valve

196
198

12 199
197

201

14
200

RKZ02810

1 - Take out the lock nut (196).

196

RKZA7350

2 - Remove the solenoid coil (197).

197

RKZA7360

30-124 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION TRANSMISSION

3 - Remove the O-ring seal (198) and the valve rod (199).

198
199
RKZA7370

4 - Remove the check valve (200).

H Do not dismantle the check valve. If it gives pro-
blems, put in a completely new group.

200
RKZA7380

WB91R-2 WB93R-2 30-125

REMOVAL AND INSTALLATION TRANSMISSION

20. Re-assembly of the 4th speed solenoid valve

H Put in new O-rings and lubricate them with transmis- 201
sion oil.
1 - Install the check valve (200) in the body (201).

200
RKZA7381

2 - Mount the complete valve rod (199).

Rod: 22 Nm
3 - Mount the O-ring (198).

198
199
RKZA7390

4 - Mount the solenoid coil (197).

197

RKZA7360

5 - Mount the lock nut (196).

Lock nut: 8 Nm

196

RKZA7350

30-126 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION TRANSMISSION

21. Dismantling the distributor

210

202
206

204 205
209
203 214
207 213
211 208

216
212 222
223
221
215
235
225 217
227 218
219
229
220
224
234 226
233
232 228

231 237
236
230
RKZ02820

1 - Remove the retaining nut (202) of the coils (203) and

(204).
204

203

RKZA7400

WB91R-2 WB93R-2 30-127

REMOVAL AND INSTALLATION TRANSMISSION

2 - Remove the copper washers (205).

3 - Remove the outer coil (205).
203

205
RKZA7410

4 - Remove the O-ring (206) from the outer coil (203).

5 - Remove the intermediate O-ring (207).

206 207
RKZA7420

6 - Remove the intermediate O-ring (204).

7 - Remove the O-ring (208) from the internal coil.

204 208
RKZA7430

8 - Remove the last O-ring (209).

9 - Do not dismantle the rear check device of the coil
connector (210). This check device must only be di-
smantled when substituting a coil.

210

209

RKZA7440

30-128 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION TRANSMISSION

10 - Loosen the complete valve group (211).

211
RKZA7450

11 - Remove the valve group (211) complete with spool

(212).

212
211
RKZA7460

12 - Take out the screws (213) and remove the cover

(214).

214 213
RKZA7470

13 - Extract the outer modulation piston (215) from the co-

ver (214).

214

215
RKZA7480

WB91R-2 WB93R-2 30-129

REMOVAL AND INSTALLATION TRANSMISSION

14 - Remove in sequence the spring (216), the spring

(217), the spring (218) and the pin (219).
H Replace the springs.

217

216
219
218

RKZA7490

15 - Remove the first gasket (220).

H Throw the gasket away.
16 - Remove the plate (221).

220 221
RKZA7500

17 - Remove the ball (222) and the spring (223).

18 - Remove the second gasket (224).
H Throw the gasket away.

223
222

224
RKZA7510

19 - Remove the inner modulation piston (225).

20 - Remove the snap ring (226).

226

225
RKZA7520

30-130 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION TRANSMISSION

21 - Remove the flow regulator (227).

22 - Remove the spring (228).
H Put in a new spring.

227 228

RKZA7530

23 - Remove the flow regulator piston (229).

24 - Remove the cap (230).

229 230
RKZA7540

Only if necessary
25 - Remove the snap ring (231). 231

RKZA7550

26 - Remove the cap (232) of the spool that selects the di-
rection of movement.
27 - Remove the spring (233).

232 233
RKZA7560

WB91R-2 WB93R-2 30-131

REMOVAL AND INSTALLATION TRANSMISSION

28 - Remove the spacer (234).

234

RKZA7570

Only if necessary
29 - Remove the four caps (235) and (236). 235
H Beneath each cap there is a copper washer that
must be substituted each time it is dismantled.
236

RKZA7580

30-132 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION TRANSMISSION

22. Re-assembly of the distributor

1 - Install the spacer (234) in the distributor body (237). 237
H The chamfer on the central hole must face to-
wards the inside of the distributor.
2 - Mount the spring (233).

234 233
RKZA7590

3 - Mount the cap (232).

H Substitute the O-ring.
4 - Mount the cap (230).
H Substitute the O-ring.

232 230
RKZA7600

5 - Lubricate the regulating piston (229) with transmis-

sion oil and mount it in the body of the distributor
(237).
228
H The perforated surface must face towards the in-
side of the distributor.
6 - Mount the spring (228). 237

229
RKZA7610

7 - Mount the flow regulator (227).

8 - Mount the snap ring (226) and push it home in the
seating with a plunger.
H Make sure that the snap ring is completely inser- 227
ted into its seating. 226

RKZA7620

WB91R-2 WB93R-2 30-133

REMOVAL AND INSTALLATION TRANSMISSION

9 - Lubricate the innermodulation piston (225) with tran-

smission oil and mount it so that the extremity with
the smallest diameter hole faces towards the inside
of the distributor. 223

10 - Mount the spring (223).

225
RKZA7630

11 - Mount the first gasket (224).

12 - Mount the ball (222).
224 222

RKZA7640

13 - Position the plate (221).

14 - Position the second gasket (220).
221
220

RKZA7650

15 - Mount concentrically the pin (219), the small spring

(218), then the medium spring (217) inserted into
the spring with the largest diameter (216).
H The springs must be new.

219

216 217 218

RKZA7660

30-134 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION TRANSMISSION

16 - Insert the pin and spring group into the distributor

(237).
H The pin (219) must face towards the inside of the
distributor.

219

237

RKZA7670

17 - Lubricate the outermodulation piston (215) and

mount it in the cover (214).
H The closed extremity of the piston (215) must face
towards the cover (214).
214

215

RKZA7680

18 - Mount the cover (214) and secure it with the screws

(213).
Screws: 11 Nm
H Tighten using the alternating crosswise method.

214 213
RKZA7470

19 - Mount a new O-ring on the solenoid plunger (211).

H Lubricate the O-ring with transmission oil.
211

RKZA7690

WB91R-2 WB93R-2 30-135

REMOVAL AND INSTALLATION TRANSMISSION

20 - Lubricate the spool (212), insert it in the solenoid

plunger (211), and mount the group.
H Check carefully that the extremity of the spool is
engaged in the spring mounted in phase 2.

212
211
RKZA7460

21 - Tighten the solenoid plunger (211).

Solenoid plunger: 23 Nm

211
RKZA7700

22 - Mount the O-rings (208) and (209) on both sides of the

internal coil and lubricate them with transmission oil.

209
208
RKZA7710

23 - Mount the complete internal coil (204) on the solenoid

plunger (211).

211
204
RKZA7720

30-136 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION TRANSMISSION

24 - Mount the O-rings (207) and (206) on both sides of the

external coil and lubricate them with transmission oil.

207
206
RKZA7730

25 - Mount the complete external coil (203) on the sole-

noid plunger (211).

211
203

RKZA7740

26 - Mount the copper washer (205).

205
RKZA7750

27 - Mount the nut (202) and tighten it, keeping the two
coils aligned.
Nut: 7 ± 10 Nm

202

RKZA7401

WB91R-2 WB93R-2 30-137

REMOVAL AND INSTALLATION CONVERTOR

REMOVAL OF THE CONVERTOR

Lower the working equipment completely until it
rests on the ground and stop the engine.
Raise the engine hood and disconnect the cable 2
from accumulator negative terminal (±).
Release all residual pressure in all circuits. (For de-
tails, see «20. TESTING AND ADJUSTMENTS»). 1
H Drain the hydraulic oil.

Hydraulic oil: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ,
H Drain the oil from the gearbox.

Gearbox oil: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ,
RKZA0820

1 - Remove the piston pump. (For details, see «REMO-

VAL OF THE PISTON PUMP»).
2 - Remove the gearbox (For details, see «REMOVAL OF
THE GEARBOX»).
3 - Slide the convertor (1) away from the gearbox shafts
(2), (primary and secondary).
H If necessary, use two levers applied in opposed
positions.
H Take great care not to damage the centering hub
of the gearbox.

INSTALLATION OF THE
CONVERTOR
. To install, reverse the removal procedure.
H Engage the two shafts (primary and secondary) by
slowly rotating the body of the convertor.
1 - Refill the tank with hydraulic oil up to maximum level.

Hydraulic oil: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ,

H Fill the pump body and the pump, bringing the

tank up to pressure.
For the method, see «20. TESTING AND AD-
JUSTMENTS».
2 - Refill the gearbox.

Gearbox oil: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ,
3 - Start the engine to circulate the oil in all circuits.
Check that there are no leaks.
4 - Bleed the air from the working equipment circuits.
(For details, see «20. TESTING AND ADJUST-
MENTS»).
5 - Stop the engine, check the levels and, if necessary,
top them up.

30-138 WB91R-2 WB93R-2

 TRANSMISSION-REVERSE, DIRECTION INDICATOR AND
REMOVAL AND INSTALLATION HEADLIGHT DIPPER BEAM CONTROL GROUP

REMOVAL OF THE TRANSMISSION-REVERSE, DIRECTION

INDICATOR AND HEADLIGHT DIPPER BEAM CONTROL GROUP
Lower the working equipment completely until it
rests on the ground, and stop the engine.
Raise the engine hood and disconnect the cable
from accumulator negative terminal (±).
2 3
1 - Raise the protective sleeve (1) and disconnect the
connectors (2) and (3).

1
RKZA0830

2 - Take out the two screws (4) that hold the switching
groups (5) and (6).
3 - Remove the right-hand half-clamp (7) (4 screws).

6
RKZA0840

4 - Take off the central cap (8) of the steering wheel.

5 - Remove the retaining nut (9) and its washer. Remove
the steering wheel (10).
7
6 - Take out the switching groups (5) and (6) complete
with their protective sleeve (1). 11

INSTALLATION OF THE
TRANSMISSION-REVERSE, RKZA0850

DIRECTION INDICATOR AND

HEADLIGHT DIPPER BEAM
CONTROL GROUP 8
. To install, reverse the removal procedure.

H Check that the reference pin (11) enters fully into the
steering column and that the transmission-reverse
gear control unit is perfectly attached to the steering
9
column.

10 10
Steering column retaining nut: 40 Nm RKZA0860

WB91R-2 WB93R-2 30-139

REMOVAL AND INSTALLATION STEERING UNIT

REMOVAL OF THE STEERING UNIT

Lower the working equipment completely until it
rests on the ground and stop the engine and remove
the ignition wrench.
Release all residual pressure in all circuits. (For de- 2 1
tails, see «20. TESTING AND ADJUSTMENTS»).
Raise the engine hood and disconnect the cable
from accumulator negative terminal (±).

1 - Disconnect the five pipes (2) from the steering unit (1)
and plug them to prevent entry of impurities.
H Mark the positions to prevent exchanges during
re-connection. RKZA0870

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

wheel.

3
RKZA0880

3 - Raise the protective sleeve (4) and disconnect the

connectors (5) and (6).
4 - Disconnect the connector (7) and the relay (8).
5 - Loosen the steering column retaining screws (9) and 5 6
the steering unit (1).
6 - Take out the screws (11) and remove the plate (12)
that supports the steering column and the steering
unit.
7 - Take out the screws (9) and remove the steering unit
4
(1).
RKZA0831

INSTALLATION OF THE
10
STEERING UNIT
. To install, reverse the removal procedure.
9 8 7

H Bleed the air from the Load Sensing circuit. (For de-
tails, see «20. TESTING AND ADJUSTMENTS»).
H Start the engine and perform several complete stee-
ring manoeuvres in both directions, to bleed the air 11
12
out of the steering system.
RKZA0890

30-140 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION WORKING BRAKE PUMP GROUP

REMOVAL OF THE WORKING BRAKE PUMP GROUP

Lower the working equipment completely until it
rests on the ground, and stop the engine. 1
Raise the engine hood and disconnect the cable
from accumulator negative terminal (±). 2
1 - Remove the cap (1) of the oil tank (2) and draw out the 6
oil contained inside it. 6
2 - Remove the oil tank (2). 4
3 - Remove the clip (3) that holds the delivery lines (4). 7

4 - Remove the delivery lines (4) from the pumps (5). 3

5
RKZA0900

5 - Take out the four screws (6) and remove the pump
group (5).
H If only one pump is to be removed, also discon-
nect the pressure- equalizing pipe (7).

INSTALLATION OF THE
WORKING BRAKE PUMP GROUP
. To install, reverse the removal procedure.

H Bleed the air from the braking circuit. (For details, see
«20. TESTING AND ADJUSTMENTS»).

H Make sure that the push-rods (8) center the seating of

the pistons.
H After installation, check the idle stroke and parallelism
of the brake pedals and, if necessary, adjust the cou-
pling microswitches for 4-wheel brake control. (For de-
tails, see «20. TESTING AND ADJUSTMENTS»).

Pipe fitting: 20 Nm
8 9
RKZA0910

WB91R-2 WB93R-2 30-141

REMOVAL AND INSTALLATION FRONT WORKING EQUIPMENT CONTROL VALVE

REMOVAL OF THE FRONT WORKING EQUIPMENT

CONTROL VALVE
Lower the working equipment completely until it
rests on the ground and stop the engine and remove
the ignition wrench.
Cut off the supply of electricity by turning the accu-
mulator-disconnecting switch in a counter-clockwise
direction, and remove the handle.
Release all residual pressure in all circuits. (For de- 1
tails, see «20. TESTING AND ADJUSTMENTS»).
2
1 - Remove the grip (1) of the hand accelerator and di- 4
sengage the protective sleeves (2), (3) and (4). 3

2 - Take out the screws (5) and remove the guard (6). 6 RKZA7810

3 - Disconnect the spool control tie-rods (8) from the con-

trol valve (7).

RKZA2012

4 - Disconnect from the control valve all pipes and lines

for the actuators (9), pump delivery (10), drainage
(11), Load Sensing (12) and steering unit delivery 7 10
(13), and plug them. 12
H Mark the pipes to avoid exchanging positions du-
ring reconnection. 13

5 - Take out the four control valve retaining screws. 9

6 - Remove the control valve (7). 11

RKZA2100

INSTALLATION OF THE FRONT

WORKING EQUIPMENT CONTROL
VALVE
. To install, reverse removal procedure.
1 - Start the engine to circulate the oil, and check that
there are no leaks.
2 - Bleed the air from all circuits. (For details, see «20.
TESTING AND ADJUSTMENTS»).
3 - Stop the engine and check the oil level in the tank.

30-142 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION FRONT AXLE

REMOVAL OF THE FRONT AXLE

1 - Start the engine and force the front bucket down-

wards in order to raise the machine and the front
wheels.
2 - Place two stands «A» and some blocks beneath the
chassis.
3 - Slowly lower the machine onto the blocks, checking
that the wheels remain at least 5 cm above the
ground. A
Fully raise the front working equipment and engage
1
the safety stop. Also make the backhoe safe.
RKZA0940

4 - Engage the parking brake.

5 - Stop the engine and eliminate residual pressure from
all circuits. (See «20. TESTING AND ADJUST- 1
MENTS»).
Raise the engine hood and disconnect the cable
from accumulator negative terminal (±).
2
6 - Take off the front wheels (1).
Wheel: 65 kg
7 - Remove the front guard (2). (For details, see «REMO-
VAL OF FRONT GUARD»).
3
RKZA0591

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

9 - Disconnect the lines (5) from the steering cylinder 5

and plug them to prevent entry of impurities
10 - Disconnect the lubrication tube (6) for the axle oscilla-
tion pin (7).
5
6

4
3

RKZA0402

11 - Position a jack «B» and some blocks «C» beneath the

axle. Raise the jack until the blocks can be forced un-
der the axle arms (3). 3
H It should be possible to lower the jack 10 cm in or-
der to disengage the axle from the fulcrum sup- C
ports.

B
RKZA1670

WB91R-2 WB93R-2 30-143

REMOVAL AND INSTALLATION FRONT AXLE

12 - Take out the nut and remove the retaining screw (7)
of the axle oscillation pin (7).
13 - Screw an eyebolt into the central hole of the axle
oscillation pin (7). Extract the axle oscillation pin. 7
8

RKZA0950

14 - Lower the jack until the axle is disengaged.

15 - Extract the entire axle (3).

Front axle: 316 kg

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

Nuts for front wheels: 350w9.8 Nm

Front closing screws: 300w30 Nm

Screws on gearbox side: 70 Nm

Self-locking nuts on axle side: 70 Nm

H Bleed the air from the Load Sensing circuit. (For de-
tails, see «20. TESTING AND ADJUSTMENTS».

Axle oscillation pin - bushings: ASL800050

1 - Check the oil level in the tank and start the engine.
2 - Perform a few complete steering manoeuvres in both
directions to bleed the air from the steering circuit.

30-144 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION FRONT AXLE

DISASSEMBLY OF FRONT AXLE

1. Final Drive
1 - Remove the screws (1) that secure the planetary car- 1 3
rier (2).

RKZA2460

2 - Use a puller to remove the shoulder studs (3).

3
RKZA2470

3 - Use a plastic mallet to separate the complete planeta-

ry carrier (2) from the axle and remove it.

RKZA2480

4 - Remove the snap ring (4).

RKZA2490

WB91R-2 WB93R-2 30-145

REMOVAL AND INSTALLATION FRONT AXLE

5 - Remove the pinion (5) and the spacer (6).

RKZA2500

6 - Remove the screws (7) that secure the complete ring

bevel gear group (8).
7
8

RKZA2510

7 - Screw two M10 screws into the threaded holes of the

planetary carrier (8). Act on these two screws alterna-
tely until the entire bevel ring gear group (8) has been
extracted, complete with the centering bushings.
8

RKZA2520

8 - Use a puller to remove the hub (9) and outer bearing

(10) from the swivel housing.
9

10

RKZA2530

30-146 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION FRONT AXLE

9 - Use two levers to remove the inner bearing (11).

H Take great care not to damage the bearing.
11

RKZA2540

10 - Remove the snap ring (12) that secures the planetary

carrier. Remove the planetary carrier (13).
12

13

RKZA2550

11 - Remove the snap rings (14) and lift out the planetary
gear retainer (15).
14 15

14

RKZA2560

12 - Remove the complete planetary gears (16) together

with the lower retainer (17) and the roller bearings
(18). 18
16

17
RKZA2570

WB91R-2 WB93R-2 30-147

REMOVAL AND INSTALLATION FRONT AXLE

Only where necessary

13 - Remove the outer retainers (10) and (11) and the seal
ring (19) from the wheel hub (9).
9
19

RKZA2580

16
18 14
17

1 15 19
6
11
5

2
10
12

3
8
9

13

RKZ02000
7

30-148 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION FRONT AXLE

2. Removal of the swivel housing

H Remove the final drive. (For details, see previous pa-
ragraph). 11
1 - Remove the inner bearing (11).
H Take great care not to damage the bearing.

RKZA2540

2 - Loosen the nut (20) on the ball joint (21), but do not
remove it. 21
Use a puller to detach the joint (21) from the swivel
20
housing (22). 22

RKZA2590

3 - Remove the nut (20) and detach the ball joint (21)
from the swivel housing (22). 21

22

RKZA2600

4 - Remove the screws (23) that secure the upper (24)

and lower (25) knuckle pins.

23 24

RKZA2610

WB91R-2 WB93R-2 30-149

REMOVAL AND INSTALLATION FRONT AXLE

5 - Use two levers to remove first the upper knuckle pin

(24) and then the lower knuckle pin (25).

24

RKZA2620

6 - Remove the Belleville washer (26), the upper ball joint

washer (27) and the Belleville washer (28) of the lower 24
ball joint.
26

27

28 25

RKZ02880

7 - Remove the swivel housing (22) and extract the axle

shaft (29).
22

29

RKZA2630

8 - Use a puller to remove the upper bushing (30) and

the spherical seating of the lower bushing (31).

30

RKZA2640

30-150 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION FRONT AXLE

9 - Use a puller to remove the seal ring (33) and the bus-
32 34
hing (34) from the axle body (32).
33

RKZA2650

10 - Use a puller to remove the seal ring (35) from the swi-
vel housing (22).

35

RKZA2660

11 - Place the swivel housing (22) beneath a press and ex-

tract the bushing (36).

22

RKZA2670

Only where necessary

12 - Using an extremely sharp chisel, partially remove the
spherical bushing (37) from the lower knuckle pin
(25). 37
Complete the extraction of the bushing (37) using a
separator and a press. 25
37

RKZA3610

WB91R-2 WB93R-2 30-151

REMOVAL AND INSTALLATION FRONT AXLE

26
27

30
21
29
23
32
35
24
31 22
37
34
28 33 36

20

25
23
RKZ02020

3. Dismantling the universal joint

1 - Remove the four snap rings (38).
38
29

RKZA2680

2 - Position the joint (29) on a «V»-shaped block beneath

a press.
29
With the appropriate plunger, press the lower bearing
cover (39) down until it rests on the «V»-shaped block.

39
RKZA2690

30-152 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION FRONT AXLE

3 - Place the bearing cover (39) in a vise and use a cop-

per mallet to extract the joint (29) from the bearing co- 29
ver.

RKZA2700

4 - Reposition the joint (29) upside down on the «V»-sha-

ped block and press the second bearing cover (39).

39
RKZA2710

5 - Remove the fork (40) or (41) complete with cross-jour-

nal (42).
Remove the second bearing cover from the joint follo-
wing the same procedure described under point 3
above. 42

RKZA2720

6 - Position the fork complete with cross-journal (42) be-

neath the press and remove in sequence the first bea-
ring cover, the cross-journal and the second bearing
cover.
H Follow the procedures described in points 2 and
3.
42

RKZA2730

WB91R-2 WB93R-2 30-153

REMOVAL AND INSTALLATION FRONT AXLE

4. Removal and dismantling of the differential

group 21
20
H Perform the same operations for both final drive
groups. 22
1 - Loosen the nut (20) of the ball joint (21) but do not ta-
ke it out.
Use a puller to extract the joint (21) from the swivel
housing (22).

RKZA2590

2 - Put a sling round the final drive group (43) as shown,

and attach it to a hoisting tackle. 43
Remove the screws (23) of the knuckle pins (24) and
(25). Remove the nut (20) and detach the ball joint
25
(21) from the swivel housing (22).
23

RKZA2740

3 - Remove the upper (24) and lower (25) knuckle pins to-
gether with their Belleville washers and shims.
H Make a note of the assembly sequence and the
arrangement.

25
RKZA2750

4 - Remove the final drive group (43) complete with the

axle shaft (29).
43
29

RKZA2760

30-154 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION FRONT AXLE

5 - Loosen and remove the RH tie-rod (44).

44

RKZA2770

6 - Loosen and remove the screws (45) that secure the

steering cylinder (46). 46
Use a plastic mallet to remove the cylinder (46). 45

RKZA2780

7 - Loosen and remove the screws (47) that secure the

differential group (48).
48

47

RKZA2790

8 - Put a sling around the differential group (48) and lift it

off with the help of a lever.
Place the differential group on a work-bench for re-
pairs.

48

RKZA2800

WB91R-2 WB93R-2 30-155

REMOVAL AND INSTALLATION FRONT AXLE

9 - Hold the bevel pinion (49) steady and measure the

clearance of the ring bevel gear with a centesimal
comparator.
H Make a note of the value measured.

49

RKZA2810

10 - Make a mark on the bearing support (50) on the ring

bevel gear side and remove the screws (51) and the
lock nut retainers (52).
51

52 54

50

RKZA2820

11 - Loosen the screws (53) that secure the bearing co-

vers (50) and (54).
54
53

RKZA2830

12 - Use the tool F1 to loosen the clearance adjustment

lock nuts (55).

55

F1

RKZA2840

30-156 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION FRONT AXLE

13 - Take out the screws (53) and remove the bearing co-
vers (50) and (54). 53
50

54

RKZA2850

14 - Remove the differential (56) complete with adjust-

ment lock nuts (55) and the bearings (57). Remove 56 57
the outer rings from the bearings.
57 55

55

RKZA2860

15 - Loosen and remove the screws (58) that secure the

ring bevel gear (59).

57
59 58

RKZA2870

16 - Remove the ring bevel gear (59).

59

RKZA2880

WB91R-2 WB93R-2 30-157

REMOVAL AND INSTALLATION FRONT AXLE

17 - Separate the two half boxes of the differential.

H Mark the two half boxes for re-assembly.

RKZA2890

18 - Take out the thrush washer (60) and the differential

gear (61).

60

61

RKZA2900

19 - Take out the planetary gear group (62) complete with

pin (63) and shims (64). 64 62
63

RKZA2910

20 - Take out the second differential gear (65).

65

RKZA2920

30-158 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION FRONT AXLE

21 - Take out the thrush washer (66).

66

RKZA2930

22 - Use a separator and a press to remove the bearings

(57) from the half boxes.

44

46

45

21 23

24

53 22
50
55
57 59
56 29
60 64
20
54
53
58
65
43
62
51 25
61 52 23
63
49
55
66
64
48 56
47 RKZ02030
57

WB91R-2 WB93R-2 30-159

REMOVAL AND INSTALLATION FRONT AXLE

5. Removal of the bevel pinion

1 - Remove the cover (67).

67

RKZA2940

2 - Use a narrow-bladed chisel to remove the lock nut

(68) caulking from the bevel pinion well.
H Take great care not to damage the pinion threa-
ding. 68

RKZA2950

3 - Use tools F2 and F3 to remove the lock nut (68).

F3
F2

RKZA2960

4 - Remove the tabbed washer (69) of the lock nut (68).

69

RKZA2970

30-160 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION FRONT AXLE

5 - Use a soft mallet to extract the bevel pinion from the

outer bearing (70).

70

RKZA2980

6 - Remove from the pinion (71) the washer (72), the spa-
cer (73) and the second washer (74).
The spacer (73) cannot be used again, and must 71
be replaced by a new one every time it is di- 72
smantled.

73
74

RKZA2990

7 - Place the pinion (71) beneath a press and use a sepa-

rator to remove the inner bearing (75).

71

75

RKZA3000

8 - Remove the shim (76) from the pinion (71).

71

76

RKZA3010

WB91R-2 WB93R-2 30-161

REMOVAL AND INSTALLATION FRONT AXLE

Only if the bearings need replacing

9 - Remove the differential support (77), and the outer
bearing-rings (70) and (75).

77

RKZA3020

10 - Remove the seal ring (78) and the O-ring (79) from the
cover (67).

79 67

78

RKZA3030

30-162 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION FRONT AXLE

ASSEMBLY OF FRONT AXLE

1. Re-assembly of the bevel pinion
1 - Using the tool F4, insert the outer retainers of the pi- F4
nion bearings (70) and (75).

75

RKZA3040

2 - Mount into the differential support (77) the bearings

(70) and (75), the gauge block F5, with the lock nut
77
(68), the gauge tube F6, and the lock nuts F7.
In order to pre-load the bearings (70) and (75) tighten
the lock nut (68) until the pinion becomes hard to turn. F7
F7

F6 F5
68
RKZ01790

3 - Mount the bearing covers (50) and (54) and tighten

the screws (53) uniformly until the lock nuts F7 are 53 50
held fast.
54

F7

RKZ01800

4 - Use a deep calliper to take the measurement «B» bet-

ween the gauge tube F6, and the surface inside the
gauge F5.
H Write down the «B» measurement.

F5

RKZ01810

WB91R-2 WB93R-2 30-163

REMOVAL AND INSTALLATION FRONT AXLE

5 - Make a note of the value «N» marked on the head of

the pinion (71).
Calculate the thickness «S» to be installed beneath
the pinion, using the formula:
S=B±N
H «S» is the thickness of the shim (76).

71
RKZA3050

6 - Dismantle the special tools and remove the bearings

(70) and (75) from the differential support (77).
77

75

F7
RKZ01791

7 - Mount the shim (76) onto the pinion (71) and press
the inner bearing (75) using the tool F8.
F8
H The chamfer on the inner diameter of the shim
must face the toothing.
75

71

76

RKZA3060

8 - Mount onto the pinion the first washer (74), the new
spacer (73) and the second washer (72).
71
72

73
74

RKZA2990

30-164 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION FRONT AXLE

9 - Lubricate the bearings with gear oil. Mount the pinion 77

group (71) into the differential support (77) and posi-
tion the outer bearing (70).

70

71
RKZA3070

10 - Mount the tabbed washer (69) and the lock nut (68).

69

68

RKZA3080

11 - Use the tools F2 and F3 to tighten the lock nut (68) a

little at a time until the clearance is eliminated and the
bearings are slightly pre-loaded.
H Rotate the gauge tube by a few turns between
one lock nut tightening increment and the next.

F3

F2

RKZ01820

12 - Wind a wire line round the pinion (71), uniformly and

without overlapping. Connect it to a dynamometer
and check the force «P» required to rotate the shaft.
The force should be that needed for continual ro-
tation. Do not take into consideration the thrust
force.

71
P
RKZ01830

WB91R-2 WB93R-2 30-165

REMOVAL AND INSTALLATION FRONT AXLE

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

nut (68) taking dynamometric measurements at inter-
vals until the indicated force «P» has been obtained.
H If the maximum permissible value is exceeded, a
new spacer must be fitted and all the bearing pre-
loading operations must be repeated. P=(9.2 ± 13.7) daN
(1 daN=10N)

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

caulk the lip of the lock nut (68) to correspond to 71
the well of the pinion (71).

68
RKZA3090

15 - Mount the seal ring (78) and the O-ring (79) in the co-
ver (67).

78
79

67

RKZA3100

16 - Lubricate the O-ring (79) and the seal ring (78) and
use the tool F9 to mount the cover (67).

F9

67
RKZA3110

30-166 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION FRONT AXLE

2. Re-assembling and mounting the differential

1 - Using the tool F10, mount the bearings (57) on the F10
two half boxes.
H All the components parts of the differential must
be lubricated with oil beforehand. 57
H Thoroughly decrease the threaded holes in the
half box.

RKZA3120

2 - Mount the thrust washer (66) and the planetary gear

(65) in the half box with the threaded holes.

66 65
RKZA3130

3 - Mount the bevel gears (81) and the spherical shim

washers (64) on the pinion (80). 81
81 80

64
64 RKZA3140

4 - Mount the pin (63) and the complete bevel gear group
in the half box (82).
63

82
RKZA2911

WB91R-2 WB93R-2 30-167

REMOVAL AND INSTALLATION FRONT AXLE

5 - Coat the threaded holes of the half box (82) with Loc-
tite.
Holes: Loctite 270

82

RKZA3150

6 - Mount the second differential gear (61).

61

RKZA3160

7 - Mount the thrust washer (60) in the other half box.

60

83

RKZA3170

8 - Assemble the two half boxes (82) and (83).

H Respect the markings.

83

82

RKZA2891

30-168 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION FRONT AXLE

9 - Make sure that the surfaces are perfectly clean and

mount the toothed ring gear (59).
59

RKZA2880

10 - Place the group beneath a press to stop it rotating.

Place the screws (58) in the holes and tighten them
employing the crosswise alternate method.
56

Screws: 95 Nm

RKZA3180

11 - Position the assembled differential group in the diffe-

rential support (77).
H The toothed ring gear should face the markings
on the support.
H Lubricate the bearings with gear oil.

77

RKZA3190

12 - Mount the outer retainers (57).

57

RKZA3200

WB91R-2 WB93R-2 30-169

REMOVAL AND INSTALLATION FRONT AXLE

13 - Mount the bearing covers (50) and (54).

53
H Respect the markings made while dismantling. 54
Mount the screws (53).
50

RKZA3210

14 - Tighten the screws (53) as much as is necessary to

hold in position and catch the outer bearing lock nuts.
53

RKZA3220

15 - Screw down the adjustment lock nuts (55) and tigh-

ten them, taking care to leave some clearance bet-
ween the pinion and the ring bevel gear. Use the tool
F1 to tighten the lock nuts (55).
55

F1

RKZA3230

16 - Position a centesimal comparator and measure the

clearance at four points at 90ë.
H If differences are found, adjust the clearance whe-
re the measurement is lower.
H Clearance limit: 0.17 ± 0.23 mm
H If neither the pinion nor the ring bevel gear have
been substituted, the clearance should be the sa-
me as that measured when dismantling.

RKZA2811

30-170 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION FRONT AXLE

17 - To increase the clearance, loosen the lock nut on the

ring bevel gear side by one notch and tighten the op-
posite lock nut by one notch. To decrease the clea-
rance, reverse these actions.
H Before measuring the clearance, knock lightly on
the bearing covers with a mallet to ensure that
they are securely positioned.

RKZA3240

18 - When the clearance between pinion and ring bevel

gear is correct, tighten the screws (53) of the bearing
covers (50) and (54) until the adjustment lock nuts 53 54
(55) are locked.
H Final tightening should be performed after the fol-
lowing checks. 55

50
RKZA3250

19 - Using the same method employed to check the pinion

rotation torque, check the force «T» required to rotate
the entire group.
H Force required:
T=(P+3.9) ± (P+5.9) daN
(P=the force found for the pinion)
H The force should be that of continual rotation. Do
not take the thrust force into consideration.

T
RKZ01831

20 - If the force is not within permissible limits:

a - Tighten both the lock nuts to the same extent to
increase the force «T».
b - Loosen both the lock nuts to the same extent to
decrease the force «T».
The clearance between the ring bevel gear and
the pinion must remain within permissible limits.

WB91R-2 WB93R-2 30-171

REMOVAL AND INSTALLATION FRONT AXLE

21 - Check the centering of the contact area using the fol-

lowing procedure:
a -Coat both surfaces of the teeth of the ring bevel
gear with a marking substance.
b -Rotate the pinion.
If the contact area is excessive near to the edge of the
teeth, the ring bevel gear must be brought closer to
the pinion.
If the contact area is excessive on the side of the
teeth, the ring bevel gear must be moved away from
the pinion.
When moving the ring bevel gear away from the RKZ01840

pinion, the lock nuts must be turned to an equal

extent in the opposite direction.

RKZ01850

22 - Give the screws (53) a final tightening.

Screws: 266 Nm
53

RKZA3251

23 - Mount the lock nut retainers (52) and secure them

with the screws (51). 51
Screws: 13 Nm

52

RKZA3260

30-172 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION FRONT AXLE

24 - Coat the supporting surface and install the differential

group (48).
Surface: Loctite 510

48

RKZA3270

25 - Secure the group (48) with the screws (47).

Screws: 169 Nm
48
H Tighten the screws employing the crosswise alter-
nate method.

47

RKZA2790

26 - Mount the steering cylinder (46).

46

RKZA3280

27 - Secure the cylinder (46) with the screws (45).

46
Screws: 120 Nm 45

RKZA3290

WB91R-2 WB93R-2 30-173

REMOVAL AND INSTALLATION FRONT AXLE

28 - Connect and tighten the RH tie-rod (44).

44
Tie-rod: 300 Nm

RKZA3300

29 - Install the final drive group (43) complete with the axle
shaft (29).
43
H Take great care not to damage the seal ring inside
the axle body. 29
H The assistance of a second person may be requi-
red to rotate the pinion.

RKZA2760

30 - Mount the knuckle pins (24) and (25), the shim (27),
the Belleville washers (26) and (28) and the self-loc-
king screws (23).
H For details, see «4. Installation of the swivel hou-
sing».
25

23

RKZA3310

31 - Connect the ball joint (21) to the swivel housing (22)

and mount the nut (20). 21
22

RKZA3320

30-174 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION FRONT AXLE

32 - Secure the knuckle pins with the screws (23). 20

Screws: 190 Nm
23

RKZA3330

33 - Secure the ball joint (21) with the nut (20).

Nut: 220 Nm 21

RKZA3340

3. Assembling the universal joint

41 39
1 - Press a bearing cover (39) into a fork (41).
H Press until the cover protrudes through the fork by
6 mm.

RKZA3350

2 - Turn the fork (41) upside down, position the cross-

journal (42) by centering the bearing cover assem- 41 39
bled during phase 1.
Position the second bearing cover (39) and press it in-
to the fork.
42
H Press until the cover protrudes through the fork by
9 mm.

RKZA3360

WB91R-2 WB93R-2 30-175

REMOVAL AND INSTALLATION FRONT AXLE

3 - Raise the cross-journal (42) and, keeping it engaged

in the two bearing covers (39), press the covers into 39
the fork (41). 41

42

39

RKZA3370

4 - Using the appropriate plunger, press the bearing co-

vers (39) into the fork (41) in order to mount the snap 38
rings (38).
Mount the snap rings.

39
41
RKZA3380

5 - Use a «V»-shaped block to support the joint (84) and

press a bearing cover until it is flush with the outer 84
diameter of the joint (84).

RKZA3390

6 - Turn the joint (84) upside down and position the

cross-journal (42) by centering the bearing cover 84
mounted during phase 5.
Position the second bearing cover and press it into 42
the joint until it protrudes by 6 mm.

RKZA3400

30-176 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION FRONT AXLE

7 - Raise the cross-journal (42) and, holding it steady in 39

the two bearing covers (39), press the covers into
the joint. 42

RKZA3410

8 - Using the appropriate plunger, press the bearing co-

vers (39) into the joint (84) in order to mount the snap
rings (38). 39 84
Mount the snap rings.
38

RKZA3420

4. Installation of the swivel housing

F11 32
1 - Use the tool F11 to mount the bushings (34) and (36)
in the axle body (32) and in the swivel housing (22).
Insert it to protrude 8 mm beyond the edge of the hole
of the axle body and 4 mm beyond the edge of the ho-
le of the swivel housing.
Use the tool F12 to mount the seal rings (33) and (35)
of the axle body (32) and of the swivel housing (22).
H Check the direction of assembly of the seal rings.

RKZA3430

2 - Use the tool F13 to push the upper bushing (30) ho-
me in the axle body.
With the tools F13 and F14, insert the lower bushing
(37).
F13

30

RKZA3440

WB91R-2 WB93R-2 30-177

REMOVAL AND INSTALLATION FRONT AXLE

3 - Install the axle shaft (29).

29
H Take great care not to damage the seal ring (33).

RKZA3450

4 - Install the swivel housing (22).

H Take great care not to damage the seal ring (35). 22

RKZA3620

5 - Mount the shim (27), the Belleville washer (26), the

upper knuckle pin (24) and the self-locking screws
(23). 23

24

RKZA3460

6 - Tighten the screws (23) to secure the knuckle pin

(24). 23
Screws: 190 Nm

24

RKZA3470

30-178 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION FRONT AXLE

7 - Install the lower knuckle pin (25), the Belleville wash-

er (28) and the self-locking screws (23).
H If the spherical swivel housing has been removed,
use a press to mount the new swivel housing be-
fore installing the knuckle pin (25).

25

RKZA3480

8 - Tighten the screws (23) to secure the knuckle pin

(24).
Screws: 190 Nm

25

23
RKZA3490

9 - Engage the ball joint (21) and tighten the nut (20) to
hold it in place. 21
Nut: 220 Nm

RKZA3500

WB91R-2 WB93R-2 30-179

REMOVAL AND INSTALLATION FRONT AXLE

5. Assembly of the final drive

9
1 - If the retainers (10) and (11) have been removed, use F15
the tool F15 to install them in the hub (9).
H Check the orientation.

RKZA3510

2 - Use the tool F16 to install the new seal (19).

H The words «OIL SIDE» should face towards the in-
side of the hub.
H Take care not to damage the seal (19). 19

RKZA3520

3 - Coat ASL800050 grease on one side of the bevel

gears (16) and inside the hole, and install the retainer
(17).

17

16
RKZA3530

4 - Turn the bevel gears upside down (16) and insert

eighteen roller bearings (18) into each gear. 18

16
RKZA3540

30-180 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION FRONT AXLE

5 - Mount the gears (16) complete with roller bearings

(18) and ring (17) on the shafts of the planetary car- 18
riers.
H The retainer should touch the planetary carriers 16
(2).

17
RKZA2570

6 - Mount the retainer of the planetary carriers (15) and

hold it in position with snap rings (14).
14 15

14

RKZA2560

7 - Mount the ring bevel gear carrier (13) in the gear and
12
hold it in position with a snap ring (12).
13

RKZA3550

8 - Heat the internal bearing (11) to approx. 120 ëC and

mount it in the swivel housing (22). 11
H Do not heat beyond 149 ëC.

22
RKZA3560

WB91R-2 WB93R-2 30-181

REMOVAL AND INSTALLATION FRONT AXLE

9 - Lubricate the bearing (11) with oil and mount the hub
9
(9).

RKZA3570

10 - Heat the external bearing (10) to approx. 120 ëC and

mount it on the swivel housing (22).
H Do not heat beyond 149 ëC.

10

RKZA3580

11 - Mount the complete ring bevel gear (8), aligning the

holes with the bushings (85).
Use the tool F17 to push the bushings (85) home. 8
H Insert the bushings a little at a time, employing 85
the crosswise alternate method.

RKZA3590

7
12 - Insert the screws (7) and tighten them as much as 8
possible, employing the crosswise alternate method.
Screws: 230 Nm

RKZA2510

30-182 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION FRONT AXLE

13 - Mount the spacer (6) and the pinion (5) on the shaft.

RKZA2500

14 - Mount the snap ring (4).

RKZA2490

15 - Thoroughly decrease the coupling surfaces and coat

the hub surfaces with liquid sealant.
Hub: Loctite 510
Mount the complete planetary carrier (2).

RKZA3600

16 - Mount the screws (1) that secure the planetary car-

rier. 1
Screws: 80 Nm

RKZA2461

WB91R-2 WB93R-2 30-183

REMOVAL AND INSTALLATION FRONT AXLE

17 - Mount the shoulder studs (3) and tighten them.

Shoulder studs: Loctite 542
Shoulder studs: 70 Nm

3
RKZA2470

30-184 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION REAR AXLE

REMOVAL OF THE REAR AXLE

1 - Lower the backhoe outriggers (1) and force them

downwards in order to raise the rear wheels (2) by ap-
prox. .... cm.
2 - Prepare a safety stand «A», approx. 65 cm high, be-
neath the backhoe chassis. Pull up the outriggers un-
til the machine is resting on the stand «A».
3 - Stop the engine and take off the rear wheels (2). 2
1
Wheel: 163 kg
1 A
RKZA0960

4 - Start engine, remove the stand "A" and set two

stands "B" 50 cm high under the frame.
Pull up the outriggers until the machine is resting on
the stands "B".

B
RKZA1651

5 - For safety's sake, rest the backhoe bucket with its

back on the ground, keeping the arm vertical. Also
rest the front bucket on the ground.
5 - Stop the engine and completely release residual pres-
sures from all the circuits. (For details, see «20.TE-
STING AND ADJUSTMENTS»).

RKZA0970

7 - Disconnect the working brake hoses (3) and the diffe-

rential lock tube (4) from the axle. 5
H Plug the pipes to prevent entry of impurities.
8 - Disconnect the parking brake command cable (5). 3
3
9 - Disconnect the cardan shaft (6) from the rear axle.

6
4
RKZA0391

WB91R-2 WB93R-2 30-185

REMOVAL AND INSTALLATION REAR AXLE

10 - Partially loosen the self-locking nuts (8) in order to eli-

minate the tightening torque and thus facilitate sub-
sequent dismantling. 7
H Loosen the nuts in criss-cross sequence. 10

8
RKZA0980

11 - Place a jack «C» and some blocks beneath the axle

(7). Raise the jack until the blocks can be forced un- 7
der the arms of the axle.
H Leave free the nuts (8) and plates (9) that secure
the axle.
H It should be possible to lower the jack by approx.
20 cm.
12 - Remove the self-locking nuts (8), the plates (9) and
the screws (10).
12 - Lower the jack until the axle (7) is disengaged from C
the chassis. RKZA1650

13 - Extract the entire axle (7).

INSTALLATION OF THE
REAR AXLE
. To install, reverse the removal procedure.

Wheel nuts: 500w9.8 Nm

H Bleed the air from the braking circuits.

(See «20. TESTING AND ADJUSTMENTS»).

H Adjust the stroke of the parking brake lever.

(See «20. TESTING AND ADJUSTMENTS»).

Self-locking nuts on axle side: 70 Nm

Screws on gearbox side: 70 Nm

Self-locking nuts for securing axle: 570 Nm

H Tighten in two stages, using the criss-cross me-

thod.
1 - Check the level in the tank and start the engine.

30-186 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION REAR AXLE FINAL DRIVE

DISASSEMBLY OF REAR AXLE FINAL DRIVE

The seal rings must be replaced by new ones each
time they are dismantled.

14
13

15

25

23
22
6 11
21
23
12 4
9 20
8 3 20
7 18 24
19
9 5

10 16 1 2

17 RKZ01640

1 - Apply a stud bolt puller and remove the two shoulder 1

studs (1) that secure the planetary carrier (2). 2

RKZA3630

2 - Remove the two screws (3) that secure the planetary

carrier (2).
2

RKZA3640

WB91R-2 WB93R-2 30-187

REMOVAL AND INSTALLATION REAR AXLE FINAL DRIVE

3 - Remove the planetary carrier (2) and the half-axles 2

(4).

RKZA3650

4 - Loosen and take out the eight screws (5).

RKZA3660

5 - Screw into two threaded holes in the planetary carrier

(6) the two screws (5) removed in the preceding pha-
se. 5
Tighten the screws alternately in order to extract the
ring bevel gear group (6) from the bushings (7).
H If extraction proves difficult, use four screws (5).
6

RKZA3670

6 - Remove the complete planetary group (6).

6

RKZA3680

30-188 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION REAR AXLE FINAL DRIVE

7 - Remove the outer snap ring (9).

RKZA3690

8 - Remove the planetary carrier (8) and the inner snap

ring (9).
8 9

RKZA3700

9 - Using a plunger with appropriate guide, extract the

bushings (7) from the planetary carrier.

7
8

RKZA3710

10 - Use a plastic mallet to strike some blows all round the

circumference of the wheel hub (11) in order to loosen
the outer bearing (12). 11

12

RKZA3720

WB91R-2 WB93R-2 30-189

REMOVAL AND INSTALLATION REAR AXLE FINAL DRIVE

11 - Remove the outer bearing (12).

12

RKZA3730

12 - Remove the wheel hub (11).

11

RKZA3740

13 - Remove the inner bearing (13).

H If necessary use a puller. 13
13

RKZA3750

14 - Use a puller to remove the seal ring (14).

14

RKZA3760

30-190 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION REAR AXLE FINAL DRIVE

15 - Use a puller to remove the bronze bushing (15).

15

RKZA3770

16 - Remove the screws (16) and then the cover (17) from
the planetary carrier (2). 2

17

16

RKZ01860

17 - Place the planetary carrier (2) beneath a press and,

using an appropriate plunger, remove the shaft (18),
complete with O-ring (19). 2

18

19
RKZA3780

18 - Beneath the planetary carrier (2) place a container in

which to catch the roller bearings (20) and the retai- 2
ner (21). Take out the bevel gear (22) and the upper
and lower shims (23).
H Repeat these last two operations for all the plane-
tary gears.
23

22

RKZA3790

WB91R-2 WB93R-2 30-191

REMOVAL AND INSTALLATION REAR AXLE FINAL DRIVE

19 - Only if substitution is necessary.

Remove the shim (24).

24

RKZA3800

20 - Use a puller to remove the seal ring (25) from the

wheel hub (11).

11

RKZA3810

21 - If the bearings (12) and (13) need replacing, remove

the outer rings from the wheel hub (11).

11

RKZA3820

NOTE.
1 - Thoroughly clean all parts with a light solvent.
2 - Throw away all seals and O-rings.
3 - Carefully check bearings, bushings, gears and
half-axles. If any pitting, scratching, flattened
areas, general wear and tear or any other damage
is found, replace the parts.

30-192 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION REAR AXLE FINAL DRIVE

ASSEMBLY OF REAR AXLE FINAL DRIVE

1 - Mount the outer rings of the bearings (12) and (13) in

the wheel hub (11). 11
(Use a universal tool for bearing rings, or any other
suitable tool).
H Check the orientation.

RKZA3830

2 - Use tools G1 and G2 to mount the seal ring (25) in the

wheel hub (11).
H The side on which is written «OIL SIDE» should fa-
ce towards the inside of the wheel hub.
H The seal ring (25) must rest on the shoulder. Any
further pressure might damage the ring. G2
G1

11

RKZA3840

3 - Only if the shim has been moved

Press the shim (24) into the seating of the planetary
carrier (2).

24

RKZA3800

4 - Coat the hole and the shim part of the gears (22) with
a layer of ASL800050 grease and place a shim (23) in
position.
H Make sure that the shim (23) has adhered to the
gear (22). 23

22

RKZA3850

WB91R-2 WB93R-2 30-193

REMOVAL AND INSTALLATION REAR AXLE FINAL DRIVE

5 - Turn the planetary gear (22) upside down and mount

the first set of roller bearings (20) in the hole. 20
Mount the bearing ring (21), coat the upper part and
the shim surface with ASL800050.
23
Mount the second set of roller bearings (20) and the
shim (23).
H Make sure that the roller bearings have adhered
to the hole. 22

RKZA5260

6 - Place the planetary gear group (22) in the planetary

carrier (2), using the pin (18) to align the holes. 2
H Make sure that the shim holes (23) are correctly
aligned.

22

RKZA5270

7 - Mount the new O-ring (19) on the pin (18).

Lubricate the pin (18) and the O-ring (19) with oil and
mount them in the planetary carrier (2), centering the
pinion group (22) and the shims (23).
Press the pin completely home. 18

19

RKZA5720

8 - Mount the cover (17) on the planetary carrier (2) and

secure it with the screws (16). 2
Screw: 23 Nm
Cover: Loctite 518
17

16

RKZ01860

30-194 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION REAR AXLE FINAL DRIVE

9 - Lubricate the bronze bushing (15) with oil and use the
tool G3 to mount the bushing in the arm.
H Insert it to the point where the tool makes contact
with the shoulder. 15

G3
RKZA3860

10 - Lubricate the ring (14) with oil and use the tool G4 to
mount the ring in the arm.
H Check the orientation.
H Insert it to the point where the tool makes contact 14
with the arm.

G4
RKZA3870

11 - Lubricate the inside of the bearing (13) with oil and

use a punch and hammer to knock it home on the
shoulder of the arm. 13
H Strike light blows round the entire circumference.

RKZA3880

12 - With a solution of 50% white spirit and 50% water,

clean the sealing edge of the ring seal (25) of the 11
hub (11) and the sealing area of the axle in order to
remove all traces of lubricant.
H Mount the hub.
Do not oil the sealing area of the ring (25).

RKZA3740

WB91R-2 WB93R-2 30-195

REMOVAL AND INSTALLATION REAR AXLE FINAL DRIVE

13 - Lubricate with oil the inside of the bearing (12) and

mount it on the arm. 12
Use a punch and hammer to knock the bearing home.
H Strike lightly over the entire circumference.

RKZA3890

14 - Use the tool G5 to mount the pilot bosses (7) in the

ring bevel gear carrier disc (8).

7 8
G5

RKZA3900

15 - Mount the inner snap ring (9) in the ring bevel gear
(10).

10
RKZA3910

16 - Install the ring bevel gear carrier disc (8) and the ou-
ter snap ring (9).
8

9
RKZA3920

30-196 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION REAR AXLE FINAL DRIVE

17 - Install the complete ring bevel gear group (6) and use
the screws (5) to hold it in position.
Tighten the screws, employing the alternating cros- 6
swise method, until the ring bevel gear carrier rests
on the arm.
Carry out the final tightening.
Screws: 230 Nm

5
RKZA3930

18 - Install the axle shafts (4) by engaging them in the in-

ner joint.
H Take great care not to damage the seal ring (14).

4
RKZA3940

19 - Apply an unbroken trace of sealant around the hub

flange (11) inside the line of stud bolts and threaded
holes.
Flange: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

RKZA3950

20 - Install the complete planetary carrier group (2) on the

hub (11). 2 11
H Rotate the group (11) in both directions to facilita-
te the engagement of the gears.

RKZA3651

WB91R-2 WB93R-2 30-197

REMOVAL AND INSTALLATION REAR AXLE FINAL DRIVE

21 - Mount the two screws (3) and secure the planetary

carrier (2).
Screws: 80 Nm 1

22 - Partially insert the shoulder studs (1). Screw in and

lock two nuts M22x15, and fully tighten the studs (1).
Stud bolts: 70 Nm
Stud bolts: Loctite . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3

2
RKZA3960

30-198 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION REAR AXLE

DISASSEMBLY OF REAR AXLE

1. Removal of the axle arms
Seal rings must be changed each time they are di-
smantled.

30
29
29
32 30 27

26
36
31

28
33
35 36

32
34
RKZ01650

1 - Loosen and remove the breather-pipe assembly.

Make a reference mark on the hexagonal-head screw
of the pipe (26) to correspond to the grooving.
H Detach the vent plug (27) from the pipe (26) only if 27
it needs replacing.

26

RKZA3970

2 - Attach the complete arm group to some hoisting tack-

le.

RKZA3980

WB91R-2 WB93R-2 30-199

REMOVAL AND INSTALLATION REAR AXLE

3 - Make a mark on the central body (28), the brake cylin- 28

ders (29) and the seatings of the brake disks (30), to 29 29
prevent exchanges during re-assembly. 30
30

RKZA3990

4 - Loosen and remove the screws (31), with the excep-

tion of the top screw.
Slowly loosen the remaining top screw, adjust the hoi-
sting cable to balance the axle arm (32) and take out
the last screw (31). 31
32

RKZA4000

5 - Keep the axle arm (32) level and separate it from the
brake group (30).
30
32

RKZA4010

6 - Remove the joint (33) complete with snap ring (35)

and extract the half axle (34) from the central body
(28).
H Throw away the O-ring seal (36).

34
RKZA4020

30-200 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION REAR AXLE

2. Removal of the brake cylinder and disk seatings

44 47

45 48
46
39 37

38

40

38
40
49
41
42
29
RKZ01660

1 - Remove the outer reaction plate (37).

37

RKZA4030

2 - Remove the clutch plate (38).

38

RKZA4040

WB91R-2 WB93R-2 30-201

REMOVAL AND INSTALLATION REAR AXLE

3 - Remove the sleeve (39) and the remaining clutch

group (intermediate reaction plate (40) and the clutch 41
plate (41).
H The internal reaction plate (42) remains in its sea- 39
ting on the cylinder (43).
H Continue dismantling the 2nd brake disc (38) and
the 2nd reaction plate (40), following the previou-
sly-described procedures.

RKZA4050

4 - Remove the oil-recirculation pipe (44), complete with

O-ring (45).

45
44
45

RKZ01870

5 -Push two supporting pins "A" into the two upper holes
and remove the screws (46). 46
A

43

RKZA4060

6 - Remove the seatings (47) of the clutch plates.

47

RKZA4070

30-202 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION REAR AXLE

7 - Remove the O-ring (48) and the braking cylinder

group (29) complete with O-ring (49).
29

RKZA4080

3. Braking cylinder
56
57
48 59
66
42 60
54
52 61
53
55 58
51 69

62
79
64 77
65 63 76
75
50
80
81
78 82
68
83
73 67
74
72
71
70 29 49 RKZ01700

1 - Loosen and remove the screws (50) and remove the

flange (51).
50

51

RKZA4090

WB91R-2 WB93R-2 30-203

REMOVAL AND INSTALLATION REAR AXLE

2 - Remove the complete internal reaction plate (42).

H The isolator ring (52) and the piston could fall and
be damaged. 42

RKZA4100

3 - Remove the isolator ring (52).

52

RKZA4110

4 - Screw three screws "B" into the holes in the piston

(53) and, using a screwdriver as a lever, remove the
piston (53). 53

RKZA4120

5 - Remove the external O-ring (54) and the internal O-ring

(55) from the piston (53).

53

55

54

RKZA4130

30-204 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION REAR AXLE

6 - Remove the screw (56) and the washer (57).

56

57

RKZA4140

7 - Mark the position between the shaft (58) and the lever
(59).
Use a mallet to raise the lever (59) until a rotation is
59 60
obtained that cancels out the action of the spring (60).

RKZA4150

8 - Remove the lever (59), and spring (60) and the spacer
(61).

60

61

RKZA4160

9 - Remove the retaining screws (62) of the support (63).

62 63

RKZA4170

WB91R-2 WB93R-2 30-205

REMOVAL AND INSTALLATION REAR AXLE

10 - Remove the support (63) complete with adjustment

screws (64) and nut (65) and the O-ring seal (66).
63
66

RKZA4180

11 - Use a lever to raise the cam (67) to cancel out the ac-
tion of the spring (68). Apply a pair of self-locking
58
pliers to hold the shaft (58) in position.
H Take care not to damage the shaft (58).

67

RKZA4190

12 - Mark on the cam (67) its position in relation to the

screw (69).
Remove the screw (69). 67

69

RKZA4200

13 - Remove the shaft (58), the cam (67) and the spring
(68).
68

67

RKZA4210

30-206 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION REAR AXLE

14 - On the shaft (58) trace a alignment sign between the

cam (67) and the screw hole (69).
58

67

RKZA4220

15 - Loosen the screws (70) to release the action of the pi-

ston return springs.

70

RKZA4230

16 - Remove the screws (70), then remove the spring re-

tainers (71), the centering bushings (72), the internal
springs (73) and external springs (74).

74
73
71
70

RKZA4240

17 - Loosen and remove the screws (75), the washers (76)

and the centering bushings (77).

77
76
75

RKZA4250

WB91R-2 WB93R-2 30-207

REMOVAL AND INSTALLATION REAR AXLE

18 - Remove the flange (78).

78

RKZA4260

19 - Remove from the cylinder the slack adjuster bushings

(79).
H Be very careful because the bushings (79) are
compressed.

79
RKZA4270

20 - Remove the air bleeder screw (80).

80

RKZA4280

H The following operations are only to be carried out if

the differential bearings and pinion or the bevel gear
pair need to be replaced.
82

21 - Loosen and take out the screw (81) and remove the
stop (82) of the adjustment lock nut (83). 81

83
RKZA4290

30-208 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION REAR AXLE

22 - Use the tool G6 to remove the adjustment lock nut

(83). 83

G6

RKZA4300

23 - Use a plunger to remove the outer ring (104) of the

differential bearing.
104

RKZA4310

WB91R-2 WB93R-2 30-209

REMOVAL AND INSTALLATION REAR AXLE

4. Dismantling the differential locking group

84
85

99
94
95

97 96
98
93 91

97
92
90 87
89
88
86

RKZ01690

H Remove the axle arms and the braking groups. (For

details, see «2. Removal of brake cylinders»).
1 - Loosen and take out the screws (84) and the remove
the complete cylinder (85).

84

85
RKZA4320

2 - Slowly and alternately loosen the screws (86) until the

action of the spring (87) has been cancelled.
Take out the screws (86), the cover (88) complete with
the O-ring (89) and the spring (87).
88

86 87

RKZA4330

30-210 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION REAR AXLE

3 - Move the complete differential in such a way as to de-

tach it from the fork (91).
Extract the differential from the ring bevel gear side.

91
RKZA4340

4 - Remove the complete fork group (90) from the central

housing.

90

RKZA4350

5 - Compress the spring (93) and remove the snap ring

(94) and the spacer (95). Take out the spacer (92).
92
93
94

95

RKZA4360

6 - Remove the spring (93) and slide the shaft (96), com-
plete with snap ring (97) out of the fork (91).
91 97
93 96 91

RKZA4370

WB91R-2 WB93R-2 30-211

REMOVAL AND INSTALLATION REAR AXLE

7 - Remove from the cylinder (85) the O-ring (97) and the 85
85
piston (98) complete with O-rings (99).
Take out the O-rings (99).

99

97 98
RKZA4380

5. Dismantling the differential

112
111
112
109

111
112 113
114
115
106
104 110
116
101 111
100 102
103 112
104
102

107
108
102
103
102 105
RKZ01670

1 - Push the differential lock ring (100) downwards and

remove the snap ring (101).

101

100

RKZA4390

30-212 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION REAR AXLE

2 - Remove the lock ring (100), the pegs (102) and the
springs (103) from the differential.

103
102

100

RKZA4400

3 - Use a puller to remove the bearings (104) from the dif-

ferential.

104

RKZA4410

4 - Remove the screws (105) that secure the ring bevel

gear (106).
105
106

RKZA4420

5 - Turn the differential upside down and remove the ring

bevel gear (106).
H Use a plastic mallet to strike blows all round the
circumference.

106

RKZA4430

WB91R-2 WB93R-2 30-213

REMOVAL AND INSTALLATION REAR AXLE

6 - Remove the differential half box (107) on the locking

side.
H The differential half boxes are both marked to fa-
cilitate re-assembly.

107

RKZA4440

7 - Remove the thrust washer (108) and the differential

gear (109).

108

109

RKZA4450

8 - Remove the shafts (110) that form the cross journal,

the bevel gears (111) and the spherical thrust wash-
ers (112).

110

112
RKZA4460

9 - Remove the second differential gear (113) and its

shim (114).

113
114

RKZA4470

30-214 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION REAR AXLE

10 - Take the cross journal shafts (110) to pieces by remo-

ving the bevel gears (111) and the thrust washers
(112).
111 110

112

RKZA4480

11 - Only if necessary
Extract the bushing (116) from the half box (115) on
the ring bevel gear side.

116

115

RKZA4490

WB91R-2 WB93R-2 30-215

REMOVAL AND INSTALLATION REAR AXLE

6. Dismantling the bevel pinion

123
122
120
119
118
117
28

124
125
124 121

127
126
RKZ01680

1 - Use a chisel to move the cover (117).

117

RKZA4500

2 - Use two levers on opposite sides to extract the cover

(117) complete with O-ring (118) and the seal ring 28
(119) from the central housing (28).

117

RKZA4510

30-216 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION REAR AXLE

3 - Use a chisel to raise the caulked area of the lock nut

(120) from the pinion grooving (121).

120
121
RKZA4520

4 - Use the tools G7 and G8, to loosen the lock nut (120)
of the pinion (121).
G7
G8

RKZA4530

5 - Take out the lock nut (120) and the special washer
(122).

122

RKZA4540

6 - Use a puller as demonstrated in the figure to push the

pinion (121) into the central housing (28). 28

121

RKZA4550

WB91R-2 WB93R-2 30-217

REMOVAL AND INSTALLATION REAR AXLE

7 - Remove the outer bearing (123).

123
RKZA4560

8 - Remove the pinion (121) complete with washers

(124), spacer (125), inner bearing (126) and thrust
washer (127). 126
H Throw away the spacer (125), which should be re- 125 124
124
placed every time it is dismantled.

RKZA4570

9 - Take the outer bearing rings (123) and (126) out of the
central housing (28). 28

RKZA4580

10 - Apply a separator "C" and, using a press, extract the

bearing (126) and the shim (127) from the pinion
(121).
121

126

RKZA4590

30-218 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION REAR AXLE

11 - Use a puller to take the seal ring (119) out of the cover
(117). 117
119

RKZA4600

12 - Take the O-ring (118) out of the cover (117).

117

118

RKZA4610

WB91R-2 WB93R-2 30-219

REMOVAL AND INSTALLATION REAR AXLE

ASSEMBLY OF THE REAR AXLE

1. Braking cylinder
1 - Mount into the cylinder (29) the outer bearing ring
(104) of the differential. 29
H The ring (104) should lie just beneath the edge of
the hole.
104

RKZA4620

2 - Use the tool G6 to screw in the lock nut (83).

H Do not lock the lock nut at this point. 83

G6

RKZA4300

3 - Mount the air vent plug (80) in the cylinder (29).

Plug: 8 ± 12 Nm

80
29

RKZA4281

4 - Use the tool G9 to mount the bushings (79) up to the

edge of the hole.

79
G9

RKZA4630

30-220 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION REAR AXLE

5 - Mount the isolator ring (52) onto the inner reaction

plate (42). 52
42

RKZA4640

6 - Mount the outer O-ring (54) and the inner O-ring (55)
onto the piston (53).
Lubricate the O-rings with ASL800050
53

55

54

RKZA4130

7 - Position the group formed by the inner reaction plate

(42) and the isolator ring (52) on the piston (53). 52

42

53

RKZA4650

8 - Insert the flange (78) into the cylinder (29).

Place the brake seating (47) on the cylinder (29), ta-
king care that the marks coincide. 78
In order to maintain the alignment, provisionally insert
the two retaining screws of the brake seating into the
cylinder.
47

29

RKZA4660

WB91R-2 WB93R-2 30-221

REMOVAL AND INSTALLATION REAR AXLE

9 - Install the piston group (53) complete with the reac-

tion plate (42) in the brake seating and push it into
42
the cylinder (29).
H If necessary use a rubber mallet to strike blows all
round the circumference, in order to insert the pi-
ston into the cylinder.
H Align the grooves in the reaction plate with the
grooves in the brake seating.

RKZA4670

10 - Remove the brake seating (47) and the screws.

47

RKZA4680

11 - Install the flange (51) and hold it steady with two

screws (50) mounted opposite to each other, and se-
cured provisionally. 50

51

RKZA4690

12 - Mount into the cylinder (29) the spring (68), the cam
(67) and the shaft (58), aligning the reference marks 58 29
made during the dismantling phase.
H Check that the thrust surface of the cam (67) fa- 68
ces towards the contact surface of the flange (51).
67

RKZA4700

30-222 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION REAR AXLE

13 - Raise the cam (67) with a lever, insert a shim "D" and
install the screw (69).
Screw: 10 Nm
D
H Remove the shim "D". 69

67
RKZA4710

14 - Install the flange (51) with the screws (50), tightened

provisionally.
50
H The screws (50) will be locked in place finally after
adjustment of the differential bearings.
51

RKZA4720

15 - Lubricate the O-ring (66) with oil and push it into its
seating. Mount the support (63) and secure it with
the screws (62). 63
66 62
H Do not tighten the screws at this point.

RKZA4730

16 - Mount the spacer (61) and position the spring (60).

61 60

RKZA4740

WB91R-2 WB93R-2 30-223

REMOVAL AND INSTALLATION REAR AXLE

17 - Position the lever (59), aligning the reference marks

made during the dismantling phase.
H Do not hook up the spring (60). 59

RKZA4750

18 - Mount new O-ring seals, (48) and (49), on both sides

of the brake cylinder.
48
49

RKZA4760

30-224 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION REAR AXLE

2. Installation of the pinion

1 - Place the outer bearing ring (123) of the pinion in the
central section (28).
123
H Carefully check the orientation of the bearing ring.

28
RKZA4770

2 - Position the tool G10 from the front of the central hou-
sing.
G10

RKZA4780

3 - Assemble the tool G10 by inserting the inner bearing

ring (126) of the pinion.
H Carefully check the orientation of the bearing ring.

126
G10

RKZA4790

4 - Keep the central rod of the tool G10, locked in posi-

tion and screw in the nut until the bearing ring is com-
pletely inserted.
Remove the tool G10.
G10

RKZA5240

WB91R-2 WB93R-2 30-225

REMOVAL AND INSTALLATION REAR AXLE

5 - Install the bearings (123) and (126) and the special

tools G11, G12, G13 which are needed to measure G13 G12
the depth of the pinion. G11

RKZA4800

G12

G13

RKZA4810

6 - Use a thickness gauge to measure the space "X" bet-

ween the gauge block G12 and the pinion depth gau-
G13 G12
ge G13.
Insert the value "X" into the formula shown in the dia-
gram on the next page.

RKZA4820

7 - Measure the height "V" marked on the pinion and in-

sert it into the formula shown in the diagram on the
next page.

117

RKZA4830

30-226 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION REAR AXLE

5
A B
X 1
4

RKZ01890

S=Shim measurement
1 - Tool G11 4 - Clearance measured A=Tool measurement (constant)
2 - Tool G12 5 - Bearing group B=Tool measurement (constant)
3 - Tool G13 X=Clearance measured
V=Value of pinion reading

8 - Select the shim "S" (127) from amongst the various

shims available.
H Range of shims: 2.5 ± 3.4 mm with an increment S (127)
of 0.1 mm.
H The shim "S" (127) should be mounted between
the pinion (121) and the inner bearing (126).
9 - Take away the special tools.

S (127)
RKZ01900

10 - Position the pinion (121) on the bed of a press and

mount the shim (127) and the bearing (126).
H Pay attention to the orientation of the bearing. 126 G14
11 - Use the tool G14 to press the bearing (126) onto the
back of the shim (127). 127
121 126

RKZA4840

WB91R-2 WB93R-2 30-227

REMOVAL AND INSTALLATION REAR AXLE

12 - Lubricate the inner bearing (126) with gear oil, then

mount the first washer (124), the new spacer (125)
and finally the second washer (124) onto the pinion 121 126
124
(121). 124 125
Insert the group into the central housing (28).

28
RKZA4571

13 - Lubricate the outer bearing (123) with gear oil and

press it onto the pinion (121).

121
123
RKZA4561

14 - Mount the special washer (122) and the lock nut (120)
onto the pinion (121).
122 120

121 121
RKZA4850

15 - Use the tools G7 and G8 to tighten the lock nut (120)

until the bearing group is tightly assembled.
G7

G8

RKZA4860

30-228 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION REAR AXLE

16 - Measure the preloading "P" of the bearings with a dy-

namometer and a line wound round the pinion (121).
H Preloading P: 9.2 ± 13.8 daN
(1 daN=10 N)
17 - Gradually adjust by tightening the lock nut (120) with
small rotation increments.
H The reloading must be controlled without seal
rings.

RKZA4870

18 - Caulk the lip of the lock nut (120) into the pinion groo-
ve (121).

120

121

RKZA4880

3. Re-assembly of the differential

1 - If the bushing (116) has been moved, insert it into the
half box (115) on the ring bevel gear side.
For insertion, use the tool G16.
116
G16
115

RKZA4890

2 - Lubricate the thrust washers (112), the differential

gears (111) and the cross-journal shafts (110).
Install the groups.
111 110

112

RKZA4480

WB91R-2 WB93R-2 30-229

REMOVAL AND INSTALLATION REAR AXLE

3 - Lubricate the inside surface of the half box (115) with

grease and install the shim (114) and the differential 114 113
gear (113).
Surface: ASL800050

115
RKZA4900

4 - Install the shafts (110) that form the cross-journal

complete with the bevel gears (111) and the shims
(112).

110

112
RKZA4460

5 - Position the differential gear (109) and the thrust

washer (108).
H The protruding parts of the thrust washer should
be oriented for insertion into the wells of the diffe- 108
rential half case.
109

RKZA4450

6 - Mount the half box (107) on the locking side, taking

care to respect the alignment marks.

107

RKZA4440

30-230 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION REAR AXLE

7 - Turn the group upside down and check that both the
surface of the half box and the reference pin of the
ring bevel gear are perfectly clean.

107

RKZA4910

8 - The pinion (121) and the ring bevel gear (106) belong
to one single set and have been marked.
H Make sure that the number marked on the pinion
corresponds to the number marked on the ring
bevel gear.

43

121
RKZA4831

9 - Coat the coupling surface of the differential box (107)

with adhesive and mount the ring bevel gear (106), 106
43
centering it on the reference pin.
Adhesive: Loctite 638

107
RKZA4920

10 - Fix the entire differential group with screws (105) and

tighten them using the alternating crosswise method. 105
Screws: 155 Nm
Screws: Loctite 270

RKZA4930

WB91R-2 WB93R-2 30-231

REMOVAL AND INSTALLATION REAR AXLE

11 - Use the tool G17, to mount the bearings (104).

G17 G17

104 104

RKZA4940

12 - Mount the springs (103) and the pegs (102) into the
differential box (107).
103 107
102

RKZA4950

13 - Position the differential-locking ring (100) and, pres-

sing on the pegs (102), push it home.
100

102

RKZA4960

14 - Install the snap ring (101).

101

100

RKZA4390

30-232 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION REAR AXLE

4. Installation of the differential lock

85 85
1 - Mount new O-rings (99) onto the piston (98).
Lubricate the seals and insert the complete piston in-
to the cylinder (85).
Mount a new O-ring (97) onto the cylinder.

99
98 97
RKZA5250

2 - Mount the shaft (96) complete with snap ring (97) into
the fork (91). 96 97 91

RKZA4970

3 - Install the spring (93) onto the shaft (96).

Compress the spring (93) and install the spacer (95).
93
95

RKZA4980

4 - Install the snap ring (94) and release the spring (93).
Mount the spacer (92) on the shaft (96).
92
94
96

RKZA4990

WB91R-2 WB93R-2 30-233

REMOVAL AND INSTALLATION REAR AXLE

5 - Install the fork group (90) in the central housing.

90

RKZA4350

6 - Install the complete differential group, moving it so as

to engage the fork (90) in the differential lock ring.

91
RKZA4340

7 - Install the spring (87) in the central housing and

mount the cover (88) complete with O-ring (89).
Fasten the cover with the screws (86), employing the
alternating crosswise method. 88
Screws: 23 Nm

86 87

RKZA4330

8 - Lubricate the seals (97) of the cylinder (85) and mount

the cylinder in the central housing.
Fasten the group with the screws (84), employing the
alternating crosswise method.
Screws: 23 Nm
84

85
RKZA4320

30-234 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION REAR AXLE

5. Completing the assembly of the axle

A
1 - Install two guide pins "A" in the central housing. Lu-
bricate the O-ring seals (48) and (49) of the brake cy-
linder group (29).
Install the group on the central housing.
H Check that the markings correspond.

RKZA5010

2 - Install the brake disk seating (47) on the guides "A".

H Check that the markings correspond.
47

RKZA5020

3 - Use the axle shaft (34) to raise the differential group

into position for centering some bearings in the outer
bearing ring of the brake cylinder.
Push the brake cylinder and the brake disc seating
against the central housing.

34
RKZA5030

4 - Use the axle shaft to hold the group in position and

completely insert the two screws (46).
H Do not lock the screws at this point.
46

46
RKZA5040

WB91R-2 WB93R-2 30-235

REMOVAL AND INSTALLATION REAR AXLE

5 - Lubricate the O-ring seals (45) and insert the oil re-cir-
culation pipe (44).
H Make sure that the pipe (44) has been pushed 45
completely home in the central housing. 44
45

RKZ01870

6 - Give a final tightening to the screws (46) that secure

the cylinder (29) and the brake disk seating (47). 46
Screws: 120 Nm
H Repeat the assembly operations for the brake cy-
linder (29) and the brake disk seating (47) also on
the other side.

46

RKZA4061

7 - Remove the flange (51) in order to reach the lock nuts

(83) that adjust the differential.
51

83

RKZA5050

8 - Mount the tool G18 on the pinion (121).

121
G18

RKZA5060

30-236 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION REAR AXLE

9 - Attach a centesimal comparator perpendicular to the

notch "W" cut into the gauge block. Pre-load the com-
parator by about 4 mm.
10 - Rotate the pinion by hand in both directions to check
the clearance between the differential pinion teeth.
H Clearance allowed between the teeth:
0.2 ± 0.28 mm

RKZA5070

11 - If the clearance between the teeth does not fall within

the permissible values, proceed as follows:
1 - Clearance above the limit
a - Unscrew the adjustment lock nut (1) by one
notch. 106
b - Screw in the lock nut (2) by one notch.
2 - Clearance below limit
a - Unscrew the adjustment lock nut (2) by one
notch.
b - Screw in the lock nut (1) by one notch.
1 2
H Repeat these operations until the clearance fall
within permissible limits.
H Use the tool G6 to turn the lock nuts.

RKZ01880

WB91R-2 WB93R-2 30-237

REMOVAL AND INSTALLATION REAR AXLE

12 - Once the clearance between the teeth has been de-

termined, check that the total pre-loading "T" of the
bearings falls within permissible limits.
H Pre-loading: T=(P+3.23)/(P+4.84) daN
(1 daN=10 N)
H P=pre-loading of the pinion bearings.
This check is performed in the same was as the
check on the pre-loading P of the pinion bearings.

RKZA4870

13 - If the pre-loading does not fall within permissible li-

mits, proceed as follows:
1 - Pre-loading above the limit
a - Unscrew the lock nuts (1) and (2) by one notch.
2 - Pre-loading below the limit 106
a - Screw in the lock nuts (1) and (2) by one notch.
H Repeat these operations until the pre-loading falls
within permissible limits.
H Use the tool G6 to turn the lock nuts.
1 2

RKZ01880

14 - Lubricate the seal ring (119) with oil and, using the
tool G16, insert it into the cover (117).
Also mount the O-ring (118).

119

118
117

RKZA5080

30-238 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION REAR AXLE

15 - Lubricate the O-ring (118) and, using the tool G19,

mount the complete cover (117) into the central hou-
sing. 117
Remove the tool G19.

G19
RKZA5090

16 - Mount the adjusting ring locks (82) and block them

with the screws (81).
Screws: 13 Nm
82

81

RKZA5100

17 - Place the flange (51) in its final position and secure it

with the screws (50) tightening them progressively.
Screws: 23 Nm 50

51
RKZA5110

H If new brake disks (41) and (38) are to be installed,

make sure that the disks have been soaked in oil.
At the very least the disks should be lubricated on 41
both sides.
18 - Install the first brake disk (41).

RKZA5120

WB91R-2 WB93R-2 30-239

REMOVAL AND INSTALLATION REAR AXLE

19 - Install the intermediate reaction plate (40), making su-

re that the teeth of the outer circumference are enga- 40
ged in the slots in the seating (47).

47

RKZA5130

20 - Install the sleeve (39), engaging the toothing in the

brake disk (41). 41
H Engage the brake disk in the short grooved part of
the sleeve.
39

RKZA4050

21 - Install the second brake disk (38), aligning the holes

with those of the first disk.
H Continue the assembly with the second reaction
plate (40) and the third brake disk (38), following 38
the previous procedures.

RKZA4040

22 - Install the outer reaction plate (37), making sure that

the teeth of the outer circumference are engaged in 2
the slots of the seating (47).
H The marked face should be turned towards the
outside of the central housing.

22

RKZA5270

30-240 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION REAR AXLE

23 - If the joint (33) on the axle shaft (34) has been moved,
re-assemble it.
H Check that the coupling (35) is mounted inside the 33
joint (33).
34

RKZA5140

24 - Install the shaft (34) in the axle arm (32).

36 32
H Make sure that the joint is engaged on the axle
shaft (4) of the final drive.
Lubricate the O-ring (36) and mount it on the flan-
ge of the axle arm (32).
34

RKZA5150

25 - Raise the complete axle arm (32) horizontally and en-

gage the axle shaft (34) with the brake group (30).
30 32
H If necessary rotate the bevel pinion to engage the
shaft (34).

RKZA5160

26 - Push the axle body (32) against the central housing.

Mount the screws (31) and employ the alternating
crosswise method to tighten them.
Screws: 130 Nm
31
H Repeat these assembly operations for the other 32
axle body.

RKZA4000

WB91R-2 WB93R-2 30-241

REMOVAL AND INSTALLATION REAR AXLE

6. Final re-assembly
80
1 - Loosen the air breather plugs (80).
2 - Connect a hand-pump, supplied with braking circuit
oil and a pressure gauge, to a braking group.
3 - Pump the oil in, and tighten the breather plug when
oil comes out without any trace of air.
4 - Bring the pressure up to 40 bar to settle the braking
group.
5 - Repeat these operations for the other group and re-
move the pump. RKZA5170

6 - Tighten the two levers (59) of the parking brake by ap-

plying a force of 5 kg on each lever, and checking that
the center distance between the holes is 300 ± 310 mm
with the levers inclined symmetrically.
H If necessary, raise the levers and engage them on
the grooves of the shaft in a different position, ma-
king marks to indicate the new position.
H Check that each lever makes a return stroke of
at least 3 mm (center distance measurement
306 ± 316 mm).

RKZA5280

8 - Raise the levers (59) and the springs (60). Hook up

the springs and pre-load them by rotating the levers
inside the supports (63).
H Make sure that the shaft rotates with the levers.
59

60
63

RKZA5180

9 - Use a mallet to push the levers (59) home on the shaft

(58).
58
10 - Install the retaining washer (57) and the screw (56). 59
Screw: 35 Nm

57

RKZA5190

30-242 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION REAR AXLE

11 - Move the supports (63) until the adjustment screws

(64) are perpendicular to the levers (59). Lock them 63
in position with the screws (62).
64

62

59

RKZA5200

12 - Adjust the return stroke of the levers from the braking

position to 3 mm, and lock the adjustment screws (64)
with the nuts (65).
65 64

RKZA5210

13 - Install the breather pipe (26) and tighten it until the re-
ference mark made during the dismantling phase is in
the correct position.
Breather pipe: 10 Nm

26

RKZA5220

14 - If the plug (128) has been removed to drain the oil, re-
place it in the central housing.
Plug: 80 Nm 129
128
15 - Fill the axle up with oil and replace the cap (129).
Plug: 80 Nm

RKZA5230

WB91R-2 WB93R-2 30-243

REMOVAL AND INSTALLATION FRONT BUCKET BOOM-RAISING CYLINDER

REMOVAL OF THE FRONT BUCKET BOOM-RAISING CYLINDER

Lower completely the working equipment until it
rests on the ground and stop the engine.
A
1 - Put a sling round the cylinder (1) and insert some
blocks «A» between the boom (2) and the fulcrum le- 2
ver spacer (3). 3
2 - Take off the snap-ring and the internal retaining spa-
cer for the piston attachment pin (4). 4
3 - Take out the pin (4) in order to free the piston head 1
(5), but leave the fulcrum lever engaged (3).
4 - Start the engine to retract the piston (1). 5
RKZA2160

H Bind the piston head with wire to secure the fully re-
tracted position and stop the engine.

Release all residual pressure in all circuits. (For de-

tails, see «20. TESTING AND ADJUSTMENTS»).
Cut off the supply of electricity by turning the accu- 1
mulator-disconnecting switch in a counter-clockwise
direction, and remove the handle.

5 - Disconnect the tubes (6) and (7) and plug them to pre-
7
vent entry of impurities.
6
6 - Remove the snap-ring (8) and the spacer (9).
7 - Remove the cylinder (1). RKZA1951

9
1 8
INSTALLATION OF FRONT
BUCKET BOOM-RAISING
CYLINDER
. To install, reverse the removal procedure.

When aligning the positions between the hole and

the pin, turn the engine over at low idling speed.
Do not insert fingers into the holes to check align-
RKZA2170

ment.

Internal bushing: ASL800050

1 - Start the engine and bleed the air from the cylinders.
(For details, see «20. TESTING AND ADJUST-
MENTS»).
H After bleeding the air, check the oil level in the tank.

30-244 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION FRONT BUCKET TILT CYLINDERS

REMOVAL OF THE FRONT BUCKET TILT CYLINDERS

Lower the working equipment completely until it
rests on the ground and stop the engine. 3
1 - Loosen the clips (1) and remove the tube protection
(2).
H For the right-hand cylinder only
Disconnect the sensor (3) and remove the bucket po-
sition indicator (4).
2 - Place a sling round the cylinder (5) and insert a block 1
«A» between the spacer (7) of the piston fulcrum lever 2 1 4
and the lever (8).
3 - Take off the snap-ring and the internal retaining spa- RKZA1020

cer for the piston attachment pin (9).

4 - Take out the pin (9).
5 - Start the engine to retract the piston (10).
6

H Bind the piston head with wire to secure the fully re-
tracted position and stop the engine.
7
Release all residual pressure in all circuits. (For de- A 4
tails, see «20. TESTING AND ADJUSTMENTS»).
Cut off the supply of electricity by turning the accu-
mulator-disconnecting switch in a counter-clockwise 5
direction, and remove the handle. RKZA1030

6 - Take out the screw (11) and remove the clamp (12).
7 - Disconnect the tubes (13) and (14) and plug them to
prevent entry of impurities.
9
8 - Remove the snap-ring (15) and the spacer (16).
9 - Remove the cylinder (5).

INSTALLATION OF THE FRONT 11

BUCKET TILT CYLINDERS 8 10
. To install, reverse the removal procedure. RKZA1040

When aligning the positions between the hole and 4 12

the pin, turn the engine over at low idling speed.
Do not insert fingers into the holes to check align-
ment.

Internal bushing: ASL800050

1 - Start the engine and bleed the air from the cylinders.
(For details, see «20. TESTING AND ADJUST-
MENTS»). 13
H After bleeding the air, check the oil level in the tank. RKZA1050

WB91R-2 WB93R-2 30-245

REMOVAL AND INSTALLATION FRONT BUCKET

REMOVAL OF THE FRONT BUCKET

Lower the bucket to the ground, resting on its back,
but without forcing it downwards.

1 - Stop the engine and release residual pressures.

RKZA1060

2 - Take out the screws (1) and remove the pins (2) of the
lever (3).
Rest the lever (3) on the boom.

2
RKZA1460

3 - Take out the screws (4) and remove the pins (5) of the
bucket fulcrum.
4
4 - Start the engine and put the machine into reverse
gear in order to disengage the boom (6).

5
RKZA1470

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

When aligning the positions between the hole and

the pin, turn the engine over at low idling speed.
Do not insert fingers into the holes to check align-
ment.

Internal bushing: ASL800050

30-246 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION FRONT WORKING EQUIPMENT

REMOVAL OF THE FRONT WORKING EQUIPMENT

Lower the working equipment completely until it
rests on the ground stop the engine and remove
the ignition wrench.
Release all residual pressure in all circuits. (For de-
tails, see «20. TESTING AND ADJUSTMENTS»).
1 - Remove the tilt cylinders. (See «REMOVAL OF FRONT
BUCKET TILT CYLINDERS»).

RKZA7900

2 - Disconnect the cylinders (2) from the boom and rest

them on wooden blocks «A» placed on the front axle.

2
A
RKZA2220

3 - Put a sling round the boom (1) as shown in the figure,

and attach it to the hoisting tackle. Apply a slight ten-
sion to the cables.

4 4

RKZA1090

4 - Open the front hood (3) and take out the screws (4)
that lock the axle oscillation pins of the boom (1).
Close the front hood. 1

RKZA7910

WB91R-2 WB93R-2 30-247

REMOVAL AND INSTALLATION FRONT WORKING EQUIPMENT

5 - Using a puller, take out the axle oscillation pins (5) of

the boom (1).
6 - Start the engine and put the machine into reverse 5
gear travel until the boom is disengaged. 1
H If the working equipment is to be detached to aid
the removal of the engine-gearbox-pump group,
and the machine cannot travel automatically, it
can be towed using the towing hooks of the bac-
khoe.
7 - Place two stands in position and lower the boom until
it is resting on them. RKZA7920

INSTALLATION OF THE FRONT WORKING EQUIPMENT

. To install, reverse the removal procedure, if necessa-
ry using the front towing hook.

When aligning the positions between the hole and

the pin, turn the engine over at low idling speed.
Do not insert fingers into the holes to check align-
ment.

Internal bushing: ASL800050

. Start the engine and bleed the air from the cylinders.
(For details, see «20. TESTING AND ADJUST-
MENTS»).
H After bleeding the air, check the oil level in the tank.

30-248 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION BACKHOE CONTROL VALVE

REMOVAL OF THE BACKHOE CONTROL VALVE

1 - Swing the backhoe completely to the right of the ma-

chine, and rotate the boom to approx. 45ë to the right.
2 - Lower the outriggers to the ground, open the bucket
and rest the arm on a block «A», keeping it perpendi-
cular to the ground.
3 - Rest the bucket teeth on the ground, release the bac-
khoe plate and stop the engine.

Release all residual pressure in all circuits. (For de-

tails, see «20. TESTING AND ADJUSTMENTS»).
RKZA1680

4 - Take out the lower window (1) of the cab and comple-
tely raise the upper window.

RKZA1100

5 - Remove the grips (2) of the control levers of the ou-

triggers and the grip (3) of the lever-locking device.
2
6 - Raise the protective sleeves (4) of the control levers,
take out the screws (5) and remove the cover (6).

4
4
5
3
6
RKZA1110

H If any optional devices have been fitted, unhook

the spool command tie-rods (7) and remove the 8 9
pedals (8) and the supports (9).

RKZA1120

WB91R-2 WB93R-2 30-249

REMOVAL AND INSTALLATION BACKHOE CONTROL VALVE

7 - Disconnect the connector (10) of the solenoid (11) of

the control valve (12).
13
8 - Disconnect the lever command tie-rods from the con-
trol valve. 12 11
9 - Disconnect from the control valve the pipes (14) (de-
livery, return, Load Sensing and actuators). Plug
10
them to prevent entry of impurities.
H Mark the pipes to prevent exchanging positions 14
during re-connection.
10 - Attach the control valve (12) to some hoisting tackle
RKZA2251
and apply a slight tension to the cables.
11 - Remove the four screws (15) and then the entire con-
trol valve.

Control valve: 6-spool 47 kg

7-spool 53 kg
8-spool 59 kg

15 15

RKZA2260

INSTALLATION OF THE
BACKHOE CONTROL VALVE
. To install, reverse the removal procedure.
H Bleed the air from Load Sensing circuits and from the
hydraulic circuits of all the actuators. (For details, see
«20. TESTING AND ADJUSTMENTS).

30-250 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION BACKHOE BOOM CYLINDER

REMOVAL OF BACKHOE BOOM CYLINDER

1- 1-
Remove the lubrication nipple and the extension (1).
1 5
Extend the arm (2) completely and fully open the
bucket (3).
Manoeuvre the front equipment until the bucket teeth
are resting on the ground, the arm on a block «A»
about 10 cm high, and the joint between the arm
and the boom on a stand «B», about 70 cm high.

2 - Stop the engine and release residual pressures. 6

3 - Place a sling around the cylinder (4).

RKZA1150

4 - Take out the screws (5) and remove the pin (6).

10
5 - Start the engine and retract the piston.
H Secure the position of total retraction by binding
the piston head rod with wire.
2 9
6 - Stop the engine and release any residual hydraulic
pressures. (For details, see «20. TESTING AND AD- 3
JUSTMENTS»).
7 - Disconnect the pipes (7) and (8) and plug them to pre-
vent entry of impurities.
B
8 - Take out the screw (9) and remove the pin (10). A RKZA0140

9 - Remove the cylinder (4).

Cylinder: WB91R-2 65 kg
WB93R-2 78 kg
5

INSTALLATION OF THE
BACKHOE BOOM CYLINDER
6
. To install, reverse the removal procedure.

When aligning the positions between the hole and RKZA1170

the pin, turn the engine over at low idling speed.

Do not insert fingers into the holes to check align-
ment.
4

Internal bushing: ASL800050

1 - Start the engine and bleed the air from the cylinders.
(For details, see «20. TESTING AND ADJUST-
MENTS»).
H After bleeding the air, check the oil level in the
tank. 7
8
RKZA1180

WB91R-2 WB93R-2 30-251

REMOVAL AND INSTALLATION BACKHOE ARM CYLINDER

REMOVAL OF THE BACKHOE ARM CYLINDER

Extend the arm (1) completely and fully open the
bucket (2). Lower the arm (3) until the joint between
the arm and the boom is resting on a stand «A» about
90 cm high, and tip of the arm on a block «B» about 3
10 cm high. Rest the bucket teeth on the ground. 1
2
1 - Stop the engine and release the pressures in the cy-
linder by moving the control lever several times.
2 - Place a sling around the cylinder (4).
3 - Take out the screws (5) and remove the pin (6). A
B
RKZA1160

4 - Start the engine and retract the piston (7).

H Secure the position of total retraction of the piston
(7) by binding the piston head rod with wire.
5 - Stop the engine and release the residual hydraulic 5
pressures. (For details, see «20. TESTING AND AD-
JUSTMENTS»).
6 - Disconnect the pipes (8) and (9) and plug them to pre-
vent entry of impurities.
7 - Take out the snap-ring (10) and remove the pin (11).
6
4
8 - Remove the cylinder (4). RKZA1190

Cylinder: 69 kg

8
7
4 9

INSTALLATION OF THE
BACKHOE ARM CYLINDER
. To install, reverse the removal procedure.

RKZA1200

When aligning the positions between the hole and

the pin, turn the engine over at low idling speed.
Do not insert fingers into the holes to check align-
ment. 11 4

Internal bushing: ASL800050

1 - Start the engine and bleed the air from the cylinders.
(For details, see «20. TESTING AND ADJUST-
MENTS»).
H After bleeding the air, check the oil level in the tank.
10
RKZA1210

30-252 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION BACKHOE BUCKET CYLINDER

REMOVAL OF THE BACKHOE BUCKET CYLINDER

Extend the arm (1) completely and fully open the
bucket (2). Lower the boom (3) until the arm is resting
on a stand «A» about 90 cm high, and tip of the arm
on a block «B» about 10 cm high. Rest the bucket 3
teeth on the ground. 1
4
2
1 - Stop the engine and release the pressures in the cy-
linder (4) by moving the control lever several times.
2 - Place a sling around the cylinder (4).
3 - Take out the lock-nut (5) and the washer and remove A
the pin (6). B
RKZA1161

4 - Start the engine and retract the piston (7).

H Secure the position of total retraction of the piston
by binding the piston head rod with wire.
5 - Stop the engine and release the residual hydraulic
pressures. (For details, see «20. TESTING AND AD-
4
JUSTMENTS»).
6 - Disconnect the bracket (8) and the pipes (9) and (10),
and plug them to prevent entry of impurities. 7
7 - Take out the snap-ring (11) and remove the pin (12).
5

8 - Remove the cylinder (4). 6 RKZA1220

Cylinder: 49 kg

9 10
INSTALLATION OF THE
BACKHOE BUCKET CYLINDER 11

. To install, reverse the removal procedure.

4
When aligning the positions between the hole and 12
the pin, turn the engine over at low idling speed. 8
Do not insert fingers into the holes to check align-
ment.
RKZA1230

Internal bushing: ASL800050

Pin-retaining lock-nut: . . . . . . . . . . . . . . . . . . . . . Nm
1 - Start the engine and bleed the air from the cylinders.
(For details, see «20. TESTING AND ADJUST-
MENTS»).
H After bleeding the air, check the oil level in the tank.

WB91R-2 WB93R-2 30-253

REMOVAL AND INSTALLATION OUTRIGGER CYLINDERS

REMOVAL OF THE OUTRIGGER CYLINDERS

Position the backhoe with the equipment centered,
the arm vertical and the back of the bucket resting
on the ground.

1 - Extend the outriggers (1) of about 15 cm, stop the en-

gine and release the cylinders pressures.

1
RKZA0971

2 - Place a lifting platform "A" beneath outrigger (2).

Raise this until it is forced up against the outrigger.
1

RKZA1240

3 - Remove the clamp (3). 4

5
4 - Disconnect from cylinder (5) the pipe (4) and plug
them to avoid impurity entry.
Plug also the union to avoid the movement of piston. 4
5 - Remove screw (6) and extract the pin (7) until the cy-
linder (5) is free.
3

7
6
RKZA1250

6 - Raise the lifting platform "A" to disengage the cylin-

der head (5) from frame.
Place a sling round the cylinder (5) and apply slight
tension to the cables. 5

RKZA1260

30-254 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION OUTRIGGER CYLINDERS

7 - Take out the screw (9) and remove the pin (10).
8
8 - Remove the cylinder (5).

RKZA1270

INSTALLATION OF THE
OUTRIGGER CYLINDERS
. To install, reverse the removal procedure.

Do not insert fingers into the holes to check align-

ment.

Internal bushing: ASL800050

1 - Start the engine and bleed the air from the cylinders.
(For details, see «20. TESTING AND ADJUST-
MENTS»).
H After bleeding the air, check the oil level in the tank.

WB91R-2 WB93R-2 30-255

REMOVAL AND INSTALLATION BACKHOE SWING CYLINDERS

REMOVAL OF THE BACKHOE SWING CYLINDERS

Position the backhoe with the equipment centered,
the arm vertical and the back of the bucket resting
on the ground.

1 - Stop the engine and release cylinder pressures by

moving the control levers several times.
2 - Take out the screws (1) and remove vertically the upper
support (2) of the cylinder fulcrum.

3 - Disconnect the four tubes (4) from the cylinders (3)

and plug them to prevent entry of impurities.
4 - Take out the screws (5) and remove the pins (6). RKZA0970

5 - Rotate the cylinders to disengage the piston heads

from the swing bracket (7) and remove the cylinders
(3). 1

Cylinder: 30 kg
2

INSTALLATION OF THE 1
BACKHOE SWING CYLINDERS 3
RKZA1280

1 - Mount the cylinders (3) and the upper cylinder ful-

crum support (6). Secure the support with the four
screws (1).
4
6
Support screw: Loctite 262
Support screw: 100w10 kgm

2 - Connect the four tubes (4) to the cylinders. 3

3 - Start the engine and swing the boom in order to cen- 5
ter one of two pins (8). Secure the 1st pin with the
screw (7).
7
Perform the same operation for the other pin.
RKZA1290

When aligning the positions between the hole and

the pin, turn the engine over at low idling speed.
Do not insert fingers into the holes to check align-
ment.

Internal bushing: ASL800050

4 - Start the engine and bleed the air from the cylinders.
(For details, see «20. TESTING AND ADJUST-
MENTS»).
H After bleeding the air, check the oil level in the tank.

30-256 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION BACKHOE BACKFRAME LOCK CYLINDER

REMOVAL OF BACKHOE BACKFRAME LOCK CYLINDER

H Set the backhoe with the centered attachments with

the arm in vertical position and the bucket leaned
on the back at level ground.
1 - Unlock the backframe (1).
2 - Stop the engine and release the residual hydraulic
pressures. (For details, see «20. TESTING AND AD-
JUSTMENT»).
3 - Disconnect from cylinder (2) the pipes (3) and (4) and
plug them to avoid impurity entry.
4 - Remove screws (5) and cylinders (2). RKZA0970

3 2

4
1 5

RKZA1300

INSTALLATION OF BACKHOE
BACKFRAME LOCK CYLINDER
. To install, reverse the removal procedure.

Locking screw: Loctite 262

Locking screw: 41w4 kgm

Cylinder seat: ASL800050

1 - Start the engine, lock and unlock the backframe seve-
ral times to make the circuit feeling.

WB91R-2 WB93R-2 30-257

REMOVAL AND INSTALLATION CYLINDERS

DISASSEMBLY OF CYLINDERS
(Front bucket raise and tilt, boom, arm, bucket, outriggers and telescopic arm)
1 - Place the cylinder (1) on the tool A1. Engage the cy-
linder head in the tools A2 appropriate to the diame- A2
ter of the hole.
A2

A1

1
RKZA1540

For the arm cylinder with side-digging boom first ex- 3 2

tract the snap-rings (2) and the ball-and-socket joint
(3).

1 4

RKZA1530

2 - Using the specially-made wrench A4 unscrew the cy-

linder head (4) and extract it from the cylinder (1).
For the side-digging boom cylinder, first remove 6
the lock-nut (5) that secures the piston-rod seal.
3 - Raise the cylinder (1) and attach the piston head to
the mobile group of the tool.
A1
4 - Extract the piston-rod group (6) from the cylinder (1).
4
5 - Remove the cylinder (1) and the piston-rod group (6).

RKZA1560

30-258 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION CYLINDERS

6 - Secure the piston-rod group (6) on the tool A1.

7
7 - For the side digging boom cylinder: remove the
snap-spin (10). 1° BRACCIO 9
BOOM
8 - For the piston rod of the boom cylinder: remove the
screw (7).
9 - Use the appropriate socket wrench A7 on the piston
hexagon (11) and unscrew the piston.
H Measurement of the socket wrench: 8
For raising the front bucket: 55 mm
For tilting the front bucket: 55 mm
Boom: 65 mm
RKZ00020

Arm: 55 mm
Bucket: 55 mm
Outriggers: 46 mm
Telescopic arm: 46 mm SIDEPISTONE
DIGGING
Side digging boom: 46 mm
10
BOOM PISTON
DEPORTABILE

10 - For the piston rod of the boom cylinder: Take out

the ball bearings (8) and the cushion plunger (9).
11 - Dismantle all the groups by removing all the seals,
the dust-seals, the guide rings, and the fulcrum bus- 6
hings. 11
The seals, the dust seals and the guide rings
2°ARM
BRACCIO
cannot be used again.
Carefully check the pistons (11). If both safety-
caulked areas show wear, the pistons must be
replaced.

6
11
RAISING
SOLLEVAMENTO
TILTING
ROVESCIAMENTO

6
11 RKZ00010

WB91R-2 WB93R-2 30-259

REMOVAL AND INSTALLATION CYLINDERS

ASSEMBLY OF CYLINDERS
(Front bucket raise and tilt, boom, arm, bucket, outriggers and jig arm)
H Take great care not to damage the seals and the sli-
ding surfaces. 16 15
H Prepare each individual component before the final
assembly.

1. ASSEMBLY OF THE CYLINDER HEAD

1.1 Only for the cylinders for front bucket raise
and tilt, boom, arm, bucket, outriggers, jig arm
1 - Mount the gasket (12) in the cylinder head.
2 - Mount the gasket (13) in the cylinder head. 14 13 12
H Make sure that the lips are turned towards the in-
RKZ00040

side of the cylinder.

3 - Mount the guard ring (14) using the tool A8.
22 21 20
4 - Mount the O-ring (15) and the anti-extrusion ring (16)
on the outside of the cylinder head.
5
1.2 Cylinder for side digging boom
1 - Insert the gasket (17) in the cylinder head, and let it
beat on seat bottom, then insert the anti-extrusion
ring (18).
H Check carefully the assembly orientation.
2 - Mount the guard ring (19) in the lock-nut (5). 19 18 17 23
RKZ00050

3 - Tighten the lock nut (5) until leaning lightly on anti-ex-

trusion ring (18).
4 - Assemble on head the O-ring (20), the anti-extrusion
(21), the O-ring (22) and the ring (23).
25 26 27
2. RE-ASSEMBLING THE PISTON 26 11
2.1 Only for the cylinders for front bucket raise
and tilt, boom, arm, bucket, outriggers, jig arm 24
1 - Use the tool A9 with the appropriate diameter, mount
the ring (24) the external ring (25) and the anti-extru-
sion rings (26) onto the piston (11).
2 - Prepare the guide ring (27). RKZ00090

H There are two guide rings (27) for the boom pi-
ston.
3 - For the boom piston only: insert the O-ring (28) into
the internal seating. 27

28

A9

RKZA1580

30-260 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION CYLINDERS

2.1 Side digging boom cylinder

H This mounting should be performed directly on piston.
33 31 30 31 34
1 - Mount central ring (29), rubber ring (30) and anti-ex-
trusion ring (31). 32 35
36
2 - Mount on piston first washer (32), guide ring (33), cen-
tral ring assembly (29), second guide ring (34) and se- 10
cond washer (35).
3 - Tighten nut (36) and lock the piston group after loc-
king rod head under the press. (See «3. RE-ASSEM-
BLING THE PISTON-ROD GROUP»). 29
RKZ00060

4 - Insert the snap ring (10).

3. RE-ASSEMBLING THE PISTON-ROD GROUP

1 - Only for the cylinders for front bucket raise and 6
tilt, boom, arm, bucket and side digging boom:
using a press and tools A2 with the appropriate dia-
meter, insert the bushing (37) into the piston head (6). 37

A1
A2

RKZA1500

2 - Mount the bushing A10 of the correct diameter onto

the tip of the piston rod (6). 6
A10 6 4
3 - Slightly lubricate the cylinder head seals (4) and slide
the group onto the piston rod (6).
Seals: ASL800050

RKZA1510

4 - For the cylinders of the outriggers only: mount the

spacer (38) with the O-ring (39). 39 38 6 A10
H Check carefully the assembly orientation.
For the arm cylinder only: insert the spacer (40). OUTRIGGERS
STABILIZZATORI

40
ARM
2° BRACCIO

RKZ00070

WB91R-2 WB93R-2 30-261

REMOVAL AND INSTALLATION CYLINDERS

5 - Remove from the tip of the piston rod (6) the bushing
A10 and mount the piston (11) and the nut (36).
11
6 7
H Grease the piston threading.
9
Piston locking nut: Loctite 262
Piston locking nut:
Front bucket raise: 290w29 kgm
Front bucket tilt: 290w29 kgm
Arm: 290w29 kgm
Bucket: 290w29 kgm 8
Outriggers: 155w15 kgm
Telescopic arm: 155w15 kgm
6 - For the boom cylinder: mount the cushion plunger
RKZ00021

(9), slide the eleven ball-bearings (8) into the hole,

and mount the dowel bolt (7).
Dowel bolt: Loctite 262 11 6
Dowel bolt: 23w2 Nm
7 - Screw the complete piston (11) onto the piston rod,
and secure it with the dynamometric wrench.
Piston: 120 ± 125 kgm
8 - Caulk the piston (11) to correspond to the slot in the
piston rod (6) not previously used.

RKZA1550

4. RE-ASSEMBLING THE CYLINDERS

1 - Mount onto the apparatus A1 the tools A2 with the A2
appropriate diameter. A2
2 - For the boom, arm, bucket and side digging boom 1
cylinders only: A1
Position the bushing (41) and mount it in the cylinder
head (1).
H There are two bushings for the arm cylinder, with
a spacer between them.
H Leave the cylinder in position for subsequent as- 41
sembly. RKZA1541

3 - Lubricate the threading and the first part of the cylin-

der (1).
1 A11
Cylinder: ASL800050
4 - Mount the two halves of the tool A11 with the appro-
priate diameter at the mouth of the cylinder (1).

RKZA1520

30-262 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION CYLINDERS

5 - Mount the piston rod group (6) on the apparatus A1

and raise the mobile part to the end of its stroke.
6 - Place the cylinder (1) in a vertical position and guide
6
the piston into the tool A11.
7 - Lower the apparatus that supports the piston rod (6)
in order to center the piston in the tool A11.
A1
8 - Mount the first guide ring (27) onto the piston and in- 4
sert part of the piston into the tool A11.
For the boom cylinder only: mount the second gui-
de ring (27) and fully insert the piston.
A11
Insert the piston slowly in order to calibrate the guide
rings (27) without overheating them.
9 - Take the cylinder out of the tool A11 and then lower
the apparatus A1 further in order to bring the cylinder
head (4) and the piston rod head closer to the cylin-
der. 1
10 - Bring the cylinder (1) into position for screwing in the
cylinder head (4).
11 - Insert the cylinder head into the cylinder and screw it
in by hand for several turns.
12 - Use the right special wrench A4, A5, A6 to screw the
cylinder head (4) home. RKZA1561

Cylinder head: 95 ± 100 kgm

13 - For the side digging boom cylinders only: tighten

the lock-nut (5).
Lock-nut: 50 kgm

RKZ00080

WB91R-2 WB93R-2 30-263

REMOVAL AND INSTALLATION BOOM SWING CYLINDER

DISASSEMBLY OF BOOM SWING CYLINDER

9
5 1

2
6

4
7 8
RKZ00100

1 - Place the cylinder (1) on the apparatus A1. Engage

the axle oscillation pins in the tools A3.
2 - Using the specially-designed wrench A6, unscrew the
cylinder head (2) and extract it completely from the
cylinder (1).
3 - Remove the safety dowel bolt (10).
4 - Raise the cylinder (1) and attach the piston head to
the mobile group of the apparatus A1.
5 - Extract the piston rod group (4) from the cylinder.
6 - Remove the cylinder and the piston rod group.
7 - Secure the complete piston rod (4) to the apparatus
A1.
8 - Raise the part caulked for safety purposes and un-
screw the piston using the tool A7.
Check the piston (5) carefully. If both safety-caulked
areas have been used, the piston must be replaced.

9 - Remove the snap-ring (6) from the piston and extract

the ring (7) and the spacer ring (8).
H Make a note of the order of assembly of the ring
(7).
10 - Using a puller remove the swing bushings (9) from
the cylinder axle oscillation pins.
11 - Dismantle the groups by removing all the seals, the
guard rings, the guide rings and the piston fulcrum
bushing.
The seals, guard rings and guide rings must not
be used again.

30-264 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION BOOM SWING CYLINDER

ASSEMBLY OF BOOM SWING CYLINDER

H Take great care not to damage the seals and the sli-
ding surfaces. 13 14 2 15
H Prepare each individual component before the final
assembly.

1. Assembly of the cylinder head

1 - Mount the gasket (10) and the gasket (11) in the cylin-
der head.
H Make sure that the lips are turned towards the in-
side of the cylinder. 10 11 12
RKZ00110
2 - Mount the scraper ring (12).
3 - Mount the O-ring (13), the anti-extrusion ring (14) and
lastly the O-ring (15) of the front seal.
19 18 17 18 19
2. Re-assembling the piston
1 - Use the tool A9 with the appropriate diameter, mount
the rubber ring (16) and the seal ring (17) onto the pi-
ston. Remove the tool A9 and mount the anti-extru- 16
sion rings (18).
A9
2 - Prepare the guide rings (19). 20
3 - Mount the O-ring (20) in the internal seating of the pi-
ston. RKZA1600

3. Re-assembling the piston-rod group

1 - Using a press and tools A2 with the appropriate dia-
meter, insert the bushing (21) into the piston head (4). 3
A10
2 - Insert the ring (8) into the piston rod (4).
H Check carefully the direction of assembly of the 21
ring (8).
3 - Insert the spacer ring (7) and secure the group with A2
the snap-ring (6).
4 - Mount the bushing A10 of appropriate diameter on
the tip of the piston rod (4). RKZA1590

5 - Lightly lubricate the cylinder head gaskets (2) and sli-

de the group onto the piston rod (4).
Gaskets: ASL800050
5 22 4
6 - Lubricate the O-ring seals (22) and screw the piston
(5) onto the piston rod (4) by hand for several turns.
O-ring seal: ASL800050 7
7 - Position the group on the tool A1 and tighten the pi-
ston with the round prong wrench A7. 6
Piston: 95 ± 100 kgm

8
RKZ00120

WB91R-2 WB93R-2 30-265

REMOVAL AND INSTALLATION BOOM SWING CYLINDER

4. Re-assembling cylinders
1 - Mount on the apparatus A1 the tool A3 and engage
the cylinder axle oscillation pins (1).
2 - Lubricate the threading and the first part of the cylin-
der (1).
Cylinder: ASL800050
3 - Mount the two halves of the tool A11 with the appro-
priate diameter at the mouth of the cylinder (1).
4 - Mount the piston rod group on the apparatus A1 and
raise the mobile part up to the end of its stroke.
5 - Place the cylinder (1) in a vertical position.
6 - Lower the mobile part of the apparatus in order to
center the piston (5) in the tool A11.
7 - Wind the first guide ring (19) round the piston and in-
sert part of the piston into the tool A11. Wind the se-
cond guide ring (19) and fully insert the piston.
Insert the piston slowly in order to calibrate the guide
rings (19) without overheating them.
8 - Insert the cylinder head (2) and screw it in by hand for
several turns.
9 - Use the special wrench A6 to screw the cylinder head
(4) home.
Cylinder head: 95 ± 100 kgm
10 - Screw the brake cylinder (3) into the cylinder (1).
Brake cylinder: Loctite 270
Brake cylinder: 8 2 kgm
11 - Remove the cylinder from the equipment.
12 - Using and press and the appropriate tool A3 mount
the swing bushings (9).

30-266 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION BACKHOE BACKFRAME LOCK CYLINDER

DISASSEMBLY OF BACKHOE BACKFRAME LOCK CYLINDER

1 - Plug one of the two cylinder (1) ports.

3 2
2 - Connect to the other port compressed air (max. 3
bar).
1

3 - Slowly insert pressure up to piston (2) comes out.

H Retain piston and protect from oil using gloves
and a protection.
4 - Remove gasket (3).
The gasket has be replaced.

RKZ00190

ASSEMBLY OF BACKHOE
BACKFRAME LOCK CYLINDER
1 - Use the tool A9 with the appropriate diameter, mount
the seal ring (3) onto the piston (2).
H Make sure that the lips are turned towards the in-
side of the cylinder.
2 - Put the piston (2) onto cylinder (1).
Cylinder: ASL800050
3 - Apply an elastic band for piston ring and using a
press insert the piston.

WB91R-2 WB93R-2 30-267

REMOVAL AND INSTALLATION BOOM SAFETY CYLINDER

REMOVAL OF THE BOOM SAFETY CYLINDER

Center the backhoe with the arm vertical and the
back of the bucket on the ground.

1 - Make sure that the safety stop (1) is raised.

2 - Stop the engine and release the residual hydraulic
pressures.
3 - Disconnect the tube (2) that feeds the cylinder (3).
Plug the tube to prevent entry of impurities.
4 - Take out the cotter pins, remove the pins (4) and (5)
and the cylinder (3).
RKZA0970

1
3
4

RKZA1310

INSTALLATION OF THE BOOM

SAFETY CYLINDER
. To install, reverse the removal procedure.

Pin seatings: ASL800050

H Install new cotter pins.

1 - Start the engine and perform several lock and release
manoeuvres to fill up and bleed air from the unit.

30-268 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION BACKHOE WORKING EQUIPMENT

REMOVAL OF THE BACKHOE WORKING EQUIPMENT

Fully extend the arm and open the bucket complete-
ly. Lower the equipment until it is resting on the
ground.

1 - Stop the engine and release the residual hydraulic 1

pressures. (For details, see «20. TESTING AND AD- 2
JUSTMENTS»).
2 - Remove the boom cylinder. (For details, see «REMO-
VAL OF BOOM CYLINDER»).
3 - Take out the bracket (1) mounted inside the boom. Di-
sconnect the tubes (2) from the arm cylinders and the
bucket. Plug all tubes to prevent entry of impurities. RKZA1320

H Mark the tubes to prevent exchanging positions

during re-connection.
4 - Put a sling round the equipment (3) and apply slight
tension to the cables.
5 - Take out the snap-rings and remove the pin (4).

3
6 - Remove the working equipment (3).
Working equipment: . . . . . . . . . . . . . . . . . . . . . . kg

4
RKZA1330

INSTALLATION OF THE BACKHOE

WORKING EQUIPMENT
. To install, reverse the removal procedure.

When aligning the positions between the hole and

the pin, turn the engine over at low idling speed. 5
Do not insert fingers into the holes to check align-
ment.

RKZA1340

Internal bushing: ASL800050

H Pass the tubes of the cylinders inside the brackets (5).

1 - Start the engine and bleed the air from the cylinders.
(For details, see «20. TESTING AND ADJUST-
MENTS»).
H After bleeding the air, check the oil level in the tank.

WB91R-2 WB93R-2 30-269

REMOVAL AND INSTALLATION BACKHOE BUCKET

REMOVAL OF THE BACKHOE BUCKET

Place the bucket on a level surface, resting on its
back. 7
4
1 - Take out the safety pin (1) and remove the connecting
6
pin (2) between bucket (3) and tie-rods (4).
2
5
2 - Take out the safety pin (5) and remove the pin (6) that
attaches the bucket to the arm. 1
3

INSTALLATION OF THE
BACKHOE BUCKET
RKZA1350

. To install, reverse the removal procedure.

When aligning the positions between the hole and

the pin, turn the engine over at low idling speed.
Do not insert fingers into the holes to check align-
ment.

Internal bushing: ASL800050

30-270 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION ARM

REMOVAL OF THE ARM

1 - Remove the bucket. (For details, see «REMOVAL OF 4

BUCKET»).
2 - Remove the bucket cylinder and the lever (1). (For de-
tails, see «REMOVAL OF THE BUCKET CYLINDER»).
1
3 - Take off the lock-nut (2), and the washers, and remo- 3
ve the pin (3) and the lever (4).
4 - Start the engine, bring the arm into a vertical position
and lower it to the ground. 2

5 - Stop the engine and release residual pressures from

the cylinder. RKZA1360

6 - Put a sling around the arm cylinder (5), remove the

screws (6) and remove the pin (7).
7 - Start the engine and retract the piston completely (8).
H Secure the fully retracted position by binding the 8 5
piston head with wire.
8 - Rest the cylinder (5) on a block «A».
9 - Stop the engine.
10 - Attach the arm (9) to the hoisting tackle and apply a
slight tension to the cable.
11 - Take out the screws and remove the pin (10).
RKZA1201

12 - Remove the arm (9).

Arm: 213 kg 6
7

INSTALLATION OF THE ARM

. To install, reverse the removal procedure.

When aligning the positions between the hole and

the pin, do not insert fingers into the holes to check
alignment. RKZA1370

Internal bushing: ASL800050

Pin-retaining lock nut:. . . . . . . . . . . . . . . . . . . . . Nm

9
10
When aligning the positions between the hole and
the pin, turn the engine over at low idling speed. A
Do not insert fingers into the holes to check align-
ment.

RKZA1380

WB91R-2 WB93R-2 30-271

REMOVAL AND INSTALLATION BACKHOE BOOM

REMOVAL OF THE BACKHOE BOOM

1 - Remove the arm. (For details, see «REMOVAL OF

THE ARM»).
2 - Remove the arm cylinder. (For details, see «REMO-
1
VAL OF THE ARM CYLINDER»).
2
3 - Start the engine and rest the boom on the ground.
4 - Remove the boom cylinder. (For details, see «REMO-
VAL OF THE BOOM CYLINDER»).
5 - Take out the bracket (1) and disconnect the tubes (2)
from the arm cylinders and the bucket. Plug all tubes
to prevent entry of impurities. RKZA1320

H Mark the tubes to prevent exchanging positions

during re-connection.
6 - Put a sling round the boom (3).
7 - Take out the snap-rings and remove the pin (4).

3
8 - Remove the boom (3).
Boom: 323 kg

4
INSTALLATION OF THE
BACKHOE BOOM RKZA1390

. To install, reverse the removal procedure.

When aligning the positions between the hole and

the pin, turn the engine over at low idling speed.
Do not insert fingers into the holes to check align-
ment.

Internal bushing: ASL800050

H Pass the cylinder tubes inside the brackets (5). RKZA1340

1 - Start the engine and bleed the air from the cylinders.
(For details, see «20. TESTING AND ADJUST-
MENTS»).
H After bleeding the air, check the oil level in the tank.

30-272 WB91R-2 WB93R-2

REMOVAL AND INSTALLATION BACKHOE SWING BRACKET

REMOVAL OF THE BACKHOE SWING BRACKET

1 - Remove the working equipment. (For details, see

«REMOVAL OF THE WORKING EQUIPMENT»).
2
2 - Take out the screws (1) and remove the pins (2) that
connect the swing cylinders (3).
3 - Disconnect the tube (4) of the boom safety cylinder (5)
and remove the retaining clip (6). Plug the tube to pre- 3
vent entry of impurities.
1
4 - Take out the four screws (7) and remove the boom sa-
fety group (8).
5 - Put a sling round the swing bracket (9). RKZA7760

6 - Take out the screws (10) and (11) and remove the
swing bracket axle oscillation pins (12) and (13).
8
5
7 - Remove the swing bracket (9) and the relative shim
adjustments to given clearance.
7
Bracket: 133 kg
4

RKZA1400

INSTALLATION OF THE
10
BACKHOE SWING BRACKET 12
9
. To install, reverse the removal procedure.

When aligning the positions between the hole and

the pin, turn the engine over at low idling speed. 13
Do not insert fingers into the holes to check align-
11
ment.

RKZA1410

Internal bushing: ASL800050

Safety group screws: 27w3 kgm

H Insert the shims. 9

1 - Start the engine and bleed the air from the cylinders.
(For details, see «20. TESTING AND ADJUST-
MENTS»).
H After bleeding the air, check the oil level in the tank.

RKZA1420

WB91R-2 WB93R-2 30-273

REMOVAL AND INSTALLATION BACKHOE BACKFRAME

REMOVAL OF BACKHOE BACKFRAME

1 - Remove the equipment. (For detail see «REMOVAL 5 6

OF BACKHOE WORKING EQUIPMENT»).
2 - Remove the swing cylinders. (For detail see «REMO-
VAL OF SWING CYLINDER»). 1 2

3 - Remove the swing bracket. (For detail see «REMO-

VAL OF SWING BRACKET»).
4 - Disconnect from union (1) the feeding pipes (2) of
backhoe backframe and plug them to avoid impurity
entry.
5 - Loose nuts (4) and remove washers (5) and four RKZA1430

screw (6).
Loose partially lateral nuts (4) to remove backframe
(3) from frame (8).
7 4 5
6 - Put a sling round the backframe (3) and apply slight 8
tension to the cables.
7 - Remove external nuts (4), washers (5) and screws (6).

8 - Remove the sliding piece (7) and then lower the back
frame (3) and remove it.
Backframe:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . kg 3
RKZA1440

INSTALLATION OF
BACKHOE BACKFRAME
. To install, reverse the removal procedure.
3

Nut: Loctite 262

Nut: 100w10 kgm
1 - Start the engine and bleed the air from the cylinders.
(For details, see «20. TESTING AND ADJUST-
MENTS»).
H After bleeding the air, check the oil level in the tank. RKZA1660

30-274 WB91R-2 WB93R-2

 STANDARD MAINTENANCE

Transmission . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 3 3-spool control valve . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 20

Front axle . . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 8 3-spool control valve
Differential .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 8 (With return to dig) . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 22
Planetary - Joint . . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . 9 6-spool control valve . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 24
Steering unit cylinder . . . . .. . . . . .. . . . .. . . . . .. . . . .. . 10 7-spool control valve . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 27
Rear axle . . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 11 8-spool control valve . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 29
Differential .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 11 Brake pump .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 31
Planetary . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 12 Shovel cylinder . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 32
Brake .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 13 Backhoe cylinder .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 34
Differential lock .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 14 Front working equipment . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 38
Hydraulic pump . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 16 Swing bracket . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . 40
2-spool control valve . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . 18 Backhoe working equipment . . . .. . . . . .. . . . . .. . . . .. . . . 42

WB91R-2 WB93R-2 40-1

40-2 WB91R-2 WB93R-2
TRANSMISSION

F A

23 Nm

23 Nm

C C
H H
E E
B B

23 Nm
23 Nm 23 Nm RKZ00971

WB91R-2 WB93R-2 40-3

 50w2.5 Nm

50w2.5 Nm

23w1 Nm

40w4 Nm
139w7 Nm

Loctite 518

30w1.5 Nm
with Loctite 542

23w1 Nm
Loctite 510

RKZ00981
Sezione A - A
Section A - A

40-4 WB91R-2 WB93R-2

 23w1 Nm 80w4 Nm 10w0.5 Nm

50w2.5 Nm
with Loctite 542

Sezione B - B
Section B - B

23w1 Nm

D D

30w1.5 Nm 26 ± 30 Nm

Section CC -- C
Sezione C RKZ01260

WB91R-2 WB93R-2 40-5

 9 ± 11 Nm

7 ± 10 Nm

21.5 ± 24.5 Nm

Section
SezioneDD- -DD

5 ± 8 Nm 22w1 Nm 23w1 Nm

Section
SezioneEE- -EE
RKZ01270

40-6 WB91R-2 WB93R-2

 40w2 Nm

100w10 Nm 23w1 Nm 50w2.5 Nm

with Loctite 270

Sezione F
F -- FF Section G -- G
Sezione G G
Section

Loctite 638

RKZ01280
Section H -- H
Sezione H H

WB91R-2 WB93R-2 40-7

FRONT AXLE

Differential

95w5 Nm
with Loctite 270 13 Nm
266w13 Nm

60w3 Nm
Loctite 510
169w8.5 Nm
Loctite 242
Loctite 270
2
. . . . . . . . . Nm

3
57w3 Nm 4

RKZ00810

Unit: mm

Në Check item Criteria Remedy

Standard clearance Clearance limit

1 Axle clearance

Backlash of crown wheel

2 0.17 ± 0.23
and pinion
Adjust
Pinion preload
3 9.2 ± 13.7 daN
(without seal ring)

Pinion-crown wheel preload

4
(without seal ring)

40-8 WB91R-2 WB93R-2

Planetary - Joint

190w9.5 Nm
80 Nm 1 8 Nm

230w11.5 Nm

70 Nm 8 Nm
with Loctite 270

70 Nm RKZ00820
with Loctite 542

Unit: mm

Në Check item Criteria Remedy

1 Hub rotation torque Adjust

2 Drive shaft axle clearance Replace

WB91R-2 WB93R-2 40-9

Steering unit cylinder

120w6 Nm
B

C 300w15 Nm 350w9.8 Nm

A
500

A
250w12.5 Nm
1984
+
1984 +02

1 ........

220w11 Nm 150w7.5 Nm
Sezione A - A Sezione B - B Particolare C
Section A - A Section B - B Detail C RKZ00840

Unit: mm

Në Check item Criteria Remedy

Tolerance
Standard Standard Clearance
size clearance limit Replace bus-
Clearance between Shaft Hole
1 hing
bushing and pin
and pin
50

40-10 WB91R-2 WB93R-2

REAR AXLE

Differential

13 Nm 155w7.8 Nm
130w6.5 Nm
with Loctite 270
25w1.25 Nm
230w11.5 Nm Loctite 638 with Loctite 638

80w4 Nm

1 120w6 Nm
. . . . . . . . . Nm 2

Loctite 542
70w3.5 Nm

3
4 RKZ00870

Unit: mm

Në Check item Criteria Remedy

Standard clearance Clearance limit

1 Axle clearance

Backlash of crown wheel

2
and pinion
Adjust
Pinion preload
3 9.2 ± 13.8 daN
(without seal ring)

Pinion-crown wheel preload

4
(without seal ring)

WB91R-2 WB93R-2 40-11

Planetary - Joint

70w3.5 Nm
with Loctite 542

70 Nm
500w9.8 Nm with Loctite 270

230w11.5 Nm

35w1.75 Nm

Loctite 518

60w3 Nm

80 Nm Loctite 518
RKZ00880

Unit: mm

Në Check item Criteria Remedy

1 Hub rotation torque Adjust

2 Drive shaft axle clearance

40-12 WB91R-2 WB93R-2

Brakes

2 1
10w0.5 Nm

8 ± 12 Nm
10 Nm 35w1.75 Nm

15 Nm
10w0.5 Nm
with Loctite 270
Sezione A - A
Section A - A
A
A

10w0.5 Nm RKZ00890

Unit: mm

Në Check item Criteria Remedy

Standard size Repair limit

Replace if
Free Installed Installed Free Installed
1 Brake disc return spring damaged or
installed length load installed load
deformed

Standard thickness Min. thickness

2 Disc thickness Replace

WB91R-2 WB93R-2 40-13

Differential lock

23 Nm 23 Nm

RKZ00900

40-14 WB91R-2 WB93R-2

WB91R-2 WB93R-2 40-15
HYDRAULIC PUMP

1 5 2

A
3

Particolare A RKZ01290
Detail A
Unit: mm

Në Check item Criteria Remedy

1 Ball-bearing loading 0 ± 0.05 Adjust

Tolerance
Standard Standard Clearance
Backlash between piston size clearance limit
2 Shaft Hole
and cylinder

Backlash between piston

3
and shoe

Standard value Max. value

4 Drive shaft diameter

Tolerance
Standard Standard Clearance
size clearance limit
5 Spring Shaft Hole

40-16 WB91R-2 WB93R-2

 1 2 3

. . . . . . . . . Nm . . . . . . . . . Nm . . . . . . . . . Nm
Sezione C - C
Section C - C

. . . . . . . . . Nm 5 . . . . . . . . . Nm . . . . . . . . . Nm
4

. . . . . . . . . Nm 6 . . . . . . . . . Nm . . . . . . . . . Nm
7

SectionDD- -DD
Sezione RKZ00641

Unit: mm

Në Check item Criteria Remedy

Standard size Repair limit
Free
Installed Installed Free Installed
1 Spring installed
length load installed load
x ée

Power regulation spring

2
(external)
Power regulation spring
3
(internal)
4 PC valve spring (external)
5 PC valve spring (internal)
6 LS valve spring (external)
7 LS valve spring (internal)

WB91R-2 WB93R-2 40-17

2-SPOOL CONTROL VALVE

D C A
. . . . . . . . . Nm
. . . . . . . . . Nm

. . . . . . . . . Nm

D C A

25 Nm 20 Nm
20 Nm
with Loctite 542
B

8 Nm
with Loctite 542 1

25 Nm
with Loctite 542
2
B
25 Nm
Section
Sezione A
A -- A
A Section B
Sezione B -- B
B RKZ01081

Unit: mm

Në Check item Criteria Remedy

Standard size Repair limit
Free
Installed Installed Free Installed
1 Check valve spring installed
length load installed load
x ée

2 Priority valve spring

40-18 WB91R-2 WB93R-2

 10w1 Nm 10w1 Nm
10w1 Nm E
E
70w7 Nm 70w7 Nm

. . . . . . . . . Nm

. . . . . . . . . Nm

E
1 10w1 Nm 1 E 10w1 Nm
Sezione
Section CC--C
C
Section
Sezione D
D -- D
D

30w3 Nm 2

RKZ00661
Sezione E - E
Section E - E

Unit: mm

Në Check item Criteria Remedy

Standard size Repair limit
Free
Installed Installed Free Installed
1 Spool return spring installed
length load installed load
x ée

2 Check valve spring

WB91R-2 WB93R-2 40-19

3-SPOOL CONTROL VALVE

D C A
. . . . . . . . . Nm . . . . . . . . . Nm

. . . . . . . . . Nm

D C A
E
25 Nm
20 Nm 20 Nm
B with Loctite 542

8 Nm
with Loctite 542
1
25 Nm
with Loctite 542

2
B 100 Nm
Sezione A - A Sezione B - B RKZ01071
Section A - A Section B - B

Unit: mm

Në Check item Criteria Remedy

Standard size Repair limit
Free
Installed Installed Free Installed
1 Spool return spring installed
length load installed load
x ée

2 Check valve spring

40-20 WB91R-2 WB93R-2

 70w7 Nm 10w1 Nm
F F 10w1 Nm
70w7 Nm

. . . . . . . . . Nm

1 70w7 Nm
. . . . . Nm
2
F
70w7 Nm

F
F 10w1 Nm
. . . . . . .Nm 3
Section C
Sezione C -- C
C
10w1 Nm Sezione D - D
Section D - D

70w7 Nm

30w3 Nm 4

4
. . . . . . . . . Nm

70w7 Nm Sezione F - F
Section F - F

F
Section
Sezione E -EE- E RKZ01300

Unit: mm

Në Check item Criteria Remedy

Standard size Repair limit
Free
Installed Installed Free Installed
1 Spool return spring installed
length load installed load
x ée

2 Spool locking spring

3 Spool return spring
4 Check valve spring

WB91R-2 WB93R-2 40-21

3-SPOOL CONTROL VALVE
With return to dig

D C A

. . . . . . . . . Nm

. . . . . . . . . Nm

. . . . . . . . . Nm

C A

E D
25 Nm 20 Nm 20 Nm
B with Loctite 542

8 Nm
with Loctite 542
1

2
B
100 Nm

SectionAA--AA
Sezione
SectionBB--B
Sezione B RKZ01091

Unit: mm

Në Check item Criteria Remedy

Standard size Repair limit
Free
Installed Installed Free Installed
1 Spool return spring installed
length load installed load
x ée

2 Spool locking spring

3 Spool return spring
4 Check valve spring

40-22 WB91R-2 WB93R-2

 10w1 Nm 10w1 Nm F 10w1 Nm
F
70w7 Nm
70w7 Nm

. . . . . . . . . Nm

. . . . . Nm 1 3

2
70w7 Nm
70w7 Nm
F
F
. . . . . . . . . Nm
. . . . . . . . . Nm Section
SezioneCC--CC
F
. . . . . . . . . Nm

Sezione D - D
70w7 Nm Section D - D

30w3 Nm 4

. . . . . . . . . Nm 4

70w7 Nm

Sezione F - F
Section F - F
F
Sezione E - E
Section E - E RKZ00941

Unit: mm

Në Check item Criteria Remedy

Standard size Repair limit
Free
Installed Installed Free Installed
1 Spool return spring installed
length load installed load
x ée

2 Spool locking spring

3 Spool return spring
4 Spool return spring
5 Check valve spring

WB91R-2 WB93R-2 40-23

6-SPOOL CONTROL VALVE

G E B D D C B A
H . . . . . . . . . Nm

H
G E B D D C B A

G 10w1 Nm
70w7 Nm
70 Nm 45 Nm

20 Nm
with Loctite 542

. . . . . . . . . Nm

70 Nm
70w7 Nm
Sezione A
Section A -- A
A
1 10w1 Nm
G
Sezione B - B RKZ00231
Section B - B

Unit: mm

Në Check item Criteria Remedy

Standard size Repair limit
Free
Installed Installed Free Installed
1 Spool return spring installed
length load installed load
x ée

40-24 WB91R-2 WB93R-2

 F 10w1 Nm 10w1 Nm F 10w1 Nm
70w7 Nm
70w7 Nm

. . . . . . . . . Nm

70w7 Nm 70w7 Nm
F 1
1 F 10w1 Nm
SezioneDD- -DD
Section
Sezione C - C
Section C - C

10w1 Nm F 10w1 Nm

70w7 Nm

2
30w3 Nm

10w1 Nm
Section FF -- F
Sezione F
70w7 Nm F 1
RKZ01310
Sezione E - E
Section E - E
Unit: mm

Në Check item Criteria Remedy

Standard size Repair limit
Free
Installed Installed Free Installed
1 Spool return spring installed
length load installed load
x ée

2 Check valve spring

WB91R-2 WB93R-2 40-25

 25 Nm

10 Nm

20 Nm 20 Nm
SectionGG--GG
Sezione
RKZ00791
Sezione H - H
Section H - H

Unit: mm

Në Check item Criteria Remedy

Standard size Repair limit
Free
Installed Installed Free Installed
1 Unloading valve spring installed
length load installed load
x ée

40-26 WB91R-2 WB93R-2

7-SPOOL CONTROL VALVE

For jig arm

A

A
RKZ00241

For side digging boom

B RKZ00251

For hammer
C

C
RKZ00261

WB91R-2 WB93R-2 40-27

 10w1 Nm 10w1 Nm

70w7 Nm 70w7 Nm

. . . . . . . . . Nm . . . . . . . . . Nm

70w7 Nm
10w1 Nm
10w1 Nm 1 70w7 Nm 10w1 Nm
1
Sezione A - A Sezione B - B
Section A - A Section B - B

10w1 Nm

70w7 Nm

. . . . . . . . . Nm

. . . . . . . . . Nm

70w7 Nm 10w1 Nm
1
Sezione C - C
Section C - C RKZ00961

Unit: mm

Në Check item Criteria Remedy

Standard size Repair limit
Free
Installed Installed Free Installed
1 Spool return spring installed
length load installed load
x ée

40-28 WB91R-2 WB93R-2

8-SPOOL CONTROL VALVE

For hammer and jig arm

C A
a b

d C A
RKZ00271

For side digging boom and jig arm

B A
e b

f B A c RKZ00281

WB91R-2 WB93R-2 40-29

 10w1 Nm 10w1 Nm

70w7 Nm 70w7 Nm

. . . . . . . . . Nm . . . . . . . . . Nm
70w7 Nm

10w1 Nm
1 70w7 Nm 10w1 Nm
10w1 Nm 1
Sezione A - A Sezione B - B
Section A - A Section B - B

10w1 Nm

70w7 Nm

. . . . . . . . . Nm

. . . . . . . . . Nm

70w7 Nm 10w1 Nm
1
Sezione C - C
Section C - C RKZ00961

Unit: mm

Në Check item Criteria Remedy

Standard size Repair limit
Free
Installed Installed Free Installed
1 Spool return spring installed
length load installed load
x ée

40-30 WB91R-2 WB93R-2

BRAKE PUMP

1 2 3

4
RKZ00931

Unit: mm

Në Check item Criteria Remedy

Standard size Repair limit

Free Installed Installed Free Tolerance

1 Ball valve spring
installed length load installed load
Replace if
damaged or
w8 N
deformed
2 Spring

3 Pump spring

4 Spring

WB91R-2 WB93R-2 40-31

SHOVEL CYLINDER

DUMP CYLINDER

290w29 kgm

3 1 2

RKZ00780

RAISE CYLINDER

290w29 kgm

3 1 2

RKZ00770

Unit: mm

Në Check item Criteria Remedy

Tolerance
Standard Standard Clearance
Cylinder
size clearance limit
Tolerance between Shaft Hole
1 piston rod and
cylinder head Raise 50

Dump 50

Tolerance between Raise 45

2 bushing and piston
rod mounting pin Dump 45

Tolerance Raise 50
between bushing
3
and cylinder
mounting pin Dump 50

40-32 WB91R-2 WB93R-2

WB91R-2 WB93R-2 40-33
BACKHOE CYLINDER

BOOM

95 ± 100 kgm

1 3
2

RKZ00750

ARM

95 ± 100 kgm 290w29 kgm

1 3
2

RKZ00740

BUCKET

95 ± 100 kgm 290w29 kgm

2 1 3

RKZ00730

40-34 WB91R-2 WB93R-2

BOOM SWING

95 ± 100 kgm

1
2

RKZ00720

Unit: mm

Në Check item Criteria Remedy

Tolerance
Standard Standard Clearance
Cylinder
size clearance limit
Shaft Hole

Clearance between Boom 55

1 piston head and Replace
cylinder head Arm 60

Bucket 60

Boom swing 50

Boom 45

Tolerance between Arm 45

2 bushing and piston
head mounting pin Bucket 45
Replace
Boom swing 50 pin and
spring
Boom 45
Tolerance
between bushing
3 Arm 45
and cylinder
mounting pin
Bucket 45

WB91R-2 WB93R-2 40-35

OUTRIGGER

155w15 kgm

RKZ00710

JIG ARM

155w15 kgm

RKZ00700

SIDE DIGGING BOOM

95 ± 100 kgm

3 2 4

RKZ00680

40-36 WB91R-2 WB93R-2

ARM (for side digging boom)

3 1 5

RKZ00670

Unit: mm

Në Check item Criteria Remedy

Tolerance
Standard Standard Clearance
Cylinder
size clearance limit
Shaft Hole
Clearance between
Outrigger 40
1 piston rod and
cylinder head
Arm for side
60
digging boom

Jig arm 40

Clearance between
Side digging
2 piston rod and 45
boom
bushing
Replace
Side digging
40
Tolerance between boom
3 bushing and piston
rod mounting pin Arm for side
45
digging boom

Tolerance
between bushing Side digging
4 40
and cylinder boom
mounting pin

Clearance between
Arm for side
5 bearing and bearing 75
digging boom
seat

WB91R-2 WB93R-2 40-37

FRONT WORKING EQUIPMENT

E
C
C E

D
B
B
A

1 2 3

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

Sezione C - C
Section C - C

5
4

Sezione D - D
Section D - D Sezione E - E
Section E - E RKZ02270

40-38 WB91R-2 WB93R-2

 Unit: mm

Në Check item Criteria Remedy

Tolerance
Standard Standard Clearance
size clearance limit
Clearance between bushing Shaft Hole
1
and bucket mounting pin
±0.050 +0.080
45 0.130 ± 0.329
±0.089 +0.240

Clearance between bushing ±0.050 +0.080

2 45 0.130 ± 0.329
and link mounting pin ±0.089 +0.240
Replace
Clearance between bushing ±0.050 +0.080
3 45 0.130 ± 0.208
and tilt lever mounting pin ±0.089 +0.119

Clearance between bushing ±0.050 +0.080

4 45 0.130 ± 0.208
and link mounting pin ±0.089 +0.119

Clearance between bushing ±0.038 +0.080

5 50 0.118 ± 0.323
and boom mounting pin ±0.093 +0.240

WB91R-2 WB93R-2 40-39

SWING BRACKET

A C
1
3
4

Section B
Sezione B -- B
B
2

1 6
Section
Sezione A
A -- A
A

Section
SezioneCC- C
-C
RKZ02720

40-40 WB91R-2 WB93R-2

 Unit: mm

Në Check item Criteria Remedy

Tolerance
Standard Standard Clearance
Clearance between rotating size clearance limit
Shaft Hole
1 bushing and boom swing
cylinder bushing
± 0.060 + 0.090
55 0.120 ± 0.196
± 0.106 + 0.060

Clearance between bushing

± 0.060 + 0.190
2 and (lower) swing bracket 65 0.250 ± 0.370
± 0.106 + 0.264
rotating pin
Replace
bushing
Clearance between bushing
± 0.060 + 0.190 and pin
3 and (upper) swing bracket 65 0.250 ± 0.370
± 0.106 + 0.264
rotating pin

Standard size Limit size

Clearance between bushing
4
and mounting pin
4.75 0.1

5 Central shim thickness 4.75 0.1

6 Lower shim thickness 4.75 0.1

WB91R-2 WB93R-2 40-41

BACKHOE WORKING EQUIPMENT

C
C

B A
A
D

3
2

1
4

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

5 6 6

Sezione D - D
Sezione C - C Section D - D RKZ02900
Section C - C

40-42 WB91R-2 WB93R-2

 Unit: mm

Në Check item Criteria Remedy

Tolerance
Standard Standard Clearance
Clearance between link size clearance limit
Shaft Hole
1 bushings and bucket
mounting pin
± 0.050 ± 0.080
40 0.130 ± 0.329
± 0.089 ± 0.240

Clearance between arm

± 0.050 ± 0.080
2 bushings and bucket 40 0.130 ± 0.329
± 0.089 ± 0.240
mounting pin
Replace
Clearance between arm spring and
± 0.050 ± 0.080
3 bushings and lever 45 0.130 ± 0.329 pin
± 0.089 ± 0.240
mounting pin

Clearance between bushings ± 0.050 ± 0.080

4 45 0.130 ± 0.329
and tilt lever mounting pin ± 0.089 ± 0.240

Clearance between bushings ± 0.050 ± 0.080

5 50 0.130 ± 0.208
and arm mounting pin ± 0.089 ± 0.119

Clearance between
± 0.038 ± 0.080
6 bushings and boom 50 0.118 ± 0.202
± 0.083 ± 0.119
mounting pin

WB91R-2 WB93R-2 40-43

40-44 WB91R-2 WB93R-2