WB97R 2

WEBM001001
40-28 PC15R-8
CONTENTS
Page
10 STRUCTURE AND FUNCTION........................................................................................ 10-1
20 TESTING AND ADJUSTING ............................................................................................ 20-1
30 DISASSEMBLY AND ASSEMBLY .................................................................................. 30-1
40 MAINTENANCE STANDARD ........................................................................................... 40-1
WB97R-2 00-1
PAGE INTENTIONALLY
LEFT BLANK
REVISED PAGES
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 be-
low.
❍ Page to be newly Add
● Page to be replaced Replace
( ) Page to be delete Discard
Pages having no marks are those previously revised or

made additions.
LIST OF REVISED PAGES
Tim e of Tim e o f Time of T im e of Tim e of

Mark Page Mark Page Mark Page Mark Page Mark Page
revision revision revision revision revision
00-1 10-17 10-58 20-2 20-43

00-2 10-18 10-59 20-3 20-44
00-2-1 10-19 10-60 20-4 20-45
00-2-2 10-20 10-61 20-5 20-46
00-3 10-21 10-62 20-6 20-47
00-4 10-22 10-63 20-7 20-48
00-5 10-23 10-64 20-8 20-49
00-6 10-24 10-65 20-9 20-50
00-7 10-25 10-66 20-10 20-51
00-8 10-26 10-67 20-11 20-52
00-9 10-27 10-68 20-12 20-53
00-10 10-28 10-69 20-13 20-54
00-11 10-29 10-70 20-14 20-55
00-12 10-30 10-71 20-15 20-56
00-13 10-31 10-72 20-16 20-57
00-14 10-32 10-73 20-17 20-58
00-15 10-33 10-74 20-18 20-59
00-16 10-34 10-75 20-19 20-60
00-17 10-35 10-76 20-20 20-61
00-18 10-36 10-77 20-21 20-62
00-19 10-37 10-78 20-22 20-63
00-20 10-38 10-79 20-23 20-64
00-21 10-39 10-80 20-24 20-65
00-22 10-40 10-81 20-25 20-66
10-41 10-82 20-26 20-67
10-1 10-42 10-83 20-27 20-68
10-2 10-43 10-84 20-28 20-69
10-3 10-44 10-85 20-29 20-70
10-4 10-45 10-86 20-30 20-71
10-5 10-46 10-87 20-31 20-72
10-6 10-47 10-88 20-32 20-73
10-7 10-48 10-89 20-33 20-74
10-8 10-49 10-90 20-34 20-75
10-9 10-50 10-91 20-35 20-76
10-10 10-51 10-92 20-36 20-77
10-11 10-52 10-93 20-37 20-78
10-12 10-53 10-94 20-38 20-79
10-13 10-54 10-95 20-39 20-80
10-14 10-55 10-96 20-40
10-15 10-56 20-41 30-1
10-16 10-57 20-1 20-42 30-2
WB97R-2 00-2-1
REVISED PAGES
Tim e o f Time of T im e of Tim e of Tim e o f

Mark Page Mark Page Mark Page Mark Page Mark Page
revision revision revision revision revision
30-3 30-66 30-129 30-192 30-255

30-4 30-67 30-130 30-193 30-256
30-5 30-68 30-131 30-194 30-257
30-6 30-69 30-132 30-195 30-258
30-7 30-70 30-133 30-196 30-259
30-8 30-71 30-134 30-197 30-260
30-9 30-72 30-135 30-198 30-261
30-10 30-73 30-136 30-199 30-262
30-11 30-74 30-137 30-200
30-12 30-75 30-138 30-201 40-1
30-13 30-76 30-139 30-202 40-2
30-14 30-77 30-140 30-203 40-3
30-15 30-78 30-141 30-204 40-4
30-16 30-79 30-142 30-205 40-5
30-17 30-80 30-143 30-206 40-6
30-18 30-81 30-144 30-207 40-7
30-19 30-82 30-145 30-208 40-8
30-20 30-83 30-146 30-209 40-9
30-21 30-84 30-147 30-210 40-10
30-22 30-85 30-148 30-211 40-11
30-23 30-86 30-149 30-212 40-12
30-24 30-87 30-150 30-213 40-13
30-25 30-88 30-151 30-214 40-14
30-26 30-89 30-152 30-215 40-15
30-27 30-90 30-153 30-216 40-16
30-28 30-91 30-154 30-217 40-17
30-29 30-92 30-155 30-218 40-18
30-30 30-93 30-156 30-219 40-19
30-31 30-94 30-157 30-220 40-20
30-32 30-95 30-158 30-221 40-21
30-33 30-96 30-159 30-222 40-22
30-34 30-97 30-160 30-223 40-23
30-35 30-98 30-161 30-224 40-24
30-36 30-99 30-162 30-225 40-25
30-37 30-100 30-163 30-226 40-26
30-38 30-101 30-164 30-227 40-27
30-39 30-102 30-165 30-228 40-28
30-40 30-103 30-166 30-229 40-29
30-41 30-104 30-167 30-230 40-30
30-42 30-105 30-168 30-231 40-31
30-43 30-106 30-169 30-232 40-32
30-44 30-107 30-170 30-233 40-33
30-45 30-108 30-171 30-234 40-34
30-46 30-109 30-172 30-235 40-35
30-47 30-110 30-173 30-236 40-36
30-48 30-111 30-174 30-237 40-37
30-49 30-112 30-175 30-238 40-38
30-50 30-113 30-176 30-239 40-39
30-51 30-114 30-177 30-240 40-40
30-52 30-115 30-178 30-241
30-53 30-116 30-179 30-242
30-54 30-117 30-180 30-243
30-55 30-118 30-181 30-244
30-56 30-119 30-182 30-245
30-57 30-120 30-183 30-246
30-58 30-121 30-184 30-247
30-59 30-122 30-185 30-248
30-60 30-123 30-186 30-249
30-61 30-124 30-187 30-250
30-62 30-125 30-188 30-251
30-63 30-126 30-189 30-252
30-64 30-127 30-190 30-253
30-65 30-128 30-191 30-254
00-2-2 WB97R-2
SAFETY
IMPORTANT SAFETY NOTICE

Proper service and repair is extremely important for the safe operation of your machine.
The service and repair techniques recommended by Komatsu Utility and describe in this manual are both ef-
fective and safe methods of operation. Some of these operations require the use of tools specially designed
by Komatsu Utility for the purpose.
To prevent injury to workers, the symbols and are used to mark safety precautions in this manual.
The cautions accompanying these symbols should always be carefully followed. If any danger arises or may
possibly arise, first consider safety, and take necessary steps to face.
SAFETY
GENERAL PRECAUTIONS PREPARATIONS FOR WORK
Mistakes in operation extremely dangerous. 7. Before adding or making any repairs, park the ma-
Read all the Operation and Maintenance Manual care- chine on hard, level ground, and block the wheels to
fully BEFORE operating the machine. prevent the machine from moving.
1. Before carrying out any greasing or repairs, read all 8. Before starting work, lower outrigger, bucket or any
the precautions written on the decals which are suck other work equipment to the ground. If this is not
on the machine. possible, use blocks to prevent the work equipment
2. When carrying out any operation, always wear safe- from falling down. In addition, be sure to lock all the
ty shoes and helmet. Do not wear loose work control levers and hang warning sign on them.
clothes, or clothes with buttons missing. 9. When disassembling or assembling, support the
• Always wear safety glasses when hitting parts machine with blocks, jacks or stands before starting
with a hammer. work.
• Always wear safety glasses when grinding 10. Remove all mud and oil from the steps or other plac-
parts with a grinder, etc. es used to get on and off the machine. Always use
3. If welding repairs are needed, always have a the handrails, ladders or steps when getting on or off
trained, experienced welder carry out the work. the machine.
When carrying out welding work, always wear weld- Never jump on or off the machine.
ing gloves, apron, glasses, cap and other clothes If it is impossible to use the handrails, ladders or
suited for welding work. steps, use a stand to provide safe footing.
4. When carrying out any operation with two or more
PRECAUTIONS DURING WORK
workers, always agree on the operating procedure
before starting. Always inform your fellow workers 11. When removing the oil filler cap, drain plug or hy-
before starting any step of the operation. Before draulic pressure measuring plugs, loosen them
starting work, hang UNDER REPAIR signs on the slowly to prevent the oil from spurting out.
controls in the operator’s compartment. Before disconnecting or removing components of
the hydraulic circuit and engine cooling circuit, first
5. Keep all tools in good condition and learn the correct
remove the pressure completely from the circuit.
way to use them.
12. The water and oil in the circuits are not hot when the
6. Decide a place in the repair workshop to keep tools
engine in stopped, so be careful not to get burned.
and removed parts. Always keep the tools and parts
Wait for the oil water to cool before carrying out any
in their correct places. Always keep the work area
work on the cooling water circuits.
clean and make sure that there is no dirt or oil on the
floor. 13. Before starting work, remove the leads from the bat-
Smoke only in the areas provided for smoking. Nev- tery. Always remove the lead from the negative ( – )
er smoke while working. terminal first.
WB97R-2 00-3
SAFETY
14. When raising heavy components, use a hoist or 19. Be sure to assemble all parts again in their original
crane. Check that the wire rope, chains and hooks places. Replace any damage parts with new parts.
are free from damage. When installing hoses and wires, be sure that they
Always use lifting equipment which has ample ca- will not be damaged by contact with other parts
pacity. Install the lifting equipment at the correct when the machine is being operated.
places. 20. When installing high pressure hoses, make sure
Use a hoist or crane and operate slowly to prevent that they are not twisted. Damaged tubes are dan-
the component from hitting any other part. gerous, so be extremely careful when installing
Do not work with any part still raised by the hoist or tubes for high pressure circuits. Also, check that
crane. connecting parts are correctly tightened.
15. When removing covers which are under internal 21. When assembling or installing parts, always use
pressure or under pressure from a spring, always specified tightening torques.
leave two bolts in position on opposite sides. Slowly When installing the parts which vibrate violently or
release the pressure, then slowly loosen the bolts to rotate at high speed, be particulary careful to check
remove. that they are correctly installed.
16. When removing components, be careful not to 22. When aligning two holes, never insert your fingers
break or damage the wiring. or hand.
Damage wiring may cause electrical fires.
23. When measuring hydraulic pressure, check that the
17. When removing piping, stop the fuel or oil from spill- measuring tool is correctly assembled before taking
ing out. If any fuel or oil drips on to the floor, wipe it up any measurement.
immediately.
Fuel or oil on the floor can cause you to slip, or can 24. Take sure when removing or installing wheels.
even start fires.
18. As a general rule, do not use gasoline to wash parts.
In particular, use only the minimum of gasoline
when washing electrical parts.
00-4 WB97R-2
FOREWORD
FOREWORD
This shop manual has been prepared as an aid to improve the quality of repairs by giving the operator an accurate
understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure
you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service work-
shop.
The manual is divided into chapters on each main group of components; these chapters are further divided into the
following sections.
STRUCTURE AND FUNCTION

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

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

This section explains the order to be followed when removing, installing, disassembling or assembling each
component, as well as precautions to be taken for these operations.
MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.
NOTE
The specifications contained in this shop manual are subject to change at any time and without any no-
tice.
Contact your Komatsu Utility distributor for the latest information.
WB97R-2 00-5
HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL

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

DISTRIBUTION AND UPDATING
Any additions, amendments or other changes will be Special safety precautions
sent to Komatsu Utility distributors. are necessary when
Get the most up-to-date information before you start any performing the work.
work.
Safety
Extra special safety precautions
are necessary when performing
FILING METHOD the work because it is under in-
1. See the page number on the bottom of the page. ternal pressure.
File the pages in correct order.
Special technical precautions or
2. Following examples show you how to read the page
number. ★ Caution
other precautions for preserving
standards are necessary when
Example: performing the work.
10 - 3 Weight of parts or systems.

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

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

(➀ ➁ ➂ ....)
When a manual is revised, an edition mark is recorded
on the bottom outside corner of the pages.
REVISIONS
Revised pages are shown on the LIST OF REVISED PA-
GES between the title page and SAFETY page.
00-6 WB97R-2
HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
Hooks have maximum strength at the middle por-
tion.
Heavy parts (25 kg or more) must be lifted
with a hoist etc. In the Disassembly and Assem-
bly section, every part weighing 25 kg or more is
clearly indicated with the symbol
1. If a part cannot be smoothly removed from the ma-

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

sixth or one-seventh of the breaking strength of the
rope used.
2) Sling wire ropes from the middle portion of the hook.
Slinging near the edge of the hook may cause the
rope to slip off the hook during hoisting, and a se-
rious accident can result.
WB97R-2 00-7
STANDARD TIGHTENING TORQUE

The following charts give the standard tightening torques of bolts and nuts.
Exceptions are given in section of «Disassembly and Assembly».
1. STANDARD TIGHTENING TORQUE OF BOLTS AND NUT
Width across flat

Thread Pitch of (mm)
diameter of bolts bolts
(mm) (mm) kgm Nm kgm Nm
6 1 10 8 0.96±0.1 9.5±1 1.3±0.15 13.5±1.5
8 1.25 13 6 2.3±0.2 23±2 3.2±0.3 32.2±3.5
10 1.5 17 8 4.6±0.5 45±4.9 6.5±0.6 63±6.5
12 1.75 19 10 7.8±0.8 77±8 11±1 108±11
14 2 22 12 12.5±1 122±13 17.5±2 172±18
16 2 24 14 19.5±2 191±21 27±3 268±29
18 2.5 27 14 27±3 262±28 37±4 366±36
20 2.5 30 17 38±4 372±40 53±6 524±57
22 2.5 32 17 52±6 511±57 73±8 719±80
24 3 36 19 66±7 644±70 92±10 905±98
27 3 41 19 96±10 945±100 135±15 1329±140
30 3.5 46 22 131±14 1287±140 184±20 1810±190
33 3.5 50 24 177±20 1740±200 250±27 2455±270
36 4 55 27 230±25 2250±250 320±35 3150±350
39 4 60 ---- 295±33 2900±330 410±45 4050±450
This torque table does not apply to bolts or nuts which have to fasten nylon or other parts non-ferrous metal washer.
★ Nm (newton meter): 1 Nm = 0.102 kgm
00-8 WB97R-2
2. TIGHTENING TORQUE FOR NUTS OF FLARED
Use these torques for nut part of flared.
Thread diameter Width across flats TIGHTENING TORQUE

of nut part of nut part
(mm) (mm) kgm Nm
1/2” - 20 17 2.6±0.5 25.5±4.9
9/16” - 18 17 4±0.5 39.2±4.9
3/4” - 16 22 6.7±2 65.7±19.6
7/8” - 14 27 8 ±2 78.5±19.6
1.1/16 - 12 32 9.7±3 95.15±29.4
1.5/16 - 12 38 17±3 166.7±29.4
1.5/8 - 12 50 20±5 196.2±49
22 27 8 ±2 78.5±19.6
33 41 20±5 196.2±49
Sealing surface
Thread diameter Width across flats TIGHTENING TORQUE

of nut part of nut part
(mm) (mm) kgm Nm
9/16” - 18 17 2.3–2.5 23–25
11/16” - 16 22 3.4–3.9 33–38
13/16” - 16 24 5.2–5.8 51–57
1” - 14 30 8.2–9.2 80–90
1.3/16 - 12 36 12.2–13.3 120–130
1.7/16 - 12 41 15.3–17.3 150–170
1.11/16 - 12 50 18.4–20.4 180–200
2” - 12 57 20.4–24.4 200–240
WB97R-2 00-9
COATING MATERIALS
COATING MATERIALS
The recommended coating materials prescribed in Komatsu Utility Shop Manuals are listed below:
Nomenclature Code Applications
ASL800010 Used to apply rubber pads, rubber gaskets and cork plugs.
Used to apply resin, rubber, metallic and non-metallic parts when a fast, strong
ASL800020
seal is needed.
Loctite 222 Used for low resistance locking of screws, check nuts and adjustment nuts.
To prevent the loosening of bolts, nuts and plugs and the leakage of oil. Used for
Loctite 242 medium resistance locking of screws and nuts of every type, and for locking
keys and bearings.
Loctite 262 Used for high resistant of threaded parts that can be removed with normal tools.
Adhesives Used for high resistant locking and for sealing threaded parts, bolts and stud
Loctite 270
bolts.
Loctite 542 Used for sealing the union threads for hydraulic tubes.
Used for sealing rather exact plane surfaces when the option of possible future
Loctite 573
dismantling is required.
Used for high resistant locking of mechanical components that can be removed
Loctite 601
only after heating
Used to lock cylindrical couplings and for the permanent locking of threaded
Loctite 675
parts, and also to lock shafts to bearings, gears, pulleys, pins, bushings, etc.
Used by itself to seal grease fittings, tapered screw fittings and tapered screw
ASL800060
fittings in hydraulic circuits of less than 50 mm in diameter.
Used by itself on mounting flat surface

Gasket sealant Loctite 510
(Clearance between surfaces within 0.2 mm)
Used by itself on mounting flat surface

Loctite 518
(Clearance between surfaces within 0.5 mm
Antifriction compound
Applied to bearings and taper shaft to facilitate press-fitting and to prevent
(Lubricant including ASL800040
sticking, burning or rusting.
Molybdenum disulfide)
Grease Applied to bearings, sliding parts and oil seals for lubrication, rust prevention
ASL800050
(Lithium grease) and facilitation of assembling work.
Vaseline ----- Used for protecting battery electrode terminals from corrosion
00-10 WB97R-2
ELECTRIC WIRE CODE
ELECTRIC
In the wiring diagrams various colour and symbols are employed to indicate the thickness of wires.
This wire code table will help you understand WIRING DIAGRAMS.
Example: R–N 1.5 indicates a cable having a nominal number 1.5 and red coating with black stripe.
CLASSIFICATION BY THICKNESS
Copper wire
Nominal Cable O.D. Current rating
number Number Ø of strands Cross section (mm) (A)
strands (mm) (mm)
0.5 16 0.20 0.35 1.55 3.5
1 14 0.30 0.99 2.80 11
1.5 21 0.30 1.48 3.35 14
2.5 35 0.30 2.47 3.80 20
4 56 0.30 3.95 4.60 28
6 84 0.30 5.93 5.20 37
10 84 0.40 10.55 7.10 53
50 399 0.40 50.11 14 160
CLASSIFICATION BY COLOUR AND CODE

Primary Auxiliary
Code A A–B A/B A–G – A–N A/N A–R A/R A–V A/V
Colour Light Blue Light Blue – White Light Blue–Yellow Light Blue–Black Light Blue–Red Light Blue–Green
Code B B–G – B–N B/N B–R B/R – B/V – –
Colour White White–Yellow White–Black White–Red White–Green –
Code C C–B C/B C–L – C–N – – – – –
Colour Orange Orange–White Orange–Blue Orange–Black – –
Code G G–N G/N G–R – G–V – – – – –
Colour Yellow Yellow–Black Yellow–Red Yellow–Green – –
Code H H–L – H–N H/N – – – – – –
Colour Grey Grey–Blue Grey–Black – – –
Code L L–B L/B L–G – – L/N – – – –
Colour Blue Blue–White Blue–Yellow Blue–Black – –
Code M M–B – M–N M/N M–V – – – – –
Colour Brown Brown–White Brown–Black Brown–Green – –
Code N – – – – – – – – – –
Colour Black – – – – –
Code R R–G – R–N R/N R–V – – – – –
Colour Red Red–Yellow Red–Black Red–Green – –
Code S S–G – S–N – – – – – – –
Colour Pink Pink–Yellow Pink–Black – – –
Code V V–B – V–N V/N – – – – – –
Colour Green Green–White Green–Black – – –
Code Z Z–B Z/B Z–N Z/N – – – – – –
Colour Violet Violet–White Violet–Black – – –
COMPOSITION OF THE COLOURS

The coloration of two-colour wires is indicated by the composition of the symbol listed.
Example: G–V = Yellow-Green with longitudinal colouring
G/V = Yellow-Green with transversal colouring
WB97R-2 00-11
WEIGHT TABLE
WEIGHT TABLE
This weight table is a guide for use when transporting or handling components.
Unit: kg
Machine model WB97R-2
From serial number 97F20743-
Engine assembly - Muffler - Exhaust pipe 410
Radiator - exchanger 37
Hydraulic oil tank (empty) 77
Fuel tank (empty) 73
Front counterweight 300
Engine hood 27
Cabin (without seat) 595
Seat 34
Engine-gear box-pump group 740
Piston pump 38
Transmission 230
Front axle 316
Rear axle 511
Front wheel 65
Rear wheel 163
2-spool control valve 24
3-spool control valve 30
Work equipment 960
• Boom 370
• Bucket 427
• Fulcrum lever 13x4
• Tilt lever 48x2
• Raise cylinder 40x2
• Tilt cylinder 45x2
Work equipment
• with standard arm 850
• with long arm 885
• with jig arm 1030
Boom 323
Arm 213
Long arm 245
Boom swing bracket 133
Backframe 237
Control valve (6-spool) 47
Jig arm 392
Outriggers 57
Boom cylinder 78
Arm cylinder 69
Bucket cylinder 49
Outriggers cylinder 42
Swing cylinder 30
Bucket 156
00-12 WB97R-2
TABLE OF OIL AND COOLANT QUANTITIES

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

Crankcase sump 7.9 7.9
• API CD SAE 30
SAE 40
OIL
Hydraulic circuit SAE 10W-30 150 92
• API CD
Hydraulic circuit
with biodegradable 150 92
oil
Front axle
6.5 6.5
• Differential
• Final reduction gear

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

1.5 1.5
(each.)
Hydraulic OIL
24.5 24,5
transmission GM DEXRON® II D
(DEXRON® is a
registered
Braking system General Motors 0.8 0.8
Corporation)
✽
Fuel tank FUEL 130 –
ASTM D975 N.2
WATER +
14 –
ANTI-FREEZE
Engine coolant
WATER 14 –
system
PERMANENT
14 –
LIQUID
✽ ASTM D975 N.
ASTM: America Society of Testing and Materials
SAE: Society of Automotive Engineers
API: American Petroleum Institute
MIL: Military Specification
CCMC: Common Market Constructors Committe
First filling quantity:
total quantity of oil, including the oil for the components and pipes.
Oil change quantity:
quantity of oil necessary to fill the system or unit during the normal inspection and maintenance operations.
WB97R-2 00-13
NOTE:
(1) When the diesel oil sulphur content is less then 0.5%, change the engine oil according to the periodic maintenance
intervals indicated in the operation and maintenance manual. In the diesel oil sulphur content exceeds 0.5% change
the engine oil according to the following table:
Sulphur content Engine oil change interval

from 0.5 to 1.0% 1/2 of regular interval
over 1.0% 1/4 of regular interval
(2) When starting the engine at temperatures below 0 °C, use engine oil SAE 10W, 20W-20 and 10W-30, even if during
the day the temperature increases by 10 °C.
(3) Use engine oil with CD classification; if oil with CD classification is used, reduce the engine oil change interval by a
half.
(4) Use original products, which have characteristics specifically formulated and approved for the engine, the hydraulic
circuit of equipment and for reductions.
00-14 WB97R-2
CONVERSION TABLE
CONVERSION TABLE
METHOD OF USING THE CONVERSION TABLE
The conversion table in this section is provided to enable simple conversion of figures.
For details of the method of using the conversion table, see the example given below.
EXAMPLE
• Method of using the conversion table to convert from millimeters to inches.
1. Convert 55 mm into inches.
1 - Locate the number 50 in the vertical column at the left side, take this as A , then drow a horizontal line from
A.
2 - Locate the number 5 in the row across the top, take this as , then draw a perpendicular line down from B .
3 - Take the point where the two lines cross as C . This point C gives the value when converting from mil-
limeters to inches. Therefore, 55 mm =2.165 in.
2. Convert 550 mm into inches

1 - The number 550 does not appear in the table, so divide by 10 (move the decimal point one place to the left) to
convert it to 55 mm.
2 - Carry out the same procedure as above to convert 55 mm to 2.165 in.
3 - The original value (550 mm) was divided by 10, so multiply 2.165 in. by 10 (move the decimal point one place to
the right) to return to the original value. This gives 550 mm = 21.65 in.
From millimeters to inches B

1 mm = 0.03937 in.
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
C
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
A
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
WB97R-2 00-15
CONVERSION TABLE
From mm to in.
1 mm = 0.03937 in.
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
From kg to lb.
1 kg = 2.2046 lb.
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.24 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
00-16 WB97R-2
CONVERSION TABLE
From liter to U.S. Gall.

1 ᐉ = 0.2642 U.S. Gall.
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
From liter to U.K. Gall.

1 ᐉ = 0.21997 U.K. Gall.
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.969 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 12.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
WB97R-2 00-17
CONVERSION TABLE
From Nm to lb.ft.
1 Nm = 0.737 lb.ft.
0 1 2 3 4 5 6 7 8 9
0 0 0.737 1.474 2.211 2.948 3.685 4.422 5.159 5.896 6.633
10 7.370 8.107 8.844 9.581 10.318 11.055 11.792 12.529 13.266 14.003
20 14.740 15.477 16.214 16.951 17.688 18.425 19.162 19.899 20.636 21.373
30 22.110 22.847 23.584 24.321 25.058 25.795 26.532 27.269 28.006 28.743
40 29.480 30.217 30.954 31.691 32.428 33.165 33.902 34.639 35.376 36.113
50 36.850 37.587 38.324 39.061 39.798 40.535 41.272 42.009 42.746 43.483
60 44.220 44.957 45.694 46.431 47.168 47.905 48.642 49.379 50.116 50.853
70 51.590 52.327 53.064 53.801 54.538 55.275 56.012 56.749 57.486 58.223
80 58.960 59.697 60.434 61.171 61.908 82.645 63.382 64.119 64.856 65.593
90 66.330 67.067 67.804 68.541 69.278 70.015 70.752 71.489 72.226 72.963
100 73.700 74.437 75.174 75.911 76.648 77.385 78.122 78.859 79.596 80.333
110 81.070 81.807 82.544 83.281 84.018 84.755 85.492 86.229 86.966 87.703
120 88.440 89.177 89.914 90.651 91.388 92.125 92.862 93.599 94.336 95.073
130 95.810 96.547 97.284 98.021 98.758 99.495 100.232 100.969 101.706 102.443
140 103.180 103.917 104.654 105.391 106.128 106.865 107.602 108.339 109.076 109.813
150 110.550 111.287 112.024 112.761 113.498 114.235 114.972 115.709 116.446 117.183
160 117.920 118.657 119.394 120.131 120.868 121.605 122.342 123.079 123.816 124.553
170 125.290 126.027 126.764 127.501 128.238 128.975 129.712 130.449 131.186 131.923
180 132.660 133.397 134.134 134.871 135.608 136.345 137.082 137.819 138.556 139.293
190 140.030 140.767 141.504 142.241 142.978 143.715 144.452 145.189 145.926 146.663
00-18 WB97R-2
CONVERSION TABLE
From Nm to kgm
1 Nm = 0.102 kgm
0 1 2 3 4 5 6 7 8 9
0 0 0.102 0.204 0.306 0.408 0.510 0.612 0.714 0.816 0.918
10 1.020 1.222 1.224 1.326 1.428 1.530 1.632 1.734 1.836 1.938
20 2.040 2.142 2.244 2.346 2.448 2.550 2.652 2.754 2.856 2.958
30 3.060 3.162 3.264 3.366 3.468 3.570 3.672 3.774 3.876 3.978
40 4.080 4.182 4.284 4.386 4.488 4.590 4.692 4.794 4.896 4.998
50 5.100 5.202 5.304 5.406 5.508 5.610 5.712 5.814 5.916 6.018
60 6.120 6.222 6.324 6.426 6.528 6.630 6.732 6.834 6.936 7.038
70 7.140 7.242 7.344 7.446 7.548 7.650 7.752 7.854 7.956 8.058
80 8.160 8.262 8.364 8.466 8.568 8.670 8.772 8.874 8.976 9.078
90 9.180 9.282 9.384 9.486 9.588 9.690 9.792 9.894 9.996 10.098
100 10.200 10.302 10.404 10.506 10.608 10.710 10.812 10.914 11.016 11.118
110 11.220 11.322 11.424 11.526 11.628 11.730 11.832 11.934 12.036 12.138
120 12.240 12.342 12.444 12.546 12.648 12.750 12.852 12.954 13.056 13.158
130 13.260 13.362 13.464 13.566 13.668 13.770 13.872 13.974 14.076 14.178
140 14.280 14.382 14.484 14.586 14.688 14.790 14.892 14.994 15.096 15.198
150 15.300 15.402 15.504 15.606 15.708 15.810 15.912 16.014 16.116 16.218
160 16.320 16.422 16.524 16.626 16.728 16.830 16.932 17.034 17.136 17.238
170 17.340 17.442 17.544 17.646 17.748 17.850 17.952 18.054 18.156 18.258
180 18.360 18.462 18.564 18.666 18.768 18.870 18.972 19.074 19.176 19.278
190 19.380 19.482 19.584 19.686 19.788 19.890 19.992 20.094 20.196 20.298
WB97R-2 00-19
CONVERSION TABLE
From kgm to lb.ft.

1 kgm = 7.233 lb.ft.
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.2 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 876.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
00-20 WB97R-2
CONVERSION TABLE
From bar to psi (lb/in2)

1 bar = 14.503 psi
0 1 2 3 4 5 6 7 8 9
0 0 14.5 29.0 43.5 58.0 72.5 87.0 101.5 116.0 130.5
10 145.0 159.5 174.0 188.5 203.0 217.5 232.0 246.5 261.0 275.6
20 290.0 304.6 319.1 333.6 348.1 362.6 377.1 391.6 406.1 420.6
30 435.1 449.6 464.1 478.6 493.1 507.6 522.1 536.6 551.1 565.6
40 580.1 594.6 609.1 623.6 638.1 652.6 667.1 681.6 696.1 710.6
50 725.1 739.6 754.1 768.6 783.2 797.7 812.2 826.7 841.2 855.7
60 870.2 884.7 899.2 913.7 928.2 942.7 957.2 971.7 986.2 1000.7
70 1015.2 1029.7 1044.2 1058.7 1073.2 1087.7 1102.2 1116.7 1131.2 1145.7
80 1160.2 1174.7 1189.2 1203.7 1218.2 1232.7 1247.2 1261.8 1276.3 1290.8
90 1305.3 1319.8 1334.3 1348.8 1363.3 1377.8 1392.3 1406.8 1421.3 1435.8
100 1450.3 1464.8 1479.3 1493.8 1508.3 1522.8 1537.3 1551.8 1566.3 1580.8
110 1595.3 1609.8 1624.3 1638.8 1653.3 1667.8 1682.3 1696.8 1711.3 1725.8
120 1740.4 1754.9 1769.4 1783.9 1798.4 1812.9 1827.4 1841.9 1856.4 1870.8
130 1885.4 1899.9 1914.4 1928.9 1943.4 1957.9 1972.4 1986.9 2001.4 2015.9
140 2030.4 2044.9 2059.4 2073.9 2088.4 2102.9 1217.4 2131.9 2146.4 2160.9
150 2175.4 2189.9 2204.4 2218.9 2233.5 2248.0 2262.5 2277.0 2291.5 2306.0
160 2320.5 2335.0 2349.5 2364.0 2378.5 2393.0 2407.5 2422.0 2436.5 2451.0
170 2465.5 2480.0 2494.5 2509.0 2523.5 2538.0 2552.5 2567.0 2581.5 2596.0
180 2610.5 2625.0 2639.5 2654.0 2668.5 2683.0 2697.7 2712.1 2726.6 2641.1
190 2755.6 2770.0 2784.6 2799.1 2813.6 2828.1 2842.6 2857.1 2871.6 2886.1
200 2900.6 2915.1 2929.6 2944.1 2958.6 2973.1 2987.6 3002.1 3016.6 3031.1
210 3045.6 3060.1 3074.6 3089.1 3103.6 3118.1 3132.6 3147.1 3161.6 3176.1
220 3190.7 3205.2 3219.7 3234.2 3248.7 3263.2 3277.7 3192.2 3306.7 3321.2
230 3335.7 3350.2 3364.7 3379.2 3393.7 3408.2 3422.7 3437.2 3451.7 3466.2
240 3480.7 3495.2 3509.7 3524.2 3538.7 3553.2 3567.7 3582.2 3596.7 3611.2
WB97R-2 00-21
CONVERSION TABLE
TEMPERATURE
Fahrenheit-Centigrade conversion; a simple way to convert a Fahrenheit temperature reading into a Centigrade tem-
perature reading or vice versa is to enter the accompanying table in the center or boldface column of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit tem-
peratures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of Centigrade va-
lues and read the corresponding Fahrenheit temperature on the right.
1 °C = 33.8°F
°C °F °C °F °C °F °C °F
–40.4 –40 –40.0 –11.7 11 51.8 7.8 46 144.8 27.2 81 117.8

–37.2 –35 –31.0 –11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
–34.4 –30 –22.0 –10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
–31.7 –25 –13.0 –10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
–28.9 –20 –4.0 –9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
–28.3 –19 –2.2 –8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

–27.8 –18 –0.4 –8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
–27.2 –17 1.4 –7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
–26.7 –16 3.2 –7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
–26.1 –15 5.0 –6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
–25.6 –14 6.8 –6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

–25.0 –13 8.6 –5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
–24.4 –12 10.4 –5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
–23.9 –11 12.2 –4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
–23.3 –10 14.0 –3.9 25 77.0 15.6 60 140.0 35.0 95 203.0
–22.8 –9 15.8 –3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

–22.2 –8 17.6 –2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
–21.7 –7 19.4 –2.2 28 72.4 17.2 63 145.4 36.7 98 208.4
–21.1 –6 21.2 –1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
–20.6 –5 23.0 –1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
–20.0 –4 24.8 –0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

–19.4 –3 26.6 0.0 32 89.6 19.4 67 152.6 43.3 110 230.0
–18.9 –2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
–18.3 –1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
–17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
–17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

–16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
–16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
–15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 2930
–15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
–14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

–13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
–13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
–12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
–12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
00-22 WB97R-2
GROUP 10
40-28 PC15R-8
STRUCTURE AND FUNCTION
Power train ................................................................ 2 Safety valve..............................................................72

Transmission ............................................................. 4 Brake pump ..............................................................74
Drive shafts................................................................ 8 Shovel cylinder .........................................................75
Control valve block .................................................. 10 Backhoe cylinder ......................................................76
Front axle................................................................. 12 Air-conditioning unit..................................................80
Rear axle ................................................................. 15 How the air-conditioning unit functions.....................81
Hydraulic pump........................................................ 20 Electrical diagram (1/6) ............................................83
Steering unit ............................................................ 41 Electrical diagram (2/6) ............................................85
Hydraulic circuit ....................................................... 43 Electrical diagram (3/6) ............................................87
Shovel control valve ................................................ 44 Electrical diagram (4/6) ............................................89
Backhoe control valve ............................................. 50 Electrical diagram (5/6) ............................................91
CLSS ....................................................................... 57 Electrical diagram (6/6) ............................................93
Solenoid valve ......................................................... 71 Electrical diagram (air conditioning) .........................95
WB97R-2 10-1
STRUCTURE AND FUNCTION POWER TRAIN
POWER TRAIN
1 2
3 4
5 7 8
6
RKZ01061
DESCRIPTION
• The driving power for the engine (1) is transmitted • The driving power is transmitted from the transmis-
through the flywheel to the converter (2). sion flanges (3) to the front (5) and rear (6) axles
The converter (2) uses hydraulic oil to convert the through the Cardan drive shafts (7 and 8).
torque transmitted by the engine (1) into driving • The driving power transmitted to the front (5) and
power. The converter (2) transmits motion to the rear (6) axles is reduced by the differentials and then
drive shaft of the transmission (3) and to the drive transmitted to the planetary gear through the differ-
shaft of the hydraulic pump (4). ential shafts.
• The transmission (3) has two hydraulically-activat-
ed clutches that can be selected by an electrically-
controlled gear selector. It also has manual gear se-
lection (four forward gears and four reverse gears).
10-2 WB97R-2
STRUCTURE AND FUNCTION POWER TRAIN
Front axle Rear axle

Gears
Transmission Differential Planetary Total Transmission Differential Planetary Total
1st gear 4.374 62.592 5.440 92.893
2nd gear 2.436 34.859 3.030 51.740
2.436 6.000 2.846 6.000
3rd gear 1.232 17.630 1.532 26.160
4th gear 0.651 9.316 0.810 13.832
6 Z=37
Z=15
Z=75
4
Z=13
9
8
3
1 10
Z=13
Z=15
5 Z=31 Z=75
RKZ01031
1. Diesel engine 5. Front axle 9. Rear wheels

2. Convertor 6. Rear axle 10. Front wheels
3. Transmission 7. Front Cardan drive shaft
4. Hydraulic pump 8. Rear Cardan drive shaft
WB97R-2 10-3
STRUCTURE AND FUNCTION TRANSMISSION
TRANSMISSION
Diagram of the power train
4
Z=17 Z=59 5
Z=58 Z=51
Z=27 Z=37 Z=41
3
Z=30
Z=27
Z=58
Z=37
Z=30 Z=44
Z=45
6
2
RKZ04470
1. Engine 4. Hydraulic pump

2. Convertor 5. Rear flange
3. Transmission 6. Front flange
10-4 WB97R-2
Hydraulic convertor-transmission circuit diagram
1st Gear clutch 3rd Gear clutch Forward clutch Reverse clutch 4th Gear clutch 4WD Clutch 2nd Gear clutch
11–13 bar - 900 rpm 11–13 bar - 900 rpm 13.5–15.5 bar - 900 rpm
12–14 bar - 2200 rpm 12–14 bar - 2200 rpm 15–17 bar - 2200 rpm
14 15 13.5–15.5 bar - 900 rpm
14.5–16.5 bar - 2200 rpm
13.5–15.5 bar - 900 rpm
14.5–16.5 bar - 2200 rpm
16 26 17
1.5–2.0 bar 1.5–2.0 bar 21 23 1.5–2.0 bar 1.5–2.0 bar
32
31 33 20 22 24 Tube 25 Tube 27
18 19
13–15 bar - 900 rpm 13–15 bar - 900 rpm 13–15 bar - 900 rpm 14–16 bar - 900 rpm 13.5–15.5 bar - 900 rpm
Tube Tube 14.5–16.5 bar - 2200 rpm 15–17.5 bar - 2200 rpm 15–17 bar - 2200 rpm Tube
14.5–16.5 bar - 2200 rpm 14.5–16.5 bar - 2200 rpm
5 6 7 8 9 10 11 13
9–11 bar
28 2
1–4.5 bar - 900 rpm 30
Selector valve 6–11 bar - 2200 rpm 14–16 bar - 900 rpm
15.5–18 bar - 2200 rpm
29 12 Max oil pressure 11 bar

Max oil temperature 127 °C Opens at
3.45 bar Delivery filter
0.2–1.8 bar - 900 rpm 112–118 °C 10 µm
0.7–2.5 bar - 2200 rpm Motor
Oil flow 20+26 L/1° - 900 rpm
Oil cooler
3 50+65 L/1° - 2200 rpm
Oil Max 18 Bar
Hose Hose
pump
Ø 3.5mm
Bearing
Opens at
Output shaft
Flow 14+27 L/1° - 900 rpm

Input shaft
Primary shaft
25+45 L/1° - 2200 rpm Motor 23–26 bar

1
Suction filter
250 µm
Air breather
Opens at
5.5 bar
4
Transmission sump
RKZ06331
1 - Filter pressure relief valve 10 - 4WD clutch solenoid valve 19 - 3rd gear clutch - pressure check point 28 - Torque converter - pressure check point
2 - Oil flow divider 11 - 2nd gear clutch solenoid valve 20 - Forward gear clutch - pressure check point 29 - Lubrication - pressure check point
3 - Torque converter 12 - Oil temperature sensor (alarm) 21 - Forward gear clutch - pressure check point 30 - General oil clutch - pressure check point
4 - Torque converter pressure relief valve 13 - Oil pressure sensor (alarm) 22 - Reverse gear clutch - pressure check point 31 - 1st gear - antishock valve
5 - 1st gear clutch solenoid valve 14 - 1st gear filling - pressure sensor 23 - Reverse gear clutch - pressure check point 32 - 2nd gear - antishock valve
6 - 3rd gear clutch solenoid valve 15 - 3rd gear filling - pressure sensor 24 - 4th gear clutch - pressure check point 33 - 3rd gear - antishock valve
7 - Forward clutch proportional solenoid valve 16 - 4th gear filling - pressure sensor 25 - 4WD gear clutch - pressure check point
8 - Reverse clutch proportional solenoid vulvae 17 - 2nd gear filling - pressure sensor 26 - 4WD gear clutch - pressure check point
9 - 4th gear clutch solenoid valve 18 - 1st gear clutch - pressure check point 27 - 2nd gear clutch - pressure check point
WB97R-2 10-5
TRANSMISSION
1 b 2 c 3
7
a
A
X
4 A
9 5 12
11
6 10
View
VistaXX
RKZ03042
a. From the oil cooler 5. Plug
b. To the oil cooler 6. Suction filter
c. To the solenoid valve group ST1 (P Port) 7. Oil temperature sensor (C16)
d. From the solenoid valve group ST1 (T Port) 8. 4th gear filling pressure sensor (C11)
9. 1st gear filling pressure sensor (C08)
1. Control valve group
10. Speedmeter sensor (C02)
2. Convertor
11. 3rd gear filling pressure sensor (C10)
3. Filter
12. 2nd gear filling pressure sensor (C09)
4. Plug
10-6 WB97R-2
2 3
5
6
7
9
8
Section A -- A
Sezione A A RKZ03052
1. Hydraulic pump drive shaft 6. Flange

2. Propeller shaft 7. Front output shaft
3. Reverse gears idler shaft 8. 4WD engagement device
4. Drive shaft 9. Flange
5. Rear output shaft
WB97R-2 10-7
STRUCTURE AND FUNCTION DRIVE SHAFTS
DRIVE SHAFTS
Drive shaft for forward and reverse movement
1 2
a b c
6
5
4 3
RKZ03070
a. Port commanding reverse clutch 1. Reverse gear clutch (Z=37) 4. Forward clutch piston
b. Port commanding forward clutch 2. Forward gear clutch (Z=37) 5. Thrust ring
C. Lubrication port 3. Reverse clutch piston 6. Driven shaft
Drive shaft
3
1
2
4
a
5 RKZ03090
a. Drive gear for 2nd gear 3. Drive gear 4th gear (Z=58)
4. Drive gear 1st gear (Z=17)
1. Drive gear 3rd gear (Z=45)
5. Control piston 2nd gear
2. Drive gear 2nd gear (Z=30)
10-8 WB97R-2
STRUCTURE AND FUNCTION DRIVE SHAFTS
Driven gear shaft

5
2
4
1
3 c
a b 6
10
9 8 7
RKZ03060
a. Port commanding 4th gear 5. Driven gear for 1st gear (Z=59)
b. Port commanding 3rd gear 6. Rear output shaft
c. Port commanding 1st gear 7. Control piston 1st gear
1. Driven gear for 3rd gear (Z=44) 8. Control piston 4th gear
2. Driven gear for 2nd gear (Z=58) 9. Control piston 3rd gear
3. Driven gear for 4th gear (Z=30) 10. Speedmeter disc
4. Drive gear for 4WD (Z=51)
Driven shaft 4WD

2 3
1 a
5
4 RKZ03080
a. 4WD disengagement command port 3. 4WD driven gear

1. Front output shaft 4. Piston (No. 3)
2. 4WD disengagement command piston 5. Spring
WB97R-2 10-9
STRUCTURE AND FUNCTION CONTROL VALVE BLOCK
CONTROL VALVE BLOCK
1 2 3 4 5 6 7
8
M2 MP M4 M3
2ª 4WD IND 4ª AV 3ª 1ª
M2ª M4WD M4ª M3ª M1ª

RKZ03101
ELECTRICAL COMPONENT CHECK POINT

1. C24 - 2nd gear clutch solenoid valve (ED6) M2ª 2nd gear pressure
2. C27 - 4WD disengagement clutch solenoid valve (ED5) M2 Torque converter pressure
3. C26 - 4th gear clutch solenoid valve (ED2) M4WD 4WD disengagement pressure
4. C21 - Reverse clutch proportional solenoid valve (ED4) M4ª 4th gear pressure
5. C22 - Forward clutch proportional solenoid valve (ED3) MP General oil clucth pressure
6. C25 - 3rd gear clutch solenoid valve (ED7) M4 Reverse clucth pressure
7. C23 - 1st gear clutch solenoid valve (ED1) M3 Forward clucth pressure
8. C07 - Oil pressure sensor (alarm) M3ª 3rd gear pressure
M1ª 1st gear pressure
10-10 WB97R-2
PAGE INTENTIONALLY
LEFT BLANK
STRUCTURE AND FUNCTION FRONT AXLE
FRONT AXLE
Differential
1 2 3 1
4
5
6
7 7
17 16
15
8
14
9
13
10
12
RKZ00581
11
1. Planetary gear 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 WB97R-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 RKZ00611
1. Planetary carrier 13. Bearing

2. Planetary (Z =29) 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
WB97R-2 10-13
Steering cylinder
B 1
C 2 3
A
A
a b
7 7
5
4 Section
Sezione B
B -- B
B 6
Section
Sezione A
A -- A
A Detail C
Particolare C
RKZ00591
1. Steering cylinder a Port - From the steering unit (L Port)

2. Oil refilling plug b Port - From the steering unit (R Port)
3. Oil drain plug
4. Nut
5. Adjustment screw
6. Nut
7. Bushing
10-14 WB97R-2
STRUCTURE AND FUNCTION REAR AXLE
REAR AXLE
Differential
7 1 2 3 4 5 6 7
15
14
8
13 9
10
12 11
RKZ04970
1. Bearing 9. Bearing
2. Planetary gear 10. Nut
3. Bevel gear 11. Seal
4. Ring bevel gear (Z=37) 12. Flange
5. Differential housing 13. Spacer
6. Lock nut 14. Bevel pinion (Z=13)
7. Half-axle 15. Differential housing
8. Pin
WB97R-2 10-15
Final reduction
4 2 3
5
6 7 8
1
16
10
15
9
14 11
13 12 RKZ04980
1. Planetary gear carrier 10. Planetary gear (Z=15)

2. Stud bolt 11. Bushing
3. Wheel hub 12. Snap ring
4. Planetary gears (Z=28) 13. Ring gear (Z=75)
5. Ring bevel gear carrier 14. Oil plug
6. Bearing 15. Steady pin
7. Seal 16. Pin
8. Joint
9. Half-axle
10-16 WB97R-2
Brakes
1 A
9 7
8
3 10
4
2
6
5
1
Detail B B
Particolare
Section
Sezione A - A
A
RKZ04990
1. Bushing 6. Brake disk

2. Parking brake control rod 7. Piston
3. Bleeder valve 8. Spring
4. Parking brake lever 9. Pressure disk
5. Parking brake control cam 10. Intermediate disk
WB97R-2 10-17
Differential locking
1 2
7
RKZ05000
6 5 4 3
a. From the solenoid valve block ST1 (Port 2)

1. Sleeve
2. Pin
3. Control rod
4. Spacer
5. Fork
6. Piston
7. Cover
8. Snap ring
10-18 WB97R-2
PAGE INTENTIONALLY
LEFT BLANK
STRUCTURE AND FUNCTION HYDRAULIC PUMP
HYDRAULIC PUMP
A 3
D
c
B B
D
A
a b
RKZ04930
1. Delivery variation group a. Port B - To the shovel control valve (Port P)

2. Y1 solenoid valve working mode b. Port X2 - From the shovel control valve
3. Delivery control valve (Port LS)
c. Port L - To the hydraulic oil tank
d. Port S - To the hydraulic oil tank
10-20 WB97R-2
C C 3 4
2
1
Section
SezioneAA -- A
7 8 9
6
12 11 Section
SezioneBB -- B
B 10 RKZ00380
1. Seal 7. Positioning piston

2. Bearing 8. Spring
3. Central spring 9. Cylinder block
4. Bearing 10. Positioning piston
5. Control rod 11. Piston
6. Swash plate 12. Guide shoe
WB97R-2 10-21
1 2 3 4 5
7 6
Section
SezioneCC -- C
C
8 9 10
15 14 13 12 11
Section
SezioneDD-- D
D RKZ00642
POWER GOVERNOR LS VALVE

1. Spring 11. External spring
2. Piston rod 12. Internal spring
3. Bushing 13. Throttles
4. Initial adjustment spring 14. Throttles
5. Pressure cut calibration spring 15. Spool
6. Pressure cut calibration screw
7. Initial adjustment calibration screw
PC VALVE
8. Spool
9. Spring (internal)
10. Spring (external)
10-22 WB97R-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 require-
ments.
• The amount of oil delivered can be modified by
changing the angle of the swash plate.
1 2 3 4 5 6 7
B A a RKZ01120
STRUCTURE
• The cylinder block (6) is supported and connected • The pistons (5) perform their relative movements in
to the shaft (1) by the spline a and the shaft (1) is an axial direction, inside cylindrical chambers fash-
supported by the front and rear bearings. ioned in the cylinder block (6).
• The tip of the piston (6) is ball-shaped. The shoe (4) • The oil is brought up to pressure in the chambers of
is caulked to it to form one unit in such a way that the the cylinder block (6) by the rotatory movement of
piston (5) and the shoe (4) together form a spherical the block itself. The areas of pressure and suction
bearing. are determined by the swash plate (7).
• The swash plate (3) has a flat surface A and the The surface of the swash plate is so designed that
shoe (4) remains pressed against this surface while the oil pressure always remains within acceptable
sliding in a circular movement. limits.
The swash plate brings highly pressurized oil onto The oil in each chamber is drawn in and discharged
the cylindrical surface B fashioned in the pump body through holes in the valve plate (7).
(2), which means that the swash plate (3) slides on a
hydrostatically-supported bearing.
WB97R-2 10-23
OPERATION
1. Pump operation
1 - The cylinder block (7) rotates together with the
shaft (1) and the shoe (4) slides on the flat sur-
1 3 A 4 5 6 D
face A. The swash plate (3) moves along the
cylindrical surface B. The angle = formed be-
tween the center line of the shaft (1) and the
center line X of the swash plate (3) changes,
thus modifying the axial position of the pistons
in relation to the cylinder block.
The angle = is known as the swash plate angle.
2 - When the center line X of the swash plate (3)

maintains the angle = in relation to the center

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

portional to the swash plate angle =.
C
RKZ01110
10-24 WB97R-2
2. Control of Delivery
1 - As the swash plate angle = grows larger, the
difference between volumes C and D increas- 2 3 9 D
es, and the delivery Q also increases.
The swash plate angle is modified by servo-pi-
stons (8) and (9).
2 - The servo-piston (8) moves in a reciprocating
linear motion ( ) caused by pressure sig-
nals from the PC and LS valves.
The linear movement is transmitted to the
swash plate (3), which is supported by the cy-
lindrical surface of the cradle (2). The swash
plate therefore has a semi-circular reciprocat-
ing movement ( ).
3 - The surfaces of the servo-pistons receiving the

pressures PP and LS are dissimilar. The deliv-
ery pressure PP of the main pump is always
passed into the smaller (upper) pressure 8 C
chamber, whereas the pressure PEN coming RKZ01130
from the LS valve is passed into the larger (low-
er) pressure chamber.
The movement of the servo-piston is governed
by the relationship between pressures PP and
PEN, as well by the proportions between the
surfaces (larger and smaller) of the servo-pi-
ston.
WB97R-2 10-25
PC VALVE, LS VALVE, SERVO PISTON

1 2
Control valve
To the actuator
7 6 RKZ01141
SERVO-PISTON PC VALVE
1. Spring 6. Servo-piston
2. Servo-piston 7. Spring
3. Servo-piston
LS VALVE
4. Piston
5. Spring
10-26 WB97R-2
LS VALVE
FUNCTION
• The LS valve controls the pump delivery according
to the stroke of the control valve level, i.e., in func-
tion of the delivery demands made by the actuators.
• The LS valve detects the actuator’s delivery needs
by means of the differential pressure ,PLS existing
between the pump delivery pressure PP and the
pressure PLS coming from the control valve. This
reading permits control of the main pump delivery
Q.
(PP, PLS and ,PLS are, respectively, the pump
pressure, the Load Sensing pressure, and the dif-
ference in pressure between these two values).
• In other words, the LS valve detects the pressure
difference ,PLS generated by the passage of the
oil flow through the surface freed by the control
valve spool, and controls the pump delivery Q so as
to keep the pressure drop constant.
It can therefore be assumed that the pump delivery
is proportional to the demands made known by the
control valve.
WB97R-2 10-27
OPERATION
1. When the control valve is in a «NEUTRAL» position
PP T PLS
c d a 6
To the actuator
Control valve
Min Max
PP
M 3 X
Y
2 RKZ01151
• The pressure PLS of the LS coming from the control • For this reason the piston (4) is thrust to the right
valve outlet passes into chamber a of the spring of ( ) and a passage is formed between the delivery
the LS valve. The pressure PP of the pump passes lines c and d. This opening enables the pump pres-
into chamber b of the opposite side. sure PP to enter chamber X of the servo-piston (3).
• The piston rod movement (4) is determined by the • Although the pump pressure PP is always passed
combination of the force generated by the pressure into chamber Y of the servo-piston (2), since the
PLS, the force of the spring (6) and the force gen- force exerted by that pressure on piston (3) exceeds
erated on the side opposite the piston rod by the the force exerted on piston (2), the servo-piston (1)
pressure PP. moves to the right ( ), i.e. towards the side of the
• Before the engine is started the servo-piston (3) is minimum angle of the swash plate.
pushed to the right by the spring (1) (corresponding
to the maximum angle of the swash plate).
• If all the control valve spools are in their «NEU-
TRAL» position when the engine is started, the
pressure PLS of the LS will remain at 6±2 bar be-
cause no oil is flowing through the control valve.
At the same time the pump pressure PP increases
and is maintained at a value of about 27 bar.
10-28 WB97R-2
2. When a control valve lever is activated
PP T PLS
c d e a 6
To the actuator
Control valve f
Min Max
PP
M 3 X
1
Y RKZ01161
2
• When the control valve lever is moved out of its • Equilibrium is re-established in the system when the
NEUTRAL position, the opening f is determined, al- pressure ,PLS generates on the spool (4) the dif-
lowing an LS signal to be generated. ference in force exerted by the spring (6), and the
• Until the ,PLS generates a force less than the force passage between delivery lines c and d is re-
exerted by the spring (6) on the spool (4), the system opened.
will remain stable.
When the opening f is such as to provoke a reduc-
tion in ,PLS, the spool (4) moves to the left ( ) to
form a passage between delivery lines d and e. The
chamber X loses pressure and the servo-piston
causes the swash plate to move towards maximum
displacement.
WB97R-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
Control valve f
Min Max
PP
M 3 X
1
Y RKZ01161
2
• When the control lever is moved to full stroke, in oth- • The pressurized oil present in the chamber X of the
er words, when the spool opening reaches its max- servo-cylinder (3) flows through the lines d and e
imum, the difference between the pump pressure and reaches the pump drainage chamber, so that
PP and the LS pressure PLS becomes smaller (dif- the pressure in chamber X of the servo-cylinder (1)
ferential pressure ,PLS). becomes equal to the drainage pressure.
• The LS pressure PLS introduced into the chamber a • The servo-piston (3) is thus moved to the right ( )
of the LS valve becomes about the same as the by swash plate movement due to the pressure PP in
pump pressure PP and the piston (4) is moved to the the chamber Y of the servo-cylinder (2).
left ( ) by the combined forces generated by the In other words, it is drawn in the direction of the in-
pressure PLS and the spring (6). crease in angle of the swash plate.
The piston movement closes the delivery line c and
forms a passage between lines d and e.
10-30 WB97R-2
4. When the spool makes very small movements (fine-control)
PP T PLS
c d e a 6
To the actuator
Control valve
f
Min Max
PP
M 3 X
1
Y
2 RKZ01171
• When the control valve lever moves in very small in- • If the differential pressure ,PLS generates on the
crements towards the «NEUTRAL» position, i.e. spool (4) a force difference that does not exceed the
when the control valve opening f diminishes, the dif- force exerted by the spring (6), the spool (4) moves
ferential pressure ,PLS between the pump pres- to the left ( ) and a passage is formed between
sure PP and the LS pressure PLS increases. the delivery lines d and e.
• If the differential pressure ,PLS generates on the The chamber X loses pressure and the servo-piston
spool (4) a difference in force that exceeds the force provokes a movement of the swash plate towards
exerted by the spring (6), the spool moves to the maximum displacement.
right ( ) and a passage is formed between the • Equilibrium is re-established in the system when the
delivery lines c and d. The pressure PP is intro- pressure ,PLS generates on the spool (4) the dif-
duced into the chamber X and the swash plate ference in force exerted by the spring (6), and hence
moves towards its minimum angle. the passage between delivery lines c and d is also
• When the control valve lever performs small move- re-opened.
ments towards the position of maximum opening,
i.e. when the opening f of the control valve increas-
es, the differential pressure ,PLS diminishes.
WB97R-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
Control valve
PEN
Hold
PP
A1
M 3 X
PP 1
A2
Y RKZ01181
2
• Let A1 be the surface of the servo-piston (3), A2 the A flow of oil is introduced into the servo-cylinder (3)
surface of the servo-piston (2), PEN the pressure at a pressure that balances the force generated by
acting on the piston (1) and PP the pressure acting the pump pressure PP in the cylinder (2).
on the piston side (2). (PEN x A1=PP x A2).
When pump delivery reaches the quantity demand- • The stability of the equilibrium is guaranteed by a
ed by the control valve, the pump pressure PP in flow stabilized by the throttle g.
chamber b of the LS valve is in equilibrium with the • The force of the spring (6) is regulated so that the pi-
combined forces of the LS pressure PLS in cham- ston (4) is in equilibrium when
ber a, and the force exerted by the spring (6). PP – PLS = ,PLS =18 bar.
Once equilibrium has been reached the piston (4) • In practice, the pump flow is made proportional to
stops in the central position. the section of the opening of the control valve, which
• In this condition the passage from chamber c to maintains the differential pressure
chamber d remains only slightly open in order to ,PLS = 18 bar.
maintain pressure in chamber d.
10-32 WB97R-2
PC VALVE
FUNCTION
• The PC valve performs an approximate power
check, and ensures that the hydraulic horse-power
absorbed by the pump does not exceed the horse-
power delivered by the endothermal engine.
This is achieved by limiting the pump delivery Q in
Pump discharge amount Q

function of the delivery pressure PP, even if the LS
valve requests an increase in delivery Q due to the
larger section freed by the control valve spool, in the
presence of high pressure pump delivery.
• In other words, when during operation the delivery
Q increases and the delivery pressure PP also in-
creases simultaneously, the PC valve reduces the
pump delivery Q. When the delivery pressure PP
decreases, the PC valve increases the pump flow.
• The relationships between the pump delivery pres- Pump discharge pressure PP
sure PP and the delivery Q are shown in the dia- RKP01181
gram.
WB97R-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
Control valve
2 1
PP
Min Max
M 8 X
RKZ01191
• When a higher delivery is required, the LS valve re- • The opening of the passage between the chambers
ceives a signal from the control valve to bring the b and a generates a flow of oil and hence, due to the
pump up to maximum displacement. calibrated hole (6), a , P is generated between
When the swash plate moves it also moves the chambers f and g at the sides opposite the spool (5).
bushing (2) joined to it (by the pin (1)), which re- (,P =PP – PPC)
leases the spring (3). • When the value of PP exceeds the value of the
• As the pressure of the actuators increases, pres- spring loading (7) the spool (5) moves to the right
sure also increases in the delivery line c. When the ( ) opening the passage between the delivery
calibrated setting of the spring (3) is reached, the pi- lines d and e and sending the pump pressure PP to-
ston rod (4) is thrust to the left ( ) and the pas- wards the servo-cylinder (8).
sage between chamber b and the pump drainage
chamber a is opened.
10-34 WB97R-2
• The pressure PP introduced into chamber X of the cylinder (8) pushes it towards the minimum angle of the swash
plate ( ).
2. When equilibrium has been reached
5 g 6 7
f ∆p
c PPC
e
a 2 b 4
PPC PP PEN LS
10
To the actuator
Control valve
PP
Hold
A1
M 8 X
A2
9 RKZ01201
• When the piston (8) is pushed to the left ( ) the • In this condition the passage from chamber d# to
bushing (2) is also moved. chamber e remains only slightly open in order to
The oil flow between the chambers b and a is re- maintain pressure in chamber e. A flow of oil is in-
duced and the PPC pressure tends to approach the troduced into the cylinder (8) at a pressure that bal-
PP pressure value. ances the force generated by the pump pressure PP
The ,P decreases and the spool (5) is pushed to the acting on the cylinder (9). (PEN x A1 = PP x A2)
left ( ) by the force of the spring (7). • The stability of this equilibrium is generated by a
• Equilibrium is reached when the force generated by continuous stabilized flow from the throttle (10).
the PP pressure, the force generated by the PPC
pressure, and the force of the spring (7) are all bal-
anced. (The force generated by PP = the force gen-
erated by the PPC + the spring force (7)).
WB97R-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
Control valve
PP
Hold
M 8 X
9 Y RKZ01211
• When the load on the actuators diminishes and the and opening the passage between chambers e and
pump delivery pressure PP drops, the PPC. pres- g.
sure also drops. • The pressurized oil present in chamber X of the ser-
• The reduction in the PPC causes the spool (4) to vo-cylinder (8) passes through chambers e and g
move and the passage between chambers b, d and and reaches the pump drainage chamber, so that
a is closed. the pressure in chamber X of the servo-cylinder (7)
The PPC pressure and the PP pressure of the pump becomes equal to the drainage pressure.
are equalised due to the interruption of the oil flow • Therefore the servo-piston (7) is caused to move by
through the calibrated hole (6) and hence the ,P the PP pressure in chamber Y of the servo-cylinder
becomes zero (,P = PP – PPC=0). (9), i.e. in the direction of the increase in the angle of
• The spring (7) pushes the spool (5) to the left ( ) the swash plate.
closing the passage between the chambers d and e
10-36 WB97R-2
4. The function of the spring
3 11 4
PP PLS T LS
To the actuator
Control valve
M 8
RKZ01221
• The loading on the springs (3) and (11) of the PC

valve changes in proportion to the angle of inclina-
tion of the pump swash plate.
Spring (3) + spring (11)
• The compression of the spring (3) varies with the
movements of the servo-piston (8).

• When the piston (8) moves to the left ( ), the Spring (3)
spring (3) is compressed.
If the piston (8) moves even further to the left ( ),
the spring (11) comes into action to increase the
loading.
In other words, the overall loading of the springs is
varied by the piston (8), which either compresses or
releases them.
• The pump absorption torque curve, which indicates Pump discharge pressure PP
the relationship between the pump delivery pres- RKZ01241
sure PP and the delivery Q, is a broken line (as il-

lustrated in the diagram).
WB97R-2 10-37
• The position in which the piston (8) stops, i.e. the

pump absorption torque, is determined by the po-
sition in which the PPC pressure applied to the spool
(4) is balanced by the force exerted by the springs
(3) and (11).
• In practice, as the pump delivery pressure PP in-
creases, the delivery Q decreases, and as the pres-
sure PP diminishes the pump delivery Q increases.
10-38 WB97R-2
WORKING MODE SOLENOID VALVE

FUNCTION
• Calibration of the pump absorption torque is nor-

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

RKZ01251
OPERATION
1. WORKING MODE E
3
2 ∆ P1
4
a
1
6
12V
DC
RKZ04940
• During normal operation (Working mode E), the PC • The ,P1 is generated by the calibrated hole (3) in
valve intervenes when a ,P1 is generated equal to the spool of the PC valve (2) when, at a determined
the loading on the spring (4). pump delivery pressure P1, the valve (1) puts the
delivery line a into discharge, thus generating a flow
F1 in the delivery line a.
WB97R-2 10-39
2. WORKING MODE P
3
2
4
5
∆ P2
6
1
12V
DC
RKZ04950
• When the solenoid valve (6) is commutated (Work- • The increase in flow causes an increment of the
ing Mode P) the pressurized oil coming from the ,P2 which, when the loading value of the spring is
pump changes its route and passes through the reached, allows the spool to shift to the right ( ).
throttle (5), which has a larger diameter than the cal- • The pump starts to work in normal fashion once
ibrated hole (3). again, and all the valves recommence normal func-
• Because the throttle (5) has a larger diameter, the tioning.
,P2 generated is less than is needed to overcome
the force generated by the spring (4). The spool of
the PC valve (2) is therefore pushed to the left ( )
by the force of the spring (4).
• This shift obliges the pump to increase displace-
ment and hence the delivery (See «PC VALVE: 3.
When the load on the actuators decreases» third
paragraph).
10-40 WB97R-2
STRUCTURE AND FUNCTION STEERING UNIT
STEERING UNIT
a b d
e c
L D
240 bar 240 bar
LS
175
bar
T P
RKZ00831
a. Port LS - From the shovel control valve TECHNICAL DATA

(Port DLS) Steering unit type: LAGCSDS160P
b. Port T - To the hydraulic oil tank Displacement: 160 cc/rev.
c. Port L - To the steering cylinder (Port a)
OPERATION
d. Port R - To the steering cylinder (Port b)
• The steering unit is composed of a control valve and
e. Port P - From the shovel control valve (Port D)
a rotating oil dispenser, and is of the hydrostatic
type.
• When the steering wheel is turned, the control valve
sends oil from the pump P2 (by means of the rotat-
ing oil dispenser) to one of the sides of the steering
cylinder.
The rotating dispenser ensures that the volume of
oil supplied to the cylinder is proportionate to the an-
gle of rotation of the steering wheel.
• In the event of malfunction, the oil dispenser will
function automatically as a hand-pump, thus guar-
anteeing emergency steering.
WB97R-2 10-41
PAGE INTENTIONALLY
LEFT BLANK
STRUCTURE AND FUNCTION HYDRAULIC CIRCUIT
HYDRAULIC CIRCUIT
Telescopic
Hammer Arm Boom rotation RH Outrigger LH Outrigger Bucket Boom 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
bar
Additional
Boom Bucket equipment
T P
LS D B1 A1 B2 A2 B3 A3
DLS b
X1 b
A2 b
X2
5 bar
12V
DC 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
RKZ02862
WB97R-2 10-43
STRUCTURE AND FUNCTION SHOVEL CONTROL VALVE
SHOVEL CONTROL VALVE

2 SPOOL
D C A
a b c d
e
h g
D C A
1 2
B
6
B
i
Section
Sezione A
A -- A
A Section B
Sezione B -- BB
RKZ01082
a. Port D - To the hydraulic steering unit (Port P) i. Port DLS - To the hydraulic steering unit
b. Port A2 - To the bucket cylinders (Head side) (Port LS)
c. Port A1 - To the shovel-raising cylinders 1. Plug
(Base side) 2. Plug
d. Port LS - To the pump (Port X2) 3. Ball
e. Port T - To the hydraulic oil tank 4. Spring
f. Port P - From the pump (Port B) 5. Priority valve piston rod
g. Port B1 - To the shovel-raising cylinders 6. Priority valve spring
(Head side)
h. Port B2 - To the bucket cylinders (Base side)
10-44 WB97R-2
E 5 E
1
2
6
4
4
3 5 3
E
E
Section C -- CC
Sezione C
Section
Sezione D
D -- D
D
7 8
7
8
Section
Sezione E
E -- E
E RKZ00660
1. Plug
2. Raising command spool
3. Spool return spring
4. Compensator
5. Antishock/anticavitation valve
6. Bucket dump command spool
7. Spring
8. Check valve
WB97R-2 10-45
3 SPOOL
E
D C A
a b c d e
f
l i h
D C A
1 2 E
B
6
B
7
m
Section
SezioneAA -- A
A Section
Sezione B
B -- B
B
RKZ01072
a. Port D - To the hydraulic steering unit (Port P) 1. Plug

b. Port A3 - To the auxiliary equipment (Left side) 2. Plug
c. Port A2 - To the bucket cylinders (Head side) 3. Ball
d. Port A1 - To the shovel-raising cylinders 4. Spring
(Base side) 5. Priority valve piston rod
e. Port LS - To the pump (Port X2) 6. Priority valve spring
f. Port T - To the hydraulic oil tank 7. Plug
g. Port P - From the pump (Port B)
h. Port B1 - To the shovel-raising cylinders
(Head side)
i. Port B2 - To the bucket cylinders (Base side)
l. Port B3 - To the auxiliary equipment
(Right side)
m. Port DLS - To the hydraulic steering unit
(Port LS)
10-46 WB97R-2
1 F 8 F
2 9
3 7
7
4
1
5 10
8 F
F
Section
Sezione D
D -- D
D
F
6 12
Section C -- CC
Sezione C
11
8 14
15
14
15
13 Section
Sezione F
F -- F
F
8
F
Section
Sezione E
E -- E
E
RKZ00691
1. Plug 9. Bucket dump command spool

2. Raising command spool 10. Spool return spring
3. Spool return spring 11. Optional equipment command spool
4. Spring 12. EV1 Opened bucket 4 in 1 solenoid valve
5. Ball 13. EV2 Closed bucket 4 in 1 solenoid valve
6. Ball 14. Spring
7. Compensator 15. Check valve
8. Antishock/anticavitation valve
WB97R-2 10-47
3 SPOOL (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
m Section A -- AA
Sezione A Section
Sezione B
B -- B
B RKZ01092
a. Port D - To the hydraulic steering unit (Port P) 1. Plug

b. Port A3 - To the auxiliary equipment (Left side) 2. Plug
c. Port A2 - To the bucket cylinders (Head side) 3. Ball
d. Port A1 - To the shovel-raising cylinders 4. Spring
(Base side) 5. Priority valve piston rod
e. Port LS - To the pump (Port X2) 6. Priority valve spring
f. Port T - To the hydraulic oil tank 7. Plug
g. Port P - From the pump (Port B)
h. Port B1 - To the shovel-raising cylinders
(Head side)
i. Port B2 - To the bucket cylinders (Base side)
l. Port B3 - To the auxiliary equipment
(Right side)
m. Port DLS - To the hydraulic steering unit
(Port LS)
10-48 WB97R-2
F
1 F
8
9
2
7
3 10
7
4
1 8 11
5
F F
Section
Sezione C - C
C 6 F
8 Section
12 Sezione D
D -- D
D
13
14
13
14
7
8 F Section
SezioneFF- -FF
Section
Sezione E
E -- E
E RKZ00940
1. Plug 8. Antishock/anticavitation valve
2. Raising command spool 9. Bucket dump command spool
3. Spool return spring 10. Spool return spring
4. Spring 11. Coil
5. Ball 12. Optional equipment command spool
6. Ball 13. Spring
7. Compensator 14. Check valve
WB97R-2 10-49
STRUCTURE AND FUNCTION BACKHOE CONTROL VALVE
BACKHOE CONTROL VALVE

6 SPOOL
H F E D D C B A
b L e f g h i
c d
r L q p o n m l
H F E D D C B A
G
3
2 4
1
Section 3
Sezione A
A -- A
A 5
G
Section
SezioneBB--BB
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 WB97R-2
G G G
3 3
7 9 10 11
6
6 6
9 3
8 G 5 5
G 5 G
Section
Sezione C
C -- C
C Section D -- D
Sezione D D Section
Sezione E
E -- E
E
G
9
12
13 14
13 14
Section G -- G
Sezione G G
3 G 5
Section
SezioneFF--FF
RKZ00760
1. Ball 8. Anticavitation valve

2. Backhoe backframe lock solenoid valve 9. Plug
3. Antishock/anticavitation valve 10. Outrigger command spool
4. Boom command spool 11. Boom swing command spool
5. Spool return spring 12. Arm command spool
6. Compensator 13. Spring
7. Bucket command spool 14. Check valve
WB97R-2 10-51
3 2
4 5
Section
Sezione H
H -- H
H Section
SezioneLL -- L
L
RKZ00790
1. Valve 4. Pressure cut-out valve

2. Spring 5. Unloading valve
3. Plug
10-52 WB97R-2
PAGE INTENTIONALLY
LEFT BLANK
7 SPOOL
For jig arm
A
a
b
A RKZ00240
For side digging boom

B
c
d B RKZ00250
For hammer
C
e
C
RKZ00260
a. Port B7 - To the jig arm cylinder (Base side) d. Port A7 - To the side digging boom cylinder
b. Port A7 - To the jig arm cylinder (Head side) (Head side)
c. Port B7 - To the side digging boom cylinder e. Port B7 - To the hydraulic hammer (Left side)
(Base side)
10-54 WB97R-2
1 2 6 7
5 5
4 3 6 3
Section
Sezione A
A -- A
A Section
Sezione B
B -- B
B
4 8
6 3
Section C-C
Sezione C - C RKZ00960
1. Anticavitation valve 5. Compensator

2. Jig arm command spool 6. Anti-shock/anticavitation valve
3. Spool return spring 7. Side digging boom command spool
4. Plug 8. Hammer command spool
WB97R-2 10-55
8 SPOOL
For hammer and jig arm
a b
c RKZ00270
For side digging boom and jig arm
d b
e c RKZ00280
a. Port B7 - To the hydraulic hammer (L.H. side)

b. Port B8 - To the jig arm cylinder (Base side)
c. Port A8 - To the jig arm cylinder (Head side)
d. Port B7 - To the side digging boom cylinder (Base side)
e. Port A7 - To the side digging boom cylinder (Head side)
10-56 WB97R-2
STRUCTURE AND FUNCTION CLSS (Closed Center Load Sensing System)
CLSS (Closed Center Load Sensing System)

1. DESCRIPTION
CHARACTERISTICS
The term CLSS means Closed Center Load Sensing System, which has the following characteristics:
a) High precision control that is independent of the load applied to the movement;
b) High precision control of digging action even during delicate manoeuvres;
c) Ability to perform complex operations, guaranteed by control of oil flow in function of the aperture surfaces of the
shuttles;
d) Energy savings guaranteed by control of pump delivery.
STRUCTURE
• The CLSS system includes the variable flow pump, the control valve and the working equipment.
• The pump includes the main pump, the PC valve and the LS valve.
Attachment
PLS
Control valve
PC Valve
LS Valve
PP Piston
Piston
RKZ01711
WB97R-2 10-57
2. OPERATING PRINCIPLES
1. Control of the angle of the pumping plate.

• The angle of the swash plate (and hence the pump delivery) is controlled in such a way that the differential pressure
,PLS between the delivery pressure PP of the pump and the pressure PLS at the outlet of the control valve towards
the actuator is maintained at a constant value. (,PLS=pump delivery pressure PP – pressure PLS of delivery to the
actuator).
• If the differential pressure ,PLS becomes lower than the set pressure of the LS valve, the angle of the swash plate
increases (delivery increasing).
If the differential pressure ,PLS increases, the angle of the swash plate decreases.
★ For details about this movement, see the description of the «HYDRAULIC PUMP».
Attachment
Control valve
Pump delivery
Piston
Piston PUMP
PC Valve
High
pressure
LS Valve
High
pressure
RKZ01721
10-58 WB97R-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 ,P between the
delivery at the control valve inlet and outlets of the control valve are compensated by these valves.
We obtain the distribution of the pump flow in proportion to the areas of passage S1 and S2 of each valve.
Load
Load
Actuator
Actuator
Pressure Pressure
compensation compensation
valve valve
⌬P S1 S2 ⌬P
PUMP
RKZ01731
WB97R-2 10-59
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 min-
imum angle position) is sent to the control valve.
In these conditions, the pump delivery pressure PP is regulated to 27 bar by the spring (2) inside the valve.
(PP=PLS + spring load with PLS=6 bar)
2 1 PP
PLS T
RKZ01740
OPERATION
When the control valve is in «NEUTRAL» position • This system ensures that the pump delivery pressure
• On the two surfaces of the shuttle (1), the pump pres- PP stays regulated at 27 bar.
sure PP acts on the right-hand side, while the LS sig-
nal with pressure PLS acts on the left-hand side.
• Because a LS signal is generated with a pressure
PLS 6 ± 2 bar, when the control valve is in «NEU-
TRAL» position, the pump delivery pressure PP is
regulated by the combination of the pressure provid-
ed by the spring and by the LS pressure PLS.
• While the pump delivery pressure PP increases until it
compensates for the loading on the spring (2) and for
the LS pressure 27 bar, the shuttle (1) moves to the
left ( ) and the PP circuit is put into communication
with the tank circuit T.
10-60 WB97R-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 regulated by
the pressure PLS+21 bar.
Because the unloading valve opens when the differential pressure between the pump delivery pressure PP and the
PLS LS pressure becomes equivalent to the loading of the spring (2) (21 bar), the differential LS pressure ,PLS del
LS becomes 21 bar.
2 1 PP
PLS T RKZ01750
OPERATION
Final control of control valve

• When final control are performed with the control Consequently the exceeding pump delivery Q, rela-
valve, a pressure PLS is generated that pressurizing tive to the actuator request, is sent to the tank circuit.
the spring chamber, acts on the left-hand extremity of • The pump delivery pressure PP is regulated by the
the valve (1). combination of the pressure provided by the spring
The actuator pressure is introduced into the LS circuit (21 bar) and by the LS pressure PLS, i.e. when the
and then into the spring chamber. pressure differential ,PLS reaches the value of 21
As a result, the pump pressure PP tends to increase. bar.
• When the differential pressure between the pump de-
livery pressure PP and the LS pressure PLS has the
same value as the loading on the spring (2) (21 bar),
the shuttle (1) moves to the left ( ) and the pump
circuit PP puts itself into communication with the tank
circuit T.
WB97R-2 10-61
3. When the request for oil flow from the actuators exceeds the minimum delivery of the pump during use of the control
valve, the connection to the tank circuit is eliminated and the entire pump delivery Q is sent to the actuators.
2 1 PP
PLS T RKZ01760
OPERATION
When the control valve is in use

• When the control valve shuttle is operated to execute • The result is that the connection between the pump
a bigger stroke, the opening section of spool becomes delivery circuit PP and the tank circuit T is excluded
bigger and consequently the controlled delivery. and the entire pump delivery Q is sent to the actuators.
Because the control valve passage is large, the dif-
ference between the LS pressure PLS and the pump
delivery pressure PP is reduced up to 18 bar (LS
pump valve setting).
• Because the differential pressure between the pump
delivery pressure PP and the LS pressure PLS is not
equal to the pressure given by the spring loading (2)
(21 bar), the shuttle (1) is pushed to the right ( ) of
the spring (2).
10-62 WB97R-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 pump
PP
c d
1
RKZ01781
OPERATION
• When the shuttle (1) is activated, the pump pressure • The PLS circuit of the LS is thus in communication
PP starts to flow into the actuator circuit A through the with the tank circuit T by means of the LS decom-
duct b. pression valve (3).
• At the same time the compensator (2) moves up- (See the description of the LS decompression valve).
wards ( ) so that the flow controlled by spool (1) can • The system stabilizes when a pressure difference of
flow towards the actuator A. 18 bar is generated across the shuttle (1) between
(Check valve (4) do not allow any flow up to when pump pressure PP and PLS pressure.
pressure in chamber c is higher than pressure in
chamber b).
Pressure downstream spool (1) flows in the PLS cir-
cuit downstream the compensator valve throught the
orifice d.
WB97R-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 cause
sudden and unexpected movements acceleration in those actuators operal at lower pressure.
The adoption of the pressure compensation valve allow to control those situation guaranting the proportionality between
each actuator.
FUNCTION
Compensation of actuator deliveries occurs when, during the simultaneous activation of two or more movements, the
pressure of one actuator drops lower than that of the other, and pump delivery, if not controlled, tends to be supplied the
actuator operating at lower. (In the diagram the actuator on the left is requesting higher pressure).
A B
PB
PA
PLS
C
2
4 b
PBV
d
a
PAV
3
PP 1
RKZ02310
OPERATION
1. When activating an actuator at a pressure lower than the one already working.
(While operating actuator A starts operating actuator B)
• Until the pressure PBV downstream from the shuttle • Until the pump does not realize a ,P of 18 bar, i.e. un-
(1) reaches the same value requested by actuator B, til the increase in oil flow compensates the require-
no oil passes. ments of the two actuators, the pump will continue to
• When the pressure requested by actuator B is ex- increase delivery.
ceeded, movement can commence. This creates a • ,P of 18 bar will stabilize as soon as it is restored to.
flow that adding to the one controlled by spool (3) re- • The compensator (2) is moved upwards by the oil flow
duces the pressure upstream of spool (1) and (3) and and stops when the aperture between the chambers a
therefore the ,P between PLS and PP. and b reduces the passage sufficiently to reduce the
• The pump compares the delivery pressures PP and pressure in chamber b to be sent to the actuator.
PLS and senses that the difference ,P<18 bar. This
variation in ,P causes an increase in oil flow increas-
ing the swash plate angle.
(For the detail see «Hydraulic pump»).
10-64 WB97R-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 ,P up-
• Since pressure PB is increasing, the compensator (2) stream and downstream from the shuttle.
moves upwards to restore the ,P between the cham- (PAV<PLS<PP)
bers a and b, and therefore the ,P does not vary up- • Because the pressure PLS which is equal to the pres-
stream or downstream from the shuttle (1). sure PB acts on the upper side of the compensator
• When pressure PB exceeds pressure PA, the com- (4), and since the pressure PAV is lower, the com-
pensator (2) is fully open and the pressure PB is in- pensator (4) is pushed downwards.
troduced into the LS circuit. • The compensator stops when the aperture between
• The increase in pressure in the LS circuit obliges the the chambers c and d generates a reduction of the
pump to increase delivery until the ,P is restored to passage sufficient to reduce the pressure to be sent to
18 bar. the actuator, and to increase the pressure PAV until
the ,P is restored to the 18 bar necessary for equi-
librium.
WB97R-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 increases.
• The increase in aperture provokes a drop in ,P be-
tween the two sides of the shuttles (2) and (3), because
the flow, which has remained unchanged until now, is
divided between both the actuators.
• At the same time the pump senses the variation in ,P
and increases the oil flow until the ,P is restored to ,P
of 18 bar between the two sides of the shuttle (1) and the
compensator (4) changes position in order to restore
the ,P upstream and downstream from the shuttle (3).
10-66 WB97R-2
6. “LIFD” CONTROL SYSTEM

FUNCTION
• The Load Independence Flow Divider (LIFD) intervenes automatically when the oil-flow requested by the actuators
exceeds the maximum delivery guaranteed by the pump.
In this case, the oil-flow is divided between the various actuators in proportion to their requirements.
C B A
6 4 2
PCV PBV PAV
5 3 1
RKZ02340
OPERATION sure PBV downstream from the shuttle becomes

• When, during the simultaneous operation of more equal to the pressure PAV downstream from the shut-
than one actuator, one of them needs a higher pres- tle (1). This equalizes the pressure ,P of the shuttle
sure and the characteristics of the pump are exceed- (1).
ed, the pump guarantees a delivery limited by its • Thus the flow of each actuator is reduced by a per-
calibration curve. centage equal to the reduction or absence of pump
• At this point less oil than requested is distributed to all delivery.
the actuators. • In other words, when the request for performance is
• Because the sections of the apertures remain un- excessive, the system can nevertheless guarantee
changed, the pressure upstream and downstream proportionality and graduality for the movements in
from the shuttles drops. Since the position of the com- any load conditions.
pensator (4) is determined by the pressure of the LS • If an increase in delivery is requested, rather than an
signal, by the pressure PBV downstream from the increase in pressure, and the characteristics of the
shuttle (3) and by the flow of oil needed for the move- pump are exceeded, the system will function in the
ment, the compensator is pushed downwards by the same way as described for the above case.
higher pressure in the upper chamber until the pres-
WB97R-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
0,8
b a
0 20 250 P (bar)
RKZ02350 RKZ02360
OPERATION
• When the LS pressure reaches chamber a of the • The shuttle is pushed downwards ( ) and passage c
valve, it generates a force that opposes the force of is opened.
the spring (2). • The system is in equilibrium (i.e. the shuttle is at rest),
• Until the force generated by the LS pressure exceeds when the quantity of oil allowed to flow into the tank
the force of the spring (2) (LS pressure low) the shuttle circuit is equivalent to the quantity that generates a
(1) remains «at rest» and oil flows through the cali- pressure difference ,P such that
brated orifice b in the tank circuit. (PLSxS)=[(PLS1xS)+F] where:
• When the force generated by the LS pressure ex- PLS=LS pressure
ceeds the force of the spring (2), the shuttle is pushed PLS1=LS pressure contained in chamber d
upwards ( ) and the passages c are closed. S=section of the shuttle
Oil continues to flow into the chamber d until the force F=force of the spring
generated by the pressure contained in chamber d,
together with the force of the spring (2), exceeds the
force generated by the LS pressure.
10-68 WB97R-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 hence also
the pressure of the pump.
b 1
1
RKZ01770
OPERATION
• The pressurized oil of the LS reaches the chamber a of
the valve.
• When the force generated by the LS pressure on the
valve (1) exceeds the force of the spring (2), the valve
(1) is pushed upwards ( ) opening the passage be-
tween the chamber a and the tank circuit.
WB97R-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. Distribution
is determined by the position of the valve of the priority valve in function of the LS signal, oil delivery from the pump, the
pressure of the steering unit and the pressure of the hydraulic circuit. The position of the valve is such as to guarantee that
delivery to the steering unit will always correspond to the actual need.
P LS
D DLS
To the actuator
RKZ02371
10-70 WB97R-2
STRUCTURE AND FUNCTION SOLENOID VALVE
SOLENOID VALVE
Solenoid valve block ST1 - Differential locking - Backhoe boom locking
d
a
b c
1 2
RKZ04960
1. EV4 - Backhoe boom locking

2. EV3 - Differential locking
a. Port T - To the transmission
b. Port 1 - Boom-locking cylinder
c. Port 2 - To the rear axle
d. Port P - From the transmission
WB97R-2 10-71
STRUCTURE AND FUNCTION SAFETY VALVE
SAFETY VALVE
a b
A RKZ00850
Shovel raise Arm

a. Port Y - to the raising cylinders (Head side) a. Port Y - To the arm cylinder (Head side)
b. Port A - From the shovel control valve (Port A1) b. Port A - From the backhoe control valve
c. Port X - To the raising cylinders (Base side) (Port B1)
d. Port B - From the shovel control valve (Port B1) c. Port X - To the arm cylinder (Base side)
d. Port B - From the backhoe control valve
Bucket Dump (Port A1)
a. Port Y - To the dump cylinders (Head side)
b. Port A - From the shovel control valve (Port B2) CHARACTERISTICS
Safety valve calibration
c. Port X - To the dump cylinders (Base side)
Shovel dump: 230 bar
d. Port B - From the shovel control valve (Port A2) Boom: 350 bar
Boom Arm: 230 bar
a. Port Y - To the boom cylinder (Head side)
b. Port A - From the backhoe control valve
(Port A6)
c. Port X - To the boom cylinder (Base side)
d. Port B - From the backhoe control valve
(Port B6)
10-72 WB97R-2
STRUCTURE AND FUNCTION SAFETY VALVE
★ The drawing shows boom safety valve
2 3 4 5
6
1
15
14 13 12 11 10 9
Section
Sezione A
A -- A
A RKZ01050
1. Plug 10. Safety valve spring

2. Check valve spring 11. Safety valve
3. Check valve 12. Spool
4. Check valve spring 13. Spring
5. Check valve 14. Housing
6. Plug 15. Plug
7. Protection
8. Over-ride screw (Safety)
9. Spool
WB97R-2 10-73
STRUCTURE AND FUNCTION BRAKE PUMP
BRAKE PUMP
1 2 3 4 5 6
7
17 16 15 14 13 12 11 10 8
RKZ00932
1. Pump body CHARACTERISTICS:

2. Main piston Stroke: 36 mm
3. Seal Displacement: 15 – 28 cc
4. Differential piston Max. pressure: 150 bar
5. Spring
6. Pump spring
7. Spring
8. Check valve
9. Ball
10. Seal
11. Pin
12. Seal
13. Seal
14. Seal
15. Ball
16. Spring
17. Seal
10-74 WB97R-2
STRUCTURE AND FUNCTION SHOVEL CYLINDERS
SHOVEL CYLINDERS
RAISING CYLINDER
2 3 4 5 6 7
1 8
RKZ00310
DUMPING CYLINDER
2 3 4 5 6 7
1 8
RKZ00300
1. Bushing, base side 4. Piston seal 7. Cylinder

2. Cylinder 5. Piston 8. Bushing, head side
3. Nut 6. Piston rod
CHARACTERISTICS
Cylinder Raising Dumping
Piston rod diameter 50 50
Internal cylinder diameter 85 85
Piston stroke 730 755
Max. cylinder length 1880 2145
Min. cylinder length 1150 1390
Key size for piston safety nut 55 55
WB97R-2 10-75
STRUCTURE AND FUNCTION BACKHOE CYLINDERS
BACKHOE CYLINDERS
BOOM
2 3 4 5 6 7
8 9
1
11 10 RKZ00200
1. Head bushing, piston rod side 5. Piston 9. Bottom bushing

2. Piston rod 6. Piston ring 10. Dowel bolt
3. Cylinder head 7. Guide ring 11. Ball-bearings (9)
4. Cylinder 8. Cushion plunger
ARM
3 4 5 6 7 8 9
10
1 2
RKZ00220
1. Head bushing 5. Bushing 9. Nut

2. Piston rod 6. Piston ring 10. Bottom bushing
3. Cylinder head 7. Guide ring
4. Cylinder 8. Piston
BUCKET
2 3 4 5 6 7 8 9
1
RKZ00290
1. Head bushing 4. Cylinder 7. Guide ring

2. Piston rod 5. Piston 8. Nut
3. Cylinder head 6. Piston ring 9. Bottom bushing
10-76 WB97R-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
WB97R-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 WB97R-2
CHARACTERISTICS
Arm
Cylinder Boom With side Bucket
Standard digging boom
Piston rod diameter 55 60 60 60
Internal cylinder diameter 115 110 110 95
Piston stroke 849 920 910 765
Max. cylinder length 2049 2175 2170 1850
Min. cylinder length 1200 1255 1260 1085
Key size for piston safety nut 65 55 55 55
CHARACTERISTICS
Side digging
Cylinder Outriggers Boom swing boom Jig arm
Piston rod diameter 40 50 45 40

Internal cylinder diameter 80 100 85 70
Piston stroke 635 230 365 1140
Max. cylinder length 1690 319 830 2590
Min. cylinder length 1055 89 565 1450
Key size for piston safety nut 46 -- 46 46
WB97R-2 10-79
STRUCTURE AND FUNCTION AIR-CONDITIONING UNIT
AIR-CONDITIONING UNIT
2
Low pressure steam
Low pressure liquid/steam
High pressure steam

AIR AT AMBIENT TEMPERATURE High pressure liquid
1a
3 1
8
5
7
9
INTERIOR OF CAB
RKZ03130
1. Compressor TECHNICAL DATA

2. Condenser Operating pressure in circuit with engine at 2500 rpm
3. Drying-filter tank and ambient temperature at 25–30°C:
4. Safety pressure Normal pressure: 15 –17 bar
5. Expansion valve Low pressure: 1.6 –1.8 bar
6. Evaporator Safety pressures:
High pressure: 26 bar
7. Thermostatic clutch control sensor
Low pressure: 2.5 bar
8. Air-circulation fan in cab
Coolant fluid: R134a
9. Air conveyor
Quantity of coolant: 970±15 g
10-80 WB97R-2
STRUCTURE AND FUNCTION AIR-CONDITIONING UNIT
HOW THE AIR-CONDITIONING UNIT FUNCTIONS

The compressor (1) is driven directly by the engine shaft On leaving the evaporator (6) the coolant is drawn once
by means of a belt, and made to rotat by a pulley fitted more into the compressor (1) and a new cycle commenc-
with an electromagnetically-engaged clutch (1a). es.
A thermostatic sensor (7) controls the engagement and The yielding of heat from the atmosphere in which the
disengagement of the clutch. It disengages the clutch evaporator is positioned leads to the condensation of the
when the evaporator reaches the lower temperature limit water suspended in the air, and hence to dehumidifica-
and engages the clutch when the evaporator reaches tion. The condensate is deposited on the evaporator fins
the upper temperature limit. where, if a temperature higher than 0°C is not main-
The coolant fluid (in gaseous phase) is drawn into the tained, it freezes and inhibits the functioning of the eva-
compressor where it is subjected to compression and an porator.
intense heating process. In these conditions the fluid is The task of keeping the temperature of the evaporator
then sent into the condenser (2) where, due to the heat above 0°C (and thus within the optimum limits for heat
extracted by ambient temperature air flowing over fins, it exchange) is entrusted to a thermostatic sensor (7).
reaches condensation temperature, and passes into a The condensate that forms on the evaporator fins (6)
high-pressure liquid state. also contains dust, pollens and particles suspended in
Subsequently the coolant passes into the drying-filter the air. Continual condensation therefore effectively pu-
group (3) which performs three functions: it filters out im- rifies the air, and the droplets of condensate are dis-
purities, absorbs any moisture present in the circuit and, charged to the exterior.
finally, also functions as a reserve tank. A fixed quantity of anti-freeze oil is also introduced into
The coolant in its liquid state is then transferred to the the circuit, with the function of lubricating all the mechan-
evaporator (6), first passing through an expansion valve ical parts of the unit. A percentage of this oil circulates
(5). The task of this valve is the constant metering of the constantly throughout the unit in nebulized form, lubri-
quantity of fluid in order to maintain optimum evapora- cating the compressor (pistons and bearings) and the
tion. expansion valve.
In the evaporator the coolant fluid is subjected to expan- A pressure switch (4) has been inserted in the electrical
sion, bringing it up to the critical evaporation point at a control circuit to protect the unit in the case of a lack of co-
temperature of approximately – 8°C. olant fluid or if the quantity becomes insufficient due to
The flow of air generated by centrifugal fan (8) which leakages. This switch will inhibit the engagement of the
passes through the evaporator (6) at ambient tempera- electromagnetic clutch and hence the functioning of the
ture is considerably warmer than – 8°C. For this reason air-conditioning unit.
it yields heat to the coolant fluid, bringing it up to boiling
point and complete evaporation.
WB97R-2 10-81
PAGE INTENTIONALLY
LEFT BLANK
STRUCTURE AND FUNCTION ELECTRICAL DIAGRAM (1/6)
ELECTRICAL DIAGRAM (1/6)
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 P3 P4
P2
R1 ACC BR R2 C - - - -
H1 H2 H3 H4 H5 H6 H7 H8
R/N1
OFF ACC
R1 ST
S
rpm
i S
h i S
q i S
t i
+ + + +
A2.5
M-V1
N1.5
XS
S6 B
XS
5
XS
X17
R6 G2.5 6
X15 X15 X17 X17 X17 X17 X17 X17 X17 4 XS
3 4 13 11 12 1 4 6 5 2 1
X15 X15 X17 R/N1
1 2 X17 X17 3
3.19
X17 X17
H/N1
14 9
R-V1
Z/B1
A2.5
A2.5
M-V1
S1
V1
G2.5
7 8
R6
R/N1
V-B1
A-G1
G1
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
L4
+15 D20
2.13
1 +30 12
AL KIT 2.5
X12 COND. 8
X14
11 9 4 5
A-V1
X19
X19
3.12
X10 X10
L4
X10 1 A-R1
2.19
R4
R4
1
2.2
R-V1
M-V1
G2.5
2
X14 D19 10
K4
X12
l
KT2 KT1 2.19
X18
X18
D18
86 87a 87
2 2 XAD 7 5 D5 +15 +15 11
D17
L13 L23 D13 2.2
X11 X10 X10
A-V1
L4
D16
5 4
3
R-N1.5
85 30
R25 F7C 3.6
R-V1
M-V1
B-R1
R3 F3A
53M
53M
53S
53S
1 1 13 4
31
15
15
31
7.5A
1/4W 4.18
X11 X13 X10 12 10 R4 1/4W 7.5A
XT2
XT2
XT2
XT2
XT1
XT1
XT1
XT1
F3B R13 F7A R23
X10
X10
XAD
L4
9
1/4W 7.5A 7.5A
4.12
1/4W 1/4W
1 2 3 4
R6
L25
1 4 2 3
R4
R4
R-V1
M-V1
7
Z/N1
- 3.10
G/N1
B-N1
Z/B1
B/R1
G1
1/4W
2 L3
4.19
D11
M1
L4 +15 +15 D12
D10
FUG1 FUG2 FUG3 FUG4 K01 K02 K03 L6
Z-B1
13 4.16
86 87 86 87 86 87
60A 80A 30A 70A
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
H/N1
A-N1.5
S1
V1
V-B1
M10
B-R1
Z-B1
A-V1
R10
G2.5
B1.5 B-N1
B/V1
Z-N1
R-N1.5
2.4
B/V1
B/N1
B1.5
R50
- l 3 2 A 1 2 3 4 2 6 1
XA
XA
XAM XAM X16 X21 X21 X10 X10 X10 X10 X10
R50
30 50 30 R30 R31 R32 HA1

M 30 W Y0 S24 S21 S23 S22
G
3 t p p
G1 U
t
M1 G2 31
12Vcc
XAM X16 X21
1 B 3
N1
N1
N1.5
N1
N1
N1
N1
N1
N1
N1.5
N1.5
N50
31
2.1
RKZ04800
COMPONENTS H8 - Optional warning lamp P3 - Fuel level indicator CONNECTORS X19 - Front dashboard 9 way connector FUSES
G1 - Battery HA1 - Horn P4 - Water temperature instrument X1 - Front line (engine) 11 way connector X21 - Fuel level indicator 3 way connector F3A - Safety start fuse 7.5A
G2 - Generator K01 - Starter relay R30 - Heating start X10 - Front line-engine line 13 way connector XA - Generator 2 way connector F3B - Switch+warning light+ return to dig fuse 7.5A
H1 - Preheating warning light K02 - Preheating relay R31 - Fuel level sender X11 - Power 3 way connector XAD - Diode 2 way connector F7A - Monitor fuse 7.5A
H2 - Generator warning light K03 - Fuel shut off relay R32 - Water temperature sender X12 - Front line-cross line 3 way connector XAM- Fuel shut off valve 3 way connector F7C - Fuel shut off fuse 7.5A
H3 - Engine water high temperature K4 - Safety start relay S6 - Starting switch X13 - Front line-engine line 2 way connector XS - Multifunction instrument 16 way connector FUG1- General fuse 60A
warning light KT1 - Fuel shut off timer S21 - Engine water high temperature switch X14 - Front line-cross line 4 way connector XT1 - Fuel shut off timer 4 way connector FUG2- Preheating fuse 80A
H4 - Air filter warning lamp KT2 - Preheating timer S22 - Air filter blocked switch X15 - Start key 4 way connector XT2 - Preheating timer 4 way connector FUG3- Fuel shut off power fuse 30A
H5 - Hydraulic oil filter warning lamp M1 - Starter motor S23 - Engine oil low pressure switch X16 - Conditioner clutch 2 way connector FUG4- Generator fuse 70A
H6 - Optional warning lamp P1 - Rpm instrument S24 - Fuel gauge X17 - Lateral dashboard 21 way connector
H7 - Optional warning lamp P2 - Hour counter Y0 - Fuel shut off solenoid valve X18 - Power box 5 way connector
WB97R-2 10-83
PAGE INTENTIONALLY
LEFT BLANK
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
A-R1 A-R1
1.9 4.15
2 6 7 9 1 7 2 8 10 15/1 30/3 L/6 MANIPOLATORE 1

15/1 30/3 L/6
II I
0 H9 H10 H11 H12 2 3 4 0 1
JOYSTCK X29 0 1
NON MONTATO 0
1 2
3
NOT CONNECTED S10
3 5 10 5 6 9 49/4 30b/2 R/7
X28 X28 X28 X28 X28 X28 X28 X28 X28 X28 X28 X28
S2A S1A S2 1 2 3 4 5 6 7 8 9 10 11 12 S1 49/4 30b/2 R/7
S4 + 1
S1
V-B1
V-N1
C-N1
L-B1
M-V1
M-B1
G-V1
M-N1
C-B1
C/B1
A1.5
R/N1 R/N1
2.19 X29
A-N1
2 B-N1 4.15
V/N1
N1
4.1
C-N1
4.16
L/B1 C-L1
3.9 3.1
X18
X19
M-N1 M-N1
C-L1 4.6
M/N1
C-L1
X19
4.16
Z-B1
Z-N1
B1.5
R1.5
N1
3 7
R/N1 R/N1
2.2 3.12
M-N1
4 15 16 5 10 11 10 7 4 1 9 1 8 3 7 6
8 13
X8 X9 X9 X9 X5 X5 X5 X9 X2 X2 X9 X9 X8 X5 X5 X5 X9
1
1.20 P5 P6
D14 1.20
10
11 20
1.20 3.7
V2.5 33
4.19
17
4.18
L14
+15 18 +15
3.1
31 4.17
R5 F5A R17
F4A R14 R27 F3C K7 86 87a 87
D8 1/4W 32 4.18
15A 1/4W
86 87
7.5A 1/4W 1/4W 7.5A
85 30 85 30
L17
L5 K04
L27
+15
D22 D21
40
3.1
B/V1
12 16
1.20 4.6
M-V1
C-L1
P8
15
4.17
X3 X3 X3 X5 X3 X8 V2.5 X6 X43 X43

3 5 4 1 7 13 L4 L4 9
X25
X25
1.2
V-N2.5
B/V1 2 1
1.15
Z-N1.5
H1
A-G1
S-N1
G-N1
L-B1
1 2
V-N2.5
B-R1
6 2 3 1 5 4
X27 X27 X27 X27 X27 X27
X14
X14
l 4 3 1 2 2 3 4
X23
X23
X20
X20
X20
C-N1
X24
X24
X22 S18
C-B1
C/B1
V/N1
M-N1
3 4
M2
R1.5
53a
1
M M3 OPTIONAL S16 S15 M4 M EV1 EV2 EV3 EV4 Y1
B-R1.5
53
M 53b
B-R1
31b
p
31 S17 S19 S20
2
R1.5
N1
X24 R1
X22 1 X20 4.8
- 1
B-R1
R1
N2.5
H-N1
N1
N1
N1
N1
N1
N1
N1
N1
N1
31 31
1.20 3.1
RKZ04810
COMPONENTS M2 - Washer pump S19 - Stop light switch CONNECTORS X22 - Windshield washer pump 2 way connector FUSES
EV1 - Opened grab solenoid valve M3 - Windshield wiper motor S20 - Stop light switch X2 - Lights switch and gear shift line 9 way connector X23 - Optional 2 way connector F3C - Forward and reverse solenoid
EV2 - Closed grab solenoid valve M4 - Blower motor S1A - 4WD switch on front dashboard X3 - Front line 11 way connector X24 - Windshield wiper 4 way connector valve fuse 7.5A
EV3 - Differential lock solenoid valve S1 - Economy power push button S2A - Windshield wiper-washer switch X5 - Cabin command 11 way connector X25 - Powered blower motor 2 way connector F4A - 4WD valve-windshield
EV4 - Rear 1° boom unlock solenoid valve S2 - Rear 1° boom unlock switch on front dashboard X6 - Solenoid valves line 9 way connector X27 - Valves line 6 way connector wiper/washer fuse 7.5A
H9 - 4WD warning lamp S4 - Blower motor switch Y1 - Economy power solenoid valve X8 - Lateral dashboard 17 way connector X28 - Joystick 12 way connector F5A - Blower motor switch 15A
H10 - Engine water high temperature warning light S10 - Hammer button X9 - Front dashboard 17 way connector X29 - Convert detachment button 2 way connector
H11 - Engine oil high temperature warning light S15 - Hand brake switch X14 - Front line-cross line 4 way connector X43 - 2 way connector OPT interface
H12 - Fuel reserve warning light S16 - Brake oil low level switch X18 - Power box 5 way connector
K04 - Powered blower motor relay S17 - Stop switch X19 - Front dashboard 9 way connector
K7 - Lights switch relay S18 - Stop switch X20 - Blower motor 4 way connector
WB97R-2 10-85
PAGE INTENTIONALLY
LEFT BLANK
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 4.6
C-L1 L1.5 L-G1.5 A-R1

2.20
HA2
15/1 30/3 L/6 1 9 1 9 1 9 1 9 1 9 2 6 7 9
0 1 1 0 1 0 1 0 1 0 1 0 II
I 0 H13 H14
G/N1
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
A-N1
B-R1
L/B1 A-R1
A/R1
X19
X19
6 3 4 5 1 2
X17 X17 X17 X17 X17 2 1 X33 X33 X33 X33 X33 X33
18 16 17 10 19
R/N1 R/N1
2.20 1.14
L/N1
A-N1
R-N1.5
L/B1
S-G1
L1.5
2.2
G-V1 G-V1
4.8
15 5 14 9 16 12 1 7
X8 X2 X8 X2 X8 X9 X2 X9
P10 P9
G/N1
G/N1
7 8
1.17 1.20
+15
19
L20 4.20
F4B R15
L18 +30 +30 L19
10A 1/4W K2 R2
F6A R20
R/N1
86 87a 87
K05
1/4W
15A 1/4W D2 22uF
F5B R18 F2A R10 F1C L7 F1B L8 F2B R11 F5C R19 86 87a 87
+
L15 C1 85 30 15A 1/4W 10A 1/4W 3A 3A 7.5A 15A 1/4W
1/4W
L2 R7 R8 85 30
+15
2.10
40 L10 1/4W 1/4W L11 R-V1
+15
+15
18
2.8
3 20 12
1.20 2.5 4.5
P7 P4
X5 X6 X6 X6 X6 X6 X6 X6 X6 X6 X5 X5 X3 X5
2 4 5 7 1 3 8 2 6 17 9 6 1 4
G1 G-R1 G1
4.8
R-N1.5
4.10
M1
B1
N0.5
L-G1.5
4.1
H-L1
G1
A/R1
A-N1
A-R1
B-G1
B-G1
R-V1
1
4 3
X30 2 1
H19
R-V1
X31 X31
X31
X31
A
HA4 M5 H16
X39
Y3 HA3 X1 H15 53a
M 1 2
S27 Y6 M M8 53
M 53b H20 H21
H17 H18
X32
X32
31b
ALIM. 31
AUTORADIO
RADIO
X30 POWER SUPPLY X39 X39
2 N1 B C
N1
N1
N1
N1
N1.5
L.05
N1.5
N1.5
N1
N1
N1
N1
N1
L. CABINA
31 CABIN CABLE 31
2.20 4.1
RKZ04830
COMPONENTS HA4 - Buzzer S4L - Horn switch on lat. dashboard CONNECTORS X32 - Radio power 2 way connector FUSES
H13 - Dashboard light K05 - Return to dig relay S5L - Optional switch on lat. dashboard X1 - Front line (engine) 11 way connector X33 - Windshield wiper and beacon F1B - Right traffic light fuse 3A
H14 - Dashboard light K2 - Reverse speed relay Y3 - Plate unlock solenoid valve X2 - Lights switch and gear shift line 9 way connector 7 way connector F1C - Left traffic light 3A
H15 - Cigarette lighter lamp M5 - Fuel pump Y6 - Return to dig solenoid valve X3 - Front line 11 way connector X39 - Proximity 3 way connector F2A - Beacon fuse 10A
H16 - Cabin lamp M8 - Windshield wiper motor X5 - Cabin command 11 way connector F2B - Radio cabin lamp fuse 7.5A
H17 - Front working lamp S3 - Plate lock switch X6 - Solenoid valves line 9 way connector F4B - Forward-reverse speed fuse 10A
H18 - Front working lamp S27 - Npn Sensor X8 - Lateral dashboard 17 way connector F5B - Rear working light switch fuse 15A
H19 - Beacon S3A - Front working light switch on front dashboard X9 - Front dashboard 17 way connector F5C - Front working light switch fuse 15A
H20 - Rear working light S1L - Rear working light switch on lat. dashboard X17 - Lateral dashboard 21 way connector F6A - Windshield wiper-washer switch fuse 15A
H21 - Rear working light S2L - Windshield wiper-washer switch on X19 - Front dashboard 9 way connector
HA2 - Buzzer lat. dashboard X30 - Fuel pump 2 way connector
HA3 - Rear horn S3L - Beacon switch on lat. dashboard X31 - Cabin 5 way connector
WB97R-2 10-87
PAGE INTENTIONALLY
LEFT BLANK
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

K06
3.20 3.14
N1
53M
2.9
DEVIO LUCI
15
G-V1
31
H22 H23 H24 H25 EGM
I
LIGHTS SWITCH
N1
2 8 5 10
1 0
X45
X45
X45
X45
X45
XD1 XD1 XD1 XD1 XD1 XD1 XD1 XD1 XD1
1 2 3 4 5 6 7 8 9
OUT BLOCCAGGIO DIFF./DIFFERENTIAL LOCK

4 6 3 1 7 1 2 3 4 5
CONS. AVVIAMENTO/STARTING AGREEMENT

S4A
A/B1
M-N1
C1
2.20
B/R1
A/N1
A/N1
B-R1
A-R1
2.20
BUZZER ALLARMI/ALARM BUZZER

IN PEDALE FRENO/STOP SWITCH
N1
B-N1
2.20
C-L1
2.7
C-N1
BACK UP ALARM
MASSA/GROUND
2.20
KICK-DOWN
DECLUTCH
X18
X18
X19
+15 EGM
B1
R-N1
X19
A/V1
V1
R1.5
H-N1
A-V1
R-N1
2 1 8 9
8 4 17 3 5 11 3 2 6 2 14 1 2 3 4 5 6 7 8 9
6
X2 X9 X9 X9 X2 X9 X9 X9 X9 X2 X2 X9 X7 X7 X7 X7 X7 X7 X7 X7 X7
16
+30 2.7 13 15
1.13 2.7
D15
+30 31
K5 1.20
9 2.10
86 87a 87
K6 32
D6 L12 L22 86 87a 87 K9
2.10
D7 K8 2.17
17
85 30 +
86 87a 87 4
F2C R12 F6C R22 85 30 C R D9 1.20
2
F1A R28 10A 1/4W 10A 1/4W F4C R29 85 30 1.13
33
15A 2.17
15A 1/4W R16 1/4W
R9 L21
19
1/4W L24 3.6
+30 +15
1/4W L28 L29
L16 F6B R21 F7B R24
1/4W
L9 7.5 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
R-G1
A-B1
A-G1
G-R1
A-B1
B1
M1
A1
M1
B1
3.12
G-R1 G1
3.11
A1
L1
A1
A-B1
G1 G1
3.13 1 2 3 4 5 6 7 8 9 10 11 12 13
X40 X40 X40 X40 X40 X40 X40 X40 X40 X40 X40 X40 X40
3 1 7
2 3 6 4 2 3 6 4 4 2 8
X26
X26
X26
N1
N1
N1
X34
X34
X34
X34
X35
X35
X35
X26
X26
X26
X35
N1
G-R1
H26 H27 H30 H32
56b
56a
56b
57
57
56a
59c
59c
57
57
R
L
H31
31
31
31
31
X34 X35 X26 X26

1 1 5 6
N1.5
N1.5
N1.5
N1
N1
N1
31 31
3.20
RKZ04820
COMPONENTS K6 - Main beam relay CONNECTORS X40 - Flasher unit 13 way connector FUSES
K8 - Horn relay X2 - Lights switch and gear shift line 9 way connector X45 - Power economy unit connector F1A - Low beam fuse 15A
H22 - Indicators warning light
K9 - Flasher unit X3 - Front line 11 way connector XD1 - Lights switch 9 way connector F2C - Warning fuse 10A
H23 - Main beam warning light
H24 - Low level brake oil warning light S4A - Warning switch on front dashboard X7 - Not connected 9 way connector F4C - High beam fuse 15A
H25 - Differential lock warning light X9 - Front dashboard 17 way connector F6B - Lights switch power fuse 7.5A
H26 - Right front lamp X18 - Power box 5 way connector F6C - Warning power fuse 10A
H27 - Left front lamp X19 - Front dashboard 9 way connector F7B - Horn fuse 10A
H30 - Left rear lamp X26 - Rear line 8 way connector
H32 - Right rear lamp X34 - Right front light 6 way connector
K5 - Low beam relay X35 - Left front light 6 way connector
WB97R-2 10-89
PAGE INTENTIONALLY
LEFT BLANK
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
XD1
POS DESCRIZIONE FUNZIONE FUNCTION DESCRIPTION
1 MASSA AVV. ACUSTICO HORN GROUND
2 SEGNALE IND. DIREZIONE SX LEFT INDICATOR SIGNAL
3 ALIMENTAZIONE AVV. ACUSTICO HORN POWER SUPPLY
4 SEGNALE ABBAGLIANTI HIGH BEAM SIGNAL
5 SEGNALE LUCI DI POSIZIONE TRAFFIC LIGHT SIGNAL
6 ALIMENTAZIONE INDICATORI DIREZIONE DIRECTION INDICATORS POWER
7 SEGNALE IND. DIREZIONE DX RIGHT INDICATOR SIGNAL
8 SEGNALE ANABBAGLIANTI LOW BEAM SIGNAL
9 ALIMENTAZIONE DEVIO POWER
1 2 3 4 5 6 7 8 9
XD1
XD1
XD1
XD1
XD1
XD1
XD1
XD1
XD1
57/58 49 54S 54D
DX
SX
56a 56b 30 31 L
DEVIO LUCI
LIGHTS SWITCH
RKZ04850
WB97R-2 10-91
PAGE INTENTIONALLY
LEFT BLANK
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
MANIPOLATORE/JOYSTICK
FILO FILO FILO

COMUNE CONT. N.A. CONT. N.C.
POS DESCRIZIONE/DESCRIPTION N.O. N.C.
COM. CONTACT CONTACT
WIRE WIRE WIRE
SM2
SM1 KICK DOWN N1 M-B1
SM1 SM2 CONTROL-SQUARE C-L1 C-N1
SM3 BENNA CHIUDE/CLOSED GRAB C-L1 C/B1
SM4 STACCO CONVERTITORE/CONVERTER DETACHMENT N1 M/N1
SM5 BENNA APRE/OPENED GRAB C-L1 C-B1
SM6 BLOCCAGGIO DIFFERENZIALE/DIFFERENTIAL LOCK M-V1 M-N1
SM1 SM2 SM3 SM4 SM5 SM6
SM3 SM4
M-N1
M/N1
C-B1
M-B1
G-V1
C/B1
C-N1
C-L1
N1
POS. CONNECTOR
8 5 7 6 3 4 2 9 1
CONN. POSITION
SM6 SM5
RKZ04840
WB97R-2 10-93
PAGE INTENTIONALLY
LEFT BLANK
STRUCTURE AND FUNCTION ELECTRICAL DIAGRAM (AIR CONDITIONING)
ELECTRICAL DIAGRAM (AIR CONDITIONING)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
87
1 9
86
1 0
K04
0 86 87a 87
5 10
CONNECT WITH PRESETTING SOCKET
INSIDE LATERAL DASHBOARD 85 30
9 5 10 1
85
X58 X56 X57 X56
30
G-V1
N1
X54 3° FAN SPEED RELAY
H-G1 CONNECT TO "S4" POSITION "1"
(BLOWER MOTOR SPEED SWITCH )
N1 GROUND CONNECTION (BLACK)

(FROM OPTIONAL LAMP SWITCH CONN.)
V1 X53 INTERFACE WITH EXTANT WIRE A-V1

K10 (INSIDE LATERAL DASHBOARD )
WIRING COLOURS
86 87a 87
C1
85 30 A LIGHTBLUE
X16
85 30 86 87 CONNECT WITH PRESETTING A B WHITE
X55 CONNECTOR NEAR GENERATOR X16
X55 X55 X55 B
C ORANGE
N1 V-N1 G YELLOW
G-V1 G-V1 H GREY

COMPRESSOR
A B L BLUE
ELECTROMAGNETIC
X59 X59 CLUTCH
M BROWN
V-N1 N BLACK
G-V1 R RED
S PINK
2 1 2 1
V GREEN
X62 X62 X61 X60 Z VIOLET

X33
S40 S10 X20
p 4 EXAMPLE:
t X20
CONNECT WITH PREVIOUS 3
HEATER MOTOR CONNECTOR X20 G/V ->YELLOW/GREEN (TRANSVERSE MARKED)
2
X20
1 BLACK YELLOW GREEN
M4
M
G-V ->YELLOW-GREEN(LONGITUDINAL COLOURS)
NAME DESCRIPTION NAME DESCRIPTION
YELLOW GREEN
K04 3° FAN SPEED RELAY X56 A/C SWITCH SWF CONNECTOR
K10 COMPRESSOR ELECTROMAGNETIC CLUTCH CONTROL RELAY X57 AMP 1 WAY CONNECTOR HEATER/CONDITIONING
M4 FAN MOTOR
MOTOR UNIT
X58 AMP 1 WAY CONNECTOR
R33 SPEED RESISTOR X59 2 WAY CONNECTOR

RKZ07450
S10 NO FROST THERMOSTAT X60 NO FROST THERMOSTAT 1 WAY CONNECTOR
S39 A/C SWITCH X61 NO FROST THERMOSTAT 1 WAY CONNECTOR
S40 A/C SAFETY SYSTEM PRESSURE SWITCH X62 SAFETY PRESSURE SWITCH AMP MINITIMER 4 WAY CONNECTOR
X53 AMP 1 WAY CONNECTOR X16 COMPRESSOR ELECTROMAGNETIC CLUTCH 2 WAY CONNECTOR
X54 FEMALE FASTON X20 HEATER/CONDITIONING MOTOR UNIT AMP 4 WAY CONNECTOR
X55 MINI-RELAY CONNECTOR C1 COMPRESSOR ELECTROMAGNETIC CLUTCH
WB97R-2 10-95
PAGE INTENTIONALLY
LEFT BLANK
GROUP 20
40-28 PC15R-8
TESTING AND ADJUSTMENTS
Normal or standard technical data............................. 2 Testing and adjusting of unloading valve .................35
Special tools ............................................................ 14 Checking unloading valve functionality ....................36
Measuring engine speed ......................................... 15 Testing priority valve operation ................................37
Adjusting valve clearance ........................................ 16 Testing and setting steering control system pressure .. 38
Measuring compression pressure ........................... 17 Testing brake system ...............................................39
Testing and adjusting fuel injection timing............... 18 Control of the engine speed under load ...................41
Checking and tightening the fan - belt ..................... 20 Testing pressures in the power train group ..............43
Checking and tightening the compressor fan - belt . 21 Testing the correct functioning of the power train
Measuring accelerator pedal operating clutches ....................................................................45
travel and accelerator lever ..................................... 22 Adjusting the sensor for return to dig device ............46
Adjusting brake pedal travel, brake alignment, Analysis of causes hydraulic drift .............................47
microswitches .......................................................... 24 Testing the air-conditioning unit ...............................52
Air bleeding - releasing residual pressure ............... 25 Emptying the air-conditioning unit ............................54
Checking and setting pressure in the attachments Troubleshooting........................................................55
hydraulic circuit ........................................................ 28
Testing and adjusting of Load Sensing signal
(LS valve) ................................................................ 34
When carrying out controls, adjustments or analyses for troubleshooting, park the machine on firm, level ground.
Apply all the machine safety devices and use blocks to prevent any machine movement.
When more than one person is engaged in the work, use the prescribed notices that indicate that the machine is un-
dergoing maintenance. Do not allow any unauthorised persons to remain in the vicinity.
When checking the level of the cooling liquid, wait until this liquid has cooled. If the radiator cap is removed while the
liquid is still hot and under pressure, it may cause severe burns.
Take great care not to get entangled in moving parts (fan, alternator belt or any of the rotating elements).
WB97R-2 20-1
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA
NORMAL OR STANDARD TECHNICAL DATA

FOR ENGINE

Engine S4D106-1FA
Standard Permissible
Check item Test conditions Unit
value value
High idling rpm 2375±50 2325–2425
Engine speed Low idling rpm 1050±50 1000–1100
Set speed rpm 2200 --
Exhaust gas Sudden acceleration Bosch 0.9 1.5
colour At high idling speed index 0.5 1.0
Intake valve (20°C) mm 0.30±0.05 Max. 0.35
Valve clearance
Exhaust valve (20°C) mm 0.30±0.05 Max. 0.35
Compression
Oil temperature 69 – 72°C bar 34.3±1 27.5±1
pressure
(Engine speed) rpm 250 250
(SAE30 oil)
Blow - by
Water temperature in operating range -- --
pressure mm H2O
At high idling speed -- --
(oil SAE30)
Max. idling (in cold state) bar Max. 5.8 Max. 5.8
Engine oil
At set speed bar 4.4 3.9–4.9
pressure
At low idling bar 1 Min. 1
Oil
Entire speed range °C 120 Max. 120
temperature
Fuel injection
B.T.D.C. degrees 12.5 11.5–13.5
timing
Fan belt Deflection when pressed with finge force
mm 10 10–15
tension of approx. 10 kg
20-2 WB97R-2
FOR MACHINE

Classifi- Standard Permissible
cation value value
• Hydraulic oil temperature:

45 – 55 °C Max. 2375±50 2325–2425
• Converter oil temperature:
Accelerator pedal 80 °C
• Engine oil temperature
1050±50
Engine speed
cooling circuit: Min. 1000–1100

in the limits
rpm
• Hydraulic oil temperature:
45 – 55 °C Max. 1900±50 1850–1950
• Converter oil temperature:
Accelerator fuel 80 °C
• Engine oil temperature
cooling circuit: Min. 1050±50 1000–1100
in the limits
All controls ᐉ ᐉ a b c ᐉ a b c
(front bucket and
Control valve
a b c
backhoe) 41.5 8 8 -- -- -- -- --
mm
For front shovel arm
command only 41.5 8 8 -- -- -- -- --
(with floating arm) RKZ02580
Front bucket tilt lever Raise

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

lever Closing
• Engine stopped
Bucket backhoe control • At the centre Opening
Neutral 100 80–120
lever of knob lever Closing
• Valve reading
Boom swing mm
at the end of Right
backhoe working stroke Neutral 100 80–120
Left
control lever • Attachments
on the ground
Outriggers control Up
Neutral 50 35–65
lever Down
Fuel control
Min. Max. 70 50–90
lever
Jig arm control Out 15 10–20
Neutral
pedal In 30 20–40
Hammer and side digging Right 15 10–20
Neutral
boom control pedal Left 30 20–40
WB97R-2 20-3
FOR MACHINE

cation value value
Travel of levers and
• Engine stopped
Accelerator pedal • At the centre Min. Max. mm 80 60–100
of knob lever
pedals
• Valve reading
at the end of
working stroke Right Left
Wheel swing • Attachments rev. Max. 2.5 2.2–2.5
on the ground Left Right
Front bucket tilt lever

2.5 2–3
control
Front bucket control
2.5 2–3
lever
Boom control • Engine speed: max. 1.5 1–2
lever • Oil temperature: 45 – 55 °C
Force for levers and pedals operation
• Tool connection at the centre of knob

Arm control
(for levers) 1.5 1–2
lever • Tool connection on edge
Bucket control lever (for pedals) 1.5 1–2
Boom swing
1.5 1–2
control lever
kg
Outriggers control
3 2.5–3.5
lever
Fuel control
12 10–14
lever
Jig arm control In 4 3–4

pedal Out 8 6–10
Hammer and side digging
8 6–10
boom control pedal
Accelerator pedal 3 2–4
Brake pedal 30 Max. 60
20-4 WB97R-2
FOR MACHINE

cation value value
2-3-Spool control valve 200 200±7

Main valve pressure
• Engine speed: max.

• Oil temperature: 45 – 55 °C
• Without steering
bar
6-7-8-Spool control valve 200 200±7
Steering unit • Engine speed: 1500±50 rpm 175 175±7
Front bucket
235 235±7
(curled)
Front bucket
175 175±7
Pressures of secondary valves circuits
(dump)
Attachment
235 235±7
(3rd spool)
Boom
• Engine speed: min. 305 305±7
(raising) ✽
Boom (lowering) • Check one circuit at the time bar 235 235±7
Arm (Closing) ✽Check on test bench 235 235±7
Boom swing 245 245±7
Bucket (curled) 235 235±7
Side digging boom
275 275±7
(right-left)
Hammer (delivery) 165 165±7
Steering unit (safety) ✽ 240 240±7
WB97R-2 20-5
FOR MACHINE

cation value value
• Engine speed (without load): 2375±50

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

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

With converter
• Converter oil temperature: 80°C 2250±50 2200–2300
(TBG version) • Machine in 3rd gear

With converter and • Hydraulic oil temperature: 45 – 55 °C
• Converter oil temperature: 80°C
hydraulic circuit 2250±50 2200–2300
• Machine in 3rd gear
(TBG version) • Working brakes applied
• Front bucket curled stop
20-6 WB97R-2
★ The technical data of follow table are refered to a machine with max 500 kg shovel bucket, 600 mm (max. 160 kg)
backhoe bucket and standard arm (or telescopic arm) closed.
FOR MACHINE

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
Bucket cylinder • Oil temperature: 45 – 55°C
• Check measures as soon as engine 15 25
(cylinder in)
stops.
• Check changes every 5 min. and the total change
in 15 min
Measuring posture
Complete working
equipment
300 450
(Tip lowering of
bucket teeth)
Boom cylinders
35 50
(cylinder out)
1m 1m
Backhoe
RKZ06650 mm
• In this position check the extension of each cylin-
Arm cylinder der and the leakage with normal load on the buck-
15 25
(cylinder out) et.
• On level ground.
• Bucket: normal load (450 kg)
• Engine stopped
• Oil temperature: 45 – 55°C
Bucket cylinder • Check measures as soon as engine stops.
• Check changes every 5 min. and the total change 10 15
(Cylinder in)
in 15 min.
WB97R-2 20-7
FOR MACHINE

cation value value
Measuring posture
RKZ02670
Boom swing 15 25
• Backhoe balanced on the guides bucket in trans-
port condition.
• Arm and bucket cylinder in. Put the bucket link pin
at 1 meter from ground and swing at end of boom
Hydraulic drift working equipment
stroke in one of the two direction.

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

mm
Measuring posture
Outriggers Max 15 25
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.
20-8 WB97R-2
FOR MACHINE

cation value value
2.0
Front bucket
Boom Max. 8.0

(each cylinder)
1.6
Bucket Max. 6.0
(each cylinder)
Boom 3.3 Max. 13.5
Arm 3.0 Max. 12.0

• Engine: Max. speed
Cylinder leaking
• Oil temperature: 45--55°C

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

Boom swing 3.2 Max. 13.0
Outrigger 3.3 Max. 13.5
Side digging boom 2.0 Max. 8.0
Jig arm 1.6 Max. 6.0
WB97R-2 20-9
FOR MACHINE

cation value value
Measuring posture
Tilt lever front
Raised
bucket 3.6 3.1 – 4.1
Cylinders
extended out
Lowered
RKZ07510
Bucket on 2.5 2.1 – 2.9
Front bucket
• Engine speed: Max.

level ground • Oil temperature: 45 – 55°C
• Speed up
Measuring posture
Curled
Bucket 2.6 2.2–3.0
Cylinder out Dump
RKZ00510
Cylinder in 3.5 3.0–4.0
• Engine speed: Max.
• Speed up
Measuring posture
Work equipment speed
Lifting ●
Boom 2.6 2.2–3.0
Cylinder in
sec.
Lowered
Teeth bucket on level 0

RKZ00430
• Engine speed: 1700 + 50 rpm 1.9 1.6–2.2
ground • Oil temperature: 45 – 55°C
• Backhoe balanced
• Power mode
Measuring posture
Opening
Arm 3.6 3.1–4.1

Backhoe
Cylinder in
Closing ●
RKZ00440
Cylinder out • Engine speed: 1700 +0 50 rpm 4.5 3.9–5.1
• Power mode
Measuring posture
Dump
Bucket 2.6 2.2–3.0
Cylinder in
RKZ00450
Curled
• Engine speed: 1700 +0 50 rpm

Cylinder out • Oil temperature: 45 – 55°C 2.1 2.7–3.5
• Power mode
20-10 WB97R-2
FOR MACHINE

cation value value
Measuring posture
Right ●
3.5 3.1 – 3.9
Boom swing
Backhoe
Right end travel sec.
Left end travel RKZ02670
Left ●
0
• Engine speed: 1700 + 50 rpm 3.5 3.1 – 3.9
• Arm horizontal
• Power mode
● This time are refered to the cylinder stroke whitout the brake phase.
NOTE. The engine speed (1700 +0 50 rpm) has to be checked with the procedure described at paragraph
«MEASURING ENGINE SPEED» in this section.
WB97R-2 20-11
FOR MACHINE

cation value value
Measuring posture
Tilt lever front

0 Max. 2
bucket
RKZ00500
• Engine speed: Min.

• Check the time necessary to lift bucket from level
ground.
Measuring posture
Time lags
Boom sec. 0 Max. 2
RKZ00460

• 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
RKZ00471

• Put boom at 45°, open completely the arm with
curled bucket. Extend arm cylinder and check the
time passing between arm stop at dead centre and
the restart movement.
20-12 WB97R-2
FOR MACHINE

cation value value
Measuring posture
Bucket 0 Max. 2
RKZ00480

• Put arm in horizontal position. Tilt back bucket
cylinder an then extend it.
Work equipment
Check the time passing between bucket stop at

Time lags
dead centre and the restart movement.
Measuring posture sec.
Outriggers 0 Max. 2
RKZ00520

• Boom, arm and bucket fully retracted and putted in
machine centre position.
• Check the time necessary for outriggers to raise
the machine from when they lean on level ground.
• Check each outrigger at a time.
WB97R-2 20-13
TESTING AND ADJUSTMENTS SPECIAL TOOLS
SPECIAL TOOLS
Measurement check point Symbol Code Name Q.ty Note

Commercially
Valve clearance A 1 Feeler gauge 1 --
available
1 Compression gauge 1 Kit Yanmar
Compression pressure B ATR800280
2 Adapter 1 TOL-97190080
Commercially
1 Multiscale tachometer 1 20 - 4000 rpm
Engine speed C available
2 ATR800060 Stroboscopic tachometer 1 6 - 30000 rpm
Commercially
Oil and water temperature D 1 Digital thermometer 1 -- 50 - 1200 °C
available
Commercially
1 Pressure gauge 2 Full scale 60 bar
available
Commercially
available
Commercially
E available
Hydraulic pressure Commercially
available
5 Servocontrol kit
Differential digital 1 0 – 1000 bar
6 pressure gauge
ATR800200
1 Flow-meter 1 Delivery 0 – 300 ᐉ/min.
F
2 Pipe fitting kit 1 --
Air bleeding G 1 ATR201490 Tank cap 1 Pump air bleeding
Commercially
Hand brake L 1 Spring dynamometer 1 Full scale 20 kg
available
Commercially
1 Maintenance station 1 For coolant R134a
available
Commercially Sampling every 15
Air-conditioning unit M 2 Thermometer-hygrometer 1
available seconds
Commercially
3 Leak detector 1 For coolant R134a
available
20-14 WB97R-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
★ Check speed when following condition are reached:
• Engine water cooling temperature: 68 – 80 °C.
• Hydraulic oil temperature: 45 – 55 °C.
1 - Remove the air filter (1).
2 - Install and connect C1 tachometer.

★ If using C2 stroboscopic tachometer, mark a light
notch on, engine pulley for an easier reading.
RKZA9910
3 - Start engine and check:
• Low idling speed without load (accelerator pedal
and hand accelerator released in «minimum» po-
sition).
• High idling speed without load (accelerator pedal at
the travel end).
C1
★ Low idling speed: 1050±50 rpm
★ High idling speed: 2375±50 rpm
★ If low and high idling speed with engine without load
are not within permissible value, before going on
with other operations, check accelerator pedal
stoppers and wiring sheathings. (See «ACCELER-
ATOR LEVER ADJUSTING»).
RKZA5300
WB97R-2 20-15
TESTING AND ADJUSTMENTS ADJUSTING VALVE CLEARANCE
ADJUSTING VALVE CLEARANCE

★ Engine: in cold state.
★ Adjust clearance between valves and rocker levers as 2 1 4
follows: 3
Unit: mm
At cold Engine Intake-exhaust
engine S4D106-1FA 0.30±0.05
★ Firing order: 1-3-4-2-1..... at 180° step.

★ Normal rotation sense: counterclockwise from flywheel
★ The cylinder N° 1 is on the opposite fan side.
RKZA9960
• Adjusting procedure
1 - Remove air cleaner (1), muffler (2), intake manifold
(3) and valves cover (4). 6
2 - Rotate crankshaft in normal direction as long as
5
cylinder piston to be checked is at compression
Top Dead Center (PMS).
★ In this position intake and exhaust valves are
closed.
3 - Loose lock nut (5) and unscrew tappet (6) of about
7
YES
SI NO
1 turn.
★ Check that valve insert (7) is laying flat on valve
stem and that it is not worn askew.
• If valve inserts (7) are damaged, replaced them RKZ01911
7
with new ones.
• Make sure that inserts feet and lay flat on valve
stem.
4 - Connect A1 feeler gauge between insert and rock- 6 5
er lever to adjust; rotate the tappet (6) until touching
A1 feeler gauge. A1
Tight tappet (6) with lock nut (5).
Nut: 14.7 – 19.6 Nm
★ After tightening the lock nut, check the clearance
again.
5 - Adjust with same procedures second cylinder
valve and repeat same operation for the other cyl-
inders, according to the firing order. RKZ01921
• Cover valves installation

1 - Check condition of cover valves (4), gasket (8), O- 4
Rings (9) and lock nuts (10); clean carefully contact 10
surface on cylinder head. 9
2 - Install valves cover (4), fit O-Rings (9) and lock nuts
(10).
Cover lock nut: 25±3 Nm
8
RKZ01931
20-16 WB97R-2
TESTING AND ADJUSTMENTS MEASURING COMPRESSION PRESSURE
MEASURING COMPRESSION PRESSURE

When measuring the compression pressure be careful
not to get caught in cooling fan, in the alternator belt or in 2
other rotating parts.
For this measurement the engine should be up to work-
ing temperature. Take every precaution against burns.
Check all cylinders.
★ Test condition: 1
• Engine: at operating temperature
• Hydraulic oil: 55 – 60°C.
• Battery: at full charge
RKZA5320
• Valve clearance:
adjusted (see «ADJUSTING VALVE»)
1 - Disconnect high pressure pipe (1). 4

2 - Remove nozzle holder assembly (2) of cylinder to be
checked.
3 - Disconnect connector (3) of fuel cut-off solenoid valve

(4).
4 - Crank engine with starting motor. 3
RKZA5330
5 - Install B2 adapter and connect B1 pressure gauge.

★ Check that seal is installed in the adapter and that it B1
is not damaged.
6 - Crank engine with starting motor and measure com-

pression pressure.
★ Measure the compression pressure at the point
where the pressure gauge indicator remains B2
steady.
★ When measuring the compression pressure,
check also engine speed with C2 stroboscopic ta-
chometer; if speed is not within the specified range,
refer to diagram. RKZA5340
★ Compression value:
Normal: 34.3±1 bar at 250 rpm
Minimum permissible: 27.5±1 bar at 250 rpm
★ Difference between cylinders: 2 – 2.9 bar
Compression pressure (bar)
39.2
7 - After measuring, install the nozzle holder assembly (2),
connect high pressure pipe, feedback pipe and con- 34.3
nector (3). 29.4
Nozzle holder collar bolts: 9.8 – 11.8 Nm 24.5
High pressure union: 19.6 – 24.5 Nm 19.6
200 250 300 350 400

Engine speed (rpm)
RKZ01943
WB97R-2 20-17
TESTING AND ADJUSTMENTS TESTING AND ADJUSTING FUEL INJECTION TIMING
TESTING AND ADJUSTING FUEL INJECTION TIMING

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

1cylinder piston at top dead centre (PMS).
1
Flywheel
RKZ01961
★ Top dead centre (PMS) is shown by notch (4) on pulley

(1) positioned on «zero» of the scale (5) and by closing 4
of both cylinder N. 1 valves.
★ If the notch (4) of pulley (1) is in «zero» position on the
scale (5) but cylinders N. 1 valves are not closed, rotate
the crankshaft of 1 turn.
5
★ After recognition of PMS, rotate the crankshaft in coun-
terclockwise direction (from pulley side view) of about
20°.
1
RKZA5350
2 - Disconnect cylinder N.1 high pressure pipe (2) from in-

jection pump.
3 - Rotate crankshaft slowly in clockwise direction from 2

pulley side view, checking fuel level into the N. 1 delivery
of injection pump.
Nº1
RKZA0071
4 - Stop pulley (1) rotation as soon as fuel level starts to in-

crease. Level
Nº 1
Uni on
RKZ01971
20-18 WB97R-2
TESTING AND ADJUSTMENTS TESTING AND ADJUSTING FUEL INJECTION TIMING
5 - Check notch (4) position on crankshaft pulley (1) com-

pared with scale (5); reading value corresponds to an- 5
gle of fuel injection timing.
★ Standard fuel injection timing: 12.5°±1°
NOTA. Repeat checking more than once.
4
1
RKZA5360
6 - If injection timing is not on standard value, rotate injec-

tion pump (6) toward external or toward engine after 6
loosening pump nuts (7) (quantity 4) and pump lock nuts
(8) fixing the bracket (9) to injection pump. 7
• To RETARD injection, rotate pump (6) toward ex-
ternal.
• To ADVANCE injection, rotate pump (6) toward cyl- 8
inders block.
Pump side
7 - Tight the pump lock nuts (7) at cylinder block and pump
lock nut (8) at bracket (9).
Carter side
9 Testing advance
Nuts: 34.2 – 44.1 Nm RKZA5371 injector
Bracket lock nut: 44.1 – 53.9 Nm
8 - Connect fuel delivery pipe (2) to pump.
Delivery pipe union: 19.6 – 24.5 Nm
WB97R-2 20-19
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 alternator (2) 3
and pulley (3) operating water pump; check the deflec-
tion.
With a pressure of 10 kg, deflection should be of 10 – 15
mm; if this value is not reached, tension fan belt.
★ With new belt, deflection must be of 7 – 9 mm.
1
RKZA5700
2. Fan belt tension

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

belt (1) and tighten mounting bolts (4) and (5).
3 - Check fan belt (1) tension.

★ If belt has been replaced, check tension again after
about 20 operating hours. 4
Bolts (4): 44.1 – 53.9 Nm
RKZA5690
Bolts (5): 22.5 – 28.4 Nm
Water pump
pulley
10-15 mm
Alternator
Crankshaft
pulley
RKZ01981
20-20 WB97R-2
TESTING AND ADJUSTMENTS CHECKING AND TIGHTENING THE COMPRESSOR FAN - BELT
CHECKING AND TIGHTENING THE COMPRESSOR FAN - BELT

1. Checking tension
1 - Push fan belt (1) at midway point between compressor
7-10 mm
(2) and pulley (3). Check the deflection.
With a pressure of 10 kg, deflection should be of 7 – 10
mm; if this value is not reached, tension fan belt. 3
2
★ With new belt, deflection must be of 4 – 6 mm.
RKZO3261
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.
★ If belt has been replaced, check tension again after 4
about 20 operating hours.
Bolt: 123 Nm
RKZA8560
WB97R-2 20-21
MEASURING ACCELERATOR PEDAL OPERATING
TESTING AND ADJUSTMENTS TRAVEL AND ACCELERATOR LEVER

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

1 - Make sure that accelerator pedal (1) is fully raised and
accelerator lever (2) is at minimum stroke.
RKZA9330
2 - Check that accelerator lever (3) is in contact with low

idling speed adjusting screw (4). 4 8
3
RKZA5390
3 - Adjust nut (5) and lock nut (6) of accelerator pedal ca-
bles and hand accelerator at a distance of 0.2 – 0.3 mm
from lever (7).
4 - Push accelerator pedal until accelerator lever (3) con-

tacts the high idling adjusting screw (8). 7
5 6
RKZA5400
5 - Adjust the end travel stopper (9) of accelerator pedal (1)

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

1
10
9
RKZA9340
20-22 WB97R-2
TESTING AND ADJUSTMENTS TRAVEL AND ACCELERATOR LEVER
2. Accelerator lever travel adjusting

1 - Remove mat and lateral cover (1).
RKZA9350
2 - Loosen nut (2) and tight the end lever travel bolt (3) of
some turns.
3 - Start engine and, with lever (4), bring it to the defined 3

idling speed for hand accelerator.
★ Check using the stroboscopic tachometer C2. 4
★ Engine idling speed: 1900±50 rpm
4 - Loosen end lever travel bolt (3) up to it is in contact with
lever (4) and looked with nut (2). 2
5 - Bring engine at low idling and check accelerator lever

idling speed again pushing lever at end stroke.
RKZA9360
WB97R-2 20-23
ADJUSTING BRAKE PEDAL TRAVEL,
TESTING AND ADJUSTMENTS BRAKE ALIGNMENT, MICROSWITCHES
ADJUSTING BRAKE PEDAL TRAVEL, BRAKE ALIGNMENT,

MICROSWITCHES
★ Working condition:
• Engine stopped
• Machine with attachments on ground level 1
1 - Check that pedal (1) is near to the stopper (2) and the
pedals side are at “A” measure from cab level.
If necessary, adjust height acting on the stopper (2).
★ “A” measure: 313±3 mm
★ Check that pin (3) can freely run and lock the pedals
(1). 3
RKZB0020
Master cylinder rod adjustment

2 - Loosen nut (4) locking the adjusting rod (5) and loosen
until it touches the brake pump piston seat.
3 - Tighten the adjusting rod (5) of one turn (360°) and lock
it with nut (4).
2
4 - Repeat operations 3. and 4. for the other pedal.

★ After tightened nuts (4), check that the adjusting
rod (5) touch the brake pump piston seat simulta-
neously. 6
Microswitches adjustment 7
5 - Loosen microswitches (7) locking nuts (6).
6 - Adjust microswitches (7) paying attention to guarantee 1 mm

(0.0394 in.)
(at pedals in neutral position) a minimum clearance 1
(about 1 mm) between microswitches body and the
pedal.
Checking adjustment
7 - Verify measure like shown in figure. A = 313 ± 3 mm
“A” measure: at pedal in neutral position B = 302 mm
“B” measure: at master cylinder rod touching the pump C = 292 mm
“C” measure: at pedal touching the microswitch
RKZ03671
5 4 RKZ01951
20-24 WB97R-2
TESTING AND ADJUSTMENTS AIR BLEEDING - RELEASING RESIDUAL PRESSURE
AIR BLEEDING - RELEASING RESIDUAL PRESSURE

1. Air bleeding from pump
★ Air bleeding from pump (that means the filling of pump
body) is necessary:
1 - When removing pump.
2 - When removing or replacing connection hoses be-
tween pump and hydraulic tank.
3 - When replacing hydraulic oil and hydraulic tank
overhaul.
The air bleeding is obtained as follows: G1

1 - Carry out tank oil filling and close hydraulic tank with
RKZA5450
plug G1.
2 - Remove plug (1) of breather pipe (2).
3 - Connect plug G1 to low pressure air compressed con-

nection. 1 2
4 - Introduce slowly and intermittently air compressed in
the hydraulic tank until when flows out oil without air
bubbles.
★ Max. pressure in tank: 0.5 bar
5 - Mount plug (1) and lock it.
6 - Depressurize slowly hydraulic tank, check level and, if

necessary, refill tank oil at correct level.
RKZA9380
7 - Start engine and run it for few minutes before bleeding

air from the whole system.
2. Air bleeding from cylinders

★ When hydraulic cylinders or pipe fitting have been re-
moved, it is necessary to bleed air before to use again
the machine.
★ Operate on a movement at a time starting from main cyl-
inders (lifting).
1 - Start engine and run it at high idling speed for about 5

min. to worm up oil and to pressurise hydraulic system.
2 - Return engine at low idling speed, extend and retract

the interested piston 4-5 times.
★ Extend, lower and retract pistons until about 100
mm from their end of stroke.
3 - Bring again the engine at high idling speed and repeat

operation of point 2; return the engine at low idling
speed and make a complete travel of piston until the hy-
draulic pump reaches its maximum pressure.
4 - Repeat above operation (starting from point 2) for all

cylinders.
WB97R-2 20-25
3. Air bleeding from oil tank

1 - Put the machine in oil level check position and remove
the tank plug.
★ If necessary add oil until reaching the correct level.
2 - After stopping the engine wait for some minutes, until air
bubbles on oil surface are fully disappeared.
3 - Install tank plug.
4. Hydraulic oil tank pressurization

1 - With engine at low idling speed extend slowly, up to end
of stroke, all cylinders.
2 - Stop the engine and remove tank plug.
3 - Check the condition of gasket and reassemble plug.
★ Avoid to increase the engine speed before com-
pleting all air bleeding procedures and after the
pressurization of oil tank.
★ After air bleeding procedures, operate engine at
low Idling speed for about 10 minutes before start-
ing to work.
5. Releasing residual pressure from the circuits

1 - Put work attachments on level ground, stop the engine.
2 - Move all control levers in all directions to release com-
pletely cylinders and main circuit remain pressure.
3 - Loosen slowly oil filler tank to remove remain pressure.
6. Air bleeding from braking circuit

★ Above operation is to be carried out every time main-
tenance is made on braking circuit to remove or replace
a component, or when air entered into the circuit.
★ Machine must be stopped with attachments on level MAX.
ground.
1 - Make sure that oil in brake system tank (1) is at maxi- MIN.
mum level. 1
2 - Remove pedal lock pin.
RKZA9390
3 - Remove safety plugs and applied to bleeding screws (2)

a vinyl hose to catch oil.
4 - Push brake pedals to bottom and, keeping it pushed,
loosen bleeding screw (2) of the left braking unit until the
pedals reach end of their stroke.
5 - Keeping pedal at the end stroke, tighten bleeding screw
(2).
RKZA5470
20-26 WB97R-2
6 - Release brake pedals, wait for few seconds and repeat

above operations two or three times until from bleeding
screw, oil flows out without air bubbles.
7 - Repeat same operations for the right braking unit.
8 - Disconnect pedal lock pin.
9 - Push one brake pedal to bottom and, keeping it pushed,
loosen bleeding screw (2) of one of two braking units un-
til the pedal reaches end of its stroke.
★ Check that oil flows out without air bubbles from
bleeding screw (2).
10 - Repeat same operations for the other braking unit.
★ Check frequently the oil level in the tank and carry
out filling every time level approaches to minimum.
★ After air bleeding apply on screws (2) safety plugs.
7. Checking air bleeding from braking circuit
1 - Start engine and lower the backhoe outrigger and force
them downwards in order to raise the rear wheels.
2 - Engage forward/reverse gear in order to move wheels.
3 - Return the machine in neutral and lower it and stop the
engine.
4 - Apply 50 kg on the pedal and verify measure “D”.
5 - Insert pedal lock pin and applying the same mass verify
the measure “D”.
★ “D” measure with one pedal pushed:
not less than 165 mm
★ “D” measure with both pedal pushed:
not less than 170 mm
RKZ03680
WB97R-2 20-27
CHECKING AND SETTING PRESSURE IN
TESTING AND ADJUSTMENTS THE ATTACHMENTS HYDRAULIC CIRCUIT
CHECKING AND SETTING PRESSURE IN THE ATTACHMENTS

HYDRAULIC CIRCUIT
1. Introduction
• On the machine configuration, one or two spool. Me- STEERING UNIT
chanical control valves have been installed with follow-
ing 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 overpres-
sure by a main relief valve (or general and named Pres-
sure cut off valve) with adjustable setting.
FRONT SHOVEL
CONTROL VALVE
(2-3 SPOOL)
POWER TRAIN
DIESEL
P1
MAIN RELIEF
VALVE
• Control valves are feeded by P1 pump total delivery. BACKHOE

CONTROL VALVE
• P1 pump delivery is checked by a priority valve (internal (6-7-8 SPOOLS)
to the control valve N. 1) when steering unit is used.
• Control valves include spools with following functions:
2-SPOOL CONTROL VALVE RKZ02491
Control Port
Loader arm (lifting - lowering) A1 - B1
Front bucket (curled - dump) A2 - B2
A
1 2
B
RKZ02040
20-28 WB97R-2
3-SPOOL CONTROL VALVE

Control Port
Loader arm (lifting - lowering) A1 - B1
Front bucket (curled - dump) A2 - B2 A

3 2 1
Optional attachment A3 - B3
B
RKZ02061

Control Port
Arm (closing - opening) A1 - B1
Boom swing (left - right) A2 - B2

B
L.H. outrigger (up - down) A3 - B3 1 2 3 4 5 6
R.H. outrigger (up - down) A4 - B4
A
Bucket (dump - curled) A5 - B5
Boom (lifting - lowering) A6 - B6

RKZ06690

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

B
7
A
RKZ06680

(For breaker - side digging boom)
Control Port
Breaker (L.H. side) B7

B
Side digging boom (left - right) A7 - B7 7
RKZ06670
WB97R-2 20-29

(For breaker and jig arm)
Control Port
Breaker (L.H. side) B7
Jig arm (in - out) A8 - B8

B B
7 8
A
RKZ06660
2. Testing and setting general valves

(Pressure cut off valve)
E3
★ Test condition: 1
• Hydraulic oil: 45 – 55 °C
1 - Connect the pressure gauge E3 (400 bar) to the pres-

sure adapter (1) of the front shovel control valve (2).
2 - Start the engine, bring the hand accelerator lever up to

max. speed and check the nominal pressure of the main
2
RKZA5480
relief valve (pressure cut-off valve) by forcing the front

bucket to rise to the end of its stroke.
★ Nominal pressure: 200±7 bar
★ If the main relief valve pressure do not correspond
to the nominal values, they must be re-set (See
«SETTING THE MAIN RELIEF VALVES AND THE
REDUCING VALVES»).
3. Testing and setting secondary valves

★ Test condition:
E3
• Engine: at operating temperature.
1
• Hydraulic oil: 55 – 60 °C.
• Parking brake: applied.
★ The pressure readings are to be operated from the
same check point.
1 - Connect the pressure gauge E3 (400 bar) to the pres-
sure adapter (3) of the backhoe control valve (4).
2 - Start the engine and bring the hand accelerator lever up
to 1050 rpm. 2
RKZA5480
20-30 WB97R-2
3 - Set the main relief valve (pressure cut-off valve) to a val-

ue 30 bar higher than the maximum pressure to be test-
ed.
4 - Check the single movements pressure.

The secondary valve of backhoe boom lifting, must
be checked and settled on test bench only.
Setting 2-spool control valve secondary valves

Unit: bar
Cylinder and movement Port Setting
Lifting A1 --
Front bucket
Lowering B1 --
Curled A2 235±7
Front bucket
Dump ✽ B2 175±7
✽ This setting can be carried without modifing the general valve pressure.

Unit: bar
Lifting A1 --
Front bucket
Lowering B1 --
Curled A2 235±7
Front bucket
Dump ✽ B2 175±7
A3 235±7
Optional attachment
B3 235±7

Unit: bar
Closing A1 --
Arm
Opening B1 245±7
Left A2 245±7
Boom swing
Right B2 --
Up A3 --
Right outrigger
Down B3 --
Up A4 --
Left outrigger
Down B4 --
Curled A5 235±7
Bucket cylinder
Dump B5 305±7
Lifting ✽ A6 235±7
Boom cylinder
Lowering B6 --
✽ The setting must be carried on test bench only.
WB97R-2 20-31
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
Right A7 165±7
Hammer
Left ✽ B7 --
Right A7 275±7
7 Side digging boom
Left B7 275±7
In A7 --
Jig arm
Out B7 --
Right A7 –
Hammer
Left ✽ B7 --
8
In A8 --
Jig arm
Out B8 --
★ If valve setting pressure do not correspond to the indicated ones, provide to set them (see «SETTING MAIN AND
SECONDARY VALVES»).
4 - Set the general valve pressure to the standard value.
4. Main and secondary valves setting

• General valves (Pressure cut off valve (1)
For setting, prepare machine as per pressure testing.

1
1 - Loosen lock nut (2).
2 - Force to the end of its stroke the lever commanding

whichever movement is being used for the tests.
3 - Adjust pressure with adjusting screw (2).

• To INCREASE pressure, rotate in CLOCKWISE di-
rection.
RKZA8100
• To DECREASE pressure, rotate in COUNTER-
CLOCKWISE direction.
4 - Lock position with nut (2).
3
RKZ02241
20-32 WB97R-2
• Secondary valves
For setting, prepare machine as per pressure testing.

★ This setting is valid for all the secondary valve and 2
has to be carried forcing the movement to be 1
checked at its end of stroke.
3
1 - Loosen lock nut (1).
2 - Adjust pressure with adjusting screw (2).

rection.
3 - Lock position with nut (1).
Lock nut: 10±1 Nm
When terminated the setting, Apply safety plug (3)

to avoid not authorised tamperings.
4 - Set the general valve pressure to the standard value.
RKZ02010
WB97R-2 20-33
TESTING AND ADJUSTING OF
TESTING AND ADJUSTMENTS LOAD SENSING SIGNAL (LS VALVE)
TESTING AND ADJUSTING OF LOAD SENSING SIGNAL (LS VALVE)

★ Testing conditions:
• Engine: stopped but at working temperature.
1
• Machine: front equipment on the ground, parking
brake applied and boom and arm fully extended.
• Working mode: Power
1 - Disconnect hose (1) from the Load Sensing line. Install 3

an tee and reconnect hose (1).
2 - Remove plug (2) and install a pressure adapter (M8x1).

2
3 - Connect the pressure gauge E5 to adapter. RKZB5640
4 - Start the engine and bring it to 1050±50 rpm and, with-

out any movement (lever in neutral position), read the
DP pressure.
Normal value: 21±1 bar 3
1
★ If the DP value is not inside the limits, adjusting the
Unloading valve. E5
(For details see «TESTING AND ADJUSTING OF
UNLOADING VALVE»).
5 - Raise boom up to end of stroke and read the the DP

pressure.
Normal value: 18±1 bar
2
★ If the DP value is not inside the limits, carry out the
Load Sensing valve (3) setting. RKZ07391
1. Adjusting of the Load Sensing valve

4 6 5
1 - Remove nut (4).
2 - Loosen nut (5).
3 - Adjust pressure using adjusting screw (6).

rection.
7
4 - Lock the position with nut (5). RKZ074440
Lock nut: 21 Nm
5 - Check gasket (7) and mount nut (4).

Nut: 21 Nm
20-34 WB97R-2
TESTING AND ADJUSTMENTS TESTING AND ADJUSTING OF UNLOADING VALVE
TESTING AND ADJUSTING OF UNLOADING VALVE

★ Testing conditions:
1
• Machine: front equipment on the ground, parking
brake applied and boom and arm fully extended.
• Working mode: Power
1 - Disconnect hose (1) from the Load Sensing line. Install

an tee and reconnect hose (1).
2 - Remove plug (2) and install a pressure adapter (M8x1).

2
RKZB5641
3 - Connect the pressure gauge E5 to adapter.
4 - Start the engine and bring it to 1050±50 rpm and, with-

1
out any movement (lever in neutral position), read the
DP pressure. E5
Normal value: 21±1 bar
★ If the DP value is not inside the limits, adjusting the
Unloading valve (3).
2
RKZ07390
RKZ07410
1. Adjusting the unloading valve

1 - Remove plug (4), spring (5), washers (6) and body valve 8
(7).
2 - Place a shim (8) under the spring (5) and mount the val-
ve.
• One shim of 1 mm increase pressure DP of 3 bar.
Plug: 100 Nm
4 5 6 7
RKZ07420
WB97R-2 20-35
TESTING AND ADJUSTMENTS CHECKING UNLOADING VALVE FUNCTIONALITY
CHECKING UNLOADING VALVE FUNCTIONALITY

★ Test condition:
1
• Low idling: in the permissible limit.
• Machine: in safety condition, parking brake ap- E1
plied.
• Control valve lever at neutral position. 2
1 - Disconnect hose (1) from the Load Sensing line. Install

an thee (2) and reconnect hose (1).
2 - Connect to thee (2) a pressure port and gauge E1 (60

RKZA9420
bar).
3 - Connect gauge E1 (60 bar) to rear control valve pres-

sure port (3).
E1
4 - Start the engine at low idling and without any movement
check pressure on both gauges. 3
★ Normal pressure (P) control valve gauge:
27±3 bar
★ Normal pressure Load Sensing line gauge (PLS):
6±2 bar
(This value is due to the influence of the counter-
pressure present in the steering circuit).
★ If any variations are found, they do not represent a
problem provided that the difference of 21±1 bar RKZA5511
between the two readings is respected.
5 - If the difference between the two readings is higher than

21±1 bar, stop the engine and release residual pres-
sures.
6 - Thoroughly clean the valve (4) and re-install it.

4
Valve: 20 Nm
7 - If, in spite of cleaning the valve (4), the value of 21±1 bar
still does not fall within the tolerance limits, install a new
valve.
RKZA8102
20-36 WB97R-2
TESTING AND ADJUSTMENTS TESTING PRIORITY VALVE OPERATION
TESTING PRIORITY VALVE OPERATION

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

1 - Connect a pressure gauge E2 (250 bar) to the pressure
adapter (1) of the backhoe control valve.
2 - Start the engine and bring it to idle speed of 1500±50

rpm.
RKZA5540
3 - Check on gauge E2 pressure value with stopped stee-
ring wheel (21 bar).
4 - Start a slight steering and check that pressure increas-

es. 2
5 - Continue the steering up to end of stroke and check that,
forcing the steering wheel, pressure increases till nor-
mal value.
★ Normal pressure: 175±7 bar.
★ If the pressure does not reach the normal value, re-
set the pressure of the steering unit
★ If turning the steering wheel the pressure shown by
gauge does not change and stress on steering
wheel necessary to carry out steering is high, clean RKZA5550
the priority valve (2).
2. Cleaning priority valve

1 - Remove priority valve plug (3), spring (4) and rod (5)
★ Check and make notes on the direction of assem-
bly.
6
2 - Dismantle the plug (6) and remove the ball (7) of the in-
side valve and the spring (8). 8
3 - Check that the hole (9) and the nozzle (10) are perfectly
clean. 7 9
4 - Replace the spring (8), the ball (7) and the plug (6).
Plug: Loctite 542
Plug: 20 Nm
5
★ Do not allow any Loctite to enter the hole (9). 4
★ Remove all excess Loctite from the rod (5).
10
5 - Lubricate the rod (5) and mount it in its seating, ensuring
that it slides freely.
6 - Insert the spring (4) and mount the plug (3).

3
Plug: 100 Nm.
7 - Start the motor, execute several steering manoeuvres

and, if the fault is not corrected, replace the complete
steering column with a new one. RKZ02220
WB97R-2 20-37
TESTING AND SETTING STEERING
TESTING AND ADJUSTMENTS CONTROL SYSTEM PRESSURE
TESTING AND SETTING STEERING CONTROL SYSTEM PRESSURE

★ Test condition:
• Engine: operating temperature E2
• Hydraulic oil: 55 – 60 °C 1
Testing
adapter (1) of the backhoe control valve.
2 - Start the engine and bring it to idle speed 1500±50 rpm

and carry out a total steering.
3 - Forcing the steering wheel at the end of stroke, check

RKZA5540
pressure.
★ Normal pressure: 175±7 bar
4 - Check for the other steering direction too.
6 5 4 7
Setting
If pressure is not within permissible value, carry out setting
acting on upper valve (3) of the steering unit.
1 - Remove plug (4).
2 - Insert a wrench of 4 mm and loosen screw (5).
3 - Adjust pressure with screw (6).

• To INCREASE pressure rotate in CLOCKWISE di- 3
rection. RKZA9430
• To DECREASE pressure rotate in COUNTER-

4 - Stop engine, lock the adjusting screw (6) position tight-

ening screw (5).
5 - Reassemble plug (4) checking that gasket (7) is on its

seat.
20-38 WB97R-2
TESTING AND ADJUSTMENTS TESTING BRAKE SYSTEM
TESTING BRAKE SYSTEM

★ Test condition:
• Engine: stopped
• Machine: on solid and level ground, with equipment
raised and safety devices engaged.
• Brake pedals: independent, with the container level
at maximum.
1
The system testing provides in two stages:
1 - Testing circuit and brake pump tightness.

3
2 - Leaktightness test of the braking group. 2
RKZA5570
If both the tests give a positive result, the leaks must
be sought in the pipelines of the braking system
4
1. Testing circuit and brake pump tightness
1 - Disconnect the connecting pipe (2) of the equalizers
from the brake pumps (1) of the circuit to be tested.
2 - Securely plug the equalizer orifice (plug A). 2

3 - Remove the clamp (3) and disconnect the delivery lines
(4) from the pumps. Connect a pressure gauge E2 (250
bar) to the pump (1) being tested.
4 - Move the brake pedal corresponding to the pump and A RKZA5580
bring the circuit up to a pressure of approximately 120

bar.
★ Do not exceed maximum permissible value that is
of 150±5 bar.
5 - Keep the pedal pushed for at least 2 minutes and check E2

that pedal pressure and position remain steady.
★ If the position of the pedal must be changed to
maintain pressure, the pressure loss is due to leak-
ages inside the pump.
This can be confirmed by checking the oil. If there
are leakages, it will show signs of mixing. 1
6 - Repeat test for the other brake pump.

RKZA5590
2. Testing braking group leaktightness From brake pump

5
1 - Disconnect the delivery tube (5) of the braking group be-
ing tested.
2 - Connect the tool between the delivery line (5) and the
7
100 150
50 200
braking group. 0 250
★ Check that the pressure adapter (6) is inserted be-

tween the braking group and the exclusion valve E2
(7). 6
adapter of the tool and open the cock (7). RKZ05011
WB97R-2 20-39
TESTING AND ADJUSTMENTS TESTING BRAKE SYSTEM
4 - Operate brake pump to feed pressure into the circuit to

maximum pressure of 150±5 bar.
5 - Maintaining pressure, close the valve (7) to maintain

pressure in the braking group being tested.
6 - Release the brake pedal and check for 2 minutes the

pressure indicated by gauge E2.
★ If the pressure value shows a negative change, it
means that the braking piston seals are defective.
Further confirmation of the leak can also be ob-
tained by an increase in the oil level in the axle,
which leads to a mixing of the oils. Change all the
sealing rings between the axle sections, and carry
out a complete lubrication oil change.
7 - Repeat the test for the other braking group, following the
same method.
8 - Re-assemble the braking circuit
After testing and possible repairs, bleed air from

brake units (see «AIR BLEEDING OF BRAKE CIR-
CUIT»).
20-40 WB97R-2
TESTING AND ADJUSTMENTS CONTROL OF THE ENGINE SPEED UNDER LOAD
CONTROL OF THE ENGINE SPEED UNDER LOAD

★ Test conditions:
• Power train oil: up to working temperature.
• Brake pedals: connected by a cotter-pin.
• Machine: on solid and level ground with the equip-
ment raised and safety devices engaged.
Two tests must be performed:
1 - Speed test with the torque converter under stress.
2 - Speed test with the torque converter and the hydraulic RKZA8580
system under stress.

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

1 - Prepare the rev. counter C1 to measure the engine rpm.
★ If mounting an electronic pressure transducer rev. C1
counter on a diesel delivery line to the injection noz-
zles, make sure that it is placed far away from the
clamp.
★ If using a stroboscopic tachometer C2, make a
clearly visible notch on the engine pulley to facili-
tate the reading.
Make sure that the brake pedals are fastened to-
gether by the cotter pin (1). RKZA5300
RKZB0021
WB97R-2 20-41
TESTING AND ADJUSTMENTS CONTROL OF THE ENGINE SPEED UNDER LOAD
2. Testing with the torque converter under stress

1 - Start the motor at MIN. Engage the highest FORWARD
gear and brake hard.
2 - Keeping the machine on the brake, accelerate the en-
gine gradually up to high idling and measure the speed
reached.
★ Speed: 2275±50 rpm
3 - Release the accelerator pedal and move on to the next

test.
3. Testing the torque converter and hydraulic

system under stress
1 - Start the motor at MIN. Engage the highest FORWARD
gear and brake hard.
2 - Keeping the machine on the brake, engage the upper

FORWARD gear, accelerate the engine gradually and
at the same time act on the front bucket closed (curled)
command control valve lever, steer and maintain the
steering at the end of stroke.
3 - Once the maximum engine speed and the maximum

pressure of the bucket circuit have been reached,
measure the speed reached by the engine.
★ Speed: 2250±50 rpm
• If the revs of the engine are higher than the permissible

limit, in both tests, check the pressure of delivery to the
converter and the clutch pressures. (See «TESTING
PRESSURES OF THE POWER TRAIN GROUP»).
• If the revs of the engine are lower than the permissible
limit, check the condition of the air filter, and the condi-
tions of the engine compression, the timing, the injec-
tion pump, and the valve clearances.
20-42 WB97R-2
TESTING AND ADJUSTMENTS TESTING PRESSURES IN THE POWER TRAIN GROUP
TESTING PRESSURES IN THE POWER TRAIN GROUP

The power train group can be used to perform pressure tests
on the internal hydraulic circuit. These are useful for iden-
tifying malfunctions.
Specifically, the tests involve:
1 - Converter oil pressure.
2 - Clutch engagement pressures for both directions of
travel.
• Engine: stopped.
• Brake pedals: connected by a cotter pin.
• Machine: on solid and level ground with the equip- RKZA8580
1. Preparing the machine

1 - Prepare the rev. counter C1 to measure the engine rpm.
★ If mounting an electronic pressure transducer rev. C1
counter on a diesel delivery line to the injection noz-
line-clamp.
tate the reading.
Make sure that the brake pedals are fastened to-

gether by the cotter pin (1). RKZA5300
2. Converter oil pressure

1 - Remove the plug (P28) and connect the pressure
gauge E6.
2 - Start the engine and heat the engine and all the fluids up
to working temperature. In particular make sure that the
power train oil reaches a temperature of 80±5 °C.
3 - With the engine at MIN, check the pressure on the pres-

sure gauge E6.
★ Normal pressure: Min. 1 bar - Max 4.5 bar 1
4 - Gradually increase the rev speed to 2200 rpm.
Take a new reading from the pressure gauge E6. RKZB0021
★ Normal pressure: Min. 6 bar - Max 11 bar

5 - Bring the engine back to MIN and compare the pressure
with the normal value. P20 P28
★ Normal pressure: Min. 1 bar - Max 4.5 bar
★ If the maximum pressure value drops to below the
permissible lower limit, the power train pump needs
an overhaul.
P19
RKZ06340
WB97R-2 20-43
TESTING AND ADJUSTMENTS TESTING PRESSURES IN THE POWER TRAIN GROUP
3. Clutch engagement pressure

1 - Remove the cab floor.
2 - Remove the plug (P20) and connect the pressure

gauge E6.
power train oil reaches a temperature of 80±5 °C. E6
4 - Bring the engine up to MIN. (idling), actuated the brake
pedals, insert the 4th REVERSE gear and check the P20
pressure on the pressure gauge E6. P19 RKZA8590
★ Normal pressure: max 13.5 – 15.5 bar

5 - Gradually increase the rev speed up to 2200 rpm.
Take a new reading from the pressure gauge E6.
★ Normal pressure: max 14.5 – 16.5 bar
6 - Bring the engine back to MIN and compare the pressure
with the normal value.
★ Normal pressure: 13.5 – 15.5 bar
7 - Remove the pressure adapter and replace the plug
(P20).
Cap: 23 Nm
8 - Repeat the same test for the 4th FORWARD gear, read-
ing the pressure from the orifice protected by the plug
(P19).
• If the pressures are different for the two travel di-
rections, there is a loss of pressure on the clutch pi-
ston with lower pressure.
20-44 WB97R-2
TESTING THE CORRECT FUNCTIONING
TESTING AND ADJUSTMENTS OF THE POWER TRAIN
TESTING THE CORRECT FUNCTIONING OF THE POWER TRAIN

CLUTCHES
• Brake pedals: connected by a cotter pin.
• Machine: on solid and level ground with the equip-
★ This test must be performed after having checked
the pressures of the power train group.
1. Preparation of the machine

1 - Prepare a rev. counter C1 to measure the engine rpm.
★ If mounting an electronic pressure transducer rev.
counter on a diesel delivery line to the injection noz- RKZA8580

line-clamp.
tate the reading.
C1
Make sure that the brake pedals are fastened together
by the cotter pin (1).
During the following tests, during the engine accelera-
tion phase with the gear engaged, the condition of the
brake disks can also be checked
If, while force is being exerted on the brake pedals, the
machine starts to travel (even slowly):
a - Release the accelerator immediately and stop the
RKZA5300
engine.
b - Check the wear on the brake disks and change
them before completing the tests.
(See: «30. DISMANTLING AND ASSEMBLY -
REAR AXLE»).
2. Testing
power train oil reaches a temperature of 80±5 °C.
2 - With the engine in idling condition, accelerate to MAX.
and check that in this condition the revs remain within 1
permissible limits. (See «TESTING ENGINE SPEED»).
3 - Brake hard and bring the engine up to MAX. RKZB0021
4 - Maintaining the braking action and the acceleration, en-

gage the FORWARD gear and check that the engine
speed decreases until it is once again within permissible
limits (See «TESTING THE ENGINE SPEED UNDER
STRESS»).
5 - Repeat this test in REVERSE gear.
★ If the revs are high than the permissible limits, the
clutches are worn, and must be replaced.
WB97R-2 20-45
TESTING AND ADJUSTMENTS ADJUSTING THE SENSOR FOR RETURN TO DIG DEVICE
ADJUSTING THE SENSOR FOR RETURN TO DIG DEVICE

★ Adjustment conditions:
• Machine: on solid and level ground.
• Parking brake: engaged.
1 - Rest the bucket on the ground, making sure that the bot-
tom is perfectly parallel to the surface.
RKZA9440
2 - Stop the engine and remove the sensor guard (1).
RKZA9450
3 - Check that there is a distance 3–4 mm between the sen-

sor (2) and the rod (3)
4 2
If necessary loosen the nuts (4) and adjust the distance, 3
until the indicated measurement is obtained, and se- 3 - 4 mm
cure that position.
4 - Loosen the screw (5) and move the bracket (6) towards
the rear, until the sensor is completely free of the rod (3). 7
5 - Start the engine and allow to idle. 6
5
Adjust the position of the bracket (6) until the sensor (2)
is engaged.
★ When the rod contacts the sensor, the warning RKZA9461
lamp (7) will be activated.
6 - Lock bracket (6) position.
7 - Perform several tests by raising the bucket and simu-

lating some dumping manoeuvres. If the bucket is able
to rest flat on the ground, replace the sensor guard (1).
20-46 WB97R-2
TESTING AND ADJUSTMENTS ANALYSIS OF CAUSES HYDRAULIC DRIFT
ANALYSIS OF CAUSES HYDRAULIC DRIFT

★ If working attachments have a hydraulic drift, it is nec-
essary to check if reason is due to cylinders gaskets or
to control valve.
★ All testing conditions:
• Removal and installation of pipes only after remain
pressure removal.
(See «REMOVAL OF REMAIN PRESSURE
FROM CIRCUIT»)
FRONT EQUIPMENT
1. Testing of front bucket lifting

1 - Put the machine with bucket teeth on blocks of about 10
cm and in vertical position compared to ground.
2 - Stop the engine and remove the remain hydraulic pres-

sure.
3 - Disconnect pipes (1) and (2) from lift cylinders (3) and
plug them. Block
4 - Plug cylinders, base side, and apply a temporary pipe, RKZA8131
head side, to catch possible oil leakage.
5 - Start the engine and retract the bucket until to bring the
teeth in tilt position of about 15°. 1
6 - Stop the engine and check bucket link position for 5 min- 2
utes. 3
• If bucket link has no lowering movement, drift is due
to control valve.
To check each cylinders, proceed as follow:
7 - Carry out with bucket a dump movement to let teeth lean

on ground in vertical position.
8 - Remove from one of cylinders the plug as installed on RKZA5650
base side at stage 4.
9 - Start the engine and retract the bucket until to bring

teeth in tilt position of about 15° towards upper.
10 - Stop the engine and check the bucket position for 5 min-
utes.
• If bucket link has a lowering movement, drift is due
to gaskets of plugged cylinder. 15°
11 - Repeat operation from stage 8 to stage 10 to check the

other cylinder.
RKZA1840
WB97R-2 20-47
2. Testing of front bucket dumping

1 - Put the machine with bucket on level ground and teeth
tilted of about 15°.
Put in the bucket a weight of 1500 kg.
1500 kg
RKZ02130
2 - Disconnect pipes (1) and (2) from dump cylinder (3) and
plug them to avoid impurity inlet.
3 - Plug dump cylinder hole, base side, and apply a tem- 3

porary pipe on head side to catch possible oil leakage.
2
1
RKZA5660
4 - Start the engine and raise the bucket up to the alignment

of the bucket hinge and shovel arm hinge. 1500 kg
5 - Stop the engine and check bucket teeth position for 5

minutes.
• If bucket has no swing movement, drift is due to
control valve.
To test the individual cylinders, proceed as follows:
6 - Lower the bucket to the ground.
7 - Remove from one of the cylinders the plug fitted on the

cylinder bottom side in Phase 3. RKZ02630
8 - Start the engine and raise the bucket as indicated in

phase 4.
9 - Stop the engine and check the position of the bucket

teeth for 5 minutes.
• If the bucket teeth turn, the drift is due to the gasket
seals of the plugged cylinder.
10 - Repeat the operations from phase 6 to phase 9 in order

to test the other cylinder.
20-48 WB97R-2
BACKHOE
★ Test condition:
• Backhoe aligned
• Lifted outriggers
1. Boom testing
1 - Set the machine with arm in vertical position and with
bucket on level ground leaned on the side.

sure.
RKZ02510
3 - Disconnect hoses (1) and (2) that feed cylinder (3).
4 - Plug the two hoses to avoid impurity inlet. 3
5 - Plug the cylinder head side.
6 - Apply a temporary pipe on pipe (3) base side to catch

possible oil leakage.
1
RKZA1341
7 - Start the engine and extend completely the arm.
8 - Stop the engine and check the boom position for 5 min-
utes.
• If boom has a lowering movement, drift is due to
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.

sure.
RKZ02530
WB97R-2 20-49
3 - Disconnect pipes (1) and (2) pipes from arm cylinder (3)
and plug them to avoid impurity inlet. 1
3 2
★ If safety valve is fitted, provide to removal.
4 - Plug arm cylinder hole on head side and fit a temporary
pipe on base side to catch possible oil leakage.
RKZA5680
5 - Start the engine and raise the boom.
6 - Stop the engine and check the arm position for 5 min-
utes.
• If arm has a lowering movement, drift is due to cylin-
der gaskets.
• If arm has no movement, drift is due to control
valve.
RKZ02540
3. Bucket testing
1 - Set the machine with vertical arm and horizontal bucket
leaned at level ground on the side.
Put in the bucket a weight of 450 kg or fill it with earth.
450 kg
RKZ02550

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

plug them to avoid impurity inlet
2
4 - Plug bucket cylinder hole on base side and fit a tempo- 1
rary pipe on head side to catch possible oil leakage.
3
RKZA9850
20-50 WB97R-2
5 - Start the engine and raise the boom.
6 - Stop the engine and check the bucket position for 5 min-
utes.
• If bucket has an opening movement, drift is due to
cylinder gaskets.
• If bucket has no movement, drift is due to control
valve.
RKZ02560
4. Outriggers testing
1 - Set machine with vertical arm and with bucket leaned at
ground on the side.
2 - Put blocks of about 20 cm under the outriggers.
3 - Without forcing them, lower the outriggers onto the tres-

tles.
20 cm
RKZ02200
4 - Stop the engine and release residual hydraulic pres-

sures. 2 3
5 - Remove clamp (1) and disconnect from cylinders (4) the

pipes (2) and (3).
6 - Plug cylinders pipes (2) base side and apply on head

sides temporary pipes to catch possible oil leakage. 1
4
7 - Start the engine, use force on the boom to raise the ma-
chine, and remove the trestles supporting the outrig-
gers.
RKZA1251
8 - Lower the machine and stop the engine.
9 - Check the outriggers position for 5 minutes.

• If one or both outriggers have a lowering move-
ment, drift is due to single or both cylinders.
• If there is no lowering, drift is due to control valve.
RKZ02210
WB97R-2 20-51
TESTING AND ADJUSTMENTS TESTING THE AIR-CONDITIONING UNIT
TESTING THE AIR-CONDITIONING UNIT

• Machine on level ground with the working equip-
ment raised and in safety conditions
• Parking brake engaged
1. Testing the working temperature

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

RKZA8580
4 - Select an intermediate ventilation speed inside the cab.
5 - Use the thermometer/hygrometer M2 to check that the

temperature inside the cab is equal to or lower than the
ambient temperature.
★ If the temperature of the cab is higher than the am-
bient temperature, open the doors and widows and
wait until the cab temperature stabilizes at the out-
side value.
6 - Close the doors and windows and let the A/C unit op-
erate in these conditions for 5 - 10 minutes.
7 - Use the thermometer M2 to check the temperature of

the air at the central outlets.
★ Position the probe as close as possible to the air
outlets.
8 - Compare the average value of the measured temper-

atures using the following table
Ambient
20 25 30 35
temperature (°C)
Outgoing air
6 -- 8 8 -- 10 8 -- 12 9 -- 14
temperature (°C)
9 - If the average value of the temperature measured does

not fall within the values given in the table, it will be nec-
essary to thoroughly check the unit.
20-52 WB97R-2
TESTING AND ADJUSTMENTS TESTING THE AIR-CONDITIONING UNIT
2. Checking the unit

Check the unit after the point 1., 2., 3., 4. and 6. of the prec-
edent paragraph.
A diagnosis of faults in the unit is based on the working pres-
sures.
When the pressures do not fall within the values given in the
following table, the causes must be sought by checking the
high-pressure (H.P.) and low pressure (L.P.) pressure gaug-
es.
Unit with R134a.
Outside
L.P. (kg/cm²) H.P. (kg/cm²)
Temperature (°C)
Min. Max Min. Max
20 1.2 2.5 6.0 9.0
25 1.0 2.5 7.5 10.5
30 1.1 2.4 9.5 13.0
35 1.3 2.4 12.0 15.5
40 1.5 1.8 18.0 18.8
45 1.8 1.9 21.5 22.0
The following conditions may be found:
Conditions Causes - Faults

• Electromagnetic pulley that slips or does not engage correctly
L.P. high - H.P. normal or low • Expansion valve blocked in open position
• Compressor damaged
• Expansion valve blocked in closed position or obstructed
• Filter saturated with moisture
L.P. low - A.P. high or normal
• Obstruction in the L.P. line or in the H.P. line between the filter and the evap-
oratorL.P.
• Infiltration of hot air into the evaporator group, the pipes or the cab
L.P.normal - H.P. normal • Hot air circulating in the heating group
• Formation of ice on the evaporator
• Normal condition with very high ambient temperature (higher than 43°C)
• Excess coolant(30 – 35% more)
• Overheating of condenser
L.P. high - H.P. high
• Air present in the unit
• Obstruction in the H.P. line between the compressor and the condenser-fil-
ter tube, behind the measurement point of the H.P
• Normal condition with very low temperature (lower than 5°C)
• Lack of coolant (70 - 75% less) (probable leakages)
L.P. normal or low - H.P. low • Obstruction in the H.P. line between the compressor and the condenser-fil-
ter tube, before the measurement point of the H.P.
• Compressor belt missing
L.P. roughly equal to H.P. • Electromagnetic pulley that slips or does not engage
WB97R-2 20-53
TESTING AND ADJUSTMENTS EMPTYING THE AIR-CONDITIONING UNIT
EMPTYING THE AIR-CONDITIONING UNIT

1 - Connect the maintenance station M1 to the service
valves (1) and (2) and follow the specific maintenance
station instructions relative to the drainage of the unit. 1
2 - Disconnect the group to be substituted or reconditioned
immediately after switching off the maintenance station. 2
Plug the removed or disconnected connection
tubes tightly and with a minimum of delay.
3 - Carefully check the quantity of anti-freeze oil recovered
and contained in the disassembled parts, since the
same quantity must be replaced when the air-condi-
tioning unit is refilled.
RKZA8570
20-54 WB97R-2
TROUBLESHOOTING
Front axle troubleshooting ....................................... 56

Rear axle troubleshooting........................................ 61
Transmission troubleshooting.................................. 66
Checking and inspection of the electronic control unit . 69
WB97R-2 20-55
TROUBLESHOOTING FRONT AXLE
FRONT AXLE TROUBLESHOOTING
Wheel vibration; front tyre resistance; halfshaft breakage

CAUSES REMEDY
Incorrect installation Correct installation
Replace the differential in case it does not survive any one of the
Defective axle
test phases
Remove excessive weight and redistribute load, following in-
Overloading/ incorrect weight distribution
structions related to the vehicle
Replace the tyre or adjust pressure to have same radius on both
Different rotation radius of the tyres
tyre
Bent halfshaft Replace halfshaft
Steering is difficult; vehicle goes straight while its turning.

CAUSES REMEDY
Defective axle
test phases
Remove excessive weight and redistribute load, following
instructions related to the vehicle
tyre
Broken halfshaft Replace halfshaft
No differential action; jamming while steering.

CAUSES REMEDY
Defective axle
test phases
Excess of noise
CAUSES REMEDY
Defective axle
test phases
tyre
Bent or broken halfshaft Replace halfshaft
Incorrect wheel adjustment Verify group integrity and wheel side bearings.
Contamination in the axle box or incorrect assembly Look for foreign particles. Check assembly of the various parts of
of parts the axle.
20-56 WB97R-2
Uneven wear of tyre

CAUSES REMEDY
Defective axle
test phases
tyre
Blocked halfshaft:
• Abnormal functioning of the differential or breakage/ • Verify assembly and all components
blockage of command device.
• Vehicles with wide steering angle may proceed with • Reduce the steering angle to minimum and decelerate when the
kicks, have steering difficulty or cause pneumatic vehicle begins to kick.
wearing at sharp turns.
Friction noise
CAUSES REMEDY
Defective axle
test phases
Check the condition of ring gear, pinion gear, bearings etc. Replace
Spoiled or worn out axle parts
when ever necessary.
of parts the axle.
Incorrect adjustment of bevel gearset: Parts of the
transmission worn out. Replace or adjust as required.
(transmission gears, U joints, etc.)
Vibration during forward drive, intermittent noise

CAUSES REMEDY
Defective axle
test phases
tyre
WB97R-2 20-57
Noise while driving

CAUSES REMEDY
Excessive backlash between pinion and ring gear Adjust
Worn out pinion and gear ring Replace
Worn out pinion bearings Replace
Pinion bearings loosened Adjust
Excessive axial pinion backlash Adjust
Worn out differential bearings Replace
Differential bearings loosened Adjust
Ring gear out of roundness Replace
Low lubricant level Oil level
Poor or wrong lubricant Replace
Bent halfshaft Replace
Noise while driving in neutral

CAUSES REMEDY
Noise coming from axle are usually heard when vehicle
Replace or adjust (see above)
moves in neutral gear but are not loud.
Incorrect backlash between pinion and ring (sound
heard while decelerating disappears while increasing Replace
the speed)
Pinion or input flange worn out Adjust
Intermittent noise
CAUSES REMEDY
Ring gear damaged Replace bevel gear set
Differential box bolts loosened Tighten to torque
Constant noise
CAUSES REMEDY
Ring gear teeth or pinion damaged Replace bevel gear set
Worn out bearings Replace
Pinion spline worn out Replace
Noise while steering

CAUSES REMEDY
Worn out differential gears Replace
Worn out differential box or spider Replace
Differential thrust washers worn out Replace
Half shaft spline worn out Replace
20-58 WB97R-2
Ring gear tooth broken at the outer side

CAUSES REMEDY
Excessive gear load compared to the one foreseen Replace bevel gear set
Incorrect gear adjustment (excessive backlash) Follow carefully the recommended operations for the adjustment of
Pinion nut loosened bevel gear set free backlash
Ring gear tooth broken side

CAUSES REMEDY
Load bump
Replace bevel gear set
Incorrect gear adjustment (insufficient backlash)
Adjust bevel gear set freebacklash
Pinion nut loosened
Pinion or ring gear teeth or worn

CAUSES REMEDY
Insufficient lubrication; contaminated oil; Replace bevel gear set
incorrect lubrication or depleted additives Follow carefully the recommended operations for the adjustment of
bevel gear set freeplay
Worn out pinion bearings Use correct lubricants, fill up to the right levels and replace accord-
ing to the recommended program.
Overheated ring and pinion teeth

CAUSES REMEDY
Prolong ed functioning at high temperatures Replace bevel gear set.
Insufficient lubrication; contaminated oil; Use proper lubrication, fill up to right level and replace at recom-
incorrect lubrication mended program.
Pinion teeth pitting

CAUSES REMEDY
Excessive use Replace bevel gear set.
Use correct lubrication, fill up to the right level and substitute at rec-
Insufficient lubrication ommended intervals
Axle beam body bent

CAUSES REMEDY
Vehicle over loaded
Vehicle's accident Replace axle beam body
Load bump
Worn out or pitted bearings

CAUSES REMEDY
Insufficient lubrication; contaminated oil
Excessive use Replace bearings.
Use correct lubrication fill up, to the right level and replace at rec-
Normal wear out ommended intervals
Pinion nut loosened
WB97R-2 20-59
Oil leakage form gaskets and seals

CAUSES REMEDY
Prolonged functioning at high temperature of the oil
Oil gasket assembled incorrectly Replace the gasket or seal and matching surface if damaged
Seal lip damaged Use correct lubrication and replace at recommended intervals
Contaminated oil
Excessive wearing out of input flange spline

CAUSES REMEDY
Exhaustive use
Replace the flange
Pinion nut loosened Check that the pinion spline is not excessively worn out
Replace bevel gear set if required
Pinion axle backlash
Fatigue failure of pinion teeth

CAUSES REMEDY
Exhaustive use
Continuous overload
Pinion and ring teeth breakage

CAUSES REMEDY
Crash load of differential components Check and/or replace other differential components
Side gear spline worn out

CAUSES REMEDY
Replace differential gear group.
Excessive use
Replace halfshaft if required
Thrust washer surface worn out or scratched

CAUSES REMEDY
Use correct lubrication and fill up to right level.
Insufficient lubrication; contaminated oil; Replace at intervals recommended.
incorrect lubrication Replace all scratched washers and those with 0,1mm thickness
lower than the new ones
Inner diameter of tapered roller bearing worn out

CAUSES REMEDY
Excessive use axial pinion Replace bearing.
Check pinion axial backlash.
Excessive pinion axial backlash
Use proper lubrication, fill up to right level and replace at recom-
Insufficient lubrication; contaminated oil mended intervals.
Bent or broken halfshaft or halfshaft broken at wheel side

CAUSES REMEDY
Vehicle intensively operated or overloaded
Replace.
Wheel support loosened
Check that wheel support is not worn out or wrongly adjusted.
Beam body bent
20-60 WB97R-2
TROUBLESHOOTING REAR AXLE
REAR AXLE TROUBLESHOOTING
Wheel vibration; front tyre resistance; halfshaft breakage

CAUSES REMEDY
Defective axle
test phases
tyre
Steering is difficult; vehicle goes straight while its turning.

CAUSES REMEDY
Defective axle
test phases
Remove excessive weight and redistribute load, following
instructions related to the vehicle
tyre
No differential action; jamming while steering.

CAUSES REMEDY
Defective axle
test phases
Excess of noise
CAUSES REMEDY
Defective axle
test phases
tyre
of parts the axle.
WB97R-2 20-61
Uneven wear of tyre

CAUSES REMEDY
Defective axle
test phases
tyre
Blocked halfshaft:
• Abnormal functioning of the differential or breakage/ • Verify assembly and all components
blockage of command device.
• Vehicles with wide steering angle may proceed with • Reduce the steering angle to minimum and decelerate when the
kicks, have steering difficulty or cause pneumatic vehicle begins to kick.
wearing at sharp turns.
Friction noise
CAUSES REMEDY
Defective axle
test phases
Check the condition of ring gear, pinion gear, bearings etc. Replace
Spoiled or worn out axle parts
when ever necessary.
of parts the axle.
Incorrect adjustment of bevel gearset: Parts of the
transmission worn out. Replace or adjust as required.
(transmission gears, U joints, etc.)
Vibration during forward drive, intermittent noise

CAUSES REMEDY
Defective axle
test phases
tyre
20-62 WB97R-2
Noise while driving

CAUSES REMEDY
Excessive backlash between pinion and ring gear Adjust
Worn out pinion and gear ring Replace
Worn out pinion bearings Replace
Pinion bearings loosened Adjust
Excessive axial pinion backlash Adjust
Worn out differential bearings Replace
Differential bearings loosened Adjust
Ring gear out of roundness Replace
Low lubricant level Oil level
Poor or wrong lubricant Replace
Noise while driving in neutral

CAUSES REMEDY
Noise coming from axle are usually heard when vehicle
Replace or adjust (see above)
moves in neutral gear but are not loud.
Incorrect backlash between pinion and ring (sound
heard while decelerating disappears while increasing Replace
the speed)
Pinion or input flange worn out Adjust
Intermittent noise
CAUSES REMEDY
Ring gear damaged Replace bevel gear set
Differential box bolts loosened Tighten to torque
Constant noise
CAUSES REMEDY
Ring gear teeth or pinion damaged Replace bevel gear set
Worn out bearings Replace
Pinion spline worn out Replace
Noise while steering

CAUSES REMEDY
Worn out differential gears Replace
Worn out differential box or spider Replace
Differential thrust washers worn out Replace
Half shaft spline worn out Replace
WB97R-2 20-63
Ring gear tooth broken at the outer side

CAUSES REMEDY
Excessive gear load compared to the one foreseen Replace bevel gear set
Incorrect gear adjustment (excessive backlash) Follow carefully the recommended operations for the adjustment of
Pinion nut loosened bevel gear set free backlash
Ring gear tooth broken side

CAUSES REMEDY
Load bump
Incorrect gear adjustment (insufficient backlash)
Adjust bevel gear set freebacklash
Pinion nut loosened
Pinion or ring gear teeth or worn

CAUSES REMEDY
Insufficient lubrication; contaminated oil; Replace bevel gear set
incorrect lubrication or depleted additives Follow carefully the recommended operations for the adjustment of
bevel gear set freeplay
Worn out pinion bearings Use correct lubricants, fill up to the right levels and replace accord-
ing to the recommended program.
Overheated ring and pinion teeth

CAUSES REMEDY
Prolong ed functioning at high temperatures Replace bevel gear set.
Insufficient lubrication; contaminated oil; Use proper lubrication, fill up to right level and replace at recom-
incorrect lubrication mended program.
Pinion teeth pitting

CAUSES REMEDY
Excessive use Replace bevel gear set.
Use correct lubrication, fill up to the right level and substitute at rec-
Insufficient lubrication ommended intervals
Axle beam body bent

CAUSES REMEDY
Vehicle over loaded
Vehicle's accident Replace axle beam body
Load bump
Worn out or pitted bearings

CAUSES REMEDY
Insufficient lubrication; contaminated oil
Excessive use Replace bearings.
Use correct lubrication fill up, to the right level and replace at rec-
Normal wear out ommended intervals
Pinion nut loosened
20-64 WB97R-2
Oil leakage form gaskets and seals

CAUSES REMEDY
Prolonged functioning at high temperature of the oil
Oil gasket assembled incorrectly Replace the gasket or seal and matching surface if damaged
Seal lip damaged Use correct lubrication and replace at recommended intervals
Contaminated oil
Excessive wearing out of input flange spline

CAUSES REMEDY
Exhaustive use
Replace the flange
Pinion nut loosened Check that the pinion spline is not excessively worn out
Replace bevel gear set if required
Pinion axle backlash
Fatigue failure of pinion teeth

CAUSES REMEDY
Exhaustive use
Continuous overload
Pinion and ring teeth breakage

CAUSES REMEDY
Crash load of differential components Check and/or replace other differential components
Side gear spline worn out

CAUSES REMEDY
Replace differential gear group.
Excessive use
Replace halfshaft if required
Thrust washer surface worn out or scratched

CAUSES REMEDY
Use correct lubrication and fill up to right level.
Insufficient lubrication; contaminated oil; Replace at intervals recommended.
incorrect lubrication Replace all scratched washers and those with 0,1mm thickness
lower than the new ones
Inner diameter of tapered roller bearing worn out

CAUSES REMEDY
Excessive use axial pinion Replace bearing.
Check pinion axial backlash.
Excessive pinion axial backlash
Use proper lubrication, fill up to right level and replace at recom-
Insufficient lubrication; contaminated oil mended intervals.
Bent or broken halfshaft or halfshaft broken at wheel side

CAUSES REMEDY
Vehicle intensively operated or overloaded
Replace.
Wheel support loosened
Check that wheel support is not worn out or wrongly adjusted.
Beam body bent
WB97R-2 20-65
TROUBLESHOOTING TRANSMISSION
TRANSMISSION TROUBLESHOOTING
Vehicle does not move

CAUSES REMEDY
Faulty supply to solenoid valves Check/Replace
Damaged wiring connections between
Repair/Replace
transmission and vehicle
Oxidised contacts in electrical wiring Clean
Break in electric cable Replace
Damaged solenoids Replace
Damaged sensors Replace
Short circuits or false contacts Check/replace fuses
Irregular functioning of electronic gear
Replace EGM
management (EGM)
Incorrect oil level Top up
Check for leaks Repair/Top up
Blocked intake filter Clean
Damaged oil pump Replace
Damaged oil pump relief valve Replace oil pump
Blocked/damaged transmission filter Replace
Damaged/jammed control valve Replace
Damaged converter Replace
Oil temperature below 0°C Wait for oil to reach working temperature (stall test)
Damaged rotary seals Replace
Blocked reverser lever Repair
Worn clutch unit Replace/Repair clutch unit
No drive transmission
Check/Repair/Replace
(broken gears, shafts, bearings, etc.)
Vehicle has reduced power transmission

CAUSES REMEDY
Incorrect oil temperature Wait for oil to reach working temperature (stall test)
Transmission oil overheating Restore acceptable temperature values
Incorrect operating pressure Check hydraulic circuit and replace (oil pump, filters, control valve)
Worn clutch unit Replace/Repair
4WD clutch failure Repair/Replace 4WD shaft group
Overheating solenoids Replace
Damaged transmission and vehicle wiring connections Repair/Replace
Damaged EGM logic Replace EGM
Damaged sensors Replace
20-66 WB97R-2
Overheating
CAUSES REMEDY
Damaged hydraulic cooling system Repair
Dirty heat exchanger Clean
Parking brake inadvertently activated Release
Excessive dirt on axle wheel hubs Clean
Seizing (broken gears, shafts, bearings, etc.) Check/Repair/Replace
Braking force outside transmission:
Check/Repair axle
irregular axle operation
Clutch plate drag Repair/Replace
Damaged oil thermostat Replace
Worn oil pump Replace
Wheels rotate when vehicle is raised

CAUSES REMEDY
Clutch plate drag Repair/Replace
Low oil temperature (high oil viscosity) Wait for oil to reach working temperature (stall test)
Incorrect oil specifications Replace oil and filters
Damaged control valve Replace
Faulty reverser locking Repair/Replace
Noise
CAUSES REMEDY
Damaged oil pump Replace
Aeration/Cavitation Check oil level / Check oil specifications
Seizing (broken gears, shafts, bearings, etc.) Check/Repair/Replace
Worn clutch plates Replace
Irregular actuation
CAUSES REMEDY
Electrical system fault Repair/Replace
Worn clutch plates Replace
Low oil temperature (high oil viscosity) Wait for oil to reach working temperature (stall test)
Overheating See "overheating"
Faulty EGM operation Replace EGM
Damaged hydraulic system Repair/Replace
WB97R-2 20-67
Gear remains engaged

CAUSES REMEDY
Damaged/jammed shuttleshaft lever Repair/Replace
Damaged clutch unit Repair/Replace
Irregular EGM operation Replace EGM
No 4WD power transmission
CAUSES REMEDY
Damaged 4WD clutch Replace
Hydraulic system fault Repair/Replace
Faulty brake sensor Check/Replace
Faulty EGM operation Replace EGM
Gear shift won’t engage

CAUSES REMEDY
Damaged clutch unit Repair/Replace
Damaged pressure sensors Check/Replace
Irregular EGM operation Replace EGM
20-68 WB97R-2
CHECKING AND INSPECTION OF
TROUBLESHOOTING THE ELECTRONIC CONTROL UNIT
CHECKING AND INSPECTION OF THE ELECTRONIC CONTROL UNIT

1. FAILURE
Condition in both autotest and operating mode
• Red alarm LED (1) permanently on 1
• No. 3 long beeps (1 sec)
• Numerical message on display (2) 2
• Rest state for all solenoid valves
RKZ06540
1.1 Numerical error
Numerical error code

Error code description Cause of alarm
on display
Alarm from general pressure sensor alarm Insufficient pressure in system
Insufficient electrical power.

General alarm
Electronic card defective
2. ANOMALY
Condition in autotest mode:
• Red alarm LED (1) flashing 1
• No. 3 long beeps (1 sec)
• Numerical message on display (2) 2
Flashing numerical message on display (15) in place of gear
selected
RKZ06540
2.1 Numerical error

on display
Alarm from oil thermostat Overheating
Alarm from 1st gear pressure sensor Insufficient pressure on 1st gear clutch
WB97R-2 20-69
CHECKING AND INSPECTION OF
TROUBLESHOOTING THE ELECTRONIC CONTROL UNIT

on display
Alarm from 2nd gear pressure sensor Insufficient pressure on 2nd gear clutch
Alarm from 3rd gear pressure sensor Insufficient pressure on 3rd gear clutch
Alarm from 4th gear pressure sensor Insufficient pressure on 4th gear clutch
Alarm from 1st gear solenoid valve 1st gear solenoid valve failure
Alarm from 2nd gear solenoid valve 2nd gear solenoid valve failure
Alarm from 3rd gear solenoid valve 3rd gear solenoid valve failure
Alarm from 4th gear solenoid valve 4th gear solenoid valve failure
Alarm from FORWARD FORWARD control solenoid valve

control solenoid valve failure
Alarm from REVERSE control solenoid valve REVERSE control solenoid valve failure
Alarm from 4WD control solenoid valve 4WD control solenoid valve failure
20-70 WB97R-2
GROUP 30
40-28 PC15R-8
REMOVAL AND INSTALLATION
HOW TO READ THE MANUAL................................. 3 TRANSMISSION OIL COOLER

PRECAUTIONS TO BE TAKEN WHILE WORKING . 4 Removal and installation ..........................................35
SPECIAL TOOLS ...................................................... 5 MUFFLER
Removal and installation ..........................................36
STARTING MOTOR
Removal and installation ........................................... 9 EXHAUST PIPE
Removal and installation ..........................................37
ALTERNATOR
Removal .................................................................. 10 ENGINE HOOD
Installation ............................................................... 11 Removal ...................................................................38
Installation ................................................................39
AIR-CONDITIONING UNIT COMPRESSOR
(Only for machines equipped with an CAB
air-conditioning unit) Removal ...................................................................40
Removal .................................................................. 12 Installation ................................................................43
Installation ............................................................... 13 HEAT AND AIR-CONDITIONING GROUP
INJECTION PUMP Removal ...................................................................44
Installation ............................................................... 17 FUEL TANK
INJECTION NOZZLES Removal and installation ..........................................46
Removal and installation ......................................... 18 HYDRAULIC OIL TANK
THERMOSTAT Removal and installation ..........................................47
Removal and installation ......................................... 19 ENGINE-GEARBOX-PUMP GROUP
COOLING LIQUID PUMP Removal ...................................................................48
Installation ............................................................... 21 PISTON PUMP
TURBOCOMPRESSOR Removal ...................................................................54
Installation ............................................................... 23 TRANSMISSION
CYLINDER HEAD Removal ...................................................................56
Removal .................................................................. 24 InstallationI ...............................................................59
Installation ............................................................... 26 Disassembly and assembly......................................61
FRONT COUNTERWEIGHT CONVERTOR
Removal and installation ......................................... 28 Removal and installation ........................................159
RADIATOR-OIL COOLER UNIT TRANSMISSION-REVERSE, DIRECTION
Removal .................................................................. 29 INDICATOR AND HEADLIGHT DIPPER BEAM
Installation ............................................................... 31 CONTROL GROUP
Removal and installation ........................................160
CONDENSER
(Only for machines equipped with an STEERING UNIT
air-conditioning unit) Removal and installation ........................................161
Removal and installation ......................................... 32 WORKING BRAKE PUMP GROUP
HYDRAULIC OIL COOLER Removal and installation ........................................162
Removal .................................................................. 33 FRONT WORKING EQUIPMENT CONTROL VALVE
Installation ............................................................... 34 Removal and installation ........................................163
WB97R-2 30-1
FRONT AXLE BACKHOE BACKFRAME LOCK CYLINDER
Removal ................................................................ 164 Removal and installation ........................................241
Installation ............................................................. 165 CYLINDERS
Disassembly .......................................................... 166 (Front bucket raise and tilt, boom, arm, bucket,
Assembly............................................................... 175 outriggers and jig arm)
REAR AXLE Disassembly...........................................................242
Removal ................................................................ 191 Assembly................................................................244
Installation ............................................................. 192 BOOM SWING CYLINDER
Disassembly .......................................................... 193 Disassembly...........................................................248
Assembly............................................................... 208 Assembly................................................................249
FRONT BUCKET BOOM-RAISING CYLINDER BACKHOE BACKFRAME LOCK CYLINDER
Removal and installation ....................................... 227 Disassembly...........................................................251
FRONT BUCKET TILT CYLINDERS Assembly................................................................251
Removal and installation ....................................... 228 BOOM SAFETY CYLINDER
FRONT BUCKET Removal and installation ........................................252
Removal and installation ....................................... 229 BACKHOE WORKING EQUIPMENT
FRONT WORKING EQUIPMENT Removal and installation ........................................253
Removal ................................................................ 230 BACKHOE BUCKET
Installation ............................................................. 231 Removal and installation ........................................254
BACKHOE CONTROL VALVE ARM
Removal ................................................................ 232 Removal and installation ........................................255
Installation ............................................................. 233
COMPLETE JIG ARM
BACKHOE BOOM CYLINDER Removal and installation ........................................256
Removal and installation ....................................... 234
2nd ARM
BACKHOE ARM CYLINDER Removal and installation ........................................257
2nd ARM GUIDES
JIG ARM CYLINDER Removal and installation ........................................258
BACKHOE BOOM
BACKHOE BUCKET CYLINDER Removal and installation ........................................259
BACKHOE SWING BRACKET
OUTRIGGER CYLINDERS Removal and installation ........................................260
Removal ................................................................ 238
BACKHOE BACKFRAME
Installation ............................................................. 239
Removal and installation ........................................261
BACKHOE SWING CYLINDERS
30-2 WB97R-2
REMOVAL AND INSTALLATION HOW TO READ THE MANUAL
HOW TO READ THE MANUAL

1. Removal and Installation of the groups
(1) The procedures and information needed to carry out the work of removing or Installing units or groups are given
in the removal procedure. The sequence of operations is not repeated in the installation procedure.
(2) Information needed for installation is marked with the symbol 1 ; The same symbol is repeated at the end
of each removal procedure for the same item, to indicate to which installation item it refers.
(Example)
REMOVAL GROUP ● ● ● : ......................................................Title of operation
: ............................................................................................Safety precautions to be followed when carrying

out the operation.
1 - Remove XXXX (1): ..............................................................Step in removal procedure.
★:.........................................................................................Technique or important point to remember when
removing XXXX (1)
2- ▲ ▲ ▲ (2): ................................................................ 1 This sign means that information is given
for the installation procedure
3 - Remove ■ ■ ■ (3):
........... : ......................................................................Recovery of oil or water, and the quantity to be
recovered.
INSTALLATION GROUP ● ● ● : ..............................................Title of operation
· To install, reverse removal procedure.
1 : .........................................................................................Technique to be used for installation

★:.........................................................................................Technique or important point to remember when
removing ▲ ▲ ▲ (2)
· Addition of water or oil: ........................................................Step in removal procedure
★:.........................................................................................Point to remember when adding water or oil.
2. To the precautions to be taken during the removal or installation of the groups, must be added the specific «PRE-
CAUTIONS TO BE TAKEN DURING THE OPERATIONS».
Always make sure that these precautions are taken.
3. List of special tools

(1) For details of the descriptions, codes and quantities of each tool (A1; A2 etc.) mentioned in the operational pro-
cedures, see the list «SPECIAL TOOLS» supplied in this section.
4. List of the tightening torques and weights, and the quantities oil, liquids or grease needed to fill tanks and
containers
(1) In the operating procedures, you will find the symbols , , , ; In the following order, these rep-
resent the values of «TIGHTENING TORQUES», «WEIGHT OF PARTS OR GROUPS», «QUANTITIES OF
OIL OR LIQUIDS TO BE INTRODUCED», «SCREW LOCKING MATERIAL, SEALANTS AND LUBRICA-
TION», «LUBRICATING GREASE».
NOTE
If no symbol is indicated, the values to be used are those given in the introductory sections of this manual.
WB97R-2 30-3
REMOVAL AND INSTALLATION PRECAUTIONS TO BE TAKEN WHILE WORKING
PRECAUTIONS TO BE TAKEN WHILE WORKING

★ When dismantling or installing a part, always take the following general precautions.
1. Precautions for removal operations

• If not otherwise indicated, lower the work equipment until it rests on the ground.
• If the coolant liquid contains an anti-freeze substance, follow the instructions given for drainage.
• After having removed flanges and tubes, insert plugs to prevent impurities from entering.
• Before removing a cylinder, fully retract the piston and tie it with wire.
• Use a sufficiently large container to collect the oil.
• Before removing a part from the machine, check the alignment reference marks which show the correct in-
stallation position. If necessary add further marks to avoid incorrect installation.
• While dismantling the connectors, always grasp them firmly to avoid undue strain on the wiring.
• If necessary, attach markers to the wires and tubes to avoid muddling them up during installation.
• Check the number and height of the adjustments to a given clearance and store them in a safe place.
• When raising the machine or some parts of it, use adequate equipment for the weight of the part concerned.
• When using screws or eyebolts to remove items of the machinery, screw them alternately, and as deeply as
they will go.
• Before removing a piece, clean the surrounding area and, after removal, cover the area to prevent dirt or dust
from gaining entrance.
2. Precautions to be taken during installation

• Tighten nuts and screws with the specified tightening torques.
• Install the flexible hoses, taking care not to entangle or twist them.
• Bend the cotter pins and stops in such a way as to secure them.
• When coating the threads with adhesives, clean the piece to remove oil and grease, then apply just enough
adhesive to cover the threading in a uniform manner.
• When applying a liquid sealant, clean the surface involved, remove residual oil and grease, check that there are
no dents or dirt, then apply the liquid sealant in a uniform manner.
• Clean all the parts, remove dirt, rust, burrs, or dents.
• Apply a film of engine oil over all the moving parts.
• Apply a film of anti-friction grease (ASL800040) over all surfaces assembled with pressure, to avoid sticking
• After having mounted the snap-rings, check that they are firmly positioned in their seatings.
• When installing electrical system jacks, remove any oil, dust or water that may have penetrated into them, then
connect them firmly.
• If using eyebolts, check that they are not distorted, screw them in fully, and then align the eye with the hoisting
hook.
• Mount the flanges in a uniform manner, and tighten the screws in criss-cross sequence, to avoid excessive pull
on one side only.
3. Precautions to be taken on completion of removal and installation operations.

• If the coolant liquid has been drained away, close the drainage plug and add new liquid up to normal level. Start
the engine to circulate the liquid throughout the cooling system and then top up the level once more.
• When the hydraulic equipment has been dismantled, add engine oil to the indicated level. Start up the engine
to circulate the oil in the hydraulic circuits, and then top up to the indicated level.
• If hoses or hydraulic equipment, such as hydraulic cylinders, pumps, motors, solenoid valves and valves, are
removed for repairs or substitution, bleed air from the hydraulic circuits after having re-assembled the machine.
★ For details, see «20. TESTING AND ADJUSTMENTS».
• After having re-assembled cylinder joints or cylinders, or work equipment articulations, lubricate thoroughly.
30-4 WB97R-2
REMOVAL AND INSTALLATION SPECIAL TOOLS
SPECIAL TOOLS
Nature of work Symbol Code Description Q.ty Notes

ATR200620
Cylinder disassembly -
1 See Attachment 1
assembly
960119000
Plunger Ø 40 2
Hydraulic
press Plunger Ø45 2 Assembly cylinder
2
Commercially Plunger Ø50 2 and rod bushings
available
Plunger Ø75 2
See
Bushing 1
960117005 To calibrate piston
3
See gasket
Bushing support 1
960117006
Notched wrench for
1
cylinders Ø70
Notched wrench for
1
cylinders Ø80
Notched wrench for
1
cylinders Ø85
4
Commercially Notched wrench for Disassembly-assembly
1
available cylinders Ø95 head cylinder
Notched wrench for
1
cylinders Ø115-120
Disassembly and Notched wrench for
A 1
assembly cylinder cylinders Ø110
Notched wrench for
5 1
boom cylinders
Disassembly ring nut
boom cylinder
6 ATR200300 Notched wrench 1
Boom swing head
disassembly-assembly
Socket wrench (6-point 46) 1
Commercially Removal - installation of
7 Socket wrench (6-point 55) 1
available piston
Socket wrench (6-point 65) 1
Plunger Ø40 1
Hydraulic
press Plunger Ø50 1
8 Dust seal assembly
Commercially Plunger Ø55 1
available
Plunger Ø60 1
Expander Ø70 1
Expander Ø80 1
See Expander Ø85 1
960117002
9 Expander Ø95 1 Piston gaskets assembly
960117003
960030002 Expander Ø100 1
Expander Ø110 1
Expander Ø115 1
WB97R-2 30-5
Nature of work Symbol Code Description Q.ty Notes

Bushing for rod Ø40 1
See
10 Bushing for rod Ø50 1 Head assembly on rod
960117001
Disassembly and Bushing for rod Ø70 1

A
assembly cylinder Bushing for rod Ø80 1
See
11 Bushing for rod Ø95 1 Piston-cylinder assembly
960117004
Commercially Draining and refilling
Air conditioning unit B 1 Maintenance station 1
available the unit
1 CA715404 Extractor 1 Remove oil pump
2 CA715409 Plunger 1 Mounting oil pump seal ring
Removal-installation flange
3 CA715407 Wrench 1
screw
Removal-installation
4 CA715405 Plunger 1
ring
5 CA715412 Plunger 1 Disassembly bearing
6 CA715406 Hook 1
front holder
Disassembly and 7 CA715179 Plunger 1 Mounting bearing
C
assembly transmission
8 CA715004 Plunger 1 Mounting bearing
Disassembly-assembly
clutch
11 CA715408 Extractor 1
shaft
13 CA715414 Equipment for test 1 For tightness test
30-6 WB97R-2
2 CA119030 Wrench 1
3 CA119099 Wrench 1
4 CA715022 Wrench 1
6 CA715023 False pinion 1
Measurament shim for
7 CA119206 False differential holder 1
pinion
8 CA119182 Ring nut 1
Disassembly and
D 11 CA715087 Plunger 1
assembly front axle
2 CA715265 Wrench 1
3 CA119099 Wrench 1
4 CA715022 Wrench 1
5 CA715380 Kit 1
6 CA715128 False pinion 1
7 CA715388 False differential box 1
Disassembly and 9 CA715028 Plunger 1

E
assembly rear axle 10 CA715391 Plunger 1
11 CA119033 Interchangeable handle 1
12 CA715056 Kit 1
13 CA715055 Kit 1
WB97R-2 30-7
PAGE INTENTIONALLY
LEFT BLANK
REMOVAL AND INSTALLATION STARTING MOTOR
REMOVAL OF STARTING MOTOR

Fully raise the front working equipment and engage the
safety stop.
2 1
1 - Stop the engine and engage the parking brake.
2 - Remove guard (1) from tank (2).
RKZA9480
3 - Loosen the rods (3), move battery (4) outwards and lift
the protection (5).
Disconnect the clamp (6) from battery (4) negative ter-
minal (–). 4 3
6
RKZA9490
4 - Disconnect the electric wiring (7).
5 - Loosen the two screws (8) and remove the starting mo-
tor (9). 8 7
1
RKZA0022
INSTALLATION OF THE
STARTING MOTOR
• To install, reverse the removal procedure.
1
Starting motor mounting screws: 78.4–98 Nm
WB97R-2 30-9
REMOVAL AND INSTALLATION ALTERNATOR
REMOVAL OF THE ALTERNATOR

safety stop.
2 1
1 - Stop the engine and engage the parking brake.
2 - Remove guard (1) from tank (2).
RKZA9480
3 - Loosen the rods (3), move battery (4) outwards and lift
the protection (5).
Disconnect the clamp (4) from battery (6) negative ter-
minal (–). 4 3
6
RKZA9490
4 - Disconnect the cable (7), the connector (8) and the cot-
ter pin (9).
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 WB97R-2
REMOVAL AND INSTALLATION ALTERNATOR
6 - Release the belt (14) from the pulley and remove the al-
ternator (13). 1
12 13
14
RKZA0051
INSTALLATION OF THE
ALTERNATOR
1
★ Adjust the fan-belt tension.
(For details, see «20. TESTING AND ADJUSTMENTS -
Fan-belt tension»).
WB97R-2 30-11
REMOVAL AND INSTALLATION AIR-CONDITIONING UNIT COMPRESSOR
REMOVAL OF THE AIR-CONDITIONING UNIT COMPRESSOR

(Only for machines equipped with an air-conditioning unit)
Disconnect the cable from battery negative terminal (–).
1 - Remove lateral guard (1).
RKZA8790
2 - Connect the outlets (2) and (3) to the maintenance sta-

tion for air-conditioning units B1 and drain the cooling 7
fluid.
2
3 - Disconnect the connector (4).
RKZA8571
4 - Loosen the screw (5) and remove the belt (6) that drives
the compressor (7). 1
6
RKZA8561
5 - Loosen and remove the screw (8) that holds the bracket
(9) that supports the delivery and suction lines (10), 7
(11).
2 11
★ Be careful to avoid damaging the seals. 8
9
10
RKZA8600
30-12 WB97R-2
REMOVAL AND INSTALLATION AIR-CONDITIONING UNIT COMPRESSOR
6 - Remove the front screws (12), the rear nuts (13) and lift
out the compressor (7) complete with its support (14). 7
3
14
12
13
RKZA8610
INSTALLATION OF THE
AIR-CONDITIONING UNIT
COMPRESSOR
1
Belt-tightening screw: 123 Nm
★ Apply tension to the compressor belt.
(For details, see «TESTING AND APPLYING TEN-
SION TO THE COMPRESSOR BELT»).
2
★ Tighten until the flanges rest on the compressor.
3
Compressor retaining screws: 32 Nm
1 - Connect the unit to the maintenance station B1 and refill

it.
Quantity of fluid: 970±15 g
WB97R-2 30-13
REMOVAL AND INSTALLATION INJECTION PUMP
REMOVAL OF THE INJECTION PUMP

safety stop. Also make the backhoe safe.
1
Raise the engine hood and disconnect the cable from
battery negative terminal (–).
★ Plug all tubes that have been removed or disconnected

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). 1
5
3 - Disconnect the high-pressure pipes (5). 2
4
2
3
RKZA0070
4 - Disconnect the fuel feed hose (7) and delivery tube (8)
from the feed pump (6)
7
1
5 - Disconnect the tube (9) from the oil level dip-stick and 9 8
remove it.
3
6 - Remove the support-bracket (10) of the pump.
6
10
RKZA0080
7 - Disconnect the accelerator control cable support (12)

from the lever (11).
11
12
RKZA0090
30-14 WB97R-2
8 - Disconnect the engine-stopping solenoid (13) from the

injection pump (2). Lift out the entire group. 4
13
RKZA0100
9 - Remove the retaining clip (14) of the injection pump lu-

brication tube.
10 - Disconnect the lubrication tube (15).
15
14
RKZA0110
11 - Remove the cover (16) that gives access to the distri-

bution gear and the oil filler plug (17). 5 17
16
RKZA0120
12 - Loosen and lift off the retaining nut (18) and safety
washer (19) of the pump driving gear (20). 6 19
★ Take great care not to drop the safety washer (19)
into the pump casing.
18
20
RKZA0130
WB97R-2 30-15
13 - Remove the driving gear (20) of the pump (2).

★ Before removing the pump driving gear, mark its
X2
position with respect to the idling gear. 23
★ For removal use a puller (X1). The puller screws
(X2) screw directly into the gear (20).
21
Take great care not to damage the pump shaft
thread
★ During removal, be careful not to let the wrench
(21) drop into the housing.
20 X1
X2
RKZ00030
14 - Take out the four nuts (22) and remove the injection
pump (2) with its O-ring seal (23). 7
22
RKZA0081
30-16 WB97R-2
INSTALLATION OF THE INJECTION PUMP

1
Fuel feed hoses: 24.5–34.3 Nm
2
High pressure hoses: 24.5–34.3 Nm
3
Bolt screw, pump side: 44.1–53.9 Nm
Bolt screw, engine side: 22.5–8.4 Nm
4
★ Put in a new safety cotter pin.
5
Cover gasket: ASL800070
Cover bolts for ignition gear system: 18 Nm
6
★ Align the marks between the gears before installing
the pump and mounting the nut. Injection pump
gear (20)
Gear-locking nut: 83.3–93.1 Nm
7
Pump-locking nut: 35.2–43.1 Nm
Reference
1 - Check fuel injection timing.
(For details, see «20. TESTING AND ADJUST-
MENTS»).
Idling gear
RKZ00131
WB97R-2 30-17
REMOVAL AND INSTALLATION INJECTION NOZZLES
REMOVAL OF THE INJECTION NOZZLES

safety stop. Also make the backhoe safe. 2
4 1
1 - Disconnect the sensor (1) for a clogged air-filter.
2 - Remove the air-filter (2), the supporting bracket (3) and

the intake sleeve (4). 1
3 - Remove the muffler. 3
(For details, see «REMOVAL OF THE MUFFLER»).
RKZA9500
4 - Remove the intake duct (5). 2

5 - Loosen the clip (6) and remove the high-pressure pipes 5
(7).
3
6
6 - Disconnect the fuel flow-back pipes (8).
7
RKZA9970
7 - Take out the nuts (9) that secure the collar (10) and take
out the injector (11), the seating (12 and the protection 10
piece (13).
4
9
INSTALLATION OF THE
INJECTION NOZZLES 11 13
12
1
RKZ00141
Bracket screw: Loctite 262
2
Duct screw: 45–55Nm
Bracket screw: Loctite 262
3
High-pressure pipes: 24.5–4.3 Nm
Hose-clamp screws: 9.8–11.8 Nm
4
Collar lock nuts: 9.8–11.8 Nm
30-18 WB97R-2
REMOVAL AND INSTALLATION THERMOSTAT
REMOVAL OF THE THERMOSTAT

safety stop.
Also make the backhoe safe. 4
2
★ Drain the engine coolant liquid.

Coolant liquid: 18 3
5
1 - Disconnect the cable (1) of the clogged filter indicator
1
(2) and remove the entire suction filter (3).
RKZA9501
2 - Remove the fan guard (4).
3 - Disconnect the radiator connection sleeve (6) from the

thermostat cover (5).
4 - Take out the screws and remove the thermostat cover

(5).
RKZA1780
5 - Remove the gasket (7), the thermostat (8) and the ring
seal (9).
5
Put in new seals.
8
INSTALLATION OF THE 9
THERMOSTAT
RKZ00151
1
1 - Refill the coolant liquid tank.
Coolant liquid: 18
2 - Start the engine at low idling to circulate the coolant liq-

uid through all circuits.
3 - Accelerate gradually up to 1700 rpm. After about one

minute, stop the engine and check or top up the level in
the container.
★ Check that there are no leaks.

Cover screws: 22–27.8 Nm
WB97R-2 30-19
REMOVAL AND INSTALLATION COOLING LIQUID PUMP
REMOVAL OF THE COOLING LIQUID PUMP

safety stop. Also make the backhoe safe.
1

Coolant liquid: 18
1 - Remove the engine coolant liquid container (1).
RKZA8800
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 ALTERNA-
TOR»). 5
1
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»). 4
14
RKZA8572
30-20 WB97R-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
COOLERS»).
9 - Remove the fan (9), the spacer (10) and the pulley (11).
2
6
10 - Remove the four screws (12) and then the complete

pump (13). RKZA7770
3
Replace all seals with new ones.
10
11
INSTALLATION OF THE COOLANT
LIQUID PUMP 9
1
Locking screws for alternator support:
22.5–28.4 Nm
★ Apply tension to the alternator belt. RKZA1810

MENTS»).
2
Locking screws for pulley and fan: 12
44.1–53.9 Nm
3
Pump screws: 22.5–28.4 Nm
4
Locking screw for compressor: 64 Nm 13
★ Apply tension to the compressor belt. RKZA2450
(For details, see «TESTING AND APPLYING TEN-

SION TO THE COMPRESSOR BELT»).
1 - Refill the coolant liquid circuit.
Coolant liquid: 18
2 - Start the engine at low idling to circulate the coolant liq-

uid through all circuits.

the container.
★ Check that there are no leaks.
WB97R-2 30-21
REMOVAL AND INSTALLATION TURBOCOMPRESSOR
REMOVAL OF THE TURBOCOMPRESSOR

safety stop.
Also make the backhoe safe.
2
1 - Disconnect the clogged air-filter indication (2) cable (1)

and remove the entire suction filter (3).
2 - Remove the muffler 3

(For details, see «REMOVAL OF THE MUFFLER»).
1
RKZA9502
3 - Disconnect the turbocompressor delivery coupling

sleeve (4) from the suction manifold. 16
RKZA0210
4 - Take the screws out of the clips (5) and disconnect the
tube (6) that delivers the turbocompressor lubrication
oil.
RKZA0220
5 - Take out the tube-retaining screws (7) and the two

screws (8) that secure the flange of the lubrication oil
drainage tube (9).
1
8 9
RKZA0230
30-22 WB97R-2
REMOVAL AND INSTALLATION TURBOCOMPRESSOR
6 - Take out the screws (10) that join the turbocompressor

tothecouplingsleeve,andremovethecouplingsleeve(11). 10
2
7 - Take out the screws (12) and remove the bracket (13).
11
3
13
12
RKZA1621
8 - Take out the nuts (14), and the washers (15) and lift off
the turbocompressor (16).
★ Carefully check the state of all the sealing gaskets.
Replace them if there is any sign of damage. 16
14 15
RKZA0240
INSTALLATION OF THE
TURBOCOMPRESSOR
1
Tube retaining screws: 22.5–28.4 Nm
Flange screws: 8–9 Nm
2
Coupling joint screws: 22.5–28.4 Nm
3
Bracket screws: 22.5–28.4 Nm
1 - Start the engine and check that there are no leaks in the
turbocompressor lubrication tubes.
WB97R-2 30-23
REMOVAL AND INSTALLATION CYLINDER HEAD
REMOVAL OF THE CYLINDER HEAD

safety stop.
Also make the backhoe safe 1

Coolant liquid: 18
1
1 - Remove the container (1).
RKZA8800
2 - Disconnect the cable (2) of the clogged air-filter sensor

(3) and remove the entire suction filter (4) and its sup-
port.
3
2
★ Remove the turbocompressor.
(For details, see «REMOVE THE TURBOCOMPRES-
SOR»).
2
RKZA9503
3 - Only for machines equipped with an air-condition-

ing unit
Remove the alternator (5), the compressor (6) and the
supporting bracket (7).
(For details, see «REMOVAL OF THE ALTERNATOR»
and «REMOVAL OF THE AIR-CONDITIONING 7
UNIT»). 6
3
5
RKZA8576
4 - Remove the support (8). 4
8
RKZA8563
30-24 WB97R-2
5 - Disconnect the cable (9) of the cold-start equipment.
6 - Remove the suction manifold (10) and the cold-start 13

equipment (11). 5
7 - Remove the diesel fuel filter (12) and place it to one side.
10 11 11 9
8 - Disconnect the clips (13) that secure the heating pipes.
12
RKZA9510
9 - Disconnect the breather tube (14) from the engine

head.
14
RKZA0222
10 - Remove the muffler (15).

(For details, see «REMOVAL OF THE MUFFLER»). 15
11 - Remove the muffler support bracket (16).
6
16
RKZA0252
12 - Disconnect the cables (17) from the temperature sen-

sors (18).
18
13 - Disconnect the heating pipes (19). 17
14 - Remove the radiator connection pipes (20).
15 - Remove the coolant liquid pump. (For details, see «RE- 20

MOVAL OF THE COOLANT LIQUID PUMP»).
19
RKZA1783
WB97R-2 30-25
16 - Disconnect the fuel return hose (21) from the injector

nozzles and remove the nozzles. 22
(For details, see «REMOVAL OF THE INJECTOR 21
NOZZLES»).
6 7
17 - Remove the cover of the tappets (22). 8
RKZA0173
18 - Remove the valve rocker-arm shaft (23).

★ Loosen the nuts and unscrew the tappets by 2-3
26 23
turns
19 - Take out the rocker-arm control rods (24).

25
24
RKZ00161
20 - Take out the screws (25) and remove the entire cylinder
head (26). Follow the indicated sequence for loosening BOLT LOOSENING ORDER
the screws.
10
★ Sequence to be followed: see drawing. 7 16 14 6

1 9 18 12 4
Loosen the cylinder head retaining screws in two

3 11 17 10 2
stages. 5 13 15 8
RKZ00171
INSTALLATION OF THE
CYLINDER HEAD
1
★ Fill up the cooling circuit.
Coolant liquid: 18
★ Check carefully that there are no leaks.
30-26 WB97R-2
2
Support screws: 35.2 Nm
3
Frontal screw (M8): 32 Nm
Lateral screws (M10): 64 Nm
4
Frontal screws (M10): 64 Nm
Lateral screw (M8): 32 Nm
5
Bracket screws: 45–55 Nm
Screws for intake line: Loctite 262
Screws for intake line: 45–55 Nm
6
High-pressure pipe fittings: 24.5–34.3 Nm
7
Collar lock nuts: 9.8–11.8 Nm
8
★ Check the condition of the seals of the tappet cover and
the O-rings of the fastening nuts. Thoroughly clean the
contact surfaces on the cylinder heads.
Cover fastening nuts: 25±3 Nm
9
★ Check that the tappets are firmly engaged in their rods
and that the valve collars are correctly assembled.
Rods - tappets: Engine oil
Start tightening the rocker-arm shaft from the center to-
wards the outside
Screws and nuts for the rocker-arm shaft:
22.5–28.4 Nm
★ Adjust the valve clearances. (For details, see «20.
TESTING AND ADJUSTMENTS»).
10
★ Assemble a new gasket.
Bolt and cylinder block threadings: Engine oil.
★ Tighten the screws, manually at first, and then in two
stages, following the sequence indicated. BOLTS TIGHTENING ORDER
Cylinder head bolts:

First tightening: 88.3–98.1 Nm
12 3 5 13
Final tightening: 181.4–191.2 Nm 18 10 1 7 15
1 - Start the engine at low idling to circulate the coolant liq- 16 8 2 9 17

uid through all circuits. 14 6 4 11

the container. RKZ00181
WB97R-2 30-27
REMOVAL AND INSTALLATION FRONT COUNTERWEIGHT
REMOVAL OF THE FRONT COUNTERWEIGHT

safety stop.
1 - Partially loosen the screws (1) to eliminate the tighten-

ing torque, and thus to facilitate the subsequent dis-
mantling procedure.
3
1
1
1 3
2
RKZA1840
2 - Insert the prongs of a fork-lift truck into the ventilation

slits, and force them gently upwards to compensate for
the weight of the counterweight (2).
3 - Remove the screws (1) and the washers (3).
4 - Remove the Front counterweight (2).
Counterweight: 300 kg
2
RKZA1850
INSTALLATION OF THE
FRONT COUNTERWEIGHT
1
Screws: 300±30 Nm
30-28 WB97R-2
REMOVAL AND INSTALLATION RADIATOR-OIL COOLER UNIT
REMOVAL OF THE RADIATOR-OIL COOLER UNIT

safety stop.
2
1
1 - Disconnect the safety gas cylinders (1) for opening the
engine hood. Remove the engine hood.
(For details, see «REMOVAL OF ENGINE HOOD»). 1
★ Place some soft material between the engine hood
and the front closing mechanism.
RKZA1860
Completely eliminate all residual pressures in all cir-

cuits. (For details, see «20. TESTING AND ADJUST- 5
MENTS»).
★ Drain the cooling liquid.
Cooling liquid: 18
2
3
3 - Disconnect the cable (3) and remove the acoustic alarm 4

(4).
4 - Remove the air filter suction line (5). RKZA1872

ing unit
Drain the air conditioning unit, and disconnect the tubes
(6), (7). (For details, see «20. TESTING AND ADJUST- 7
MENTS»).
6
3
RKZA8622
6 - Remove the container (8).

10 9
7 - Disconnect the engine coolant circuit hoses (10) and
(11) from the radiator (9). 8
8 - Remove the brackets (12).
11
12
RKZA1742
WB97R-2 30-29
9 - Slowly loosen the hoses (13) and (14) to drain the hy-
draulic oil from the oil cooler (15). When the oil is fully
drained, complete disconnection of the hoses, and plug
them to prevent entry of impurities. 4
14 15
13 RKZA1882
10 - Remove plug (16) to drain the oil from the transmission

oil cooler (17). When the oil is fully drained, complete
disconnection of the hoses (18) and plug them to pre-
vent entry of impurities. 5
17
18
16
RKZA7821
11 - Disconnect the conveyor (19) from the radiator (9) and

move it towards the engine.
19
RKZA9520
12 - Take out the nuts (20) of the lower anti-vibration units

and remove the entire radiator - oil cooler group (9).
13 - Remove the rubber conveyor situated between chassis

and radiator
9
20
20
RKZA7842
30-30 WB97R-2
INSTALLATION OF THE RADIATOR – OIL COOLER GROUP

1
★ First connect the positive pole (+).
2
★ Refill the coolant liquid circuit.
Coolant liquid: 18
3
★ Refill the air-conditioning unit.
Quantity of fluid (R134a): 970±15 g

Quantity of oil: See the amount recovered.
4
★ Ensure that the level of hydraulic oil in the tank is at max-
imum.
5
★ Ensure that the level of transmission oil is at maximum.
1 - Start the engine at low idling to circulate all the fluids and
to fill up the oil coolers.

minute, stop the engine and top up all levels.
★ Check carefully that there are no leaks.
3 - Stop the engine and replace the rubber conveyor.
WB97R-2 30-31
REMOVAL AND INSTALLATION CONDENSER
REMOVAL OF THE CONDENSER

(Only for machines equipped with an air-conditioning unit)
Completely raise the front working equipment and en-
gage the parking brake.
Also place the backhoe in its secure position.
1
6
1 - Drain the air-conditioning unit.
MENTS»).
2 - Disconnect the cable (1) and remove the klaxon (2). 5
2
RKZA8630
3 - Disconnect the tubes (3) and (4)

★ 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 condenser 3

(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
1 - Refill the air-conditioning unit.

Quantity of oil: see the amount recovered.
30-32 WB97R-2
REMOVAL AND INSTALLATION HYDRAULIC OIL COOLER
REMOVAL OF HYDRAULIC OIL COOLER

safety stop.
1 - Disconnect the safety gas cylinders (1) from the engine

hood. Accompany the hood until it is completely open.
★ Place some soft material between the engine hood
1
and the front closing mechanism.
Completely release residual pressures from all circuits.
MENTS»). RKZA1862
2 - Disconnect the cable (2) and remove the acoustic alarm

(3).
7
8
2
3
RKZA1871

ing unit
Remove the condenser (11) without detaching the
tubes, and put it to one side.
11
RKZA8650
4 - Slowly loosen the hoses (4) and (5) to drain the hydrau-
lic oil from the cooler (6). When all the oil has been drai-
ned, disconnect the hoses completely and plug them to 4
prevent entry of impurities. 1
RKZA1881
WB97R-2 30-33
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-
crum screws and washers (10). 7
7 - Remove the rubber conveyor.
6
8
10 9
RKZA7841
INSTALLATION OF THE
HYDRAULIC OIL COOLER
1
★ 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.

minute stop the engine and, if necessary, top up the lev-
el of oil in the tank.
3 - Replace the rubber conveyor.
30-34 WB97R-2
REMOVAL AND INSTALLATION TRANSMISSION OIL COOLER
REMOVAL OF THE TRANSMISSION OIL COOLER

safety stop.
1 - Remove the radiator - oil cooler group.

(For details, see «REMOVAL OF THE RADIATOR - OIL
COOLER GROUP»). 1
3
2 - Loosen the retaining clip (1) of the coupling (2) on the ra-
diator (3). 5
1 2
RKZA0321
3 - Take out the nuts (4) and remove the oil cooler (5).
5
RKZA7850
INSTALLATION OF THE
TRANSMISSION OIL COOLER
1
★ Make sure that the levels of the transmission oil, the hy-
draulic oil and the engine cooling liquid are all at max-
imum.
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.
WB97R-2 30-35
REMOVAL AND INSTALLATION MUFFLER
REMOVAL OF THE MUFFLER

safety stop.
1 - Loosen the retaining clip (1) of the hose (2) and discon-
nect it from frame.
2
1
RKZA9920
2 - Take out screws (3).
RKZA9931
3 - Take out the four screws (4) and remove the complete
muffler (5).
4
5
RKZA9941
INSTALLATION OF THE MUFFLER

★ Put in a new sealant.
30-36 WB97R-2
REMOVAL AND INSTALLATION EXHAUST PIPE
REMOVAL OF THE EXHAUST PIPE

1 - Loosen the clip (1) and disconnect the flexible hose (2).
2
1
RKZA9920
2 - Take out two of the three lower screws (3) of the con-
necting flange (4).
★ Loosen the third screw and leave it in place for safe-
ty.
RKZA0341
3 - Take out the nut (5) and the washer of the upper anti-vi-
bration unit (6).
4 - Take out the last screw (3) and remove the exhaust pipe
6 5
(7).
RKZA0351
INSTALLATION OF THE
EXHAUST PIPE
WB97R-2 30-37
REMOVAL AND INSTALLATION ENGINE HOOD
REMOVAL OF THE ENGINE HOOD

Lower the working equipment completely until it is rest-
ing on the ground. Stop the engine and remove the ig-
nition key.
1 - Open the engine hood (1) take out the safety pins (2) 1
and disconnect the hood from the gas cylinders (3).
RKZA9530
2 - Raise the hood (1) to a vertical position and attach it to

some hoisting tackle.
★ To attach it, use the hole in the opening cavity.
RKZA7880
3 - Take out the two screws (4) and remove the hood (1).
Engine hood: 27 kg 1
4
RKZA7871
30-38 WB97R-2
REMOVAL AND INSTALLATION ENGINE HOOD
INSTALLATION OF THE ENGINE HOOD

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

the screws (5).
5
RKZA9540
WB97R-2 30-39
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.
Release all residual pressure in all circuits.
★ Only for machines equipped with an air-condition-

ing unit
Drain the air conditioning unit.
MENTS»).
1
1 - Disconnect the pedal accelerator and hand accelerator

cables (1) from the injection pump. Disengage the
sheathings from the support (2). 2 2
RKZA0091
2 - Disconnect the braking circuit pipes (4) and the differ-

ential lock tube (5) from the rear axle (3). 4
3
★ Plug the pipes and pipe-fittings to prevent entry of
impurities. 6 3
RKZA9550
3 - Disconnect the steering cylinder pipes (6) from the rear

axle.
★ Mark the positions of the pipes to prevent exchang- 6
ing positions when reconnecting. 6
impurities.
3
4
RKZA9562
30-40 WB97R-2
4 - Disconnectthesteeringcylinderpipes(7)fromthefrontaxle.
5
★ Mark the positions of the pipes to prevent exchang-
ing positions when reconnecting.
impurities.
RKZA9570
5 - Disconnect the pipes of the L-T-P ports (8, 9 and 10)

from the steering unit.
★ Mark the positions of the pipes to prevent exchang-
ing positions when reconnecting. 8
impurities.
9
10
RKZA9580
6 - Disconnect from gearbox the connectors (11) and (12)

and the grounding cable (13). 16
7 - Disconnect the five connectors (14) of sensor, the con-
trol speed connector (15) and the solenoid connector 12 17
(16) from the transmission.
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 disen- 20 21

gagement and backhoe boom disengagement sole-
noids.
18
12 - Disconnect the power increment solenoid connector
(21) installed on the piston pump. 19
RKZA0430
WB97R-2 30-41
13 - Disconnect the connectors (22) of the rear acoustic

alarm, the connector (23) of the rear lights and finally the
connector (24) of the solenoid of the backhoe control
valve.
23
22 24
RKZA0440
14 - Disconnect the heating unit tubes (25) and (26).

(For details, see «REMOVAL OF THE CAB HEATING
GROUP»). 25 29
ing unit.
Disconnect the tubes (27), (28) connecting the unit to
the drying filter (29) and the expansion valve (30).
★ Immediately plug the tubes and the orifices tightly 26 28
to prevent moisture from entering into the air-con-
ditioning circuit.
27 30
RKZA8710
16 - Lift off the lower left-hand guard of the cab and discon-
nect the connector (31) of the fuel level indicator and the
connector of the self-supply pump, if any.
31
17 - Also lift off the lower right-hand guard.
RKZA1922
18 - Remove the floor-mat (32) and remove the lateral cover

(33).
★ Push the protective sleeve (34) of the gearbox lever
down into the side cover (33).
33
34
32
RKZB0031
30-42 WB97R-2
19 - Remove the grips (35) of the outrigger control levers

and lift off the cover (36) of the control levers.
35
20 - Remove the self-locking nuts (37) and the four screws
that secure the cab. 6
21 - Disconnect the hoses (38) and (39) from control valve
37
(40).
36
22 - Remove the protective plugs and screw two eyebolts
“A” into the holes supplied for hoisting purposes.
Attach the cab (41) to the hoisting tackle and apply a
slight tension.
RKZA9600
23 - Slowly raise the cab, directing its movement in such way

that the gear lever slides out.
★ Make sure that all the electrical leads and the ac-
celerator cables are free.
40
Cab: circa 630 kg
38
INSTALLATION OF THE CAB

• To install, reverse the removal procedure. 39
RKZA9990
1
★ Drain and refill the air-conditioning unit

★ Check and adjust the stroke of the hand and pedal ac-
A
celerators. (For details, see «20. TESTING AND AD-
JUSTMENTS»).
3 41
★ Adjust the stroke of the parking brake lever. (For details,
see «20. TESTING AND ADJUSTMENTS»).
★ Bleed the air from the braking circuit.

MENTS»).
★ Bleed the air from the steering circuit. (For details, see
«20. TESTING AND ADJUSTMENTS»).
6
Cab retaining screws: 169±9.8 Nm
RKZA0482
WB97R-2 30-43
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 1
unit.
the ground, and stop the engine.
★ Drain the engine cooling liquid. 6
Coolant liquid: 18
5
1 - Drain the air-conditioning unit.
RKZA8820
MENTS»).
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.
5
6 - Disconnect the connector (8) from the pressure switch
6 3
(7).
RKZA8840
7 - Disconnect the delivery pipe (11) and the return pipe
(12) from the expansion valve (9) and the dryer filter
(10).
★ Immediately plug the tubes and the orifices tightly 8
to prevent moisture from entering into the air-con- 13
ditioning circuit. 7
★ Re-use the O-ring.
6
8 - Loosen the clip and remove the drying filter (10).
★ Immediately plug the delivery tube (11) and the ex- 9 10
pansion valve (9) tightly to prevent moisture from
entering into the air-conditioning circuit.
11
★ Re-use the O-ring.
12
9 - Remove the four screws (13) and remove the group (3). RKZA8711
30-44 WB97R-2
REMOVAL AND INSTALLATION HEAT AND AIR-CONDITIONING GROUP
INSTALLATION OF THE HEATING AND AIR-CONDITIONING GROUP

1 - Refill the cooling liquid.
Coolant liquid: 18
2 - Drain and refill the air-conditioning unit.
Quantity of fluid (R134a): 970±15 g.

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

leaktightness of the air-conditioning unit.
WB97R-2 30-45
REMOVAL AND INSTALLATION FUEL TANK
REMOVAL OF THE FUEL TANK

the ground and stop the engine. 2 3 1
1 - Remove the lower left-hand guard (1) of the cab.
2 - Take the cap (2) off the filling inlet of the fuel tank (3) and
remove also the bottom plug in order to drain the fuel. 6
Fuel: max. 130
5
3 - Remove the nut (4) in order to free the clips (5).
4
RKZA9610
4 - Remove the guard (6), loosen the rods (7) until the bat-
tery (8) is free (8) from the bracket (9).
Disconnect the clamps (10) and (11) and remove the 11
battery (8). 9
8 10
First remove the clamp of the negative battery ter-
minal (8) (–).
7
5 - Disconnect the connector (12) of the level indicator (13)
and the connector (14) of the self-supply pump, if fitted.
6 - Disconnect the fuel suction and flow-back hoses (15)

and (16) and the pipe of the self-supply pump, if fitted.
★ Plug the pipes to prevent entry of impurities. RKZA9491
★ Mark the pipes to avoid exchanging them during in-

stallation.
7 - Remove the screws (17) and the guard (18). 18

8 - Support the fuel tank (3) with hoisting tackle and remove 15 16 14 12
the four retaining screws (19). 1
17
9 - Remove the fuel tank (3).
Fuel tank: 73 kg
13
INSTALLATION OF THE RKZA1923
FUEL TANK
1
Retaining screws for fuel tank: 120 Nm
1 - Refill the fuel tank.

19
Fuel: max. 130
2 - Bleed the air from the fuel circuit.
3 - Start the engine.
RKZA1952
30-46 WB97R-2
REMOVAL AND INSTALLATION HYDRAULIC OIL TANK
REMOVAL OF HYDRAULIC OIL TANK

the ground and stop the engine. 1
2
Eliminate completely any residual pressures from all
circuits.
MENTS»).
1 - Take off the lower right-hand guard (1) of the cab.
2 - Remove the guard (2).

12
3 - Remove the oil drainage cap (3).
★ Drain the hydraulic oil. RKZA9620
Hydraulic oil: 92
4 - Disconnect the lower suction (5) and drainage (6) hoses

from the tank (1).
★ Plug the hoses to prevent entry of impurities.
3
5 - Disconnect the upper pipes (7), (8) and (9), remove the
check valve (10) and the T-piece (11).
★ Make a note of the assembly sequence.
6 - Support the tank (4) with hoisting tackle and remove the
four retaining screws (12). 4
1
7 - Remove the tank (4).
RKZA9630
Oil for the tank: 77 kg
HYDRAULIC OIL TANK
1
Tank retaining screws: 120 Nm
1 - Refill the tank.

6
Hydraulic oil: 92
RKZA9640
2 - Refill the pump (For details, see «20. TESTING AND
ADJUSTMENTS»).
3 - Start the engine to let the oil circulate through all the hy-
draulic systems and check for leaks. 7
10
4 - Bleed the air from the hydraulic systems.
MENTS»).
11
5 - Stop the engine, check the oil level in the tank, and top it 8
up if necessary.
9
RKZA1991
WB97R-2 30-47
REMOVAL AND INSTALLATION ENGINE-GEARBOX-PUMP GROUP
REMOVAL OF THE ENGINE-GEARBOX-PUMP GROUP

1
MENTS»).
★ Drain the hydraulic oil.

Hydraulic oil: 92
2 1
★ Drain the engine cooling liquid. RKZA2000
Coolant liquid: 18
★ Drain the oil from the gearbox.

Gearbox oil: 16 3
4
ing unit.
Drain the air conditioning unit.
MENTS»).
2 - Remove the front working equipment.

(For details, see «REMOVAL OF THE FRONT WORK-
ING EQUIPMENT»). RKZB0050
3 - Take off the engine hood.

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

(For details, see «REMOVAL OF THE RADIATOR-OIL 6
COOLER GROUP»).
6 - Lift the protection (3), disconnect connector (4). RKZA9660
2
7 - Disconnect rear cardan shaft (7) from transmission (6).
3
8 - Remove front cardan shaft (8). 3
RKZA9571
30-48 WB97R-2
9 - Disconnect the suction hose (10) and the drainage pipe

(11) from the pump (9).
Disconnect also the power increment solenoid connec-
9
tor.
4
★ Plug the pipes to prevent entry of impurities.
10
11
RKZA9670
10 - Disconnect the Load Sensing signal pipe (12) and the

delivery pipe (13) from valve (14).
14
13
12
RKZA9411
11 - Disconnect from the transmission (15) the solenoid

valve (16) connectors and the oil cooling circuit pipes 16 16
(17).
15
17
RKZB0040
12 - Disconnect from thermostat (19) and from speed sen-

sor (20) the sensors (18) connectors. 18
19
18
18
20
RKZO3270
WB97R-2 30-49
13 - Disconnect from the engine the sensor (21) and (22)
14 - Disconnect the cab heating pipes (23) from the coolant

21
pump. 22
23
RKZA7890
15 - Disconnect the connector (24) of the oil pressure sensor

and the connector (25) of the solenoid that stops the en-
gine.
24
25
RKZA0660
16 - Disconnect the cable (26) of the cold-start equipment,

the cab heating-pipe support clip (27), and the fuel tank
flow-back hose (28). 5
27
28
26
RKZA1762
17 - Disconnect the cables (29) of the pedal and hand ac-

celerators. Disengage the support sheathing (30).
30
29
RKZA0092
30-50 WB97R-2
18 - Disconnect the fuel lines (32) from the separator (31)

and plug them. 32
19 - Remove the separator.
31
RKZA0670
20 - Disconnect the cables (33) from the starting motor (34)

and the cables (35) from the alternator (36).
33
35
36
34
RKZA0680

41 39
ing unit.
Save the coolant R134a and disconnect the delivery
tubes (38) and suction tubes (39) from the compressor
(37).
★ Immediately plug the tubes and orifices tightly to
prevent moisture from entering into the air-condi- 37
tioning circuit.
38
★ Disconnect the air-conditioning unit connectors
(40) and (41).
40
RKZA8575
22 - Remove the plate (42) and push it towards the back of

the machine.
42
RKZA9690
WB97R-2 30-51
23 - Disconnect the flexible return hose (44) from the muffler

(43).
44
43
RKZB0060
24 - Attach the entire group to some hoisting tackle using the

engine bracket (45) and the muffler support (46). Apply
a slight tension to the hoisting chains.
45 46
RKZA0702
★ The chains should have a total length of about 800 mm

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

mm apart at the height of the muffler.
RKZA1640
25 - Loosen and remove the nuts (47) of the anti-vibration

supports (48) of the engine and gearbox, and take out
the screws (49).
6
49 48
26 - Raise the entire group until the chassis supports are dis- 48
engaged, and than accompany the group in order to 47
slide it away from the front part of the chassis.
Engine-gearbox-pump group: 740 kg 47 49
RKZA9700
30-52 WB97R-2
INSTALLATION OF THE ENGINE GEARBOX-PUMP GROUP

1 - Fill the hydraulic oil tank up to its maximum level.
Hydraulic oil: 92
2 - Fill the gearbox up to its maximum level.
Gearbox oil: 16
3 - Refill the coolant liquid.
Coolant liquid: 18
4 - Drain and refill the air-conditioning unit.

1
Screws for front counterweight: 300±30 Nm
2
Screws on gearbox side: 70 Nm
Screws on gearbox side: Loctite 262
3
Nut on axle side: 70 Nm
4
★ Fill up the pump casing and the pump, to bring the tank
up to pressure.
For the method see «20. TESTING AND ADJUST-
MENTS».
5
★ Bleed the air from the fuel lines.
6
Nuts from the anti-vibration supports:
196±19.6 Nm
4 - Start the engine to circulate the oil and coolant liquid.

Check that there are no leaks.
5 - Use a leak detector to check the leaktightness of the de-

livery and return pipes of the air-conditioning unit com-
pressor.
6 - Bleed the air from the working equipment circuits.

MENTS»).
7 - Stop the engine, check the levels and, if necessary, top

them up.
WB97R-2 30-53
REMOVAL AND INSTALLATION PISTON PUMP
REMOVAL OF THE PISTON PUMP

Release residual pressure fully in all circuits. 1
MENTS»).
★ Drain the hydraulic oil. 2

Quantity of oil: 92
3
RKZA9671
1 - Disconnect the suction hose (2) and the drainage pipe

(3) from piston pump (1). 1 6
2 - Disconnect the delivery pipe (4) and the Load Sensing
signal line (5).
3 - Disconnect the solenoid connector (6) 4
RKZB0010
4 - Take out the rear cardan shaft (7).

2 3
1
5 - Attach under pump (1) a pit jack and a suitable support.
8
RKZA9710
6 - Take out the two screws (8) and remove the pump (1)
complete with its O-ring (9). 3 1
Pump: 40 kg
RKZA9720
30-54 WB97R-2
REMOVAL AND INSTALLATION PISTON PUMP
INSTALLATION OF THE PISTON PUMP

1 - Fill the tank with hydraulic oil up to maximum level.
Hydraulic oil: 92
★ Fill the pump body and the pump, bringing the tank
up to pressure.
For the method, see «20. TESTING AND ADJUST-
MENTS».
1
Screws for suction flange: 100 Nm
Screws for delivery flange: 60 Nm
2
Screws on gearbox side: Loctite 262
Nut on axle side: 70 Nm
3
Pump retaining screws: Loctite 262
Pump retaining screws: 220 Nm
2 - Start the engine to circulate the oil in all hydraulic cir-

cuits.
3 - Stop the engine, check the oil level in the tank and, if
necessary, top it up.
WB97R-2 30-55
REMOVAL AND INSTALLATION TRANSMISSION
REMOVAL OF THE TRANSMISSION

Make the backhoe safe.


MENTS»).
★ Drain the hydraulic oil. 1

Hydraulic oil: 92
★ Drain the oil from the gearbox. 2

Gearbox oil: 16
1 - Remove the piston pump. (For details, see «REMOVAL 1
OF THE PISTON PUMP»). 3
2
2 - Raise the lever (1) protective sleeve, disconnect the
connector (2) of the transmission disengagement.
4
RKZB0051
3 - Disconnect the pipe (3) that fills the gearbox with oil.
5
4
4 - Take out the front cardan shaft (4). 6
3
RKZA9731
5 - Take off the cover (5) of the flywheel oil-sump and take
out the six retaining screws (6) of the converter coupling
flange (7). 7 5
7 6
RKZA9741
30-56 WB97R-2
6 - Disconnect the connectors (9) of the solenoids and the

tubes (10) for oil circulation and controls from transmis- 9 9
sion (8).
10
RKZB0041
7 - Disconnect the connectors from sensors (11), from

thermostat (12) and from speed sensor (13). 11
12
11
11
13
RKZO3271
8 - Remove the plate (14) and push it towards the back of

the machine.
14
RKZA9692
9 - Attach the engine-gearbox group to the hoisting tackle

using the engine bracket (15) and the muffler support
(16). Apply tension to the hoisting chains.
15 16
RKZA2081
WB97R-2 30-57
10 - Loosen and remove the nuts (17), and screws (18) and
the anti-vibration nuts (19). 8
11 - Remove the gearbox supports (20). 9
19
19
17 18
18 17
20
RKZA9761
12 - Attach in the place of the supports (20) a support with

spacer “A” and mounted it on a pit jack “B” which can be
lowered by approx. 60 cm.
★ Secure the support with the screws “C”. C
C
A
B
RKZA9771
13 - Loosen and remove the twelve screws (21) that hold the
engine and gearbox together. 10
14 - Remove the entire gearbox, by shifting it towards the
back of the machine in order to disengage the conver- 21
tor. Lower it slowly and turn the group in a clockwise di-
rection to disengage it from the chassis in order to
extract it.
Transmission: 230 kg
RKZA8770
30-58 WB97R-2
INSTALLATION OF THE TRANSMISSION

1
Hydraulic oil: 92
Gearbox oil: 16
3
★ Fill the pump body and the pump in order to pressurise
the tank.
MENTS».
4
Screws for securing lever: 120 Nm
5
Screws: Loctite 262
6
7
Flange screws: Loctite 262
Flange screws: 70 Nm
8
Anti-vibration nuts: 196±19.6 Nm
9
Support screws: Loctite 262
Support screws: 90 Nm
10
Engine-gearbox screws: Loctite 262
Engine-gearbox screws: 90 Nm
1 - Start the engine to circulate the oil. Check that there are
no leaks.
2 - Bleed the air from the working equipment circuits. (For

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

them up.
WB97R-2 30-59
PAGE INTENTIONALLY
LEFT BLANK
DISASSEMBLY AND ASSEMBLY OF TRANSMISSION

1. Disassembly converter
2
1
RKZ06380
1- Drain oil from transmission hydraulic circuit and remove

torque converter (1). 1
RKZB1540
2 - Remove fastening screws (2) of bellhousing (3).
3
RKZ06390
WB97R-2 30-61
3 - Remove bellhousing (3).
3
RKZ06400
4 - Remove seal (4)
4
RKZ06410
2. Assembly converter
1 - Locate seal (4) on bellhousing (3).
3
RKZ06420
2 - Fit bellhousing (3) to transmission.
3
RKZ06400
30-62 WB97R-2
3 -Insert bellhousing (3) fastening screws (2).
Screw: 170 Nm
3
RKZ06390
4 - Fit converter (1).

Turn the torque converter until engaging the relative 1
splined shafts.
RKZB1540
WB97R-2 30-63
3. Disassembly plugs and filters
2
3
4 1
RKZ06430
1 - Drain oil from transmission hydraulic circuit and remove

oil drain plugs (1). Clean the magnet.
RKZB1550
2 - Remove oil filling/drain plug (2).
RKZB1560
30-64 WB97R-2
3 - With a filter wrench remove filter (3).
RKZB1570
4 - Remove plug (4) and clean the magnet.
RKZB1580
5 - Remove filter (5).

★ Filter must be replaced every disassembly.
4
RKZB1590
4. Assembly plugs and filters

1 - Assemble filter (5). 5
RKZB1600
WB97R-2 30-65
2 - Assemble plug (4).
Plug: 80 Nm
RKZB1580
3 - Apply a thin film of grease on filter (3) seal and assem-

ble. Tighten by hand.
3
RKZB1610
4 - Assemble oil drain plugs (1).
Plug: 25 Nm
RKZB1550
30-66 WB97R-2
5. Disassembly oil pump
4
RKZ06440
1 - Drain oil from transmission hydraulic circuit. Remove

screws (1).
★ Mark pump position before remove the screw.
RKZB1620
2 -Remove the oil pump (2) by means of tool C1

★ Take a care to not damage the oil pump seal. 2
C1
4
RKZB1631
WB97R-2 30-67
3 -Remove O-ring (3) and seal ring (4).
RKZB1640
6. Assembly oil pump

1 - Assemble seal ring (4) on oil pump (2). Use tool C2.
C2 4
RKZB1651
2 - Fit O-ring (3).
RKZB1660
3 - Before oil pump assembly, check that oil passage holes

between pump (2) and half-case or the visual marks co- 2
incide.
RKZB1670
30-68 WB97R-2
4 - Apply a thin film of grease on the coupling seat with the

front half-case.
5 - Assemble the oil pump (2). 2
RKZB1680
6 - Fit screws (1).

★ Make sure that the marks on oil pump and bell-
housing are aligned.
Screw: 23 Nm
1
RKZB1620
WB97R-2 30-69
7. Disassembly pipes and sensors
11
3 10
4
1
8 9
24 17 20
7
2 5
27
6
21
16
15 22
25 18
26 23
12 28
14
13 19 RKZ06450
1 - Drain oil from transmission hydraulic circuit, disconnect

all electrical connections and untighten 3rd speed pipe
upper fitting (1).
RKZB1690
30-70 WB97R-2
2 - Untighten 3rd speed pipe lower fitting and remove pipe

(2).
RKZB1700
3 - Remove 3rd speed antishock valve (6).
RKZB1730
4 - Untighten 1st speed pipe upper fitting (3).

3
RKZB1710
5 - Untighten the 1st speed pipe (4) and lower fitting (5).
4
RKZB1720
WB97R-2 30-71
6 - Remove 1st speed antishock valve (7).
RKZB1740
7 - Remove 4 th speed pressure sensor 2 bar (8).
RKZB1750
8 - Remove 1st speed pressure sensor 2 bar (9).
9
RKZB1760
9 - Remove pressure sensor 11 bar (10).
10
RKZB1770
30-72 WB97R-2
10 - Remove oil temperature sensor (11).
11
RKZB1780
11 - Remove screws (12) of sensor cover.
12
RKZB1790
12 - Remove sensor cover (13) and relative seal (14).
14 13
RKZB1800
13 - Remove sensor/inductor (15) and O-ring (16).

15
16
RKZB1810
WB97R-2 30-73
14 - Untighten FWD delivery pipe (18) and upper fitting (17).
17
18
RKZB1820
15 - Untighten FWD delivery pipe (18) and lower fitting (19).
18
19
RKZB1830
16 - Untighten upper fitting (20) and 2nd speed delivery pipe

(21).
20
21
RKZB1840
17 - Untighten lower fitting, 2nd speed pipe (21) and upper fit-
ting (20).
18 - Remove pipe (21) and fitting (20). 21
RKZB1850
30-74 WB97R-2
19 - Remove 2nd speed antishock valve (22) and lower fit-

ting (23).
22
23
RKZB1870
20 - Untighten 3rd speed pipe upper fitting (24).
24
RKZ06450
21 - Untighten 4th speed pipe (26) lower fitting (25) and re-
move pipe.
25
26
RKZB1860
22 - Remove 2nd speed pressure sensor 2 bar (27).
27
RKZB1880
WB97R-2 30-75
24 - Remove 4th speed pressure sensor 2 bar (28).

28
RKZB1890
8. Assembly pipes and sensors

1 - Assemble 1st speed antishock valve (7).
★ Make sure that arrow is directed towards clutch.
Valve: 50 Nm
RKZB1900
2 - Assemble lower fitting (23) and 2nd speed antishock

valve (22).
Valve: 40 Nm
22
23
RKZB1910
3 - Assemble 3rd speed antishock valve (6).

Valve: 25 Nm
RKZB1920
30-76 WB97R-2
4 - Assemble 2nd speed pipe (21) and tighten fitting (20).
Pipe: 26–30 Nm
Fitting: 40 Nm 20
21
RKZB1930
5 - Assemble 1st speed pipe (4) and tighten fitting (3).
Pipe: 26–30 Nm
3
Fitting: 40 Nm
4
RKZB1940
6 - Assemble 3rd speed pipe (2) and tighten fitting
Pipe: 26–30 Nm
Fitting: 40 Nm
RKZB1950
7 - Assemble FWD delivery pipe (18) and tighten fittings.

18
Pipe: 26–30 Nm
Fitting: 40 Nm
RKZB1960
WB97R-2 30-77
8 - Assemble 4th speed pipe (26) and tighten fittings.
Pipe: 26–30 Nm
Fitting: 40 Nm
26
RKZB1970
9 - Assemble oil temperature sensor (11).

Sensor: 23 Nm
11
RKZB1780
10 - Assemble pressure sensor 2 bar (8), 3rd speed.
Sensor: 25 Nm
8
RKZB1750
11 - Assemble pressure sensor 2 bar (9), 1st speed.
Sensor: 25 Nm
RKZB1980
30-78 WB97R-2
12 - Assemble pressure sensor 11 bar (10).
Sensor: 25 Nm 10
RKZB1770
13 - Assemble pressure sensor (28) 2 bar 4th speed.

28
Sensor: 25 Nm
RKZB1890
14 - Assemble pressure sensor (27) 2 bar 2nd speed.

Sensor: 25 Nm
27
RKZB1880
15 - Assemble O-ring (16) and sensor (15) by centering it on

its reference pin.
15
16
RKZB1990
WB97R-2 30-79
16 - Assemble seal (14) and its sensor cover (13).

13
14
RKZB2000
17 - Assemble screws (12).

Screw: 23 Nm
12
RKZB2010
30-80 WB97R-2
9. Disassembly hydraulic control valve
6
4
8
5
1 7
RKZ06470
1 - Drain oil from transmission hydraulic circuit.
2 - Disconnect all electrical connections.
3 - Untighten all the fitting of the delivery pipes connected

with the control valve.
RKZB1841
WB97R-2 30-81
4 - Unscrew screw (1) fixing the control valve on transmis-

sion.
1
RKZB2020
5 - Lift control valve (2) and remove seal (3).
RKZB2030
6 - Untighten the solenoid valve retaining nut (4).
7 - Remove O-ring (5), solenoid valve (6) and O-ring (7).
4 5 6 7
RKZB2040
8 - Untighten solenoid valve inductor (8).
RKZB2050
30-82 WB97R-2
10. Assembly hydraulic control valve

1 - Assemble solenoid valve inductor (8).
RKZB2050
2 - Assemble O-ring (7), solenoid valve (6), O-ring (5) and

then tighten nut (4) by hand.
4 5 6 7
RKZB2040
3 - Assemble seal (3) on transmission.
RKZB2060
4 - Assemble control valve (2).

2
RKZB2070
WB97R-2 30-83
5 - Assemble screws (1) and tighten them in a cross se-

quence.
RKZB2080
6 - Assemble all the fittings of the delivery pipes connected

with the control valve.
RKZB1941
30-84 WB97R-2
11. Disassembly transmission housing
A
15
14
17 11
35 16
12
36
32 13
19
B
20 18
1 27
31
25
A 26
E
9
7 8 28
6 29
5 30
21
4 34 23 22
2 37
10
33
E 3 RKZ0660
1 - Drain oil from transmission hydraulic circuit.

1
2 - Remove bearing retaining ring (1).
RKZB2090
WB97R-2 30-85
3 - Remove flange retaining screw (2), washer (3) and O-

ring (4). Use tool C3. to avoid flange rotation.
2 3 4
RKZB2620
4 - Remove flange (5).
RKZB2630
5 - Remove screws (6), cover (7) and O-ring (8).
7 8
RKZB2120
6 - Remove bearing (9).
RKZB2130
30-86 WB97R-2
7 - Remove oil seal (10). Use tool C4.
C4 10
RKZB2141
8 - Remove screws (11).
11
RKZB2150
9 - Remove flange (12) and O-ring (13).

13 12
RKZB2160
10 - Remove transmission shaft PTO (14); by pushing lightly

on the opposite side.
14
RKZB2170
WB97R-2 30-87
11 - Remove retaining ring (15).
15
RKZB2180
16
RKZB2190
13 - Extract bearing (17) with tool C5.
C5
17
RKZB2201
14 - Remove screws (18) and cover (19).

19
18
RKZB2640
30-88 WB97R-2

20
RKZB2220
21
22
RKZB2650

23
RKZ06610
18 - Remove flange retaining screw (24), washer (25) and O-

ring (26). Use tool C3.
24 25 26
RKZB2660
WB97R-2 30-89
19 - Remove flange (27).
27
RKZB2670
29
28
RKZB4790

30
RKZB2680
22 - Remove oil seal (31). Use tool C4.
C4 31
RKZB2281
30-90 WB97R-2
23 - Tap with a rubber hammer from the opposite side until

removing bearing retaining ring (36) from the contact 36
with the housing.
Then extract with a normal extractor.
RKZ06620
32
RKZB2290
33 RKZB2300
26 - Insert a lever in the special slot “A” and remove the cover
(34) and (36).
36
34
RKZB2310
WB97R-2 30-91
27 - Lift the front half-housing (34). Use tool C6.

C6
34
RKZB2321
12. Assembly transmission housing

1 - Replace O-ring (35). 35
RKZB2330
2 - Apply a thin film of Loctite 510 on the rear half-housing

(36).
36
RKZB2340
3 - Using tool C6, locate front half-housing (34) on rear half-

housing (36).
C6
34
36
RKZB2351
30-92 WB97R-2
Screw: 50 Nm
32
RKZB2290

Screw: 50 Nm 33
RKZB2360
6 - Assemble bearing retaining ring (1).
1
RKZB2370
7 - Assemble bearing (9). Use tool C7.
RKZB2380
WB97R-2 30-93
8 - Assemble seal ring (10) on cover (7).
10
C4
RKZB2391
9 - Assemble O-ring (8) and cover (7).

7
RKZB2400
Screw: 50 Nm
RKZB2410
11 - Assemble flange (5), O-ring (4) and washer (3).
3
RKZB2690
30-94 WB97R-2
12 - Assemble screw (2). Use tool C3 to avoid flange rota-

tion.
Screw: 50 Nm
RKZB2430
13 - Assemble bearing (30).

30
RKZB2680
14 - Apply a thin film of Loctite 510.
RKZB2720
15 - Assemble seal ring (31) on cover (29). Use tool C4.
C4 31
29
RKZB2462
WB97R-2 30-95
16 - Assemble cover (29) and tighten with screw (28).
Screw: 139 Nm
29 28 RKZB2470
17 - Assemble flange (27), O-ring (26) and washer (25).
27
26
25
RKZB2740
18 - Assemble screw (24). Use tool C3 to avoid flange ro-

tation.
Screw: 139 Nm
24
RKZB2750
19 - Using tool C8, assemble bearing (36).
36 C8
RKZB2442
30-96 WB97R-2
20 - Assemble retaining ring (23).

23
RKZ06610
RKZB2720
22 - Assemble cover (22) and tighten screws (21).

Screw: 50 Nm
22
21
RKZB2770
20
RKZB2530
WB97R-2 30-97
RKZB2540
25 - Assemble cover (19) and tighten screws (18).

19
Screw: 50 Nm
18
RKZB2800
26 - Assemble bearing (17) on transmission shaft PTO (14).
14
17
RKZB2560
16
RKZB2570
30-98 WB97R-2
15
RKZB2580
29 - Insert transmission shaft PTO (14) to the stroke.
14
RKZB2590
30 - Assemble O-ring (13) and apply a thin film of grease on

the flange inner diameter (12).
13
12
RKZB2600

Screw: 50 Nm
11
RKZB2610
WB97R-2 30-99
13. Disassembly shaft A
42 16
D 16
16
41 10
11
32
9 31
17 33
8 17
7
17
5
3 4
2 36
1
37
40
A
24 A
30
27
6 12
38
20 27 21
22
19 23
34 26
15 18 34
14 13 25
34
26
39
29
28
35
35
RKZ06500 35
1 - Grasp with pliers shaft assembly A and shaft assembly

D and lift.
D
A
RKZB2810
30-100 WB97R-2
2 - Widen and remove rotary seal (1).
RKZB2820
3 2
RKZB2830
4 - By means of an extractor remove bearing (3).
RKZB2840
5 - Remove spacer (4) and washer (5).

4
RKZB2850
WB97R-2 30-101
6 - Remove spring pin (6).
RKZB2860
7 - Remove gear (7).
RKZB2870
8 - Remove roller retainers (8) and washer (9).
9
RKZB2880
9 - Lower stop washer (11) to allow retaining ring (10) re-

moval. Use a drift and a hammer.
11
10
RKZB2890
30-102 WB97R-2
10 - Remove retaining ring (10) and stop washer (11).

11
10
RKZB2900
11 - Lower spring retaining cover (15). Remove spring pin

(12). Use tool C9 and a hydraulic press.
12
RKZB2910
14
RKZB2920
13 - Remove spring retaining cover (13) and spring (15).

13
15
RKZB2930
WB97R-2 30-103
14 - Remove disc pack (16) and counterdiscs (17).

17
16
RKZB2940
15 - Remove clutch piston (18) by blowing in compressed air

through the delivery hole.
18
RKZB2950
19
RKZB2960
20 RKZB2970
30-104 WB97R-2
18 - Widen and remove rotary seals (38).
38
RKZB2980
21
RKZB3000
20 - Remove bearing (22) by means of an extractor.
22
RKZB3010
21 - Remove bearing (23)

22
23
RKZB3020
WB97R-2 30-105
24
RKZB3030

25
RKZB3040
24 - Remove roller retainers (26), spacer (27) and washer

(39).
27
26 39
RKZB3050
25 - Lower stop washer (28) to allow retaining ring (29) re-

moval. Use a drift and a hammer.
29
28
RKZB2891
30-106 WB97R-2
26 - Remove retaining ring (29) and stop washer (28).

29
28
RKZB3060
27 - Lower spring retaining cover (33). Remove spring pin

30
RKZB3070
32
RKZB3080

31
33
RKZB3090
WB97R-2 30-107

35
34
RKZB3100

through the delivery hole. 36
RKZB3110
32 - Remove rotary seal (37).
37
RKZB3120
40 RKZB4800
30-108 WB97R-2
34 - Remove shaft D axle bearing (41) by means of an ex-

tractor.
41
RKZB3130
35 - Remove shaft D axle bearing (42) by means of an ex-

tractor.
42
RKZB3140
14. Assembly shaft A

1 - Insert rotary seal (40).
40
RKZB3150
2 - Insert rotary seal (37) on clutch piston (36).
36
37
RKZB3160
WB97R-2 30-109
3 - Apply a thin film of grease on the outer edge and in the in-
ner part of clutch piston (36).
36
RKZB3170
4 - Insert spring (33), spring retaining cover (31).
5 - Lower the spring retaining cover (33). Insert retaining

ring (32). Use tool C9 and a hydraulic press.
31
32
33
RKZB3180
6 - Assemble spring pin (30), align the hole with the cover
notch (31).
31 30
RKZB3190
7 - Insert washer (39), roller retainers (26) and spacer (27).
26
27
26
39
RKZB3200
30-110 WB97R-2
8 - Assemble disc pack (34), counterdiscs (35) and stop

washer (28) on gear (25).
35
34
28
25
RKZB3210
9 - Insert the assembly by means of two screwdrivers.
RKZB3220
10 - Lift gear (25) to allow retaining ring (29) assembly.
25
29
RKZB3230
11 - Assemble spring pin (24).
24
RKZB3240
WB97R-2 30-111
12 - Assemble washer (23), bearing (22) and insert retaining

ring (21). Use tool C8.
21
22
23
RKZB3250
13 - Insert and close rotary seal (38).
38
38
RKZB3260
14 - Insert rotating seal ring (20).
20
RKZB3270

19
18
RKZB4810
30-112 WB97R-2
ner part of clutch piston (18) and insert.
18
RKZB3280
17 - Insert spring (15) and spring retaining cover (13) and lov-
er the spring retaining cover.
18 - Insert retaining ring (14). Use tool C9 and a hydraulic

press.
14
13
15 RKZB3290
12
RKZB3300
20 - Insert washer (9) and roller retainers (8).
RKZB4820
WB97R-2 30-113
21 - Assemble disc pack (16), counterdiscs (17) and stop

washer (10) on gear (7).
17
16
10
RKZB3310
RKZB3320
23 - Lift gear (7) to allow retaining ring (11) assembly.

7
11
RKZB3330
RKZB3340
30-114 WB97R-2
25 - Assemble washer (5), spacer (4) and bearing (3). Use

tool C8.
RKZB3350
26 - Insert retaining ring (2). Insert and close rotary seal (1).
RKZB3350
27 - Check for proper operation by blowing in compressed air

into the special hole, about 6 bar.
RKZB3360
28 - Assemble D shaft bearing (41). Use tool C100.

C10 41
RKZB3371
WB97R-2 30-115
29 - Assemble D shaft bearing (42). Use tool C10.

C10
42
RKZB3381
30 - Reposition shaft assembly D.
RKZB4840
31 - Reposition shaft assembly A.
RKZB4960
30-116 WB97R-2
15. Disassembly shaft B
16
16
14
12
13
11 15
10 15
7 B
9 15
5 6
24
4 25
3 1 26
2
B
17
18 8
23
22
21
RKZ06490 19 20
1 - Lift the three shafts B-C-E, at the same time. Use tool
C11. C11
RKZB3401
WB97R-2 30-117
RKZB3390
RKZB3410
4 - Remove spacer (3).
RKZB3420
5 - By means of an extractor remove bearing (4).
RKZB3430
30-118 WB97R-2

4
RKZB3440
7 - Remove spacer (6) and washer (7).
RKZB3450
RKZB3460
RKZB3470
WB97R-2 30-119
10 - Remove roller retainers (10) and washer (11).
10
11
RKZB3480
11 - Slightly press stop washer (12).
12
RKZB3490
13
RKZB3500
13 - Remove stop washer (12) by means of two screwdriv-

ers.
12
RKZB3510
30-120 WB97R-2
14 - Remove Belleville washer (14), disc pack (15) and

counterdiscs (16).
16
15
14
RKZB3520
17
RKZB3530
16 - Lower spring retaining cover (20). Remove retaining

19
20
RKZB3540
18
20
RKZB3550
WB97R-2 30-121

through the delivery. 22
19 - Remove the rotary seal (22).
21
RKZB3560
23
RKZB3570
21 - Remove retaining ring (24) and washer (25).
24
25
RKZB3590
RKZB3600
30-122 WB97R-2
16. Assembly shaft B

C10 26
RKZB3611
2 - Insert washer (25) and assemble retaining ring (24).
24
25
RKZB3620
3 - Insert and close rotary seal (23).
23
RKZB3630
21
22
RKZB3640
WB97R-2 30-123
ner part of clutch piston (21). 21
RKZB3650
6 - Insert clutch piston (21), spring (20) and spring retaining

cover (18).
7 - Lower spring retaining cover (20) and insert retaining

19
18 20
RKZB3660
17
RKZB4850
9 - Insert washer (11) and roller retainers (10).
10
11
RKZB3670
30-124 WB97R-2
10 - Assemble disc pack (15), counterdiscs (16), Belleville

washer (14) and stop washer (12) on gear (9). 15 16
14
12
RKZB3680
RKZB3690

13
RKZB3700
RKZB3710
WB97R-2 30-125
14 - Assemble washer (7), spacer (6) and gear (5).
6
5
RKZB3720
C7 4
RKZB3731
16 - Insert spacer (3) and assemble retaining ring (1).

1
RKZB3740
17 - Insert rotary seal (2).

2
RKZB3750
30-126 WB97R-2

RKZB3360
19 - Lift the three shafts B-C-E at the same time and insert
into the rear half-housing. Use tool C11. C11
RKZB3771
WB97R-2 30-127
17. Disassembly shaft C
13
13
13
49
C 51
5
2 3 4 53
55
12
12
12
12 52
11
30
10 9 54
56 30
6 30
7 50
14 31
1 8
20 29
19 29
18 C
16 29
15 17
27 38 39
40
28 39
48 41 24
48 42 38
43
25
45
44 21
46 22
37
47 23
47 36 26
35
34
33
RKZ06510 32
1 - Lift the three shaft B-C-E at the same time. Use tool C11.
C11
RKZB3401
30-128 WB97R-2
RKZB3780
RKZB3790
4 - Remove washer (3).
RKZB3800
5 - By means of an extractor remove bearing (4), phonic

wheel (5) and gear (6).
4
5
RKZB3810
WB97R-2 30-129
6 - Remove roller retainers (7) and pin (8).
7
8
7
RKZB3820
RKZB3830

10
RKZB3840
9 - Remove the pack including stop washer (9), Belleville

washer (11), discs (12) and counterdiscs (13). 9
11
12
13
RKZB3850
30-130 WB97R-2
10 - Remove washer (15) and spring pin (14).
15
14
RKZB3860
11 - Lower spring retaining cover (18) and remove retaining

17
18
RKZB3870
12 - Remove spring retaining cover (16), spring (18).

16
through the delivery hole. Remove the rotary seal (20). 18
19
20
RKZB3880
24
RKZB3910
WB97R-2 30-131
15 - By means of an extractor remove 1st speed gear (25)

and bearing (26).
26
25
RKZB3920
16 - Slightly lower stop washer (27).

27
RKZB3930

28
RKZB3940
18 - Remove stop washer (27) by means of two screwdriv-

ers. 27
RKZB3950
30-132 WB97R-2
29
30
RKZB3960
20 - Remove Belleville washer (31).
31
RKZB3970
21 - Lower spring retaining cover (34) to allow retaining ring

removal (32). Use tool C9 and a hydraulic press.
32
34
RKZB3980
23 - Remove retaining ring (32), spring retaining cover (33)

32
and spring (34).
33
34
RKZB3990
WB97R-2 30-133

through the delivery hole. Remove rotary seal (36). 35 36
RKZB4000
37
RKZB4860
26 - Remove roller retainer (38), bushings (39) and spacer

(40).
38
39 40
38
39
RKZB4870

41
RKZB4010
30-134 WB97R-2
42
RKZB4020
29 - Remove roller retainers (43).
43
RKZB4030
30 - Slightly lower stop washer (44).
44
RKZB4040

45
RKZB4050
WB97R-2 30-135
32 - Remove stop washer (44) by means of two screwdri-

vers.
44
RKZB4060
33 - Remove Belleville washer (46), discs (47), counterdiscs

(48) and washer (49).
46
47 48
RKZB4070
34 - Remove spring ring (50).
50
RKZB4080
35 - Lower spring retaining cover (53). Use tool C9 and a hy-

draulic press.
53
RKZB4090
30-136 WB97R-2
36 - Remove retaining ring (51), spring retaining cover (52)

and spring (53).
51
52
53
RKZB4950

through the delivery hole. Remove rotary seal (55). 55
54
RKZB4100
18. Assembly shaft C

55
54
RKZB4110
54
RKZB4120
WB97R-2 30-137

cover (52).
52
53
54
RKZB4130

51
53
RKZB4140
5 - Insert stop washer (44), Belleville washer (46), discs

(47) and counterdiscs (48) on gear (42).
48
47
46
42
44
RKZB4150
50
RKZB4160
30-138 WB97R-2
7 - Apply a thin film of grease under washer (49) to avoid its

falling when overturning the shaft.
49
RKZB4170
8 - Align discs (47), counterdiscs (48) and stop washer (44).
9 - Insert the preassembled main shaft (56).

56
47 48
44 RKZB4180
10 - Insert roller retainers (43).
43
43
RKZB4190
45
RKZB4890
WB97R-2 30-139
12 - Lift retaining ring (45) with a screwdriver to insert into its

seat.
45
RKZB4200
13 - Insert and close rotary seal (37) on gear (25).
25 37
RKZB4900
14 - Insert and close rotary seal (36) on clutch piston (35).

35 36
RKZB4210
ner part of clutch piston (35). 35
RKZB4220
30-140 WB97R-2

cover (33). 33
34
35
RKZB4230
17 - Lower spring retaining cover (34) and assemble retai-

ning ring (32). Use tool C9 and a hydraulic press. 32
34
RKZB4240
18 - Insert gear (41), roller retainers (38), bushings (39) and

spacer (40) on main shaft. 38
39
40 39
38
41
RKZB4250
19 - Insert stop washer (27), disc pack (29), counterdiscs 56

(30) and Belleville washer (31) on main shaft (56) mak- 30
ing sure they are all aligned.
29 31
27
RKZB4260
WB97R-2 30-141
20 - Insert gear assembly (25) on main shaft (56).

25
56
RKZB4270
21 - Assemble retaining ring (28) making sure it is correctly

seated.
28
RKZB4280
22 - Insert and close rotary seals (24).
24
RKZB4290

26
C8
RKZB4301
30-142 WB97R-2
24 - Insert and close rotary seal (20) on clutch piston (19).
19
20
RKZB4320
19
RKZB4330
26 - Insert clutch piston, spring (18) and spring retaining cov-

er (16).
16
18
RKZB4340

17
18
RKZB4350
WB97R-2 30-143
14
RKZB4360
29 - Apply a thin film of grease under washer (15) to avoid its

falling when overturning the shaft.
15
RKZB4370
30 - Insert stop washer, Belleville washer, discs (12) and

counterdiscs (13) on gear (6).
12
11
13
6
9
RKZB4910
31 - Insert roller retainers (7).
RKZB4380
30-144 WB97R-2
32 - Insert gear (6) with the disc pack on the main shaft.
6
RKZB4390
33 - Locate the pack assembly by means of two screwdriv-

ers.
RKZB4400
34 - Lift gear (6) for retaining ring assembly.
RKZB4410
35 - Assemble retaining ring (10) and gear.
10
RKZB4420
WB97R-2 30-145
36 - Assemble pin (8).
8
RKZB4920
37 - Assemble phonic wheel (5).
RKZB4430

C7
4
RKZB4441
39 - Insert washer (3) and retaining ring (2).

2
RKZB4450
30-146 WB97R-2
40 - Insert rotary seals (1).
RKZB4460
41 - Lift the three shafts B-C-E at the same time and insert the
unit into the half-housing. Use tool C11. C11
RKZB4471

RKZB3760
WB97R-2 30-147
19. Disassembly shaft E
2
16
2 15
17
6
4
5 17
4
3 17
13
E 19 18 E
18
9 1 18
7 21
22
23
11 20
10
12
8 14 RKZ06530
1 - Lift the three shafts B-C-E at the same time. Use tool
C11. C11
RKZB3401
30-148 WB97R-2
RKZB4480
3 - Lower Belleville washers (2) and remove retaining ring

★ Take care not to damage the Belleville washers.
3
C9
2
RKZB4491
4 - Remove washers (4) and spacers (5).
4
3
RKZB4500
5 - Remove spacer (6) and Belleville washers (2).
6 2
RKZB4510
WB97R-2 30-149
6 - Remove clutch piston (7) from its seat. To remove the pi-
ston blow compressed air into output shaft. 19
RKZB4520
7 - By means of an extractor remove clutch piston (7).
RKZB4530
8 - Remove O-rings, inner (8) and outer (9).

9
8
RKZB4540
9 - Remove the three pins (10) and the relative O-rings (11).
10
10
11
10
RKZB4930
30-150 WB97R-2
12
RKZB4550
14
RKZB4560
15
RKZB4570

16
RKZB4580
WB97R-2 30-151
14 - Remove stop washer (15).

15
RKZB4590
15 - Remove disc pack (17), counterdiscs (18) and brake ac-

tuating disc (13). 17
18
13
RKZB4600
16 - Remove spacer (22).
22
RKZB4610
17 - Remove bearing (23) by means of two levers.
23
RKZB4620
30-152 WB97R-2
18 - Remove all bearing (23) parts.
23
RKZB4630
20. Assembly shaft E

1 - Assemble bearing (14) and the relative retaining ring 12
(12). Use tool C12.
14
RKZB4640
2 - Insert inner (8) and outer (9) O-rings on clutch piston (7).
9
RKZB4650
3 - Insert O-rings (11) on the relative pins (10).
10
11
RKZB4660
WB97R-2 30-153
4 - Position the pins (10) on clutch piston (7) in correspond-

ence with the holes on output shaft and insert clutch pi-
ston.
7
RKZB4670
5 - Insert stop ring (15), disc pack (17), counterdiscs (18)

and brake actuator (13) on gear (20). 15
18
17
20
13
RKZB4940
6 - Assemble shaft (19) on gear (20).
19
20
RKZB4680
7 - Insert shaft (19) by using a rubber hammer.
19
RKZB4690
30-154 WB97R-2
8 - Assemble retaining ring (16) after lifting gear (20).
16 20
RKZB4700
9 - Make sure that the disc pack, the counterdiscs and the
piston are correctly seated.
RKZB4710
10 - Preassemble spacer (6), washers (4) and retaining ring

(3). 3
RKZB4720
11 - Insert retaining ring (3) to measure dimension X.

Calculate the shim S with this formula:
S=X–(S1+S2)
S1 = retaining ring (3)

S1
S2 = washer thickness (4)

3
X
S2
S
5
RKZB4730
WB97R-2 30-155
12 - Insert Belleville washers (2), spacer (6), washers (4) and

shims (5).
4
2
5
RKZB4740
13 - Lower Belleville washers (2) and assemble retaining

3
C9
2
RKZB4491
14 - Insert a pressure of about 10 bar with an oil pump to

check the seal of ring (8) and (9). Use tool C13. 9
C13
8
RKZ06521
15 - Insert rotary seals (1).
RKZB4750
30-156 WB97R-2
C14
23
RKZB4761
17 - Insert spacer (22).
22
RKZB4770
18 - Using tool C11, lift the three shafts B-C-E at the same
time and insert the unit into the half-housing.
RKZB4780
WB97R-2 30-157
PAGE INTENTIONALLY
LEFT BLANK
REMOVAL AND INSTALLATION CONVERTOR
REMOVAL OF THE CONVERTOR

1
the ground and stop the engine. 2
MENTS»).
★ Drain the hydraulic oil.
Hydraulic oil: 92
★ Drain the oil from the gearbox. RKZA8730
Gearbox oil: 16
1 - Remove the piston pump. (For details, see «REMOVAL

OF THE PISTON PUMP»). 1
2 - Remove the gearbox.
(For details, see «REMOVAL OF THE GEARBOX»).
3 - Slide the convertor (1) away from the gearbox shafts

(2), (primary and secondary).
★ If necessary, use two levers applied in opposed po-
sitions.
★ Take great care not to damage the centering hub of
the gearbox.
INSTALLATION OF THE
CONVERTOR
★ Engage the two shafts (primary and secondary) by
slowly rotating the body of the convertor.
1 - Refill the tank with hydraulic oil up to maximum level.
Hydraulic oil: 92
1
★ Fill the pump body and the pump, bringing the tank
up to pressure.
MENTS».
2 - Refill the gearbox.
Gearbox oil: 16
3 - Start the engine to circulate the oil in all circuits. Check
that there are no leaks.
4 - Bleed the air from the working equipment circuits. (For
details, see «20. TESTING AND ADJUSTMENTS»)
them up.
WB97R-2 30-159
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
the ground, and stop the engine. 1
Raise the cable from battery negative terminal (–).
1 - Remove four nut (1) and divide the transmission-re-

verse (2) from direction and headlight dipper beam con-
trol group (3).
RKZA8660
2 - Remove two screw (4) and guard (5).
3
4
5
RKZA8670
3 - Raise the protective sleeve (6) and disconnect the con-

nector (7); remove the direction and headlight dipper 6
beam control group. 7
RKZA8680
4 - Rotate in counterclockwise direction the ring (8) and

disconnect the control group (2).
INSTALLATION OF THE
TRANSMISSION REVERSE,
DIRECTION INDICATOR AND
8
HEADLIGHT DIPPER BEAM 2
CONTROL GROUP
RKZA8690
30-160 WB97R-2
REMOVAL AND INSTALLATION STEERING UNIT
REMOVAL OF THE STEERING UNIT

wrench.
Release all residual pressure in all circuits. 2 1
MENTS»).
1 - Disconnect the five pipes (2) from the steering unit (1)
and plug them to prevent entry of impurities. 1
★ Mark the positions to prevent exchanges during re- RKZA0870
connection.
2 - Remove the central guard (3) beneath the steering

wheel.
3 5
RKZA8700
3 - Remove the guard (4) raise the protective sleeve (5)

and disconnect the connectors (6) and (7).
4 - Disconnect the connector (8) and the relay (9).

7
5 - Loosen the steering column (11) retaining screws (10)
and the steering unit (1).
6 - Remove screw (10) and remove the steering unit (1).
6
INSTALLATION OF THE
STEERING UNIT RKZA8890
1
★ Bleed the air from the Load Sensing circuit. 11
MENTS»). 8
9
★ Start the engine and perform several complete steering 10
manoeuvres in both directions, to bleed the air out of the
steering system.
RKZA9791
WB97R-2 30-161
REMOVAL AND INSTALLATION WORKING BRAKE PUMP GROUP
REMOVAL OF THE WORKING BRAKE PUMP GROUP

1
2 7
1 - Remove the cap (1) of the oil tank (2) and draw out the oil 5
contained inside it. 3
7
2 - Disconnect the connectors (3).
4
3 - Remove the oil tank (2). 6
4 - Remove the clip (4) that holds the delivery lines (5). 8
RKZA9800
5 - Remove the delivery lines (5) from the pumps (6).

1
6 - Take out the four screws (7) and remove the pump
group (6).
2
★ If only one pump is to be removed, also disconnect
the pressure- equalizing pipe (8).
3
INSTALLATION OF THE
WORKING BRAKE PUMP GROUP
1
★ Bleed the air from the braking circuit.
MENTS»).
2
★ Make sure that the push-rods (9) center the seating of
the pistons.
9 10
★ After installation, check the idle stroke and parallelism
RKZA0911
of the brake pedals and, if necessary, adjust the cou-
pling microswitches for 4-wheel brake control. (For de-
tails, see «20. TESTING AND ADJUSTMENTS»).
3
Pipe fitting: 20 Nm
30-162 WB97R-2
REMOVAL AND INSTALLATION FRONT WORKING EQUIPMENT CONTROL VALVE
REMOVAL OF THE FRONT WORKING EQUIPMENT CONTROL VALVE

wrench.
3
MENTS»).
1 - Remove the mat (1) and disengage the protective

sleeves (2), (3).
RKZB0071
2 - Take out the screws (4) and remove the guard (5).
3
5
1 4
RKZB0032
3 - Disconnect the spool control tie-rods (7) from the con-

trol valve (6). 7
4 - Disconnect from the control valve all pipes and lines for
the actuators (8), pump delivery (9), drainage (10), Load 6
Sensing (11) and steering unit delivery (13), and plug
them.
★ Mark the pipes to avoid exchanging positions dur-
ing reconnection.
5 - Take out the four control valve retaining screws.
6 - Remove the control valve (6).

RKZA8780
INSTALLATION OF THE FRONT

WORKING EQUIPMENT
6 9
CONTROL VALVE 11
• To install, reverse removal procedure.
1 - Start the engine to circulate the oil, and check that there 12
are no leaks.
8
2 - Bleed the air from all circuits.
10
MENTS»).
11
3 - Stop the engine and check the oil level in the tank. RKZA9992
WB97R-2 30-163
REMOVAL AND INSTALLATION FRONT AXLE
REMOVAL OF THE FRONT AXLE

1 - Start the engine and force the front bucket downwards
in order to raise the machine and the front wheels.
2 - Place two stands “A” and some blocks beneath the

chassis.
3 - Slowly lower the machine onto the blocks, checking that

the wheels remain at least 5 cm above the ground.

safety stop. A
1
RKZA0940
4 - Engage the parking brake.

1
5 - Stop the engine and eliminate residual pressure from all
circuits. (See «20. TESTING AND ADJUSTMENTS»).
6 - Take off the front wheels (1). 2

1
Wheel: 65 kg
7 - Remove the front guard (2).

(For details, see «REMOVAL OF FRONT GUARD»).
2 3
RKZA0591
8 - Disconnect the cardan shaft (4) from the axle (3).

5
3
9 - Disconnect the lines (5) from the steering cylinder and
plug them to prevent entry of impurities. 4 5
6
10 - Disconnect the lubrication tube (6) for the axle oscilla-
tion pin (7).
3
RKZA9572
11 - Position a jack “B” and some blocks “C” beneath the ax-
le. Raise the jack until the blocks can be forced under
the axle arms (3). 3
★ It should be possible to lower the jack 10 cm in order
to disengage the axle from the fulcrum supports. C
B
RKZA1670
30-164 WB97R-2
12 - Take out the nut and remove the retaining screw (8) of
the axle oscillation pin (7).
13 - Screw an eyebolt into the central hole of the axle oscil- 8

lation pin (7). Extract the axle oscillation pin. 5
14 - Lower the jack until the axle is disengaged.
15 - Extract the entire axle (3).
Front axle: 316 kg 7
RKZA2120
INSTALLATION OF THE
FRONT AXLE
1
Nuts for front wheels: 350±9.8 Nm
2
Front closing screws: 300±30 Nm
3
Self-locking nuts on axle side: 70 Nm
4
★ Bleed the air from the Load Sensing circuit.
MENTS»).
5
Axle oscillation pin - bushings: ASL800050
1 - Check the oil level in the tank and start the engine.
2 - Perform a few complete steering manoeuvres in both di-

rections to bleed the air from the steering circuit.
WB97R-2 30-165
DISASSEMBLY OF FRONT AXLE

1. Steering cylinder group disassembly
3 2
1 - Unloose the guide rod (2) locknut (1) of some turns till it
is over the end of the threaded pin.
Beat on the nut (1) with a hammer in order to disjoin the
guide rod (2) from the swivel housing (3).
★ Don’t beat on the end of the threaded pin.
★ This is a destructive operation for the nut.
3 1
RKZB5580
2 - Remove the guide rod link (4) by unloosing the nut (5)
with a suitable wrench, then check its conditions. 4
3 - Unscrew the fastening screws (6) of the cylinder, then 7

take the cylinder (7) out of its housing and, if necessary,
use a rubber hammer.
6
5
★ Remove only that parts that need to be overhauled
and/or replaced. 4
5
RKZ07110
4 - Detach the cylinder head (8) from the cylinder case (10).
Remove off the cylinder head and the rod (9) from the 10
cylinder case.
5 - Remove all the sealings and O-Rings (11), both from 9

the cylinder head and the rod.
8
11
RKZ07120
2. Epicyclic reduction gear disassembly

2
Before draining the oil, position the wheel hub (1) with
the plug (2) on the upper part and loosen it of some turns
in order to eliminate any possible inner pressure, then
remove it completely. Turn the wheel hub upside-down
till the hole is in the lowest point.
Drain the oil completely.
RKZB0101
30-166 WB97R-2
1 - Unscrew and remove both fastening screws (3) and the

2 stud bolts (4) of the planetary carrier with a standard
wrench. 3
★ Don’t ruin the thread of the two stud bolts.
2 - Remove the planetary carrier from the wheel hub.
Position the planetary carrier on a workbench and che-
ck its wear conditions.
4
RKZ07130
2.1 Replacements of the planetary gears

(if necessary) 9
1 - Remove the snap ring (5). 8

5
2 - Remove the thrust washer (6).
3 - Take the planetary gears (7) out of the pins (8).

7
6
4 - Collect the needle bearings (9), checking their condi- 10
tions.
5 - Remove the thrust washers (10).

RKZ07140
★ With new planetary gears is advisable to assembly new

roller bearings.
3. Wheel hub group disassembly 2
Before disassembling the wheel hub, it is advisable to

1
secure it with a belt or a rope on a hoist or any other sup-
porting device, in order to avoid its accidental fall that
could damage either the operator or the wheel hub
group.
1
1 - Remove the steel lock ring (1) from the axle shaft (2) by
using a suitable plier.
2
2 - Remove and collect the lock ring, the sleeve (3) and the 4
spacer (4) from the axle shaft. 3 RKZB0131
3 - Unscrew and remove the fastening screws (5) from the 6

wheel carrier (6) group.
5
RKZB0140
WB97R-2 30-167
4 - In order to remove the wheel carrier group (6) from its

housing, screw (5) at least two of the just removed
screws in the threaded extraction holes “A”.
6
A
RKZB0150
5 - Extract and remove the wheel carrier (6) together with

the epicyclic ring gear (8).
6 - Remove the steel lock ring (7) and disjoin the wheel car- 9
rier (6) from the epicyclic ring gear (8).
★ Check the wear conditions of the components.
7 - Only if necessary, remove the centering bushes (9) of
the hub lock ring gear with a hammer and the special
tool D1.
6
7
8
RKZB5590
8 - Remove the hub (10), using levers and a hammer to fa-

cilitate the operation.
★ Collect the bearing cone (11).
10
11
RKZB0170
9 - Position on a flat surface the hub and take the seal ring
out (12) with a lever. 13
★ This is a destructive operation for the seal ring.
10 - Take the bearing cups out (11) and (13), on both sides of
the hub, using a hammer and a suitable tool to be be-
aten.
12
11 - Remove the bearing cone (13) from the swivel housing
end, using a suitable extractor.
10
11
RKZ07150
30-168 WB97R-2
12 - Unscrew and remove the fastening screws (14) from the

upper (15) and lower (16) king pin.
14
Before removing the king pins, secure the swivel

housing with a belt or a rope to a hoist or any other
supporting device.
15
13 - Remove the king pins (15) and (16).
16
RKZB5620
14 - Remove the swivel housing (17) from the axle beam

and from the short shaft (18) of the U-Joint.
18
17
RKZB0211
15 - Position the swivel housing (17) on a flat surface and

take the seal ring (19) out with a lever.
★ This is a destructive operation for the seal ring. 17
16 - Turn the swivel housing (17) and take the bush (20) out,
19 20
using a driver and a hammer.
RKZB5630
4. Axle beam group disassembly

1 - Remove the U-Joint (1) from the axle beam.
RKZ07160
WB97R-2 30-169
2 - Take the seal ring (2) out of the axle beam with a lever.
★ This is a destructive operation for the seal ring. 9 4
3 - Remove the cup springs (4) and (8) from the king pin 5
housings in the axle beam. 3
4 - Remove thickiness (9) from the upper part of axle beam. 2
5 - Remove the bush (3) from the beam with a suitable ex-
tractor.
★ Examine the bush before the removal and replace it 6
only if the wear conditions require this.
2 8
RKZ07170
6 - Take the upper (5) and lower (6) bushes out of the king
pin housings (7) and out of king pin with a suitable ex-
tractor. 7
RKZ07400
7 - Remove the seal rings (10) from the pivot with a suitable
tool. 10
★ Destructive operation for the seal rings.
If necessary, replace the bushings with a standard
three-gripping point extractor or a suitable driver and a
hammer.
RKZB5500
5. Differential support group disassembly

1 - Remove the fastening screw (1) and the nut (2) from the
flange (3).
Using a small chisel, detach the oil seal cover just enou- 2
gh to fit a lever. 1
2 - Remove the oil seal cover from the central beam as-
sembly, using two levers.
RKZ07180
30-170 WB97R-2
3 - Remove the seal ring (4) from the oil seal cover, using a
suitable tool.
RKZB5480
4 - Put the O-ring (5) from the oil seal cover in a safe place.
RKZB5490
5 - Loosen and remove the screws on the differential sup-

port (6).
Remove the differential carrier (6).
Support the differential carrier with a rope or other

appropriate means.
RKZ07190
6 - Loosen and remove the screws (7) to remove the two

ring nut retainers (8). 7
RKZ05281
WB97R-2 30-171
7 - Before removing bolts, mark halfbridles (9) and the dif-

ferential carrier with permanent reference marks to avo-
id inverting them when re-assembling the unit. Mark the 9
9
area between the ring buts and the differential carrier as
well.
RKZ05291
8 - Unscrew the adjuster ring nuts (10) using tool D2 and a

wrench. 10
10
D2
RKZ05302
9 - Loosen and remove the 4 screws (11) and remove the 2

half-collar (9). 11
RKZ05311
10 - Take out the differential case (12). 13

★ Take care not to loose the cups bearing (13) that
are removed together with the differential case
12
(12).
13
★ Not mismatch the cups of the bearings (13) if they
are not to be replaced. 14
★ Check that the bushes (14) remains in their hou-
sings.
RKZ05321
30-172 WB97R-2
6. Pinion group disassembly

1
1 - Fit the differential carrier (1) in a vise.
2 - Unscrew the lock nut using special tools D3 and D4. D4

★ This operation will irretrievably damage the ring
nut.
D3
RKZ05330
3 - Remove the ring nut (2) and collect its retaining washer
(3).
3
2
RKZ07200
4 - Tap the shaft with a soft hammer to remove the bevel pi-
nion (4). 6
★ Take care not to drop the pinion.
5 - Collect the washers (5), the collapsible spacer (6) and
the inner cone of the tapered roller bearing (7).
7
5
4 RKZ05350
6 - Place the differential carrier on a flat surface as shown in

the figure and remove the outer cups of the taper roller
bearing (7) using a driver and a hammer.
RKZ05360
WB97R-2 30-173
7 - To remove the inner cone of the tapered roller bearing

(7) of the pinion (4), use a standard extractor.
8 - Collect the bearing cone and the underlying shim (8).
RKZ05370
9 - Check all pinion components for wear.

The ring nut and the snap spacer must be replaced
when reassembling the unit.
RKZ07370
7. Differential group disassembly

1 - Collect the differential (1) and put it in a clamp.
2 - Unscrew all the fastening screws (2) of the bevel gear

crown (3).
★ This will make both differential half boxes free, so 3
take care not to drop the internal components.
3 - Remove the bevel gear crown. 2
1
RKZB0570
4 - Disassemble the differential box in two half boxes (3)

complete with the relevant components. 4
5 - Recover the components from both half boxes.
6 - Check the operating and wear conditions of the com-

ponents.
4 5
7 - Take the bearing (5) out of the differential half box (4),
using two levers or a three-hold extractor.
5 RKZ07210
30-174 WB97R-2
ASSEMBLY OF FRONT AXLE

1. Pinion group assembly
1 - Place the differential support (3) on a workbench.
1
2 - Fit the outer cups of the new bearings (1) and (2) using
the special tool D5 and a hammer. 3
RKZ05380
3 - In order to measure the distance, use the kit consisting

of the special tools called “false pinion” D6 and “false dif-
ferential box” D7 e D8.
3
4 - Insert the false pinion with D6, together with its bearings
and its ring nut (4), in the just mounted housings for the D8
D8
bearings.
Tighten without exceeding, till the backlash is elimina-
ted.
D7 D6
4
RKZ07230
5 - Install special tools D7 and D8 to the differential group

supports and screw in the half collar bolts (5) and (6).
6 5
D7
5
D8
RKZ07240
6 - Use a deep gauge to take the measurement “X”.

★ Write down the “X” measurement.
RKZ07250
WB97R-2 30-175
7 - Make a note of the value “V” marked on the head of the

pinion.
Calculate the thickness “S” to be installed beneath the V
pinion, using the formula:
S=X--V
107.00
“S” is the thickness of the shim. 00
RKZ05080
9 - Mount the shim (8) onto the pinion (7) and press the in-
ner bearing (1) using the tool D9. 9
★ The chamfer on the inner diameter of the shim must 10
face the toothing. 1
10 - Mount onto the pinion the first washer (9), the new spac- 9
er (10) and the second washer (9).
8
7 7
RKZ07430
11 - Insert the bevel pinion unit (7) into the differential sup-
port housing (3) (from the internal axle side) and the se- 2
3
cond bearing cone (2) into the pinion end, from the
opposite side.
★ In order to force the second bearing into position,
use the special tool D9 and a hammer.
7
RKZ05351
12 - Insert a ring nut washer (11) and screw a new lock ring
nut (4) on the pinion end.
11
4
RKZ07260
30-176 WB97R-2
13 - Screw the ring nut in, using the wrench for ring nut D3
and for pinion retainer D4.
★ The torque setting is given by the preloading me-
asurement on bearings. Tighten the ring nut gra-
dually. D3
★ If the tightening is excessive, the elastic spacer
must be replaced and the procedure repeated.
When you check the preloading, it is advisable to
beat slightly both pinion ends with a soft hammer,
so as to help setting the bearings.
D4
RKZ05332
14 - Wind a wire line round the pinion, uniformly and without

overlapping. Connect it to a dynamometer and check
the force “P” required to rotate the shaft.
The force should be that needed for continual ro-
tation.
Do not take into consideration the thrust force.
15 - Using the tools mentioned in point 13, tighten the lock
nut (4) taking dynamometric measurements at intervals
until the indicated force “P” has been obtained.
P= (9.2–13.7) daN P
If the maximum permissible value is exceeded, a new RKZ07270
spacer must be fitted and all the bearing pre-loading
operations must be repeated.
2. Differential group assembly

1 - Assemble the cones of the new taper roller bearings (1) 2
on the half boxes (2), using the special tool D10 and a
hammer. 2
1
RKZ07221
2 - After occurate cleaning and after checking both the ope-

ration conditions and the components wear, it is possi-
ble to assemble the differential parts.
RKZ07380
WB97R-2 30-177
3 - Position a half box on a workbench and assemble all its

inner components (sun gears, planetary gears, thrust 2
washers pin and differential lock counterdiscs) as illu-
strated in the figure.
Join the two half boxes (2).
RKZ07211
4 - Position the ring bevel gear (3) and then fix the whole by
tightening the screws (4).
3
Screw: 95 Nm
Screw: Loctite 270 4
RKZB1290
3. Differential carrier group assembly

1 - Position the complete differential box (1), with the outer
1
cups (2) of the tapered roller bearings already assem-
bled, on the differential carrier. 2
Take care not to invert the outer races of the tape-

red roller bearings and check you are working on
the right side of the bevel crown assembly.
RKZ05600
2 - Place the differential group and the two halfbridles (3)

4
and bolts in their seat.
Check the right position of the halfbridles with the pre-
viously-traced reference marks. 3
Position and tighten slightly the halfbridles bolts (4). 3
RKZ07290
30-178 WB97R-2
3 - Assemble and tighten the two adjustment ring nuts (5) in

5
the differential support with tool D2, so as to pre-load the
differential bearings slightly. Knock lightly with a soft
hammer in order to properly set the bearings in position.
★ Take care not to reverse the ring nuts; align the pre-
viously-traced reference marks. 5
D2
RKZ05303
4 - Position a magnetic-base dial gauge “A” on the differ-

ential carrier, so that the feeler stylus touches the sur-
face of one tooth of the crown gear with a 90° angle. A
Lock the pinion and move the crown gear alternatively
and note the pinion-ring gear backlash, measured with
the comparator.
Repeat the operation on 2 or more points (teeth), rotat-
ing the crown gear, so that to obtain an average value.
Permissible backlash: 0.18 – 0.25 mm
RKZ05620
5 - If the measured backlash is lesser than the given to-

lerance range, screw the ring nut from the side opposite
to the ring gear and unscrew the opposite one of the
same measure.
If the measured backlash is higher than the given to-
lerance range, screw the ring nut from the side of the
ring gear and unscrew the opposite one of the same me-
asure.
★ Before measuring the clearance, knock lightly on
the bearing covers with a mallet to ensure that they
are securely positioned.
RKZ05640
6 - Tighten screw (4).

4
RKZ05630
WB97R-2 30-179
7 - Using the same method employed to check the pinion

rotation torque, check the force “T” required to rotate the
entire group.
★ Force required:
(P+3.9) < T < (P+5.9) daN
P= the force found for the pinion
★ The force should be that of continual rotation. Do
not take the thrust force into consideration.
8 - If the force is not within permissible limits:
a - Tighten both the lock nuts to the same extent to in- T
crease the force “T”.
RKZ07300
b - Loosen both the lock nuts to the same extent to de-
The clearance between the ring bevel gear and the
pinion must remain within permissible limits.
9 - Check the centering of the contact area using the fol-

lowing procedure:
a - Coat both surfaces of the teeth of the ring bevel
gear with a marking substance.
b - Rotate the pinion.
If the contact area is excessive near to the edge of the
teeth, the ring bevel gear must be brought closer to the
pinion.If the contact area is excessive on the side of the
teeth, the ring bevel gear must be moved away from the
RKZ01840
pinion.
RKZ01850
10 - Tighten the bolts (4).
Screw: 266 Nm
4
RKZ07310
30-180 WB97R-2
11 - Once you have completed adjustment operations, fit

the adjuster nut (6) retainers screws (7). 7
Screw: 13 Nm 6
RKZ05690
12 - Fit the seal ring (8) in the bevel pinion cover (9) with spe-
cial tool D11. D11
RKZB5560
13 - Fit new O-ring (10) onto the bevel pinion cover (9).
10
9
RKZB5570
14 - Assemble the bevel pinion cover (9) with a suitable be-

ater.
★ Do not damage the O-ring (10).
RKZ07320
WB97R-2 30-181
15 - Before matching two surfaces make sure they are per-

fectly clean. Degrease and clean with the appropriate
cleaner. Spread a film of Loctite 510 on the contact sur-
face between the axle beam and the differential carrier.
Position the differential carrier (11) on the axle housing.
Re-place and tighten retaining screws (12) to the pre-
scribed torque with a torque wrench. 12
Screw: 169 Nm
11
RKZ07191
16 - Insert the flange (13) on the pinion end.

Fit the flange fastening screws (14) with the relative nuts
on the flange (13).
Tighten screws and nuts with dynamometric wrench to 13
the requested torque.
Screw: 56 Nm
14
RKZ07330
4. Axle beam group assembly 1 2

1 - Assemble two new bushings (1) respectively (assemble
the longer bushing from the bevel pinion side) and two
new seal rings (2) in the central unit pivot by using spe-
cial tools D12 and D13.
D12 D13
RKZB5470
2 - Assemble the upper king pin bush (3) and (4) on the axle
beam with the special tool D14 and a hammer. 3 D14
★ To make the assembly easier, it is suggest to cool 3
the cup of the ball bearing at a temperature less
than –100°C.
D14
4
4
RKZB5650
30-182 WB97R-2
3 - Assemble the bush (5) on the axle beam with the special
tool D15 and a hammer.
5 6
4 - Assemble the seal ring (6) on the beam with the special
tool D16 and a hammer.
Fill ¾ of the seal ring cavity with grease.
D15 D16
RKZB1002
5 - Lubricate the bush (5) and the seal ring lip (6).
Insert the U-Joint (7) inside the axle beam.
★ Be careful not to damage the seal.
RKZB0252
5. Wheel hub group assembly

1 - Force the bush (1) into the swivel housing (2) with the
special tool D17 and a hammer or a press. D18 D17
2 - Assemble the seal ring (3) on the swivel housing (2) with 1 3
the special tool D18 and a hammer.
Fill ¾ of the seal ring cavity with grease.
2
RKZB1012
3 - Position the lower king pin (4) on a workbench and as-

semble the cone of the spherical joint (5) with the special 6
5
tool D19 under a press. Put the shim under the Belleville
washer on the upper part.
Grease well the king pin housings with specific grease.
4 - Position the Belleville washers (6) on the king pin hou- 4

sings.
6
RKZB5660
WB97R-2 30-183
5 - Secure the swivel housing (7) group with a rope.

Lubricate the seal ring lip and protect the splined end of 7
the axle shaft by winding it with thin adhesive tape to
8
avoid damage to the seal ring. After assembly, remove
completely the adhesive tape. Assemble the swivel
housing on the axle beam.
10
6 - Assemble the two king pins, the upper (9) and the lower
(8), and tighten the retaining screws (10).
Screw: 190 Nm 9
★ Make sure that the Belleville washers remain in the-
ir position. RKZB1411
7 - Position the wheel hub (11) on a workbench and force

both cups of the taper roller bearings (12) e (13) in po- 13 14
sition with the special tool D20 under a press or with a 12
hammer.
8 - Insert the seal ring (14) into the wheel hub (11) with the
special tool D21 and a hammer.
D20 D21
D20 11
RKZB1423
9 - Assemble the cone of the taper roller bearing (13) on the

swivel housing end (7). 7 11
10 - Assemble the wheel hub (11) on the swivel housing (7) 13

and fit the other cone of the taper roller bearing (12) in
position.
12
RKZB1432
11 - Position the wheel carrier (15) on a workbench and for-

ce the bushes (16) to the carrier surface level with the
special tool D1. 16
At least two bushes (diametrically-opposed) should be
set slightly higher than the carrier surface level to be
used as dowel pins.
15
RKZB1092
30-184 WB97R-2
12 - Preassemble the wheel carrier-epicyclic ring gear

group (17) and (18) with the special locking ring (19) 18
shown in figure.
17
19
RKZ05732
13 - Assemble the wheel carrier group (20) on the wheel hub

using the two projecting bushes (16) as dowel pins and
screw the relative screws in order to put in contact the 20
ring bevel gear with the wheel hub.
16
RKZB1102
14 - Force all the hub dowel bushes completely with the spe-
cial tool D1 and a hammer. 20
Assemble the wheel carrier (20) fastening screws (21) 21
and tighten.
Screw: 230 Nm
RKZB1442
15 - In the case the bearings (22) and (23) are substituted,

verify that the measure “A”, “B” and “C” are in the limits.
A = 17.950 – 18.000
B = 64.275 – 64.325 23
C = 23.070 – 23.172 22
C A C
RKZ05742
WB97R-2 30-185
16 - Slide the spacer (24) onto the axle shaft of the double
joint, fit the sleeve (25) and assemble the lock ring (26)
by inserting it at the end of the splined hub and pushing
it into its housing. 26
25
26
24 RKZB0132
6. Epicyclic reduction gear assembly

2
1 - Position the planetary carrier on a workbench.
2 - Insert the planetary gear (1) the rolls (2), the upper trust
3
washers (3), the snap rings (4) and the plate (5) in the
planetary carrier pins.
1
5
4
RKZ07142
3 - Assemble the epicyclic reduction gear on the wheel

hub.
Apply Loctite 542 on hub side thread of the 2 special 6
stud bolts.
4 - Screw in the fastening screws (6) and the 2 stud bolts (7)
and tighten with dynamometric wrench.
Screw: 80 Nm
Stud: 70 Nm
7
RKZ07131
7. Steering cylinders group assembly

1 - Assemble new seal rings (1) on the cylinder head (2), on 4
the piston (3) and on the cylinder body (4).
2
RKZ07340
30-186 WB97R-2
2 - Slide pre-assembled rod into the cylinder body (4).
RKZB0092
3 - Fit the guide rods (5) to the ends of the cylinder rod and
tighten with dynamometric wrench.
Guide rod: 300 Nm

5 5
4 - Install the steering cylinder on the central body, with gui-
de rods (5) already assembled on the stem. 6
5 - Install the spacer flange.
6 - Assemble and tighten the steering cylinder fastening

screws (6) with dynamometric wrench.
Guide rod: 120 Nm

RKZB5460
7 - Align the swivel housings with the axle (parallel wheel

hub).
Screw the guide rod (5) so that the ball joint can be in-
serted into the swivel housing arm. 7 5
★ It is important to unscrew the locking nut (7) to carry
out this operation.
RKZB1162
8 - Insert the ball joint (8) (into its own housing on the swivel
housing.
Assemble and tighten the lock nut (9) with dynamome- 8
tric wrench.
Lock nut: 220 Nm
9 - Screw in the lock nut (7) of the guide rod (5) only when
the toe-in adjustment has been carried out.
RKZB1172
WB97R-2 30-187
8. Toe-in adjustment
1 - Put two equal one-meter-long linear bars “A” on the A
wheel sides and lock them with two nuts on the wheel
hub stud bolt.
★ The two bars should be fixed on their middle so that
they are perpendicular to the supporting surface
and parallel to the pinion shaft axis.
Align the two bars.
50 cm 50 cm
RKZB1190
2 - Measure the distance in mm “M” between the bar ends

with a tapeline.
Keep the minimum value, swinging the measurement
point. M
RKZB1200
3 - Check that the difference of the measurements betwe-

en the wheel hubs diameters ends is within the reque-
sted tolerance range.
The nominal toe-in (A) value is referred to the external
A -0 2
diameter of the wheel hubs flange,therefore the mea-
sured toe-in value (M) at the bars ends must be related
to the ratio between lenght of the bar anf flange diame-
ter.
nominal toe-in = A --0 2
measured toe-in = M --0 5
A
M -0 5
M
RKZ07350
30-188 WB97R-2
4 - If toe-in is incorrect, operate with two wrenches on the

guide rods screwing in and out the two joint tie rods
equally till the toe-in is within the requested tolerance.
RKZB1210
5 - After adjusting, screw in the lock nuts of the guide rods.
Lock nut: 250 Nm
RKZB1221
9. Steering angle adjustment

A
1 - Use the same bars “A” assembled for the toe-in adju-
stment and a long bar perfectly leant over the machined
part of the central body (pinion side), so that the two bars
form an acute angle at the maximum steering.
RKZB1230
2 - Adjust a goniometer to the angle of 50° and position it on

the long bar.
Move a wheel side till it forms, with the two bars, the an-
gle fixed by the goniometer.
RKZB1240
WB97R-2 30-189
3 - Adjust the steering mechanical retainer, screwing in or

out the special screws (1) on the bar body, locking them
with a locknut (2). 2 1
Lock nut: 150 Nm
Steer completely towards the other side and repeat the

same operations.
RKZB1250
30-190 WB97R-2
REMOVAL AND INSTALLATION REAR AXLE
REMOVAL OF THE REAR AXLE

1 - Lower the backhoe outriggers (1) and force them down-
wards in order to raise the rear wheels (2) by approx. 5 2
cm.
2 - Prepare a safety stand “A”, approx. 65 cm high, beneath

the backhoe chassis. Pull up the outriggers until the ma-
chine is resting on the stand “A”.
3 - Stop the engine and take off the rear wheels (2).
1
Wheel: 163 kg 1 A
1
RKZA2130
4 - 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.TESTING AND ADJUST-
MENTS»).
RKZA2140
6 - Disconnect the parking brake cable (4) and the differ-

ential lock tube (5) from the rear axle (3). 2 4
7 - Disconnect the cardan shaft (6) from the rear axle. 6 3
RKZA9550
8 - Disconnect the working brake hoses (7) and remove

screws (8). 3
7
7
RKZA9561
WB97R-2 30-191
9 - Partially loosen the self-locking nuts (9) in order to elim-

inate the tightening torque and thus facilitate subse-
quent dismantling. 4
★ Loosen the nuts in criss-cross sequence. 11
10
9 9
RKZA9810
10 - Place a jack “B” and some blocks beneath the axle (3).
Raise the jack until the blocks can be forced under the
arms of the axle.
★ Leave free the nuts (9) and plates (10) that secure
the axle.
★ It should be possible to lower the jack by approx. 20
cm.
11 - Remove the self-locking nuts (9), the plates (10) and the
screws (11). B
12 - Lower the jack until the axle (3) is disengaged from the
chassis. RKZA9820
13 - Extract the entire axle (3).
INSTALLATION OF THE
REAR AXLE
1
Wheel nuts: 500±9.8 Nm
2
★ Adjust the stroke of the parking brake lever.
(See «20. TESTING AND ADJUSTMENTS»).
3
★ Bleed the air from the braking circuits.
(See «20. TESTING AND ADJUSTMENTS»).
4
Self-locking nuts for securing axle: 570 Nm
★ Tighten in two stages, using the criss-cross method.
1 - Check the level in the tank and start the engine.
30-192 WB97R-2
DISASSEMBLY OF REAR AXLE

1. Epicyclic reduction gear disassembly
Before draining the oil, position the hub with the plug on
the upper part and loosen it of some turns in order to eli- 1
2
minate any possible inner pressure, and then remove it
completely.
Turn the hub upside-down till the hole is in the lowest
point.
Drain the oil completely.
1 - Unscrew and remove the two fastening screws (1) of the

planetary carrier (2) with a wrench.
RKZB0110
2 - Remove the planetary carrier (2) from the wheel hub (3).
Position the planetary carrier on a table and check its
wear conditions. 4
3 - Remove the O-ring (4) and check its conditions.
3
RKZB0121
4 - To replace the epicyclic gears (5), if necessary, remove

6
the screw (6) and relevant washers (7) and (8).
★ Treat the pin (9) with care. 7
9 8
RKZ05212
5 - Remove the epicyclic gear (5) from its seat, taking care
11 14
not to lose the two units of rollers (10) and thrust washer
(11) and (12) inside it. 5
★ If the pins (13) of the pinion gears are in poor con-
dition, replace the entire planetary train with pre-fit-
ted pins. 12
★ If the halfshaft stop (14) is worn, replace the entire
planetary carrier.
10
13
RKZ07460
WB97R-2 30-193
2. Wheel hub group disassembly

2
Before disassembling the wheel hub, it is advisable to
secure it with a belt or a rope on a hoist or any other sup-
porting device, in order to avoid its accidental fall that
could damage either the operator or the wheel hub
group.
1
1 - Remove the short half-shaft.
Unscrew and remove the fastening screws (1) from the
wheel the hub-lock ring gear (2).
RKZB5601
2 - To remove the hub-lock ring gear (2) from its housing,

screw at least two of the just removed screws (1) in the
threaded extraction holes “A”. 2
A
RKZB0151
3 - Extract and remove the hub-lock ring gear (2) together

with the epicyclic ring gear (3).
3
2
RKZB0161
4 - Remove the steel stop ring (4) and disjoin the hub-lock
ring gear (2) from the epicyclic ring gear (3).
5 - Only if necessary, remove the centering bushes (5) of 9

the hub lock ring gear with a hammer and the special
tool E1.
6
7
8
RKZB0181
30-194 WB97R-2
6 - Remove the hub (6), using levers and a hammer to fa-

cilitate the operation.
★ Collect the bearing (7) cone.
7
RKZB0171
7 - Position on a flat surface the hub and take the seal ring
out (8) with a lever.
8 - Take the bearing cups out (9) and (10), on both sides of
the hub, using a hammer and a suitable tool to be be-
aten.
9 8
Remove the bearing (10) cone from the swivel housing 10
RKZ06880
3. Axle beam trumpets and brake groups

disassembly
Drain oil from the axle, removing the breathers first, for
to release the axle inner pression, then loosen the plug
very carefully. 2
1 - Extract from the axle beam trumpet the seal ring (1) out 1
with a lever.
2 - In order to replace it inside the axle beam trumpet, the
bushing (2) to be cut and destroyed with a chisel.
★ Do not ruin the bushing seat
RKZ06890
3 - Put alignment marks on the axle beam body and on the

differential supporting flanges, in order to identify the ri-
ght side and the left side with certainty.
RKZB0281
WB97R-2 30-195
4 - Position the axle on supports fitted to hold either the

central body or the two beam trumpets, even after their
disjunction, or secure the three disjointed groups to a lif-
ting device with ropes or belts.
RKZB1300
3 - Unscrew the fastening screws (3) to disassemble the

axle beam trumpet.
RKZB0291
4 - Spread apart the axle beam trumpet.

4
★ Once the axle beam trumpet has been removed,
the brake disks are free.
5 - Remove the O-ring (4) from its seat and the oil passage
hole and check the conditions.
Remove the long axle shaft (5) and the sleeve. Remove
the snap ring from the sleeve.
5
RKZB0941
6 - Remove the first brake counter disck (6).
RKZB0311
30-196 WB97R-2
7 - Remove the other disks (7) and counter disks (8) as far
as the brake splined sleevem, being careful how the dif-
ferent parts are positioned.
8 7
RKZB1311
8 - Remove the brake splined sleeve (9), recording the in-

dent position compared to the brake group.
★ The brake splined sleeve should be reassembled
in the same position as the one before disassem- 9
bling.
RKZB1321
9 - Remove the last counter disk (10).
10
RKZB0321
10 - Secure the brake flange to a hoist with ropes or safety

belts.
Unscrew the lower screw (11).
Remove the differential supporting flange (12) from the 12
central body, together with the bevel gear backlash-
adjusting ring nut and the brake control unit.
★ This operation frees the differential box, that must 11
be kept to avoid its fall.
RKZB0341
WB97R-2 30-197
11 - Remove the O-ring (13) from its housing and check its
conditions.
13
RKZB0351
12 - Remove the O-Ring (14) from the two oil pipe holes and
check its conditions.
14
RKZB0361
13 - Remove the oil blow-by tube (15) from the central body.
14 - Remove the O-Rings (16) and check their conditions

16
15
16
RKZ06900
4. Brake control group disassembly

1 - Remove the brake group and position it on a workbench
or fix it in a clamp.
1
2 - Unloose the locknut (1) and unscrew the adjusting 2
screw on the supporting bracket (2).
Remove the adjusting screw.
RKZB4980
30-198 WB97R-2
3 - Unscrew and remove the lever fastening screw (3) at

the shaft end (4).
3
RKZB0401
4 - Remove the washer (5).
RKZB0411
5 - Put an alignment mark on the lever (4) and shaft (6) spli-
nes for use during installation and to distinguish betwe-
en right and left control (for example: you can put two
marks on the right and only one on the left).
6
4
RKZB1330
6 - Loosen the lever (4) to release the tension on the spring

(7).
4
7
RKZB1340
WB97R-2 30-199
7 - Remove the lever (4).
4
7
RKZB1351
8 - Remove the spring (7).

8
9 - Remove the washer (8) and the spacer (9).
9
RKZB4990
10 - Remove the two bracket (2) fastening screws (10).
10
RKZB0420
11 - Remove the bracket (2).
RKZB0431
30-200 WB97R-2
12 - Make an alignment mark on the cam (11) near the set-

screw (12) align with the top of the roll pin, for use during
assembly.
★ Distinguish between right operation side and left 11
one.
12
RKZB5010
13 - Free the cam unscrewing the setscrew (12).
12
RKZB0440
14 - Unscrew the shaft setscrew (13), being careful the steel

ball (14) does not get lost.
13
RKZB0450
15 - Collect the steel ball (14).
14
RKZB0460
WB97R-2 30-201
16 - Remove the O-Ring (15), taking the shaft (16) out.

15
16
RKZB0470
17 - Remove the shaft (16) and collect the cam (11).
16
11
RKZB0480
18 - Unscrew the upper screws (17) of kit brake mechanism

return and take the springs (18) and the bushes out (19).
17 18 19
RKZB0490
19 - Unscrew the lower self-adjust kit screws (20) and take

the bushes (21) and the spacers (22) out.
20 21 22
RKZB0500
30-202 WB97R-2
20 - Unloose the brake flange (24) bleed (23).
23 24
RKZB0510
21 - Take the piston out (25).

If necessary, blow in air through the brake bleeder vent
to eject the piston, using the minimum pressure.
★ Possible swift ejection of the piston.
25
RKZB1380
22 - Remove the O-Rings (26) and (27) from the piston (25)
and check their conditions.
25
26
27
RKZB0520
23 - Unscrew the fastening screw (28) of the ring nut retainer

(29).
28
29
RKZB0530
WB97R-2 30-203
24 - Remove the ring nut retainer (30).
30
RKZB0541
25 - Unscrew the ring nut (32) with suitable E2 special tool.

Remove the ring nut.
31
E2
RKZB0551
26 - Remove the bearing cup (31) with a hammer and a su-

itable tool.
32
RKZB0561
5. Differential group disassembly

1 - Collect the differential and put it in a clamp.
Unscrew all the fastening screws (1) of the bevel gear
crown (2).
★ This will make both differential half boxes free, so
take care not to drop the internal components.
3
1
RKZB0570
30-204 WB97R-2
2 - Disassemble the differential box in two half boxes (3)

complete with the relative components. 3
★ Mark the two half boxes (3) before disjoining them,
in order to reassemble them in the same position as
the one before disassembling.
3 - Disassemble all the components and check the opera- 4

ting and wear conditions of the components.
4
★ Take the bearing (4) out of the differential half box,
using two levers or a three-hold extractor.
RKZ06910
6. Pinion group disassembly

1 - Remove the snap ring (1) and slide the input flange (2).
★ Collect the O-ring (3) and the shim (4). 3
2
RKZ06920
2 - Remove the seal ring (5) from the central housing with a
puller.
3 - Position the central body on a steady plane, before di-
sassembling it.
RKZ06930
4 - Unscrew the ring nut (6) with the special tools E3 and
E4.
E4
E3
RKZB0602
WB97R-2 30-205
5 - Once the ring nut washer (7) has been removed, take
the pinion (8) out of its housing, by beating with a ham-
7
mer made of soft material on the splined end.
RKZB0611
6 - Collect the washers (9), the elastic spacer (10) and the
cones of the taper roller bearing (11).
★ When the elastic spacer is removed, it should be re-
placed by a new one. 11
9
10
RKZB0621
8 - Take the bearing (12) cone out of the bevel pinion (8)
9 - Remove the adjusting shim (13) placed under the be-

aring and check its wear conditions.
12
13
RKZB0631
10 - In order to remove the differential lock device unscrew

the cylinder support screws (14), then remove off it col- 15
lecting the O-Rings and the piston (15). 17
Remove the Seeger ring (16), holding the bush (17) that 18
is pushed outside by the spring (19), remove off the
bush and the spring from the shaft (18). 14
Remove the cover (20) paying attention to the spring
16 21
(21) that could still be under load.
20
Remove off the shaft (18) by collecting the O-Ring, the
spring, the spacer and the snap ring.
RKZ06940
30-206 WB97R-2
11 - Extract differential lock fork (22) from the central body.

★ Check the integrity of all components disassem-
bled.
22
RKZ06950
12 - Take the cups of the taper roller bearing out of the cen-
tral body (23), using a chisel and a hammer.
23
RKZB0641
WB97R-2 30-207
ASSEMBLY OF REAR AXLE

1. Pinion group assembly
1 - Position the central body (1) on a workbench.
2 - Insert the cups of the taper roller bearings on their hou-

sings using the special tools included on the kit E5
E5
RKZB0651
3 - In order to measure the distance, the kit composed of

the special tools E5 and E6, respectively called “false pi-
nion” and “false differential box”, is used. E6
4 - Insert the false pinion with E5, together with its bearings
(2) and (3) and its ring nut (4), in the just mounted hou-
sings for the bearings.
Tighten without exceeding, till the backlash is elimina-
ted.
2 3 4
RKZB0661
5 - Check the correct positioning of the right and left flan-

ges, using the reference marks on them and on the cen- 6
tral body.
Assemble the two brake flanges (5) and fix them with 5
their screws (6) M14X120.
Screw: 79 Nm
★ Screw in at least two ones diametrically-opposed
for each flange).
RKZB0670
6 - Insert the false differential box with E6 into the central

body to measure the distance. 5
Check that the false box is inserted in both brake flan-
ges’ housings (5).
E7
RKZB0681
30-208 WB97R-2
7 - Carry out the measurement “A” with a depth gauge

through the suitable false pinion hole and calculate the
measure “X”.
B= 100 mm
C= 50 mm
C
X
(A+C) - B= X
A
B
RKZ05070
8 - Make a note of the value “V” marked on the head of the

pinion.
Calculate the thickness “S” to be installed beneath the
pinion, using the formula: V
S=X--V
★ “S” is the thickness of the shim. 107.00
00
RKZ05420
9 - Remove the false pinion, the bearings (2) and (3) and
the ring nut (4) from the central body (1). 1
Disassemble the false differential box from the flanges
(5) and then unscrew the screws to remove the flanges. 3
E7
4
2 RKZ05101
10 - Mount the shim (8) onto the pinion (7) and press the in-
ner bearing (2) using the tool E8.
★ Use always a new elastic spacer. E8 2
RKZB0691
WB97R-2 30-209
11 - Insert the bevel pinion unit (7) into the central body hou-
sing (1) and the second bearing (3) cone into the pinion 1
end.
In order to force the bearing into position use the special
tool E8 and a hammer.
3
RKZB0700
12 - Insert into the pinion shaft (7) a new ring nut washer (9)
and the ring nut (4) retainer.
13 - Screw the ring nut in, using the wrench for ring nut E3
and for pinion retainer E4.
★ The torque setting is given by the preloading me-
asurement on bearings. 9 4
★ Tighten the ring nut step by step.
★ If it is tightened too much, the elastic spacer should
be replaced and the procedure repeated. E3
E4
RKZB0603
14 - Carry out the preloading measurement P of the pinion

taper roller bearings, using a dynamometer whose cord
is wound on the 34.87 mm diameter of the pinion spline.
★ The adjustment is carried out by increasing the ring
nut torque setting gradually, being careful not to
exceed.
★ All preloadings should be measured without the
seal ring.
15 - Once you got the requested preloading value, caulk the

ring nut, using a hammer and a chisel.
P=9.2–13.8 daN RKZB0711
30-210 WB97R-2
2. Differential group assembly

1 - Assemble the cones of the new taper roller bearings (1)
on the half boxes (2), using the special tool E9 and a E9
hammer. 1
RKZB0722
2 - Position a half box (2) on a workbench and assemble all

its inner components (sun gears, planetary gears, 2
thrust washers, pins, discs and counterdiscs) as per fi-
gure.
Join the two half boxes (2), aligning the reference marks
made upon them. 2
1
1
RKZ06911
3 - Position the ring bevel gear (3), apply Loctite 270 on the
thread and then fix the whole by tightening the screws
3
(4).
Screw: 155 Nm
4
RKZB1290
3. Brake flange and differential housing assembly

1 - Position the flange on a flat surface and force the cup of
the taper roller bearing (1) in position, using the special
tool E10, interchangeable handle E11 and a hammer
E11
1
E10
RKZB0731
WB97R-2 30-211
2 - Collect the brake piston (3).

Push the elastic pin (2) into the self-adjust kit housing till
they are leveled with the piston supporting inner surfa-
ce.
2 3
Assemble the O-rings (4) and (5) on the piston and lu-
bricate the faying surface piston flange with a light layer
of grease.
2 5
2 4
RKZB0740
3 - Apply a slight coat of grease on the piston surfaces and

especially on the O-rings already inserted, insert the pi-
ston (3) into the brake flange (6) and position the special
tool E12 or a disk on the piston and with a lever ancho-
red to an eyebolt, exert a pressure just enough to insert
the piston into the brake flange.
3
E12
6
RKZB0751
4 - Take the components of the self-adjst kit and fit them on

the piston (3) as shown in the figure.
Screw the securing screws (7) of the two kits and tighten
them.
Screw: 10 Nm
3
7 RKZ06960
5 - Insert the new O-rings in their relative housings (oil pipe

hole) on the central body. Before assembling, lubricate 8
the O-rings (8).
9
Insert two new O-rings (9) in the oil pipe hole housings
(10). 10
Grease the O-rings.
6 - Insert the oil blow-by tube.

Insert the differential locking fork (10) in the central bo-
dy, respecting the showed position.
★ Do not invert the fork assembly position.
9
8
RKZ06970
30-212 WB97R-2
7 - Insert a new O-ring (11) on the flange. Lubricate the O-

ring. Assemble the left flange on the central body. 11
8 - Tighten the securing screw of the brake cylinder with a
torque-wrench.
Screw: 79 Nm
★ Check that the reference marks made in the disas-
sembly between flange and central body coincide.
RKZ06980
9 - Before the adjustment of the ring bevel gear bearings

preloading, prefasten the brake cylinders with two ad-
ditive screws M14X120.
Tighten at 79 Nm.
Once adjustment is made, remove them.
★ Respect the correct assemble side of the differen-
tial box with its relative components.
10 - Overturn and position the flange central body on a flat

surface.
Insert the differential box.
RKZB5520
★ The differential locking device elements have to be as-

sembled by respecting the relative position pointed out
in the figure.
RKZ06941
11 - Once the snap ring (13) has been introduced into the
shaft (12) till about 20 mm from the flatted end, introduce
the shaft into its housing in the central body, on the gear
14
side, slipping it into the fork (14).
★ Do not put the snap ring in the housing.
12
13
RKZ06990
WB97R-2 30-213
12 - Insert the spring (20) and the bush (21) into the shaft
(12), operating into the central body on the opposite 22
21
side of the gear, then assemble the snap ring (22) in its
housing. 20
12
RKZ07000
13 - Insert the piston (24) in the cylinder (27), with new O-

Ring (23) and (25) Assemble a new O-Ring (26) in the
cylinder support (27), and then insert the support, with
the piston, in the central body, fastening it with relative
screws (28), tightened with dynamometric wrench. 28
Screw: 27.6 Nm
★ Before the assembly lubricate properly the seal rin-
gs and the faying surfaces. 27
26
25
24
23 RKZ07010
14 - Push the seeger lock ring (13) in its housing in the dif-
ferential locking device of the shaft (12), by operating in 14
the central body on the bevel gear side. Then let the se-
eger ring sliding along the shaft with a pipe or a suitable
12
tool. Insert the spacer (15) and the spring (16) into the 15
shaft. Assemble a new lubricate O-Ring (17) upon the
16
cap (18). Assemble the cap (18) upon the central body 17
at the flatted end of the shaft, tightening the relative 18
screws (19). 13 19
Screw: 27.6 Nm
RKZ07020
15 - Assemble the right brake flange. Tighten the securing

screw of the brake flange with a torque-wrench.
Screw: 79 Nm
Once the correct assembly side of the differential box it

has been checked, assemble the second brake flange
on the opposite bevel gear side. Insert and screw the
adjusting ring nuts of the pinion-ring, using the wrench
with E2 till the bearing backlash is eliminated. Then me-
asure the pinion-ring gear backlash.
RKZB5530
30-214 WB97R-2
16 - Assemble the special tool E13 on the pinion end.

Move the pinion end alternatively and note the pinion
gear backlash, measured with a comparator “A”, so that
the feeler is in contact and at 90° with the bracket sur-
face on the special tool in correspondence with the ref-
erence mark. A
Check if the measured backlash value is within the re-
quest range.
★ Backlash: 0.18 – 0.23 mm
Carry out the adjustment by operating on the two ring E13
nuts with the tool E2.
Adjust the ring nuts remembering that: RKZB0771
- If the measured backlash is less than the given tol-

erance range, screw the ring nut from the side opposite
to the ring gear and unscrew the opposite one of the
same measure;
- If the measured backlash is higher than the given
tolerance range, screw the ring nut from the side of the
ring gear and unscrew the opposite one of the same
measure.
17 - Once you have carried out the adjusting of the pinion-

ring gear backlash, check also that there is a minimum
preloading on the differential box bearings.
Repeat the whole sequence of the above mentioned
operations till the indicated conditions are reached. RKZ05111
18 - Once the pinion gear backlash has been established,

measure the total preloading “T” of the bearings (pinion-
ring gear system), using a dynamometer whose cord
“B” is wound on the diamater 34.87 mm of the pinion
spline shaft.
★ Force required:
(P+3.73) < T < (P+5.55) daN
P= the force found for the pinion
★ The force should be that of continual rotation. Do

not take the thrust force into consideration. B
19 - If the force is not within permissible limits:
RKZ05121
a - Tighten both the lock nuts to the same extent to in-
b - Loosen both the lock nuts to the same extent to de-

The clearance between the ring bevel gear and the

pinion must remain within permissible limits.
WB97R-2 30-215
20 - Check the centering of the contact area using the fol-

lowing procedure:
a - Coat both surfaces of the teeth of the ring bevel
gear with a marking substance.
b - Rotate the pinion.
If the contact area is excessive near to the edge of the
teeth, the ring bevel gear must be brought closer to the
pinion.If the contact area is excessive on the side of the
teeth, the ring bevel gear must be moved away from the
pinion.
RKZ01840
RKZ01850
21 - Insert the ring nut retainer (29) turning the ring nut sli-
ghtly in order to align it to the retainer.
Screw in and tighten the screw (30) of the ring nut re-
tainer with a dynamometric wrench. 29
Screw: 13 Nm
30
RKZB0781
22 - The seal ring into the central housing using seal driver
E14.
E14
RKZ07030
30-216 WB97R-2
23 - Coat the seal lip and O-ring with oil and insert on the pi-
nion shaft the shim together with a new O-ring and input
flange.
Secure the assembled parts with snap ring (4).
4
RKZ07040
4. Brake control group asselmbly

3
1 - Insert the cam (2) and the shaft (3), on the side you are
operating, on the brake flange (1). They can be reco-
gnized by the reference marks previously put.
1
2
RKZB0791
2 - When the shaft is inserted into the cam, align the refe-
rence mark with the cam setscrew (4) hole.
RKZB0801
3 - Insert the cam setscrew (4).

2
RKZB0811
WB97R-2 30-217
4 - Screw in the cam setscrew (4) with dynamometric wren-

ch.
Screw: 10 Nm
2
RKZB0820
5 - Insert the steel ball (5) that sets the shaft and the relative
screw (4).
RKZB0461
6 - Put on the shaft setscrew (6) thread a slight layer of SI-

LASTIC. 6
Screw in and tighten the shaft setscrew (6) with dyna-
mometric wrench.
Screw: 25 Nm
RKZB0831
7 - Insert a new O-Ring (7) on the shaft (3).
7
3
RKZB0840
30-218 WB97R-2
8 - Position the supporting bracket (8).

Insert the fastening screws (9).
9
8
RKZB0850
9 - Screw in and tighten the bracket fastening screws (9)

with dynamometric wrench.
Screw: 35 Nm
9
RKZB0861
10 - Insert the spacer (11) the washer (10) and the spring
(12) on the shaft end.
12
10
11
RKZB0870
11 - Insert the brake control lever (13), respecting the refe-

rence marks put during disassembly.
13
RKZB0880
WB97R-2 30-219
5. Brake and axle beam groups assembly

1 - Insert the first shaped brake counterdisc (1), respecting 1
the indicated position compared to the cam position.
RKZB0890
2 - Check that the friction discs and the counterdiscs do not

present any sign of burning; if yes, replace them. Fur-
thermore check friction disc wear and if necessary re- 4
place them.
★ Friction disc thickness: min. 4.03 mm
1
3 - Reassemble all the components of the brake group (di-
scs (2), counterdiscs (4) and coupling (3)) inside the
flange as per the sequence in the figure.
★ The coupling should be inserted after the first disc
and positioned with the shortest spline against the 2
differential.
3
★ If new brake discs are installed, before assembling, RKZ07050
they should be dipped in the suitable oil.

★ The discs and counterdisc unit are free.
4 - Insert the long half-shaft (5) into the axle central body 6
(6).
Position the seeger ring (7) on the inner seat of sleeve
(8).
Insert the sleeve on the long half-shaft. 5
★ The sleeve must be inserted with the inner seeger
ring resting against on the long half-shaft 7
8
RKZ07060
5 - Before assembly, check the reference marks carried

out during disassembly for the correct positioning of the
axle beam trumpets.
RKZB5610
30-220 WB97R-2
6 - Drive the bushing (9) in the seat on the axle beam trum-
pet by means of the special tool E15.
RKZ07070
7 - Assemble a new O-ring into the axle beam trumpet and

into the two oil blow-by holes. Lubricate the O-rings.
Assemble the axle beam trumpet on the flange, being
careful to the fastening holes’ alignment.
★ Support the groups properly as already pointed out
for disassembly phase.
8 - Screw in and tighten the fastening screws (10) of the

axle beam trupet with a dynamometric wrench.
Screw: 176 Nm
10
★ Assemble the brehater adapter with the nocht ali-
gned to half-shaft. RKZ07080
9 - Lubricate with care the lip of the new seal ring.

Insert the new seal ring (11) in the seat on the axle beam
trumpet by means of the special tool E16.
11
RKZ07090
10 - Insert the short half-shaft (12) on the axle beam trum-

pet.
12
RKZ07100
WB97R-2 30-221
11 - Set the brake group, putting the system under pressure.

It is advisable to use compressed air at high pressure
blown through the breather.
★ The braking system (piston, discs, self-adjust kit
and kit brake mechanism return) should be set, be-
fore moving the brake control levers.
12 - Operate the control levers, setting them on braking po-

sition (locked levers).
★ The lever return springs should not be inserted.
⫼310.5 mm
301⫼
13 - Measure the distance between the middle of the con-
nection holes at the ends of the control levers and check RKZ06201
that it is within the foreseen range:
301–310.5 mm
• If the value is not within the foreseen range, correct
13
the lever position: take them out of the shaft and
reinsert them shifted of one spline so that the error 14
can be compensated.
Repeat the checking operation and the further adjust-

ment till the requested conditions are reached.
14 - Release the brake control levers, screw in the fastening

screws (13) and the relative washers (14).
RKZB0921
15 - Tighten the fastening screw (13) of the control lever with

dynamometric wrench.
Screw: 35 Nm
13
RKZB0951
16 - Hitch the return spring (15) to the brake control lever

(16).
Repeat all the described operations also for the other 16
brake group.
15
RKZB0961
30-222 WB97R-2
17 - Check that, in rest position, the measure between the

middle of the connection holes at the lever ends is hi-
gher than the minimum value 320 mm.
⫼329.5 mm
320⫼
RKZ06191
18 - Assemble the adjusting screws (17) on the brackets and

screw in them, till they are in contact with the levers.
17
RKZB0971
19 - Screw in the two screws of the same measure to be

within the foreseen range for the levers in rest position:
320–329.5 mm (about 3 mm between lever and bracket
will remain).
⫼329.5 mm
320⫼
RKZ06191
20 - If the screw (17) is not perpendicular to the side surface

of the lever (16), adjust its position by moving the sup-
porting bracket. 90°
16 17
RKZ06211
WB97R-2 30-223
6. Wheel hub group assembly

3 4
1 - Position the wheel hub (1) on a workbench and force the 2
two cups of the taper roller bearings (2) and (3) in po-
sition with the special tool E17 under a press or with a
hammer.
2 - Insert the seal ring (4) into the wheel hub with the special E17 E18
tool E18 and a hammer.
E17 1
RKZB1422
3 - Assemble the cone of the taper roller bearing (3) on the

beam trumpet (5) end. 5 1
4 - Assemble the wheel hub (1) on the beam trumpet (5) 3

and force the other cone of the taper roller bearing (2) in
position.
RKZB1431
5 - Position the wheel carrier (6) on a workbench and force

the bushes (7) to the carrier surface level with the spe-
cial tool E1. 7
At least two bushes (diametrically-opposed) should be
set slightly higher than the carrier surface level to be
used as dowel pins.
6
RKZB1091
6 - Preassemble the wheel carrier group (8), epicyclic ring

gear (9), with the special snap ring (10) shown in the fi- 9
gure.
10
RKZ05731
30-224 WB97R-2
7 - Assemble the wheel carrier group (8) on the wheel hub

(1) using the two projecting bushes (7) as dowel pins. 1 8
RKZB1101
8 - Force all the hub dowel bushes completely with the spe-
cial tool E1 and a hammer. 8
Assemble the wheel carrier fastening screws (11) and 11
tighten.
Screw: 230 Nm
RKZB1441
9 - In the case the bearings (2) and (3) are substituted, ver-
ify that the measure “A”, “B” and “C” are in the limits.
A = 17.950 – 18.000
B = 64.275 – 64.325
C = 23.070 – 23.172 3
2 C A C
RKZ05741
7. Epicyclic reduction gear assembly

1
1 - Place the planetary carrier on a work bench and fit the
epicyclic gears (1) and respective washers (2) on the
dowels already fitted. 2
RKZ05750
WB97R-2 30-225
2 - Insert all the rollers (3) into the epicyclic gears (4), then
place the two thrust washers (5) and (6).
★ The first washer must be aligned with the dowel pin. 4
5
3 RKZ05760
3 - Fit and tighten the epicyclic gears (4) fixing bolts (7), ti-
ghtening.
4
Screw: 79 Nm
7
RKZ05770
4 - Insert a new O-ring on the centering diameter of wheel

hub.
5 - Fit the planetary carrier to the wheel hub (8). Insert and 8
9
tighten the fixing bolts (9) to the prescribed torque.
Screw: 25 Nm
RKZB0111
30-226 WB97R-2
REMOVAL AND INSTALLATION FRONT BUCKET BOOM-RAISING CYLINDER
REMOVAL OF THE FRONT BUCKET BOOM-RAISING CYLINDER

Lower completely the working equipment until it rests on
the ground and stop the engine.
1 - Put a sling round the cylinder (1) and insert some blocks A
“A” between the boom (2) and the fulcrum lever spacer 2
(3). 3
2 - Take off the snap-ring and the internal retaining spacer
for the piston attachment pin (4). 4
3 - Take out the pin (4) in order to free the piston head (5), 1
but leave the fulcrum lever engaged (3).
5
4 - Start the engine to retract the piston (1). RKZA2160
★ Bind the piston head with wire to secure the fully re-
tracted position and stop the engine.
1 2
MENTS»). 1
Cut off the supply of electricity by turning the battery-dis-
connecting switch in a counter-clockwise direction, and
remove the handle.
7
5 - Disconnect the tubes (6) and (7) and plug them to pre-
6
vent entry of impurities.
RKZA1951
6 - Remove the snap-ring (8) and the spacer (9).
7 - Remove the cylinder (1).

9
Cylinder: 40 kg 1 8
INSTALLATION OF FRONT
BUCKET BOOM-RAISING
CYLINDER
RKZA2170
1
When aligning the positions between the hole and the
pin, turn the engine over at low idling speed.
Do not insert fingers into the holes to check alignment.
2
Internal bushing: ASL800050
1 - Start the engine and bleed the air from the cylinders.
MENTS»).
★ After bleeding the air, check the oil level in the tank.
WB97R-2 30-227
REMOVAL AND INSTALLATION FRONT BUCKET TILT CYLINDERS
REMOVAL OF THE FRONT BUCKET TILT CYLINDERS

the ground and stop the engine.
1 - Loosen the clips (1) and remove the tube protection (2). 3
4
★ For the right-hand cylinder only
Disconnect the sensor (3) and remove the bucket po-
sition indicator (4).
2 - Place a sling round the cylinder (5) and insert a block “A”
1 1
between the spacer (6) of the piston fulcrum lever (7) 2
and the link (8).
3 - Take off the snap-ring and the internal retaining spacer
for the piston attachment pin (9). RKZA9451
4 - Take out the pin (9).

5 - Start the engine to retract the piston (10).
1 2
★ Bind the piston head with wire to secure the fully re-
tracted position and stop the engine.
7
5
MENTS»). A
Cut off the supply of electricity by turning the battery-dis- 8
connecting switch in a counter-clockwise direction, and 6
remove the handle.
RKZA2190
6 - Take out the screw (11) and remove the clamp (12).
7 - Disconnect the tubes (13) and (14) and plug them to
8 - Remove the snap-ring (15) and the spacer (16). 10
Cylinder: 45 kg
INSTALLATION OF THE FRONT 14

12
9
BUCKET TILT CYLINDERS
• To install, reverse the removal procedure. 11 RKZA2200
1
Do not insert fingers into the holes to check alignment. 16
2
12
MENTS»). 15
★ After bleeding the air, check the oil level in the tank. 11
RKZA2210
30-228 WB97R-2
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.
RKZA7900
2 - Take out the screws (1) and remove the pins (2) of the
lever (3).
Rest the lever (3) on the boom.
1 2
2
RKZA1460
3 - Take out the screws (4) and remove the pins (5) of the
bucket fulcrum.
1 2 4
4 - Start the engine and put the machine into reverse gear
in order to disengage the boom (6).
5
RKZA1470
INSTALLATION OF THE
FRONT BUCKET
1
2
WB97R-2 30-229
REMOVAL AND INSTALLATION FRONT WORKING EQUIPMENT
REMOVAL OF THE FRONT WORKING EQUIPMENT

the ground stop the engine and remove the ignition
wrench.

MENTS»).
1 - Remove the tilt cylinders. (See «REMOVAL OF FRONT

BUCKET TILT CYLINDERS»).
RKZA7900
2 - Disconnect the cylinders (2) from the boom (1) and rest
them on wooden blocks «A» placed on the front axle.
1 2
2
A
RKZA2220
3 - Open the front hood (3) and take out the screws (4) that
lock the axle oscillation pins of the boom (1).
Close the front hood.
4 4
RKZA1090
4 - Put a sling round the boom (1) as shown in the figure,

and attach it to the hoisting tackle. Apply a slight tension
to the cables. 1
RKZA7910
30-230 WB97R-2
REMOVAL AND INSTALLATION FRONT WORKING EQUIPMENT
5 - Using a puller, take out the axle oscillation pins (5) of the
boom (1). 1 2
6 - Start the engine and put the machine into reverse gear
5
travel until the boom is disengaged.
1
★ If the working equipment is to be detached to aid the
removal of the engine-gearbox-pump group, and
the machine cannot travel automatically, it can be
towed using the towing hooks of the backhoe.
7 - Place two stands in position and lower the boom until it

is resting on them.
Work equipment: 960 kg RKZA7920
INSTALLATION OF THE FRONT

WORKING EQUIPMENTI
• To install, reverse the removal procedure, if necessary
using the front towing hook.
1
2
• Start the engine and bleed the air from the cylinders.
MENTS»).
WB97R-2 30-231
REMOVAL AND INSTALLATION BACKHOE CONTROL VALVE
REMOVAL OF THE BACKHOE CONTROL VALVE

1 - Swing the backhoe completely to the right of the ma-
chine, and rotate the boom to approx. 45° to the right.
2 - Lower the outriggers to the ground, open the bucket and

rest the arm on a block “A” keeping it perpendicular to
the ground.
3 - Rest the bucket teeth on the ground, release the back-

hoe plate and stop the engine.

MENTS»).
RKZA1680
4 - Take out the lower window (1) of the cab and completely
raise the upper window.
RKZA1100
5 - Remove the grips (2) of the control levers of the outrig-

gers.
2
6 - Raise the protective sleeves (3) of the control levers,
take out the screws (4) and remove the cover (5).
3 3
4
5
RKZA9830
★ If any optional devices have been fitted, unhook the

spool command tie-rods (6) and remove the pedals (7)
and the supports (8). 8
7
RKZA9840
30-232 WB97R-2
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 (13) from the
control valve.
12 11
9 - Disconnect from the control valve the pipes (14) (deliv-
ery, return, Load Sensing and actuators). Plug them to
★ Mark the pipes to prevent exchanging positions 14
during re-connection.
10 - Attach the control valve (12) to some hoisting tackle and

RKZA2251
apply a slight tension to the cables.
11 - Remove the four screws (15) and then the entire control
valve.
Control valve:6-spool 47 kg
7-spool 53 kg
8-spool 59 kg
15 15
RKZA2260
INSTALLATION OF THE
BACKHOE CONTROL VALVE
★ Bleed the air from Load Sensing circuits and from the
hydraulic circuits of all the actuators.
MENTS).
WB97R-2 30-233
REMOVAL AND INSTALLATION BACKHOE BOOM CYLINDER
REMOVAL OF BACKHOE BOOM CYLINDER

1 - Remove the lubrication nipple and the extension.
Extend the arm (2) completely and fully open the bucket
(3).
1 5
Manoeuvre the front equipment until the bucket teeth
are resting on the ground, the arm on a block “A” about
10 cm high, and the joint between the arm and the boom
on a stand “B”, about 70 cm high.
2 - Stop the engine and release residual pressures.

6
3 - Place a sling around the cylinder (4).
4 - Take out the screws (5) and remove the pin (6). RKZA1150
1 2
5 - Start the engine and retract the piston. 10
★ Secure the position of total retraction by binding the
piston head rod with wire.
6 - Stop the engine and release any residual hydraulic

2 9
pressures. (For details, see «20. TESTING AND AD-
JUSTMENTS»). 3
7 - Disconnect the pipes (7) and (8) and plug them to pre-
8 - Take out the screw (9) and remove the pin (10). B
1 2 A RKZA0140
Cylinder: 78 kg
5
INSTALLATION OF THE
BACKHOE BOOM CYLINDER
6
1
pin, turn the engine over at low idling speed. RKZA1170
2
4
MENTS»).
7
8
RKZA1180
30-234 WB97R-2
REMOVAL AND INSTALLATION BACKHOE ARM CYLINDER
REMOVAL OF THE BACKHOE ARM CYLINDER

(2). Lower the arm (3) until the joint between the arm and
the boom is resting on a stand “A” about 90 cm high, and
tip of the arm on a block “B” about 10 cm high. 3
Rest the bucket teeth on the ground. 1
1 - Stop the engine and release the pressures in the cylin-
2
der by moving the control lever several times.
3 - Take out the screws (5) and remove the pin (6). A
1 2 B
RKZA1160
4 - Start the engine and retract the piston (7).

★ Secure the position of total retraction of the piston
(7) by binding the piston head rod with wire.
5 - Stop the engine and release the residual hydraulic pres- 5

sures. (For details, see «20. TESTING AND ADJUST-
MENTS»).
6 - Disconnect the pipes (8) and (9) and plug them to pre-
7 - Take out the snap-ring (10) and remove the pin (11). 6
1 2 4
8 - Remove the cylinder (4). RKZA1190
Cylinder: 69 kg
8
7
4 9
INSTALLATION OF THE
BACKHOE ARM CYLINDER
1
pin, turn the engine over at low idling speed. RKZA1200
2
Internal bushing: ASL800050 11 4
MENTS»).
10
RKZA1210
WB97R-2 30-235
REMOVAL AND INSTALLATION JIG ARM CYLINDER
REMOVAL OF THE JIG ARM CYLINDER

Open the arm (1) completely and lower it until it rests on
a trestle “A” that is roughly 40 cm high.
Extend the jig arm (2) until it rests on a block “B”, and let 1
the bucket teeth rest on the ground. 4
1 - Stop the engine and release the cylinder (3) pressures,
by moving the command pedal several times.
2
2 - Put a sling around the cylinder (3).
3 - Take off the snap ring and remove the pin (4).
A
1 2
B
4 - Start the engine to retract the piston. RKZA7930
★ Secure the fully retracted position of the piston by

binding it with wire.
5 - Stop the engine and release the residual hydraulic pres-

sures.
5
(For details see «20. TESTS AND ADJUSTMENTS»).
6 - Take out the safety pin (5).
7 - Disconnect the hoses (6), (7), (8) and (9), and plug them
to prevent entry of impurities.
8 - Remove the clamp (10). 3
9 - Remove the screws (11) and the pin (12). 1 2

RKZA7940
INSTALLATION OF THE 11 10
JIG ARM CYLINDER 6
8
1 12
When aligning positions between hole and pin, let the
engine turn over at low idling.
Do not insert fingers into the holes to check on align-
ment. 9 7
RKZA7950
2
Internal bushings: ASL800050
(For details, see «20. TESTS AND ADJUSTMENTS»).
30-236 WB97R-2
REMOVAL AND INSTALLATION BACKHOE BUCKET CYLINDER
REMOVAL OF THE BACKHOE BUCKET CYLINDER

(2). Lower the boom (3) until the arm is resting on a
stand “A” about 90 cm high, and tip of the arm on a block
“B” about 10 cm high. 3
Rest the bucket teeth on the ground. 1
4
1 - Stop the engine and release the pressures in the cylin- 2
der (4) by moving the control lever several times.
3 - Take out the lock-nut (5) and the washer and remove
the pin (6). A
1 2 3 B
RKZA1161
4 - Start the engine and retract the piston (7).
★ Secure the position of total retraction of the piston
by binding the piston head rod with wire
sures. (For details, see «20. TESTING AND ADJUST- 4
MENTS»).
6 - Disconnect the pipes (8) and (9), and plug them to pre-
7
7 - Take out the snap-ring (10) and remove the pin (11).
1 2 5
★ For jig arm: loosen nut (12) and remove pin (13).
8 - Remove the cylinder (4). 6 RKZA1220
Cylinder: 49 kg
BACKHOE BUCKET CYLINDER 8
1
pin, turn the engine over at low idling speed. 4
Do not insert fingers into the holes to check alignment. 11
2 RKZA9851
3
★ Tighten the locknut completely, then release it half a
turn.
MENTS»).
12
RKZA9950
WB97R-2 30-237
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) of cylin-

der to be remove.
Raise this until it is forced up against the outrigger. 1
RKZA1240
3 - Remove the retainer pipes clamp (3).

4
5
4 - Disconnect from cylinder (5) the pipes (4) and plug them
to avoid impurity entry.
Plug also the union to avoid the movement of piston.
4
5 - Remove screw (6) and extract the pin (7) until the cylin-
der (5) is free. 1 2
3
7
6
RKZA1250
6 - Raise the lifting platform “A” to disengage the cylinder

head (5) from frame
Place a sling round the cylinder (5) and apply slight ten-
sion to the cables. 5
RKZA1260
30-238 WB97R-2
REMOVAL AND INSTALLATION OUTRIGGER CYLINDERS
7 - Take out the screw (8) and remove the pin (9).
1 2
8
Cylinder: 42 kg
RKZA1270
INSTALLATION OF THE
OUTRIGGER CYLINDERS
1
2
MENTS»).
WB97R-2 30-239
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 mov-

ing the control levers several times.
2 - Take out the screws (1) and remove vertically the upper
support (2) of the cylinder fulcrum. 1 3
3 - Disconnect the four tubes (4) from the cylinders (3) and
plug them to prevent entry of impurities.
4 - Take out the screws (5) and remove the pins (6). RKZA0970
2 3
5 - Rotate the cylinders to disengage the piston heads from
the swing bracket (7) and remove the cylinders (3).
Cylinder: 30 kg 1
BACKHOE SWING CYLINDERS
1
1 - Mount the cylinders (3) and the upper cylinder fulcrum
support (2). Secure the support with the four screws (1).
3
RKZA1280
1
Support screws: Loctite 262
Support screws: 981±98 Nm 4
6
2 - Connect the four tubes (4) to the cylinders.
3 - Start the engine and swing the boom in order to center

one of two pins (6). Secure the 1st pin with the screw.
Perform the same operation for the other pin. 3
2 5
pin, turn the engine over at low idling speed. 7
Do not insert fingers into the holes to check alignment. RKZA1290
3
4 - Bleed the air from the cylinders. (For details, see «20.
TESTING AND ADJUSTMENTS»).
30-240 WB97R-2
REMOVAL AND INSTALLATION BACKHOE BACKFRAME LOCK CYLINDER
REMOVAL OF BACKHOE BACKFRAME LOCK CYLINDER

★ Set the backhoe with the centered attachments with the
arm in vertical position and the bucket leaned on the
back at level ground.
RKZA0970
1 - Unlock the backframe (1).
2 - Stop the engine and release the residual hydraulic pres- 3 2

sures. (For details, see «20. TESTING AND ADJUST-
MENT»).
3 - Disconnect from cylinder (2) the pipes (3) and (4) and
plug them to avoid impurity entry.
4
4 - Remove screws (5) and cylinders (2).
1 5
1 2
RKZA1300
INSTALLATION OF BACKHOE
BACKFRAME LOCK CYLINDER
1
Locking screw: Loctite 262
Locking screw: 420±40 Nm
2
Cylinder seat: ASL800050
1 - Start the engine, lock and unlock the backframe several

times to make the circuit feeling.
WB97R-2 30-241
REMOVAL AND INSTALLATION CYLINDERS
DISASSEMBLY OF CYLINDERS
(Front bucket raise and tilt, boom, arm, bucket, outriggers and jig arm)
1 - Place the cylinder (1) on the tool A1.
A2
A2
A1
1
RKZA1540
For the arm cylinder with side-digging boom first extract

the snap-rings (2) and the ball-and-socket joint (3).
3 2
RKZ06310
2 - Using the specially-made wrench A4, A5, A6 unscrew

the cylinder head (4) and extract it from the cylinder (1).
1
For the side-digging boom cylinder, first remove 4
the lock-nut (5) that secures the piston-rod seal.
3 - Extract the piston-rod group (6) from the cylinder (1)
4 - Remove the cylinder (1) and the piston-rod group (6).
RKPB1460
30-242 WB97R-2
5 - Secure the piston-rod group (6) on the tool A1.

7
6 - For the side digging boom cylinder: remove the
snap-spin (10). BOOM OUT
RIGGER 9
7 - For the piston rod of the boom cylinder: remove the
screw (7).
8 - Use the appropriate socket wrench A7 on the piston

hexagon (11) and unscrew the piston.
★ Measurement of the socket wrench: 8
For raising the front bucket.: 55 mm
For tilting the front bucket.: 55 mm
RKZ00022
Boom: 65 mm
Arm: 55 mm
Bucket: 55 mm
Outriggers: 46 mm
Jig arm: 46 mm
Side digging boom: 46 mm
SIDE DIGGING 10
BOOM PISTON
9 - For the piston rod of the boom cylinder: Take out the
ball bearings (8) and the cushion plunger (9).
10 - Dismantle all the groups by removing all the seals, the

dust-seals, the guide rings, and the fulcrum bushings. 6
11
The seals, the dust seals and the guide rings can-
not be used again. ARM
Carefully check the pistons (11). If both safety-

caulked areas show wear, the pistons must be re-
placed.
6
11
RAISING
TILTING
6
11 RKZ00012
WB97R-2 30-243
ASSEMBLY OF CYLINDERS
(Front bucket raise and tilt, boom, arm, bucket, outriggers and jig arm)
★ Take great care not to damage the seals and the sliding
surfaces.
16 15
★ Prepare each individual component before the final as-
sembly.
1. Assembly of the cylinder head
1.1 Only for the cylinders for front bucket raise and tilt,
boom, arm, bucket, outriggers, jig arm
1 - Mount the gasket (12) in the cylinder head.

14 13 12
2 - Mount the gasket (13) in the cylinder head. RKZ00040
★ Make sure that the lips are turned towards the in-
side of the cylinder.
3 - Mount the guard ring (14) using the tool A8. 22 21 20

4 - Mount the O-ring (15) and the anti-extrusion ring (16) on
the outside of the cylinder head.
5
1.2 Cylinder for side digging boom
1 - Insert the gasket (17) in the cylinder head, and let it beat
on seat bottom, then insert the anti-extrusion ring (18).
★ Check carefully the assembly orientation.
2 - Mount the guard ring (19) in the lock-nut (5). 19 18 17 23
RKZ00050
3 - Tighten the lock nut (5) until leaning lightly on anti-ex-

trusion ring (18).
4 - Assemble on head the O-ring (20), the anti-extrusion

(21), the O-ring (22) and the ring (23).
25 26 27
26 11
24
RKZ00090
2. Re-assembling the piston
2.1 Only for the cylinders for front bucket raise and tilt, 27
boom, arm, bucket, outriggers, jig arm
28
1 - Use the tool A9 with the appropriate diameter, mount
the ring (24) the external seal (25) and the anti-extrusion
rings (26) onto the piston (11). A9
2 - Prepare the guide ring (27).
★ There are two guide rings (27) for the boom piston.
3 - For the boom piston only: insert the O-ring (28) into the
internal seating. RKZA1580
30-244 WB97R-2
4 - Gauge the diameter of the seal (25) of the piston (11)

mounting the group under a press and use the tools A3
for the piston diameter.
11
A3
RKPB1491
2.1 Side digging boom cylinder
★ This mounting should be performed directly on piston. 33 31 30 31 34

1 - Mount central ring (29), rubber ring (30) and anti-extru- 32 35
sion ring (31). 36
2 - Mount on piston first washer (32), guide ring (33), cen-
10
tral ring assembly (29), second guide ring (34) and sec-
ond washer (35).
3 - Tighten nut (36) and lock the piston group after locking
rod head under the press. (See «3. RE-ASSEMBLING 29
THE PISTON-ROD GROUP»). RKZ00060
4 - Insert the snap ring (10).
3. Re-assembling the piston-rod group

6
1 - Only for the cylinders for front bucket raise and tilt,
boom, arm, bucket and side digging boom: using a
37
press and tools A2 with the appropriate diameter, insert
the bushing (37) into the piston head (6).
A1
A2
RKZA1500
2 - Mount the bushing A10 of the correct diameter onto the

tip of the piston rod (6).
6 6
A10 4
3 - Slightly lubricate the cylinder head seals (4) and slide
the group onto the piston rod (6).
Seals: ASL800050
RKZA1510
WB97R-2 30-245
4 - For the cylinders of the outriggers only: mount

the spacer (38) with the O-ring (39). 39 38 6 A10
★ Check carefully the assembly orientation.
For the arm cylinder only: insert the spacer (40). OUTRIGGERS
40
ARM
RKZ00071
5 - Remove from the tip of the piston rod (6) the bushing
A10 and mount the piston (11) and the nut (36). 11
★ Grease the piston threading. 6 7
9
Piston locking nut: Loctite 262
Piston locking nut:
Front bucket raise: 2845±284 Nm
Front bucket tilt: 2845±284 Nm
Arm: 2845±284 Nm
Bucket: 2845±284 Nm
8
Outriggers: 1520±152 Nm
Jig arm: 1520±152 Nm RKZ00021
6 - For the boom cylinder: mount the cushion plunger (9),

slide the eleven ball-bearings (8) into the hole, and
mount the dowel bolt (7).
Dowel bolt: Loctite 262

6 11
Dowel bolt: 23±2 Nm
7 - Screw the complete piston (11) onto the piston rod (6),
and secure it with the dynamometric wrench.
Piston: 2697–3924 Nm
8 - Caulk the piston (11) to correspond to the slot in the pi-

ston rod (6) not previously used. RKPB1470
4. Re-assembling the cylinders

1 - For the boom, arm, bucket and side digging boom
cylinders only:
Position the bushing (41) and mount it in the cylinder
41
head (1) using tool A2 of the correct diameter.
★ There are two bushings for the arm cylinder, with a 1
spacer between them.
★ Leave the cylinder in position for subsequent as- A2
sembly.
RKZ06320
30-246 WB97R-2
2 - Lubricate the threading and the first part of the cylinder

(1).
1 A11
Cylinder: ASL800050
3 - Mount the two halves of the tool A11 with the appropri-
ate diameter at the mouth of the cylinder (1).
RKZA1520
4 - Mount the piston rod group (6) and the cylinder (1) on
the apparatus A1.
1 A11
5 - Guide the piston and center it in the tool A11. A1 4 6
6 - Mount the first guide ring (27) onto the piston and insert
part of the piston into the tool A11.
For the boom cylinder only: mount the second guide
ring (27) and fully insert the piston.
Insert the piston slowly in order to calibrate the

guide rings (27) without overheating them.
7 - Take the cylinder out of the tool A11 and bring the cylin- RKPB1480
der head (4) and the piston rod head closer to the cylin-
der.
8 - Bring the cylinder (1) into position for screwing in the

cylinder head (4).
9 - Insert the cylinder head into the cylinder and screw it in

by hand for several turns.
10 - Use the right special wrench A4, A5, A6 to screw the

cylinder head (4) home.
Cylinder head: 932–980 Nm
11 - For the side digging boom cylinders only: tighten the

lock-nut (5).
Lock-nut: 490 Nm
RKZ00080
WB97R-2 30-247
REMOVAL AND INSTALLATION BOOM SWING CYLINDER
DISASSEMBLY OF BOOM SWING CYLINDER
9
5 1
2
6
4
7 8
RKZ00100
1 - Place the cylinder (1) on the apparatus A1. Engage the

fulcrum pins in the suitable support.
2 - Using the specially-designed wrench A6, unscrew the

cylinder head (2) and extract it completely from the
cylinder (1).
3 - Remove brake cylinder (3).
4 - Attach the piston head to the mobile group of the ap-

paratus A1.
5 - Extract the piston rod group (4) from the cylinder.
6 - Remove the cylinder and the piston rod group.
7 - Secure the complete piston rod (4) to the apparatus A1.
8 - Raise the part caulked for safety purposes and unscrew

the piston using the tool A7.
Check the piston (5) carefully. If both safety-caulked ar-

eas have been used, the piston must be replaced.
9 - Remove the snap-ring (6) from the piston and extract

the ring (7) and the spacer ring (8).
★ Make a note of the order of assembly of the ring (7).
10 - Using a puller remove the swing bushings (9) from the
cylinder axle oscillation pins.
11 - Dismantle the groups by removing all the seals, the

guard rings, the guide rings and the piston fulcrum
bushing.
The seals, guard rings and guide rings must not be

used again.
30-248 WB97R-2
ASSEMBLY OF BOOM SWING CYLINDER

★ Take great care not to damage the seals and the sliding
surfaces. 13 14 2 15
★ Prepare each individual component before the final as-
sembly.
1. Assembly of the cylinder head
1 - Mount the gasket (10) and the gasket (11) in the cylinder
head (2).
★ Make sure that the gasket lips (11) are turned to-
wards the inside of the cylinder.
2 - Mount the scraper ring (12).

10 11 12
RKZ00110
3 - Mount the O-ring (13), the anti-extrusion ring (14) and

lastly the O-ring (15) of the front seal.
2. Re-assembling the piston
1 - Use the tool A9 with the appropriate diameter, mount

19 18 17 18 19
the rubber ring (16) and the seal ring (17) onto the pi-
ston. Remove the tool A9 and mount the anti-extrusion
rings (18).
2 - Prepare the guide rings (19). 16

3 - Mount the O-ring (20) in the internal seating of the pi- A9
ston. 20
RKZA1600
4 - Gauge the diameter of the seal (16) of the piston mount-

ing the group under a press and use the tools A3 for the
piston diameter.
A3
RKPB1490
WB97R-2 30-249
3. Re-assembling the piston rod group

1 - Using a press and tools A2 with the appropriate diam-
eter, insert the bushing (21) into the piston head (4). 3
A10
2 - Insert the ring (8) into the piston rod (4).
★ Check carefully the direction of assembly of the ring (8).
21
3 - Insert the spacer ring (7) and secure the group with the
snap-ring (6).
4 - Mount the bushing A10 of appropriate diameter on the A2
tip of the piston rod (4).
5 - Lightly lubricate the cylinder head gaskets (2) and slide
the group onto the piston rod (4). RKZA1590
Gaskets: ASL800050
6 - Lubricate the O-ring seals (22) and screw the piston (5)
onto the piston rod (4) by hand for several turns. 5 22 4
O-ring seal: ASL800050
7 - Position the group on the tool A1 and tighten the piston
with the round prong wrench A7. 7
Piston: 932–980 Nm
6
4. Re-assembling cylinders
1 - Place the cylinder (1) on the apparatus A1. Engage the
fulcrum pins in the suitable support. 8
RKZ00120
2 - Lubricate the threading and the first part of the cylinder
(1).
Cylinder: ASL800050
3 - Mount the two halves of the tool A11 with the appropri-
ate diameter at the mouth of the cylinder (1).
4 - Mount the piston rod group on the apparatus A1.
5 - Center the piston (5) in the tool A11.
6 - Wind the first guide ring (19) round the piston and insert
part of the piston into the tool A11. Wind the second
guide ring (19) and fully insert the piston.
Insert the piston slowly in order to calibrate the guide rin-
gs (19) without overheating them.
7 - Insert the cylinder head (2) and screw it in by hand for
several turns.
8 - Use the special wrench A6 to screw the cylinder head
home.
Cylinder head: 932–980 Nm
9 - Screw the brake cylinder (3) into the cylinder (1).
Brake cylinder: Loctite 270
Brake cylinder: 804 Nm
10 - Remove the cylinder from the equipment A1.
11 - Using a press and the appropriate tool A2, mount the
swing bushings (9).
30-250 WB97R-2
REMOVAL AND INSTALLATION BACKHOE BACKFRAME LOCK CYLINDER
DISASSEMBLY OF BACKHOE BACKFRAME LOCK CYLINDER

1 - Plug one of the two cylinder (1) ports.
2 - Connect to the other port compressed air (max. 3 bar). 3 2

1
3 - Slowly insert pressure up to piston (2) comes out.
★ Retain piston and protect from oil using gloves and
a protection.
4 - Remove gasket (3).
The gasket has be replaced.
RKZ00190
ASSEMBLY OF BACKHOE
BACKFRAME LOCK CYLINDER
1 - Use the tool with the appropriate diameter, mount the
seal ring (3) onto the piston (2).
★ Make sure that the lips are turned towards the in-
side of the cylinder.
2 - Put the piston (2) onto cylinder (1).

Internal Cylinder: ASL800050
3 - Apply an elastic band, tighten gasket (3) and using a

press insert the piston at the end of stroke.
WB97R-2 30-251
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.
RKZA0970
1 - Make sure that the safety stop (1) is raised.
2 - Stop the engine and release the residual hydraulic pres- 1

sures.
3 - Take out the cotter pins (2) and remove the pin (3).
1 2
2
3
RKZA9860
4 - Disconnect the tube (4) that feeds the cylinder (5). Plug
the tube to prevent entry of impurities.
5 - Take out the snap ring (6) and remove the cylinder (5).
5
1
6
RKZA9890
INSTALLATION OF THE BOOM

SAFETY CYLINDER
1
Pin seatings: ASL800050
2
★ Install new cotter pins.
1 - Start the engine and perform several lock and release

manoeuvres to fill up and bleed air from the unit.
30-252 WB97R-2
REMOVAL AND INSTALLATION BACKHOE WORKING EQUIPMENT
REMOVAL OF THE BACKHOE WORKING EQUIPMENT

Fully extend the arm and open the bucket completely.
Lower the equipment until it is resting on the ground.
1
sures. (For details, see «20. TESTING AND ADJUST- 2
MENTS»).
2 - Remove the boom cylinder. (For details, see «REMO-
VAL OF BOOM CYLINDER»).
3 - Take out the bracket (2) mounted inside the boom. Di-
sconnect the tubes (1) from the arm cylinders.
★ Plug all tubes to prevent entry of impurities.
★ Mark the tubes to prevent exchanging positions
during re-connection. RKZA9900
4 - Remove bracket (3).

5 - Put a sling round the equipment (4) and apply slight ten-
sion to the cables. 3
6 - Take out the snap-rings and remove the pin (5).
1 2
7 - Remove the working equipment (4).
3
Standard work equipment: 850 kg
★ While remove the equipment, extract the control RKZA9870
hoses and take care to not stress them.
INSTALLATION OF THE BACKHOE

WORKING EQUIPMENT
4
1
5
2 RKZA1331
3
★ Pass the tubes of the cylinders inside the brackets (6).
MENTS»).
6
RKZA1342
WB97R-2 30-253
REMOVAL AND INSTALLATION BACKHOE BUCKET
REMOVAL OF THE BACKHOE BUCKET

Place the bucket on a level surface, resting on its back.
7
1 - Take out the safety pin (1) and remove the connecting 4
pin (2) between bucket (3) and tie-rods (4).
6
1 2 2
2 - Take out the safety pin (5) and remove the pin (6) that at- 5
taches the bucket to the arm (7).
1 2 1
3
RKZA1350

BUCKET
1
2
30-254 WB97R-2
REMOVAL AND INSTALLATION ARM
REMOVAL OF THE ARM

1 - Remove the bucket.
(For details, see «REMOVAL OF BUCKET»).
4
2 - Remove the bucket cylinder and the lever (1).

(For details, see «REMOVAL OF THE BUCKET
CYLINDER»). 1
3
3 - Take off the lock-nut (2), and the washer, and remove
the pin (3) and the levers (4). 1 2
4 - Start the engine, bring the arm into a vertical position 2
and lower it to the ground.
5 - Stop the engine and release residual pressures from RKZA1360
the cylinder.
6 - Put a sling around the arm cylinder (5), remove the

screws (6) and remove the pin (7). 2 3
7 - Start the engine and retract the piston completely (8).
8 5
★ Secure the fully retracted position by binding the pi-
ston head with wire.
8 - Rest the cylinder (5) on a block “A”.
9 - Stop the engine.
10 - Attach the arm (9) to the hoisting tackle and apply a

slight tension to the cable.
RKZA1201
11 - Take out the screws and remove the pin (10).

1 2 6
7
12 - Remove the arm (9).
Arm: 213 kg
INSTALLATION OF THE ARM

1
RKZA1370
pin, do not insert fingers into the holes to check align-
ment.
2
9
10
turn. A
3
pin, turn the engine over at low idling speed
RKZA1380
WB97R-2 30-255
REMOVAL AND INSTALLATION JIG ARM
REMOVAL OF COMPLETE JIG ARM

1 - Remove the bucket.
4
2 - Remove the bucket cylinder and the link (1).

(For details, see REMOVAL OF BUCKET CYLIN-
DER»). 1
3
3 - Take out the lock nut (2) and the washer, and remove
the pin (3) and the cylinder link (4). 1 2
2
RKZA1360
4 - Disconnect the jig arm hoses (5) and (6), the bucket
cylinder hoses (7) and (8), and the hoses of the auxiliary
equipment (9) and (10).
★ Mark the hoses to avoid exchanging them during
11
INSTALLATION. 6
5 - Remove the clamp (11).
6 - Proceed with the removal as for the arm. 10

7
(See «REMOVAL OF THE ARM»).
Jig arm cylinder: 392 kg 9 8

5
RKZA7970
INSTALLATION OF THE
COMPLETE JIG ARM
• To install reverse the removal procedure.
1
When aligning positions between hole and pin, do not
insert fingers into the holes to check on alignment.
2

turn.
30-256 WB97R-2
REMOVAL AND INSTALLATION 2nd ARM
REMOVAL OF 2nd ARM

1 - Remove the bucket (1).
2 - Remove the bucket cylinder (2) and the link (3).

(For details, see «REMOVAL OF THE BUCKET
1 2
CYLINDER»).
3
3 - Remove the 2nd arm cylinder.
(For details, see «REMOVAL OF THE 2nd ARM CYLIN-
DER»).
★ For safety, tightly plug all the disconnected hoses.
7
RKZA7980
4 - Take out the lock nut (4), and the washer and remove
the pin (5) and the links (6). 1 2 3 6
5 - Connect the 2nd arm (7) to some hoisting tackle.
★ Use the bucket pin hole and the safety pin holes.
5
6 - Start the engine and, maintaining constant tension on 3
the section of cable or chain connected to the bucket
coupling, slowly raise the boom until both sections of ca-
4
ble or chain are under slight tension.
7 - Stop the engine and loosen by several turns the gib ad-
justment screws.
★ Loosen the screws on both sides.
RKZA7990
8 - Slide out the 2nd arm (7).

2nd arm: 160 kg
INSTALLATION OF 2nd ARM

1
RKZA8000
When aligning the positions between hole and pin, do

not insert fingers into the holes to check on alignment.
2
3
turn.
WB97R-2 30-257
REMOVAL AND INSTALLATION 2nd ARM GUIDES
REMOVAL OF 2nd ARM GUIDES

1 - Remove the bucket (1).
(For details, see «REMOVAL OF BUCKET»). 2
1
2 - Partially extend the 2nd arm (1).
3 - Rest the arm (2) on a trestle “A” about 80 cm (3.5 ft.)

high.
RKZA8010
4 - Loosen and remove the screws (3), the spring washers

and remove the upper guides (4). 1
5 - Connect the 2nd arm (1) to some hoisting tackle.
★ Use the bucket pin hole and the safety pin holes.
6 - Slowly raise the 2nd arm (1) until it rests on the sup- 3
porting surfaces of the upper guides.
5 6
RKZA8020
7 - Loosen the nuts (5) and remove the adjustment dowel

bolts (6). 3
8 - Raise the lower guides (7) and slide them out. 1
4
6
7
RKZ02390
INSTALLATION OF 2nd ARM

2
GUIDE 1
1
Guides and 2nd arm guides: ASL800040
1 - Adjust the clearances, keeping the jig arm (1) aligned

with respect to the 2nd arm (2). (For details, see «20.
TESTS AND ADJUSTMENTS»).
RKZA8030
30-258 WB97R-2
REMOVAL AND INSTALLATION BACKHOE BOOM
REMOVAL OF THE BACKHOE BOOM

1 - Remove the arm.
(For details, see «REMOVAL OF THE ARM»).
2 - Remove the arm cylinder.

(For details, see «REMOVAL OF THE ARM CYLIN-
1
DER»).
3 - Start the engine and rest the boom on the ground. 2
4 - Remove the boom cylinder.

(For details, see «REMOVAL OF THE BOOM CYLIN-
DER»).
5 - Take out the bracket (1) and disconnect the tubes (2) RKZA9871
from the arm cylinders and the bucket. Plug all tubes to
prevent entry of impurities.
6 - Put a sling round the boom (3).
7 - Take out the snap-rings and remove the pin (4).

3
1 2
8 - Remove the boom (3). 3 4
Boom: 323 kg
RKZA9880

BOOM
1
5
2
RKZA1340
3
★ Pass the cylinder tubes inside the brackets (5).
MENTS»).
WB97R-2 30-259
REMOVAL AND INSTALLATION BACKHOE SWING BRACKET
REMOVAL OF THE BACKHOE SWING BRACKET

1 - Remove the working equipment.
(For details, see «REMOVAL OF THE WORKING
EQUIPMENT»). 2
2 - Take out the screws (1) and remove the pins (2) that
connect the swing cylinders (3). 1 2
3 - Remove boom safety cylinder (4). 3
(For details, see «REMOVAL OF BOOM SAFETY
CYLINDER»). 1
RKZA7760
4 - Remove snap ring (5), pin (6) and link (7). 3

5 - Put a sling round the swing bracket (8).
6 - Take out the screws (9) and (10) and remove the swing 4
bracket axle oscillation pins (11) and (12).
5
1 2 7
7 - Remove the swing bracket (8) and the relative shim ad-
justments to given clearance.
4 6
Bracket: 133 kg
RKZA9891
INSTALLATION OF THE
BACKHOE SWING BRACKET 11
9
1
12
10
2
RKZA1411
3
Pin: ASL800050
4
13
★ Insert the shims.
MENTS»).
13
RKZ01330
30-260 WB97R-2
REMOVAL AND INSTALLATION BACKHOE BACKFRAME
REMOVAL OF BACKHOE BACKFRAME

1 - Remove the equipment.
(For details, see «REMOVAL OF BACKHOE WORK- 5 6
ING EQUIPMENT»).
2 - Remove the swing cylinders. 1 2

(For detail see «REMOVAL OF SWING CYLINDER»).
3 - Remove the swing bracket.

(For detail see «REMOVAL OF SWING BRACKET»).
4 - Disconnect from union (1) the feeding pipes (2) of back-

hoe backframe and plug them to avoid impurity entry.
RKZA1430
5 - Loose nuts (4) and remove washers (5) and four screw
(6).
7 4 5
Loose partially lateral nuts (4) to remove backframe (3) 8
from frame (8). 1
6 - Put a sling round the backframe (3) and apply slight ten-
sion to the cables.
7 - Remove external nuts (4), washers (5) and screws (6).
1
3
RKZA1440
8 - Remove the sliding piece (7) and then lower the back
frame (3) and remove it.
Backframe: 237 kg
3
INSTALLATION OF
BACKHOE BACKFRAME
1
RKZA1660
Nuts: Loctite 262
Nuts: 980±98 Nm
MENTS»).
WB97R-2 30-261
PAGE INTENTIONALLY
LEFT BLANK
GROUP 40
40-28 PC15R-8
STANDARD MAINTENANCE
Transmission ............................................................. 2 7-Spool control valve................................................23

Front axle................................................................... 5 8-Spool control valve................................................25
Rear axle ................................................................... 8 Brake pump ..............................................................27
Hydraulic pump........................................................ 12 Shovel cylinders .......................................................29
2-Spool control valve ............................................... 14 Backhoe cylinders ....................................................30
3-Spool control valve ............................................... 16 Front working equipment..........................................34
3-Spool control valve (With Return to Dig) .............. 18 Swing bracket...........................................................36
6-Spool control valve ............................................... 20 Backhoe working equipment ....................................38
WB97R-2 40-1
STANDARD MAINTENANCE TRANSMISSION
TRANSMISSION
C
B A
C L
D D
F F
E
A
........... Nm
23±1 Nm H H
RKZ03043
40-2 WB97R-2
50±2.5 Nm
23±1 Nm
50±2.5 Nm
23±1 Nm
50±2.5 Nm
Loctite 510
139±7 Nm
50±2.5 Nm
139±7 Nm
Loctite 510
Loctite 510
RKZ03053
Section A-A
Sezione A - A
WB97R-2 40-3
50±2.5 Nm
25±1 Nm
23±1 Nm
Section B - B Section
Sezione C
C -- C
C
Sezione B - B
25±1 Nm
25±1 Nm Section D-D

Sezione D - D
80±4 Nm
Section
Sezione E
E -- E
E
RZ03110
23±1 Nm
80±4 Nm
Section G -- G
Sezione G G
Section
Sezione F
F -- F
F
26–30 Nm
50±2.5 Nm
25±1 Nm
Section 26–30 Nm
Sezione H
H -- H
H
40±2 Nm
Detail L
Particolare L
RZ03120
40-4 WB97R-2
STANDARD MAINTENANCE FRONT AXLE
FRONT AXLE
Differential
95±5 Nm
with Loctite 270 13 Nm
266±13 Nm
1
60±3 Nm
Loctite 510
169±8.5 Nm
Loctite 638
Loctite 270
2
92 – 137 Nm
3
56 Nm 4
RKZ00811
Unit: mm
N° Check item Criteria Remedy
Standard clearance Clearance limit

1 Axle clearance
---- ----
Backlash of crown wheel
2 and pinion 0.17 – 0.23 0.23
Adjust
Pinion preload
3 92 – 137 Nm
(without seal ring)
Pinion-crown wheel preload
4 (without seal ring) 95.9 – 142.9
WB97R-2 40-5
Planetary - Joint
Loctite 510 190±9.5 Nm

80 Nm 1
8 Nm
230±11.5 Nm
70 Nm 8 Nm
with Loctite 270
70 Nm
with Loctite 270
RKZ00821
Unit: mm
1 Hub rotation torque ---- Adjust
2 Drive shaft axle clearance ---- Replace
40-6 WB97R-2
Steering unit cylinder
120±6 Nm
B
350±9.8 Nm
C
300±15 Nm
A
500
A
250±12.5 Nm
+
1984 +02
220±11 Nm 150±7.5 Nm
Section
Sezione A
A -- A
A Section
Sezione B
B -- B
B Detail C
Particolare C
RKZ00842
Unit: mm
Tolerance
Standard Standard Clearance
size clearance limit Replace
Clearance between Shaft Hole
1 bushing and pin
bushing
and pin
50 ---- 50.19+0 0.04 ---- ----
WB97R-2 40-7
STANDARD MAINTENANCE REAR AXLE
REAR AXLE
Differential
13 Nm
155 Nm
with Loctite 270
79 Nm 1
176 Nm
2
Loctite 542
3
4
RKZ04971
Unit: mm
Standard clearance Clearance limit

1 Axle clearance
---- ----
Backlash of crown wheel
2 and pinion 0.17 – 0.23 0.23
Adjust
Pinion preload
3 (without seal ring) 92 – 138 Nm
Pinion-crown wheel preload

4 95.23 – 141.84 Nm
(without seal ring)
40-8 WB97R-2
Planetary
500 Nm 70 Nm
with Loctite 270
79 Nm
230 Nm
60 Nm
25 Nm
RKZ04981
Unit: mm
1 Hub rotation torque ---- Adjust
2 Drive shaft axle clearance ---- Replace
WB97R-2 40-9
Brakes
A
10 Nm
1
35 Nm 3
8 – 12 Nm
10 Nm
15 Nm 25 Nm
2
Detail B B
Particolare
10 Nm
Section A -- AA
Sezione A RKZ04991
Unit: mm
Standard size Repair limit
Installed
Free Installed Installed Free load
1 Brake disc return spring installed length load installed Replace if
on screw damaged or
deformed
27 13 127 Nm 21 10 Nm
2 Disc return spring 35 19 369 Nm 21 10 Nm
Standard thickness Min. thickness
3 Disc thickness Replace
0
5 -- 0.15 3.3
40-10 WB97R-2
Differential lock
27 Nm 27 Nm
RKZ05001
WB97R-2 40-11
STANDARD MAINTENANCE HYDRAULIC PUMP
HYDRAULIC PUMP
1 5 2
A
3
Detail A A
Particolare RKZ01290
Unit: mm
1 Ball-bearing loading 0 – 0.05 Adjust
Tolerance
Backlash between piston size Shaft Hole clearance limit
2 and cylinder
20 ---- 0.065
Backlash between piston
3 and shoe 0.15
Standard value Max. value

4 Drive shaft diameter
34.91
Free
installed Installed Installed Free Installed
5 Spring length load installed load
x Øe
---- 88.7 276±12 N
40-12 WB97R-2
STANDARD MAINTENANCE HYDRAULIC PUMP
1 2 3
60 Nm 21 Nm
.25 Nm
Section
SezioneCC- -CC
5 35 Nm 21 Nm
12 Nm 4
12 Nm
6 7 35 Nm 21 Nm
Section
Sezione D
D -- D
D RKZ00643
Unit: mm

Free
Installed Installed Free Installed
1 Spring installed length load installed load
x Øe
---- ---- ---- ---- ----
Power regulation spring
2 (external) 125.4±10 N
Power regulation spring

3 (internal) 180.2±12.5
4 PC valve spring (external) 40.2±2.8

5 PC valve spring (internal) 81.7±14.5
6 LS valve spring (external) 81.7±14.5
7 LS valve spring (internal) 40.2±2.8
WB97R-2 40-13
STANDARD MAINTENANCE 2-SPOOL CONTROL VALVE
D C A
27±2 Nm
............ Nm
............ Nm
D C A
25 Nm 20 Nm
20 Nm
B with Loctite 542
8 Nm
with Loctite 542 1
25 Nm
with Loctite 542
2
B
25 Nm
Section
Sezione A
A -- A Section
A Sezione B
B -- B
B RKZ01081
Unit: mm

Free
1 Check valve spring installed x installed load
length load
Øe
2 Priority valve spring
40-14 WB97R-2
10±1 Nm 10±1 Nm 10±1 Nm

E
E 70±7 Nm
70±7 Nm
............ Nm
............ Nm
E
1 10±1 Nm 1 10±1 Nm
E
Section
Sezione C
C -- C
C
Section
Sezione D
D -- D
D
30±3 Nm 2
Section
Sezione E
E -- E
E RKZ00661
Unit: mm

Free
1 Spool return spring installed x length installed load
load
Øe
2 Check valve spring
WB97R-2 40-15
D C A
............ Nm 27±2 Nm
............ Nm
D C A
E
25 Nm 20 Nm
20 Nm with Loctite 542
B
8 Nm
with Loctite 542
1
25 Nm
with Loctite 542
2
B 100 Nm
Section
Sezione A
A -- A
A Section
SezioneBB -- B
B RKZ01071
Unit: mm

Free
1 Spool return spring installed x length load Installed load
Øe
40-16 WB97R-2
70±7 Nm 10±1 Nm
F F 10±1 Nm
70±7 Nm
............ Nm
1 70±7 Nm
............ Nm
2
F
70±7 Nm
F
F 10±1 Nm
............ Nm Section C -- CC
Sezione C 3
Section
Sezione D
D -- D
D
10±1 Nm
70±7 Nm
30±3 Nm 4
4
............ Nm
70±7 Nm Section
SezioneFF--FF
F
Section E -- EE
Sezione E RKZ01300
Unit: mm
Free
1 Spool return spring installed x length load installed load
Øe
2 Spool locking spring

3 Spool return spring
WB97R-2 40-17
STANDARD MAINTENANCE 3-SPOOL CONTROL VALVE (With Return to Dig)
3-SPOOL CONTROL VALVE (With Return to Dig)
D C A
27±2 Nm
............ Nm
............ Nm
C A
E D
25 Nm 20 Nm
20 Nm
B with Loctite 542
8 Nm
with Loctite 542
1
25 Nm
with Loctite 542
2
B
100 Nm
Section
Sezione A
A -- A
A Section
Sezione B
B -- B
B RKZ01091
Unit: mm

Free
1 Check valve spring installed x length load installed load
Øe
40-18 WB97R-2
STANDARD MAINTENANCE 3-SPOOL CONTROL VALVE (With Return to Dig)
10±1 Nm 10±1 Nm F 10±1 Nm

F
70±7 Nm 70±7 Nm
............ Nm
1 3
............ Nm
2
70±7 Nm
70±7 Nm
F
F
............ Nm
............ Nm Section
Sezione C
C -- C
C
F
10±1 Nm
Section
Sezione D
D -- D
D
70±7 Nm
30±3 Nm
4
............ Nm 4
70±7 Nm
Section
Sezione FF -- F
F
F
Section
SezioneEE -- E
E
RKZ00941
Unit: mm
Free
Øe
2 Spool locking spring

WB97R-2 40-19
G E B D D C B A
H 27±2 Nm
H
G E B D D C B A
G 10±1 Nm
70±7 Nm
70 Nm 45 Nm
20 Nm
with Loctite 542
............ Nm
70 Nm
Section
Sezione A
A -- A
A 70±7 Nm
10±1 Nm
1 G
Section
Sezione B
B -- B
B RKZ00231
Unit: mm

Free
Øe
40-20 WB97R-2
F 10±1 Nm 10±1 Nm F 10±1 Nm

70±7 Nm
70±7 Nm
............ Nm
70±7 Nm 70±7 Nm
F 1
1 10±1 Nm
F
Section
Sezione D
D -- D
D
Section
Sezione C
C -- C
C
10±1 Nm F 10±1 Nm
70±7 Nm
2
30±3 Nm
10±1 Nm Section
Sezione FF -- F
F
70±7 Nm F 1
Section
Sezione E
E -- E
E
RKZ01310
Unit: mm

Free
1 Spool return spring installed length load installed load
x Øe
WB97R-2 40-21
25 Nm
10 Nm
20 Nm 20 Nm
Section
Sezione G
G -- G
G
Section
SezioneHH -- H
H RKZ00791
Unit: mm

Free
1 Unloading valve spring installed x length load installed load
Øe
40-22 WB97R-2

For jig arm
A
A
RKZ00241
For side digging boom
B RKZ00251
For hammer
C
C
RKZ00261
WB97R-2 40-23
10±1 Nm 10±1 Nm
70±7 Nm 70±7 Nm
............ Nm ............ Nm
70±7 Nm
10±1 Nm
10±1 Nm 1 70±7 Nm 10±1 Nm
1
Section
Sezione A
A -- A
A Section
Sezione B
B -- B
B
10±1 Nm
70±7 Nm
............ Nm
............ Nm
70±7 Nm 10±1 Nm
1
Section
Sezione C
C -- C
C RKZ00961
Unit: mm

Free
Øe
40-24 WB97R-2

For hammer and jig arm
C A
C A
RKZ00272
For side digging boom and jig arm
B A
B A RKZ00282
WB97R-2 40-25
10±1 Nm 10±1 Nm
70±7 Nm 70±7 Nm
............ Nm ............ Nm
70±7 Nm
10±1 Nm
10±1 Nm 1 70±7 Nm 10±1 Nm
1
Section
Sezione A
A -- A
A Section
Sezione B
B -- B
B
10±1 Nm
70±7 Nm
............ Nm
............ Nm
70±7 Nm 10±1 Nm
1
Section
Sezione C
C -- C
C RKZ00961
Unit: mm

Free
Øe
40-26 WB97R-2
STANDARD MAINTENANCE BRAKE PUMP
BRAKE PUMP
1 2 3
4
RKZ00931
Unit: mm
Free
1 Ball valve spring installed x length load installed load
Øe Replace if
damaged or
25 13 20 N 18–22 N deformed
2 Spring 21 13 7.3 N 7.3–7.8 N
3 Pump spring 91 60 72 N 65–79 N
4 Spring 14 7.3 4N 36–44 N
WB97R-2 40-27
STANDARD MAINTENANCE SHOVEL CYLINDERS
SHOVEL CYLINDERS
DUMP CYLINDER
2845±284 Nm 932 Nm
3 1 2
RKZ00780
RAISE CYLINDER
2845±284 Nm 961 Nm
3 1 2
RKZ00770
Unit: mm
Criteria
N° Check
item Cylinder Standard Tolerance Minimum Clearance Remedy
size clearance limit
Shaft Hole
Raise 50 -- 0.025 + 0.064 0.05 0.114

Tolerance between -- 0.050 + 0.025
1 piston rod and Replace
cylinder head
Dump 50 -- 0.025 + 0.064 0.05 0.114
-- 0.050 + 0.025
Raise 45
-- 0.050 + 0.24
0.13 0.329
2 bushing and piston
rod mounting pin
Dump 45 -- 0.050 + 0.24 0.13 0.329
-- 0.089 + 0.08 Replace
pin and
Raise 50 -- 0.038 + 0.24 0.118 0.323 bushing
3 bushing and cylinder
mounting pin Dump 50
-- 0.038 + 0.24
0.118 0.323
-- 0.083 + 0.08
40-28 WB97R-2
PAGE INTENTIONALLY
LEFT BLANK
STANDARD MAINTENANCE BACKHOE CYLINDERS
BACKHOE CYLINDERS
BOOM
932 – 980 Nm
1 3
2
RKZ00750
ARM
932 – 980 Nm 2845±284 Nm
1 3
2
RKZ00740
BUCKET
932 – 980 Nm 2845±284 Nm
2 1 3
RKZ00730
40-30 WB97R-2
BOO M SWING
932 – 980 Nm
1
2
78 +0 20 Nm
with Loctite 542
RKZ00720
Unit: mm
Criteria
N° Check
item
Cylinder Tolerance Remedy
Standard Minimum Clearance
Shaft Hole
Boom 60 -- 0.030 + 0.076 0.06 0.136

-- 0.060 + 0.030
Arm 60
-- 0.030 + 0.076
0.06 0.136
Clearance between -- 0.060 + 0.030
1 piston head and
cylinder head Bucket 60
-- 0.030 + 0.076
0.06 0.136 Replace
-- 0.060 + 0.030
Boom swing 50 + 0.025 + 0.064 0.05 0.114

+ 0.050 + 0.025
Boom 50
-- 0.050 + 0.24
0.13 0.329
-- 0.089 + 0.08
Arm 45
-- 0.050 + 0.24
0.13 0.329
2 bushing and piston head
mounting pin
Bucket 50 -- 0.050 + 0.24 0.13 0.329
-- 0.089 + 0.08
Boom swing 50
-- 0.050 + 0.119
0.13 0.208
-- 0.089 + 0.080 Replace
pin and
Boom 50
-- 0.050 + 0.24
0.13 0.329
bushing
-- 0.089 + 0.08
Tolerance between
3 bushing and cylinder Arm 45 -- 0.050 + 0.24 0.13 0.329
mounting pin
-- 0.089 + 0.08
Bucket 45
-- 0.050 + 0.24
0.13 0.329
-- 0.089 + 0.08
WB97R-2 40-31
OUTRIGGERI
1520±152 Nm
932 – 980 Nm
RKZ00710
JIG ARM
1520±152 Nm
932 – 980 Nm
RKZ00700
SIDE DIGGING BOOM
932 – 980 Nm 785 Nm
3 2 4
RKZ00680
40-32 WB97R-2
ARM (FOR SIDE DIGGING BOOM)
932 – 980 Nm 1520±152 Nm
3 1 5
RKZ00671
Unit: mm
Criteria
N° Check
item
Cylinder Tolerance Remedy
Shaft Hole
Outrigger 40 -- 0.025 + 0.064 0.050 0.114

-- 0.050 + 0.025
Arm for side
1 piston rod and 60 0.060 0.136
cylinder head digging boom -- 0.060 + 0.030
Jig arm 40
-- 0.025 + 0.064
0.114 0.050
-- 0.050 + 0.025

Side digging
2 piston rod and 45 0.049 0.405
bushing
boom -- 0.025 + 0.040
Replace
Side digging
40 -- 0.050 + 0.119 0.130 0.208
Tolerance between boom -- 0.089 + 0.080
3 bushing and piston rod
mounting pin Arm for side -- 0.050 + 0.119
digging boom 45 -- 0.089 + 0.080 0.130 0.208
Tolerance between Side digging -- 0.050 + 0.119

4 bushing and cylinder 40 0.130 0.208
mounting pin
boom -- 0.089 + 0.080
Clearance between
Arm for side 0 0
5 bearing and
digging boom 75 -- 0.013 -- 0.035 ---- 0.013
bearing seat
WB97R-2 40-33
STANDARD MAINTENANCE FRONT WORKING EQUIPMENT
FRONT WORKING EQUIPMENT
E
C
C E
D
B
B
A
1 2 3
Section
SezioneAA -- A
A Section
Sezione B
B -- B
Section
SezioneCC--CC
5
4
Section
Sezione D
D -- D
D
Section
SezioneEE--EE
RKZ02270
40-34 WB97R-2
STANDARD MAINTENANCE FRONT WORKING EQUIPMENT
Unit: mm
Criteria
N° Check item Tolerance

Clearance
Remedy
Standard Standard
Shaft Hole
Clearance between bushing -- 0.050 + 0.080

1 45 0.130–0.329
and bucket mounting pin -- 0.089 + 0.240
2 Clearance between bushing

45 -- 0.050 + 0.080 0.130–0.329
and link mounting pin -- 0.089 + 0.240

45
-- 0.050 + 0.080
0.130–0.208 Replace
and tilt lever mounting pin -- 0.089 + 0.119

45
-- 0.050 + 0.119
0.130–0.208
and link mounting pin -- 0.089 + 0.080

50 -- 0.038 + 0.080 0.118–0.323
and boom mounting pin -- 0.093 + 0.240
WB97R-2 40-35
STANDARD MAINTENANCE SWING BRACKET
SWING BRACKET
A C
1
3
4
Section
Sezione B
B -- B
B
1 6
Section
Sezione A
A -- A
A
Section
SezioneCC-- C
C
RKZ02720
40-36 WB97R-2
STANDARD MAINTENANCE SWING BRACKET
Unit: mm
Criteria
N° Check item Tolerance

Standard
Remedy
Standard Clearance
Shaft Hole
Clearance between rotating -- 0.060 + 0.090

1 bushing and boom swing 55 -- 0.106 + 0.060 0.120–0.196
cylinder bushing
Clearance between bushing -- 0.060 + 0.190

2 and (lower) swing bracket 65 0.250–0.370
rotating pin -- 0.106 + 0.264
Clearance between bushing -- 0.060 + 0.190 Replace

3 and (upper) swing bracket 65 0.250–0.370 bushing
rotating pin -- 0.106 + 0.264
and pin
Standard size Limit size
4 Upper shim thickness
4.75 --0 0.1
5 Central shim thickness 4.75 --0 0.1
6 Lower shim thickness 4.75 --0 0.1
WB97R-2 40-37
STANDARD MAINTENANCE BACKHOE WORKING EQUIPMENT
BACKHOE WORKING EQUIPMENT
C
C
B A
A
D
3
2
1
4
Section
Sezione A
A -- A
A
Section
Sezione B
B -- B
B
5 6 6
Section
Sezione D
D -- D
D
Section C -- CC
Sezione C RKZ02900
40-38 WB97R-2
STANDARD MAINTENANCE BACKHOE WORKING EQUIPMENT
Unit: mm
Criteria
N° Check item Tolerance Remedy

Shaft Hole
Clearance between link -- 0.050 --- 0.080

1 bushings and bucket 40 0.130–0.329
mounting pin -- 0.089 --- 0.240
Clearance between arm

2 bushings and bucket 40 -- 0.050 --- 0.080 0.130–0.329
-- 0.089 --- 0.240
mounting pin
Clearance between arm -- 0.050 --- 0.080

3 bushings and lever 45 -- 0.089 --- 0.240 0.130–0.329 Replace
mounting pin
4 Clearance between bushings

45
-- 0.050 --- 0.080 0.130–0.329
and tilt lever mounting pin -- 0.089 --- 0.240
5 Clearance between bushings

50 -- 0.050 --- 0.080 0.130–0.208
and arm mounting pin -- 0.089 --- 0.119
6
Clearance between bushings
50
-- 0.038 --- 0.080 0.118–0.202
and boom mounting pin -- 0.083 --- 0.119
WB97R-2 40-39
PAGE INTENTIONALLY
LEFT BLANK

WB97R 2

Uploaded by

Copyright:

Available Formats

WB97R 2

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

WB97R 2

Uploaded by

Copyright:

Available Formats

WEBM001001

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

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

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

The affected pages are indicated by the use of the

● Page to be replaced Replace

( ) Page to be delete Discard

Pages having no marks are those previously revised or

LIST OF REVISED PAGES

Tim e of Tim e o f Time of T im e of Tim e of

00-1 10-17 10-58 20-2 20-43

Tim e o f Time of T im e of Tim e of Tim e o f

30-3 30-66 30-129 30-192 30-255

IMPORTANT SAFETY NOTICE

STRUCTURE AND FUNCTION

TESTING AND ADJUSTING

DISASSEMBLY AND ASSEMBLY

HOW TO READ THE SHOP MANUAL

Symbol Item Remarks

10 - 3 Weight of parts or systems.

Parts to be coated with adhe-

REVISED EDITION MARK

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

The allowable load value is estimated to be one-

STANDARD TIGHTENING TORQUE

1. STANDARD TIGHTENING TORQUE OF BOLTS AND NUT

Width across flat

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

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

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

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

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

16 2 24 14 19.5±2 191±21 27±3 268±29

18 2.5 27 14 27±3 262±28 37±4 366±36

20 2.5 30 17 38±4 372±40 53±6 524±57

22 2.5 32 17 52±6 511±57 73±8 719±80

24 3 36 19 66±7 644±70 92±10 905±98

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

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

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

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

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

2. TIGHTENING TORQUE FOR NUTS OF FLARED

Use these torques for nut part of flared.

Thread diameter Width across flats TIGHTENING TORQUE

1/2” - 20 17 2.6±0.5 25.5±4.9

9/16” - 18 17 4±0.5 39.2±4.9

3/4” - 16 22 6.7±2 65.7±19.6

1.1/16 - 12 32 9.7±3 95.15±29.4

1.5/16 - 12 38 17±3 166.7±29.4

1.5/8 - 12 50 20±5 196.2±49

Thread diameter Width across flats TIGHTENING TORQUE

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

1.3/16 - 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

Nomenclature Code Applications